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MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
PowerCEMS100
Customized analyzer system
Installation, operation, maintenance
Cover
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Described product
Product name: PowerCEMS100
Document identification
Title: Operating instructions PowerCEMS100
Document ID: 8019897
Version: V2-0
Date of issue: 2016-04
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Telephone: +49 (0)7641 469 0
Fax: +49 (0)7641 469 1149
E-mail: info.pa@sick.de
Production location
SICK AG
Nimburger Str. 11 · 79276 Reute · Germany
Legal notices
This work is protected by copyright. The associated rights are reserved
by 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, expurgation 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.
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Contents
1 About this document................................................................................. 7
1.1 Limitation of liability........................................................................................7
1.2 Purpose of this document...............................................................................7
1.3 Target groups ..................................................................................................7
1.4 Further information .........................................................................................7
1.5 Other relevant technical documents/information .........................................8
1.6 Document conventions ...................................................................................8
2 Safety information..................................................................................... 9
2.1 Supplementary safety notes........................................................................... 9
2.2 Safety conventions..........................................................................................9
2.3 Warning symbol.............................................................................................10
2.4 Mandatory signs............................................................................................10
2.5 Warning on the system .................................................................................11
2.6 Safety notes ..................................................................................................11
2.7 Notes .............................................................................................................13
2.8 Intended use .................................................................................................13
2.9 Requirements for the qualification of personnel.........................................13
3 Product description .................................................................................15
3.1 Characteristics of the PowerCEMS100........................................................15
3.2 Operating principle........................................................................................15
3.3 Principle of operation....................................................................................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 the system components .......................................................18
3.8.1 Exterior view..................................................................................18
3.8.2 Interior view ..................................................................................19
3.8.3 Bill of materials.............................................................................19
3.9 Gas flow plan.................................................................................................20
4 Transport...................................................................................................23
4.1 Remove transport locks ................................................................................23
4.2 Check the mountings and connections........................................................23
4.3 Insert filter elements and diffuser beads ....................................................23
5 Installation ................................................................................................25
5.1 Preparing the setup location ........................................................................25
5.2 Inserting the NO
x
converter cartridge (optional)..........................................26
5.3 Preparation of the gas sampling probe........................................................26
5.4 Gas lines........................................................................................................26
Contents
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5.5 Preparation for the electrical installation.................................................... 28
5.5.1 Cable input on the analyzer cabinet............................................ 29
5.5.2 Preparing the supply voltage ....................................................... 29
5.6 External components and signaling devices ............................................... 29
5.7 Connection to the customer system ............................................................ 29
6 Commissioning ........................................................................................ 31
6.1 Commissioning of the humidifier containers (optional).............................. 31
6.2 Before switching on ...................................................................................... 31
6.3 Switching on the PowerCEMS100 analysis system .................................... 32
6.4 Commissioning the sample gas cooler........................................................ 32
6.5 Commissioning the analyzers ...................................................................... 32
6.6 Commissioning the NO
x
converter (optional) .............................................. 33
6.7 Commissioning the cabinet air conditioning ............................................... 33
6.8 Commissioning the heated gas sampling probe ......................................... 34
6.9 Recommissioning after extended downtime............................................... 35
7 Operation ..................................................................................................37
7.1 Operation of the system components.......................................................... 37
7.2 Arrangement and functions of system components ................................... 37
7.3 System parameters ...................................................................................... 37
7.4 Operating elements on the BCU control console ........................................ 37
7.5 Switching on.................................................................................................. 38
7.6 BCU operating functions overview – menu structure in SOPAS................. 39
8 Adjusting ................................................................................................... 41
8.1 Purpose of an adjustment............................................................................ 41
8.2 The adjustment process............................................................................... 41
8.3 Adjustment procedure.................................................................................. 42
8.4 Test gas pressure ......................................................................................... 42
8.5 Flow values ................................................................................................... 42
8.6 Stopping adjustment .................................................................................... 42
8.6.1 Troubleshooting............................................................................ 43
8.6.2 Resetting the maintenance requirement after automated
adjustment stoppage ................................................................... 43
8.6.3 Manual adjustment stoppage 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 poisonous/damp sample gases.................. 45
9.1.3 Switching off ................................................................................. 46
9.1.4 Shutting down............................................................................... 46
9.1.5 Storage ......................................................................................... 46
9.2 Disposal ........................................................................................................ 47
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10 Repair ........................................................................................................49
10.1 Important safety notes for repairs................................................................49
10.2 Operating mode – maintenance...................................................................50
10.3 Visual inspection/operational 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 Incident management (BCU error messages)..............................................59
11.3 Incident management (other faults) ............................................................60
11.4 Starting conditions/supplement to troubleshooting ...................................61
12 Specifications...........................................................................................63
12.1 EU declaration of conformity ........................................................................63
12.2 Dimensions....................................................................................................63
12.3 Technical data ...............................................................................................64
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ABOUT THIS DOCUMENT 1
1About this document
1.1 Limitation of liability
1.2 Purpose of this document
This document describes the:
● Installation
● Operation
● Repair
of the PowerCEMS100
1.3 Target groups
This document is intended for qualified persons who install, operate and repair the
PowerCEMS100.
