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Summary of Contents for Endress+Hauser MCS200HW-MP
- Page 1 Products Solutions Services 8029890/1SIK/V1-1/2025-06 Operating Instructions MCS200HW-MP Multi-component gas analyzer Version with installation plate...
- Page 2 This work is protected by copyright. Any rights derived from the copyright shall be reserved for Endress+Hauser SICK GmbH+Co. KG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law.
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Page 3: Table Of Contents
MCS200HW-MP Contents Contents About this document................Function of this document................Scope of application..................Target groups....................Further information..................Symbols and document conventions............1.5.1 Warning symbols................1.5.2 Information symbols..............Data integrity....................Safety information................. Basic safety information................2.1.1 Electrical safety................2.1.2 Dangerous substances.............. - Page 4 Contents MCS200HW-MP 5.4.8 Connecting the span gases............5.4.9 Connecting the exhaust gas outlet..........Electrical installation................30 Safety......................Equipment protection..................Disconnecting device..................Socket for Service work.................. Connecting the voltage supply..............Performing a high voltage test............... Commissioning..................32 Prerequisites for switching on................
- Page 5 MCS200HW-MP Contents 11.2 Error messages and possible causes............11.3 Replacing the Electronics module filter pad..........Decommissioning.................. 53 12.1 Switching off....................12.1.1 Switching off.................. 12.1.2 Shutdown..................12.2 Return delivery....................12.2.1 Shipping for repair................. 12.2.2 Cleaning the device before returning........... 12.3 Transport......................
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Page 6: About This Document
These Operating Instructions are only applicable for the measuring device described in the product identification. They are not applicable to other Endress+Hauser measuring devices. The standards referred to in these Operating Instructions are to be observed in the respec‐ tive valid version. -
Page 7: Warning Symbols
Important information for electrical or electronic functions Data integrity Endress+Hauser uses standardized data interfaces, such as standard IP technology, in its products. The focus here is on the availability of the products and their properties. Endress+Hauser always assumes the integrity and confidentiality of data and rights affected in connection with the use of the products are ensured by the customer. - Page 8 About this document MCS200HW-MP In all cases, the customer is responsible for the implementation of safety measures suit‐ able for the respective situation, e.g., network separation, firewalls, virus protection and Patch Management. Endress+Hauser O P E R A T I N G I N S T R U C T I O N S...
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Page 9: Safety Information
Do not remove, add or change any components in or on the device unless such changes are officially allowed and specified by the manufacturer. Use only original spare parts and wear and tear parts from Endress+Hauser. If you do not observe this: The manufacturer's warranty becomes void. -
Page 10: Dangerous Substances
Safety information MCS200HW-MP Endangerment of electrical safety through power line with incorrect rating Electrical accidents can occur when the specifications for installation of a power line have not been adequately observed. Always observe the exact specification in the Manual when installing a power cable ►... -
Page 11: Requirements On The Personnel's Qualification
MCS200HW-MP Safety information The analysis system is designed for indoor installation. See the System Documentation delivered for the configuration of your device. Requirements on the personnel's qualification Table 4: Qualification requirements Tasks User groups Qualification Mounting Qualified personnel • General knowledge in meas‐... -
Page 12: Product Description
Product description Product identification Overview Product name MCS200HW-MP Manufacturer Endress+Hauser SICK GmbH+Co. KG Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany Type plate Type plates are located on the right on the installation plate. Type plates Figure 1: Type plate of complete device, schematic representation... -
Page 13: Layout And Function
MCS200HW-MP Product description Layout and function 3.3.1 System overview Overview Gas sampling unit Heated sample gas line Hose bundle line Installation plate Voltage supply Interfaces 1 x Ethernet: Connections Customer-specific analog and digital inputs and outputs, see wiring diagram Instrument air inlet Observe the quality of the operator's instrument air. -
Page 14: Installation Plate
Product description MCS200HW-MP • The analysis system uses status indicators to signal the current operating state: • The analysis system switches to operating state “System Stop” automatically when a malfunction occurs “System Stop” corresponds to classification “Failure”: The sample gas line and the sample gas path in the analyzer are automatically °... - Page 15 MCS200HW-MP Product description View Analyzer module 1 Cell module • Ejector pump • Inlet filter 2 Optics module 3 Electronics module Installation plate 4 Valve block 5 I/O module 6 Span gas unit 7 Display module 8 Sample gas outlet...
