Siemens SIPROCESS UV600 User manual

Continuous gas analysis
Gas analyzer for measuring UV-
active gases
SIPROCESS UV600
Operating Instructions
7MB2621
10/2013
A5E03529375
-02
Introduction
1
Safety notes
2
Description
3
Mounting and connecting
4
Startup
5
Operation
6
Important functions
(selection)
7
Maintenance and
troubleshooting
8
Spare parts/accessories
9
Technical data
10
Appendix
A
Lists
B

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: A5E03529375
Ⓟ
02/2014 Technical data subject to change
Copyright © Siemens AG 2011 - 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.

SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 5
Table of contents
1 Introduction............................................................................................................................................. 9
1.1 Purpose of this documentation ......................................................................................................9
1.2 History ............................................................................................................................................9
1.3 Checking the consignment.............................................................................................................9
1.4 Notes on warranty........................................................................................................................10
2 Safety notes.......................................................................................................................................... 11
2.1 Precondition for use .....................................................................................................................11
2.2 Requirements for special applications .........................................................................................11
2.3 Proper use....................................................................................................................................12
2.4 Responsibilities of the operating company ..................................................................................13
3 Description............................................................................................................................................ 15
3.1 Benefits ........................................................................................................................................15
3.2 Field of application .......................................................................................................................16
3.3 Design ..........................................................................................................................................17
3.3.1 Device configuration ....................................................................................................................17
3.3.2 Display and control panel.............................................................................................................17
3.3.3 Input and outputs .........................................................................................................................18
3.3.4 Communication ............................................................................................................................18
3.4 Gas path.......................................................................................................................................18
3.5 Materials wetted by sample gas...................................................................................................19
3.6 Operating principle.......................................................................................................................20
4 Mounting and connecting ...................................................................................................................... 23
4.1 Dimensions for preparing installation...........................................................................................23
4.2 Safety instructions........................................................................................................................24
4.3 Installation requirements..............................................................................................................25
4.3.1 Environmental conditions.............................................................................................................25
4.3.2 Installation conditions...................................................................................................................25
4.4 Gas path and gas connections ....................................................................................................26
4.4.1 Gas connections ..........................................................................................................................26
4.4.2 Sample gas inlet pipe...................................................................................................................27
4.4.3 Sample gas outlet ........................................................................................................................28
4.4.4 Calibration gases .........................................................................................................................28

Table of contents
SIPROCESS UV600
6Operating Instructions, 10/2013, A5E03529375-02
4.5 Electrical connections ................................................................................................................. 29
4.5.1 Power connection........................................................................................................................ 30
4.5.1.1 Safety instructions for power connection .................................................................................... 30
4.5.1.2 Measures of the operating company........................................................................................... 31
4.5.1.3 Power connection........................................................................................................................ 32
4.5.2 Signal cables............................................................................................................................... 32
4.5.2.1 Safety instructions....................................................................................................................... 33
4.5.2.2 Connection of the signal cables .................................................................................................. 33
4.5.2.3 Signal cable................................................................................................................................. 34
4.5.2.4 Pin assignments.......................................................................................................................... 35
5 Startup.................................................................................................................................................. 41
5.1 Safety instructions....................................................................................................................... 41
5.2 Preparation for startup ................................................................................................................ 42
5.2.1 Gas sampling and preparation .................................................................................................... 42
5.2.2 Leak test...................................................................................................................................... 43
5.2.3 Last measures prior to startup .................................................................................................... 44
5.3 Startup......................................................................................................................................... 44
5.4 Basic parameter assignment ...................................................................................................... 45
5.4.1 Introduction to operation ............................................................................................................. 45
5.4.2 Setting the contrast ..................................................................................................................... 46
5.4.3 Setting the language ................................................................................................................... 47
5.4.4 Changing the access privileges .................................................................................................. 48
5.4.5 Displaying/adjusting the setpoints of the calibration gases ........................................................ 50
5.5 Initial calibration .......................................................................................................................... 51
6 Operation.............................................................................................................................................. 53
6.1 Control panel, display and control elements ............................................................................... 54
6.1.1 Control panel............................................................................................................................... 54
6.1.2 LEDs............................................................................................................................................ 55
6.1.3 Control keys ................................................................................................................................ 56
6.1.4 Messages in the status line......................................................................................................... 57
6.1.5 Checking the operating state ...................................................................................................... 58
6.1.6 Menu system............................................................................................................................... 59
6.1.7 User levels................................................................................................................................... 60
6.2 Initial operating steps .................................................................................................................. 60
6.2.1 Introduction to operation ............................................................................................................. 60
6.2.2 Changing the access privileges .................................................................................................. 62
6.2.3 Character input............................................................................................................................ 64

