SICK DUSTHUNTER C200 Dust Concentration Monitor Operating Instructions

DUSTHUNTER C200

Dust Concentration Monitor

Description

Installation

Operation

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

Document Information

Described Product

Product name: DUSTHUNTER C200

Document ID

Title:

Part No.:

Version:

Release:

Operating Instructions DUSTHUNTER C200

8011952

2.1a

2012-08

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Phone: +49 7641 469-0

Fax:

E-mail:

+49 7641 469-1149 [email protected]

Place of Manufacture

SICK Engineering GmbH

Bergener Ring 27 · 01458 Ottendorf-Okrilla · Germany

Trademarks

Windows is a trademark of the Microsoft Corporation.

Other product names used in this document may also be trademarks and are only used for identification purposes.

Original Documents

The English edition 8011952 of this document is an original document of SICK AG.

SICK AG assumes no liability for the correctness of an unauthorized translation.

Please contact the manufacturer or your local representative in case of doubt.

Legal information

Subject to change without notice.

© SICK AG. All rights reserved.

2 DUSTHUNTER C200 · Operating Instructions · 8011952 V2.1a · © SICK AG

Warning Symbols

Hazard (general)

Hazard by voltage

Hazard by laser radiation

Warning Levels / 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 personal injury or property damage.

NOTICE

Hazard which could result in property damage.

Information Symbols

Important technical information for this product

Supplementary information

Link to information at another place

DUSTHUNTER C200 · Operating Instructions · 8011952 V2.1a · © SICK AG 3

4

Contents

Content

1

1.1

1.1.1

1.1.2

1.1.3

1.2

1.3

1.3.1

1.3.2

2

2.2

2.2.1

2.2.2

2.2.3

2.2.4

2.2.5

2.2.6

2.2.7

2.1

2.1.1

2.1.1.1

2.1.1.2

2.1.2

2.1.3

2.3

3

3.1

3.2

3.2.1

3.2.2

3.2.3

3.2.4

3.3

3.3.1

3.3.2

3.3.3

3.3.4

3.3.5

3.3.6

Important Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hazards from hot and/or aggressive gases and/or high pressure. . . . . . . . . . . . . . . 8

Hazards through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hazards through laser beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Product Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Measuring principle, measured variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Transmission measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Scattered light measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Function control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Device components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Reflector/scattered light receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

MCU control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation accessories (order separately) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Test equipment for linearity test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Device configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Assembly and Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fitting the flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Fitting the MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Fitting the optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Fitting the weatherproof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

General information, prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Connecting/starting the optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . 40

Installing the purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Connecting the MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connecting the reflector/scattered light receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fitting and connecting optional Interface and I/O modules. . . . . . . . . . . . . . . . . . . . 46

DUSTHUNTER C200 · Operating Instructions · 8011952 V2.1a · © SICK AG

Inhaltsverzeichnis

4.1.3.5

4.1.4

4.1.5

4.2

4.2.1

4.2.2

4.2.3

4.2.4

4.2.5

4.3

4.3.1

4.3.2

4

4.1

4.1.1

4.1.2

4.1.3

4.1.3.1

4.1.3.2

4.1.3.3

4.1.3.4

4.4.8

4.4.9

4.5

4.5.1

4.5.2

4.6

4.6.1

4.6.2

4.6.3

4.6.3.1

4.6.3.2

4.6.4

5

5.1

4.4

4.4.1

4.4.2

4.4.3

4.4.4

4.4.5

4.4.6

4.4.7

4.4.7.1

4.4.7.2

Start-up and Parameter Settings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Installing the operating and parameter program SOPAS ET . . . . . . . . . . . . . . . . . . . . 48

Connecting to the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Configuring the interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Establish connection via "Network Scan Assistant" directory . . . . . . . . . . . . . . . 53

Establish connection via "Connection Wizard" menu (valid for SOPAS ET Version

02.32)54

Selecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Information on using the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Application specific settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Preparatory work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Focussing the sender light beam for transmission measurement . . . . . . . . . . . . . . 61

Scaling the measuring system for transmission measurement. . . . . . . . . . . . . . . . . 64

Adjusting the laser beam for scattered light measurement . . . . . . . . . . . . . . . . . . . . 64

Entering application specific parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Installing the sender/receiver unit and reflector/scattered light receiver . . . . . . . . . . 67

Connecting the sender/receiver unit and reflector/scattered light receiver to the purge air supply67

Fitting and connecting the sender/receiver unit and reflector/scattered light receiver on the duct67

Setting standard parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Assigning the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Determining the function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Setting the analog outputs parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Setting the analog inputs parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Setting the response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Calibrating for dust concentration measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Calibrating dust concentration measurement based on extinction . . . . . . . . . . 77

Calibrating dust concentration measurement based on scattered light intensity

78

Data backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Starting normal measuring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Setting the Interface module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Setting the Ethernet module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Operating/setting parameters via the LC-Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

General information on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Parameter setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Using SOPAS ET to modify display settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96


Content

6

6.1

6.2

6.3

5.2

5.2.1

5.2.2

5.3

5.3.1

5.3.2

5.4

7

7.3

7.3.1

7.3.2

7.3.3

7.3.4

7.3.5

7.3.6

7.3.7

7.4

7.4.1

7.4.2

7.4.3

7.5

7.1

7.2

7.2.1

7.2.2

7.2.3

7.2.4

7.2.5

7.2.6

Maintenance on the sender/receiver unit and reflector/scattered light receiver . . . 98

Maintenance on the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Performing maintenance on the reflector/scattered light receiver . . . . . . . . . . . . 101

Maintenance on the purge air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Control unit with integrated purge air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Malfunctions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Dimensions, Part Nos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Reflector/scattered light receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Flange with tube121

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MCU control unit122

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional external purge air unit124

Weatherproof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Connection cable, sender/receiver unit - MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Connection cable, sender/receiver unit - reflector/scattered light receiver . . . . 126

Purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Assembly parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Device check accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Options for MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Misc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Consumable parts for 2-years operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Sender/receiver unit and reflector/scattered light receiver . . . . . . . . . . . . . . . . . . 127

Control unit MCU with integrated purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128



DUSTHUNTER C200

1

Important Information

Main hazards

Intended use

Responsibility of user


1.1

1.1.1

1.1.2

1.1.3


Main hazards

Hazards from hot and/or aggressive gases and/or high pressure

The optical subassemblies are fitted directly on the gas-carrying duct. On equipment with low hazard potential (no danger to health, ambient pressure, low temperatures), the installation or removal can be performed while the equipment is in operation providing the valid regulations and equipment safety notices are observed and suitable protective measures are taken.

WARNING: Danger from exhaust gas



On equipment with gases detrimental to health, high pressure or high temperatures, the sender/receiver unit and reflector/scattered light receiver components fitted on the duct may only be installed/removed when the equipment is at a standstill.

Hazards through electrical equipment

The DUSTHUNTER C200 measuring system is operational equipment for use in industrial high-voltage current plants.

WARNING: Danger through mains voltage



Disconnect mains lines before working on mains connections or parts carrying mains voltage.



Refit any contact protection removed before switching the mains voltage back on again.

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.



1.2

Intended use

Purpose of the device

The DUSTHUNTER C200 measuring system only 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

Restrictions of use



The DUSTHUNTER C200 measuring system is not approved for use in potentially explosive atmospheres.


10

1.3

1.3.1

1.3.2


Responsibility of user

General information

Designated users

The DUSTHUNTER C200 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.

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.



Carry out work according to the local conditions specific for the equipment as well as operational hazards and regulations.

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.

Safety information and protective measures

Protection devices

NOTICE:

Suitable protection devices and safety equipment for persons must be available according to the respective hazard potential and be used by the personnel.

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 if the purge air supply fails.

NOTICE:

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)



Optical subassemblies are removed from the duct if the purge air supply fails and the duct opening is closed off (e.g. with a flange cover)



Preventive measures for operating safety

NOTICE:

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

NOTICE:

The operator must ensure the following to avoid malfunctions that can indirectly or directly lead to injuries to persons or material damage:



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.




Product Description

DUSTHUNTER C200

2

Product Description

Measuring principle, measured variables

Device components

Device configuration


Product Description

2.1

2.1.1

Measuring principle, measured variables

Functional principle

The DUSTHUNTER C200 measuring system operates as transmissometer with double beam path and as scattered light measuring device with forward dispersion.

Figure 1

Concave mirror

Measuring principle with transmission and scattered light measurement with forward dispersion

Scattered light receiver

Beam splitter

Active measuring path Transmission measurement

Effective measuring distance

Scattered light measurement

LED Laser diode

Monitor receiver

Measurement receiver (4 quadrant element)

2.1.1.1

Active measuring volume Scattered light measurement

Transmission measurement

A high performance LED sends light in the visible range (white light, wavelength approx.

450 to 700 nm) through the active measuring path containing particles to the reflector

where it is bounced back to the receiver (

 Fig. 1). A highly sensitive measurement receiver

accepts the signal weakened by particles, amplifies the signal electrically and feeds it to the measuring channel of a microprocessor as central part of the measuring, control and evaluation electronics.

Continuous monitoring of the sender output (partial beam to monitor receiver) registers the smallest changes in brightness of the light beam sent which then serves to determine the measurement signal.

Measured variables

The measuring system uses transmission (T) as primary optical measured variable. The other measured variables opacity (O), relative opacity (ROPA), extinction (E) and dust concentration (c) are derived from this variable.

Transmission, opacity, relative opacity:

T = N



I

I mon

O = 1 T

N = scaling constant

Imeas = light received

Imon = monitor signal

ROPA = 1 e

E





D

Do meas

D

Do

D meas

= Duct diameter at the outlet

= active measuring path

Transmission, opacity and relative opacity are usually specified in percent.

Reflector


Product Description

2.1.1.2

Extinction:

E = log

 

T

Dust concentration:

Based on the Beer-Lambert law, the dust concentration is derived from the extinction as follows: c =

2 31

 k L

E

=

 k = extinction constant

L = 2x active measuring path (due to double beam path)

Extinction is directly proportional to dust concentration for constant particle size and uniform dust distribution.

Particle size, dust density and dust distribution during differing load states influence transmission and extinction values and therefore the measuring system must be calibrated using a gravimetric comparison measurement for exact dust concentration measurement.

The calibration coefficient determined can be entered directly in the measuring system as c = cc2

·

E² + cc1

·

E + cc0

(Entry

 p. 77, §4.4.7; standard factory setting: cc2 = 0, cc1 = 1, cc0 = 0).


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 receiver 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.

In the same manner as for transmission measurement, continuous monitoring of the sender output registers smallest changes in brightness of the light beam sent which then serves to determine the measurement signal.

Determining the dust concentration

Measured scattered light intensity (SL) 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

·

SL² + cc1

·

SL + cc0

(Entry

 p. 77, §4.4.7; standard factory setting: cc2 = 0, cc1 = 1, cc0 = 0).


16

2.1.2

Figure 2

2.1.3

Product Description

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.

Response time

Measured value in %

92

90

88

86

84

100

98

96

94

Response time

90% of the signal peak

Measured value with response time

Process change

10 20 30 40 50 60 70 80 90 t in s

Function control

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 (

 p. 71, §4.4.3). 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

A function check comprises:

● Approx. 65 s measurement of contamination on optical interfaces, zero and control value

The measurement time depends on the increase in contamination value (change >

0.5% → measurement is repeated up to 2 times → measurement time will be longer).

● Every 90 s (standard value), output of values determined (output duration is configur-

able,

 p. 71, §4.4.3).


Product Description

Figure 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)

*: 4% for activated

EPA mode

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 (

 p. 71, §4.4.3,  p. 72, §4.4.4).

● 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.

● During a function check the relay 3 (

 p. 44, Fig. 27) is activated and the

green LED of the alignment display in the control window of the sender/ receiver flashes (

 p. 20, Fig. 7).

● A function check is not started when the measuring system is in

"Maintenance" mode.

● "Function control" is displayed on the LC-Display of the control unit during the function check.

● If the start timepoint or cycle interval are changed, a function check 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). An error signal is generated when the "zero value" is outside the specified range.

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 fault message is cleared again when the next function check runs successfully. The control value is determined with high precision through statistical evaluation of a high number of intensity changes.

The value calculated theoretically (70%) is output for scattered light measurements at very low dust concentrations (< approx. 1 mg/m³).


18

Figure 4

Product Description

Contamination measurement

The glass panes positioned in the sender beam during normal measurement are swiveled away during contamination determination (time delayed for sender/receiver unit and reflector/scattered light receiver). The values measured and the reference values determined at every scaling (

 p. 64, §4.2.3) are used to calculate the contamination value.

The values measured in normal operation are reduced by the contamination value so that any contamination is compensated completely in this way.

Contamination measurement principle

Sender/receiver unit Reflector/scattered light receiver

Figure 5

Swivel plate

For contamination values < 40% (default value) a value between live zero and 20 mA proportional to contamination is output on the analog output. If this value is exceeded, the

status "Malfunction" is output (on the analog output the error current;

 p. 70, §4.4.2,  p. 72, §4.4.4).

● The contamination limit can be set freely (

 p. 65, §4.2.5) for operation of

the measuring system according to European standards.

● The contamination limit for "Warning " is always 10% below the value for

"Malfunction".

