SICK MARSIC280 User manual

OPERATING INSTRUCTIONS
MARSIC280
Ship Emission Measuring Devices

Described product
MARSIC280
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.
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Subject to change without notice

Contents
1 About this document........................................................................ 9
1.1 Function of this document....................................................................... 9
1.2 Scope of application................................................................................. 9
1.3 Target groups............................................................................................ 9
1.4 Further information................................................................................... 9
1.5 Symbols and document conventions...................................................... 9
1.5.1 Warning symbols...................................................................... 9
1.5.2 Warning levels / Signal words................................................. 10
1.5.3 Information symbols................................................................ 10
1.6 Data integrity............................................................................................. 10
2 Safety information............................................................................ 11
2.1 Basic safety information........................................................................... 11
2.1.1 Electrical safety........................................................................ 11
2.1.2 Dangerous substances............................................................ 12
2.2 Warning information on device................................................................ 12
2.3 Intended use............................................................................................. 13
2.4 Unintended use......................................................................................... 13
2.5 Requirements on the personnel's qualification...................................... 13
3 Product description........................................................................... 15
3.1 Product identification............................................................................... 15
3.2 Gas supply terminology............................................................................ 15
3.3 Layout and function.................................................................................. 16
3.3.1 System overview...................................................................... 16
3.3.2 Analyzer.................................................................................... 16
3.3.3 Sample conditioning and distribution unit............................. 17
3.3.4 Gas sampling unit for indoor installation............................... 18
3.3.5 Gas sampling unit for outdoor installation............................. 19
3.3.6 Hose bundle line...................................................................... 20
3.3.7 Sample gas line, heated.......................................................... 20
3.3.8 Instrument air, conditioning.................................................... 21
3.4 Interfaces.................................................................................................. 21
3.4.1 Extended interfaces (option)................................................... 21
3.5 Remote maintenance (option)................................................................. 22
4 Transport and storage....................................................................... 23
4.1 Transport................................................................................................... 23
4.2 Storage...................................................................................................... 23
5 Mounting............................................................................................. 24
5.1 Safety......................................................................................................... 24
5.2 Scope of delivery....................................................................................... 24
5.3 Screw fittings............................................................................................. 24
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5.3.1 Installing the stainless steel screw fitting.............................. 24
5.3.2 Using a plastic fitting............................................................... 24
5.3.3 Using a push-in fitting (pneumatic)........................................ 25
5.4 Mechanical and electrical installation.................................................... 25
5.5 Installation sequence............................................................................... 26
5.5.1 Wall fitting................................................................................ 26
5.5.2 Laying the sample gas lines.................................................... 27
5.5.3 Laying the hose bundle line.................................................... 28
5.5.4 Connecting the hose bundle line to gas sampling unit (115
V)............................................................................................... 29
5.5.5 Connecting the hose bundle line to gas sampling unit (230
V)............................................................................................... 31
5.5.6 Connecting the hose bundle line to the sample condition‐
ing and distribution unit (one measuring point).................... 34
5.5.7 Connecting the hose bundle line to the sample condition‐
ing and distribution unit (two measuring points)................... 34
5.5.8 Fitting the sample gas line on the gas sampling unit........... 35
5.5.9 Connecting the hose bundle line to the sample condition‐
ing and distribution unit (one measuring point).................... 36
5.5.10 Connecting the hose bundle line to the sample condition‐
ing and distribution unit (two measuring points)................... 37
5.5.11 Connecting the discharge hose to the condensate pump.... 38
5.5.12 Connecting the condensate container (option)..................... 38
5.5.13 Connecting the filling level sensor to the condensate con‐
tainer (option).......................................................................... 39
5.5.14 Connecting the valve block..................................................... 40
5.5.15 Connecting the gas connections on the analyzer.................. 40
5.5.16 Closing the shut-off valve of the control gas.......................... 41
5.5.17 Connecting the instrument air................................................ 42
5.5.18 Fitting the gas sampling unit................................................... 43
5.5.18.1 Fitting the welding neck flange.............................. 43
5.5.18.2 Fitting the gas sampling unit on the flange.......... 44
6 Electrical installation........................................................................ 46
6.1 Safety......................................................................................................... 46
6.2 Equipment protection............................................................................... 46
6.3 Disconnecting device................................................................................ 46
6.4 Socket for Service work............................................................................ 46
6.5 Electrical connection of control unit........................................................ 46
