SICK DUSTHUNTER SB30 User manual

MMM
I
MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
DUSTHUNTER SB30
Dust Measuring Device
Title Page

28026957/AE00/V1-0/2021-08 | SICKOPERATING INSTRUCTIONS |DUSTHUNTERSB30
Subject to change without notice
Described Product
Product name: DUSTHUNTER SB30
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone: [phone]
E-Mail: [email protected]
Trademarks
Windows is a Microsoft Corporation trademark.
Other product names used in this document may also be trademarks and are only used
for identification purposes.
Legal Information
This document is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law.
Any modification, shortening or translation of this document is prohibited without the
express written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.

CONTENTS
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1 Important information .............................................................................. 6
1.1 Main hazards...................................................................................................6
1.1.1 Hazard through hot and/or aggressive gases and high
pressure ..........................................................................................6
1.1.2 Hazards through electrical equipment ..........................................6
1.1.3 Hazards through laser beam..........................................................6
1.2 Symbols and document conventions .............................................................7
1.2.1 Warning Symbols ...........................................................................7
1.2.2 Warning levels and signal words....................................................7
1.2.3 Information symbols .......................................................................7
1.3 Intended use ...................................................................................................7
1.4 Responsibility of user......................................................................................8
1.4.1 General information........................................................................8
1.4.2 Safety information and protective measures ................................8
2 Product description .................................................................................10
2.1 Measuring principle, measured variables....................................................10
2.1.1 Functional principle ......................................................................10
2.1.2 Response time ..............................................................................11
2.1.3 Function check..............................................................................12
2.2 Device components ......................................................................................13
2.2.1 Sender/receiver unit ....................................................................15
2.2.2 Flange with tube ...........................................................................17
2.2.3 Optional external purge air unit ...................................................18
2.2.4 Voltage and purge air supply........................................................18
2.2.5 Installation accessories................................................................18
2.2.6 Test equipment for linearity test..................................................19
2.3 SOPAS ET (PC program) ................................................................................19
3 Assembly and installation ......................................................................20
3.1 Project planning ............................................................................................20
3.2 Assembly .......................................................................................................22
3.2.1 Fitting the flange with tube ..........................................................22
3.2.2 Work to be performed...................................................................23
3.2.3 Fitting the optional external purge air unit. .................................23
3.2.4 Assembly work ..............................................................................24
3.2.5 Fitting the weather hood ..............................................................25
3.2.6 Fitting the optional MCU control unit ...........................................25
Contents
Contents

CONTENTS
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3.3 Electrical installation .................................................................................... 26
3.3.1 Electrical safety ............................................................................ 26
3.3.1.1 Properly installed power isolating switches............. 26
3.3.1.2 Lines with correct rating........................................... 26
3.3.1.3 Grounding the devices.............................................. 26
3.3.1.4 Responsibility for system safety .............................. 26
3.3.2 General information, prerequisites ............................................. 27
3.3.3 Connecting the optional MCU control unit .................................. 27
3.3.4 Installing the purge air supply ..................................................... 27
3.3.4.1 Optional external purge air unit ............................... 27
3.3.4.2 Installing the non-return valve option...................... 29
3.3.5 Connecting the sender/receiver unit .......................................... 30
3.3.5.1 Work to be done ....................................................... 30
3.3.5.2 Connection of connection line ................................. 30
3.3.5.3 Standard connection (without options) ................... 31
4 Start-up and parameter settings ........................................................... 32
4.1 Fitting the sender/receiver unit ................................................................... 32
4.1.1 Adapting the sender/receiver unit to the duct diameter............ 32
4.1.2 Fitting and connecting the sender/receiver unit on the duct .... 35
4.2 Setting the measuring system parameters ................................................. 36
4.2.1 Factory settings ............................................................................ 36
4.2.2 Changing settings using the jumper on the processor board .... 37
4.2.2.1 Setting measuring range and limit value................. 37
4.2.2.2 Addressing ................................................................ 38
4.2.3 Measuring range parameterization ............................................. 38
4.2.3.1 Manual measuring range parameterization on the
device........................................................................ 39
4.2.3.2 Automatic measuring range parameterization via
SOPAS ET .................................................................. 39
4.2.4 Installing SOPAS ET...................................................................... 40
4.2.4.1 Password for SOPAS ET menus................................ 40
4.2.5 Connection to the device via USB line ........................................ 40
4.2.5.1 Finding the DUSTHUNTER COM port........................ 40
4.2.6 Connection to the device via Ethernet (option) .......................... 41
4.2.7 Factory settings ............................................................................ 43
4.2.8 Resetting parameters .................................................................. 44
4.2.9 Setting Modbus® parameters ..................................................... 45
4.2.10 Calibration for dust concentration measurement ...................... 46
4.2.11 Data backup in SOPAS ET............................................................ 47
4.2.12 Starting measurement mode....................................................... 48
4.2.13 Setting the Ethernet module parameters ................................... 49
5 Transport and storage............................................................................. 50
5.1 Transport....................................................................................................... 50
5.2 Storage.......................................................................................................... 50

