Operating Instructions
O P E R A T I N G INSTRUCTIONS
I N S T R U C T I O N SMMMI
MMMOPERATING
DUSTHUNTER SP100 Ex
Dust Concentration Monitor
Installation, Operation, Maintenance
Described Product
Product name:
DUSTHUNTER SP100 Ex
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone:
+49 35205 524-10
Fax:
+49 35205 524-50
E-Mail:
info.pa@sick.de
Trademarks
Windows is a Microsoft Corporation trademark.
Other product names used in this document may also be trademarks and are only used
for identification purposes.
Legal Information
This document is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK Engineering GmbH. Reproduction of this document or parts of this
document is only permissible within the limits of the legal determination of Copyright
Law.
Any modification, shortening or translation of this document is prohibited without the
express written permission of SICK Engineering GmbH.
The trademarks stated in this document are the property of their respective owner.
© SICK Engineering GmbH. All rights reserved.
Original document
This document is an original document of SICK Engineering GmbH.
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Contents
Contents
Contents
1
Important Information .............................................................................. 7
1.1
1.2
Main hazards................................................................................................... 7
1.1.1
Hazard through hot and/or aggressive gases and high pressure 7
1.1.2
Hazards through electrical equipment .......................................... 7
1.1.3
Hazards through laser beam.......................................................... 7
1.1.4
Hazards through explosive or combustible gases......................... 7
Symbols and document conventions ............................................................. 8
1.2.1
2
1.2.2
Warning levels and signal words.................................................... 8
1.2.3
Information symbols ....................................................................... 8
1.3
Information on operation in potentially explosive atmospheres................... 9
1.4
Intended use .................................................................................................10
1.5
Responsibility of user....................................................................................11
1.5.1
General information......................................................................11
1.5.2
Safety information and protective measures ..............................11
Product description .................................................................................14
2.1
2.2
2.3
2.4
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Warning Symbols ........................................................................... 8
Measuring principle, measured variables....................................................14
2.1.1
Functional principle ......................................................................14
2.1.2
Response time ..............................................................................15
2.1.3
Function check..............................................................................16
Device components ......................................................................................18
2.2.1
Sender/receiver unit ....................................................................19
2.2.2
Flange with tube ...........................................................................21
2.2.3
MCU control unit ...........................................................................22
2.2.3.1
Standard interfaces ..................................................22
2.2.3.2
Versions .....................................................................23
2.2.3.3
Type code ..................................................................25
2.2.3.4
Modules .....................................................................26
2.2.4
Optional external purge air unit ...................................................28
2.2.5
Installation accessories................................................................28
2.2.6
Non-return valve ...........................................................................29
2.2.7
Test equipment for linearity test ..................................................29
Device configuration .....................................................................................30
2.3.1
Sender/receiver unit ...................................................................30
2.3.2
Voltage and purge air supply .....................................................30
SOPAS ET (PC program) ................................................................................31
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Contents
3
Assembly and Installation...................................................................... 32
3.1
Project planning............................................................................................ 32
3.2
Assembly ....................................................................................................... 34
3.3
3.2.1
Fitting the flange with tube .......................................................... 34
3.2.2
Fitting the MCU control unit ......................................................... 36
3.2.3
Fitting the optional external purge air unit ................................. 38
3.2.4
Assembly work.............................................................................. 39
3.2.5
Fitting the weatherproof cover .................................................... 40
Electrical installation .................................................................................... 41
3.3.1
Electrical safety ............................................................................ 41
3.3.1.1
3.3.1.2
Lines with correct rating........................................... 41
3.3.1.3
Grounding the devices.............................................. 41
3.3.1.4
Potential equalization of explosion-protected
devices ...................................................................... 41
3.3.1.5
Responsibility for system safety .............................. 42
3.3.2
General information, prerequisites ............................................. 43
3.3.3
Installing the purge air supply ..................................................... 44
3.3.4
3.3.5
3.3.6
4
3.3.3.1
Control unit with integrated purge air supply
(MCU-P) ..................................................................... 44
3.3.3.2
Optional external purge air unit ............................... 44
3.3.3.3
Purging with instrument air ..................................... 46
3.3.3.4
Installing the non-return valve option...................... 46
Connecting the MCU control unit................................................. 47
3.3.4.1
Work to be done ....................................................... 47
3.3.4.2
MCU processor board connections .......................... 48
3.3.4.3
Connection of connection line to MCU .................... 49
3.3.4.4
Standard connection ................................................ 50
Connecting the MCU remote control unit .................................... 51
3.3.5.1
Connection to the MCU control unit......................... 51
3.3.5.2
Connection to the MCU remote control unit............ 51
Fitting the interface and I/O module (option) ............................. 52
Start-up and Parameter Settings .......................................................... 53
4.1
Basics............................................................................................................ 53
4.1.1
General information ..................................................................... 53
4.1.2
Installing SOPAS ET ...................................................................... 53
4.1.2.1
4.1.3
4.1.4
4.2
Password for SOPAS ET menus................................ 53
Connection to the device via USB line ........................................ 53
4.1.3.1
4
Properly installed power isolating switches............. 41
Finding the DUSTHUNTER COM port........................ 54
Connection to the device via Ethernet (option) .......................... 55
Installing the sender/receiver unit .............................................................. 56
4.2.1
Adapting the sender/receiver unit to the flow direction ............ 56
4.2.2
Fitting and connecting the sender/receiver unit ........................ 57
4.2.3
Assigning the sender/receiver unit to the measuring location
(in SOPAS ET)................................................................................ 58
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Contents
4.3
4.4
4.5
Standard configuration .................................................................................60
4.3.1
Assigning the MCU to the sender/receiver unit ..........................60
4.3.2
Factory settings.............................................................................61
4.3.3
Determining the function check...................................................62
4.3.4
Setting the analog outputs parameters.......................................63
4.3.5
Setting the analog inputs parameters .........................................65
4.3.6
Setting the response time ............................................................66
4.3.7
Calibration for dust concentration measurement .......................67
4.3.8
Data backup in SOPAS ET ............................................................69
4.3.9
Starting measurement mode .......................................................70
Setting the Interface module parameters....................................................71
4.4.1
General information......................................................................71
4.4.2
Setting the Ethernet module parameters .................................72
Operating/setting parameters via the optional LC-Display .........................73
4.5.1
General information on use .........................................................73
4.5.2
Password and operating levels ....................................................73
4.5.3
Menu structure .............................................................................74
4.5.4
Parameter setting .........................................................................74
4.5.5
5
Sender/receiver unit .................................................77
Using SOPAS ET to modify display settings .................................78
5.1
General ..........................................................................................................80
5.2
Maintenance on the sender/receiver unit ..................................................82
5.4
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MCU ...........................................................................74
4.5.4.2
Maintenance.............................................................................................80
5.3
6
4.5.4.1
5.2.1
Cleaning the optics of the sender/receiver unit..........................82
5.2.2
Checking the contamination value ..............................................83
5.2.3
Checking restricted breathing ......................................................84
Maintenance on the purge air supply ..........................................................85
5.3.1
Control unit MCU with integrated purge air supply .....................86
5.3.2
Optional external purge air unit ...................................................87
Shutdown.......................................................................................................88
Troubleshooting .......................................................................................89
6.1
General ..........................................................................................................89
6.2
Sender/receiver unit .....................................................................................91
6.3
MCU control unit ...........................................................................................92
6.3.1
Malfunctions .................................................................................92
6.3.2
Warning and error messages in the SOPAS ET program ............92
6.3.3
Replacing the fuse ........................................................................94
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Contents
7
Specifications........................................................................................... 95
7.1
Compliances ................................................................................................. 95
7.2
Technical Data .............................................................................................. 96
7.3
Dimensions, part Nos. .................................................................................. 98
7.4
7.5
6
7.3.1
Sender/receiver unit ................................................................... 98
7.3.2
Flange with tube ........................................................................... 99
7.3.3
MCU control unit.........................................................................100
7.3.4
Optional external purge air unit .................................................102
7.3.5
Weatherproof covers ..................................................................103
Accessories .................................................................................................104
7.4.1
Line sender/receiver unit - MCU................................................104
7.4.2
Purge air supply..........................................................................104
7.4.3
Assembly parts ...........................................................................104
7.4.4
Device check accessories ..........................................................104
7.4.5
Options for MCU control unit .....................................................105
7.4.6
Miscellaneous ............................................................................105
Consumable parts for 2-years operation ...................................................105
7.5.1
Sender/receiver unit ..................................................................105
7.5.2
MCU with integrated purge air supply .......................................105
7.5.3
Optional external purge air unit .................................................105
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IMPORTANT INFORMATION 1
1
Important Information
1.1
Main hazards
1.1.1
Hazard through hot and/or aggressive gases and high pressure
The optical subassemblies are fitted directly on the gas-carrying duct. In installations with a
low hazard potential (no danger to health, low pressure, low temperatures in the gas duct),
these units can be installed and removed while the installation is in operation, providing
the applicable specifications and safety regulations for the system are adhered to and all
necessary and suitable protective measures are taken.
WARNING: Danger from exhaust gas
▸ In plants with gases detrimental to health, overpressure, high temperatures,
risk of explosions, the sender/receiver unit fitted on the duct may only be
installed/removed when the plant is at a standstill.
1.1.2
Hazards through electrical equipment
WARNING: Danger through power voltage
▸ Disconnect power supply lines before working on power connections or
parts carrying power voltage.
▸ Refit any contact protection removed before switching the power voltage
back on again.
1.1.3
Hazards through laser beam
WARNING: Hazards through laser beam
!▸ Never look directly into the beam path
!▸ Do not point the laser beam at persons
▸ Pay attention to laser beam reflections.
1.1.4
Hazards through explosive or combustible gases
The DUSTHUNTER SP100 Ex measuring system may be used in potentially explosive atmospheres only according to the respective specifications.
WARNING: Hazards by explosive or combustible gases
▸ In potentially explosive atmospheres, only use the version of the DUSTHUNTER SP100 Ex specified for such use (see “Information on operation in
potentially explosive atmospheres”, page 9).
WARNING: Hazards by explosive or combustible gases
▸ Only specially trained service personnel may open the sender/receiver unit,
so that ignition protection is maintained.
This service personnel must have been specially trained by SICK for the
DUSTHUNTER SP100 Ex measuring system.
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1 IMPORTANT INFORMATION
1.2
Symbols and document conventions
1.2.1
Warning Symbols
Symbol
Significance
Hazard (general)
Hazard by voltage
Hazards through laser radiation
Hazard in potentially explosive atmospheres
1.2.2
Warning levels and signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
NOTICE
Hazard which could result in property damage.
1.2.3
Information symbols
Symbol
Significance
Important technical information for this product
Important information on electric or electronic functions
Information on product condition relating to protection against explosions (general)
Information on product condition with regard to Explosion Protection Directive ATEX
2014/34/EU
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IMPORTANT INFORMATION 1
1.3
Information on operation in potentially explosive atmospheres
The electronics unit of the sender/receiver unit corresponds to ATEX 2014/
34/EU with identification:
ATEX II 3G Ex nR op is IIC T1-6 Gc
● The explosion protection marking is on the type plate (example):
●
EU Type Examination Certificate: BVS 16 ATEX E 068 X
Character “X” following the certificate number indicates the following special condition for safe application of the device:
The correct temperature class selection is required.
● The maximum allowable surface temperature of the enclosure of the electronics unit is 70°C. The external heat source (duct walls) must be insulated
so that 70°C is not exceeded.
●
!▸ Do not remove, add or change any components on the sender/receiver unit
▸
▸
!▸
!▸
▸
▸
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unless described and specified in the official manufacturer information.
Otherwise the approval for use in potentially explosive atmospheres
becomes void.
Observe the stipulated start-up procedure (see “Start-up and Parameter
Settings”, page 53).
Adhere to the prescribed maintenance intervals (Section“Maintenance”,
page 80).
Do not insert or remove the plug on the sender/receiver unit when under
voltage.
System components without Ex marking must not be used in potentially
explosive atmospheres.
Ex atmospheres
– Observe regulations for transport in Ex atmospheres, e.g. no transport of
packaging materials in Ex atmospheres.
– Do not perform installation work in Ex atmospheres.
Start-up and shutdown may only be performed when it is verified that no
explosive media are present (verification by gas detector).
– The enclosure of the sender/receiver unit may not be opened and
screwed down in Ex atmospheres.
Ex protection zone
– Use only suitable tools for the Ex protection zone.
– Observe behavior rules to prevent sparks.
– Only work that does not affect ignition protection is allowed.
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1 IMPORTANT INFORMATION
1.4
Intended use
Purpose of the device
The DUSTHUNTER SP100 Ex measuring system serves continuous measurement of dust
concentrations in exhaust gas and exhaust air plants.
Correct use
▸
Use the device only as described in these Operating Instructions. The manufacturer
bears no responsibility for any other use.
▸ Observe all measures necessary for conservation of value, e.g., for maintenance and
inspection and/or transport and storage.
● Do not remove, add or modify any components to or on the device unless described and
specified in the official manufacturer information. Otherwise
– the device could become dangerous
– the manufacturer’s warranty becomes void
Application limitations
WARNING: Risk of explosion in potentially explosive atmospheres
▸ Only use the measuring system in potentially explosive atmospheres according to the device identification (see “Information on operation in potentially
explosive atmospheres”, page 9.
▸ Only use the measuring system within the temperature limits as specified in
these Operating Instructions as well as on the type plate.The specified values must not be exceeded even for brief periods.
!▸ Do not install any components, apart from the electronics unit and the
sender/receiver unit, in lines, tanks, or other installation areas where explosive gas and/or dust mixtures may be present.
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IMPORTANT INFORMATION 1
1.5
Responsibility of user
1.5.1
General information
Designated users
The DUSTHUNTER SP100 Ex measuring system may only be installed and operated by
skilled technicians who, based on their technical training and knowledge as well as
knowledge of the relevant regulations, can assess the tasks given and recognize the
hazards involved.
For devices used in potentially explosive atmospheres:
Installation, commissioning, maintenance and testing may be performed
only by experienced persons who have knowledge of the rules and regulations for potentially explosive atmospheres, particularly:
– Ignition protection types
– Installation regulations
– Zone classification
● Applicable standards (examples):
– IEC 60079-0: Electrical apparatus for explosive gas atmospheres; Part 0:
General requirements
– IEC 60079-15: Equipment protection by type of protection “n”
●
Special local conditions
▸
▸
Observe the valid legal regulations as well as the technical rules deriving from implementation of these regulations applicable for the respective equipment during work
preparation and performance (e.g. Ex protection zones).
Carry out work according to the local conditions specific for the equipment as well as
operational hazards and regulations.
Risk assessment
The operator must perform a risk assessment according to the ATEX Directive for operators
1999/92/EC.
Retention of documents
Keep the Operating Instructions belonging to the measuring system as well as equipment
documentation onsite for reference at all times. Pass the respective documentation on to
any new owner of the measuring system.
1.5.2
Safety information and protective measures
Protection devices
NOTE:
Depending on the particular hazard potential, an adequate number of suitable
protection devices and personal safety equipment must be available and used
by the personnel.
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1 IMPORTANT INFORMATION
Behavior during purge air failure
The purge air supply serves to protect optical subassemblies fitted on the duct against hot
or aggressive gases. Leave the supply switched on when the equipment is at a standstill.
Optical subassemblies can be severely damaged in a short time or combustible gases can
escape causing a risk of explosion if the purge air supply fails.
NOTE:
The user must ensure that:
▸ The purge air supply runs reliably and continuously
▸ Failure of the purge air supply is immediately detected (e.g., by using pressure monitors)
WARNING: Risk of explosion
▸ If there is an overpressure of acidic or ignitable sample gas in the duct or
the sample gas temperatures exceed 100°C, it is strongly recommended to
use a non-return valve to minimize the risk of damage to the equipment
when there is a purge air failure and to maintain ignition protection.
The sender/receiver unit must be disconnected immediately and removed
from the duct when a purge air failure occurs. Before the device is put into
operation again, ensure that no ignitable gas is in the enclosure and protection continues to exist by the restricted breathing enclosure.
Preventive measures for operating safety
NOTE:
The user must ensure that:
▸ Neither failures nor erroneous measurements can lead to operational states
that can cause damage or become dangerous
▸ The specified maintenance and inspection tasks are carried out regularly by
qualified, experienced personnel.
Recognizing malfunctions
Every deviation from normal operation is to be regarded as a serious indication of a functional impairment. These are, amongst others:
●
●
●
●
●
●
Warning displays (e.g. heavy contamination)
Significant drifts in measured results
Increased power consumption
Higher temperatures of system components
Monitoring devices triggering
Smells or smoke emission.
Avoiding damage
NOTE:
In order to avoid malfunctions that can cause direct or indirect personal injury
or property damage, the operator must ensure:
▸ The responsible maintenance personnel are present at any time and as fast
as possible
▸ The maintenance personnel are adequately qualified to react correctly to
malfunctions of the measuring system and any resulting operational interruptions (e.g., when used for measurement and control purposes)
▸ The malfunctioning equipment is switched off immediately in case of doubt
and that switching off does not cause collateral malfunctions.
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IMPORTANT INFORMATION 1
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2 PRODUCT DESCRIPTION
2
Product description
2.1
Measuring principle, measured variables
2.1.1
Functional principle
The measuring system works according to the scattered light measurement principle
(forward dispersion). A laser diode beams the dust particles in the gas flow with modulated
light in the visual range (wavelength approx. 650 nm). A highly sensitive detector registers
the light scattered by the particles, amplifies the light electrically and feeds it to the measuring channel of a microprocessor as central part of the measuring, control and evaluation electronics. The measuring volume in the gas duct is defined through the intersection
of the sender beam sent and the receive aperture.
Continuous monitoring of the sender output registers the smallest changes in brightness of
the light beam sent which then serves to determine the measurement signal.
Fig. 1: Measuring principle ‚









