Siemens SIPROCESS GA700 User manual

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Continuous gas analysis
SIPROCESS GA700
Wall-mounted device
Operating Instructions
05/2018
A5E31930403
-06
Introduction
1
Safety instructions
2
General information
3
Description
4
Combined operation
5
Installing the device
6
Installing / removing and
connecting analyzer and
option modules
7
Connecting the device
8
Commissioning
9
Operation
10
Maintenance and servicing
11
Decommissioning,
dismantling and disposal
12
Technical specifications
13
Dimension drawings
14
Appendix
A

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E31930403
Ⓟ05/2018 Subject to change
Copyright © Siemens AG 2013 - 2018.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Table of contents
1 Introduction............................................................................................................................................. 9
1.1 Purpose of this document .........................................................................................................9
1.2 History.......................................................................................................................................9
1.3 Purpose...................................................................................................................................10
1.4 Field of application..................................................................................................................10
1.5 Proper use ..............................................................................................................................11
1.6 Qualified personnel.................................................................................................................11
1.7 Checking delivery....................................................................................................................11
1.8 Transportation and storage.....................................................................................................12
1.9 Warranty conditions ................................................................................................................13
2 Safety instructions................................................................................................................................. 15
2.1 Requirements for safe use......................................................................................................15
2.1.1 Laws and directives ................................................................................................................15
2.1.2 Conformity with European directives ......................................................................................16
2.2 Basic safety instructions .........................................................................................................16
3 General information .............................................................................................................................. 19
3.1 KC Safety note - Information for Korea only...........................................................................19
3.2 Requirements for special applications ....................................................................................19
3.3 Automatic reset .......................................................................................................................20
3.4 Measuring high oxygen concentrations ..................................................................................20
4 Description............................................................................................................................................ 21
4.1 Overview .................................................................................................................................21
4.2 Structure of the wall enclosure ...............................................................................................22
4.3 Device/module identification ...................................................................................................23
4.3.1 Nameplate layout ....................................................................................................................23
4.3.2 Design of module nameplate ..................................................................................................24
4.4 OXYMAT 7..............................................................................................................................25
4.4.1 Module design.........................................................................................................................25
4.4.2 Principle of operation of OXYMAT 7.......................................................................................26
4.4.3 Reference gas monitoring.......................................................................................................28
4.5 ULTRAMAT 7..........................................................................................................................29
4.5.1 Module design.........................................................................................................................29
4.5.2 How the ULTRAMAT 7 works.................................................................................................30
4.5.3 Reference gas monitoring.......................................................................................................32

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4.6 CALOMAT 7........................................................................................................................... 32
4.6.1 Module design........................................................................................................................ 32
4.6.2 How the CALOMAT 7 works .................................................................................................. 33
4.7 Option modules...................................................................................................................... 33
5 Combined operation.............................................................................................................................. 35
5.1 Slots for analyzer modules..................................................................................................... 35
5.2 Operating modes.................................................................................................................... 36
5.2.1 Setting note ............................................................................................................................ 36
5.2.2 Serial/parallel operation ......................................................................................................... 36
5.2.3 Pressure operation/Suction operation ................................................................................... 36
5.2.4 Changing the operating mode................................................................................................ 37
5.3 Gas connections .................................................................................................................... 37
5.4 Application planning............................................................................................................... 41
5.4.1 General safety instructions .................................................................................................... 41
5.4.2 Notes on applications planning .............................................................................................. 42
5.4.3 Operation with at least one OXYMAT 7................................................................................. 42
5.4.4 Operation with at least one ULTRAMAT 7............................................................................. 43
5.4.5 Operation with at least one CALOMAT 7............................................................................... 43
5.4.6 Operation with different analyzer modules ............................................................................ 44
5.4.7 Retrofitting sample gas restrictors ......................................................................................... 45
5.4.8 Enclosure purging .................................................................................................................. 46
5.4.9 Sample gas disposal.............................................................................................................. 47
5.5 Plug & measure permitted activities ...................................................................................... 47
5.5.1 General information ............................................................................................................... 47
5.5.2 Notes on configuration change .............................................................................................. 48
5.5.3 Case differentiations .............................................................................................................. 49
6 Installing the device .............................................................................................................................. 53
6.1 General safety instructions for installation ............................................................................. 53
6.2 Installation instructions........................................................................................................... 55
6.3 Installing the wall-mounted device......................................................................................... 56
7 Installing / removing and connecting analyzer and option modules ........................................................ 59
7.1 General safety instructions for configuration change............................................................. 59
7.2 Wall housing tool.................................................................................................................... 60
7.3 Cables .................................................................................................................................... 60
7.4 Installation of analyzer modules............................................................................................. 62
7.5 Connecting analyzer modules................................................................................................ 64
7.5.1 Wiring OXYMAT 7.................................................................................................................. 64
7.5.2 Connecting the ULTRAMAT 7 ............................................................................................... 65
7.5.3 Connecting CALOMAT 7 ....................................................................................................... 66
7.6 Removal of analyzer modules................................................................................................ 67
7.7 Installing option modules ....................................................................................................... 68
7.7.1 Mounting locations of option modules ................................................................................... 68
7.7.2 Installing option modules ....................................................................................................... 70

