SICK MCS200HW-MP User manual

OPERATING INSTRUCTIONS
MCS200HW-MP
Multicomponent Analysis System

Described product
MCS200HW-MP
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
2O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

Contents
1 About this document........................................................................ 7
1.1 Function of this document....................................................................... 7
1.2 Scope of application................................................................................. 7
1.3 Target groups............................................................................................ 7
1.4 Further information................................................................................... 7
1.5 Symbols and document conventions...................................................... 7
1.5.1 Warning symbols...................................................................... 7
1.5.2 Warning levels / Signal words................................................. 8
1.5.3 Information symbols................................................................ 8
1.6 Data integrity............................................................................................. 8
2 Safety information............................................................................ 9
2.1 Basic safety information........................................................................... 9
2.2 Warning information on device................................................................ 10
2.3 Intended use............................................................................................. 11
2.4 Requirements on the personnel's qualification...................................... 11
3 Product description........................................................................... 13
3.1 Product identification............................................................................... 13
3.2 Gas supply terminology............................................................................ 13
3.3 Layout and function.................................................................................. 14
3.3.1 System overview...................................................................... 14
3.3.2 Installation plate...................................................................... 15
3.3.3 Instrument air, conditioning.................................................... 16
3.4 Extended interfaces (option).................................................................... 17
4 Transport and storage....................................................................... 18
4.1 Transport................................................................................................... 18
4.2 Storage...................................................................................................... 18
5 Mounting............................................................................................. 19
5.1 Safety......................................................................................................... 19
5.2 Scope of delivery....................................................................................... 19
5.3 Overview of mechanical and electrical installation................................ 19
5.4 Installation sequence............................................................................... 20
5.4.1 Wall mounting.......................................................................... 20
5.4.2 Installing the sample gas line................................................. 21
5.4.2.1 Laying the sample gas lines................................... 21
5.4.2.2 Connecting the heated sample gas line to the
analyzer................................................................... 22
5.4.3 Using a push-in fitting (pneumatic)........................................ 22
5.4.4 Laying the hose bundle line.................................................... 23
5.4.5 Connecting the signal lines on the analyzer.......................... 23
5.4.6 Setting the pressure reducer module.................................... 23
CONTENTS
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 3
Subject to change without notice

5.4.7 Connecting the valve block..................................................... 24
5.4.8 Connecting the span gases..................................................... 25
5.4.9 Connecting the exhaust gas outlet......................................... 26
6 Electrical installation........................................................................ 28
6.1 Safety......................................................................................................... 28
6.2 Equipment protection............................................................................... 28
6.3 Disconnecting device................................................................................ 28
6.4 Socket for Service work............................................................................ 28
6.5 Connecting the power supply................................................................... 28
6.6 Performing a high voltage test................................................................. 29
7 Commissioning.................................................................................. 30
7.1 Prerequisites for switching on.................................................................. 30
7.2 Switching on.............................................................................................. 30
7.3 Recognizing the safe operating state...................................................... 30
7.4 Adjusting.................................................................................................... 30
7.4.1 Performing zero point adjustment.......................................... 30
7.4.2 Performing reference point adjustment................................. 31
7.4.2.1 Adjustment with internal adjustment filter........... 31
7.4.2.2 Adjustment with span gas...................................... 31
7.4.2.3 O2 adjustment......................................................... 32
8 Operation............................................................................................ 33
8.1 Operating concept.................................................................................... 33
8.2 User groups............................................................................................... 33
8.3 Display....................................................................................................... 33
8.4 Tiles........................................................................................................... 34
8.5 Measuring Screen..................................................................................... 35
9 Menus.................................................................................................. 37
9.1 Password................................................................................................... 37
9.2 Menu tree.................................................................................................. 37
10 Maintenance...................................................................................... 41
10.1 Safety......................................................................................................... 41
10.2 Important information.............................................................................. 41
10.3 Maintenance plan..................................................................................... 42
10.4 Cleaning..................................................................................................... 43
10.4.1 Clean surfaces and parts with media contact....................... 43
10.4.2 Cleaning the display................................................................ 43
10.5 Checking the system................................................................................ 44
10.5.1 Check assemblies.................................................................... 44
10.5.2 Check external instrument air supply..................................... 44
10.5.3 Check span gases.................................................................... 44
10.5.4 Check environment.................................................................. 44
10.5.5 Check gas sampling unit......................................................... 45
CONTENTS
4O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

