FW100 Dust Concentration Monitor - SICK

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

DescriptionInstallationOperation

Title

FW100Dust Concentration Monitor

Document Information

Described ProductProduct name: FW100

Document IDTitle: Operating Instructions FW100Part No.: 8008905Version: 1.1Release: 2012-12

ManufacturerSICK AGErwin-Sick-Str. 1 · 79183 Waldkirch · GermanyPhone: +49 7641 469-0Fax: +49 7641 469-1149E-mail: [email protected]

Place of ManufactureSICK Engineering GmbHBergener Ring 27 · 01458 Ottendorf-Okrilla · Germany

TrademarksIBM is a trademark of the International Business Machine Corporation. MS-DOS is a trademark of the Microsoft Corporation.Windows is a trademark of the Microsoft Corporation.Other product names used in this document may also be trade-marks and are only used for identification purposes.

Original DocumentsThe English edition 8008905 of this document is an original docu-ment of SICK AG.SICK AG assumes no liability for the correctness of an unauthor-ized translation.Please contact the manufacturer or your local representative in case of doubt.

Legal informationSubject to change without notice.

© SICK AG. All rights reserved.

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Operating Instructions FW100

Dust Concentration Monitor

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Contents

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

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

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

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

1.3 Safety Information and Protection Measures.................................................................81.3.1 Danger from Electrical Equipment ................................................................................................. 9

1.3.2 Danger due to Hot, Corrosive, or Pressurized Gases ............................................................ 9

1.3.3 Danger due to Laser Beam............................................................................................................... 9

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

1.3.5 Detecting and Preventing Malfunctions .................................................................................... 10

1.3.6 Shutdown, Removal from Service, and Storing System Components........................... 10

2 Product Description.......................................................................................................... 11

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

2.2 Operating Principle and Measured Variables .............................................................. 142.2.1 Operating Principle ............................................................................................................................ 14

2.2.2 Response time ................................................................................................................................... 15

2.2.3 Check Cycle.......................................................................................................................................... 15

2.3 Device Components............................................................................................................. 182.3.1 Transmitter/Receiver Unit .............................................................................................................. 18

2.3.2 Assembly Elements for Transmitter/Receiver Units ............................................................. 21

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

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

2.3.5 Adapter fpr Instrument Air Supply................................................................................................ 24

2.3.6 Data Acquisition, Communication, Measured Value Output, and Display Options.... 25

2.3.7 ASC Option............................................................................................................................................ 26

2.3.8 Elbow Plug............................................................................................................................................. 26

2.3.9 Check Filter Set for FW100............................................................................................................ 26

2.4 Device Configuration ........................................................................................................... 27

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

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FW100 Operating Instructions


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2.6 Dimensions and Order Numbers....................................................................................... 302.6.1 Transmitter/Receiver Unit .............................................................................................................. 30

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

2.6.3 Tri-Clamp• Flange ............................................................................................................................. 31

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

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

2.6.6 Weatherproof Cover for Transmitter/Receiver Unit .............................................................. 34

3 Assembly and Installation...............................................................................................35

3.1 Project Planning .................................................................................................................... 37

3.2 Assembly ................................................................................................................................. 283.2.1 Installing the Assembly Elements for the Transmitter/Receiver Units ........................... 38

3.2.2 Installing the Connection Unit ....................................................................................................... 40

3.2.3 Installing the Optional External Purge-Air Unit ........................................................................ 41

3.2.4 Fitting the Weatherproof Covers .................................................................................................. 42

3.3 Installation............................................................................................................................... 433.3.1 General Instructions and Prerequisites .................................................................................... 43

3.3.2 Connection Unit .................................................................................................................................. 43

3.3.3 Connecting/Commissioning the Optional External Purge-Air Unit ................................... 45

3.3.4 Installing the Purge-Air Supply ....................................................................................................... 46

3.3.5 Connecting optional Devices ........................................................................................................ 48

4 Commissioning and Parameterization ........................................................................51

4.1 Basics ....................................................................................................................................... 534.1.1 General Notes .................................................................................................................................... 53

4.1.2 Prerequisites ....................................................................................................................................... 53

4.2 Installing and Connecting the Transmitter/Receiver Unit....................................... 544.2.1 Aligning the Transmitter/Receiver Unit ....................................................................................... 54

4.2.2 Starting up the Transmitter/Receiver Unit ................................................................................ 55

4.3 Connecting the Device........................................................................................................ 56

4.4 Parameterization ................................................................................................................... 574.4.1 Customer-Specific Parameterization........................................................................................... 57

4.4.2 Calibration for Dust Concentration Measurement................................................................. 59

4.4.3 Filter Bag Control ................................................................................................................................ 60

4.4.4 Data backup ........................................................................................................................................ 62

4.4.5 Starting Standard Measuring Mode ............................................................................................ 63

4.5 Parameterizing Optional Devices ................................................................................... 644.5.1 Data Memory / Event Memory ..................................................................................................... 64

4.5.2 CAN Module ......................................................................................................................................... 67

4.5.3 Second Analog Output ..................................................................................................................... 68

4.5.4 LCD .......................................................................................................................................................... 68

4.5.5 ASC Option............................................................................................................................................ 69

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5 Maintenance....................................................................................................................... 71

5.1 General ..................................................................................................................................... 73

5.2 Maintaining the Transmitter/Receiver Unit.................................................................. 745.2.1 Cleaning the Transmitter/Receiver Unit (Externally) ............................................................. 74

5.2.2 Cleaning the Optical Boundary Surfaces................................................................................... 74

5.3 Maintaining the Purge-Air Supply .................................................................................... 765.3.1 Connection Unit with Integrated Purge-Air Supply ................................................................. 77

5.3.2 External Purge-Air Unit (Optional) ................................................................................................. 78

5.4 Removal from Service.......................................................................................................... 79

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

6.1 Malfunctions........................................................................................................................... 83

6.2 Warnings and Malfunction Messages .......................................................................... 846.2.1 Warnings ................................................................................................................................................ 84

6.2.2 Malfunction Messages ..................................................................................................................... 85

6.2.3 Other Malfunctions and Abnormal Behavior ............................................................................ 87

6.3 Removal of Malfunctions.................................................................................................... 886.3.1 Adjusting the Laser Beam............................................................................................................... 88

6.3.2 Checking the Laser Beam for free Transit (FW101) ............................................................ 89

6.3.3 Checking the FW101 Receiver Optics for Correct Movement ......................................... 90

6.4 Test and Diagnosis Options............................................................................................... 916.4.1 Testing the Signal Output ................................................................................................................ 91

6.4.2 Check Cycle.......................................................................................................................................... 91

6.4.3 Linearity Check.................................................................................................................................... 92

7 Repairs.................................................................................................................................. 93

7.1 Transmitter/Receiver Unit.................................................................................................. 967.1.1 Replacing the Cover and/or Protection tube (FW101)........................................................ 96

7.1.2 Replacing the Sintered Metall Flter (FW101) .......................................................................... 96

7.1.3 Replacing the Entire T/R Unit Connector................................................................................... 96

7.1.4 Checking/Replacing the Battery for the Transmitter/Receiver Unit ................................ 98

7.2 Connection Unit..................................................................................................................... 997.2.1 Connection Unit without Purge-Air Supply................................................................................. 99

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

7.2.3 Replacing the LCD Module ...........................................................................................................103

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

8.1 Standard Components.......................................................................................................1078.1.1 Transmitter/Receiver Units .......................................................................................................... 108

8.1.2 Assembly Elements ........................................................................................................................ 108

8.1.3 Connection Units.............................................................................................................................. 109

8.1.4 External Purge-Air Units (Optional) ........................................................................................... 109

8.1.5 Miscellaneous................................................................................................................................... 109

8.2 Options ...................................................................................................................................1108.2.1 Transmitter/Receiver Units .......................................................................................................... 110

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

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

8.2.4 Accessories for Testing the Device.......................................................................................... 111

8.2.5 Miscellaneous .................................................................................................................................. 111

8.3 Consumable Parts for 2-Year Operation......................................................................1118.3.1 Transmitter/Receiver Units .......................................................................................................... 111

8.3.2 Connection Unit with Internal Purge-Air Supply.................................................................... 111

8.3.2 External Purge-Air Unit (Optional) .............................................................................................. 111

8.4 Spare Parts............................................................................................................................1128.4.1 Transmitter/Receiver Unit ............................................................................................................ 112

8.4.2 Connection Unit................................................................................................................................ 112

8.4.3 Miscellaneous .................................................................................................................................. 112

9 Appendix............................................................................................................................ 113

9.1 Standard Settings for the FW100..................................................................................1159.1.1 FW101................................................................................................................................................. 115

9.1.2 FW102................................................................................................................................................. 116

9.2 Password ...............................................................................................................................117

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Notes On This DocumentSu

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Notes On This Document

These operating instructions describe the functioning of the FW100 opto electronic dust

concentartion monitor in both variations FW101 and FW102. They serve for understanding

the device function and 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.

ATTENTION

Important

Indicates a risk of damage to the device or system components and potential functional

impairments.

DANGER

Warning

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!

8008905 · © SICK AG 7



Safety Instructions

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1 Safety Instructions

1.1 Intended Use

The FW100 measuring system is used for measuring the dust concentration in exhaust

gases and waste air ducts. It must only be operated in the manner intended by the

manufacturer 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 defined 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

FW100 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.

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1.3.1 Danger from Electrical Equipment

The FW100 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.

1.3.2 Danger Due to Hot, Corrosive, or Pressurized Gases

The transmitter/receiver unit is 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), this unit 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.

DANGER

Warning

Installations with toxic gases, high temperatures, high pressure, or risk of explosion must be

shutdown before these components are installed or removed!

1.3.3 Danger Due to Laser Beam

WARNING

The FW100 uses a laser with laser class 2. To prevent blinding:

‡ Never look directly into the laser beam.

‡ Do not direct the FW100 laser beam towards people.

‡ Take into account reflections of the laser beam.

1.3.4 Purge-Air Failure

The purge-air supply protects the transmitter/receiver unit 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. For this reason, the operator must

ensure that:

ATTENTION

‡ The purge-air supply operates reliably and without interruption.

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

‡ The transmitter/receiver unit is removed from the duct in the event of a purge-air failure

and the duct openings are covered (for example, with a flange cover).

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Safety Instructions

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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:

‡ Significant drifts in the measurement results

‡ A rise in power consumption

‡ A rise in system component temperature

‡ Actuating of monitoring devices

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

‡ Smoke or unusual odors.

1.3.6 Shutdown, Removal from Service, and Storing System Components

The FW100 measuring system must remain switched on when the plant is shut down. The

purge-air supply must never be switched off.

If the FW100 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 8008905 · © SICK AG

Features and Applications

Operating Principle

Device Components

Device Configuration

Technical Data

Dimensions and Part Numbers

FW100


Product Description



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2 Product Description

2.1 Features and Applications

The FW100 series from SICK is designed to conduct continuous measurements of very low

(0.1 mg/m3) to medium (200 mg/m3 and higher) dust concentrations in gases (temperature

above dew point). These measuring devices can be used in a wide range of application and

feature by low installation effort and simple handling.

System features and advantages

• High resolution and measuring speed

• Measuring of the dust content independent of height and fluctuations of the gas velocity

• No influence of moisture or charge of the particles

• Defined zero point

• Easy to install, no mechanical adjustment required

• No calibration to dust-free measuring path required

• Simple operation and configuration with user-friendly software

• Automatic check cycle

• Automatic compensation of contaminations (type FW101)

• Minimum maintenance requirements.

Application range

Applications ‡ In pure gas, downstream of electrostatic precipitators

– Continuous measurement and monitoring of dust concentrations

– Protection of flue gas desulfurization plants

‡ In pure gas, downstream of modern fabric filters

– Monitoring, detection, and identification of defective filters and bags

– Prevention of the release of expensive production materials and toxic contents in

continuous processes

‡ For monitoring and/or closed-loop control purposes in exhaust/intake air systems

Sectors • Power supply: Power stations, heating systems

• Waste disposal: Refuse incineration plants

• Process engineering: Grinding and metering plants

• Metal processing: Steel and aluminum processing

• Foodstuff industry: Filling bulk materials

• Brake linings and Eternit production

Compliance The measurement system is approved according to Federal German Pollution Control Act

(13th, 17th and 27th Implementing Ordinance) and German Clean Air Regulations, an-

nounced in GMBL 2000, no. 60, pg. 1192.

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Product Description

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2.2 Operating Principle

2.2.1 Operating Principle

The FW100 operates according to the scattered light measurement principle (forward

scattering). Since it is extremely sensitive, this principle is particularly suitable for measuring

very small particle concentrations.

A laser diode directs a beam of modulated light in the visible range (wavelength approx.

650 nm) at the dust particles in the gas flow. The light scattered by the particles is recorded

by a highly sensitive detector which is positioned in an angle of approx. 15 ° to the beam

axis. The received signal is electrically amplified and supplied to the measuring channel of a

microprocessor as the central part of the measuring, control and evaluation electronics. The

point of intersection between the transmitted beam and the receiver aperture defines the

measuring volume in the gas duct.