6.6 Connecting data communication............................................................. 47
6.6.1 Connecting the signal line (option)......................................... 47
6.6.2 Connecting Ethernet (option).................................................. 47
7 Commissioning.................................................................................. 48
7.1 Switching on.............................................................................................. 48
7.1.1 Switch-on procedure for one measuring point....................... 48
7.1.2 Switch-on procedure for two measuring points..................... 48
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7.2 Connecting with SOPAS ET....................................................................... 49
7.3 Changing the IP address on the BCU...................................................... 50
7.4 Adjusting.................................................................................................... 50
7.4.1 Setting the test gas.................................................................. 50
7.4.2 Setting the test gas with SOPAS ET........................................ 50
7.4.3 Determining adjustment gas purging times........................... 51
7.4.4 Determining calibration gas purging times with SOPAS ET... 51
7.4.5 Selecting the gas sampling unit for validation and calibra‐
tion............................................................................................ 51
7.4.6 Performing zero point validation and adjustment................. 52
7.4.7 Performing zero point validation and adjustment with
SOPAS ET.................................................................................. 52
7.4.8 Performing sensitivity validation or adjustment.................... 53
7.4.9 Performing sensitivity validation or adjustment with SOPAS
ET.............................................................................................. 53
7.4.10 Programming automatic adjustment and validation............. 53
7.4.11 Setting automatic validation and adjustment with SOPAS
ET.............................................................................................. 54
7.5 Parameterization....................................................................................... 54
7.5.1 Setting the time....................................................................... 54
7.5.2 Setting the heating controller................................................. 55
7.5.3 Setting the cooler temperature............................................... 55
7.5.4 Checking the condensate pump cooler.................................. 56
7.5.5 Setting the instrument air flow............................................... 56
7.5.6 Adjusting the flow sensor with SOPAS ET............................... 56
7.5.7 Setting the measuring and purging times.............................. 57
7.5.8 Setting the measuring and purge times with SOPAS ET....... 57
7.5.9 Activating and deactivating measuring points....................... 58
7.5.10 Activating and deactivating measuring points with SOPAS
ET.............................................................................................. 58
7.5.11 Setting analog outputs with SOPAS ET................................... 59
7.5.12 Testing analog outputs with SOPAS ET................................... 59
7.6 Performing the leak tightness check....................................................... 59
7.7 Recognizing the safe operating state...................................................... 61
7.7.1 Recognizing the safe operating state..................................... 61
8 Operation............................................................................................ 62
8.1 Operating and display elements.............................................................. 62
8.1.1 LED........................................................................................... 62
8.1.2 Function buttons ..................................................................... 62
8.2 Status messages...................................................................................... 63
8.2.1 Opening the logbook................................................................ 63
8.2.2 Checking the DEFOR hours of operation................................ 63
8.3 Activating Standby mode.......................................................................... 64
8.4 Switching the device off........................................................................... 64
8.5 Modbus functions..................................................................................... 64
8.5.1 Activating Modbus functions................................................... 64
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8.5.2 Measured value inquiry MBO DESOX..................................... 65
8.5.3 Enabling Modbus inputs......................................................... 65
8.5.4 Setting Modbus functions....................................................... 65
9 Menus.................................................................................................. 67
9.1 Password................................................................................................... 67
9.2 Menu tree.................................................................................................. 67
9.3 Changing the user level............................................................................ 68
9.4 Changing the user level in SOPAS ET: .................................................... 68
10 Maintenance...................................................................................... 69
10.1 Safety......................................................................................................... 69
10.2 Maritime Hotline....................................................................................... 69
10.3 Data backup and data recovery............................................................... 69
10.3.1 Backing up the data................................................................ 69
10.3.2 Recovering the data................................................................. 69
10.4 Maintenance plan..................................................................................... 70
10.5 Consumable, wearing and spare parts................................................... 71
10.6 Regular checks......................................................................................... 71
10.6.1 Checking the device and environment................................... 71
10.6.2 Checking operation.................................................................. 72
10.6.3 Checking the sample gas ine filter......................................... 72
10.6.4 Checking the water trap.......................................................... 72
10.7 Cleaning..................................................................................................... 73
10.7.1 Clean surfaces and parts with media contact....................... 73
10.7.2 Cleaning the display................................................................ 73
10.8 Setting the maintenance signal............................................................... 73
10.9 Setting the maintenance condition with SOPAS ET................................ 74
10.10 Maintenance work.................................................................................... 74
10.10.1 Servicing the gas sampling unit.............................................. 74
10.10.1.
