operation manual SMG100 industrial dust measuring - Test

operation manual
SMG100
industrial dust measuring device
SAXON Junkalor GmbH
Alte Landebahn 29
06846 Dessau-Roßlau
Germany
Tel.:
++49 / 340 / 5510 200
Fax:
++49 / 340 / 5510 201
Hotline: ++49 / 340 / 5510 214
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Without prior written permission from
SAXON Junkalor GmbH no part of
this manual may be reproduced or
transmitted
by
electronic
or
mechanical means, by photocopying
or any other means of recording and
storage.
©2014 SAXON Junkalor GmbH. All rights reserved.
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0.
PREAMBLE ..................................................................................................5
1.
SAFETY HINTS ...................................................................................5
1.1.
1.2.
GAS SAFETY ...........................................................................................5
ELECTRICAL SAFETY...............................................................................5
2.
INSTALLATION AND ASSEMBLY .................................................6
2.1.
2.2.
2.4.
SCOPE OF DELIVERY ...............................................................................6
PLACE OF INSTALLATION ........................................................................6
SELECTION OF POINT OF PROBE ..............................................................7
3.
COMPONENTS .......................................................................................8
3.1. OPERATING AND DISPLAY ELEMENTS .....................................................8
3.2. REAR PANEL ...........................................................................................8
3.2.1.
MECHANICAL CONNECTORS ...............................................................8
3.2.2.
WATER TRAP AND FILTER...................................................................8
3.2.3.
DATA TRANSMISSION ..........................................................................9
3.2.3.1.
MEARURING VALUES ......................................................................9
3.3.2.2.
BLUETOOTH ....................................................................................9
3.3.2.3.
POWER ............................................................................................9
4.
STARTUP AND MEASUREMENT .....................................................10
4.1. STARTUP ...............................................................................................10
4.2. MEASUREMENT .....................................................................................10
4.3. MENUES ................................................................................................10
4.3.1.
MEASURING MENU ...........................................................................10
4.3.2.
PARAMETERS ....................................................................................10
4.3.2.1.
SOFTWARE INFORMATION .............................................................10
4.3.2.2.
HARDWARE INFORMATION ...........................................................11
4.3.2.3.
LEAK TEST ....................................................................................11
4.3.2.4.
SOFTWARE UPDATE ......................................................................11
4.3.2.5.
LANGUAGE....................................................................................11
4.3.2.2.
SENSOR CHECK .............................................................................11
5.
MAINTENANCE ...............................................................................12
5.1.
5.2.
5.2.1.
5.2.2.
5.2.
5.3.
5.4.
5.5.
VISUAL CHECK .....................................................................................12
CLEANING .............................................................................................12
CLEANING AFTER THE MEASUREMENT .............................................12
WEEKLY CLEANING ...........................................................................13
CHANGE OF FILTER INSERT ...................................................................13
WATER TRAP ........................................................................................13
LEAK CHECK.........................................................................................14
CHANGE FUSES .....................................................................................14
6.
6.1.
6.2.
6.3.
7.
7.1.
7.2.
7.3.
7.4.
7.5.
7.6.
SENSOR CHECK AND CALIBRATION ...........................................15
PRELIMINARY OF SENSOR CHECK .........................................................15
SENSOR CHECK .....................................................................................15
CALIBRATION........................................................................................15
TROUBLESHOOTING.........................................................................16
DEVICE DON´T OPERATE .......................................................................16
ERROR MESSAGES ................................................................................16
ERRORS AT SENSOR CHECK ....................................................................17
RS232 – NON OR WRONG DATA .............................................................17
BLUETOOTH – NO CONNECTION OR NO DATA ........................................17
FURTHER ERRORS ..................................................................................17
8. DECOMMISSIONING AND DEPOLLUTION ......................................18
9. RESHIPMENT ...........................................................................................18
10. WEAR AND SPARE PARTS ..................................................................19
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11.
11.1.
11.2.
11.3.
11.4.
11.5.
11.6.
11.7.
11.8.
TECHNICAL DATA ......................................................................... 20
OPERATING CONDITIONS .................................................................. 20
TRANSPORT AND STORAGE CONDITIONS .......................................... 20
MEASURING PARAMETERS ............................................................... 20
MEDIA CONDITIONS ......................................................................... 20
SYSTEM TIMINGS .............................................................................. 20
INTERFACES ...................................................................................... 21
CONSTRUCTION AND ASSEMBLING ................................................... 21
POWER SUPPLY................................................................................. 21
12.
