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Siemens Set CEM CERT Operating Instructions Manual

Continuous gas analysis
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Summary of Contents for Siemens Set CEM CERT

  • Page 3 Introduction General information Description Continuous Gas Analysis Application planning Set CEM CERT Standard Measuring System for Installation Continuous Emission Monitoring Set CEM CERT Connection Operating Instructions Commissioning Operation Functions Service and maintenance Alarm, fault and system messages Technical specifications Dimension drawings...
  • Page 4 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.

  • Page 5: Table Of Contents

    Connection ..............................29 Mechanical installation ........................29 6.1.1 Gas connections ..........................29 6.1.2 Condensate outlet ..........................30 6.1.3 Gas outlet ............................30 6.1.3.1 Gas outlet ............................30 6.1.3.2 Overpressure in the gas channel ....................31 Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 6 Safety information ..........................55 10.2 Maintenance intervals ........................56 10.3 Eliminating the moisture alarm ...................... 58 10.4 Harmful substances in the condensate ..................58 10.5 Emptying the condensate tank ...................... 59 10.6 Spare parts/accessories ......................... 59 Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 7 Returns ............................... 73 A.2.1 Returns ............................... 73 A.2.2 Return address ..........................74 A.2.3 Error Description ..........................75 ESD guidelines ............................77 List of abbreviations ..........................79 List of abbreviations ........................79 Index ................................81 Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 8 Table of contents Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 9: Introduction

    Siemens. The product described in this document has been developed manufactured, tested and documented in compliance with relevant safety standards.

  • Page 10: Disclaimer Of Liability

    We have reviewed the contents of this publication to ensure consistency with the hardware and softwaredescribed. 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. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 11: General Information

    In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions only form one element of such a concept.
  • Page 12 • Prior to its disposal, dilute the condensate with tap water until it turns neutral and the litmus paper does not change color. Alternatively, you can also neutralize the condensate with a weak sodium carbonate solution (Na Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 13 The information in the manuals below must also be observed for proper operation of the Set CEM CERT system: • SIMATIC S7 – S7-1200 Programmable Controller – System Manual • SIMATIC HMI – HMI Devices – Comfort Panels – Operating Instructions There you will also find safety information to be observed when operating the HMI or connecting the system to the S7-1200 programmable controller.

  • Page 14: Notes On Use

    These components are: • Gas analyzers • Gas sampling components • Gas preparation components • System controller • Components for heating, air conditioning and temperature control • System cabinets • NO converter Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 15: Information On Recycling

    It must therefore not be disposed of in this way. Therefore, please be environmentally conscious: • Ensure that this product is recycled at the end of its life cycle through the relevant local facilities. • Observe the relevant regulations in your country. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 16 General information 2.3 Notes on use Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 17: Description

    Overview Set CEM CERT is a standardized and certified continuous emission monitoring system. The Set CEM CERT system is suitable for use in many plants that require a permit in accordance with EU Directive 2010/75/EU, the Industrial Emissions Directive. The modular CEMS meets the current quality standards of EU directives EN 15267 and EN 14181 (QAL1/2/3, AST).
  • Page 18 – Electric heaters and air conditioning units can be configured to extend the ambient temperature range – Version with appropriate sampling probes and heated sample gas lines can be selected Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 19 – DeSOx systems Note Plants in which corrosive aerosols (acid mist) are likely Suitable measures must be taken to remove the corrosive aerosols from the gas matrix. This requires project-specific technical clarification in advance. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 20: Design

    The overall modular measuring system consists of the following tested individual components: • Analyzers for measurement of multiple components. The Set CEM CERT modular measuring system can consist of up to three analyzers in combination with a system cabinet. The performance-tested analyzer(s) are selected separately from the system using the specific article number(s).
  • Page 21 – Bühler, type: GAS222 • Heated sample gas line: max. length 50 m, hold temperature 180 ... 200 °C, 100 W/m Core: PTFE DN 4/6 • Temperature controller: Siemens, type 3RS1042-1GW70 • Two-stage compressor gas cooler: – M&C, type: CSS-V;...
  • Page 22 SIPROCESS GA700 OXYMAT 7 0 ... 25 vol. % 0 ... 5 vol. % (electro- ULTRAMAT 23 7MB2355-Z-T23/-T24/-T25 0 ... 25 vol. % 0 ... 5 vol. % chemical) ULTRAMAT 23 7MB2357-Z-T23/-T24/-T25 ULTRAMAT 23 7MB2358-Z-T23/-T24/-T25 Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 23: Principle Of Operation

    The gas is collected from the gas outlets of the analyzers and discharged from the cabinet via the sample gas outlet (screwed gland for tube DN10/12). Starting from the sample gas outlet, the sample gas must be discharged without back pressure or pressure variations. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 24 Description 3.3 Principle of operation The standard way of operating the Set CEM CERT system is via a touch screen control panel (SIMATIC HMI, KTP700 Basic), which is installed on the front of the system cabinet. Alternatively, the measuring system can also be operated via the individual analyzers.