CONTENTS
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6 Maintenance.............................................................................................51
6.1 General ..........................................................................................................51
6.2 Maintenance on the sender/receiver unit ..................................................53
6.3 Maintenance on the purge air supply ..........................................................54
6.3.1 Control unit MCU with integrated purge air supply .....................55
6.3.2 Replacing the button cell in the control unit ...............................56
6.3.3 Optional external purge air unit ...................................................57
6.4 Shutdown.......................................................................................................58
7 Troubleshooting .......................................................................................59
7.1 General ..........................................................................................................59
7.2 Sender/receiver unit.....................................................................................60
8 Specifications...........................................................................................61
8.1 Compliances..................................................................................................61
8.2 Technical data...............................................................................................62
8.3 Dimensions, part numbers ...........................................................................64
8.3.1 Sender/receiver unit ...................................................................64
8.3.2 Flange with tube ...........................................................................65
8.3.3 MCU control unit ...........................................................................66
8.3.4 Optional external purge air unit ..................................................68
8.3.5 Weather hoods..............................................................................69
8.4 Accessories ...................................................................................................70
8.4.1 Connections for sender/receiver unit..........................................70
8.4.2 Line, sender/receiver unit - MCU ................................................70
8.4.3 Purge air supply ............................................................................70
8.4.4 Assembly parts..............................................................................70
8.4.5 Device check accessories ............................................................70
8.5 Consumable parts for 2-years operation ....................................................70

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1IMPORTANT INFORMATION
1 Important information
1.1 Main hazards
1.1.1 Hazard through hot and/or aggressive gases and high pressure
The optical assemblies are fitted directly on the gas-carrying duct. On equipment with low
hazard potential (no danger to health, ambient pressure, low temperatures), the installation
or removal can be performed while the equipment is in operation providing the valid
regulations and equipment safety notices are observed and suitable protective measures
are taken.
1.1.2 Hazards through electrical equipment
1.1.3 Hazards through laser beam
WARNING: Danger from exhaust gas
▸On equipment with gases detrimental to health, high pressure or high
temperatures, the sender/receiver unit component fitted on the duct may
only be installed/removed when the equipment is at a standstill.
WARNING: Danger through power voltage
The DUSTHUNTER SB30 measuring system is classified as electrical.
▸Disconnect power supply lines before working on power connections or
parts carrying power voltage.
▸Refit any contact protection removed before switching the power voltage
back on again.
WARNING: Hazards through laser beam
▸Never look directly into the beam path.
▸Do not point the laser beam at persons.
▸Pay attention to laser beam reflections.

