SICK GM700 User manual

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MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
GM700
TDLS Analyzer for NH3, HF or HCI
Version with Measuring Probe
Installation, Operation, Maintenance

28010100/YK22/V4-0/2015-12 | SICKOPERATING INSTRUCTIONS | GM700
Subject to change without notice
Document ID
Title: Operating Instructions GM700
Part No.: 8010100/YK22
Release: 2015-12
Described Product
Product name: GM700
Product variant: Measuring probe
Version: V4-0
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Place of Manufacture
SICK AG
Nimburger Str. 11 · D-79276 Reute · Germany
Original Documents
The English version 8010100/YK22 of this document is an original document from
SICK AG.
SICK AG assumes no liability for the correctness of an unauthorized translation.
In case of doubt, contact SICK AG or your local representative.
Legal Information
Subject to change without notice.
© SICK AG. All rights reserved.

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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.
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
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

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CONTENTS
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1 Safety Information...................................................................................10
1.1 Main hazards.................................................................................................10
1.1.1 Electrical safety.............................................................................10
1.1.2 Grounding the device ...................................................................10
1.1.3 Protection against hazards through gases .................................11
1.1.4 Protection against laser radiation................................................12
1.1.5 Behavior during purge air failure .................................................14
1.2 Intended use .................................................................................................14
1.2.1 Purpose of the device...................................................................14
1.3 Responsibility of user....................................................................................14
1.3.1 Disposing of device parts harmful to the environment ..............15
2 Product Overview .....................................................................................16
2.1 Product identification ...................................................................................16
2.2 GM700 system, measuring probe version, layout.......................................17
2.2.1 Measuring probe in detail ............................................................19
2.2.1.1 GMP probe with open measuring gap ......................20
2.2.1.2 GPP gas diffusion probe in dry or wet version .........21
2.2.1.3 GM700 measuring probes in comparison ...............22
2.2.1.4 Special versions ........................................................22
2.3 GM700 options and accessories .................................................................22
2.4 Measuring principle ......................................................................................23
2.4.1 Reference cuvette for wavelength stabilization ..........................23
2.4.2 Signal evaluation ..........................................................................23
3 Project Planning Information.................................................................24
3.1 Work steps from system selection to start-up .............................................24
3.2 Project Planning Checklist ............................................................................24
3.3 Initial onsite installation ...............................................................................27
3.3.1 Installation preparation at the sampling point ............................27
3.3.2 Uncovering the duct......................................................................28
3.3.3 Installing the flanges with tube ....................................................28
3.3.3.1 Installing the flange with tube ..................................29
3.3.4 Installation preparation for the purge air unit (for GMP probe)..30
3.3.5 Duct insulation..............................................................................30
3.3.6 Installation preparation for the evaluation unit ..........................30
3.4 Preparations for electrical installation .........................................................31
3.4.1 Signal and power supply cables...................................................31
3.4.2 CAN bus wiring ..............................................................................33
4 Installation ................................................................................................34
4.1 Preparations ..................................................................................................34
4.1.1 Checking the scope of delivery ....................................................34
4.1.2 Installation prerequisites..............................................................34