Sender/receiver unit
Gas duct
Receiver
Measuring volume
Sender
Approx. 15°

Determining the dust concentration
Measured scattered light intensity (SI) is proportional to dust concentration (c). Scattered
light intensity not only depends on the number and size of particles but also on the optical
characteristics of the particles and therefore the measuring system must be calibrated
using a gravimetric comparison measurement for exact dust concentration measurement.
The calibration coefficients determined can be entered directly in the measuring system as
c = cc2 · SI² + cc1 · SI + cc0
(Entry see “Calibration for dust concentration measurement”, page 67; standard factory
setting: cc2 = 0, cc1 = 1, cc0 = 0).
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PRODUCT DESCRIPTION 2
2.1.2
Response time
The response time is the time required to attain 90% of the signal peak after a sudden
change in the measurement signal. It can be set anywhere between 1 and 600 s. As the
response time increases, transient measured value fluctuations and interruptions are
damped stronger and stronger which “smoothes out” the output signal.
Fig. 2: Response time
Measured value
100
in %
98
90% of the signal peak
96
Measured value with response time
94
Process change
92
90
88
Response time
86
84
0
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10
20
30
40
50
60
70
80
90
t in s
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2 PRODUCT DESCRIPTION
2.1.3
Function check
A function check can be triggered at fixed intervals as from a definable starting timepoint
for an automatic function check of the measuring system. The setting can be made using
the SOPAS ET operating program (see “Determining the function check”, page 62). Any
unallowed deviations from normal behavior that may occur are signaled as errors. A
function check triggered manually can help localize possible error causes should a device
malfunction occur.
Further information → Service Manual
The function check comprises:
Approx. 45 s measurement of zero value, control value and contamination of the optical
interfaces
The measuring time depends on the increase in contamination value (change > 0.5% →
measurement is repeated up to 2 times).
● Every 90 s (standard value) output of values determined (duration parameter can be
modified, see “Determining the function check”, page 62).
●
Fig. 3: Function check output on a plotter
Contamination degree
(Live Zero = 0%,
20 mA = 40%)
Contamination output
Control value output
(70% value, span)
Zero value output (Live Zero)
●
●
●
●
●
●
●
Function check
start
Control value
determination
Paper feed
Function check
end
The analog output must be activated to output control values on the analog output
(see “Setting the analog outputs parameters”, page 63).
The value measured last is output on the analog output during control value determination.
If the control values are not output on the analog output, the current measured value
is output when control value determination has completed.
Relay 3 is switched on during a function check (see “MCU processor board connections”, page 48).
A function check is not started automatically when the measuring system is in
“Maintenance” mode.
If the start timepoint or cycle interval are changed, a check cycle timed between
parameter setting and new start timepoint is still carried out.
Changes to the interval time are first effective after the next start timepoint.
Zero value measurement
The sender diode is switched off for zero point control so that no signal is received. This
means possible drifts or zero point deviations are detected reliably in the overall system
(e.g., due to an electronic defect). A warning signal is generated when the “zero value” is
outside the specified range.
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PRODUCT DESCRIPTION 2
Control value measurement (Span test)
Sender beam intensity changes between 70 and 100% during control value determination.
The light intensity received is compared against the standard value (70%). The measuring
system generates an error signal for deviations greater than ±2%. The error message is
cleared again when the next functional check runs successfully. The control value is determined with high precision through statistical evaluation of a high number of intensity
changes.
Contamination measurement
For contamination measurement the receiver optics is slewed into a reference position
and the light intensity is measured. The measured value determined and the value defined
as factory setting are used to calculate a correction factor. This fully compensates any contamination that occurs.
A value between live zero and 20 mA is output on the analog output for contamination
values < 40% ; when this value is exceeded, the “Malfunction” status is output (on the
analog output the set error current; see “Factory settings”, page 61, see “Setting the
analog outputs parameters”, page 63).
Fig. 4: Contamination and control value measurement
 Receiver optics in reference position
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2 PRODUCT DESCRIPTION
2.2
Device components
Measuring system DUSTHUNTER SP100 comprises the components:
Sender/receiver unit DHSP-T
Connection line to connect the sender/receiver unit to the control unit MCU (lengths 5
m, 10 m)
● Flange with tube
● Control unit MCU
to control, evaluate and output the data of the sender/receiver unit connected via the
RS485 interface
– With integrated purge air supply, for internal duct pressure -50 ... +10 hPa
– Without purge air supply, therefore additionally required:
● Optional external purge air unit, for internal duct pressure -50 ... +30 hPa
●
●
Fig. 5: Device components DUSTHUNTER SP100 Ex (Electronics unit in version for zone 2)
Safe zone






Safe zone
Safe zone


USB 1.1
(RS 232)

Safe zone








Duct
MCU-N without purge air supply (option)
External purge air unit (option)
Flange with tube
Connection cable
Antistatic purge air hose DN40
 Operating and parameter program SOPAS ET
 Power supply
 MCU-P with purge air supply
 Sender/receiver unit
 Zone 2
Communication between sender/receiver unit and MCU
As standard, each sender/receiver unit is connected to one control unit via the connection
line.
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PRODUCT DESCRIPTION 2
2.2.1
Sender/receiver unit
The sender/receiver unit comprises two main subassemblies:
Electronics unit
It contains the optical and electronics subassemblies to send and receive the light beam
as well as to process and evaluate the signals.
● Measuring probe
The measuring probe is available in different versions and nominal lengths as well as for
various gas temperature ranges and defines the device variant (see “Device configuration”, page 30).
●
Data transfer to and power supply (24 V DC) from the control unit MCU run via a shielded
line with 4 wires and plug-in connector. A USB interface is available for service purposes.
Clean air to cool the probe and keep the optical surfaces clean is fed via a purge air connection.
The sender/receiver unit is fastened to the duct with a flange with tube (see “Device components”, page 18).
Type code
A type code identifies the special version of the sender/receiver unit:
Sender/receiver unit:
DHSP-T X X X X EX3GTX
Maximum permissible gas temperature:
- 2:
220 °C
- 4:
400 °C
Probe material
- V:
Stainless steel
- H:
Hastelloy
- M:
Hastelloy probe + stainless steel protective tube
Measuring probe nominal length (NL)
- 1:
435 mm
- 2:
735 mm
Flange version
- 1:
Reference circle k100
Ex certification
- EX3G: Electronics unit version zone 2 (gases)
Maximum surface temperature
- T1-T6 according to EN 60079-0:2012
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2 PRODUCT DESCRIPTION
Fig. 6: Sender/receiver unit DHSP-T2VxxEX3G







NL

 
 Electronics unit
 Flange with tube
 Duct wall
 Protective tube
 Probe head with receiver optics
 Sight glass




Connection for connection cable
Cleaning opening for sender optics
Purge air connection G1/2”
Measuring opening
NOTE:
●
20
The maximum distance between internal duct wall and measuring opening is NL 280 mm.
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PRODUCT DESCRIPTION 2
2.2.2
Flange with tube
The flange with tube is available in different steel grades and dimensions (see “Flange with
tube”, page 99). Selection depends on the wall and isolation thickness of the duct wall (→
nominal length) and the duct material.
Fig. 7: Flange with tube
Standard version


Material St 37 or
1.4571
NL
 Marking for assembly position
 Securing bolt
Gas temperature
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Sender/receiver unit nominal length (in mm)
435
735
< 150 °C
130, 240
130, 240, 500
> 150 °C
240
500
NL (in mm)
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2 PRODUCT DESCRIPTION
2.2.3
MCU control unit
Control unit MCU has the following functions:
●
●
●
●
●
Control of the data traffic and processing of the sender/receiver unit data connected via
the RS485 interface
Signal output via analog output (measured value) and relay outputs (device status)
Signal input via analog and digital inputs
Power supply for the connected measuring unit via 24 V switch-mode power supply with
wide range input
Communication with higher level control systems via optional modules
Equipment and device parameters can be set easily and conveniently via a USB interface
using a PC and a user-friendly operating program. The parameters are stored reliably even
in the case of a power failure.
Control unit MCU has a sheet steel enclosure as standard.
2.2.3.1
Standard interfaces
Analog output
3 outputs 0/2/4...22 mA
(electrically isolated,
active) to output:
● Scattered light intensity
(corresponds to the
uncalibrated dust concentration),
● Dust concentration, calibrated
● Dust concentration,
scaled
Resolution 10 bits
22
Analog inputs
2 inputs 0...20 mA
(standard; without
electric isolation);
resolution 10 bits
Relay outputs
5 changeover
contacts (48 V, 1 A)
to output status
signals:
● Operation/malfunction
● Maintenance
● Function check
● Maintenance
request
● Limit value
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Digital inputs
Communication
4 inputs to connect
● USB 1.1 and
potential-free contacts
RS232 (on termi(e.g. to connect a
nals) for measured
maintenance switch,
value inquiries, settrigger a function
ting parameters
check or further error
messages)
and software
updates.
● RS485 for sensor
connection
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PRODUCT DESCRIPTION 2
2.2.3.2
Versions
●
Control unit MCU-N without purge air supply
Fig. 8: Control unit MCU-N with options




DISPLAYMODUL

Reset
Term
com nc. no. com nc. no. com nc. no. com nc. no. com nc. no.
relay 3
relay 4
relay 5
relay 1
relay 2
 Display module (option)
 Processor board
 Interface module (option)
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BUS
Term
 I/O module (option)
 Display module (option)
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2 PRODUCT DESCRIPTION
●
MCU-P control unit with integrated purge air supply
This version is also fitted with a purge air blower, air filter and purge air connection to
connect the purge air hose to the sender/receiver unit.
Fig. 9: Control unit MCU-P with integrated purge air supply












