SICK MERCEM300Z Operating Instructions Manual
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SICK MERCEM300Z Operating Instructions Manual

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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
MERCEM300Z
Mercury Analyzer
Installation, Operation, Maintenance

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  • 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 MERCEM300Z Mercury Analyzer Installation, Operation, Maintenance...
  • Page 2 SICK AG assumes no liability for the correctness of an unauthorized translation. In case of doubt, contact SICK AG or your local representative. Legal information Subject to change without notice. © SICK AG. All rights reserved. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 3 Risk or hazardous situation which could result in severe personal injury or death. CAUTION Hazard which could result in less severe or minor injuries. NOTICE Hazard which could result in property damage. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 4: Table Of Contents

    Ethernet interface ............29 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 5 Disposal ..............57 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 6 MERCEM300Z Indoor ........

  • Page 7: Important Information

    Important Information MERCEM300Z Important Information Main instructions for operation Intended use Own responsibility MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 8: Important Information

    1. 2 Purpose of the device 1.2.1 MERCEM300Z and MERCEM300Z Indoor (referred to as "device" in the following) are extractive gas analysis systems and serve continuous measurement of mercury and mercury compounds in the exhaust gases of industrial combustion plants (emission measuring system).

  • Page 9: Installation Location

    Important Information Installation location 1.3.1 MERCEM300Z Indoor Installation location: In air-conditioned rooms (IP43). MERCEM300Z Installation location: Indoors or outdoors (IP55). MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 10: Responsibility Of User

    Retention of documents 1.4.4 These Operating Instructions and the System Documentation:  Must be available for reference.  Must be passed on to new owners. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 11: Additional Documentation/Information

    Operating Instructions Heated Sample Gas Line ● Operating Instructions Instrument Air Conditioning (Option) ● Operating Instructions Modular I/O System ● Documentation on individual settings ● Installation Plan ● MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 12 Important Information MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 13: Product Description

    Product Description MERCEM300Z Product Description Device characteristics Functional principle Device description MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 14: Device Characteristics

    MERCEM300Z front side view  1 Operator panel ( p. 39, §5.2)  2 Air conditioner Fig. 2 MERCEM300Z Indoor front side view  1 Operator panel ( p. 39, §5.2) MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 15 7 Vaporizer for test gas generator CALSIC300 (option)  8 Pressure control module  9 Valve block  10 Instrument air conditioning  11 Test gas generator CALSIC300 with storage container (option)  MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 16: Gas Flow Plan

      1 Gas sampling system 2 Instrument air conditioning 3 Thermal converter and cell 4 Test gas generator CALSIC300 (option) 5 Vaporizer (of test gas generator CALSIC300) MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 17: Method Of Operation

    Test gas feeding is started cyclically or manually ( p. 41, §5.4). ● Instrument air conditioning (option) 2.2.3 Option: Integrated instrument air conditioning. For more information on instrument air conditioning  Operating Instructions for instrument air conditioning. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 18: Operation

    2.5.3 OPC is a standardized software interface that allows to exchange data between the appli- cations of different manufacturers. The SICK OPC server is required. System bus: Ethernet. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 19: Sopas Et (Pc Program)

     SOPAS ET Help menu Language 2.6.1 Language setting exclusively in SOPAS ET: Menu: Diagnosis/System info (User level: Authorized operator). Then change once to any menu on the operator panel. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 20 Product Description MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 21: Preparations For Initial Start-Up

    Preparations for Initial Start-up MERCEM300Z Preparations for Initial Start-up Installation Assembly MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 22: Overview Of Work To Be Performed

    Operator ---- Installation SICK Customer Service ---- Initial start-up SICK Customer Service ---- Scope of delivery 3. 2 Please see the delivery documents for the scope of delivery. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 23: Preparing The Installation Location

    Provide (individual) attachments for the system cabinet. ● For installation on gratings: When working on the device, parts could drop or liquids drip and cause injuries.  Provide a suitable base plate. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 24: Transport And Installation

     Connection of the gas lines to the device may only be performed by SICK Customer Service.