  • Page 25: Application Planning

    7 days. Also check the following: • Are the surfaces of the system and its components clean and undamaged? • Have any lines been loosened after transport? Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 26 Application planning 4.2 Checking the delivery Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 27: Installation

    T times Note Follow the installation instructions for installing heated sample gas lines (e.g. correct bending radius, routed with a downward slope if possible, no routing of heated sample gas lines side-by-side). Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 28: Installing The Measuring System

    Use lifting equipment designed for the weight of the system (approximately 200 to 400 kg depending on components) for installing the Set CEM CERT system. Generally, only the lifting eyes on the top of the base frame are to be used for lifting the cabinet.

  • Page 29: Installing The Individual Components

    If possible, the probe installation fitting should be at a slight incline from the center of the channel. The installation location should be weather-protected (heat, cold, vibrations). Observe the information and directions in the relevant operating instructions when installing the sampling probes. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 30: Installation Of The Sample Gas Line

    For additional information, refer to the manufacturer's instructions. Connect the sample gas line to the associated connection on the outside of the cabinet and connect the heatable sample gas line to the PTFE tube. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 31: Connection

    The gas lines are typically PTFE tubes that are fastened to the cabinet wall with a PVDF screwed gland. Due to the need for leak-tightness and the high temperature load, stainless steel tubing with a stainless steel fitting (SS316) is provided for hydrogen lines. Figure 6-1 Gas tube Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 32: Condensate Outlet

    Gas outlet Ensure that the exhaust gas line is correctly dimensioned for the number of analyzers. High pressure variations or any back pressure at all is not permitted at the sample gas outlet. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 33: Overpressure In The Gas Channel

    • Voltage: 400 V (-15%, +10%), 50 or 60 Hz, including main switch, 3-phase The fuse protection on the customer end must be selected according to the calculation created by Siemens. This calculation will be created individually upon receipt of the order.

  • Page 34: Connection Of The Power Supply And Signal Lines

    • -X99 Test terminals for analog signals to be measured • -X100 Messages and faults as binary signal (floating contact) • -X101 Analog signals • -X103 Signals for sample gas line and probe Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 35: Commissioning

    Danger of burns Hot contact surfaces > 55°C are marked with a warning notice. Burns may result if these surfaces are touched with bare skin. • Only touch these surfaces when wearing protective gloves. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 36: Leak Test

    If the pressure drop is greater, you must locate the leak. Leak detector spray can be very helpful for this. In this case, also check the gaskets and glands. The leak test can also be performed as a vacuum test with a vacuum pump. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 37: Operating Gases

    • Introduce the calibration gases and perform a manual calibration or autocalibration. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 38: Warm-Up Phase

    The sample gas pump starts up, provided that: • No fault signal 'Moisture in gas path' is pending. • The sample gas cooler has reached its operating temperature (approximately 4 °C). Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 39: Settings After Commissioning

    5. → Select Set calibration gas setpoints 6. → Input sample gas concentration for MR1 and MR2 7. → To save, press the <MEAS> key Repeat this procedure for other components as needed. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 40: Ultramat 6

    3. → (Function) 24 Select AUTOCAL/check 4. → Select AUTOCAL/check sequence 5. You can now assemble the sequence of the AUTOCAL from various parameters 6. → To save the AUTOCAL sequence, press the <MEAS> key Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 41: Operation

    (in this case 'System OK'). You reach the main menu via the <Menu> button. Below the display are eight function keys. On Set CEM CERT, only the <F1> and <F8> keys are active. They have the following meaning: Meaning Access to the input menus;...