WARRANTY ..................................................................................... 22
13.
PACKAGING AND TRANSPORT ................................................. 22
14.
ANNEX ............................................................................................... 23
ABB.1 SMG100 – FRONT PANEL ..................................................................... 23
ABB.2 SMG100 – REAR PANEL ....................................................................... 23
ABB.3 DIMENSIONS .......................................................................................... 24
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0.
Preamble
In the follwing operation manual we give you all information you will
need for a stable and proper operation of the dust measuring device
SMG100.
If you have questions about any points, if you have hints or if you miss
information we are glad to get your call. You can reach our serviceteam at
+49 340 5510 214
1.
Safety Hints
For your safety please consider the following hints!
A save and error free operation of SMG100 requires an appropriate
transport and storage, professional installation and initiation, an approved
operation and an accurate maintenance.
1.1.
Gas Safety
Without and special safety procedures it is not allowed to measure flammable or explosive gas or dust mixtures with the SMG100. This does also
for gas or dust mixtures which can be flammable or explosive in environmental air. Possible safety procedures may be e.g. the flushing with an inert
gas or the application of flame barriers.
1.2.
Electrical Safety
If it is necessary to open the device for justification, maintenance or repair
it has to switch voltage free first (remove power plug).
If it is necessary to work under live-work conditions during adjustment or
maintenance work, the work have to carried out only by trained personnel
familiar with the potential hazards of the instrument as well as its operation
and maintenance. The personnel must be in possession of appropriate qualifications for the tasks performed.
Strictly obey any safety regulations marked with "Caution" in these operating instructions! Failure to comply with these safety specifications may
result in fatal accidents, bodily harm or damage to the instrument.
If hazard-free operation of the instrument can no longer be assumed, immediately remove the instrument from service and secure it against unauthorized startup.
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2.
Installation and Assembly
2.1.
Scope of Delivery
The scope of delivery of SMG100 comprises:
•
•
•
•
•
•
•
2.2.
dust measuring device SMG100
power cord with two-pole and earthing-pin plug
probe with 2m heated hose (option)
zero point filter
checkpen (option)
cleaning set (option)
CD with operation manual and software
Place of Installation
Select a place of installation near of probe point. Extending of hose is not
allowed. At long distances from probe point to place of evaluation please
use the wireless Bluetooth interface.
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Put the SMG100 at a horizontal stable surface, the inclination (angle to
horizontal layer) may have maximum ±15°.
Protect the dust measuring device against direct solar radiation and heavy
heat radiation. Please consider the limit value for the temperature.
The installation place also should be free of shocks or vibrations.
Please take care that there is enough free air around the analyzer, please
prevent from heat accumulation.
Caution!
It is not allowed to operate in explosion hazardous areas.
2.4.
Selection of Point of Probe
An error free and low maintenance operation with correct measure values
is only possible by proper installation of the complete measuring system.
Most important is the selection of point of probe itself.
Please observe following hints:
•
The particle flow at the probe point must be mixed all-over. Beware
of probe points directly after changes of flow direction or behind
components in the flow (e.g. other probes, electro filters). The particle flow should flow at least a distance of two times of pipe diameter unhindered to the point of probe.
•
Place the probe cone in the middle of particle leading pipe.
•
To prevent against condensing water the hose is heated. Please
don´t extend it with another hose (heated or unheated), because this
can lead to wrong measured values. In worst case the SMG100 can
be damaged irreversible.
•
High dew points lead to condensate inside of probe and device. If it
is not possible to prevent from high dew points please do a maintenance after every measurement.
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3.
Components
3.1.
Operating and Display Elements
3.1.1. Power Switch
With the power switch the SMG100 is started. A light inside shows the
current status.
3.1.2. Operation Panel
All inputs and outputs are done at the touch screen. It shows the measured
values, the device parameters and the data of dust measuring device
SMG100.
The temperature module in the lower part controls the heating of the probe.
3.2.
Rear Panel
3.2.1. Mechanical Connectors
At the back panel you find following connectors:
gas input (snap connector)
gas output
condensate output (tap)
All connectors are labeled.
Never close the gas output during operation.
3.2.2. Water Trap and Filter
The water trap collects the water during measurement. Check it after
every measurement and drain it on demand.
The filter protects the gas guides from dust. Check the status of the filter
after everry measurement and change it on demand.