The transmitting power of the laser diode is continuously controlled by measuring a part of

the transmitted intensity with a microchip in the laser diode. This received signal is also

amplified and supplied to the monitor channel of the microprocessor. In this way lowest

brightness changes of the transmitted laser beam can be detected and take into account

in the determination of the output signal.

Fig. 2.1: FW100 Operating principle

The measured scattered light intensity is proportional to the dust concentration. Since the

scattered light intensity doesn't only depend on the particle number (dust content) but also

on the visual qualities of the particles, the FW100 must be calibrated with a gravimetric

comparison measurement to secure an exact measuring of the dust concentration. The

calibration coefficients determined at this measurement are entered in FW100 (see

Section. 4.4.2) in the form:

cc2: square

cc1: linear

cc0: absolute

c = cc2 · SI² + cc1 · SI + cc0 c = Dust concentration

SI = Scattered light intensity

cc = calibration coefficiant

The manufacturer settings are cc2 = 0, cc1 = 1, cc0 = 0.

Transmitter/receiver unit

Laser diode

Gas duct

Detector

Measuring volume

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2.2.2 Response Time

The response time (t90) is the time taken by the FW100 to reach 90% of the end value after

a sudden change in the measured value (see Fig. 2.2). The t90 time can be set to any value

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.

Fig. 2.2: Response time

2.2.3 Check Cycle

The check cycle is used for automatically checking that the transmitter/receiver is

functioning properly. 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).

The check values can be given out at the analog output (see Section 4.4.1).

Notes • When the check values are being determined, the value last measured is given out at the

analog output.

• If the check values are not given out at the analog output, the current measured value is

given out 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 from the parameterized time interval.

A re-start begins if the interval setting is changed or 1 min after:

– Change from „Maintenance“ to „Measure“ mode

– Reset (power off/on)

– Switch-on of the power voltage after power failure.

Measured

value

in %

Measured value with t90 response time

90 % of the peak

Process change

t90

t in s

100

98

96

94

92

90

88

86

8410 20 30 40 50 60 70 80 90 100

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Product Description

1

Check cycle FW101

If a check cyle is carried out, inadmissible deviations appearing by the normal behavior are

signaled as a malfunction. 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 lasts approx. 310 s and comprises:

The values are only given

out to the analog output in

case of activation (see

Section 4.4.1).

• 40 s contamination measurement of the optical boundary surfaces, zero and check value

• 90 s output of the contamination value

• 90 s output of the check value

• 90 s output of the zero value.

Fig. 2.3: FW101 check cycle output on plotter

Contamination Measurement

In order to measure the contamination on the optical boundary surfaces, the FW101 moves

the receiver optics mechanically to a reference position. As a result, the optics measure the

light emitted by the laser diode directly. The intensity value measured during the movement

is compared with the factory settings to calculate a correction factor. In this way, the FW101

can fully compensate for any contamination levels.

If the contamination value is lower than 70 %, a analog value is given out during the check

cycle in a range between Live Zero and 20 mA and proportional to the contamination value

(device status „Operation“). For contamination values higher than 70 % always Live Zero is

given out (device status „Malfunction“).

Fig. 2.4: FW101 contamination and check value measurement

Check Value Measurement

(Span test)

Following to the contamination measurement, the check value is determined (receiver

optics is in reference position). Once a reference measurement has been carried out with a

light intensity of 100 %, the FW101 reduces the intensity of the laser diode to 70 % and

compares the value measured by the receiver with the expected value. If these two value

deviate more than ±2 %, the device generates an error signal. The error message is lifted

again if the next check cycle passes successfully.

Degree of

contamination

Check value (70 % value, span)Zero value (Live Zero)

End

check cycle

Start

Check cyclecontamination

output

Zero value

output

Paper feed

Check value

output

Receiver optics in reference position

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Zero Value Measurement

In order to monitor the zero point, the FW101 deactivates the laser diode, and the reception

signal must also be zero. In this way, drifts or zero-point eviations in the entire system (e.g.

caused by an electronic defect) can be reliably detected. If the “zero-value” deviation is out-

side the specified range, an error signal is generated.

Check cycle FW102

At the FW102, the measuring linearity is checked during a check cycle. The check cycle lasts

approx. 200 s and comprises a:

• 20 s measurement of zero and check value

The values are only given

out to the analog output in

case of activation (see

Section 4.4.1).

• 90 s output of the check value

• 90 s output of the zero value.

Fig. 2.5: FW102 check cycle output on plotter

Check Value Measurement

(Span test)

The FW102 measures the check point with the receiver optics in the measuring position.

During this time, the light intensity changes between 70 and 100%. Thanks to a large

number of intensity shifts, which are evaluated statistically, the FW102 enables the check

point to be measured with pinpoint accuracy (prerequisite: dust contents > approx. 2 mg/

m³, otherwise the theoretically calculated 70 % value is given out.

The check value is evaluated in the same way as with the FW101 (error messages in case

of deviations of more than ±2 %).

Zero Value Measurement

The FW102 carries out a zero-point measurement in the same way with the FW101.

Start

Check cycle

Check value (70 % value, span)

Zero value

output

Output

check value

Zero value (Live Zero)

End

check cycle

Paper feed

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2.3 Device Components

Device Variants

• FW101 for use in gas ducts with a diameter greater than 250 mm.

The device is mounted on the duct using a flange with tube.

• FW102 for use in gas ducts with a diameter greater than 150 mm.

The FW102 can be mounted on a flange with fitting (Tri-Clamp®) or a 1” sleeve on the

duct.

FW100 Components

Possible device configurations see section 2.4.

• Transmitter/receiver unit

• Flange with pipe / flange with fitting / 1” sleeve

• Connection unit

– with integrated purge-air supply (for internal duct pressure -70 ... +10 mbar)

– without purge-air supply. The following is, therefore, required:

• External purge-air supply (for internal duct pressure -70 ... +70 mbar)

Fig. 2.6 Overview of the FW100 components

Connection unit with

purge-air supply

Connection

unit without

purge-air

supply

External purge-air

unit option

Transmitter/receiver unit

Purge-air hose

Signal cable

MEPA-FW

operating and

configuration

program

Flange with pipe

RS 232

Power supply

Duct Optional

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2.3.1 Transmitter/Receiver Unit

The transmitter/receiver unit consists of two main modules:

• Electronic unit

It contains the optical and electronic modules for transmitting and receiving the light be-

am, as well as processing and evaluating signals.

• Measuring probe

The measuring probe is designed in different forms, nominal lengths and for different gas

temperature ranges and defined the device variant.

The transmitter/receiver unit is connected to the connection unit using a 16-pole cable with

a connector, and has a 24 V d.c. power supply. Clean purging air is supplied to a purge-air

nozzle to cool the probe and keep clean the optical boundary surfaces.

FWSE101 Transmitter/Receicer Unit

The transmitter/receiver units are available in the following versions:

Fig. 2.7: FWSE101 transmitter/receicer unit nominal length 435 / 735 mm

Nominal lengthNL in mm

max. Gas temperature

in °C

Protection tube Use for

Length L in mm Material

435220

300

Stainless steel

Hastelloy Corrosive gases

400 Stainless steel

735220

600

Stainless steel

Hastelloy Corrosive gases

400 Stainless steel

1035220

900Stainless steel Wall and isolation thick-

ness up to 720 mm400 Stainless steel

1335220

1200Stainless steel Wall and isolation thick-

ness up to 1020 mm400 Stainless steel

Electronic unit

Probe head

with receiver

optics

Purge-air nozzle

Purge-air outlets at high temperature

version (HT) up to 400 °C

Cleaning opening for transmitter optics

NL

Connector for signal cable

L

(Flange with pipe)

(Duct wall)

Protection tube

Measuring

opening

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Fig. 2.8 FWSE101 transmitter/receicer unit nominal length 1035 / 1335 mm

Notes • Transmitter/receiver units with nominal length > 735 mm are exclusive scheduled for the

installation in thick-wall or double walled ducts with wall and isolation thickness of approx.

400 mm to 1020 mm.

• The distance between inside duct wall and measuring opening may be max. 450 mm

(see Fig. 2.8).

FWSE102 Transmitter/Receicer Unit

The following versions are available:

Fig. 2.9: FWSE102 1“ transmitter/receicer unit (NL 280 mm is shown)


NL

(485 mm)

Laser with drive electronics in housing

(must be within the channel wall/isolation)

max. 450 mm

(Duct wall/isolation)

L

Nominal length NLin mm

Mounting type Duct diameter in mm

1801“ sleeve

> 150Flange with fitting (Tri-Clamp®)

2801“ sleeve

Flange with fitting (Tri-Clamp®)

Purge-air nozzle

Connector for signal cable


NL

Electronic unit Measuring probe

Probe head with

receiver optics

1“ thread

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Fig. 2.10: FWSE102 Tri-Clamp® transmitter/receicer unit (NL 180 mm is shown)

Interfaces of the Transmitter/Receiver Unit

The interfaces are available at the terminal strip in the connection unit.

The operating status is also signaled by two LEDs on the rear of the housing:

(green = operation, red = malfunction).

Options The transmitter/receiver unit can be equipped in addition with the options data memory/

event memory, CAN module or second analog output (see Section 2.3.6).

Note We recommand to use weatherproof covers if the transmitter/receiver unit is to be installed

outdoors (see Fig. 2.24 and Fig. 2.25).

2.3.2 Assembly Elements for Transmitter/Receiver Unit

Flange with Pipe(for FWSE101)

Fig. 2.11: Flange with pipe

The pipe length (meas. L) depends on the wall and isolation thickness, the maximmum gas

temperature and the nominal length of the transmitter/receiver unit.

Analog output (1x) 0/2/4 ... 20 mA

Relay outputsMax. load: 48 V, 1 A

Digital input RS 232interface

For outputting the

measured variable

dust concentration

For outputting the status signals:

• Operation/malfunction

• Limit value

• Maintenance (check cycle)

E.g.: for connecting

the maintenance

switch with floating

contact

For parameterization

with the MEPA-FW

operating program

NL

Tri-Clamp® ring

TOP

L

Material St 37

or 1.4571

Securing bolts

for FWSE101

Mounting indicator

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Product Description

2

Flange with Fitting / 1“ Sleeve (for FWSE102)

Fig. 2.12 Assembly elements for FWSE102

2.3.3 Connection Unit

The connection unit contains the power supply for the transmitter/receiver unit, 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

Fig. 2.13: Connection unit without purge-air supply

Connection Unit with Integrated Purge-air Supply

This version also has a purge-air fan, air filter, and purge-air nozzle for connecting the purge-

air hose for the transmitter/receiver unit.

Gas temperature

Nominal length of the FWSE101 transmitter/receiver unit (in mm)

435 735 1035 1335

< 150 °C 130

240

130

240

500 800 1100

Measure L

(in mm)> 150 °C 240 500

Seal Tri-Clamp• Fitting

flange

Flange with fitting (Tri-Clamp®) 1“ sleeve

Power supply unit

LCD option

Terminal block

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Fig. 2.14: Connection unit with integrated purge-air supply

The connection units can also be fitted with the LCD module with additional relay outputs

(see section 2.3.6).

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

- 03: 3 m

- 10: 10 m

Supply voltage

- WR: Power supply 100 ... 240 V AC (wide-range power unit)

- 02: 24 V DC

LCD option

- N: No display

- D: Display

Special version

- 0: Without

- S: Special design (e.g. stainless steel housing)

Note At use of the connection unit with integrated purge-air supply, a purge-air hose with nominal

diameter 25 mm is required in addition to sypply the transmitter/receiver unit sends (see

Section 8.1.5). The length must be the same as the cable length.

Purge-air fan

Air filter

Power supply unit

(on rear of mounting plate)

LCD option

I/O board with

terminal block

Mounting plate

Purge-air nozzle

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2.3.4 External Purge-Air Unit (Optional)

The connection unit with integrated purge-air supply cannot be used if the internal duct

pressure is greater than +10 mbar. In this case, the option with an external purge-air unit

must be used. It features a high-performance fan and is suitable for use in pressurized ducts

of up to 70 mbar.

Fig. 2.15: Pugre-air unit SLV 4 with purge-ait reduction

The purge-air hose nominal diameter 40 mm (length 5 m or 10 m, scope of supply ) is

connected to purge-air nozzle of the transmitter/receiver unit via the separate component

purge-air reduction (see Section 8.1.4).

A weatherproof cover is available if the system is to be used outdoors (see Fig. 2.23).

2.3.5 Adapter for Instrument Air Supply

The FW100 can be operated also with instrument air instead of the purge-air supplies from

the connection unit AK1-P or an external purge-air unit. To connect the instrument air, an

adapter is available with connection thread G 1/4“ and installed reduction nozzle (installing

at the purge-air nozzle of the transmitter/receiver unit).

Fig. 2.16: Adapter for instrument air supply

Puge-air

hose

Air filter

Fan (standard

type 2BH13)

BaseplateCover with opening

(part of the purge-air reduction)

(Purge-air nozzle)

Purg-air

reduction

Reduction

nozzle

Inner

diameter

Admission

pressure

D3 3 mm 1 ... 3 bar

D2 2 mm 3 ... 6 bar

Reduction nozzle

G 1/4“

(Ø 25)

Purge-air consumption

approx. 6 ... 13 m³/h

(depending on admission

pressure)

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2.3.6 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

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).