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Page 16: Gas Sampling Unit
Product description MCS200HW-MP 3.3.3 Gas sampling unit Overview Filter housing Gas sampling tube (unheated) Weather hood Pre-filter (optional) Function The gas extraction unit extracts flue gas from the stack via the gas sampling tube. After filtration, the flue gas is passed to a measuring device for analysis. -
Page 17: Sample Gas Line
MCS200HW-MP Product description 3.3.4 Sample gas line Overview Figure 3: Heated sample gas line Connection to gas sampling unit (without electrical connections) Connection to measuring device (with electrical connections) Protective cap PT100 connections Power supply Cable gland Locknut Function The heated sample gas line leads the flue gas from the gas sampling unit to the measuring device. -
Page 18: Instrument Air Conditioning
As standard, analog and digital signals are used for device communication with customer peripherals. Alternatively, output can be performed using the Modbus-TCP protocol. Optionally, Endress+Hauser offers various converter modules that are installed by the customer and communicate with the device via Modbus® TCP. - Page 19 The Endress+Hauser Meeting Point Router (MPR) is available for remote diagnostics via the internet. • The MPR links a plant-side machine network with the Endress+Hauser remote archi‐ tecture. • A firewall which decouples the machine network from the internet or the operating company network is integrated in the MPR.
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Page 20: Transport And Storage
Transport and storage MCS200HW-MP Transport and storage Transport Overview Transport the device horizontally with suitable hoisting equipment (e.g. jack lift with ade‐ quate lifting capacity). Important information NOTICE The measuring device may only be transported and installed by qualified persons who, based on their training and knowledge as well as knowledge of the relevant regulations, can assess the tasks given and recognize the dangers involved. -
Page 21: Mounting
MCS200HW-MP Mounting Mounting Safety Qualification The measuring device may only be installed by trained specialists. Scope of delivery Please see the delivery documents for the scope of delivery. Overview of mechanical and electrical installation Important information NOTICE Observe the order of assembly. -
Page 22: Installation Sequence
Mounting MCS200HW-MP Installation sequence 5.4.1 Mounting at target location Overview Prerequisites • Adequate clearances for the heated sample gas line. • Observe clearances for incoming and outgoing lines (approx. 20 cm clearance at the top, bottom, side of the measuring device). -
Page 23: Installing The Sample Gas Line
MCS200HW-MP Mounting 5.4.2 Installing the sample gas line 5.4.2.1 Laying the sample gas lines Overview Figure 4: Heated sample gas line Connection to gas sampling unit (without electrical connections) Connection to measuring device (with electrical connections) Protective cap PT100 connections... -
Page 24: Installing The Stainless Steel Screw Fitting
Mounting MCS200HW-MP Roll up excess length at the gas sampling unit. Leave enough length for pulling the gas sampling unit. Fasten the sample gas line accordingly (e.g. on cable trays). 5.4.2.2 Connecting the heated sample gas line to the analyzer Procedure Unscrew cell cover and remove. -
Page 25: Using A Push-In Fitting (Pneumatic)
MCS200HW-MP Mounting 5.4.4 Using a push-in fitting (pneumatic) Overview Figure 7: Push-in fitting with retaining ring (example shown) Retaining ring Tube Procedure Fitting the tube Push the tube in. Removing the tube Press the retaining ring in. Pull the tube out. -
Page 26: Setting The Pressure Reducer Module
Mounting MCS200HW-MP ≥ 100 mm Figure 8: Lines – clearance and bending radius Fasten the hose bundle line accordingly (e.g. on cable trays). 5.4.6.1 Connecting the signal lines on the analyzer Connect the signal lines according to the wiring diagram. -
Page 27: Connecting The Valve Block
MCS200HW-MP Mounting Important information NOTE INSTRUMENT AIR QUALITY The quality requirement for instrument air used exclusively as ejector air is lower than for usage as zero/control air (zero gas quality). Procedure Connection of shared instrument air supply Connect instrument air with zero gas quality on inlet 1. -
Page 28: Connecting The Span Gases
Mounting MCS200HW-MP Important information WARNING Hazard when pressure is too high Hoses can burst when the pressure is too high. • The maximum permissible operating pressures must not be exceeded. Related topics • Specification of the pressures to be used: see "Gas supply", page 58... - Page 29 MCS200HW-MP Mounting NOTICE Condensate could accrue in the exhaust gas line. Use a suitable hose line to run the condensate outlet into an open condensate ► container or a waste disposal line. Lay the line so that it always runs downwards.
