MMM
I
MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
PowerCEMS100
Customer-specific Analysis System
Installation, Operation, Maintenance
Title Page
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Described Product
Product name: PowerCEMS100
Document ID
Title: Operating Instructions PowerCEMS100
Document ID: 8019897
Version: V2-0
Release: 2017-12
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Phone: +49 7641 469-0
Fax: +49 7641 469-1149
E-mail: [email protected]
Place of Manufacture
SICK AG
Nimburger Str. 11 · D-79276 Reute · Germany
Legal Information
This work is protected by copyright. Any rights derived from the copyright shall be reserved
for SICK AG. Reproduction of this document or parts of this document is only permissible
within the limits of the legal determination of Copyright Law.
Any modification, shortening or translation of this document is prohibited without the
express written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
CONTENT
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1 About this document................................................................................. 7
1.1 Limitation of liability........................................................................................7
1.2 Purpose of the Document...............................................................................7
1.3 Target groups ..................................................................................................7
1.4 Further information.........................................................................................7
1.5 Other applicable technical documents/information: .................................... 8
1.6 Document conventions ...................................................................................8
2 For your safety............................................................................................ 9
2.1 Supplementary safety information .................................................................9
2.2 Safety conventions..........................................................................................9
2.3 Warning signs................................................................................................10
2.4 Mandatory signs............................................................................................10
2.5 Warning information on the system .............................................................11
2.6 Safety information.........................................................................................11
2.7 Note ...............................................................................................................12
2.8 Intended use .................................................................................................13
2.9 Requirements on the personnel's qualification...........................................13
3 Product description .................................................................................15
3.1 Features of the PowerCEMS100 ..................................................................15
3.2 Method of operation .....................................................................................15
3.3 Functional principle ......................................................................................15
3.4 Internal functional units................................................................................16
3.5 External functional units...............................................................................17
3.6 Measuring components ................................................................................17
3.7 Interfaces ......................................................................................................17
3.8 Description of system components..............................................................18
3.8.1 Exterior view..................................................................................18
3.8.2 Interior view ..................................................................................19
3.8.3 Parts list ........................................................................................19
3.9 Gas flow plan.................................................................................................20
4 Transport ...................................................................................................23
4.1 Removing the transport safety devices........................................................23
4.2 Checking attachments and connections......................................................23
4.3 Insert filter elements and bubbling frits ......................................................23
5 Installation ................................................................................................25
5.1 Preparing the installation location ...............................................................25
5.2 Inserting the NO
x
converter cartridges (option)...........................................26
5.3 Preparing the gas sampling probe ...............................................................26
5.4 Gas lines........................................................................................................26
Content
CONTENT
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5.5 Preparing the electrical installation............................................................. 28
5.5.1 Cable inlet on the system cabinet ............................................... 29
5.5.2 Preparing the main power supply ................................................ 29
5.6 External components and signal generators............................................... 29
5.7 Connecting to the customer plant ............................................................... 29
6 Commissioning ........................................................................................ 31
6.1 Commissioning of the humidifier containers (option)................................. 31
6.2 Before switching on ...................................................................................... 31
6.3 Switching on the PowerCEMS100 analysis system .................................... 32
6.4 Commissioning of sample gas cooler .......................................................... 32
6.5 Commissioning of the analyzers .................................................................. 32
6.6 Start-up for the NO
x
converter (option)........................................................ 33
6.7 Commissioning of cabinet climate control ................................................. 33
6.8 Commissioning of the heated gas sampling probe..................................... 34
6.9 Restarting after longer shutdown ................................................................ 35
7 Operation ..................................................................................................37
7.1 Operating the system components.............................................................. 37
7.2 Layout and functions of system components ............................................. 37
7.3 System parameters ...................................................................................... 37
7.4 Operating elements on the BCU operator panel ......................................... 37
7.5 Switching on................................................................................................. 38
7.6 BCU operating functions overview – Menu structure in SOPAS................. 39