CAN Module


A separate evaluation unit is available to complement the existing input/output and

connection options (see section 8.2.5). 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 FW100 systems can be connected to the evaluation unit with a data

transfer of up to 1000 m.

Second Analog Output


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 technical 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 LED

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.

The LCD shows the following status information:

Indications on the LCD Meaning

„Limit1 “ Limit 1 is exceeded

„ Limit2“ Limit 2 is exceeded

„Limit1 Limit2“ Limit 1 and limit 2 are exceeded

„Soft “ „Maintenance“ mode is set via MEPA-FW (Software maintenance)

„Hard (In1)“ „Maintenance“ mode is set by using of an external switch (hardware

maintenance; see section 3.3)

„Soft Hard (In1)“ Hardware and software maintenance are set

„Warning xxx“ see Section 6.2.1

„Malfunction xxx“ see Section 6.2.2

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2.3.7 ASC Option (Automatic Self Control, only for FW102)

Using this option, the FW102 can be checked for proper device function. Especially at very

low dust concentrations near to zero an information is possible with it whether the device

still measures or has a malfunction (= Live Zero at the analog output).

The supervision is based on a permanent determination of the difference between the hig-

hest and lowest measuring value in an adjustable time interval. The device works normal if

a preselectable value was exceeded at least once (parameterization see Section 4.5.5).

Otherwise a malfunction message appears (“Automatic Self Control“). In this case it has to

be checked, whether there is really a device malfunction or merely minimal dust concentra-

tions are existing no longer measurable with the FW100.

2.3.8 Elbow Plug

To prevent damages at the signal cable to the connection unit by installation the FWSE101

in vertical ducts (cable connection from the side, see Fig. 4.1) and use of the weatherproof

cover for analyzer (see Fig. 2.24), we recommend to connect the transmitter/receiver unit

via the elbow plug option (see Section 8.2.1).

2.3.9 Check Filter Set for FW100

A linearity test can be performed to check the correct device function (see Section 6.4.3).

Absorption filters with defined transmission values are placed in the beam path and the

values are compared with those measured by the FW100. If the results match and are

within the permissible tolerance, the FW100 is functioning correctly. The absorption filters

and brackets are supplied with a case (see Section 8.2.4)

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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.

Transmitter/Receiver Unit

Note Choose the nominal length of the transmitter/receiver unit so that the measuring opening

has a sufficient distance of the duct inside wall (> 100 mm). The measuring opening (see

Fig. 2.7) must not be in the middle of the duct!

Power and Purge-Air Supply

*: Instrument air provided by the customer (free of dust, oil, humidity, condensates, non corrosive)

ATTENTION

Important

If the gas temperature is higher than 220 °C, the optional external purge-air unit must be

installed! Only FWSE101 transmitter/receicer units up to 400 °C can be used.

Flange with Pipe (only for FWSE101)

The pipe length is assigned tightly to the nominal length of the transmitter/receiver unit (see

Section 2.3.2).

Internal duct diameterr

in mm

Wall and isolation thickness

in mm

Exhaust gases, waste air Type of the transmitter/receiver unit

max. temperaturein °C

Composition

> 150

max. 10

220 Low corrosive

FWSE102 1“ NL180

FWSE102 Tri-Clamp® NL180

max. 100FWSE102 1“ NL280

FWSE102 Tri-Clamp® NL280

> 250 max. 150220

Low corrosive FWSE101 NL435, up to 220 °C

Strongly corrosive FWSE101 NL435 Hastelloy, up to 220 °C

400 FWSE101 NL435, up to 400 °C

> 300

max. 400220

Low corrosive FWSE101 NL735, up to 220 °C

Strongly corrosive FWSE101 NL735 Hastelloy, up to 220 °C

400 FWSE101 NL735, up to 400 °C

400 ... 720220

Low corrosive

FWSE101 NL1035, up to 220 °C

400 FWSE101 NL1035, up to 400 °C

700 ... 1020220 FWSE101 NL1335, up to 220 °C

400 FWSE101 NL1335, up to 400 °C

Internal duxt pressure mbar

Connection and supply components

Purge-air Power

-50 ... +10 AK1 -P-XXXX-X-X + purge-air hose DN 25

-50... +70Optional external purge-air supply

+ purge-air reduction AK1 -N-XXXX-X-X

-50 ... 1000 Adapter for instrument air supply *

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2.5 Technical Data

Measured value acquisition

Measured variable Scattered light intensity

after gravimetric comparision measurement, dust concentration in mg/m³

Measuring range Minimum range: 0 ... 5 mg/m³ higher ranges avaliable on request

stepplessly variableMaximum range: 0 ... 200 mg/m³

Measuring accuracy ±2 % of upper range limit (full scale)

Response time 0.1 ... 600 s; freely selectable

Application data

Gas temperature (above

dewpoint)

FW101, FW102 standard version -20 °C ... 220 °C

FW101 high temperature version -20 °C ... 400 °C

Internal duct pressure Connection unit with purge-air supply -50 mbar ... +10 mbar

External purge-air unit (optional) -50 mbar ... +70 mbar

Instrument air (provided by the customer) -50 mbar ... 1 bar

Ambient temperature Transmitter/receiver unit -20 ... +50 °C

Connection unit with purge-air supply;

Purge air intake temperature

-20 ... +45 °C

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; further relay with optional LCD

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 FW100 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: 100...240 V AC, 47...63 Hz; opt. 24 V d.c. ± 2 V

Power consumption: max. 15 W without purge-air supply

approx. 70 W with purge-air supply

Transmitter/receiver unit Power supply: 24 V from connection unit

Power consumption: max. 4 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

Rated current: 2,6 A/Y 1,5 A

Motor rating: 0.37 kW at 50 Hz; 0.45 kW at 60 Hz

Dimensions (W x H x D)

Transmitter/receiver unit FW101 NL 435 mm 150 mm x 150 mm x 645 mm

NL 735 mm 150 mm x 150 mm x 945 mm

NL 1035 mm 150 mm x 150 mm x 1245 mm

NL 1335 mm 150 mm x 150 mm x 1545 mm

FW102 150 mm x 150 mm x 440 mm

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Dimensions (W x H x D)

Connection unit without purge-air supply 200 mm x 200 mm x 130 mm

with purge-air supply 300 mm x 400 mm x 220 mm

External purge-air unit (optional) 550 mm x 550 mm x 258 mm; with weatherproof cover: 605 mm x 550 mm x 350 mm

Weight

Transmitter/receiver unit FW101 NL 435 mm 5.0 kg

NL 735 mm 6.3 kg

NL 1035 mm 8.0 kg

NL 1335 mm 9.5 kg

FW102 2.7 kg

Connection unit without purge-air supply 3.7 kg

with purge-air supply 13.5 kg

External purge-air unit (optional) 14 kg

Miscellaneous

Class of protection Transmitter/receiver unit, connection unit IP 65

External purge-air unit (optional) IP 54

Electrical safety According to EN 61010-1

• Connection unit and external purge-air unit (optional) protection class I

• Transmitter/receiver unit protection class III

Laser Laser class 2; Power < 1 mW; wavelength between 640 nm and 660 nm

Signal cable length 3 m, 10 m (LiYCY 8x2x0,25 mm²) other lengths available on request

Length of purge-air hose DN 25 3 m , 10 m other lengths available on request

Purge air flow rate Connection unit with internal purge-air supply ca. 5 ... 10 m³/h

External purge-air unit (optional) ca. 40 ... 60 m³/h

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2.6 Dimensions and Part Numbers

All dimensions in mm


Fig. 2.17 FW101 transmitter/receiver unit

81 55

Ø 6

0

15

0

Ø 5

3

NL

NL

L

L1

128

L

(485) Ø 7

6

Ø 25

FWSE101 NL 435 / 735

FWSE101 NL 1035 / 1335

NL L

435 300

735 600

1035 900

1335 1200

FWSE102 1“

NL L1 L2

180 50 179

280 150 79

FWSE102 Tri-Clamp®

81

Ø 2

5

15

0

NL

L1

L2

Ø 25

Type Transmitter/receiver unit Part no.

FWSE101 NL435, up to 220 °C 7047500

FWSE101 NL735, up to 220 °C 7047501

FWSE101 NL435, up to 400 °C 7047502

FWSE101 NL735, up to 400 °C 7047503

FWSE101 Hastelloy NL435, up to 220 °C 7047570

FWSE101 Hastelloy NL735, up to 220 °C 7047571

FWSE101 NL1035, up to 220 °C 7047576

FWSE101 NL1335, up to 220 °C 7047577

FWSE101 NL1035, up to 400 °C 7047578

FWSE101 NL1335, up to 400 °C 7047579

FWSE102 Tri-Clamp® NL180 7047505

FWSE102 1“ NL180 7047506

FWSE102 Tri-Clamp® NL280 7047507

FWSE102 1“ NL280 7047508

L2 NL

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2.6.2 Flange with Pipe

Fig. 2.18 Flange with pipe

2.6.3 Tri-Clamp® Flange

Abb. 2.19 Tri-Clamp• flange and seal

TOP

D1

LD2

D3

Dim. Flange with pipe

D100 D150

D1 Ø 76 Ø 127

D2 Ø 100 Ø 150

D3 Ø 130 Ø 190

L 240, 500 800, 1100

G M10 M12

45° 45°

G

Typ Flange with pipe Part no.

D100

Length 130 mm, St37 2017845

Length 240 mm, St37 2017847

Length 500 mm, St37 2017849

Length 130 mm, V4A 2017846

Length 240 mm, V4A 2017848

Length 500 mm, V4A 2017850

D150

Length 800 mm, St37 7047580

Length 1100 mm, St37 7047581

44.5

Ø 3

8.1

Ø 3

4.8

Ø 4

3

Ø 5

0.5

Tri-Clamp®-FDA seal 1 1/2“ Tri-Clamp® flange

Part no. 7047770 Part no. 7047779

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Connection Unit without Purge-air Supply

Fig. 2.20 Connection unit without purge-air supply (version with LCD)


Fig. 2.21 Connection unit with integrated purge-air supply (version with LCD)

200 130

20

0

160

22

0

Ø 8

(see section 2.3.3 for type key)

Connection unit type Part no.

AK1-N-03WR-N-0 7040350

AK1-N-10WR-N-0 7040351

AK1-N-0302-N-0 7040352

AK1-N-1002-N-0 7040353

AK1-N-03WR-D-0 7040354

AK1-N-10WR-D-0 7040355

AK1-N-0302-D-0 7040356

AK1-N-1002-D-0 7040357

40

0

300 220

42

0

260Ø 8

(see section 2.3.3 for type key)

Connection unit type Part no.

AK1-P-03WR-N-0 7040358

AK1-P-10WR-N-0 7040359

AK1-P-0302-N-0 7040360

AK1-P-1002-N-0 7040361

AK1-P-03WR-D-0 7040362

AK1-P-10WR-D-0 7040363

AK1-P-0302-D-0 7040364

AK1-P-1002-D-0 7040365

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Fig. 2.22 External purge-air unit (optional)

Fig. 2.23 Weatherproof cover for external purge-air unit

550

258

ø 144

70

55

0

40

40 470

128

40

Purge-air unit type Part no.

SLV4-21112

with fan (2BH13) and

purge-air hose

(length: 10 m)

1012409

SLV4-21111

with fan (2BH13) and

purge-air hose

(length: 5 m)

1012424

550

605

350

245

55

0

Component Part no.

Weatherproof cover

for purge-air unit

5306108

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2.6.6 Weatherproof Cover for Transmitter/Receiver Unit

Weatherproof Cover for FWSE101 Transmitter/Receiver Unit

Fig. 2.24 Weatherproof cover for analyzer

Weatherproof Cover for Housing of Transmitter/Receiver Unit (FWSE101 and FWSE102)

Fig. 2.25 Weatherproof cover for housing FWSE/FWR-D

492 365

239

36

0

Component Part no.

Weatherproof cover

for analyzer

2702407

Weatherproof cover

for FWSE101 long

7047582

160 166

15

7

Component Part no.

Weatherproof cover

for housing FWSE/

FWR-D

7040394

Spacer pins

(Housing of transmitter/receiver)

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Project Planning

Assembly

Installation

FW100


Assembly and Installation



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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 must be of

sufficient length, each

at least 3 x "hydraulic

diameter" (Dh)

Round and square ducts:

Dh = duct diameter

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

Rectangular ducts:

Dh = 4 x cross-section divided by circumference

• Homogeneous flow

distribution

• Representative dust

distribution

If possible, no bends, cross-section variations, feed

pipes, discharge pipes, flaps, or fittings in the inlet

and outlet sections.

If this cannot be ensured, determine

the flow profile to VDI 2066 and

choose the best possible location.

Mounting position of

the transmitter/

receiver unit

Must not be installed vertically on horizontal ducts

or ducts positioned at an angle; max. measurement

axis angle to the horizontal: 45 °

Choose the best possible location

Accessibility, accident

prevention

The device components must be easily and safely

accessible

Provide platforms if necessary

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

Choose the

purge-air

supply

Sufficient purge-air pre-

pressure (depending

on the internal duct

pressure)

• Up to +10 mbar connection unit with integrated

purge-air supply

• Up to +70 mbar external purge-air unit option

• Up to +1 bar instrument air

Determine the supply type

Clean intake air 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

Internal duct diameter,

duct wall strength with

insulation

Nominal length of transmitter/receiver unit, flange

with pipe

Choose the components according to

the configuration table and notes in

Section 2.4; nominal length of the

transmitter/receiver units only as long

as required (measuring not necessary

in the middle of the duct).

