FW61-1 Opacity Meter

US

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IN

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RU

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IO

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FW 56-IDust Concentration Monitor

3

Contents

Contents

Introduction .................................................................................. 7

1 Safety instructions ............................................................... 101

1.1 Important safety notes ...................................................................................... 101

1.2 Use in accordance with instructions, conditions of use .............. 1021.2.1 Use .................................................................................................................. 1021.2.2 Instructions for safeguarding the equipment ........................ 102

1.3 Authorized users ................................................................................................... 103

1.4 Safety precautions, protective measures .............................................. 1041.4.1 Danger from items of electrical equipment ......................... 1041.4.2 Preventative measures for safe operation ............................. 1041.4.3 Avoiding consequential damage in the event

of malfunction ........................................................................................... 104

1.5 Procedure in the event of purge air failure ......................................... 105

1.6 Environmental information and instructions for disposal ............ 105

2 Description of instrument .................................................. 201

2.1 Characteristics ......................................................................................................... 201

2.2 Component parts ................................................................................................. 202

2.3 Mode of operation .............................................................................................. 2032.3.1 Function........................................................................................................ 2032.3.2 Transmission, opacity, extinction ................................................. 2042.3.3 Differential transmission ..................................................................... 2052.3.4 Dust concentration ............................................................................... 2062.3.5 Response time .......................................................................................... 2072.3.6 Real-time clock ........................................................................................ 2082.3.7 Check cycle ............................................................................................... 208

2.4 Data memory and additional functions .................................................. 2092.4.1 Storing data ................................................................................................ 2092.4.2 Intelligent measurement value calculation ............................ 2092.4.3 Storing events in the FW 56-I ....................................................... 210

2.5. Input/output options of the FWA56-I evaluation unit ................. 2112.5.1 Display functions ..................................................................................... 2112.5.2 Binary inputs .............................................................................................. 2142.5.3 Analog output .......................................................................................... 2142.5.4 Relay outputs ............................................................................................ 2142.5.5 Serial interface .......................................................................................... 215

3 Installation including electrical work................................ 301

3.1 Preparations for installation, project planning .................................... 301

3.2 Installation .................................................................................................................. 303

4

Contents

3.2.1 Sequence of installation work ........................................................ 3033.2.2 Installation work to be performed by the customer ...... 3053.2.2.1 General ....................................................................................................... 3053.2.2.2 Installation with mounting flanges (standard)..................... 3063.2.2.3 Installing the device with FWSE purge air attachment

without a mounting flange ............................................................... 3093.2.3. Installing the evaluation unit ............................................................ 3093.2.4 Mounting the S/R unit and reflector .......................................... 310

3.3 Installing the optional device components .......................................... 3113.3.1 Installing the purge air unit ............................................................... 3113.3.2 Installing the weatherproof cover for the purge

air unit ............................................................................................................ 3113.3.3 Adding a filter insert ............................................................................. 3113.3.4 Installing the weatherproof cover for the FWM and

FWA56-I ...................................................................................................... 3123.3.5 Removal ........................................................................................................ 312

3.4 Electrical installation ............................................................................................ 3133.4.1 Instructions for electrical installation .......................................... 3133.4.2 Electrical installation .............................................................................. 3133.4.3 Electrical installation of the purge air unit .............................. 315

3.5 Removal ...................................................................................................................... 316

4 Commissioning and parameterization ............................. 401

4.1 Preparations for commissioning .................................................................. 401

4.1.1 Authorized access .................................................................................... 401

4.1.2 Overview of commissioning work ................................................ 401

4.2 Setting the sender/receiver unit .................................................................402

4.3 Calibration ................................................................................................................. 404

4.4 Parameterization with the MEPA56I program .................................. 4044.4.1 General .........................................................................................................4044.4.2 Default settings of the MEPA56I .................................................. 4074.4.3 Selecting the measuring variable and storage mode ...... 4074.4.4 Defining the output variable ........................................................... 4084.4.5 Display functions and graphics display ...................................... 4094.4.6 Miscellaneous/options ......................................................................... 4114.4.7 Test and diagnosis functions ............................................................ 412

4.5 Settings via the front panel ............................................................................. 412

5 Servicing and maintenance ................................................ 501

5.1 General ........................................................................................................................ 501

5.2 Cleaning of the optical surfaces of the FWM56 and FWR56 . 501

5.3 Servicing the optional purge air unit ........................................................ 5025.3.1 Inspection work ...................................................................................... 5025.3.2 Changing the filter insert ................................................................... 502

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6 Troubleshooting .................................................................. 601

6.1 Testing the I/O functions ................................................................................. 6016.1.1 Troubleshooting table ......................................................................... 601

7 Technical data ...................................................................... 701

7.1 Overview of technical data ............................................................................ 701

7.2 FW 56-I standard ................................................................................................. 703

7.3 Options, accessories ........................................................................................... 703

7.4 Consumables for 2-year operation .......................................................... 703

7.5 Spare parts ................................................................................................................ 703

7.6 FW 56-I diagrams (to scale) ......................................................................... 704

7.7 Diagram of purge air unit (to scale) ......................................................... 706

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These Operating Instructions contain all of the information relating tothe FW 56-I Dust Monitor. They provide basic information on safety,system features, planning, installation, commissioning and regular servic-ing of the device components.

In accordance with the definition of users, the level of information inthese Operating Instructions is geared to the customer's operator andinstaller. The device documentation (Operating Instructions and leafletenclosed with the packed goods) cannot allow for every possible varia-tion in deployment and attachment. Consequently, these Operating In-structions contain only the information required for a standard applica-tion and associated installation.

Please observe all safety instructions very carefully - in the interest ofyour own safety, the safety of your staff, and equipment reliability. SeeChapter 1 Safety Instructions. Certain work requires specialist knowl-edge; the qualifications of those carrying out the work must match thedegree of difficulty of such work. See Section 1.3 Authorized Users.

Additional provisions

For special applications, the SICK centre concerned will provide youwith the necessary support.

System components which come complete from other suppliers, e.g.the side-channel compressors of the purge air units, generally have theirown user information. These documents should be observed with equalattention.

The content of the Operating Instructions does not constitute a part ofany previous or existing agreement, assurance or legal relationship, noris it intended to modify any of the aforementioned. All obligations ofSICK AG arise from the purchase contract concerned, which also con-tains the complete and solely applicable warranty provisions. These con-tractual provisions are not extended by the device documentation.

1600 people work for the SICK group worldwide. We are in close con-tact with the users of our products in order to meet the constantlygrowing demands of practical applications. Our wish is that our custom-ers will be satisfied with the quality of our products and service. If youhave any suggestions for improvement, please write to use. We will bepleased to act on them.

Introduction

Notes on these instructions

Operating Instructions

Safety instructions

Special applications

Relevant documents from suppliers

Warranty provisions

SICK AGNimburger Straße 11D -79276 Reute

101

1.1 Important safety notes

1 Safety instructions

The following symbols are used as important safety instructions for theuser in these Operating Instructions. They are found in each case withinthe section where such information is relevant. It is essential that thesesafety instructions, in particular the warnings, be noted and obeyed.

Dangerindicates possible damage to persons, especially from electrical equip-ment.

Warningindicates possible hazards to persons if the system components are han-dled incorrectly.

Importantindicates risk to system components or possible functional restrictions.

Notecontains important additional information for the user on the system orsystem components and provides further tips.

102


1.2 Use in accordance with instructions, conditions of use

1.2.1 Use

The FW 56-I should be operated in the manner prescribed by themanufacturer.

PreconditionIt is assumed that the installation planning, mounting, installation, com-missioning, servicing and maintenance work will be carried out byadequately trained personnel, and that this work will be checked byresponsible qualified staff.

Correct proceduresThe responsible qualified staff shall ensure in particular that� all system components are used only for their intended purpose.� the application corresponds to the technical data and the details on

possible use, installation, connection, environmental and operatingconditions (to be obtained from the order documents, the devicesummary data, type plates and documents supplied).

� the general installation and safety instructions are observed.� work is carried out in accordance with the site and installation-

specific factors, also taking into account hazards and rules due tooperations factors.

� tools, lifting and conveying equipment are used correctly.� system components with no protective system as supplied are fitted

with effective protective devices on the operating side.� there is sufficient safety equipment and personal protective clothing

and that this is used by staff.

1.2.2. Instructions for safeguarding the system

Transport, storageThe FW 56-I is a sophisticated electronic sensor system which requirescareful handling in all operations, transport and storage:� Never store the unit unprotected in the open!� Transport and store only in original packaging� Store in a dry place� Never leave cable ends or plugs unprotected. Always insulate cable

ends. When not in use, always protect cable plugs against moistureand dirt with protective covers or suitable packaging materials.Corroded connectors can cause malfunctions!

103

1.3 Authorized users


It is essential that those responsible for safety ensure that:� installation design, assembly, installation, commissioning, servicing and

maintenance work are carried out only by trained and qualified em-ployees or qualified persons and that this is checked by responsiblequalified staff.Qualified employees are persons conforming to DIN VDE 0105 orIEC 364 or directly equivalent standards. Qualified persons havebeen authorized to undertake this work by those responsible forpersonal and equipment safety on the basis of their education andtraining, experience or instruction, and their knowledge of the rele-vant standards, instructions, accident prevention regulations andequipment conditions. It is essential that such persons be able torecognize and avoid potential hazards promptly.Knowledge of First Aid and of local rescue equipment is required andassumed.

� these persons have accurate knowledge of operational hazards, forexample risks due to gases, gas-liquid mixtures or other media whichare hot, toxic or pressurized.

� for work on power installations, the ban on employment of non-qualified persons (governed by DIN VDE 0105 or IEC 364) isobserved.

� work on or at close proximity to hazardous system components bynon-qualified persons is forbidden.

104


1.4 Safety precautions, protective measures

1.4.1 Danger from items of electrical equipment

The FW 56-I and its components are designed for use in industrialpower systems. During installation, commissioning, operation andservicing, it is possible for:� open components or uninsulated parts to be live at dangerously high

voltages,� motors or valves to start up on their own without warning,� physical injury or material damage to be caused by unauthorized re-

moval of the necessary coverings, incorrect operation, improper useor inadequate servicing of the system components of the installation.

1.4.2 Preventive measures for safe operation

If the FW 56-I is used as a sensor in combination with a control system,the operator must ensure that any failure or malfunction on the FW 56-I cannot lead to operating conditions which are dangerous or can causeunacceptable damage.In order to prevent device malfunctions, it is necessary to have the pre-scribed servicing and inspection work carried out regularly by qualifiedand experienced staff.

Detecting malfunctionsVariations from normal operation are indications of functionalrestrictions and must be taken seriously. These include, among otherthings:� response of the monitoring devices,� excessive drifting of the measuring results,� increased power consumption of individual components,� higher unit temperatures,� excessive vibration of units,� unusual noises and� unusual odours

1.4.3 Avoiding consequential damage in the event ofequipment malfunctions

In order to avoid malfunctions which could cause personal injury orphysical damage directly or indirectly, the operator must ensure that:� the responsible servicing personnel can be alerted at any time and as

quickly as possible,� the servicing personnel are trained to react correctly to faults in the

FW 56-I and associated operational malfunctions,� any switching off does not lead to indirect consequential damage.

