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Contents

MERCEM300Z · Operating Instructions · 8013255 V2.0 · © SICK AG

Scheduled Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.1

Maintenance intervals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.1.1

Maintenance by operator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.1.2

Maintenance by Customer Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

7.2

Expendable and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3

Maintenance work

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.3.1

Before commencing maintenance work:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.3.2

Visual inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

7.3.3

Replacing the test solution

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Clearing Malfunctions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

8.1

If the device does not function at all …

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.2

When measured values are obviously incorrect …

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.3

Malfunction messages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.4

Stand-by

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

8.5

External UPS (option)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

8.6

Fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

8.7

Error messages and possible causes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Technical Documentation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

9.1

Compliances and approvals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9.1.1

Electrical protection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9.2

Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

9.2.1

MERCEM300Z

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

9.2.2

MERCEM300Z Indoor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

9.3

Technical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Summary of Contents for MERCEM300Z

Page 1: ...MMMI MMMOPERATING INSTRUCTIONS OPE R A T I NG I NS T R UC T ION S MERCEM300Z Mercury Analyzer Installation Operation Maintenance Title Page...

Page 2: ...rmation Subject to change without notice SICK AG All rights reserved Glossary CAN Bus Control Area Network A field bus Ethernet Computer networking technology Basis for network protocols such as TCP I...

Page 3: ...UTION Hazard which could result in less severe or minor injuries NOTICE Hazard which could result in property damage Information Symbols Hazard general Hazard by voltage Hazard by explosive substances...

Page 4: ...ing option 17 2 3 Operation 18 2 3 1 Operation via SOPAS ET option 18 2 4 Interfaces 18 2 5 Remote control 18 2 5 1 Ethernet 18 2 5 2 Modbus 18 2 5 3 OPC option 18 2 6 SOPAS ET PC program 19 2 6 1 Lan...

Page 5: ...rd 36 5 Menus 37 5 1 Menu tree 38 5 2 Main menu 39 5 3 Maintenance 39 5 3 1 Maintenance maintenance signal 39 5 3 2 Maintenance operating states 40 5 4 Adjustment 41 5 4 1 Adjustment test 41 5 4 2 Adj...

Page 6: ...62 7 3 2 Visual inspection 62 7 3 3 Replacing the test solution 63 8 Clearing Malfunctions 67 8 1 If the device does not function at all 68 8 2 When measured values are obviously incorrect 68 8 3 Malf...

Page 7: ...tant Information MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 7 Subject to change without notice MERCEM300Z 1 Important Information Main instructions for operation Intended use Own responsib...

Page 8: ...ING Risk to health through contact with toxic gases The modules and devices contain enclosed potentially dangerous gases that can escape due to a defect or leak Refer to the Table below for these gase...

Page 9: ...perating Instructions 8013255 V2 0 SICK AG 9 Subject to change without notice 1 3 1 Installation location MERCEM300Z Indoor Installation location In air conditioned rooms IP43 MERCEM300Z Installation...

Page 10: ...the device only as described in these Operating Instructions The manufacturer bears no responsibility for any other use Perform the specified maintenance work Do not remove add or modify any component...

Page 11: ...dition to these Operating Instructions Instructions delivered with the System Documentation Operating Instructions SCU Operating Instructions Cooling Unit Operating Instructions Gas Sampling System Op...

Page 12: ...12 MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG Important Information Subject to change without notice...

Page 13: ...duct Description MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 13 Subject to change without notice MERCEM300Z 2 Product Description Device characteristics Functional principle Device descript...

Page 14: ...3255 V2 0 SICK AG Product Description Subject to change without notice 2 1 Device characteristics Fig 1 MERCEM300Z front side view Fig 2 MERCEM300Z Indoor front side view 1 Operator panel p 39 5 2 2 A...

Page 15: ...view MERCEM300Z example 1 Thermal converter and cell 2 Optical unit 3 Electronics with data interfaces and heater control 4 Power supply Fuses p 69 8 6 5 Ejector 6 Sample gas line inlet Gas outlet at...

Page 16: ...G Product Description Subject to change without notice 2 2 Gas flow plan Fig 4 Gas flow plan 1 Gas sampling system 2 Instrument air conditioning 3 Thermal converter and cell 4 Test gas generator CALSI...

Page 17: ...Option Integrated test gas generator CALSIC300 position p 15 Fig 3 The initial solution an HgCl2 solution is in a storage container position p 15 Fig 3 Using a vaporizer the test gas generator genera...

