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Product Information

FW 100
Dust Concentration Monitor
FW 100 Introduction Product Information

Dust Concentration Monitor

Introduction

Compliances
‡ Qualification tested according:
FW 101 for TA Air Act, 13. Large Furnace Order) and 17. BImSchV (Order on Waste Inci-
neration Plants)
FW 102 for TA Air Act and 27. BImSchV (Order on Cremation Plants)
‡ TÜV approved
‡ EMC-conformity in accordance with EN 50081-1/EN 50082-2
‡ CE-certification pursuant to the EMV 89/336 EWG and
NSP 72/23/EWG
‡ VDE guidelines in accordance with EN 61010 (IEC 1010-1, VDE 0411)
class of protection 1, degree of protection IP 65
‡ SICK AG is certified to ISO 9001.

About this document


This document consists of:
■ Product Information, which describes the scope of delivery of the FW 100 in all variants
■ Project Planning to help you project and prepare the measuring point before the device
is delivered

Among other things, the document contains important information on:


■ Application ranges, advantages and device components of the FW 100
■ Technical data
■ Planning checklist in detail and hints for installation.

Validity and amendments


As with all products from SICK AG the FW 100 is permanently undergoing further
development. The information contained in this document, therefore, may differ from the
specifications of the device you are using. In the event of any discrepancies between this
documentation and the documentation supplied with your device, please always refer to the
latter.
Are you familiar with our If you would like to know more about the SICK range of dust monitors, velocity measuring
product range? devices and gas analyzers and systems please ask for our free product brochures (order
no. dust monitors – 8 007 556, gas analyzers – 8 008 966, velocity measuring devices –
8 008 385). We can also provide tailor-made all-in-one solutions using technology that is
best suited to your measuring task.
Where do I go ‡ For further information on choosing your variant of the FW 100 and planning your project,
from here? please contact your project consultant at SICK AG or your local representative – we will
gladly advise you and provide you with the support you need to plan, install, and start up
your solution.
Each device is supplied with a complete set of documentation containing detailed informa-
tion on how to install, start up, operate, and maintain the FW 100, including relevant extracts
from this Product Information.

2 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Produkt Information Table of Contents FW 100

Dust Concentration Monitor

Table of Contents

1 Description of the FW 100 .............................................................................................. 4


1.1 Range of Applications .......................................................................................................... 4
1.2 Features .................................................................................................................................... 4
1.3 Overview of the FW 100 ...................................................................................................... 5
1.3.1 FW 100 Variants ...................................................................................................................................... 5
1.3.2 Components of the FW 100 ................................................................................................................ 5
1.3.3 FW 100 Configuration ............................................................................................................................ 7
1.3.4 Interfaces .................................................................................................................................................... 8
1.3.5 Operation .................................................................................................................................................... 9
1.4 Technical Data ..................................................................................................................... 11
1.5 Dimensions ........................................................................................................................... 13

2 Project Planning ............................................................................................................... 15


2.1 Planning Checklist .............................................................................................................. 15
2.2 Installation Procedure ....................................................................................................... 17
2.3 Preparations for Installation ............................................................................................ 17
2.3.1 Installation Proposal ............................................................................................................................. 17
2.3.2 Mounting the Connection Unit .......................................................................................................... 17
2.3.3 Mounting flanges with tube ............................................................................................................... 18
2.4 Preparations for Electrical Installation ........................................................................ 21
2.4.1 Important Information .......................................................................................................................... 21
2.4.2 Cable Specifications/Interfaces ...................................................................................................... 22

8 008 903/08-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 3


FW 100 Description of the FW 100 Product Information

Dust Concentration Monitor

1 Description of the FW 100

1.1 Range of Applications


Purpose The FW 100 series from SICK AG is designed to conduct continuous measurements of very
low (0.1 mg/m3) to medium (200 mg/m3) dust concentrations – independent of the gas ve-
locity, humidity, or charge of the particles involved.
Highlights The probe design is particularly suitable for mounting on one side of the gas duct and does
not require any mechanical adjustment or calibration with a dust-free measurement path.
The measuring device can be used for a wide range of applications, including gas ducts with
extremely small or large diameters, as well as thick and thin-walled stacks.