105


1.5 Procedure in the event of a purge air failure

1.6 Environmental information and instructions for disposal

Measures for restricting damage due to a purge air failureThe purge air protects the FW 56-I from contamination of the opticalsurfaces, aggressive gases and high smoke temperatures. If the purge airsupply fails, hot and corrosive gases can destroy the dust monitor'ssender/receiver unit and reflector unit within a few minutes.

The operator must ensure that:� the power supply of the purge air unit operates reliably and without

interruption,� any failure of the purge air unit supply is detected immediately (pres-

sure monitors are available for this purpose),� maintenance staff can be at the installation within a few minutes.

� The modules are easily disassembled and thus easily disposed of.� All materials used in the FW 56-I are harmless to groundwater.

Electronic scrap such as printed-circuit boards must be disposed of asproblem waste.

� The external housing of the sender/receiver unit is made of cast alu-minium, the evaluation unit from plastic, and the mounting flange ismade of steel or stainless steel.

� Electronic sensor components should not be disposed of in domesticrefuse, but at a suitable site.

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Blank page for notes

201

2 Description of instrument

2.1 Characteristics

Transmissiometer

Use

The FW 56-I Dust Monitor is a infrared optics transmissiometer. It con-tains no moving parts and is therefore highly durable and reliable.

The FW 56-I Dust Monitor is used for the following purposes:� Measuring dust in exhaust gas ducts (can be calibrated)� Monitoring filter systems to check functional capability� Early detection of failures of individual filter bags (filter crack)� Monitoring emissions from industrial installations to check compliance

with limit values� Measuring opacity or transmission in exhaust gas ducts

Features� High measurement and signal processing flexibility with the result that

one measuring device can be adapted to various measuring tasks andconcentration ranges

� Continuous, uninterrupted in-situ measurement of:• transmission• differential transmission• opacity• extinction• differential extinction• dust concentration in mg/m³ after gravimetric comparison

measurement� Display of instantaneous values on LC display.� Status display for mode, limit value, warning, malfunction via LEDs.� Synchronized mean value calculation for suppression of individual

malfunctions.� Storage of 5000 measuring values from 1s to 2h.

(e.g. half-hourly average values over 104 days can be stored).� Registration of 500 events with date and time.� Measurement value output via analog signal 0 ... 20mA, with variable

live zero (0/2/4mA).� Status signal output via floating relay contacts.� User-friendly parameterization of measuring device with PC (laptop)

via RS 232 interface on the front panel using the MEPA software andoutput of stored measuring values and events.Additional electrically isolated RS 232 interface on terminal strip.

� Optional RS 485/RS 422 interface for remote data transfer.� High operating reliability by means of implemented self-test functions.� Simple to assemble and install with low maintenance.� Excellent cost-benefit relation

Measuring variables

Displays

Device functions

Interfaces

Special characteristics

202

2.2 Component parts


The Dust Monitor comprises the following components:

� FWM56 sender/receiver unitThe sender/receiver unit contains the optical and electronic modulesfor transmitting and receiving the IR light beam. It can be aligned pre-cisely with the centre of the reflector using the integrated sight. It issecured to the purge air attachment by means of fasteners.

� FWR56-2 or FWR56-4 reflectorFor short or long distances between the FWM56 and reflector; withbracket for securing on the purge air attachment.

� FWA56-I evaluation unitThe evaluation unit contains the electronics for measuring value cal-culation and signal input/output, the LCD for displaying the measuringvariables, LEDs for indicating the device status and the control but-tons for selecting the measuring variable and device status. An RS232 interface is available on the front panel for defining parametersand exchanging data. The signal outputs are implemented on termi-nal strips (in the terminal box).

� 2 FWS56 purge air attachmentsWith purge air gland and snap-on fasteners for mounting the S/R unitand reflector. The purge air attachment contains laminated inserts forprotecting the optical surfaces from contamination. Depending onthe gas temperature and pressure (see 3.1), a purge air supply canbe connected to the purge air gland.

� MEPA56IMEnu-drive PArameterization software for configuring the device forthe measurement application; supplied on 3.5" disks for PC (laptop)for DOS version 3.1 or higher.

Optional device components� 2 mounting flanges (flange with tube) for installing the S/R unit and

reflector on the duct� a purge air unit for purge air supply� a pair of measuring stands for adjusting (calibrating) the FW 56-I

Dust Monitor on a dust-free section (zero-point reference section).� a zero-point reference section (zero tube) for calibration - as an al-

ternative to the measuring stands (recommended for ambient airwith high dust content)

203

ReflekFWR

AuswerteFWA56Anschlußkabel

Montage-flansch

Spülluftvorsatz Spülluftvorsatz

Gaskanal

Visier

Netzanschluß

Spülluftstutzenmit Verschlußkappe


2.3 Mode of operation

Pulse operation

2.3.1 Function

The optics of the FWM56 sender/receiver unit comprise a system withsending and receiving lenses (see Fig. 2301). The light source is an infra-red diode, the light from which is emitted from the sender through thedust-laden exhaust-gas duct to the reflector, from which it is reflectedback to the S/R unit. The light attenuated by passing through the dusttwice is registered in the receiver and fed via the connection cable tothe evaluation unit as an electrical signal.

The sending power of the infrared LED, the brightness of which de-pends on the ambient temperature and power loss, is monitored con-tinuously. A correction factor is calculated via a monitor channel whichregisters the brightness of the sender diode. This prevents corruption ofthe measuring values.The sender LED is triggered in pulses. As a result, the measurement isinsensitive to daylight, since the measuring signals are filtered via a high-pass filter. The corrected and calibrated transmission value is determined50 times a second and represents an instantaneous value.

The light quantity detected by the receiver is referred to asI (intensity) in the following sections.

The I0 (basic intensity) value, which represents the light quantity

detected over a section which is absolutely dust-free (based on therespective measuring section), is also stored in the system. I0 isdetermined during calibration.All of the measuring variables described here are derived from themagnitude and time characteristics of these two values. The measuringvariables described in Chapters 2.3.2 to 2.3.4 can be set as required.

Fig. 2201 Components of the FW 56-I

Sende-/EmpfangseinheitFWM 56

Purge air glandwith seal

Evaluation unitFWA56-I

Sender/receiverunit FWM56

ReflectorFWR56

Mounting

flangeGas duct

Connection cable

Power supply

Sight Purge air

attachment

Purge air

attachment

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MEPA


Fig. 2301 Functional principle of FW 56-I

Measuring variables

Purge air intake(option)

2.3.2 Transmission, opacity, extinction

Transmission, opacity and extinction are standard physical variables en-countered in the area of dust monitoring. The variable used depends onthe application and the national regulations.

The measuring variables are calculated as follows:

T = I/I0 (2.1)

O = 1 - I/I0 = 1 - T (2.2)

E = log (I0/I) = log (1/T) (2.3)

T = TransmissionO = OpacityE = Extinction

The transmission and opacity values are usually given in %. The valuescalculated with formulae 1 and 2, therefore, must be multiplied by 100%.The logarithmic extinction value is proportional to the dust concentra-tion (at constant grain size and homogenous dust distribution).

Purge air intake(option)

Purge air attachment Purge air attachment

Flange with tube

Sender/receiverunit FWM56

EvaluationunitFWA56-I

Connection options:binary inputs, relay out-puts, analog output

ReflectorFWR56

Gas duct

205


2.3.3 Differential transmission

The differential transmission is calculated as follows:The Filter Watch performs 50 individual measurements per second. Anaverage value of the absolute transmission is determined over the last 5minutes "T5min".The differential transmission "∆T" is calculated by subtracting the currentor instantaneous transmission value from "T

5min".

∆T = T5min

- Tcurr.

(2.4)

"T5min" is a transmission value which is attenuated by a low-pass filter.This filter is set unsymmetrically, i.e. the attenuation at ∆T< 0 is lessthan at ∆T ≥ 0.A slow change in transmission, such as may occur due to contamination,does not affect the differential transmission measurement. In this way, ahigher sensitivity can be attained than with the absolute transmissionmeasurement, as only changes in transmission are evaluated. Interfer-ence due to contamination, temperature dependencies, drift etc., whichgenerally vary slowly, can therefore be eliminated. Consequently, forexample, the FW 56 D/T provides reliable detection of dust peakswhich occur during cleaning of the filter systems. Differential transmis-sion measurement can still be calculated even with a contaminationlevel of up to 50% on the optical surfaces.

Differential transmission ∆T > 0.2% is detected reliably (or considerablyless, depending on the installation conditions).

Fig. 2302 Cleaning cycle

1,60

1,40

1,20

1,00

0,80

0,60

0,40

0,20

0 50 100 150 200 25090

100

0,00

Time in seconds

Differential transmission

Absolute transmission

Diff

eren

tial t

rans

mis

sio

n ∆T

in %

Abs

olu

te t

rans

mis

sio

n T

in %

9 0

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2.3.4 Dust concentration

The dust concentration display is generally required in mg/m³. In orderto measure values in ranges less than mg/m³ and in serveral g/m³ withthe required precision, the dust concentration can be determined with 2different measuring variables. These are selected before the start of themeasurement and set as parameters.a) for larger dust concentrations, approx. from 50mg/m³ * m, the stand-ard extinction is used (see Chap. 2.3.2).b) for smaller dust concentrations, a measuring variable based on thedifferential transmission is used (see Chap. 2.3.3). In addition to the highsensitivity, this method also has the advantage that is insensitive to thecontamination level. This measuring method is based on the fact thatthere is a monotonous relationship between the mean transmissionvalue and the (very small) statistical fluctuations around this mean value.This measuring principle is immediately evident when the emission char-acteristics of a cloth filter installation are considered. In this case, almostno dust is emitted in the intervals between the cleaning cycles. The ma-jority of the total dust content is emitted in the form of "dust peaks" dur-ing the cleaning cycles. The concentration values, therefore, vary con-tinuously. The measuring value described is the differential extinction dE.It is calculated in a similar way as the standard extinction

E = log (1/T) (2.5)

dE = log [1/(1-dT)] (2.6)

Since the differential transmission dT in a smoke-free section is zero andthe transmission value is equal to 1, the value T in the equation (2.5)must be replaced with 1-dT in the equation (2.6).In order to calculate the dust concentration from the differential extinc-tion with the required precision, the mean value is determined.Since the extinction and dust concentration depends on the grain sizeand density of the dust as well as the measuring section, this correlationmust be determined by means of a calibration procedure using a gravi-metric comparison measurement (as with all other dust monitors). Thecoefficients determined from the corresponding linear or quadratic re-gression calculation are entered in the instrument as follows

c = A2* x² + A1* x + A0 (2.7)

c = dust concentration in mg/m³

A0, A1, A2 , = regression coefficients

x = either E or dE


The differential extinction is alwaysmultiplied with the factor 1000 be-fore it is output

207

2.3.5 Response time

The response time t90

is the time required by the device to reach 90%of the final value after an abrupt change in the measuring signal. The t90

time can be set over a broad range. Fig. 2304 illustrates this correlation.By setting a high value for t90, brief fluctuations in the measuring valuesand interference signals can be attenuated more effectively, thus pro-ducing a "smoother" output signal.

