Siemens Set CEM CERT User manual

Continuous Gas Analysis
Set CEM CERT Standard
Measuring System for
Continuous Emission Monitoring
Set CEM CERT
Operating Instructions
7MB1957
03/2020
A5E34491309-11
Introduction
1
General information
2
Description
3
Application planning
4
Installation
5
Connection
6
Commissioning
7
Operation
8
Functions
9
Service and maintenance
10
Alarm, fault and system
messages
11
Technical specifications
12
Dimension drawings
13
Wiring diagrams
14
Appendix
A
ESD guidelines
B
List of abbreviations
C

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E34491309
Ⓟ07/2020 Subject to change
Copyright © Siemens AG 2020.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to
prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a
safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices
shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger
will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning
relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the
specific task in accordance with the relevant documentation, in particular its warning notices and safety
instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant
technical documentation. If products and components from other manufacturers are used, these must be
recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning,
operation and maintenance are required to ensure that the products operate safely and without any
problems. The permissible ambient conditions must be complied with. The information in the relevant
documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of
the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in
subsequent editions.

Set CEM CERT
Operating Instructions, 03/2020, A5E34491309-11 3
Table of contents
1 Introduction .................................................................................................................................................7
1.1 Purpose of this document ................................................................................................................ 7
1.2 History .................................................................................................................................................. 7
1.3 Intended use ....................................................................................................................................... 7
1.4 Disclaimer of Liability........................................................................................................................ 8
2 General information ...................................................................................................................................9
2.1 Disclaimer............................................................................................................................................ 9
2.2 Safety information.............................................................................................................................. 9
2.3 Notes on use ..................................................................................................................................... 12
2.3.1 Requirements for safe use............................................................................................................. 12
2.3.2 Additional information..................................................................................................................... 12
2.3.3 Information on recycling ................................................................................................................. 13
3 Description ............................................................................................................................................... 15
3.1 Overview............................................................................................................................................. 15
3.2 Design................................................................................................................................................. 18
3.3 Principle of operation ...................................................................................................................... 21
4 Application planning................................................................................................................................ 23
4.1 Transport ........................................................................................................................................... 23
4.2 Checking the delivery ...................................................................................................................... 23
5 Installation................................................................................................................................................ 25
5.1 Preparing the installation location ............................................................................................... 25
5.2 Installing the measuring system ................................................................................................... 26
5.3 Installing the individual components ........................................................................................... 27
5.3.1 Installation of the sampling probe................................................................................................ 27
5.3.2 Installation of the sample gas line................................................................................................ 28
6 Connection................................................................................................................................................ 29
6.1 Mechanical installation................................................................................................................... 29
6.1.1 Gas connections............................................................................................................................... 29
6.1.2 Condensate outlet............................................................................................................................ 30
6.1.3 Gas outlet .......................................................................................................................................... 30
6.1.3.1 Gas outlet .......................................................................................................................................... 30
6.1.3.2 Overpressure in the gas channel .................................................................................................. 31

Table of contents
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4Operating Instructions, 03/2020, A5E34491309-11
6.2 Electrical installation........................................................................................................................31
6.2.1 Laws and directives .........................................................................................................................31
6.2.2 Supply connection ............................................................................................................................31
6.2.3 Connection of the power supply and signal lines ......................................................................32
7 Commissioning......................................................................................................................................... 33
7.1 Preparations ......................................................................................................................................33
7.1.1 Visual inspections.............................................................................................................................33
7.1.2 Leak test.............................................................................................................................................34
7.1.3 Operating gases ................................................................................................................................35
7.2 Commissioning..................................................................................................................................35
7.2.1 Function test......................................................................................................................................35
7.2.2 Warm-up phase.................................................................................................................................36
7.2.3 Settings after commissioning.........................................................................................................37
7.2.3.1 ULTRAMAT 23...................................................................................................................................37
7.2.3.2 ULTRAMAT 6.....................................................................................................................................38
8 Operation .................................................................................................................................................. 39
8.1 Display and input keys.....................................................................................................................39
8.2 Menu-based operation ....................................................................................................................40
8.2.1 Status traffic light.............................................................................................................................40
8.3 Main menu .........................................................................................................................................41
8.4 Submenus...........................................................................................................................................42
8.4.1 Service submenu...............................................................................................................................42
8.4.2 Calibration submenus –ULTRAMAT 23 ......................................................................................43
8.4.3 Calibration submenus –ULTRAMAT 6.........................................................................................45
8.4.4 Trend submenu –ULTRAMAT 23/ULTRAMAT 6.......................................................................47
8.4.5 Messages submenu .........................................................................................................................48
9 Functions .................................................................................................................................................. 49
9.1 Calibrating..........................................................................................................................................49
9.1.1 General................................................................................................................................................49
9.1.2 Calibration of ULTRAMAT 23.........................................................................................................50
9.1.2.1 ULTRAMAT 23 AUTOCAL calibration of zero point...................................................................50
9.1.2.2 ULTRAMAT 23 –Full-scale value calibration of the individual components.......................51
9.1.3 Calibration of ULTRAMAT 6/OXYMAT 6 .....................................................................................52
9.1.3.1 ULTRAMAT 6 –AUTOCAL calibration of the zero point and full-scale value......................52
9.1.3.2 ULTRAMAT 6 –Single calibration of components.....................................................................53
10 Service and maintenance ....................................................................................................................... 55
10.1 Safety information ............................................................................................................................55
10.2 Maintenance intervals .....................................................................................................................56
10.3 Eliminating the moisture alarm......................................................................................................58
10.4 Harmful substances in the condensate .......................................................................................58
10.5 Emptying the condensate tank ......................................................................................................59
10.6 Spare parts/accessories .................................................................................................................59

