SICK PowerCEMS100 Operating Instructions Manual
SICK PowerCEMS100 Operating Instructions Manual

SICK PowerCEMS100 Operating Instructions Manual

Customer-specific analysis system
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Title Page
MMMOPERATING INSTRUCTIONS
MMMI
O P E R A T I N G I N S T R U C T I O N S
PowerCEMS100
Customer-specific Analysis System
Installation, Operation, Maintenance

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Summary of Contents for SICK PowerCEMS100

  • Page 1 Title Page MMMOPERATING INSTRUCTIONS MMMI O P E R A T I N G I N S T R U C T I O N S PowerCEMS100 Customer-specific Analysis System Installation, Operation, Maintenance...
  • Page 2 Original document This document is an original document of SICK AG. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 3: Table Of Contents

    (option) ...........26 Preparing the gas sampling probe ...............26 Gas lines ......................26 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 4 Decommissioning ................. 46 9.1.5 Storage ..................46 Disposal ......................47 O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 5 12.1 EU Declaration of Conformity ...............63 12.2 Dimensions....................63 12.3 Technical data ....................64 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 6 CONTENT O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 7: About This Document

    Must be passed on to a new operator / new qualified personnel ● 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 8: Other Applicable Technical Documents/Information

    All units and of measurement in this document are metric units. Subject to change without notice. Illustrations may differ from the actual design. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 9: For Your Safety

    NOTE indicates potential damage to property and materials. Note Important information and useful tips. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 10: Warning Signs

    Significance Wear respiratory equipment Wear head protection Wear foot protection O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 11: Warning Information On The System

    Install monitoring (on LEL). ▸ Perform regular leak tightness checks. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 12: Note

    Do not ignore system components or parts damaged during transport. ▸ Contact SICK Service in this case. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 13: Intended Use

    8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 14 FOR YOUR SAFETY O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 15: Product Description

    Should a malfunction occur, the device switches automatically to “Stand-By”. ● Functional principle Fig. 1: Functional principle PowerCEMS100 (example) 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 16: Internal Functional Units

    Terminal strips for customer analog/digital connection ● Interface modules (options) ● O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 17: External Functional Units

    – 115V, 50Hz – 115V, 60Hz UPS connection / supply (option) ● 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 18: Description Of System Components

    Position: Roof or door (not shown) Note The layout can vary specific to the system. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 19: Interior View

    Refer to the Technical System Documentation for a detailed parts list of the system components. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 20: Gas Flow Plan

    PRODUCT DESCRIPTION Gas flow plan Fig. 4: PowerCEMS100 gas flow plan O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 21 Design and designations of system components can vary specific to the system. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 22 PRODUCT DESCRIPTION O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 23: Transport

    Filter elements and bubbling frits must be installed and/or filled before commissioning. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 24 TRANSPORT O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 25: Installation

    Dispose of condensate according to valid local environment protec- tion guidelines. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 26: Inserting The No X Converter Cartridges (Option)

    The system-specific version of the PowerCEMS100 system cabinet may vary, refer to the view drawings in the Technical System Documentation. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 27 ▸ Wear suitable protective gloves and respiratory equipment. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 28: Preparing The Electrical Installation

    Never disconnect or remove the protective conductors in the measuring system or in the power supply line. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 29: Cable Inlet On The System Cabinet

    – Voltage supply – Signal lines – Integration of all external components 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 30 INSTALLATION O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 31: Commissioning

    ▸ Catalyzer cartridge inserted in NO converter. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 32: Switching On The Powercems100 Analysis System

    Refer to the details on clearing malfunctions in this system description as well as in the Analyzer Operating Instructions. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 33: Start-Up For The No X Converter (Option)

    / ambient temperatures are too low or high. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 34: Commissioning Of The Heated Gas Sampling Probe

    Serious injuries of the respiratory system or death. ▸ Wear suitable respiratory equipment. ▸ Ensure adequate ventilation. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 35: Restarting After Longer Shutdown