Applications ‡ In pure gas, downstream of electrostatic precipitators


– Continuous measurement and monitoring of dust concentrations
– Protection of flue gas desulfurization plants at too high dust load
‡ In pure gas, downstream of modern fabric filters
– Monitoring, detection, and identification of defective filters and bags
– Prevention of the release of expensive production materials and toxic contents in con-
tinuous processes
‡ For monitoring and/or closed-loop control purposes in exhaust/intake air systems

Sectors ■ Power supply: power stations,


■ Waste disposal: refuse incineration plants
■ Process engineering: grinding and metering plants
■ Metal processing: steel and aluminum processing
■ Foodstuff industry: filling bulk materials
■ Brake linings and eternit production

1.2 Features
■ Easy to install and simple to operate
■ Practically no maintenance
■ Menu-driven parametrization with MEPA software
■ No mechanical adjustment required
■ No calibration to dust-free measuring path required
■ Measuring accuracy immune to changes in gas velocity
■ High resolution
■ Automatic check cycle
■ Contamination monitor (FW 101)
■ Connection unit with integrated purge-air and power supply

4 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Product Information Description of the FW 100 FW 100

Dust Concentration Monitor

1.3 Overview of the FW 100

1.3.1 FW 100 Variants


The FW 100 is available in the following versions:
■ FW 101: for use in gas ducts with a diameter greater than 500 mm.
The device is mounted on the duct using a flange with tube.
■ FW 102: for use in gas ducts with a diameter greater than 150 mm. The FW 102 can be
mounted on a flange with quick-release lock or a 1” coupling on the duct.

1.3.2 Components of the FW 100

Component Version

Transmitter/receiver unit FW 101 FW 102

FWSE 101 with flange: FWSE 102 flange with quick-release lock
Rated length: 435 or 735 mm Rated length: 180 or 280 mm

FWSE 102 with 1” thread


Rated length: 180 or 280 mm

• Flange with tube, FW 101 FW 102


• Flange for quick- Mounting:
Mounting:
release lock flange with tube Flange for quick-release lock (TRI-CLAMP®)
• 1” coupling
See 2 Project Planning

Mounting: 1” coupling

8 008 903/08-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 5


FW 100 Description of the FW 100 Product Information

Dust Concentration Monitor

Connection unit FW 101 and FW 102 FW 101 and FW 102


Connection unit without purge-air supply* Connection unit with purge-air supply

* External purge-air unit (see Fig. 1.1) or


instrument air connection (see Fig. 1.2)
required

MEPA program
MEPA
For menu-driven
parametrization via PC

Tab. 1.1: Components of the FW 100

Options:
■ External purge-air supply for higher duct pressures

Purge-air hose

Fig. 1.1 2BH 13 purge-air unit

■ Adapter (throttle element) for connecting external instrument air supply

Instrument air con- Purge-air connection


nection (on-site) (FW 101/FW 102)

Fig. 1.2 Adapter for instrument air connection

6 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Product Information Description of the FW 100 FW 100

Dust Concentration Monitor

Options (continued):
■ Measurement value and event memory
The FW 100 transmitter/receiver unit can be equipped with a measurement value and
event memory as well as a realtime clock. With it the FW 100 can store up to 3000 mea-
surement values, which are detected over a predefined period of time (e.g. half-hourly
values), and assign them a timestamp using the realtime clock. In addition, up to 100
events are stored in parallel. These include any changes in the operating status of the
device (maintenance, limit value violations, errors). The MEPA menu-driven parametriza-
tion program imports this data or displays it graphically.

Accessories
■ Weather-proof covers for the T/R unit of the FW 101 and for the external purge-air unit.