Table of contents
SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 7
7 Important functions (selection) .............................................................................................................. 67
7.1 Setting the language ....................................................................................................................67
7.2 Diagnostics functions ...................................................................................................................68
7.2.1 Menu tree for diagnostics functions .............................................................................................68
7.2.2 Overview ......................................................................................................................................70
7.2.3 Status ...........................................................................................................................................71
7.2.4 Display logbook............................................................................................................................74
7.2.5 Display measured values.............................................................................................................75
7.2.6 Results of calibrations and validations.........................................................................................79
7.2.7 Inputs and outputs .......................................................................................................................81
7.2.8 System overview..........................................................................................................................85
7.2.9 IO overview ..................................................................................................................................86
7.2.10 Product information......................................................................................................................86
7.2.11 Operating hours ...........................................................................................................................88
7.2.12 Service information ......................................................................................................................89
7.3 Calibration and validation functions .............................................................................................90
7.3.1 Menu tree for calibration and validation functions .......................................................................90
7.3.2 Settings ........................................................................................................................................92
7.3.2.1 General settings for calibration and validation.............................................................................92
7.3.2.2 Configuring automatic calibration.................................................................................................94
7.3.2.3 Configuring calibration gases.......................................................................................................98
7.3.3 Carrying out a manual calibration ..............................................................................................108
7.3.4 Display calibration results ..........................................................................................................112
7.3.5 Carrying out a manual validation measurement ........................................................................113
7.3.6 Display validation results ...........................................................................................................117
7.3.7 Group functions..........................................................................................................................118
7.4 Maintenance functions ...............................................................................................................120
7.4.1 Menu tree for maintenance functions ........................................................................................120
7.4.2 Maintenance status on/off..........................................................................................................121
7.4.3 Saving/restoring data .................................................................................................................122
7.4.4 Testing the input and output functions .......................................................................................123
7.4.5 Restart BCU...............................................................................................................................126
7.5 Parameter assignments .............................................................................................................127
7.5.1 Menu tree for parameterization functions ..................................................................................127
7.5.2 Activate/deactivate measured values ........................................................................................130
7.5.3 Configuration of measured-value display ..................................................................................
132
7.5.4 Selecting output ranges .............................................................................................................134
7.5.5 Adjusting the damping ...............................................................................................................136
7.5.6 Setting limits...............................................................................................................................139
7.5.7 Pump settings ............................................................................................................................140
7.5.8 Setting parameters for inputs and outputs.................................................................................142
7.5.8.1 Configuring the analog outputs..................................................................................................142
7.5.8.2 Configuring the digital outputs ...................................................................................................145
7.5.8.3 Configuring the digital inputs......................................................................................................147
7.5.8.4 Configuring the analog inputs ....................................................................................................149
7.5.9 Parameterization of digital communication ................................................................................150
7.5.9.1 Configuring a LAN connection ...................................................................................................150
7.5.9.2 Configuring a Modbus connection .............................................................................................151
7.5.10 Setting the date and time ...........................................................................................................151