Page 18: ...ET option Operator menus and measured value displays are also available on an external PC via the Ethernet connection with the SOPAS ET engineering tool p 19 2 6 2 4 Interfaces 2 x analog outputs 4 x...

Page 19: ...et the device parameters and provides access to the log book SOPAS ET runs on an external PC connected to the device via the Ethernet interface p 29 3 7 2 6 1 Language Language setting exclusively in...

Page 20: ...20 MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG Product Description Subject to change without notice...

Page 21: ...Preparations for Initial Start up MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 21 Subject to change without notice MERCEM300Z 3 Preparations for Initial Start up Installation Assembly...

Page 22: ...the delivery documents for the scope of delivery Work to be performed Authorized personnel Reference Preparation of installation location Operator p 23 3 3 Setting up Operator p 24 3 4 Laying the gas...

Page 23: ...least 200 mm 8 in distance Clearance for cable ducts MERCEM300Z The cables can be fed on the base only from the front or the rear Maintain 150 mm 6 in distance Clearance for cable ducts MERCEM300Z Ind...

Page 24: ...as leaks out Risk of damage to the device and adjacent equipment if the sample gas is corrosive or could create corrosive liquids in combination with water e g humidity The measured values could possi...

Page 25: ...e sample gas line when putting the device into operation Otherwise there is a risk of sample gas condensation in the sample gas path CAUTION Noxious and aggressive exhaust gases Exhaust gases can cont...

Page 26: ...Connection of test gas line for manual test gas feeding on the gas sampling system Fig 6 Test gas connection Throughflow during test gas feed Approx 500 l h The device builds up only slight counterpr...

Page 27: ...n or for test purposes by persons carrying out the work under consideration of the valid safety regulations WARNING Endangerment of electrical safety through incorrect measure ment of the mains line E...

Page 28: ...ough the device base MERCEM300Z Indoor The signal lines are routed through the right side panel Let SICK Customer Service connect the signal lines on the device 3 6 4 Preparation of mains supply The w...

Page 29: ...See SOPAS ET p 19 2 6 To change the addresses as from SOPAS 3 0 Note The device and PC must be in the same network segment a Doubleclick the device in the Device catalog b The device is shown in its o...

Page 30: ...30 MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG Preparations for Initial Start up Subject to change without notice...

Page 31: ...Operation MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 31 Subject to change without notice MERCEM300Z 4 Operation Access Operation Status messages...

Page 32: ...ring system has not yet reached its Measuring operating state e g the operating temperature has not yet been reached Only the green POWER status LED lights Display Heating Classification Uncertain 7 R...

Page 33: ...o Maintenance p 34 4 4 2 Pressing the MEAS button does not affect the Maintenance state In the Measuring screen Toggle between list bar and line representation p 35 4 5 If the MEAS button is pressed f...

Page 34: ...ET in the Digital outputs menu Maintenance Wartung The device is switched to Maintenance via the menu or program The status bar shows Maintenance Current Held4 4 The last valid measured value is held...

Page 35: ...easured values in tabular form The List Measuring screen is displayed Automatically after the start of the system When the MEAS button is pressed Update interval 1 second default 4 5 2 Bar graph Measu...

Page 36: ...e changes of the measuring range are protected with a password The password is prompted automatically when such a menu is called up Fig 10 Password input Example Reset menu The password consists of 4...

Page 37: ...Menus MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 37 Subject to change without notice MERCEM300Z 5 Menus Menu tree Menus...

Page 38: ...automatic p 44 5 4 3 2 3 1 Optical Adjustm 2 3 2 Zero Analyzer 2 3 3 Zero System 2 3 4 Adjust Analyzer 2 2 5 Adjust System 2 3 6 Drift Check 2 3 7 Drift Correction 2 3 8 Cancel 2 4 Parameter p 45 5 4...

Page 39: ...p 41 5 4 p 49 5 5 p 52 5 6 Measuring Back Enter 1 Maintenance 2 Adjustment 3 Diagnosis 4 Parameter 1 p 39 5 3 1 p 40 5 3 2 Measuring Back Enter 1 Maintenance signal 2 Operating states Maintenance Main...

Page 40: ...2 1 Switch to Measuring operation Switch Adjustm manual on Switches the valves on the gas sampling system for manual gas feeding Restart For test gas generator option Start purging of hoses and vapori...

Page 41: ...ent sequences p 17 2 2 1 The parameters for automatic test gas feed are not changed No correction factors are calculated 2 p 41 5 4 1 p 42 5 4 2 p 44 5 4 3 p 45 5 4 4 Measuring Back Enter Adjustment A...