10.5.6 Check measured values (when system in operation)........... 45
10.6 Maintaining the instrument air conditioning.......................................... 45
10.6.1 Maintaining the instrument air conditioning (option)............ 45
10.6.2 Maintaining the external instrument air conditioning
(option)..................................................................................... 45
10.7 Replacing the Electronics module filter pad........................................... 46
11 Troubleshooting................................................................................. 47
11.1 Safety......................................................................................................... 47
11.2 Important information.............................................................................. 47
11.3 Error messages and possible causes..................................................... 47
12 Decommissioning............................................................................. 52
12.1 Switching off.............................................................................................. 52
12.1.1 Switching off............................................................................. 52
12.1.2 Shutdown................................................................................. 52
12.2 Return delivery.......................................................................................... 52
12.2.1 Shipping for repair................................................................... 52
12.2.2 Cleaning the device before returning..................................... 53
12.3 Transport................................................................................................... 53
12.4 Disposal..................................................................................................... 53
13 Technical data.................................................................................... 54
13.1 Dimensional drawings.............................................................................. 54
13.2 Technical data........................................................................................... 54
13.2.1 Measured values..................................................................... 55
13.2.2 Ambient conditions.................................................................. 56
13.2.3 Housing.................................................................................... 56
13.2.4 Interfaces and protocols......................................................... 56
13.2.5 Power supply............................................................................ 57
13.2.6 Gas supply................................................................................ 57
13.2.7 Tube connections..................................................................... 57
13.2.8 Sample gas conditions............................................................ 58
13.2.9 Connections in analyzer.......................................................... 58
13.2.9.1 Power supply - connection / fuses........................ 58
13.2.9.2 Electronics fuses..................................................... 59
13.2.9.3 Connections for heated components.................... 60
13.2.9.4 Connections for interfaces and SD card............... 61
13.2.10 Heated sample gas line (option)............................................. 63
13.2.11 Switching on the circuit breakers again................................. 63
13.2.12 Torques for screw fittings........................................................ 63
14 Annex.................................................................................................. 65
14.1 Conformities.............................................................................................. 65
14.2 Licenses.................................................................................................... 65
14.2.1 Liability disclaimer................................................................... 65
14.2.2 Software licences.................................................................... 65
CONTENTS
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 5
Subject to change without notice

14.2.3 Source codes........................................................................... 65
CONTENTS
6O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

1 About this document
1.1 Function of this document
These Operating Instructions describe:
•Device components
•Installation
•Commissioning
•Operation
•Maintenance work required for reliable operation
•Troubleshooting
•Decommissioning
1.2 Scope of application
These Operating Instructions are only applicable for the measuring device described in
the product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 Target groups
This Manual is intended for persons who install, commission, operate and maintain the
device.
1.4 Further information
•System documentation
•Option: SFU Gas Sampling Unit Operating Instructions
•Option: Sample Gas Line Operating Instructions
•Option: MPR (Meeting Point Router) Operating Instructions
•Option: Instrument Air Conditioning Operating Instructions
•Option: GMS800 FIDOR / FIDORi Operating Instructions
•Option: Condensate Container Operating Instructions
1.5 Symbols and document conventions
1.5.1 Warning symbols
Table 1: Warning symbols
Symbol Significance
Hazard (general)
Hazard by electrical voltage
Hazard by acidic substances
ABOUT THIS DOCUMENT 1
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 7
Subject to change without notice