1.3.3 FW 100 Configuration


The configuration of the device is selected in accordance with the operating conditions:

Selecting the device variant


‡ FW 101
‡ FW 102

Selecting the purge-air supply


‡ The purge-air supply is selected in accordance with the pressure within the gas duct

Application FW 100 Configuration (standard)

‡ With duct pressure TR unit


≤ 10 mbar

Connection unit without


MEPA purge-air supply
software

MEPA

Cable
Power supply
Purge-air hose

Inputs/
outputs

8 008 903/08-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 7


FW 100 Description of the FW 100 Product Information

Dust Concentration Monitor

Application FW 100 Configuration

‡ With duct pressure of TR unit


≤ 70 mbar

MEPA Adapter
software Connection unit without
purge-air supply
MEPA
Ext. purge-air unit
(option)

Cable
Power supply

Purge-air hose
Inputs/
outputs
Power supply

‡ With duct pressure of TR unit


≤ 1 bar

MEPA Adapter
software Connection unit without
purge-air supply
MEPA

Cable
Power supply
Instrument air
(provided by customer)
Inputs/
outputs

1.3.4 Interfaces
The input and output connections are established via the connection unit. The following in-
puts and outputs are available:
Connection Unit • Relay outputs for status signals:
– Malfunction, limit value, and maintenance
• Analog output with 0/2/4 to 20mA
• Serial interface
– RS 232 for parametrization with MEPA FW 100
• Binary input
– Connection for a maintenance switch with floating contact
Note For parametrization, see FW 100 Operating Instructions.

8 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Product Information Description of the FW 100 FW 100

Dust Concentration Monitor

1.3.5 Operation

Measuring Principle of the FW 100


The FW 100 operates according to the scattered light measurement principle (forward scat-
tering). Since it is extremely sensitive, this principle is particularly suitable for measuring very
small particle concentrations.

Light source Measuring volume

Detector

Fig. 1.3 Measuring principle

A laser diode directs a beam of modulated light (in the visible range) at the dust particles in
the gas flow. The light scattered by the particles is recorded by a highly sensitive detector.
The point of intersection between the transmitted beam and the receiver aperture defines
the measuring volume in the gas duct. The measured scattered light intensity is proportional
to the dust concentration. After a gravimetric comparison measurement, for example ac-
cording to VDI 2066, therefore, a measurement signal that is directly proportional to the
dust concentration can be output.

Check Cycle (FW 101)


The check cycle lasts approx. 310 s and comprises a:
• contamination measurement on the optical boundary surfaces
• zero-point measurement
• check point measurement
The check value is recorded for approx. 40 s (last measurement value is maintained); the
check values are then output at the analog output.

8 008 903/08-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 9


FW 100 Description of the FW 100 Product Information

Dust Concentration Monitor

Zero-point

End check cycle


Output
zero-point
Output
check point
Output
contamination

0 2 6 8 10 12 14 16 18 20

Check point (span)

Degree of contamination Start check cycle

Fig. 1.4 Check cycle output (via analog output on the FW 101)

Contamination In order to measure the contamination on the optical boundary surfaces, the FW 101 moves
Measurement the receiver optics mechanically to a reference position. As a result, the optics measure the
(FW 101 only) light emitted by the laser diode directly. The measured intensity value is compared with the
factory or original settings to calculate a correction factor. In this way, the FW 101 can fully
compensate for any contamination levels.

Receiver optics in
reference position

Fig. 1.5 Contamination measurement (FW 101)

Check-Point The FW 101 measures the check point by moving the receiver optics to the reference po-
Measurement sition. Once a reference measurement has been carried out with a light intensity of 100 %,
(Span Test) the FW 101 reduces the intensity of the laser diode to 70 % and compares the value mea-
sured by the receiver with the expected value. If these two values deviate from the upper
range limit by more than 2 %, the device generates an error signal.

Zero-Point In order to monitor the zero point, the FW 101 deactivates the laser diode. Since no light is
Measurement present in the duct, the reception signal must also be zero. In this way, drifts or zero-point
deviations in the entire system (e.g. caused by an electronic defect) can be reliably detect-
ed. If the “zero-value” deviation is outside the specified range, an error signal is generated.