Page 42: ...rameter Adj Test Par 1 Span pt 1 2 Span pt 2 3 Span pt 3 4 Span pt 1 5 Span pt 2 3 0 g m3 6 3 g m3 9 0 g m3 Activate Activate To change a value 1 Select the desired span point 2 Enter 3 Change the val...

Page 43: ...centration correction factor is set If the deviation is too large parameter settings SOPAS ET the device switches to Maintenance request p 34 4 4 7 Press Back to exit the menu 8 Go to the Accept menu...

Page 44: ...or test gas generator preset 7 Drift Correction Drift check with automatic acceptance of correction with internal adjust ment cell or test gas generator preset 8 Cancel Cancel test or adjustment 2 3...

Page 45: ...or 4 Start time 1 8 5 Start time 9 16 2 4 1 The nominal values for 3 test gas concentrations of the external test medium for manual test gas feed are entered in this menu Recommendation 20 50 90 of fu...

Page 46: ...2 The correction factor can be changed in this Menu item To change the correction factor 1 Select the correction factor 2 Enter 3 Enter the numeric value Minus sign As first digit Press several times...

Page 47: ...6 3 g m3 9 0 g m3 9 3 g m3 The nominal values for 3 test gas concentrations of the internal test gas generator CALSIC300 for automatic test gas feed are entered in this menu Recommendation 20 50 90 o...

Page 48: ...Start time Activation deactivation of start 1 Select the start time 2 Enter Measuring Back Enter Start time 1 8 Adj Par Start 1 Optical Adjustm 2 Mon Feb 7 19 00 00 3 Span pt System 4 Mon Feb 7 12 00...

Page 49: ...g 1 Check values 2 Temperatures 3 System info 4 Error messages 3 1 p 49 5 5 1 1 p 50 5 5 1 3 p 50 5 5 1 3 p 50 5 5 1 4 Measuring Back Enter Check values Diag Chkv 1 Zero drift 2 Span pt drift 3 Refere...

Page 50: ...pt 2 0 3 5 Span pt 3 0 1 3 1 3 The current reference energy in percent is shown in this menu This value is monitored automatically If the value is below a limit value default 60 the device switches t...

Page 51: ...eg 61 deg 3 3 Device numbers and software versions are shown in this menu Name of the system Serial number of device Serial number of cell System software version etc Measuring Back System info Diag I...

Page 52: ...5 6 Parameter setting Menu 4 Parameter 5 6 1 Parameter settings display Menu 4 1 Parameter Display 4 p 52 5 6 1 p 54 5 6 2 Measuring Back Enter Parameter Para 1 Display 2 Reset 4 1 p 53 5 6 1 1 p 53 5...

Page 53: ...update interval 1 second Measuring Back Enter Maintenance Back Save Scale 1 8 Hg_A Para Disp Scal Para Desp Scal Beg01 1 Hg_A 2 Hg_E 3 etc 00000 000 Ext _A Normalization start value _E Normalization...

Page 54: ...energies for all components are set to 0 for zero or span point drift 100 for reference energy The complete drift history is lost Perform the reset only when you are sure that you want to reset the v...

Page 55: ...Shutdown MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 55 Subject to change without notice MERCEM300Z 6 Shutdown Switch off Shutting down Transport Disposal...

Page 56: ...solution 2 Switch the heaters off if necessary Information for cooling the thermal converter The cooling of the thermal converter takes approx 6 hours The air conditioner must remain switched on duri...

Page 57: ...evant local conditions for the disposal of industrial waste The following subassemblies contain substances that may have to be disposed of separately Lamp Contains mercury Electronics Capacitors recha...

Page 58: ...58 MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG Shutdown Subject to change without notice...

Page 59: ...Scheduled Maintenance MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 59 Subject to change without notice MERCEM300Z 7 Scheduled Maintenance Maintenance plan Spare parts...

Page 60: ...om x x x Check whether status signals are pending ormessages are or were active Menu 3 Diagnosis x x x Check lines hoses and connections and whether exhaust gas line is free of bends x x x Air dryer C...

Page 61: ...0733 Gas sampling system Gas sampling filter 2 spare parts set 1 x 2039002 Glass fiber gas sampling filter spare parts set 1 x 2043616 Bellow seal valve spare parts set for SFU 1 x 2060250 Heating car...

Page 62: ...the Diag button for more information Perform a visual inspection of the device enclosures Dryness Corrosion Unusual odor Unusual noises Perform a visual inspection of the test gas generator CALSIC300...