Fig. 2304 Response time


100 98 96 94 92 90 88 86 84 82 80

0

Fig. 2303 Correlation between extinction and dust concentration

100

9 0

8 0

7 0

6 0

5 0

4 0

3 0

2 0

1 0

0

↔

↔ ↔

3µm5µm 2µm = Particle dia.Reference:in each case80% < 2µm etc.

Dus

t co

nten

t m

g/m

3

Reference:load-related on flue dustρ = 2.5 g/cm3

Free duct dia. = 1 m

Extinction

Transmission %

Measuring range 100 to 80%Transmission 80 % = 0.097 ext.

Fig. 2303 illustrates the correlationbetween extinction and dust concen-tration. The same correlation existsbetween dE and c.

90% of change

Transmission with response time t90

100,00

98,00

96,00

94,00

92,00

90,00

88,00

86,00

84,0010 20 30 40 50 60 70 80

t90

Instantaneous transmission

T in %

t in s

0,01 0,02 0,03 0,04 0,05 0,06 0,07 0,08 0,09 0,097

208

2.3.6 Real-time clock

The FW 56-I features a battery-buffered real-time clock with date.The time and date can be set with the MEPA parameterization program.The data is stored for at least 1 year (without power supply) or 5 years(with power supply connected for at least 80% of the time).

2.3.7 Check cycle

The check cycle is used for checking the measuring functions of thedevice.The trigger and interval for the check cycle can be set using theparameterization program (enter interval in minutes).

� Check cycle sequence:90 s output zero value• zero value on analog output• zero value on RS 232, corresponding mA value, status90 s output 70% value• 70% value on analog output• 70% value on RS 232, corresponding mA value, status

� Signals:• Display (check cycle)• Relay 2 active• "warning" LED• Interface status byte x4x.xx (3rd column)

The check values are determined as follows in the individual modes:

� Transmission, opacity, extinction, differential transmission, dust con-centration from extinction:• 0% and 70%

� Differential extinction:• Zero value: the low-pass filter is always set symmetrically when

the mean transmission value is calculated. For this reason, the po-sitive and negative proportions cancel each other out if thefunction and linearity of all of the components are correct.

• 70% value: the brightness of the sender LED is modulated to suchan extent so as to produce a 70% change in the transmissionvalue (same affect as moving the filter into position), starting withthe mean value of the transmission in the last 5 minutes. The testincludes all optical and electronic components. The low-pass filteris set symmetrically and attenuated further to counteract theeffects of dust fluctuations in the duct during this time. Therecorded value is converted according to the defined measuringrange.


209


2.4.1 Storing data

Up to 5000 measuring values can be stored in the battery-backed RAMof the FW 56-I (mains-failure protection!). The output value which wasselected for the analog output and display is also stored. Each storedvalue corresponds to the actual mean value of the last measuring inter-val. The measuring interval can vary between 1 s and 2 h.

The storage function can be used as an electronic logbook for installa-tion. If half-hourly mean values are set, the memory can store the re-corded values for more than 100 days. The oldest measuring value isoverwritten when the memory is full.

WarningIn order to ensure a unique assignment, all of the measuring values arecleared each time a parameter which affects the measuring valuememory is modified. The function of the measuring value memory in Fil-ter Mode 1 is different (see Section 2.4.2).

2.4.2 Intelligent mean value calculation(evaluation mode: Filter Mode 1)

Intelligent mean value calculation is a special function for suppressing in-terference when monitoring the limit values of filter cloth installations.It should be noted that:� this function is only effective with differential transmission measure-

ment� this function can only be used with cleaning cycles performed at

fixed intervals, and not with cleaning cycles owing to pressure� the mean values are stored during cleaning cycles

A synchronous pulse from the plant, indicating the start of a cleaning cy-cle, is required for intelligent mean value calculation

Mean value calculation is performed via a configurable number of cyclesas follows :� 1 s mean values are calculated� each mean value calculation cycle is started with a synchronous

pulse. The measured values are numbered internally.� each current n - te measured value is weighted (1 ... 0.1) and aver-

aged with the n - te measured values from the previous cycles, andeach n +1st value is averaged with the n +1st values from the previ-ous cycles and so on.

� the current mean value is always output at the analog output� the calculated limit values refer to the mean value� If a new synchronous pulse is not received within 4999 seconds, the

device switches to standard Measuring mode and outputs a malfunc-tion message. The mean value calculation mode is continued auto-matically with the next pulse.

2.4 Data memory and additional functions

A low-level signal with a minimumduration of 600 ms at input IN3 isrequired as a synchronous pulse

210


� The 4999 1s mean values are averaged in the measuring valuememory and stored over the defined "n" cycles, starting with the syn-chronous pulse (t = 0).

Intelligent mean value calculation prevents the limit value from beingtriggered inadvertently by transient statuses (e.g. plant start-up, releaseof deposits due to vibration etc.). The filter bag which triggered the limitvalue can be determined by analysing the analog signal on the stripchart recorder (or display).

The function is illustrated in Fig. 2401.

2.4.3 Storing events in the FW 56-I

500 events can be stored with the date and time in the FW 56-I forsupporting the plant logbook. Events include:� limit value violations� warnings� collective faults� maintenance� parameter modifications (data written to EEPROM)� mains failure� calibration procedures (also registered as a parameter modification)� deletion of event memory

The start (+) and end (-) of an event are registered.The oldest entry is overwritten when the event memory is full.

Cycle 1

Cycle 2

Cycle 3

Cycle 4

MEAN VALUE

Normal cleaning peaks

Interference

Interference suppressed

Fig. 2401 Mean value over 4 cycles - synchronous pulse at t = 0

Cyclical cleaning peak withnormal size

211

2 Description of installation

2.5 Input and output options of the FWA56-I evaluation unit

2.5.1 Display functions

The LC display contains 2 lines for displaying:� selected measuring variables or events (check cycle, maintenance,

calibration)� value with unit, time or malfunction code

In Filter Mode 1: the seconds since the last synchronous pulse are alsocounted in the 1st line.

The time is displayed if no events are present. Malfunction codes - XY -are decoded as follows:

The LEDs on the front panel have the following meaning:

Status Signal Explanation

LED green

LED red

LED yellow

LED red

Device in Measuring mode (nomalfunctions)

Malfunction; no valid measuringvalues supplied from device

Warning: transmission too low;or alternative check cycle ac-tive

Selected measuring variable hasviolated the limit value

operation

malfunction

warning

limit value

X

1

2

4

0

0

0

Y

0

0

0

1

2

4

Designation

Data transfererror

Current range

RAM test error

Meas. head error

Transmission mal-function

EEPROM readingerror

Explanation

Data cannot be sent or received correctly via the serial interface (RS 232).

The measuring range for the measuring variable (0 ... 20 mA), defined in the"Parameters/output parameters" menu has been exceeded.

The data in the RAM are subjected to a plausibility test after a reset and whenthe system is started. A negative test result means that data has been lost. Thiscould be caused by a battery failure.

The measuring signal in the FWM56 is outside the tolerance range.

The malfunction value set in the "Parameters/output parameters" menu hasbeen undershot.

This message is generated if a checksum error occurs when the parametrizationdata is read from the EEPROM.

Combinations of the above are also possible. For example:

Explanation

Current output range exceeded and meas. signal error

Current output range exceeded and data loss in RAM

X

2

6

Remedy

See Section 6.1

Y

1

0

212


Fig. 2501 Graphics display of measuring values

Fig. 2502 Measuring value table

213


On laptop with the MEPA program:� Display of current measuring values in 3 columns (as in table 2511)� Display as above but with continuous storage on disk/hard drive� Display of current measuring values in graphic form (Fig. 2501)� Measured values stored in FW 56-I as table with time

Important: The most recent measured value, i.e. the 1st measuringvalue after the synchronous pulse, is displayed in the first line of thefirst column. The values can be stored on disk or printed out.An empty line is output if a mains failure or an error occurs (Fig.2502).

� Graphics display of stored measured values� Display of results as table. The results can be stored on disk or

printed out (Fig. 2503).

Fig. 2503 Events displayed as table

Note:See Section 6 for starting and settingthe MEPA

214


Column 1 (selected measured value) Column 2 Column 3

Status

Status

Status

Status

Status

Status

Differential transmission [%]

Transmission [%]

Opacity [%]

Differential extinction * 1000

Dust concentration [mg/m3](from extinction)

Dust concentration [mg/m3](from differential extinction)

Mean trans-missionvalue [%]

Current[mA]

Current[mA]

Trans [%]

Current[mA]

Current[mA]

Table 2511 Output of measuring values to serial interface

2.5.2 Binary inputs

Binary inputs can be connected by means of floating contacts and havea common ground.

� IN1 Binary input for maintenance switchThe "Maintenance" status can also be set with the MEPA program.A current of 0.5 mA is output at the analog output.

� IN2 Binary input for limit value acknowledgementIf this input is jumpered (shorted), the limit value (relay andLED) is only displayed the limit value is violated. Otherwise, limitvalue display remains until it has been acknowledged with theHold function.

� IN3 Input for synchronous pulse from filter (see Chap. 2.4.2)

2.5.3 Analog output 0/2/4 ... 20 mA

� The selected measured variable is output� Configurable live zero value: 0, 2 or 4mA� Configurable measuring range� Galvanically isolated, max. load 750ohmThe measured value is updated once a second.

2.5.4 Relay outputs

All relays:� changeover contact� max. 250 V peak, max. 1A peak; continuous operation 125 VA AC or

60 W DC; also connected to corresponding LED.

215


Pin 2 (txd)

Pin 3 (rxd)

Pin 5 (gnd)

Pin assignment

Pin 2 (rxd)

Pin 3 (txd)

Pin 5 (gnd)

Pin 3 (rxd)

Pin 2 (txd)

Pin 7 (gnd)

FW 56-I socket Connector (9-pin) Connector (25 pin)

a) Relay 1, limit value� indicates that the limit value has been exceeded� always refers to the selected measuring variable� based on mean values (with intelligent mean value calculation func-

tion)� updated every 20 ms

b) Relay 2, warningindicates alternatively:� that a transmission value has been undershot (can be used as a con-

tamination warning with differential transmission and differential ex-tinction; otherwise to signal a 2nd limit value)

� check cycle active, (automatic with permitted check cycles)� updated every second

c) Relay 3, malfunction� signals a malfunction� error mask in the MEPA can be under menu (diagnosis/test/instru-

ment diagnosis� minimum transmission which leads to an error can be set under

menu Parameters/output parameters (cannot be used for groupalarm with input of 0%)

� also indicates a mains failure� updated every second

ImportantAfter the measuring variable has been set to Measuringmode, the limitvalues are set in such a way as to avoid erasing the limit value (e.g. 0%transmission).The limit value must be entered by the user manually.All of the limit values are monitored with a hysteresis value of 10%.

2.5.5 Serial interface

� RS 232 on 9-pin Sub-D connector on front panel(Important: not galvanically isolated from other circuit componentsand terminal lugs)

� RS 232 also on terminal trip (galvanically isolated)� Remote data transfer possible with additional RS 485/RS 422 module� Data output once a second

216


301

3.1 Preparations for installation, project planning

3 Installation and electrical work

D4AU

=

The measuring point at which the device is to be installed should be lo-cated in the flue duct in such a way as to ensure representative record-ing of transmission across the cross-section of the duct. The optimumpoint is a location with uninterrupted, homogenous dust and velocitydistribution in the duct. Deviations and changes in the cross-section ofthe duct in the immediate vicinity of the FW 56-I may in certain circum-stances have adverse affects on measurements.Settled, undisturbed sections are most likely to be found in long inletand outlet sections. In existing installations, the best possible choiceshould be made. With new installations, the following points should betaken into account at the planning stage:The length of the inlet or outlet section should be at least three timesthe "hydraulic diameter" (therefore a total length of at least six times thehydraulic diameter). With round and square duct cross-sections the hy-draulic diameter and the duct diameter are the same.