If the filter is fogged inside drain it with the tap at the bottom.
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3.2.3. Data transmission
3.2.3.1.
Mearuring Values
From the serial interface at the rear panel you can request device and
measurement data during the measurement.
USB connector ist for service only.
3.3.2.2.
Bluetooth
You can forward device and measuring data live by Bluetooth to a suitable
device. Bluetooth Class 1 has a range of up to 100m.
3.3.2.3.
Power
Only use the power voltage and frequency given at the type label.
Caution!
BA SMG100
Only connect the SMG100 with a power supply
with a grounding-type plug.
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4.
Startup and Measurement
4.1.
Startup
Check the device visual according point 7.1.
Connect the power plug of probe. Therefore plug the connector and tighten
it manually. Connect the zero point filter.
If you want to use RS232 interface, connect it with the notebook / computer.
Connect the SMG100 with the power supply and turn it on. It starts with a
warm-up phase.
On demand couple the Buetooth link with the notebook / computer now.
4.2.
Measurement
Press the button measuring and select your required measurement time in
menu. Than do the zero point justification, remove the zero point filter and
plug the gas connector of probe.
Now start the measurement. You can stop it every time.
4.3.
Menues
4.3.1. Measuring
You start the measurement in measurement menu. Set the duration of
measurement, do the zero point justification and start the measuring.
During measuring you will see the corrent particle mass concentration
related to DEHS as well as measured minimum and maximum values.
With the stop button you can interrupt the measuring.
4.3.2. Parameters
4.3.2.1.
Software Information
The menu software information shows the serial numbers of measuring
chamber and of the device. Also you see the Bluetooth adress of your
SMG100.
These and further information showed in this menu may needed for
service.
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4.3.2.2.
Hardware Information
Inside of SMG100 are a lot of sensors for temperature, pressure and flow
to watch and control the functions of SMG100.
4.3.2.3.
Leak Test
The successfull leak test guarantees the reliable media transport inside of
SMG100.
4.3.2.4.
Software Update
This point the service team needs to update your SMG100.
4.3.2.5.
Language
Choice your desiged menu language.
4.3.2.2.
Sensor Check
The sensor check tests the precision of the SMG100. For this sensor
check you need the checkpen you can source from our company.
By the sensor check you spare expensive and extensive check-ups at the
manufactures site, and you get the guarantee that you SMG100 measures
correct data.
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5.
Maintenance
Caution !
Live parts may be exposed when covers are removed. Terminals may be
live.
The instrument must be disconnected from the supply before being opened
for repair and maintenance purposes.
If repair or maintenance of the instrument is possible only with the
instrument open and still connected to the power supply, then this work
may
be carried out only by trained personnel who are fully aware of the hazards
involved.
Always replace fuses with new fuses of the same type and current rating.
If safe operation of the instrument can no longer be guaranteed, remove it
from service and ensure that it cannot be started up accidentally.
5.1.
Visual Check
Check your SMG100 at apparent failures and damages. Watch especially
at:
- apparent damages at SMG100
- scratches and damages at touch screen
- cracks at the filter
- not fixed or damaged hoses
If you find failures or damages don´t start the SMG100 and call our service
team.
5.2.
Cleaning
5.2.1. Cleaning after the Measurement
Turn off your SMG100 before you clean it.
Don´t use any kind of liquids!
Clean the display with a dry cloth.
Flush possible condensate with the tap and flush the condensate trap.
Blow through the probe and the hose with a hand ball pump.
Caution! Never use pressurized air.
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5.2.2. weekly Cleaning
For the weekly cleaning you need the cleaning set which you can source
from us.
Do the cleaning after 5.2.1 first.
On demand change the filter insert (point 5.3.).
Turn the SMG100 upside down. Open the bottom plate by removing of the
knurled screws. Unscrew the two measuring chamber screws, remove the
chamber lid and put it sidewise at the bottom.
Clean the gas input at the rear panel with the small brush from your cleaning set. Next take the big brush and clean the gas pipe in the middle of the
chamber. Clean the optics inside of the chamber, the measuring chamber
and the chamber lid with a cleaning cloth you find in the cleaning set.
Put the chamber lid back on the chamber and screw it manually. Fix the
bottom plate.
Finally do a leak test (point 5.5).
5.3.
Change of Filter Insert
If the filter insert has fade to gray or at least after a month please change it.