1
Replacing the glass fiber filter element................
75
10.10.1.
2
Replacing the non-return valves............................
78
10.10.2 Replacing the sample gas line................................................ 79
10.10.2.
1
Switching the analyzer off......................................
79
10.10.2.
2
Removing the sample gas line...............................
79
10.10.2.
3
Laying the sample gas lines...................................
80
10.10.2.
4
Fitting the sample gas line on the gas sampling
unit........................................................................... 81
10.10.2.
5
Swapping the temperature sensors on the sam‐
ple gas line.............................................................. 82
10.10.3 Replacing the sample gas fine filter....................................... 83
10.10.4 Replacing the condensate pump hose................................... 83
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10.10.5 Replacing the water trap......................................................... 84
10.10.6 Replacing the filter pad........................................................... 85
10.10.7 Emptying the condensate container....................................... 86
10.10.8 Replacing the analyzer............................................................ 86
10.10.8.
1
Remove the analyzer..............................................
86
10.10.8.
2
Fit the analyzer........................................................
87
10.10.9 Replacing the complete analyzer module.............................. 88
10.10.9.
1
Remove the complete analyzer module ...............
88
10.10.9.
2
Fit the complete analyzer module.........................
89
10.10.10 Replacing the analyzer door with control unit........................ 91
10.10.10
.1
Remove the analyzer door with control module
(BCU)........................................................................ 91
10.10.10
.2
Fit the analyzer door with the control module
(BCU)........................................................................ 91
10.10.11 Replacing the power supply unit............................................. 92
10.10.11
.1
Remove the analyzer power supply unit................
92
10.10.11
.2
Fit the analyzer power supply unit.........................
93
10.10.12 Replacing the analyzer fuse.................................................... 93
10.10.13 Replacing the DEFOR module................................................. 95
10.10.14 Replacing the CO2 module (FINOR)........................................ 96
10.10.15 Replacing the gas module....................................................... 96
11 Troubleshooting................................................................................. 98
11.1 Safety......................................................................................................... 98
11.2 Maritime Hotline....................................................................................... 98
11.3 Malfunctions............................................................................................. 98
11.3.1 Logbook description................................................................ 98
12 Decommissioning............................................................................. 111
12.1 Switching off.............................................................................................. 111
12.1.1 Switching the device off.......................................................... 111
12.2 Transport................................................................................................... 111
12.3 Return delivery.......................................................................................... 111
12.3.1 Shipping for repair................................................................... 111
12.3.2 Cleaning the device before returning..................................... 112
12.4 Disposal..................................................................................................... 112
13 Technical data.................................................................................... 113
13.1 Dimensional drawings.............................................................................. 113
13.2 Technical data........................................................................................... 113
13.2.1 Measured values..................................................................... 114
13.2.2 Ambient conditions.................................................................. 114
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13.2.3 Sample gas conditions............................................................ 114
13.2.4 Housing.................................................................................... 115
13.2.5 Interfaces and protocols......................................................... 115
13.2.6 Power supply............................................................................ 116
13.2.7 Line cross-sections.................................................................. 116
13.2.8 Gas supply................................................................................ 117
13.2.8.1 Tube connections.................................................... 117
13.2.9 Heated sample gas line........................................................... 117
13.2.10 Torques for screw fittings........................................................ 118
14 Annex.................................................................................................. 119
14.1 Licenses.................................................................................................... 119
14.1.1 Liability disclaimer................................................................... 119
14.1.2 Software licences.................................................................... 119
14.1.3 Source codes........................................................................... 119
CONTENTS
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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
•SFU Gas Sampling Unit Operating Instructions
•SFU Gas Sampling Unit with weather hood Operating Instructions
•Sample Gas Line Operating Instructions
•BCU Operating Instructions
•Safety information (for SICK analyzer devices)
•Optional: MPR (Meeting Point Router) Operating Instructions
•Optional: Instrument Air Conditioning Operating Instructions
•Optional: Pressure Test Tool 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
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Symbol Significance
Hazard by toxic substances
Hazard by high temperature
Hazard by UV radiation
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
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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
•Basis of this Manual is the delivery of the device according to the preceding
project planning (e.g., based on the SICK application questionnaire) and the rele‐
vant delivery state of the device (see delivered System Documentation).