● The contamination limit for "Warning " is fixed at 3% and the value for

"Malfunction" is fixed at 4% when operated according to EPA standard.

Swivel plate settings on the sender/receiver unit

Measuring position

Glass pane

Control reflector (only on the sender side)

Swivel plate

Contamination measurement


Product Description

2.2

Figure 6

MCU-P with purge air supply

Power supply

USB 1.1

(RS 232)

Device components

Measuring system DUSTHUNTER C200 comprises the components (

 Fig. 6):

● Sender/receiver unit DHC-T

● Connection cable to connect the sender/receiver unit to the control unit (lengths 5 m,

10 m)

● Reflector/scattered light receiver DHC-R

● Connection cable to connect the reflector/scattered light receiver to the sender/ receiver unit (lengths 5 m, 10 m, 20 m)

● Flange with tube

● Control unit MCU to control, evaluate and output the data of the sender/receiver unit(s) connected via the RS485 interface

– With integrated purge air supply, for internal duct pressure -50 ... +2 hPa

– Without purge air supply, therefore additionally required:

● Optional external purge air unit, for internal duct pressure -50 ... +30 hPa

● Purge air hose DN25 for supply by control unit MCU-P

DUSTHUNTER C200 device components

Sender/receiver unit

Flange with tube

Reflector/scattered light receiver

Optional

MCU-N without purge air supply

Connection cable

Purge air hose

Connection cable

Purge air hose

Optional external purge air unit

Operating and parameter setting program

SOPAS ET

Communication between sender/receiver unit and MCU

As standard, each sender/receiver unit is connected to one control unit via the connection cable.


20

2.2.1

Figure 7

Product Description


The sender/receiver unit contains the optical and electronic subassemblies to send and receive the reflected light beam of the transmission measurement as well as to process and evaluate the signals. Swivel mechanisms are also fitted for contamination measurement and self-alignment (

 p. 18, Fig. 5 and  p. 21, Fig. 8).

Data transfer to and voltage supply (24 V DC) from the control unit run via a shielded cable with 4 wires with plug-in connector. Clean air to cool the device 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 (

 p. 19, Fig. 6).

Sender/receiver unit DHC-T for transmission and scattered light measurement

4

1 2 3

A

A

5

B

B

9

7

6

Alignment display

8

Control window

Status display

Distance scale

9 10

1 Housing cover (swivel-mounted)

2 Cover screw for laser adjustment

3 Control window

4 Mounting holes

5 Flange

6 Purge air connection

7 Knurled screw

8 Handle

9 Connection for connection cable to reflector/ scattered light receiver

10 Connection for connection cable to MCU

11 Hinge

The alignment of the optical axes as well as the current device state (operation/ malfunction) are shown in the control window.

The housing with fitted sender/receiver unit can be swiveled to the side after the knurled screws have been loosened. Optics, electronics and mechanical components can then be easily accessed for maintenance work.

For correct measurement of the scattered light intensity, the laser beam can be readjusted to various duct diameters after the cover screw has been loosened.


Product Description

Figure 8

How self-alignment works

The sender module can be moved horizontally and vertically using motors and bevel gears so that the sender light beam can be adjusted by approximately 2° in all directions.

Tracking is performed using the measurement signal on the 4 quadrant elements of the measurement receiver. This allows automatic compensation of optical axis misalignment caused by, for example, distortion of duct walls due to temperature fluctuations.

Self-alignment principle design

(Sender/receiver unit)

Base plate

A

Retaining bracket

Sender module

A

Bevel gear

2.2.2

Tension spring Drive


This component contains a reflector to reflect the sender light beam back to the receiver in the sender/receiver unit and a scattered light receiver with a light trap. Two versions are available to adapt to different internal duct diameters. A type code identifies the versions:

Reflector/scattered light receiver:

Measuring path:

- 0: Short (0.5 ... 3 m)

- 1: Long (2.5 ... 8 m)

DHC-Rx


22

Product Description

Figure 9 Reflector/scattered light receiver for short measuring paths

Housing with electronics (swivel-mounted)

A

A

Mounting holes

Flange

Purge air nozzle

Knurled screw

B

Handle

B

Light trap

Opening for reflector

Attachment for scattered light receiver

Connection for connection cable to sender unit

Hinge

Figure 10 Reflector/scattered light receiver for long measuring paths

Housing with electronics

(swivel-mounted)

A

Flange Mounting holes

A

Purge air nozzle

B

Knurled screw

Handle

B

Attachment for scattered light receiver

Opening for reflector

Light trap for scattered light measurement

Hinge

Connection for connection cable to sender unit


Product Description

2.2.3

Figure 11

Flange with tube

The flanges with tube serve to fit the sender/receiver unit and reflector/scattered light receiver on the duct wall. These are available in various sizes (partial circle diameter D1), types of steel and graded nominal lengths (NL). Selection depends on the components to be fitted (

 active measuring path), wall and isolation thickness of the duct wall ( nominal length) and the duct material (

 Fig. 11).

Flange with tube

Marking for assembly position

TOP

Securing bolt

Material St 37 or

1.4571

NL

D1

D2

2.2.4

MCU control unit

The control unit has the following functions:

● Control of the data traffic and processing of the measuring 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.

The control unit has a sheet steel housing as standard.

Standard interfaces

Analog output

3 outputs 0/2/4...22 mA

(electrically isolated, active) to output:

● Dust concentration Ext a.c.

● Dust concentration Ext s.c.

● Dust concentration SL a.c.

● Dust concentration SL s.c.

● Scattered light intensity

● Opacity

● Extinction

● Transmission

● relative opacity

Resolution 10 bits

Analog inputs

2 inputs 0...20 mA

(Standard; without electric isolation)

Resolution 10 bits

Relay outputs

5 changeover contacts

(48 V 1A) to output status signals:

● Operation/malfunction

● Maintenance

● Function check

● Maintenance request

● Limit value

Digital inputs

4 inputs to connect potential-free contacts

(e.g. to connect a maintenance switch or trigger a function check)

Communication

● USB 1.1 and RS232

(on terminals) for measured value inquiries, setting parameters and software updates.

● RS485 for sensor connection


Product Description

Versions

● Control unit MCU-N without purge air supply

Figure 12

Display module

Control unit MCU-N with options

Optional Interface module Optional I/O module Display module

LED

Control keys

Processor board

Term

BUS - S/E unit 2 relay 1 relay 2 relay 4 relay 5 BUS - S/E unit 1

BUS

Term

DISPLAYMODUL

Figure 13

● Control unit MCU-P 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.

Control unit MCU-P with integrated purge air supply

Purge air blower

Display module

Air filter

Processor board

Installation plate

24

Purge air inlet

Power supply unit

(on back of installation plate)

Purge air connections

The purge air hose (standard lengths 5 and 10 m;

 p. 126, §7.3.3) is a separate part of

the measuring system (must be ordered separately).


Product Description

Figure 14

Display module

Module to display measured values and status information of the connected sender/ receiver unit, selection via control keys.

● Displays

Type

LED

Power (green)

Failure (red)

Maintenance request (yellow)

Display

Voltage supply OK

Function fault

Maintenance requirement

LC-Display

Graphic display

(main screen)

Text display

– Dust concentration

– Transmission

– Opacity

– Extinction

– Scattered light intensity

2 measured values (see graphic display) and 8 diagnosis values (

 p. 89, Fig. 76)

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).

LC-Display with graphic (left) and text (right) display

● Control keys

Key

Meas

Arrows

Diag

Menu

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 main menu and selection of submenus


Product Description

I/O module

Apart from the standard analog output, the DUSTHUNTER SP100 has an Analog module with two outputs 0/4 ... 22 mA (max. load 500

) integrated to output further measured variables. The module is plugged onto a module carrier connected to the processor board with a special cable.

Options

1 1x Analog Input module with two inputs 0/4 ... 22 mA to read-in values from external sensors (gas temperature, internal duct pressure, moisture, O

2

) 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 or Ethernet, to plug onto hat rails. A corresponding cable serves to connect the module to the connection board.

Profibus DP-V0 to transfer via RS485 according to DIN 19245 Part 3 as well as IEC 61158.


Product Description

2.2.5

Type code

The following type code defines the various configuration options in the same manner as for sender/receiver units and reflector/scattered light receivers:

Type code control unit: MCU-X X O D N X 1 0 0 0 N N N E

Integrated purge air supply

- N:

- P:

Without (no)

With (purged)

Voltage supply

- W: 90 ... 250 V AC

- 2: Optional 24 V DC

Housing variants

- O: Wall housing, 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:

- n:

Without

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 mod.; 48 V DC, 5 A;

2 changeovers per mod.)

- 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: Without

- E:

- P:

Ethernet

Profibus

Special versions

- N: No special features

EX certification

- N: without EX certification

Software

- E: Emission measurement


The control unit with integrated purge air supply cannot be used when the internal duct pressure is greater than +2 hPa or when using the DHC-R1 reflector/scattered light receiver for long measuring paths. Use the optional external purge air unit in this case. It has a powerful blower and can be used for excess pressure in the duct up to 30 hPa. The scope of delivery includes a purge air hose with 40 mm nominal diameter (length 5 m or

10 m).


Product Description

Figure 15 Optional external purge air unit with adapter

To purge air connection of sender/receiver unit

To purge air connection of reflector/ scattered light receiver

Base plate

Adapter 40-25

Air filter

Not required for reflector/scattered light receiver DHC-R1

Purge air hose

Blower

(Standard type 2BH13 )

A weatherproof cover is available for use outdoors (

 p. 125, Fig. 7.2.6).

2.2.6

Installation accessories (order separately)

Purge air supply

Component

Purge air hose DN25

Purge air hose DN40

Adapter 40-25

Supply by MCU-P control unit for sender unit for reflector/ scattered light receiver

DHC-R0 DHC-R1

1x

-

1x -

1x

-

Supply by external purge air option for sender/ receiver unit for reflector/ scattered light receiver

DHC-R0 DHC-R1

-

1x

1x

1x

1x

1x

-

Purge air hoses can have different lengths.

Connection cables

One cable each is necessary for the connection of the sender/receiver unit to the MCU and the reflector/scattered light receiver to the sender/receiver unit. The respective lengths are

5 or 10 m (for connecting the reflector/scattered light receiver to the sender/receiver unit also 20 m).

Weatherproof covers

Weatherproof covers are available for sender/receiver units and reflector/scattered light

receivers used outdoors (

 p. 125, Fig. 102).

2.2.7

Test equipment for linearity test

A linearity test can serve to check the correct function of transmission measurement (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

DUSTHUNTER C200. 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.


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.

Sender/receiver unit, reflector/scattered light receiver, flange with tube

NOTICE:

The reflector/scattered light receiver may not look out of the flange tube. The at most possible wall and isolation thickness is limited with that on the values listed in the table.

Distance flange - flange

0,5 ... 3 m

2,5 ... 6 m

Maximum wall and isolation thickness

Sender/ receiver unit

40 mm

Reflector/


DHC-R0

DHC-T

270 mm DHC-R1

Flange with tube


Flange with tube k100

NL 130/240/500 mm

Reflector/



NL 110 mm


NL 350 mm

Cable for reflector/ scattered light receiver x

Voltage and purge air supply

Internal duct pressure up to +2 hPa

> +2 hPa

Distance MCU - sender/ receiver unit or reflector/ scattered light receiver max. 3 m

Connection and supply components

Purge air Voltage

MCU-P + purge air hose DN 25

(to sender /receiver unit and reflector/scattered light receiver DHC-R0) or purge air hose DN 40 (to reflector/scattered light receiver DHC-R1)

Optional external purge air unit + adapter 40-25 (for sender/receiver unit) MCU-N


Product Description



DUSTHUNTER C200

3

Assembly and Installation

Project planning

Assembly

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

Determine the measuring and installation location for the device components

Select the purge air supply

Requirements Work step

Inlet and outlet paths according to DIN EN

13284-1 (inlet at least 5x hydraulic diameter d outlet at least 3x d h least 5x d h h,

; distance to stack opening at

– Uniform flow distribution

– Representative dust distribution

Assembly position for sender/receiver unit and reflector/scattered light receiver

For round and square ducts: d h

= duct diameter

For rectangular ducts: d h

= 4x cross-section divided by circumference

Whenever possible, no deflections, cross-section variations, feed and drain lines, flaps or fittings in the area of the inlet and outlet paths

Do not fit vertically on horizontal or slanted ducts; max. measuring axis angle to horizontal

45°

Accessibility, accident prevention

Installation free of vibrations

Ambient conditions

Sufficient primary purge air pressure depending on internal duct pressure

Clean intake air

The device components must be easily and safely accessible

Acceleration < 1 g

– Follow specifications for new equipment

– Select best possible location for existing equipment;

– For too short inlet/outlet paths: Inlet path > outlet path

If conditions cannot be ensured, define flow profile according to DIN EN 13284-1 and select best possible location

Select best possible location

Limit values according to Technical Data If necessary:

– Provide weatherproof covers/sun protection

– Enclose or lag device components

– Up to +2 hPa, control unit with integrated purge air supply

– Above +2 hPa to +30 hPa, optional external purge air unit

Whenever possible, low amount of dust, no oil, moisture or corrosive gases

Provide platforms or pedestals as required

Eliminate/reduce vibrations through suitable measures

Select supply type

Select best possible location for air intake

Determine required purge air hose length



Select device components

Plan calibration openings

Plan power supply

Measuring path, duct wall thickness with insulation

Internal duct pressure

Fitting locations

Access

Distances to measuring level

Operating voltage, power requirements

Sender/receiver unit, reflector/ scattered light receiver, flange with tube

Type of purge air supply

Cable and purge air hose lengths

Easy and safe

– Select components according to Con-

figuration Table (

 p. 29, §2.3);

– if necessary, plan additional measures

to fit the flange with tube (

 p. 34,

§3.2.1)

Provide platforms or pedestals as required

No mutual interference between calibration probe and measuring system

According to Technical Data (

§7.1)

 p. 114,

Plan sufficient distance between measuring and calibration level (approx.

