SICK FWE200 Operating instructions

Brand: SICK

Model: FWE200

Category: Measuring & layout tools

Type: Operating instructions

OPERATING INSTRUCTIONS

Description

Installation

Operation

Title

FWE200

Dust Concentration Monitor

2 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Document Information

Described Product

Product name: FWE200

Document ID

Title: Operating Instructions FWE200

Part No.: 8009018

Version: 1.0

Release: 2015-05

Manufacturer

SICK AG

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

Phone: +49 7641 469-0

Fax: +49 7641 469-1149

E-mail: info.pa@sick.de

Place of Manufacture

SICK Engineering GmbH

Bergener Ring 27 · 01458 Ottendorf-Okrilla · Germany

Trademarks

IBM is a trademark of the International Business Machine

Corporation.

MS-DOS is a trademark of the Microsoft Corporation.

Windows is a trademark of the Microsoft Corporation.

Other product names used in this document may also be trade-

marks and are only used for identification purposes.

Original Documents

The English edition 8009018 of this document is an original docu-

ment of SICK AG.

SICK AG assumes no liability for the correctness of an unauthor-

ized translation.

Please contact the manufacturer or your local representative in

case of doubt.

Legal information

Subject to change without notice.

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 3

Warning Symbols

Warning Levels / Signal Words

DANGER

Risk or hazardous situation which will result in severe personal

injury or death.

WARNING

Risk or hazardous situation which could result in severe personal

injury or death.

CAUTION

Hazard or unsafe practice which could result in personal injury or

property damage.

NOTICE

Hazard which could result in property damage.

Information Symbols

Hazard (general)

Hazard by voltage

Hazard by laser radiation

Hazard by magnetic fields

Important technical information for this product

Supplementary information

Link to information at another place

Content

4 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Subject to change without notice

1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Main safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.1 Hazards from hot and/or aggressive gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

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

1.3.1 Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 Features and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.1 Features an Advantages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1.2 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 FWE200 operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.1 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2.2.2 Isokinetic behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2.3 Scattered light measuring principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2.4 Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2.5 Check Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3.1 Test Gas Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3.2 Flange with pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.3.3 Measuring and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.3.3.2 Test cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3.3.3 Transmitter/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.3.4 Fan Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.3.5 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4 Input/Output functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4.1 Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2.1 Installing flange with pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2.2 Installing the measuring and control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2.3 Installing the Fan Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3.2 Connecting the fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3.3 Connecting the cables for the analog and status signals, and the digital inputs . 36

3.3.4 Connecting the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.3.5 Second analog output option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Content

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 5

Subject to change without notice

4 Commissioning and Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1 Startup procedure for the FWE200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.1.1 Assembling the measuring and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4.1.2 Startup of fan unit........................... . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . 41

4.1.3 Connecting the test gas probe. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.1.4 Starting the FWE200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.1.5 Installing the test gas probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1.6 Adjusting the Extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2 Preparing the parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.2 Connecting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.3 Parameterizing the FWE200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.3.1 Customer-Specific parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.3.2 Calibration for dust concentration measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.3.3 Determining the flow limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.3.4 Parameterizing second analog output option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.3.5 Data backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.3.6 Starting standard measuring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

5Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.2 Maintenance work ... . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.2.1 Preparation work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.2.2 Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.2.3 Cleaning the inlet nozzle in the thermo cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.2.4 Cleaning the ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.2.5 Cleaning the test gas probe, and extraction and return hose . . . . . . . . . . . . . . . . . . 65

5.2.6 Cleaning the vortex chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.2.7 Cleaning the transmitter/receiver unit and the test cell . . . . . . . . . . . . . . . . . . . . . . . 66

5.2.7.2 Cleaning the test cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.2.8 Checking / replacing the filter insert on the fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . 69

5.3 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.1 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

6.2 Warnings and malfunction messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.2.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

6.2.2 Malfunction messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6.2.3 Other Malfunctions or abnormal behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

6.3 Removal of malfunctions of the transmitter/receiver unit. . . . . . . . . . . . . . . . . . . . . . . . 80

6.3.1 Checking/adjusting the laser beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6.3.2 Checking the laser beam for free transit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