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IMPORTANT INFORMATION 1
1.2 Symbols and document conventions
1.2.1 Warning Symbols
1.2.2 Warning levels and 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 less severe or minor injuries.
NOTICE
Hazard which could result in property damage.
1.2.3 Information symbols
1.3 Intended use
Purpose of the device
The DUSTHUNTER SB30 measuring system only serves continuous measurement of dust
concentrations in exhaust gas and exhaust air plants.
Correct use
▸Use the device only as described in these Operating Instructions. The manufacturer
bears no responsibility for any other use.
▸Observe all measures necessary for conservation of value, e.g., for maintenance and
inspection and/or transport and storage.
●Do not remove, add or modify any components to or on the device unless described and
specified in the official manufacturer information. Otherwise
– the device could become dangerous
– the manufacturer’s warranty becomes void
Restrictions of use
●The DUSTHUNTER SB30 measuring system is not approved for use in potentially
explosive atmospheres.
Symbol Significance
Hazard (general)
Hazard by voltage
Symbol Significance
Important technical information for this product
Important information on electric or electronic functions

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1IMPORTANT INFORMATION
1.4 Responsibility of user
1.4.1 General information
Designated users
The measuring system DUSTHUNTER SB30 may only be installed and operated by skilled
technicians who, based on their technical training and knowledge as well as knowledge of
the relevant regulations, can assess the tasks given and recognize the hazards involved.
Special local conditions
▸Observe the valid legal regulations as well as the technical rules deriving from
implementation of these regulations applicable for the respective equipment during
work preparation and performance.
▸Carry out work according to the local conditions specific for the equipment as well as
operational hazards and regulations.
Retention of documents
Keep the Operating Instructions belonging to the measuring system as well as equipment
documentation onsite for reference at all times. Pass the respective documentation on to
any new owner of the measuring system.
1.4.2 Safety information and protective measures
Protection devices
Behavior during purge air failure
The purge air supply serves to protect optical assemblies fitted on the duct against hot or
aggressive gases. Leave the supply switched on when the equipment is at a standstill.
Optical assemblies can be severely damaged in a short time if the purge air supply fails.
Preventive measures for operating safety
NOTE:
Depending on the particular hazard potential, an adequate number of suitable
protection devices and personal safety equipment must be available and used
by the personnel.
NOTE:
When no fail-safe shutters are fitted:
The user must ensure that:
▸The purge air supply runs reliably and continuously
▸Failure of the purge air supply is immediately detected (e.g., by using
pressure monitors)
▸Optical assemblies are removed from the duct if the purge air supply fails
and the duct opening is closed off (e.g. with a flange cover).
NOTE:
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.

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IMPORTANT INFORMATION 1
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
●Significant drifts in measured results
●Increased power consumption
●Higher temperatures of system components
●Monitoring devices triggering
●Smells or smoke emission
●Heavy contamination.
Avoiding damage
Electrical connection
Ensure the device can be switched off with a power isolating switch/circuit breaker in
accordance with EN 61010-1.
NOTE:
In order to avoid malfunctions that can cause direct or indirect personal injury
or property damage, the operator must ensure:
▸The responsible maintenance personnel are present at any time and as fast
as possible
▸The maintenance personnel are adequately qualified to react correctly to
malfunctions of the measuring system and any resulting operational
interruptions (e.g., when used for measurement and control purposes)
▸The malfunctioning equipment is switched off immediately in case of doubt
and that switching off does not cause collateral malfunctions.

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2PRODUCT DESCRIPTION
2 Product description
2.1 Measuring principle, measured variables
2.1.1 Functional principle
The measuring system works according to the scattered light measurement principle
(backward dispersion). A laser diode beams the dust particles in the gas flow with
modulated light in the visual range (wavelength approx. 650 nm). A highly sensitive
detector registers the light scattered by the particles, amplifies the light electrically and
feeds it to the measuring channel of a microprocessor as central part of the measuring,
control and evaluation electronics. The measuring volume is defined by the overlap of the
sender beam and the field of view of the receiver optics.
Fig. 1: Measuring principle
In the case of small duct diameters (< 2 m or in the most unfavorable conditions for
background radiation due to brightness or reflection), a light trap and associated flange
may be necessary (see “Assembly parts”, page 70).
Determining the dust concentration
Measured scattered light intensity (SI) is proportional to dust concentration (c). Scattered
light intensity not only depends on the number and size of particles but also on the optical
characteristics of the particles and therefore the measuring system must be calibrated
using a gravimetric comparison measurement for exact dust concentration measurement.
The calibration coefficients determined can be entered directly in the measuring system as
c = cc2 ·SI² + cc1 ·SI + cc0
(Entry see “Calibration for dust concentration measurement”, page 46; standard factory
setting: cc2 = 0, cc1 = 1, cc0 = 0).