Purge air blower
Air filter
Optional Display module
Processor board




Installation plate
Power supply unit (on back of installation plate)
Purge air connection
Purge air inlet
The purge air hose (standard lengths 5 and 10 m (see “Purge air supply”, page 104)) is a
separate part of the measuring system and must be ordered separately.
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PRODUCT DESCRIPTION 2
2.2.3.3
Type code
The following type code defines the various configuration options in the same manner as
for the sender/receiver unit:
Type code control unit MCU:
MCU-X X O D N X 1 0 0 0 N N N E
Integrated purge air supply
- N:
Without (no)
- P:
With (purged)
Voltage supply
- W:
- 2:
90 ... 250 V AC
Optional 24 V DC
Enclosure variants
- O:
Wall enclosure, SICK, orange
Display module
- D:
With
Other options
- N:
Without
Analog input option (plug-in module; 0/4...20 mA; 2 inputs per module)
- 0:
Without
- n:
With, n = 1
Analog output option (plug-in module; 0/4...20 mA; 2 outputs per module)
- n:
With, n = 1
Digital input option (plug-in module; 4 inputs per module)
- 0:
Without
Digital output power option (plug-in module; 48 V DC, 5 A; 2 changeovers per module)
- 0:
Without
Digital output low power option (plug-in module; 48 V DC, 0.5 A;
4 make contact elements per module)
- 0:
Without
Optional Interface module
- N:
- E:
- J:
- P:
- E:
Special versions
- N:
EX certification
- N:
Software
- E:
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Without
Ethernet type 1, COLA-B
Modbus TCP
Profibus
Ethernet type 2, COLA-B
No special features
Without EX certification
Emission monitoring
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2 PRODUCT DESCRIPTION
2.2.3.4
Modules
1 Display module
Module to display measured values and status information and for configuration during
start-up, selection via operating buttons.
a) Displays
Type
Power (green)
Failure (red)
Maintenance
request (yellow)
LED
LC-Display
Graphic display
(main screen)
Text display
Display
Voltage supply OK
Function fault
Maintenance request
– Dust concentration
– Scattered light intensity
Two measured values (see graphic display) and 8 diagnosis values (see “LC-Display menu structure”, page 74)
The graphic display shows two main measured values of a connected sender/receiver unit
selected at the factory or calculated values from the MCU (e.g., scaled dust concentration)
as bar charts. Alternatively, up to 8 single measured values of a sender/receiver unit can
be displayed (toggle with “Meas” button).
Fig. 10: LC-Display with graphic (left) and tet display (right)
8.6
ConcSL
0.0
mg/m³
8.6 mg/m³
8.6
200.0
8.6
SL
0.0
ConcSL
SL
200.0
Menu
Menu
b) Control buttons
Button
Meas
Arrows
Diag
Menu
26
Function
● Toggle between text and graphic display
● Display the contrast setting (after 2.5 s)
Select next/previous measured value page
Display alarm or fault message
Display of main menu and selection of submenus
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PRODUCT DESCRIPTION 2
2 I/O module
Apart from the standard analog output, the DUSTHUNTER SP100 Ex has an Analog module
with two outputs 0/4 ... 22 mA (max. load 500 Ω) integrated to output further measured
variables. The module is plugged onto a module carrier connected to the processor board
with a special line.
Options
1 1x analog input module with two inputs 0/4 ... 22 mA (see “Options for MCU control
unit”, page 105) to read-in values from external sensors (gas temperature, internal duct
pressure, moisture, O2) to calculate the dust concentration in standard state.
An additional module carrier docked to the existing ones is required for this option.
2 Interface module
Module to pass on measured values, system status and service information to higher
level control systems, optionally for Profibus DP V0, Modbus TCP or Ethernet (type 1 or
type 2), to plug onto a hat rail (see “Options for MCU control unit”, page 105).
A corresponding line serves to connect the module to the processor board.
Profibus DP-V0 for transfer via RS485 according to DIN 19245 Part 3 as well as IEC
61158.
3 MCU remote control unit
The MCU remote control unit has identical functions to the MCU display near the device,
however, it can be installed further away.
– Operating function the same as the MCU display
– Distance to the device:
- MCU remote control unit without separate power supply unit: Max. 100 m
- MCU remote control unit with own power supply unit: Max. 1000 m
– The MCU and the MCU remote control unit are interlocked (it is not possible to operate both MCUs at the same time).
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2 PRODUCT DESCRIPTION
2.2.4
Optional external purge air unit
The MCU control unit with integrated purge air supply cannot be used when the internal
duct pressure is greater than +10 hPa. Use the optional external purge air unit in this case
(see “Optional external purge air unit”, page 102). It has a powerful blower and can be
used for excess pressure in the duct up to 30 hPa. scope of delivery includes a purge air
hose with 40 mm nominal diameter (length 5 m or 10 49m).
Fig. 11: Optional external purge air unit with purge air reduction











Air filter
 Purge air hose (antistatic within the Ex zone)
Blower (standard type 2BH13)  Purge air reduction
Base plate
 Purge air connection of sender/receiver unit
Cover cap with opening
(part of the purge air reduction)
A weatherproof cover is available for use outdoors (see “Weatherproof covers”, page 103).
2.2.5
Installation accessories
Separate parts of the measuring system (order separately) are:
Purge air hose with 25 mm nominal diameter for purge air supply to the sender/receiver
unit from the MCU-P control unit,
● Purge air reduction (see “Optional external purge air unit with purge air reduction”,
page 28) to connect the DN40 mm purge air hose when using the optional external
purge air unit
● Connection line from the MCU to the sender/receiver unit.
●
Weatherproof cover
A weatherproof cover is available when using the sender/receiver unit outdoors (see
“Weatherproof covers”, page 103).
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PRODUCT DESCRIPTION 2
2.2.6
Non-return valve
When the measuring system is used at overpressure with acidic and ignitable sample gas
in the duct or at sample gas temperatures above 150°C, the manufacturer strongly recommends fitting a non-return valve at the purge air connection of the sender/receiver unit.
The non-return valve protects the sender/receiver unit, the purge air unit and the environment in case of a possible failure of the purge air supply.
2.2.7
Test equipment for linearity test
A linearity test can serve to check the correct measurement function (see Service Manual).
In this case, filter glasses with defined transmission values are positioned in the beam
path and the values compared against those measured by the measuring system. Compliance within the allowed tolerance means the measuring system is working correctly. The
filter glasses with holder required for the check are deliverable including a carrying case.
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2 PRODUCT DESCRIPTION
2.3
Device configuration
The device components required for a measuring system depend on the respective application conditions. The following Table should serve to assist you in your selection.
2.3.1
Sender/receiver unit
Wall and isolation thickness
[mm]
Max. 150
Nominal length Protective tube
Exhaust gas, exhaust air
NL
length
Max.temperature
Composition
[mm]
[mm]
in °C
Non-corrosive/low corrosion
220
Corrosive
435
300
Non-corrosive/low corrosion
400
Corrosive
220
Max. 400
735
600
400
●
●
2.3.2
Sender/receiver
unit type
DHSP-T2V11EX3G
DHSP-T2H11EX3G
DHSP-T4V11EX3G
DHSP-T4H11EX3G
Non-corrosive/low corrosion DHSP-T2V21EX3G
Corrosive
DHSP-T2H21EX3G
Non-corrosive/low corrosion DHSP-T4V21EX3G
Corrosive
DHSP-T4H21EX3G
Select the nominal length of the sender/receiver unit so that the measuring opening
is an adequate distance away from the internal duct wall (> 100 mm). The measuring opening (see “Sender/receiver unit DHSP-T2VxxEX3G”, page 20) does not have
to be in the center of the duct.
Limit values for corrosive gas composition (reference values, lower values should be
used for mixtures of several components):
– HCl:
10 mg/Nm³
– SO2:
800 mg/Nm³
– SO3:
300 mg/Nm³
– NOx:
1000 mg/Nm³
– HF:
10 mg/Nm³.
Voltage and purge air supply
Internal duct
pressure
[hPa ]
-50 ... +10
-50... +30
-50 ... +100
Connection and supply components
Purge air
Voltage
MCU-P + purge air hose DN40
Optional external purge air unit + purge air reduction
MCU-N
Instrument air[1]
[1] Instrument air onsite (free of dust, oil, moisture, non-corrosive)
NOTE:
For temperatures above 220°C:
▸ Always use the optional external purge air supply or instrument air and
sender/receiver unit DHSP-T4xxxNNXX type up to 400°C.
We recommend using the optional external purge air unit instead of the MCU-P (with
integrated purge air) when distance between the MCU control unit and the sender/
receiver unit is more than 10 m.
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PRODUCT DESCRIPTION 2
2.4
SOPAS ET (PC program)
SOPAS ET is a SICK Software for easy operation and configuration of the DUSTHUNTER.
SOPAS ET runs on a laptop/PC connected to the DUSTHUNTER via a USB line or Ethernet
interface (option).
The menu structure simplifies changing settings. Further functions are also available (e.g.,
data storage, graphic displays).
SOPAS ET is delivered on the product CD. Alternatively, you can download SOPAS ET free of
charge from the SICK homepage (“Downloads”).
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3 ASSEMBLY AND INSTALLATION
3
Assembly and Installation
3.1
Project planning
The following Table provides an overview of the project planning work necessary as prerequisite for trouble-free assembly and subsequent device functionality. You can use this Table
as a Checklist and check off the completed steps.
Task
Requirements
Inlet and outlet paths
according to DIN EN
13284-1 (inlet at least 5x
hydraulic diameter dh, outlet at least 3x dh; distance
to stack opening at least
5x dh)
Homogeneous flow distribution
Determine the Representative dust distrimeasuring and bution
installation
locations for the Fitting position for the
device compo- sender/receiver unit
nents
For round and square ducts:
dh = duct diameter
For rectangular ducts:
dh = 4x cross-section divided by circumference

Whenever possible, no deflections,
If conditions cannot be ensured, define
cross-section variations, feed and
flow profile according to DIN EN 13284drain lines, flaps or fittings in the area
1 and select best possible location
of the inlet and outlet paths
Do not fit vertically on horizontal or
slanted ducts;
Select best possible location
max. measuring axis angle to horizontal 45°
Accessibility, accident pre- The device components must be easvention
ily and safely accessible
Installation free of vibraAcceleration < 1 g
tions
Ambient conditions
Work step
● Follow specifications for new equipment
● Select best possible location for
existing equipment;
● For too short inlet/outlet paths:
Inlet path > outlet path
Limit values according to Technical
Data
Provide platforms or pedestals as
required
Eliminate/reduce vibrations through
suitable measures
If necessary:
● Provide weatherproof covers/sun
protection
● Enclose or lag device components
Up to +10 hPa, control unit with integrated purge air supply
Sufficient primary purge
Above +10 hPa to +30 hPa, optional Select supply type
air pressure depending on
external purge air unit
internal duct pressure
From +30 hPa to +10kPa with instruSelect the purge
ment air
air supply
● Select best possible location for air
Whenever possible, low amount of
intake
Clean intake air (see warndust, no oil, moisture or corrosive
● Determine required purge air hose
ing Page 33)
gases
length
Internal duct diameter,
Nominal length sender/receiver unit, Select components according to the
duct wall thickness with
flange with tube
Configuration Tables (see “Device conisolation
figuration”, page 30); nominal length of
Internal duct pressure
Type of purge air supply
the sender/receiver only as long as necSelect device
essary (measurement in duct center not
Sender/receiver unit type
components
Gas temperature
required).
(up to 220°C or up to 400°C)
If necessary, plan additional measures
For corrosive gases, probe made of
Gas composition
to fit the flange with tube (see “Fitting
Hastelloy
the flange with tube”, page 34)
Fitting locations
Line and purge air hose lengths
Access
Plan calibration
openings
Distances to measuring
level
32
Easy and safe
No mutual interference between
calibration probe and measuring
system
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
Provide platforms or pedestals as
required
Plan sufficient distance between
measuring and calibration level
(approx. 500 mm)
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ASSEMBLY AND INSTALLATION 3
Task
Plan the voltage supply
Requirements
Operating voltage, power
requirements
According to Technical Data (see
“Technical Data”, page 96)
Work step
Plan adequate line cross-sections and
fuses

WARNING: Risk of explosion
▸ The purge air units may only be used and installed according to their specifications.The associated Operating Instructions for fan and fan motor apply
without restrictions.
▸ The air transported by the fan must not contain any explosive components
(suction only from the safe area).
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33
3 ASSEMBLY AND INSTALLATION
3.2
Assembly
Carry out all assembly work onsite. This includes:
▸
▸
▸
Fitting the flange with tube
Fitting the MCU control unit,
Fitting the optional external purge air unit.
WARNING:
▸ Observe the relevant safety regulations as well as the safety notices during
all work: see “Important Information”, page 7
▸ Consider the equipment weight specifications when planning the mounting
brackets.
▸ Only carry out assembly work on equipment with hazard potential (hot or
aggressive gases, higher internal duct pressure) when the equipment is at a
standstill.
▸ Take suitable protection measures against possible local hazards or hazards arising from the equipment.
All dimensions specified in this Section are shown in mm.
3.2.1
Fitting the flange with tube
Fig. 12: Fitting the flange with tube (standard version is shown)
Assembly on steel duct
Marking for assembly
position
A
a
Assembly on brick stack
Assembly on thin-walled duct
b
A
A
A
TOP
D
Min.
1°





Nominal length of sender/receiver
unit
435 mm, 735 mm
D
Ø 76





Junction plate
Anchor plate
Duct wall
Fixing bolt for weatherproof cover
Flange with tube
NOTE:
The tube length must suit the planned sender/receiver unit depending on the
relation between gas temperature and nominal length (see “Flange with tube”,
page 21).
!▸ Do not shorten tubes.
●
●
34
Dimension a must be large enough so that a weatherproof cover can be fitted easily
when necessary (approx. 40 mm).
Dimension b must be as large as possible under consideration of dimension a.
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ASSEMBLY AND INSTALLATION 3
Work to be performed
▸
Measure the fitting location and mark the assembly location and provide sufficient
clearance to fit and remove the sender/receiver unit.
Fig. 13: Clearance for the sender/receiver unit


TOP
NL + 400
400
400
Clearance
 Duct wall
 Flange with tube
▸
▸
Remove insulation (when fitted)
Cut suitable openings in the duct wall; bore large enough holes in brick or concrete
stacks (flange tube diameter).
NOTE:
!▸ Do not let separated pieces fall into the duct.
▸
▸
▸
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Insert the flange with tube in the opening slanting slightly downwards (1 to 3°) so that
the “Top” marking points upwards and any condensate that may collect in the duct can
drain off.
Weld the flange with tube on using an anchor plate for brick or concrete stacks, insert
junction plates for thin-walled ducts.
Close off the flange opening after fitting to prevent gas escaping.
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35
3 ASSEMBLY AND INSTALLATION
3.2.2
Fitting the MCU control unit
Fit the control unit in a protected location that is easily accessible (see “MCU assembly
dimensions”, page 36). Observe the following points during fitting:
Maintain the ambient temperature according to the Technical Data; take possible
radiant heat into consideration (shield when necessary).
● Protect against direct sunlight.
● Whenever possible, choose an assembly location with minimum vibrations; dampen any
vibrations when necessary.
● Provide sufficient clearance for lines and opening the door.
●
Assembly dimensions
Fig. 14: MCU assembly dimensions
M8
b
d
c
> 250
a
e
f
Clearance for cables
Clearance to open door
Dimension
a
b
c
d
e
f
36
Control unit type
MCU-N
160
320
210
340
125
> 350
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MCU-P
260
420
300
440
220
> 540
MCU-N:
Control unit without purge air supply
MCU-P:
Control unit with purge air supply
(see “MCU control unit”, page 22)
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ASSEMBLY AND INSTALLATION 3
Using a suitable line (see “General information, prerequisites”, page 43), the MCU-N
control unit (without integrated purge air supply) can be located up to 1000 m away from
the sender/receiver unit.
We therefore recommend fitting the MCU in a control room (measuring station or similar) to
ensure free access to the MCU. This considerably simplifies communication with the measuring system in order to set parameters or to locate malfunction or error causes.
It is advantageous to provide weather protection (tin roof or similar), to be made onsite, for
use outdoors.
Requirements when using the MCU-P control unit
The following is applicable in addition to the general specifications:
Install the MCU-P control unit at a location with clean air whenever possible. The air
intake temperature must correspond to specifications in the Technical data (see “Technical Data”, page 96). In unfavorable conditions, lay an air intake hose to a location with
better conditions.
● The purge air hose to the sender/receiver unit should be as short as possible.
● We recommend using the optional external purge air unit when the sender/receiver unit
and reflector are more than 10 m away from the control unit.
●
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3 ASSEMBLY AND INSTALLATION
3.2.3
Fitting the optional external purge air unit
WARNING: Risk of explosion
Strictly observe and adhere to the use restrictions according to see “Optional
external purge air unit”, page 28 and see “Project planning”, page 32.
An antistatic purge air hose must be used within the Ex protection zone.
Consider the following points when selecting the assembly location:
▸
▸
▸
▸
38
Install the purge air unit at a location with clean air whenever possible. The air intake
temperature must correspond to specifications in the Technical data (see “Technical
Data”, page 96). In unfavorable conditions, lay an air intake hose or pipe to a location
with better conditions.
The fitting location must be easily accessible and meet all safety regulations.
Provide sufficient clearance to exchange the filter element.
Provide sufficient space to attach and remove the weatherproof cover when installing
the purge air unit outdoors see “Purge air unit layout and assembly dimensions (dimensions in mm)”, page 39).
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ASSEMBLY AND INSTALLATION 3
3.2.4
Assembly work
▸
▸
▸
Prepare holder (see “Purge air unit layout and assembly dimensions (dimensions in
mm)”, page 39).
Fasten purge air unit with 4 M8 screws.
Check whether the filter element is fitted in the filter housing otherwise fit when
necessary.
Fig. 15: Purge air unit layout and assembly dimensions (dimensions in mm)