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7.7.3 Installing "Options" terminal block ..........................................................................................72
7.8 Wiring option modules ............................................................................................................75
8 Connecting the device........................................................................................................................... 79
8.1 Gas connections .....................................................................................................................79
8.1.1 General safety instructions on gas connection.......................................................................79
8.1.2 Connection information...........................................................................................................80
8.1.3 Installing/removing the sample gas restrictor .........................................................................82
8.1.4 Gas connections at the device................................................................................................83
8.1.4.1 OXYMAT 7..............................................................................................................................83
8.1.4.2 ULTRAMAT 7..........................................................................................................................85
8.1.4.3 CALOMAT 7............................................................................................................................86
8.1.4.4 Purging gas connections ........................................................................................................87
8.1.5 Connecting gas .......................................................................................................................88
8.2 Electrical connections .............................................................................................................88
8.2.1 General safety instructions for electrical connections ............................................................88
8.2.2 Connection information...........................................................................................................90
8.2.3 Requirements for electrical connection...................................................................................91
8.2.4 Connecting the signal cables..................................................................................................92
8.2.5 Connecting the Ethernet cable ...............................................................................................93
8.2.6 Connecting the power supply .................................................................................................95
8.2.7 Electrical connections and terminal assignment.....................................................................96
8.2.8 Spark suppression: This Example ........................................................................................100
9 Commissioning ................................................................................................................................... 103
9.1 General safety instructions for commissioning .....................................................................103
9.2 General information on commissioning ................................................................................105
9.3 Gas preparation ....................................................................................................................107
9.4 OXYMAT 7 / ULTRAMAT 7: Introduction of reference gas ..................................................108
9.4.1 Selection of the reference gas ..............................................................................................108
9.4.1.1 OXYMAT 7............................................................................................................................108
9.4.1.2 ULTRAMAT 7........................................................................................................................109
9.4.2 Requirements for reference gas from the gas cylinder.........................................................110
9.4.3 Introducing reference gas .....................................................................................................110
9.4.4 Check the reference gas flow ...............................................................................................110
9.4.5 Reference gas monitoring with pressure switch ...................................................................111
9.5 Zero point error .....................................................................................................................111
9.5.1 OXYMAT 7............................................................................................................................112
9.5.2 CALOMAT 7..........................................................................................................................114
9.6 Checking gas paths for leaks................................................................................................115
9.6.1 General information on leaks................................................................................................115
9.6.2 Recommended test setup.....................................................................................................116
9.6.3 Checking OXYMAT 7 for leaks .............................................................................................117
9.6.4 Checking ULTRAMAT 7 for leaks.........................................................................................117
9.6.5 Checking CALOMAT 7 for leaks...........................................................................................118
9.7 Requirements for startup ......................................................................................................119
9.8 Commissioning the device....................................................................................................119

