Siemens SIPROCESS GA700 User manual

Continuous gas analysis
SIPROCESS GA700
Rack-mounted device
Operating Instructions
05/2015
A5E31874006-03
Introduction 1
General safety instructions 2
Description 3
Application planning 4
Installing/removing modules
in the rack-mounted
enclosure 5
Installing the device 6
Connecting 7
Operation 8
Commissioning 9
Maintenance and service 10
Technical specifications 11
Dimension drawings 12
Appendix A

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.
Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E31874006
Ⓟ 07/2015 Subject to change
Copyright © Siemens AG 2013 - 2015.
All rights reserved

Table of contents
1 Introduction.................................................................................................................................................11
1.1 Purpose of this document......................................................................................................11
1.2 History....................................................................................................................................12
1.3 Notes on warranty..................................................................................................................13
1.4 Environmentally friendly use of resources.............................................................................14
1.5 Conventions...........................................................................................................................15
2 General safety instructions.........................................................................................................................17
2.1 Proper use..............................................................................................................................17
2.2 Prerequisites for safe use......................................................................................................18
2.3 Device modifications..............................................................................................................19
2.4 Laws and directives................................................................................................................20
2.5 Conformity with European directives......................................................................................21
2.6 Qualified personnel................................................................................................................22
2.7 Automatic reset......................................................................................................................23
3 Description..................................................................................................................................................25
3.1 Overview................................................................................................................................25
3.2 Rack-mounted housing..........................................................................................................26
3.3 Device/module identification..................................................................................................27
3.3.1 Nameplate layout...................................................................................................................27
3.3.2 Design of module nameplate.................................................................................................27
3.4 OXYMAT 7.............................................................................................................................29
3.4.1 Principle of operation of OXYMAT 7......................................................................................30
3.4.2 Reference gas monitoring OXYMAT 7...................................................................................31
3.4.2.1 Reference gas monitoring with pressure switch.....................................................................32
3.5 ULTRAMAT 7.........................................................................................................................33
3.5.1 How the ULTRAMAT 7 works................................................................................................34
3.5.2 Reference gas monitoring......................................................................................................35
3.6 CALOMAT 7...........................................................................................................................37
3.6.1 How the CALOMAT 7 works..................................................................................................38
3.7 Combined operation...............................................................................................................39
3.7.1 Analyzer module/installation location combinations...............................................................39
3.7.1.1 Safety instruction(s)...............................................................................................................39
3.7.2 Operating modes....................................................................................................................42
3.7.2.1 Setting instructions.................................................................................................................42
3.7.2.2 Operating modes: Selection of operating mode.....................................................................43
3.7.3 Gas connections....................................................................................................................43
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3.7.3.1 Safety instruction(s)...............................................................................................................43
3.7.3.2 Sample gas restrictors/clamping screws................................................................................45
3.7.3.3 Conditions for use/installation................................................................................................48
3.7.4 Plug & measure permitted activities.......................................................................................51
3.7.4.1 Plug & measure......................................................................................................................51
3.7.4.2 Setting instructions.................................................................................................................52
3.7.4.3 Case differentiations..............................................................................................................53
3.8 Option modules......................................................................................................................56
4 Application planning...................................................................................................................................57
4.1 Notes on applications planning..............................................................................................57
4.2 Operation with at least one OXYMAT 7.................................................................................59
4.3 Operation with at least one ULTRAMAT 7.............................................................................61
4.4 Operation with at least one CALOMAT 7...............................................................................62
4.5 Dispose of sample gas through an exhaust gas line..............................................................63
5 Installing/removing modules in the rack-mounted enclosure......................................................................65
5.1 Safety instructions..................................................................................................................65
5.2 Rack-mounted housing tool...................................................................................................67
5.3 Cables....................................................................................................................................68
5.4 Installing/removing analyzer modules....................................................................................70
5.4.1 Note on installation / connecting up.......................................................................................70
5.4.2 Installation of the analyzer module.........................................................................................71
5.4.3 Wiring OXYMAT 7..................................................................................................................72
5.4.4 Connecting the ULTRAMAT 7................................................................................................73
5.4.5 Connecting CALOMAT 7........................................................................................................74
5.4.6 Removing an analyzer module...............................................................................................75
5.5 Installing option modules........................................................................................................76
5.5.1 Mounting locations of option modules....................................................................................76
5.5.2 Installing option modules........................................................................................................77