> 140


470
(550)
Clearance to fit weatherproof cover
 Flange with tube
 Clearance to exchange filter
element
 Alternative: Mounting bracket
 Steel pipe 50 x 5 DIN 2391
 Duct
470
> 160
(550)

M8
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
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3 ASSEMBLY AND INSTALLATION
3.2.5
Fitting the weatherproof cover
WARNING: Risk of explosion
Do not install the weatherproof cover (Part No. 2702407) for the sender/
receiver unit in the Ex protection zone.
The weatherproof cover (Part No. 2047253) may be used in the Ex protection
zone.
Weatherproof cover for external purge air unit
The weatherproof cover (see “Weatherproof covers”, page 103) comprises a cover and
locking set.
Assembly:
▸
▸
▸
▸
40
Mount the locking pins from the locking set on the base plate.
Put the weatherproof cover on from above.
Insert the holding catches into the counterpieces from the side, twist and lock in.
Create potential equalization for the weatherproof cover.
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ASSEMBLY AND INSTALLATION 3
3.3
Electrical installation
3.3.1
Electrical safety
WARNING:
▸ Observe the relevant safety regulations as well as the safety notices in see
“Important Information”, page 7 during all installation work.
▸ Take suitable protection measures against possible local hazards or hazards arising from the equipment.
!▸ In the Ex protection zone, do not open devices while energized and do not
energize opened devices.
3.3.1.1
Properly installed power isolating switches
WARNING:
Endangerment of electrical safety during installation and maintenance work
when the power supply is not switched off.
An electrical accident can occur during installation and maintenance work
when the power supply to the device or lines is not switched off using a power
isolating switch/circuit breaker.
▸ Before starting work on the device, ensure the power supply can be
switched off using a power isolating switch/circuit breaker in accordance
with DIN EN 61010.
▸ Make sure the power isolating switch is easily accessible.
▸ An additional disconnecting device is mandatory when the power isolating
switch cannot be accessed or only with difficulty after installation.
▸ The power supply may only be activated again after the work or for test purposes by personnel carrying out the work under consideration of valid safety
regulations.
3.3.1.2
Lines with correct rating
WARNING:
Endangerment of electrical safety through power line with incorrect rating
Electrical accidents can occur when the specifications for replacement of a
removable power line have not been adequately observed.
▸ Always observe the exact specifications in the Operating Instructions (Technical Data Section) when replacing a removable power line.
3.3.1.3
Grounding the devices
CAUTION:
Device damage through incorrect or missing grounding.
▸ During installation and maintenance work, it must be ensured that the protective grounding to the devices and/or lines involved is effective in accordance with EN 61010-1.
3.3.1.4
Potential equalization of explosion-protected devices
WARNING:
Risk of explosion through incorrect or missing potential equalization.
▸ It must be ensured that potential equalization to the effected devices or
lines is created in accordance with DIN EN 60079-0. A connecting screw for
potential equalization exists on the device.
▸ The potential equalization must be connected before installation in the duct
and when pulling the device out.
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3 ASSEMBLY AND INSTALLATION
3.3.1.5
Responsibility for system safety
WARNING:
Responsibility for the safety of a system.
▸ The person setting the system up is responsible for the safety of the system
in which the device is integrated.
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ASSEMBLY AND INSTALLATION 3
3.3.2
General information, prerequisites
All assembly work previously described must be completed (as far as applicable) before
starting installation work.
Carry out all installation work onsite unless otherwise explicitly agreed with SICK or authorized representatives. This includes laying and connecting the power supply and signal
lines, installing switches and power fuses and connecting the purge air supply.
●
●
Plan adequate line cross-sections (see “Technical Data”, page 96).
Line ends with plugs to connect the sender/receiver unit must have sufficient free
length.
Cable requirements in the safe are (non-Ex protection zone)
Only use shielded cables with twisted pairs (e.g., UNITRONIC LiYCY (TP) 2 x 2 x 0.5 mm²
from LAPPKabel; 1 pair of wires for RS 485, 1 pair of wires for power supply; not suitable
for underground laying).
Cable requirements in the Ex protection zone
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
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The documentation for zone division according EN 60079-10 must be available.
The devices to be used must be checked for suitability for the application area.
After installation, an initial test of the device and the plant according to EN 60079-17
must be performed.
The cables must fulfill the requirements according to EN 60079-14
Cables which are especially endangered by thermal, mechanical or chemical stress,
must be protected, e.g. by laying in protective tubes which are open on both ends.
For cables not protected against smoldering, the fire behavior according to DIN VDE
0472 Part 804 Type of Inspection B / IEC 60332-1 must be demonstrated.
The cross-section of each individual wire must not be smaller than 0.5 mm².
For cable selection, it must be observed that the clamping area of the cable inlet is 6 12 mm.
Cables for Ex-e cable inlets must comply with the requirements in EN 60079-14 Section
11.3.
The existing air and creepage paths according to EN 60079-07 or EN 60079-15 may not
be reduced by connection of the cables in the terminal box.
Ex cable inlet must be suitable for the intended cable type (e.g. cables with or without
armoring).
The cables and conductors for Ex-d cable terminals must comply with the requirements
in EN 60079-14, Section 10.4.2 b). The selection there must be made according to Fig.
1.
Protect the wire ends with connector sleeves against fraying.
Replace unused cable inlets with the enclosed Exe or Ex-d sealing plugs.
Unused wires must be connected with a ground line (ground potential) or secured so
that a short circuit with other conductive parts is excluded.
Potential equalization must be carried out according to EN 60079-14 (see also the following Section).
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3 ASSEMBLY AND INSTALLATION
3.3.3
Installing the purge air supply
WARNING: Risk of explosion
The plant operator is responsible for a safe purge air supply that meets the
explosion protection requirements.
The air transported by the fan must not contain any explosive components.
▸
▸
▸
▸
3.3.3.1
Ensure the purge air is never suctioned from the Ex protection zone (Figure
5, Page 18 (valid for all purge air units).
Observe and adhere to the information in the separate Operating Instructions for the fan and fan motor.
Lay the purge air hoses with shortest paths and free of bends, shorten as required.
Maintain sufficient distance from hot duct walls.
Control unit with integrated purge air supply (MCU-P)
Connect the antistatic DN 40 purge air hose to the purge air outlet on the underside of the
MCU-P and secure with a strap retainer. The purge air outlet must be set as shown (purge
air mask position 5) for a clear vacuum and to position 4 for overpressure (correct when
necessary). Close the second purge air outlet (2) with a cap (3) (scope of supply).
Fig. 16: Underside of MCU-P

Purge air inlet
3.3.3.2



Optional external purge air unit
Connect the purge air hose
▸
▸
44
Connect the antistatic DN40 purge air hose to the Y-distributor of the purge air unit and
to the purge air reducer and secure with a D32-52 hose clamp.
Close off the second outlet opening on the Y-distributor with the cover cap.
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ASSEMBLY AND INSTALLATION 3
Fig. 17: Connecting the optional external purge air unit
Optional external purge air unit



 Purge air connection of sender/receiver unit
 Purge air reduction
 Cover cap with opening
(part of the purge air reduction)
Electrical connection
▸
Compare power voltage and frequency with the specifications on the type plate on the
purge air motor.
CAUTION:
▸ Only connect when these match!
▸
Connect the power supply line to the purge air motor terminals (refer to the supplementary sheet on the purge air motor and lid of the motor terminal box for terminal allocation).
Fig. 18: Electrical connection of the external purge air unit
Low-pressure monitor
V1
U2
V1
U1
V2
W2
U2
U1
W1
W2 U2 V2
U1
W1
V2 W2
W2 U2 V2
V1 W1 PE
U1
V1 W1 PE
Energy supply‐
4 x 1.5 mm2
L1
▸
▸
L2
L3
PE
L1
L2
L3
PE
+
_
24 V
Connect protective conductor to terminal.
Set motor circuit breakers according to the blower connection data (see Technical Data
for purge air unit) to a value 10% above the rated current.
NOTE:
In case of doubt or when using a special motor version, the operating
instructions supplied with the motor have priority over any other information.
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3 ASSEMBLY AND INSTALLATION
▸
▸
Check the function and running direction of the blower (purge air flow direction must
match the arrows on the inlet and outlet openings on the blower). For wrong direction on
3-phase motors: Swap mains connections L1 and L2.
Connect the pressure controller (option) to monitor purge air feed.
NOTE:
▸ Use a fail-safe power supply (standby unit, rails with redundant supply)
▸ Fuse the purge air unit separate from the other system components. The
fuse type must match the rated current (see technical details of purge air
unit). Fuse each phase separately.
Use circuit breakers to prevent phase failures on one side.
3.3.3.3
Purging with instrument air
NOTE:
The purge air available onsite must be free from dust, oil and condensate.
▸
Connect the instrument air hose to the thread of the special non-return valve or directly
to the purge air connection.
Fig. 19: Instrument air connection of sender/receiver unit


Purge air requirement approx. 6 ... 13 m³/h (depending on primary pressure)
 Purge air connection G 1/2“
 Special non-return valve for instrument air G 1/4“
3.3.3.4
Installing the non-return valve option
Fig. 20: Installation of special non-return valve

 Sender-receiver unit
 Special non-return valve for instrument air

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ASSEMBLY AND INSTALLATION 3
3.3.4
Connecting the MCU control unit
Fig. 21: Component layout in the MCU (without purge air supply, with options)


DISPLAYMODUL

Term
Reset


com nc. no. com nc. no. com nc. no. com nc. no. com nc. no.
relay 3
relay 4
relay 5
relay 1
relay 2
 Optional Interface module
 Optional Display module
 Terminals for power connection
3.3.4.1
BUS
Term
 Processor board
 Optional I/O modules
Work to be done
▸
Connect the connection line: see “Standard connection”, page 50.
If an onsite line is to be used, it must be connected to a suitable 7-pole socket (see
“Plug-in connector connection to onsite line”, page 49; SICK Part No.: 7045569).
▸
Connect lines for status signals (operation/malfunction, maintenance, function check,
maintenance request, limit value), analog output, analog and digital inputs according to
requirements (see “Standard connection”, page 50, p. 52, Fig. 26 Fig. “Terminal
assignment of analog input module”; only use shielded lines with twisted pairs)
NOTICE:
▸ Only use shielded lines with twisted pairs (e.g., UNITRONIC LiYCY (TP) 2 x
2 x 0.5 mm² from LAPPKabel; 1 pair of wires for RS 485, 1 pair of wires
for power supply; not suitable for underground laying).
▸
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Connect power line to terminals L1, N, PE of the MCU (see “Component layout in the
MCU (without purge air supply, with options)”, page 47).
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3 ASSEMBLY AND INSTALLATION
▸
Close off unused line openings with dummy plugs.
WARNING:
▸ Be sure to check the wiring before switching the supply voltage on.
▸ Only modify wiring when disconnected from the power supply and potentialfree.
3.3.4.2
MCU processor board connections
Fig. 22: MCU processor board connections







 Supply voltage 24 V DC
 RS232
 Connection for optional I/O
module
 Connection for Display module
 Connection for LEDs
 Connection for optional Interface module
 USB plug connector
 Connections for sender/
receiver units
 Connections for relays 1 to 5
 Connections for digital inputs 1
to 4
11 Connection for analog output
12 Connections for analog inputs
1 and 2


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ASSEMBLY AND INSTALLATION 3
3.3.4.3
Connection of connection line to MCU
Fig. 23: Plug-in connector connection to onsite line
Open
Open
A
A -A


+24 V

RS485 B

Shield
Closed
Closed
Cable provided by customer according to
page 43, §3.3.2
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A

gnd


RS485 A
Note
To open, connect the plug-in connector to the
plug on the sender/receiver unit.
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3 ASSEMBLY AND INSTALLATION
3.3.4.4
Standard connection
Fig. 24: Standard connection
MCU processor board
Maintenance
Function check
4, 5,6
3
7, 8, 9
4
10, 11, 12
5
13, 14, 15
Maintenance
Limit value
1, 2, 3
2
Maintenance
request
1
Function
check
Terminal
Operation/
malfunction
Relay
White
Brown
Green
Yellow
Switching position of the relay
contacts in currentless
condition
Connection line
(SICK line or onsite line
according to see “General
information, prerequisites”,
page 43)
Sender/receiver unit
Plug assignment
(View on pin side)
RS485 B
3
Plug
2
Socket
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5
Brown
Yellow
Green
7
White
50
RS485 A
4
1
+24 V
6
-24 V
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ASSEMBLY AND INSTALLATION 3
3.3.5
Connecting the MCU remote control unit
3.3.5.1
Connection to the MCU control unit
Electrical connection see “Standard connection”, page 50
Electrical connection of the MCU remote control unit without an own power supply unit:
– 24V supply: Terminals 36 and 37 (or equivalent)
– Signals: Terminals 38 and 39 (or equivalent)
● Electrical connection of the MCU remote control unit with an own power supply unit:
– Signals: Terminals 38 and 39 (or equivalent)
●
3.3.5.2
Connection to the MCU remote control unit
Version without power supply unit
●
Connect the connection cable to the measuring and control unit (4-wire, twisted pair, with shield)
to the connections in the control unit and the module of the remote unit.
Fig. 25: Connections in the remote control unit (version with integrated wide-range power pack)
+24 V
-24 V
Shield
RS485 A
RS485B