8 Adjusting ...................................................................................................41
8.1 Adjustment purpose ..................................................................................... 41
8.2 Principle adjustment procedure................................................................... 41
8.3 Adjustment procedure.................................................................................. 42
8.4 Test gas pressure ......................................................................................... 42
8.5 Flow rate values............................................................................................ 42
8.6 Adjustment abort .......................................................................................... 42
8.6.1 Clearing malfunctions .................................................................. 43
8.6.2 Resetting the maintenance request after automatic adjustment
abort.............................................................................................. 43
8.6.3 Manual adjustment abort on the analyzer .................................. 43
9 Decommissioning.................................................................................... 45
9.1 Safety measures before decommissioning ................................................. 45
9.1.1 Protection of external components ............................................. 45
9.1.2 Completely remove toxic/humid sample gases.......................... 45
9.1.3 Switching off ................................................................................ 46
9.1.4 Decommissioning ......................................................................... 46
9.1.5 Storage ......................................................................................... 46
9.2 Disposal ........................................................................................................ 47
CONTENT
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10 Maintenance.............................................................................................49
10.1 Important safety information on maintenance............................................49
10.2 Operating state - Maintenance.....................................................................50
10.3 Visual inspection / functional check............................................................50
10.4 Maintenance intervals ..................................................................................51
10.5 Cleaning information.....................................................................................53
10.6 Wear parts (WP) / Spare parts (SP) .............................................................53
10.7 External components - Wear parts (WP) / Spare parts (SP) .......................58
11 Troubleshooting .......................................................................................59
11.1 Important Information...................................................................................59
11.2 Clearing malfunctions (BCU error messages) ..............................................59
11.3 Clearing malfunctions (other malfunctions) ................................................60
11.4 Switch-on conditions / additions to clearing malfunctions.........................61
12 Specifications...........................................................................................63
12.1 EU Declaration of Conformity .......................................................................63
12.2 Dimensions....................................................................................................63
12.3 Technical data...............................................................................................64
CONTENT
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ABOUT THIS DOCUMENT 1
1About this document
1.1 Limitation of liability
1.2 Purpose of the Document
This document describes:
● Installation
● Operation
● Maintenance
of the PowerCEMS100
1.3 Target groups
This document is intended for qualified persons installing, operating and maintaining the
PowerCEMS100.
1.4 Further information
Special local conditions
Follow all local laws, regulations, technical rules and company policies applicable at the
installation location.
Keeping documents
This document as well as other applicable technical documents/information:
● Must be kept available for reference
● Must be passed on to a new operator / new qualified personnel
Note
This document:
● contains Information necessary during the life cycle of the PowerCEMS100.
● must be made available to all persons working with the system.
Read this document carefully and ensure that the contents are fully understood
before working with the PowerCEMS100.
Note
Applicable standards and regulations, the latest state of technological develop-
ment, and our many years of knowledge and experience have all been taken
into account when assembling the data and information contained in these
operating instructions.
The manufacturer assumes no liability for damage due to:
● Failing to observe this document
● Failing to comply with information and regulations
● Unauthorized fitting and installations
● Technical modifications
● Using spare, wear and accessory parts which are not released
The actual scope of delivery can deviate from the characteristics and informa-
tion described here for special versions, additional order options or due to the
latest technical modifications.
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1 ABOUT THIS DOCUMENT
1.5 Other applicable technical documents/information:
Individualized versions of PowerCEMS100 with adapted internal or peripheral equipment
exist. For the relevant information, see the delivered separate documentation:
● Operating Instructions for the gas analyzers.
● Operating Instructions for additional components (optional):
– Sampling probe
–Sample gas lines
– Components for temperature control of external (heated under control) sample gas
lines
–NO
x
converter
● Operating Instructions/Data Sheets for system control:
– BCU (with operator panel)
● Operating Instructions / Data Sheets for components of the control cabinet climate con-
trol and lighting (optional):
– Cabinet cooling unit
–Cabinet fan
– Control cabinet light (standard)
● Operating Instructions / Data Sheets for components for sample gas conditioning and
test gas feeding (optional):
– Sample gas pump
– Sample gas cooler (including condensate pump)
– Test gas valves (solenoid valves)
– Humidifier container
– Sample gas monitoring
– Water trap (humidity separator)
● Layout of spacial arrangement of system components
● Circuit diagram
● Connection diagram
● Wiring diagram
● Gas flow plan
1.6 Document conventions
▸ Handling instruction
All units and of measurement in this document are metric units.
Subject to change without notice. Illustrations may differ from the actual design.
Reference to another document
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FOR YOUR SAFETY 2
2For your safety
2.1 Supplementary safety information
2.2 Safety conventions
Safety symbols on the system and the system components as well as safety information
and safety identifications comply with current directives and standards.
The safety conventions for signal words used in this document comply with ANSI Z535.6:
Note
Read and follow all safety information in this document.
WARNING
▸ Read this document carefully before working on the Pow-
erCEMS100.
▸ Only qualified persons from the respective departments are
permitted to work on the PowerCEMS100.
▸ Follow the business procedures.
▸ Follow the local rules.
