SICK MCS200HW User manual

MMM
I
MMMSERVICE MANUAL
SERVICE MANUAL
MCS200HW
Multicomponent Analysis System
Title page

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Described product
Product name: MCS200HW
Document identification
Title: Service Manual MCS200HW
Part No.: 8024638
EAN: AE00
Version: V1-0
Stand: 2019-09
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Trademarks
Product names used in this document may be trademarks and are only used for
identification purposes.
Original document
This document is an original document of SICK AG.
SICK AG assumes no liability for the correctness of an unauthorized translation.
If in doubt, contact SICK AG or your local representative.
Legal information
Subject to change without notice.
© SICK AG. All rights reserved.

CONTENTS
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1 About this Manual ..................................................................................... 7
1.1 Target group of this Manual ...........................................................................7
1.2 Purpose of this Manual................................................................................... 7
1.3 Information concerning this Manual .............................................................. 7
1.4 Special hazards............................................................................................... 8
1.5 Safety rules for work on electrical systems ...................................................8
1.6 ESD .................................................................................................................. 8
1.7 Inquiries to SICK AG........................................................................................ 9
2 Tools...........................................................................................................10
2.1 Special tools and auxiliary means................................................................10
3 Maintenance.............................................................................................11
3.1 Maintenance interval ....................................................................................11
3.2 Expendable and wearing parts .....................................................................11
3.3 Working on the device cabinet .....................................................................12
3.3.1 Exchanging filter pads ..................................................................12
3.3.1.1 Door ventilator...........................................................12
3.3.1.2 Roof ventilator...........................................................13
3.4 Working on the cell .......................................................................................14
3.4.1 Removing the complete cell .........................................................15
3.4.2 Fitting the complete cell ...............................................................18
3.4.3 Cell inlet filter maintenance .........................................................21
3.4.4 Replacing the non-return valve on the cell inlet filter .................25
3.4.5 Ejector block maintenance...........................................................26
3.4.5.1 Replacing the O-ring on the middle section .............29
3.4.5.2 Replacing the sealing ring on hose connection 2....30
3.4.5.3 Replacing the O-rings on exhaust gas connection
and ejector nozzle .....................................................31
3.4.6 Mirror plates and tubes maintenance .........................................33
3.4.6.1 Replacing the O-ring of the upper mirror plate ........34
3.4.6.2 Replacing the O-rings of the lower mirror plate .......37
3.4.6.3 Tubes maintenance ..................................................40
3.5 Working on the sender/receiver unit ...........................................................43
3.5.1 Replacing the filter mat on the ventilator....................................43
3.5.2 Opening the sender/receiver unit................................................44
3.5.3 Replacing the drying agent...........................................................44
4 Functional test..........................................................................................46
4.1 IR components, drift check...........................................................................46
4.2 Oxygen sensor drift check.............................................................................46
4.3 Beamer current check ..................................................................................47
4.4 Reference energy check ...............................................................................47
Contents
Contents

CONTENTS
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4.5 Test signal transmission............................................................................... 48
4.5.1 Setting the IP address.................................................................. 48
4.5.2 MODBUS simulation ..................................................................... 49
4.5.3 Test analog and digital inputs and outputs ................................ 50
4.5.3.1 Analog outputs.......................................................... 50
4.5.3.2 Digital outputs .......................................................... 50
4.5.3.3 Analog inputs ............................................................ 51
4.5.3.4 Digital inputs ............................................................. 51
5 Repairs ...................................................................................................... 52
5.1 Working on the device cabinet..................................................................... 52
5.1.1 Replacing the door fan................................................................. 52
5.1.2 Replacing the pressure reducer unit ........................................... 54
5.1.3 Replacing the CAN node .............................................................. 55
5.1.4 Working on the valve manifold .................................................... 57
5.1.4.1 Replacing the valve manifold................................... 57
5.1.4.2 Replacing the valve .................................................. 58
5.1.5 Replacing the IO module.............................................................. 59
5.1.6 Replacing the test gas valves ...................................................... 60
5.1.7 Replacing the display ................................................................... 62
5.1.8 Replacing the 24V power supply unit.......................................... 63
5.2 Working on the cell ....................................................................................... 65
5.2.1 Removing the complete cell ........................................................ 65
5.2.2 Fitting the complete cell .............................................................. 68
5.2.3 Replacing the oxygen sensor ....................................................... 70
5.2.4 Replacing mirror plates................................................................ 73
5.2.4.1 Replacing the upper mirror plate ............................. 73
5.2.4.2 Replacing the lower mirror plate.............................. 76
5.2.5 Replacing the heating cartridges................................................. 79
5.2.6 Replacing the PT100 temperature sensor.................................. 82
5.2.7 Replacing the thermostatic switch .............................................. 85
5.3 Working on the sender/receiver unit........................................................... 88
5.3.1 Removing the electronics housing cover .................................... 88
5.3.2 Replacing the beamer .................................................................. 89
5.3.2.1 Resetting the beamer service life ............................ 90
5.3.2.2 Resetting the reference energy................................ 91
5.3.3 Removing the complete sender/receiver unit ............................ 93
5.3.4 Fitting the complete sender/receiver unit .................................. 98
5.3.5 Replacing the fan ......................................................................... 98
5.3.6 Replacing the pressure control module ...................................... 99
5.3.7 Replacing the complete beamer unit ........................................102
5.3.8 Performing optical adjustment ..................................................103