10 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Product Information Description of the FW 100 FW 100

Dust Concentration Monitor

Check cycle (FW 102)


The check cycle lasts approx. 200 s and comprises a:
• zero-point measurement
• check-point measurement
The check value is recorded for approx. 20 s (last measurement value is maintained) before
it is output on the analog output.
Check-Point The FW 102 measures the check point with the reception optics in the measuring position.
Measurement The measurement lasts approx. 90 s. During this time, the light intensity changes between
(Span Test) 70 and 100 %. Thanks to a large number of intensity shifts, which can be evaluated statis-
tically, the FW 102 enables the check point to be measured with pinpoint accuracy. This also
applies with fluctuating dust concentrations in the gas duct. Deviations in the check point by
more than 2 % of the upper range limit are evaluated in the same way as with the FW 102.
Zero-Point Like the FW 101, the FW 102 carries out a zero-point measurement. The FW 102 also sup-
Measurement plies extremely accurate measurement values without a contamination monitor, because
the purge-air flow has been optimized to take flow aspects into account. Contamination on
the optical boundary surfaces is only to be expected over longer periods of time. Further-
more, contamination on measurement devices using the scattered light principle has less
of an effect on the measurement signal than with other measurement principles.

1.4 Technical Data

Technical Data Value


General Data
Measurement variable Scattered light intensity
Measurement range Minimum range: 0 ... 5 mg/m3 higher ranges avaliable on request
Maximum range: 0 ... 200 mg/m3 stepplessly variable
Output Scattered light intensity, after gravimetric comparison measurement, dust concentration in mg/m3
Measurement accuracy 2 % of upper range limit (full scale)
Response time 0.1 ... 360 s
Application data
Gas temperature • Standard version (FW 101, 102) 0 °C … 220 °C
• High-temperature version (FW 101) 0 °C … 400 °C
Duct pressure • Standard configuration: –50 mbar … +10 mbar,
• Configuration with ext. purge-air unit: –50 mbar … +70 mbar,
• Configuration with instrument air: –50 mbar … 1 bar
Ambient temperature –20 … +50 °C for transmitter/receiver unit
–20 … +50 °C intake-air temperature for blower
Terminals
Analog output Electrically isolated, 0/2/4 ... 20 mA, max. load 750 Ω
Relay outputs max. 48 V, 1 A DC
Output 1: malfunction (error)
Output 2: limit value
Output 3: maintenance
Interfaces RS 232 for laptop/PC
Binary input Dig in 1 = connection for maintenance switch with floating contact
Tab. 1.1: Technical data (part one)

8 008 903/08-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 11


FW 100 Description of the FW 100 Product Information

Dust Concentration Monitor

Technical Data Value


Power supply
Connection unit Voltage: 90 ... 260 V AC, 47 ... 63 Hz,
optional 24 V DC
Power consumption: max. 15 W with connection unit w/o purge-air supply,
max. 70 W with connection unit with purge-air supply
Transmitter/receiver unit Voltage: 24 V from connection unit
Power consumption: FWSE 101 max. 12 W
FWSE 102 max. 4 W
External purge-air unit Voltage: 200 ... 240 V/345...415 V at 50 Hz;
(2BH13) 220...275 V/380...480 V at 60 Hz
Rated current: 2.6 A/Y 1.5 A
Motor power: 0.37 kW bei 50 Hz;
0.45 kW bei 60 Hz
Dimensions, weights
Dimensions (W x H x L) • T/R unit FWSE 101: 150 x 150 x 945 or 150 x 150 x 645 mm
• T/R unit FWSE 102: 150 x 150 x 440 mm
• Connection unit with purge air: 300 x 400 x 210 mm
• Connection unit without purge air: 200 x 200 x 120 mm
• External purge-air unit: 550 x 550 x 270 mm
Weight • T/R unit FWSE 101: 5.0 kg (rated length 435); 6.3 kg (rated length 735)
• T/R unit FWSE 102: 2.7 kg (rated length 180); 4.0 kg (rated length 280)
• Connection unit with purge air: 13.2 kg
• Connection unit without purge air: 4.0 kg
• External purge-air unit: 14 kg
Protection class • Transmitter/receiver unit: IP 65
• Connection unit: IP 65
Length of signal cable 3 m standard, (LIYCY: 8 x 2 x 0.25 mm2)
10 m (option); other lengths available on request
Length of purge-air hose 3 m standard, option: 10 m (other lengths available on request)
Laser protection class 2
Purge-air capacity Approx. 5 … 10 m3/h with connection unit with internal purge-air supply
Approx. 40 … 60 m3/h with external purge-air unit
Tab. 1.2: Technical data (continued)