Table of contents
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11 Alarm, fault and system messages ....................................................................................................... 61
11.1 Error messages................................................................................................................................. 61
12 Technical specifications......................................................................................................................... 63
13 Dimension drawings................................................................................................................................ 67
13.1 Dimension drawings........................................................................................................................ 67
14 Wiring diagrams ....................................................................................................................................... 71
14.1 Gas flow diagram ............................................................................................................................. 71
14.2 Legend for gas flow diagram ......................................................................................................... 72
A Appendix ................................................................................................................................................... 73
A.1 Service and support......................................................................................................................... 73
A.2 Returns............................................................................................................................................... 73
A.2.1 Returns............................................................................................................................................... 73
A.2.2 Return address ................................................................................................................................. 74
A.2.3 Error Description .............................................................................................................................. 75
B ESD guidelines......................................................................................................................................... 77
C List of abbreviations................................................................................................................................ 79
C.1 List of abbreviations........................................................................................................................ 79
Index.......................................................................................................................................................... 81

Table of contents
Set CEM CERT
6Operating Instructions, 03/2020, A5E34491309-11

Set CEM CERT
Operating Instructions, 03/2020, A5E34491309-11 7
1Introduction
1
1.1 Purpose of this document
This instruction manual contains all the information you need for commissioning and
using the system.
It is aimed at all persons involved in the mechanical installation, electrical connection
and commissioning of the system and who work with the system.
Read this instruction manual carefully and make sure that you understand its contents
before you work with the system.
1.2 History
The following table includes information on the different editions of this document.
Table 1- 1 History
Edition
Comment
03/2020
First edition
1.3 Intended use
Proper use within the context of this document means that the product may be used only
for the applications described in the catalog or the technical description, and only in
combination with the equipment, components and devices of other manufacturers
recommended or permitted by Siemens.
The product described in this document has been developed manufactured, tested and
documented in compliance with relevant safety standards. When the handling rules
described for the configuration, installation, proper operation and maintenance, as well
at the safety guidelines are adhered to, therefore, there is normally no risk to the health
of persons or in respect to damage to property.
This product was designed to ensure safe isolation of the primary and secondary circuits.
Low voltages that are connected must therefore also be generated with safe isolation.

Introduction
1.4 Disclaimer of Liability
Set CEM CERT
8Operating Instructions, 03/2020, A5E34491309-11
1.4 Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the
hardware and softwaredescribed. Since variance cannot be precluded entirely, we
cannot guarantee full consistency. However, the information in this publication is
reviewed regularly and any necessary corrections are included in subsequent editions.

Set CEM CERT
Operating Instructions, 03/2020, A5E34491309-11 9
2General information
2
2.1 Disclaimer
Industrial security
Siemens provides products and solutions with industrial security functions that support
the secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement –and continuously maintain –a holistic, state-of-the-art
industrial security concept. Siemens’ products and solutions only form one element of
such a concept.
Customer is responsible to prevent unauthorized access to its plants, systems, machines
and networks. Systems, machines and components should only be connected to the
enterprise network or the internet if and to the extent necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, please visit: Industrial security
(https://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends to apply product updates as soon as available
and to always use the latest product versions. Use of product versions that are no longer
supported, and failure to apply latest updates may increase customer’s exposure to
cyber threats.
To stay informed about product updates as they occur, you can sign up for our product-
specific newsletter. For further information, see Support
(https://support.industry.siemens.com/cs/start?lc=en-WW)
2.2 Safety information
DANGER
Explosions due to explosive atmosphere
Explosions in an explosive atmosphere can result in death or injuries.
•Never operate this system in an explosive atmosphere

