SICK DUSTHUNTER SP100 Operating Instructions Manual Download

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MMMI

MMMOPERATING INSTRUCTIONS

O P E R A T I N G I N S T R U C T I O N S

DUSTHUNTER SP100

Dust Concentration Monitor

Installation, Operation, Maintenance

Title Page

Summary of Contents for DUSTHUNTER SP100

Page 1: ...MMMI MMMOPERATING INSTRUCTIONS OPERATI NG INSTRUCTIO NS DUSTHUNTER SP100 Dust Concentration Monitor Installation Operation Maintenance Title Page...

Page 2: ...s and are only used for identification purposes Legal Information This document is protected by copyright Any rights derived from the copyright shall be reserved for SICK AG Reproduction of this docum...

Page 3: ...1 4 2 Safety information and protective measures 9 2 Product Description 11 2 1 Measuring principle measured variables 11 2 1 1 Functional principle 11 2 1 2 Response time 12 2 1 3 Function check 13 2...

Page 4: ...3 3 Purging with instrument air 45 3 3 3 4 Installing the non return valve option 46 3 3 4 Connecting the MCU control unit 47 3 3 4 1 Work to be done 47 3 3 4 2 MCU processor board connections 48 3 3...

Page 5: ...rating setting parameters via the optional LC Display 75 4 5 1 General information on use 75 4 5 2 Password and operating levels 75 4 5 3 Menu structure 76 4 5 4 Configuration 76 4 5 4 1 MCU 76 4 5 4...

Page 6: ...3 MCU control unit 103 7 3 4 Optional external purge air unit 105 7 3 5 Weatherproof covers 106 7 4 Accessories 107 7 4 1 Line sender receiver unit MCU 107 7 4 2 Purge air supply 107 7 4 3 Assembly p...

Page 7: ...tion which will result in severe personal injury or death WARNING Risk or hazardous situation which could result in severe personal injury or death CAUTION Hazard or unsafe practice which could result...

Page 8: ...r bears no responsibility for any other use Observe all measures necessary for conservation of value e g for maintenance and inspection and or transport and storage Do not remove add or modify any com...

Page 9: ...owner of the measuring system 1 4 2 Safety information and protective measures Protection devices Behavior during purge air failure The purge air supply serves to protect optical subassemblies fitted...

Page 10: ...ing damage Electrical connection Ensure the device can be switched off with a power isolating switch circuit breaker in accordance with EN 61010 1 NOTE In order to avoid malfunctions that can cause di...

Page 11: ...ough the intersection of the sender beam sent and the receive aperture Continuous monitoring of the sender output registers the smallest changes in brightness of the light beam sent which then serves...

Page 12: ...ter a sudden change in the measurement signal It can be set anywhere between 1 and 600 s As the response time increases transient measured value fluctuations and interruptions are damped stronger and...

Page 13: ...urther information Service Manual Contamination degree Live Zero 0 20 mA 40 Function check start Zero value output Live Zero Control value output 70 value span Contamination output Control value deter...

Page 14: ...greater than 2 The error message is cleared again when the next function check runs successfully The control value is deter mined with high precision through statistical evaluation of a high number of...

Page 15: ...terface With integrated purge air supply for internal duct pressure 50 10 hPa Without purge air supply therefore additionally required Optional external purge air unit for internal duct pressure 50 30...

Page 16: ...he electronics unit is in a pressure proof enclosure Measuring probe The measuring probe is available in different versions and nominal lengths as well as for various gas temperature ranges and define...

Page 17: ...C in version for internal duct pressure up to 200 kPa Probe material V Stainless steel H Hastelloy M Hastelloy probe stainless steel protective tube S SS HS probe SS Da88 protective tube C Stainless...

Page 18: ...Probe head with receiver optics Measuring opening Purge air connection Connection for connection cable to MCU Handle Adjustment opening Laser module Cleaning opening for sender optics NL 485 mm Max 4...

Page 19: ...notice PRODUCT DESCRIPTION 2 Fig 7 Sender receiver unit DHSP T2V11NNXX for internal duct pressure up to 200 kPa Electronics unit Protective tube Cleaning opening for sender optics Flange with tube Pr...

Page 20: ...sions see Flange with tube page 102 Selection depends on the wall and isolation thickness of the duct wall nominal length and the duct material Fig 8 Flange with tube TOP Material St 37 or 1 4571 NL G...

Page 21: ...dly operating program The parameters are stored reliably even in the case of a power failure Control unit MCU has a sheet steel enclosure as standard 2 2 3 1 Standard interfaces Analog output Analog i...