  • Page 42: Menu-Based Operation

    This is an example display for explanation of the individual statuses. The colors have the following meaning: Color Meaning Green System is running properly Fault with corresponding message Yellow Maintenance on Orange AUTOCAL -BAx is running Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 43: Main Menu

    Calibration of Access to the calibration menu of the U23/U6/F6 U23/U6/F6 Trend U23/U6/F6 Access to the measured value trend display Service General settings (date/time) Pump on/off Switch-on/switch-off of pump Back Exit the menu Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 44: Submenus

    Access to the setting of time and date Stop runtime Shutdown of the display; this allows access to the basic settings of the HMI → see HMI manual Change language Language selection (English, German, French) Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 45: Calibration Submenus - Ultramat 23

    Control panel Meaning Display of the current time Setting of the start time of a daily AUTOCAL Start AUTOCAL Start of AUTOCAL Calibrate component , e.g. Calibrate Access to the calibration menu Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 46 ENTER Acceptance of the newly calibrated value Start MEAS End of the calibration, return to measuring mode Input of a reference value for the calibration; is currently being used for scaling the Y-axis. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 47: Calibration Submenus - Ultramat 6

    4 = Wednesday Display of the current time Setting of the weekday on which an AUTOCAL is to take place every week Setting of the start time of a weekly AUTOCAL Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 48 Selection of the full-scale value calibration Calibrate Start of a single calibration ENTER Acceptance of the newly calibrated value Start MEAS End of the calibration, return to measuring mode Input of a reference value for the calibration Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 49: Trend Submenu - Ultramat 23/Ultramat 6

    In this submenu, you will find the measured value trend together with the display of the current measured values. This submenu is the same for all analyzers. The submenu for ULTRAMAT 6 is shown here by way of example. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 50: Messages Submenu

    • C (incoming): Pending message • CG (incoming + acknowledged): Acknowledged but still pending message • CQ (incoming + outgoing): Outgoing message Symbol Meaning Information text (none provided here) Selected message will be acknowledged Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 51: Functions

    These are included with the end customer documentation when the analyzer is delivered or can be ordered or downloaded via the Siemens Industry Online Support (SIOS) SIOS Process Analytics (https://support.industry.siemens.com/cs/products?dtp=Manual&mfn=ps&pnid=13613...

  • Page 52: Calibration Of Ultramat 23

    9.1.2 Calibration of ULTRAMAT 23 The Set CEM CERT system is configured so that the ULTRAMAT 23 analyzer (option C10, C20, C30) automatically performs an AUTOCAL with ambient air every 24 hours. This adjusts the zero point and sensitivity of the IR channels. The sensitivity of the O channel (if present) is also adjusted.

  • Page 53: Ultramat 23 - Full-Scale Value Calibration Of The Individual Components

    7. Set the 3/2-way ball valve -RB1 to the "Measure" position in order to resume the measurement. The analyzer then ends the function check set at the beginning; the measured value is valid again. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 54: Calibration Of Ultramat 6/Oxymat 6

    9.1.3 Calibration of ULTRAMAT 6/OXYMAT 6 The Set CEM CERT system is configured so that the ULTRAMAT 6 analyzer automatically performs an AUTOCAL (here: zero and full-scale value calibration) with the permanently connected zero and calibration gases once per week. The timing for this can be set.

  • Page 55: Ultramat 6 - Single Calibration Of Components

    " for a zero point calibration or full-scale value " calibration, respectively. As soon as the value is stable, press "Calibrate . To restart the ". measurement after the calibration, press "Start MEAS Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 56 Functions 9.1 Calibrating Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 57: Service And Maintenance

    • Ensure proper disposal of the purged toxic process media by using an environmentally-compatible purging process. WARNING Improper connection after maintenance Possible analyzer damage. • Correctly connect the analyzer involved after maintenance. • Close the analyzer and the system after maintenance. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 58: Maintenance Intervals

    The maintenance intervals specified there are based on the extensive experience of Siemens AG. The maintenance intervals can be further optimized if local conditions and empirical values suggest this. It is up to the system owner to decide whether to shorten or extend the maintenance interval on a system-related basis.
  • Page 59 SIPROCESS UV600) Calibrate full-scale value S* S* S* S* S* S* Check for leaks Check connections Check display * This maintenance work is subject to legal requirements (see certificate of the measuring system) Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 60: Eliminating The Moisture Alarm

    • Prior to its disposal, dilute the condensate with tap water until it turns neutral and the litmus paper does not change color. Alternatively, you can also neutralize the condensate with a weak sodium carbonate solution (Na Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 61: Emptying The Condensate Tank

    5. Reconnect the tank using the coupling and attach the capacitive sensor together with the mounting bracket between the tank and tank handle. 10.6 Spare parts/accessories For spare parts, please refer to the SIOS Process Analytics (https://support.industry.siemens.com/cs/products?dtp=Manual&mfn=ps&pnid=13613 &lc=en-WW). Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 62 Service and maintenance 10.6 Spare parts/accessories Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 63: Alarm, Fault And System Messages