500 mm)

Plan adequate cable cross-sections and fuses



Figure 16

Installation of sender/receiver unit and reflector/scattered light receiver at horizontal pipes

Sender/receiver unit and reflector/scattered light receiver must be installed according to

Fig. 16 to prevent that particles come by the flow into the attachment (1) of the scattered light receiver and contaminate the optics with that. The flanges with tube (4) have to be welded correspondingly.

Installation of sender/receiver unit and reflector/scattered light receiver at horizontal pipes

(view for long measuring paths)

2 3

4

1

4

Flow direction


3.2


Assembly

Carry out all assembly work onsite. This includes:



Fitting the flange with tube



Fitting the control unit



Fitting the optional external purge air unit.

WARNING:



Observe the relevant safety regulations as well as the safety notices in

Section 1 during all assembly work.



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

Figure 17 Fitting the flange with tube

Marking for assembly position

A

TOP

A

Approx

. 1°

Assembly on steel duct a

>30

A

Assembly on brick stack

A

Assembly on thin-walled duct

Flange with tube Duct wall

Fixing bolt for weatherproof cover

Anchor plate Junction plate

Component

DHC-T sender/receiver unit

DHC-R0 reflector/ scattered light receiver

DHC-R1 reflector/ scattered light receiver

D

Ø 76

Ø 159

Dimension a must be large enough so that a weatherproof cover can be fitted easily when necessary (approx. 40 mm).



Figure 18

Work to be performed



Measure the fitting location and mark the assembly location.

Leave enough clearance around the flange with tube to fit the sender/receiver unit and reflector/scattered light receiver (

 Fig. 18).

Clearance for sender/receiver unit and reflector/scattered light receiver (dimensions in mm)

TOP a 400

Flange with tube

Clearance

Duct wall

Component

Sender/receiver unit a

400 mm

Reflector/scattered light receiver 350 mm



Remove insulation (when fitted)



Cut suitable openings in the duct wall; bore large enough holes in brick or concrete stacks (flange tube diameter (

 p. 121, Fig. 97)

)

NOTICE:

 Do not let separated pieces fall into the duct.



Insert the flange with tube in the opening so that the "Top" marking points upwards (

 p. 34, Fig. 17).



Align the flanges with tube roughly to each other and weld on with a few welding spots

(on the anchor plate for brick or concrete stacks, insert junction plates for thin-walled ducts

 p. 34, Fig. 17).



Use a suitable tube (for narrower ducts) or the adjusting device from SICK to align the flange tubes to each other exactly after welding (

 p. 36, Fig. 19); axes deviation to each other max. ± 1°.


36


Figure 19 Aligning the flange with tube

Aligning with auxiliary tube

Auxiliary tube

3.2.2

Flange with tube

Duct wall

Aligning with adjusting device

(

 p. 126, §7.3.6; also available on loan)

Light source

A

A

Duct wall

Target optics

Flange with tube

Use the target optics to align the flange so that the light spot of the lamp appears in the center of the target optics.



Finally, weld the flange tubes tight all-round and, at the same time, check for exact alignment and correct when necessary. When using the adjusting device, assemble both the flange plate with light source and the flange plate with target optics before welding the second flange tube.



Close off the flange opening after fitting to prevent gas escaping.

Fitting the MCU control unit

Fit the control unit in a protected location that is easily accessible (

 Fig. 20). 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.

● Leave enough clearance for cables and opening the door.

Using a suitable cable (

 p. 40, §3.3.1), 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.



Figure 20

Assembly dimensions

MCU assembly dimensions c

M8 a

Clearance for cables e f

Clearance to open door c d a b f e

Dimension

MCU-N

160

320

210

340

125

> 350

Control unit type

MCU-P

260

420

300

440

220

> 540

(

MCU-N:Control unit without purge air supply

MCU-P:Control unit with purge air supply

 p. 23, §2.2.4)

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 (

 p. 114,

§7.1). In unfavorable conditions, lay an air intake hose to a location with better condi-

tions.

● The purge air hoses to the sender/receiver unit and reflector/scattered light receiver should be as short as possible.

● Whenever possible, lay the purge air hoses so that no water can collect.

● We recommend using the optional external purge air unit when the sender/receiver unit and reflector/scattered light receiver are more than 10 m away from the control unit.


38


3.2.3

Figure 21

Fitting the optional external purge air unit

Consider the following points when selecting the assembly location:

● 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 (

 p. 29, §). 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.

● Install the purge air unit only as far as necessary below the flange with tube for the sender/receiver unit and reflector/scattered light receiver so that the purge air hoses can be laid downwards (avoids water collecting).

● 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

 Fig. 21).

Assembly work



Prepare holder (

 Fig. 21).



Fasten purge air unit with 4 M8 screws.



Check whether the filter element is fitted in the filter housing otherwise fit when necessary.

Purge air unit layout and assembly dimensions (dimensions in mm)

Flange with tube

Duct

Flange with tube

Clearance to fit weatherproof cover

Clearance to exchange filter element

470

(550)

> 160

Steel pipe 50 x 5

DIN 2391

M 8

Alternative: Mounting bracket



3.2.4

Figure 22

Fitting the weatherproof cover

Weatherproof cover for analyzer

This weatherproof cover serves to protect the sender/receiver unit and reflector/scattered

light receiver (see

 p. 125, Fig. 102). It comprises a base plate and a cover.

Assembly:



Push the base plate sideways onto the flange with tube, slot onto the threaded bolts of the duct-side surface of the flange plate and screw tight (

 Fig. 22).



Put the cover on from above.



Insert the side holding catches into the counterpieces, twist and lock in.

Fitting the weatherproof cover for analyzer (dimensions in mm)

Clearance to lift off

Cover Base plate

(239)

Duct

(492) (365)

Flange with tube Threaded bolts Holding catch

Weatherproof cover for external purge air unit

The weatherproof cover (

 p. 125, Fig. 7.2.6) comprises a cover and locking set.

Assembly:



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.


40


3.3

3.3.1

3.3.2

Figure 23

Installation

WARNING:




Section 1 during all installation work.




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 cables, installing switches and mains fuses and connecting the purge air supply.

● Plan adequate line cross-sections (

 p. 114, §7.1).

● Cable ends with plugs to connect the sender/receiver unit must have sufficient free length.

Connecting/starting the optional external purge air unit




Compare mains voltage and frequency with the specifications on the type plate on the purge air motor.

NOTICE:



Only connect when these match!



Connect the power supply cable 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; principle illustration

 Fig. 23).

Electrical connection of the external purge air unit

U2 V1

U1

W2

W2 U2 V2

W1

V2

U1 V1 W1 PE

V1

V2

W2

U2

U1

W2 U2 V2

W1

U1 V1 W1 PE

Low-pressure monitor

Power supply

4 x 1.5 mm

2

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.

NOTICE:

In case of doubt and for special versions, the Operating Instructions delivered with the motor have priority over other specifications.



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.

NOTICE:



Use a fail-safe power supply (standby unit, rails with redundant supply)



Fuse the purge air unit separate from the other system components. Use fuses according to the rated current (see Technical Data for purge air unit).

Fuse each phase separately.

Use circuit breakers to prevent phase failures on one side.


42


3.3.3

Figure 24

Installing the purge air supply



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 thepurge air hose to the purge air outlets on the underside of the MCU-P (



Fig. 24) and secure with a strap retainer. Set the purge air outlets as shown (correct when

necessary).

Control unit underside with integrated purge air supply

1 Purge air inlet

2 DN 25 purge air outlet for sender/receiver unit and

DHC-R0 reflector/scattered light receiver

3 DN 40 purge air outlet for DHC-R1 reflector / scattered light receiver

Figure 25

1 2 3 2


Connect the DN 40 purge air hose to the Y-distributor of the purge air unit and to the adapter, and secure with D32-52 hose clamps.

Connecting the optional external purge air unit

To purge air connection of sender/receiver unit

To purge air connection of reflector/scattered light receiver DHC-R0


Adapter 40-25

Not required for scattered light receiver

DHC-R1



3.3.4

Figure 26

Connecting the MCU control unit

Component layout in the MCU (without purge air supply, with options)

Optional Interface module Display module

DISPLAYMODUL

Optional I/O module

Processor board

Terminals for mains connection

Term

BUS - S/E unit 2 com nc. no. com nc. no. com nc. no. com nc. no. com nc. no.

relay 1 relay 2 relay 3 relay 4 relay 5 BUS - S/E unit 1

Work to be done



Connect connection cable according to

 p. 45, Fig. 29.

If an onsite cable is to be used, it must be connected to a suitable 7-pole socket

 p. 44, Fig. 28; SICK Part No.: 7045569).



Connect cables for status signals (operation/malfunction, maintenance, function check, maintenance request, limit value), analog output, analog and digital inputs according to requirements (

 p. 45, Fig. 29, Fig. 30 and Fig. 31).

NOTICE:



Only use cables with twisted-pairs and screen (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).



Connect power cable to terminals L1, N, PE of the MCU (

 p. 43, Fig. 26).



Lock not used cable bushings with blind stoppers.

WARNING:



Be sure to check the wiring before switching the supply voltage on.



Only modify wiring when disconnected from the mains and potential-free.



10

11

12

Figure 27

1

MCU processor board connections

MCU processor board connections

2 3 4

5

6

7

1 Supply voltage 24 V d.c.

2 RS232

3 Connection for optional I/O module

4 Connection for Display module

5 Connection for LEDs

6 Connection for optional

Interface module

7 USB plug connector

8 Connections for measuring unit

9 Connections for relays 1 to 5

10 Connections for analog inputs

1 and 2

11 Connection for analog output

12 Connections for digital inputs

1 to 4

Figure 28

9 8

Onsite connection cable connection to MCU

Plug-in connector connection on onsite cable

Open

Open

A

Closed

Cable provided by customer

according to page 43, §3.3.4

Closed

A

A -A

1

+24 V

2

3

RS485 B

7

Screen

6

-24 V

4

RS485 A

5

Note

To open, connect the plug-in connector to the plug on the sender/receiver unit.



Figure 29

Standard connection

Standard connection

MCU processor board

Maintenance

Function check

Reflector/ scattered light receiver

Switching position of the relay contacts in currentless condition


Connection cable

(SICK cable or onsite cable according

to page 43, §3.3.4)

Plug

Socket

SICK cable

Plug

Socket

Plug

Socket Whi

2

1

+24 V

Plug assignment

(View on pin side)

RS485 B

3

RS485 A

4

5

7

6

-24 V



3.3.5

3.3.6

Figure 30

Connecting the reflector/scattered light receiver

Connect the cable belonging to this component (

 p. 126, §7.3.2) to the sender/receiver

unit and reflector/scattered light receiver and screw tight.

Fitting and connecting optional Interface and I/O modules

Plug interface modules and module carriers for I/O modules onto the hat rail in the MCU (

 p. 43, Fig. 26) and connect to the associated connection on the processor board with the cable with plug-in connector (

 p. 44, Fig. 27). Then plug the I/O module on the module

carrier.

Connect I/O modules using the the terminals on the module carrier (

 Fig. 30, Fig. 31), the

Profibus module using the terminals on the module and the Eternet module via customer provided network cable.

Terminal assignment AO module

Terminal assignment analog output module

Analog output module Module carrier

AO 2

+ -

+ -

AO 1

Figure 31

Terminal assignment AI module

Terminal assignment analog input module

Analog output module Module carrier

+ -

AI 2

+ -

AI 1



DUSTHUNTER C200

4

Start-up and Parameter Settings

Basics

Application specific settings

Installing the sender/receiver unit and reflector/scattered light receiver

Setting standard parameters

Setting the Interface module parameters

Operating/setting parameters via the LC-Display


48

4.1

4.1.1

4.1.2


Basics

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:

● Setting the measuring system to the duct dimensions

● Fitting and connecting the sender/receiver unit and reflector/scattered light receiver

● Customizing parameter settings according to the respective requirements.

To achieve exact measurement, the measuring system must first be calibrated using a

gravimetric comparison measurement (

 p. 77, §4.4.7) before being used for continuous

measurement of dust content.

The operating and parameter program SOPAS ET is provided to set the parameters. The

Menu structure simplifies changing settings. Further functions are also available (e.g. data storage, graphic displays).

Installing the operating and parameter program SOPAS ET

Administrator rights are required to install the program.

Requirements

● Laptop/PC with:

– Processor: Pentium III (or comparable type)

– USB interface (alternative - RS232 via adapter)

– Working memory (RAM): At least 256 MB

– Operating system: MS Windows ME/2000/XP/Vista (not Windows 95/98/NT)

● USB interface cable to connect the Laptop/PC to the measuring system (MCU).