If the FW 56-I is to be installed in a plant subject to planning permission,the measuring site must be specified by experts (e.g. by certification of apermitted measuring site according to §§ 26,28 BImSchG). Expert opin-ion should be consulted before planning!

The installation point for the FWA56-I evaluation unit should have mini-mal vibration. Minimalvibration at an installation point means noaccelerations > 1g (gravity) are present. If the acceleration values arehigher than this, the evaluation unit must not be mounted as shown inFig. 3201. It must be mounted at a different point and not in the duct.

If the installation point has excessive vibrations (acceleration > 1g), aspecial, vibration damping variant may have to be installed (all inquiriesto the factory!).

The Filter Watch is attached to the mounting flange which should pref-erably be mounted horizontally in the duct. With other mounting posi-tions, increased contamination of the optical surfaces of the device is tobe expected. The measuring point should be easily accessible, so thatservicing can be carried out without difficulty.Under certain conditions, a mounting flange may not be necessary (seeSection 3.2.2). All of the other installation instructions however, still ap-ply.Mounting in steel ducts is the standard arrangement. Stone chimneys orthick-walled ducts require suitable flange tubes which can either be pro-vided by the customer or designed by SICK.

Comp. VDI 2066 Sheet 1

Inlet and outlet sections

Hydraulic diameter

Designation of the measuring siteby an expert

Installation

A = cross-sectional area

U = circumference

302


0 1 2 3 40,3 0,6 1,4 2,5

Fig. 3101 Permissible measuring distances of the FW 56-I

On request

Safe application range(data acc. to specification)

Attachment must be resistantto vibration and distortion

FWR56-2

FWR56-4

As early as the project planning stage, it is necessary to select the cor-rect size of the mounting flange for the reflector, the purge air attach-ment and the reflector itself. For longer measuring sections, the (larger)components with -4 as the last digit in the designation should be se-lected, and for shorter sections components with -2 as the last digit inthe designation. The exact limits are shown in Fig. 3101; the dimensionsrepresent the clearance between the reflector and the optics of thesender/receiver unit - they are not flange-flange dimensions.

The technical data for the conditions of use and ambient conditionsmust be noted carefully! The ambient temperature at the installationpoint must not exceed 50 °C. If necessary, appropriate measures are to betaken at the installation point in order to reduce the ambient tempera-ture (e.g. insulate heat conducting parts or provide sufficient ventilation).

An external purge air supply (optional) must be provided in installationswith gas temperatures >140 °C and/or pressurized ducts in order to en-sure that the optical surfaces of the sender/receiver unit and the reflec-tor are kept clean. A purge air supply is also required in systems con-taining corrosive gases, irrespective of the temperature and pressurewithin the installation.

A standard ventilator for the purge air supply unit is sufficient for ductpressures of up to 20 mbar. All of the device components must be eas-ily accessible for installation and servicing purposes. (It is advisable to in-stall the measuring device in such a way that it is can be accessed with-out risk, i.e. at a minimum of 1.0 m above the ground or by means of aplatform).

If a purge air supply is used, ensure that the air is supplied from an areawhich is free of dust, oil or humidity. The purge air entering the ductmust not be below the dew point. Heat the purge air if necessary. The

Ambient conditions

Purge air

303


purge air unit should be mounted between the FWM56 sender/receiverunit and the FWR56 reflector unit if possible, in order to ensure that theair flow in both units flows uniformly.

ImportantThe hose lengths of the purge air unit to the S/R and reflector unit mustbe identical!

NoteWith underpressure and temperatures lower than 140°C in the duct,an optionally available filter element (see pt. 7.3) can be connected tothe purge air supports to extend the maintenance intervals. This is par-ticularly advisable in cases where high dust concentrations and/or tem-peratures under the dew point can be found on the optical surfaces.

An electrical connection must be provided for the FWA56-I evaluationunit (115/230V, max. 20W, 50/60Hz). When using a purge air ventila-tor, a connection must be provided in accordance with the electricalload rating of the ventilator motor.The purge air unit must be fitted with a weatherproof cover if it is in-stalled outdoors. A weatherproof cover is also recommended for theFW 56-I sender/receiver unit and evaluation unit.

NoteThe "lance version" of the FW 56-I can be provided under certain con-ditions whereby installation points are only accessible from one side or ifthe duct diameter is greater than the maximum permissible range.Please contact your nearest SICK representative.

304


3.2 Installation

Alternative: retaining bracket

Overshoot with circularcross-section

➊

➋➊

Max. permitted ambient temperature+50 °C,other wise insulation against radiant heat mustbe provided.

The dimension can vary depending on the insu-lation (min. 35mm).

470M8

35

60

50

45300

M5

50

Steel tube

198

212

145

184

470

30021

0

50

Steel tube50 x 5 DIN 2391

Mounting area60 x 60 x 8

DIN 174

Steel tube50 x 5 DIN 2391

Attachment for purge air unit

Stack wall

Mounting plate forFWA56-I evaluation unit:Steel plate, install in a vi-bration and distortion freearea!

➋

➊

Fig. 3201 Overview of installation dimensions for the mounting flange, FWA56-I and purge air unit

Flanges aligned to within 1°Position of

bolts

Externalsurface

InsulationMounting flange

3.2.1 Sequence of installation work

1. Define the measuring point for the S/R unit and the reflector unit.2. Select the installation point for the evaluation unit and the optional

purge air unit (where applicable), as well as for the operating plat-form (see Fig. 3201).

3. Determine the correct size of the flange on the reflector side.4. Determine whether a mounting flange is to be used or whether the

purge air attachments are to be welded in directly - depending onthe selected purge air attachments.

5. Weld on the mounting flange (flange with tube); weld the purge airattachments on directly if a mounting flange is not to be used.

6. Mount the purge air attachments (if mounting flange is available).7. Lay the connection cables.8. Connect the purge air hoses to the purge air unit and switch on the

purge air supply.9. Mount the S/R and reflector units and align them correctly.

10. Switch on the device, check the functions and set the deviceparameters.

in flange areaif weather-proof cover isused

305


Fig. 3202 Overview of installation dimensions

Power supply

Evaluation unitFWA56-I

Purge air glandwith seal

Snap-on lock

ReflectorFW R56

Sight Purge airattachment

Purge airattachment

Distance bet. S/R unit and reflector

Ø 7

0

Ø 7

6

Cup springs

Duct diameter200 -3600 mm Sealing tape

Ø 40

200

Gas duct

Mountingflange

3.2.2 Installation work to be performed by the customer

3.2.2.1 GeneralBefore commencing installation work, determine whether the mountingflange is to be used or whether the purge air flange is to be welded ondirectly.The FWS or FWSE purge air attachments must be aligned accordingly.When doing so, take the following into account:

Standard variants with mounting flanges:� are available in ST or VA steels� are easier to align� are suitable for high gas temperatures� have removable purge air attachments� requires simple welding precision� are compatible with other SICK products (e.g. RM 61/OMD 41)

variants with FWSE:� are less expensive� require less space� have FWSE purge air attachments only available in stainless steel (V4A)� must be precisely aligned when welding within ±0.5°� require S/R housing which can be opened to adjust the FWM56

(can be problematic in environments with high contamination levels)� are not suitable for gas temperatures above 200 °C

Fig. 3202 provides an overview of the most important dimensions

Ø 1

30

Sender/re-ceiverunit FWM56

Minimum distance flange/flange:300 � 3700 mm

Connecting cableLength 3 m

(optionally 10 m)

306

3.2.2.2 Installation with mounting flanges (standard)

� Mark the installation point for the mounting flange, burn out a holeand tack weld the mounting flange. In doing so, ensure that themeasuring distance and dimensions are correct (as shown in Figs.3101 and 3202).

� The axes of the mounting flanges must be aligned precisely to oneanother. Angular deviations of the flange tubes must be less than 2°.The sensitivity to deviation declines (+1%) outside the limits shownin Fig. 3101. If the distance between the FWM56 and FWR56 is >1.4 m, the mounting flange with diameter 70 mm (for FWS-2 purgeair attachment and FWR-2 reflector) can only be used if distortion isruled out and the flange is aligned carefully.


Note:The mounting flanges are also desig-nated "Flange with tube" in the SICKprice lists

Fig. 3203 Optional mounting flanges

M10 x 54

Top

Ø 100

45°45°

Material:ST 37 or1.4571

L1: 60 mm130 mm240 mm500 mm

Ø 130

Ø 7

6

L1

10

90*

M8 x 25

Top

Ø 160

45° 45°

* smallest tube length, for others see Chap. 7

Ø 1

80

Ø 1

08

TOP

307

Otherwise, use the flange with diameter 108 mm (for the FWS-4purge air attachment and FWR-4 reflector)

� To align the flanges to one another use either a tube (see Fig. 3204)or an adjustment device (see Fig. 3205).

� Roughly align the first flange and tack weld it into place.� Align the 2nd flange and tack weld it into place.� Check alignment; the mounting flange must be aligned precisely to

within 2°. Adjust if necessary and weld around the circumference.


Fig. 3204 Alignment of the flange with tube

Fig. 3205 Alignment of the flange with adjustment device

Tube

Duct wallMounting flange

A

A

ReceiverLight source

Mounting flanges

Duct wall

The mounting flange with different tube lengths, and made of steel orstainless steel are available from SICK.

308


Installing the FWS purge air attachment

On the FWR56 reflector unit:� Screw the purge air attachment to the mounting flange securely us-

ing the self-locking M8 brass nuts. Seal the flange connection on theFWR56-2 with tape.

On the purge air attachment of the FWM56 S/R unit :� Fit 4 pairs of cup springs on each of the 3 M8 bolts; at the same time

position the cup springs consecutively in pairs with the crowns facingoutwards so that there is a hollow space between each pair of springs.

� Fit the purge air attachment and tighten it securely with the M8 brassnuts until there is a gap of approx. 6 mm to ensure sufficient pre-stressing.

� Seal the flange with sealing tape.

Fig. 3206 Mounting and aligning the FW 56-I S/R unit

❶❸

❻

❺ ❹

❷

❼

❸ ❹ ❺

Horizontal Point of fixture

Vertical

1 S/R unit with purge air attach-ment2 Mounting flange3 Nut, self-locking4 Sealing tape5 Cup springs6 Sight7 Snap-on fasteners

309


3.2.3 Installing the FWA56-I evaluation unit

The length of the connection cable between the evaluation unit and theS/R unit must be taken into account when installing the evaluation unit.Standard length: 3mOptional: 10m

The FWA56-I evaluation unit must be mounted on a level base, for ex-ample:� On a baseplate 212 x 184 mm, where it is easily accessible and pro-

tected� According to Fig. 3302 when using the optional purge air unit.

Note� Read the Technical Data (see Section 7) and all of the project plan-

ning instructions carefully (see Section 3.1), before selecting the in-stallation point.

