SICK GM700 User manual

OPERATING INSTRUCTIONS
GM700
TDLS Analyzer for NH3, HF, HCl or O2
Cross-Duct Version
Installation
Operation
Maintenance

2 GM700 · Operating Instructions · 8011543 V3.1 · © SICK AG
Document Information
Document ID
Title: Operating Instructions GM700
Part No.: 8011543
Version: 3.1
Release: 2014-03
Described Product
Product name: GM700
Variants: Cross-Duct
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Place of Manufacture
SICK AG
Nimburger Str. 11 · 79276 Reute · Germany
Original Documents
The English edition 8011543 of this document is an original
document from SICK AG.
SICK AG assumes no liability for the correctness of an
unauthorized translation.
Please contact SICK AG or your local representative in case of
doubt.
Legal information
Subject to change without notice.
© SICK AG. All rights reserved.
Warning Symbols
Warning Levels / Signal Words
DANGER
Risk or hazardous situation which will result in severe personal
injury or death.
WARNING
Risk or hazardous situation which could result in severe personal
injury or death.
CAUTION
Hazard or unsafe practice which could result in personal injury or
property damage.
NOTICE
Hazard which could result in property damage.
Information Symbols
IMMEDIATE HAZARD
of severe injuries or death
Hazard (general)
Please consult the documentation
Hazard by corrosive substances
Hazard by voltage
Hazard by unhealthy substances
Hazard by toxic substances
Hazard by laser radiation
Hazard by high temperature or hot surface
Information about the use in potentially explosive
atmospheres
Important technical information for this product
Important information on electric or electronic
functions
Nice to know
Supplementary information
Link to information at another place

GM700 · Operating Instructions · 8011543 V3.1 ·©SICKAG 3
Contents
1SafetyInformation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Main operating information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Protection against hazards through gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 Protection against laser radiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.3 Behavior during purge air failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.3.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Responsibility of user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 Disposing of device parts harmful to the environment . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 GM700 system, Cross-Duct version, layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 GM700 options and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Measuring principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Reference cuvettes for wavelength stabilization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.2 Signal evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3 Project Planning Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Work steps from system selection to start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Project Planning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Initial onsite installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.1 Assembly preparation at the sampling point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.2 Uncovering the duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3.3 Mounting the flanges with tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3.4 Assembly preparation for the purge air unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.5 Duct insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3.6 Assembly preparation for the evaluation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4 Preparations for electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4.1 Signal and power supply cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4.2 CAN bus wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.1.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.1.2 Installation prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.2 Fitting system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.2.1 Information on fitting the sender/receiver unit or reflector . . . . . . . . . . . . . . . . . . . . 33
4.3 Installing the purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3.1 Terminal box with 24 V power supply unit (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4 Installing the evaluation unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4.1 Installing the evaluation unit – sheet metal enclosure version . . . . . . . . . . . . . . . . . 34
4.4.2 Installing the evaluation unit – cast-metal enclosure version . . . . . . . . . . . . . . . . . . 35
4.5 Electrical connection of system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.5.1 CAN bus wiring options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.5.2 Electrical connection in the evaluation unit EvU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4GM700 · Operating Instructions · 8011543 V3.1 ·©SICKAG
Contents
5 Handling the Evaluation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.1 User qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2 Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2.1 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1 Preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1.1 Required qualifications and further prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2 Start-up steps overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3 Mechanical preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3.2 Cleaning optical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 Measuring path free from sample gas - zero path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4.1 Preparing a zero path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4.2 Fitting the GM700 system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4.3 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.4.4 Optical alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.4.5 Zero adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.6 Preparing the system for zero adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.7 Performing zero adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.4.8 Installing the purge air fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.9 Purge air units start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.4.10 Sender/receiver unit and reflector start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.5 Installing weatherproof covers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.5.1 Evaluation unit start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.5.2 Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.5.3 Gas connections for oxygen measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.5.4 Starting operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.5.5 Starting the increased nitrogen purging for oxygen measurement . . . . . . . . . . . . . 68
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.1.1 Maintenance protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.2 Preparation and general preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.3 Maintenance work on SR-unit and reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.3.1 Visual inspection and enclosure cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.3.2 Cleaning the front window on the SR-unit and on the reflector . . . . . . . . . . . . . . . . 71
7.4 Evaluation unit (EvU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.5 Controlling and tracking the laser working point during measurement . . . . . . . . . . . . 73
7.5.1 Connecting the test gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.5.2 Starting the tracking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.5.3 Filter box measurement to check the measuring channels for NH3, HF or HCl. . . 75
7.5.4 Determining the necessary test gas concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.5.5 Installing the filter box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.5.6 Carry out filter box measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.6 Checking the gas analyzer with test cell GMK10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
7.6.1 Assembly of the GM700 components with the test cell GMK10 . . . . . . . . . . . . . . . 81
7.6.2 Carrying out measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