Table of contents
SIPROCESS UV600
8Operating Instructions, 10/2013, A5E03529375-02
7.5.11 Automatic measuring point switchover ..................................................................................... 152
7.5.11.1 Programming the measuring point switchover.......................................................................... 153
7.5.11.2 Status output for the switchover phase..................................................................................... 155
7.5.11.3 Selecting the measuring point display ...................................................................................... 155
7.5.12 Starting user functions .............................................................................................................. 156
7.5.13 Display settings ......................................................................................................................... 157
7.5.13.1 Setting the waiting time for automatic logoff ............................................................................. 157
7.5.13.2 Setting the waiting time for automatic display switch-off .......................................................... 158
8 Maintenance and troubleshooting.........................................................................................................159
8.1 Safety instructions..................................................................................................................... 159
8.2 Cleaning .................................................................................................................................... 160
8.3 Maintenance.............................................................................................................................. 160
8.3.1 Maintenance carried out by user............................................................................................... 161
8.3.2 Maintenance carried out by authorized specialists ................................................................... 162
8.4 Troubleshooting ........................................................................................................................ 163
8.4.1 Measures in event of complete failure ...................................................................................... 163
8.4.2 Response in case of fault displays............................................................................................ 163
8.5 Shutting down ........................................................................................................................... 164
9 Spare parts/accessories.......................................................................................................................165
9.1 19" rack housing........................................................................................................................ 165
9.2 Control unit................................................................................................................................ 165
9.3 Input/output module .................................................................................................................. 166
9.4 UV module................................................................................................................................. 166
9.5 Gas module and pneumatic supply........................................................................................... 167
10 Technical data .....................................................................................................................................169
10.1 Technical data........................................................................................................................... 169
10.2 Dimension drawing.................................................................................................................... 173
A Appendix .............................................................................................................................................175
A.1 ESD guidelines.......................................................................................................................... 175
B Lists.....................................................................................................................................................177
B.1 List of abbreviations .................................................................................................................. 177
Index ...................................................................................................................................................181

SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 9
Introduction
1
1.1
Purpose of this documentation
These instructions contain all information required to commission and use the device. It is
your responsibility to read the instructions carefully prior to installation and commissioning. In
order to use the device correctly, first review its principle of operation.
The instructions are aimed at persons mechanically installing the device, connecting it
electronically, configuring the parameters and commissioning it, as well as service and
maintenance engineers.
1.2
History
Issue
Comment
01
10/2011
First edition
02
10/2013
Revision of significant functions
1.3
Checking the consignment
Check the device packaging for damage. Inform your supplier of any damage. Retain the
damaged parts for clarification.
Check the scope of delivery by comparing the shipping documents with your order for
correctness and completeness.
Do not take damaged or incomplete devices into operation under any circumstances.
Special conditions for storage and transportation of device listed in Section "Auto-Hotspot".

Introduction
1.4 Notes on warranty
SIPROCESS UV600
10 Operating Instructions, 10/2013, A5E03529375-02
1.4
Notes on warranty
The contents of this manual shall not become part of or modify any prior or existing
agreement, commitment or legal relationship. The sales contract contains all obligations on
the part of Siemens as well as the complete and solely applicable warranty conditions. Any
statements regarding device versions described in the manual do not create new warranties
or modify the existing warranty.
The content reflects the technical status at the time of publishing. Siemens reserves the right
to make technical changes in the course of further development.

SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 11
Safety notes
2
2.1
Precondition for use
This device left the factory in good working 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.
2.2
Requirements for special applications
Due to the large number of possible applications, each detail of the described device
versions for each possible scenario during commissioning, operation, maintenance or
operation in systems cannot be considered in the instructions. If you need additional
information not covered by these instructions, contact your local Siemens office or company
representative.
Note
Operation under special ambient conditions
We highly recommend that you contact your Siemens representative or our application
department before you operate the device under special ambient conditions as c
an be
encountered in nuclear power plants or when the device is used for research and
development purposes.