Symbol Significance
Hazard by toxic substances
Hazard through hot surface
Hazard for the environment/nature/organic life
1.5.2 Warning levels / Signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
Note
Hints
1.5.3 Information symbols
Table 2: Information symbols
Symbol Significance
Important technical information for this product
Important information for electrical or electronic functions
1.6 Data integrity
SICK AG uses standardized data interfaces, such as standard IP technology, in its
products. The focus here is on product availability and features.
SICK AG always assumes that the customer is responsible for the integrity and confi‐
dentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection
and Patch Management.
1 ABOUT THIS DOCUMENT
8O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

2 Safety information
2.1 Basic safety information
bRead and observe these Operating Instructions.
bObserve all safety instructions.
bIf anything is not clear: Please contact SICK Customer Service.
Document retention
These Operating Instructions
bMust be kept for reference.
bMust be passed on to new owners.
Correct project planning
•Basis of this Manual is the delivery of the measuring device according to the
preceding project planning (e.g., based on the SICK application questionnaire)
and the relevant delivery state of the measuring device (see delivered System
Documentation).
bContact SICK Customer Service if you are not sure whether the measuring
device corresponds to the state defined during project planning or to the
delivered System Documentation.
Correct use
bUse the device only as described in “Intended use”.
The manufacturer assumes no responsibility for any other use.
bCarry out the specified maintenance work.
bDo not carry out any work or repairs on the device that are not described in this
Manual.
Do not remove, add or change any components in or on the device unless such
changes are officially allowed and specified by the manufacturer.
If you do not observe this:
°The manufacturer's warranty becomes void.
°The device could become dangerous.
Special local conditions
In addition to the information in this Manual, follow all local laws, technical rules and
company-internal operating and installation directives applicable wherever the device is
installed.
SAFETY INFORMATION 2
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 9
Subject to change without notice

Electrical safety
DANGER
Danger to life through electric shock
There is a risk of electric shock when working on the device with the voltage supply
switched on.
bBefore starting work on the device, ensure the voltage supply can be switched
off in accordance with the valid Standard using a power isolating switch/circuit
breaker.
bMake sure the disconnector switch is easily accessible.
bAn additional disconnecting device is mandatory when the power disconnector
switch cannot be accessed or only with difficulty after installation of the device
connection.
bSwitch off the voltage supply before starting any work on the device.
bAfter completion of the work or for test purposes, calibration of the power supply
may only be activated again by authorized personnel complying with the safety
regulations.
WARNING
Endangerment of electrical safety through power supply line with incorrect rating
Electrical accidents can occur when the specifications for installation of a power supply
line have not been adequately observed.
bAlways observe the exact specifications in the Operating Instructions (see "Techni‐
cal data", page 54) for installation of a power supply line.
Dangerous substances
DANGER
Danger to life through leaks in the gas path
When the measuring device is used to measure toxic gases: A leak, for example in the
purge air supply, can be an acute hazard for persons..
bRegularly check all gas-carrying components for leaks
bTake suitable safety measures. For example:
°Attach warning signs to the device
°Attach warning signs in the operating area
°Adequately vent the operating area.
°Safety-oriented instruction of persons that could be in this area.
2.2 Warning information on device
Warning information on device
The following safety symbols are on the device:
Table 3: Warning symbols
Symbol Significance
Warning for general hazard
Warning for hazard by electric voltage, possibly also by residual electric voltage
2 SAFETY INFORMATION
10 O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

Symbol Significance
Warning for hazard through hot surfaces
If you need to work on a subassembly marked with such a symbol:
bRead the relevant Section in these Operating Instructions
bObserve all the safety information in the relevant Section
2.3 Intended use
The MCS200HW-MP is a multicomponent analysis system for continuous flue gas
monitoring of industrial combustion plants (emission measuring system). The sample
gas is extracted at the measuring point and fed through the analysis system (extractive
measurement).
The analysis system is designed for indoor installation.
bRefer to the system documentation delivered for information on the device equip‐
ment.
2.4 Requirements on the personnel's qualification
Table 4: Qualification requirements
Tasks User groups Qualifications
Installation Qualified personnel •General knowledge in
measurement technology,
specialist device knowledge
(possibly customer training
at SICK)
Electrical Installation Qualified personnel •Authorized electrician
(authorized skilled electri‐
cian or person with similar
training)
•General knowledge in
measurement technology,
specialist device knowledge
(possibly customer training
at SICK)
Initial commissioning Authorized operator Ü•General knowledge in
measurement technology,
specialist device knowledge
(possibly customer training
at SICK)
Recommissioning
Decommissioning •Operator / system integra‐
tor
•Authorized operator Ü
•General knowledge in
measurement technology,
specialist device knowledge
(possibly customer training
at SICK)
•Authorized electrician
(authorized skilled electri‐
cian or person with similar
training)
•Service training
Operation
Troubleshooting
SAFETY INFORMATION 2
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 11
Subject to change without notice