12 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Product Information Description of the FW 100 FW 100

Dust Concentration Monitor

1.5 Dimensions

FW 101 Transmitter/Receiver Unit


81 128 NL
NL L1
435 300
735 600
150

Ø53
Ø25
L1 55

FW 102 Transmitter/Receiver Unit with 1” thread


81 L2 NL
NL L1 L2
Ø25
18050 179
L1
280150 79
Ø25
150

440

FW 102 Transmitter/Receiver Unit with TRICLAMP®

81 L2 NL NL L1 L2

Ø25 18050 179


L1
280150 79
Ø25
150

440

Fig. 1.6 Dimensions of the FW 100 variants

8 008 903/08-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 13


FW 100 Description of the FW 100 Product Information

Dust Concentration Monitor

Connection Unit with Integrated Connection Unit without


Purge-Air Supply Purge-Air Supply

300
200

200
400

120
210

Fig. 1.7 Dimensions of the FW 100 variants

External Purge-Air Unit The dimensions of SLV 4 external purge-air unit from SICK are documented separately. See
data sheet (order no. 8 008 088).

14 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/08-2000


Project Planning Project Planning FW 100

Dust Concentration Monitor

2 Project Planning

2.1 Planning Checklist


Overview The checklist provides an overview of the project planning measures required for the FW
100 measuring device. Before you use the device for the first time, it is imperative that you
check all of the steps below and verify them by ticking the boxes in column 3.
Selection Steps Measure ✓
FW 101/102 nominal ‡ Duct diameter ✓ Take the nominal length of the FW 100
length ‡ Insulation into account
see 1.3.2 Components of the
FW 100 ‡ Wall thickness

Variants ‡ Check duct pressure:


see Product Information, • Pressure: –50 ... ≤ +10 mbar ✓ Choose connection unit with integrated
1.3 Overview of the FW 100 purge-air supply
• Pressure: –50 ... ≤ +70 mbar ✓ Choose connection unit w/o purge-air
supply and external purge-air unit
• Pressure: –50 mbar ... ≤ 1 bar ✓ Choose connection unit w/o purge-air
supply and adapter for instrument air
Measuring point ‡ Observe inlet/outlet distance:
Observe national regulations,
e.g. VDI 2066
• With round duct diameter ✓ 3x duct diameter
• With rectangular duct diameter ✓ Hydraulic diameter D = 4A --------
U
• If these specifications cannot be ✓ Inlet distance > outlet distance,
observed e.g. 2/3 : 1/3
‡ Ambient conditions:
• Flow characteristics ✓ Homogeneous in vicinity of measuring
point, if possible
• Representative ✓ Measuring location should be representa-
tive of dust content in the duct
• Plant subject to offical approval ✓ Obtain statutory approval:
• Calibration aperture ✓ Provide at points difficult to access
• Mutual interference ✓ Must be prevented between calibration
probe and FW 100
‡ Gas temperature:
• 0 ... 220 °C ✓ Standard version (FW 102, FW 102)
• 0 ... 400 °C ✓ High-temperature version (FW 101)
‡ Ambient temperature ✓ –20 … +50 °C
Flange mounting, ‡ Location:
see 2.3.3 Mounting flanges • Steel ducts ✓ Installation as standard
with tube
• Brick stacks/thick-walled ducts ✓ Anchor plate required for flange
‡ Duct walls:
• Thin-walled ducts ✓ Provide suitable reinforcement or sup-
porting constructions
Table 2.1: Planning Checklist (continued, see page 16)

