fos4X fos4Strain expert User manual

INSTRUCTIONS FOR USE
fos4Strain expert Product Type Sensor
Product Version 1.3.x
Document Version 4.0
Issue Date 2019-11-26
anguage en-us
INSTRUCTIONS FOR USE
fos4Strain expert Product Type Sensor
Product Version 1.3.x
Document Version 4.0
Issue Date 2019-11-26
anguage en-us

Imprint
Imprint
fos4X GmbH
Thalkirchner Str. 210
81371 Munich
Germany
Phone: [phone]
Fax: [phone]
www.fos4X.de
WEEE-Reg.-Nr. DE: 70390148
©2019 fos4X®
Distribution and reproduction of this document, exploitation and communication
of its contents are prohibited unless expressly permitted. Violations will result in the
liability for damages. All rights reserved in the event of patent, utility model or design
registration.
All rights reserved.
fos4X is a trademark of fos4X GmbH.
Brand names and protected trademarks are the property of their respective owners.
The naming of brand names and protected trademarks has only descriptive character.
Named trademarks are not part of any partnership or cooperation with fos4X.
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Table of Contents
Table of Contents
1 About this Document......................................................................................... 6
1.1 Target Audience..................................................................................................... 6
1.2 Objective of these Operating Instructions.................................................... 6
1.3 Identification of Information............................................................................. 6
1.3.1 Safety-relevant Information................................................................. 6
1.3.2 Non-safety-related Information.......................................................... 7
1.4 Abbreviations...........................................................................................................7
2 Safety.................................................................................................................... 8
2.1 Changes to the Product......................................................................................8
2.2 Qualification of Personnel..................................................................................8
2.3 Intended Use........................................................................................................... 9
2.4 Residual Risks..........................................................................................................9
2.4.1 Explosion Protection................................................................................ 9
2.4.2 Working Environment Blade Manufacturing Facility....................9
2.4.3 Working Environment Wind Turbine...................................................9
2.4.4 Adhesives................................................................................................... 10
2.5 Personal Protective Equipment......................................................................10
3 Product Descri tion...........................................................................................12
3.1 Functional Description....................................................................................... 12
3.1.1 Function...................................................................................................... 12
3.1.2 Overview.....................................................................................................12
3.1.3 Operation....................................................................................................13
3.1.4 Calculation of strain............................................................................... 13
3.2 Technical Data...................................................................................................... 14
3.2.1 Measurement and Optical Data........................................................ 14
3.2.2 Cable Data................................................................................................. 14
3.2.3 Environmental Conditions....................................................................14
3.2.4 Mechanical Data..................................................................................... 15
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Table of Contents
3.2.5 Dimensions................................................................................................ 16
3.3 Markings on the Product..................................................................................16
3.3.1 Type Plate.................................................................................................. 16
4 Packaging and Trans ort................................................................................. 17
4.1 Scope of Delivery................................................................................................. 17
4.2 Packaging................................................................................................................17
4.3 Unpacking...............................................................................................................18
4.4 Packing....................................................................................................................18
4.5 Transport................................................................................................................ 19
4.6 Storage.................................................................................................................... 19
5 Installation..........................................................................................................20
5.1 Important Safety Notes for Installation......................................................20
5.2 Preparing the Installation Position.................................................................21
5.3 Attaching the Sensor......................................................................................... 23
5.3.1 Attaching the Sensor with ergo 1665..............................................23
5.3.2 Attaching the Sensor with UHU P US B ACK............................... 27
5.4 Attaching the Cable............................................................................................32
5.5 Connecting a Sensor.......................................................................................... 33
6 Commissioning and O eration....................................................................... 35
7 Troubleshooting................................................................................................ 36
8 Maintenance.......................................................................................................37
8.1 Preventive Maintenance................................................................................... 37
8.2 Corrective Maintenance....................................................................................37
8.2.1 Cleaning E-2000/APC Connections................................................. 37
9 Taking out of Service and Dis osal............................................................... 39
9.1 Taking out of Service......................................................................................... 39
9.2 Disassembly..........................................................................................................40
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Table of Contents
9.3 Disposal..................................................................................................................40
10 fos4X Su ort.................................................................................................... 41
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1. About this Document
1 About this ocument
1.1 Target Audience
This documentation intended for technically trained personnel.