6.3.3 Checking the receiver optics for correct swivel movement. . . . . . . . . . . . . . . . . . . . .83

6.4 Test and diagnosis options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.4.1 Test signal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.4.2 Check cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

6.4.3 Linearity check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Content

6 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Subject to change without notice

7Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.2 Gas-carrying components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.2.1 Thermo cyclone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.2.1.3 Replacing the Vortex Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.2.2 Temperature sensor for measurement gas temperature . . . . . . . . . . . . . . . . . . . . . . 90

7.2.3 Replacing other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

7.3 Transmitter/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.3.1 Replacing the cover and/or the protection tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.3.2 Replacing the sintered metal filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

7.3.3 Replacing the entire t/r unit connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7.4 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7.4.1 Exchanging the I/O module board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7.4.2 Replacing the sensor board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.3 Replacing the processor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

7.4.4 Replacing the power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

8.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

8.2 Dimensions and Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.2.1 Test gas probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8.2.2 Flange with pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.2.3 Measuring and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8.2.4 Fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

8.3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.3.1 Mounting rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.3.2 Weatherproof cover for fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.3.3 Measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.3.4 Accessories for testing the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.3.5 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.4 Consumable parts for 2-year operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.4.1 Transmitter/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.4.2 Fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.5 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.1 Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.2 Thermo cyclone. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.3 Test cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.4 Ejector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

8.5.5 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.5.6 Transmitter/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

8.5.7 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

9 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

9.1 Standard settings for the FWE200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

9.2 Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Important Information

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 7

Subject to change without notice

FWE200

1 Important Information

Main safety notes

Intended use

Responsibility of user

8 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Important Information

Subject to change without notice

1.1 Main safety notes

1.1.1 Hazards from hot and/or aggressive gases

On equipment with low hazard potential (no danger to health, ambient pressure, low

temperatures), the test gas probe can be installed or removed while the equipment is in

operation providing the valid regulations and equipment safety notices are observed and

suitable protective measures are taken.

1.1.2 Hazards through electrical equipment

1.1.3 Hazards through laser beam

WARNING: Danger from exhaust gas

Hot or aggressive gases may escape from the gas-carrying components (test

gas probe, hoses, thermo cyclone, test cell, ejector) and can cause serious in-

jury at unprotected staff.



Switch off the measuring system before the work is started.



Carry out all work only with suitable protective equipment (protective

clothing, protecting mask).



Touch gas-carrying and hot system components only after sufficient cooling

or with protective equipment.



Install/remove the test gas probe on equipment with gases detrimental to

health, high pressure or high temperatures only when the equipment is at a

standstill.

WARNING: Danger through mains voltage

The FWE200 measuring system is operational equipment for use in industrial

high-voltage current plants.



Switch off the power supply before working on mains connections or parts

carrying mains voltage.



Refit any contact protection removed before switching the mains voltage

back on again.

WARNING: Hazards through laser beam

The transmitter/receiver unit of the FWE200 uses a laser with laser class 2.

 Never look directly into the beam path

 Do not point the laser beam at persons



Pay attention to laser beam reflections.

Important Information

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 9

Subject to change without notice

1.2 Intended use

Purpose of the device

The FWE200 measuring system only serves continuous measurement of dust

concentrations in wet gases.

Correct use



Use the device only as described in these Operating Instructions. The manufacturer

bears no responsibility for any other use.



Observe all measures necessary for conservation of value, e.g. for maintenance and

inspection and/or transport and storage.

 Do not remove, add or modify any components to or on the device unless described and

specified in the official manufacturer information. Otherwise

– the device could become dangerous

– the manufacturer’s warranty becomes void

Restrictions of use

 The FWE200 measuring system is not permitted for use in potentially explosive atmo-

spheres.

10 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Important Information

Subject to change without notice

1.3 Responsibility of user



Take the FWE200 only into operation when you have read the operating instructions.



Follow all safety instructions.



If you do not understand something: Please contact the SICK service.

Designated users

The FWE200 measuring system may only be installed and operated by skilled technicians

who, based on their technical training and knowledge as well as knowledge of the relevant

regulations, can assess the tasks given and recognize the hazards involved.