•
•
•
•
•
•
5.4.
unscrew the clear cap of the filter and check it for cracks
unscrew the stay with the filter insert
remove the insert, put the new insert on the stay and turn it in the
filter carrier so that it is not possible to turn the insert
check the seal ring inside of the filter carrier
turn the clear cap on the filter manually, check it for correct fitting
do a leak test (point 5.5)
Water Trap
The water inside of the water trap may never reach the lower yellow ring.
If there is too much water in the water trap the gas flow is interrupted and
the measurement shows wrong measuring values.
Pull the water trap out of its clip and remove both hoses. Pull the lower
insert out of the clear cap, flush out the water and dry it with a dry flufffree cloth. Also check the water trap for pollution.
Assembly the water trap, mount the hoses and put it back on the rear panel.
Watch for the mounting direction (arrows upward).
Do a leak test (point 5.5).
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5.5.
Leak Check
After every maintenance and after a long-time non operation do a leak test
at your SMG100.
Start it at parameters – leak test and follow the instruction at the display.
If the leak test is not successful please check all external components
(hoses, filter, seal rings, measuring chamber lid, water trap) for cracks and
damages. Also check that the condense tap is closed.
If you don´t find the cause for leakage please call our service.
5.6.
Change Fuses
Turn off your SMG100 and unplug the power cord.
The fuses are located in the jack for power cord at the rear panel of
SMG100.
fuse parameters:
for 200 ... 240 V :
2,0 A lazy
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6.
Sensor Check and Calibration
Your SMG100 is a sensitive optical measuring device. To guarantee the
precision of your measurement it has to check every year.
6.1.
Preliminary of Sensor Check
To do a successfull sensor check it is necessary that your SMG100 operates
properly. If you see one or more error messages please call our service.
Do a cleaning according point 5.2.2.
6.2.
Sensor Check
The sensor check determines the internal parameters of SMG100 for
measurement of particle mass concentration.
For the sensor check you need a checkpen. If you don´t have on, you can
source it from our service team. Alternative our service team can do the
sensor check and further mainenance.
Start the sensor check and follow the instructions at the display.
.
6.3.
Calibration
If the sensor check is not successfull your SMG100 don´t measure correctly
and has to recalibrate.
For recalibration you must ship you SMG100. Please call our service for
the nearest service point.
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7.
Troubleshooting
At this part of manual you find information about causes of malfunctions
of your SMG100 and corresponding hints for fault recovery.
If you can remove a malfunction please call our service.
7.1.
Device don´t Operate
error
no display
dubious or incorrect display
possible cause
non or wrong power
supply
fuse damaged
error inside of device
init error
hints / correction
check power cord and
power supply
change fuse
call service
turn device device off
and after 1min on
call service
error in electronics
7.2.
Error Messages
Following error messages you can find at the upper right corner at the
screen.
error
bottom plate open
possible cause
bottom plate not fixed
or in wrong direction
temperature error
operation temperature
of a heated component
not correct
flow error
leak in gas flow or
blocked gas flow
pump error
pump or electronic damaged
error at the probe
green temperature
display not 60 (after >10min)
implausible measuring values
device polluted
device or probe are
leaky
BA SMG100
Ausgabe 1
hints / correction
please check bottom
plate for correct
assembly
if you already see this
error messages after 10
min please call our service
check the external components and the measuring chamber lid for
cracks and fixture. Also
check the assembly of
filter and water trap. Do
a leak check
call our service
change probe
please clean the
SMG100 (point 5.2.1.)
check, do leak test
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error in electronics
7.3.
call service
errors at sensor check
error
sensor check not
successfull
possible cause
device polluted
hint / correction
please clean your
SMG100 ( point 5.2.1)
and repeat the
sensorcheck
check it, on demand call
service
error messages
7.4.
RS232 – non or wrong data at notebook / computer program
error
no data
possible cause
wrong cable or cable
damaged
wrong protocol
data incorrect or
contain special
characters
protocol error
7.5.
hint / correction
please use a standard
RS-232 cable
please use following
configuration:
115200bps, 8bit, one
stopbit, no parity, no
hardware protocoll
please use following
configuration:
115200bps, 8bit, one
stopbit, no parity, no
hardware protocoll
Bluetooth – no connection or no data
Fehler
Bluetooth link not
possible
Mögliche Ursache
wrong SMG100
Hinweise / Behebung
please check for the
right SMG100
Please ensure that the
receiver also supports
Bluetooth Class 1
distance to high
7.6.
further errors
If you get other errors as described please call our service team.