Tasks User groups Qualifications
Maintenance •Operator / system integra‐
tor
•Authorized operator Ü
•General knowledge in
measurement technology,
specialist device knowledge
(possibly customer training
at SICK)
•Service training
2 SAFETY INFORMATION
12 O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

3 Product description
3.1 Product identification
Overview
Product name MCS200HW-MP
Manufacturer SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Type plate Type plates are located on the right on the installation plate.
Type plates MCS200HW-MP
Figure 1: Type plate of complete device, schematic representation
1Product name
2Item number
3Technical details
4Serial number
5Marking symbols
6Measuring modules
Analyzer type plate
Figure 2: Analyzer type plate, schematic representation
1Product name
2Item number
3Technical details
4Serial number
5Marking symbols
3.2 Gas supply terminology
Definition of utility gases:
•Zero gas: Gas to adjust the zero point. Instrument air or nitrogen (N2)
•Span gas: Gas to adjust the measuring range full scale value
•Instrument air: Compressed air free of oil, water and particles
PRODUCT DESCRIPTION 3
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 13
Subject to change without notice

3.3 Layout and function
3.3.1 System overview
Overview
1
2
3
4
56
7
8
7
1Gas sampling unit
2Heated sample gas line
3Hose bundle line
4Installation plate
5Voltage supply
6Interfaces 1 x Ethernet: Connections
Customer-specific analog and digital inputs
and outputs, see wiring diagram
7Instrument air inlet
Option: Instrument air conditioning
Observe the quality of the operator's instru‐
ment air.
A separate instrument air supply can also be
connected as zero gas (IR components) or
span gas (O2 sensor).
8Exhaust gas outlet
Measuring principle
•IR components: Single-beam infrared photometer with interference filter and gas
filter correlation method
•Oxygen: Zirconium dioxide sensor
Measuring components
Output of measured values in mg/m³ or percentage volume, relative to humid flue gas.
Refer to the system documentation provided for the configuration of your system.
Function
•The system operates independently.
•Sampling of flue gas at the measuring point with a heated gas sampling unit
•Sample gas feed to the analyzer in a heated sample gas line
3 PRODUCT DESCRIPTION
14 O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

•Heating temperature of all parts with sample gas contact: 200 °C
•Pump: Ejector pump in cell (operated with instrument air)
•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 automati‐
cally purged with instrument air in this mode.
°Measured values are updated further.
Check (validation) and adjustment
•Zero point adjustment
•Reference point adjustment
•Adjustment with internal adjustment filter
Operating using the display
It is possible to operate the device using the display.
Operation via external PC (optional)
Operator menus and measured value displays are also available for easy use on an
external PC via the Ethernet connection (with Google Chrome browser and SOPASair).
3.3.2 Installation plate
Overview
On the installation plate:
•Control unit
•Measurement technology
•Analog and digital interfaces
PRODUCT DESCRIPTION 3
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 15
Subject to change without notice

View
Analyzer module
1Cell module
•Ejector pump
•Inlet filter
2Optics module
3Electronics module
Installation plate
4Valve block
5I/O modules
6Span gas unit
7Display module
8Sample gas outlet
9Pressure reducer module
3.3.3 Instrument air, conditioning
Overview
If the supplied instrument air does not meet the required quality, an instrument air
conditioner can be connected upstream from the pressure reducer module.
3 PRODUCT DESCRIPTION
16 O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