Page 22: ...RIPTION 2 2 3 2 Versions Control unit MCU N without purge air supply Fig 9 Control unit MCU N with options DISPLAYMODUL relay 3 relay 4 relay 5 BUS Term Term relay 1 relay 2 com nc no com nc no com nc...

Page 23: ...urge air connection to connect the purge air hose to the sender receiver unit Fig 10 Control unit MCU P with integrated purge air supply The purge air hose standard lengths 5 and 10 m see Purge air su...

Page 24: ...y module D With Other options N Without Analog input option plug in module 0 4 20 mA 2 inputs per module 0 Without n With n 1 Analog output option plug in module 0 4 20 mA 2 outputs per module n With...

Page 25: ...er unit can be displayed toggle with Meas button Fig 11 LC LC Display with graphic left and text right display b Control buttons Type Display LED Power green Voltage supply OK Failure red Function fau...

Page 26: ...s is required for this option 2 Interface module Module to pass on measured values system status and service information to higher level control systems optionally for Profibus DP V0 Modbus TCP or Eth...

Page 27: ...Optional external purge air unit page 105 It has a powerful blower and can be used for excess pressure in the duct up to 30 hPa The scope of delivery includes a purge air hose with 40 mm nominal diam...

Page 28: ...measuring system order separately are Purge air hose with 25 mm nominal diameter for purge air supply to the sender receiver unit from the MCU P control unit Purge air reduction see Optional external...

Page 29: ...he sender receiver unit see Installation of non return valve page 46 2 2 8 Test equipment for linearity test A linearity test can serve to check the correct measurement function see Service Manual In...

Page 30: ...orrosive DHSP T2H3xNNXX 400 Non corrosive low corrosion DHSP T4V3xNNXX Corrosive DHSP T4H3xNNXX 700 1020 1335 1200 220 Non corrosive low corrosion DHSP T2V4xNNXX Corrosive DHSP T2H4xNNXX 400 Non corro...

Page 31: ...air reduction MCU N 50 100 Adapter for instrument air 1 1 Instrument air onsite free of dust oil moisture non corrosive 800 2000 Non return valve 2 for instrument air connection 1 2 Part of sender re...

Page 32: ...sy operation and configuration of the DUSTHUNTER SOPAS ET runs on a laptop PC connected to the DUSTHUNTER via a USB line or Ethernet interface option The menu structure simplifies changing settings Fu...

Page 33: ...and safely accessible Provide platforms or pedestals as required Installation free of vibra tions Acceleration 1 g Eliminate reduce vibrations through suitable measures Ambient conditions Limit values...

Page 34: ...DUSTHUNTER SP100 Subject to change without notice 3 ASSEMBLY AND INSTALLATION Plan the volt age supply Operating voltage power requirements According to Technical Data see Technical Data page 98 Plan...

Page 35: ...s higher internal duct pressure when the equipment is at a standstill Take suitable protection measures against possible local hazards or hazards arising from the equipment All dimensions specified in...

Page 36: ...itable openings in the duct wall bore large enough holes in brick or concrete stacks flange tube diameter Insert the flange with tube in the opening slanting slightly downwards 1 to 3 so that the Top...

Page 37: ...a take possible radiant heat into consideration shield when necessary Protect against direct sunlight Whenever possible choose an assembly location with minimum vibrations dampen any vibrations when n...

Page 38: ...r causes It is advantageous to provide weather protection tin roof or similar to be made onsite for use outdoors Requirements when using the MCU P control unit The following is applicable in addition...

Page 39: ...echnical Data page 98 In unfavorable conditions lay an air intake hose or pipe to a location with better conditions The fitting location must be easily accessible and meet all safety regulations Insta...

Page 40: ...imensions dimensions in mm page 40 Fasten purge air unit with 4 M8 screws Check whether the filter element is fitted in the filter housing otherwise fit when necessary Fig 17 Purge air unit layout and...

Page 41: ...and screw tight see Fitting the weatherproof cover for analyzer dimensions in mm page 41 Put the cover 1 on from above Insert the side holding catches 3 into the counterpieces twist and lock in Fig 18...

Page 42: ...off using a power isolating switch circuit breaker in accordance with DIN EN 61010 Make sure the power isolating switch is easily accessible An additional disconnecting device is mandatory when the p...

Page 43: ...horten as required Maintain sufficient distance from hot duct walls 3 3 3 1 Control unit with integrated purge air supply MCU P Connect the purge air hose DN25 to the purge air outlet DN25 1 on the un...

