1 FW300 Dust Concentration Monitor Operating Instruction

OPERATING INSTRUCTIONS

FW300 Dust Concentration Monitor

In-situ Dust Measurement and Output of Transmission, Opacity, Extinction and Dust Concentration

Analyzers and Process Instrumentation

Operating Instructions


Contents

Notes on this Document ............................................................................ ........................ 7

1 Safety Instructions...............................................................................................................8 1.1

Intended Intended Use .................. ........................... ................... ................... .................. ................... ................... ................... ................... .................. ................... ................... .............8 ....8

1.2

Authorized Authorized Personnel.............. Personnel....................... ................... ................... ................... ................... .................. .................. .................. .................. .................... .............8 ..8

1.3

Safety Information Information and Protection Protection Measures................. Measures.......................... ................... .................... .................... ...................8 .........8 1.3.1

Danger Danger from Electrical Electrical Equipment Equipment ............... ...................... ............... ............... .............. ............... ............... .............. ............... ............... ............... ............... ......... 9

1.3.2

Danger Danger Due to Hot, Corrosive, Corrosive, or Pressurize Pressurized d Gases Gases ............... ...................... .............. ............... ............... .............. .............. ......... 9

1.3.3

Purge-Air Purge-Air Failure Failure ........ ............... ............... ............... .............. .............. .............. ............... ............... .............. .............. ............... ............... .............. ................ ................ .............. .............. ....... 9

1.3.4

Detecting Detecting and Preventing Preventing Malfunct Malfunctions ions ............... ...................... .............. .............. ............... ................ ............... .............. .............. ............... .............. ...... 9

2 Product Product Descriptio Description........ n.............. ............. ............. ............ ............. ............. ............. ............. ............. ............. ............. ............. ............ ............. ............. .......... 11 2.1

Features Features and Applications Applications ................... ............................. ................... .................. ................... ................... ................... ................... .................. ............ ... 13

2.2

Operating Operating Principle Principle and Measured Measured Variables Variables ................... ............................. ................... ................... ................... .............. ..... 14

2.3

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2.2.1

Operating Operating Principle Principle ............... ...................... ............... ............... .............. .............. ............... ............... .............. ............... ............... .............. .............. .............. ............... ............... ....... 14

2.2.2

Calculati Calculating ng Transmiss Transmission, ion, Opacity, Opacity, and Extinction............ Extinction.................... ............... ............... ............... .............. .............. ............... .......... 14

2.2.3

Determini Determining ng the Dust Concentrat Concentration............ ion.................... ................ ............... .............. .............. ............... ................ ............... .............. ............... ........... ... 15

2.2.4

Response Response time ......... ................ ............... ............... .............. .............. .............. ............... ............... ............... ............... .............. .............. .............. .............. ............... ............... ............ ..... 16

2.2.5

Check Check Cycle.............. Cycle..................... ............... ............... ............... ............... .............. .............. ............... ................ ............... .............. .............. ............... .............. ............. ............... ............... ....... 17

Device Components............... Components........................ ................... ................... .................. ................... ................... ................... ................... ................... ................... ......... 18 2.3.1

Transmitt Transmitter/Rec er/Receiver eiver Unit .............. ...................... ............... .............. .............. .............. ............... ............... ............... ............... .............. .............. ............... ............... ......... 18

2.3.2

Reflector.. Reflector......... ............... ............... ............... ............... .............. .............. .............. ............... ............... ............... ............... .............. .............. .............. ............... ............... .............. ............... ............ .... 20

2.3.3

Device Device Attachmen Attachmentt ............... ....................... ............... .............. .............. .............. ............... ............... ............... ............... .............. .............. ............... .............. .............. ............... ....... 21

2.3.4

Flange Flange with Pipe ............... ...................... ............... ............... .............. .............. ............... ............... .............. ............... ............... .............. ............... ............... .............. .............. ............ ..... 22

2.3.5

Connection Connection Unit ......... ................. ............... .............. .............. ............... ............... .............. ............... ............... .............. .............. ............... ............... .............. .............. ............... ........... ... 22

2.3.6

External External Purge-Air Purge-Air Unit (Optional) (Optional) ............... ...................... ............... ............... ............... ............... .............. ............... ............... .............. ............... ............... ....... 24

2.3.7 2.3.7

Data Data Acquis Acquisiti ition, on, Commu Communic nicati ation, on, Meas Measure ured d Value Value Output, Output, and and Display Display Optio Options.. ns...... 24

2.3.8

Optional Optional Components Components for Monitorin Monitoring g Air in Workshops Workshops .............. ...................... ............... ............... ............... .............. .......... ... 25

2.3.9

Optional Optional Components Components for Higher Higher Internal Internal Duct Pressures............. Pressures..................... ............... ............... ............... ............. ...... 26

2.3.10

Accessorie Accessoriess for Testing the Device........... Device.................. .............. .............. ............... ............... ............... ............... .............. .............. .............. ............... ............ 26

2.4

Device Configuratio Configuration n ................... ............................ ................... ................... ................... ................... ................... .................... ................... .................. ............ ... 27

2.5

Technical Technical Data .............. ........................ ................... ................... ................... .................. ................... ................... .................. .................. .................. .................... ........... 28

© SICK MAIHAK GmbH · Germany · All rights reserved

3



2.6

Dimensions and Order Numbers....................................................................................... 30 2.6.1

Transmitter/Receiver Unit .............................................................................................................. 30

2.6.2

Reflector................................................................................................................................................. 30

2.6.3

Device Attachment ............................................................................................................................ 31

2.6.4

Flange with Pipe ................................................................................................................................. 31

2.6.5

Connection Unit...................................................................................................................................32

2.6.6

External Purge-Air Unit (Optional) ................................................................................................ 33

2.6.7

Weatherproof Cover For Transmitter/Receiver Unit and Rotating Reflector ............... 34

2.6.8

Optional Components for Monitoring Air in Workshops ...................................................... 35

3 Assembly and Installation...............................................................................................37 3.1

Project Planning .................................................................................................................... 39

3.2

Assembly ................................................................................................................................. 40

3.3

3.2.1

Installing the Flanges with Pipe .................................................................................................... 40

3.2.2

Installing the Connection Unit ....................................................................................................... 42

3.2.3

Installing the Optional External Purge-Air Unit ........................................................................ 43

3.2.4

Fitting the Weatherproof Covers .................................................................................................. 44

3.2.6

Installing optional Components for Monitoring Air in Workshops .................................... 45

Installation............................................................................................................................... 46 3.3.1

General Instructions and Prerequisites .................................................................................... 46

3.3.2

Connection Unit .................................................................................................................................. 46

3.3.3

Connecting/Commissioning the Optional External Purge-Air Unit ................................... 48

3.3.4

Mounting the Device Attachments .............................................................................................. 49

3.3.5

Installing the Purge-Air Supply ....................................................................................................... 50

3.3.6

Connecting optional Devices ........................................................................................................ 51

4 Commissioning and Parameterization ........................................................................55 4.1

4.2

4

Basics....................................................................................................................................... 57 4.1.1

General Notes .................................................................................................................................... 57

4.1.2

Prerequisites ....................................................................................................................................... 57

Normalization.......................................................................................................................... 58 4.2.1

Basics .................................................................................................................................................... 58

4.2.2

Focusing the Transmitter Light Beam......................................................................................... 59

4.2.3

Normalization....................................................................................................................................... 60

4.3

Installing and Connecting the Transmitter/Receiver Unit and Reflector ........... 62

4.4

Parameterization ................................................................................................................... 63

©

4.4.1

Customer-Specific Parameterization........................................................................................... 63

4.4.2

Parameterization for Dust Concentration Measurement .................................................... 65

4.4.3

Data backup ........................................................................................................................................ 66

4.4.4

Starting Standard Measuring Mode............................................................................................ 67

SICK MAIHAK GmbH · Germany · All rights reserved

8 010 038 / 08-2006



4.5

Parameterizing Optional Devices ................................................................................... 68 4.5.1

Data Memory / Event Memory ..................................................................................................... 68

4.5.2

CAN Module ......................................................................................................................................... 71

4.5.2

Second Analog Output ..................................................................................................................... 72

4.5.3

LCD .......................................................................................................................................................... 72

5 Maintenance....................................................................................................................... 73 5.1

General ..................................................................................................................................... 75

5.2

Maintaining the Transmitter/Receiver Unit and Reflector ...................................... 76

5.3

Maintaining the Purge-Air Supply .................................................................................... 77

5.4

5.3.1

Connection Unit with Integrated Purge-Air Supply ................................................................. 78

5.3.2

External Purge-Air Unit (Optional)................................................................................................. 79

Removal from Service.......................................................................................................... 80

6 Troubleshooting................................................................................................................. 81 6.1

No Indication .......................................................................................................................... 83

6.2

Warnings and Malfunction Messages .......................................................................... 84

6.3

6.2.1

Malfunction Messages..................................................................................................................... 84

6.2.2

Warnings................................................................................................................................................ 86

6.2.3

Other Malfunctions and Abnormal Behavior ............................................................................ 86

Test and Diagnosis Options............................................................................................... 88 6.3.1

Testing the Signal Output ................................................................................................................ 88

6.3.2

Check Cycle.......................................................................................................................................... 88

6.3.3

Linearity Check.................................................................................................................................... 89

7 Repairs.................................................................................................................................. 91 7.1

7.2

7.3

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Transmitter/Receiver Unit.................................................................................................. 93 7.1.1

Replacing the LP Processor ........................................................................................................... 94

7.1..2

Replacing the Optics Holder with Receiver Electronics ....................................................... 94

7.1.3

Replacing the Entire T/R Unit Connector................................................................................... 95

7.1.4

Replacing the FW300SE Housing................................................................................................ 95

7.1.5

Checking/Replacing the Battery for the Transmitter/Receiver Unit................................ 96

Rotating Reflector ................................................................................................................ 97 7.2.1

Replacing the Reflector.................................................................................................................... 97

7.2.2

Replacing the Front Window with the Holder........................................................................... 98

7.2.3

Replacing the Housing for the Rotating Reflector.................................................................. 98

Connection Unit..................................................................................................................... 99 7.3.1

Connection Unit Without Purge-Air Supply................................................................................ 99

7.3.2

Connection Unit with Integrated Purge-Air Supply ...............................................................101

© SICK MAIHAK GmbH · Germany · All rights reserved

5



8 Parts Overview.................................................................................................................105 8.1

8.2

8.3

8.4

Standard Components.......................................................................................................107 8.1.1

Transmitter/Receiver Units.......................................................................................................... 107

8.1..2

Reflectors........................................................................................................................................... 107

8.1.3

Device Attachments....................................................................................................................... 108

8.1.4

Flanges with Pipe............................................................................................................................. 108

8.1.5

Connection Units.............................................................................................................................. 108

8.1.6

External Purge-Air Units (Optional) ........................................................................................... 108

8.1.7

Purge-Air Hoses ............................................................................................................................... 109

8.1.8

Power Supply Cables for the Rotating Reflectors............................................................... 109

8.1.9

Miscellaneous .................................................................................................................................. 109

Options ...................................................................................................................................110 8.2.1

Transmitter/Receiver Units.......................................................................................................... 110

8.2..2

Connection Units.............................................................................................................................. 110

8.2.3

Device Attachments....................................................................................................................... 111

8.2.4

Purge-air Connection...................................................................................................................... 111

8.2.5

Weatherproof Covers ................................................................................................................... 111

8.2.6

Optional Components for Monitoring Air in Workshops ................................................... 112

8.2.7

Optional Components for Higher Internal Duct Pressures .............................................. 112

8.2.8

Accessories for Testing the Device.......................................................................................... 112

8.2.9

Miscellaneous .................................................................................................................................. 112

Consumable Parts for 2-Year Operation......................................................................113 8.3.1

Connection Unit with Internal Purge-Air Supply.................................................................... 113

8.3.2

External Purge-Air Unit (Optional).............................................................................................. 113

Spare Parts............................................................................................................................114 8.4.1

Transmitter/Receiver Unit ............................................................................................................ 114

8.4.2

Reflector.............................................................................................................................................. 115

8.4.3

Device Attachment ......................................................................................................................... 115

8.4.4

Connection Unit................................................................................................................................ 115

8.4.5

Miscellaneous .................................................................................................................................. 115

9 Appendix............................................................................................................................ 117

6

9.1

Standard Settings for the FW300..................................................................................119

9.2

Password ...............................................................................................................................120

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Notes On This Document



Notes On This Document These operating instructions describe the functioning of the FW300 dust measuring system. They contain general information on planning, assembly, installation, commissioning, maintenance, and troubleshooting. The description of the available device components is intended to help you during the planning phase to determine the optimum configuration for the particular application. These operating instructions only cover standard applications that conform to the technical data listed. Your SICK representative will be glad to provide you with additional information and support for special applications. We strongly advise that you contact a SICK specialist for consultation on special applications.

Note

• Always read these operating instructions carefully before commencing work. The safety instructions and warnings must be followed at all times. • Some system components (such as the side-channel compressor of the purge-air units) are supplied with separate user information. This information must also be read carefully.

Symbols used in this document For quick access and reasons of clarity, important safety information is specially highlighted in these operating instructions. They are provided at the relevant points in the chapters.

Note

Provides information on the features of the device or system, along with additional tips.

Important Indicates a risk of damage to the device or system components and potential functional impairments. ATTENTION

Warning

DANGER

Identifies potential danger for personnel, particularly due to electrical equipment or as a result of incorrect handling of the device or system components. These warnings are intended to protect you from (fatal) injuries.

Always read warnings carefully and follow them at all times!

8 010 038 / 08-2006

© SICK

MAIHAK GmbH · Germany · All r ights reserved

7

Safety Instructions

FW300


Dust Concentration Monitor

1

Safety Instructions 1.1 Intended Use The FW300 measuring system measures transmission, opacity, and dust concentration. It must only be operated in the manner intended by the manufact urer and in accordance with the following information. In particular, it is important that:

• The system is operated in accordance with the technical data and specifications regarding assembly, connection, ambient, and operating conditions (see the documentation supplied, the order documents, device documents, and rating plates) • All of the measures required to maintain the device, for example, for maintenance and inspection requirements, are provided.

1.2 Authorized Personnel Those responsible for personal safety must ensure that:

• All work on the measuring system is carried out by qualified personnel and checked by the experts responsible. These persons must be qualified by virtue of their expertise (training, education, experience) or understanding of the relevant standards, specifications, accident prevention regulations, and properties of the system. It is crucial that these persons be able to identify and avoid potential hazards in good time. Technical experts are those persons defin ed in DIN VDE 0105, IEC 364, or other directly equivalent standards. • These persons must be familiar with the hazards posed during operation, such as those caused by hot, toxic, or pressurized gases, gas/liquid mixtures, or other media, and must have received special training on how to operate the measuring system.

1.3

General Safety Information and Protection Measures Handling or using the device incorrectly can result in personal injury or material damage. Read this chapter carefully and ensure that you observe the safety precautions for the FW300 at all times. Always observe the warnings provided in these operating instructions. The following applies at all times:

• The relevant legal stipulations and associated technical regulations must be observed when preparing and carrying out work on the installation. • All work must be carried out in accordance with the local, system-specific conditions and with due consideration paid to the operating dangers and specifications. • The operating instructions for the measuring system and plant documentation must be available on site. The instructions for preventing danger and damage contained in these documents must be observed at all times. • Suitable safety equipment and personal protection measures must be available in accordance with the potential hazard and must be used by the personnel.

1.3.1

Danger from Electrical Equipment The FW300 measuring system is an item of electrical equipment designed for use in industrial power installations. When working on power connections or on live components, make sure that the power supply is switched off. If necessary, replace shock protection measures before reconnecting the power supply.

8

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8 010 038 / 08-2006

Safety Instructions



1.3.2

Danger Due to Hot, Corrosive, or Pressurized Gases The transmitter/receiver unit and reflector are mounted directly on the gas-carrying duct. In installations with a low hazard potential (no risk of injury, ambient pressure, low temperatures, no risk of explosion), these units can be installed and removed while the installation is in operation, provided that the applicable specifications and safety regulations for the installation are adhered to and all necessary and suitable protective measures are taken.

Warning Installations with toxic gases, high temperatures, high pressure, or risk of explosion must be shutdown before these components are installed or removed! DANGER

1.3.3

Danger Due to Laser Beam The FW300 uses a laser with protection class 2. To prevent blinding:

WARNING

1.3.4

‡

Never look directly into the laser beam.

‡

Do not direct the FW300 laser beam towards people.

‡

Take into account reflections of the laser beam.

Purge-Air Failure The purge-air supply protects the components fitted in the duct against hot or corrosive gases. It must remain switched on when the plant is shut down. A purge-air supply failure can quickly destroy the transmitter/receiver unit and reflector. For this reason, the operator must ensure that: ‡

The purge-air supply operates reliably and without interruption.

‡ A ‡

ATTENTION

8 010 038 / 08-2006

failure is detected immediately (for example, by using pressure monitors).

The transmitter/receiver unit and reflector are removed from the duct in the event of a purge-air failure and the duct openings are covered (for example, with a flange cover).

© SICK


9

Safety Instructions

FW300



1.3.5

Detecting and Preventing Malfunctions Any deviations from normal operation must be regarded as a serious indication of a functional impairment. These include: ‡

1.3.6

Significant drifts in the measurement results

‡ A

rise in power consumption

‡ A

rise in system component temperature

‡

Triggering of monitoring devices

‡

Unusually strong vibrations / unusual operating noise from a purge-air fan

‡

Smoke or unusual odors

Shutdown, Removal from Service, and Storing System Components The FW300 measuring system must remain switched on when the plant is shut down. The purge-air supply must never be switched off. If the FW300 operating voltage is switched off for a prolonged period (more than 3 days), all the device components must be disassembled and stored in a dry, dust-free location.