If necessary, plan additional measures

to install the flange with pipe

(see section 3.2.1).

Internal duct pressure Type of purge-air supply

Gas temperature Transmitter receiver unit version (up to 220 °C or

to 400 °C)

Gas condition For korrosive gases up to 220 °C Hastelloy

protection tube

Installation locations Cable and purge-air hose lengths

Plan the

calibration

openings

Accessibility Easy and safe Provide platforms/pedestals if

necessary

Distances to the

measurement level

No mutual interference between calibration probe

and FW100

Ensure sufficient distance between the

measurement and calibration level

(distance approx. 500 mm)

Plan the

power supply

Operating voltage,

maximum demand

According to the technical data in section 2.5 Ensure sufficient cable cross-sections

and fuse

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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, Tri-Clamp® flange or 1“ sleeve.

‡ Installing the connection unit.

‡ Installing the external purge-air unit (optional).

DANGER

Warning

• When carrying out assembly and installation work, observe the relevant safety regulations

and the safety information in Chapter 1!

• 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 Assembly Elements for the Transmitter/Receiver Units

Installation Flange with Pipe

ATTENTION

Important

• The pipe length must match the nominal length of the scheduled transmitter/receiver unit

depending on the gas temperature in accordance with section 2.3.2.

• The pipes may not be shortened!

Fig. 3.1 Installing the flanges with pipe

Notes Meas. a: The distance between flange and outer duct wall/insulation must be so large that

a weatherproof cover to be installed if necessary can be mounted without pro-

blems (approx. 40 mm).

Meas. b: The distance between inside duct wall and pipe end must be as large as possible

considering measure a.

TOP

Installation in a steel duct Installation in a brick duct Installation in a thin-walled

duct

Duct wall Armature base plate Junction plateFlange with pipe

A AAA

Marking for

mounting ba

approx.

1°

Ø 7

6

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Installing the Tri-Clamp® flanges

Fig. 3.2: Installing the Tri-Clamp• flanges

Installation 1“ sleeve

Fig. 3.3: Installing 1“ sleeve

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. 3.1; for Tri-Clamp® flange see Fig. 3.2; for

1“ sleeve see Fig. 3.3)

ATTENTION

Important

Make sure that parts do not fall into the duct!

‡ Put the assemly element easily inclined to below (1 to 3 °, see Fig. 3.1 and Fig. 3.2) in

the aperture (1“ sleeve centrically in the aperture) so that possible existing condensate

can drain away to the channel, and weld it

Notes – Insert the flange with pipe into aperture in such a way that the marking "Top" faces

upwards (see Fig. 3.1) .

– With brick or concrete ducts, weld the assembly element onto the armature base

plate; with thin-walled ducts, use junction plates (see Fig. 3.1)

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

approx. 5 °

approx. 1°

(Ø 3

8.1

)

(44.5)

Duct wallWelded seam

Installation in a brick duct or

thin-walled duct in the same

way as for flanges with pipe

Dimensions in mm

Ø 3

5 ...

40

Duct wallWelded seam

approx. 1° Installation in a brick duct or

thin-walled duct in the same

way as for flanges with pipe

Dimensions in mm

8008905 · © SICK AG 39




4

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. 3.4 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.

Fig. 3.4: 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.

a

b

c

Dim. Connection unit type

AK1 -N-XXXX-X-X AK1-P-XXXX-X-X

a 160 260

b 220 420

c > 350 > 550

Clearance for opening

the door

Clearance for cables

(and purge-air hoses) > 3

00

M6

(All dimensions

in mm)

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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. 3.5).

Fig. 3.5: Structure and installation dimensions for the purge-air unit

Installation work

‡ Prepare the bracket as shown in Fig. 3.5.

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

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

> 160

(55

0)

Duct

Clearance for replacing filter insert

> 1

40

(550)

Flange with pipe

47

0

Alternative:

retaining bracket50 x 5 steel pipe

DIN 2391

50

470

M 8

Clearance for fitting the weatherproof cover

Dimensions in mm

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3.2.4 Fitting the Weatherproof Covers

Weatherproof cover for analyzer

This weatherproof cover protects the transmitter/receiver unit (see Fig. 2.24). 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. 3.6).

‡ Mount the cover from above.

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

Fig. 3.6: Fitting the weatherproof cover for the analyzer

Weatherproof cover for FWSE/FWR-D housing

This weatherproof cover is secured directly onto the rear of the transmitter/receiver unit and

reflector housing (see Fig. 2.25).

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. 2.23) comprises a cover and lock set.

Installation:

‡ 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.

Lock bolt

Lifting clearanceCover Baseplate

(492) (365)

(239)> 2

50

(36

0)

Flange with pipe Threaded pin

Duct

Dimensions in mm

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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 must be

of adequate length.

DANGER

Warning

• All installation work must be carried out in line with the relevant safety regulations and

instructions listed in Chapter 1.

• Suitable measures must be taken to protect against danger.

3.3.2 Connection UnitThe power supply cables (terminals L1, N, and PE) and signal cables (analog output, digital

inputs/outputs) must be connected to the terminal strip as shown in Fig. 3.7.

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Fig. 3.7: Terminal strip connections for the customer wiring

RS 232 connection

Analog output (LiY 2x 0.5 mm² (approx.)

Digital input (maintenance) (LiY 2x 0.5 mm² (approx.)

Digital input (input for synchronization filter bag control

Maintenance

Limit value

Malfunction

115/230 V AC; 50/60 Hz

Terminal strip

White

Bro

wn

Yello

w

Gre

en

Pin

k

Gre

y

Red

Blu

e

Purp

le

Bla

ck

Gre

y/Pin

k

Red/B

lack

White/G

reen

Bro

wn/G

reen

White/Y

ello

w

Bro

wn/Y

ello

w

Bro

wn

Blu

e

Yello

w/G

reen

Signal cablePower

cable

Re

lay

1

Re

lay

2

Re

lay

3

G

nd +

0...

20

mA

–

Dig

in 1

Dig

in 2

RS 232

Txd

Rxd

GndCustomer wiring

RS 232 assignment

Socket

(9 pole)

FW100

Plug

(9 pole)

PC

2 Txd 2 Rxd

3 Rxd 3 Txd

5 Gnd 5 Gnd

Connection units with 24 V DC power supply:

Instead of L1 Instead of N

+ -

Fuse T1A

Shield

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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.

ATTENTION

Important

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

‡ 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. 3.8).

‡ Connect a protective conductor to the terminal.

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.

‡ 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 fan (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

ATTENTION

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

• The purge-air unit must be fused separately 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.

Fig. 3.8: Electrical connections for the external purge-air unit

Power supply4 x 1.5 mm2 L1 L1

U1 U1

U1

U1

V1 V1

V1

V1

W1 W1

W1

W1

PE PE

W2 W2

W2

W2

V2 V2

V2V2

U2 U2

U2

U2

L2 L2 + 24 VL3 L3 _PE PE

Low-pressure monitor

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3.3.4 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 the purge air is flowing in the right direction.


‡ Adjust the purge-air connector according to Fig. 3.9 (FW101) oder Fig. 3.10 (FW102)

(loosen the upper securing screw and rotate the connector correspondingly).

Note At applications with duct inside pressure greater 0 mbar (overpressure), adjust the con-

nector generally in accordance with Fig. 3.10 .

‡ Push the purge-air hoses DN 25 onto the purge-air connector and secure it with the hose

clamp.

Fig. 3.9: Underside of the connection unit with integrated purge-air supply, adjustment for FW101

Fig. 3.10: Underside of the connection unit with integrated purge-air supply, adjustment for FW102

Upper

securing screw

Purge-air outlet

must be closed

with cover

Purge-air outlet

Purge-air connector

Purge-air inlet

Purge-air inlet

Upper

securing screw

Purge-air outlet

must be closed

with cover

Purge-air outlet

Purge-air connector

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Optional External Purge-air Unit

‡ Push the purge-air hoses DN 40 onto the Y distributor of the optional external purge-air

unit and the purge-air reduction, and secure them with hose clamps.

‡ Close the second outlet at the Y distributor of the purge-air unit with the cover.

Fig. 3.11: Connection of the optional external purge-air unit

Note For FWSE101 transmitter/receiver units in high temperature version up to 400 C use the

purge-air reduction installed at the instrument.

Purging with Instrument air

ATTENTION

Important

The instrument air to be provided by the customer must be free of dust, oil, humidity and

condensates!

‡ Choose the reduction nozzle(scope of supply) corresponding to the admission pressure

of the instrument air and screw it into the adapter for instrument air supply.

‡ Connect the instrument air hose to the screw at the adapter.

Note The adapter for instrument air supply can be delivered on request with reducing nipple for

other connection threads.

Fig. 3.12: Connection of the adapter for instrument air supply

Optional external purge-air unit

Cover with opening (part of the purge-air reduction)

Purge-air reduction

Purge-air connector of the transmitter/receiver unit

Reduction nozzle Inner diameter Admission pressure

D3 3 mm 1 ... 3 bar

D2 2 mm 3 ... 6 bar

Reduction nozzle

G 1/4“

Purge-air connector of the transmitter/receiver unit

Connection for instrument air

Purge-air consumption approx. 6 ... 13 m³/h

(depending on admission pressure)

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3.3.5 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.

Fig. 3.13: 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).

ATTENTION

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).

RS 232 connection

Analog output (LiY 2x 0.5 mm² (approx.)

Digital input (maintenance) (LiY 2x 0.5 mm² (approx.)

Digital input (input for synchronization filter bag control

115/230 V AC; 50/60 Hz

Terminal strip

White

Bro

wn

Yello

w

Gre

en

Pin

k

Gre

y

Red

Blu

e

Purp

le

Bla

ck

Gre

y/P

ink

Red/B

lack

White/G

reen

Bro

wn/G

ree

n

White/Y

ello

w

Bro

wn/Y

ello

w

Bro

wn

Blu

e

Yello

w/G

reen

Signal cablePower

cable

Rela

y 1

Rela

y 2

G

nd +

0...

20

mA

–

Dig

in 1

Dig

in 2

RS 232

Txd

Rxd

GndCustomer wiring

Fuse T1A

Option CAN

module or 2nd

analog output

Limit value

Malfunction

Option Terminal 15 Terminal 16

CAN module CAN + high CAN - low

2nd analog output + -

Connection units with 24 V d.c. power supply:


+ -

RS 232 assignment

Socket

(9 pole)

FW300

Connector

(9 pole)

PC

2 Txd 2 Rxd

3 Rxd 3 Txd

5 Gnd 5 Gnd

Shield

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Evaluation Unit EVU

EVU at the bus end

Fig. 3.14: Connection of the optional EVU

H L

H L

CAN 1

CAN 1

15 16

15 16

15 16

15 16

15 16

15 16

EVU

Connection unit

FW100

(Connection unit

FW100)

(Connection unit

FW100)

Terminating resistor

(value equal to line impedance)

Terminating resistor of the EVU

(realized by a jumper)

Connect the terminating

resistor in the connection

unit which is removed

from the EVU furthest.

EVU in the middle of the bus

Connection unit

FW100

(Connection unit

FW100)

(Connection unit

FW100)

Connect the terminating

resistors in the connection

units which are removed

from the EVU furthest

The terminating resistor

of the EVU is not needed

(remove the jumper)

If only one FW100 is connected to the EVU, the terminating resistors must be con-

nected in the EVU and connection unit.

The terminating resistors in the connection units have to be supplied by the customer.

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LCD

If the optional LCD is installed, the terminal strip in the connection unit for the customer

wiring (see Fig. 3.7) is replaced by an additional board with terminals to which the cables

for the analog and status signals are attached as shown in Fig. 3.15.

Fig. 3.15 Terminal assignment with optional LCD

Fig. 3.16: Signal cable connection

Analog output

Malfunction

Option CAN module

or 2nd analog

output

Limit value 1Digital input (maintenance)

115/230 V AC; 50/60 Hz

Connections for the signal cables to the T/R unit

Re

lay

1

R

ela

y 2

G

nd +

0...

20

mA

–

Dig

in 1

Dig

in 2

RS 232

Txd

Rxd

Gnd

Customer wiring

RS 232 connection

(Assignment as shown in Fig. 3.7) Board

Terminal block 2

Connection for shield

Terminal block 1

Re

lay

4

Re

lay

5

Re

lay

6

Check

cycle

Maintenance

Limit value 2

Option Terminal 15 Terminal 16

CAN module CAN + high CAN - low

2nd analog output + -

Connection units with 24 V DC power supply:


+ -

Shield

Digital input (input for synchronization filter bag control)

White

Bro

wn

Ye

llow

Gre

en

Pin

k

Gre

y

Re

d

Blu

e

Purp

le

Bla

ck

Gre

y/P

ink

Re

d/B

lack

White

/Gre

en

Bro

wn/G

ree

n

White

/Ye

llow

Bro

wn/Y

ello

w

Scre

en

Board

Signal cable

50 8008905 · © SICK AG

Basics

Installing and Connecting the Transmitter/Receiver Unit

Parameterization

Parameterizing Optional Devices

FW100


Commissioning and Parameterization



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4 Commissioning and Parameterization

4.1 Basics

4.1.1 General Notes

Commissioning the FW100 involves the following steps:

‡ Mounting the transmitter/receiver unit at the duct.