1.4 Further information
Special local conditions
The local laws, regulations, technical rules and internal company operating instructions at
the usage site must be observed.
Storage of documents
This document and other relevant technical documents/information:
● Must be kept for reference purposes.
● Must be handed on to new operating entities/new specialist personnel.
Note
This document:
● Contains information required during the life cycle of the PowerCEMS100.
● Must be made available to all those who work with the system.
Read this document carefully and ensure that you have fully understood the
contents before you work with the PowerCEMS100.
Note
Applicable standards and regulations, the latest state of technological
development, and our many years of knowledge and experience have all been
taken into account when assembling the data and information contained in this
document.
The manufacturer accepts no liability for damage caused by:
● Failure to observe this document
● Non-compliance with notes and regulations
● Unauthorized mounting and installation
● Technical modifications
● Use of unauthorized spare parts, consumables, and accessories
With special variants, where optional extras have been ordered, or owing to
the latest technical changes, the actual scope of delivery may vary from the
features and illustrations shown here.
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1 ABOUT THIS DOCUMENT
1.5 Other relevant technical documents/information
There are customized designs of the PowerCEMS100 with adjusted internal or peripheral
equipment. Corresponding information can be found in separate supplied documents.
● Gas analyzer operating instructions.
● Operating instructions of additional components (optional):
– Sampling probe
–Sample gas lines
– Components for the temperature regulation of the external (controlled heated)
sample gas lines
–NO
x
converter
● Operating instructions/data sheet for the system control unit:
– BCU (with operating console)
● Operating instructions/data sheets for components of the control cabinet air
conditioning system and illumination (optional):
– Cabinet cooling device
–Cabinet fan
– Control cabinet light (standard)
● Operating instructions/data sheets for sample gas preparation and test gas supply
components (optional):
– Sample gas pump
– Sample gas cooler (including condensate pump)
– Test gas valves (solenoids)
– Humidifier container
– Sample gas monitoring
– Water trap (moisture separator)
● Display of the spatial arrangement of system components
● Circuit diagram
● Connection diagram
● Wiring plan
● Gas flow plan
1.6 Document conventions
▸ Usage instruction
All units of measurement in this document are metric units.
Subject to change without notice. Figures may differ from the actual design.
Reference to another document
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SAFETY INFORMATION 2
2 Safety information
2.1 Supplementary safety notes
2.2 Safety conventions
Safety symbols on the system and the system components, as well as safety notes and
safety labels, correspond to the current guidelines and standards.
The safety conventions for signal words used in this document correspond with ANSI Z535.6:
Note
Read and follow the safety notes in this document.
WARNING
▸ Read this document carefully before working on the PowerCEMS100.
▸ Only qualified persons from the relevant departments are allowed to
work on the PowerCEMS100.
▸ Follow operating processes.
▸ Follow local regulations.
▸ Follow local regulations concerning working with gas and electrical
components.
▸ Only authorized persons are allowed access to the PowerCEMS100.