Page 44: ...r motor and lid of the motor terminal box for terminal allo cation Fig 21 Electrical connection of the external purge air unit Connect protective conductor to terminal Optional external purge air unit...

Page 45: ...ent air hose to the adapter thread Fig 22 Adapter connection for instrument air supply NOTE In case of doubt or when using a special motor version the operating instructions supplied with the motor ha...

Page 46: ...connection of sender receiver unit for internal duct pressure up to 200 kPa 3 3 3 4 Installing the non return valve option Fig 24 Installation of non return valve G 1 4 Purge air requirement approx 6...

Page 47: ...N PE of the MCU see Component layout in the MCU without purge air supply with options page 47 Close off unused line openings with dummy plugs DISPLAYMODUL relay 3 relay 4 relay 5 BUS Term Term relay 1...

Page 48: ...ig 26 MCU processor board connections Supply voltage 24 V DC RS232 Connection for optional I O module Connection for Display module Connection for LEDs Connection for optional Inter face module USB pl...

Page 49: ...SSEMBLY AND INSTALLATION 3 3 3 4 3 Connection of connection line to MCU Fig 27 Plug connector connection to onsite line Cable provided by customer according to page 43 3 3 2 Closed Closed Open Open A...

Page 50: ...ion line SICK line or onsite line according to see General information prerequisites page 43 Socket White Brown Green Yellow White Yellow Green Brown Plug assignment View on pin side RS485 B 3 RS485 A...

Page 51: ...equivalent 3 3 5 2 Connection to the MCU remote control unit Version without power supply unit Connect the connection cable to the measuring and control unit 4 wire twisted pair with shield to the co...

Page 52: ...ON NOTICE During installation it must be possible to switch the power supply off using a power isolating switch circuit breaker in accordance with EN 61010 1 After completion of the work or for test p...

Page 53: ...the processor board with the line with plug connector see MCU processor board connections page 48 Then plug the I O modules on the module carriers Connect the Interface modules using the customer prov...

Page 54: ...according to Section 3 before starting the work described in the following Start up and parameter setting comprise Fitting and connecting the sender receiver unit Customizing parameter settings accord...

Page 55: ...Click the desired MCU 7 Make the settings Ethernet communication always clicked USB communication always clicked Serial communication Click 8 Do not specify IP addresses 9 A list of COM ports is shown...

Page 56: ...N S DUSTHUNTER SP100 Subject to change without notice 4 START UP AND PARAMETER SETTINGS 3 This message is shown 4 OK 5 The Device Manager opens See Ports COM LPT 6 Now connect the MCU with the laptop...

Page 57: ...ly oriented search 8 Click the desired MCU 9 Make the settings Ethernet communication always clicked USB communication always clicked Serial communication Do not click 10Specify the IP addresses IP ad...

Page 58: ...the duct direction horizontal or vertical is not specified in the order In this case the following steps are required for horizontal fitting Loosen knurled screws 1 and pull probe flange 2 off electr...

Page 59: ...ases dusts danger to health high pressure high tem peratures only when the equipment is at a standstill Type of purge air supply Activity MCU P control unit Push the DN 25 purge air hose onto the conn...

Page 60: ...am and connect to the measuring system see Connection to the device via USB line page 55 Select device file DH SP100 and move it to the Project Tree window Enter password level 1 Set the sender receiv...

Page 61: ...69 Sets 1 to 3 can be used when the highest precision is not decisive Set Regression coefficients setting Typical application Regression coefficients Quadratic Linear Absolute Set 0 Freely selectable...

Page 62: ...CU is swapped later The following steps are then necessary Connect the measuring system to the SOPAS ET program Enter the Level 1 password see Password and operating levels page 75 Set the sender rece...

Page 63: ...ice via USB line page 55 the Level 1 password set and the Maintenance mode set Parameter Value Function check Every 8 h output of control values every 90 s on standard analog output Analog output AO m...

Page 64: ...Check Automatic directory Fig 38 SOPAS ET menu MCU Adjustment Function Check Automatic example Default values see Factory settings page 63 Entry field Parameter Remark Output duration of function cont...

Page 65: ...lect the Configuration IO Configuration Output Parameters directory to set the analog outputs Fig 39 SOPAS ET menu MCU Configuration IO configuration Output Parameters Default values see Factory setti...

Page 66: ...ered light intensity Live zero Zero point 0 2 or 4 mA Select 2 or 4 mA to ensure being able to differentiate between measured value and switched off device or interrupted current loop Output checkcycl...