� Ensure that the installation point selected is free of vibration!

3.2.2.3 Installing the device with FWSE purge air attachmentwithout a mounting flange

� The FWSE purge air attachment is attached to the duct as shown inFig. 3205.

� The alignment precision of the FWSE purge air attachments must be≤ 0.5°.Note:Use a suitable tube as an alignment aid.

� The dimensions shown in Figs. 3201 and 3202 also apply here.� Install the device as shown in Fig. 3205.

Fig. 3207 Mounting the device with a purge air attachment

Duct wall Purge air hose Cage

Note material pairs with duct wall when weldingPurge air hose consists of 1.4301

200

50

310


3.2.4 Installing the FWM56 S/R unit and FWR56 reflector

Secure the FWM56 to the purge air attachment by means of the snapfasteners. The fasteners must be prestressed so that they can closedwith minimal force (max. 10 N). Align the connected FWM56 in the fol-lowing way:When using mounting flange and FWS purge air attachment:� Tighten the 3 self-locking nuts so that the adjustment cross is centred

in the reflecctor aperture when viewed through the sight on the topof the housing.

Alignment when using the FWSE purge air attachment:� Loosen the 4 screws (accessible from the front side) and carefully

remove the housing lid.� Adjust the unit by following the procedure for the mounting flange

using the 3 adjustment nuts (see Fig. 3208).

After the alignment procedure has been completed, the reflector canbe secured to the purge air attachment using the snap-on fasteners.

Fig. 3208 Adjusting the S/R unit with FWSE purge air attachments

Installation including a purge air deviceRequirementThe purge air supply must be installed and in operation to prevent hot orcorrosive substances penetrating the purge air attachments from the gasduct. Therefore, before installing the FWM56 and the FWR56 check that:� the purge air hoses are securely fixed to the purge air attachment

connectors.� the purge air supply is working and the direction of flow is correct

Install the connected FWM56 and FWR56 as described above and adjust.

See sections 3.3 and 3.4

Adjusting nut (3x)

311


3.3.1 Installing the purge air unit

The purge air unit should be installed close to the measuring site. Thetemperature of intake air must not exceed +50 °C. If necessary, ie. if theintake air has a high dust content, lay an intake line to an area withmore favourable conditions.

3.3 Installing the optional device components

� Secure the base plate of the purge air unit with 4 M8 screws.� Connect the purge air hoses to the connector on the purge air at-

tachments and secure with hose clamps.� If installing the purge air unit outside mount the weatherproof cover.

Ø14 Air filter with integr. prefilter

Fig. 3301 Purge air unit

Terminal boxfor purge airblower

Purge airblower

Under-pressuremonitor

128

258470

550

40Base plate

Purge air outlet(double hoseconnection)

40

40

40

470

550

3.3.2 Installing the weatherproof cover for the purge air unit

The weatherproof cover (see section 7.7) comprises a cover and lock set.

� Set the lock sections into the lock set on the baseplate.� Fit the cover from above.� Insert the lateral retaining bar into the mating sections, turn and al-

low them to engage.

3.3.3 Adding a filter insert

The optionally available filter insert (art. no. 7040182) is connected tothe air outlet on the purge air attachment connectors and secured witha hose clamp.

Comp. section 3.1

312


3.3.4 Installing the weatherproof cover for the FWM andFWA 56-I

A weatherproof cover is advisable if the device is to be installed out-doors or in dirty surroudings. Fig. 3302 shows an installation proposalwith purge air attachments, FWM and FWA56-I.

Fig. 3302 Installing the FW 56-I with weatherproof cover

3.3.5 Removal

It is advisable to remove the filter monitor if the plant is to be shutdown for longer periods of time.It is essential that the FW 56-I be removed if the purge air unit is re-moved from service or if there is a risk of corrosive or hot gases pen-etrating the purge air attachments.WarningToxic gases could escape from the duct when the S/R unit and the re-flector are removed from the flange. Appropriate protective measuresmust be taken!

Procedure� Switch off the device (do not switch off the purge air supply).� Loosen the snap-fasteners on the S/R unit and reflector and remove

the components from the purge air attachment.� If the purge air attachment is to be dismantled; remove the sealing

tape from the flange cup; loosen the self-locking nuts and removethe purge air attachment.

� Turn off the purge air unit.� Loosen the hose clamp on the purge air attachment and take off the

purge air hose. Seal the hose end if it will not be used for a long time.

FWM56 Sender/receiver unit

509

190

OMD 41 Weatherproof coverDuct wall

Purge air adapter

200

188 208

395

160

54

313


3.4 Electrical installation

Fig. 3401 Connecting the 56-I evaluation unit (routing diagram)

0 . .

. 20

mA

2x

0.5m

m2

twis

ted

pair

s, s

cree

ned

N L1 PE

Note:PE is not necessary,as it is not connectedinternally

SICK standard scope of supply

Rel

ay 9

x0.

25 m

m2

RS

232

elec

tric

ally

iso

late

d; b

inar

yin

put

10x

0.25

mm

2Co

nnec

tion

cabl

e 3m

(o

ptio

nal 1

0m)

3x

1.5

mm

2

3.4.2 Electrical installation

3.4.1 Instructions for electrical installation

The installation work and final wiring must be performed by the cus-tomer, unless otherwise agreed with SICK.

Important notes:� A separate, permanent mains supply must be provided for the FWA

56-I evaluation unit and optional purge air unit (see VDE 0411/8.8)and fused separately.

� When using the purge air unit:Install a separate mains isolating switch, or motor protection switch ifpossible, within the vicinity of the measuring devices (see VDE 0411/5.1.2.2.2).

� The signal lines for analog output, binary inputs and relay outputsshould be twisted pairs or screened.With screened cables:Connect screen to earth or PE on installation side.

314


Connecting the FWA56-I evaluation unitThe external connection leads to the evaluation unit must be wired bythe customer, together with the connection cables from the FWA56-Isender/receiver unit to the evaluation unit. If the connection cable istoo long, it can be cut to the required length.

Procedure� Open the terminal box cover on the front panel of the unit.� Insert the connection cable and the connection leads on the installa-

tion side through the PG-connection provided and wire up accord-ing to Fig. 3402.

� Check whether the voltage selector switch setting corresponds withthe mains voltage; if necessary, remove the front panel and correctthe selector switch (default setting 230 V).

Fig. 3402 FW 56-I Connection diagram

~=

+

+

~=

Connections 11 to 14 are switched externally

mains power supply (115V/230V: opt. 24V)

Digital output: limit value

Digital output: maintenance

Digital output: operation/malfunction

FWA

56-I

Eva

luat

ion

unit

Rel

ay 3

Rel

ay 2

Rel

ay 1

Temp.

Meas.

Mon.

+12V

12V -

115/

230V

Si 1

Si 2

2 x T125mAPE

L1 (+24V)N (- 24V)

n.c.n.o.c.n.c.n.o.c.n.o.n.c.c.25

2627

293031

3332

28

24

2221201918

16

anal

ogue

bina

ry in

puts

outp

utin

1in

4in

3in

2

galv. isol.

23

1514

1213

1110987654321

gndtempgnd

gndmon- 12V+12V-

gnd+ired

in 1gnd

in 2gndin 3gndin 4

+gnd

txdgndrxd

0-20

mA

maintenance

limit value

used

used

not

Meas

Mon.- 12V

+12V

scre

en

greypinkbrownwhite

yellow

blue

green

-

FWM56 Sender /receiver unit

gnd grey meas pink gnd brownmon white- 12V blue+12V red

+ired yellow

temp

gnd

17

meas

red

acknowledge

used

not

not

green

315Fig. 3403 Electrical connection of ventilator motors and underpressure monitor

Motor circuit breaker

Customer installation

Ventilator motor indelta connection

Ventilator motorin star connection

Underpressure monitor

3.4.3 Electrical installation of the purge air unit

The electrical connection of the purge air ventilator should be carriedout according to Fig. 3403.

� Connect the purge air motor according to the values in the terminalbox. Note carefully the direction of movement.

� Turn on the motor and check the direction of rotation.NoteThe correct direction of rotation is indicated by an arrow on thefront of the ventilator.

� Check the operation of the motor protection switch (if installed) andbe set to a current value equal to 10% greater than the nominal cur-rent according to the connection information for the ventilator.

� Connect the underpressure monitor and check its operation.

WarningThe mains voltage and frequency must correspond to the values shownon the rating plate.The links on the terminal board must be laid out asshown on the circuit diagram.

316

3.5 Removal

If the device is only left idle temporarily, mark the leads and note the as-signment and colour codes.

The following VDE safety instructions must be noted:� When removing the unit, ensure that live components are not ac-

cessible without appropriate protection.� Always insulate the cable ends and protect them from dirt and water

in a suitable way.� Switches which must not be activated for safety reasons must be

marked as such with a sign and protected by means of switch barri-ers.

401

4 Commissioning and parameterization

4.1 Preparations for commissioning

4.1.1 Authorized access

When the FW 56-I is used as a performance-tested measuring system,access to certain functions must be restricted in order to prevent ma-nipulation of the measuring results as a result of unauthorized modifica-tions to the parameters. Access to these functions can be restricted bychanging the default password (see Section 4.4.2 for entering and modi-fying the password). The password is freely definable (max. 8 characters).New passwords are only activated after they have been entered twice.When the default password is modified, access to the� Calibration� Check cyclefunctions is no longer possible with the result that the evaluation unitcannot be called via the keypad on the front panel. (This can be resetby entering the master password).

The user or authorized measuring centre for testing and controlling themeasuring instrument, as defined in para. 26 and 28 of the BlmSchG, isresponsible for password administration and not the device manufac-turer (SICK).

The device parameters cannot be modified if the new passwords arelost. Modified passwords can only be deactivated at the factory (devicemust be sent to the factory).

4.1.2 Overview of commissioning work

Requirements for commissioning� Zero point reference section available (see 4.2)� Installation has been performed in accordance with Chapter 3

Commissioning work� Clean the optical surfaces� Set up of the zero point reference section� Set FWM56 - FWR56 distance� Align the FWM56 S/R unit with the FWR56 reflector by aligning the

zero tubes� Switch on the power supply for the FWA56-I� Connect PC (Laptop) via RS 232 interface cable and start MEPA56I

program, (call menu option "Connection")� Allow the device to operate undisturbed for approx. 30 min. (at least

10 min.)� Check the gain setting� Adjust the FW 56-I to 100% -transmission (calibrate)� Check analog input, binary inputs and relay outputs� Set parameters with MEPA56I� Check FWM56 alignment� Remove FWM56 from zero point reference section and mount purge

air hose (if necessary) and switch on purge air ventilator

402


4.2 Setting the S/R unit

Setting up the zero point reference sectionThe zero point reference section is the smoke-free, emission-free re-production of the measuring section and is used:� for checking purposes at regular intervals by trained and qualified

personnel or official experts� for adjusting the FW 56-I to the precise measuring section (calibra-

tion to 100% transmission)

The zero point reference section must fulfil the following conditions:� The distance between the optical surfaces of the S/R unit and the re-

flector is identical to the measuring section for the zero point refer-ence section (±1%).