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8. Decommissioning and Depollution
Turn off the power supply.
To protect the environment in many countries it is not allowed
to depollute the SMG100 with urban waste (haushold
garbage). Please depollute the SMG100 according the local
laws / rules.
The materials the SMG100 is made from recyclable materials. We
developed the SMG100 also for a simple seperation of components, we
use reusable materials.
If you don´t have the possibility to depollute the old device please call our
service. Our service co-operates with you to depollute the device in our
company.
9. Reshipment
To protect the environment and our employees we can only carry, check,
repair or depollute devices without any risks for our team and
environment.
Please add the contamination declaration to every return. You find the
form at www.saxon-junkalor.de unter Service. Reshipments without
contamination declaration we don´t accept.
If you have worked with hazardous materials please execute an approved
decontamination and add a certificate of decontamination to the shipment.
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10. Wear and Spare Parts
zero point filter
filter insert
stay for filter insert
clear cap for filter with seal ring
seal ring for clear filter cap
water trap
site cover 2pcs
bottom plate
set knurled screws for bottom plate
edge protector (rubber bumps) 2 pcs
fuses (10pcs)
cleaning set
- 10x cleaning cloth
- 2x big cleaning brush
- 10x small cleaning brush
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Art. 38728
Art. 38723
Art. 38739
Art. 38741
Art. 38962
Art. 39277
Art. 38299
Art. 38581
Art. 38932
Art. 38548
Art. 39035
Art. 39309
19
11.
Technical Data
11.1.
Operating Conditions
operating temperature:
+5°C ... +40°C
+41°F … +104°F
< 75% annual average
95% at most 30 days a year
dew not allowed
860 ... 1060 hPa
horizontal or inclination of at
most 15° in all directions
relative humidity:
air pressure:
orientation:
11.2.
Transport and Storage Conditions
temperature:
-25°C ... +65°C
-13°F … +149°F
at most 95% relative humidity
humidity:
11.3.
Measuring Parameters
measuring range:
precition:
repeatability:
particle dimensions:
reference:
11.4.
5 … 150mg/m³
< ±5% of range
< ±3%
0.1 … >10µm
normalized at DEHS
Media Conditions
gas temperature:
flow:
dew point:
probe
11.5.
< 400°C / <752°F
2,88Nl/min ±5%
< 70°C / < 158°F
hot extractive / cold extractive
isokinetic
System Timings
response time:
warm-up time:
zero point:
< 15s (at 2m probe)
< 10min
20s
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11.6.
Interfaces
RS232:
115200bps
one stopbit
no parity
no hardware protocol
Bluetooth Class 1 (100m)
Bluetooth:
11.7.
Construction and Assembling
type:
material of housing:
dimensions of housing:
protection class:
weight:
11.8.
mobile measuring system
aluminium
190 x 275 x 330mm³
IP 40
7,5kg / 16,5lbs
Power Supply
voltage:
frequency:
power consumption:
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230 VAC +10/-15%
50 Hz ±2 %
220 VA
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12.
Warranty
We give a warranty of 24 months at appropriate handling and operation of
SMG100.
Not included are all wear parts as filters and filter inserts.
We only accept a guarantee claim if we got a guarantee notification with a
SAXON Junkalor GmbH register number. Also we only accept guarantee
claims notified with the Junkalor faximile document.
For repair services we give a guerantee of six months. This is only valid for
errors reported by customer and corrected by Junkalor. If there will be
another error during this time this error isn´t covert by the given guarantee.
The guarantee expired at unauthorized treatment.
13.
Packaging and Transport
Please ship your SMG100 in the original package. If you don’t have it put
your SMG100 in at least two layers of air bubble film and put it in a suitable
box. Please check that spaces in the box are filled with shock damping material (e.g. cellular material).
If you send us a SMG100 please note that there must be the contamination
declaration (www.junkalor.com at service) included!
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14.
Annex
Abb.1 SMG100 –
front panel
1
2
3
4
touch screen
probe heating
power switch
rubber protectors
Abb.2 SMG100 –
rear panel
1
2
3
4
5
6
7
8
9
media input
probe heating
water trap
filter
RS232
power connector with
fuse
condense tap
media output
rubber protectors
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280
Abb.3 Dimensions
365
205
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