10

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Product Description

Features and Applications Operating Principle and Measured Variables Device Components Device Configuration Technical Data

Product Description



2

Product Description 2.1

Features and Applications The FW300 measuring system from SICK AG is a two-step direct transmissiometer. It enables continuous, instantaneous in-situ measurement and can output the following measured variables: ‡

Transmission

‡

Opacity

‡

Extinction

‡

Dust concentration in mg/m³ in the operating status (in accordance with gravimetric comparison measurement)

Features and benefits • Very long measuring path (0.5 m to 15 m) • Modular design Depending on the application conditions, the FW300 can be assembled using individual components in such a way that it can fulfill a wide range of requirements and can thus be used in many different applications. • Integrated measurement of the dust content across the duct diameter, independent of the flow velocity, humidity, and particle burden. • Digital processing of the measurement values ensures a high level of accuracy and low susceptibility to interference. • No fittings in the gas flow, which means that device components do not come into direct contact with the medium to be measured. • Straightforward installation and commissioning • Simple operation and configuration with user-friendly software • Minimum maintenance requirements Applications

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‡

Monitoring emissions from industrial plants to ensure that they remain within limits.

‡

Monitoring filter installations to ensure that they are in working order.

‡

Measuring the dust concentration in flue and exhaust gas ducts.

‡

Monitoring dust burdens in workshops.

‡

Measuring dust emissions on slag heaps, as well as in quarries and mills.

© SICK


13

Product Description

FW300



2.2 2.2

Oper Operat atin ing g Pri Princ ncip iple le and and Mea Measu sure red d Vari Variab able les s

2.2. 2.2.1 1

Oper Operat atin ing g Pri Princ ncip iple le The FW300 uses the transmissiometry measu ring principle. An LED (for measuring paths of up to 2 m) or a laser diode (for measuring paths of up to 15 m) acts as a light source. The light in the visible range (wavelength: approx. 650 nm) is sent to the reflector across the particle-laden measuring path and reflected to the receiver (see Fig. 2.1 ). When the light l ight passes through the measuring path twice, it is attenuated by the particles and captured by the measuring detector (photo-diode). Its reception signal is a mplified as an electrical signal and fed to the measuring channel of a micro-processor, which is a central component of the measurement, control, and analysis systems. The transmitter power of the transmitter diode is continuously monitored and maintained at a steady level. A beam-splitting mirror in front of the transmitter/receiver unit outlet diverts part of the beam to the monitor detector. Its reception signal is also amplified and then fed to the monitor duct of the micro-processor. This enables even the smallest changes in the brightness of the light beam to be detected and taken into account when the output signal is determined.

Monitor detector (reference) Transmitter diode

Reflector

Measuring detector

Measuring path

Fig. 2.1: FW300 measuring principle

2.2.2 2.2.2

Calcula Calculatin ting g Transmi Transmissi ssion, on, Opaci Opacity, ty, and and Extinct Extinction ion The FW300 uses the following measured variables: transmission, opacity, and extinction. Transmission is the optical variable from which the other measured variables are derived. Transmission is defined as follows: I T= where:

14

©

I0

T = transmission, I = light received I0 = light light emitt emitted ed


8 010 038 / 08-2006

Product Description



Provided that the light is not attenuated by particles, the following result is calculated: I = I0 In other words, the transmission transmis sion is no more than 1 or 100 %. Sinc e the light received is also attenuated by device-specific and distance-related influences along the particle-free measuring path, a normalization constant (N) must also be used to ensure that transmissi on really is 1 or 100%. With the FW300, measuring signal Imeasure is used instead of I and Imon is used instead of I0. In this way, transmission is calculated on the basis of the constant (N) determined (see section 4.2 ) and saved during normalization. normali zation. The following formula formu la is used: Imeasure

T= N•

Imon

The measured variables 'opacity' and 'extinction' are derived from 'transmission' in accordance with the following formulas. Opacity:

O= 1 - T

Extinction:

E = log

1

(T )

'Transmission' and 'opacity' are normally specified in %; the results of the formulas must then be multiplied by 100 % accordingly.

2.2. 2.2.3 3

Determ Determin inin ing g the Dust Dust Conc Concent entra rati tion on The attenuation of a light beam through absorption and particle scattering is described by the Lambert-Beer law. I = I0 • e where:

-c •

k•L

c = dust co concentration k = exti extinc ncti tion on cons consta tant nt L = double double measurin measuring g path (due (due to double double transmiss transmission; ion; see see Fig. 2.1 )

Conversion to c results in: ln c=

( II ) 0

- k • L

Using extinction, the result is as follows: c=

2.31 • E k • L

=K•E

This means that with a consistent particle size and homogeneous dust distribution, extinction is directly proportional to the dust concentration in mg/m³. Fig. 2.2 shows the ideal correlation between extinction and dust concentration.

8 010 038 / 08-2006

© SICK


15

Product Description

FW300



5 µm

3 µm

2 µm

100 90

Particle size Reference: Each 80 % under the specified value

80

m g m n n o t a r t n e c n o c t s u

70 60 50

Values for fly ash with 2.5 g/m³ density and 1 m measuring path

40 30 20 10

Transmission in %

0 100

98

96

92

94

90

88

86

84

82

80

Extinction 0

0,01

0,02

0,03

0,04

0,05

0,06 0,07 0,08 0,09 0,097

Fig. 2.2: Corr elation between transmission, extinction, and dust concentration

cc = cc2: cc1: cc0: cc0:

To take into account the effect th at different particle sizes, dust density, and dust dist ribution under different load conditions have on transmission and, in turn, extinction values when the dust concentration is determined, the measu ring system must be calibrated by a gravimetric comparison measurement. During parameterization, the regression coefficients calculated during this process are entered in the FW300 as follows:

calibrati calibration on coefficien coefficientt square linear abs absolut olute e

concentr concentratio ation= n= cc2 • Ext² + cc1 • Ext + cc0 (see section 4.4.2 ; standard factory setting: cc2 = 0, cc1 = 1, cc0 = 0).

Ext = Extinction

2.2.4

Respo espon nse Tim Time The response time (t90 ) is the time taken by the FW300 to reach 90% 90% of the end value after a sudden change in the measured value (see Fig. 2.3 ). The t90 time can be set to any value valu e between 0.1 and 600 s. Setting a higher t90 time provides better attenuation of transient fluctuations in the measured value and malfunctions to produce a "smoother" output signal. Measured value in %

100 90 % of the peak

98 96

Measured value with t 90 response time

94 Process change 92 90 t90

88 86 84

t in s 10

20

30

40

50

60

70

80

90

100

Fig. 2.3: Response time

16

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8 010 038 / 08-2006

Product Description



2.2.5

Check Cycle The check cycle is used for automatically checking that the transmitter/receiver and reflector are functioning properly. Any impermissible deviations from the standard behavior are signaled as errors. The check cycle can be triggered automatically at fixed intervals (setting in MEPA-FW, see section 4.4.1 ) and/or manually (1 min after the power supply has been connected, or the system has been switched from "Maintenance" to "Measure" in MEPA-FW). If a malfunction is present, you can trigger a check cycle manually to locate the cause of the problem (see Chapter 6). The check cycle consists of a zero-point check and span test. The system displays the check values regardless of the set measured variable. The zero point is checked by switching the system off; the span value (70 % of the set measuring range) is checked by modulating the light source accordingly. The check values can be output via the analog output (see section 4.4.1 ).

Check cycle (automatic) ‡

20 s Determination of the check values

‡

90 s Output at the analog output (70 % value) (provided output is activated)

‡

90 s Output at the analog output (zero value) (provided output is activated)

Zero value

Check value 70 %

Fig. 2.4: Check cycle output on plotter

Notes

• When the check values are being determined (duration: approx. 20 s), the value last measured is output at the analog output. • If the check values are not output at the analog output, the current measured value is output once the check value has been determined. • The "Maintenance" relay is activated to signal that a check cycle is in process. • With the LCD option, a check cycle is indicated with a plain-text "check cycle" display and as a status output at relay 6. • Automatic check cycles are carried out periodically f rom the parameterized time interval, until the interval setting is changed (or the device is reset). After a device reset (or power failure), the check cycle begins at the defined time when the device resumes operation.

8 010 038 / 08-2006

© SICK


17

Product Description

FW300



2.3 Device Components The FW300 measuring system comprises the following components (see Fig. 2.5 ):

• Transmitter/receiver unit • Reflector • Device attachment

Possible device configurations see section 2.4 .

• Flange with pipe • Connection unit – with integrated purge-air supply (for internal duct pressure -70 ... +2 mbar) – without purge-air supply. The following is, therefore, required: • External purge-air supply (for internal duct pressure -70 ... +30 mbar) Duct

Transmitter/receiver unit

Flange with pipe Reflector Optional

Connection unit with purge-air supply Meas. path

Connection unit without purge-air supply

Device attachment

Power supply

External purgeair unit option

RS 232 Purge-air hose MEPA-FW operating and configuration program

Sensor cable Power supply for reflector

Fig. 2.5 Overview of the FW300 components

2.3.1

Transmitter/Receiver Unit The transmitter/receiver unit contains the optical and electronic modules for transmitting and receiving the light beam, as well as processing and evaluating signals. An integrated sight enables you to align the light beam with the center of the reflector. The transmitter/ receiver unit is connected to the connection unit using a 16-pole cable with a connector, and has a 24 V DC power supply. It is secured to the device attachment with clamps.

Receiver lens

Clamp fixing bracket

Connection for connection cable

Fig. 2.6: FW300SE transmitter/receiver unit

18

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Product Description


The transmitter/receiver units are available in two versions:

• With light diode (for measuring paths between 0.5 and 2 m) • With laser diode (for measuring paths between 1.5 and 15 m) The basic version features the following interfaces (on the terminal strip in the connection unit): Analog output (1x) 0/2/4 ... 20 mA

Relay outputs Max. load: 48 V, 1 A

For outputting the following measured variables: • Transmission • Opacity • Extinction • Dust concentration

For outputting the following status signals: • Operation/malfunction • Limit value • Maintenance (check cycle)

Digital input E.g.: for connecting the maintenance switch with floating contact

RS 232 interface For parameterization with the MEPA-FW operating program

The operating status is also signaled by two LEDs on the rear of the housing: (green = operation, red = malfunction). The basic versions can also be equipped with a data memory/event memory, CAN module, or a second analog output (see section 2.3.7 ). The different versions are defined by a type key: Transmitter/receiver unit: Type - 1: - 2:

FW3X0XX- XXX-XX

Measuring path: 0.5 ... 2 m; light source: LED Measuring path: 1.5 ... 15 m; light source: laser diode

Basic version - SE: Standard - EX: Protected for use in hazardous locations Data memory/event memory - N: No memory - M: Memory Optional modules - N: No module - A: Second analog output module - C: CAN module LCD activation (in the connection unit) - N: No display activation - D: Display activation Special version - 00: No extras - SO: Special design (e.g. stainless steel housing) Example:

FW320SE-MAD-00

Transmitter/receiver unit type 320, standard, with laser diode and: Data memory/event memory Second analog output LCD activation No extras

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Product Description

FW300



2.3.2

Reflector A special film attached to a glass substrate reflects the light beam to the receiver in the transmitter/receiver unit. Two different reflector types are available: Fixed reflector

Reflector type

Rotating reflector

FW-R-055-F-000

FW-R-055-D-000

FW-R-105-D-000

0.5 m to 2 m

1.5 m to 8 m

6 m to 15 m

Measuring path Effective diameter of the active optical surface

55 mm

105 mm

Rotating

Fixed Optical axis

Fixing bracket Active optical surface

Power supply connector

Fig. 2.7: FW300 reflectors

With the rotating reflector, a motor rotates the glass substrate and film around the optical axis. This reduces the swing sensitivity of the measuring system and increases the accuracy of the measurements. The reflection surface and drive are installed in a housing unit with the same external dimensions as the transmitter/receiver unit. The reflector is also secured to the device attachment with clamps. Type key for the different versions: Reflector

FW-R-XXX-X-XXX

Diameter of the active optical surface (055/105) Version (F=fixed reflector, D=rotating reflector) Special version (000)

Note

20

Weatherproof covers are available if the transmitter/receiver unit and rotating reflector are to be installed outdoors (see Fig. 2.22 and Fig. 2.23 ).

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Product Description



2.3.3

Device Attachment The device attachment is used for securing the transmitter/receiver unit and reflector, as well as purging the optical surfaces with purified ambient air. This protects device components against contamination, overheating, corrosion, and damage caused by hot, corrosive gases. A disk assembly can be installed to improve the effect of the purge air. 2nd Purge-air nozzle at FW-V-105-P-00

Purge-air nozzle

Clamp Fig. 2.8: Device attachment with purge-air nozzle

A rubber sealing strip ensures that the device attachment and flange with pipe are firmly sealed. The device attachments are available in different versions to suit different applications (see table below). Device attachment type

Internal disk For mounting the diameter

Purge-air Special connection version

Standard

FW-V-030-P-000

30 mm


Ø 40 mm

none

FW-V-055-P-000

55 mm

Reflector FW-R-055

Ø 40 mm

none

FW-V-105-P-000

105 mm

Reflector FW-R-105

Ø 40 mm

none

FW-V-030-N-000

30 mm

Reflector FW-R-055

none

none

FW-V-055-N-000

55 mm

Reflector FW-R-055

none

none

FW-V-055-N-H00

55 mm

none

with heater

Options

Type key for the different versions: Device attachment

FW-V-XXX-X-XXX

Internal disc diameter (030/055/105) Purge-air nozzle (P=purged/N= not purged) Special version (000/H00)

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FW300

Product Description



2.3.4

Flange with Pipe The flange with pipe is used for connecting the device attachment to the duct wall and is available in graded nominal lengths, different steel types, and different sizes. Your choice depends on the wall and insulation thicknes s of the duct ( → nominal length), reflector type/ device attachment ( → size), and duct material (see Fig. 2.9 ). Mounting indicator

Material St 37 or 1.4571

TOP

Securing pins for device attachment

Fig. 2.9: Flange with pipe

D100 is for device attachments FW-V-030-X-XXX and FW-V-055-X-XXX; D160 is for device attachment FW-V-105-P-000.

2.3.5

Connection Unit The connection unit contains the power supply for the transmitter/receiver unit and rotating reflector, terminals for the network connection and input/output signals, and an RS 232 interface (9-pole Sub-D socket) for connecting a PC/laptop. The connection cable for the transmitter/receiver unit (16-pole, shielded) is securely attached to the connection unit. The cable length is 3 m or 10 m. Two versions are available:

Connection unit without purge-air supply LCD

Power supply unit

Terminal block

Fig. 2.10: Connection unit without purge-air supply

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Product Description


Connection unit with integrated purge-air supply This version also has a purge-air fan, air fi lter, and purge-air nozzle for connecting the purgeair hose for the transmitter/receiver unit and reflector.

LCD

Purge-air fan

Air filter

I/O board with terminal block

Mounting plate

Purge-air nozzle

Power supply unit (on rear of mounting plate)

Fig. 2.11: Connection unit with integrated purge-air supply

The connection units can also be fitted with the LCD module with additional relay outputs (see section 2.3.7 ). The different versions are also defined by a type key: Connection unit:

AK1-X-XXXX-X-X

Integrated purge-air supply - P: With - N: Without Cable length (= length of purge-air hose to to transmitter/receiver unit for type AK1-P) - 03: - 10:

3m 10 m

Supply voltage - WR: Power supply 100 ... 240 V AC (wide-range power unit) - 02: 24 V DC LCD - N: - D:

No display Display

Special version - 0: Without - S: Special design (e.g. stainless steel housing)

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Product Description

FW300



Purge-air hose and power supply for the rotating reflector The purge-air hoses to the transmitter/receiver unit and reflector, and the cable for supplying power to the rotating reflector are separate components of the measuring system. They are available in the standard lengths of 3, 5, 10, and 25 m, which ensu res that the device can be easily configured for a wide range of applications with just a limited range of options. The purge-air hoses for the transmitter/receiver unit and reflector can be of different lengths.

Purge-air distributor Using the FW-R 105-D-000 rotating reflector we recommend to install the optional purgeair distributor for a better distribution of the purge air inside the FW-V 105-P 000 device attachment (see section 3.3.5 and 8.2.4 ).

2.3.6

External Purge-Air Unit (Optional) The connection unit with integrated purge-air supply cannot be used if the internal duct pressure is greater than +2 mbar or the large FW-R-105-D-000 rotating reflector is used. In this case, the option with an external purge-air unit must be used. It features a highperformance fan and is suitable for use in pressurized ducts of up to 30 mbar.

Baseplate

Air filter

Fan (standard type 2BH13)

Purge-air hose

Fig. 2.12: Purge-air unit SLV 1

The different purge-air requirements for the transmitter/receiver unit and reflector can be distributed using a purge-air aperture (see section 3.3.5 ). A weatherproof cover is available if the system is to be used outdoors (see Fig. 2.21 ).

2.3.7

Data Acquisition, Communication, Measured Value Output, and Display Options

Note

The options described here can only be installed by the manufacturer.

Data memory/event memory Installed in transmitter/ receiver unit

24

This option enables up to 7,280 measured values and 100 events to be recorded in continuous operation. The measured values can be saved as mean values over a definable period (e.g. every half hour) and assigned a time stamp by an integrated real-time clock. All changes in the device operating status (maintenance, limit value violation, error statuses) are recorded as events The menu-driven MEPA-FW parameterization program reads or displays the data (see section 4.5.1 ).

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Product Description



CAN module Installed in transmitter/ A separate evaluation unit is available to complement the existing input/output and receiver unit connection options (see section 8.2.9 ). To enable communication with this evaluation unit via the CAN bus, the transmitter/receiver unit must be equipped with this module. In this way, up to three FW300 systems can be connected to the connection unit with a data transfer of up to 1000 m.