● The operating and parameter program as well as the USB driver (scope of delivery) must be installed on the Laptop/PC.

● The power supply must be switched on.

Start the file "setup.exe" when the start screen does not appear.

Install the SOPAS ET program

Insert the delivered CD in the PC drive, select the language, select "Software" and follow the instructions.

Install the USB driver

A special software driver is required for communication between the operating and parameter program SOPAS ET and the measuring system via the USB interface. Connect the MCU to the supply voltage and to the PC via USB cable to install the driver. A message appears on the display that new hardware has been detected. Then insert the delivered CD in the PC drive and follow the installation instructions (

 p. 49, Fig. 32).

The driver can also alternatively be installed by using the hardware installation program of the Windows system control.

The USB driver creates a new COM port which has to be used for connecting

the SOPAS ET program to the device (

 p. 51, §4.1.3.2).



Figure 32 Installing the USB driver


50


4.1.3

4.1.3.1

Figure 33

Connecting to the device

Basic settings



Connect the USB cable to the MCU control unit (

 p. 44, Fig. 27) and the Laptop/PC.



Start the program in the "SICK\SOPAS" start menu.



The Start dialog appears on the screen (can be suppressed for further program usage).

Start dialog

Project selection

Deactivating the Start dialog

Figure 34

The following Start menu appears after confirmation with "OK".

Start menu



If required, select the desired language in the "Tools / Language" menu (

 p. 51, Fig. 35), confirm with "OK", and restart the program .



Figure 35 Change of language settings

4.1.3.2

Figure 36

Configuring the interface

COM Port



Click the "Network Configuration" button in the start menu (

 p. 50, Fig. 34) and select

„Standard Protocol”.



Select the COM port in the "Select COM Ports" group that appears after connection of

MCU and Laptop/PC, click the "Advanced..." button and configure according to

 Fig. 36

(settings only required during the first connection to the measuring system).

COM port selection and configuration



Figure 37

Ethernet

The Ethernet interface module (

 p. 126, §7.3.6) must be installed in the MCU

(

 p. 46, §3.3.6) and configured ( p. 85, §4.5.2) to get a connection to the

measuringg system via Ethernet.



Click the "Network Configuration" button in the start menu (

 p. 50, Fig. 34) and select

"Internet Protocol (IP)".



Click the "Add "button, enter the IP address and confirm with "OK".

Ethernet interface selection (example settings)

Figure 38



Click the "Advanced..." button and configure the interface according to Fig. 38.

Configuring the Ethernet interface



4.1.3.3

Bild 39

Establish connection via "Network Scan Assistant" directory



Click the "Network Scan" button in the "Network Scan Assistant" directory.

Search for connected devices

Connection via COM port

Connection via Ethernet

The following message appears when no device is found (Troubleshooting, see

Service Manual):

Problems with Ethernet connection can be caused by incorrect addressing

→ contact system administrator.



Confirm search for connected devices with "OK".



4.1.3.4

Figure 40

Establish connection via "Connection Wizard" menu (valid for SOPAS ET Version 02.32)



Select "Communication / Connection Wizard" menu and activate "Show all connected devices".

"Communication / Connection Wizard" menu

Figure 41



Click "Next >" button and select the interface ("Standard Protocol" for connection via

COM port, "Internet Protocol (IP)" for connection via Ethernet).

Interface selection

54



Check interface configuration for setting according to S. 51, §4.1.3.2 and change accord-

ingly if necessary.



Click "Next >" button.



Figure 42 Search for connected devices


Connection via Ethernet

The following message appears when no device is found (Troubleshooting, see

Service Manual):



4.1.3.5

Figure 43

Selecting the device


Select the required device file in the "Network Scan Assistant / Detected devices" register and move it to the "Project Tree" window (drag-and-drop per mouse or click the "Add" button).

Selecting the device file

Figure 44

Connection via "Connection Wizard" menu

Activate the checkbox of the required device file in the "Connection Wizard / Found devices" (

 p. 55, Fig. 42) and Click "Next >" button. This transfers the device file to the

"Project Tree" window.

Transferring the device file



4.1.4

Figure 45

Information on using the program

Password

Certain device functions are first accessible after a password has been entered (

 p. 57,

Fig. 45). Access rights are assigned in 3 levels:

User level

0 Operator

1 Authorized Operator

(Authorized Client) *

2 Service

Access to

Displays measured values and system states

Displays, inquiries as well as start-up resp. adjustment to customer-specific demands and diagnosis of necessary parameters

Displays, inquiries as well as all parameters required for service tasks (e.g. diagnosis and clearance of possible malfunctions)

*): Depends on the program version

The Level 1 password is contained in the Annex.

Password entry



4.1.5

Figure 46

Online help

The individual menus and setting options are described in detail in the online help and are therefore not described further here.

Online help

The installed version is displayed



4.2

Application specific settings

The measuring system must first be set to the respective internal duct diameter to ensure correct measurement of transmission and scattered light intensity. The following steps are required:

Measuring principle

Transmission measurement


Work step

Focussing the sender light beam

Scaling the measuring system to a path free of particles

Adjusting the laser beam

Aim

The light spot on the reflector must lie within the optical active reflection surface under consideration of the active measuring path and the swivel angle allowed.

Influences on measuring results specific to the device and dependent on the distance must be eliminated.

The path free from particles must be identical to the active measuring path

(distances between the optical interfaces of the sender/receiver unit and reflector/ scattered light receiver must be the same).

The laser beam must always be aligned to the light trap on the scattered light receiver.

4.2.1

Figure 47

Preparatory work



Assemble the measuring system away from the installation location at a place as dustfree as possible with available power supply:

There are two options here:

– Using the optional adjusting stand

Creating a smoke-free path with adjusting stands

Sender/receiver unit Reflector/scattered light receiver

A

Figure 48

Adjusting stand

Connection cable

A =distance flange - flange

– Onsite installation of a "zero tube" (tube with suitable diameter with flanges)

Creating a smoke-free path with a zero tube

A

X

X: Dimensions between flange and tube according to reflector/scattered light receiver type

(

 p. 119, §7.2.2

,

 p. 121, §7.2.3

)



Figure 49



Connect the sender/receiver unit to the MCU and the reflector/scattered light receiver to the sender/receiver unit using the accompanying cables.



Connect the MCU to the supply voltage.



Start the SOPAS ET program and connect to the measuring system (

 p. 50, §4.1.3).



Select the "DH C200" device file and move it to the "Project Tree" window (

 p. 56,

§4.1.3.5).

The respective device type connected is displayed automatically



Enter the Level 1 password (

 p. 54, §4.1.3.4), activate the "Maintenance Sensor" check-

box in the "Maintenance / Maintenance" directory and click "Set State".

Setting "Maintenance" mode



Clean the optical boundary surfaces on sender /receiver unit and reflector/scattered

light receiver (

 p. 98, §5.2.1 and  p. 101, §5.2.2).



Wait approx. 30 min before starting the following work (measuring system must be in operation conditions).



4.2.2

Figure 50

Focussing the sender light beam for transmission measurement



Select the "Adjustment / Manual Adjustment / Transmission set reference“ directory and activate the "Permanent LED light“ checkbox.

"Adjustment / Manual Adjustment / Transmission set reference“ directory



Figure 51



Loosen the knurled screws (

 p. 20, Fig. 7), swivel the electronic unit to the side and

remove the swivel plate cover (1).



Screw the cover screw (2) out of the focussing opening using a screwdriver.

Cover screw for focussing opening

1

2



Insert the screwdriver in the focussing opening and set the adjustment screw so that the scale pointer in the control window points to the distance between the optical surfaces of sender/receiver unit and reflector/scattered light receiver (= distance of the base plates).

Measuring distance 0.5 ... 3 m: Distance = measure A in Fig. 47 + 343 mm

Measuring distance 2.5 ... 8 m: Distance = measure A in Fig. 47 + 348 mm

Figure 52

4 quadrant display

Focussing the sender light beam

Electronic unit Focussing opening Base plate

Control window

62

S/E- Unit distance meter

10 3 2 1

Reflector

Scale pointer

Measuring path longer

Measuring path shorter

The scale illumination lights up when the measuring system is switched to

"maintenance"or up to 10 min after device reboot.



Screw in the cover of the focussing opening again, swivel the electronic unit back and lock with the knurled screws.



Click "Mechanical centring" (‚Step 1‘) in the "Adjustment / Manual Adjustment / Transmission set reference“ directory (

 p. 61, Fig. 50).



Figure 53



Align the optical axes of the sender/receiver unit and reflector/scattered light receiver to each other.

Align the sender/receiver unit so that the sender spot lies on the middle of the opening for the reflector (

 p. 22, Fig. 9). Align the reflector/scattered light receiver so that the

sender spot (1) can be seen in the centrical marking in the middle of the control window (2) on the back of the housing (3).

Sender spot on reflector/scattered light receiver side

1

2

3



Deactivate the "Permanent LED light“ checkbox.



Check the alignment.

The optical axes are aligned exactly, if:

– the green LED in the 4 quadrant display in the control window of the sender/receiver unit shines (

 p. 62, Fig. 52),

– in the "Adjustment / Manual Adjustment / Transmission set reference“ directory (

 p. 61, Fig. 50), the sender spot (black circular area in the "Show justification" window) is inside the green circle.

A non-exact alignment is signaled by shining of LED in the 4 quadrant display in the control window in the following manner:

LED shining Misalignment of the light spot on the reflector green and yellow Deviation max. approx. 0.1 ° in the shown direction; measured values are valid yellow yellow and red

Deviation max. approx. 0.1 ° to 0.3 ° in the shown direction; measured values are valid

Deviation max. approx. 0.3 ° to 0.4 ° in the shown direction; measured values are valid, possibly larger swivel error as lsted in the technical data red red LED shine in a circle

Deviation > approx. 0.4 ° in the shown direction; measured values are valid, possibly larger swivel error as lsted in the technical data

Deviation > approx. 0,5 °or transmission < approx. 10 %; dust concentration too high or measurement system wrong scaled; self-alignment not possible

Only rough alignment is necessary because an internal self-alignment is fitted. Click the "Optical centring" button in the "Adjustment / Manual

Adjustment / Transmission set reference“ directory (group "Ajustment aids") to start automatic fine adjustment.

The measuring system must then be scaled after focussing has completed.

NOTICE:

The measuring system must be scaled again after every focus change.


64


4.2.3

4.2.4

Figure 54

Scaling the measuring system for transmission measurement

NOTICE:

The optical surfaces must be clean (clean if necessary before performing the following steps;

 p. 98, §5.2).



Carry out the steps listed in the "Transmission reference value" group in the "Adjustment / Manual Adjustment / Transmission set reference“ directory (

 p. 61, Fig. 50) after each other. The corresponding indication changes to yellow when step 1 to 6 is in process.



Check whether the transmission is shown as 100% in the "Transmission reference value" window after this process completes (

 p. 61, Fig. 50). Click "Set reference" at smaller deviations (< approx. 1%), repeat the normalization at greater deviations.

The values shown in the field "Set reference result” window "Sender/receiver unit reference value” and "Reflector reference value” shall not exceed 8%

(otherwise a device defect exists under circumstances

 contact SICK

Service).

Adjusting the laser beam for scattered light measurement



Take off the sender/receiver unit cover and use an SW 7 socket wrench to set the adjusting nut so that the laser beam disappears in the light trap on the reflector/scattered light receiver.

NOTICE:

Don't change the alignment of sender/receiver unit and reflector/scattered light receiver.

Sender/receiver unit and reflector/scattered light receiver must be connected via the connection cable, otherwise no laser beam can be seen.

Aligning the laser beam to the light trap

Sender unit


X

Y

X Light trap

Y



Put the cover back on.



4.2.5

Figure 55

Entering application specific parameters

"Configuration / Application parameters" directory (example)



Group

Device identification

Concentration calibration coefficients

= f (extinction)

Concentration calibration coefficients

= f (Scattered light)

Primary measuring principle cc2 cc1 cc0

Span2 transmission

Limit contamination and average

EPA Conformity

Window

Mounting location

Parameter Remark

Name of the measuring place Assignment of the measuring system to the respective measuring location

Flange - Flange Flange distance measured at the stack

Opt. measuring distance for registration purposes (e.g. for repetition scalings on a dustfree path) active measuring path length Input required for the calculation of the relative opacity

Chimney opening

Duct diameter at the top

Correction faktor Value cc2 cc1 cc0 quadratic coefficient linear coefficient absolute coefficient

Adapting the relative opacity to the geometric dimensions of the duct

Entering the regression coefficients determined on basis extinction to measure the dust concentration in mg/m³ (

 p. 77, §4.4.7.1) .

quadratic coefficient linear coefficient absolute coefficient

Entering the regression coefficients determined on basis scattered light to measure the dust concentration in mg/

m³ (

 p. 78, §4.4.7.2) .

Primary measuring principle

Span2

Transmission

Transmission

Scattered light activated deactivated

Reference value Transmission value in %

Assigning the light source (LED at 'transmission', laser at

'scattered light') for determination of control values ??in function control

During function check the second control value is compared with the reference value.

The second control value is not used.

Entering a second control value for function check (

 p. 16, §2.1.3)

Activation and entering the reference value is only possible if the "EPA conformity" check box is activated.