Sender/receiver unit  Receiver

Sender  Measuring volume length

Laser beam  Dust laden exhaust gas
 Receiver field of view




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PRODUCT DESCRIPTION 2
2.1.2 Response time
The response time is the time required to attain 90% of the signal peak after a sudden
change in the measurement signal. It can be set anywhere between 1 and 600 s. As the
response time increases, transient measured value fluctuations and interruptions are
damped stronger and stronger which “smoothes out” the output signal.
Fig. 2: Response time
100
98
96
94
92
90
88
86
84
Response time
t in s
Measured value with response time
90% of the signal peak
Process change
0 10 20 30 40 50 60 70 80 90
Measured value
in %

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2PRODUCT DESCRIPTION
2.1.3 Function check
The measuring system has an integrated function check with selectable interval times
allowing an automatic check for correct function (necessary settings see “Factory
settings”, page 43). Any unallowed deviations from normal behavior that may occur are
signaled as errors.
The function check can also be triggered manually by switching the supply voltage off and
on again.
The function check comprises:
●Approx. 30 s measurement of zero and control value
●Output of values determined every 90 s (standard value)
Fig. 3: Function check output on a plotter
Zero value measurement
The sender diode is switched off for zero point control so that no signal is received. This
means possible drifts or zero point deviations are detected reliably in the overall system
(e.g., due to an electronic defect). A warning signal is generated when the “zero value” is
outside the specified range.
Control value measurement (Span test)
Sender beam intensity changes between 70 and 100% during control value determination.
The light intensity received is compared against the standard value (70%). The measuring
system generates an error signal for deviations greater than ±2%. The error message is
cleared again when the next function check runs successfully. The control value is
determined with high precision through statistical evaluation of a high number of intensity
changes.
The value calculated theoretically (70%) is output for very low dust concentrations
(< approx. 1 mg/m³).
Further information Service Manual
Zero value output (Live Zero)
Control value output
(70% value, span)
Function check
end
Paper feed
Control value
determination
Function check
start
●The analog output must be activated to output control values on the analog output
(see “Factory settings”, page 43).
●The value measured last is output on the analog output during control value determi-
nation.
●If the control values are not output on the analog output, the current measured value
is output when control value determination has completed.
●A function check is not started automatically when the measuring system is in “Main-
tenance” mode.

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PRODUCT DESCRIPTION 2
2.2 Device components
Measuring system DUSTHUNTER SB comprises the components:
●Sender/receiver unit DHSB30
●Flange with tube
●Optional MCU control unit MCU (details upon request)
to control, evaluate and output the data of the sender/receiver unit connected via the
RS485 interface
– With integrated purge air supply, for internal duct pressure -50 ... +2 hPa
– Without purge air supply, therefore additionally required:
●Optional external purge air unit, for internal duct pressure -50 ... +30 hPa
●Optional SCU (details on request)
for operating several measuring systems

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2PRODUCT DESCRIPTION
Fig. 4: Device components DUSTHUNTER SB30M







RS 485


RS 485
AO Analog output
4 ... 20 mA
Modbus®

DI 1 Maintenance / Operation
DI 2 Filter measurement / function check

Connection on plug connector 1
Connection on plug connector 2
Connection on plug connector 3
DI3 Calibration curve switching
DI4 Filter monitoring
DO1 Operation/failure
DO2 Limit value
DO3 Warning / maintenance
Function check (selectable)
Purge air hose
●DN25 with integrated fan
●DN40 to external purge air unit
(and purge air reduction)

Sender/receiver unit

External voltage supply*

Flange with tube  MCU (option)**

Duct  Purge air hose

Operating and parameter program SOPAS ET  Digital inputs

External purge air unit (option) Digital outputs, analog outputs
* Not required when optional MCU is present ** Information on request

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PRODUCT DESCRIPTION 2
2.2.1 Sender/receiver unit
The sender/receiver unit contains the optical and electronic assemblies to send and
receive the light beam as well as to process and evaluate the signals. An RS485 interface
is available for service purposes. Clean air to cool the device and keep the optical surfaces
clean is fed via a purge air connection.
The sender/receiver unit is fastened to the duct with a flange with tube (see “Device
components DUSTHUNTER SB30M”, page 14).
Fig. 5: Sender/receiver unit DHSB-T
The current device state (operation/failure, maintenance/maintenance request) is
signaled on the rear side of the enclosure (green = operation, red = failure, yellow =
maintenance).