Second analog output Installed in transmitter/ receiver unit

Instead of a CAN module, the transmitter/receiver unit can be fitted with a second, electrically isolated analog output (0/2/4 ... 20 mA). It has the same techn ical specifications as the standard output. The measuring range can be parameterized independently (see section 4.5.3 ).

Note

If a CAN module or second analog output is installed, you can only install two additional relay outputs (operation/malfunction and limit value/maintenance; can be parameterized in MEPA-FW). The following option is recommended here.

LCD Installed in connection unit

To display the measured values and status information, a module with a 2-row LCD, two LCD for signaling "Maintenance" (green) and "Malfunction" (red), and three additional relays for maintenance, the second limit value, and the check cycle can be integrated in the connection unit. This module is activated by the transmitter/receiver unit, which must be configured accordingly, that is, it must be ordered with the LCD (see type key, section 2.3.1 ). The LCD shows the following status information (warnings and malfunction messages see section 6.2 ): Indications on the LCD Meaning „Limit1

“ Limit 1 is exceeded

„

Limit2“ Limit 2 is exceeded

„Limit1

Limit2“

„Soft

“ „Hard (In1)“

„Soft

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Hard (In1)“

Limit 1 and limit 2 are exceeded „Maintenance“ mode is set via MEPA-FW (Software maintenance) „Maintenance“ mode is set by using o f an external switch (hardware maintenance; see section 3.3 ) Hardware and software maintenance are set


25

Product Description

FW300



2.3.8

Optional Components for Monitoring Air in Workshops If the transmitter/receiver unit and reflector are to be installed outside (e.g. for monitoring slag heaps) or in workshops, a light/dust protection tube is available with a suitable bracket (see Fig. 2.13 ). This provides a vibration-free installation for instantaneous measurements over distances of up to 10 m. The light/dust protection tube is available with or without a heater and insulation cover.

Light/dust protection tube (without heater and insulation cover) Transmitter/receiver unit or reflector Light/dust protection tube bracket

Fig. 2.13: Light/dust protection tube with bracket

2.3.9

Optional Components for Higher Internal Duct Pressures Special modules for installing the transmitter/receiver unit and reflector in the duct can be supplied if the FW300 is to be located in areas where the pressure is between +30 mbar and +30 bar (see section 8.2.7 ).

2.3.10 Accessories for Testing the Device Linearity test equipment A linearity test can be performed to check that the transmission is being measured correctly (see section 6.3.3 ). Absorption filters with defined transmission values are placed in the beam path and the values are compared with those measured by the FW300. If the results match and are within the permissible tolerance, the FW300 is functioning correctly. The absorption filters and bracket are supplied with a case.

Adjustment bracket for normalization Adjustment brackets are available for checking the transmission measurement on a smokefree section (see section 2.2.2 ). They are placed at set distances away from the transmitter/ receiver unit and reflector, and must be arranged in such a way that the optical axes are identical (see section 4.2 ). The calculated transmission value is set to 100 % and represents the norm for the measurement in the dust-burdened measuring path.

Zero pipe for normalization Instead of an adjustment bracket, a pipe with a defined length c an be used to normalize the FW300 (see section 4.2 ). This enables the transmitter/receiver unit and reflector to be installed and aligned on a smoke-free section more easily and accurately. When not in use, the zero pipe is sealed with end caps so that dust cannot enter it. This option is highly recommended if a dust-free atmosphere cannot be ensured during normalization.

26

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Product Description



2.4 Device Configuration The components required for the measuring system depend on the application. The following table will help you decide which components you need. Meas. path [m] Transmitter/ receiver unit Type FW310

FW310SE XXX-XX

0.5 - 2 1.5 - 8

FW320SE XXX-XX

Type FW320 6 - 15

Purge-air supply

Duct components Reflector

Device attachment for T/R unit

Flange with pipe for

Reflector

T/R unit

FW-R-055-F000

FW-V-055-P000 FW-R-055-D- FW-V-030-P000 000

D100 D100

FW-V-105-P000

FW-R-105-D000

D160

Connection and supply components

Measuring path [m]

Max. internal duct pressure: +2 mbar

Max. internal duct pressure: +30 mbar

0.5 - 8

AK1 -P-XXXX-X-X

AK1 -N-XXXX-X-X and external purge-air unit

Permissible 6 - 15 Not permissible

Max. measuring path in m

Notes

Reflector

AK1 -N-XXXX-X-X and device attachment FW-V-055-N-000 or FW-V-055-H00

0.5 - 8

Purge-air hose length in m when component is used AK1 -P-XXXX-X-X

External purge-air unit (optional)

To T/R unit

To reflector

To T/R unit

To reflector

2

3

3

3

5

3

3

5

3

5

4

3

10

5

5

6

3

10

3

10

7

10

10 (5)

5

10

9

10

10

10

10

15

10

25

10

25

• The connection cable and purge-air hose to the transmitter/receiver unit and the supply cable and purge-air hose for the rotating reflector must be the same length. • Depending on the actual installation conditions, you can order the purge-air hoses in the standard lengths shown in the table below (connection unit with integrated purge-air supply: x 2; external purge-air unit: x 1). You can also order just one purge-air hose and divide it accordingly (provided that it is sufficiently long).

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Product Description

FW300



2.5

Technical Data

Measured value acquisition Measured variables

Transmission

Opacity

Extinction

Dust concentration

Measuring range

Any value between 100 and 0 %

Any value between 0 and 100 %

Any value between 0 and 2.5

Minimum range

100 - 80 %

0 - 20 %

0 - 0.1

Depending on the measuring path and particle content/size; see separate table

± 0.4 %

± 0.4 %

± 0,002

Measuring accuracy

1)

Response time

Any value between 0.1 and 600 s

Application data Measuring path (upper limits for instantaneous installation only)

0.5 - 2 m with FW310SE-XXX-XX and FW-R-055-F-000

1.5 - 8 m with FW320SE-XXX-XX and FW-R-055-D-000

6 - 15 m with FW320SE-XXX-XX and FW-R-105-D-000

F/F measurement tolerance 2) (in % transmission or opacity)

± 0.8 % at 1 m;

± 0.8 % at 1 m; ± 1.5 % at 8 m

± 1 % at 6 m; ± 1.5 % at 15 m

1 ° at 1 m; 0.15 at 8 m

0.4° at 6 m; 0.15 at 15 m

1 ° at 1 m

Alignment tolerance angle

0 °C to 600 °C

Gas temp. (above dewpoint) Internal duct pressure

3)

Ambient temperature

-50 ... +2 mbar -50 ... +30 mbar

Connection unit with purge-air supply External purge-air unit (optional)

-20 ... +50 °C -20 ... +45 °C

Transmitter/receiver unit Connection unit with purge-air supply Purge air intake temperature

Connections Analog output

Electrically isolated, 0/2/4 ... 20 mA, max. load 750 Ω; 10 bit, resolution ± 1 %

Relay outputs

For status signals operation/malfunction, limit value, maintenance; Load carrying capacity: 48 V, 1 A; floating

Interfaces

RS 232 for laptop/PC (9600, 8, N, 1)

Digital input

Dig in 1 = connection for maintenance switch with floating contact

Options LCD

2-row display for the measured variables, as well as warning and malfunction messages With additional relay outputs for maintenance, second limit value, check cycle

Second analog output

Electrically isolated, 0/2/4 ... 20 mA, max. load 750 Ω; can be parameterized separately

CAN module

For connecting the FW300 to an evaluation unit

Data memory/event memory

For storing and displaying up to 7,280 measured values and 100 events

Power supply Connection unit

Power supply: Power consumption:

100...240 V AC, 47...63 Hz; opt. 24 V DC max. 15 W without purge-air supply approx. 70 W with purge-air supply



24 V from connection unit max. 4 W

Rotating reflector


24 V from connection unit 1 W in standard operation; max. 12 W

External purge-air unit (optional) (with fan: 2BH13)

Power supply:

200 ... 240 V/345...415 V at 50 Hz; 220...275 V/380...480 V at 60 Hz 2.6 A/Y 1.5 A 0.37 kW at 50 Hz; 0.45 kW at 60 Hz

Rated current: Motor rating: 1)

: Absolute value; instantaneous and between 0 °C and 40 °C

2)

: Within maximum alignment tolerance angle

3):

28

©

-50 mbar ... +6 bar / +30 bar with optional components for high internal duct pressure


8 010 038 / 08-2006

Product Description



Dimensions (W x H x D) Transmitter/receiver unit

150 mm x 150 mm x 110 mm

Reflector

Ø 80 mm x 34 mm 150 mm x 150 mm x 110 mm

Fixed reflector Rotating reflector

Device attachment

Ø 126 mm x 200 mm Ø 179 mm x 300 mm

Type FW-V-030-X-XXX and FW-V-055-X-XXX Type FW-V-105-P-000

Connection unit

300 mm x 400 mm x 220 mm 200 mm x 200 mm x 130 mm

with purge-air supply without purge-air supply


550 mm x 550 mm x 258 mm; with weatherproof cover: 605 mm x 550 mm x 350 mm

Weight Transmitter/receiver unit

2 kg

Reflector

0.4 kg 2.2 kg

Fixed reflector Rotating reflector

Device attachment

1.4 kg 4.5 kg

Type FW-V-030-X-XXX and FW-V-055-X-XXX Type FW-V-105-P-000

Connection unit

13.5 kg 3.7 kg

with purge-air supply without purge-air supply


14 kg

Miscellaneous Class of protection

Transmitter/receiver unit Rotating reflector Connection unit

IP 65 IP 65 IP 65

Signal cable length

3 m, 10 m

other lengths available on request

Length of purge-air hose and cable for supplying power to the rotating reflector

3 m, 5 m, 10 m, 25 m

other lengths available on request

Laser

Class of protection 2;

Purge air flow rate

Approx. 30 ... 50 m³ /h Approx. 50 ... 100 m³ /h

Power < 1 mW; wavelength between 640 nm and 660 nm

connection unit with internal purge-air supply external purge-air unit (optional)

Dust concentration measuring range The range limits have been defined on the basis of empirical evidence gathered over many years by SICK. They are used for assessing the area of application and are valid on the assumption that particle sizes are consistent and evenly distributed. Precise range limits cannot be specified because conditions may vary from application to application. Meas. Average down particle stream size Cloth filters

3•m

Electrostatic precipitators

5•m

Spin filters

10 • m

Meas. range

Dust concentration in mg/m³ with measuring path in m 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

190

95

65

48

38

32

27

24

21

19

17

16

15

14

13

maximum 5000 2500 1660 1240 1000 830

710

625

555

500

460

420

390

360 330

minimum

38

34

30

27

24

22

21

19

maximum 7000 3500 2350 1750 1400 1170 1000 880

850

770

700

640

590

500 470

minimum

51

46

42

38

35

33

minimum

270

460

135

230

90

153

67

115

54

92

45

77

66

58

maximum 12000 6000 4000 3000 2400 2000 1700 1500 1330 1200 1100 1000 920

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18

31

850 800

29

Product Description

FW300



2.6 2.6

Dime Dimen nsion sions s an and Ord Order er Numb Number ers s All dimensions in mm mm

2.6. 2.6.1 1

Tran Transm smit itte ter/ r/Re Rece ceiv iver er Unit Unit

0 5 1

Ø 80 150

80

27

Fig. 2.14 FW300 transmitter/receiver unit

Transmitter/ receiver unit type

Order no.

FW310SE-NNN-00 FW310SE-NND-00

7040370 7040371

FW31 FW310S 0SEE-MN MNNN-00 00

7040 704037 372 2

FW31 FW310S 0SEE-MN MNDD-00 00

7040 704037 373 3

FW310SE-NAN-00 FW310SE-NAD-00

7040374 7040375

FW31 FW310S 0SEE-MA MANN-00 00

7040 704037 376 6

FW31 FW310S 0SEE-MA MADD-00 00 FW310SE-NCN-00

7040 704037 377 7 7040378

FW310SE-NCD-00

7040379

FW31 FW310S 0SEE-MC MCNN-00 00

7040 704038 380 0

FW31 FW310S 0SEE-MC MCDD-00 00

7040 704038 381 1

FW320SE-NNN-00 FW320SE-NND-00

7040300 7040301

FW32 FW320S 0SEE-MN MNNN-00 00

7040 704030 302 2

FW32 FW320S 0SEE-MN MNDD-00 00

7040 704030 303 3

FW320SE-NAN-00 FW320SE-NAD-00

7040304 7040305

FW32 FW320S 0SEE-MA MANN-00 00

7040 704030 306 6

FW32 FW320S 0SEE-MA MADD-00 00 FW320SE-NCN-00

7040 704030 307 7 7040308

FW320SE-NCD-00

7040309

FW32 FW320S 0SEE-MC MCNN-00 00

7040 704031 310 0

FW32 FW320S 0SEE-MC MCDD-00 00

7040 704031 311 1

(see section 2.3.1 for type key)

2. 6. 2

Reflector

Fixed reflector

9 6 Ø

0 8 Ø

Rotating reflector

0 5 1

D

Reflector type

Order no.

FW-R-055-F-000 FW-R-055-D-000

7 0403 34 704033 1

FW-R-105-D-000

704033 2

(see section 2.3.2 for for type key)

14

20

27

80 Dim. D

150 Rotating reflector type FW FW-R-055-D-000 FW-R-105-D-000 80

14 0

Fig. 2.15 FW300 reflectors

30

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8 010 038 / 08-2006

Product Description



2.6. 2.6.3 3

Devi Device ce Atta Attach chme ment nt 45°

45°

1 D

Attachment type

Order no.

FW-V-030-P-000

7040340

FW-V-055-P-000 FW-V-105-P-000

7040341 7040342

FW-V-030-N-000

7040343

FW-V-055-N-000 FW-V-055-N-H00

7040344 7040345

(see section 2.3.3 for type key)

D2 D3 D4

40 L

Dim.

x: 2nd Purge-air nozzle nozzle only for FW-V-105-P-00

Device attachment type FW-V FW-V-0 -030 30-X -X-X -XXX XX,, FW-V FW-V-0 -055 55-X -X-X -XXX XX

FW-V FW-V-1 -105 05-P -P-0 -000 00

D1 D2

76 56

133 101

D3

100

160

D4 L

126 2 00

179 300

Fig. 2.16 Device attachment

2.6. 2.6.4 4

Flan Flange ge with with Pipe ipe 45

45 TOP TOP

G

1 D

Flan Flange ge wit with h pipe pipe typ type e D100

Orde Orderr no. no.

Length 130 mm, St37

2017845

Length 240 mm, St37

2017847

Length 500 mm, St37

2017849

Length Length 130 mm, V4A 201784 2017846 6

D2

L

Length Length 240 mm, V4A 201784 2017848 8 Length Length 500 mm, V4A 201785 2017850 0

D3

D160

Dim.

Length 100 mm, 7040128 St37 Length 200 mm, 7040137 St37 Length Length 100 mm, V4A 704013 7040138 8

Flange with pipe D100

D16 0

D1

Ø 76

Ø 10 8

D2 D3

Ø 10 0 Ø 13 0

Ø 160 Ø 180

L

130, 240, 500

100, 200

G

M10

M8

Length Length 200 mm, V4A 704013 7040139 9

Fig. 2.17 Flange with pipe

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31

Product Description

FW300



2.6. .6.5

Conn onnecti ction Un Unit Connection unit without purge-air supply Ø8

160 Conn Connec ecti tion on unit unit type type

0 2 2 0 0 2

200

130

Orde Orderr no. no.

AK1-N-03WR-N-0

7040350

AK1-N-10WR-N-0 AK1-N-0302-N-0

7040351 7040352

AK1-N-1002-N-0

7040353

AK1-N-03WR-D-0

7040354

AK1-N-10WR-D-0 AK1-N-0302-D-0

7040355 7040356

AK1-N-1002-D-0

7040357


Fig. 2.18 Connection unit unit without purge-air supply (with LCD)

Connection unit with integrated purge-air supply

260

Ø8

0 0 2 0 4 4

Conn Connec ecti tion on unit unit type type

Orde Orderr no. no.

AK1-P-03WR-N-0 AK1-P-10WR-N-0

7040358 7040359

AK1-P-0302-N-0

7040360

AK1-P-1002-N-0 AK1-P-03WR-D-0

7040361 7040362

AK1-P-10WR-D-0

7040363

AK1-P-0302-D-0

7040364

AK1-P-1002-D-0

7040365


3 00

22 0

Fig. 2.19 Connection unit with integrated purge-air supply (with LCD)

32

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Product Description



2.6.6

External Purge-Air Unit (Optional)

ø 14 Purge-air unit type

SLV4-21112 1012409 with fan (2BH13) and purge-air hose (length: 10 m)

0 0 5 7 5 4

SLV4-21111 1012424 with fan (2BH13) and purge-air hose (length: 5 m)

0 4

0 4 40

Order no.

128 470

258

550

Fig. 2.20 External purge-air unit (optional)

245

0 5 5

550

Component

Order no.

Weatherproof cover for purge-air unit

5306108

350

605

Fig. 2.21 Weatherproof cover for external purge-air unit

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33

Product Description

FW300



2.6.7

Weatherproof Cover for Transmitter/Receiver Unit and Rotating Reflector Weatherproof cover for transmitter/receiver unit and reflector (incl. device attachment)

239

0 6 3

365

492

Component Weatherproof cover for analyzer

Order no. 2702407

Cannot be used for rotating reflector FW-R-105-D-000

Fig. 2.22 Weatherproof cover for analyzer

Weatherproof cover for FW-R-105-D-000 rotating reflector Outside dimensions like weatherproof cover for analyzer ( Fig. 2.22 ), mounting dimensions according to flange with pipe D160 ( Fig. 2.17 ). Order number: 2021457

Weatherproof cover for transmitter/ receiver unit and rotating reflector housing (without device attachment)

164

160

7 5 1

Component

Order no.