Limit contamination

Limit warning

Value in %

75 % of limit contamination

Average active activated deactivated

Determination of a contamination limit value, selectable

40 % (default value), 20%, 10%, 6%, 4%

The limit value 4% is firmly assigned if the "EPA conformity" check box is activated.

Automatic assignment depending on the set limit value

An average value is calcutated from the values measured in the set interval if the check box is activated.

Average interval Intervallzeit

Selection measured value

EPA-mode activated

1/2/3/4/5/6min

Measuring variable activated deactivated

Selection of the interval time (6 min for use according to

EPA standards)

Selection of the measuring variable whose values are to be averaged required for use according to EPA standard no use according to EPA standard

After deactivation of "EPA conformity" the values for "Limit contamination" and

"Limit warning"are reset to default values (40% and 30%).



4.3

4.3.1

4.3.2

Figure 56

Installing the sender/receiver unit and reflector/scattered light receiver

Remove sender/receiver unit and reflector/scattered light receiver from the smoke-free path and take the components to the measuring location when the work described before is completed.

Connecting the sender/receiver unit and reflector/scattered light receiver to the purge air supply



Check whether the purge air supply is available (the flow direction must be correct and the purge air hoses fitted tight on the connections).



For purge air supply by the MCU-P control unit, push the DN 25 purge air hose onto the connections of the sender/receiver unit and reflector/scattered light receiver and secure with D20-32 hose clamps; with the optional external purge air unit, push the 40-

25 adapters onto the respective connections and secure with D20-32 hose clamps.

Fitting and connecting the sender/receiver unit and reflector/scattered light receiver on the duct



Attach the sender/receiver unit and reflector/scattered light receiver to the flange with tube and fasten with the accompanying assembly kit (

 p. 126, §7.3.4). Screw the self-

locking nuts as tight as possible.

Fitting the sender/receiver unit / reflector/scattered light receiver on the duct

A B

2 3

1

C

4

1 pair

1 Sender unit

2 Self-locking nut

3 Sealing tape

4 Cup springs (4 pairs)

A Horizontal alignment

B Fixing point

C Vertical alignment


68


Figure 57



Connect the cable MCU - sender/receiver unit and the cable sender/receiver unit - reflector/scattered light receiver at the respective connectors (

 p. 20, Fig. 7,  p. 21,

Fig. 8 and

 p. 22, Fig. 9) and screw tight.



Start the SOPAS ET program and connect to the measuring system, select the "DH

C200" device file and move it to the "Project Tree" window.



Enter the Level 1 password and set the sender/receiver unit to "Maintenance"mode.



Click "Mechanical centring" (‚Step 1‘) in the "Adjustment / Manual Adjustment / Transmission set reference“ directory (

 p. 61, Fig. 50).



Align the optical axes of the sender/receiver unit and reflector/scattered light receiver

according to p. 67, Fig. 56 so that the sender spot is in the middle of the control window

on the back of the housing of the reflector/scattered light receiver.



Check that the laser beam disappears into the light trap on the reflector/scattered light receiver. To do this, loosen the knurled screws, swivel the housing to the side, hold a transparent foil (1) over the light opening (2) and check whether the laser beam (3) can be seen in the center of the opening.

WARNING: Hazards when looking at the laser beam



Never look directly into the laser beam.

Laser beam in light trap opening

1

2

3



Readjust the laser beam according to p. 64, Fig. 54 when this is not the case.



4.4

4.4.1

Figure 58

Setting standard parameters

Assigning the sensor

The MCU must be assigned to the connected sender unit. A malfunctions is signalised in case of unconformity. If the setting is not possible at the factory (e.g. when several devices are delivered at the same time or the MCU is swapped later), the assignment must be made after installation. The following steps are then necessary:



Connect the measuring system to the SOPAS ET program, select "MCU" device file and

move it to the "Project Tree" window (

 p. 56, §4.1.3.5).



Enter the Level 1 password (

 p. 57, §4.1.4) and set the measuring system to "Mainte-

nance" mode (activate the "Maintenance on/off" checkbox in the "Maintenance / Maintenance" directory and click "Set State").




Switch to the "Configuration / Application selection“ directory (

 p. 70, Fig. 59).



The basis type of the connected sender/receiver unit is shown in the window "Connected variant" (group "Application selection"). Click "Safe selection" to assign the

MCU.

The sender/receiver unit must be connected to the MCU.


Figure 59 Assigning the sensor


70

4.4.2

Factory settings

Parameter

Function check

Analog output (AO)

[mA]

Live zero (LZ)

Upper measuring range value

(MBE)

Current during maintenance

Current by malfunction

Response time

Measured variable

Opacity [%]

Dust concentration act. Ext [mg/m³]

Output on AO

1

2

Dust concentration act. Ext [mg/m³] 3

Regression coefficients (for dust concentration Ext)

Regression coefficients (for dust concentration SL)

Value

Every 8 h; output of check values (90 s for every value) on standard analog output

4

20

0.5

21 (optional 1)

60 s for all measured variables

Value at LZ

0

0

Value at MBE

100

200

0

0.00 / 1.00 / 0.00

0.00 / 1.00 / 0.00

200

The steps required to modify these settings are described in the following Sections.

Prerequisite: The device data are located in the "Project Tree" window, the Level 1 password has been entered and "Maintenance" mode set.



4.4.3

Figure 60

Determining the function check

Interval time, control value output on the analog output and the starting timepoint for automatic function checks can be modified in the "Adjustment / Function Check -

Automatic" directory.

Default values

 p. 70, §4.4.2

"Adjustment / Function Check - Automatic" directory (example for settings)

Entry field

Function check output duration

Check interval

Function check

Function check start time

Parameter

Value in seconds

Time between two function checks

Hours

Minutes

Remark

Output duration of control values

 p. 16, §2.1.3

Defining a start timepoint in hours and minutes

The value measured last is output during control value determination (

 p. 17,

Fig. 3).



4.4.4

Figure 61

Setting the analog outputs parameters

Select the "Configuration / IO Configuration / Output Parameters" directory to set the analog outputs.

● Default values

 p. 70, §4.4.2

● To output the dust concentration under standard conditions

("Concentration s.c. (Ext)" or "Concentration s.c. (SL)), set the parameters

for the analog inputs according to §4.4.5.

"Configuration / IO Configuration / Output Parameters" directory



Field

Analog

Outputs

-General

Configurationn

Optional

Analog Output

Modules

Current in maintenance

Parameter

Output Error current yes no

Error Current Value < Live Zero (LZ) or > 20 mA

User defined value

Last value

Maintenance current

Use first analog output module

Measured value

Whenever possible, value

≠

LZ

Inactive

Active

Analog Output

1 Parameter

Value on analog output 1

Conc. a.c.(SL)

Conc. s.c.(SL)

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

Not permitted for DUSTHUINTER C200 (AO 2 and AO 3 available per default).

Opens the fields to set parameters for AO 2 and AO 3 (standard on

DUSTHUNTER C200)

Dust concentration under operating (actual) conditions (based on scattered light intensity)

Dust concentration under standard conditions

(based on scattered light intensity)

The selected measured variables are output on the analog output.

Opacity

Extinction

Transmission

SL

Rel. opacity

Conc. a.c. (Ext)

Analog Output

1 Scaling

Live zero

Output function check results on the AO

Write absolute value

Range low

Range high

Conc. s.c. (Ext)

Zero point

(0, 2 or 4 mA)

Inactive

Active

Inactive

Active

Lower measuring range limit

Upper measuring range limit

Scattered light intensity

Relative opacity

Dust concentration under operating (actual) conditions (based on Extinction)


(based on Extinction)

Select 2 or 4 mA to ensure being able to differentiate between measured value and switched off device or interrupted current loop.

Control values (

 p. 16, §2.1.3) are not output on the analog output .

Control values are output on the analog output (the "Output control values at AO" checkbox in the "Adjustment / Function Check -

Automatic" directory must be activated).

It‘s distinguished between positive and negative measured values.

The amount of the measured value is output (not relevant for

DUSTHUNTER C200).

Physical value at live zero

Physical value at 20 mA



Field

Limiting Value Limit value

Hysteresis

Type

Switch On

Limit Switch

Parameter

Limit value

Hysteresis

Parameter

Conc. a.c.(SL)

Conc. s.c.(SL)

Opacity

Extinction

Transmission

SL

Rel. opacity

Conc. a.c. (Ext)

Conc. s.c. (Ext)

Percent

Absolute

Over Limit

Under Limit

Value

Value

Remark

Dust concentration under operating (actual) conditions (based on scattered light intensity)


(based on scattered light intensity)


Relative opacity

Dust concentration under operating (actual) conditions (based on Extinction)


(based on Extinction)

Select the measured variable for which a limit value is to be monitored..

Assignment of the value entered in the "Hysteresis

Type" field as relative or absolute value of defined limit value

Specification of the switching direction

The limit value relay switches when the entered value is exceeded or underflown.

Defines a tolerance for resetting the limit value relay

Set the parameters for "Analog Output 2(3) Parameter" and "Analog Output

2(3) Scaling" in the same manner as for "Analog Output 1 Parameter" and

"Analog Output 1 Scaling" .



4.4.5

Figure 62

Setting the analog inputs parameters

Select the "Configuration / IO Configuration / Input Parameters" directory to set the analog inputs.

"Configuration / IO Configuration / Input Parameters" directory

Field

Temperature

Source

Pressure

Source

Moisture

Source

Oxygen

Source

Parameter

Constant Value

Analog Input 1

Constant Value

Analog Input 2

Constant Value

Analog input 3

Constant Value

Analog Input 4

Remark

A fixed value is used to calculate the scaled value.

This parameter opens the "Constant Temperature" 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 parameters for the lower and upper range limit values and the Live Zero value.


This parameter opens the "Constant Pressure" 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 parameters for the lower and upper range limit values and the Live Zero 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 parameters for the lower and upper range limit values and the Live Zero value.


This parameter opens the "Constant Oygen" 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 4 -Oxygen" field to set the parameters for the lower and upper range limit values and the Live Zero value.



4.4.6

Figure 63

Setting the response time

Select the "Configuration / Value Damping" directory to set the response time.

"Configuration / Value Damping" directory

Field

Response time

Sensor 1

Parameter

Value in s

Remark

Response time for the selected measured variable (

 p. 16, §2.1.2)



4.4.7

4.4.7.1

Calibrating for dust concentration measurement

NOTICE:

The steps described here serve to avoid input errors. Carrying out comparison measurements demands special knowledge that is not described in detail here.

For exact dust concentration measurement, the relation between the primary measured variable transmission (→ Extinction) or 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 or comparable regulations and set in relation to the values measured at the same time by the measuring system.

Calibrating dust concentration measurement based on extinction



Select device "MCU", set the measuring system to "Maintenance" mode and enter the

Level 1 password (

 p. 54, §4.1.3.4).



Select the "Configuration / IO Configuration / Output Parameter" directory (

 p. 72, Fig.

61) and assign the "Extinction" measured variable to an analog output.



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 to output the extinction value.



Select device "DH C200", set the sender/receiver unit to "Maintenance" mode and

enter the Level 1 password (

 p. 54, §4.1.3.4).



Switch "Maintenance" off.



Carry out the gravimetric comparison measurement according to DIN EN 13284-1 or comparable regulations.



Determine regression coefficients from the mA values of the analog output for "Extinction" and the dust concentrations act. measured gravimetrically.

c = K2 I out

2

+

 out

+ K0 c: dust concentration in mg/m³

K2, K1, K0: regression coefficients of the function c = f (Iout )

Iout: current output value in mA

(1)

I out

=



MBE

(2)

Ext: measured value

LZ: Live Zero

MBE: defined upper range limit (entered value for 20 mA; normally

2.5 x fixed limit value)



Enter the calibration coefficients

There are two possibilities:

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

NOTICE:

The coefficient set entered in the sender/receiver unit and measuring range entered in the MCU may not be changed in this case any more. If the LCD option is used, the dust concentration is displayed in mg/m³ as an uncalibrated value.


78

4.4.7.2


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

a)In this case the correlation to the extinction has to be determined. To do so, calculate the regression coefficients cc2, cc1, cc0 to be entered in the measurement system from K2, K1, K0.

c =



2

+ + cc0

(3)

By using (2) in (1), the result is as follows: c = K2







LZ Ext



MBE





2

+ K1







LZ Ext



Using (3), the result is as follows:

MBE



+ cc0 = K2 LZ

2

+ cc1 cc2 =

=



K2







+ K0

MBE





2





-----------------------------



 a)Enter then the determined regression coefficients cc2, cc1 and cc0 in the "Configuration / Application parameters" directory (

 p. 65, Fig. 55) (Set the sender/receiver

unit into "Maintenance" mode, enter level 1 password and switch the unit back to

"Measurement" mode after setting the coefficients).

This method allows changing the parameters for the selected measuring range as desired.

Calibrating dust concentration measurement based on scattered light intensity




Level 1 password.



Select the "Configuration / IO Configuration / Output Parameter" directory and assign the "Scattered light intensity" measured variable to an analog output.



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 to output the scattered light intensity.



Select device "DH C200", set the sender/receiver unit to "Maintenance" mode and enter the Level 1 password.



Switch "Maintenance" off.



Carry out the gravimetric comparison measurement according to DIN EN 13284-1 or comparable regulations.