  • Page 25: Laying The Sample Gas Lines

     Protect the line from frost.  Gas outlet: – MERCEM300Z: The gas outlet is routed through the base at the rear. – MERCEM300Z Indoor: The gas outlet is routed through the right side panel. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 26: Test Gas Feeding On Gas Sampling System

    – Regulate the flow via the pressure. – Max. pressure: 0.5 bar (50 kPa) overpressure.  After unscrewing the test gas line: Screw the dummy cap back on. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 27: Electrical Installation

    Do not connect the device to the voltage supply.  Let SICK Customer Service connect the electrical connection of the device. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 28: Laying The Tube Bundle Cable Of The Gas Sampling System

    ● MERCEM300Z: The signal lines are routed through the device base. ● MERCEM300Z Indoor: The signal lines are routed through the right side panel. ●  Let SICK Customer Service connect the signal lines on the device. Preparation of mains supply 3.6.4...

  • Page 29: Ethernet Interface

    When the device is operated on the Ethernet, there is the risk of undesired access to the device via the Ethernet (“hacking”).  Only operate the device with firewall protection. Let SICK Customer Service lay the Ethernet cable in the system cabinet and connect the Ethernet cable. Fig. 8...
  • Page 30 Preparations for Initial Start-up MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 31: Operation

    Operation MERCEM300Z Operation Access Operation Status messages MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 32: Putting The Device Into Operation

    The device requires up to 1 h after closing the cabinet door to attain stable operation - depending on the external temperature.  Keep the cabinet door closed during operation and secure against unauthorized opening. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 33: Controls And Indicators/Displays

    Diag is shown only when there is a message. When this button is pressed, the current message is shown. More information on diagnosis  p. 51, §5.5.4 List of error messages  p. 70, §8.7 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 34: Status And Classification

    The device is in "Stand-by" state ( p. 68, §8.4) Typical default ( System Documentation). Option ( System Documentation). See SOPAS ET in the “Digital outputs” menu. The last valid measured value is held. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 35: Measuring Screens

    “Bar graph” Measuring screen 4.5.2 Display of 2 measured values each time in bar format. Update interval: 1 second  Parameter settings of display areas  p. 53, §5.6.1.2 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 36: Line Graph" Measuring Screen

    The password is: “1234” (default) ● The password level remains valid for 30 minutes (default). ● The password and duration of validity can be changed in SOPAS ET ( p. 19, §2.6). MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 37: Menus

    Menus MERCEM300Z Menus Menu tree Menus MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 38: Menu Tree

    4.1.1 Scale 1-8 4.1.2 Scale 9-16 4.1.3 Timeline  p. 54, §5.6.2 Reset 4.2.1 Zero drift 4.2.2 Span pt drift 4.2.3 Reference energy 4.2.4 Lamp energy 4.2.5 Status MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 39: Main Menu

    1 On  Set the maintenance signal. Then: – Classification: “Maintenance” ( p. 34, §4.4.2) 2 Off – Status bar: “Maintenance”.  Reset the maintenance signal. /Maint/Sig Back Enter MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 40: Maintenance/Operating States

     To exit the Menu: Press the “Back” button.  To switch the measuring operation on again: Back - Press “Measuring”. - Switch the maintenance signal off ( p. 39, §5.3.1). MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 41: Adjustment

    Analog outputs (switching logic see SOPAS ET) 2 Start/Stop sequence ● 3 Parameter  Starts the test gas feed sequence (according to configura- tion).  Enter parameters  p. 42, §5.4.1.1 /Adj/Test Back Enter MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 42: Adjustment/Manual

    1 Span points 2 Accept  If a new span point was set in submenu 2.1.1: Start adjustment here with new span points. p. 43, §5.4.2.2 /Adj/Man Back Enter MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 43 6.0 6.0 2 Span pt 2 3 Span pt 3 9.0 9.0 1.00000 Factor: 4 Factor ● Calculated correction factor /Adj/Man/Accept Back  Set measured value and correction factor. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 44: Adjustment/Automatic