1.2 Objective of these Operating Instructions
These instructions for use describe all tasks for the intended use of the product.
1.3 Identification of Information
1.3.1 Safety-relevant Information
These o erating instructions contain the following safety information:
■Safety information in the Safety chapter applies to the entire use of the product.
See Safety, page 8.
■Safety notes at the beginning of a section apply to the entire section.
■Safety notes before a step apply to the entire following section.
Safety notes are shown in the operating instructions as follows:
DANGER Nature and cause of risk
Consequences
uMeasures to avoid the risk.
The safety notes with the signal words Caution and Notice have the following
meanings:
CAUTION Risk which, if not avoided, could result in minor injury.
NOTICE Risk which, if not avoided, will result in damage to property.
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1. About this Document
1.3.2 Non-safety-related Information
TIP Advice on the optimal use of the product.
Symbols and Meaning
Table 1: Representation of the information in the operating instructions
Symbol Meaning
Task:
1. First step
2. Second step
Instruction with task and several steps
Task:
uStep Instruction with a single step
PResult Result of an instruction
List:
■Point 1
■Point 2
Enumeration with title
Identification of Information,
page Cross reference
Bold Text Highlighting of particularly important information
1.4 Abbreviations
CFRP Carbon Fiber Reinforced Polymer
GRP Glass-fibre reinforced plastic
GTIN Global Trade Item Number
IP International Protection
Max Maximum
Min Minimum
MTBF Mean Time Between Failures
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2. Safety
2 Safety
2.1 Changes to the Product
Changes to the product may only be carried out by fos4X.
2.2 Qualification of Personnel
efinitions
■Instructed ersonnel: Personnel instructed in the tasks assigned to them.
■Trained ersonnel: Personnel trained in the operation and safe use of the
product.
■Qualified ersonnel: Personnel who, based on their specialist training, knowledge
and experience and knowledge of the relevant regulations, are able to assess the
work assigned to them and identify possible hazards.
Assignment of tasks
Tasks within the scope of use may only be carried out by the personnel defined below.
Table 2: Tasks
Task Personnel
Packaging and Transport Instructed personnel
Installation
Commissioning
Operation
Trained personnel
Troubleshooting Qualified personnel
Maintenance
Taking out of Service Trained personnel
Disassembly
Disposal
fos4X or specialized disposal
company
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2. Safety
2.3 Intended Use
The sensor fos4Strain expert is optimized for use on GRP or CFRP in rotor blades.
For the use of the fos4Strain expert on other substrates, qualified personnel from
fos4X must be consulted.
Any other use or use going beyond this is considered improper use.
2.4 Residual Risks
2.4.1 Explosion Protection
The product is not suitable for use in potentially explosive environments.
2.4.2 Working Environment Blade Manufacturing Facility
The use of the product in blade manufacturing facilities requires special risk prevention
measures.
Risk revention measures in blade manufacturing facilities:
uObtain and observe safety and work regulations:
– Qualification and training of personnel
– Personal protective equipment
– Required permits
uEnsure that the use of the product is permitted on the wind turbine.
2.4.3 Working Environment Wind Turbine
The use of the product in wind turbines requires special risk prevention measures.
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2. Safety
Measures for risk revention on wind turbines:
uObtain and observe safety and work regulations:
– Qualification and training of personnel
– Personal protective equipment
– Required permits
uEnsure that the use of the product is permitted on the wind turbine.
2.4.4 Adhesives
Adhesives can cause severe irritation and allergic skin reactions.
uAvoid skin contact.
uObserve the safety data sheet of the adhesive.
uUse personal protective equipment according to the safety data sheet of the
adhesive. See Personal Protective Equipment, page 10.
Fumes from adhesives can cause damage to health and allergic reactions.
uDo not inhale fumes.
uObserve the safety data sheet of the adhesive.
uUse adhesives only in sufficiently ventilated rooms.
Adhesives can cause severe environmental damage.
uObserve the safety data sheet of the adhesive.
uDispose of adhesives and adhesive packaging in accordance with applicable
environmental regulations.