bIf you are not sure whether the device corresponds to the state defined
during project planning or to the delivered system documentation: Please
contact SICK Customer Service.
•Only use the measuring device as described in “Correct use”.
The manufacturer bears no responsibility for any other use.
•Perform the specified maintenance work.
•Do not perform any work or repairs on the measuring device not described in this
manual.
Do not remove, add or modify any components to or on the device unless descri‐
bed and specified in the official manufacturer information.
•Use only original spare parts and expendable parts from SICK.
By non-observance:
•The manufacturer's warranty becomes void.
•The device could become dangerous.
•The approval for use in potentially explosive atmospheres is no longer valid.
Special local conditions
In addition to the information in these Operating Instructions, follow all local laws,
technical rules and company-internal operating and installation directives applicable
wherever the device is installed.
2.1.1 Electrical safety
Hazard through electrical shock
There is a risk of electric shock when working on the measuring device with the voltage
supply switched on.
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•Before starting work on the measuring device, ensure the power supply can be
switched off using a power isolating switch or circuit breaker in accordance with
the valid standard.
•Make sure the power isolating switch is easily accessible.
•An additional disconnecting device is mandatory when the power isolating switch
cannot be accessed or only with difficulty after installation of the device connec‐
tion.
•Switch off the power supply before carrying out any work on the measuring device.
•After completion of the work or for test purposes, calibration, the voltage supply
may only be activated again by authorized personnel complying with the safety
regulations.
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 Operating Instructions when instal‐
ling a power line (see "Technical data", page 113).
•The user must ensure that the power cable is designed in accordance with the
applicable standards.
2.1.2 Dangerous substances
Danger through leaks in the gas path with toxic gases
A leak, e.g., in purge air supply, can represent an acute danger for persons.
•Regularly check all gas-carrying components for leaks.
•Take suitable safety measures. E.g.:
°Marking the measuring device with warning signs.
°Marking the operating area with warning signs.
°Ventilating the operating room sufficiently.
°Safety-related instruction of personnel who could be in the vicinity of the
installation site.
Danger through caustic condensate
Health hazard due to toxic compounds in the condensate
•Observe all safety regulations for the application.
•Take appropriate protective measures for work (e.g., by wearing a safety mask,
protective gloves and acid resistant clothes).
•In case of contact with the skin or eyes, rinse the affected parts immediately with
clear water and consult a doctor.
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
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Symbol Significance
Warning for hazard through hot surfaces
Warning for hazard by UV radiation
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
MARSIC280 is a modular multi-component analyzer system for continuous measure‐
ment of exhaust gas concentrations of SO2 and CO2 from exhaust gas cleaning sys‐
tems on vessels.
2.4 Unintended use
The system is designed for inside installation below deck. The system must not be
installed on deck or outside.
2.5 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
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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
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3 Product description
3.1 Product identification
Overview
Product name MARSIC280
Manufacturer SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Type plate Type plates are located on the outside on the right of the housing.
Type plate
Figure 1: Analyzer type plate, schematic representation
1Product name
2Item number
3Specification on voltage supply
4Serial number
5Barcode
3.2 Gas supply terminology
Definition of supply gases:
•Zero gas: Gas for zero point adjustment. Instrument air or nitrogen (N2)
•Reference gas: Gas for measuring range end scale value adjustment
•Test gas: Generic term for zero and reference gas
•Instrument air: Clean compressed air
PRODUCT DESCRIPTION 3
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3.3 Layout and function
3.3.1 System overview
Overview
23
3
4
5
6
7
8
1
2
1
1Gas sampling unit (Option: 2 gas sampling units)
2Heated sample gas line (Option: 2 gas sampling lines)
3Hose bundle line (Option for 2 measuring points: 2 hose bundle lines)
4Analyzer cabinet and sample conditioning and distribution unit
5Power supply
6Interfaces: 1 x Ethernet
7Instrument air inlet (Option: Instrument air conditioning)
8Sample gas outlet
Function
The system operates independently. The flue gas is extracted by a heated gas sampling
unit at one or more measuring points and passed through a heated sample gas line for
conditioning in the analyzer.