‡ Customer-specific parameterization in accordance with requirements.

If the FW100 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 2.3.6 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 graphic display functions) are also available.

Certain instrument functions can only be accessed once you have entered a password (see

appendix). The access rights are assigned in 3 stages:

4.1.2 Prerequisites

‡ Laptop/PC with:

– Processor: Pentium 2 or higher

– VGA graphics card

Pin assignment – 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

FW100.

‡ 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.

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).

RS 232

socket in

connection

unit

PC

connector,

9 pole

Pin 2 (txd) Pin 2 (rxd)

Pin 3 (rxd) Pin 3 (txd)

Pin 5 (gnd) Pin 5 (gnd)

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4.2 Installing and Connecting the Transmitter/Receiver Unit

First ensure that the assembly element for transmitter/receiver unit has been mounted at

the duct (see Section 3.2.1) and the purge-air supply is in operation (insure that the flow

direction is correct and the purge-air hoses are securely attached to the connector).

4.2.1 Aligning the Transmitter/Receiver Unit

The transmitter/receiver unit (FWSE 101, FWSE 102) must be aligned in the duct so that

the particle loaded gas can flow unhindered through the measuring volume.

To ensure that the labeling on the cover of the transmitter/receiver unit is clearly legible, the

cover should rotate through 90 ° in case of mounting the transmitter/receiver unit at a

vertical duct (loosen the securing screws, rotate the cover according to Fig. 4.1 or Fig. 4.2

and remount it again).

FWSE101 Alignment

Fig. 4.1: FWSE101 alignment

Notes • To prevent the device from being aligned incorrectly the next time it is mounted (e.g. after

maintenance), the holes on the bayonet catch that are not required should be sealed

using the cover supplied.

• Use the optional elbow plug in case of mounting the transmitter/receiver unit in a vertical

duct and using the weatherproof cover for the analyzer (see Section 2.3.8).

Horizontal duct Vertical duct

Flow

direction Flow

direction

Cover

Option

Elbow

plug

Connector

Cover of the electronic unit

rotated through 90 °

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FWSE102 Alignment

Fig. 4.2: FWSE102 alignment

4.2.2 Starting up the Transmitter/Receiver Unit

‡ Connect the transmitter/receiver unit type FWSE101 and FWSE102 Tri-Clamp® to the

purge-air supply. Depending of the direction of the supply, practice the following:

– Connection unit with integrated purge-air supply:

Push the purge-air hose DN 25 onto the purge-air nozzle of the transmitter/receiver

unit and secure it with a hose clamp.

– Optional external purge-air unit:

Push the purge-air hose DN 40 onto the purge-air reduction and then the reduction

onto the purge-air nozzle of the transmitter/receiver unit, and secure hose and reduc-

tion with a hose clamp (see Fig. 3.11.).

Note For FWSE101 transmitter/receiver units in high temperature version up to 400 °C use

the purge-air reduction installed at the instrument.

– Instrument air supply:

Connect the instrument air hose to the adapter for instrument air supply (see Fig. 3.12), push the adapter onto the purge-air nozzle of the transmitter/receiver unit and

secure it with a hose clamp.

‡ Install the transmitter/receiver unit in the duct.

– FWSE101:

Insert it unit into the flange and secure it with the 3 nuts of the flange/reflector

installation set (see Section 8.1.5).

– FWSE102 Tri-Clamp® version:

Insert it in the right alignment into the Tri-Clamp® flange and secure it with the fitting.

– FWSE102 1“ version: Screw it in the 1“ sleeve, align it according to Fig. 4.2 and fix it

with the locknut. Immediately after this connect the transmitter/receiver unit to the

purge-air supply as described below.

‡ Connect the signal cable to the connection unit tightly to the connector (or elbow plug).

Horizontal duct Vertical duct

Flow

direction

Flow

directionOption

Elbow

plug

Connector

Cover of the electronic unit

rotated through 90 °

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5

4.3 Connecting the Device

‡ 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.

Fig. 4.3: „Connection“ menu

‡ Enter password level 1 (only necessary if parameters have to be changed).

‡ Connect to the FW100.

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.

Note You cannot connect to the device while the system is calculating the check values during

a check cycle (duration max. 40 s; the information is 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).

Fig. 4.4: MEPA-FW start menu

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

Menu bar

Status bar

Desktop

Tab page

Displayed only with 2nd analog output

option

Current measured valuet

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4.4 Parameterization

The FW100 is shipped with default settings (see Fig. 4.5). 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 FW100 in your installation

straight away.

4.4.1 Customer-Specific Parameterization

If you do have to change the parameters, set the password level 1 (see Section 4.1.1) once

the connection to MEPA-FW has been established, and activate "Maintenance" mode

(menu "Operating mode / Maintenance" or with external maintenance switch at the

terminals for the digital input Dig in 1). The device status is displayed in the „Measured values“ tab page by shining the system state LED „Maintenance“ (when the status is set via

MEPA-FW, the addition „(SOFT)“ for software setting is signaled). Then choose the "Parameter" tab page (see Fig. 4.5).

Fig. 4.5: "Parameter“ tab page

"Signal calculation" field

‡ Response time t90 (see Section 2.2.2)

Enter a value between 0.1 s and 600 s in the relevant field (in the format: XXX.XX).

Note The t90 time setting affects the response behavior of the measured 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 FW100 is extremely quick (noise is greater).

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‡ Calibration function

To realize the correlation between the primary measured variable scattered light intensity

and the dust concentration in the duct as exactly as possible, a regression function is in-

stalled in the field “Calibration function“. This function can be set as a quare or linear func-

tion. A total of 4 coefficient sets are supplied:

In the coefficient set 0 the regression coefficients can entered as required. This set has

to be selected if the FW100 must be calibrated to measure the dust concentration.

The coefficient sets 1 – 3 cannot be modified. The corresponding default set is activated

when you select one of these coefficient sets. You can use them if a maximum level of

precision is not essential. These sets are based on SICK’s extensive experience.

Note The regression coefficients of set 1 - 3 refer to dusts with a mean density of 2,5 g/m³, approximately spherical grain structure and even distribution of the dust in the duct cross-

section.

"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 value relay has a hysteresis equal to 10 % of the

defined limit value.

Set Setting of the regression

coefficients

Typical application Regression coefficients

square linear absolute

Set 0 freely selectable all 0 1 0

Set 1 fix; for small particle sizes

(average size 2 µm)

downstream of

cloth filter systems

0 0,5 0

Set 2 fix; for medium particle

sizes (average size 5 µm)

downstream of

electrostatic preci-

pitators

0 2 0

Set 3 fix; for big particle sizes

(average size 10 µm)

downstream of

coarse filters (cyc-

lone dust separa-

tors)

0 3 0

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"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.

‡ Define the cycle time

In the "Interval" window, enter the time between the start 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 2.2.3).

Notes • 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 FW100 is in "Maintenance" mode at the

starting time.

ATTENTION

Important

• After entering of the parameters these must be transferred to the FW100. To do this,

press the button „Write to device“.

• If you change to another tab page before the parameter are transferred to the FW100,

the parameters set before parameterization remain valid.

4.4.2 Calibration for Dust Concentration Measurement

To measure the dust concentration exactly, the correlation between the primary measured

variable scattered light intensity 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 measurement to VDI 2066 or ISO 9096 and compared to the scattered light

intensity values measured simultaneously by the FW100.

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.

‡ Check whether the regression coefficients cc2 = 0, cc1 = 1, cc0 = 0 are set in the MEPA-

FW (if not, correct them accordingly). The measured scattered light intensity is directly

assigned to the mA value as a mg value at the analog output.

‡ Estimate the necessary measuring range and enter it in the "Parameter" tab page (see

Fig. 4.5).

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

‡ Determine the regression coefficients

First, determine the correlation between the gravimetrically measured dust

concentrations and the mA values of the FW100.

c = K2 · I out² + K1 · Iout + K0 (1)

c: dust concentration in mg/m³K2, K1, K0: regression coefficients of the function c = f (Iout )

Iout: current output value in mA

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Iout = LZ + SI · (2)

SI = measured scattered light intensity value

LZ = Live Zero

URL = defined upper range limit (entered value for 20 mA;

normally 2.5 x fixed limit value)

‡ Enter the regression coefficients

There are two possibilities:

– Direct input of K2, K1, K0 into a measurement computer.

The coefficient set and measuring range entered in the FW100 will not be changed

any more.

– Use of the FW100 regression function (no measurement computer necessary).

In this case the correlation to the scattered light intensity has to be determined. To do

so, the regression coefficients cc2, cc1, cc0 to be entered in the FW100 have to be

calculated from K2, K1, K0.

c = cc2 · SI² + cc1· SI + cc0 (3)

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

c = K2 · (LZ + SI · ) + K1 · (LZ + SI · )+ K0

Using (3), the result is as follows:

cc2 = K2 · ( )

cc1 = (2 · K2 · LZ + K1) ·

cc0 = K2 · LZ2 + K1 · LZ + K0

‡ Enter regression coefficients cc2, cc1, and cc0 in the FW100.

Notes • A special program is available for calculating the regression coefficients.

• If a data memory / event memory is available, the FW100 measured values can be saved

as a file, from which the coefficients can be determined in MS Excel.

• If the new regression coefficients cc2, cc1 and cc0 are entered into the FW100 (but not

into a measurement computer), the analog output parameterization can be changed in

every way.

4.4.3 Filter Bag Control

The FW100 can be used to locate defective filter bags in cyclically cleaned hose or other

filter installations consisting of several individual filters (filter bags).

The check is carried out by continuously evaluating the cleaning peaks of all the filter bags

in a cleaning cycle. If the current filter value exceeds the limit value set in the FW100, the

limit value violation is assigned to the filter in question by means of an internal counter.

20 mA - LZ

URL

20 mA - LZ

URL

20 mA - LZ

URL

20 mA - LZ

URL

20 mA - LZ

URL

2

2

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To use this feature, the following prerequisites must be available:

• Debounced synchronization signal of 25 … 900 ms for triggering a measurement cycle.

This synchronization signal must be provided by the plant operator and applied to

terminals 10 (DIG IN2) and 4 (GND) in the FW100 connection unit (e.g. connect terminals

10 and 4 with a relay contact).

• The time between the cleaning cycles of two consecutive filter bags must be greater than

twice the t90 time of the FW100, and equal to at least 2 sec.

Parameterization

Open the „Filterwatch“ tab page and activate the button „Stop“ (the „Measure“ mode is

automatically set when opening the tab page).

Fig. 4.6: „Filterwatch“ tab page

To assign the current measured value or limit value violation to a filter bag, enter the fol-

lowing parameters (see Fig. 4.6):

Adjustment range in bra-

ckets before the re-

spective input field

• Input field "Cleaning impulses": Number of filter groups to be cleaned in a cycle

• Input field „Delay": Delay between the synchronization signal and

the time at which the dust clouds reach the

measuring site

• Input field "Impulse interval": Time that elapses before the next filter bag is

cleaned.

Measuring window

Event table

Counter for limit value violations Maximum measuring value

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4.4.4 Data Backup

In some cases, you may have to reconfigure the parameter settings. You have the following

possibilities for the registration necessary for it:

‡ Print out the parameter log ("Protocol" tab page , button "Print protocol"; see Fig. 4.7)

and keep it with your documentation on the instrument.

Prerequisite: A printer has to be avalilable at the measuring site.

‡ Save the parameter log into a file (button "Save to file", define a new name if necessary).

This can be reloaded (button „Load from file“) and printed at a later time again. The

FW100 need not be connected to do so (select „Connection“ menu, interface „Simulati-

on“).

The parameter log can also be useful for determining the cause of malfunctions (send the

log to SICK).

Fig. 4.7: Parameter log (example)

Notes • The value shown on the field "Status code“ serves for the evaluation by the manufacturer

in the case of device malfunctions. If you want to analyze the instrument status, please

change to the "Diagnosis/Test" tab page. Possible messages displayed there and

corrective measures are described in Section 6.2.

• 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. 4.8).

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Fig. 4.8: „Printer selection“ menu

4.4.5 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. 4.9).

Fig. 4.9: "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 instrument also switches to measuring mode when you close the MEPA-FW

operating and parameterization program. If “Maintenance“ mode has been set, the

FW100 automatically switches to "Measure".

• A check cycle is automatically triggered 1 min after the system has switched to measuring

mode.

• The current measuring values are displayed in the diagram when a check cycle is carried

out or if the FW100 is set into “Maintenance“ mode. Conversely, the check values are

given out at the analog output (if so parameterized, see Section 4.4.1) or the live zero

value in status maintenance.

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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.

Note The respective option must be installed in the factory (indicate it at ordering). Retrofitting is

only possible by the manufacturer.

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. If these prerequisites exist and the system has

been connected, the data memory / event memory is available on the "Data memory / event memory" tab page.

Fig. 4.10: "Data memory / Event memory" tab page

Notes • The measured value and event table displays a maximum of 10 values/events along with

their date and time. If more exist, you can go to the required area by scrolling through the

table.

