SICK MCS200HW User manual
OPERATING INSTRUCTIONS
MCS200HW
Multicomponent Analysis System
Described product
MCS200HW
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
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 modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten 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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Subject to change without notice
Contents
1 About this document........................................................................ 6
1.1 Function of this document....................................................................... 6
1.2 Scope of application................................................................................. 6
1.3 Target groups............................................................................................ 6
1.4 Further information................................................................................... 6
1.5 Symbols and document conventions...................................................... 6
1.5.1 Warning symbols...................................................................... 6
1.5.2 Warning levels / Signal words................................................. 7
1.5.3 Information symbols................................................................ 7
1.6 Data integrity............................................................................................. 7
2 Safety information............................................................................ 8
2.1 Basic safety information........................................................................... 8
2.2 Warning information on device................................................................ 8
2.3 Intended use............................................................................................. 9
2.4 Responsibility of user............................................................................... 9
2.5 User qualification...................................................................................... 10
3 Product description........................................................................... 11
3.1 Product identification............................................................................... 11
3.2 Gas supply terminology............................................................................ 11
3.3 Layout and function.................................................................................. 12
3.3.1 Analyzer cabinet....................................................................... 14
3.3.2 Gas sampling unit.................................................................... 15
3.3.3 Heated sample gas line........................................................... 15
3.3.4 Hose bundle line...................................................................... 15
3.3.5 Instrument air conditioning (option)....................................... 15
3.3.6 Integrated GMS811 FIDORi (option)...................................... 16
3.4 Extended interfaces (optional)................................................................. 16
3.5 Remote maintenance (optional).............................................................. 16
4 Transport and storage....................................................................... 17
4.1 Transport................................................................................................... 17
4.2 Protective measures for long-term storage............................................. 18
5 Mounting............................................................................................. 19
5.1 Safety......................................................................................................... 19
5.2 Scope of delivery....................................................................................... 19
5.3 Checklist for mechanical and electrical installation............................... 19
5.4 Installing the analyzer cabinet................................................................. 20
5.5 Assembly information for sample gas lines and hose bundle line........ 20
5.6 Installation sequence............................................................................... 21
5.6.1 Connect the sample gas line to the analyzer......................... 21
5.6.2 Tube screw fittings................................................................... 22
CONTENTS
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5.6.3 Connecting the signal lines to the analyzer........................... 22
5.6.4 Setting the pressure reducer module.................................... 22
5.6.5 Connecting the valve block..................................................... 23
5.6.6 Connecting the span gases..................................................... 24
5.6.7 Connect sample gas outlet..................................................... 25
6 Electrical installation........................................................................ 26
6.1 Safety......................................................................................................... 26
6.2 Equipment protection............................................................................... 26
6.3 Disconnecting device................................................................................ 26
6.4 Socket for Service work............................................................................ 26
6.5 Electrical connections.............................................................................. 26
7 Commissioning.................................................................................. 28
7.1 Before switching on.................................................................................. 28
7.2 Switching on.............................................................................................. 28
7.3 Recognizing the safe operating state...................................................... 28
7.4 Adjusting.................................................................................................... 28
7.4.1 Performing zero point adjustment.......................................... 28
7.4.2 Performing reference point adjustment................................. 29
8 Operation............................................................................................ 31
8.1 Operating concept.................................................................................... 31
8.2 User groups............................................................................................... 31
8.3 Display....................................................................................................... 31
8.4 Tiles........................................................................................................... 32
8.5 Measuring Screen..................................................................................... 33
9 Menus.................................................................................................. 34