Safety notes
2.3 Proper use
SIPROCESS UV600
12 Operating Instructions, 10/2013, A5E03529375-02
2.3
Proper use
The SIPROCESS UV600 gas analyzer measures the concentration of one gas or several
gases in a gas mixture.
The following conditions apply when selecting the location of use of the analyzer and the
condition of the supplied sample gas:
Location of use
●The SIPROCESS UV600 may only be used in closed rooms
●The SIPROCESS UV600 must not be used in potentially explosive atmospheres
Sample gas
The SIPROCESS UV600 is
not
suitable for measuring
flammable and/or explosive gases
and gas mixtures
!
In addition, the sample gas must be free from:
●Substances which could attack the materials of the gas path in the analyzer
●Particles which could deposit in the gas path in the analyzer
●Gas components which could condense in the analyzer during normal operation
Additional information is available in the Auto-Hotspot . In case of doubt, we recommend that
you discuss your application with our technical department.
It is also possible that components may be present in the sample gas which influence the
measurement (cross-sensitivity). In such a case, the displayed value deviates from the
actual measured value. In order to minimize or eliminate cross-sensitivities, we recommend
that you discuss your application with our technical department

Safety notes
2.4 Responsibilities of the operating company
SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 13
2.4
Responsibilities of the operating company
Qualified personnel
Installation, commissioning, operation, and maintenance of the SIPROCESS UV600 gas
analyzer may only be carried out by qualified personnel.
Qualified personnel in the sense of the safety-related information in this Manual are persons
who are
●either familiar with the safety concepts of automation equipment as system planning and
design engineers
or
●have been trained to work with automation equipment and are conversant with the
contents of this Manual as operating personnel
or
●are trained to repair such automation equipment and authorized to energize, tag, connect
and ground circuits and devices/systems in accordance with established safety practices
as commissioning and/or service personnel.
Correct usage
●The SIPROCESS UV600 must only be used in compliance with this Manual and further
Manuals.
●The described maintenance work must be carried out, and the defined maintenance
periods must be observed.
●No parts on or in the device may be removed, modified or added unless described and
specified by the manufacturer.
●Gas preparation must be provided in accordance with the measuring task and the
composition of the sample gas.
●All laws, directives, and technical regulations applicable at the location of use must be
observed.

Safety notes
2.4 Responsibilities of the operating company
SIPROCESS UV600
14 Operating Instructions, 10/2013, A5E03529375-02
Responsibility when handling dangerous substances
DANGER
Danger to life with leaks in gas path
If the sample gas contains substances which are harmful to health, a leak in the gas path is
an acute health hazard, or also a danger to the life of personnel at corresponding
concentrations.
The following measures must be taken to avoid such situations:
•
Use appropriate safety measures to avoid leaks. Make sure that these safety measures
function permanently and are observed
WARNING
Health hazard resulting from contact with toxic gases
The analyzer is filled with potentially dangerous gases which can escape in the event of a
fault or leak. These are CO, NO, NO2, SO2, NH3, H2O, hydrocarbons, freons with a
maximum concentration of 1000 ppm.
•Regularly check the condition of the analyzer's gaskets
•Only open the analyzer in well ventilated areas, especially if leaking of a component is
suspected.

SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 15
Description
3
The SIPROCESS UV600 gas analyzer is an ultraviolet measuring instrument which can
simultaneously measure up to three components. As a result of its spectral range, the
SIPROCESS UV600 can measure NO highly selectively as well as a number of further UV-
active gases such as NO2, SO2, and H2S. Furthermore, there is no cross-sensitivity with CO2
and H2O.
3.1
Benefits
●Very low cross-sensitivity with other gases
●All modules are temperature-controlled, and thus independent of the ambient temperature
●Simultaneous measurement of NO and NO2with subsequent calculation of total.
Therefore neither an NO2converter nor a CLD analyzer is required.
●Measurement in the UV range:
–No cross-sensitivity with H2O and CO2
–Very low SO2and NO measuring ranges possible
●UV resonance absorption spectrometry:
–Measurement of very low NO concentrations
–Very low cross-sensitivity possible
●Very long service life of UV lamp (usually 2 years)
●Low drifts and high stability thanks to four-channel measuring method with double
generation of quotient
●True reference measurement for low-drift, stable results
●Interface for remote monitoring in networks and linking to process control systems
●Optional calibration unit
–Filter wheel with calibration cells which can be automatically swung into the optical
path
–Low consumption of calibration gas
–Manual or automatic calibration possible