• 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 what each column indicates.

Measured value table

Graphical display of

measured values

Zoom option

Zoom area

Event table

Events Centralized malfunctionIndividual faults

System mode-dependent

display

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• 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.

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. 4.11).

Fig. 4.11: Setting the storage intervals

Event memory

The following events are registered in this memory:

• When they occur (= 1):

– Start...=Device restart (reset)

– Mea...= Data memory deletion

– Eve... = Event memory deletion

• At start ( = 1) and end (= 0)

– Wro.. = Wrong file format

– Limit...= Limit value violation

– War... = Warning contamination

– Mai... = Maintenance

– M=... = Centralized malfunction

set/reset when one of the following faults is present / no longer present

- M1... = Device temperature > 75 °C- M2... = Span test not successful

- M3... = Monitor signal too low

- M4... = Real-time clock has failed

- M5... = Contamination > 70 %

- M6... = Trigger level check cycle

- M7... = Measured value override

- M8... = EEPROM check sum

- M9... = Communication with display

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Description

Note The "Save to file" and "ASCII export" functions can only be used if measured values or

events have already been read.

Function Description

"Read data memory" • When you press the "Read data memory" button, the measured values stored in the

connected FW100 are displayed in tabular and graphical 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 interval. 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 set storage interval time ("Parameter" tab

page).

"Read event memory" • When you press the "Read event memory" button, the events stored in the connected

FW100 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 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!

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Setting the real-time clock

The FW100 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. 4.12). This sets the device-

internal clock to the time and date of the connected PC.

ATTENTION

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.

4.5.2 CAN Module

An address must be assigned to the FW100 so that it can communicate with the evaluation

unit. Enter this in the "Option CAN-Bus" on the "Parameter" tab page (see Fig. 4.12). The

address can be set in a range of 73 to 127.

Fig. 4.12: Parameterizing optional devices

For communication between FW100 and evaluation unit, only the addresses 73, 74 and 75

are selectable. The assignment to the connected FW100 is displayed on the LCD of the eva-

luation unit in the following way:

• FW_1: FW100 with address 73



Only displayed if the

option is installed

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4.5.3 Second Analog Output

You can set the required measuring range in the "Option measurement range analog output

2" field on the "Parameter" tab page (see Fig. 4.13). The range limits are set in the same

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 3.3.5), 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.

Fig. 4.13: 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. 4.13).

No further parameterization is required.

Only displayed

if the option is

installed

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4.5.5 ASC Option (Automatic Self Control, only for FW102)

Using this option, the FW102 can be checked for proper device function. To do this, enter

the supervision time interval between 0 and 45 hours and the difference limit between the

highest and lowest measuring value in a range of 0.1 to 1000 mg/m³ in the „ASC - Automa-

tic Self Control“ field on the “Parameter“ tab page (see Fig. 4.14).

The device works normal if the difference value was exceeded at least once in the set time

intervall. Otherwise a malfunction message appears (“Automatic Self Control“, see Section

6.2.2).

Fig. 4.14: „Parameter“ tab page (only for FW102)

Notes • If the difference value was exceeded in a time interval, a new one is automatically started

as well after changing the check values.

• The ASC option is deactivated by entering of zero for the difference limit.

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General

Maintaining the Transmitter/Receiver Unit

Maintaining the Purge-Air Supply

Removal from Service

FW100


Maintenance



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5 Maintenance

5.1 General

The FW100 is designed for long-term and nearly maintenance-free operation. You simply

have to ensure that the optical boundary surfaces are clean and the purge-air supply is

functioning properly.

Before you carry out these maintenance tasks, you have to set the FW100 to

"Maintenance" mode. You can do this by connecting the digital input Dig in 1 (terminals 4,

9; see Fig. 3.7/Fig. 3.13/Fig. 3.15) 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 given out at the analog output.

• If the FW100 was set into "Maintenance" mode via MEPA-FW („Software maintenance“),

this status is reset at a voltage loss (in this case the FW100 switch automatically into

„Measurement“ after the operating voltage is switched on).

• If „Maintenance“ is set by an external switch, the FW100 remains in this status as long

as the contact is closed at the terminals 4, 9.

Maintenance intervals

The plant operator is responsible for defining the maintenance 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. The maintenance intervals are normally in the

starting time approx. 4 weeks for the FW101 and approx. 2 weeks for the FW102, and can

gradually be prolonged up to a year if the corresponding conditions are available. 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.

DANGER

Warning

All installation work must be carried out in line with the relevant safety regulations and

instructions listed in Section 1.3 (especially Section 1.3.3).

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5.2 Maintaining the Transmitter/Receiver Unit

DANGER

Warning

• Make sure that none of the components or accessories of the FW100 are damaged

when performing maintenance work on.

• The purge-air supply must not be interrupted.

Required tools:

• Brush, cloth, cotton buds,

• 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).

5.2.1 Cleaning the Transmitter/Receiver Unit (Externally)

Clean the outside of the FW100 transmitter/receiver unit (particularly the measuring probe)

at regular intervals. Remove deposits with water or suitable mechanical aids.

To clean the transmitter/receiver unit remove it from the duct in the following way:

‡ For FW101 loosen the securing nuts.

‡ For FW102 in Tri-Clamp® version loosen the Tri-Clamp®-Fitting.

‡ For FW102 in 1“version loosen the locknut and remove the purge-air connection.

‡ Pull or turn out (FW102 1“) the transmitter/receiver unit.

After cleaning the transmitter/receiver unit install it in the duct.

5.2.2 Cleaning the Optical Boundary Surfaces

The "optical boundary surface" is the surface of the optics or glass that faces the duct.

The optical boundary surfaces of the T/R unit only require cleaning if they are visibly dirty or

if the current degree of contamination is reached and is monitored by FW101; limit 50 %

for warning, 70 % for malfunction).

Procedure

‡ Remove the transmitter/receiver unit from the duct.

‡ Unscrew the cap (black) on the cleaning opening; for FW101 also the cover at the top of

the probe.

‡ Clean the optics carefully with cotton buds, also the light trap if necessary (see Fig. 5.1

bzw. Fig. 5.2).

‡ Reassemble the transmitter/receiver unit and install it in the duct.

Note We recommend to check the the laser beam alignment in connection with cleaning of the

optical boundary surfaces (see Section 6.3.1).

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Fig. 5.1: Cleaning the optical boundary surfaces for FW101

Fig. 5.2: Cleaning the optical boundary surfaces for FW102

Note To clean the light trap for FW102, remove the cover and the small pipe.

Cleaning opening for transmitter optics Protection tube

Cap

Transmitter

optics

Cover

Receiver optics Light trap

Cover

(Small pipe )

Transmitter

optics Receiver optics

Cleaning opening for

transmitter optics

Light trap

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Maintenance

7

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 in

short intervalls (approx. 2 weeks) after commissioning. The maintenance intervals can then

be optimized accordingly.

ATTENTION

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.

• You must ensure that the purge-air supply is functioning properly when the transmitter/

receiver unit is installed. When replacing a damaged purge-air hose, you must remove the

transmitter/receiver unit beforehand (see section 5.4).

Inspection

‡ 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

Note You must not switch off the purge-air supply when cleaning the filter housing or replacing

the filter insert, which means that the transmitter/receiver unit do not have to be removed

from the duct.

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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 remove 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.

ATTENTION

Important

You must only use a cloth soaked in water to wet-clean the components. Make sure that

you dry the components thoroughly.

Spare part:

Filter insert C1140,

Part no. 7047560

‡ Insert the new filter insert.

‡ Replace the filter housing cover and turn it against the direction of the arrow until it clicks

into position.

‡ Place the filter housing back into the connection unit.

Fig. 5.3: Changing the filter insert for the connection unit with purge-air supply

Clamping tape

Filter housing

Filter housing cover 2

Intake hose

1

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ATTENTION

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. 5.4).

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.

ATTENTION

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 purge-

air glands is unfiltered.

‡ 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.

ATTENTION

Important

You must only use a cloth soaked in water to wet-clean the components. Make sure that

you dry the components thoroughly.

Spare part:

Filter insert Micro-Top

element C11 100,

Part no. 5306091

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

‡ Mount the filter housing cover and ensure that 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.

Fig. 5.4: Replacing the filter insert

9 1 2 3 4

8 7

6 5

1 Filter housing 6 Hose clamp

2 Filter insert 7 Purge-air hose

3 Filter housing cover 8 Hose clamp

4 Quick-release lock 9 Low-pressure monitor

5 Air intake gland

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5.4 Removal from Service

The FW100 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)

ATTENTION

Important

The purge-air supply must never be switched off or interrupted when the FW100 is installed

in the duct!

Activities

‡ Loosen the cable to the connection unit.


‡ Seal the assembly elements 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.

DANGER

Warning

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

• 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

‡ 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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Malfunctions

Warnings and Malfunction Messages

Removal of Malfunctions

Test and Diagnosis Options

FW100


Troubleshooting



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6 Troubleshooting

6.1 Malfunctions

Symptom Possible cause Remedy

Transmitter/receiver unit LEDs

do not light up

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

• Processor board defective

• LCD defective

‡ Disconnect the device from the power supply

‡ Open the connection unit cover

‡ Check the fuse (see Section 7.2.1)

‡ 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)

‡ Check the plug connection and cable

ImportantAlways observe the relevant safety regulations when carrying out

work on live components!

No laser beam • Laser diode temperature >

70 °C• Laser failure

‡ Cool the device

‡ Examine operating conditions

‡ Check parameterization

‡ Contact SICK service.

Analog output on Live Zero • Device is set in status „main-

tenance“.

• Device has malfunction(s).

‡ Check device status

‡ Check the device for malfunctions and remove them as far as

possible.


No analog signal or output of a

fix value greater than Live Zero

D/A converter defective Contact SICK service.

Laser beam can be seen but no

measuring signal

• Laser beam not correctly

adjusted

• Receiver optics, optical fiber

cable or receiver electronics

defective

‡ Adjust the laser beam (see Section. 6.3.1)


Probe protection tube badly

corroded (stainless steel ver-

sion)

Unfavorable application

conditions

Replace the protection tube; with Hastelloy version if necessary

(see Section 7.1.1).

Probe internal damaged by too

high gas temperature

• Use doesn’t correspond to

the device specification (gas

temperatur is over the limit for

the selected type).

• Purge-air failure

‡ Check the device type in relation to the existing application

conditions; change t/r unit for FW101 high temperature type

if necessary.

‡ Check purge-air supply; change connection to fail-safe power

supply if necessary.

‡ Send the device to the manufacturer for repair.

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6.2 Warnings and Malfunction Messages

6.2.1 Warnings

Since no malfunctions are present when warning messages are given out, 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")). The current measuring value is given out via

the analog output.

Current warnings can also be interrogated in MEPA-FW on the "Diagnosis/Test" tab page

(see Fig. 6.1). In the "Warnings" field, all warnings currently present are displayed as a short

text. Comments are also available for each warning, although they are only displayed when

a message is selected.

Fig. 6.1: "Diagnosis/Test" tab page

If the LCD option is installed, warnings are also signaled in the second line of the display in

plain text.

These are only displayed if

the LCD option is installed

Comment fieldShort text

Comment fieldShort text

Warning message Possible cause Remedy

MEPA-FW LCD

„Current contami-nation > 50 %“ (only FW101)

• Deposits on the optical boundary

surfaces

• Purge air unclean or purge-air supply

has failed

• openings on the purge-air outlets or

aperture plates inside the probe

• Laser beam is out of alignment

‡ Clean optical boundary surfaces (see Section

5.2.2).

‡ Check purge-air filter; replace it if necessary

(see Section 5.3).

‡ Check the laser beam for free transit; clean the

probe inside or adjust the laser beam if

necessary (see Sections 6.3.1 and 6.3.2).

Compared to the reference

value, the current light intensity

in the contamination check has

dropped by more than 50 %. The

measuring signal is internally corrected.

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Notes Contamination values up to approx. 10 % displayed also after cleaning the optical boundary

surfaces indicate on wear and tear of the surfaces but have no influence on measuring

behavior and accuracy.

6.2.2 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"). The set Live Zero value is given out via the analog output.

Current malfunction messages can also be interrogated in MEPA-FW on the "Diagnosis/Test" tab page (see Fig. 6.1) in the same way as for warnings. If the LCD option is installed,

malfunction messages are also signaled in the second line of the display in plain text.

Warning message Possible cause Remedy

MEPA-FW LCD

"Test mode active"

Analog and relay outputs are set to fix

values by activation of the "Test mode

on" checkbox in the "Test output signals"

field.

You have to deactivate the "Test mode on"

checkbox before you exit the "Diagnosis/Test" tab

page or MEPA-FW (see Section 6.4.1).Measuring values are invalid

"Reset real-time clock"

"Battery low" The real-time clock can be addressed,

but it has lost the date and time.

‡ Reset the clock (see section 4.5.1)

‡ Check the battery voltage; replace battery if

necessary (see Section 7.1.4)

‡ If a warning is still present, send the device back

to the manufacturer for repair.

Only with data memory/event memory

option

Only time differences can be

measured; absolute times cannot be

specified.