Correct use

● Basis of this manual is the delivery of the FWE200 according to a previous configura-

tion (e.g. by means of the SICK application questionnaire) and a correspondingly

delivery status of the FWE200 (→ supplied system documentation).



If you are not sure whether the FWE200 corresponds to the configured state or the

supplied system documentation:

Please contact the SICK service.



Use the FWE200 only as described in these Operating Instructions. The manufacturer

bears no responsibility for any other use.



Perform the specified maintenance work.

 Do not perform any work and repairs on FWE200 that are not described in this manual.

Do not remove, add or modify any components to or on the device unless described and

specified in the official manufacturer information. Otherwise

– the manufacturer’s warranty becomes void

– the device could become dangerous

Special local conditions



Observe all local laws, regulations and internal operating procedures that apply at the

installation location..

Important Information

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 11

Subject to change without notice

1.3.1 Safety information and protective measures

Protection devices

Preventive measures for operating safety

Recognizing malfunctions

Every deviation from normal operation is to be regarded as a serious indication of a

functional impairment. These are, amongst others:

● Warning displays (e.g. heavy contamination)

● Significant drifts in measured results

● Increased power consumption

● Higher temperatures of system components

● Monitoring devices triggering

● Smells or smoke emission

Avoiding damage

NOTICE:

Suitable protection devices and safety equipment for persons must be

available according to the respective hazard potential and be used by the

personnel.

NOTICE:

The user must ensure that:



Neither failures nor erroneous measurements can lead to operational

states that can cause damage or become dangerous



The specified maintenance and inspection tasks are carried out regularly

by qualified, experienced personnel.

NOTICE:

The operator must ensure the following to avoid malfunctions that can

indirectly or directly lead to injuries to persons or material damage:



The FWE200 is connected to a safe (uninterrupted) power supply.



The responsible maintenance personnel are present at any time and as

fast as possible.



The maintenance personnel are adequately qualified to react correctly to

malfunctions of the measuring system and any resulting operational

interruptions (e.g. when used for measurement and control purposes).



The malfunctioning equipment is switched off immediately in case of

doubt.



The switching off does not cause collateral malfunctions.



Either the FWE200 is operated furthermore or else switched off if the

installation is out of operation (



p. 70, §5.3).

12 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Important Information

Subject to change without notice

Product Description

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 13

Subject to change without notice

FWE200

2 Product Description

Features and Applications

FWE200 operating principle

System Components

Input/Output functions

14 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Product Description

Subject to change without notice

2.1 Features and Applications

The FWE200 measurement system is designed to conduct continuous measurements of

very low (0.1 mg/m3) to medium (200 mg/m3 and higher) dust concentrations in gases

(temperature below dew point). These measuring devices can be used in a wide range of

application and feature by low installation effort and simple handling.

2.1.1 Features an Advantages

● Extraction of a partial flow of gas from the gas duct

● Drying and overheating of the wet extracted gas with adjustable electrical heating for

constant test gas temperature to rule out measurement errors caused by droplets exist-

ing before

● Gas extraction and return with one test gas probe, with the result that only one mount-

ing flange is required

● Determination of dust content using a scattered light measurement for low to medium

dust concentrations in a test cell with free-jet flow

● Compact design, thereby simplifying mounting and installation

● Operating values and system status are displayed on one LCD

● Supervision of the extracted flow with integrated difference pressure measurement

● Simple operation and configuration with user-friendly MEPA-FW software

● Self-controlled by automatic check cycle

2.1.2 Applications

● Measuring dust emissions in power stations downstream of flue-gas desulfurization

plants

● Measuring dust in wet purifiers of waste and refuse incineration plants

● Measuring dust content in wet exhaust gas from industrial processes

Product Description

FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG 15

Subject to change without notice

2.2 FWE200 operating principle

2.2.1 Operating principle

The FWE200 functions as a bypass system. A partial gas flow is extracted from the flue gas

duct via a test gas probe and overheated in a thermo cyclone to vaporize the water drops.

The overheated test gas is fed to a test cell. This test cell contains the receiver part of the

transmitter/receiver unit measuring the scattered light intensity from the particles in the

test gas as a measure of the dust concentration. Then the test gas is fed via an ejector and

the test gas probe back to the duct. The test gas is transported via the ejector by means of

a fan unit that also supplies the transmitter/receiver unit with a partial flow for keeping the

optical components clean and cool.