    Drift check without acceptance of values (with internal adjustment cell or test gas generator (preset)). Drift Correction Drift check with automatic acceptance of correction (with internal adjust- ment cell or test gas generator (preset)). Cancel Cancel test or adjustment. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 45: Adjustment/Parameter

    Enter the numeric value. 00003.000 µg/m3  Minus sign: As first digit: Press several times. To save: “Save”. The password is queried ( p. 36, §4.6) /Adj/Para/Conc/1 Back Save MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 46 Enter the numeric value.  Minus sign: As first digit: Press several times. 001.0000 To save: “Save”. The password is queried ( p. 36, §4.6) /Adj/Par/Fact/1 Back Save MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 47 Enter the numeric value. 00003.000 µg/m3  Minus sign: As first digit: Press several times. To save: “Save”. The password is queried ( p. 36, §4.6) /Adj/Para/Conc/1 Back Save MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 48 Select the sequence control program 3 Span pt : System “Enter”. 4 Mon Feb 7 12:00:00 Start time Activation/deactivation of start: /Adj/Par/Start Select the start time Back Enter “Enter”. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 49: Diagnosis

    3.1.1 The zero drift is recalculated during each zero adjustment. This value can be used for system diagnosis. 1 Reset at 24.10.2010 2 Total Hg 0.0020 /Diag/Chkv/Zero Back MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 50 (parameters can be set in SOPAS ET), the device switches to the “Maintenance request” classifica- 97.23% 2 Lamp tion. A “Reset”( p. 54, §5.6.2, e.g. during maintenance) sets the reference energy to 100%. /Diag/Chkv/Ints Back MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 51: Diagnosis/Temperatures

    Source (e.g.: System, measured component, receiver, etc. ) ● Error cause (error number and clear text) /Diag/Error ● (list of messages  p. 70, §8.7) Back MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 52: Parameter Setting

    Menu 4.1: Parameter/Display Measuring Display  p. 53, §5.6.1.1 1 Scale 1-8  p. 53, §5.6.1.1 2 Scale 9-16  p. 53, §5.6.1.2 3 Timeline /Para/Display Back Enter MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 53: Back Enter

    Timeline 4.1.3 Graph update interval: Depending on scale ( p. 36, §4.5.3) 6 minutes 15 minutes  Timeline end value (specified times) 30 minutes 60 minutes /Para/Disp/Timel Back MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 54: Parameter/Reset

    2 Span pt drift want to reset the values. 3 Reference energy 4 Lamp energy 5 Status /Para/Rst  Reset of all existing messages. Back  Execute selected menu item. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 55: Shutdown

    Shutdown MERCEM300Z Shutdown Switch off Shutting down Transport Disposal MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 56: Switching Off (For A Period Up To Approx. 2 Weeks)

    ● Ambient temperature: -20 ... +40 °C (without Hg chloride solution) ● Relative humidity max. 80%, without condensation. ● Recommendation: Store the device in dry conditions whenever possible. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 57: Disposal

    Sample gas filters: Sample gas filters could be contaminated by pollutants. ● With test gas generator: The contained liquid is acidic and contains sub- ● stances that are toxic or harmful to the environment. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 58 Shutdown MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 59: Scheduled Maintenance

    Scheduled Maintenance MERCEM300Z Scheduled Maintenance Maintenance plan Spare parts MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 60: Maintenance Intervals

    Check values w = weekly, q = quarterly, h = every half year Maintenance by Customer Service 7.1.2 Maintenance by SICK Customer Service: Every 5 years at the latest. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 61: Expendable And Wearing Parts

    5319343 Quantity per maintenance interval 1/2y=1/2-yearly, 1y=yearly, 2y=2-yearly, 5y=5-yearly CAUTION: Consumables only from SICK The HgCl solution to be replaced during maintenance may only be obtained from SICK. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 62: Maintenance Work