Weatherproof cover for housing FWSE/ FWR-D

7040394

(Transmitter/receiver unit and rotating reflector housing) Spacer pin

Fig. 2.23 Weatherproof cover for housing FWSE/FWR-D

34

©


8 010 038 / 08-2006

Product Description



2.6.8

Optional Components for Monitoring Air in Workshops

45

Clamp

45

6 7 Ø

Ø 100 Ø 122

250

150 800

Component

Order no.

Light/dust protection tube

7041168

Light/dust protection tube bracket

7040233

Fig. 2.24 Light/dust protection tube (without heater or insulation cover)

0 5 3

0 8 2

240

(230) 2 1 8

3 1

8 2 1

4 2

Fig. 2.25 Light/dust protection tube bracket

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© SICK


35

FW300

Product Description



36

©


8 010 038 / 08-2006


Assembly and Installation

Project Planning Assembly Installation




3

Assembly and Installation 3.1 Project Planning The following table provides an overview of the project planning work you have to carry out to ensure that the device is correctly installed and fully functional. You can use this table as a checklist by ticking off all the steps you have carried out.

Task

Requirements

Step

Determine the measuring and installation locations for the device components.

Inlet and outlet sections Round and square ducts: must be of sufficient Dh = duct diameter length, each at least 3 x Rectangular ducts: "hydraulic diameter" (D h ) Dh = 4 x cross-section divided by circumference

Comply with specifications for new installations; choose the best possible location for existing installations; if the inlet/outlet sections are too short: inlet section > outlet section

• Homogeneous flow distribution • Representative dust distribution



If possible, no bends, cr oss-section If this cannot be ensured, determine the variations, feed pipes, discharge pipes, flaps, flow profile to VDI 2066 and choose the or fittings in the inlet and outlet sections. best possible location.

Mounting position of the Must not be installed vertically on horizontal Choose the best possible location transmitter/ ducts or ducts positioned at an angle; max. receiver unit and reflector measurement axis angle to the horizontal: 45 ° Accessibility, accident prevention

The device components must be easily and Provide platforms if necessary safely accessible

Vibration-free installation Accelerations < 1 g

Take appropriate measures to eliminate/reduce vibrations

Ambient conditions

For limit values, see "Technical data".

If necessary: • Fit weatherproof covers/sun protection • Cover or insulate the device components

• Up to +2 mbar (connection unit with

Determine the supply type

Choose the Sufficient purge-air prepurge-air supply pressure (depending on the internal duct pressure) Clean intake air

integrated purge-air supply) • From + 2 mbar to +30 mbar (external purge-air unit option) As little dust as possible, no oil, humidity, corrosive gases

• Choose the best possible intake location

• Determine the required purge-air hose lengths Choose the device components

Plan the calibration openings

Measuring distance, duct Transmitter/receiver unit, reflector, device wall strength with attachment, flange with pipe or light/dust/ insulation protection tube with bracket

Choose the components in accordance with the configuration table in 2.4 ; If necessary, plan additional measures to install the flange with pipe (see section 3.2.1 )

Internal duct pressure

Connection unit and, if necessary, external purge-air unit (optional) or components for higher internal duct pressures

Installation locations

Cable and purge-air hose lengths

Accessibility

Easy and safe

Provide platforms/pedestals if necessary

Distances to the measurement level

No mutual interference between calibration probe and FW300

Ensure sufficient distance between the measurement and calibration level (distance approx. 500 mm)

See "Technical Data" in section 2.5

Ensure sufficient cable cross-sections and fuse

Plan the power Operating voltage, supply maximum demand

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FW300



3.2 Assembly All of the assembly and installation work has to be carried out by the customer. This includes: ‡

Installing the flanges with pipe (or weld-on flanges for high-pressure versions).

‡

Installing the connection unit

‡

Installing the external purge-air unit (optional).

‡

Fitting the optional components for monitoring the air in workshops or for high internal duct pressures.

Warning • When carrying out assembly and instal lation work, observe the relevant safety regulations and the safety information in Chapter 1! DANGER

• Assembly and installation work on potentially dangerous machinery (hot, corrosive, or explosive gases, high internal duct pressure) must only be carried out when the machinery is shut down! • Suitable measures must be taken to protect against local or installation-specific hazards!

3.2.1

Installing the Flanges with Pipe Activities ‡

Measure out the mounting locations and mark the mounting location.

‡

Remove the insulation (if present).

‡

Cut out suitable apertures in the duct wall; with brick and concrete ducts, drill suitably sized holes (for flange pipe diameter, see Fig. 2.17 )

Important Make sure that parts do not fall into the duct! ATTENTION

Installation in a steel duct >50 A

A

Installation in a brick duct

Installation in a thin-walled duct

A

A

30

TOP

Marking for mounting

Flange with pipe

Duct wall

Armature base plate

Junction plate

Fig. 3.1 Installing the flanges with pipe ‡

40

©

Insert the flange with pipe into aperture in such a way that the marking "Top" faces upwards (see Fig. 3.1 )


8 010 038 / 08-2006




‡

Roughly align the flange and pipe and tack into position with a few spot welds (with brick or concrete ducts, tack onto the armature base plate; wi th thin-walled ducts, use junction plates, see Fig. 3.1 ).

‡

Use a suitable pipe (for smaller ducts) or a SICK alignment device to precisely align it (see Fig. 3.2 ); max. axis deviation: ± 1°. gnmen usng

e aux ary p pe

Auxiliary pipe Duct wall

Flange with pipe

Alignment using the alignment device A

The alignment device (see section 8.2.9 ) can also be hired out.

A Light source Flange with pipe

Duct wall

Target optic

Fig. 3.2: Aligning the flanges with pipe

Note

8 010 038 / 08-2006

Align the flange with the target optics in such a way that the light spot from the lamp is visible in the center of the target optics. ‡

Weld on the flange pipes around their circumference, while constantly ensuring that the alignment is exact (correct if necessary). If you are using the alignment device, you first have to reposition the flange plate with the light source and flange plate with target optics before you weld on the second flange pipe.

‡

Once installed, cover the the flange aperture to prevent gas from escaping.

© SICK


41

FW300




3.2.2

Installing the Connection Unit The following points must be taken into account when selecting the mounting location: ‡

The connection unit must be mounted on a level, vertical base at an accessible, protected location (see Fig. 3.3 for dimensions).

‡

The mounting location must be vibration free.

‡

The ambient temperatures must be within the permissible range (see section 2.5 ) (take into account any radiant heat).

‡

The connection unit with the integrated purge-air supply must be mounted at a location with clean air. If necessary, lay an intake hose or pipe at a location where the conditions are more favorable.

‡

You must take into account the length not only of the connection cables to the transmitter/receiver unit and, if used, rotating reflector, but also the purge-air hoses for the connection unit with integrated purge-air supply.

‡

The connection cable and purge-air hoses must be routed out on the underside.

a

M6

b

0 0 3 >

c Clearance for cables (and purge-air hoses)

Dim. (All dimensions in mm)

a b c

Clearance for opening the door

Connection unit type AK1 -N-XXXX-X-X AK1-P-XXXX-X-X 160 260 220 420 > 350 > 550

Fig. 3.3: Mounting dimensions for the connection unit

Note At the securing points, you are advised to use M6 pins that can be used to attach the connection unit and secure it with self-locking nuts.

42

©


8 010 038 / 08-2006




3.2.3

Installing the Optional External Purge-Air Unit The following points must be taken into account when selecting the mounting location: ‡

The purge-air unit must be mounted at a location with clean air. The intake temperature must match the values specified in the technical data (see section 2.5 ). If necessary, lay an intake hose or pipe at a location where the conditions are more favorable.

‡

The mounting location must be easily accessible and fulfill all the applicable safety requirements.

‡

You must ensure that sufficient space is available for changing the filter insert.

‡

When installing the purge-air unit outdoors, you must ensure that sufficient space is available for fitting and lifting the weatherproof cover (see Fig. 3.4 ).

Flange with pipe

Duct 0 4 1 >

Clearance for fitting the weatherproof cover ) 0 5 5 (

0 7 4

470

Clearance for replacing filter insert

(550)

> 160

Alternative: retaining bracket

50 x 5 steel pipe DIN 2391 M8

0 5

Fig. 3.4: Structure and installation dimensions for the purge-air unit

Installation work

8 010 038 / 08-2006

‡

Prepare the bracket as shown in Fig. 3.4.

‡

Secure the purge-air unit with 4 bolts (M8).

‡

Check whether the filter insert is installed in the filter housing (install if necessary).

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43


FW300



3.2.4

Fitting the Weatherproof Covers Weatherproof cover for analyzer This weatherproof cover protects the transmitter/receiver unit and reflector, including the device attachment (see Fig. 2.22 ). It comprises a baseplate and cover. Installation: ‡

Mount the baseplate sideways on the flange with pipe and secure it onto the surface of the flange plate using the threaded pins (see Fig. 3.5 ).

‡

Mount the cover from above.

‡

Insert the side lock bolts into the counterparts, and rotate them until they latch into place.

Lifting clearance

0 5 2 >

Cover

Baseplate (239)

Duct ) 0 6 3 (

(365)

(492) Flange with pipe

Threaded pin

Lock bolt

Fig. 3.5: Fitting the weatherproof cover for the analyzer

Weatherproof cover for FWSE/FWR-D housing This weatherproof cover is secured directly onto th e rear of the transmitter/receiver unit and reflector housing (see Fig. 2.23 ). Installation: ‡

Remove the M6 plastic covers.

‡

Screw the spacer pins into the thread openings on the rear of the housing.

‡

Secure the weatherproof cover onto the spacer pins.

Weatherproof cover for external purge-air unit The weatherproof cover (see Fig. 2.21 ) comprises a cover and lock set. Installation:

44

‡

Mount the lock parts from the lock set on the baseplate.

‡

Fit the cover from above.

‡

Insert the lock bolts into the counterparts sideways, and rotate them until they latch into place.

©


8 010 038 / 08-2006




3.2.5

Installing Optional Components for Monitoring Air in Workshops The bracket for the light/dust protection tube must be mounted on a level, vibration-free surface (see Fig. 2.25 and Fig. 3.7 for dimensions). Following the light/dust protection tubes are to be inserted and secured.

Important Take into account specifying the mounting locations that the optics of transmitter/receiver unit and reflector may not be spotlighted directly by light sources (spotlight, sun or other). ATTENTION

Lamp, spotlight inferior sun

Fig. 3.6: Inadmissible installation

You can use the alignment device to align the optical axes (see 8.2.9 ). To do so, proceed as follows: ‡

Secure the alignment device onto the light/dust protection tube.

‡ Align

the bracket for this light/dust protection tu be in such a way that the light/dust protection tube lies centrally in the field of vision.

‡

Secure the alignment device onto the other light/dust protection tube and repeat the procedure.

Warning! The transmitter/receiver unit and reflector must not be installed. ATTENTION

(800)

A

Opposite light/dust protection tube

(250) max. 10 m in stable, distortion-free installation ) 0 5 3 (

A Alignment tool

Dimensions in mm Fig. 3.7: Installing and aligning the optional components for monitoring the air in workshops

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© SICK


45


FW300



3.3 Installation 3.3.1

General Instructions and Prerequisites Before you start the installation work, you must have carried out the steps described in section 3.2 . Unless otherwise agreed with SICK or an authorized SICK representative, all of the installation work must be carried out by the customer. This includes laying and connecting the power supply and signal cables, installing circuit-breakers and power fuses, fitting the device attachments, and connecting the purge-air supply.

Notes

‡

Ensure the cable cross-sections are of sufficient size (see section 2.5 , "Technical Data").

‡

The cable ends with the connector for connecting the transmitter/receiver unit and rotating reflector must be of adequate length.

Warning • All installation work must be carried out in line with the relevant safety regulations and instructions listed in Chapter 1. DANGER

3.3.2

46

• Suitable measures must be taken to protect against danger.

Connection Unit The power supply cables (terminals L1, N, and PE, as well as 7 and 8 for the rotating reflector) and signal cables (analog output, digital inputs/outputs) must be connect ed to the terminal strip as shown in Fig. 3.8.

©


8 010 038 / 08-2006




RS 232 connection

RS 232 assignment Socket (9 pole) FW300

Plug (9 pole) PC

2 Txd

2 Rxd

3 Rxd

3 Txd

5 Gnd

5 Gnd

Terminal strip

Power cable n e e r G / n w o w e l l o u r l e B B Y

Fuse T1A

Signal cable

w n n e w o l e o l l e l e r e e k k r c n l Y i a G G Y / / / / n w n n n e k P B / l e e e t t t o e k y d e r y / w w p i w i i c l d h o u u l a a n a r i r e l r e h o r e e r h o r W B Y G P G R B P B G R W B W B

d – + d 1 d d x n d n + n n x R G A G T n G i m w e g i RS 232 u D o l 0 r B 2 115/230 V AC; 50/60 Hz . . B . 0 Power supply for rotating reflector (24 V DC)

Customer wiring

1 y a l e R

2 y a l e R

3 y a l e R

Shield

Maintenance (LiY 2x 0.5 mm² (approx.) )

Analog output

Limit value

Digital input (maintenance) (LiY 2x 0.5 mm ² (approx.) )

Malfunction

Connection units with 24 V DC power supply: Instead of L1

Instead of N

+

-

Fig. 3.8: Terminal strip connections for the customer wiring

The power supply cable for the rotating reflector is one of the device components, although it can be adapted on site if required (open the connector as shown in Fig. 3.9 and connect the cable accordingly).

Open

Closed

Open

Closed

A

A

Connection cable (LiY 2x 0.5 mm² (approx.) )

A -A

Brown (+)

Blue (-) 24 V

Note To open the connecter, plug it into the plug on the rotating reflector.

Fig. 3.9: Terminal assignment of the connector for supplying the rotating reflector

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© SICK


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FW300



3.3.3

Connecting/Commissioning the Optional External Purge-Air Unit Activities ‡

Compare the supply voltage and frequency with the specifications on the rating plate of the purge-air motor.

Important Do not connect the purge-air unit if the values do not match. ATTENTION

If you are in doubt, or if you are using a special motor version, the operating instructions supplied with the motor take priority over any other information.

‡

Connect the power supply cable to the terminals on the purge-air motor (see supplementary sheet on purge-air motor and cover of motor terminal box; see the connection arrangement shown in Fig. 3.10 ).

‡

Connect a protective conductor to the terminal.

‡

Set the motor circuit-breakers in accordance with the connection data of the fan (see technical data of purge-air unit) to a value 10% greater than the rated current.

‡

Check the functioning and running direction of the fa n (flow direction of the purge-air unit must match the arrows at the inlet and outlet openings on the fan). If the direction of running on 3-phase motors is incorrect, swap power connections L1 and L2.

‡

Connect the (optional) pressure monitor for monitoring the purge-air supply.

Important • Use a fail-safe power supply (emergency power supply, bar with redundant supply).

ATTENTION

• The purge-air unit must be fused separat ely from the other system components. The fuse type must match the rated current (see technical details of purge-air unit). Fuse each phase separately. Provide circuit-breakers to protect against a phase failure on one side.

Low-pressure monitor V1 U2

V1 V2

W2

U1

U2

W1

W2 U2

V2

V1

U1 W2 U2

W1 PE

W1

W2

V2 U1

U1

V2

V1

W1 PE

Power supply 4 x 1.5 mm2

L1

L2

L3

PE

L1

L2

L3

PE

+

_

24 V

Fig. 3.10: Electrical connections for the external purge-air unit

48

©


8 010 038 / 08-2006




3.3.4

Mounting the Device Attachments



  1 pair

 

  Flange with pipe  Disk springs (4 pairs)  Device attachment  Self-locking nuts  Rubber sealing strip

Fig. 3.11: Mounting the device attachments

The device attachments are mounted in accordance with the number sequ ence in Fig. 3.11 on the flange with pipe (remove any flange covers beforehand).

Important

ATTENTION

8 010 038 / 08-2006

When mounting the device attachments, observe the relevant safety information (when mounting device attachments on potentially hazardous devices, ensure that the device is switched off; take the appropriate protective measures; see Chapter 1)!

Note

You do not need the disk springs when mounting the device attachment for the reflector.

3.3.5

Installing the Purge-Air Supply ‡

Lay the purge-air hoses without kinks along the shortest path (shorten the purge-air hoses if necessary). Provide sufficient distance from hot duct walls.

‡

Switch on the connection unit with purge-air supply or optional external purge-air unit (switch on the power supply) and ensure that th e purge air is flowing in the right direction.

‡

Push the purge-air hoses onto the relevant purge-air nozzles and secure them with the clamping tape.

© SICK


49


FW300



Notes

• For the connection unit with the integrated purge-air supply, assign the outputs as shown in Fig. 3.12. The nozzle for the transmitter/receiver unit must be mounted in the shown way (adjust if necessary).

Purge-air inlet

Purge-air outlet for the transmitter/receiver unit

Purge-air outlet for the reflector

Fig. 3.12: Underside of the connection unit with the integrated purge-air supply

• If you are using the optional external purge-air unit, the purge-air volume to the transmitter/receiver unit and reflector must be distributed at a ratio of approx. 1:4. The purge-air aperture (see section 8.2.4 ), which is available as an accessory, can also be used.