    Refer to the Operating Instructions for the individual system components for further details and information. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 36 COMMISSIONING O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 37: Operation

    MEAS - Measuring screen Function buttons F1, F2, F3, F4 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 38: Switching On

    Refer to the “Supplementary Operating Instructions BCU” for detailed informa- tion on operating the BCU operator panel. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 39: Bcu Operating Functions Overview - Menu Structure In Sopas

    Location ● IP address CAN baud rate Time | Temperature 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 40 “Supplementary Operating Instructions BCU” for detailed informa- tion on the BCU operating functions. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 41: Adjusting

    The specific adjustment cycles depend on the application and are not the responsibility of SICK AG. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 42: Adjustment Procedure

    Only then can a new adjustment procedure be started. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 43: Clearing Malfunctions

    After a manual adjustment abort, the adjustment values are discarded. ▸ Maintenance request is not activated. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 44 ADJUSTING O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 45: Decommissioning

    Refer to the Operating Instructions of the respective analyzer for details on operation and menu functions. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 46: Switching Off

    “dry”, neutral gas. This helps to prevent condensation. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK...
  • Page 47: Disposal

    Refer to the relevant Operating Instructions for information on disposal of cabinet cooling unit. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 48 DECOMMISSIONING O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 49: Maintenance

    Wear personal protective equipment (gloves, respiratory protection). DANGER HOT SURFACES Serious skin burns. ▸ Wear gloves. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 50: Operating State - Maintenance

    – Connections of the PowerCEMS100 – Connections of the probe O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 51: Maintenance Intervals

    Caution: Serious damage to environment, nature and health by toxic condensate. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 52 Clean or replace lines / hoses as necessary. Control cabinet Note: Observe relevant Operating Instructions. cooler (option) O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 53: Cleaning Information

    1 pc./ 1 y. Fi56NK3 Front fitted filter Diaphragm fine filter (view filter) 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 54 5 312 319 Coalescence filter K-AGF- 1 pc./ 1 y. Sales unit=1 pc. PV-30-A (5317088) O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 55 5 310 689 Peltier cooler M&C/ECP102 1 pc./ 3 y. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 56 230 V / 50 Hz; 115 V / 60 Hz (01P1000) O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 57 1 pc./ 1 y. Stainless steel wool filling, T=660°C, with spare O-ring set. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 58: External Components - Wear Parts (Wp) / Spare Parts (Sp)

    5 306 625 Gas sampling probe SP180-H 2 pcs./ 1 y. O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 59: Troubleshooting

    Replace heating element. temperature too high / too [1] Heating circuit 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 60: Clearing Malfunctions (Other Malfunctions)

    Replace faulty or corroded ground- ing. Inadequate power supply. Check. Check. Faulty interfaces O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 61: Switch-On Conditions / Additions To Clearing Malfunctions

    – Monitoring the pump function is controlled via the gas analyzer. 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 62 TROUBLESHOOTING O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 63: Specifications

    Fig. 9: PowerCEMS100 outer dimensions Legend 800 mm 2100 mm 600 mm 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 64: Technical Data

    RS-422 (option) RS-485 (option) Ethernet TCP/IP Bus protocol Modbus TCP O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 8019897/V2-0/2017-12| SICK Subject to change without notice...
  • Page 65 Automatic check and adjustment with test gases Options converter Cooling unit Heating Bypass pump 8019897/V2-0/2017-12| SICK O P E R A T I N G I N S T R U C T I O N S | PowerCEMS100 Subject to change without notice...
  • Page 66 Phone +36 1 371 2680 Phone +386 591 78849 E-Mail ertekesites@sick.hu E-Mail office@sick.si India South Africa Phone +91-22-6119 8900 Phone +27 (0)11 472 3733 E-Mail info@sick-india.com E-Mail info@sickautomation.co.za Further locations at www.sick.com SICK AG | Waldkirch | Germany | www.sick.com...

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