8 008 903/07-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 15


FW 100 Project Planning Project Planning

Dust Concentration Monitor

Selection Steps Measure ✓


Transmitter/receiver unit ‡ Choose mounting location ✓ Mounting location should be free of vibra-
tion (acceleration < 1g)
‡ Choose duct aperture:
• Aperture size, possibly with wall ✓ Provide sufficient access
insulation removed
• Installation outdoors ✓ Plan room for weatherproof cover
Connection unit ‡ Choose mounting location:
• Free of vibration ✓ Mounting location should be free of vibra-
tion (acceleration < 1g)
• Accessibility ✓ Ensure device is accessible
• Installation outdoors ✓ Provide room for weatherproof cover
• Connection unit with • Distance from T/R unit ✓ Plan distance from T/R unit
purge-air supply (<3 m, max. 10 m)
‡ Intake air ✓ Temperature: –20 … +40 °C;
✓ Free of dust and oil
External purge-air unit ‡ Choose mounting location:
(option) • Free of vibration ✓ Mounting location should be as free of vi-
bration as possible (acceleration < 1g)
• Maintenance ✓ Ensure device is accessible
• Installation outdoors ✓ Provide room for weatherproof cover
• Distance from T/R unit ✓ Plan distance from T/R unit
(<3 m, max. 10 m)
‡ Intake air ✓ Temperature: -20 … +50 °C
✓ As free of dust and oil as possible
Mounting platform ‡ Platform ✓ Provide appr. 1.5 m below measurement
aperture
‡ Accident prevention ✓ All components must be easily accessible
without any danger
✓ Observe applicable national regulations/
specifications regard. accident prevention.
Table 2.2: Planning checklist (continued from page 15)

16 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/07-2000


Project Planning Project Planning FW 100

Dust Concentration Monitor

2.2 Installation Procedure


Step 1: Project planning the FW 100:
‡ Carry out the planning activities (see 2.1)
Step 2: Preparations for installation:
‡ Note the data in the installation proposal (see 2.3.1)
‡ Mount the flange with tube (see 2.3.3)
‡ Mount the 1” coupling (see )
Step 3: Preparations for electrical installation (see 2.4)
Step 4: Carry out the installation steps

2.3 Preparations for Installation

2.3.1 Installation Proposal

Flange with tube


(Position of Marking for installation
threaded bolts position
drawn with
a 45° shift)

Top
xxxx
xxxx
Ø 76

35 30

M8
470
Attachment for purge-air system

470

FL. 60 x 8 x 60
DIN 174
50

Tubular steel
50x 5
DIN 2391

Fig. 2.1 Installation proposal with mounting flange and external purge air unit

2.3.2 Mounting the Connection Unit


• When choosing the mounting location for the connection unit, take the lengths of the sig-
nal cable and purge-air hose into account!
Signal cable: 3 m standard; 10 m optional.
• Ensure that the mounting location is free of vibration!

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FW 100 Project Planning Project Planning

Dust Concentration Monitor

L1

Connection unit w/o purge air

L2
L1 = 160L2 =
Connection unit with purge air
L1 = 260L2 =

Fig. 2.2 Attachment dimensions of the connection unit

2.3.3 Mounting flanges with tube


In the section below, the term “flange” is used to refer to the flange with tube. The most suit-
able flange in each case depends on the duct data. The standard dimensions are: overall
length 130 mm and outside diameter 76 mm.
‡ Suitable reinforcements or support constructions must be provided on thin-walled ducts.
‡ The pipe stubs of the flange should protrude approx. 30 mm into the duct. Adjust the pipe
glands if necessary.
‡ Once the flange has been mounted, cover the opening to prevent gas from leaking at the
measuring point.