CONTENTS
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5.3.9 Replacing the chopper motor.................................................... 105
5.3.10 Replacing the filter wheel motor ............................................... 107
5.3.10.1 Filter wheel motor 1 ............................................... 108
5.3.10.2 Filter wheel motor 2 ............................................... 111
5.3.10.3 Filter wheel motor 3 ............................................... 113
5.3.11 Replacing the lens on filter wheel housing 1 ........................... 116
5.3.12 Replacing the LPMS03 detector cable ..................................... 117
5.3.13 Replacing the LPMS03 detector circuit board ......................... 118
5.3.14 Replacing the cable and light barrier on the filter wheel
motor .......................................................................................... 120
5.3.15 Replacing the LPMS04 circuit board ........................................ 121
5.3.16 Replacing the heating cartridges .............................................. 122
5.3.17 Replacing the PT100 temperature sensor ............................... 125
5.3.18 Replacing the sender/receiver windows .................................. 127
5.3.19 Adjusting the zero point............................................................. 128
5.4 Working on the electronics unit................................................................. 129
5.4.1 Removing and fitting the electronics unit................................. 129
5.4.2 Replacing the LPMS01 circuit board ........................................ 132
5.4.3 Replacing the LINUX CPU .......................................................... 135
5.4.3.1 Performing a firmware update............................... 137
5.4.3.2 Swapping the SD card............................................ 138
5.4.4 Replacing the LPMS02 circuit board ........................................ 139
5.4.5 Replacing the LPMS02 fan........................................................ 142
5.4.6 Replacing the LPMS01 to LPMS04 connection cable ............. 145

CONTENTS
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ABOUT THIS MANUAL 1
1AboutthisManual
1.1 Target group of this Manual
The actions and measures described in this Manual are intended exclusively for trained
and authorized service technicians of SICK AG and their representatives.
1.2 Purpose of this Manual
This Manual serves as guide for the following tasks on the MCS200HW:
●Maintenance
●Clearing malfunctions “on site and with common tools”.
This Manual is only complete in combination with the Operating Instructions of the
MCS200HW. Availability and knowledge of the MCS200HW Operating Instructions is
assumed.
The technical layout of your MCS200HW can differ from the version described in this
Manual due to changes made by the manufacturer or customer.
▸When necessary, clarify with the customer and/or SICK AG Helpdesk the correct state
the MCS200HW should be in.
1.3 Information concerning this Manual
Basic knowledge of handling SOPAS is required. The SOPAS project tree and the SOPAS
menu are referred to in some Chapters. The SOPAS project tree refers to the current
directory structure on the left side in SOPAS. The SOPAS menu refers to the menu line in
SOPAS. Furthermore, operating the operator panel is not described here. Handling the I/O
modules is also not explained in detail.
Intervention on the MCS200HW by unauthorized persons voids the guarantee by the
SICK AG.
WARNING: Damage as a result of improper working
Improper working can damage health and equipment and affect measuring precision.
Corrosive, toxic or caustic gases can escape depending on the sample gas composition.
●The actions and measures described in this Manual may only be carried out by
trained and authorized Service technicians of SICK AG and their representatives,
who have been professionally trained and are qualified appropriately on the device
and for the following tasks.
–Workingwithgasanalyzers
– Mechanical installations
– Electrical installations
– Making and testing gas-tight connections
– Handling technical gases
Do not carry out any work on the MCS200HW without previous training.
This Manual is intended exclusively for trained service personnel and is not an
instruction manual.
If you have questions concerning this Manual, if there is something you do not under-
stand or whenever something is missing:
▸Please contact the SICK AG Helpdesk.