Determine regression coefficients from the mA values of the analog output for "Scattered light intensity" and the dust concentrations act. measured gravimetrically.

c =

 out

2

+ out

+ K0

(1) c: dust concentration in mg/m³

K2, K1, K0: regression coefficients of the function c = f (Iout )

Iout: current output value in mA



I out

=

SL:

LZ:

MBE:



MBE

(2) measured scattered light intensity value

Live Zero defined upper range limit (entered value for 20 mA; normally

2.5 x fixed limit value)



Enter the calibration coefficients

There are two possibilities:

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

NOTICE:

The coefficient set entered in the sender/receiver unit and measuring range entered in the MCU may not be changed in this case any more. If the LCD option is used, the dust concentration is displayed in mg/m³ as an uncalibrated value.

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

a)In this case the correlation to the scattered light intensity has to be determined. To do so, calculate the regression coefficients cc2, cc1, cc0 to be entered in the measurement system from K2, K1, K0.

c = cc2 SL

2

+ + cc0

(3)

By using (2) in (1), the result is as follows: c = K2







LZ SL



MBE





2

+ K1







LZ SL



Using (3), the result is as follows:

MBE



+ cc0 =



2

+ cc1 cc2 =

=



K2







+ K0

MBE





2





-----------------------------



 a)Enter then the determined regression coefficients cc2, cc1 and cc0 in the "Configuration / Application parameters" directory (

 p. 65, Fig. 55) (Set the sender/receiver

unit into "Maintenance" mode, enter level 1 password and switch the unit back to

"Measurement" mode after setting the coefficients).

This method allows changing the parameters for the selected measuring range as desired.



4.4.8

Figure 64

Data backup

All parameters relevant for recording, processing and input/output of measured values as well as current measured values can be saved and printed. This allows easy reentering of set device parameters as needed (e.g. after a firmware update) as well as the registration of device data or device states for diagnostic purposes.

The following options are available.

● Saving as a project

Saving the data as a project allows saving not only device parameters but also data logs.

● Saving as a protocol

Device data and parameters are recorded in the Parameter protocol.

A Diagnosis protocol can be created for analysis of the device function and recognition of possible malfunctions.

See the Service Manual for a description

● Saving as a protocol

Device data and parameters are recorded in the Parameter protocol.

A Diagnosis protocol can be created for analysis of the device function and recognition of possible malfunctions.

Saving as a project



Select device, select the "Project / Export Device" directory and define target directory and file name.



The name of the file to be stored can be chosen freely. It is useful to specify a name with a reference to the sampling point involved (name of the company, equipment name).

"Project / Save Project" menu



Figure 65

Saving as a protocol



Select device and actualize the device parameters using the "Upload all Parameters from Device" menu.

Actualising the device parameters

Figure 66



Select the "Diagnosis / Protocols" directory and click the button for the desired type of registration.

"Diagnosis / Protocols" directory


Figure 67


The file name and storage location must be specified for export to a PDF file.

Specifying file name and storage location

Figure 68

Parameter protocol example

DUSTHUNTER C200 Parameter protocol (example)



4.4.9

Figure 69

Starting normal measuring operation

Set the measuring system to "Measurement" mode after entering/modifying parameters.

To do this, switch to the "Maintenance / Maintenance" directory, deactivate the

"Maintenance on/off" checkbox in the "Set Operating State" window and click "Set State" (



Fig. 69). Standard start-up is now completed.

Setting the operational state



4.5

4.5.1

Figure 70

Setting the Interface module parameters

General information

The following steps are necessary to select and set the optionally available Interface modules Profibus DP and Ethernet:




Level 1 password (

 p. 57, §4.1.4).



Switch to the "Configuration / System Configuration" directory.

The Interface module installed is shown as "Interface Module".



Configure the Interface module according to requirements.

"Configuration / System Configuration" directory

84

GSD file and measured value assignment are available for the Profibus DP module on request.



4.5.2

Figure 71

Setting the Ethernet module parameters

NOTICE:

For communication via Ethernet exists a risk of unwanted access to the measuring system.



Operate the measurement system only behind a suitable protective equipment (eg. Firewall).

Assigning the Ethernet module a new IP address

An IP address specified by the customer is entered at the factory when the address is available when the device is ordered. Otherwise the standard address 192.168.0.10 is entered.



Select the "Configuration / IO Configuration / Interface Module" directory.



Enter the desired network configuration in the "Ethernet Interface Configuration“ group and click "Reset module" under "Expansion module information".

Assigning the Ethernet module a new IP address new address



Figure 72

Assigning the new IP address to the SOPAS ET program



Select the "Network Scan Assistant" register and click "Network Configuration".



Select the "Internet Protocol (IP)" directory, set the "Enable IP Communication" entry field to active and click "Add".



Enter the new IP address set in the "Configuration / IO Configuration /Interface Module" directory and confirm with "OK".

Entering the IP address (example)

Figure 73



Click "Advanced..." in the "Internet Protocol (IP)“ window.



Select port address "2111" and confirm with "OK" (all other settings and values according to Fig. 73).

Specifying the TCP port



Figure 74



Activate only the required TCP-Port.



Activate the checkbox "Custom” and enter the port number in the window besides this if a TCP port shall be used different from 2111 or 2112.



Select the "Network Scan Assistant" register, click "Network Scan" and check whether the set address is displayed.

Network scanning

NOTICE:

During communication on Ethernet disturbances in the data transfer can appear which are not caused by the measuring system.



If measured values are transferred exclusively via Ethernet and used to control processes, disturbances are possible in the plant operation for which the manufacturer of the DUSTHUNTER C200 is not responsible.

Increase the value in field "Scantimeout" from 500 ms to 3000 ms if disturbances appear in the Ethernet communication.



4.6

4.6.1

Figure 75

Operating/setting parameters via the LC-Display

General information on use

The display and operating interface of the LC-Display contains the functional elements shown in Fig. 75.

LC-Display functional elements

Status bar

Status LED

Display field

Current button function

Control keys

Button

Diag

Back

Arrow



Arrow



Enter

Start

Save

Meas

Button functions

The function shown depends on the Menu currently selected. Only the function shown in the button is available.

Function

Display diagnostic information (warnings and errors during a start using the Main menu, sensor information during a start using the Diagnostics menu

 p. 89, Fig. 76)

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

Toggle between test and graphic display

Display the contrast setting (after 2.5 s)



4.6.2

Figure 76

ConcEx

1.5

0.0 mg/m³ 200.0

ConcSL

18.1

0.0 mg/m³ 200.0

Menu

Menu structure

LC-Display menu structure

Opac 96.7 %

ConcSL 18.1 mg/m³

C oncEx 1.51 mg/m³

Ext 1.4795

R_Opac 81.8 %

Trans 3.3 %

Menu

Root Menu

/

Back Enter

4.6.3

4.6.3.1

I/O (MCU)

1 Operating Mode

2 Adjustment

3 I/O Diagnosis

4 I/O Parameter

/io/

Back Enter

Operating Mode

/io/mode

Back Enter

Adjustment

1 Start Check cycle

/io/adj

Back Enter

I/O Diagnosis

1 Analog output

2 Analog input

3 Device Info

/io/diag

Back Enter

I/O (MCU)

1 Operating mode

2 Adjustment

3 I/O Diagnosis

}

1)

4 I/O Parameter

I/O (MCU)

/io/

Back Enter

AO Live Values

1 AO1: 7.01mA

2 AO2: 7.02mA

I/O (MCU)

/io/diag/ao

Back Enter

AI Live Values

1 AI1: 0.00mA

2 Ai2: 0.00mA

I/O (MCU)

/io/diag/ai

Back Enter

Device Info

1 Location

2 Dresden

3 SN:08378651

4 Firmware:

5 1.0.52

I/O (MCU)

/io/info

Back Enter

Operating Mode

/io/mode

Back Enter

I/O Parameter

1 AO Parameter

2 AI Parameter

3 MCU Variant

2)

/io/param

Back Enter

Sensor 1

1 Operating Mode

2 Parameter

3 Diagnosis

4 Device Info I/O (MCU)

/Sensor/1

Back Enter

Operating Mode

/sensor/1/mode

Back Enter

Sensor 1

1 Operating Mode

2 Parameter

3 Diagnosis

4 Device Info

}

1)

I/O (MCU)

/sensor/1

Back Enter

Operating Mode

/ sensor/1 /mode

Back Enter

Diagnosis

1 Contam. 1.8 %

2 Span70 69,52 %

3 Zero point 0.10 %

4 LEDMon 1.895 V

5 LD_Mon 4.0 V

6 LD_I -2 mA

7 Temp 28 °C

8 Q1-4 0.03 V

/sensor/1/diag

Back Enter

Parameter

1 cc2

2 cc1

3 cc0

3)

/ sensor/1 /param

Back Enter

Device Info

1 Location

2 Dresden

3 SN:09058608

4 Firmware:

5 01.04.06

I/O (MCU)

/ sensor/1 /info

Back Enter

1): as in the operating mode

2):

3):

 p. 89, §4.6.3.1

 p. 91, §4.6.3.2

Parameter setting

MCU

Analo outputs / analog inputs



Set the MCU in maintenance mode and call 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).



Figure 77 Menu structure for setting the a nalog output / input parameters and assigning the MCU variant

90

Assigning the MCU variant

The following steps are required to assign the MCU later to the existing sender/receiver

unit of the DUSTHUNTER C200 (

 p. 69, §4.4.1), :



Set the MCU in maintenance mode, call the „MCU Variant” submenu, and select the type „DUSTHUNTER C”.



Enter the default password and store the type with „Save” (confirm 2x).

The other assigning possibilities are not practicable here.



4.6.3.2

Figure 78


The following steps are required to enter the regression coefficients:



Set the sender/receiver unit into"Maintenance" and select the "Parameter" submenu.



Choose the parameter to be entered and set the default password "1234".



Select the calculated coefficient using the "^" and/or "→" buttons and write it to the device with "Save" (confirm 2x).

Entering the regressions coefficients



4.6.4

Figure 79

Using SOPAS ET to modify display settings

To modify factory settings, select type "MCU" in the "Project Tree" window, enter the Level 1 password and select the "Configuration / Display Settings" directory.

"Configuration / Display Settings" directory

Window

Common Display

Settings

Overview Screen

Settings

Entry field Significance

Display Language Language version shown on the LC-Display

Display Unit System Unit of measurement system used in displays

Bar 1 to 8 Sensor address for the first measured value bar in the graphic display

Value

Use AO scaling

Limit low

Limit High

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



Measured value assignment

MCU measured value

Measured value 1

Measured value 2

Measured value 3

Measured value 4

Measured value 5

Measured value 6

Measured value 7

Measured value 8

MCU Value 1

MCU Value 2

Sender/receiver unit measured value

Opacity

Concentration a.c. (SL)

Concentration a.c. (Ext)

Extinction

Rel. opacity

Transmission

Scattered light

Not used

Concentration s.c. (SL)

Concentration s.c. (Ext)




Maintenance

DUSTHUNTER C200

5

Maintenance

General

Maintenance on the sender/receiver unit and reflector/scattered light receiver

Maintenance on the purge air supply

Shutdown


Maintenance

5.1

Figure 80

General

The maintenance work to be carried out consists of:

● Cleaning work (

 p. 98, §5.2),

● Securing the purge air supply function (

 p. 103, §5.3),

● Checking/correction the optical alignment of sender/receiver unit and reflector/scattered light receiver (

 p. 61, §4.2.2 and  p. 64, §4.2.4).

Take the following steps to set the measuring system to "Maintenance" mode before starting maintenance work.



Connect the measuring system via the USB cable to the laptop/PC and start the SOPAS

ET program.



Click the "Network Scan" button in the "Network Scan Assistant" directory, select "MCU"

device file and move it to the "Project Tree" window (

 p. 57, §4.1.4).



Switch to the "Maintenance/Maintenance" directory, activate the "Maintenance on/off" checkbox in the "Maintenance / Operation" group and click "Set State" (see

 Fig. 80).


96

WARNING:

Observe the relevant safety regulations as well as the safety notices (

 p. 10,

§1.3) during all work.

Resume measuring operation after completing the work (deactivate the "Maintenance on/ off" checkbox in the "Maintenance / Operation" window and click "Set State").


Maintenance

● The "Maintenance" mode can also be set by using the keys on the LC display on the MCU (

 p. 89, §4.6.2) or connecting an external maintenance

switch to the terminals for Dig In2 (17, 18) in the MCU (

 p. 43, §3.3.4).

● During "Maintenance", an automatic function check is not performed.

● The control window on the back of the reflector/scattered light receiver (

 p. 63, Fig. 53) is illuminated for easier check of the optical alignment.

● The value set for "Maintenance" is output on the analog output (

 p. 72,

§4.4.4). This also applies in case of malfunction (signalised at the relay

output).

● The "Maintenance" state 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.

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. Therefore only general recommendations can be made here. Normally, the maintenance intervals are about 4 weeks during the initial period and can be steadily incremented to up to a year depending on the respective 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 desired, SICK Service or authorized Service support centers can carry out all maintenance work. SICK offers cost-effective maintenance and repair contracts. SICK carries out all maintenance and repair work within the framework of such an agreement. Any repairs will be made by specialists onsite whenever possible.

