Siemens SIPROCESS GA700 User manual

Rack-mounted device
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Continuous gas analysis
SIPROCESS GA700
Rack-mounted device
Operating Instructions
01/2013
A5E31874006-01
Introduction
1
General safety instructions
2
Description
3
Application planning
4
Installing the analyzer
modules and option module
5
Installing the device
6
Connecting
7
Operation
8
Commissioning
9
Maintenance and service
10
Technical specifications
11
Dimension drawings
12
Spare parts/accessories
13
Appendix
A
ESD guidelines
B
Abbreviations
C

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E31874006
Ⓟ 02/2013 Technical data subject to change
Copyright © Siemens AG 2013.
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.

Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 3
Table of contents
1 Introduction................................................................................................................................................ 7
1.1 Purpose of this document ..............................................................................................................7
1.2 Notes on warranty..........................................................................................................................7
2 General safety instructions ........................................................................................................................ 9
2.1 Proper use......................................................................................................................................9
2.2 Prerequisites for safe use ..............................................................................................................9
2.3 Device modifications ......................................................................................................................9
2.4 Laws and directives .....................................................................................................................10
2.5 Conformity with European directives ...........................................................................................10
2.6 Qualified personnel ......................................................................................................................11
3 Description............................................................................................................................................... 13
3.1 Design..........................................................................................................................................14
3.1.1 Nameplate layout .........................................................................................................................15
3.1.2 OXYMAT 7...................................................................................................................................16
3.1.3 Design of module nameplate .......................................................................................................17
3.2 Essential characteristics ..............................................................................................................18
3.2.1 OXYMAT 7...................................................................................................................................18
3.3 Functional principles ....................................................................................................................19
3.3.1 OXYMAT 7...................................................................................................................................19
3.4 Reference gas monitoring, OXYMAT 7 .......................................................................................21
3.4.1 Reference gas monitoring with pressure switch ..........................................................................21
4 Application planning................................................................................................................................. 23
4.1 Operation with at least one OXYMAT 7.......................................................................................24
5 Installing the analyzer modules and option module ................................................................................. 27
5.1 Tools ............................................................................................................................................27
5.2 Safety notes for installation..........................................................................................................27
5.3 Installation of the analyzer modules ............................................................................................28
5.3.1 Device expansion by a second analyzer module.........................................................................28
5.3.2 OXYMAT 7...................................................................................................................................28
5.3.3 Parameter assignment.................................................................................................................31
5.4 Installing the option module OM 2.1 ............................................................................................32
5.5 Cabling.........................................................................................................................................34

Table of contents
Rack-mounted device
4 Operating Instructions, 01/2013, A5E31874006-01
6 Installing the device ................................................................................................................................. 35
6.1 Safety instructions for installation ............................................................................................... 35
6.2 Notes on installation.................................................................................................................... 36
6.3 Installing ...................................................................................................................................... 37
7 Connecting .............................................................................................................................................. 39
7.1 Safety notes for connection......................................................................................................... 39
7.2 Electrical connection of the power supply................................................................................... 39
7.3 Connection of the signal lines ..................................................................................................... 41
7.4 Electrical connections, pin assignment ....................................................................................... 42
7.5 Gas connections ......................................................................................................................... 44
8 Operation................................................................................................................................................. 47
8.1 Operation..................................................................................................................................... 47
9 Commissioning ........................................................................................................................................ 49
9.1 General information..................................................................................................................... 50
9.2 OXYMAT 7 .................................................................................................................................. 51
9.2.1 Selection of the reference gas .................................................................................................... 51
9.2.2 Reference gases ......................................................................................................................... 51
9.2.3 Zero point error ........................................................................................................................... 52
9.2.4 Introducing reference gas ........................................................................................................... 54
9.2.5 Reference gas from the gas cylinder .......................................................................................... 54
9.2.6 Checking the reference gas flow................................................................................................. 54
9.2.7 Sample gas inlet conditions ........................................................................................................ 54
9.2.8 Checking the sample gas path for leaks ..................................................................................... 55
10 Maintenance and service......................................................................................................................... 57
10.1 Safety instructions for maintenance............................................................................................ 57
10.2 Instructions for maintenance....................................................................................................... 58
10.3 Replace basic device .................................................................................................................. 58
10.4 Replacing the processing unit..................................................................................................... 59
10.5 Errors........................................................................................................................................... 61
10.6 Return procedure ........................................................................................................................ 62
11 Technical specifications........................................................................................................................... 63
11.1 Technical specifications .............................................................................................................. 63
11.2 OXYMAT 7 technical specifications ............................................................................................ 65
12 Dimension drawings ................................................................................................................................ 71
13 Spare parts/accessories .......................................................................................................................... 73
13.1 Spare parts list for rack-mounted housing .................................................................................. 73
13.2 Spare parts list OXYMAT 7......................................................................................................... 74