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10 Operation.............................................................................................................................................121
11 Maintenance and servicing...................................................................................................................123
11.1 General safety instructions .................................................................................................. 123
11.2 General information on maintenance................................................................................... 125
11.3 Cleaning the device ............................................................................................................. 125
11.4 Maintaining analyzers .......................................................................................................... 125
11.5 Replacing seals.................................................................................................................... 126
11.6 Replacing the basic device .................................................................................................. 128
11.7 Replacing the processing module........................................................................................ 130
11.8 Replacing option modules.................................................................................................... 133
11.9 Replacing the cable gland set.............................................................................................. 134
11.10 Eliminating faults and errors ................................................................................................ 136
12 Decommissioning, dismantling and disposal.........................................................................................137
12.1 Safety instructions for decommissioning ............................................................................. 137
12.2 Decommissioning the device ............................................................................................... 138
12.3 Dismantling the device......................................................................................................... 139
12.4 Disposing of the device........................................................................................................ 139
12.5 Information on recycling....................................................................................................... 139
13 Technical specifications .......................................................................................................................141
13.1 Determining the technical specifications.............................................................................. 141
13.2 Technical specifications of the wall housing ........................................................................ 141
13.3 Technical specifications of analyzer modules...................................................................... 143
13.3.1 OXYMAT 7 technical specifications ..................................................................................... 143
13.3.2 Technical data ULTRAMAT 7 .............................................................................................. 148
13.3.3 CALOMAT 7 technical specifications................................................................................... 151
14 Dimension drawings.............................................................................................................................155
A Appendix .............................................................................................................................................157
A.1 Conformity with European directives ................................................................................... 157
A.2 Certificate ............................................................................................................................. 158
A.3 Abbreviations ....................................................................................................................... 158
A.4 References........................................................................................................................... 159
A.5 Spare parts/accessories ...................................................................................................... 161
A.5.1 Notes.................................................................................................................................... 161
A.5.2 Spare parts wall-mounted device......................................................................................... 162
A.5.3 Spare parts OXYMAT 7 ....................................................................................................... 164
A.5.4 Spare parts ULTRAMAT 7 ................................................................................................... 168
A.5.5 Spare parts CALOMAT 7 ..................................................................................................... 174

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A.6 Technical support..................................................................................................................175
A.7 Return procedure ..................................................................................................................176
Index................................................................................................................................................... 177

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8
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Introduction
1
1.1
Purpose of this document
These operating instructions include all the necessary information on the operating principle
and the safe usage of the device. These are instructions on the mounting, commissioning,
operation, servicing, decommissioning and dismantling of the device.
These operating instructions are intended for qualified personnel who have been instructed
in all work on a device in non-hazardous areas and in possible dangers arising from
improper conduct and who have been trained.
It is your responsibility to read the operating instructions thoroughly and understand them
before beginning work. To ensure correct handling, become acquainted with the principle of
operation of the device.
The operating instructions belong to the device. Keep them in the direct vicinity of the device
1.2
History
The following table includes information on the different editions of this document.
Table 1- 1 History
Edition
Comment
01/2013 First edition
05/2014 Expansion option modules OM 1.1 and OM 2.2 (analog inputs, digital inputs, digital out-
puts), corrections
05/2015 Extension for analyzer modules CALOMAT 7 and ULTRAMAT 7
03/2016 Additional module combinations for CALOMAT 7 and ULTRAMAT 7.
Extended ULTRAMAT 7 area of application: measurement of components NO, N2O,
SO
2
, CH
4
, C
2
H
4
, NH
3
06/2017 ULTRAMAT 7: Measurement of two components simultaneously.
Corrosion resistant versions of ULTRAMAT 7 and OXYMAT 7
Cleaned for O2: Variants with specially cleaned gas path for sample gases with high
oxygen content
05/2018 Wall-mounted device: Expansion with high-temperature OXYMAT 7 and ULTRAMAT 7
analyzer modules.
Extending and updating the document

Introduction
1.3 Purpose
10
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Operating Instructions, 05/2018, A5E31930403-06
1.3
Purpose
The device is designed for the concentration analysis of gases in gas mixtures. Depending
on the installed analyzer module, different gases can be examined.
Use the device only for measuring/analysis of gas concentrations in gas mixtures according
to the information in section "Technical specifications (Page 141)".
Note
This device meets the requirements of NAMUR Recommendation 53.
Note
Use in home environment
This equipment of Class A Group 1 is intend
ed solely for use in industrial areas.
If used in homes, the device may cause radio interference.
Note
For more information on the compatibility of the hardware and firmware, refer to:
Siemens Industry Online Support (
https://support.industry.siemens.com/cs/en/en/ps/17731).
You will find more information in the operating instructions, see
"References (Page 159)".
1.4
Field of application
These operating instructions only describe
non
explosion-proof SIPROCESS GA700 wall-
mounted devices. You can find information about explosion-poof SIPROCESS GA700
devices please in the compact operating instructions "Devices in explosion-proof designs",
see "Table A-6 References 5 - Compact Operating Instructions Ex (Page 160)".
A SIPROCESS GA700 wall-mounted device consists of an enclosure for wall mounting into
which up to two replaceable analysis modules can be inserted. The analyzer modules are
selected according to the measuring task and local conditions.
The following analyzer modules are available for wall-mounted devices:
●Standard analyzer modules OXYMAT 7, ULTRAMAT 7 and CALOMAT 7, up to two
analyzer modules per wall-mounted device possible
●Heated analyzer modules OXYMAT 7 and ULTRAMAT 7; only one analyzer module per
wall-mounted device possible.