 Connection cable to
the MCU measuring
and control unit
 Power cable
Version with integrated wide-range power pack:
●
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Connect the 2-wire cable (twisted pair, with shield) to the connections for RS485 A/B
and shield in the control and remote control unit.
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3 ASSEMBLY AND INSTALLATION
●
Connect the 3-wire mains cable with sufficient cross-section to the onsite power supply
and the corresponding terminals in the remote unit.
NOTICE:
 During installation, it must be possible to switch the power supply off
using a power isolating switch/circuit breaker in accordance with EN
61010-1.
 After completion of the work or for test purposes, the power supply may
only be activated again by the personnel who carried out the work and
complying with the valid safety regulations.
3.3.6
Fitting the interface and I/O module (option)
Plug Interface modules and module carriers for I/O modules onto the hat rail in the MCU
(see “Component layout in the MCU (without purge air supply, with options)”, page 47) and
connect to the associated connection on the processor board with the line with plug-in connector (see “MCU processor board connections”, page 48). Then plug the I/O modules on
the module carriers.
Connect the Interface modules using the customer provided network line to the local
network. Use the terminals on the module carrier to connect I/O modules.
Terminal assignment of AO module
Fig. 26: Terminal assignment of analog output module
 Module carrier

AO 2
23
24
13
14
22
11
12
21
AO2
Shield
1
+
AO1
+
2
+ -
+ - AO 1
Terminal assignment of AI module
Fig. 27: Terminal assignment of analog input module
 Module carrier

AI 2
23
24
14
22
12
13
21
11
AI2
AI1
1
+
Shield
+
2
+ -
+ - AI 1
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START-UP AND PARAMETER SETTINGS 4
4
Start-up and Parameter Settings
4.1
Basics
4.1.1
General information
Assembly and installation must have been completed according to Section 3 before
starting the work described in the following.
Start-up and parameter setting comprise:
●
●
Installing and connecting the sender/receiver unit,
Customizing parameter settings according to the respective requirements.
To achieve exact measurement, the measuring system must first be calibrated using a
gravimetric comparison measurement (see “Calibration for dust concentration measurement”, page 67) before being used for continuous measurement of dust content.
4.1.2
Installing SOPAS ET
Install SOPAS ET on a laptop/PC.
Start SOPAS ET.
● Following the installation instructions of SOPAS ET.
●
●
4.1.2.1
Password for SOPAS ET menus
Certain device functions are first accessible after a password has been entered.
User level
4.1.3
0
Operator
1
Authorized operator
Access to
Displays measured values and system states
No password required
Displays, inquiries as well as start-up or adjustment to customerspecific demands and diagnosis of necessary parameters.
Pre-set password: sickoptic
Connection to the device via USB line
Recommended procedure:
1 Connect the USB line to the MCU control unit (see “MCU processor board connections”,
page 48) and the laptop/PC.
Switch the device on.
Start SOPAS ET.
“Search settings”
“Device family oriented search”
Click the desired MCU.
Make the settings:
– Ethernet communication (always clicked)
– USB communication (always clicked)
– Serial communication: Click
8 Do not specify IP addresses.
9 A list of COM ports is shown.
Specify the COM port of the DUSTHUNTER.
If you do not know the COM port: see “Finding the DUSTHUNTER COM port”, page 54
10 Assign a name for this search.
11 “Finish”
2
3
4
5
6
7
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4 START-UP AND PARAMETER SETTINGS
4.1.3.1
Finding the DUSTHUNTER COM port
If you do not know your COM port: You can find the COM port with the Windows Device
Manager (Administrator rights are not required).
1 Disconnect the DUSTHUNTER from your laptop/PC.
2 Input: devmgmt.msc
3 this message is shown:
4 “OK”
5 The Device Manager opens.
See: “Ports (COM & LPT)”
6 Now connect the MCU with the laptop/PC.
A new COM port is shown.
Use this COM port for communication.
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START-UP AND PARAMETER SETTINGS 4
4.1.4
Connection to the device via Ethernet (option)
The Ethernet interface module (see “Options for MCU control unit”, page 105) must be
installed in the MCU (see “Fitting the interface and I/O module (option)”, page 52) and
configured (see “Setting the Ethernet module parameters”, page 72) to connect to the
measuring system via Ethernet.
Recommended procedure:
The MCU must be switched off.
Connect the MCU with the network.
Connect the PC to the same network.
Switch the MCU on.
Start SOPAS ET.
“Search settings”
“Device family oriented search”
Click the desired MCU
Make the settings:
– Ethernet communication (always clicked)
– USB communication (always clicked)
– Serial communication: Do not click
10 Specify the IP addresses
IP address: see “Setting the Ethernet module parameters”, page 72
11 Do not click a COM port
12 Assign a name for this search
13 “Finish”
1
2
3
4
5
6
7
8
9
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4 START-UP AND PARAMETER SETTINGS
4.2
Installing the sender/receiver unit
WARNING: Risk of explosion
▸ Before installation, check whether the type code / the type plate matches
the intended application.
▸ The potential equalization must be connected before installation in the duct
and when pulling the device out.
4.2.1
Adapting the sender/receiver unit to the flow direction
Sender/receiver unit
Fig. 28: Probe alignment
Vertical duct
Horizontal duct

The gas loaded with
particles must flow freely
through the measuring
volume.
 Flow direction
The sender/receiver unit is delivered for vertical fitting as standard when the duct direction
(horizontal or vertical) is not specified in the order. Rotate the sender/receiver unit 90°
when fitting on a horizontal duct (see Service Manual).
WARNING: Hazards by explosive or combustible gases
▸ Only specially trained service personnel may unscrew and rotate the enclosure, so that ignition protection is maintained.
This service personnel must have been specially trained for the DUSTHUNTER SP100 Ex measuring system by SICK.
With a vertical duct, the purge air connection points to the side. A bracket can be installed
as an option to direct the purge air downwards.
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START-UP AND PARAMETER SETTINGS 4
4.2.2
Fitting and connecting the sender/receiver unit
WARNING: Danger from exhaust gas
▸
▸
Install the sender/receiver unit on the duct of equipment with hazard potential (e.g.,
toxic, aggressive, explosive gases/dusts, danger to health, high pressure, high temperatures) only when the equipment is at a standstill.
Connect the sender/receiver unit to the purge air supply and check whether the flow
direction is correct and the purge air hose is fitted tight on the connection.
Type of purge air supply
MCU-P control unit
External purge air unit
Instrument air
Activity
Push the DN 25 purge air hose onto the connection of the sender/
receiver unit and secure with a strap retainer.
Push the DN 40 purge air hose with purge air reduction onto the
connection of the sender/receiver unit (see “Connecting the optional
external purge air unit”, page 45) and secure with a strap retainer.
Connect the instrument air hose to the thread of the special nonreturn valve for instrument air supply, (see “Instrument air connection
of sender/receiver unit”, page 46), screw the hose to the special nonreturn valve.
For gas flow rates < 5 m/s we recommend to reduce the purge air flow by installation of an onsite pressure reducer to a value which approximately equals the gas
flow rate.
▸
▸
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Push the sender/receiver unit with the correct alignment (see “Probe alignment”,
page 56) into the flange with tube (do not forget the seal) and fasten with the assembly
kit. Make sure the probe head is not damaged during fitting.
Connect the connection line to the MCU on the plug connector and screw tight.
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4 START-UP AND PARAMETER SETTINGS
4.2.3
Assigning the sender/receiver unit to the measuring location (in SOPAS ET)
The sender/receiver unit can be assigned explicitly to the respective measuring location.
The following steps are then necessary:
▸
▸
Start the SOPAS ET program and connect to the measuring system (see “Connection to
the device via USB line”, page 53).
Select device file “DH SP100” and move it to the “Project Tree” window.
The respective device type connected is displayed automatically
▸
▸
Enter password level 1.
Set the sender/receiver unit to “Maintenance”: Click “Maintenance sensor”.
Fig. 29: SOPAS ET menu: DH SP100/Maintenance/Maintenance
▸
Select the “Configuration / Application Parameters” directory and enter the desired data
in the “Mounting location” entry field under “Device Identification”.
Fig. 30: SOPAS ET menu: DH SP100/Configuration/Application parameter
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Defining regression coefficients
The “Calibration coefficients for calculation of concentration with scattered light” field
serves to select a coefficients set freely (set 0) or a fixed default setting (sets 1 to 3).
Set
Regression coefficients
setting
Typical application
Set 0
Set 1
Freely selectable
Fixed: For small particle
sizes (on average 2 μm)
Fixed: For medium particle
sizes (on average 5 μm)
Fixed; for large particle sizes
(on average 10 μm)
Any
Usage after cloth filter
plants
Usage after electrofilter
Set 2
Set 3
Regression coefficients
Quadratic Linear
Absolute
0
1
0
Usage after coarse filter
(cyclone filter)
0
0,5
0
0
2
0
0
3
0
The regression coefficients in sets 1 to 3 refer to dusts with an average density of 2.5 g/
cm³, almost spherical particle structure and even dust distribution across the duct
cross-section.
Select set 0 when the measuring system must be calibrated (see “Calibration for dust concentration measurement”, page 67).
Sets 1 to 3 can be used when high precision is not decisive.
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4 START-UP AND PARAMETER SETTINGS
4.3
Standard configuration
4.3.1
Assigning the MCU to the sender/receiver unit
The MCU must be set to the sender/receiver unit to be connected. A malfunction is
reported in case of a mismatch. Assignment must be made after installation when the
setting is not possible at the factory (e.g., when several devices are delivered at the same
time or when the MCU is swapped later). The following steps are then necessary:
▸
▸
▸
Connect the measuring system to the SOPAS ET program.
Enter the Level 1 password (see “Password and operating levels”, page 73).
Set the sender/receiver unit to “Maintenance”: Click “Maintenance sensor”.
Fig. 31: SOPAS ET menu: MCU/Maintenance/Maintenance
▸
▸
Change to the “Configuration / Application selection” directory (see “SOPAS ET menu:
MCU/Configuration/Application selection”, page 60).
The basic type of the sender/receiver unit connected is displayed in the “Connected
variant” window (field “Application selection”). Click “Save selection” to assign to the
MCU.
The sender/receiver unit must be connected to the MCU.
Fig. 32: SOPAS ET menu: MCU/Configuration/Application selection
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4.3.2
Factory settings
Parameter
Function check
Value
Every 8 h; output of control values (every 90 s)
on standard analog output
Analog output (AO) Live zero (LZ)
4
[mA]
Upper measuring range value 20
(MBE)
Current during maintenance 0,5
Current by malfunction
21 (optional 1)
Response time
60 s for all measured variables
Output on AO
Value at LZ
Value at MBE
Measured variable
1
0
200
Dust concentration [mg/m³]
2
Scattered light intensity
Coefficients set (only for dust concentration)
0.00 / 1.00 / 0.00
The steps required to modify these settings are described in the following Sections. For this
purpose, the devices must be connected in SOPAS ET (see “Connection to the device via
USB line”, page 53), the Level 1 password set and the “Maintenance” mode set.
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4 START-UP AND PARAMETER SETTINGS
4.3.3
Determining the function check
Interval time, control value output on the analog output and the starting timepoint for automatic function check can be modified in the “Adjustment / Function Check - Automatic”
directory.
Default values see “Factory settings”, page 61
Fig. 33: SOPAS ET menu: MCU/Adjustment/Function Check - Automatic (example)
Entry field
Output duration of
function control
value
Function check
interval
Function Check
Start Time
Parameter
Value in seconds
Remark
Output duration of control values.
Time between two
check cycles
Hours
Minutes
see “Function check”, page 16
Defining a start timepoint in hours and minutes.
The value measured last is output during control value determination (see “Function
check output on a plotter”, page 16).
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4.3.4
Setting the analog outputs parameters
Select the “Configuration / IO Configuration / Output Parameters” directory to set the
analog outputs.
●
●
Default values see “Factory settings”, page 61
In order to output the dust concentration under standard conditions (“Conc. s.c.”
(Ext)), set the parameters for the analog outputs according to see “Setting the analog inputs parameters”, page 65.
Fig. 34: SOPAS ET menu: MCU/Configuration/IO configuration/Output Parameters
Field
Analog
Outputs
- General
configuration
Output Error
current
Error Current
Current in
maintenance
Maintenance
current
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Parameter
Yes
No
Value < Live Zero (LZ)
or > 20 mA
User defined value
Value measured last
Measured value
output
Whenever possible,
value ≠ LZ
Remark
Error current is output.
Error current is not output.
mA value to be output in “Malfunction” state (error case) (size depends
on connected evaluation system).
A value to be defined is output during “Maintenance”
The value measured last is output during “Maintenance”
The current measured value is output during “Maintenance”.
mA value to be output in “Maintenance” state
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4 START-UP AND PARAMETER SETTINGS
Field
Optional
Analog Output Modules
Parameter
Use first analog Inactive
output module
Active
Analog Output 1 Parameters
Value on
analog
output 1
Concentration a.c.
(SI)
Conc.s.c.dry O2 corr.
(SI)
Live zero
Output
checkcycle
results on the
AO
Write absolute
value
Analog Output 1 Scaling
Range low
Range high
Limiting Value Limit value
SI
Zero point
(0, 2 or 4 mA)
Inactive
Active
Inactive
Active
Lower measuring
range limit
Upper measuring
range limit
Concentration a.c.
(SI)
Conc.s.c.dry O2 corr.
(SI)
Limit Switch
Parameters
SI
Hysteresis type Percent
Absolute
Switch at
Value exceeded
Underflow
Limit value
Value
Hysteresis
64
Value
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Remark
Not permitted for DUSTHUNTER SP100 (results in error, because AO 2
and AO 3 are available by default).
Opens the fields to set parameters for AO 2 and AO 3 (standard on
DUSTHUNTER SP100)
Dust concentration under standard
The selected measured
conditions (based on scattered light
variables are output on the
intensity)
analog output.
Dust concentration under standard
conditions (based on scattered light
intensity)
Scattered light intensity
Select 2 or 4 mA to ensure being able to differentiate between measured
value and switched off device or interrupted current loop.
Control values (see “Function check”, page 16) are not output on the
analog output.
Control values are output on the analog output .
Positive and negative measured values are differentiated.
The amount of the measured value is output.
Physical value at live zero
Physical value at 20 mA
Dust concentration under standard
Select the measured variable
conditions (based on scattered light
for which a limit value is to be
intensity)
monitored.
Dust concentration under standard
conditions (based on scattered light
intensity)
Scattered light intensity
Assignment of the value entered in the “Hysteresis value” field as relative
or absolute value of defined limit value
Define the switching direction
The limit value relay switches when the entered value is overflown or
underflown.
Define a tolerance for resetting the limit value relay
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4.3.5
Setting the analog inputs parameters
Select the “Configuration / I/O Configuration / Input Parameters DUSTHUNTER” directory
to set the analog inputs.
Fig. 35: SOPAS ET menu: MCU/Configuration/IO configuration/Input Parameters
Field
Parameter
Temperature Constant Value
Source
Analog Input 1
Pressure
Source
Constant Value
Analog Input 2
Moisture
Source
Constant Value
Analog Input 3
Oxygen
Source
Constant Value
Analog Input 4
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Remark
A fixed value is used to calculate the scaled value.
This parameter opens the “Temperature Constant” field to enter the scaling value in °C (° F for
imperial units) or K.
The value from an external sensor connected to analog input 1 (standard scope of delivery) is
used to calculate the scaled value.
This parameter opens the “Analog input 1 - Temperature” field to set the lower and upper range
limit values and the Live Zero value.
A fixed value is used to calculate the scaled value.
This parameter opens the “Constant Temperature” field to enter the scaling value in mbar (=
hPa).
The value from an external sensor connected to analog input 2 (standard scope of delivery) is
used to calculate the scaled value.
This parameter opens the “Analog input 2 - Pressure” field to set the lower and upper range limit
values and the Live Zero value.
A fixed value is used to calculate the scaled value.
This parameter opens the “Constant Moisture” field to enter the scaling value in %.
The value from an external sensor connected to analog input 3 (optional module required) is
used to calculate the scaled value.
This parameter opens the “Analog input 3 - Moisture” field to set the lower and upper range
limit values and the Live Zero value.
A fixed value is used to calculate the scaled value.
This parameter opens the “Constant Oxygen” field to enter the scaling value in %.
The value from an external sensor connected to analog input 4 (optional module required) is
used to calculate the scaled value.
This parameter opens the “Analog input 4 - Oxygen” field to set the lower and upper range limit
values and the Live Zero value.
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4 START-UP AND PARAMETER SETTINGS
4.3.6
Setting the response time
Select the “Configuration / Value Damping” directory to set the damping time.
Fig. 36: SOPAS ET menu: MCU/Configuration/Value Damping
Field
Parameter
Damping time Value in s
for Sensor 1
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Remark
Response time for the selected measured variable (see “Response
time”, page 15)
Setting range 1 ... 600 s
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4.3.7
Calibration for dust concentration measurement
For exact dust concentration measurement, the relation between the primary measured
variable scattered light intensity and the actual dust concentration in the duct must be
established. To do this, the dust concentration must be determined based through a gravimetric comparison measurement according to DIN EN 13284-1 and set in relation to the
values measured at the same time by the measuring system.
NOTE:
Carrying out a gravimetric comparison measurement demands special knowledge that
cannot be described in detail here.
Steps to be carried out
▸
▸
▸
▸
▸
▸
▸
Select device file “MCU”, set the measuring system to “Maintenance” mode
Enter the Level 1 password (see “Password and operating levels”, page 73).
Select the “Configuration / IO Configuration / Output Parameter DUSTHUNTER”
directory (see “SOPAS ET menu: MCU/Configuration/IO configuration/Output Parameters”, page 63) and assign the “Scattered light intensity” measured variable to one of
the three analog outputs available.
Estimate the measuring range required for the dust concentration in operational state
and enter this in the “Analog output 1 (2/3) Scaling” field assigned to the selected
analog output assigned to the scattered light intensity.
Deactivate “Maintenance” mode.
Carry out the gravimetric comparison measurement according to DIN EN 13284-1.
Determine regression coefficients from the mA values of the analog output for “Scattered light intensity” and the actual dust concentrations measured gravimetrically.
2
(1)
c = K2 ⋅ I out + K1 ⋅ I out + K0
c:
Dust concentration in mg/m³
K2, K1, K0:
Iout:
Regression coefficients of the function c = f (Iout )
Current output value in mA
20mA – LZ
I out = LZ + SL ⋅ ----------------------------MBE
LZ:
MBE:
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(2)
SI: Measured scattered light intensity
Live Zero
Defined upper range limit value
(value entered for 20 mA;
normally 2.5 x fixed limit value)
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4 START-UP AND PARAMETER SETTINGS
 Enter the regression coefficients
There are two options:
– Direct input of K2, K1, K0 in a measured value computer.
NOTE:
In this case, the regression coefficients set in the sender/receiver unit and the
measuring range set in the MCU may not be changed anymore. On the optional
LC Display (when used), the dust concentration is displayed as uncalibrated
value in mg/m³.
– Use of the regression function of the measuring system (use without measured value
computer).
In this case, the correlation to the scattered light intensity has to be determined. To
do this, calculate the regression coefficients cc2, cc1, cc0 to be entered in the measuring system from K2, K1, K0.
2
c = cc2 ⋅ SL + cc1 ⋅ SL + cc0
(3)
Using (2) in (1), the result is as follows:
20mA – LZ 2
20mA – LZ
c = K2 ⋅  LZ + SL ⋅ ----------------------------- + K1 ⋅  LZ + SL ⋅ ----------------------------- + K0


