Endress+Hauser POWERCEMS100 Operating Instructions Manual
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Endress+Hauser POWERCEMS100 Operating Instructions Manual

Endress+Hauser POWERCEMS100 Operating Instructions Manual

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8030341/1AOJ/V4-0/2023-07
Operating Instructions
POWERCEMS100

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Summary of Contents for Endress+Hauser POWERCEMS100

  • Page 1 Products Solutions Services 8030341/1AOJ/V4-0/2023-07 Operating Instructions POWERCEMS100...
  • Page 2 01458 Ottendorf-Okrilla Germany Legal notice This work is protected by copyright. Endress+Hauser SICK GmbH+Co KG retains the rights conferred by it. Reproduction of this work or parts thereof is only permitted within the limits of the statutory provisions of copyright law.

  • Page 3: Table Of Contents

    Sources of danger ................... 8 System warranty....................9 RoHS Directive ....................9 Safety conventions..................9 Warning signs....................10 Mandatory signs....................11 Product description .................13 Features of the POWERCEMS100..............13 Method of operation ..................13 Functional principle ..................13 Internal functional units................14 External functional units................15 Measuring components ................15 Interfaces ......................15 Description of system components..............16...
  • Page 4 Connecting to the customer plant ............... 24 Commissioning ..................25 Commissioning of the humidifier containers (option)......... 25 Before switching on ..................25 Switching on the POWERCEMS100 analysis system ........26 Commissioning of sample gas cooler ............26 Commissioning of analyzers ................ 26 Commissioning of NO converter (option) ...........
  • Page 5 1.43 Perform Leak Test..................56 Disposal.....................57 Specifications...................59 13.1 EU Declaration of Conformity ...............59 13.2 Dimensions....................59 13.3 Technical data....................60 Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8030341/1AOJ/V4-0/2023-07...
  • Page 6 CONTENT Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8030341/1AOJ/V4-0/2023-07...

  • Page 7: About This Document

    Follow all local laws, regulations, technical rules and company policies applicable at the installation location. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 System Documentation/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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 9: For Your Safety

    8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Sources Of Danger

    Use suitable undamaged lifting equipment. ▸ Wear personal protective equipment (safety helmet, safety gloves). O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 11: System Warranty

    Indicates a situation that can lead to material damage if ignored. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Warning Signs

    Warning of dangers to environment, nature and organic life Hazard warning on the control cabinet door O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 13: Mandatory Signs

    Wear foot protection Switch off prior to maintenance or repair 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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) 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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

    Span gas / test gas feed unit: ● – Solenoid valves O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 17: External Functional Units

    – 115V, 50Hz – 115V, 60Hz UPS connection / supply (option) ● 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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

    Optional RJ45 socket - BCU Ethernet connection 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 19: Interior View

    Refer to the Technical System Documentation (EPLAN) for a detailed parts list of the system components. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 21: Transport

    Filter elements and bubbling frits must be installed and/or filled before commission- ing. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 TRANSPORT O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 23: Installation

    Normally, the converter fitted in the POWERCEMS100 analysis system is delivered with the catalyzer cartridge already fitted and ready for operation. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Preparing The Gas Sampling Probe

    Sample gas line inlet Zero gas/span gas Gas outlet Roof vent opening O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...
  • Page 25 The pressure at the sample gas outlet should not be increased significantly. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Preparing The Electrical Installation

    – Voltage supply – Signal lines – Integration of all external components O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 27: Commissioning

    ▸ Catalyzer cartridge inserted in NO converter. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 29: Commissioning Of No X Converter (Option)

    8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Commissioning Of 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 31: Restarting After Longer Shutdown

    2 Fill, if necessary 3 Replace the water trap when condensate is present 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 Refer to the Operating Instructions for the individual system components for fur- ther details and information. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 33: Operation

    Function buttons F1, F2, F3, F4 Current menu branch Current menu Status bar Menu number 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Switching On

    Refer to “Supplementary Operating Instructions BCU” for further, detailed information on operation via 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 35: Bcu Operating Functions Overview - Menu Structure In Sopas

    CAN baud rate Time | Temperature System Serial number | Tag No. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 “Supplementary Operating Instructions BCU” for detailed information on the BCU operat- ing functions. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 37: Adjusting

    The specific adjustment cycles depend on the application and are not the responsibility of SICK AG 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Adjustment Procedure

    When the adjustment procedure is aborted, it has to be acknowledged by pressing the key switch. 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 39: Clearing Malfunctions

    After a manual adjustment abort, the adjustment values are discarded. ▸ Maintenance request is not activated. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 ADJUSTING O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 41: Decommissioning

    Refer to the Operating Instructions of the relevant analyzer for details on operation and menu functions. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Switching Off

    To avoid condensation, purge the sample gas paths of the POWERCEMS100 analysis sys- tem with a dry, neutral gas before storage. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 43: Maintenance

    ▸ Wear personal protective equipment (gloves, respiratory protection) 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 45: Maintenance Intervals

    Caution: Serious damage to environment, nature and health by toxic condensate. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 ▸ Clean or replace lines / hoses as necessary. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 47: Cleaning Information

    1 pc. / 1 Y. Fi56NK3 Front fitted filter Diaphragm fine filter (visible contamination) 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 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 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...
  • Page 49 5 310 689 Sample gas cooler ECM 1 pc. / 1 Y. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 1 pc. / 3 Y. in housing, flow rate approx. 250 l/h O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...
  • Page 51 Stainless steel wool filling, T=660 °C, with spare O-ring set. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: External Components - Wear Parts (Wp) / Spare Parts (Sp)

    5 306 625 Gas sampling probe 2 pcs. / 1 Y. SP180-H O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 53: Troubleshooting

    Disposal according to local and legal environment regulations and guidelines. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Clearing Malfunctions (Bcu Error Messages)

    / too low Temperature sensor PT100 Replace temperature sensor. defective. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 55: Clearing Malfunctions (Other Malfunctions)

    Replace faulty or corroded grounding. Inadequate power supply. Check. Faulty interfaces Check. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Switch-On Conditions / Additions To Clearing Malfunctions

    ● – Monitoring the pump function is controlled via the gas analyzer. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 57: Leak Test

    To protect the Testo 324, all lines must be free of oil, dust and moisture. 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Leak Test

    – Measurement result is displayed. 3. Document and save the measurement result in the test log. O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser...

  • Page 59: Disposal

    Air conditioning: ● Refrigerant in the air conditioner 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 DISPOSAL O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...

  • Page 61: Specifications

    Fig. 10: PowerCEMS100 outer dimensions Legend 800 mm 2100 mm 600 mm 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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: Technical Data

    RS-422 (option) Interfaces RS-485 (option) Ethernet TCP/IP Modbus TCP Bus protocol O P E R A T I N G I N S T R U C T I O N S | POWERCEMS100 8030341/1AOJ/V4-0/2023-07| Endress+Hauser Subject to change without notice...
  • Page 63 Automatic check and adjustment with test gases converter Cooling unit Options Heating Bypass pump 8030341/1AOJ/V4-0/2023-07| Endress+Hauser 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 8030341/1AOJ/V4-0/2023-07 www.addresses.endress.com...

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