Page 67: ...tant Pressure field to enter the scaling value in mbar hPa Analog Input 2 The value from an external sensor connected to analog input 2 standard scope of delivery is used to calculate the scaled value...

Page 68: ...ARAMETER SETTINGS 4 3 6 Setting the response time Select the Configuration Value Damping directory to set the damping time Fig 41 SOPAS ET menu MCU Configuration Value Damping Field Parameter Remark D...

Page 69: ...O configuration Output Parameters page 65 and assign the Scattered light intensity measured variable to one of the three analog outputs available Estimate the measuring range required for the dust con...

Page 70: ...w enter the regression coefficients cc2 cc1 and cc0 determined in directory Configu ration Application parameters see Assigning the sender receiver unit to the measuring location in SOPAS ET page 60 s...

Page 71: ...ta and states for diagnostic purposes The following options are available Saving as a project Not only device parameters but also data logs can be saved Saving as a device file Saved parameters can be...

Page 72: ...without notice 4 START UP AND PARAMETER SETTINGS 4 3 9 Starting measurement mode Set the measuring system to Measurement mode after entering modifying parameters To do so cancel Maintenance Deselect M...

Page 73: ...fibus DP Modbus TCP and Ethernet type 1 1 Select device file MCU set the measuring system to Maintenance mode Enter the Level 1 password see Password and operating levels page 75 Switch to the Configu...

Page 74: ...e Set the desired network configuration in the Expansion module information field and click Reset module Fig 45 SOPAS ET menu MCU Configuration IO configuration Interface Module NOTICE The risk of und...

Page 75: ...atus LED Display field Control buttons Status bar Current button function Button Function Diag Display diagnostic information warnings and errors during a start using the Main menu sensor information...

Page 76: ...5 4 1 MCU Analog outputs inputs Set the MCU to Maintenance mode and select the I O Parameter submenu Select the desired parameter and enter the default password 1234 using the scrolls from 0 to 9 and...

Page 77: ...2016 08 SICK OP E RATI N G I N S TR UC TI ON S DUSTHUNTER SP100 Subject to change without notice START UP AND PARAMETER SETTINGS 4 Fig 48 Menu structure for configuring analog outputs inputs and sett...

Page 78: ...llowing steps are required to set the MCU for the DUSTHUNTER SP100 sender receiver unit to be connected see Assigning the MCU to the sender receiver unit page 62 Set the MCU to Maintenance mode select...

Page 79: ...see Password and operating levels page 75 Set the calculated coefficients see Calibration for dust concentration measurement page 69 using the and or buttons and write to the device with Save confirm...

Page 80: ...UP AND PARAMETER SETTINGS 4 5 5 Using SOPAS ET to modify display settings To modify the factory settings connect SOPAS ET with the MCU see Connection to the device via USB line page 55 enter the Leve...

Page 81: ...ed value bar Use AO scaling When activated the measured value bar is scaled to the associated analog output If not activated define the limit values separately Range low Values for separate scaling of...

Page 82: ...cify the maintenance intervals The period depends on existing operating parameters such as dust content and state gas temperature how the equipment is run and ambient conditions The equipment operator...

Page 83: ...the equipment operator Only qualified personnel according to Section 1 should be allowed to do the work If requested all main tenance activities can also be performed by SICK Service or an authorized...

Page 84: ...nternal duct pressure up to 200 kPa Remove the sender receiver unit from the duct Close off the flange with tube with a blind flange Unscrew cover screw 6 from the cleaning opening for sender optics s...

Page 85: ...ces We recommend checking the O ring 7 for wear and to replace it as required see Device check accessories page 107 Sender receiver unit with NL up to 735 mm Receiver optics Sender receiver unit with...

Page 86: ...nd check the contamination value again by triggering a renewed function check Reassemble the sender receiver unit remove the cover from the probe flange cover or flange with tube blind flange and inst...

Page 87: ...ew on the non return valve and remove them from the purge air connection of the sender receiver unit Unscrew the non return valve Check tappet for free movement Check seal and other parts for damage c...

Page 88: ...noise of the blower at regular intervals increases in the noise level can indicate a blower failure Check that all hoses are secure and free of damage Check the filter element for contamination Excha...

Page 89: ...rrow direction and remove the cover Take out the filter element and replace with a new element Clean the inside of the filter housing and the filter housing cover with a cloth and brush Insert new fil...

Page 90: ...Micro Top element C11 100 Part No 5306091 Mount the filter housing cover ensuring that it is aligned correctly with the housing and snap the snap locks into place Reconnect the purge air hose to the f...