A
A
B
B
 
á





Enclosure with electronics

Mounting flange

Handle

Purge air connection

Fixing holes

Opening for measurement receiver

Opening for sender beam

Signaling of device state

Plug connector 2 (connection for
analog output and status signals)
Plug connector 3 (connection for
service adapter or digital inputs)
àPlug connector 1 (connection for external
voltage supply 24 V DC, optional MCU or
optional SCU
áHinge
C
C

à



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2PRODUCT DESCRIPTION
The enclosure with fitted sender/receiver unit can be swiveled to the side after the
CAMLOCK clips have been loosened. Optics, electronics and mechanical components can
then be easily accessed for maintenance work.
Fig. 6: Relation between scattering angle, immersion depth (T) and measuring volume length (L)
Immersion depth and measuring volume length can be changed easily onsite (see
“Adapting the sender/receiver unit to the duct diameter”, page 32)
Type code, optical components
Name: DUSTHUNTER SB30
Short immersion depth
0 400 650
Long immersion depth
0 800 1800
T L
T = 400
L = 250
T = 800
L = 1000
Measures in mm
T L
Sender/receiver unit DHSB - T30 x x x
DUSTHUNTER
Scattered light backward
Transceiver SB30
Immersion depth
- 0: 400
- 1: 800
Fieldbus
- N: Without
- M: Modbus®
Special version
- S: Standard
- X: Special device
- M: Sample version

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PRODUCT DESCRIPTION 2
Sender/receiver unit interfaces
The following interfaces are available directly on the sender/receiver unit.
2.2.2 Flange with tube
The flange with tube is available in different steel grades and dimensions (see “Flange with
tube”, page 65). Selection depends on the wall and isolation thickness of the duct wall
(nominal length) and the duct material.
Fig. 7: Flange with tube
Analog output (1x)
0/2/4 ... 20 mA
Relay outputs
Load 48 V, 1 A
Digital input Service / MCU
interface
For output of
measurand dust
concentration
For output of status
signals:
●Operation/failure
●Limit value
●Warning/mainte-
nance/function
check (selectable)
E.g. for selection of
maintenance, function
check, linearity check,
calibration curve
switching, filter
monitoring synchronous
signal
For configuration with
SOPAS-ET or
connecting a MCU
NOTE:
A weather hood is mandatory when used outdoors. This prevents rainwater
from being sucked in (see “Weather hoods”, page 69).
TOP



NL

Marking for assembly position

Securing bolt

Material St 37 or 1.4571

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2PRODUCT DESCRIPTION
2.2.3 Optional external purge air unit
The MCU control unit with integrated purge air supply cannot be used when the internal
duct pressure is greater than +2 hPa. Use the optional external purge air unit in this case. It
has a powerful blower and can be used for excess pressure in the duct up to 30 hPa. The
scope of delivery includes a purge air hose with 40 mm nominal diameter (length 5 m or
10 m).
Fig. 8: Optional external purge air unit
A weather hood is available for use outdoors (see “Weather hoods”, page 69).
2.2.4 Voltage and purge air supply
2.2.5 Installation accessories
Separate parts of the measuring system (order separately) are:
●Purge air hose, nominal diameter 40 mm, for purge air supply to the sender/receiver
unit via the MCU-P control unit.
●Connection line from the MCU to the sender/receiver unit.
Weather hood
A weather hood is available when using the sender/receiver unit outdoors (see “Weather
hoods”, page 69).