2.5 Personal Protective Equipment
Protective Gloves
For all tasks where surfaces are heated:
uWear protective gloves with the following characteristics:
– General requirements according to DIN EN 420
– Protection against contact heat: Performance level 2 according
to DIN EN 407
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2. Safety
For all tasks with adhesives:
uWear protective gloves according to EN ISO 374-1 (nitrile, min.
0.4 mm).
For all tasks with ergo. 1665:
uWear protective gloves according to EN ISO 374-1 (butyl, min.
0.5 mm).
Safety Goggles
For all tasks with adhesives:
uWear safety goggles with side protection according to DIN EN 166.
When grinding GRP:
uWear safety goggles with side protection according to DIN EN 166.
Protective Clothing
For all tasks:
uWear protective clothing (long-sleeved work clothing).
Respiratory Protection
When grinding GRP:
uWear respiratory protection with protection level A2 P2 according to
DIN EN 140.
For all tasks with ergo. 1665:
uIn case of insufficient ventilation: Wear respiratory protection with
protection level A P2 according to DIN EN 140.
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3. Product Description
3 Product escription
3.1 Functional escription
3.1.1 Function
The fos4Strain expert is a fiber-optical strain sensor based on a fiber-Bragg grating.
The sensor was developed for the strain monitoring of composite structures and in
particular of rotor blades of wind turbines.
The sensor has passive temperature compensation adapted to the expansion
coefficient of the structure.
3.1.2 Overview
Figure 1: Overview
1Cable with step protection
2Sensor with step protection
3Centre of the measuring range
4Fan-out cable without step protection
5E-2000/APC connector
The fos4Strain ex ert consists of the following com onents:
■Sensor with GRP base plate and step protection.
■Cable with step protection and E-2000/APC connector.
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3. Product Description
3.1.3 Operation
Figure 2: Centre of the measuring range
1Measuring range
The position of the sensor is selected so that the measuring range of the sensor
measures a defined strain of the structure. See Fig. 2: Centre of the measuring range,
page 13.
The surface of the structure is prepared so that the surface is flat, dust-free and dry.
The sensor is then glued to the structure with ergo. 1665 or UHU P US B ACK.
The sensor is connected to a compatible measuring device.
The wavelength of the sensor can then be used to determine the strain of the
structure. See Calculation of strain, page 13.
3.1.4 Calculation of strain
The strain is calculated on the basis of the measured wavelength difference as follows:
(ε: Strain; kε: k-factor; λ: current wavelength; λ0: rest wavelength)
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3. Product Description
3.2 Technical ata
3.2.1 Measurement and Optical ata
For technical data on the measurement and optical properties, see the sensor data
sheet.
Data sheets available at www.fos4x.de/en/downloads.
3.2.2 Cable ata
Table 3: Cable Data
Pro erty Value Unit
ength *See type plate -
Diameter (cable with step protection) 6 ± 0.5 mm
Min. Bending radius (cable with step
protection) 50 mm
Min. bending radius (fan-out cable) 15 mm
Cable exchangeable No -
Connector type E-2000/APC -
* ength from sensor end to connector end.
3.2.3 Environmental Conditions
Table 4: Environmental Conditions
Pro erty Value Unit
IP protection class*IP67 -
Maximum operating altitude 3000 m
Permitted temperature
(Transport and storage) -40 … +80 °C
Permitted relative humidity
(Transport and storage) 0 … 95 %
Permitted temperature
(Operation) -40 … +55 °C
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3. Product Description
Pro erty Value Unit
Permitted relative humidity
(Operation) 0 … 95 %
* The specified protection class only applies if the cable connections have the same or a higher
protection class.
3.2.3.1 Load cycles and MTBF
Table 5: oad cycles and MTBF
Pro erty Value Unit
oad cycles at ±1000 µm/m 108-
MTBF >400 Years
3.2.4 Mechanical ata
Table 6: Mechanical Data
Pro erty Value Unit
ength 260 mm
Height 12 mm
Width 70 mm
Total weight*0.2 kg
* fos4Strain expert without cable and packaging
Installation
Table 7: Installation
Pro erty Value Unit
Installation method Glued -
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3. Product Description
3.2.5 imensions
Figure 3: Dimensions
1fos4Strain expert
2Cable with step protection
3Fan-out cable without step protection
4E-2000/APC connector
ACable length total
BCable length fan-out
3.3 Markings on the Product
3.3.1 Type Plate
Contents of the ty e late (exam le data
from gra hic):
■QR-code of the serial number
■Product category and number:
ABC1234
■Product version: v1.2.3
■Serial number: S/N: 1234-5678
■IP protection class: IP67
■Product name: fos4Strain expert
(dyn)
■Other product data: Color marking,
cable length.