CONTENTS
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4.2 Fitting system components .......................................................................... 35
4.2.1 Information on the SR-unit and measuring probe ...................... 35
4.3 Installing the purge air units (for GMP probe)............................................. 35
4.3.1 Terminal box with 24 V power supply unit (option)..................... 35
4.4 Installing the evaluation unit........................................................................ 36
4.4.1 Installing the evaluation unit – sheet metal enclosure version . 36
4.4.2 Installing the evaluation unit – cast-metal enclosure version ... 37
4.5 Electrical connection of system components.............................................. 38
4.5.1 CAN bus wiring options ................................................................ 38
4.5.2 Electrical connection in the evaluation unit EvU ........................ 40
5 Handling the Evaluation Unit ................................................................. 42
5.1 User qualifications........................................................................................ 42
5.2 Operating elements ...................................................................................... 42
5.2.1 Menu overview ............................................................................. 43
6 Start-up...................................................................................................... 46
6.1 Preparations ................................................................................................. 46
6.1.1 Required qualifications and further prerequisites...................... 46
6.2 Start-up steps overview ................................................................................ 46
6.3 Mechanical preparation .............................................................................. 47
6.3.1 Checking the scope of delivery .................................................... 47
6.3.1.1 Transport safety devices .......................................... 47
6.3.2 Fitting the SR-unit on the measuring probe ................................ 48
6.3.3 Electrical connections on the sender/receiver unit.................... 49
6.3.4 Optical alignment ......................................................................... 50
6.3.4.1 Optical alignment for device version for NH3 and
HF measurement ...................................................... 50
6.3.4.2 Optical alignment of device version for HCl
measurement .......................................................... 51
6.3.5 Zero adjust.................................................................................... 52
6.3.5.1 Types of zero point checks....................................... 52
6.3.6 Fitting the weatherproof cover for the SR-unit............................ 54
6.3.7 Evaluation unit start-up................................................................ 56
6.3.8 Operating states ........................................................................... 57
6.3.8.1 Gas connections on the GPP measuring probe for
zero gas and/or test gas .......................................... 57
6.3.9 Starting operating mode .............................................................. 58
7 Maintenance............................................................................................. 60
7.1 Maintenance intervals.................................................................................. 60
7.1.1 Maintenance protocol .................................................................. 60
7.2 Preparation and general preparatory work ................................................. 60
7.3 Maintenance work on SR-unit...................................................................... 61
7.3.1 Visual inspection and enclosure cleaning................................... 61
7.3.2 Cleaning the front window on the SR-unit .................................. 61
7.4 Evaluation unit (EvU) .................................................................................... 62

CONTENTS
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7.5 Controlling and tracking the laser working point during measurement .....63
7.5.0.1 Selecting the ambient temperature range ..............63
7.5.1 Filter box measurement to check the measuring channels for
NH3, HF or HCl ..............................................................................63
7.5.2 Determining the necessary test gas concentration ....................65
7.5.3 Installing the filter box..................................................................65
7.5.4 Carry out filter box measurement ................................................66
7.6 Checking the gas analyzer with test cell GMK10 ........................................68
7.6.1 Installation of the GM700 components with the test cell
GMK10 ..........................................................................................69
7.6.2 Carrying out measurement...........................................................70
8 Troubleshooting and Clearing Malfunctions ........................................73
8.1 Malfunction categories/possible effects .....................................................73
8.2 Purge air failure.............................................................................................73
8.3 Integrated monitoring and diagnosis system ..............................................73
8.3.1 Display and retrieval of messages on the evaluation unit..........74
8.3.2 Troubleshooting and clearing malfunctions, evaluation unit .....75
8.3.3 Error messages .............................................................................76
8.3.4 Warning messages .......................................................................78
8.3.5 Further tips on troubleshooting ...................................................79
9 Technical Data, Expendable and Spare Parts .....................................80
9.1 Technical data GM700 probe system ..........................................................80
9.2 Dimension drawing .......................................................................................85
9.2.1 Dimension drawing sender/receiver unit GM700 (dimensions
in mm) ...........................................................................................85
9.2.2 Dimensions of open measuring probe - GMP..............................86
9.2.3 Dimensions of GPP measuring probes ........................................87
9.2.4 Dimension drawing evaluation unit GM700: Sheet steel
enclosure (dimensions in mm).....................................................88
9.2.5 Dimension drawing evaluation unit GM700: Cast metal
enclosure (dimensions in mm).....................................................88
9.2.6 Connection unit GM700 (Can bus option) (dimensions in mm) .88
9.2.7 Dimensions of weatherproof cover for GM700 SR-unit .............89
9.2.8 Dimension drawings of flange with tube ....................................89
9.3 Accessories, expendable and spare parts ...................................................90
9.3.1 Consumable parts for 2-years operation .....................................90
9.3.2 Spare parts for the sender/receiver unit.....................................90
9.3.3 Spare parts for the measuring probe ..........................................90
9.3.4 Spare parts for the evaluation unit ..............................................92
9.3.5 Fixing accessories.........................................................................92
9.3.6 Spare parts assignment for sender/receiver unit.......................93
10 Annex.........................................................................................................97
10.1 User information “Laser safety” ...................................................................97
10.2 Positioning the probe reflector when the probe must be realigned ...........99