Figure 1 FWE200 structure and functional principle

Measuring and control unit

Fan Unit

Duct

*: Gas extraction and return do

not correspond to the actual

installation situation.

1Heater 1

2Heater 2

3 Thermo cyclone

4Test cell

5 FWSE200 transmitter/

receiver unit

6 Purge air

7Ejector

8 Control cabinet

PAD

S MEPA-FW software

P Power supply 115 / 230 V AC

A Output signal 0 ... 20 mA

D Status signals

Test gas probe *

16 FWE200 · Operating Instructions · 8009018 V1.0 · © SICK AG

Product Description

Subject to change without notice

2.2.2 Isokinetic behaviour

Due to the specific design, the measuring behavior of the FWE200 doesn’t depend on

changes of the gas velocity in the duct in a wide range. Therefore an isokinetic extraction

(extraction velocity = gas velocity in the duct) is not required. It is merely necessary to

select the extraction aperture of the test gas probe in accordance with the mean velocity

(vrated) as shown in the following table. In this way the gas flow through the measuring

system can be adapted to the respective plant conditions, and a safe operation also at

changing gas velocities can be grant. Otherwise the following effects could occur:

● Flow rate too low

→ particles can be deposited in the gas leading parts.

● Flow rate too high, gas and/or ambient temperature very low, gas wetness very high

→ the set test gas temperatur e cannot be reached → Aerosols/water droplets not

vaporize completely (heating energy of the thermo cyclone is limited).

2.2.3 Scattered light measuring principle

The FWE200 operates according to the scattered light measurement principle (forward

scattering). Since it is extremely sensitive, this principle is particularly suitable for

measuring very small particle concentrations.

A laser diode directs a beam of modulated light in the visible range (wavelength approx.

650 nm) at the dust particles in the gas flow. The light scattered by the particles is

recorded by a highly sensitive detector which is positioned in a angle of approx. 15 ° to the

beam axis. The received signal is electrically amplified and supplied to the measuring

channel of a microprocessor as the central part of the measuring, control and evaluation

electronics. The point of intersection between the transmitted beam and the receiver

aperture defines the measuring volume in the gas duct.

Continuous monitoring of the sender output registers the smallest changes in brightness of

the light beam sent which then serves to determine the measurement signal.

Figure 2 Measuring principle

Gas velocity in the duct in m/s Extraction aperture of the test gas probe

min

rated

max

Nominal diameter Extraction cross section [mm²]

6 9 12 DN 25 581,1

11 18 23 DN 20 353,0

14 23 29 DN 15 206,1

● If v

rated

is not known at order (e.g. no information in the Technical

questionnaire), the test gas probe with the standard value DN 20 is

supplied.

● In addition it is possible to adjust the flow rate by means of the recirculated-

air valve on the ejector during system startup (



p. 45, §4.1.6).

Laser diode

Detector

Measuring volume

Product Description

Subject to change without notice

Determining the dust concentration

The measured scattered light intensity SL is proportional to the dust concentration c. Since

the scattered light intensity doesn't only depend on the number and size of particles but

also on the optical characteristics of the particles, the FWE200 must be calibrated with a

gravimetric comparison measurement to secure an exact measuring of the dust

concentration. The calibration coefficients determined at this measurement cc0

(absolute), cc1 (linear) and cc2 (square) are entered in FWE200 (



p. 52, §4.3.2) in the form

c = cc2

· SL² + cc1 · SL + cc0

The standard factory setting is cc2 = 0, cc1 = 1, cc0 = 0.

2.2.4 Response time

The response time (t90) is the time taken by the FWE200 to reach 90% of the end value

after a sudden change in the measured value. The t90 time can be set to any value

between 0.1 and 600 s. Setting a higher t90 time provides better attenuation of transient

fluctuations in the measured value and malfunctions to produce a "smoother" output

signal.