Purge-air nozzle

Device attachment for the transmitter/receiver unit

Purge-air aperture Hose clamping tape Purge-air hose Fig. 3.13: Installing the purge-air aperture

• If the FW-V-105-P-000 device attachment is installed, both purge-air nozzles should be attached to the purge-air supply for a better purge air distribution. You can use for this the optionally deliverable purge-air distributor (see Section 8.2.4 ) Purge-air distributor (T-piece with hoses and clamping tapes)

FW-V-105-P-000 device attachment Clamp

Purge-air hose from the purge-air supply

50

©


8 010 038 / 08-2006




Fig. 3.14: Connection of the purge-air distributor

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© SICK


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FW300



3.3.6

Connecting Optional Devices CAN Module and Second Analog Output The "Maintenance" relay output (relay 3) is not required when the optional CAN module or second analog output is installed. The cables to the connection unit for the CAN bus or analog signal are used instead. RS 232 connection

RS 232 assignment Socket (9 pole) FW300

Connect or (9 pin) PC

2 Txd

2 Rxd

3 Rxd

3 Txd

5 Gnd

5 Gnd

Terminal strip

Signal cable

Power cable

Fuse T1A

n e e r G / n w o w e l o u r l e B B Y

w n n w l o e e o l e l k r e k c e r e Y n l i a G G Y / / / n e k P n B / / e n w e n e t t o e k y d e l y / w t p i i w i w l c l d r e a a o o h o h h u a n r r r r e r r e l u l e i W B Y G P G R B P B G R W B W B

d – + d 1 x d x d n d n + n n T R G A n G i G g m w e i RS 232 u D l 0 o r B 2 115/230 V AC; 50/60 Hz . . . B 0 Power supply for rotating reflector (24 V DC)

Customer wiring

1 y a l e R

2 y a l e R

Option CAN module or 2nd analog output Limit value

(LiY 2x 0.5 mm² (approx.) )

Analog output

Shield

Malfunction

Digital input (maintenance) (LiY 2x 0.5 mm ² (approx.) ) Connection units with 24 V DC power supply: Instead of L1

Instead of N

+

-

Option

Terminal 15

Terminal 16

CAN module

CAN + high

CAN - low

+

-

2nd analog output

Fig. 3.15: Terminal assignment when the optional CAN module or 2nd analog output is installed

Note

Instead of relay 3, which is not required, relay 2 can be used to signal the "Maintenance" operating status (setting in MEPA-FW, see section 4.5.2 ).

Important To ensure that data is transmitted reliably on the CAN bus, you must connect a terminating resistor to the end of the bus (terminating resistor equal to line impedance value). ATTENTION

52

©


8 010 038 / 08-2006




Evaluation Unit EVU E

EVU

CAN 1 H L

Terminating resistor of the EVU (realized by a jumper)

Connect the terminating resistor in the connection unit which is removed from the EVU furthest.

15 16

Connection unit AK1

15 16

(Connection unit AK1)

Terminating resistor (value equal to line impedance)

15 16


EVU in the middle of the bus

CAN 1 H L

Connect the terminating resistors in the connection units which are removed from the EVU furthest

15 16


15 16

Connection unit AK1

The terminating resistor of the EVU is not needed (remove the jumper)

15 16


If only one FW300 is connected to the EVU, the terminating resistors must be connected in the EVU and connection unit. The terminating resistors in the connection units have to be supplied by the customer.

Fig. 3.16: Connection of the optional EVU

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© SICK


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FW300



LCD If the optional LCD is installed, the terminal strip in the connection unit for the customer wiring (see Fig. 3.8 ) is replaced by an additional board with terminals to which the cables for the analog and status signals are attached as shown in Fig. 3.17. Connections for the signal cables to the T R

RS 232 connection (Assignment as shown in Fig. 3.8 )

Board Terminal block 2 Connection for shield

Terminal block 1

Customer wiring

115/230 V AC; 50/60 Hz

d d d + – + d d n 1 x x n n n A n G i T R G G m w e g i RS 232 u D o l 0 r B 2 B . . . 0

1 y a l e R

2 y a l e R

Power supply for rotating reflector (24 V DC)

4 y a l e R

5 y a l e R

6 y a l e R

Shield

Option CAN module or 2nd analog output

Check cycle

Analog output

Limit value 1

Limit value 2

Digital input (maintenance)

Malfunction

Maintenance

Connection units with 24 V DC power supply: Instead of L1

Instead of N

+

-

Option

Terminal 15

Terminal 16

CAN module

CAN + high

CAN - low

+

-

2nd analog output Fig. 3.17 Terminal assignment with optional LCD

w n n w l o e e o l l e l e r e k k c r G e Y n i l a G / Y / / / P n n e k / / n B e e w w e n t t w i t o e k y d e l w p i i l c y l d r e e e o o h o h h u a n r e l u l r e r e r i r r W B Y G P G R B P B G R W B W B

n e e r c S

Signal cable

Board

Fig. 3.18: Connection of the optional EVU

54

©


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Commissioning and Parameterization

Basics Normalization Installing and Connecting the Transmitter/Receiver Unit and Reflector Parameterization Parameterizing Optional Devices




4

Commissioning and Parameterization 4.1 Basics 4.1.1

General Notes Commissioning the FW300 involves the following steps: ‡

Focusing the transmitter light beam.

‡

Normalizing the measuring system for a smoke-free section.

‡

Mounting the transmitter/receiver unit and reflector on the device attachments.

‡

Customer-specific parameterization in accordance with requirements.

If the FW300 is to be implemented for continuously measuring dust content, it must be calibrated using a gravimetric comparison measurement to ensure accurate measurements (see Section 4.4 ). The process of setting options in accordance with Section 2.3.7 is described in Section 4.5 . The MEPA-FW parameterization program is shipped with the device. The required settings can be easily configured using the program menus. Other functions (such as data storage and graphical display functions) are also available. Certain device functions can only be accessed once you have entered a password (see appendix). The access rights are assigned in 3 stages:

4.1.2

Level

Password

Access to

"User"

none

Measured value displays, device status query, display/output parameter log; parameterization not possible

"Authorized user"

Level 1

Displays, queries, and parameters for commissioning and customizing.

"Service"

Level 2

Displays, queries, and all parameters. For performing all on-site service activities (for example, diagnosis and troubleshooting).

Prerequisites ‡

– – – – –

Pin assignment RS 232 socket in connection unit

PC connector, 9-pin

Pin 2 (txd)

Pin 2 (rxd)

Pin 3 (rxd)

Pin 3 (txd)

Pin 5 (gnd)

Pin 5 (gnd)

8 010 038 / 08-2006

Laptop/PC with: Processor: Pentium 2 or higher VGA graphics card Serial interface COM 1 or COM 2 Main memory (RAM): minimum 32 MB Operating system: Microsoft Windows 95 or higher

‡

Interface cable (serial cable; see Options, Section 8.2 ) for connecting a laptop/PC to the FW300.

‡

The MEPA-FW operating and parameterization program must be installed on the laptop/ PC. To install the program, insert the disk/CD supplied into your disk/CD drive, call up the corresponding drive, run the "mepa-fw_setup.exe" file, and follow the instructions.

‡

The power supply must be connected.

© SICK


57


FW300



4.2 Normalization 4.2.1

Basics To eliminate device-specific and distance-related interference with the measurement result, the FW300 must be normalized on a particle-free section. This section must be identical to the measuring path (the distances between the optical boundary surfaces of the transmitter/receiver unit and the reflector must be identical). Two options are available for mounting the measuring equipment for normalization (see Fig. ): 4.1 ) • Adjustment bracket for normalization (see Section 8.2.8

• On-site installation of a "zero pipe" (with suitable diameter and clamps) When mounting the measuring equipment, you must ensure that the electrical connections to the connection unit are installed properly (if necessary, use an adapter cable or a separate power supply (supplied by SICK I MAIHAK on request)). Normalization with calibration adjustment brackets A


Reflector

Adjustment bracket for normalization

Adjustment bracket for normalization (order no. 7040131)

(order no. 7040131 for FW-R-055-F or FW-R-055-D; order no. 7040156 for FW-R-105-D)

Normalization with zero pipe


Reflector

A

2 x 1 . 6 7 Ø

Clamp TL110-A1 (order no. 7045516)

Antiglare louvre

D

Pipe

D = D1 in Fig. 2.16

A = length of device attachments with mounting kits + distance flange - flange

Fig. 4.1 Possible configuration for normalization

58

© SICK

MAIHAK GmbH · Germany · All rights reserved

8 010 038 / 08-2006




4.2.2

Focusing the Transmitter Light Beam The transmitter light beam must be focused to ensure that the light spot on the reflector lies within the active optical reflection surface. When focusing the beam, you must take into account the measuring path and permissible swing angle (see Section 2.3.2 ). The following guide values apply: Measuring path

Light spot diameter

Up to 2 m

20 ... 25 mm

Greater than 2 m

12 ... 15 mm

Make the setting as follows:

Check the alignment (see Section 4.3 )

‡

Prepare the measuring path with the transmitter/receiver unit and reflector in accordance with Fig. 4.1 .

‡ Attach a

sheet of white paper to the adjustment holder or zero pipe opening as a reflector.

‡

Connect the cable to the connection unit to provide the power supply.

‡

Unscrew the securing bolts on the housing cover of the transmitter/receiver unit and remove the cover.

‡

Insert a small screwdriver (or other suitable tool) through the focusing aperture in the processor board and into the hole for the setting wheel. Turn it clockwise or counterclockwise (see Fig. 4.2 ) until the light spot is the right diameter.

‡

Replace and secure the cover.

‡

Mount the reflector.

Housing

Focusing aperture

Processor

Light spot gets smaller

Light spot gets bigger

Setting wheel

Hole

Fig. 4.2: Setting the light spot

The FW300 must then be normalized.

Important The FW300 must be re-normalized every time the focus settings are changed! ATTENTION

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FW300



4.2.3

Normalization ‡

Connect the interface cable to the connection unit and laptop/PC.

‡

Start the "MEPA-FW.EXE" operating and parameterization program.

‡

The "Connection" menu appears on the screen.

The type displayed in this window must be the same as the connected device.

Fig. 4.3: "Connection" menu

Note

‡

Enter password level 1.

‡

Connect to the FW300. Choose the serial interface on the PC (e.g. COM 1) and click "Connection". The active parameter set for the device is then imported to MEPA-FW. You cannot connect to the device while the system is calculating the check values during a check cycle (duration approx. 20 s, see section 2.2.5 ; the information is then displayed in a separate window). Once you have successfully connected to the device, the start menu is displayed and shows a graphical representation of the measured values, system state, and analog value(s).

Menu bar Tab page

Desktop

Current measured

Displayed only with 2nd analog output option

Status bar Fig. 4.4: "Measured values" tab page

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‡

If necessary, change the language setting under "Options / Language".

‡

Switch the FW300 to "Maintenance" mode (menu: "Operation mode / Maintenance" or with an external maintenance switch connec ted at the terminals for Dig in 1; seeFig. 3.8 or Fig. 3.15 / 3.17 ). The status of the device is shown by the "Maintenance" indicator (if configured with MEPA-FW and with "(SOFT)" specified as the software setting).

‡

Press the "Set reference" button on the "Diagnosis/Test" tab page. The normalization window is then displayed and shows a graphical representation of the current transmission values and input fields (see Fig. 4.5 ).

Fig. 4.5: Normalization window ‡ Allow

the FW300 to function without intervention for approximately 20 min (must be in position for normalization). You can check the status using the graph.

‡

This value enables the distance to reproduced in subsequent normalization processes.

Note If correct, press "OK" to confirm.

Press the "Distance T/R unit - reflector" button, enter the actual measuring path in mm (see Fig. 2.5 ), and save.

‡

Press the "Set reference" button and wait approximately 50 s (normalization process is indicated with separate progress bars).

The mean average transmission value that is then displayed must be 100 ± 0.2 %. If not, repeat the normalization process. ‡

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Mount the transmitter/receiver unit and reflector onto the duct in accordance with Section 4.3.

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FW300



4.3 Installing and Connecting the Transmitter/Receiver Unit and Reflector First ensure that the device attachments have been mounted (see Section 3.3.4 ) and the purge-air supply (if available) is in operation (ensure that the flow direction is correct and the purge-air hoses are securely attached to the connector).

Activity ‡

Place the transmitter/receiver unit and reflector on the appropriate device attachments and secure with the clamps. The clamps must be closed with reasonable force (approx. 10 to 15 N) (may have to be readjusted).

‡

Connect the cable from the connection unit (screw the connectors tight!).

‡ Align

the transmitter light beam in accordance with Fig. 4.6 or Fig. 4.7.

Transmitter/ receiver unit

Horizontal alignment

Fixed

Vertical alignment

Sight Device attachment

Tighten the nuts in such a way that the transmitter light beam is in the center of the reflection surface of the reflector.

Fig. 4.6: Aligning the transmitter/receiver unit with the device attachment

Adjustment method during normalization on the on-site zero pipe

Carefully adjust the securing pins once you have removed the housing cover (pre-loading of the disk springs must be maintained!)

l a c i t r e v

horizontal


Fig. 4.7: Aligning the optical element in the transmitter/receiver unit

Two methods are available for checking the alignment:

• With a mounted reflector If the alignment is correct, a strong reflection is clearly visible in the sight on the rear of the transmitter/receiver unit housing. • Without reflector You can check the alignment using a sheet of paper (e.g. white photocopying paper) on the device attachment for the reflector (light spot must be in the center of the aperture).

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4.4 Parameterization The FW300 is shipped with default settings. The standard values are enclosed in the parameter log. You can also view these settings on the "Protocol" tab page in MEPA-FW. If you do not have to change these settings, you can use the FW300 in your installation straight away. If you do have to change the parameters, set the password once the connection to MEPAFW has been established, activate "Maintenance" mode, and choose the "Parameter" tab page (see Fig. 4.8 ).

The regression function is only displayed if you select the measured variable 'concentration'.

Fig. 4.8: "Parameter“ tab page

4.4.1

Customer-Specific Parameterization "Signal calculation" field ‡

Note

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Response time t90 (see Section 2.2.4 ) Enter a value between 0.1 s and 600 s in the relevant field (in the format: XXX.XX). The t90 time setting affects the response behavior of the measu red value and the output of analog values and the limit value relay. If you enter a high t90 time, the limit value relay does not respond to transient, high measured value peaks. At low t90 times , the response behavior of the FW300 is extremely quick (noise is greater).

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FW300


Dust Concentration Monitor ‡

Measured variable (see Section 2.2.2 and 2.2.3 ) The measured variable selected in this field (transmission, opacity, extinction, concentration) is output to the analog output a nd graphically displayed on the "Measured values" tab page in MEPA-FW (and on the LCD, if installed). When you choose "Concentration" (= dust concentration), the system opens an additional window for entering the regression factors determined in a compa rison measurement (see Fig. 4.8 ).

Important If the option Data memory / event memory is installed, these memories are deleted at a change of the measured variable (see also Section 4.5.1 ). ATTENTION

"Output" field The current output and limit value relay is set in this field. ‡ Analog

output

– Live Zero (LZ) You can set the zero point to 0.2, or 4 mA.

Recommendation

This value should ideally be set to 2 or 4 mA to differentiate between the measured value and when the device is switched off or the power supply is interrupted. – Measuring range (MR) You must enter the lower MR limit for LZ and the upper MR limit for 20 mA. ‡

Limit value Enter a value below or above which (depending on the selected measured variable) the limit value relay is to drop out. The limit valu e relay has a hysteresis equal to 10 % of the defined limit value.

"Check cycle" field The check cycle is activated by default and the cycle time is set to 8 hours. You can deactivate it by deselecting the "Enable" checkbox.

Notes

‡

Define the cycle time In the "Interval" window, enter the time between the sta rt of one check cycle and the next check cycle (range: between 2 and 24 hours).

‡

Output at analog output When you activate the "Check values analog output" checkbox, the check values calculated during the cycle check are output at the analog output (see section 2.2.5 ).

• Each time you switch on the device, and when the device exits "Maintenance" mode, a check cycle is triggered after 60 s and the check cycle time begins again. • An automatic check cycle is not triggered if the FW300 is in "Maintenance" mode at the starting time. After entering of the parameters these must be transferred to the FW300. To do this, press the button „Write to device“. Only after this it can be changed to another tab page.

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4.4.2

Parameterization for Dust Concentration Measurement To measure the dust concentration exactly, the correlation between the extinction calculated from the primary 'transmission' measured variable and the actual dust concentration in the duct must be established. For this purpose, the dust concentration must be determined by means of a gravimetric measurem ent to VDI 2066 or ISO 9096 and compared to the extinction values measured simultaneously by the FW300. To be able to model the correlation between the extinction and dust concentration as precisely as possible (see section 2.2.3 ), a regression function is stored in the FW300 that can be set as a quadratic or linear function.

Required steps The steps described here will help you avoid making input errors. Comparison measurements require special knowledge that cannot be described in detail here.

‡

Choose the measured variable 'concentration' in the "Parameter" tab page ("Maintenance" mode and password must be set).

‡

Check whether the regression coefficients correlate with "Concentration" = 0 • Ext² + 1 • Ext + 0 (see Fig. 4.8 ) (if not, correct them accordingly). The dust concentration is thus the same as the extinction and is directly assigned to the mA value as an mg value at the analog output.

‡

Carry out the gravimetric measurement to VDI 2066 or ISO 9096.

‡

Check the necessary measuring range (see Section 2.5 ) and enter it in the "Parameter" tab page (see Fig. 4.8 ).

‡

Determine the regression coefficients First, use a regression calculation to calculate the correlation between the gravimetrically measured dust concentrations and the mA values of the FW300. c

= K2 • Iout² + K1 • Iout + K0

c Iout

= dust concentration in mg/m³ = current output value in mA

Iout

= LZ + Ext •

(1)

20 mA - LZ

(2)

URL

Ext = measured extinction value LZ = Live Zero URL = defined upper range limit (entered value for 20 mA; normally 2.5 x fixed limit value) You must then use regression coefficients K2, K1, and K0 of function c = f (Iout ) to determine coefficients cc2, cc1, and cc0 to be entered in the device. "Concentration“ = cc2 • Ext² + cc1 • Ext + cc0

(3)

By using (2) in (1), the result is as follows:

(

c = K2 • LZ + Ext •

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20 mA - LZ 2 + K1 • LZ + Ext • URL

)


(

20 mA - LZ URL

)+ K0

65


FW300



Using (3), the result is as follows: cc2 = C2 •

(

20 - LZ 2 URL

)

cc1 = (2 • C2 • LZ + K1) •

20 - LZ URL

cc0 = C2 • LZ2 + C1 • LZ + C0 ‡

Notes

Enter regression coefficients cc2, cc1, and cc0 in the FW300.