Table of contents
Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 5
A Appendix.................................................................................................................................................. 75
A.1 Certificate.....................................................................................................................................75
A.2 Literature and catalogs ................................................................................................................75
A.3 Technical support.........................................................................................................................76
B ESD guidelines ........................................................................................................................................ 77
B.1 ESD Guidelines............................................................................................................................77
C Abbreviations........................................................................................................................................... 79
C.1 Abbreviations ...............................................................................................................................79
Glossary .................................................................................................................................................. 81
Index........................................................................................................................................................ 83
Tables
Table C- 1 Units .............................................................................................................................................79
Table C- 2 Other abbreviations......................................................................................................................79

Table of contents
Rack-mounted device
6 Operating Instructions, 01/2013, A5E31874006-01
Figures
Figure 3-1 Rack-mounted housing ................................................................................................................14
Figure 3-2 Structure of high-pressure version, sample gas path with pipes .................................................16
Figure 3-3 Module nameplate........................................................................................................................17
Figure 3-4 Principle of operation of OXYMAT 7 ............................................................................................19
Figure 5-1 Installation of OXYMAT 7.............................................................................................................29
Figure 5-2 AM PCB interfaces.......................................................................................................................30
Figure 5-3 Installation of option module OM 2.1 ...........................................................................................32
Figure 5-4 Connecting option module OM 2.1 to analyzer modules 1 and 2 using example of
OXYMAT 7 ...................................................................................................................................33
Figure 5-5 Cabling of OM2.1 with AM1 and AM2..........................................................................................33
Figure 5-6 Cabling example ..........................................................................................................................34
Figure 6-1 Dimension drawing.......................................................................................................................37
Figure 7-1 Electrical connection ....................................................................................................................40
Figure 7-2 Example of rear panel with OXYMAT 7, connecting the signal lines...........................................41
Figure 7-3 Pin assignments of processing unit .............................................................................................42
Figure 7-4 Pin assignments of option module 2.1.........................................................................................43
Figure 7-5 Example rack-mounted device, rear panel ..................................................................................45
Figure 10-1 Cabling .........................................................................................................................................59
Figure 12-1 Dimension drawings of rack-mounted housing............................................................................71
Figure B-1 Electrostatic voltages which an operator can be subjected to.....................................................78

Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 7
Introduction 1
1.1 Purpose of this document
This instruction manual contains all information that you will require to commission and use
the device.
It is intended for persons who assemble the device mechanically, connect it electrically, and
commission it.
1.2 Notes on warranty
The contents of this manual shall not become part of or modify any prior or existing
agreement, commitment or legal relationship. All obligations on the part of Siemens AG are
contained in the respective sales contract, which also contains the complete and solely
applicable warranty conditions. Any statements on the device versions described in the
manual do not create new warranties or modify the existing warranty.
The contents reflect the technical status at the time of printing. We reserve the right to make
technical changes in the course of further development.

Introduction
1.2 Notes on warranty
Rack-mounted device
8 Operating Instructions, 01/2013, A5E31874006-01

Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 9
General safety instructions 2
2.1 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 (see also the chapter
Description (Page 13) in this manual), and only in combination with the equipment and
components of other manufacturers recommended or permitted by Siemens.
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.
2.2 Prerequisites 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 instructions and all the
specifications 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.
2.3 Device modifications
WARNING
Device modifications
Modifications to the device can result in danger to personnel, plant and environment. Only
carry out changes that are described in the instructions for the device.