Air filter

Cover cap with opening (part of the purge air
reduction)

Blower (standard type 2BH13)

Purge air hose

Base plate

To purge air connection of sender/receiver unit
Internal duct
pressure
[hPa ]
Connection and supply components
Purge air Voltage
-50 ... +2
MCU-P + purge air hose DN40
-50... +30
Optional external purge air unit
MCU-N
We recommend using the optional external purge air unit when the sender/receiver unit
is more than 10 m away from the MCU control unit.

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PRODUCT DESCRIPTION 2
Purge air heater
It is recommended to use an optional purge air heater available for delivery (see “Purge air
supply”, page 70) to prevent condensation in the device or flange tube when the measuring
system is operated at gas temperatures close to the dew point or very low ambient
temperatures
Option non-return valve
When the measuring system is used in applications with overpressure in the duct, it is
possible to protect the sender/receiver unit, external purge air unit and the environment
against the consequences of purge air supply failure by installing a non-return valve on the
purge air connection of the sender/receiver unit (see “Installing the non-return valve
option”, page 29).
2.2.6 Test equipment for linearity test
A linearity test can serve to check the correct measurement function (see Service Manual).
In this case, filter glasses with defined transmission values are positioned in the beam
path and the values compared against those measured by the measuring system.
Compliance within the allowed tolerance means the measuring system is working correctly.
The filter glasses with holder required for the check are deliverable including a carrying
case.
2.3 SOPAS ET (PC program)
SOPAS ET is a SICK Software for easy operation and configuration of the DUSTHUNTER.
SOPAS ET runs on a laptop/PC connected to the DUSTHUNTER via an RSB adapter or
Ethernet interface (option).
The menu structure simplifies changing settings. Further functions are also available (e.g.,
data storage, graphic displays).
SOPAS ET is delivered on the product CD. Alternatively, you can download SOPAS ET free of
charge from the SICK homepage (“Downloads”).
The purge air heater can only be used for purge air supply with an external purge air
unit.

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3ASSEMBLY AND INSTALLATION
3 Assembly and installation
3.1 Project planning
The following Table provides an overview of the project planning work necessary as
prerequisite for trouble-free assembly and subsequent device functionality. You can use
this Table as a Checklist and check off the completed steps.
Task Requirements Work step
Determine
measuring
location and
fitting loca-
tions for the
device compo-
nents
Inlet and outlet paths accord-
ing to DIN EN 13284-1 (inlet
at least 5x hydraulic diameter
d
h,
outlet at least 3x d
h
;
distance to stack opening at
least 5x d
h
)
For round and square ducts:
d
h
= duct diameter
● Follow specifications for new equip-
ment
● Select best possible location for exist-
ing equipment
● For too short inlet/outlet paths:
Inlet path > outlet path
For rectangular ducts:
d
h
= 4x cross-section divided by
circumference
Homogeneous flow distribu-
tion
Representative dust distribu-
tion
Whenever possible, no deflections,
cross-section variations, feed and
drain lines, flaps or fittings in the area
of the inlet and outlet paths
If conditions cannot be ensured, define
flow profile according to DIN EN 13284-1
and select best possible location
Fitting position for the
sender/receiver unit Select best possible location
Accessibility, accident
prevention
The device components must be easily
and safely accessible
Provide platforms or pedestals as
required
Installation free of vibrations Acceleration < 1 g Eliminate/reduce vibrations through
suitable measures
Ambient conditions Limit values according to Technical
Data
If necessary:
● Provide weather hoods/sun protec-
tion
● Enclose or lag device components
Select the
purge air
supply
Sufficient primary purge air
pressure depending on
internal duct pressure
Plan a purge air heater for gas
temperatures close to the dew point or
very low ambient temperatures
Select supply type
Clean intake air
Whenever possible, low amount of
dust, no oil, moisture or corrosive
gases
● Select best possible location for air
intake
● Determine required purge air hose
length
Select device
components
Duct wall thickness with
isolation Flange with tube Set the immersion depth depending on the internal duct diameter (
see “Adapt-
ing the sender/receiver unit to the duct
diameter”, page 32
)
If necessary, plan additional measures
to fit the flange with tube (
see “Fitting
the flange with tube”, page 22
)
Internal duct pressure Type of purge air supply
Fitting locations Line and purge air hose lengths

45°