MBE 
MBE 
Using (3), the result is as follows:
2
cc0 = K2 ⋅ LZ + K1 ⋅ LZ + K0
20mA – LZ
cc1 = ( 2 ⋅ K2 ⋅ LZ + K1 ) ⋅  -----------------------------
 MBE 
20mA – LZ
cc2 = K2 ⋅  -----------------------------
 MBE 
2
Now enter the regression coefficients cc2, cc1 and cc0 determined in directory “Configuration/Application parameters” (see “Assigning the sender/receiver unit to the measuring
location (in SOPAS ET)”, page 58) (set sender/receiver unit to “Maintenance” state and
enter the Level 1 password).
Reset the sender/receiver unit back to “Measurement” state afterwards.
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4.3.8
Data backup in SOPAS ET
All parameters relevant for recording, processing and input/output of measured values as
well as current measured values can be saved in SOPAS ET and printed. This allows easy
reentering of set device parameters as needed or registering device data and states for
diagnostic purposes.
The following options are available:
Saving as a project
Not only device parameters but also data logs can be saved.
● Saving as a device file
Saved parameters can be processed without a device connected and transferred to the
device again later.
●
Description, see SOPAS ET Help menu and ‐DUSTHUNTER Service Manual.
●
Saving as a protocol
Device data and parameters are registered in the Parameter protocol.
A Diagnosis protocol can be created for analysis of the device function and recognition
of possible malfunctions.
Parameter protocol example
Fig. 37: DUSTHUNTER SP100 Parameter protocol (example)
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4 START-UP AND PARAMETER SETTINGS
4.3.9
Starting measurement mode
Set the measuring system to “Measurement” mode after entering/modifying parameters.
To do so, cancel “Maintenance”: Deselect “Maintenance Sensor”.
Fig. 38: SOPAS ET menu: MCU/Maintenance/Maintenance
Standard start-up is now completed.
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4.4
Setting the Interface module parameters
4.4.1
General information
The following steps are necessary to select and set the optionally available Interface
modules Profibus DP, Modbus TCP and Ethernet type 1:1
▸
▸
▸
▸
Select device file “MCU”, set the measuring system to “Maintenance” mode
Enter the Level 1 password (see “Password and operating levels”, page 73).
Switch to the “Configuration / System Configuration” directory.
The installed interface module is displayed in the field “Installed Interface Module”.
Configure the Interface module according to requirements.
Fig. 39: SOPAS ET menu: MCU/Configuration/System Configuration
GSD file and measured value assignment are available for the Profibus DP module on
request.
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4 START-UP AND PARAMETER SETTINGS
4.4.2
Setting the Ethernet module parameters
NOTICE:
The risk of undesired access to the measuring system is inherent when communicating
via Ethernet.
▸ Operate the measuring system only behind suitable protection (e.g., Firewall).
The configuration of interface module Ethernet type 2 (see “Options for MCU control
unit”, page 105) is not possible with program SOPAS ET. A special software with
description is supplied with the program.
Standard setting: 192.168.0.10
A predefined IP address is set on request.
To change the settings:
▸
▸
Select directory “Configuration / I/O Configuration / Interface Module”.
Set the desired network configuration in the “Expansion module information” field and
click “Reset module”.
Fig. 40: SOPAS ET menu: MCU/Configuration/IO configuration/Interface Module
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4.5
Operating/setting parameters via the optional LC-Display
4.5.1
General information on use
The display and operating interface of the LC-Display contains the functional elements
shown in Fig. “LC-Display functional elements”.
Fig. 41: LC-Display functional elements





 Status LED
 Control buttons
 Current button function
 Display field
 Status bar
Button functions
The function shown depends on the Menu currently selected. Only the function shown in
the button is available.
Button
Diag
Back
Arrow 
Arrow 
Enter
Start
Save
Meas
4.5.2
Function
Display diagnostic information (warnings and errors during a start using the Main
menu, sensor information during a start using the Diagnostics menu)
Switch to higher level menu
Scroll up
Scroll down
Execution of the action selected with an arrow button (switch to a submenu, confirm
parameter selected during parameter setting)
Start an action
Store a changed parameter
Switch from main measured values to measured sensor values
Display the contrast setting (after 2.5 s)
Password and operating levels
Certain device functions are first accessible after a password has been entered.
User level
0 Operator
1
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Authorized operator
Access to
Displays measured values and system states
No password required
Displays, inquiries as well as start-up or adjustment to customerspecific demands and diagnosis of necessary parameters
Pre-set password: 1234
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4 START-UP AND PARAMETER SETTINGS
4.5.3
Menu structure
Fig. 42: LC-Display menu structure
} 1)
2)
} 1)
3)
1): as in the operating state
2): see “MCU”, page 74
3): see “Sender/receiver unit”,
page 77
4.5.4
Parameter setting
4.5.4.1
MCU
Analog outputs / inputs
▸
▸
▸
74
Set the MCU to “Maintenance” mode and select the “I/O Parameter” submenu.
Select the desired parameter and enter the default password “1234” using the “^”
(scrolls from 0 to 9) and/or “→” (moves the cursor to the right) buttons.
Select the desired value using the “^” and/or “→” buttons and write it to the device with
“Save” (confirm 2x).
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Fig. 43: Menu structure for configuring analog outputs/inputs and setting the MCU variant
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4 START-UP AND PARAMETER SETTINGS
Setting the MCU variant
The following steps are required to set the MCU for the DUSTHUNTER SP100 sender/
receiver unit to be connected (see “Assigning the MCU to the sender/receiver unit”,
page 60):
▸
▸
Set the MCU to “Maintenance” mode, select the “MCU Variant” submenu and select the
type “DUSTHUNTER S”.
Enter the default password and store the type with “Save” (confirm twice).
The other selection options have no significance here.
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4.5.4.2
Sender/receiver unit
The following steps are required to enter the regression coefficients:
▸
▸
▸
Set the sender/receiver unit to “Maintenance” and select the “Parameter” submenu.
Select the desired parameter and enter the password (see “Password and operating
levels”, page 73).
Set the calculated coefficients (see “Calibration for dust concentration measurement”,
page 67) using the “^” and/or “→” buttons and write to the device with “Save” (confirm
twice).
Fig. 44: Entering the regression coefficients
Parameter
Parameter
Parameter
Password
000.000
-01.130.
XXXX
Back
Save
Parameter
Parameter
Back
Save
Parameter
Back
Save
Parameter
1
1 cc2
2
2 cc1
Password
001.000
3
3 cc0
000.560.
XXXX
/sensor/1/param
Back
Enter
Back
Save
Parameter
Back
Save
Parameter
Save
Parameter
Password
000.000
Back
-06.780
XXXX
Back
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Save
Back
Save
Back
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Save
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4 START-UP AND PARAMETER SETTINGS
4.5.5
Using SOPAS ET to modify display settings
To modify the factory settings, connect SOPAS ET with the “MCU” (see “Connection to the
device via USB line”, page 53), enter the Level 1 password and select the “Configuration /
Display Settings” directory.
Fig. 45: SOPAS ET menu: MCU/Configuration/Display Settings
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Window
Common Display
Settings
Overview Screen
Settings
Entry field
Display language
Display Unit System
Bars 1 to 8
Value
Use AO scaling
Security settings
Range low
Range high
Authorized operator
Idle time
Significance
Language version shown on the LC-Display
Unit of measurement system used in displays
Number of measured value for the first measured
value bar in the graphic display
Measured value index for the respective measured
value bar
When activated, the measured value bar is scaled to
the associated analog output. If not activated, define
the limit values separately
Values for separate scaling of the measured value bar
independent of the analog output
Password input for the Display menu operating level
“Authorized Operator”
Default: 1234
Time until user level “Authorized Operator” is automatically switched off again.
Measured value assignment
MCU measured value
Value 1
Value 2
Value 3
Value 4
Value 5
Value 6
Value 7
Value 8
MCU Value 1
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Sender/receiver unit measured value
Not used
Concentration a.c. (SI)
Not used
Not used
Not used
Not used
Scattered light
Not used
Conc.s.c.dry O2 corr. (SI)
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5
Maintenance
5.1
General
The maintenance work to be carried out is limited to cleaning work and securing the purge
air supply function. On the sender/receiver unit DUSTHUNTER SP100 Ex, restricted
breathing must be checked additionally when the enclosure was opened (see Service
Manual).
WARNING: Hazards by explosive or combustible gases
▸ Only specially trained service personnel may open the enclosure, so that
ignition protection is maintained.
This service personnel must have been specially trained for the DUSTHUNTER SP100 Ex measuring system by SICK.
Take the following steps to set the measuring system to “Maintenance” mode before
starting maintenance work.
▸
▸
▸
▸
Connect the MCU to the laptop/PC using the USB line and start program SOPAS ET.
Connect with the MCU (see “Connection to the device via USB line”, page 53).
Enter the Level 1 password (see “Password and operating levels”, page 73).
Set the measuring system to “Maintenance” mode: Click “Maintenance Sensor”
Fig. 46: SOPAS ET menu: MCU/Maintenance/Maintenance
WARNING:
Observe the relevant safety regulations as well as the safety notices (see “Responsibility of user”, page 11) during all work.
Resuming measuring operation
Resume measuring operation after completing the work (deactivate the “Maintenance on/
off” checkbox in the “Maintenance / Operation” window and click “Set State”).
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MAINTENANCE 5
●
●
●
●
“Maintenance” mode can also be set using the buttons on the display on the MCU
(see “Menu structure”, page 74) when the LC-Display option is present or by connecting an external maintenance switch to the terminals for Dig In2 (17, 18) in the
MCU (see “Connecting the MCU control unit”, page 47).
An automatic functional check is not carried out during “Maintenance”.
The value set for “Maintenance” is output on the analog output (see “Setting the
analog outputs parameters”, page 63). This is also applicable when a malfunction is
present (signaled on relay output).
The “Maintenance” mode is reset when there is a voltage failure. In this case, the
measuring system switches automatically to “Measurement” after the operating voltage is switched on again. If “Maintenance” mode is set via the external maintenance
switch (see top item), the mode is also maintained when there is a voltage failure.
Maintenance intervals
The equipment operator must specify the maintenance intervals. The period depends on
existing operating parameters such as dust content and state, gas temperature, how the
equipment is run and ambient conditions.
The equipment operator must specify the specific work to be carried out and its performance in a Maintenance Manual.
Maintenance contract
Scheduled maintenance work can be carried out by the equipment operator. Only qualified
personnel according to Section 1 should be allowed to do the work. If requested, all maintenance activities can also be performed by SICK Service or an authorized Service partner.
Any repairs will be made by specialists onsite whenever possible.
Auxiliary means required
Brush, cleaning cloth, cotton swabs
Water
● Replacement air filter (for suction)
●
●
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5 MAINTENANCE
5.2
Maintenance on the sender/receiver unit
NOTE:
▸
▸
Do not damage any device parts during maintenance work.
Do not interrupt the purge air supply.
Clean the outside of the sender/receiver unit in regular intervals. Remove deposits with
water or mechanically using suitable auxiliary means.
Clean the optical interfaces when deposits can be seen or before contamination reaches
the 30% warning limit value (40% for malfunction).
If contamination on the glass surfaces cannot be removed with the optics cloth, clean
the glass surfaces with soap suds and then dry.
WARNING: Hazard through gas and hot parts
Dismantle the sender/receiver unit from the duct for cleaning and then fit it back on
again.
▸ Observe the relevant safety regulations as well as the safety notices (see “Responsibility of user”, page 11) during all work.
▸ Only carry out assembly work on equipment with hazard potential (higher internal
duct pressure, hot or aggressive gases) when the equipment is at a standstill.
▸ Take suitable protection measures against possible local hazards or hazards arising
from the equipment.
WARNING: Risk of explosion
▸ Start-up and shutdown may only be performed when it is verified that no
explosive media are present (verification by gas detector).
▸ Check the potential equalization for corrosion / other damage and safe contacts.
▸ Check the cable and cable socket for damage and strain relief.
▸ Check that the locking parts of the device are firmly locked (laser adjustment opening, cleaning opening, purge air connection, cover, plug, sight
glass).
!▸ Only SICK service personnel may change the device connection plug.
Restricted breathing must then be checked.
5.2.1
Cleaning the optics of the sender/receiver unit
Sender/receiver unit
▸
▸
▸
▸
▸
82
Remove the sender/receiver unit from the duct.
Close off the flange with tube with a blind flange.
Unscrew cover screw (6) from the cleaning opening for sender optics (see “Cleaning the
optical interfaces”, page 83).
Loosen fastening screws (3) for cover (4) and take off cover.
Clean the optics carefully with cotton swabs and, if necessary, light trap (5) as well.
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MAINTENANCE 5
Fig. 47: Cleaning the optical interfaces
Sender/receiver unit