General safety instructions
2.4 Laws and directives
Rack-mounted device
10 Operating Instructions, 01/2013, A5E31874006-01
2.4 Laws and directives
The failure to observe directives and laws when connecting and mounting increases the
danger of explosion and leakage due to improper handling. When connecting and installing,
follow only the test certifications, stipulations and laws applicable in your country in order to
avoid danger.
2.5 Conformity with European directives
The manufacturer of the gas analyzers listed below is authorized to provide the respective
labels with a CE marking:
Gas analyzers SIPROCESS GA700
Types 7M83000-abcd0-eAA0
•a = 0, 3
•b = X, D
•c = X, D
•d = 0, 6
•e = 0, 2
The version of the identified product sold by the manufacturer conforms with the directives of
the following European guidelines:
2004/108/EC
EMC
Directive of the European Parliament and of the Council on the
harmonization of the laws of the Member States relating to
electromagnetic compatibility and repealing Directive 89/336/EEC.
2006/95/EC
LVD
Directive of the European Parliament and of the Council on the
harmonization of the laws of Member States relating to electrical
equipment designed for use within certain voltage limits.
Conformity with the specified directives is proven through adherence to the following
standards (depending on the version):
Directive Standard Edition
2004/108/EC EN 61326-1* 2006
2006/95/EC EN 61010-1 2010
* " all environments included"
The declaration of conformity is present on the data medium supplied with the product.

General safety instructions
2.6 Qualified personnel
Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 11
2.6 Qualified personnel
Qualified personnel are people who are familiar with the installation, mounting,
commissioning, and operation of the product. These people have the following qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures and
aggressive as well as dangerous media.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the safety regulations.

General safety instructions
2.6 Qualified personnel
Rack-mounted device
12 Operating Instructions, 01/2013, A5E31874006-01

Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 13
Description 3
General
The rack-mounted device has a modular structure. It consists of a rack-mounted housing
and at least one analyzer module. It may also contain an option module.
These operating instructions describe only non-explosion-proof devices.
Definition of terms
● Rack-mounted housing, basic unit: this includes the metal enclosure with local user
interface, built-in processing unit (PU), and power supply unit. It is prepared for
installation of the analyzer and option modules.
● Rack-mounted device: this includes a rack-mounted housing (basic unit) with at least one
analyzer module (AM) installed.

Description
3.1 Design
Rack-mounted device
14 Operating Instructions, 01/2013, A5E31874006-01
3.1 Design
1
2
76
5
3
4
① Power supply unit ⑤Door
② Processing unit ⑥Keyboard
③ Mounting location AM1 ⑦Display
④ Mounting location AM2
Figure 3-1 Rack-mounted housing

Description
3.1 Design
Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 15
● The device is fastened, for example, in a cabinet or frame with four screws, see Installing
(Page 37).
● The front panel is equipped with a display ⑦, a keypad ⑥, and a removable door ⑤.
The door can be opened for maintenance purposes by loosening the screw, see Tools
(Page 27).
Note
Tightening the screw
Tighten the screw on the door with a torque of
•0.7 Nm
● The device has space for the installation of two option modules and two analyzer
modules AM1 ③ and AM2 ④. The power supply unit ① and the processing unit ② are
located on the left.
3.1.1 Nameplate layout



① Order number ② Serial number
③ Development stage
The nameplate with the order number and other important information is located on the left
of the housing exterior.

Description
3.1 Design
Rack-mounted device
16 Operating Instructions, 01/2013, A5E31874006-01
3.1.2 OXYMAT 7






① Reference gas inlet ⑤ Power supply 24 V
② n.c. ⑥ Analog current output, digital output
③ Sample gas outlet ⑦ CAN connection
④ Sample gas inlet
Figure 3-2 Structure of high-pressure version, sample gas path with pipes
Note
Condensation in the analyzer module
Use a sample gas cooler that reduces the dew point of the sample gas to the extent that the
gas in the analyzer does not condense. The internal sample gas paths are not heated; the
measuring chamber is regulated to 72 °C.