Mounting on Steel Ducts

L
L = 130, 240 or
500 mm 30

Mounting position marking Top


xxxx

Ø 76
Arrangement of
stud bolts (shown
rotated through
45°)

Fig. 2.3 Steel duct

Welding work on the duct


• All work on the duct should be carried out when the plant is shut down.
• When welding on the duct, ensure that none of the parts cut out fall into the stack!
ATTENTION

‡ Mark the mounting point of the flange with tube


‡ Burn out a suitable opening

18 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/07-2000


Project Planning

a
8 008 903/07-2000
Note
Project Planning

so that any condensate can drain off.


‡ Weld the pipe securely to the duct.

Mounting on a Brick Stack

Arrangement of
stud bolts (shown
rotated through
45°)

Anchor plate

Fig. 2.4 Brick stack

Mounting on a Thin-Walled Duct


Top
xxxx
a
The pipe stub of the flange with tube should protrude into the duct by between approx.
5 mm (small ducts) and 30 mm (large ducts).
Ensure that the flange is aligned correctly (with “Top” pointing upwards).
‡ Weld the flange into position at an angle of approx. 1° toward the duct wall

‡ On brick stacks, the flange must be welded to a suitable anchor plate (provided by the
customer) attached to the wall of the stack.

L= 130, 240 or
500 mm

Mounting position marking


L

30

‡ Junction plates (provided by the customer) must be provided for reinforcement on thin-
walled ducts or mounting locations subject to vibration.

Mounting position
marking
Top
xxxx

Fig. 2.5 Junction plates for reinforcing the mounting location

© SICK AG · Environmental Monitoring · Germany · All rights reserved


FW 100

Dust Concentration Monitor

Ø 76

19
FW 100 Project Planning Project Planning

Dust Concentration Monitor

Note Mounting the bracket for the purge-air unit


‡ Mount the brackets on the duct wall as shown in 2.3.1 Installation Proposal, see Fig. 2.1.

Mounting the FW 102 with 1” coupling or TRICLAMP®


The transmitter/receiver unit of the FW 102 can be mounted on the duct using a 1” coupling
or a flange for a quick-release lock (TRICLAMP®). In order to do so, first weld the 1” coupling
or flange for the quick-release lock to the duct.

Mounting the FW 102 with 1” Thread

Welding work on the duct


• All work on the duct should be carried out when the plant is shut down.
• When welding on the duct, ensure that none of the parts cut out fall into the stack!
ATTENTION

‡ Mark the mounting point of the coupling


‡ Cut a suitable opening the duct wall
‡ Weld on the flange or coupling
‡ Provide suitable reinforcements on thin-walled ducts or at mounting points that are sub-
ject to vibration.
Always weld the 1” coupling at an angle facing upwards of 1° so that any condensate can
drain off.
Note A “11/2 : 1” reducing coupling can be used instead of a 1” coupling.

L
Duct wall

Welded seam

Ø di

1“ coupling:
di [mm] L [mm]

30.29 43

Fig. 2.6 1“ coupling on the duct

20 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/07-2000


Project Planning Project Planning FW 100

Dust Concentration Monitor

Mounting the FW 102 with TRICLAMP®

Welding work on the duct


• All work on the duct should be carried out when the plant is shut down.
• When welding on the duct, ensure that none of the parts cut out fall into the stack!
ATTENTION

‡ Mark the mounting point of the flange with quick-release lock (TRICLAMP®)
‡ Cut out a suitable opening in the duct wall
‡ Weld the pipe into position
‡ Always weld the pipe so that it is inclined upwards that condensate can drain out
‡ Provide suitable reinforcements on thin-walled ducts or at mounting points subject to vi-
brations.

ca. 5
Welded seam

Ø 34,8

Ø 38,1

Duct wall
44,5

Fig. 2.7 Flange with quick-release lock (TRICLAMP®) on the duct

2.4 Preparations for Electrical Installation


All installation must be carried out by the customer, unless otherwise agreed with SICK AG.

2.4.1 Important Information


‡ Before you start, check the version and configuration of your FW 100 and plan the cabling
and wiring accordingly.
VDE 0411/8.8 ‡ The power supply for the connection unit and purge-air motor (for optional purge-air unit)
must be permanently installed and electrically isolated.
VDE 0411/5.1.2.2.2 ‡ Plan the cable lengths.