Page 91: ...Storage Store dismantled device parts in a clean dry location Use suitable auxiliary means to protect the connection line plug connectors against dirt and moisture Secure purge air hoses against pene...

Page 92: ...the measuring system to SOPAS ET and start the device file DH SP100 or MCU Move the mouse to the respective message to display more details on the significance of individual messages in a separate wi...

Page 93: ...te Symptom Possible cause Action LEDs of the sender receiver are not on No laser beam No supply voltage Connection line not connected correctly or defective Defective plug connector Check plug connect...

Page 94: ...PAS ET program Fig 60 SOPAS ET menu MCU Diagnosis Error messages Warnings Display of error or warning With LED symbol Description of error or warning In the description field of SOPAS ET Symptom Possi...

Page 95: ...ure Check configuration see Set ting the analog inputs parame ters page 67 Contact SICK Customer Service Interface Module No communication via Interface module No parameters set for module Connection...

Page 96: ...G 6 3 3 Replacing the fuse Control unit MCU must be disconnected from the power supply and potential free Open the door of the MCU remove and open fuse holder 1 Replace the defective fuse 2 see Miscel...

Page 97: ...EN 14181 Stationary source emissions Quality assurance of automated measuring systems Electrical protection Insulation Protection class 1 according to EN 61010 1 Insulation coordination Measuring cat...

Page 98: ...al linearity check Using a reference filter Output Signals Analog Outputs 3 outputs 0 2 4 22 mA max load 750 resolution 10 bits electrically isolated Relay outputs 5 potential free outputs changeover...

Page 99: ...6 0 kg 18 0 kg 7 5 kg MCU control unit MCU P MCU N 13 5 kg 3 7 kg Optional external purge air unit 14 kg Miscellaneous Protection class Sender receiver unit MCU control unit Optional external purge ai...

Page 100: ...ceiver unit DHSP T2V21NNXX 1043884 Sender receiver unit DHSP T4V11NNXX 1043885 Sender receiver unit DHSP T4V21NNXX 1043886 Sender receiver unit DHSP T2H11NNXX 1043891 Sender receiver unit DHSP T2H21NN...

Page 101: ...4 Sender receiver unit DHSP T2VX2NNXX 1061685 Sender receiver unit DHSP T4V32NNXX 1043889 Sender receiver unit DHSP T4V42NNXX 1043890 Sender receiver unit DHSP T4V62NNXX 1051652 Sender receiver unit D...

Page 102: ...pe k100 Flange with tube Di 70 2 Length 130 mm St37 2017845 DHSP Txx1 DHSP Txx2 Flange with tube Di 70 2 Length 240 mm St37 2017847 Flange with tube Di 70 2 Length 500 mm St37 2017849 DHSP Txx2 Flange...

Page 103: ...MCU N control unit Meas 300 210 160 320 340 120 Designation Part No Control unit MCU NWODN01000NNNE in wall mounted enclosure orange Supply voltage 90 250 V AC without purge air unit with display 1045...

Page 104: ...ntegrated purge air supply Fig 68 MCU P control unit 300 220 455 420 400 260 8 Designation Part No Control unit MCU PWODN01000NNNE in wall mounted enclosure orange Supply voltage 90 250 V AC with purg...

Page 105: ...out notice SPECIFICATIONS 7 7 3 4 Optional external purge air unit Fig 69 Optional external purge air unit 550 258 14 470 550 40 40 470 128 4 0 Designation Part No Purge air unit with blower 2BH13 and...

Page 106: ...ig 70 Weatherproof cover for external purge air unit Weatherproof cover for sender receiver unit Fig 71 Weatherproof cover for sender receiver unit 550 605 350 245 550 Designation Part No Weatherproof...

Page 107: ...Designation Part No Purge air hose DN 25 length 5 m 2046091 Purge air hose DN 25 length 10 m 7047536 Purge air reduction 7047538 Purge air adapter for instrument air 7047539 Non return valve DN25 2042...

Page 108: ...arrier 6033578 Interface Profibus module DP V0 2048920 Interface module Ethernet type 1 2055719 Interface module Ethernet type 2 2069666 Modbus TCP module 2059546 Designation Part No Cover 2052377 Fus...

Page 109: ...rtant Information 7 Installation site 8 Intended use 8 Interfaces 21 M Malfunctions 93 MCU 15 21 MCU remote control unit 26 Measured values 8 Measuring function general 8 Menu structure 76 P Parameter...

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