Description
3.1 Design
Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 17
3.1.3 Design of module nameplate








① Module version OXYMAT OXYMAT ANALYZER MODULE
② Order number
③ Order no. suffix
④ Serial number
⑤ Development stage
⑥ Measuring range 1 OXYMAT O2 0-0.5/100%
⑦ Measuring range 2 To be
determined
⑧ Measuring range 3 To be
determined
Figure 3-3 Module nameplate
The module nameplate with the order no. and other important information is located below
the gas connections on the module exterior.

Description
3.2 Essential characteristics
Rack-mounted device
18 Operating Instructions, 01/2013, A5E31874006-01
3.2 Essential characteristics
3.2.1 OXYMAT 7
● Depending on the reference gas, the physical zero point can be set between 0% and
100% oxygen
● Measuring range identification
● Electrically isolated measured value output 0/2/4 to 20 mA (also inverted)
● Storage of measured values possible during calibration
● Short response time
● Low long-term drift
● Internal pressure sensor for correction of pressure variations in sample gas in the range
from 500 to 2500 hPa (absolute)
● Monitoring of sample gas and reference gas (option)
● Smallest measuring spans (up to 0.5% O2) possible
● Vibration compensation as option
● Suitable for use with corrosive sample gases
● Hardware adapted to application

Description
3.3 Functional principles
Rack-mounted device
Operating Instructions, 01/2013, A5E31874006-01 19
3.3 Functional principles
3.3.1 OXYMAT 7
5
4
2
1
3
6
9
1
11
10
2
7 8
2

2

2

2

2

2

① Reference gas inlet ⑦ Paramagnetic measurement effect
② Restrictors ⑧ Electromagnet with alternating current strength
③ Reference gas channels ⑨ Sample gas and reference gas outlet
④ Microflow sensor ⑩ Microflow sensor in the vibration compensation system
(flow-type)
⑤ Sample gas inlet ⑪ Vibration compensation system (optional)
⑥ Measuring chamber
Figure 3-4 Principle of operation of OXYMAT 7

Description
3.3 Functional principles
Rack-mounted device
20 Operating Instructions, 01/2013, A5E31874006-01
In contrast to other gases, oxygen is highly paramagnetic. This physical property is used to
determine oxygen concentration in gases.
Oxygen molecules in an inhomogeneous magnetic field always move toward the higher field
strength. This results in a higher oxygen concentration where the field strength is higher
(higher oxygen partial pressure). If two gases with differing oxygen content are combined in
a magnetic field, a partial pressure difference arises between them. The measuring effect is
therefore always based on the difference in the oxygen content of the two gases. The two
gases are referred to as the sample gas and the reference gas.
To measure oxygen in the OXYMAT 7, the reference gas (nitrogen, air or oxygen) flows
through two reference gas channels ③ into the measuring chamber ⑥. One of these partial
flows enters the measuring chamber in the area of the magnetic field ⑦. If the sample gas
contains no oxygen, the reference gas can flow freely into the measuring chamber. If the
sample gas does contain oxygen, the oxygen molecules concentrate in the area of the
magnetic field. The reference gas can then no longer flow freely into the measuring
chamber. There is a slight build-up of dynamic pressure, which depends on the
concentration of oxygen in the sample gas. In an oscillating magnetic field, oscillating
pressure is also generated and this results in alternating flow. This alternating flow is
converted into an alternating current signal by two microflow sensors ④ located between the
reference gas channels ③.
The microflow sensors consist of two nickel-plated grids each, which are arranged together
with two further nickel-plated grids to form a measuring bridge. The alternating flow results in
a change in the resistance of the nickel-plated grids. The resulting offset in the bridge is a
measure of the concentration of oxygen in the sample gas.
The microflow sensors ④ are surrounded by reference gas. This arrangement protects them
from corrosion by the sample gas.
Vibrations at the installation site can interfere with the measured signal (e.g. large
fluctuations in the output signal). This behavior can be compensated by two further (optional)
microflow sensors ⑩, which function as a vibration sensor.