DANGER
DANGER describes a hazardous situation which will result in death or
severe injury if not avoided.
WARNING
WARNING describes a hazardous situation which may result in severe
or fatal injuries if not avoided.
CAUTION
CAUTION indicates a potentially hazardous situation, which may lead
to property damage if not prevented.
NOTE
NOTE indicates possible damage to property or material damage.
Note
Important information and useful notes.
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2 SAFETY INFORMATION
2.3 Warning symbol
2.4 Mandatory signs
Sign Meaning
Warning about a hazardous point
Warning about hazardous electrical voltage
Warning about explosive atmospheres
Warning about explosive substances
Warning about flammable substances
Warning about oxidizing substances
Warning about poisonous substances
Warning about corrosive substances
Warning about substances that are detrimental to health or irritating
Warning about gas bottles
Warning about suspended loads
Warning about hazards for the environment, nature and organic life
Sign Meaning
Wear breathing protection
Use headgear
Use foot protection
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SAFETY INFORMATION 2
2.5 Warning on the system
2.6 Safety notes
CAUTION
HAZARDOUS GASES
Risk of poisoning due to inhalation.
▸ Conduct pressure and leakage tests at regular intervals.
▸ Observe the operating instructions
Note
▸ The operating entity has sole responsibility for conducting the pressure and
leakage tests.
▸ For this purpose, observe the corresponding certification decision, the
official regulations as well as the TÜV suitability test.
DANGER
TOXIC GASES
Risk of poisoning due to inhalation. Serious injury or death.
▸ Operate the system in sufficiently ventilated areas or rooms.
▸ Use gas monitoring systems.
▸ Conduct regular leak tightness tests.
DANGER
DANGER OF EXPLOSIONS IN EXPLOSIVE ATMOSPHERE
Death and serious injuries.
▸ Do not operate the PowerCEMS100 in explosive atmospheres (areas).
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2 SAFETY INFORMATION
DANGER
DANGER DUE TO EXPLOSIVE AND FLAMMABLE GASES
Death and serious injuries.
▸ Do not seal or block exhaust openings in the cabinet roof.
▸ Do not operate the PowerCEMS100 in closed rooms.
▸ Install monitoring (at LEL).
▸ Conduct regular leak tightness tests.
DANGER
HAZARDOUS ELECTRICAL VOLTAGE
The system is supplied with mains voltage. Risk of electric shocks.
Contact causes death, burns or shock.
▸ Only qualified specialist personnel may conduct electrical work on
the system.
▸ Interrupt the voltage supply.
▸ Check residual voltages on the system components.
▸ Increased attention.
DANGER
SUSPENDED LOADS
Risk due to suspended loads. Severe injury or death.
▸ Never stand under suspended loads.
▸ Pay close attention when lifting loads.
▸ Comply with lifting instructions in order to prevent head injuries and
other accidents.
▸ Use suitable lifting tools.
▸ Wear a protective helmet and safety shoes.
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SAFETY INFORMATION 2
2.7 Notes
2.8 Intended use
The PowerCEMS100 is a multi-component analysis system and is used for continual flue
gas and emission monitoring in industrial combustion systems and for the monitoring of
processes.
The sample gas is collected at a measuring point and guided through the analysis system
(extractive measurement).
If the product is used for any other purpose or modified in any way, any warranty claim
against SICK AG shall become void.
2.9 Requirements for the qualification of personnel
NOTE
SYSTEM WARRANTY
Any claim under warranty shall expire if:
● Safety notes and measures in this document are ignored.
● Parts or components are installed, assembled or changed on the PowerCEMS100
without authorization.
● The PowerCEMS100 is changed or modified.
NOTE
SYSTEM DAMAGE
Damage to system components or parts may lead to malfunctions of the entire
PowerCEMS100.
▸ Do not ignore system components or parts damaged during transport.
▸ In such cases, contact SICK service.
Note
Qualified persons
● Qualified persons have the specialist training, skills, and experience, as well
as knowledge of the relevant regulations and standards, to be able to
perform work assigned to them and to identify and avoid any potential
dangers independently.