• A special program is available for calculating the regression coefficients. • If a data memory / event memory is availa ble, the FW300 measured values can be saved as a file, from which the coefficients can be determined in MS Excel.

4.4.3

Data Backup In some cases, you may have to reconfigure the parameter settings. For the sake of simplicity, we recommend that you save and/or print out the paramet er log and keep it with your device documentation. The parameter log can also be usef ul for determining the cause of malfunctions (send the log to SICK I MAIHAK). To save your parameter settings, choose the "Protocol" tab page and then "Save to file" or "Print protocol" (see Fig. 4.9 ).

With the button "Load from file“ you can reload a later time again a stored file, also if there is no connection to the FW300 (select "Connection“ menu, interface "Simulation“).

Fig. 4.9: Parameter log (example)

Notes

66

• The value shown on the field "Status code“ serves for the evalu ation by the manufacturer in the case of device malfunctions. If you want to analyze the device status, please change to the "Diagnosis/Test" tab page. Possible messages displayed there and corrective measures are described in Section 6.2 .

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• The device protocol can be changed also into a text file (ASCII format) and then edited using any editor or text program. To do this, press the button “Print protocol“ and activate the checkbox “Print to text file“ in the “Printer selection“ menu (see Fig. 4.10 ).

Fig. 4.10: „Printer selection“ menu

4.4.4

Starting Standard Measuring Mode Standard measuring mode is started when you switch to "Measure" mode ("Operation mode / Measure" menu). This completes the standard commissioning procedure. The measured values are displayed graphically on the "Measured values" tab page in MEPA-FW and as a current value of the analog output (see Fig. 4.11 ).

Fig. 4.11: "Measured values" tab page

Notes

• You can change the resolution of the displayed measured values in the "Diagram scale" field by resetting the value in the "Peak auto scale" and entering a value between 1 and 10000 in the "Maximum" field • The device also switches to measuring mode when you close the MEPA-FW operating and parameterization program. If "Maintenance" mode has been set, the FW300 automatically switches to "Measure". • A check cycle is automatically triggered 1 min after the system has switched to measuring mode.

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FW300



4.5 Parameterizing Optional Devices This section describes the settings required for the data memory / event memory, CAN module, second analog output, and LCD options. Before you can enter or change the parameters, you must switch to "Maintenance" mode and enter the relevant password.

4.5.1

Data Memory / Event Memory The data is saved by additional hardware in the transmitter/receiver unit and activated by a release code entered by the manufacturer. Once the system has been connected, the data memory / event memory is available on the "Data memory / event memory" tab page in MEPA-FW.

Measured value table Graphical display of measured values Zoom option Zoom area

Events

Centralized malfunctionIndividual faults

Event table

System mode-dependent display Fig. 4.12: "Data memory / Event memory" tab page

Notes

• The measured value and event table displays a ma ximum of 10 values/events along with their date and time. If more exist, you ca n go to the required area by scrolling through t he table. • The system displays the measured values for the set measured variables. • In the measured value display, you can activate/deactivate the zoom function in the center of the screen to choose all of the measured values that have been saved or just those visible in the measured value table. You can scroll through the zoom area in the table in the same way. • When you call up this tab page, the column headers in the event table are always displayed in abbreviated form. You can click the column header to display them in their full form (column becomes wider), which enables you to see wh at each column indicates. • The "Erase data memory" and "Erase event memory" buttons are only displayed when the password is set (inactive display). The system must be in "Maintenance" mode for active use.

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Data memory The measured value is averaged over the set period, whereby the current measured value is totaled every 500 ms and, after the time interval has elapsed, the sum is divided by the number of times it has been totaled. A prerequisite here is that no faults are present and the system is not in maintenance mode. The resulting average value is not written to the data memory, however, until the current measured values have been valid for at least 2/3 of the time interval, that is, the total sum of the times for "Maintenance", "Malfunction", or check cycle was less than 1/3 of the time interval. You can set or change the interval period for saving the measured values in the "Option memory measurement value/save interval" field on the "Parameter" tab page within a range of 1 s to 2 h (see Fig. 4.13 ).

Fig. 4.13: Setting the storage intervals

Event memory The following events are registered in this memory:

• When they occur (= 1): – Ger... = Device restart (reset) – Me... = Data memory deletion – Ere... = Event memory deletion • At start ( = 1) and end (= 0) – Nor... = Normalization – Gre... = Limit value violation – Ers... = Reference measuring path activation – War...= Maintenance – S=... = Centralized malfunction set/reset when one of the following faults is present / no longer present - S1... = Device temperature > 75 C - S2... = Span test not successful - S3... = Monitor signal too low - S4... = Real-time clock has failed - S5... = Steady light signal too high - S6... = Normalization not successful - S7... = Measured value override - S8... = EEPROM check sum - S9... = Communication with display

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FW300



Description Function

Description

"Read data memory"

• When you press the "Read data memory" button, the measured values stored in the connected FW300 are displayed in tabular and graphi cal form. Up to 7,280 measured values can be displayed. • The time range starts with the first measured value interval read and ends with the storage time of the last (current) measuring in terval. If (o) (=overflow) appears at the end of the row, the data memory has overflowed at least once since it was last cleared. • The time information for the measured values in the table always relates to the end of an averaging interval (the storage time). • If the cyclic backup was interrupted (power off, maintenance), the next measured value is assigned a new time stamp. In this case, the row may not appear in full in the table.

"Erase data memory"

The data memory is deleted after you have confirmed the system prompt. This function is only available in "Maintenance" mode after you have entered your password.

Important The data memory is also cleared if you change the measured variable or the set storage interval time ("Parameter" tab page). "Read event memory"

• When you press the "Read event memory" button, the events stored in the connected FW300 are displayed in tabular and graphical form. Up to 100 events can be displayed. • The time range starts with the first event read and ends with the storage time of the last (current) event. • The time information for the measured values in the table always relates to the the storage time.

"Erase event memory"

The event memory is cleared after you have confirmed the system prompt. This function is only available in "Maintenance" mode after you have entered your password.

"Load from file"

You can choose and read a measured value file (*.dat) or event file (*.eve) stored in the system (separate MEPA format).

"Save to file"

The measured values or events displayed are store in a measured value or event file (separate MEPA format).

"ASCII export"

The measured values or events displayed can be stored in an ASCII file (*.txt). The data can then, for example, be processed subsequently for a graphical analysis in a spreadsheet program (such as Excel) or processed for logging purposes in a word processing program.

Important The ASCII file cannot be re-read by MEPA-FW!

Note

70

The "Save to file" and "ASCII export" functions can only be used if measured values or events have already been read.

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Setting the real-time clock The FW300 has a battery-buffered real-time clock that is set by the manufacturer before shipment. If required, this clock can be synchronized with the system time of a connected PC. Ensure that the clock in the PC has the right date (year numbers from 2000 [00] to 2066 [66] only). To set the clock, press the "Set with PC time" button in the "Option memory measurement value" field on the "Parameter" tab page in MEPA-FW (see Fig. 4.14 ). This sets the deviceinternal clock to the time and date of the connected PC.

Important

Important

Changing the time or date does not automatically reset the data memory / event memory, which means that time ranges may occur twice or gaps may exist in the relevant memories. ATTENTION

4.5.2

CAN Module An address must be assigned to the FW300 so that it can communicate with the evaluation unit. Enter this in the "Option CAN-Bus" on the "Parameter" tab page (see Fig. 4.14 ). The address can be set in a range of 73 to 127.

Only displayed if the option is installed

Fig. 4.14: Parameterizing optional devices

For communication between FW300 and eval uation unit, only the addresses 73, 74 and 75 are selectable. The assignment to the con nected FW300 is displayed on the LCD of the evaluation unit in the following way:

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• FW_1:

FW300 with address 73

• FW_2:


• FW_3:


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FW300



4.5.3

Second Analog Output You can set the required measuring range in the "Option m easurement range analog output 2" field on the "Parameter" tab page (see Fig. 4.15 ). The range limits are set in the sa me way as for the standard output (see section 4.4.1 ). The standard output values apply for live zero. Since the lines for relay 3 are used for this option (see also section 3.3.6 ), relay 2 can be set to signal either maintenance mode or the limit value. You make the assignment in the "Relay 2 signals“ field by choosing the appropriate checkbox.

Only displayed if the option is installed

Fig. 4.15: Parameterizing option 2 (analog output and LCD)

4.5.4

LCD This option enables you to define a second limit value. Enter the value in the "Option limit value 2" field on the "Parameter" tab page (see Fig. 4.15 ). No further parameterization is required.

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Maintenance

General Maintaining the Transmitter/Receiver Unit and Reflector Maintaining the Purge-Air Supply Removal from Service

Maintenance



5

Maintenance 5.1 General The FW300 is designed for long-term and almost maintenance-free operation. You simply have to ensure that the optical boundary surfaces are clean and the purge-air supply is functioning properly. Maintenance must be carried out, for example, if the transmission values are constantly decreasing, or opacity and extinction are increasing due to contamination. Before you carry out these maintenance tasks, you have to set the FW300 to "Maintenance" mode. You can do this by connecting the digital input Dig in 1 (terminals 4, 9; see Fig. 3.8 / Fig. 3.15 / Fig. 3.17 ) externally on the hardware side, or by choosing "Operating mode / Maintenance" in the MEPA-FW menu on the software side. Once you have completed these activities, switch the system back to measuring mode (switch off the external maintenance switch or choose "Measure" in the "Operating mode" menu).

Note

When the maintenance switch is set, warning and fault messages are suppressed. The live zero value is output at the analog output.

Maintenance intervals The plant operator is responsible for defining the m aintenance intervals. This will depend on specific operating parameters, such as dust content and type, gas temperature, plant operational procedures, and ambient conditions. For this reason, only general recommendations can be provided here. Maintenance is generally carried out every 2 to 6 weeks. The activities required and their completion must be documented by the operator in a maintenance log.

Maintenance agreement Regular maintenance activities can be carried out by the plant operator. These activities must be carried out by qualified persons (as described in Chapter 1) only. If requested, all maintenance activities can also be performed by the SICK Service department, or an authorized service partner. SICK offers a range of economical maintenance and repair agreements. SICK undertakes all maintenance and servicing work specified in these agreements. Wherever possible, specialists carry out repairs on site.

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Maintenance

FW300



5.2 Maintaining the Transmitter/Receiver Unit and Reflector The "optical boundary surface" is the surface of the optics or glass that faces the duct.

The optical boundary surfaces should be cleaned at regular intervals. The intervals depend on the operating conditions, although experience has shown that maintenance is required every 2 to 6 weeks. At the very latest, they must be cleaned when the maximum permissible level of contamination has been reached.

Required tools: • Brush, cloth, water, compressed air (dust and oil free; e.g. compressed air in 200 to 500 ml spray cans) • A blind plug for the device attachment (if required) Warning • When carrying out work on the system, always observe the relevant safety precautions and instructions provided in Section 1.3 (in particular, in Section 1.3.3 ). DANGER

• The purge-air supply must not be interrupted.

Procedure

76

‡

Loosen the clamps on the device attachments and carefully remove the transmitter/ receiver unit and reflector.

‡

Blow off any loose dust on the optical boundary surfaces, wet the SICK optics cloth with water, and clean the optics. Polis h the optics with a dry optics cloth . Blow or brush off any lint.

‡

Carefully place the transmitter/receiver unit and reflector back onto the device attachments and secure with the clamps.

‡

Ensure that the optical axes are correctly aligned.

‡

If necessary, re-normalize the FW300 (see Section 4.2 ).

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Maintenance



5.3 Maintaining the Purge-Air Supply You must carry out the following maintenance activities:

• Inspect the entire purge-air supply • Clean the filter housing • Replace the filter insert (if necessary) The dust load and wear on the filter insert depend on the degree of contamination of the ambient air that is drawn in. For this reason, we cannot provide specific recommendations regarding maintenance intervals, although you are advised to inspect the purge-air unit every 1 to 2 weeks after commissioning. The maintenance intervals can then be optimized accordingly.

Important • If the purge-air supply is not maintained at regular intervals or maintenance is not thorough enough, it can fail and destroy the transmitter/receiver unit and reflector. ATTENTION

• You must ensure that the purge-air supply is functioning properly when the transmitter/ receiver unit and reflector are installed. When replacing damaged purge-air hoses, you must remove the transmitter/receiver unit and reflector beforehand (see section 5.4 ).

Inspection

Note

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‡

Check the running noise of the fan at regular intervals; an increased noise level can indicate a fan failure.

‡

Check that all the hoses are secure and free of damage.

‡

Check the filter insert for contamination. You must replace the filter insert when: – a high degree of contamination is visible on the filter surface – the purge-air quantity is considerably less than during operation with a new filter You must not switch off the purge-air suppl y when cleaning the filter housing or replacing the filter insert, which means that the transmitter/receiver unit and reflector do not have to be removed from the duct.

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Maintenance

FW300



5.3.1

Connection Unit with Integrated Purge-Air Supply Cleaning or replacing the filter insert ‡

Open the door of the connection unit using the appropriate key.

‡

Remove the clamping tape at the filter output (1) and remo ve the filter from the gland (2).

‡

Remove the filter housing.

‡

Turn the filter housing cover in the direction of the arrow to "OPEN" and remove it.

‡

Remove the filter insert and replace it with a new one.

‡

Clean the filter housing and housing cover with a cloth and brush.

Important You must only use a cloth soaked in water to wet-clean the compon ents. Make sure that you dry the components thoroughly. ATTENTION

Spare part: Filter insert C1140, Order no. 7047560

‡

Insert the new filter insert.

‡

Replace the filter housing cover and tu rn it against the direction of the arrow unt il it clicks into position.

‡

Place the filter housing back into the connection unit.

Clamping tape Filter housing Filter housing cover

2 1

Intake hose

Fig. 5.1: Changing the filter insert for the connection unit with purge-air supply

78

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Maintenance



5.3.2

External Purge-Air Unit (Optional) Important The purge-air unit must be maintained at the very latest when the low-pressure monitor at the filter output is activated (see Fig. 5.2 ).

ATTENTION

Replacing the filter insert ‡

Ensure that you have a new filter insert (2) ready.

‡

Loosen the hose clamp (6) on the purge-air hose (7) and remove the hose. Secure the hose onto a clean surface.

Important Attach the end of the hose in such a way that no foreign bodies can enter it (danger of destroying the fan), but do not seal it! During this time, the purge-air entering the purgeair glands is unfiltered.

ATTENTION ‡

Remove any dust from the outside of the filter housing (1).

‡

Press the two quick-release locks (4) on the filter housing cover (3) to remove it.

‡

Remove the filter insert (2) by turning it counter-clockwise.

‡

Clean the filter housing and housing cover with a cloth and brush.

Important You must only use a cloth soaked in water to wet-clean the component s. Make sure that you dry the components thoroughly. ATTENTION

Spare part: Filter insert Micro-Top element C11 100, Order no. 5306091

‡

Insert the new filter insert by turning it clockwise while applying pressure.

‡

Mount the filter housing cover and ensure tha t it is properly aligned with the housing. Snap the quick-release locks into position.

‡

Reconnect the purge-air hose to the filter outlet using the hose clamp.

9

1

6 8

2

5

7

1 2 3 4 5

Filter housing Filter insert Filter housing cover Quick-release lock Air intake gland

3

6 7 8 9

4

Hose clamp Purge-air hose Hose clamp Low-pressure monitor

Fig. 5.2: Replacing the filter insert

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Maintenance

FW300



5.4 Removal from Service The FW300 must be removed from service: ‡

as soon as the purge-air supply fails

‡

if the plant is shut down for a prolonged period (more than approx. 1 week)

Important The purge-air supply must never be switched off or interrupted wh en the FW300 is installed in the duct! ATTENTION

Activities ‡

Loosen the cable to the connection unit.

‡

Loosen the clamps and remove the transmitter/receiver unit and reflector from the device attachments.

‡

Loosen the nuts and remove the device attach ments from the flanges with pipe (see Fig. ). 3.11

‡

Seal the flange with pipe using a blind plug.

‡

Switch off the purge-air supply.

‡

Loosen the hose clamping bands and detach the purge-air hoses from the glands. Seal the ends of the hoses to prevent dirt and moisture from entering.

‡

Disconnect the connection unit from the power supply.

Warning • When disassembling the system, observe the relevant safety regulations and the safety information in Chapter 1! DANGER

• Disassembly work on potentially dangerous machinery (high internal duct pressure, hot, corrosive, or explosive gases) must only be carried out when the machinery is shut down! • Suitable measures must be taken to protect against danger! • Switches that must not be activated for safety reasons are labeled accordingly and safeguarded to prevent unintentional activation.

Storage

80

‡

Store the components in a clean, dry location.

‡

Take suitable measures to protect cable connectors against dirt and moisture.

‡

Ensure that no dirt or moisture can enter the purge-air hoses.

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Troubleshooting

No Indication Warnings and Malfunction Messages Test and Diagnosis Options

Troubleshooting



6

Troubleshooting 6.1 No Indication

Symptom

Possible cause

Remedy

Transmitter/receiver unit LEDs do not light up

• • • •

‡ Disconnect the device from the power supply

LEDs on LCD do not light up, no indication on display

No power supply Fuse defective Power supply unit defective Signal cable defective or not properly connected • Transmitter/receiver unit connector defective • LP processor defective • LCD defective

‡ Open the connection unit cover ‡ Check the fuse (see Section 7.3.1 ) ‡ Check the power supply after connecting it to terminals N and

L1 ‡ Check the 24 V supply in the connection unit at terminals 7 (+) and 8 (Gnd) and in the transmitter/receiver unit at test point +24 V and ground (e.g. spacer pin) (see Fig. 7.1 and Fig. 7.2 ) ‡ Check the plug connection and cable

Important Always observe the relevant safety regulations when carrying out work on live components! ATTENTION

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6.2 Warnings and Malfunction Messages 6.2.1

Malfunction Messages Device malfunctions are signaled when the red LED on the rear of the transmitter/receiver unit lights up and, if the device is connected to MEPA-FW, the status indicator on the "Measured values" tab page ("System status" field) switches from green ("Operation") to red ("Malfunction"). If the LCD option is installed, malfunctions are also signaled in the second line of the display in plain text (English) (see the following table). Current malfunctions can also be interrogated in MEPA-FW on the "Diagnosis/Test" tab page (see Fig. 6.1 ). In the "Malfunctions" field, all malfunctions currently present are displayed as a short text. Comments are also available for each malfunction message, although they are only displayed when a message is selected. To supplement the displays in MEPA-FW, individual malfunction messages are available. These are explained in detail in the following section.