Page 63: ...CALSIC300 3 Remove cover from test gas generator upwards CAUTION Consumables only from SICK The HgCl2 solution to be replaced during maintenance may only be obtained from SICK If the interval half a y...

Page 64: ...ution into the device 11 Refit the cover 12 Set the device to Measuring again Close the canister with used solution with the lid and dispose of it HgCl2 in an environ mentally compatible manner Canist...

Page 65: ...change without notice 7 3 3 1 Function check after replacing the HgCl2 solution WARNING Health risk through escaping gases A check of the safe function is necessary every time the HgCl2 solution is re...

Page 66: ...66 MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG Scheduled Maintenance Subject to change without notice...

Page 67: ...Clearing Malfunctions MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 67 Subject to change without notice MERCEM300Z 8 Clearing Malfunctions Fuses Status messages Implausible measuring results...

Page 68: ...fuses Internal fuse defective Check fuses p 69 8 6 Software not working correctly Switch the device off with the external mains switch and switch it on again after a few seconds Possible cause Notes...

Page 69: ...UPS Air conditioner MERCEM300Z Test gas generator CALSIC300 Electronics The following subassemblies are not supplied with power Heaters 8 6 Fuses Location of fuses p 15 Fig 3 Fig 13 System cabinet fu...

Page 70: ...tings of connected analog output and adapt if required S006 Voltage range The input range of an analog input was exceeded S007 Check sum error S008 Cell flow Flow through cell is outside tolerance ran...

Page 71: ...ominal configuration Please contact SICK Customer Service S035 Temperature Temperature outside limit value Check temperature parame ters in menu 3 2 Diagnosis Temperatures Check heating circuits S037...

Page 72: ...ning Initiator Code Error text Classifi cation Description Possible clearance System S057 Communication problem Uncer tain Communication fault between system and subassembly Check cable connections in...

Page 73: ...Technical Documentation MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 73 Subject to change without notice MERCEM300Z 9 Technical Documentation Dimensions Technical Data...

Page 74: ...censes Exclusion of liability The firmware of this device was developed using open source software The user is exclu sively responsible for any modifications made to open source components All warrant...

Page 75: ...tructions 8013255 V2 0 SICK AG 75 Subject to change without notice 9 3 Dimensions 9 3 1 MERCEM300Z Fig 14 Dimensions Pay attention to side clearances p 23 3 3 744 30 3 196 7 7 351 13 8 1744 68 6 1438...

Page 76: ...8013255 V2 0 SICK AG Technical Documentation Subject to change without notice Fig 15 Dimensions view with air conditioner opened Fig 16 Bottom plate Pay attention to side clearances p 23 3 3 1488 58 8...

Page 77: ...cumentation MERCEM300Z Operating Instructions 8013255 V2 0 SICK AG 77 Subject to change without notice 9 3 2 MERCEM300Z Indoor Fig 17 Dimensions Pay attention to side clearances p 23 3 3 2156 5 100 18...

Page 78: ...xD Weight MERCEM300Z 250 kg MERCEM300Z Indoor 220 kg Material MERCEM300Z Aluminium double walled MERCEM300Z Indoor Steel Enclosure color Grey Heating temperature Gas sampling system Max 200 C 390 F Sa...

Page 79: ...s electrically insulated relay changeover contact 50 V max 4 A Digital inputs1 4 inputs electrically insulated 24 V 0 3 A Analog outputs1 2 outputs 0 4 20 mA electrically insulated max load 500 Ohm Da...

Page 80: ...Failure status 34 Flow 71 Cell 71 Flow plan 16 Fuses 69 G Gas connections 24 Gas flow plan 16 Gas sampling system 16 Glossary 2 I Information Symbols 3 Installation 23 24 Instrument air conditioning...

Page 81: ...eset menu 54 Storage 56 Switch off 56 Symbols explanation 3 System info menu 51 System stop menu 40 T Target group 10 Technical Data 78 Temperatures menu 51 Test gas feed 17 automatic 44 Gas sampling...

Page 82: ...V iJ 3KRQH 0DLO RIILFH VLFN KX Nederland 3KRQH 0DLO LQIR VLFN QO 1RUJH 3KRQH E Mail sick sick no sterreich 3KRQH 0DLO RIILFH VLFN DW 3ROVND 3KRQH 0DLO LQIR VLFN SO Rom nia 3KRQH 0DLO RIILFH VLFN UR Ru...

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