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Page 30: Electrical Installation
Electrical installation MCS200HW-MP Electrical installation Safety Qualification The measuring device may only be installed by trained specialists. Equipment protection Short-circuit protection must be provided by the customer in accordance with the appli‐ cable standards by means of fuses or circuit breakers with short-circuit protection and overload protection. -
Page 31: Performing A High Voltage Test
MCS200HW-MP Electrical installation Procedure Connect the electric lines. Performing a high voltage test Overview Figure 11: Voltage supply connections Procedure To avoid erroneous measurements during a high-voltage test, the bridges described in Figure see figure 11, page 31 must be removed. -
Page 32: Commissioning
Commissioning MCS200HW-MP Commissioning Prerequisites for switching on Procedure Check the measuring device. Instrument air must be connected and open. If the instrument air has changed: Check the instrument air quality. Check pressure settings on the pressure reducer unit. Related topics •... -
Page 33: Performing Reference Point Adjustment
MCS200HW-MP Commissioning If the deviation is higher than a specified limit value, the system switches to classification “Maintenance request” and the zero point is however corrected. Procedure Click tile “Zero point adjustment”. ✓ The operating state switches to zero point adjustment. - Page 34 Commissioning MCS200HW-MP Procedure Start adjustment with “O2 adjustment”. ✓ The operating state switches to O2 adjustment. ✓ The time elapsed and the remaining time of the state and of the respective active step is displayed. The system switches back to original state automatically when adjustment has been completed.
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Page 35: Operation
MCS200HW-MP Operation Operation Operating concept Operation The analysis system is equipped with a display with touchscreen. • All menus and functions are shown on the display. • The menus and functions are called up using the tiles. • The current operating state is displayed by the status indicator (Namur). -
Page 36: Tiles
Operation MCS200HW-MP Color Status signal Significance Function check Sporadically no valid output signal Failure No valid output signal Tiles Symbol Name Function Login symbol Calls up the Login menu. Menu symbol Calls up the menu. Home symbol Goes back to start screen (measured value over‐... -
Page 37: Measuring Screen
MCS200HW-MP Operation Measuring Screen Overview Figure 12: Measuring Screen Legend of displayed measured values Measured value concentration Measuring time and date Tiles Measuring Screen tiles Symbol Name Function Visibility Switches the visibility of the measured value curve on and off. - Page 38 Operation MCS200HW-MP Symbol Name Function Reduce Reduces display of time axis. Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029890/1SIK/V1-1/2025-06...
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Page 39: Menus
MCS200HW-MP Menus Menus Password Configuration is only possible on level “Authorized Client”. Login is performed using tile “Login” and a password prompt. Password for “Authorized Client”: HIDE (preset) Menu tree Menu level Explanation Tasks Quick access to the most important func‐... - Page 40 Menus MCS200HW-MP 2.4.4 Reference point drift (span gas) Displays the determined percentage devi‐ ation of measuring component concen‐ tration after validation with span gas. Settings 2.5.1 Span gas concentrations Entry fields for updating the span gas concentrations. 2.5.2 Component-specific parameters Displays the parameters of the individual measuring components.
- Page 41 MCS200HW-MP Menus 3.4.4 Digital inputs Displays digital input status. Digital inputs switched off are marked with “.” , those switched on with “I”. 3.4.5 Modbus outputs Displays values of the individual Modbus outputs. 3.4.6 Modbus inputs Displays values of the individual Modbus inputs.
- Page 42 Menus MCS200HW-MP 4.3.6 Modbus inputs 4.3.7 Modbus 4.3.8 OPC outputs 4.3.9 4.3.10 Hardware plan (CAN) Date and time Set date and time. Device information Displays device information. Measuring Screen Displays individual preset Measuring Screens. Measuring Screen 1 Measuring Screen 2...