Introduction
1.5 Proper use
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The following table provides an overview of the device versions:
Table 1- 2 SIPROCESS GA700 device with analyzer modules
Device variants
MLFB number1)
Basic device:
Wall-mounted device 7MB3000-3****-****
7MB3000-4****-****
Analyzer modules, standard version:
OXYMAT 7 7MB3020-0***0-*AA*
ULTRAMAT 7
7MB3010-0****-0A**
CALOMAT 7
7MB3040-0****-0***
Analyzer modules, high-temperature version:
High temperature OXYMAT 7
7MB3020-1***0-*AA*
High temperature ULTRAMAT 7
7MB3010-1****-0A**
1) Machine-readable product designation
1.5
Proper use
Proper use within the context of this manual means that the product may be used only for
the applications described in the catalog or the technical description, and only in combination
with the equipment, components and devices of other manufacturers recommended or
approved by Siemens.
1.6
Qualified personnel
Persons who install, connect, commission, operate, service, maintain and disassemble the
device must have the following specific qualifications:
●They are authorized and trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures and
corrosive as well as hazardous media.
●They are trained or instructed in the maintenance and use of appropriate safety
equipment according to the pertinent safety regulations.
1.7
Checking delivery
1. Check the packaging and the device for visible damage caused by inappropriate handling
during shipping.
2. Report any claims for damages immediately to the shipping company.
3. Retain the damaged parts until clarification.

Introduction
1.8 Transportation and storage
12
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Operating Instructions, 05/2018, A5E31930403-06
4. Check the scope of delivery for correctness and completeness on the basis of the
delivery note. Compare the serial numbers on the delivery note with the serial numbers
on the basic device or on the analyzer modules.
5. Check whether the package includes the following items:
–CD-ROM "Manual Collection" CD-ROM "Manual Collection"
–This printed copy of the Compact Operating Instructions (not with loose delivery).
Note
Installation of analyzer modules
The analyzer module is only installed in the basic device
at the factory if you select the
options "D00 to D99" when ordering an analyzer module.
If you do not specify the module assignment/installation location during the ordering process,
the analyzer module is delivered separately from the basic device ("sepa
rate delivery").
If the analyzer module is delivered separately, you must install it in the basic device yourself.
Information on this point is only available in the Operating Instructions of the unit,
see
"References (Page 159)".
See also
Installing / removing and connecting analyzer and option modules (Page 59)
1.8
Transportation and storage
To ensure sufficient protection during transport and storage, observe the following:
●Keep the original packaging for subsequent transportation.
●Devices/replacement parts should be returned in their original packaging.
●If the original packaging is no longer available, please ensure that all shipments are
sufficiently protected during transport by the replacement packaging. The manufacturer
accepts no liability for additional costs resulting from damage during transportation.
●Store the device in a dry place, vibration-free and horizontal.
Note
Insufficient protection during storage
The packaging only provides limited protection against moisture and infiltration.
•
Provide additional packaging as necessary.
Special conditions for storage and transportation of the device are listed in section
"Technical specifications (Page 141)".

Introduction
1.9 Warranty conditions
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1.9
Warranty conditions
We expressly point out that the product quality is exclusively and conclusively described in
the sales contract. The content of this product documentation is neither a part of a previous
or existing agreement, promise or legal relationship, nor is it intended to modify these. All
obligations on the part of Siemens AG are contained in the respective sales contract, which
also contains the complete and solely applicable liability provisions. The provisions defined
in the sales contract for the responsibility for defects are neither extended nor limited by the
remarks in this document.

Introduction
1.9 Warranty conditions
14
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Safety instructions
2
2.1
Requirements for safe use
In terms of safety, this device left the factory in perfect condition. In order to maintain this
status and to ensure safe operation of the device, observe these operating instructions and
all the information relevant to safety.
Observe the information and symbols on the device. Do not remove any information or
symbols from the device. Always keep the information and symbols in a completely legible
state and renew it, if necessary.
Symbol
Description
Consult operating instructions
Hot surface
Dangerous electrical voltage
2.1.1
Laws and directives
Observe the test certification, provisions and laws applicable in your country during
connection, assembly and operation in the respectively valid version. These include, for
example:
●National Electrical Code (NEC - NFPA 70) (USA)
●Canadian Electrical Code (CEC) (Canada)
Additional information is available at:
Certificate (Page 158)