Important information
NOTICE
Malfunction of the measuring device due to unsuitable instrument air
Operation with air not satisfying the specifications voids the warranty and does not
ensure proper functioning of the measuring device.
bOnly feed conditioned instrument air to the measuring device.
bThe instrument air quality must meet the specification.
Function
The instrument air conditioning serves to condition the compressed air provided by the
operator.
Additional information
A separate instrument air supply as zero gas or test gas can be connected as an
alternative.
Related topics
•Instrument Air Conditioning Operating Instructions
•Instrument air quality: see "Gas supply", page 57
3.4 Extended interfaces (option)
As standard, analog and digital signals are used for device communication with cus‐
tomer peripherals. Alternatively, output can be performed using the Modbus-TCP proto‐
col.
Optionally, SICK offers various converter modules that are installed by the customer
and communicate with the device via Modbus® TCP.
Optionally available
•PROFIBUS / PROFINET
Modbus
Modbus® is a communication standard for digital controls to create a connection
between a »Master« device and several »Slave« devices. The Modbus protocol defines
the communication commands only but not their electronic transfer; therefore it can be
used with different digital interfaces (Ethernet).
The measuring device is equipped with a digital interface for data transmission in
accordance with Guideline VDI 4201, Sheet 1 (General requirements) and Sheet 3
(Specific requirements for Modbus). Refer to the documentation delivered (Modbus
signal list) for assignment of the Modbus registers. Only SICK Service may perform
parameter settings.
PRODUCT DESCRIPTION 3
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 17
Subject to change without notice

4 Transport and storage
4.1 Transport
Overview
Transport the device horizontally with suitable hoisting equipment (e.g. jack lift with
adequate 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.
Transport
The device may only be transported horizontally.
The device is picked up with suitable hoisting equipment using the fastening openings
on the installation plate.
4.2 Storage
Protective measures for long-term storage
•When gas lines have been unscrewed: Close all gas connections (with sealing
plugs) to protect internal gas paths against moisture, dust or dirt penetrating
•Close off open electrical connections dust-tight
•Protect the display against sharp-edged objects. Possibly attach a suitable protec‐
tive cover (e.g. made of cardboard or hard foam)
•Select a dry, well-ventilated room for storage
•Wrap the device (e.g. with stretch foil)
•When high air humidity can be expected: Include a drying agent (Silica-Gel) in the
packing
4 TRANSPORT AND STORAGE
18 O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice

5 Mounting
5.1 Safety
Qualification
The measuring device may only be installed by trained specialists.
5.2 Scope of delivery
Please see the delivery documents for the scope of delivery.
5.3 Overview of mechanical and electrical installation
Important information
NOTICE
Observe the order of assembly.
If the assembly sequence is incorrect, there is a risk of contamination of the gas sam‐
pling unit. This can cause exhaust gas to enter the unheated analyzer and condense
out.
bFirst connect instrument air and voltage supply.
bOnly then install the gas sampling unit in the flue gas duct.
Installation sequence
•Fit the installation plate
•Electrical connections on analyzer
•Connect signal lines to analyzer
•Install SFU gas sampling system
•Connect heater hose
•Air and gas connections on analyzer
•Connect sample gas line to analyzer
•Sample gas outlet
MOUNTING 5
8026608/AE00/V1-0/2021-10 | SICK O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 19
Subject to change without notice

5.4 Installation sequence
5.4.1 Wall mounting
Overview
23
1.847
1.823
598
666
Prerequisites
•Observe 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).
•Observe clearances for maintenance work.
•Ensure the mounting location has sufficient load-bearing capacity.
•Observe relevant ambient conditions.
Procedure
1. Mount installation plate with 4 screws (optionally M8, M10 or M12 screws with
strength 8.8 or higher) on the wall.
Use at least 2 screws at the top and 2 screws at the bottom of the installation
plate.
Related topics
•see "Ambient conditions", page 56
•see "Dimensional drawings", page 54
5 MOUNTING
20 O P E R A T I N G I N S T R U C T I O N S | MCS200HW-MP 8026608/AE00/V1-0/2021-10 | SICK
Subject to change without notice