5.5.3 Wiring option modules............................................................................................................78
6 Installing the device....................................................................................................................................79
6.1 Safety information..................................................................................................................79
6.2 Installing.................................................................................................................................81
7 Connecting.................................................................................................................................................83
7.1 Electrical connections............................................................................................................83
7.1.1 Note on safety........................................................................................................................83
7.1.2 Connecting the power supply.................................................................................................83
7.1.3 Connection of the signal lines................................................................................................85
7.1.4 Electrical connections, pin assignment..................................................................................86
7.1.5 Spark suppression: Example.................................................................................................89
7.2 Gas connections....................................................................................................................92
7.2.1 Restrictors/clamping screws..................................................................................................92
7.2.1.1 Safety instructions..................................................................................................................92
7.2.1.2 Installation/removal of restrictors...........................................................................................93
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7.2.2 OXYMAT 7.............................................................................................................................94
7.2.3 ULTRAMAT 7.........................................................................................................................96
7.2.4 CALOMAT 7...........................................................................................................................97
8 Operation....................................................................................................................................................99
9 Commissioning.........................................................................................................................................101
9.1 Safety instructions................................................................................................................101
9.2 Gas preparation...................................................................................................................103
9.3 OXYMAT 7...........................................................................................................................104
9.3.1 Selection of the reference gas.............................................................................................104
9.3.2 Reference gases..................................................................................................................104
9.3.3 Zero point error....................................................................................................................105
9.3.4 Introduction of reference gas...............................................................................................107
9.3.5 Reference gas from the gas cylinder...................................................................................107
9.3.6 Checking the reference gas flow..........................................................................................108
9.3.7 Sample gas inlet conditions.................................................................................................108
9.3.8 Checking the sample gas path for leaks..............................................................................108
9.4 ULTRAMAT 7.......................................................................................................................110
9.4.1 Sample gas inlet conditions.................................................................................................110
9.4.2 Flow-type reference gas compartment.................................................................................110
9.4.3 Interference gases/zero point error......................................................................................111
9.4.4 Checking the sample gas and reference gas path for leakage............................................111
9.5 CALOMAT 7.........................................................................................................................113
9.5.1 Zero point error....................................................................................................................113
9.5.2 Sample gas inlet conditions.................................................................................................114
9.5.3 Checking the sample gas path for leaks..............................................................................114
10 Maintenance and service..........................................................................................................................115
10.1 Safety instructions................................................................................................................115
10.2 Cleaning the device..............................................................................................................117
10.3 Replace basic device...........................................................................................................118
10.4 Replacing the processing unit..............................................................................................119
10.5 Replacing option modules....................................................................................................121
10.6 Errors...................................................................................................................................122
11 Technical specifications............................................................................................................................123
11.1 Determining the technical specifications .............................................................................123
11.2 Technical specifications of rack-mounted housing...............................................................124
11.3 Technical specifications of analyzer modules......................................................................126
11.3.1 OXYMAT 7 technical specifications ....................................................................................126
11.3.2 Technical data ULTRAMAT 7..............................................................................................129
11.3.3 CALOMAT 7 technical specifications...................................................................................132
12 Dimension drawings.................................................................................................................................135
A Appendix...................................................................................................................................................137
A.1 ESD Guidelines....................................................................................................................137
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A.2 Abbreviations.......................................................................................................................139
A.3 References...........................................................................................................................141
A.4 Technical support.................................................................................................................144
A.5 Certificate.............................................................................................................................145
A.6 Spare parts/accessories.......................................................................................................146
A.6.1 Notes....................................................................................................................................146
A.6.2 Spare parts slide-in device...................................................................................................147
A.6.3 Spare parts OXYMAT 7.......................................................................................................148
A.6.4 Spare parts ULTRAMAT 7...................................................................................................149
A.6.5 Spare parts CALOMAT 7.....................................................................................................151