Auxiliary means required

● Brush, cleaning cloth, cotton swabs

● Water

● Replacement air filter, preliminary filter (for suction)


Maintenance

5.2

5.2.1

Figure 81

Maintenance on the sender/receiver unit and reflector/scattered light receiver

NOTICE:



Do not damage any device parts during maintenance work.



Do not interrupt the purge air supply.

Clean the outside of the sender/receiver unit and reflector/scattered light receiver 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).

Maintenance on the sender/receiver unit



Switch the sender/receiver unit to maintenance mode (

 p. 60, Fig. 49) and enter level 1 password.



Loosen the knurled screws and swivel the housing to the side.



Check assembly flange and purge air nozzle for contamination, and clean if necessary.



Lock the assembly flange with cover (

 p. 126, §7.3.7).



Switch to the "Adjustment / Manual Adjustment / Motor Control " directory and click

"Mounting" at "Pivoted shutter sender/receiver".

The swivel plate moves then to the cleaning position.

"Adjustment / Manual Adjustment / Motor control" directory


Maintenance

Figure 82



Remove swivel plate cover (1), press the tension spring (2) and take swivel plate (3) off the axis (4).



Carefully clean glass pane (5) (both sides), zero point reflector (6) and sender optics (7) with an optics cloth.

Cleaning the optical interfaces on the sender/receiver unit

1

3

6

Zero point reflector, rear side

4

2

7

5

Figure 83



Lay the toothed belt on the drive axis, press the the tension spring and push the swivel plate back onto the axis.



Initate a function check (move the "MCU" device file from the "Network Scan Assistant" tab to the "Project Tree" window, open the "Adjustment / Function Check -Manual" directory and click "Start Manual Function Check").

"Adjustment / Function Check -Manual" directory

The function check can also be triggered by using the keys on the LC display of the MCU (

 p. 89, §4.6.2).


Maintenance

Figure 84



Select the "DH C200" device file in the "Project Tree" window, open the "Diagnosis /

Check values" subdirectory and check the contamination value.

"Diagnosis / Check values" subdirectory

100



Store the measured values for contamination, zero point and span in the device by clicking "Update values" ("Check values" group) if they are within the allowed range; if not, repeat cleaning and check once more the contamination value by triggering a renewed function check.

● The contamination value can also be displayed on the LC display of the

MCU (initiate a function check and switch to the "C200/Diagnosis" menu;

 p. 89, §4.6.2).

● If the contamination value does not sink below the value for warning in spite of several cleaning processes, the device is probably defective → contact the SICK Service.

● If the contamination value is negative after cleaning (e.g. due to scaling with contaminated optics), the measuring system must be scaled again

(

 p. 64, §4.2.3).



Put the swivel plate cover back on, remove the cover from the assembly flange, swivel the housing back in and lock in with the knurled screws.



Move the swivel plate back into the measuring position. To do this, click "Measurement" in the "Adjustment / Manual adjustment / Motor control“ directory (

 p. 98, Fig. 81).



Resume measuring operation.


Maintenance

5.2.2

Figure 85

Performing maintenance on the reflector/scattered light receiver



Switch the measuring system to maintenance mode (

 p. 96, §5.1), loosen the knurled

screws and swivel the housing to the side.

Maintening the scattered light receiver



Press the spring (1) to the side, pull the clamp (2) to the front and pull the scattered light receiver optic (3) carefully out of the tube.



Lock the assembly flange with cover (

 p. 126, §7.3.7).



Open the grips (5) at the scattered light receiver optic for large measuring distances and remove the attachment (6).



Carefully clean the lens of the scattered light receiver (6) and reflector optics (7) with an optics cloth.



Check purge air tube (8), ligth trap (9) and O ring (10) for deposits, and clean if necessary.

Cleaning the optical interfaces on the scattered light receiver

8 1 2

3

4

9

Scattered light receiver for short measuring distances

2

Scattered light receiver for long measuring distances

5 7 10 6

7

5


Maintenance

Figure 86

Maintening the reflector



Select "DH C200" device file in the "Project tree" window, switch to the "Adjustment /

Manual adjustment / Motor control “ directory and click "Mounting" at "Pivoted shutter reflector" (

 p. 98, Fig. 81).

The swivel plate moves then to the cleaning position.



Remove the swivel plate cover (1), press the tension spring (2) and take the swivel plate

(3) off the axis (4).



Carefully clean glass pane (5) (both sides) and reflector optics (6) with an optics cloth.

Cleaning the optical interfaces on the reflector/scattered light receiver

3

6

5

4

2

1

102



Lay the toothed belt on the drive axis, press the the tension spring and push the swivel plate back onto the axis.



Initate a function check (select the "Adjustment / Function Check -Manual" directory in the "MCU" device file and click "Start Manual Function Check";

 p. 99, Fig. 83).



Check the contamination value (

 p. 98, §5.2.1,  p. 100, Fig. 84).



Store the measured values for contamination, zero point and span in the device by clicking "Update values" ("Check values" group) if they are within the allowed range; if not, repeat cleaning and check once more the contamination value by triggering a renewed function check.



Put the swivel plate cover back on, remove the cover from the assembly flange, put the scattered light receiver optic back in and fasten it



Swivel the housing back in and lock in with the knurled screws.



Move the swivel plate back into the measuring position. To do this, click "Measurement" at "Pivoted shutter reflector" in the "Adjustment / Manual Adjustment / Motor control" directory (

 p. 98, Fig. 81).



Resume measuring operation.


Maintenance

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 the inspection of the purge air supply after start-up at short intervals (approx. 2 weeks) and to optimize the maintenance intervals over a longer operating time.

NOTICE:

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 purge air supply when the optical components sender/ receiver unit and reflector/scattered light receiver are fitted on the duct.



Disassemble the connected components before exchanging damaged

purge air hoses (

 p. 106, §5.4).

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.


Maintenance

5.3.1

Figure 87

Control unit with integrated purge air supply

Cleaning or replacing the filter element



Open the door of the MCU with the appropriate key.



Open the strap retainer (1) on filter outlet and pull the filter housing (2) off connection piece.



Remove the filter housing.



Rotate the filter housing cover 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 connection unit.

Exchanging the filter element for the control unit with purge air supply

1

2

3


Maintenance

5.3.2

Figure 88


NOTICE:

The purge air unit must be serviced at the latest when the low-pressure

monitor at the filter outlet triggers (

 Fig. 88).

Replacing the filter element

Replacing the filter element

7 1 6 5

2

3

4



Clean the filter housing (1) outside.



Loosen hose clamp (2) and clamp the purge air hose (3) at 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, unfiltered purge air enters the purge air connection.



Press the two quick-release snap locks (4) and remove the filter housing cover (5).



Remove filter element (6) by pulling and twisting it counterclockwise at the same time.



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 the filter element by twisting and pressing it clockwise at the same time.

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 quick-release snap locks into place.



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


5.4

Maintenance

Shutdown

The measuring system must be shut down:

● Immediately when the purge air supply fails

● If the equipment is to be shutdown for a longer period of time (as from approx. 1 week)

NOTICE:

Never switch off or interrupt the purge air supply when the sender/receiver unit and reflector/scattered light receiver are fitted on the duct.




Loosen the connection cable to the MCU



Dismantle the sender/receiver unit and reflector/scattered light receiver from the duct.

WARNING:




Section 1 during all disassembly work.



Only carry out disassembly work for measuring systems on equipment with hazard potential (hot or aggressive gases, higher internal duct pressure) when the equipment is at a standstill.






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 flange



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 control unit from mains voltage.

Storage



Store dismantled device parts in a clean, dry location.



Use suitable auxiliary means to protect the connection cable plug-in connector against dirt and moisture.



Secure purge air hoses against penetration by dirt and moisture.


Malfunctions

DUSTHUNTER C200

6

Malfunctions

General


Control unit


108

Malfunctions

6.1

Figure 89

General

Warning or error messages are output in the following manner:

● On the MCU, the respective relay is switched on (

 p. 45, Fig. 29).

● "Maintenance requ." or "Failure" is displayed in the status bar of the LCD (

 p. 88,

§4.6.1). In addition, the respective LED shines ("MAINTENANCE REQUEST" for warnings,

"FAILURE" for errors).

Possible causes are shown as a short information after pressing the key "Diag" on the menu "Diagnosis" and selecting the device file ("MCU" or "DH C200").

Display at the LCD

ConcEx

1.5

0.0 mg/m³ 200.0

ConcSL

18.1

0.0 mg/m³ 200.0

Menu

Diagnosis

/diag

Back Enter

I/O Diagnosis

/i/o/status

Back Enter

Diagnosis

Indication of the current warning or error

/sensor/status

Back Enter

Detailed status information about the current device statust is provided by the "Diagnosis /

Errors/Warnings" directory. Connect the measuring system to the SOPAS ET program and

start the "DH C200" or "MCU" device file (

 p. 56, §4.1.3.5) to display the relevant

information.

The significance of the individual messages is described in more detail in a separate window after moving the cursor to the respective display. Clicking on the display shows a short description of possible causes and corrections under "Help" (

 p. 109, Fig. 90,  p. 111, Fig. 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 device failure.

Warning messages do not imply a malfunction of the measuring system. The current measured value is still output via the analog output.

See the service manual for more detailed description of the messages and possibilities for the remedying.


Malfunctions

6.2

Figure 90

Sender/receiver unit

Malfunctions

Symptom

● LEDs of the sender/ receiver unit are not on

● No laser beam

Possible cause

● No supply voltage

● Connection cable not connected correctly or defective

● Defective plug connector

Action



Check plug connectors and cable.



Contact SICK service.

Warning and error messages in the SOPAS ET program

"Diagnosis / Errors/Warnings" directory

Description Indicator

Warning or error messages currently existing or appeared earlier and stored in the error memory can be shown by selection of "actual" or "memory" in the "Selection" window.


Malfunctions

The following malfunctions can be removed under circumstances at site.

Message Significance Possible cause Action

Reflector communication No connection between sender/receiver unit and reflector/scattered light receiver

● Connection cable not connected or not connected correctly

● Defective connection cable

● Defectice reflector

● RS485 interface of the sender/receiver unit defective



Check connection cable.




LED monitor overflow

Q1-4 overflow

Set reference

Contamination

Overdriving of the monitor channel when scaling

Group signal of quadrant measurement too high

Scaling not possible

Current contamination value is higher than the permitted limit value (

p. 114, §7.1)



Incorrect alignment of the optical axes of sender/receiver unit and reflector

● Measuring system not yet scaled

● Changed alignment of optical axes

● Reduced active measuring path

Measurement or monitor signal too low

(contamination, incorrect alignment)

● Deposits on the optical surfaces

● Unclean purge air





Check/correct alignment.

Repeat scaling.



Scale measuring system.












Clean the optical surfaces (

 p. 98, §5.2).



Clean the optical surfaces (

 p. 98, §5.2).



Check purge air filter and replace, if required (

 p. 103, §5.3).




Power supply (24 V) < 18 V Supply voltage too low ● Cabel provided by customer doesn‘t

Power supply (24 V) < 19 V match the specification (

 p. 43,

§3.3.4)

● Voltage loss on the connection cable

(core cross-section too low in relation to the cable length)



Check the connection cable.



Contact SICK Service.


Malfunctions

6.3

Figure 91

Control unit

Malfunctions

Symptom Possible cause

No display on the LCD ● No supply voltage

● Cable to the LCD not connected or damaged

● Defective fuse

Action



Check the power supply.



Check the connetction cable.



Exchange the fuse (T 2 A).




Warning and error messages in the SOPAS ET program

"Diagnosis / Errors/Warnings" directory

Description Indicator


Malfunctions

The following malfunctions can be removed under circumstances at site.

Message Significance

AO configuration The number of configured analog outputs does not match the number of connected outputs.

AI configuration The number of configured analog inputs does not match the number of connected outputs.

Interface Module No communication via interface module

No sensor found sender/receiver unit was not

Variant configuration error

Testmode enabled recognized

MCU setting doesn't match attached sensor

MCU is in test mode.

Possible cause

● No parameters set for AO

● Connection error

● Module failure

● No parameters set for AI


● Module failure

● No parameters set for module


● Module failure

Action



Check the parameter settings (

 p. 72, §4.4.4).







 p. 75, §4.4.5).







 p. 89, §4.6.2).




● Communication problems on

RS485 line

● Supply voltage problems

● Sensor type was changed



Check the system settings.



Check the connection cable.



Check the power supply.



Check the termination.






Correct application settings (

 p. 69, §4.4.1).



Deactivate the "System Test" status

("Maintenance" directory)

Figure 92

Replacing the fuse



Disconnect the measuring system from the mains.



Open the door of the MCU, remove and open the fuse bracket (1).



Replace the defective fuse (2) against a new one (

 p. 126, §7.3.7).



Close the fuse bracket and install.



Close the door and connect the power supply.

Replacing the fuse

1

2


Specifications

DUSTHUNTER C200

7

Specifications

Technical Data

Dimensions, Part Nos.

Accessories

Consumable parts for 2-years operation

Password


Specifications

7.1

Technical Data

Measurement parameter

Measured variable

Measuring range (freely adjustable)

● Transmission

● Opacity

● Relative Opacity

● Extinction

● Dust concentration

Transmission, Opacity, relative Opacity, Extinction, Scattered light intensity, Dust concentration

Min.

Max.