� The active measuring volume is free of smoke and dust.� Suitable means of fastening (as on the purge air attachments) are

provided at the ends of the zero point reference section:for FWM56 and FWR56-2: tube with diameter

76.1 x 2.0 (2.6)mmfor FWR56-4: tube with diameter

133.0 x 2.0 (2.6)mm

The zero point reference section can be implemented with the "adjust-ment mounts for zero point setting" included in the optional supplyitems. The length of the connection cable must be taken into accountwhen setting up the zero point reference section.The S/R unit and reflector can be secured to the adjustment mounts us-ing the quick-action seals.

Gain settingAll of the FW 56-I devices are set for a standard FWM56 - FWR56 dis-tance of 0.8 m at the factory. If a greater distance is selected, there is areduction in the light signal in the measuring channel. The transmission,which is reduced as a result, is naturally reset to 100%, however the re-duction in the useful signal level has an adverse effect on the resolutionand the signal-to-noise ratio of the device at greater distances. If themaximum sensitivity of the FW 56-I is required, it is advisable tooptimize the gain of the measuring channel to compensate for this dy-namic loss.

� Secure FWM56 to purge air attachment� Remove FWR56 reflector from zero point reference section and in-

stall purge air hose (if necessary).� Secure FWR56 to purge air attachment� Check device statuses (measuring values and status) for meaningful

values and rectify faults or change parameters as necessary� Reset maintenance mode if set� Close covers, fit protective covers

403


Changing the gain setting:� Remove the housing cover of the FWM56 S/R unit� Check the setting with the MEPA56I program:

In the menu option "Diagnosis/Test functions/Analog inputs",select "Actual" switch; see 4.2.7

The layout of the p.c.b. of the S/R unit when the unit is opened is shownin Fig. 4101. The block S1 contains the DIP switches.

The gain setting is optimum when the "MONITOR CHANNEL toMEASURING CHANNEL� ratio is between 0.7 and 1.3.If the ratio is >1.3, one of the DIP switches must be switched off. Checkthe setting again until the condition above is fulfilled or all of the 4 DIPswitches are set to "OFF".The gain adjustment procedure must be performed in reverse order ifthe ratio "MONITOR CHANNEL to MEASURING CHANNEL� is < 0.7.

The FW 65-I must be recalibrated each time the gain is corrected, see4.3 (first allow the device to operate undisturbed for 10 minutes).

Fig. 4101 Printed-circuit board of the S/R unit

404


4.4 Parameterization with MEPA56I

4.3 Calibration

The calibration procedure sets the transmission value to 100% (transmit-ted light not attenuated). The automatic calibration procedure for theFW 56-I can be triggered as follows:

1. On the FWA56-I evaluation unit:� Press SET button 4x� Acknowledge "set reference" query with ↵� Acknowledge "opt. path clear" query with ↵

2. With the MEPA56I program: select the "Set reference" button in the"Other/Set reference" menu.

NoteThe measuring section must be completely free of dust.

NoteThe measuring range and limit values can be set as described inChap. 4.4.4.

4.4.1 General

The MEPA56I MEnu-driven PArameterization program is a convenient,user-friendly method for defining the parameters for the FW 56-I via aPC.

RequirementsAn IBM-compatible PC, e.g. notebook (286 or higher, minimum 640 kBRAM, VGA mode 640 x 480 pixel, DOS 3.1 or higher) with a serial portand interface cable to the device is recommended.

The MEPA56I runs under DOS (cannot be started under Windows) andrequires approx. 465 kbytes of main memory.

� Install the MEPA56I:Copy all of the files from the program disk to the hard disk of your PC.

� Start MEPA56I:Enter MEPA56I; then confirm the initial screen with <ENTER>The main menu with menu bar, desktop and status bar is then dis-played on the screen.

NoteMany of the settings can only be made if or when:� the correct interface has been selected� a connection to the device has been established� the password has been entered

The filter box, available asan accessory (see section7.3), can be inserted tocheck the line.

405


SICK AG

Fig. 4301 Main menu of MEPA56

NoteIt is advisable to store changes to the standard settings and any otherchanges in a current device file (xxx.buf) (see Section 4.4.2). This filemust then loaded immediately if an error occurs (i.e. before all other ac-tions).The active menu options can be selected with the keyboard or mousewithout entering the password. The dimmed options can only beaccessed after the password has been entered.There are three types of field in the menu options of the MEPA56I pro-gram:

� Input fields: for entering texts or values

� Option fields: for selecting functions• (x) function active• ( ) function inactive

� Selection fields: "OK" • exit the menu and save newvalues;

• confirm a message"CANCEL" • exit the menu without saving the

new values"CURRENT" • update a display

The factory-set parameters arelisted in the device protocol (foundin the cover of the evaluation uniton delivery)

406


The following short-cuts are implemented throughout the program

Call help text (online) implemented in pro-gram

Jump to an active field within a window

Open the main menu;activate the corresponding function

Activate a submenu or the correspondingfunction

Confirm the input

Activate or deactivate function in selectionfield

Exit the menu;

Quit program

<F1>

Tab

<ALT> and<highlighted letter> (hotkey) in menu

Highlighted letter(hotkey)

<ENTER>

<Spacebar>

<Esc> or<ALT> and <F3>

<ALT> and <X>

Note:A comprehensive help function can be called in the program by press-ing the F1 key.The hotkeys can be entered as either upper or lower-case letters.The key combinations listed in the following sections refer to the firstmenu display (Fig. 4301).The key combination <ALT> and switches to the second menulevel which contains additional functions which can only be accessedhere.

Keys Function

407


4.4.2 Default settings of the MEPA56I

Select Option/Language option and set language

Select Option/Selection of serial interface optionand select COM1 or COM2

Connection option; the data stored in the FW 56-Iand the current data are read in

Unit data/other;The password must be entered to:• modify the device parameters• enter a new password

Select Change option (in Password option);Enter new password again to activate it and confirm

Unit data/other/set reference option; calibrate tosmoke-free measuring section; the current transmis-sion value is set to 100% (first allow the device to op-erate undisturbed for 10 minutes)

Unit data/data transfer/block transport com-mand

Data is loaded from the FW 56-I to the MEPA56I

Data is written from the MEPA56I memory to FW 56-I

Data is loaded from disk to MEPA56I memory

Data is written from the MEPA56I memory to disk

<ALT> and <O> keysfollowed by <L>

<ALT> and <O> keysfollowed by <S>

<ALT> and <C> keysfollowed by <O>

F9 key password or<ALT> and fol-lowed by <ALT> and<O> and then .

as above, then <ALT>and <C>

<ALT> and keysfollowed by<ALT> and <O> keysand then <R>

<ALT> and keysfollowed by <ALT> and<D> and then 

<L>

<S>

<A>

<T>

Language

Select serial interface

Connect toFW 56

Password• Enter

• Modify

Calibration

Save and load devicedata

Setting Key combination Explanation

4.4.2 Basic settings of the MEPA 564.4.3 Selecting the measuring variable and storage mode


<ALT> and keys followed by <ALT>and and then <M>

Evaluation mode Unit data/mode of evaluation optionSelect Save meas. data or Filter mode 1 (intelli-gent mean value calculation);with Save meas. data:Select time between two stored values;(= averaging time)with Filter mode 1:Enter weighting factor (= value with which the newmeasuring value is included in mean value calculation)Note: differential transmission is set automatically withFilter mode 1.Warning: the measuring value memory is clearedeach time a new value is selected.

408



Unit data/parameters/signal calculationSelect one of the options: transmission, diff. transmis-sion, opacity, extinction, diff. extinction and dust con-centration with the cursor keys. The selected variableis shown on the display and output at the analog out-put. The following data format is output on the RS 232interface, depending on the setting:Diff. Trans.: Diff. Trans StatusTransmission: Trans. current(mA) StatusOpacity: Opac.current(mA) StatusExtinction: Ext. current(mA) StatusDust conc.: Conc. Ext. or current StatusDiff. Ext. * 1000 Diff. E. Trans StatusSee Chap. 2.5 for status codesSet the response time parameter (s) (t

90 time) (dust

concentration setting, see below)

Unit data/parameters/signal calculationSelect the basis for calculating the dust concentration,extinction or differential extinction;Select the response time;Enter the coefficients;Note: the coefficients must be determined by meansof a gravimetric reference measurement, as standard.Set the quadratic coefficient to 0 when using linear re-gression.

<ALT> and keys<ALT> and keys fol-lowed by <S>

and then 

<ALT> and keys

<ALT> and keys

followed by <S>and 

Select measuring vari-able

Define the parametersfor the dust concentra-tion setting


Analog output

Limit values

<ALT> and keys,<ALT> and keys,<O>

<ALT> and keys,<ALT> and keys<O><L>

Unit data/parameters/output parametersSet live zero to 0, 2 or 4mAAssign the measuring values associated with live zeroor 20 mA to the defined measuring variable.

Unit data/parameters/output parametersSet the desired value at which the limit value relaysand LED are activated.Direction:with transmission - value falls below set value;with differential transmission, opacity, extinction, dustconcentration - response when set value exceeded;

4.4.4 Defining the output variables

409


Warning and errors

t90 time

Check cycle


<ALT> and keys,<ALT> and keys,<O><W>

<ALT> and <G> keys,<ALT> and keys,<O><M>

<ALT> and keys<ALT> and keys, <S>, 

<ALT> and keys<ALT> and <O> keys,<C>

<S>

Unit data/parameters/output parametersValue based on transmission below which a warning istriggered (e.g. contamination);

Value based on transmission below which an errormessage is generated;

Unit data/parameters/signal calculationTime constant which determines the smoothing extentand thus the response time of the device (see Chap.2.3.5 for an explanation)

Unit data/other/check cycle optionSelect yes/no to define whether a check cycle is to beperformed (see Chap. 2.3.7)If <YES> is selected, the interval between two con-secutive cycles must be entered.A cycle is triggered immediately (only if permitted!)

<ALT> and <V> keys fol-lowed by <O>

<ALT> and <V> keys,followed by <S>


Continuous output ofmeasuring values forcurrent settings

Continuous output ofmeasuring values forcurrent settings;additional storage todisk

View/output of measured data;Column 1: defined measuring variableColumn 2: calculated current in mAColumn 3: status2xx.xx limit value violation1xx.xx recorded limit value violation (hold limit value)x2x.xx service statusxx1. from group malfunction000.00 OK

View/storage of measured data;Backup the output values to an additional file; the filename is freely definable. An hourly memory capacityof 90Kbytes must be available. The MEPA switches toDisplay mode. The storage function is terminatedwhen Display mode is exited. The data is stored inASCII format and can be displayed and printed withany editor (e.g. DOS editor).

4.4.5 Display functions and graphics display

410



Display table of meas-uring values stored inthe FW 56-I

Display measuring val-ues stored in a file ingraphics form

Display events in table

<ALT> and keys,<ALT> and <A> keys,<V>

<A>

<L><O><S><C>

<ALT> and keys<ALT> and <A> keys,followed by <V> and<G> keysF1F2→←ESC

<ALT> and keys,<ALT> and <A> keys,<E>

<A><L><O><S><C>

Unit data/evaluation/values optionThe measuring values are first transferred to the MEPAvia the serial interfaces (max. 1 minute):The defined measuring value is then displayed with thedate and time.ImportantThe most recent measuring value is displayed first (topleft). Interruptions in the measuring sequence due to amains failure or defect are indicated by means of dots.

Read in current values; press ESC to interrupt!