    Peripherals Sampling and draining of sample gas, tubes: Condition. ● Test gas supply: Condition, availability (use-by date), pressures. ● If fitted: Purge gas supply: Condition, availability, pressures. ● MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 63: Replacing The Test Solution

    – In both cases, the following is valid: If an adjustment cycle is due to start in this period: The cycle does not run. Fig. 11 Test gas generator CALSIC300 Cover of the test gas generator CALSIC300 3 Remove cover from test gas generator upwards. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 64 This waste must be disposed off according to legal regula- tions and as hazardous waste when necessary. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 65 A check of the safe function is necessary every time the HgCl2 solution is replaced.  Carry out a one-point calibration.  Make a visual check of hose connections for leaks. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 66 Scheduled Maintenance MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 67: Clearing Malfunctions

    Clearing Malfunctions MERCEM300Z Clearing Malfunctions Fuses Status messages Implausible measuring results MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 68: If The Device Does Not Function At All

     Press the <Diag> button for more information. More information concerning the causes:  Classifications (device state)  p. 34, §4.4.2  List of error messages and possible causes  p. 70, §8.7 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 69: External Ups (Option)

    It is possible that the fuses of your device have a different assignment.  Refer to the delivered System Documentation ( p. 11, §1.5) for fuse assign- ment. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 70: Error Messages And Possible Causes

    Lamp energy is outside tolerance range. Check lamp energy in SOPAS ET menu Diagnosis/Sensor val- ues/Lamp. S014 Lamp ignition Lamp ignition failure. Reinitialize device in menu 1.2.4 Maintenance/Change operational state. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 71 ETH1. If this error occurs, there is no communication between the test gas generator and the device. Check cables. MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 72 Classifi- Description Possible clearance cation System S085 Module not found Extended I/O (EXIST) Please contact SICK Customer Service S091 Communication problem Communication problem S094 System start System start MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 73: Technical Documentation

    Technical Documentation MERCEM300Z Technical Documentation Dimensions Technical Data MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 74: Compliances And Approvals

    CD. Software licenses In this product, SICK uses unmodified open source software and, insofar as required and where permitted under the relevant license conditions, modified open source software.

  • Page 75: Dimensions

    Technical Documentation Dimensions 9 . 3 MERCEM300Z 9.3.1 Fig. 14 Dimensions 1038 (41) 744 (30.3) 196 (7.7) 351 (13.8)  Pay attention to side clearances  p. 23, §3.3 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 76 Fig. 15 Dimensions (view with air-conditioner opened) 1488 (58)  Pay attention to side clearances  p. 23, §3.3 Fig. 16 Bottom plate Back Top view Door side MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 77: Mercem300Z Indoor

    Technical Documentation MERCEM300Z Indoor 9.3.2 Fig. 17 Dimensions 1832  Pay attention to side clearances  p. 23, §3.3 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...

  • Page 78: Technical Data

    Max. 3100 VA (including air conditioner) – MERCEM300Z Indoor Max. 2200 VA Test gas generator 1000 VA Heated sample gas line 95 VA/m Gas sampling system 450 VA MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 79 95 VA/m (2.43 VA/in.) Internal test gas generator CALSIC300 (option) Generated test gas HgCl Test gas concentration. Depending on measuring range Contained test liquid HgCl , approx. 10 l MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 80 Glossary ........2 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 81 Visual inspection ......62 MERCEM300Z · Operating Instructions · 8013255 V 2.0 · © SICK AG...
  • Page 82 Australia E-Mail sick@sick.no E-Mail sales@sick.com.au Österreich Belgium/Luxembourg Brasil România Canada Russia E-Mail sick@sick.cz Schweiz China Slovenija E-Mail sick@sick.dk Deutschland France Suomi Sverige India Taiwan Israel Italia USA/México Nederland SICK AG | Waldkirch | Germany | www.sick.com...

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