9.1 Password................................................................................................... 34
9.2 Menu tree.................................................................................................. 34
10 Maintenance...................................................................................... 38
10.1 Important information.............................................................................. 38
10.1.1 Information on span gases..................................................... 39
10.2 Cleaning..................................................................................................... 39
10.3 Maintenance plan..................................................................................... 40
10.4 Checking the system................................................................................ 40
10.5 Maintaining the instrument air conditioning........................................... 41
10.6 Replacing the filter pads.......................................................................... 42
11 Troubleshooting................................................................................. 44
11.1 Important information.............................................................................. 44
11.2 Error messages and possible causes..................................................... 45
11.3 Measured values erroneous.................................................................... 48
11.4 Replacing the electronics filter pad......................................................... 48
CONTENTS
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12 Decommissioning............................................................................. 49
12.1 Switch-off states....................................................................................... 49
12.2 Shipping for repair.................................................................................... 49
12.3 Transport................................................................................................... 50
12.4 Disposal..................................................................................................... 50
13 Technical data.................................................................................... 51
13.1 Dimension drawings................................................................................. 51
13.2 Technical data........................................................................................... 52
13.2.1 Measuring parameters............................................................ 52
13.2.2 Ambient conditions.................................................................. 53
13.2.3 Design....................................................................................... 53
13.2.4 Interfaces and protocols......................................................... 54
13.2.5 Voltage supply.......................................................................... 54
13.2.6 Supply gases............................................................................ 55
13.2.7 Tube connections..................................................................... 55
13.2.8 Sample gas conditions............................................................ 55
13.2.9 Heated sample gas lines......................................................... 55
13.2.10 Connections in analyzer.......................................................... 56
13.2.11 Circuit breakers........................................................................ 59
13.2.12 Torques..................................................................................... 60
14 Annex.................................................................................................. 61
14.1 Conformities.............................................................................................. 61
14.2 Licences.................................................................................................... 61
CONTENTS
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1 About this document
1.1 Function of this document
These Operating Instructions describe:
•Device components
•Assembly
•Commissioning
•Operation
•Maintenance work required for reliable operation
•Troubleshooting
•Decommissioning
1.2 Scope of application
These Operating Instructions are only applicable for the measuring device described in
the product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 Target groups
This Manual is intended for persons commissioning, operating and maintaining the
device.
1.4 Further information
•SFU Gas Sampling Unit Operating Instructions
•Sample Gas Line Operating Instructions
•System documentation
•Option: MPR (Meeting Point Router) Operating Instructions
•Option: Instrument Air Conditioning Operating Instructions
•Option: GMS800 FIDOR / FIDORi Operating Instructions
•Option: Condensate Container Operating Instructions
1.5 Symbols and document conventions
1.5.1 Warning symbols
Table 1: Warning symbols
Symbol Significance
Hazard (general)
Hazard by voltage
Hazard by acidic substances
Hazard by noxious substances
1 ABOUT THIS DOCUMENT
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Symbol Significance
Hazard by toxic substances
Hazard by high temperature
Hazard for the environment/nature/organic life
1.5.2 Warning levels / Signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
Note
Hints
1.5.3 Information symbols
Table 2: Information symbols
Symbol Significance
Important technical information for this product
Important information on electric or electronic functions
1.6 Data integrity
SICK AG uses standardized data interfaces such as, for example, standard IP technol‐
ogy, in its products. The focus here is on product availability and features.
SICK AG always assumes that the customer is responsible for the integrity and confi‐
dentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection
and patch management.
ABOUT THIS DOCUMENT 1
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2 Safety information
2.1 Basic safety information
Electrical safety
DANGER
Danger to life through electric shock
There is a risk of electric shock when working on the device with the voltage supply
switched on.
bBefore starting work on the device, ensure the voltage supply can be switched off
in accordance with the valid Standard using a power isolating switch/circuit
breaker.
bMake sure the disconnector switch is easily accessible.
bAn additional disconnecting device is mandatory when the power disconnector
switch cannot be accessed or only with difficulty after installation of the device
connection.
bSwitch off the voltage supply before starting any work on the device.
bAfter completion of the work or for test purposes, calibration the power supply may
only be activated again by authorized personnel complying with the safety regula‐
tions.
WARNING
Danger to life by electric voltage
bOnly allow an authorized electrician to work on the electric system
bDisconnect the device from the power supply before performing work on the
device.