Safety instructions
2.2 Basic safety instructions
16
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2.1.2
Conformity with European directives
The CE marking on the device shows conformity with the regulations of the following
European guidelines:
Electromagnetic compatibil
i
ty
EMC 2014/30
/EU
Directive of the European Parliament and of the Council
of 26 February 2014 on the harmonization of the laws of the
Member States relating to electromagnetic compatibility (new
version)
Low voltage directive LVD
2014/35/EU
Directive of the European
Parliament and of the Council of 26
February 2014 on the harmonization of the laws of the Me
m
ber
States relating to the making available on the market of electr
i-
cal equipment designed for use within certain voltage limits
(new version)
Atmosphère explosi
ble
ATEX 2014/34/EU
Directive of the European Parliament and of the Council of 26
February 2014 on the harmonization of the laws of the Me
m
ber
States relating to equipment and protective systems i
ntended
for use in potentially explosive atmospheres (new version)
Restriction of certain
Hazardous Substances
RoHS 2011/65/EU
Directive of the European Parliament and of the Council
of 8 June 2011 on the restriction of the use of certain hazar
d-
ous substances in electrical and electronic equipment (new
version)
The standards applied can be found in the EU Declaration of Conformity for the associated
device.
2.2
Basic safety instructions
WARNING
Introduction of combustible gases
Explosion hazard
Devices in standard version are not designed for use in hazardous areas.
•Do not use a standard version of the analyzer in hazardous areas.
•Supply gases with flammable components at concentrations above the lower explosion
limit (LEL) only in devices with pipes.

Safety instructions
2.2 Basic safety instructions
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WARNING
Device modifications
Danger to personnel, system and the environment can result from modifications and repairs
to the device.
•
Only carry out modifications or repairs that are described in the operating instructions for
the device.
•Failure to observe this requirement cancels the manufacturer's warranty and the product
approvals.
WARNING
Faults in the process resulting from incorrectly displayed measured values
An incorrectly displayed measured value can result in misinterpretations or faults in the
process.
Take appropriate measures to guarantee a fault-free process.

Safety instructions
2.2 Basic safety instructions
18
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General information
3
3.1
KC Safety note - Information for Korea only
Class A Equipment (Industrial Broadcasting & Communication Equipment)
This equipment is Industrial (Class A) electromagnetic wave suitability equipment and seller
or user should take notice of it, and this equipment is to be used in the places except for
home.
MSIP 요구사항 - For Korea only
A급기기(업무용 방송통신기자재)
이 기기는 업무용(A급) 전자파 적합기기로서 판매자 또는 사용자는 이점을 주의하시기
바라며, 가정 외의 지역에서 사용하는것을 목적으로 합니다.
3.2
Requirements for special applications
Due to the number or possible applications, this document does not include all detailed
information on the described device versions. This means not every possible scenario for
commissioning, operating, maintenance or operation in plants is taken into consideration.
Should you require additional information which is not included in these instructions, please
contact your local SIEMENS office or your SIEMENS partner.
Note
Operation under special ambient conditions
If you want to use the device under special ambient conditions, for example, in nuclear
power plants or for research and development pur
poses,
we recommend:
First contact your local SIEMENS partner or our application department. Explain the specific
application and clarify the operating conditions.

General information
3.3 Automatic reset
20
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3.3
Automatic reset
All SIPROCESS GA700 devices feature internal monitoring. When this monitoring is
activated, the standard digital outputs switch after about 4 seconds for a period of approx. 60
seconds to "inactive", i.e. to a recognized safe operating mode. These times are valid for
devices manufactured as of 09/2017. You can find this information on the nameplate. It can
take up to 10 seconds for older devices to switch over, and up to 100 seconds to switch to
safe operating mode.
If you are using SIPROCESS GA700 devices in critical processes, observe the following
information:
●Monitor the limits externally via the control system.
●If an option module 2.1 is installed,
read out the device status via the digital outputs of the
option module.
●Use an available manual measuring range switchover instead of the autoranging.
●Only use the "Total" parameter with the "Off" setting for the measuring range switchover.
●If you use the "Correction of cross-interference" and "External pressure compensation"
functions, store suitable substitute values.
●Only access the measured value via an analog output.
3.4
Measuring high oxygen concentrations
Note
Measuring high oxygen concentrations
For the measurement of high O
2concentrations in excess of 25%, it is absolutely necessary
that all parts that come in contact with the sample gas are free
of oil and grease and do not
contain any particles that could react with O
2.
We highly recommend you use specially cleaned analyzer modules with the "Cleaned for
O2" option for such measurements.