Operation
Operation is performed via the control module in the analyzer door.
Alternatively, operation can be performed via an external computer and the SOPAS
Engineering Tool (SOPAS ET).
Check (validation) and adjustment
•Zero point adjustment
•Reference point adjustment
•Purging the gas sampling unit
3.3.2 Analyzer
Overview
The analyzer comprises:
•Control module
•Measurement technology
•Analog and digital interfaces
3 PRODUCT DESCRIPTION
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View
1Analyzer top part with electronics
2Control module
3Analyzer bottom part with measurement technology
4Sample gas inlet
5Sample gas outlet
6Analyzer on/off switch
7Data interfaces
8Fuses / distribution board
9Analyzer module CO2 (FINOR)
ßAnalyzer module SO2 (DEFOR)
àGas module (flow/humidity/pressure)
3.3.3 Sample conditioning and distribution unit
View
PRODUCT DESCRIPTION 3
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1Cooler
2Pump
3Valve block
4Flow meter
5Filter
6Water trap
7Instrument air connection
8Relay of the heating power control
9Heating control
ßFan
àPower supply
áFuses
3.3.4 Gas sampling unit for indoor installation
Overview
1
2
3
4
Figure 2: Gas sampling unit for indoor installation (system-specific)
1Filter housing
2Gas sampling tube (unheated)
3Weather hood
4Pre-filter (optional)
Prerequisites
•Flue gas extraction takes place inside.
Function
The gas extraction unit SFU extracts flue gas from the stack via the gas sampling tube.
After filtration, the flue gas is passed to a measuring device for analysis.
Characteristics
•Gas sampling tube unheated and without pre-filter
•Gas sampling tube reinforced for maritime application
•Gas sampling tube available in different lengths (option)
•Gas sampling unit is thermostatically controlled.
•The analyzer regulates the heating.
•When no voltage is applied, the heated sample gas line and the analyzer are
purged with instrument air.
3 PRODUCT DESCRIPTION
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3.3.5 Gas sampling unit for outdoor installation
Overview
1Weatherproof enclosure
2Gas sampling tube
3SFU filter housing
4Flange
5Silicone press ring seal (gas sampling tube seal)
Prerequisites
•Flue gas extraction takes place outside on the ship.
Function
The gas extraction unit SFU extracts flue gas from the stack via the gas sampling tube.
After filtration, the flue gas is passed to a measuring device for analysis.
Characteristics
•Gas sampling tube unheated and without pre-filter
•Gas sampling tube available in different lengths (option)
•Gas sampling unit is thermostatically controlled.
•The analyzer regulates the heating.
•When no voltage is applied, the heated sample gas line and the analyzer are
purged with instrument air.
PRODUCT DESCRIPTION 3
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3.3.6 Hose bundle line
Overview
1
4
2
3
6
5
1Power supply
2Signal line
3Grounding conductor
4PTFE hose, white, DN4/6
5PA hose, black, DN6/8, labeled "1"
6PA hose, blue, DN6/8, labeled "2"
Function
The hose bundle line connects the gas sampling unit with the measuring device. The
hose bundle line contains the power supply line, signal lines and gas lines.
3.3.7 Sample gas line, heated
Overview
1
5
4
7
6
3 2
Figure 3: Heated sample gas line
1Connection to gas sampling unit (without electrical connections)
2Connection to measuring device (with electrical connections)
3Protective cap
42 × PT100 connections (1 as reserve)
5Power supply
6Cable gland
7Locknut
Function
The heated sample gas line leads the flue gas from the gas sampling unit to the
measuring device.
3 PRODUCT DESCRIPTION
20 O P E R A T I N G I N S T R U C T I O N S | MARSIC280 8021339/1CHC/V1-1/2021-07 | SICK
Subject to change without notice