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2 SAFETY INFORMATION
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PRODUCT DESCRIPTION 3
3 Product description
3.1 Characteristics of the PowerCEMS100
The PowerCEMS100 is a CD (cold dry) multi-component analysis system for the continual
measurement and monitoring of gases.
Suitability-tested version (EN 15267-3): GMS800
The PowerCEMS100 works on an extractive basis, i.e. the gas to be measured is removed
from the gas channel using a gas sampling probe and guided to the analysis system via
heated (controlled or self-limiting) sample gas lines.
The individual system-specific equipment and the project-specific design of the
PowerCEMS100 analysis system can be found in the technical system documentation
3.2 Operating principle
● Test gas tasks are carried out cyclically and can also be started manually.
● "Unsafe operational statuses" are visualized in status displays.
The PowerCEMS100 analysis system remains in measurement mode
● In the event of a fault, there is an automated switch to "stand-by" mode.
3.3 Principle of operation
Fig. 1: PowerCEMS100 principle of operation (example)
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3.4 Internal functional units
● GMS811 gas analyzers.
● BCU (Basic Control Unit).
● Components for the supply/regulation of heated (external) sample gas lines and heated
gas sampling probes (optional).
● Sample gas conveyor:
– Pump module GMS800
>
Filter
>
Pressure measurement
>
Moisture measurement
– External sample gas pump with hose lengths > 25 m
– Regulating valves/needle valves (optional)
– Flow meter (optional)
● Sample gas preparation:
– Sample gas cooler with optional:
>
Flow meter
>
Needle valve
>
Condensate pump
>
Filter
>
Moisture sensor
– Sample gas filter (optional)
– Condensate collection container with level monitoring
– Water trap
– Sample gas monitoring (flow)
● Reference gas/test gas feeding unit:
– Solenoids
– Humidifier container (optional)
● (NO
x
) sample gas converter (optional)
● Terminal strips for customer connection analog/digital
● Interface modules (optional)
Legend
1
Test equipment
2
Gas conditioner
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 output
13
Calibration gas inputs
14
Sample gas inlet
Further information can be found in the relevant operating instructions and
technical information.
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PRODUCT DESCRIPTION 3
3.5 External functional units
● Gas sampling probes
● Sample gas lines
● In-process (stack, shaft, channel) (optional)
–Temperature sensors
– Pressure sensors
– Gas velocity measurement devices (e.g. FLOWSIC)
– Dust measuring devices (e.g. DUSTHUNTER)
3.6 Measuring components
System-specific details and information on the measuring components can be found in the
information on the analyzer and the system/project documentation.
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)
– 400 V, 50 Hz
– 400 V, 60 Hz
– 230 V, 50 Hz
– 230 V, 60 Hz
– 115 V, 50 Hz
– 115 V, 60 Hz
● UPS connection/supply (optional)
The external functional units are project/system-specific. Details can be found
in the technical system documentation.
Possible measuring components
[1]
[1] As per installed 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 the system components
3.8.1 Exterior view
Fig. 2: PowerCEMS100 exterior view front side without air conditioning device
Legend
1
Air inlet (optional, side-mounted air conditioning device)
2
Mains switch
3
Status displays: Measuring/maintenance/failure
4
BCU (Basic Control Unit) control console
5
Key-operated pushbutton – probe calibration
6
Key-operated pushbutton – maintenance
Optional RJ45 female connector – BCU Ethernet connection
Position: roof or door (not shown)
Note
The structure may vary on a system-specific basis.
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PRODUCT DESCRIPTION 3
3.8.2 Interior view
Fig. 3: PowerCEMS100 interior views
3.8.3 Bill of materials
Legend
1
Condensate container
2
Sample gas cooler
3
Gas analyzers
4
BCU signal unit
5
Terminal strips/fuses/relay
6
BCU operating console (rear)
7
Temperature controller for sample gas lines
8
Exhaust collector
9
Sample gas pump
10
Zero gas humidification
Note
The structure may vary on a system-specific basis.
The detailed parts list for the system components can be found in the technical
system documentation.
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3.9 Gas flow plan
Fig. 4: PowerCEMS100 gas flow plan
/