Malfunction messages Possible cause Remedy

MEPA-FW LCD

"Checksum EEPROM"

"Checksum EEPROM"

• The last parameters could not be

saved due to reset or power failure

• EEPROM security area violated

Reload the device parameters

‡ Switch to the "Protocol" tab page and press the

"Load from file" button (the parameters must be

saved beforehand; see Section 4.4.4)

‡ Press the "Write to device" button (password

level 1 and "Maintenance" operating mode must be

set).

‡ Connect the FW100 to a fail-safe power supply.

A checksum is calculated from the data

in the EEPROM. This error is generated

if the data and checksum differ.

"Overflow meas. value"

"Meas. overflow" • FW101 receiver optics is not in

measurement position.

• Direct light irradiation (sun, lamp)

on receiver optics

• Damping relay defective.

‡ Start a check cycle (switch from „Maintenance“ into

„Measurement“ mode or power reset) and check

the run (remove cover at probe head).

‡ Change the arrangement so that no external light

source can shine directly on the receiver optics.


If the scattered light intensity is too

high, damping relays are activated

electronically. This error is generated if

the damping cannot be increased.

„Span test not successful“

• Sudden change in measurement

conditions during the check value

determination (e.g. foreign parts in

the laser beam)

• Direct light irradiation (sun, lamp)

on receiver optics

• Electronic defective

‡ Repeat check cycle.

‡ Check cable between laser and processor board

(see Fig. 6.3).

‡ Change the arrangement so that no external light

source can shine directly on the receiver optics.


The check value determined during

check cycle deviates more than ±2 %

from the 70 % value. The measuring

accuracy cannot be guaranteed.

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Malfunction messages Possible cause Remedy

MEPA-FW LCD

„Trigger level check cycle“ (only FW101)

• Openings on the purge-air outlets,

aperture plate or sintered metal fil-

ter inside the probe are blocked.


• Receiver optics don't move correct-

ly during the contamination

measurement

• Laser diode failure

• Failure of the motor or move me-

chanics for receiver optics (wear)

‡ Check the laser beam for free transit; clean the pro-

be inside or adjust the laser beam if necessary (see

Sections 6.3.1 and 6.3.2).

‡ Repeat check cycle after cleaning the optical

boundary surfaces.

‡ If the error appears again, deactivate the check cyc-

le („Parameter“ tab page) and restart the device

(error is no longer displayed, measurement values

are corrected with the last contamination value that

was measured).


The current contamination level could

not be calculated in the contamination

measurement (see Section. 2.2.3).

This error is generated if the minimum

light intensity is not reached (signal too

low).

„Current contami-nation > 70 %“ (only FW101)

• Deposits on the optical boundary

surfaces

• Purge air unclean or purge-air

supply has failed

• Openings on the purge-air outlets,

aperture plate or sintered metal

filter inside the probe are blocked


• Wearing of the optical fiber cable

‡ Clean optical boundary surfaces (see Section

5.2.2).

‡ Check purge-air filter; replace it if necessary (see

Section 5.3).

‡ Check the laser beam for free transit; clean the pro-

be inside or adjust the laser beam if necessary (see

Sections 6.3.1 and 6.3.2).


Compared to the reference value, the

current light intensity in the

contamination check has dropped by

more than 70 %. The measuring

accuracy cannot be guaranteed.

„Automatic Self Control“ (only FW102)

• Plant is out of order


• Openings on the purge-air outlets

are blocked

• Laser diode failure

‡ Check the plant state.

‡ Check the laser beam, adjust it if necessary (see

Section 6.3.1).

‡ Contact SICK service.Change of the dust concentration

below the set difference limit (see

Section 4.5.5)

"Monitor signal too low"

"Monitor signal" • Laser diode failure (defective)

• Transmitter diode has been

switched off because temperature

is too high

‡ Check laser current ("Protocol" tab page, "Factory

settings" field).

The value must be between 30 mA and 60 mA

(temperature dependent; permissible range:

+20 ... +70 °C).


Transmission electronics and light

intensity are checked automatically by

a monitor measurement. This error is

generated if the monitor value is not

sufficiant. The measuring values are

invalid.

"Device temperature > 75 °C"

"Temp. > 70 grdC"

• Internal device temperature too

high

• Temperature sensor defective

• Temperature sensor incorrectly

calibrated

‡ Check installation conditions.

‡ Protect transmitter/receiver unit against ambient or

radiant heat (insulate).

‡ Check the temperature sensor (comparison

measurement with separate sensor).


=> Laser is switched off until the

temperature reaches < 70 °C

"Real-time clock" "Real-time clock" Real-time clock cannot be addressed Contact SICK service.

Only with data memory/event memory

option

Control cycle cannot be triggered /

measured values cannot be saved

automatically

"No display communication"

"Comm. failureWaiting for data"

Defective connection ‡ 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 MEPA-FW

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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6.2.3 Other Malfunctions or Abnormal Behavior

Symptom Measure

Severely fluctuating measured

values, dust concentration too

high (implausible)

‡ Check that the optical boundary surfaces are not excessively contaminated or damaged.

‡ Check the laser beam for free transit; clean the probe inside or adjust the laser beam if necessary

(see Sections 6.3.1 and 6.3.2).

‡ Ensure that fittings in the electronic unit of the transmitter/receiver unit (laser board, processor

board) are secure and undamaged.

Important!The disk springs for adjusting the Laser board in the transmitter/receiver unit must have sufficient

pre-loading strength (see Section 6.3.1).

Check values generated during

the check cycle are not output

via the analog output or are

outside tolerance (± 2 %).

‡ Check the device status.

Malfunction messages (see Section 6.2.2;): 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 (if activated).

Temporary contamination on

optical boundary surfaces

‡ Check the purge-air supply (replace filter if necessary); check the hoses for damage or leakage

(replace hoses if necessary).

‡ Check the duct pressure for fluctuations or surges.

‡ Check whether the fan power is sufficient (use a more powerful fan if necessary).

‡ 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 that 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 Removal of Malfunctions

The reasons for some of the malfunctions described in the previous sections can be

recognized and cleared by the following points.

WARNING

Warning

When checking the laser beam for correct alignment, free transit and during adjustment

work, observe the safety information at all times:

• Never look directly into the laser beam.

• Never direct the laser beam at other persons.

• Make sure that the laser beam is not aimed at a reflective surface.

6.3.1 Adjusting the Laser Beam

The laser beam must be placed in the middle of the light trap opening. To check this please

do the following:


‡ Loosen the securing bolts for the cover and remove it (only FW101).

‡ For FW101 put one finger behind the light trap, for FW102 cover it of the front with half

transparent material (see Fig. 6.2).

‡ Check if laser beam is placed in the middle .

Fig. 6.2: Check of laser beam alignment

‡ If not, remover the cover of the electronic unit and adjust the laser board by means of the

3 screws (siehe Fig. 6.3).

ATTENTION

Important

Loosen the screws only as far as the adjustment is possible. The initial tension by the disk

springs must remain unchanged.

half transparent

material

Light trap opening

Laserbeam

FW101 FW102

To avoid laser adjustment

failures due to parallax

observe the horizontal

position of the laser

beam from the top and

the vertical position from

the side.

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Fig. 6.3: Adjustment points for the laser board

Assemble the transmitter/receiver unit after adjustment and install it at the duct.

6.3.2 Checking the Laser Beam for free Transit (FW101)

Check and correction of

the FW102 are only

possible by the manuf-

acturer.

The laser beam must go centrically through the aperture plate (see Fig. 6.4). If this is not so

but the laser beam is adjusted correctly, the aperture plate has to be adjusted. To this the

following steps are necessary:


‡ Remove the cover and the protection tube (see Fig. 5.1) (for protection tube use hexa-

gon socket screw key w/s 4).

Replace the sintered

metal filter in case of

bad contamination (see

Section Part no.).

‡ Check the beam transit and re-adjust the aperture plate if necessary.

If there are contaminations at the aperture plate opening, inside the sintered metal filter

or the purge-air outlets which influence the laser beam or block it, remove them.

‡ Assemble the transmitter/receiver unit, check if the laser beam is adjusted correctly ac-

cording to the previous section, and re-adjust if necessary.


Fig. 6.4: Check of the FW101 beam path

Electronic unit

Receiver diode

Laser board

Processor board

Adjustment screws

Aperture plate Cover for check Sintered Purge-air outlet

metal filter

Securing bolts Laser beam Securing bolts

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6.3.3 Checking the FW101 Receiver Optics for Correct Movement

The receiver optics is moved during a check cycle from the measuring position (approx.

15 ° inclined towards the beam axis) into the reference position and back. For different

reasons (particularly for an older device) it can happen that the receiver optics has moved

from the correct start position. In this case the check cycle cannot be exactly carried out

(→ malfunction messages „Trigger level check cycle“).

Fig. 6.5: Receiver optics

Check


‡ Remove the cover from the top of the probe.

‡ Start a check cycle (switch from „Maintenance“ into „Measurement“ mode or power

reset) and pay attention to the following (see Fig. 6.5):

– The sliding bar must be just visible in measuring position.

– The receiver optics must be freely mobile (sufficiently big slit between optics housing

and bracket).

– The laser beam must run completely centric about the optics with the movement of

the receiver optics in the reference position and back.

Correction

• Start position sliding bar

Wait during the check cycle is carried out until you can just see the sliding bar still and

disconnet at this moment the transmitter/receiver unit from the power supply (remove

the cable to the connection unit). Then connect the power supply and check again.

• Movement of the receiver optics

If the case grips during the movement, turn it carefully according to Fig. 6.5 until a suffici-

ent distance to the bracket is available.

Sliding bar Receiver optics

Movement direction of the laser beam Slit Bracket

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6.4 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. 6.6). 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. 6.6: "Diagnosis/Test" tab page

6.4.1 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.

ATTENTION

Important

You have to deactivate test mode again before you exit the "Diagnosis/Test" tab page,

otherwise the measurement cannot be carried out properly.

6.4.2 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 output if the check was

successful:

Zero point OK

Check point deviation < 2 %

Acknowledge the message by clicking "OK".

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6.4.3 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 FW100 Check Filter Set can be

used here. This equipment has been specially designed for the FW100. It consists of an

adapter for integrating special transmission filters and 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.

92 8008905 · © SICK AG

Transmitter/Receiver Unit

Connection Unit

FW100


Repairs



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7 Repairs

Any repair work on the FW300 is limited to replacing the system components listed under

the spare parts (see 8.4) (e.g. 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 and w/s 4

• 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)

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7.1 Transmitter/Receiver Unit

7.1.1 Replacing the Cover and/or Protection tube (FW101)

Spare part:

Cover, part no. 7047705;

Protection tube NL 435,

part no.7047704;

Protection tube NL 735,

part no.7047710;

Protection tube NL 435

Hastelloy, part

no.7047891; Protection

tube NL 735 Hastelloy, part

no.7047890


‡ Unplug the connection cable to the connection unit.

‡ Remove the cover and the protection tube (see Fig. 5.1).

‡ Reassemble the transmitter/receiver unit with the new parts and reconnect the

connection cable.

‡ Check the laser beam alignment (see Section. 6.3.1 and 6.3.2) and adjust it if necessary.


7.1.2 Replacing the Sintered Metall Flter (FW101)

Spare part:

Sintered metal filter

part no. 7047714



‡ Remove the cover and the protection tube (see Fig. 5.1).

‡ Loosen the securing bolts for the sintered metal filter (see Fig. 6.4) and replace it with a

new one.

‡ Reassemble the transmitter/receiver unit and reconnect the connection cable.

‡ Check the laser beam alignment (see Section. 6.3.1 and 6.3.2) and adjust it if necessary.


7.1.3 Replacing the Entire T/R Unit Connector

Spare part: En-

tire T/R Unit Connector,

part no. 7040432



‡ Remove the cover of the electronic unit.

‡ Loosen the nuts for securing the processor board (see Fig. 7.1).

ATTENTION

Important

Use only socket wrenches w/s 7 for loosening or screwing the securing nuts!

‡ Loosen the screws for securing the optical fiber cable.

‡ Loosen the connector from the processor board and remove the board carefully from the

housing.

‡ 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 (see Fig. 7.2).

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

‡ Remove the contact plate and seal (on housing interior) and replace them with new ones

(supplied with the module).

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Fig. 7.1: Electronic unit opened

Fig. 7.2: Electronic unit without laser and processor board

‡ Insert the new board with connector and re-assemble the transmitter/receiver unit by

carrying out the above steps in reverse order.

‡ Reconnect the connection cable to the connection unit.

‡ Adjust the laser beam according to Section 6.3.1.


1 Laser board

2 Nuts for securing the laser board

3 Processor bord

4 Screws for securing the optical fiber cable

5 Nuts for securing the processor board

5

4

3

2

1

5

Test point +24 V

Contact plate

Connector

T/R Unit

(assembly)

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Repairs

9

7.1.4 Checking / Replacing the Battery for the Transmitter/Receiver Unit

The battery is soldered onto the processor board 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

‡ Unplug the connection cable to the connection unit from the connector on the bottom of

the housing.

‡ 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.

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

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

‡ Remove the transmitter/receiver unit from the stack.

‡ Loosen the signal cable to the connection unit.

‡ Remove the processor board as described in Section 7.1.3.

‡ Unsolder the battery (see Fig. 7.3).

‡ Solder the new battery on.