    The fault messages must be acknowledged on the SIMATIC HMI display after correction of the fault. The group fault message is also output when the system is switched on. It is normally reset automatically after the warm-up period ends. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 64 Maintenance mode activated Measurement invalid Invalid measurement Maintenance request from system Maintenance request from system, e.g. filter change, full condensate tank -BS4 condensate tank level L > max: Condensate tank is full Maintenance request Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 65: Technical Specifications

    -15 °C ... +40 °C • With heating in GRP cabinet Max. +52 °C • With air conditioning Permissible ambient humidity 75% RH (relative humidity) annual average, non-condensing The conditions of EN 15267-3 must be observed. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 66 Max. 5000 VA without heated sample gas line Electrical inputs and outputs Output signals 4 … 20 mA (corresponding to the analyzer information) Additional digital inputs and outputs via PLC Fusing of electronic loads 1-pin or 2-pin (selectable) Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 67 24 h must be set for the automatic zero point calibration (Thermo • ULTRAMAT 23 AUTOCAL function activated). • ULTRAMAT 6 A weekly interval must be provided for the automatic zero and refer- ence point calibration. Maintenance See current certificate Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 68 Technical specifications Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 69: Dimension Drawings

    Dimension drawings 13.1 Dimension drawings Figure 13-1 Set CEM CERT, right side view and front view with cabinet closed Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 70 Dimension drawings 13.1 Dimension drawings Figure 13-2 Set CEM CERT, front view with cabinet open, folded out hinged frame and left side view Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 71 Sample gas pump Terminal strips for signals XM1 ... XM7 TS1/X31L Miniature circuit breakers F1 ... F11, FM Temperature controller for heated sample gas line Terminal strip for external connections EL1/XS1 Operating window Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 72 Dimension drawings 13.1 Dimension drawings Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 73: Wiring Diagrams

    Wiring diagrams 14.1 Gas flow diagram Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 74: Legend For Gas Flow Diagram

    Regulating valve for zero gas and calibration gases -RV7, -RV8, -RV9 -RV10 Regulating valve for AUTOCAL flow rate ULTRAMAT 23 -VF1, -VF2, Condensate trap -VF3, -VF4, -VF5, -VF10 -WS1 Gas sampling probe Human Machine Interface S7-1200 Control unit Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 75: A Appendix

    Appendix Service and support Technical support is available on the Internet at: Services & Support (https://support.industry.siemens.com/cs/gb/en/sc) Your regional Siemens representative can be found here: Contact partner (https://w3.siemens.com/aspa_app/) Returns A.2.1 Returns Note Return delivery of contaminated device components Device components which have come into contact with radioactive gases or substances, or have been exposed to radioactive or high-energy radiation, may no longer be returned.

  • Page 76: Return Address

    Check the item after it has been cleaned. SIEMENS will return devices or spare parts to you at your expense if a decontamination declaration is not included.

  • Page 77: Error Description

    It is confirmed that the returned part has not come into contact with highly toxic or radioactive gases or substances, or been exposed to radioactive or high-energy radiation. Company, department Last name, first name Location: Date: Signature: Software update ( ) yes ( ) no Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 78 Appendix A.2 Returns Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 79: Besd Guidelines

    The electrostatic discharge current may lead to latent failure of a module, that is, this damage may not be significant immediately, but in operation may cause malfunction. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 80 PCB traces. In this way, the discharged energy can not affect the sensitive devices. Discharge your body before you start taking any measurements on a module. Do so by touching grounded metallic parts. Always use grounded measuring instruments. Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 81: C List Of Abbreviations

    Wales Millimeter, unit of length NDIR Non-dispersive infrared Generic designation for different nitrogen oxides PVDF Polyvinylidene fluoride, a plastic PTFE Polytetrafluoroethylene, a plastic; Teflon is one of its trade names Quality Assurance Level Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...
  • Page 82 Technischer Überwachungsverein, monitoring and certification authority in Germany Uninterruptible power supply Volt, unit of voltage Volt-ampere, unit of apparent power Verband der Elektrotechnik, Elektronik und Informationstechnik (German Asso- ciation for Electrical, Electronic and Information Technologies) Vol. Volume Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

  • Page 83: Index

    System design, 63 Guidelines Technical support, 73 ESD guidelines, 77 Test certificates, 31 Hazardous area Laws and directives, 31 Inputs Technical specifications, 64 Laws and directives Disassembly, 31 Personell, 31 Outputs Technical specifications, 64 Set CEM CERT Operating Instructions, 03/2020, A5E34491309-11...

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