100 ... 90 %

0 ... 10 %

0 ... 10 %

0 ... 0.045


0 … 5 mg/m³

0 … 200 mg/m³

Transmission (dependent on measuring path and particle characteristics; see special graphic)

0 … 200 mg/m³

0 … 10,000 mg/m³

± 2%

1 ... 600 s; freely selectable

100 ... 0 %

0 ... 100 %

0 ... 100 %

0 ... 2

Uncertainty

1)

Response time

Measurement conditions

Distance flange - flange

2)

Effective measuring distance

(Scattered light measurement)

3)

Swivel error 4)

Gas temperature (above dew point)

Internal duct pressure

With reflector/scattered light receiver DHC-R0:




0.2% Transmission

-40 ... 300°C Higher on request

0.5...3 m

2.5...8 m approx. 0.1 m approx. 0.3 m

Ambient temperature

-50 hPa ... +2 hPa

-50 hPa ... +30 hPa

-40 ... +60°C

-40 ... +45°C

MCU control unit


Sender/receiver unit, reflector/scattered light receiver, MCU-N control unit

MCU-P control unit, intake temperature for purge air

Function Check

Automatic self-test

Manual linearity check

Output Signals

Analog output

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 500

 (standard output max. 750  resolution 10 bits; electrically isolated

2 further analog outputs by using an analog output module (option,

 p. 23, §2.2.4)

5 potential-free outputs (changeover contacts) for status signals; load 48 V, 1 A; Relay output

Input Signals

Analog input

Digital input

2 inputs 0...20 mA (standard; without electric isolation); resolution 10 bits;

2 further analog inputs by using an analog input module (option,

 p. 23, §2.2.4)

4 inputs to connect potential-free contacts (e.g. for external maintenance switch, triggering function checks);

Communication Interfaces

USB 1.1, RS 232 (on terminals) For measured value inquiries and software updates per PC/laptop using the operating program

RS485

Optional Interface module

To connect the sender/receiver unit(s)

To communicate with the Host PC, optional for Profibus, Ethernet

1)

2)

3)

:

:

:

4):

In temperature range - 20 °C ... +50 °C

Upper limit only with distortion-free fitting

 p. 14, Fig. 1

With swivel angle ± 0.3°; total swivel range ±1°


Specifications

Energy Supply

Control unit



(with blower 2BH13)

Weight


Power supply:

Power consumption:

Power supply:

Power consumption:

Voltage supply:

Rated current:

Motor rating:

9,5 kg

Reflector/scattered light receiver 8,0 kg

12,0kg

Control unit 13,5 kg

4,5 kg

90...250 V AC, 47...63 Hz; opt. 24 V DC ± 2 V

Max. 30 W without purge air supply

Max. 70 W with purge air supply

24 V from control unit

Max. 17 W

200 ... 240 V/345...415 V at 50 Hz;

220...275 V/380...480 V at 60 Hz

2.6 A/Y 1.5 A

0.37 kW at 50 Hz; 0.45 kW at 60 Hz

DHC-R0

DHC-R1

MCU-P

MCU-N

Optional external purge air unit 14 kg

Misc.

Protection class

Connection cable length

Purge air hose length

Sender LED

Laser

Purge air feed volume

IP 66

IP 54

5 m, 10 m, 20 m

5 m, 10 m

5)

Sender/receiver unit, reflector/scattered light receiver, control unit


Other lengths on request

Other lengths on request

White light, wavelength between 450 nm and 700 nm

Degree of protection 2; capacity < 1 mW; wavelength between 640 nm and 660 nm

Max. 20 m³/h

Max. 63 m³/h

MCU control unit


5)

: for connecting the reflector/ scattered light receiver to the sender/receiver unit

Dust concentration measuring range

The limits for the smallest/largest measuring range depend on the extinction measuring range, active measuring path and optical particle characteristics. Therefore exact range limits cannot be specified here. The following charts can be used to estimate the ranges used. These have been determined based on SICK's many years of experience and are valid assuming constant particle size and characteristics.


116

Figure 93 Measuring ranges for dust concentration measurement based on extinction

Smallest measuring range

Dust concentration in mg/m³

250

200

Average particle size

10 μm (after swirl filter)

5 μm (after electric filter)

3 μm (after cloth filter)

150

100

50

0

1 2 3

Largest measuring range

Dust concentration in mg/m³

10000

9000

8000

7000

6000

5000

4000

3000

2000

1000

0

1 2 3

4 5 6

Active measuring path in m

Average particle size

10 μm (after swirl filter)

5 μm (after electric filter)

3 μm (after cloth filter)

4 5 6

Active measuring path in m

7

7

8

8

Specifications


Specifications

Compliances

The technical design of this device complies with the following EU directives and EN standards:

● EU Directive NSP 2006/95/EC

● EU Directive EMC 2004/108/EC

Applied EN standards:

● EN 61010-1, Safety requirements for electrical equipment for measurement, control and laboratory use

● EN 61326, Electrical equipment for measurement technology, control technology and laboratory use - EMC requirements

Electrical protection

● Insulation: Protection class 1 according to EN 61010-1.

● Insulation coordination: Measuring category II according to EN 61010-1.

● Contamination: The control unit operates safely in an environment up to degree of contamination 2 according to EN 61010-1 (usual, non-conductive contamination and temporary conductivity by occasional moisture condensation).

● Electrical energy: The wiring system to the mains supply voltage of the system must be installed and fused according to the relevant regulations.

Approvals

The measuring system is approved according to EN 15267 and may be used for continuous emission monitoring in plants requiring approval and plants according to the

27th FICA.


118

7.2

7.2.1

Figure 94

Dimensions, Part Nos.

All measures are specified in mm.



347

25 r = 28

0

212

Name

Sender/receiver unit DHC-T

Part number

1044863

Specifications


Specifications

7.2.2

Figure 95


Reflector/scattered light receiver DHC-R0 for short measuring paths

Reflector/scattered light receiver DHC-R0 r = 240

347

25

70

220

Name

Reflector/scattered light receiver DHC-R0

Part number

1044864


Figure 96

Reflector/scattered light receiver DHC-R1 for long measuring paths


Specifications r = 240

40

352

223

191

104

208

Name


Part number

1044865


Specifications

7.2.3

Figure 97

Flange with tube

Flange with tube

45° 45°

Flansch mit Rohr k100 Flansch mit Rohr k225

M10

M12

D2

D3

Maß

D2

D3

L

L k100

Flansch mit Rohr

Ø 100

Ø 130

110, 130, 240, 500 k225

Ø 225

Ø 265

350

Name

Flange type k100

Flange with tube, Di = 70.2 Length 130 mm, St37



Flange with tube, Di = 70.2 Length 130 mm, 1.4571


Flange with tube, Di = 70.2, length 500 mm, 1.4571



Flange type k225

Flange with tube, Di = 152 Length 350 mm, St37

Flange with tube, Di = 152 Length 350 mm, 1.4571

L

Part No.

2017845

2017847

2017849

2017846

2017848

2017850

2054535

2054536

2045418

2045420

Usage on

DHC-T

DHC-R0

DHC-R1


7.2.4

Figure 98

MCU control unit

MCU-N control unit without purge air supply

MCU-N control unit

210

160

120

Specifications

Meas

Name

Control unit MCU-NWODN01000NNNE in wall housing (orange),

Supply voltage 90 ... 250 V AC, without purge air unit, with display

Control unit MCU-N2ODN01000NNNE in wall housing (orange),

Supply voltage 24 V DC, without purge air unit, with display

Part number

1045001

1045003


Specifications

Figure 99

Control unit MCU-P with integrated purge air supply

MCU-P control unit

260

Ø 8

300

Name

Control unit MCU-PWODN01000NNNE in wall housing (orange),

Supply voltage 90 ... 250 V AC, with purge air unit, with display

Control unit MCU-P2ODN01000NNNE in wall housing (orange),

Supply voltage 24 V DC, with purge air unit, with display

220

Part number

1045002

1045004


7.2.5

Figure 100



ø

14

40

40

470

550

128

258

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

Part number

1012424

1012409

Specifications


Specifications

7.2.6

Figure 101

Weatherproof cover



245

550

605

350

Name

Weatherproof cover for purge air unit

Part number

5306108

Figure 102

Weatherproof cover for sender/receiver unit and reflector/scattered light receiver


Part no.. 2702407

239

Part no. 2048657

492

Name


Weatherproof cover flange k225

365


Part number

2702407

2048567

Part number

DHC-T, DHC-R0

DHC-R1

125

126

7.3

7.3.1

7.3.2

7.3.3

7.3.4

7.3.5

7.3.6

7.3.7

Specifications

Accessories

Connection cable, sender/receiver unit - MCU

Name

Connection cable, length 5 m


Part number

7042017

7042018

Connection cable, sender/receiver unit - reflector/scattered light receiver

Name




Part number

2045416

2045417

2048674

Purge air supply

Name

Purge air hose DN 40, yard good

Purge air hose DN 25, length 5 m

Purge air hose DN 25, length 10 m

Adapter 40-25

Hose clamp D20-32

Hose clamp D32-52

Part number

5304683

2046091

7047536

7047814

7045039

5300809

Assembly parts

Name

Assembly kit, flange - analyzer

(for sender/receiver unit and reflector/scattered light receiver DHC-R0)

Assembly kit receiver (for scattered light receiver DHC-R1)

Device check accessories

Name

Check filter set

Adjusting stand

Part number

2018183

2060477

Part number

2048676

2042907

Options for MCU control unit

Name

Analog input module, 2 channels, 100

, 0/4...22 mA, electrically isolated

Module carrier for AI module

Connection cable for AI module

Interface, Profibus module DP V0

Interface module Profibus DP V0

Interface module Ethernet

Misc.

Name

Optical adjusting device for flange assembly

Cover

Set of fuses T 2 A

Set of fuses T 4 A (for MCU with 24 V supply)

Part number

2034656

6028668

2040977

2040961

2040961

2040965

Part number

1700462

2052377

2054541

2056334


Specifications

7.4

7.4.1

7.4.2

7.4.3

Consumable parts for 2-years operation

Sender/receiver unit and reflector/scattered light receiver

Name

Sealing tape

Sealing tape 235x50x2 (for DHC-R1)

Number

4

2

Part number

4704676

4058792

Control unit MCU with integrated purge air supply

Name

Filter element C1140

Optics cloth

Number

4

4


Name

Filter element Micro-Topelement C11 100

Optics cloth

Number

4

4

Part number

7047560

4003353

Part number

5306091

4003353


128

Specifications

7.5

Password

Passwort „Autorisierter Bediener“

Nach dem Start des Bedien- und Parametrierprogrammes SOPAS ET sind nur die Programmfunktionen verfügbar, die keinen Einfluss auf die Gerätefunktion haben.

Nicht eingewiesenes Personal kann keine Änderungen der Parameter vornehmen.

Zur Nutzung des erweiterten Funktionsumfanges wird das

Passwort

sickoptic

benötigt.

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

Password "Authorized operator"

After the start of the SOPAS ET operating and parameterization program, only menus are available which have no effect on the functioning of the device.

Untrained personnel cannot alter the device parameters. To access the extended range of functions the password

sickoptic

must be entered

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


Specifications


DUSTHUNTER C200

SICK worldwide

You will find our local subsidiary or agency at:

www.sick.com

Your local sales and service partner

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

SICK DUSTHUNTER C200 Dust Concentration Monitor Operating Instructions

Assistant Bot

DUSTHUNTER C200

Dust Concentration Monitor

Description

Installation

Operation

Document Information

Warning Symbols

Warning Levels / Signal Words

Information Symbols

Important Information

Product Description

Assembly and Installation

Start-up and Parameter Settings

Maintenance

Malfunctions

Specifications

Important Information

Main hazards

Hazards from hot and/or aggressive gases and/or high pressure

Hazards through electrical equipment

Hazards through laser beam

Intended use

Responsibility of user

General information

Safety information and protective measures

Product Description

Measuring principle, measured variables

Functional principle

Response time

Function control

Device components

Sender/receiver unit

Reflector/scattered light receiver

Flange with tube

MCU control unit

Optional external purge air unit

Installation accessories (order separately)

Test equipment for linearity test

Device configuration

Assembly and Installation

Project planning

Assembly

Fitting the flange with tube

)

Fitting the MCU control unit

Fitting the optional external purge air unit

Fitting the weatherproof cover

Installation

General information, prerequisites

Connecting/starting the optional external purge air unit

Installing the purge air supply

Connecting the MCU control unit

Connecting the reflector/scattered light receiver

Fitting and connecting optional Interface and I/O modules

Start-up and Parameter Settings

Basics

General information

Installing the operating and parameter program SOPAS ET

Connecting to the device

Information on using the program

Online help

Application specific settings

Preparatory work

Focussing the sender light beam for transmission measurement

Scaling the measuring system for transmission measurement

Adjusting the laser beam for scattered light measurement

Entering application specific parameters

Installing the sender/receiver unit and reflector/scattered light receiver

Connecting the sender/receiver unit and reflector/scattered light receiver to the purge air supply

Fitting and connecting the sender/receiver unit and reflector/scattered light receiver on the duct

Setting standard parameters

Assigning the sensor

Factory settings

Determining the function check

Setting the analog outputs parameters

Setting the analog inputs parameters

Setting the response time

Calibrating for dust concentration measurement