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1SAFETY INFORMATION
1 Safety Information
1.1 Main hazards
Important safety information in short form.
Operational safety
1.1.1 Electrical safety
1.1.2 Grounding the device
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 connections from the power supply
and secure against unauthorized start-up.
WARNING: Hot surfaces when enclosure open
Pay attention to hot surfaces on the measuring cell when opening the GM700
enclosure.
WARNING: Hazard by voltage
▸Pay careful attention to power supply connections.
▸Do not interrupt protective conductor connections.
WARNING: Endangerment of electrical safety by not switching the power
supply off during installation and maintenance work.
An electrical accident can occur when the power supply to the equipment or
the lines is not switched off using a power isolating switch/circuit breaker for
installation and maintenance work.
▸Before starting work on the equipment, ensure the power supply can be
switched off using a power isolating switch/circuit breaker in accordance
with DIN EN 61010.
▸Make sure the power isolating switch is easily accessible.
▸An additional disconnecting device is mandatory when the power isolating
switch is difficult to access or cannot be accessed when connecting the
equipment after installation.
▸After completion of the work or for test purposes, the power supply may
only be activated again by authorized personnel complying with the safety
regulations.
WARNING: Endangerment of electrical safety through power cable with
incorrect rating
When a removable power cable is used, electrical accidents can occur when
the specifications are not fully observed.
▸Always observe the exact specifications in the Operating Instructions
(Technical Data Section) when replacing a removable power cable.
CAUTION: Equipment damage through erroneous or missing grounding
Ensure the protective grounding of the equipment and/or lines involved during
installation and maintenance work in accordance with EN 61010-1.

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SAFETY INFORMATION 1
1.1.3 Protection against hazards through gases
WARNING: Hot and/or aggressive sample gases
▸Wear suitable protective clothing and mask when using hot and/or aggressive
sample gases and/or 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.
WARNING: Toxic and caustic substances in parts in contact with sample gas
●Depending on the sample gas composition, parts of the GM700 in contact with
sample gas can contain toxic or caustic substances.
●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 this cell not only
contains gaseous HF but also a certain amount of liquid (max. 0.1 g HF for 8 cm
cell). 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 protective 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 gluconate 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 gas path of the GM700 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.
WARNING: Risk of fire through hot gas escaping in installations with
overpressure conditions
On installations with overpressure, the purge air hose can be severely
damaged by escaping hot gas and can catch fire depending on the
temperature.
On plants with overpressure as well as gas temperatures over 200°C:
▸Ensure reverse flow is prevented by fitting a (trip) flap or a valve.
▸Regularly check the functionality of the reverse flow safeguard.

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1SAFETY INFORMATION
1.1.4 Protection against laser radiation
The GM700 laser warning sign is located on the sender/receiver unit.
Fig. 1: Laser warning sign on the GM700 sender/receiver unit
Fig. 2: Laser sign for NH3measurement
WARNING: Eye injuries possible due to laser radiation
 Observe all relevant information in these Operating Instructions.
NOTE: Deviations of EN60825-1:2014-08 “Laser safety” from the Directive
2006/25/EC
Due to the Implemented health and safety regulation for artificial optical radiation
concerning the Directive, deviations of EN60825-1:2014-08 “Laser safety” from
Directive 2006/25/EC have occurred.
▸Always observe the user information in the Annex of these Operating Instructions!
“User information “Laser safety””, page 97.
Laser outlet
Laser warning sign