General information
2.2 Safety information
Set CEM CERT
10 Operating Instructions, 03/2020, A5E34491309-11
WARNING
Toxic and/or corrosive gases
When measuring toxic or corrosive gases, leaks in the gas path may cause harmful
sample gas concentrations to accumulate in the system or in individual analyzers.
Health risks up to and including danger to life exist in the case of the following sample
gas components:
•Carbon monoxide (CO):
Colorless, odorless and tasteless, highly flammable, toxic; can result in death
depending on concentration and duration of exposure.
•Carbon dioxide (CO2):
Colorless, odorless and tasteless, heavier than air, displaces breathing air and can
thereby result in death by asphyxiation.
•Sulfur dioxide (SO2):
Colorless, pungent-smelling and sour-tasting, toxic, irritates mucous membranes.
•Nitric oxide (NO):
Colorless, oxidizing, toxic, causes chemical burns to eyes and skin.
•Nitrogen dioxide (NO2):
Colorless, toxic, causes chemical burns to eyes and skin.
To prevent a poisoning hazard or damage to analyzer parts, the relevant analyzer or the
system must be purged with inert gas (e.g. nitrogen). The gas displaced by purging
must be collected using appropriate equipment and disposed of environmentally-
friendly via an exhaust line.
WARNING
Harmful substances in the condensate
The condensate at the sample gas cooler or condensation trap can be corrosive,
depending on the composition of the sample gas (e.g.: through SO2, NO, H2S, HCl, etc.).
When you dip litmus paper into the condensate it will turn red.
•Wear protective clothing, protective goggles and protective gloves when handling the
condensate!
•Prior to its disposal, dilute the condensate with tap water until it turns neutral and
the litmus paper does not change color. Alternatively, you can also neutralize the
condensate with a weak sodium carbonate solution (Na2CO3).

General information
2.2 Safety information
Set CEM CERT
Operating Instructions, 03/2020, A5E34491309-11 11
DANGER
Electric shock due to electrical voltage
This system is operated with electric current. This inevitably produces dangerous
voltages that, if contacted, may result in death or injuries.
•Before working on the system, disconnect it from the power supply system and
secure it against being inadvertently connected again.
•When the system is in normal measuring mode, ensure that no conductive parts are
openly accessible.
NOTICE
Manipulation of the system
Physical access to the system allows undesired manipulations of the system to take
place. As a result of this, the system can lose its measuring characteristics and become
unusable.
•Make sure that the system is installed in a protected area that only authorized
persons can access.
•If no settings have to be made, lock the system to prevent unauthorized or
unintentional access.
The information in the manuals below must also be observed for proper operation of the
Set CEM CERT system:
•SIMATIC S7 –S7-1200 Programmable Controller –System Manual
•SIMATIC HMI –HMI Devices –Comfort Panels –Operating Instructions
There you will also find safety information to be observed when operating the HMI or
connecting the system to the S7-1200 programmable controller.

General information
2.3 Notes on use
Set CEM CERT
12 Operating Instructions, 03/2020, A5E34491309-11
2.3 Notes on use
2.3.1 Requirements for safe use
In terms of safety, this system left the factory in perfect condition. In order to maintain
this condition and to ensure safe operation of the system, adhere to the instructions in
this instruction manual and all safety-relevant information.
Also observe the notices and symbols on the device. Do not remove any notices or
symbols from the system. Always keep the notices and symbols in a completely legible
condition.
Only qualified personnel are permitted to operate this measuring system or carry out
interventions on the system.
Qualified personnel for the purpose of these instructions or the safety notices on the
product itself are persons that are familiar with the setup, installation, commissioning
and operation of the product. These persons have the following qualifications:
•As configuration personnel, they are familiar with the safety concepts of automation
engineering
•As operating personnel, they are trained to handle automation engineering equipment
and know the content of this manual related to operation
•As commissioning and service personnel, they have had training that qualifies them to
repair this type of automation engineering equipment or are authorized to
commission, ground and mark electric circuits and systems/devices in accordance
with safety engineering standards.
2.3.2 Additional information
This measuring system includes various individual components that can be customized
according to customer needs.
For safe operation of this system, all operating instructions and technical documents for
the individual components must be observed in addition to this instruction manual.
These components are:
•Gas analyzers
•Gas sampling components
•Gas preparation components
•System controller
•Components for heating, air conditioning and temperature control
•System cabinets
•NOxconverter

General information
2.3 Notes on use
Set CEM CERT
Operating Instructions, 03/2020, A5E34491309-11 13
2.3.3 Information on recycling
This product is from an environmentally-friendly manufacturer and
complies with the directive 2012/19/EU on Waste Electrical and Elec-
tronic Equipment (WEEE).
This product may contain substances that are potentially harmful to
the environment if disposed of improperly (landfills, incineration
plants). It must therefore not be disposed of in this way.
Therefore, please be environmentally conscious:
•Ensure that this product is recycled at the end of its life cycle
through the relevant local facilities.
•Observe the relevant regulations in your country.