■GTIN: P/N: 4251141234567
Figure 4: Type Plate
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4. Packaging and Transport
4 Packaging and Transport
4.1 Scope of elivery
The fos4Strain ex ert is delivered with the following sco e of delivery:
■1x fos4Strain expert
■1x Test certificate outgoing goods
4.2 Packaging
TIP uKeep the transport packaging.
In the original packaging, the product is best protected for
transport.
The fos4Strain expert is packed in a box.
One box contains up to
6 fos4Strain expert.
The box has the dimensions
180 x 390 x 410 mm (length x width x
height).
Figure 5: Packaging
The box has the following transport and storage conditions:
Table 8: Transport and storage conditions of the packaging
Pro erty Value Unit
Permitted temperature
(Transport and storage) -40 ... +80 °C
Permitted relative humidity
(Transport and storage) 0 ... 50 %
Max. Storage duration 5 Years
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4. Packaging and Transport
4.3 Unpacking
Un acking the fos4Strain ex ert:
1. Open the box.
2. Remove the fos4Strain expert from the box.
3. Check the scope of delivery. See Scope of Delivery, page 17.
4. If parts of the scope of delivery are missing: Contact fos4X Support. See fos4X
Support, page 41.
4.4 Packing
NOTICE Damage to the fiber-optical cables.
Too small bending radii and kinks can irreparably damage the
fibers in fiber-optical cables.
uObserve the min. bending radii of the cable. See
Technical Data, page 14.
uDo not kink fiber optical cables.
Packing the fos4Strain ex ert in the original ackaging:
1. Wind up the fos4Strain expert and cable. Min. bending radius of the cable 50 mm.
2. Open the box.
3. Put the fos4Strain expert in a compartment of the box.
4. Close the box.
Pfos4Strain expert ready for transport or shipping.
Alternative: Packing the fos4Strain ex ert in a different ackaging:
1. Wind up the fos4Strain expert and cable. Min. bending radius of the cable 50 mm.
2. Select a box so that the fos4Strain expert with padding material fits into the box.
3. Open the box.
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4. Packaging and Transport
4. Pack the fos4Strain expert in the box with padding material. Make sure the
fos4Strain expert is protected against shocks from all sides.
5. Close the box.
Pfos4Strain expert ready for transport or shipping.
4.5 Transport
Trans orting the fos4Strain ex ert:
uHandle the fos4Strain expert with care during transport.
uObserve the transport conditions. See Environmental Conditions, page 14.
uPack the fos4Strain expert in a transport packaging. See Packing, page 18.
4.6 Storage
Storing the fos4Strain ex ert:
uStore the fos4Strain expert in a dry and clean place.
uStore the fos4Strain expert in a transport packaging. See Packing, page 18.
uObserve the environmental conditions. See Environmental Conditions, page 14.
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5. Installation
5 Installation
uObserve the safety instructions. See Safety, page 8.
5.1 Important Safety Notes for Installation
For all tasks:
NOTICE Damage to the fiber-optical cables.
Too small bending radii and kinks can irreparably damage the
fibers in fiber-optical cables.
uObserve the min. bending radii of the cable. See
Technical Data, page 14.
uDo not kink fiber optical cables.
When working with ergo 6305 or Sikaflex-512UV:
CAUTION Severe irritations and allergic reactions caused by contact
with adhesive.
uWear protective gloves according to EN ISO 374-1 (nitrile,
min. 0.4 mm).
uWear safety goggles with side protection according to
DIN EN 166.
uObserve the safety data sheet of the adhesive.
CAUTION Health damage and allergic reactions caused by inhalation of
adhesive fumes.
uDo not inhale fumes.
uEnsure adequate ventilation.
uObserve the safety data sheet of the adhesive.
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