▸ Follow the local rules with respect to working with gas and electric
components.
▸ Only authorized persons are permitted access to the Pow-
erCEMS100.
DANGER
DANGER describes a dangerous situation which leads to death or
serious injuries if not prevented.
WARNING
WARNING describes a dangerous situation which can lead to serious
or fatal injuries in case of non-observance.
CAUTION
CAUTION indicates a potentially dangerous situation which can lead to
property damage if not prevented.
NOTE
NOTE indicates potential damage to property and materials.
Note
Important information and useful tips.
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2 FOR YOUR SAFETY
2.3 Warning signs
2.4 Mandatory signs
Sign Significance
Warning of danger area
Warning of dangerous electric voltage
Warning of explosive atmosphere
Warning of explosive substances
Warning of inflammable substances
Warning of oxidizing substances
Warning of toxic substances
Warning of acidic substances
Warning of noxious or irritant substances
Warning of gas cylinders
Warning of suspended loads
Warning of dangers to environment, nature and organic life
Sign Significance
Wear respiratory equipment
Wear head protection
Wear foot protection
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FOR YOUR SAFETY 2
2.5 Warning information on the system
2.6 Safety information
CAUTION
HAZARDOUS GASES
Danger of intoxication by inhalation.
▸ Perform pressure and leak tightness tests in regular intervals.
▸ Observe Operating Instructions
Note
▸ The operator is responsible for performing pressure and leak tightness
checks.
▸ Observe the respective approval document, legal specifications as well as
the TÜV performance test.
DANGER
TOXIC GASES
Danger of intoxication by inhalation. Serious injuries or death.
▸ Operate the system in adequately vented areas or rooms.
▸ Use gas detection systems
▸ Perform regular leak tightness checks.
DANGER
RISK OF EXPLOSIONS IN EXPLOSIVE ATMOSPHERES
Death and serious injuries.
▸ Do not operate PowerCEMS100 in explosive atmospheres (areas).
DANGER
HAZARD BY EXPLOSIVE AND COMBUSTIBLE GASES
Death and serious injuries.
▸ Do not lock or block exhaust air openings in the cabinet top.
▸ Do not operate PowerCEMS100 in closed rooms.
▸ Install monitoring (on LEL).
▸ Perform regular leak tightness checks.
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2 FOR YOUR SAFETY
2.7 Note
DANGER
DANGEROUS VOLTAGE
The system is supplied with power voltage. Danger of electric shock.
Contact causes death, burns or shock.
▸ Only qualified personnel may perform electrical work on the system.
▸ Interrupt the power supply.
▸ Check residual voltages on system components.
▸ Increased attention.
DANGER
SUSPENDED LOADS
Danger through suspended loads. Serious injuries or death.
▸ Never stand under suspended loads.
▸ Special attention when lifting the loads.
▸ Comply with the lifting instructions to prevent head injuries and
other accidents.
▸ Use suitable lifting equipment.
▸ Wear protective helmet and safety boots.
NOTE
SYSTEM GUARANTEE
Any guarantee claim becomes void when:
● Safety information and measures in this document are disregarded.
● Parts or components on the PowerCEMS100 are installed, fitted or changed without
authorization.
● The PowerCEMS100 is changed or modified.
NOTE
SYSTEM DAMAGE
Damage on system components or parts can cause malfunctions of the complete Pow-
erCEMS100.
▸ Do not ignore system components or parts damaged during transport.
▸ Contact SICK Service in this case.
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FOR YOUR SAFETY 2
2.8 Intended use
The PowerCEMS100 is a multi-component analysis system designed for continuous flue
gas and emission monitoring for industrial combustion plants and processes.
The sample gas is taken at a sampling point and fed through the analysis system
(extractive measurement).
Any warranty claim against SICK AG becomes void when the product is used for any other
purpose or is modified.
2.9 Requirements on the personnel's qualification
Note
Qualified persons
● Qualified persons are those who, based on their training, knowledge and
experience as well as their knowledge of relevant regulations and standards,
are capable of carrying out the tasks given and recognizing and avoiding
independently hazards involved.
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2 FOR YOUR SAFETY
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PRODUCT DESCRIPTION 3
3 Product description
3.1 Features of the PowerCEMS100
The PowerCEMS100 is a cold dry multi component analysis system for continuous
measurement and monitoring of gases.
Performance-tested version (EN 15267-3): GMS800
The PowerCEMS100 operates in extractive mode, i.e. the gas to be measured is withdrawn
from the gas duct using a gas sampling probe and fed to the analysis system via a heated
(controlled or self-limiting) sample gas line.