Receiver optics





5.2.2

Cover
Fastening screws
Light trap
Cover screw
Checking the contamination value
▸
Figure 48
Start the function check by moving device file “MCU” to the “Project tree” window”,
select the “Adjustment / Function Check Manual” directory and click the “Start Manual
Function Check” button.
SOPAS ET menu: MCU/Adjustment/Function Check - Manual
The function check can also be started via the LC-Display on the MCU (see “Menu
structure”, page 74).
▸
Figure 49
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Select the “DH SP100” device file in the “Project Tree” window, select the “Diagnosis /
Check values” directory and check the contamination value.
SOPAS ET menu: DH SP100/Diagnosis/Check values
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5 MAINTENANCE
▸
If the measured values for contamination, zero point and span are within the allowed
ranges, save them to the device by clicking the “Refresh” button (“Check values” field); if
not, repeat cleaning and check the contamination value again by triggering a renewed
function check.
●
●
▸
▸
5.2.3
The contamination value can also be displayed on the LC display of the MCU
(initiate a function check and select the “SP100/Diagnosis” menu, see “Menu
structure”, page 74).
If the contamination value does not sink below the value for warning (30%) in
spite of several cleaning processes, the device is probably defective → contact
SICK Service.
Reassemble the sender/receiver unit, remove the cover from the probe flange (cover) or
flange with tube (blind flange) and install the sender/receiver unit on the duct.
Resume measuring operation (see “Resuming measuring operation”, page 80).
Checking restricted breathing
Restricted breathing must be checked:
–
–
–
–
When the enclosure has been opened
After a purge air failure
When there are severe mechanical or thermal effects to the device
When the device connection plug was changed (only SICK service personnel may
change the device connection plug)
– During regular maintenance work (min. 1x per year)
Restricted breathing must be checked by specially trained service personnel. This service
personnel must have been specially trained by SICK for the DUSTHUNTER SP100 Ex
measuring system.
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MAINTENANCE 5
5.3
Maintenance on the purge air supply
Maintenance work to be carried out:
Inspecting the entire purge air supply
Cleaning the filter housing
● Replacing the filter element, if necessary.
●
●
The dust load and wear on the filter element depend on the degree of contamination of the
intake ambient air. It is therefore not possible to specify precise time intervals for these
tasks. We recommend inspecting the purge air supply at short intervals (approx. 2 weeks)
and then optimizing maintenance intervals over a longer period of operation.
NOTE:
Irregular or insufficient maintenance of the purge air supply can cause it to fail and thus
cause severe damage to the sender/receiver unit.
▸ Always ensure the purge air supply when the optical component sender/receiver unit
is fitted on the duct.
▸ Disassemble the connected components before exchanging damaged purge air
hoses (see “Shutdown”, page 88).
Inspection
▸
▸
▸
▸
Check the running noise of the blower at regular intervals; increases in the noise level
can indicate a blower failure.
Check that all hoses are secure and free of damage.
Check the filter element for contamination.
Exchange the filter element when:
– Severe contamination (deposits on the filter surface) is visible
– The purge air volume is reduced considerably as compared to operation with a new
filter.
The purge air supply does not have to be switched off to clean the filter housing or
to replace the filter element, i.e. the components can remain on the duct.
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5 MAINTENANCE
5.3.1
Control unit MCU with integrated purge air supply
Cleaning or replacing the filter element
▸
▸
▸
▸
▸
▸
Open the door of the MCU with the appropriate key.
Loosen strap retainer (1) on the filter outlet and pull filter housing (2) off the connection
piece.
Remove the filter housing.
Rotate filter housing cover (3) in the “OPEN” arrow direction and remove the cover.
Take out the filter element and replace with a new element.
Clean the inside of the filter housing and the filter housing cover with a cloth and brush.
NOTICE:
▸
▸
▸
▸
For wet cleaning, use only a water-soaked cloth and then dry the parts well.
Insert new filter element.
Spare part: Filter element C1140, Part No. 7047560
Mount the cover on the filter housing cover and rotate opposite to the direction of the
arrow until it clicks into place.
Reinstall the filter housing in the control unit.
Fig. 50: Exchanging the filter element for the control unit with purge air supply



 Strap retainer
 Filter housing
 Filter housing cover
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MAINTENANCE 5
5.3.2
Optional external purge air unit
NOTICE:
The purge air unit must be serviced at the latest when the low-pressure monitor (7) at
the filter outlet triggers (see “Replacing the filter element”, page 87).
Replacing the filter element
Fig. 51: Replacing the filter element











▸
▸
Low-pressure monitor
Filter housing
Filter element
Filter housing cover
 Snap lock
 Purge air hose
 Strap retainer
Clean outside of filter housing (2).
Loosen strap retainer (7) and clamp purge air hose (6) to a clean location.
NOTICE:
▸
▸
▸
▸
Place the end of the hose in a safe place so that foreign objects cannot be
sucked in (this will cause irreparable damage to the blower), but do not close the
end of the hose! During this time, the purge air entering the purge air connection
pieces is unfiltered.
Press snap locks (5) together and take off filter housing cover (4).
Remove filter element (3) with twisting-pulling movements.
Clean the inside of the filter housing and the filter housing cover with a cloth and brush.
NOTICE:
▸
▸
▸
▸
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For wet cleaning, use only a water-soaked cloth and then dry the parts well.
Insert the new filter element with twisting-pressing movements.
Spare part: Filter element Micro-Top element C11 100, Part No. 5306091
Mount the filter housing cover, ensuring that it is aligned correctly with the housing, and
snap the snap locks into place.
Reconnect the purge air hose to the filter outlet using the hose clamp.
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5 MAINTENANCE
5.4
Shutdown
The measuring system must be shut down:
●
●
Immediately when the purge air supply fails
If the equipment is to be put out of operation for a longer period of time (as from approx.
1 week)
NOTE:
Never switch off or interrupt the purge air supply when the sender/receiver unit is fitted
on the duct.
Work to be performed
▸
▸
Loosen the connection line to the MCU.
Dismantle the sender/receiver unit from the duct.
WARNING: Hazard through gas and hot parts
▸
▸
▸
▸
▸
▸
▸
▸
Observe the relevant safety regulations as well as the safety notices in Section 1
during all disassembly work.
Only remove the sender/receiver unit on equipment with hazard potential (higher
internal duct pressure, hot, aggressive, explosive gases/dusts) when the equipment is at a standstill.
Take suitable protection measures against possible local hazards or hazards arising from the equipment.
Secure switches that should not be switched on again for safety reasons with
signs and safeguards to prevent unintentional switching.
Close off the flange with tube with a blind plug.
Switch off the purge air supply
Loosen the hose clamps and pull the purge air hose off the connections and secure the
hose ends against dirt and moisture
Disconnect the MCU control unit from the supply voltage.
Storage
▸
▸
▸
88
Store dismantled device parts in a clean, dry location.
Use suitable auxiliary means to protect the connection line plug-in connectors against
dirt and moisture.
Secure purge air hoses against penetration by dirt and moisture.
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TROUBLESHOOTING 6
6
Troubleshooting
6.1
General
WARNING: Hazard through gas and hot parts
Dismantle the sender/receiver unit from the duct for cleaning and then fit it back on
again.
▸ Observe the relevant safety regulations as well as the safety notices (see “Responsibility of user”, page 11) during all work.
▸ Only carry out assembly work on equipment with hazard potential (higher internal
duct pressure, hot or aggressive gases) when the equipment is at a standstill.
▸ Take suitable protection measures against possible local hazards or hazards arising
from the equipment.
WARNING: Risk of explosion
▸ Open the flameproof enclosure of the sender/receiver unit only when this
component is outside the Ex protection zone.
▸ Only check voltages when no Ex conditions exist (plant out of operation or
connection unit outside the Ex zone).
Warning or error messages are output as follows:
●
●
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On the MCU, the respective relay is switched on (see “Standard connection”, page 50).
“Maintenance requ.” or “Failure” is displayed in the status bar of the LC-Display (see
“General information”, page 71). In addition, the respective LED goes on (“MAINTENANCE REQUEST” for warnings, “FAILURE” for errors).
After pressing the button “Diag”, possible causes are shown as short information in the
menu “Diagnosis” after selecting the device (“MCU” or “DH SP100”).
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6 TROUBLESHOOTING
Figure 52
Display on the LC-Display
ConcSL
0.0
8.6
mg/m³
200.0
SL
8.6
0.0
200.0
Diag
Menu
Diagnosis
I/O Diagnosis
/diag
Back
/i/o/status
Enter
Back
Enter
Display of current warning or malfunction
Diagnosis
/sensor/status
Back
Enter
“Diagnosis / Error messages/warnings” provides detailed information on the current
device state. To display, connect the measuring system to SOPAS ET and start the device
file “DH SP100” or “MCU”.
Move the mouse to the respective message to display more details on the significance of
individual messages in a separate window. Clicking on the display shows a short
description of possible causes and corrections under “Help” (see “Warning and malfunction messages in SOPAS ET”, page 91, ).
Warning messages are output when internal limits for individual device functions/components are reached or exceeded which can then lead to erroneous measured values or an
imminent failure of the measuring system.
Warning messages do not imply a malfunction of the measuring system. The current
measured value continues to be output on the analog output.
See the Service Manual for a detailed description of messages and options for clearance.
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TROUBLESHOOTING 6
6.2
Sender/receiver unit
Malfunctions
Symptom
●
●
Possible cause
LEDs of the
sender/receiver
are not on
No laser beam
●
●
●
Action
No supply voltage
Connection line not connected correctly
or defective
Defective plug connector
▸
▸
Check plug connectors and lines.
Contact SICK Customer Service.
Warning and malfunction messages in SOPAS ET
Fig. 53: SOPAS ET menu: DH SP100/Diagnosis/Error messages/Warnings
Current warning or error messages, or earlier messages stored in the error memory, can be
shown by selecting “actual” or “memory” in the “Selection” window.
●
●
Display of error or warning: With LED symbol
Description of error or warning: In the description field of SOPAS ET
Malfunctions listed below can probably be cleared onsite.
Message
Significance
Contamination
Current reception intensity
is lower than the allowable
limit value (see “Technical
Data”, page 96)
Possible cause
●
●
Action
Deposits on the optical
interfaces
Unclean purge air
▸ Clean the optical surfaces (see “Maintenance
on the sender/receiver unit”, page 82).
▸ Check purge air filter (see “Maintenance on
the purge air supply”, page 85)
▸ Contact SICK Customer Service.
Span test,
Zero point
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Deviation from setpoint
value > ±2%.
Sudden changes in measur- ▸ Repeat the functional check.
ing conditions during deter- ▸ Contact SICK Customer Service.
mination of control values
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6 TROUBLESHOOTING
6.3
MCU control unit
6.3.1
Malfunctions
Symptom
Possible cause
No display on the LCD ● No supply voltage
● Connection line to LC-Display not
connected or damaged
● Defective fuse
6.3.2
Action
▸
▸
▸
▸
Check voltage supply.
Check the connection line
Exchange fuse.
Contact SICK Customer Service.
Warning and error messages in the SOPAS ET program
Fig. 54: SOPAS ET menu: MCU/Diagnosis/Error messages/Warnings
●
●
92
Display of error or warning: With LED symbol
Description of error or warning: In the description field of SOPAS ET
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TROUBLESHOOTING 6
Malfunctions listed below can probably be cleared onsite.
Message
Significance
Possible cause
AO configuration
the number of available and
configured analog outputs is not
identical.
●
●
●
AI configuration
Interface Module
Number of available and
configured analog inputs not
identical.
No communication via Interface
module
●
●
●
●
●
●
No sensor found
Sender/receiver unit was not
recognized
●
●
Variant configuration MCU setting does not match the
error
connected sensor
Testmode enabled
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MCU in “Test” mode.
Action
No parameters set for
AO
Connection error
Module failure
▸
No parameters set for AI
Connection error
Module failure
▸
No parameters set for
module
Connection error
Module failure
▸
Communication problems on RS485 line
Supply voltage problems
▸
▸
▸
▸
Check system settings.
Check the connection line
Check voltage supply.
Contact SICK Customer Service.
▸
Correct application settings
(see “Assigning the MCU to the
sender/receiver unit”,
page 60).
▸
Deactivate “System Test” mode
(“Maintenance” directory)
Sensor type has been
changed
▸
▸
▸
Check configuration (see “Setting the analog outputs parameters”, page 63).
Contact SICK Customer Service.
Check configuration (see “Setting the analog inputs parameters”, page 65).
Contact SICK Customer Service.
Check configuration (see “Setting the Ethernet module
parameters”, page 72).
Contact SICK Customer Service.
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6 TROUBLESHOOTING
6.3.3
Replacing the fuse
▸
▸
▸
▸
▸
Control unit MCU must be disconnected from the power supply and potential-free.
Open the door of the MCU, remove and open fuse holder (1).
Replace the defective fuse (2) (see “Miscellaneous”, page 105).
Close and attach the fuse holder.
Close the door and connect power voltage.
Fig. 55: Replacing the fuse
 Fuse holder
 Fuse