Clear measuring value memoryOpen file from diskSave file to diskPrint the table displayedCancel

Unit data/evaluation/values/graphic optionThe measuring values, which must first be stored to afile, are displayed in graphics form (see previous sec-tion)Select high resolution displayLow resolution displayNext windowPrevious windowBack

Unit data/evaluation/event optionAll of the events are output in a table with the dateand time. The following events are displayed:Limit value (lim)Warning (warn)Malfunction (malf)Maintenance (main)Write to EEPROM (EEPR) due to parameter changesMains failure (pow)Calibration (norm)Erase event memory (clear)+ indicates the start of an event- indicates the end of an event or that an event hasnot occurred.Read in current values again; Press ESC to interruptErase measuring value memoryOpen file from diskStore file to diskPrint the table displayedCancel

411


Unit data/print/print instrument protocoloption;Output the parameterization data on any printer

Unit data/print/save instrument protocoloption;

Output the log to a freely selectable text file

Unit data/other option;FW 56-I can be set to maintenance status (reset be-fore program is exited)

Print instrument proto-col

Save instrument proto-col

Maintenance switchON/OFF


4.4.6 Others/options

Plant details

Registration

Synchronisation

Colors

Save colors

Set FW56-time

Unit data/other/plant details option; the installa-tion site and commissioning date can be entered

Unit data/other/registration option (purely in-formative);Device no.: FWM56 revision

Unit data/other/synchronisation option; the FW56-I can be synchronised with the internal clock fre-quency or the mains frequency(improved spurious signal suppression!)

Options/colors option; all of the color settings forthe screen display can be freely defined.

Options/save colours option;The current screen colour setting is saved. This coloursetting can be read in automatically when the programis started by saving the setting under the nameMEPA56.DSK.

Unit data/other/set FW56-time optionWhen this option is called, the date and time stored inthe FW 56-I are displayed.The PC time (time setting in laptop) is set in the sys-tem. The time and date entries in the input fields canbe overwritten. The new values are stored in the sys-tem; the internal FW 56-I clock is set.

<ALT> and keys<ALT> and <O> keys and <D>

<ALT> and keys<ALT> and <O> keysand <G>

<ALT> and keys<ALT> and <O> keysand <S>

<ALT> and <O> keysand <C>

<ALT> and <O> keysand <A>

<ALT> and keys<ALT> and <O> keys,<T><S>

<ALT> and keysfollowed by<ALT> and <R> keysand 

<ALT> and keysfollowed by<ALT> and <R> keysand <S>

<ALT> and keys<ALT> and <O> keysand <M>

412


<ALT> and <D> keysand <T><O>

<E>

<ALT> and <D> keys,, <M>

<A><R>

Diagnosis/test functions/output function option;check the relays and LEDs with the "Test" button. Theanalog outputs for the transmit LED and current canbe assigned a selected value. The Measuring mode ofthe FW 56-I is interrupted; the input is made with thetabulator key; select with spacebar;The A/D values of the ADC channels can be displayeddirectly.

Malfunction displays and definition of the error maskwhich triggers a group malfunction. The top 7 errorsources trigger a mandatory group alarm and cannotbe edited.The current malfunctions are displayed in the "current"column; the malfunctions which occurred since the lastreset are displayed in the "hold" column.Read in current values againReset stored malfunctions

4.4.7 Test and diagnosis functions

Test and monitoringfunctions; digital andanalog outputs

Monitoring errorsError mask setting


4.5 Settings via the keypad on the front panel

Only the most important control functions, i.e. those that are usedmost frequently, can be called up via the keys on the front panel ofthe FWA 56-I evaluation unit. All of the parameters are set with theMEPA56I program.

� Calibration (set reference)� Activate check cycle (check cycle on/off)� Set maintenance status (maintenance on/off)� Output live zero at analog output (live zero on/off)� Output full scale value at analog output (full scale on/off)

Press the Set button repeatedly until the corresponding value appearson the display.This function is activated by pressing ↵.

501

5 Servicing and maintenance

The FW 56-I Dust Monitor is designed for almost maintenance-free op-eration over a long period of time. The maintenance interval is a mini-mum of 4 weeks. Longer intervals are also possible with many applica-tions. The regular maintenance work is restricted to checking whetherthe optical surfaces are clean, cleaning these surfaces if necessary andadjusting the device. A continuous reduction in the displayed transmis-sion or an increase in the opacity or extinction is an indication that theoptical surfaces require cleaning.The maintenance switch can be set on the hardware side - via the bi-nary input IN1 or with the buttons on the front panel - as well as on thesoftware side (via the MEPA56I; "Other" menu). All error messages,warnings and malfunction signals are suppressed while the maintenanceswitch is set. A current of 0.5 mA is output at the analog output whilethe device status is set to "Maintenance". The components of the

5.1 General

5.2 Cleaning the optical surfaces of the FWM56 and the FWR56

The optical surface is either theside of the optical system whichfaces the duct, or the lens surface.

The optical surfaces should be cleaned at regular intervals. The length ofthe interval depends on the installation conditions and is normally be-tween 8 and 26 weeks.At the latest, the optical surfaces must be cleaned when the maximumpermitted level of dirt is reached. The dirt limit can be entered as a"Maintenance" limit value during parametrization at the time of installa-tion.

Procedure� Clean, new SICK optical cloths, pure alcohol and distilled water are

required. Do not use spirit!� Loosen the snap fasteners on the sender/receiver unit or the reflec-

tor unit and remove it carefully from the purge air attachment.� Blow the loose dust away from the optical surfaces, moisten the

SICK optical cloths with alcohol and clean the optical sytem carefully.Let the alcohol dry and polish with a dry cloth. Rinse with distilledwater.

� Remount the FWM56 and the FWR56 carefully onto the purge airattachments and secure the snap fasteners.

� Reset the Maintenance mode . If the dirt limit value is still exceeded,repeat the cleaning procedure.

� Recalibrate the measuring device (see section 4.3)

502


5.3 Maintenance of the optional purge air unit

FWM56 and FWR 56 can then be removed easily and cleaned with asuitable cleaning agent (water or alcohol) and the glass panels with alint-free cloth.Maintenance work on the purge air unit essentially involves cleaning thefilter housing and replacing the filter insert. It is not possible to specify ageneral idle time as the dust load depends on the respective installation.The operator must ensure that the purge air system is maintained atsuitable intervals. We recommend that you inspect the purge air unit atshorter intervals (1 to 2 weeks) initially after it is commissioned and thenoptimize the maintenance intervals accordingly after the system hasbeen in operation for a longer period of time.Servicing the purge air unit must be done at the latest, when the under-pressure monitor on the intake air flange comes on.

5.3.1 Inspection work

� Check the ventilator regularly for bearing noise; excessive noise is anindication of a possible ventilator failure

� Check all of the hoses to ensure that they sit securely and are freeof damage

� Check the filter insert for dirt. If it is very dirty the filter insert shouldbe removed, the filter housing should be cleaned and a new filter in-sert put in.

5.3.2 Changing the filter insert

ImportantWhen performing maintenance work on the purge air unit, cover theintake air flange (do not seal it) in such a way that no foreign bodies canenter it (danger of irreparable damage to the ventilator).During this time, the purge air entering the purge air attachments isunfiltered.

Procedure� Set the FW 56-I to Maintenance mode� Prepare a new filter insert (2)� Loosen the hose clamp (6) to remove the purge air hose (7) at the

intake flange and secure it in a clean place.� Wipe the filter housing (1) clean of dust.� Take off the filter housing cover (3) by releasing the snap fasteners (4).� Remove the filter insert (2) by twisting it in an anti-clockwise direction.� Clean the filter housing and its cover with a cloth and a brush.

ImportantOnly use a dampened cloth for wet cleaning. Dry the housing care-fully.

503


1 Filter housing2 Filter insert3 Filter housing cover4 Snap fasteners5 Air intake attachments6 Hose clamp7 Purge air hose8 Hose clamp9 Underpressure monitor

❶ ❷ ❸ ❹

❺❻❼

❾

❽

Fig. 5301 Maintenance work on the purge air unit

� Fit the new filter insert by twisting it in a clockwise direction.� Refit the filter housing cover, checking the alignment of the housing� Check that the snap fasteners are correctly positioned� Secure the purge air hoses to the intake flange with hose clamps.

After completion of the maintenance work on the purge air unit, cleanthe optical surfaces of the sender/receiver unit and the reflector and re-turn to Measuring mode (Reset the Maintenance status).

504


601

6 Troubleshooting

6.1 Testing the I/O functions

6.1.1 Troubleshooting

The green Operation LED on the front of the FWA56-I evaluationunit lights up continuously while the FW 56-I Dust Monitor is inMeasuring mode. The FW 56-I outputs a group alarm if a malfunctionoccurs; the following statuses can occur (analysis via MEPA56I,Diagnosis/test/instrument diagnosis option):

Error message Possible cause Remedy

• No LEDs lit• No display• No measuring value output

• Red Malfunction LED lights up• Relay 3 (malfunction) activated• With MEPA56I:

output the malfunction bits andindividual malfunctions in the 4thcolumn ("Status") via RS 232

• With MEPA56I:output individual malfunction bitsin the Diagnosis/instrumentdiagnosis/malfunctionreports option

Fuse defective

Limit violation:• Transmission:

fall below the thresholdvalue "Malfunction withtransmission" set in theMEPA.

• Differential transmission,opacity, extinction, dustconcentration:limit value defined inMEPA exceeded.

Memory error:error reading parametervalues from the EEPROM inthe FW 56-I (checksumerror)

Error transferring data via theserial interface (interfaceerror)

• Disconnect unit from power supply• Remove terminal pad lid and front

panel• Remove defective fuse• Insert new fuse, valueT 125 mA

5 x 20 mm

• Check optical surfaces on FWM56S/R unit and FWR56 reflector unitfor contamination; clean if necessary(see Chapter 5.1).

• Check system lead connections onthe FWM56 S/R unit - FWA56-Ievaluation unit and the lead itself fordamage or defects; repair if necessary

• Check the alignment of the FWM56S/R unit and the FWR56 reflectorunit; realign them if necessary(see Chapter 3.2.2).

• With MEPA56:Read the parameterization datafrom the system disk to the memory(EEPROM) via the Unit data/datatransfer/block transferinstructions/data menu(see Chapter 4.2.2).

• On the FWA56-I evaluation unit:check the interface cableconnection (RS 232)

• On laptop with MEPA56I:check the interface setting (COM1or COM2) and correct if necessary(see Chapter 4.2.2).

• Repeat transfer.

602

6 Troubleshooting

Error message Possible cause Remedy

• Relay 3 (malfunction) active• Red Malfunction LED lights up

• EEPROM error

Measuring range exceededwith analog output

External synchronisationerror (mainssynchronisation), excessivemains disturbance

Implausible light intensityreceived in monitoring ductand measuring duct (bit 1 ... 5)

Data transfer incomplete dueto power failure

• Check analog output,e.g.: with meauring range 50 ... 100%,the transmission is >100% or <50%

• Increase measuring range• With MEPA56I:

clear error bit in Diagnosis/instrument diagnosis/mal-function reports option in the"Err. mask" column.

• Switch to internal synchronisation;clear error bit in the Diagnosis/instrument diagnosis/mal-function reports option in the"Err. mask" column (bit 8).