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Page 43: Maintenance
MCS200HW-MP Maintenance Maintenance 10.1 Safety Requirements for the maintenance personnel • Only allow an authorized electrician to work on the electrical system or electrical assemblies. • The technician must be familiar with the exhaust gas technology of the operator's plant (hazard by overpressure and toxic and hot flue gases) and be able to avoid hazards when working on gas ducts. -
Page 44: Cleaning
Maintenance MCS200HW-MP NOTICE Risk of contamination of analyzer The gas sampling unit and analyzer are flushed with instrument air when the system is not in measuring operation. When the instrument air is switched off, there is the risk of contamination of the analyzer. -
Page 45: Maintenance Plan
MCS200HW-MP Maintenance Important information NOTICE Device damage through incorrect cleaning. Incorrect cleaning can lead to device damage. • Only use recommended cleaning agents. • Do not use sharp objects for cleaning. Procedure Wipe the surface with a damp soft cloth and wipe again with a dry soft cloth. -
Page 46: Check External Instrument Air Supply
Maintenance MCS200HW-MP Check grounding conductors are free from corrosion. Check valve block and pressure reducer unit for leak tightness: No permanent hissing noise should be noticeable. ° Check no air is escaping from the connections, e.g., with leakage spray °... -
Page 47: Check Measured Values (When System In Operation)
MCS200HW-MP Maintenance 10.4.7 Check measured values (when system in operation) Procedure Check display for pending error messages. Check measured values for plausibility. Check external instrument air conditioning (optional). 10.5 Maintaining the instrument air conditioning. 10.5.1 Maintaining the instrument air conditioning (option) Prerequisites •... -
Page 48: Troubleshooting
Troubleshooting MCS200HW-MP Troubleshooting 11.1 Safety Requirements for the maintenance personnel • Only allow an authorized electrician to work on the electrical system or electrical assemblies. • The technician must be familiar with the exhaust gas technology of the operator's plant (hazard by overpressure and toxic and hot flue gases) and be able to avoid hazards when working on gas ducts. -
Page 49: Error Messages And Possible Causes
MCS200HW-MP Troubleshooting NOTICE Risk of contamination of analyzer The gas sampling unit and analyzer are flushed with instrument air when the system is not in measuring operation. When the instrument air is switched off, there is the risk of contamination of the analyzer. - Page 50 Troubleshooting MCS200HW-MP Table 6: Error codes - System Code Error text Description Possible clearance S001 Temperature too high Measuring cell temperature too high When T ≥ 360.7 °C: Check plug-in connectors. When ok: Call E+H Service. When T < 360.7 °C: Call E+H Service.
- Page 51 MCS200HW-MP Troubleshooting Code Error text Description Possible clearance S008 Chopper Chopper frequency not regulated. Call E+H Service. S009 Motor filterwheel 1 Filterwheel motor does not detect reference Call E+H Service. position. S010 Motor filterwheel 2 S011 Motor filterwheel 3 S012...
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Page 52: Replacing The Electronics Module Filter Pad
Troubleshooting MCS200HW-MP Code Error text Description Possible clearance S047 Dev. O adjust too high adjustment not performed because it is Perform O adjustment again, when message is still outside the tolerable range; parameters set for pending: Call E+H Service. measured component... -
Page 53: Decommissioning
Without the Non-Risk Declaration, the device will either be cleaned by a third-party com‐ pany at the customer's expense or the package will not be accepted. Procedure Contact your local Endress+Hauser representative. Addresses: See back of the Oper‐ ating Instructions. Clean device. -
Page 54: Cleaning The Device Before Returning
Decommissioning MCS200HW-MP Pack the unit carefully and shockproof in the original packaging for transport. Enclose the Repair Form and attach it to the outside of the packaging. 12.2.2 Cleaning the device before returning Important information NOTICE Device damage through incorrect cleaning. -
Page 55: Technical Data
NOTICE Observe clearances at the installation site: • Top: 30 cm • Side 20 cm Dimension drawing Figure 14: MCS200HW-MP (dimensions in mm) 13.2 Technical data 13.2.1 Measured values Table 7: Measured variables Number of measured variables Number of measured variables... - Page 56 Technical data MCS200HW-MP Table 9: Sample volume Sample volume Sample volume 200 ... 400 l/h Table 10: Measuring ranges Measuring component Measuring range 0 ... 9 ppm; 0 ... 1840 ppm 0 ... 9 ppm / 0 ... 650 ppm 0 ... 24 ppm / 0 ... 8,000 ppm 0 ...