The following must be supplied by the customer:


• Power supply for connection unit and external purge-air unit (optional)
• Signal cables for installation by the customer

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FW 100 Project Planning Project Planning

Dust Concentration Monitor

2.4.2 Cable Specifications/Interfaces

Connection unit
• Suitable conductor material, jacket material, and insulating covering must be selected in
accordance with the conditions at the location.

Power supply 2) Cable to T/R unit 1)


115/230 V AC, conduit thread 13.5 3 m long, 16-wire, common shield,
3 x 1.5 mm2 outside diameter approx. 11 mm
conduit thread 13.5
Inputs/outputs2)
Analog output: 0 – 20 mA; max. load 750 Ω,
Digital input 1 1) Included in scope of supply
Digital outputs: relays 1 to 3: max. 48 V, 1 A AC/DC 2) Cables provided by customer

Fig. 2.8 Cable specifications and interfaces for the connection unit

Wiring for the Connection Unit (Provided by the Customer)

Connection unit – Laptop

RS 232 pin assignment RS 232 connection

Socket Connector
(9-pole) (9-pin)
2 Txd 2 Rxd
3 Rxd 3 Txd
Terminal strip
5 Gnd 5 Gnd

L1 N PE 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16
+
-
0 ... 20 mA

Dig. in 1

Relay 1

Relay 2

Relay 3

Power supply:
Gnd

115/230 V AC; 50/60 Hz


(2 x T1A-Sicherungen)
Maintenance

Analog output 0 2 4 6 8 10 12 14 16 18 20
Limit value

Digital input (maintenance) Malfunction

Fig. 2.9 Connections on the terminal strip for wiring by customer

22 © SICK AG · Environmental Monitoring · Germany · All rights reserved 8 008 903/07-2000


Project Planning Project Planning FW 100

Dust Concentration Monitor

External purge-air unit (option)


‡ A separate disconnector – if possible, a motor circuit-breaker – must be installed in the
vicinity of the measuring devices
‡ A clear warning must be provided near the switch to prevent it from being deactivated
inadvertently.
‡ A phase-failure protection switch is recommended for three-phase.
The three-phase AC motor of the fan (type 2BH1300) is connected at 3 phase conductors
L1, L2, L3. The rated voltage of the motor in operating connection must match the phase-
to-phase voltage of the network (operating voltage).
Motors with windings for 230 V (D)/400 V (Y) can be connected to the terminal board for
230 V or 400 V with direct starting and a suitable circuit.

Underpressure monitor

Power supply 24 V
4 x 1.5 mm2

Fig. 2.10 Electrical connection for the purge-air unit

8 008 903/07-2000 © SICK AG · Environmental Monitoring · Germany · All rights reserved 23


Th e d i a l o g u e c o n t i n u e s .
Copy, complete and fax to +49 7641 469 1149

Company
p lo yr t

Name

Job Title/Dept.
F a x a Rn et w

Street

ZIP, City

Phone/Fax

Industry/Field

PI 1.03 en
of Application
Yes, I would like to know more about
the field of:

In-process gas analysis I would like a detailed consultation with one


Flue gas monitoring of your project advisors. Please arrange a
meeting for me.
Emission monitoring

Dust measurement

Volume flow measurement


w w w . s i c k - m a i h a k . c o m

Data acquisition and evaluation

Water analysis

Liquid analysis

Level measurement

Tunnel sensors

Special measurement technology

Download more Product Informations at www.sick-maihak.com

8 008 903/08-2000/DIV 03.BW • Printed in Germany (11-2002) • Subject to change without prior notice

S SICK MAIHAK GmbH • Analyzers & Process Instrumentation • Nimburger Str. 11 • 79276 Reute • Germany
Phone +49 7641 469-0 • Fax +49 7641 469 11 49 www.sick-maihak.com • E-Mail: info_sick-maihak@sick.de