Figure 3 Response time

2.2.5 Check Cycle

The check cycle is used for automatically checking that the transmitter/receiver is

functioning properly. The check cycle can be triggered automatically at fixed intervals

(setting in MEPA-FW,



p. 50, §4.3.1) and/or manually (1 min after the power supply has

been connected, or the system has been switched from “Maintenance“ to “Measure“ in

MEPA-FW).

The check values can be given out at the analog output (output must be activated,



p. 50,

§4.3.1).

If a check cycle is carried out, inadmissible deviations from the normal behavior are

signaled as a malfunction. If a malfunction is present, you can trigger a check cycle

manually to locate the cause of the problem (see Chapter 6).

Measured

value

in %

Measured value with response time

90% of the peak

Process change

Response time

t in s

100

0 10 20 30 40 50 60 70 80 90

Product Description

Subject to change without notice

The check cycle lasts approx. 310 s and comprises:

● 40 s contamination measurement of the optical boundary surfaces, zero and check

value

● 90 s output of the contamination value

● 90 s output of the check value

● 90 s output of the zero value.

Figure 4 FWE200 check cycle output on plotter

Contamination measurement

In order to measure the contamination on the optical boundary surfaces, the receiver

optics is moved mechanically to a reference position. As a result, the optics measure the

light emitted by the laser diode directly. The intensity value measured during the movement

is compared with the factory settings to calculate a correction factor. In this way, any

contaminations are completely compensated.

If the contamination value is lower than 70%, a analog value is given out during the check

cycle in a range between Live Zero and 20 mA and proportional to the contamination value

(device status „Operation“). For contamination values higher than 70% always Live Zero is

given out (device status “Malfunction“).

Figure 5 FWE200 contamination and check value measurement

Check value measurement (span test)

Following to the contamination measurement, the check value is determined (receiver

optics is in reference position). Once a reference measurement has been carried out with a

light intensity of 100%, the intensity of the laser diode is reduced to 70%, and the

measured scattered light intensity is compared with the expected value. If these two value

deviate more than ±2%, the device generates an error signal. The error message is lifted

again if the next check cycle passes successfully.

Zero value measurement

To check the zero point, the laser diode is switched off, and the received signal must also

be zero. In this way, drifts or zero-point deviations in the entire system (e.g. caused by an

electronic defect) can be reliably detected. If the “zero-value” deviation is outside the

specified range, an error signal is generated.

Contamination degree

(Live Zero = 0%,

20 mA = 40%)

Contamination output

Check value output

(70%-value, span)

Zero value output (Live Zero)

Start check

cycle

Control value

determination

Paper feed

End check cycle

Receiver optics in reference position

Product Description

Subject to change without notice

● When the check values are being determined, the value last measured is

given out at the analog output.

● If the check values are not given out at the analog output, the current

measured value is given out once the check value has been determined.

● The check cycle is indicated with a plain-text “Check cycle“ at the LCD and

as a status output at relay 4 (active during check cycle).

● Automatic check cycles are carried out periodically from the parameterized

time interval. A re-start begins if the interval setting is changed or 1 min

after:

– Change from “Maintenance“ to “Measure“ mode

– Reset (power off/on)

– Switch-on of the power voltage after power failure.

Product Description

Subject to change without notice

2.3 System Components

2.3.1 Test Gas Probe

The test gas probe is used to extract and return the extracted partial gas flow. It is fixed at

a flange with pipe (



Fig. 7) to be installed at the duct by the customer.

The probes are available in two nominal lengths (600 mm and 1200 mm), the materials

PVDF (for gas temperatures < 120 °C) and Hastelloy and three nominal diameters of the

suction opening (DN 15, DN 20, DN 25).

Figure 6 Test gas probe

2.3.2

Flange with pipe

Figure 7 Flange with pipe

If required, the flange with pipe can also be supplied with other dimensions and materials.

Flange with pipe

Duct wall

Nominal length NL

Extraction pipe

Return pipe

Test gas probe

22,5 °

NL = 600 mm

1200 mm

Material St 37 or

1.4571

Flange DIN 2631 ND6, NW 125

(152)

Ø 18

200

Ro 139,7 x 4

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SICK FWE200 Operating instructions

Brand: SICK

Model: FWE200

Category: Measuring & layout tools

Type: Operating instructions

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SICK FWE200 Operating instructions

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