WARNING
Endangerment of electrical safety through power cable with incorrect rating
Electrical accidents can occur when the specifications for installation of a power line
have not been adequately observed.
bAlways observe the exact specifications in the Operating Instructions (see "Techni‐
cal data", page 51) for installation of a power line.
Dangerous substances
DANGER
Mortal/health danger as a result of gas path leakage
When the device is used to measure toxic gases: A leak, for example in the purge air
supply, can be an acute hazard for persons.
bRegularly check all gas-carrying components for leaks.
bTake suitable safety measures. For example:
°Attach warning signs to the device.
°Attach warning signs in the operating area.
°Safety-oriented instruction of persons that could be in this area.
2.2 Warning information on device
The following safety symbols are on the device:
2 SAFETY INFORMATION
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Table 3: Warning symbols
Symbol Significance
Warning for general hazard
Warning for hazard by electric voltage, possibly also by residual electric voltage
Warning for hazard through hot surfaces
If you need to work on a subassembly marked with such a symbol:
bRead the relevant Section in these Operating Instructions
bObserve all the safety information in the relevant Section
2.3 Intended use
The MCS200HW is a multicomponent analysis system for continuous flue gas monitor‐
ing of industrial combustion plants (emission measuring system). The sample gas is
extracted at the measuring point and fed through the analysis system (extractive mea‐
surement).
The analysis system is designed for indoor installation.
bRefer to the system documentation delivered for information on the device equip‐
ment.
2.4 Responsibility of user
Designated users
see "User qualification", page 10.
Correct project planning
•Basis of this Manual is the delivery of the device according to the preceding
project planning (e.g., based on the SICK application questionnaire) and the rele‐
vant delivery state of the device (see delivered System Documentation).
wIf you are not sure whether the device corresponds to the state defined dur‐
ing project planning or to the delivered system documentation: Please con‐
tact SICK Customer Service.
Correct use
bUse the device only as described in “Intended use”.
The manufacturer assumes no responsibility for any other use.
bCarry out the specified maintenance work.
bDo not carry out any work or repairs on the device that are not described in this
Manual.
Do not remove, add or change any components in or on the device unless such
changes are officially allowed and specified by the manufacturer.
If you do not observe this:
°The manufacturer's warranty becomes void.
°The device could become dangerous.
SAFETY INFORMATION 2
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Special local conditions
In addition to the information in these Operating Instructions, follow all local laws, tech‐
nical rules and company-internal operating and installation directives applicable wher‐
ever the device is installed.
Read the Operating Instructions
bRead and observe these Operating Instructions.
bObserve all safety instructions.
bIf anything is not clear: Please contact SICK Customer Service.
Document retention
These Operating Instructions
bMust be kept for reference.
bMust be passed on to new owners.
2.5 User qualification
This Manual is intended for persons commissioning, operating and maintaining the
device.
Table 4: Qualification requirements
Tasks User groups Qualification
Assembly Qualified personnel •General knowledge in mea‐
surement technology, special‐
ist device knowledge (possibly
customer training at SICK)
Electrical installation Qualified personnel •Authorized electrician (autho‐
rized skilled electrician or per‐
son with similar training)
•General knowledge in mea‐
surement technology, special‐
ist device knowledge (possibly
customer training at SICK)
Initial start-up Authorized operator Ü•General knowledge in mea‐
surement technology, special‐
ist device knowledge (possibly
customer training at SICK)
Returning to operation
Decommissioning •Operator / system integrator
•Authorized operator Ü
•General knowledge in mea‐
surement technology, special‐
ist device knowledge (possibly
customer training at SICK)
Service training
•Authorized electrician (autho‐
rized skilled electrician or per‐
son with similar training)
•Service training
Operation
Troubleshooting
Maintenance Operator / system integrator Autho‐
rized operator Ü
•General knowledge in mea‐
surement technology, special‐
ist device knowledge (possibly
customer training at SICK)
•Service training
2 SAFETY INFORMATION
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