GM700 · Operating Instructions · 8011543 V3.1 ·©SICKAG 5
Contents
8 Troubleshooting and Clearing Malfunctions. . . . . . . . . . . . . . . . . . . . 85
8.1 Malfunction categories/possible effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.2 Purge air failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.3 Integrated monitoring and diagnosis system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.3.1 Display and retrieval of messages on the evaluation unit . . . . . . . . . . . . . . . . . . . . . 87
8.3.2 Troubleshooting and clearing malfunctions, evaluation unit . . . . . . . . . . . . . . . . . . . 88
8.3.3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.3.4 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.3.5 Further tips on troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9 Technical Data, Expendable and Spare Parts. . . . . . . . . . . . . . . . . . 95
9.1 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.1.1 Compliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.1.2 Electrical protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2 Measuring components and accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2.1 Technical data, GM700 system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3 GM700 sender/receiver unit dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
9.4 Purge air fixtures for SR-unit and reflector dimensions . . . . . . . . . . . . . . . . . . . . . . . . .100
9.5 Reflector dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
9.6 Flanges with tube dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
9.7 GM700 evaluation unit, sheet metal enclosure version, dimensions . . . . . . . . . . . . .101
9.8 GM700 evaluation unit, sheet metal version, dimensions . . . . . . . . . . . . . . . . . . . . . .102
9.9 Weatherproof cover for GM700 SR-unit, dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .103
9.10 Weatherproof cover for GM700 reflector unit, dimensions . . . . . . . . . . . . . . . . . . . . . .103
9.11 Terminal box dimensions for CAN bus (option); Part No. 2020440 . . . . . . . . . . . . . .104
9.12 Accessories, expendable and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
9.12.1 Consumable parts for 2-years operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
9.12.2 Spare parts for the sender/receiver unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
9.12.3 Spare parts for the reflector unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
9.12.4 Spare parts for the purge air fixture (sender/receiver unit) . . . . . . . . . . . . . . . . . . .106
9.12.5 Spare parts for the purge air fixture (reflector side) . . . . . . . . . . . . . . . . . . . . . . . . . .106
9.12.6 Spare parts for the evaluation unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
9.12.7 Fixing accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
9.12.8 Spare parts assignment for sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

6GM700 · Operating Instructions · 8011543 V3.1 ·©SICKAG
Contents

Safety Information
GM700 · Operating Instructions · 8011543 V3.1 · © SICK AG 7
GM700
1Safety Information
Main hazards
Main operating information
Intended use
Responsibility of user

8 GM700 · Operating Instructions · 8011543 V3.1 · © SICK AG
Safety Information
1.1 Main hazards
Important safety information in short form.
Operational safety
1.2 Main operating information
1.2.1 Protection against hazards through gases
DANGER: Hazards through defective device
The GM700 is likely to be unsafe when it:
●Has been penetrated by moisture.
●Has been stored or operated under irregular conditions.
When safe operation is no longer possible:
▸ Put the GM700 out of operation, separate all connectors from the power
supply and secure against unauthorized start-up.
WARNING: Hazard by voltage
▸ Pay careful attention to power supply connections.
▸ Do not interrupt protective conductor connections.
WARNING: Hot surfaces when enclosure open
Pay attention to hot surfaces on the measuring cell when opening the GM700
enclosure.
WARNING: Eye injuries possible due to laser radiation
 Observe all relevant information in these Operating Instructions
WARNING: Hot and/or aggressive sample gases
▸ Wear suitable protective clothing and mask when using hot and/or aggres-
sive sample gases resp. with high dust loads.
▸ Never open the enclosure or switch off the purge air feed without taking
appropriate protective measures when the duct is pressurized.

Safety Information
GM700 · Operating Instructions · 8011543 V3.1 · © SICK AG 9
WARNING: Toxic and caustic substances in parts in contact with sample gas
●GM700 parts in contact with sample gas can contain toxic and caustic sub-
stances depending on the sample gas composition.
●When fitted in the measuring device, the reference cuvette contains the
respective gases to be measured. These gases must not escape.
Special care must be taken with the GME700-2 (HF) because it not only
contains gaseous HF but also a certain amount of liquid (max. 0.1 g HF for
8 cm cells, max. 0.02 g for 1 cm cells). HF/hydrofluoric acid is extremely
toxic and caustic. It is imperative to avoid inhaling or skin contact at all
times. Particularly when there are indications of leaks or defects, wear pro-
tective clothing (protective goggles, latex gloves) and carry out work in a
well ventilated room/area. Never open the cuvette under any circum-
stances. Check replacement cuvettes for any possible transport damage.
●Handle with care when test gases are used:
▸ When handling HF, keep an HF emergency set (including calcium gluco-
nate gel) available.
▸ Before working on the gas path, ask the operator which gases have been
applied to the GM700.
▸ Ask the operator whether, and how, the GM700 gas path has been cleaned.
▸ If necessary, clean the gas path with a suitable method.
▸ In case of doubt, take appropriate protective measures before working on
the gas path: Ensure adequate ventilation at the workplace or work under a
vent. Wear protective goggles or a safety mask, protective gloves and acid-
proof protective clothes.

10 GM700 · Operating Instructions · 8011543 V3.1 · © SICK AG
Safety Information
1.2.2 Protection against laser radiation
The GM700 laser warning sign is located on the sender/receiver unit.
Figure 1 Laser warning sign on the GM700 sender/receiver unit (example O2measurement)
The invisible laser beam within the SR-unit is not accessible when fitted. There is no risk for
the human eye when looking into the optic visor on the right side of the SR-unit. The CAN
connection cable to the evaluation unit must be disconnected during disassembly or main-
tenance work (e.g. cleaning the front window) otherwise the laser beam could be touched
or accessed.
Laser outlet
Laser warning sign
NOTICE: Laser classes of the GM700 sender/receiver unit:
▸ Laser class 1 in normal measuring operation – the sender/receiver unit
(SR-unit incl. purge air fixture) is fitted securely on the flange with tube
and locked or
▸ Laser class 3R when the SR-unit is unlocked and swiveled in position
and the power supply is switched on via CAN Bus cable from the evalua-
tion unit!
WARNING: Never open the reflector during operation:
This could result in dangerous exposure to radiation.