Short text

Comment field

Short text

Comment field

These are only displayed if the LCD option is installed

Fig. 6.1: "Diagnosis/Test" tab page

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Malfunction messages MEPA-FW

LCD

"Checksum EEPROM"

"Checksum EEPROM"

Possible cause

Remedy

• The last parameters could not be

Reload the device parameters ‡ Switch to the "Protocol" tab page

saved due to reset or power failure • EEPROM security area violated

‡ Press the "Load from file" button (the

parameters must be saved beforehand; see section 4.4.3 ) ‡ Press the "Write to device" button (password level 1 and "Maintenance" operating mode must be set)

"Overflow meas. value"

"Meas. overflow" The measuring distance has been shortened without being re-normalized.

Re-normalize the FW300 (see section 4.2.3 )

(Value for AN0 > 4.4 V; see "Protocol" tab page, "Factory settings" field)

"Signal too low during set reference"

"Set reference"

Measuring signal < 1 V

‡ Clean the optics ‡ Check the alignment of the optical axes and

readjust if necessary ‡ Repeat normalization

"Constant light signal too high"

"Constant light"

Direct sunlight or reflections on duct components

"Real-time clock" "Real-time clock" Real-time clock cannot be addressed Only with data memory/event memory option Control cycle cannot be triggered / measured values cannot be saved automatically

"Monitor signal too low"

"Monitor signal"

• The laser byte calculated during

Send the device back to the manufacturer for repair

‡ Check transmitter current ("Protocol" tab page,

normalization generates a defined "Factory settings" field) monitor signal The value must be between 45 mA and 100 mA (temperature dependent; permissible Laser byte 250 digit: 2.8 ... 4.4 V range: Laser byte 200 digit: 2.0 ... 4.4 V +20 ... +70 C) • Transmitter diode defective • Transmitter diode has been switched ‡ Send the device back to the manufacturer for repair off because temperature is too high

• Internal device temperature too high • Temperature sensor defective • Temperature sensor incorrectly

"Device "Temp. > 70 temperature > 75 grdC" °C"

calibrated

=> Laser is switched off until the temperature reaches < 70 °C

"No display communication"

Take appropriate measures (e.g. choose a different measuring site, or apply low-reflection paint)

Defective connection "Comm. failure Waiting for data"

Only if the LCD option is installed. No interrogation of Dig in1 to Dig in4 and no signaling of the 2nd limit value.

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‡ Check installation conditions ‡ Protect transmitter/receiver unit against

ambient or radiant heat (insulate) ‡ Check the temperature sensor (comparison measurement with separate sensor) ‡ Check the signal cable connections between the

transmitter/receiver unit and connection unit ‡ Check the LCD module connections in the connection unit ‡ Switch off power supply for approx. 5 s and switch back on again (PowerOn-Reset) ‡ Ensure that the LCD option is enabled in MEPAFW


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6.2.2

Warnings Since no malfunctions are present when warning messages are output, the "Operation" status is still displayed (the green LED on the rear of the housing lights up; the status indicator in MEPA-FW is green ("Operation")). Warnings are also displayed in MEPA-FW ( "Diagnosis/Test"; see Fig. 6.1 ) and on the LCD (if installed) in plain text (English).

Warning message MEPA-FW

Remedy

Displayed for information purposes when the "Test mode on" checkbox in the "Test output signals" field is active when the device is in "Maintenance" mode and the password has been set.

You have to deactivate the "Test mode on" checkbox before you exit the "Diagnosis/Test" tab page or MEPA-FW.

The real-time clock can be addressed, but does not display a date or time.

‡ Reset the clock (see section

LCD

"Test mode active"

"Reset real-time clock"

Possible cause

"Battery low"

Only with data memory/event memory option Only time differences can be measured; absolute times cannot be specified.

6.2.3

4.5.1 )

‡ Check the battery voltage; replace battery if

necessary (see section 7.1.5 ) ‡ If a warning is still present, send the device back to the manufacturer for repair

Other Malfunctions and Abnormal Behavior • Severely fluctuating measured values, transmission too low, or opacity/extinction/dust concentration too high (implausible) Corrective measures: – Check the normalization. – Check that the optical boundary surfaces are not excessively contaminated. – Check the alignment of the optical axes of the transmitter/receiver unit and reflector (possible thermal distortion or excessive vibrations); see Section 4.3. The reflector must be clearly visible from the direction of the transmitter/receiver unit and must not be partially or completely covered. – If you are using a rotating reflector, check whether the motor rotates (open the cover of the reflector housing). – Check the flange pipes for deposits in the beam path (remove any deposits). – Ensure that the beam path is unobstructed. Fittings or objects must not be installed in the beam path inside the duct. – Check optical boundary surfaces for internal damage or contamination. – Ensure that fittings on the transmitter/receiver unit (optics holder, LP processor) and the rotating reflector are secure and undamaged. The disk springs for adjusting the optics holder in the transmitter/receiver unit must have sufficient pre-loading strength.

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• Check values generated during the check cycle are not output via the analog output or are outside tolerance ( ± 2 %). Corrective measures: – Check the device status. Malfunction messages (see Section 6.2.1;): in "Maintenance" mode, "Live Zero" is output constantly. – Check whether the check value output via the analog output has been deactivated (MEPA-FW: "Parameters" tab page). – Start the check cycle manually and ensure that it runs correctly ("Maintenance" mode must not be active). Switch off power supply for approx. 5 s and switch back on again (PowerOn-Reset); a check cycle must be triggered after one minute.

• Temporary contamination on optical boundary surfaces Corrective measures: – Check the purge-air supply (replace filter if necessary); check the hoses for damage or leakage (replace hoses if necessary). – Check the rubber sealing strip on the transmitter/receiver unit and reflector. – Check the clamps on the transmitter/receiver unit and reflector to ensure that they are sufficiently and equally secure. – Check the duct pressure for fluctuations or surges. – Check whether the fan power is sufficient (use a more powerful fan if necessary). – If only one component is contaminated (transmitter/receiver unit or reflector), check the purge-air distribution. The purge-air volume for the reflector must be greater than that for the transmitter/ receiver unit (see Section 3.3.5 ). – If you have installed an external purge-air unit, ensure that a constant purge-air supply is available. Use a fail-safe power supply and ensure tha t the motor contactor setting is not too fine (see Section 3.3.3 ). – If the filters are heavily contaminated for a temporary period, choose a different intake location (see Section 3.2.3 ) or install additional prefilters. – Check the inside of the purge-air hoses for contamination or deposits. Clean or replace them if necessary, and establish the cause of the contamination or deposits. If very fine dust is penetrating the filter, install additional fine filters (with a more powerful fan if necessary).

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6.3 Test and Diagnosis Options You can call up the "Diagnosis/Test" tab page in MEPA-FW to check that the analog output, relay outputs, digital inputs, and LCD are functioning properly (see Fig. 6.2 ). To do so, the device must be connected to MEPA-FW via a laptop or PC, password level 1 must be set, and the device must be set to "Maintenance" mode.

Fig. 6.2: "Diagnosis/Test" tab page

6.3.1

Testing the Signal Output After you have activated the "Test mode on" checkbox in the "Test output signals" field, you can check whether the analog output and relay outputs are functioning correctly by entering an analog value and setting the radio button for the relays to "ON" or "OFF". To start the test, click the "Write to device" button.

Important You have to deactivate test mode again before you exit the "Diagnosis/Test" tab page, otherwise the measurement cannot be carried out properly. ATTENTION

6.3.2

Check Cycle Click the "Check-point verification" button to check the check values (zero and span). Do not activate the "Test mode on" checkbox. The following message is outpu t if the check was successful: Zero point OK Check point deviation < 2 % Acknowledge the message by clicking "OK".

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6.3.3

Linearity Check To ensure that the device functions properly, you are advised to check the linearity of the transmission measurement at regular intervals (e.g. during the annual functional check) to ensure that the other measured variables are accurate. The linearity test equipment can be used here. This equipment has been specially designed for the FW300. It comprises an adapter for integrating special transmission filters an d a filter set with different transmission values. For a description of the individual steps that have to be carried out in a linearity test, see the accompanying operating instructions. If you are using other options, you must ensure that the optical axes of the transmitter/ receiver unit and reflector are exactly aligned with each other, and transmission filters installed in the beam path allow the beam to pass through twice.

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Troubleshooting



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Repairs

Transmitter/Receiver Unit Rotating Reflector Connection Unit

Repairs



7

Repairs Any repair work on the FW300 is limited to replacing the system components listed under the spare parts (see Secction 8.4 ) (e.g. LP processor, housing, fan, power supply unit). Individual modules can only be repaired at the manufacturer.

Note

Repairs that are not authorized by the manufacturer may render existing warranty claims invalid.

Required tools: • Socket wrenches: w/s 7 and w/s 13 • Spanner: w/s 7 • Hexagon socket screw key: w/s 3 • Small and medium-sized recessed-head screwdriver • Medium-sized flat screwdriver (for approx. 5 mm slot length) • Medium-sized flat screwdriver (for approx. 3 mm slot length) • Screwdriver TORX 20

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7.1 Transmitter/Receiver Unit 7.1.1 The new LP processor must be compatible with the transmitter/receiver unit type (see Section 8.1.1, 8.2.1, and 8.4.1 ).

Replacing the LP Processor ‡

Unplug the connection cable to the connection unit from the connector on the bottom of the housing.

‡

Loosen the screws for securing the housing cover and remove the cover.

‡

Loosen the self-locking nuts (see Fig. 7.1 ) and carefully raise the board.

‡

Remove the socket connectors with the ribbon cable from the connectors on the underside of the board and remove the LP processor.

‡

Reassemble the transmitter/receiver unit with the new LP processor by following the above steps in reverse order (connect the socket connectors with th e ribbon cable, insert and screw on the LP processor, and then replace the cover).

‡

Reconnect the connection cable to the connection unit.

Processor board Self-locking nuts

Ribbon cable +24 V test point Connection cable Fig. 7.1: FW300 transmission/receiver unit (opened)

Note

You may have to refocus the transmitter light beam (see 4.2.2 ).

7.1.2

Replacing the Optics Holder with Receiver Electronics

Spare part for FW310SE: optics holder with receiver electronics for FW310SE (order no. 7040430)

‡

Remove the LP processor as described above.

‡

Unscrew the spacer pin (see Fig. 7.2 ) and remove the optics holder with electronics.

‡

Insert the new module and re-assemble the transmitter/receiver unit by carrying out the above steps in reverse order.

Spare part for FW320SE: optics holder with receiver electronics for FW320SE (order no. 7040431)

‡


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Repairs



Spacer pin

Socket connector with ribbon cable Optics holder with receiver electronics Spacer pin

Connector T/R unit (assembly)

Contact plate

Fig. 7.2: FW300 transmitter/receiver unit without LP processor

Notes

When removing the optics holder with the receiver electronics, you must ensure that the disk springs and spacer remain attached to the spacer bolts. If these parts fall out, however, push the spacer onto the spacer bolt and then reattach the disk springs in pairs (6 pairs; arrangement as in Fig. 3.11 for installing the device attachment). After the component has been replaced, the optical axis may have shifted due to a different pre-loading strength of the disk springs. Correct this as described in Section 4.3. This can also be corrected by opening the housing cover and tightening the spacer pins in the transmitter/receiver unit to different degrees (see Fig. 4.7 ).

7.1.3 Spare part: T/R unit connector (assembly) (order no. 7040432)

Replacing the Entire T/R Unit Connector ‡

Loosen the spacer pin (see Fig. 7.2 ) and remove the LP processor with the optics holder with receiver electronics.

‡

Loosen the screws for securing the connector on the underside of the housing.

‡

Loosen the nuts for securing the contact plate and remove them together with the washers and spring washers.

‡

Remove the board with the connector and ribbon cable from the housing.

‡

Remove the contact plate and seal (on hous ing interior) and replace them with new ones (supplied with the module).

‡

Insert the new board with connector and re-assemble the transmitter/receiver unit by carrying out the above steps in reverse order.

‡


Note

When removing the modules, ensure you do not damage the disk springs and spacers (if necessary, reinsert them as described in Section 7.1.2 ).

7.1.4

Replacing the FW300SE Housing

Spare part: FW300SE housing without optics holder or receiver electronics (order no. 7040432)

To replace damaged housing or glass on the transmitter/receiver unit, remove the LP processor and optics holder with the receiver electronics as described in Section 7.1.1 and 7.1.2 from the old housing and install them in the new FW300SE housing.

Note

The transmitter/receiver unit connector (assembly) is supplied in the spare parts module for the FW300SE housing without the optics holder or receiver electronics.

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7.1.5

Checking / Replacing the Battery for the Transmitter/Receiver Unit The battery is soldered onto the rear of the LP processor in the transmitter/receiver unit. The rated voltage is 3 to 3.3 V. The service life depends on the operation duration of the transmitter/receiver unit (constant use: more than 5 years; occasional use: 1 - 2 years).

Voltage check ‡


‡

Remove the housing cover of the transmitter/receiver unit.

‡

Connect the digital multimeter to the positions marked + and - in Fig. 7.3 and measure the voltage.

Battery (soldered onto the rear)

+

_


Processor board

Fig. 7.3: Battery for the data memory/event memory

If the voltage is less than 2.2 V, the battery must be replaced with battery type BR 2032 V (vertical installation, capacity: 190 mAh) (can be supplied by SICK on request).

Replacing the battery

96

©

‡

Save stored measured values and events to a file (see Section 4.5.1 ).

‡

Remove the LP processor as described in Section 7.1.1.

‡

Unsolder the battery (see Fig. 7.3 ).

‡

Solder the new battery on.

‡

Reassemble the transmitter/receiver unit and connect the connection cable to the connection unit.

‡

Delete the data memory/event memory (see Section 4.5.1 ).

‡

Set the real-time clock as described in Section 4.5.1.


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Repairs



7.2 Rotating Reflector 7.2.1 Spare part for FW-R-055-D: reflector D55 (order no. 7040838)

Spare part for FW-R-105-D: reflector D105 (order no. 7040272)

Replacing the Reflector ‡


‡

Loosen the screws for securing the housing cover and remove the cover.

‡

Disconnect the wires from the terminal block (push the terminal with a small screwdriver and pull the wire out); see.

‡

Loosen the securing bolts with the TORX screwdriver (see Fig. 7.4 ) and remove the reflector.

‡

Reassemble the rotating reflector by following the above steps in reverse order (insert the reflector, connect the wires, and replace the cover).

‡


Securing bolts

Red Blue Wires

Fig. 7.4: Rotating reflector, opened (type: FW-R-055-D)

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7.2.2

Replacing the Front Window with the Holder

Spare part for FW-R-055-D: holder D55 (order no. 7040814)

‡

Remove the reflector as described in the previous section.

‡

Loosen the securing bolts (see Fig. 7.5 ) and remove the holder with the window from the reflector housing.

Spare part for FW-R-105-D: holder D105 (order no. 7040276)

‡

Secure the new holder onto the housing and re-assemble the rotating reflector by carrying out the above steps in reverse order.

‡


Securing bolts Holder with window (on the outside of the housing)

Fig. 7.5: Rotating reflector, opened (type: FW-R-055-D), without reflector

7.2.3 Spare part for FW-R-055-D: housing D55 installed (order no. 7040813)

Replacing the Housing for the Rotating Reflector To replace damaged housing, remove the reflector (D55 or D105) and holder (D55 or D105) from the old housing (as described in Section 7.2.1 and 7.2.2 ) and install them in the new housing.

Spare part for FW-R-105-D: housing D105 installed (order no. 7040277)

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Repairs



7.3 Connection Unit Important

ATTENTION

7.3.1

‡

You must disconnect the connection unit from the power supply before carrying out repairs!

‡

When carrying out repairs on a connection unit with an integrated purge-air supply, you must remove the transmitter/receiver unit and reflector from the duct for the duration of the repair work.

Connection Unit Without Purge-Air Supply Replacing the fuse ‡

Open the cover of the connection unit.

‡

Fold out the fuse holder and open the cover (see Fig. 7.6 ).

‡

Remove the defective fuse and install the new one.

‡

Close and secure the fuse holder.

‡

Close the cover and reconnect the power supply.

Fuse holder Spare fuse

Cover





Fig. 7.6: Replacing the fuse

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Repairs



Replacing the power supply unit Spare part: 24 V 60 W power supply unit (order no. 7047557)

‡


‡

Loosen the lock nuts for the mounting bracket (1) (see Fig. 7.7 ).

‡

Loosen the conduit thread connections and push the connection cable a small distance into the connection unit.

‡

Remove the mounting bracket with the power supply unit and disconnect the wires.

‡

Loosen the securing bolts for the power supply unit (2). Power supply unit

 

Mounting bracket

 Fig. 7.7: Mounting bracket with power supply unit ‡

Loosen the retaining bolt or nut (3) and remove the power supply unit.





Mounting bracket

Fig. 7.8: The mounting bracket and power supply unit have been removed from the connection unit ‡

Insert and connect (see Fig. 7.9 ) the new power supply unit, and reassemble the connection unit by carrying out the above steps in reverse order.