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1 ABOUT THIS MANUAL
The following documents must be available:
●System documentation
●MCS200HW Operating Instructions
●Preventive maintenance
1.4 Special hazards
1.5 Safety rules for work on electrical systems
1.6 ESD
WARNING: Toxic and corrosive substances in parts with sample gas contact
Depending on the sample gas composition, toxic or caustic substances could be
contained in the parts of the MCS200HW and the upstream gas path which come into
contact with the sample gas.
▸Before working on the gas path, ask the operator which gases have been applied to
the MCS200HW.
▸Ask the operator whether, and how, the MCS200HW gas path has been cleaned.
▸If necessary, clean the gas path with a suitable method.
▸In case of doubt, take suitable safety precautions before working on the gas path:
Provide adequate ventilation at the workplace or work under a vent. Wear protective
goggles or a safety mask, protective gloves and acid-proof protective clothes.
WARNING: Explosion hazard through explosive sample gas
!▸ Do not apply explosive gases to the MCS200HW.
DANGER: Risk of burns due to hot surface.
Allow the MCS200HW to cool down before carrying out any work.
The five safety rules for working on electrical systems must be observed at all times.
1Switch off and disconnect from the power supply
2Secure against switching on
3Determine no voltage is applied
4Ground and short-circuit
5Cover or barrier off adjacent live parts
Risk of destruction of electronic components by electrostatic discharge (ESD)
When touching electronic subassemblies, there is a hazard of severe damage to the
subassembly by electric potential equalization.
▸ Make sure you have the same electric potential as the subassembly (e.g. by grounding) before touching the
subassembly

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ABOUT THIS MANUAL 1
1.7 Inquiries to SICK AG
Please feel free to contact the SICK AG Helpdesk if you have any questions.
▸If you have questions to the Helpdesk, provide the following information, if possible:
– Device type, serial number, firmware version
– Measured components and measuring ranges
– Ambient conditions (temperature, air humidity, possible acidic gases)
– Error messages (display) and your own error description
– Damage history
– Repairs already made and replaced parts
–Contactaddressforcallingback

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2 TOOLS
2Tools
2.1 Special tools and auxiliary means
Special tools / auxiliary means
SOPAS ET
Ethernet cable (3 m CAT5 cross-over)
ESD wristband with crocodile clip
2 mm Allen key
2.5 mm Allen key
3 mm Allen key
4 mm Allen key
5 mm Allen key
6 mm Allen key
5 mm socket wrench
5.5 mm socket wrench
7 mm socket wrench
14 mm jaw wrench
16 mm jaw wrench
18 mm jaw wrench
19 mm jaw wrench
Phillips screwdriver
Torx screwdriver TX20
Slot screwdriver
Tweezers
Pliers
Circlip pliers
Scalpel

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MAINTENANCE 3
3 Maintenance
3.1 Maintenance interval
Maintenance tasks to be carried out on the MCS200HW as well as the respective intervals
are listed in the Preventive Maintenance document.
3.2 Expendable and wearing parts
Definition
●Expendable parts: Parts that must be replaced irrespective of their condition. No
guarantee
●Wearing parts: Parts that should be replaced as required depending on their condition.
Guarantee, possibly restricted.

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3 MAINTENANCE
3.3 Working on the device cabinet
Fig. 1: Device cabinet
3.3.1 Exchanging filter pads
3.3.1.1 Door ventilator
Only replace filter mats on the device cabinet when the device is switched off.
1Pull the blue lever to open the ventilator flap.
.
Fig. 2: Ventilator flap in cabinet door
2Take old filter pad out.
.
Fig. 3: Ventilator flap in cabinet door open
1 Roof ventilator
2 Door ventilator
Spare parts set No. Contents
2099669 Filter mats for MCS200HW cabinet

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MAINTENANCE 3
3Fit new filter pad.
The labeled side must point towards the fan.
3.3.1.2 Roof ventilator
Filter mats on the device cabinet can be replaced when the equipment is switched on.
1Open the bayonet locks on the top of the roof ventilator with Torx TX20 (4 pieces).
2Remove the roof ventilator cover.
3Remove old filter mats (4 pieces).
4Insert new filter mats at the edges (4 pieces).
Labeled sides must point to the fan.
5Replace the cover.
6Close the locks.
Observe the flow direction when inserting the filter mat: The firm/labeled side points to
the clean air side, the open/soft side to the dust air side.
Tools required
Torx screwdriver TX20
Observe the flow direction when inserting the filter mat: The firm/labeled side faces the
inside of the cabinet.