A.7 Returned delivery.................................................................................................................152
A.7.1 Service and support.............................................................................................................152
A.7.2 Returned delivery.................................................................................................................152
Index.........................................................................................................................................................155
Tables
Table 1-1 History.........................................................................................................................................12
Table 1-2 Conventions on markups.............................................................................................................15
Table 1-3 Conventions on terminology........................................................................................................15
Table 3-1 Mounting conditions for the sample gas restrictor: OXYMAT 7...................................................49
Table 3-2 Mounting conditions for the sample gas restrictor: ULTRAMAT 7..............................................49
Table 3-3 Mounting conditions for the sample gas restrictor: CALOMAT 7................................................50
Table 3-4 Plug & Measure - Commissioning...............................................................................................53
Table 3-5 Plug & Measure - Installation/replacement of an AM..................................................................53
Table 3-6 Plug & Measure - Installation/replacement of a PM....................................................................54
Table 3-7 Plug & Measure - Replacement of a PU/Installation of a used AM.............................................54
Table 3-8 Plug & Measure - AM slot change...............................................................................................55
Table 4-1 Installation conditions for the sample gas restrictor....................................................................60
Table 5-1 Rack-mounted housing tool.........................................................................................................67
Table 9-1 Selection of the reference gas...................................................................................................104
Table 9-2 Overview of the reference gases...............................................................................................104
Table 9-3 Zero point error of organic gases..............................................................................................105
Table 9-4 Zero point error of noble gases.................................................................................................106
Table 9-5 Zero point error of inorganic gases...........................................................................................106
Table 9-6 Zero offset in the system H2 in N2..............................................................................................113
Table 10-1 Error messages.........................................................................................................................122
Table 11-1 Rack-mounted enclosure: General technical specifications......................................................124
Table 11-2 Rack-mounted enclosure: Electrical characteristics..................................................................124
Table 11-3 Rack-mounted enclosure: Electrical inputs and outputs...........................................................124
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Table 11-4 Rack-mounted enclosure: Option modules...............................................................................125
Table 11-5 Rack-mounted enclosure: Climatic conditions..........................................................................125
Table 11-6 OXYMAT 7: General technical specifications ...........................................................................126
Table 11-7 OXYMAT 7: Measuring ranges.................................................................................................126
Table 11-8 OXYMAT 7: Gas inlet conditions...............................................................................................126
Table 11-9 OXYMAT 7: Temperature of sample chamber and gas path....................................................127
Table 11-10 OXYMAT 7: Time response......................................................................................................127
Table 11-11 OXYMAT 7: Measuring response..............................................................................................127
Table 11-12 OXYMAT 7: Influence variables................................................................................................128
Table 11-13 OXYMAT 7: Climatic conditions................................................................................................128
Table 11-14 OXYMAT 7: Gas connections...................................................................................................129
Table 11-15 OXYMAT 7: Parts in contact with the sample gas.....................................................................129
Table 11-16 ULTRAMAT 7: General technical specifications ......................................................................129
Table 11-17 ULTRAMAT 7: Measuring ranges.............................................................................................130
Table 11-18 ULTRAMAT 7: Gas inlet conditions...........................................................................................130
Table 11-19 ULTRAMAT 7: Time response..................................................................................................130
Table 11-20 ULTRAMAT 7: Measuring response.........................................................................................130
Table 11-21 ULTRAMAT 7: Influence variables............................................................................................131
Table 11-22 ULTRAMAT 7: Electrical outputs...............................................................................................131
Table 11-23 ULTRAMAT 7: Climatic conditions............................................................................................131
Table 11-24 ULTRAMAT 7: Gas connections...............................................................................................131
Table 11-25 ULTRAMAT 7: Parts in contact with the sample gas................................................................131
Table 11-26 CALOMAT 7: General technical specifications ........................................................................132
Table 11-27 CALOMAT 7: Measuring ranges...............................................................................................132
Table 11-28 CALOMAT 7: Gas inlet conditions.............................................................................................132
Table 11-29 CALOMAT 7: Temperature of sample chamber and gas path..................................................132
Table 11-30 CALOMAT 7: Time response....................................................................................................132
Table 11-31 CALOMAT 7: Measuring response...........................................................................................133
Table 11-32 CALOMAT 7: Influence variables..............................................................................................133
Table 11-33 CALOMAT 7: Climatic conditions..............................................................................................134
Table 11-34 CALOMAT 7: Gas connections.................................................................................................134
Table 11-35 CALOMAT 7: Parts in contact with the sample gas..................................................................134
Table A-1 Units..........................................................................................................................................139
Table A-2 Other abbreviations...................................................................................................................139
Table A-3 References 1 - Operating Manuals LUI.....................................................................................141
Table A-4 References 2 - Operating Manuals PDM..................................................................................141
Table A-5 References 3 - Operating Instructions.......................................................................................141
Table A-6 References 4 - Compact Operating Instructions.......................................................................141
Table A-7 References 5 - Compact Operating Instructions Ex..................................................................142
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Table A-8 References 6 - Operating Instructions Field device "Ex d"........................................................143
Table A-9 References 6 - Catalogs............................................................................................................143
Table A-10 Spare parts list slide-in device...................................................................................................147