‡

Close the cover and connect the power supply.

Brown

Red

Blue

Blue

Fig. 7.9: Terminal assignment

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Repairs



7.3.2

Connection Unit with Integrated Purge-Air Supply

Notes

• The fuse is replaced as described in Section 7.3.1. • The filter is replaced as described in Section 5.3.1 (order no. 7047560). Replacing the power supply unit

Spare part: 24 V 60 W power supply unit (order no. 7047557)

‡


‡

If the LCD is installed, loosen the lock nuts of the I/O board (1) and fold out the board (see Fig. 7.10 ).

‡

Loosen the securing bolts for the power supply unit (2).

‡

Loosen the securing bolts for the mounting plate (3).

‡

Loosen the conduit threads and push the connection cable a small distance into the connection unit.

‡

Fold out the mounting plate and disconnect the wires.

‡

Loosen the retaining bolts (4) (see Fig. 7.11 ) and remove the power supply unit.

‡

Insert and connect the new power supply unit (see Fig. 7.11 ) and reassemble the connection unit by carrying out the above steps in reverse order.

‡

Close the cover and connect the power supply. 



Fuse holder

Mounting plate













 



I/O board

Fig. 7.10: Mounting plate with I/O board Power supply



Mounting plate

Re Blue Yellow/

Blue



Black

Fig. 7.11: Power supply unit with mounting plate (rear)

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Repairs

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Replacing the Fan Spare part: Fan, Order no. 7047042

‡

Disassemble the filter housing (see Section 5.3.1 )

‡

Remove the fan connector and protective conductor (see Fig. 7.12 )

‡

Loosen the securing bolts.

‡

Remove the clamping tape and disconnect the purge-air hose.

Connector

Securing bolts

Fan

Protective conductor Purge-air hose Fig. 7.12: Fan in the connection unit with an integrated purge-air supply ‡

Take out the fan and remove the con nection plate with the seal from the purge-air outlet (see Fig. 7.13 ).

‡

Install and connect the new fan by carrying out the above steps in reverse order.

Important Do not forget the connection for the protective conductor. ATTENTION

‡

Install and connect the filter housing.

‡


Protective conductor connection Purge-air outlet Connection plate Seal

Fig. 7.13: Fan purge-air outlet

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Repairs


Replacing the LCD module Spare part: LCD module order no. 7040434

‡


‡

Remove the connector on the LCD module (see Fig. 7.14 ).

‡

Loosen the lock nuts on the LCD and remove the module.

‡

Install, secure, and connect the new module.

‡


LCD module Connector

Lock nut Fig. 7.14: LCD module

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FW300

Repairs



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Parts Overview

Standard Components Options Consumable Parts for 2-Year Operation Spare Parts

Parts Overview



8

Parts Overview 8.1 Standard Components The standard components required for a complete measuring system depend on the measuring distance and the internal duct pressure. The following table displays the possible combinations and the quantities required:

Meas. distance [m]

0.5 - 2

1.5 - 8

6 - 15

Transmitter/ receiver unit

Reflector

Device attachment

1 x FW310SE XXX-XX

1 x FW-R055-F-000

1 x FW-V-030P-000 1 x FW-V-055P-000

1 x FW320SE XXX-XX

1 x FW-R055-D-000

1 x FW-V-030P-000 1 x FW-V-055P-000

1 x FW320SE XXX-XX

1 x FW-R105-D-000

1 x FW-V-030P-000 1 x FW-V-105P-000

Flange with pipe

Connection unit External Purge-air purge-air hose unit (optional)

Power supply cable for rotating reflector

AK1-P-XXXX-X-X

-

x2

-

AK1-N-XXXX-X-X

x1

x1

-

AK1-P-XXXX-X-X

-

x2

x1

AK1-N-XXXX-X-X

x1

x1

x1

1 x D100

AK1-P-XXXX-X-X

-

x2

x1

1 x D160

AK1-N-XXXX-X-X

x1

x1

x1

2 x D100

2 x D100

The different versions are listed in the followi ng sections. They are defined by abbreviations in accordance with the type code (see 2.3 ).

8.1.1

Transmitter/Receiver Units Name

8.1.2

Order number

Transmitter/receiver unit FW310SE-NNN-00 Measuring distance: 0.5 m - 2 m

7040370

Transmitter/receiver unit FW320SE-NNN-00 Measuring distance: 1.5 m – 15 m

7040300

Reflectors Name

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Order number

Reflector FW-R-055-F-000 Measuring distance: 0.5 m - 2 m

7040334

Reflector FW-R-055-D-000 Measuring distance: 1.5 m - 8 m

7040331

Reflector FW-R-105-D-000 Measuring distance: 6 m - 15 m

7040332

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Parts Overview

FW300



8.1.3

Device Attachments Name

8.1.4

Order number

Device attachment FW-V-030-P-000 With purge-air nozzle, for transmitter/receiver unit

7040340

Device attachment FW-V-055-P-000 With purge-air nozzle, for reflectors FW-R-055-F-000 and FW-R-055-D-000

7040341

Device attachment FW-V-105-P-000 With purge-air nozzle, for reflector FW-R-105-D-000

7040342

Flanges with Pipe Name

Order number

D100

Flanges with pipe, diameter = 70.2, length = 130 mm, St37

2017845


2017847


2017849

Flanges with pipe, diameter = 70.2, length = 130 mm, V4A

2017846


2017848


2017850

D160

8.1.5

Flanges with pipe, DN 108, length = 100 mm, St37

7040128

Flanges with pipe, DN 108, length = 200 mm, St37

7040137

Flanges with pipe, DN 108, length = 100 mm, V4A

7040138

Flanges with pipe, DN 108, length = 200 mm, V4A

7040139

Connection Units Operating voltage: 90 ... 260 V AC, 47 ... 63 Hz Name

8.1.6

Connection unit AK1-N-03WR-N-0 Without purge-air supply, signal cable length = 3 m

7040350

Connection unit AK1-N-10WR-N-0 Without purge-air supply, signal cable length = 10 m

7040351

Connection unit AK1-P-03WR-N-0 With integrated purge-air supply, signal cable length = 3 m

7040358

Connection unit AK1-P-10WR-N-0 With integrated purge-air supply, signal cable length = 10 m

7040359

External Purge-Air Units (optional) Name

108

Order number

Order number

Purge-air unit SLV4-21112 With fan 2BH13, 3ph and purge-air hose (length = 10 m)

1012409

Purge-air unit SLV4-21111 With fan 2BH13, 3ph and purge-air hose (length = 5 m)

1012424

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Parts Overview



8.1.7

Purge-Air Hoses Name

8.1.8

Order number

Purge-air hose D40/46, length = 3 m

7040396


4022766


7040397


7040398

Power Supply Cables for the Rotating Reflectors Name

8.1.9

Order number

2-core cable, length = 3 m

7040399


7040400


7040401


7040402

Miscellaneous Name

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Order number

Flange/analyzer installation set

2018183

Flange/reflector installation set

2018184

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Parts Overview



8.2 Options 8.2.1

Transmitter/Receiver Units Name

Order number

Measuring distance: 0.5 m - 2 m

Transmitter/receiver unit FW310SE-NND-00

7040371

Transmitter/receiver unit FW310SE-MNN-00

7040372

Transmitter/receiver unit FW310SE-MND-00

7040373

Transmitter/receiver unit FW310SE-NAN-00

7040374

Transmitter/receiver unit FW310SE-NAD-00

7040375

Transmitter/receiver unit FW310SE-MAN-00

7040376

Transmitter/receiver unit FW310SE-MAD-00

7040377

Transmitter/receiver unit FW310SE-NCN-00

7040378

Transmitter/receiver unit FW310SE-NCD-00

7040379

Transmitter/receiver unit FW310SE-MCN-00

7040380

Transmitter/receiver unit FW310SE-MCD-00

7040381

Measuring distance: 1.5 m -15 m

8.2.2

Transmitter/receiver unit FW320SE-NND-00

7040301

Transmitter/receiver unit FW320SE-MNN-00

7040302

Transmitter/receiver unit FW320SE-MND-00

7040303

Transmitter/receiver unit FW320SE-NAN-00

7040304

Transmitter/receiver unit FW320SE-NAD-00

7040305

Transmitter/receiver unit FW320SE-MAN-00

7040306

Transmitter/receiver unit FW320SE-MAD-00

7040307

Transmitter/receiver unit FW320SE-NCN-00

7040308

Transmitter/receiver unit FW320SE-NCD-00

7040309

Transmitter/receiver unit FW320SE-MCN-00

7040310

Transmitter/receiver unit FW320SE-MCD-00

7040311

Connection Units Operating voltage: 90 ... 260 V AC, 47 ... 63 Hz Name

Order number

Without purge-air supply

Connection unit AK1-N-03WR-D-0 With LCD, signal cable length = 3 m

7040354

Connection unit AK1-N-10WR-D-0 With LCD, signal cable length = 10 m

7040355

With integrated purge-air supply

110

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Connection unit AK1-P-03WR-D-0 With LCD, signal cable length = 3 m

7040362

Connection unit AK1-P-10WR-D-0 With LCD, signal cable length = 10 m

7040363


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Parts Overview



Operating voltage 24 V DC Name

Order number

Without purge-air supply

Connection unit AK1-N-0302-N-0 Without options, signal cable length = 3 m

7040352

Connection unit AK1-N-1002-N-0 Without options, signal cable length = 10 m

7040353

Connection unit AK1-N-0302-D-0 With LCD, signal cable length = 3 m

7040356

Connection unit AK1-N-1002-D-0 With LCD, signal cable length = 10 m

7040357

With integrated purge-air supply

8.2.3

Connection unit AK1-P-0302-N-0 Without options, signal cable length = 3 m

7040360

Connection unit AK1-P-1002-N-0 Without options, signal cable length = 10 m

7040361

Connection unit AK1-P-0302-D-0 With LCD, signal cable length = 3 m

7040364

Connection unit AK1-P-1002-D-0 With LCD, signal cable length = 10 m

7040365

Device Attachments Name

8.2.4

Order number

Device attachment FW-V-030-N-000 Without purge-air nozzle, for transmitter/receiver unit

7040343

Device attachment FW-V-055-N-000 Without purge-air nozzle, for reflector FW-R-055-F-000

7040344

Device attachment FW-V-055-N-H00 Without purge-air nozzle, with heating, for reflector FW-R-055-D-000

7040345

Purge-air Connection Name

8.2.5

Order number

Purge-air aperture

7040403

Purge-air distributor

7041075

Weatherproof Covers Name

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Order number

Weatherproof cover for analyzer

2702407

Weatherproof cover for rotating reflector FW-R-105-D-000

2021457

Weatherproof cover for housing FWSE/FWR-D

7040394

Weatherproof cover for purge-air unit

5306108

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Parts Overview

FW300



8.2.6

Optional Components for Monitoring Air in Workshops Name

8.2.7

Order number

Light/dust protection tube

7041168

Bracket for light/dust protection tube

7040233

Optional Components for Higher Internal Duct Pressures Name

Order number

Internal duct pressures up to +6 bar

Weld-on flange DN50 PN16 ST37

7040278

Ball valve DN50 PN16

7040281

Purge-air attachment PN60

7040282

Pressure reducer with filter

7040283

Weatherproof cover

7040284

Internal duct pressures up to +30 bar

High-pressure attachment

8.2.8

Accessories for Testing the Device Name

8.2.9

Order number

Linearity test equipment

7040404

Adjustment bracket for normalization (small)

7040131

Adjustment bracket for normalization (large)

7040156

Miscellaneous Name

112

7040212

Order number

Evaluation unit for connecting max. 3 x FW100/FW300

7047540

Interface cable (for connecting the evaluation unit to a laptop/PC)

7040012

Optical alignment device for mounting the flange

1700462

Adjustment tool for aligning the light/dust protection tube

7040395

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Parts Overview



8.3 Consumable Parts for 2-Year Operation 8.3.1

Connection Unit with Internal Purge-Air Supply Name

8.3.2

Quantity

Order number

Filter insert C1140

4

7047560

Optic cleaning cloth

4

4003353

Quantity

Order number

Filter insert Micro-Topelement C11 100

4

5306091

Optic cleaning cloth

4

4003353

External Purge-Air Unit (Optional) Name

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Parts Overview

FW300



8.4 Spare Parts 8.4.1

Transmitter/Receiver Unit Name

Order number

T/R unit connector (assembly)

7040432

Housing FW300SE (without optics holder or receiver electronics)

7040433

FW310SE

LP processor FW310SE-NNN (without options)

7040407

LP processor FW310SE-MNN (with data memory/event memory)

7040408

LP processor FW310SE-NAN (with 2nd analog output)

7040409

LP processor FW310SE-NCN (with CAN module)

7040410

LP processor FW310SE-MAN (with data memory/event memory and 2nd analog output)

7040411

LP processor FW310SE-MCN (with data memory/event memory and CAN module)

7040412

LP processor FW310SE-NND (with display activation)

7040413

LP processor FW310SE-MND(with data memory/event memory and display activation)

7040414

LP processor FW310SE-NAD (with 2nd analog output and display activation)

7040415

LP processor FW310SE-NCD (with CAN module and display activation)

7040416

LP processor FW310SE-MAD (with data memory/event memory, 2nd analog output and display activation)

7040417

LP processor FW310SE-MCD (with data memory/event memory, CAN module and display activation)

7040418

Optics holder with receiver electronics (for FW310SE )

7040430

FW320SE

114

LP processor FW320SE-NNN (without options)

7040818

LP processor FW320SE-MNN (with data memory/event memory)

7040419

LP processor FW320SE-NAN (with 2nd analog output)

7040420

LP processor FW320SE-NCN (with CAN module)

7040421

LP processor FW320SE-MAN (with data memory/event memory and 2nd analog output)

7040422

LP processor FW320SE-MCN (with data memory/event memory and CAN module)

7040423

LP processor FW320SE-NND (with display activation)

7040424

LP processor FW320SE-MND(with data memory/event memory and display activation)

7040425

LP processor FW320SE-NAD (with 2nd analog output and display activation)

7040426

LP processor FW320SE-NCD (with CAN module and display activation)

7040427

LP processor FW320SE-MAD (with data memory/event memory, 2nd analog output and display activation)

7040428

LP processor FW320SE-MCD (with data memory/event memory, CAN module and display activation)

7040429

Optics holder with receiver electronics (for FW320SE )

7040431

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Parts Overview



8.4.2

Reflector Name

8.4. 8.4.3 3

Order number

Reflector FW-R-055-F-000

70 40 334

Reflector D55

7 0 4 08 38

Reflector D105

7 04 0 2 72

Holder D55

704 0 8 14

Holder D105

70 40 276

Housing D55 installed

7 04 081 3

Housing D105 installed

7 04 02 77

Devi Device ce Atta Attach chme ment nt Name

8.4.4 .4.4

Order number

Louvre insert D30 (for FW-V-030-X-XXX)

7 040 34 6


7 041 02 8


7 041 03 2

Conn Connec ecti tion on Unit Unit Name

8.4.5 .4.5

Order number

24 V 60 W power supply unit

7 04 75 57

Fan (for AK1-P-XXXX-X-XX)

7 04 70 42

Filter insert (for AK1-P-XXXX-X-XX)

70 475 60

LCD module

70 40 434

Mis Miscell cellan aneo eous us Name

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Order number


7 0 403 96


4 0 227 66


70 403 97


70 403 98

Flange/analyzer installation set

20 181 83

Flange/reflector installation set

20 1 81 84

Filter insert Micro-Topelement C11 100

5 30 609 1

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FW300

Parts Overview



116

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Appendix

Standard Settings for the FW300 Password


Appendix


9

Appendix 9.1 Standard Settings for the FW300

Parameter protocol

31 Aug 2004

13:17:46

------------------------------------------------------------------------------ Productinformation ------------------------------------------------------------------------------Type FW310 Firmware 03031115 Compilation date May 12 2003 Serialnumber 03158727 Option memory measurement value Option analog output 2 Option CAN-Bus Device adress Option display ------------------------------------------------------------------------------Parameter and measured value ------------------------------------------------------------------------------Measure value Transmission Coefficients square/lin./abs. - / - / Response time 30.0 sec Limit value 80.0 % Limit value 2 % Live Zero 4 mA Range LiveZero...20 mA 30.0 ... 100.0 % Range2 LiveZero...20 mA % Save interval sec Check cycle enable Check cycle interval 02:00 hh:mm Analog output checkpoints enable Relay 2 used for Limit value Laser current 74.21 mA Distance s/r unit-reflector 800 mm ------------------------------------------------------------------------------Factory settings ------------------------------------------------------------------------------Offset 0 0.040 Burstfrequency 10000 Hz Number of impulses per Burst 50 Burstcycle 20 msec Calibration analog output 1 5 Calibration analog output 2 Statuscode 00000200

Fig. 9.1: Standard settings for the FW300 (on delivery)

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Appendix

FW300



9.2 Password

Passwort „Autorisierter Nutzer“ Nach dem Start des menügeführten Parametrierprogrammes MEPA-FW sind nur die Programmfunktionen verfügbar, die keinen Einfluss auf die Gerätefunktion haben. Nicht eingewiesenes Personal kann keine Änderungen der Parameter vornehmen. Zur Nutzung des erweiterten Funktionsumfanges wird das Passwort

SICKOPTIC

benötigt.

Falls zur Eingabe eine falsche Taste gedrückt wird, muss das Fenster geschlossen und anschließend die Passworteingabe wiederholt werden.

High level password After the start of the MEPA-FW parameterization program, the only menus available are those which have no effect on the functioning of the device. Untrained personnel cannot alter the device parameters. To access the extended range of functions the High level password

SICKOPTIC

must be entered

If a wrong key is pressed when entering the password, the window must be closed and then the password repeated.

Fig. 9.2: MEPA-FW password

The password is provided with the FW300 on delivery.

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1 FW300 Dust Concentration Monitor Operating Instruction

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