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3 MAINTENANCE
3.4 Working on the cell
Fig. 4: MCS200
1Disconnect the MCS200HW power supply.
2Let the MCS200HW cool down.
3Loosen the fastening screws of the cell cover on the right and left with a Phillips screw-
driver (4 pieces).
DANGER: Risk of burns due to hot surface.
Allow the MCS200HW to cool down before carrying out any work.
NOTE: Do not switch off the instrument air supply.
Tools required
Phillips screwdriver
1Cell
2 Sender/receiver unit with electronics unit
Do not remove the screws, only loosen them.

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MAINTENANCE 3
Fig. 5: Cell cover
4Remove the cell cover.
3.4.1 Removing the complete cell
1Disconnect the MCS200HW power supply.
2Let the MCS200HW cool down.
3Loosen the fastening screws of the cell cover on the right and left with a Phillips screw-
driver (4 pieces).
4Open the cell cover (see Chapter “Working on the cell”, page 14).
1 Fastening screws, right
Tools required
Jaw wrench, size 14/16/18
Phillips screwdriver
5 mm Allen key
DANGER: Risk of burns due to hot surface.
Allow the MCS200HW to cool down before carrying out any work.
Do not remove the screws, only loosen them.

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3 MAINTENANCE
.
Fig. 6: Cell open
5Disconnect hose connections 1 to 3 at the slots (see Fig. 7 “Slots”, page 16).
.
Fig. 7: Slots
6Disconnect the other hose connections with a jaw wrench (see Fig. 6 “Cell open”,
page 16, item numbers 1, 3 and 4).
7Optional: Disconnect the test gas line from the 90-degree bracket on the cell inlet filter
with a jaw wrench (see Fig. 6 “Cell open”, page 16, item number 5).
8Disconnect the oxygen sensor on the device (Sub-D plug).
1 Exhaust gas line
2Oxygensensor
3 Heated sample gas line 1
4 Heated sample gas line 2 (optional)
5Testgasline
6 Fastening clip for exhaust gas line
7 Slots for hose connections
Disconnect hose connections 1 to 3 at the slots, not on the cell.
To disconnect the hoses, press the metal ring down, then pull the hose off.

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MAINTENANCE 3
9Loosen the fastening clip of the exhaust gas line with a Phillips screwdriver.
10 Disconnect the power supply for the cell heater (plug connection).
.
Fig. 8: Power supply, cell heater
11 Disconnect the A-holder of the cell:
▸Loosen the fastening screws on the left with a 5 mm Allen key (3 pieces).
▸Loosen the fastening screws on the right with a 5 mm Allen key (3 pieces).
.
Fig. 9: Cell, A-holder, right
12 Lift the cell upwards and remove it from the cabinet.
The plug connection is located at slot CELL below the sender/receiver unit.
1CELLslot
1 A-holder fastening screws, right

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3 MAINTENANCE
3.4.2 Fitting the complete cell
1Guide the power supply for the cell heater through the recess in the device cabinet.
Fig. 10: Device cabinet with retaining plate
2Position the cell in the device cabinet:
▸Hook the bolts of the bracket plate of the cell into the retaining plate in the device
cabinet.
Fig. 11: Cell with bracket plate
3Screw the cell A-holder tight:
▸Fasten screws left and right with a 5 mm Allen key (3 pieces each).
Tools required
Jaw wrench, size 14/16/18
Phillips screwdriver
5 mm Allen key
1Retainingplate
2Recess
3 Power supply, cell heater
1Bracketplatewithbolts

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MAINTENANCE 3
Fig. 12: Cell, A-holder, right
4Make hose connections and electrical connections:
1Connect the power supply of the cell heater.
▸Connect the plug into the CELL slot below the sender/receiver unit.
Fig. 13: Power supply, cell heater
2Insert the oxygen sensor into the device and screw tight.
▸Fix the line of the oxygen sensor to the cell with the fastening clip.
3Connect hose lines 1 to 3 to the marked slots (see Fig. 7 “Slots”, page 16, item
number 7).
▸Fix hose lines 1 and 3 to the cell with fastening clips as necessary.
1 A-holder fastening screws, right
1CELLslot

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3 MAINTENANCE
Fig. 14: Cell, hose slots
4Connect the exhaust gas line to the ejector block (see Fig. 6 “Cell open”, page 16,
item number 1).
▸Fasten the exhaust gas line to the cell with the fastening clip (see Fig. 6 “Cell open”,
page 16, item number 6).
5Optional: Attach the test gas line to the 90-degree bracket (see Fig. 6 “Cell open”,
page 16, item number 5).
6Connect heated sample gas lines 1 and 2 (optional) to the cell inlet filter (see Fig. 6
“Cell open”, page 16, item numbers 3 and 4).
5Close the cell cover and screw tight (see Fig. 5 “Cell cover”, page 15).