General information
2.3 Notes on use
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14 Operating Instructions, 03/2020, A5E34491309-11

Set CEM CERT
Operating Instructions, 03/2020, A5E34491309-11 15
3Description
3
3.1 Overview
Set CEM CERT is a standardized and certified continuous emission monitoring system.
The Set CEM CERT system is suitable for use in many plants that require a permit in
accordance with EU Directive 2010/75/EU, the Industrial Emissions Directive.
The modular CEMS meets the current quality standards of EU directives EN 15267 and
EN 14181 (QAL1/2/3, AST). The number of components that need to be measured
depends on the type of plant as well as the fuel used. The measurement of gas
components takes place according to the cold-extractive measuring procedure. A sample
flow for measurement is continuously extracted by a gas sampling probe in the exhaust
gas stack and fed to the analysis cabinet. This cabinet can be equipped with up to three
analyzers and different sample preparation components.
The measuring system is used for simultaneous measurement of the following
performance-tested measured components: CO; NO; SO2; NO2; O2; CO2.
Figure 3-1 Set CEM CERT

Description
3.1 Overview
Set CEM CERT
16 Operating Instructions, 03/2020, A5E34491309-11
Benefits
•The tested measuring ranges are selected in such a way that a wide range of
application for the CEMS is ensured (performance-tested according to EN 15267-3:
TÜV and MCERTS).
•The complete modular package allows the certified use of system components from
different manufacturers (performance-tested according to EN 15267-3: TÜV and
MCERTS).
•Easy and fast to configure
•Very cost-effective to purchase and operate
•Modular design
–Up to 3 analyzers with different measuring ranges can be configured
–Sample gas coolers and NOXconverters of leading manufacturers can be selected
–Electric heaters and air conditioning units can be configured to extend the ambient
temperature range
–Version with appropriate sampling probes and heated sample gas lines can be
selected

Description
3.1 Overview
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Operating Instructions, 03/2020, A5E34491309-11 17
Range of application
•Emission monitoring
Power plants with solid, liquid or gaseous fossil fuels and incineration plants that
exceed a certain size or a defined mass flow of pollutants require a permit. They must
be continuously monitored on a plant-specific basis for compliance with limits for
certain air pollutants using a suitable and complete emission monitoring system,
which also requires approval. This is prescribed by the following:
–European Industrial Emissions Directive (IED)
–European Medium Combustion Plant Directive (MCPD) and its national
implementations
–Separate emission standards in EU member states and associated countries (in
Germany, for example, 13. BImSchV; 17. BImSchV; 27. BImSchV; 30. BImSchV;
44. BImSchV; TA Luft)
•Flue gas monitoring
•Process optimizations for the following:
–Emission measurements for upstream boiler controllers
–DeNOx systems
–DeSOx systems
Note
Plants in which corrosive aerosols (acid mist) are likely
Suitable measures must be taken to remove the corrosive aerosols from the gas matrix.
This requires project-specific technical clarification in advance.

Description
3.2 Design
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18 Operating Instructions, 03/2020, A5E34491309-11
3.2 Design
Tested component design
The overall modular measuring system consists of the following tested individual
components:
•Analyzers for measurement of multiple components. The Set CEM CERT modular
measuring system can consist of up to three analyzers in combination with a system
cabinet. The performance-tested analyzer(s) are selected separately from the system
using the specific article number(s). The system is certified for use of the following
analyzers:
Analyzer
Article No.
Design
ULTRAMAT 23*
7MB2358
3 NDIR components on 2 optical benches or
2 NDIR and 2 UV components on 2 optical benches
ULTRAMAT 23*
7MB2357
2 NDIR components on 2 optical benches or
1 NDIR and 2 UV components on 2 optical benches
ULTRAMAT 23*
7MB2355
1 NDIR component on 1 optical bench or
1 NDIR component or 2 UV components on 1 optical
bench
SIPROCESS UV600
7MB2621
3 UV components on 1 optical bench
ULTRAMAT 6
7MB2121
7MB2011
1 NDIR component on 1 optical bench
ULTRAMAT 6,
2-channel 19" rack
unit
7MB2123
7MB2124
2 NDIR components on 2 optical benches
OXYMAT 6
7MB2021
1 paramagnetic O2sample chamber
ULTRAMAT/
OXYMAT 6
7MB2023
7MB2024
1 NDIR component on 1 optical bench and
1 paramagnetic O2sample chamber
* Each measuring module of the ULTRAMAT 23 analyzer type can be additionally equipped
with different O2sensors.
The configuration with an O2sensor is specified by adding the following identifiers:
-Z-T13/T14: Paramagnetic O2sensor
-Z-T23/24/T25: Electrochemical O2sensor
-Z-T33/T34/T35: No O2sensor