Table A-11 Spare parts list OXYMAT 7 - standard......................................................................................148
Table A-12 Spare parts list OXYMAT 7 - Ex version ..................................................................................149
Table A-13 Spare parts list ULTRAMAT 7...................................................................................................149
Table A-14 Spare parts list CALOMAT 7.....................................................................................................151
Figures
Figure 3-1 Design of rack-mounted enclosure..............................................................................................26
Figure 3-2 Nameplate...................................................................................................................................27
Figure 3-3 Module nameplate.......................................................................................................................27
Figure 3-4 Structure of high-pressure version, sample gas path with pipes.................................................29
Figure 3-5 Principle of operation of OXYMAT 7...........................................................................................30
Figure 3-6 Design of ULTRAMAT 7, measurement and reference gas path with pipes...............................33
Figure 3-7 Principle of operation of ULTRAMAT 7.......................................................................................34
Figure 3-8 Design of CALOMAT 7, sample gas path with pipes..................................................................37
Figure 3-9 Principle of operation of CALOMAT 7.........................................................................................38
Figure 3-10 Slots for analyzer modules..........................................................................................................40
Figure 3-11 Compatibility matrix analyzer modules ↔ slots............................................................................41
Figure 3-12 Sample gas connections with sample gas restrictors..................................................................45
Figure 3-13 Distinction between sample gas restrictor and clamping screw, sectional drawing and view
from above..................................................................................................................................47
Figure 3-14 Mounting position sample gas restrictor or clamping screw........................................................48
Figure 3-15 Retrofitting of the sample gas restrictors: Example "Pressure operation, serial"........................50
Figure 3-16 Retrofitting of the sample gas restrictors: Example "Pressure operation, serial"........................51
Figure 5-1 Wiring and cabling.......................................................................................................................68
Figure 5-2 Schematic representation of the CAN bus cable.........................................................................70
Figure 5-3 Installing an analyzer module based on the example of an OXYMAT 7.....................................71
Figure 5-4 AM PCB interfaces......................................................................................................................72
Figure 5-5 AM PCB interface ULTRAMAT 7................................................................................................73
Figure 5-6 AM PCB interface CALOMAT 7..................................................................................................74
Figure 5-7 Removing an analyzer module based on the example of an OXYMAT 7...................................75
Figure 5-8 Mounting locations of option modules.........................................................................................76
Figure 5-9 Installing option module using example of OM 2.2......................................................................77
Figure 5-10 Analyzer module..........................................................................................................................78
Figure 5-11 Cabling using OM 1.1 and OM 2.1 as an example......................................................................78
Figure 6-1 Dimension drawing......................................................................................................................81
Figure 7-1 Connecting the power supply......................................................................................................84
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Figure 7-2 Example of rear panel with OXYMAT 7, connecting the signal lines..........................................85
Figure 7-3 Pin assignments of processing module.......................................................................................86
Figure 7-4 Pin assignment of optional module 1.1.......................................................................................87
Figure 7-5 Pin assignment of optional module 2.1.......................................................................................88
Figure 7-6 Pin assignment of optional module 2.2.......................................................................................89
Figure 7-7 Rack-mounted device: Example of spark suppression on a relay contact..................................90
Figure 7-8 OXYMAT 7 gas connections.......................................................................................................95
Figure 7-9 ULTRAMAT 7 gas connections...................................................................................................96
Figure 7-10 CALOMAT 7 gas connections.....................................................................................................97
Figure 10-1 Connection cables for processing unit......................................................................................119
Figure 12-1 Dimension drawings of rack-mounted enclosure......................................................................135
Figure A-1 Electrostatic voltages which an operator can be subjected to...................................................138
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Introduction 1
1.1 Purpose of this document
This instruction manual contains all information that you will require to commission and use
the device.
This instruction manual only covers non-ex devices.
It is intended for persons who assemble the device mechanically, connect it electrically, and
commission it.
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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
Introduction
1.2 History
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1.3 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
1.3 Notes on warranty
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1.4 Environmentally friendly use of resources
The device is characterized by an environmentally friendly use of resources during operation.
You can obtain detailed information, for example, on the gas consumption, from your Siemens
sales partner.
See also
Technical support (Page 144)
Introduction
1.4 Environmentally friendly use of resources
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1.5 Conventions
Overview
To allow easier navigation within this documentation, the tables below provide information on
the use of markups and terminology.
Table 1-2 Conventions on markups
Representation
type
Scope
"Add screen" ● Terminology that appears in the user interface, for example, dialog names,
tabs, buttons, menu commands
● Required inputs, for example, limits, tag values.
● Path information
"File > Edit" Operational sequences, for example, menu commands, shortcut menu com‐
mands.
<F1>, <Alt+P> Keyboard operation
[1] to [6] Numbers of the main menu in the LUI, part of the
menu name
The square brackets identi‐
fy the chapter numbers that
precede the menu names.
[1. ...] to [6] Numbering of the menus downstream from the
main menu, part of the menu name
→ Introduces a text-dependent reference to a section or a paragraph in this docu‐
mentation. The page numbers are always specified in parentheses for references
in the document. Example of a reference (hyperlink):
→ References (Page 141)
Table 1-3 Conventions on terminology
Term Convention/alternative name
Local user inter‐
face
"LUI" for short.
Auto hotspot Defective reference
"See also" At the end of the paragraph/page: Text-independent reference
Introduction
1.5 Conventions
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Introduction
1.5 Conventions
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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 25) 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.
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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.
General safety instructions
2.2 Prerequisites for safe use
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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
2.3 Device modifications
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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.
General safety instructions
2.4 Laws and directives
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