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SPECIFICATIONS 7
7
Specifications
7.1
Compliances
The technical design of this device complies with the following EU directives and EN standards:
EU Directive: LVD (Low Voltage Directive)
EU Directive: EMC (Electromagnetic Compatibility)
● EU Directive: ATEX
●
●
Applied EN standards:
●
●
●
●
●
EN 61010-1, Safety requirements for electrical equipment for measurement, control
and laboratory use
IEC 60079-0: Electrical apparatus for explosive gas atmospheres; Part 0: General
requirements
IEC 60079-15: Equipment protection by type of protection “n”
EN 61326, Electrical equipment for measurement technology, control technology and
laboratory use - EMC requirements
EN 14181, Calibration of continuously operating emission measuring devices
Electrical protection
MCU, external purge air unit: Protection class 1 according to EN 61010-1.
Insulation coordination: Overvoltage category II in accordance with EN61010-1
● Contamination: The device operates safely in an environment up to degree of contamination 2 according to EN 61010-1 (usual, not conductive contamination and temporary
conductivity by occasional moisture condensation).
● Electrical energy: The wiring system to the power supply voltage of the system must be
installed and fused according to the relevant regulations.
●
●
Approvals
DUSTHUNTER SP100 Ex is performance-tested according to EN 15267 and may be used
for continuous emission monitoring in plants requiring approval and plants according to EU
Directives.
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7 SPECIFICATIONS
7.2
Technical Data
Limit values for corrosive gas
composition .
Measurement uncertainty 1)
Response time
Measuring Conditions
Gas temperature (above dew
point)
Internal duct pressure
Internal duct diameter
Ambient temperature
Function Check
Automatic self-test
Manual linearity check
Output Signals
Analog outputs
Relay outputs
Input signals
Analog inputs
Digital input
HCl:
SO2:
SO3:
NOx:
HF:
10 mg/Nm³
800 mg/Nm³
300 mg/Nm³
1000 mg/Nm³
10 mg/Nm³
±2% of upper measuring range value
1 ... 600 s; freely selectable
Standard version DHSP-T2xxx1Ex3G:
-15 ... 220 °C
High-temperature version DHSP-T4xxxNXX:
-15 ... 400 °C
Sender/receiver unit
MCU-P control unit
-50 hPa ... +10 hPa
DHSP-T2xxx1Ex3G
Optional external purge air unit
-50 hPa ... +30 hPa
and DHSP-T4xxx1Ex3G
With onsite instrument air
-50 hPa ... +100 hPa
> 250 mm
-15 ... +60 °C
Sender/receiver unit, MCU-N control unit
-40 ... +45°C
MCU-P control unit, intake temperature for purge air
Linearity, drift, aging, contamination
Contamination limit value: From 30% warning: From 40% malfunction
Using a reference filter
3 outputs 0/2/4 ... 22 mA, max. load 750 ; resolution 10 bits; electrically isolated
5 potential-free outputs (changeover contacts) for status signal; load 48 V, 1 A
2 inputs 0...20 mA (standard; without electric isolation); resolution 10 bits
2 further analog inputs when using an Analog Input module (option, see “MCU control unit”,
page 22)
4 inputs to connect potential-free contacts (e.g., for external maintenance switch, triggering
function check);
Communication Interfaces
USB 1.1, RS 232 (on terminals) For measured value inquiries and software updates per PC/laptop using the operating
program
RS485
For connection of sender/receiver unit
Optional Interface module
To communicate with the Host PC, optional for Profibus, Ethernet
Power supply
MCU control unit
Voltage supply:
90...250 V AC, 47...63 Hz; opt. 24 V DC ± 2 V
Power consumption:
Max. 15 W without purge air supply
Max. 70 W with purge air supply
Sender/receiver unit
Voltage supply:
24 V from MCU control unit
Power consumption:
Max. 4 W
Optional external purge air unit Voltage supply (3 ph):
200 ... 240 V/345...415 V at 50 Hz;
(with blower 2BH13)
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
MCU connection line
Shielded lines with twisted pairs (e.g., UNITRONIC LiYCY (TP) 2 x 2 x 0.5 mm² from
LAPPKabel; 1 pair of wires for RS 485, 1 pair of wires for power supply; not suitable for
underground laying).
Explosion protection
Electronics unit of sender/
ATEX II 3G Ex nR op is IIC T6 Gc; restricted breathing enclosure
receiver unit
Type Examination Certificate: BVS 16 ATEX E 068 X
For zone 2 (gas)
Material: According to type code
1): In temperature range - 15 °C ... +60 °C
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SPECIFICATIONS 7
Weight
Sender/receiver unit
MCU control unit
DHSP-T2xxxEX3G
Approx. 13 kg (NL: 435 mm)
MCU-P
13.5 kg
MCU-N
3.7 kg
Optional external purge air unit 14 kg
Miscellaneous
Protection class
Sender/receiver unit, MCU control unit
IP 67
Optional external purge air unit
IP 54
Connection line length
5 m, 10 m
Other lengths on request
Purge air hose length (DN40) 5 m, 10 m
Other lengths on request
Laser
Laser class 2; capacity < 1 mW; wavelength between 640 nm and 660 nm
Purge air feed volume
Max. 20 m³/h
MCU-P control unit
Max. 63 m³/h
Optional external purge air unit (type 2BH1300)
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Subject to change without notice
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
97
7 SPECIFICATIONS
7.3
Dimensions, part Nos.
All measures are specified in mm.
7.3.1
Sender/receiver unit
Fig. 56: Sender/receiver unit
126
NL
Ø 60
Ø 53
 170
227
174
L
NL
435
735
L
300
600
Name
Sender/receiver unit DHSP-T2V11EX3GT3
Sender/receiver unit DHSP-T2V11EX3GT4
Sender/receiver unit DHSP-T2V11EX3GT6
Sender/receiver unit DHSP-T2V21EX3GT3
Sender/receiver unit DHSP-T2V21EX3GT4
Sender/receiver unit DHSP-T2V21EX3GT6
Sender/receiver unit DHSP-T4V11EX3GT1
Sender/receiver unit DHSP-T4V11EX3GT2
Sender/receiver unit DHSP-T4V21EX3GT1
Sender/receiver unit DHSP-T4V21EX3GT2
98
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
55
Part No.
1081616
1082967
1082968
1081938
1082969
1082970
1082402
1082966
1082403
1082965
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Subject to change without notice
SPECIFICATIONS 7
7.3.2
Flange with tube
Fig. 57: Flange with tube (standard version)
45°
45°
Ø 76
M10
L
Ø 100
Ø 125
Name
Part No.
Usage on
Flange with tube, Di = 70.2 Length 130 mm, St37
2017845
Flange with tube, Di = 70.2 Length 240 mm, St37
2017847
DHSP-Txx1,
DHSP-Txx2
Flange with tube, Di = 70.2 Length 500 mm, St37
2017849
DHSP-Txx2
Flange with tube, Di = 70.2 Length 130 mm, 1.4571
2017846
Flange with tube, Di = 70.2 Length 240 mm, 1.4571
2017848
DHSP-Txx1,
DHSP-Txx2
Flange with tube, Di = 70.2 Length 500 mm, 1.4571
2017850
Flange type k100
8020216/1-0/2016-08| SICK
Subject to change without notice
DHSP-Txx2
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
99
7 SPECIFICATIONS
7.3.3
MCU control unit
MCU-N control unit and MCU remote control unit without integrated purge air supply
Fig. 58: MCU-N control unit
210
120
100
300
Meas
320
340
160
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
8020216/1-0/2016-08| SICK
Subject to change without notice
SPECIFICATIONS 7
MCU-P control unit with integrated purge air supply
Fig. 59: MCU-P control unit
300
8020216/1-0/2016-08| SICK
Subject to change without notice
Ø8
400
420
455
260
220
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
101
7 SPECIFICATIONS
7.3.4
Optional external purge air unit
Fig. 60: Optional external purge air unit
40
470
550
ø 14
40
128
40
470
258
550
Name
Purge air unit with blower 2BH13 and purge air hose, length 5 m
Purge air unit with blower 2BH13 and purge air hose, length 10 m
102
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
Part No.
1012424
1012409
8020216/1-0/2016-08| SICK
Subject to change without notice
SPECIFICATIONS 7
7.3.5
Weatherproof covers
Weatherproof cover for external purge air unit
Fig. 61: Weatherproof cover for external purge air unit
550
245
550
350
605
Name
Weatherproof cover for purge air unit
Part No.
5306108
Weatherproof cover for sender/receiver unit
Fig. 62: Weatherproof cover for sender/receiver unit
360
239
492
365
Name
Weatherproof cover for sender/receiver unit with NL up to 735 mm, for Ex
protection zone
8020216/1-0/2016-08| SICK
Subject to change without notice
Part No.
2047253
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
103
7 SPECIFICATIONS
7.4
Accessories
7.4.1
Line sender/receiver unit - MCU
Name
7.4.2
Connection line, length 5 m
7042017
Connection line, length 10 m
7042018
Purge air supply
Name
7.4.3
Purge air reduction
Special non-return valve G1/4“ for instrument air
2086957
Hose flex. D40, antistatic
5319616
Hose clamp D32-52
5300809
Assembly parts
Assembly kit flange
(for sender/receiver unit with NL 435 mm and 735 mm)
Part No.
2018184
Device check accessories
Name
Control filter set DHSP
104
Part No.
2086914
Name
7.4.4
Part No.
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
Part No.
2049045
8020216/1-0/2016-08| SICK
Subject to change without notice
SPECIFICATIONS 7
7.4.5
Options for MCU control unit
Part No.
Name
7.4.6
Analog input module, 2 channels, 100 W, 0/4...22 mA, electrically
isolated
2034656
Module carrier
6033578
Interface, Profibus module DP V0
2048920
Interface module Ethernet type 1
2055719
Interface module Ethernet type 2
2069666
Modbus TCP module
2059546
Miscellaneous
Name
Part No.
Cover
2052377
Fuse set T 2 A (for MCU with power voltage supply)
2054541
Fuse set T 4 A (for MCU with 24 V supply)
2056334
7.5
Consumable parts for 2-years operation
7.5.1
Sender/receiver unit
Number
Part No.
Flange seal k100
2
7047036
O-ring 57x5
1
5328042
Optics cloth
4
4003353
Number
Part No.
4
7047560
Number
Part No.
4
5306091
Name
7.5.2
MCU with integrated purge air supply
Name
Filter element C1140
7.5.3
Optional external purge air unit
Name
Filter element Micro-Topelement C11 100
8020216/1-0/2016-08| SICK
Subject to change without notice
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
105
8 INDEX
Index
8
Index
A
T
Additional documentation (information) .......................................... 11
Troubleshooting ................................................................................. 91
Type code ........................................................................................... 25
C
Calibration .......................................................................................... 67
Check cycle ........................................................................................ 16
Circuit board connections ................................................................. 48
COM port ............................................................................................ 54
Configuration ..................................................................................... 60
Connect with SOPAS ET .................................................................... 53
Connecting Ethernet ......................................................................... 55
Control unit ........................................................................................ 18
Creating a USB connection ............................................................... 53
U
User
- Responsibility of user ..................................................................... 11
W
Warning messages ............................................................................ 91
D
Data backup ...................................................................................... 69
Display ................................................................................................ 26
E
Error clearance .................................................................................. 91
F
Fitting the I/O module ....................................................................... 52
Flange with tube ................................................................................ 21
Function check .................................................................................. 16
Functional principle ........................................................................... 14
I
I/O module ......................................................................................... 27
Important Information ..........................................................................7
Installation site .................................................................................. 10
Interfaces ........................................................................................... 22
M
Malfunctions ...................................................................................... 91
MCU ............................................................................................ 18, 22
measured values ............................................................................... 10
Measuring function (general) ........................................................... 10
Menu structure .................................................................................. 74
P
Parameter protocol ........................................................................... 69
Parameter setting .............................................................................. 53
Password For LC-Display ................................................................... 73
Password for SOPAS ET .................................................................... 53
Potentially explosive atmospheres ................................................... 10
Processor board ................................................................................ 48
Product description ........................................................................... 14
Purge air unit ..................................................................................... 28
R
Reset maintenance ........................................................................... 80
Response time ................................................................................... 15
Responsibility of user ........................................................................ 11
Restrictions of use ............................................................................. 10
Resuming measuring operation ....................................................... 80
S
Setting the Ethernet module parameters ........................................ 72
SOPAS ET ........................................................................................... 31
SOPAS ET data backup ..................................................................... 69
Symbols in this document ...................................................................8
106
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
8020216/1-0/2016-08 | SICK
Subject to change without notice
INDEX 8
8020216/1-0/2016-08 | SICK
Subject to change without notice
O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex
107
8020216/2016-08
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