Description
3.2 Field of application
SIPROCESS UV600
16 Operating Instructions, 10/2013, A5E03529375-02
3.2
Field of application
●Emission measurements
–Measurement of low NO concentrations in power plants or gas turbines
–Monitoring of NOxin DeNOx plants through direct measurement of NO and NO2and
calculation of total NOxin the analyzer
–Efficient measurement in desulfurization plants
–Monitoring of very small SO2and NO concentrations
–Emission measurements in the paper and cellulose industries
●Process monitoring
–Measurement of SO2in process gases in the paper and petrochemical industries
–Optimization of NOxemissions in exhaust gases in the automotive industry
–H2S and SO2measurements in the residual gas purification of sulfur recovery units
(SRU)

Description
3.3 Design
SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 17
3.3
Design
3.3.1
Device configuration
●19" rack unit with 4 HU for installation
–in hinged frame
–in cabinets with or without telescopic rails
●Internal gas paths: hose made of FKM or pipe made of PTFE or stainless steel
●Gas connections for sample gas inlet and outlet: pipe diameter 6 mm
3.3.2
Display and control panel
●Large LC display for simultaneous display of measured value and device status
●Sensor buttons with context-based functions
●Display protected by glass pane
●Contrast of the LC display can be adjusted
Figure 3-1 Display_and_control_panel

Description
3.4 Gas path
SIPROCESS UV600
18 Operating Instructions, 10/2013, A5E03529375-02
3.3.3
Input and outputs
●2 configurable analog inputs
●4 configurable analog outputs
●8 digital inputs
●8 digital outputs
3.3.4
Communication
Connection via SIPROCESS-UV600 SW tool
3.4
Gas path
1
Sample gas inlet
4
Filter (optional)
2
Sample gas outlet
5
Analyzer unit (UV module)
3
Moisture sensor (optional)
Figure 3-2 Gas path of SIPROCESS UV600

Description
3.5 Materials wetted by sample gas
SIPROCESS UV600
Operating Instructions, 10/2013, A5E03529375-02 19
3.5
Materials wetted by sample gas
Table 3- 1
Component
Material
Analyzer unit (sample chamber): Aluminum or stainless steel mat. no. 1.4404 [*], epoxy
resin
Optical window
CaF2or quartz [*], epoxy resin
Gas path, gaskets
FKM (Viton™), PTFE, stainless steel mat. no. 1.4571 [*]
Chamber:
Aluminum or stainless steel [*]
Gas inlet/outlet
PVDF, stainless steel mat. no. 1.4401 [*]
Moisture sensor
Stainless steel mat. no. 1.4571, platinum, epoxy resin
Diaphragm pump
Pump body
Diaphragm
PVDF
FKM (Viton™), EPDM
[*] Depending on version

Description
3.6 Operating principle
SIPROCESS UV600
20 Operating Instructions, 10/2013, A5E03529375-02
3.6
Operating principle
1
UV lamp
GFC
Gas filter correlation
2
2a
2b
Filter wheel unit
Filter wheel 1
Filter wheel 2
IFC Interference filter correlation
3
Collimator lens
M
Motor
4
Beam divider
5
Mirror
6
Sample chamber
7
Reference chamber
8
Convex lens
9
Detector
10
Calibration unit