Refer to the Technical System Documentation for individual, system-specific equipment
and/or project-specific version of the PowerCEMS100 analysis system
3.2 Method of operation
● Test gas feed is performed cyclically and can additionally be started manually.
● “Uncertain operating states” are shown in the status indicator.
The PowerCEMS100 analysis system remains in Measuring mode
● Should a malfunction occur, the device switches automatically to “Stand-By”.
3.3 Functional principle
Fig. 1: Functional principle PowerCEMS100 (example)
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3 PRODUCT DESCRIPTION
3.4 Internal functional units
● GMS811 gas analyzers.
● BCU (Basic Control Unit).
● Components for supply / regulation of heated (external) sample gas lines and heated
gas sampling probes (option).
● Sample gas delivery unit:
– Pump module GMS800
>
Filter
>
Pressure measurement
>
Humidity measurement
– External sample gas pump for hose lengths > 25 m
– Control valves / needle valves (option)
– Flowmeter (option)
● Sample gas conditioning:
– Sample gas cooler with optional:
>
Flowmeter
>
Needle valve
>
Condensate pump
>
Filter
>
Humidity sensor
– Sample gas filter (option)
– Condensate collection container with level monitor
– Water trap
– Sample gas monitoring (flow)
● Span gas / test gas feed unit:
– Solenoid valves
– Humidifier container (option)
● (NO
x
) Sample gas converter (option)
● Terminal strips for customer analog/digital connection
● Interface modules (options)
Legend
1
Test equipment
2
Gas conditioning
3
Analyzer
4
Analog output
5
NO
x
converter
6
Sample gas cooler
7
Condensate container
8
Option (test gas valves)
9
Analog
10
Binary
11
Pneumatic
12
Sample gas outlet
13
Calibration gas inlets
14
Sample gas inlet
Refer to the relevant Operating Instructions and Technical Information for
further information.
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PRODUCT DESCRIPTION 3
3.5 External functional units
● Gas sampling probes
● Sample gas lines
● on the process (stack, slot, duct) (option)
–Temperature sensors
– Pressure sensors
– Gas flow rate measuring devices (e.g. FLOWSIC)
– Dust measuring devices (e.g. DUSTHUNTER)
3.6 Measuring components
Refer to the Information of the analyzer and the System/Project Documentation for system-
specific details and information on the measuring components.
3.7 Interfaces
● Measured value, status and control outputs
– Measured value outputs (analog), freely selectable (0 / 2 / 4 ... 20 mA linear)
– Status and control outputs
● Measured value and control inputs
– Measured value inputs (analog)
(0 / 2 / 4 ... 20 mA or 0 ... 10V)
● RS485 - Modbus RTU
● Ethernet
– Modbus TCP
–OPC DA
–SOPAS ET
● Voltage supply (system-specific)
– 400V, 50Hz
– 400V, 60Hz
– 230V, 50Hz
– 230V, 60Hz
– 115V, 50Hz
– 115V, 60Hz
● UPS connection / supply (option)
The external functional units are project-specific / system-specific. Refer to the
Technical System Documentation for details.
Possible measuring components
[1]
[1] According to built-in analyzer and equipment of the PowerCEMS100
CO, NO, SO
2
, CO
2
, CH
4
, O
2
[2]
[2] Paramagnetic/electrochemical
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3.8 Description of system components
3.8.1 Exterior view
Fig. 2: PowerCEMS100 Exterior view of front panel without cooling unit
Legend
1
Air inlet (optionally fitted cooling unit on the side)
2
Main power switch
3
Status indicators: Measuring / Maintenance /
Failure
4
BCU operator panel (Basic Control Unit)
5
Key switch - probe calibration
6
Key switch - maintenance
Optional RJ45 socket - BCU Ethernet connection
Position: Roof or door (not shown)
Note
The layout can vary specific to the system.
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PRODUCT DESCRIPTION 3
3.8.2 Interior view
Fig. 3: PowerCEMS100 interior views
3.8.3 Parts list
Legend
1
Condensate container
2
Sample gas cooler
3
Gas analyzers
4
BCU signal unit
5
Terminal strips / fuses / relays
6
BCU operator panel (rear)
7
Temperature controller for sample gas lines
8
Flue gas collector
9
Sample gas pump
10
Zero gas humidification
Note
The layout can vary specific to the system.
Refer to the Technical System Documentation for a detailed parts list of the
system components.
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3.9 Gas flow plan
Fig. 4: PowerCEMS100 gas flow plan
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