‡ Reassemble the transmitter/receiver unit and connect the connection cable to the con-

nection unit.

‡ Install the transmitter/receiver unit at the duct.

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

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

Battery connections

+

_

Processor board

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7.2 Connection Unit

ATTENTION

Important

‡ 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 from the duct for the duration of the repair

work.

‡ Work on parts (e.g. power supply) leading mains voltage only may be executed by

persons qualified to do so (see Section 1 Safety Instructions).

7.2.1 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. 7.4).

Fine-wire fuse T1A

(5 x 20 mm)

‡ Remove the defective fuse and install the new one.

‡ Close and secure the fuse holder.

‡ Close the cover and reconnect the power supply.

Fig. 7.4: Replacing the fuse

Fuse holder

Cover

Spare fuse

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Replacing the Power Supply Unit

Spare part:

24 V 60 W power supply

unit (part no. 7047557)


‡ Loosen the lock nuts for the mounting bracket (1) (see Fig. 7.5).

‡ 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).

Fig. 7.5: Mounting bracket with power supply unit

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

Fig. 7.6: The mounting bracket and power supply unit have been removed from the connection unit

‡ Insert and connect (see Fig. 7.7) 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.

Fig. 7.7: Terminal assignment

Power

supply unit

Mounting

bracket

Mounting

bracket

Red

BlueBlue

Brown

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7.2.2 Connection Unit with Integrated Purge-Air Supply

Notes • The fuse is replaced as described in Section 7.2.1.

• The filter is replaced as described in Section 5.3.1 (part no. 7047560).

Replacing the Power Supply Unit

Spare part:

24 V 60 W power supply

unit (part no. 7047557)


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

(see Fig. 7.8).

‡ 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. 7.9) and remove the power supply unit.

‡ Insert and connect the new power supply unit (see Fig. 7.9) and reassemble the

connection unit by carrying out the above steps in reverse order.


Fig. 7.8: Mounting plate with I/O board

Fig. 7.9: Power supply unit with mounting plate (rear)

I/O board

Fuse holder

Mounting plate

Power supply Mounting plate

Black

Blue

Blue

Re

Yellow/

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Replacing the Fan

Spare part:

Fan, part no. 7047042

‡ Disassemble the filter housing (see Section 5.3.1)

‡ Remove the fan connector and protective conductor (see Fig. 7.10)

‡ Loosen the securing bolts.

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

Fig. 7.10: Fan in the connection unit with an integrated purge-air supply

‡ Take out the fan and remove the connection plate with the seal from the purge-air outlet

(see Fig. 7.11).

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

ATTENTION

Important

Do not forget the connection for the protective conductor.

‡ Install and connect the filter housing.


Fig. 7.11: Fan purge-air outlet

Securing bolts Fan

Connector

Protective

conductor

Purge-air hose

Protective

conductor

connection

Connection plate

Seal

Purge-air outlet

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7.2.3 Replacing the LCD Module

Spare part:

LCD module part no. 7040434


‡ Remove the connector on the LCD module (see Fig. 7.12).

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

‡ Install, secure, and connect the new module.


Fig. 7.12: LCD module

Connector

Lock nut

LCD module

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Standard Components

Options

Consumable Parts for 2-Year Operation

Spare Parts

FW100


Parts Overview



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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:

The different versions are listed in the following sections. They are defined by abbreviations

in accordance with the type code (see 2.3).

Internal duct diameter

[mm]

Wall and isolation thickness

[mm]

Max. gas temperature

[°C]

Transmitter/receiver unit Assembly element

> 150

max. 10

220

FWSE102 1“ NL180 1“ sleeve

FWSE102 Tri-Clamp® NL180 Tri-Clamp® flange

max. 100FWSE102 1“ NL280 1“ sleeve

FWSE102 Tri-Clamp® NL280 Tri-Clamp® flange

> 250 max. 150

FWSE101 NL435, max. 220 °C Flange with pipe

D100 NL240

400 FWSE101 NL435, max. 400 °C Flange with pipe

D100 NL240

> 300

max. 400


D100 NL500


D100 NL500

400 ... 720220 FWSE101 NL1035, max. 220 °C Flange with pipe

D150 NL800 400 FWSE101 NL1035, max. 400 °C

700 ... 1020220 FWSE101 NL1335, max. 220 °C Flange with pipe

D150 NL1100 400 FWSE101 NL1335, max. 400 °C

Connection unit(AK1-P up to +10 mbar)

Purge-air hose DN 25

External purge-air unit (optional)

(up to +70 mbar)

Instrument air(up to 1 bar)

AK1-P-XXXX-X-X 1 pc. - -

AK1-N-XXXX-X-X -

1 x

+ Purge-air reduction-

-1x Adapter for instru-

ment air supply

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8.1.1 Transmitter/Receiver Units

8.1.2 Assembly Elements

Name Part number

Transmitter/Receiver Unit FWSE101 NL435, max. 220 °C 7047500








Transmitter/Receiver Unit FWSE102 Tri-Clamp® NL180 7047505

Transmitter/Receiver Unit FWSE102 1“ NL180 7047506

Transmitter/Receiver Unit FWSE102 Tri-Clamp® NL280 7047507

Transmitter/Receiver Unit FWSE102 1“ NL280 7047508

Name Part number

FW101

Flange with pipe D100

Flange with pipe, Di = 70.2, length = 130 mm, St37 2017845



Flange with pipe, Di = 70.2, length = 130 mm, 1.4571 2017846



Flange with pipe D150

Flange with pipe, length 800 mm, St37 7047580

Flange with pipe, length 1100 mm, St37 7047581

FW102

Tri-Clamp®-Fittings with flange 1.5“ 7047520

1“ sleeve 7047526

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8.1.3 Connection Units

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

8.1.4 External Purge-Air Units (optional)

8.1.5 Miscellaneous

Name Part number

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

Name Part 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

Purge-air reduction 7047538

Name Part number

Flange/reflector installation set 2018184

Purge-air hose DN 25, length = 3 m 7047535


Adapter for instrument air supply 7047539

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Parts Overview

1

8.2 Options


8.2.2 Connection Units

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

Operating voltage 24 V DC

Name Part number

Transmitter/Receiver Unit FWSE101 Hastelloy NL435, max. 220 °C 7047570

Transmitter/Receiver Unit FWSE101 Hastelloy NL735, max. 220 °C 7047571

CAN-Bus module for Transmitter/Receiver Unit FW100 7047541

Data and event memory for FW100 7047542

Option Second analog output for FW100 7047572

Elbow plug 17 poles 7047563

Name Part 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


7040355

With integrated purge-air supply

Connection unit AK1-P-03WR-D-0


7040362

Connection unit AK1-P-10WR-D-0


7040363

Name Part 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


7040353

Connection unit AK1-N-0302-D-0


7040356

Connection unit AK1-N-1002-D-0


7040357

With integrated purge-air supply

Connection unit AK1-P-0302-N-0


7040360

Connection unit AK1-P-1002-N-0


7040361

Connection unit AK1-P-0302-D-0


7040364

Connection unit AK1-P-1002-D-0


7040365

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8.2.3 Weatherproof Covers

8.2.4 Accessories for Testing the Device

8.2.5 Miscellaneous

8.3 Consumable Parts for 2-Year Operation


8.3.2 Connection Unit with Internal Purge-Air Supply


Name Part number

Weatherproof cover for analyzer 2702407

Weatherproof cover for FWSE101 long 7047582

Weatherproof cover for housing FWSE/FWR-D 7040394

Weatherproof cover for purge-air unit 5306108

Name Part number

Check filter set FW100 7047547

Filter bracket for FW101 7047548

Filter bracket for FW102 7047549

Name Part number

Evaluation unit for connecting max. 3 x FW100/FW300 7047540

Interface cable (for connecting the evaluation unit to a laptop/PC) 7040012

Name Quantity Part number

Seal K100 (for FWSE101 NL435/735) 2 7047036

Seal K150 (for FWSE101 NL1035/1335) 2 7047937


Filter insert C1140 4 7047560

Optics cloth 4 4003353


Filter insert Micro-Topelement C11 100 4 5306091

Optics cloth 4 4003353

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8.4 Spare Parts



8.4.3 Miscellaneous

Name Part number

Cover FW101 7047705

Protection tube D60 NL 435 7047704




Protection tube D60 NL 435 Hastelloy 7047891

Protection tube D60 NL 735 Hastelloy 7047890

Protection tube D76 NL 1035 HT 7047947

Protection tube D76 NL 1335 HT 7047904

Sinter metal filter (for FWSE101) 7047714

Entire T/R Unit Connector 7040432

Seal K100 (for FWSE101 NL435/735) 7047036

Seal K150 (for FWSE101 NL1035/1335) 7047937

Name Part number

Signal cable with plug length = 3 m 7047530

Signal cable with plug length = 10 m 7047531

24 V 60 W power supply unit 7047557

Fan (for AK1-P-XXXX-X-XX) 7047042

Filter insert (for AK1-P-XXXX-X-XX) 7047560

LCD module 7040434

Name Part number

Purge-air hose DN 25 length = 3 m 7047535


Flange/reflector installation set 2018184

Filter insert Micro-Topelement C11 100 5306091

112 8008905 · © SICK AG12

Standard Settings for the FW100

Password

FW100


Appendix



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9 Appendix

9.1 Standard Settings for the FW100

9.1.1 FW101

Fig. 9.1: Standard settings for the FW101 (on delivery)

Parameter protocol 31 Aug 2004 12:59:37

------------------------------------------------------------------------------- Productinformation-------------------------------------------------------------------------------Type FW101Firmware 03001128Compilation date May 16 2003Serialnumber 04118735Option memory measurement value -Option analog output 2 -Option CAN-Bus -Device adress -Option display -------------------------------------------------------------------------------- Parameter and measured value-------------------------------------------------------------------------------Response time 60.00 secLimit value 15.00 mg/m³Limit value 2 - mg/m³Calibration function set 0Coefficients square/lin./abs. 0.00 / 1.00 / 0.00Live Zero 4 mARange LiveZero...20mA 0.00 ... 20.00 mg/m³Range2 LiveZero...20mA - mg/m³Save interval - secCheck cycle enableCheck cycle interval 08:00 hh:mmAnalog output checkpoints enableRelay 2 used for Limit valueLast measured contamination 1.4 %Laser current 30.14 mA------------------------------------------------------------------------------- Factory settings-------------------------------------------------------------------------------Scattering light factor 0.3998Gain101 5.39Gain102 25.10Gain103 115.50GainAN01 10.50Statuscode 00000000Offset 0 -0.20Offset 101 -0.17Offset 102 -0.01Offset 103 0.00Burstfrequency 10000 HzNumber of impulses per Burst 100Burstcycle 20 msecCalibration analog output 1 -12Calibration analog output 2 -

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9.1.2 FW102

Fig. 9.2: Standard settings for the FW102 (on delivery)

Parameter protocol 31 Aug 2004 12:24:05

------------------------------------------------------------------------------- Productinformation-------------------------------------------------------------------------------Type FW102Firmware 03001130Compilation date Apr 13 2004Serialnumber 04118734Option memory measurement value -Option analog output 2 -Option CAN-Bus -Device adress -Option display activated------------------------------------------------------------------------------- Parameter and measured value-------------------------------------------------------------------------------Response time 1.00 secLimit value 15.00 mg/m³Limit value 2 30.0 mg/m³Calibration function set 0Coefficients square/lin./abs. 0.00 / 1.00 / 0.00Live Zero 4 mARange LiveZero...20mA 0.00 ... 20.00 mg/m³Range2 LiveZero...20mA - mg/m³Save interval - secCheck cycle enableCheck cycle interval 08:00 hh:mmAnalog output checkpoints enableRelay 2 used for Limit valueLast measured contamination - %Laser current 30.63 mAASC - Difference limit 0 mg/m³ASC - Time interval 0 h------------------------------------------------------------------------------- Factory settings-------------------------------------------------------------------------------Scattering light factor 0.3642Gain101 5.47Gain102 25.40Gain103 115.00GainAN01 10.50Statuscode 00000000Offset 0 -0.55Offset 101 -0.25Offset 102 -0.04Offset 103 -0.01Burstfrequency 10000 HzNumber of impulses per Burst 100Burstcycle 20 msecCalibration analog output 1 -6Calibration analog output 2 -

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9.2 Password

Fig. 9.3: MEPA-FW password

The password is provided with the FW100 on delivery.

Passwort „Autorisierter Nutzer“

Nach dem Start des menügeführten Parametrierprogrammes MEPA-FW sind nur dieProgrammfunktionen verfügbar, die keinen Einfluss auf die Gerätefunktion haben.

Nicht eingewiesenes Personal kann keine Änderungen der Parameter vornehmen. ZurNutzung des erweiterten Funktionsumfanges wird das

Passwort benötigt.

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

High level password

After the start of the MEPA-FW parameterization program, the only menus available arethose which have no effect on the functioning of the device.Untrained personnel cannot alter the device parameters. To access the extended rangeof functions the

High level password must be entered

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

SICKOPTIC

SICKOPTIC

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SICK AG | Waldkirch | Germany | www.sick.com

8008

905/

V1.1

/201

2-12

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You will find our local subsidiary

or agency at:

www.sick.com

Your local sales and service partner

FW100

Date post:	18-Dec-2021
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