• Check electrical connectionsbetween FWM56 and FWA56-I

• Check adjustment• Check for contamination.

• Connection option• Then load device data (via unit

data/data transfer/blocktransfer instructions option;see Section 4.4.2)

If the limit value is set to 0% with the MEPA program, a malfunctionmessage is not generated at 0% transmission. All of the other individualmalfunctions which have occurred are displayed in the "Diagnosis/instrument diagnosis/malfunction reports" option of the MEPAprogram. It is also possible to block individual malfunctions so that agroup malfunction is not output when these individual malfunctionsoccur.

ResetThe printed-circuit board of the evaluation unit also contains a "Reset"button. This button is used to reset the device to its original status. Thiscan also be performed with a "Power-On Reset" after an interruptionin the power supply. In normal operation, it is not necessary to actuatethe "Reset" button. However, if malfunctions occur in the evaluationelectronics as a result of external influences, a watchdog circuitintegrated in the processor triggers a reset automatically after approx.200 ms. After it has been reset, the device requires approx. 2 minutesbefore stable operating condition is reached.

603

6 Troubleshooting

Parameter memory (EEPROM)An EEPROM is integrated in the evaluation electronics for storing thedevice parameters and calibration values of each FW 56. This memoryalso retains the stored information reliably in the event of a powerfailure. The values in the parameter memory can be read andrewritten with the control program and are therefore available at alltimes. The parameters contained in the EEPROM, as defined at thefactory, are also stored in the file "jjww87nn.buf" on the disk supplied.This file can be read in via the MEPA program and written to theEEPROM if necessary.

yy . . . Year of manufactureww . . . Week of manufacturenn . . . Serial no.

The file name is identical to the device no.

604

6 Troubleshooting

701

7 Technical data

Measuring variables

� Transmission, opacity 0 ... 100%� Differential transmission 0 ... 100%� Extinction 0 ... 0.3 up to 0 ... 1.5� Dust concentration 0 ... 20mg/m3 actual; bis 0 ... 100g/m3 actual;

Response time 0.1 ... 120 s freely adjustable

Precision

� Transmission ±0.4%� Opacity ±0.4%� Differential transmission ±0.04%, (with a reponse time of t

90≥ 10 s)

� Extinction ±0.002� Differential extinction ±0.0002 (with a response time of t90 ≥ 10 s)

Displays

2-line LC-display display of measured variables, measuring values, errorsLED displays� LED 4, operation (green) operation� LED 3, malfunction (red) collective fault� LED 2, warning (yellow) warning or check cycle� LED 1, limit value (red) limit value

Installation

Duct diameter 0.2 ... 3.6m, (larger on request)Offset range max. ±1%

Duct pressure ±20mbar; (higher on request)Gas temperature 0 ... 250 °C; (higher on request)Ambient temperature - 20 ... +50 °CProtection grade IP65

Purge air supply� without purge air unit for gas temperatures <140 °C, underpressure, non-corrosive gases� with purge air unit for gas temperatures >140 °C and/or overpressure or corrosive gases

Dimensions, weights

FWM56 sender/receiver unit 80 x 80 x 120mm;cast aluminium housing; weight: 0.8 kgFWR56-2 reflector Æ 80 x 34 mm; cast aluminium housing; weight: 0.35 kgFWA56 evaluation unit 240 x 200 x 120mm; polycarbonate housing; weight: 1.5 kg

FWS-2 purge air unit for FWM56and FWR56 V2A tube Æ 76 mm; length: 200 mm; weight: 1 kg

FWS-4 purge air unit for FW56-4 V2A tube Æ 133 mm; length: 300 mm; weight: 3.75 kg

7.1 Overview of technical data

Measuring ranges are freely selectable

702

7 Technical data

Output signals

Analog output 0�20mA; live zero 2 or 4 mA optional, max. load 750 Ohm(galv. isolated from all other circuit components!)

Floating relay contacts max. 250V; max. 1A; 125VA AC bzw. 60W DC� Limit value set measuring variables freely configurable� Warning/check cycle 0 ... 100% transmission variable or check cycle� Operation/malfunction group malfunction

Binary inputs

� Maintenance (IN1) Suppression of all relay and LED signals and 0.5 A output on currentoutput

� Limit value acknowledge (IN2) Acknowledgement of displayed limit value; if set constantly, the limitvalue display is reset automatically when the limit value conditions areno longer present

� Synchronisation signal (IN3) For synchronisation with the dedusting cycles for Filter Mode 1� High-Speed-Mode (IN4) To control the High-Speed-Mode

Interfaces

RS 232 serial interface for parameterization with MEPA56DM;9600 baud, 1 start bit, 8 data bits, 1 stop bit, no parity bits

� with 9-pin SUB-D connectors;� to mains power (galv. isolated from all other circut components)

RS 422/485 (optional) can be implemented with additional module

Power supply

Voltage supply for FWA56-I� standard 90 ... 140V AC; 50/60Hz oder 190 ... 260V AC; 50/60 Hz� optional 24V DC

Voltage supply for FWM56 via FWA56-I, ±12VPower consumption typical 10 W, max. 20WProtection class 2

Purge air unit (optional)

Component parts baseplate, air filter, purge air blower, Y-tube, underpressure monitorPower range 200...240 V / 345...415 V at 50 Hz; 220...275 V / 380...480 V at 60 HzRated voltage 2.6 A / Y 1.5 A

Motor power 0.37 kW at 50 Hz; 0.45 kW at 60 HzBearing capacity max. 63 m³/h; 48 m³/h with 30 mbar against-flow

Ambient temperature -20 ... +55 °CProtection class IP 54, insulation class FHose connections Ø 40 mm

Dimensions, weights 550 x 550 x 270 mm; weight 14 kg

(non-floating) must be connected via floating contacts!

703

7 Technical data

7.3 Consumables for 2-yeDesignation Order number

Mounting flange with ST37 tube for FWS56-2, length 60mm (standard design) 2 017 843Mounting flange with ST37 tube for FWS56-4, length 100mm (standard design) 7 040 128Mounting flange with V4A tube for FWS56-2, length 60mm 2 017 844Mounting flange with ST37 tube for FWS56-2, length 130mm 2 017 845Mounting flange with V4A tube for FWS56-2, length 130mm 2 017 846Mounting flange with ST37 tube for FWS56-2, length 240mm 2 017 847Mounting flange with V4A tube for FWS56-2, length 240mm 2 017 848Mounting flange with ST37 tube for FWS56-2, length 500mm 2 017 849Mounting flange with V4A tube for FWS56-2, length 500mm 2 017 850Mounting flange with ST37 tube for FWS56-4, length 200mm 7 040 137Mounting flange with V4A tube for FWS56-4, length 100mm 7 040 138Mounting flange with V4A tube for FWS56-4, length 200mm 7 040 139Alignment bracket for zero-point setting - FWM56 and FWR56-2 7 040 131Alignment bracket for zero-point setting - FWR56-4 7 040 156RS 232 serial interface 7 040 012Purge air unit with ventilator, Y-tube, air filter, 5m purge air hose 1 012 424and underpressure monitorWeatherproof cover for purge air unit (for outdoor installation) 5 306 108FWA56-I connection unit, operating power 24 V DC 7 040 165FWM56 sender/receiver unit with 10 m connection cable 7 040 175Filter element model no. ECD 04-5003 7 040 182FW 56 Filter box 7 040 207

7.3 Options, accessories

Designation Quantity Order number

FWM56 sender/receiver unit with cable length 3 m 1 7 040 120

FWR56-2 reflector 1 7 040 121

FWA56-I evaluation unit 1 7 040 158

Purge air attachment 2 7 040 124

Flange with ST37 tube for FWS56-2, length 60mm 2 2 017 843

7.2 FW 56-I Standard

704

7 Technical data

7.6 FW 56-I diagrams (to scale)

80

Fig. 7601 Sender/receiver unit

Designation Quantity Order number

Mico-Topelement * filter insert 4 5 306 091

7.4 Consumables for 2-year operation

* only for use with optional purge air unit

7.5 Spare parts

Designation Order number

Connection cable FWM56 � FWA56-I, length 3m 7 040 142Connection cable FWM56 � FWA56-I, length 10m 7 040 143FWA56-I electronic board with analogue output 7 040 163Optic carrier and electronic board for FWM56 7 040 147Housing for optic carrier and FWM56 electronic board 7 040 148RCP2000 Housing for FWA56-I 7 042 031Electronic board for FW 56-I display 7 040 150FW 56-I front panel 7 040 152Hose tape for sealing the flange 7 040 141Purge air hose DN 40; up to 120°C 5 304 683

15 80

12

0

50

23

705

7 Technical data

Fig. 7603 FWA56 evaluation unit

Fig. 7604 FWS56 purge air attachment

10610CoverHinge

184

124

29

59

Terminalspacecover212

Fig. 7602 FWR56-2 Reflector

Seal

Ø 8

0

Ø 6

9

14 20

60Ø 40

L

5

10

D4

D2

D1

Diameter FWS56-2 FWS56-4

D1 76 mm 133 mmD2 56 mm 101 mmD3 100 mm 160 mmD4 126 mm 179 mm

L 200 mm 300 mm

D3

706

7 Technical data

7.7 Diagram of purge air unit (to scale)

Underpressuremonitor

Purge airblower

Terminalboxes forpurge airblower470

550

550

40

40

40

470

Ø14 Air filter with integrated prefilter

128

258Baseplate

Purge air outlet(double hoseconnection) 40

Fig. 7701 Standard purge air unit SLV 1

Fig. 7702 Weatherproof cover for outdoor installation of purge air unit SLV 1

1

Appendix

FW 56 zero point reference section with smaller reflector

Distance between sender/receiver unit and reflector

machinedsmooth

Snap fastener *

Tube 76.1 x 2.0 (2.6)

(the tube thickness should bebetween 2.0 and 2.6 mm, thickertubes must be suitably machinedon the face side)

Ø 3 mm

32

10.1

6

200 -300

300

-40

0

The distance between sender/receiver unit - reflector is the sum of the individualdimensions: - flange/flange dimension - length of air-purging attachment (2 x 202 mm) - approx. 10 mm for cup springs(see Operating Instructions paragraph 3.2.2)

* Specification in steel:

Snap fastener TL 110 A

Art.-No.: 7 045 573

Specification in stainless steel:

Snap fastener TL 110 A-1

Art.-No.: 7 045 516

2

Appendix

FW 56 zero point reference section with larger reflector

Distance between sender/receiver unit and reflector

machinedsmooth

Snap fastener *

Tube 133 x 2.0 (2.6)

(the tube thickness should bebetween 2.0 and 2.6 mm, thickertubes must be suitably machinedon the face side)

Ø 3 mm

32

10.1

6

200 -300

300

-40

0

The distance between sender/receiver unit - reflector is the sum of the individualdimensions: - flange/flange dimension - length of air-purging attachment (1 x 202 mm + 1 x 304 mm) - approx. 10 mm for cup springs(see Operating Instructions paragraph 3.2.2)

200

* Specification in steel:

Snap fastener TL 110 A

Art.-No.: 7 045 573

Specification in stainless steel:

Snap fastener TL 110 A-1

Art.-No.: 7 045 516

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• 8

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GB

.RF •

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any •

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FW61-1 Opacity Meter

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