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Page 57: Ambient Conditions
Digital inputs/outputs Optional Data interface 1 x Modbus TCP/IP Profibus Configurable Profinet Configurable Remote support Endress+Hauser MPR (optional) SSG (optional) PC operation Browser Google Chrome with SOPASair via Ethernet 13.2.5 Power supply Table 17: Voltage supply Voltage supply Power input Power input •... -
Page 58: Gas Supply
Technical data MCS200HW-MP Table 18: Optional interfaces Interfaces (optional) Digital outputs 4 outputs, 24 V, 0.5 A Digital inputs Electrically isolated, 24 V, 0.3 A Table 19: Cable glands Cable glands Hose bundle line M40x1.5 D22 -32 IP68 PA-GR Main power supply M32x1.5 D18 -25 IP68 PA-GR... -
Page 59: Sample Gas Conditions
MCS200HW-MP Technical data Connection Dimension Span gas inlet Clamping ring screw connection (hose fitting) 4 mm inner diameter 6 mm outer diameter Gas outlet DN 8/10 13.2.8 Sample gas conditions Table 22: Sample gas characteristics Sample gas at sampling point... - Page 60 Technical data MCS200HW-MP ELECTRONIC TUBE 1 FILTER TUBE 2 FILTER TUBE 3 CELL DEVICE PROBE 1 PROBE 2 Fuse connections Name Fuse for ELECTRONIC Electronics TUBE 1 Sample gas line 1 FILTER/PROBE 1 Filter heater / measuring probe 1 TUBE 2...
- Page 61 MCS200HW-MP Technical data Connections - pin assignment Table 25: Connections - pin assignment Plug Assembly Assignment TUBE 1 Sample gas line 1 L (L) N (L) FILTER1 Gas sampling unit filter 1 L (L) (Lines from hose bundle line) N (L)
- Page 62 Technical data MCS200HW-MP 13.2.9.4 Connections for interfaces and SD card Overview ETHO ETH1 CAN PROFIBUS RS422/RS485 RS232 02 DISP. I/0-MOD. PT100 DIGITAL INPUTS DIGITAL OUTPUTS VALVE OUTPUTS Data interfaces - overview Table 27: Data interfaces - overview Plug Connection for ETH0 Ethernet (e.g.
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Page 63: Heated Sample Gas Line
MCS200HW-MP Technical data Table 29: Overview - pin assignment and signals Plug Assembly Assignment Pt100 Pt100 + Sample gas line 1 Pt100 – Gas sampling unit filter 1 Pt100 + Pt100 – Gas sampling unit probe tube 1 Pt100 + Pt100 –... -
Page 64: Switching On The Circuit Breakers Again
Technical data MCS200HW-MP 13.2.11 Switching on the circuit breakers again Overview The circuit breakers are located at the bottom of the electronics unit. The circuit breakers are labeled. ELECTRONIC TUBE 1 FILTER / PROBE 1 TUBE 2 FILTER / PROBE 2... - Page 65 MCS200HW-MP Technical data Dimension Slope P Tightening torque M (Nm) according to strength class (see screw head) M 14 M 16 M 18 M 20 M 22 1057 M 24 1136 1329 M 27 1176 1674 1959 M 30 1289...
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Page 66: Annex
14.2.2 Software licences In this product, Endress+Hauser uses unchanged and, as far is necessary and in compli‐ ance with relevant licence conditions, changed Open Source Software. The firmware of this device is therefore subject to the copyrights listed on the CD delivered. - Page 67 MCS200HW-MP Annex Endress+Hauser O P E R A T I N G I N S T R U C T I O N S 8029890/1SIK/V1-1/2025-06...
- Page 68 8029890/1SIK/V1-1/2025-06 www.addresses.endress.com...
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