SICK DUSTHUNTER SP100 Ex-3K User manual

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MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
DUSTHUNTER SP100 Ex-3K
Scattered Light Dust Measuring Device

28020216/1JQX/V3-1/2023-05| SICKOPERATING INSTRUCTIONS |DUSTHUNTERSP100 Ex-3K
Subject to change without notice
Described product
DUSTHUNTER SP100 Ex-3K
Version for potentially explosive atmospheres:
Zone 2 (gas / device category 3G) and Zone 22 (dust / device 3D)
Manufacturer
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Legal information
This document is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK Engineering GmbH. 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 Engineering GmbH.
The trademarks stated in this document are the property of their respective owner.
© SICK Engineering GmbH. All rights reserved.
Original document
This document is an original document of SICK Engineering GmbH.

Contents
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8020216/1JQX/V3-1/2023-05 | SICK O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
1 About this document................................................................................. 9
1.1 Function of this document..............................................................................9
1.2 Scope of application .......................................................................................9
1.3 Target groups ..................................................................................................9
1.4 Further information .........................................................................................9
1.5 Symbols and document conventions ...........................................................10
1.5.1 Warning symbols...........................................................................10
1.5.2 Warning levels and signal words..................................................10
1.5.3 Information symbols .....................................................................11
1.6 Data integrity.................................................................................................11
2 For your safety..........................................................................................12
2.1 Basic safety information ...............................................................................12
2.2 Warning information on the device ..............................................................15
2.2.1 Information on the sender/receiver unit .....................................15
2.2.2 Information on the MCUDH Ex-3K control unit............................16
2.3 Intended use .................................................................................................17
2.4 Responsibility of user....................................................................................18
3 Product description .................................................................................20
3.1 Product identification....................................................................................20
3.2 Product characteristics .................................................................................21
3.3 Layout and function ......................................................................................21
3.3.1 Functional principle ......................................................................22
3.3.2 Protection concept........................................................................23
3.3.3 DUSTHUNTER SP100 Ex-3K sender/receiver unit ......................24
3.3.4 MCUDH Ex-3K control unit ...........................................................26
3.3.5 Conventional MCU control unit ....................................................28
3.3.6 Flange with tube ...........................................................................30
3.3.7 Purge gas supply...........................................................................30
3.3.8 Connecting cable and plug protection bracket ...........................31
3.3.9 Weather protection hood..............................................................31
3.3.10 Function check..............................................................................32
3.4 Explosion protection in accordance with ATEX ............................................34
3.4.1 Operation in potentially explosive atmosphere ...........................34
3.5 Application illustration DUSTHUNTER SP100 Ex-3K ...................................35
3.6 Interfaces ......................................................................................................36
3.6.1 Standard interfaces of the MCUDH Ex-3K control unit ...............36
3.6.2 Standard interfaces of the MCU control unit...............................37
3.6.3 SOPAS ET user interface ..............................................................37
Contents
Contents

Contents
48020216/1JQX/V3-1/2023-05 | SICKO P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
4 Project planning....................................................................................... 38
4.1 Device configuration..................................................................................... 38
4.1.1 Selecting the sender/receiver unit.............................................. 38
4.1.2 Selecting the flange with tube ..................................................... 39
4.1.3 Selecting the control unit............................................................. 40
4.2 Installation location ...................................................................................... 41
4.2.1 Project planning for measuring channel ..................................... 41
4.2.2 Space requirements for system components ............................. 42
4.2.3 Purge gas supply .......................................................................... 44
4.2.4 Project checklist ........................................................................... 46
5 Transport and storage............................................................................. 47
5.1 Transport....................................................................................................... 47
5.2 Storage.......................................................................................................... 47
6 Mounting ................................................................................................... 48
6.1 Mounting information................................................................................... 48
6.1.1 Proper mounting........................................................................... 48
6.2 Preparing the measuring point .................................................................... 48
6.3 Scope of delivery .......................................................................................... 48
6.4 Installation sequence ................................................................................... 48
6.4.1 Fitting the flange with tube .......................................................... 49
6.4.2 Fitting the MCUDH Ex-3K control unit ......................................... 50
6.4.3 Fitting the optional Remote Display 100 .................................... 50
6.4.4 High-temperature version ............................................................ 51
6.4.5 Fitting the weather protection hood ........................................... 52
7 Electrical installation............................................................................... 53
7.1 Electrical installation safety information ..................................................... 53
7.2 Connection overview .................................................................................... 53
7.2.1 Connection plan .......................................................................... 54
7.3 Information on connecting cables ............................................................... 55
7.4 Connecting the sender/receiver unit........................................................... 56
7.5 Connecting the control unit.......................................................................... 56
7.5.1 MCUDH Ex-3K control unit components...................................... 56
7.5.2 MCU control unit components ..................................................... 57
7.5.3 Remote Display 100 components ............................................... 57
7.5.4 Work to be done ........................................................................... 58
7.5.5 Processor boards connections of control units .......................... 59
7.5.6 Connecting cable to control unit.................................................. 60
7.6 Installing the purge gas supply .................................................................... 60
7.7 Connecting Remote Display 100 ................................................................. 60
7.7.1 Connecting to the MCUDH Ex-3K control unit............................. 60
7.8 MCHDH communication options.................................................................. 61

Contents
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8020216/1JQX/V3-1/2023-05 | SICK O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
8 Commissioning ........................................................................................64
8.1 Safety information on commissioning..........................................................64
8.2 Requirements for commissioning ................................................................64
8.3 Inserting and switching on............................................................................65
8.3.1 Adapting the sender/receiver unit to the duct geometry............65
8.3.2 Fitting and connecting the sender/receiver unit.........................65
8.4 Recognizing the safe operating state...........................................................66
9 Configuring................................................................................................67
9.1 Prerequisites .................................................................................................67
9.2 SOPAS ET.......................................................................................................67
9.2.1 Install SOPAS ET ...........................................................................67
9.2.2 Password for SOPAS ET ................................................................67
9.2.3 Changing the password for SOPAS ET menus.............................67
9.3 Connecting to the MCUDH Ex-3K control unit..............................................68
9.3.1 Connection via RS485 Service interface to USB.........................68
9.3.2 Connection MCUDH Ex-3K via RS485 Ethernet ..........................68
9.3.3 Connecting a separate Ethernet Interface module.....................68
9.3.4 Configuring the RS485 Modbus ASCII/RTU Interface module ...69
9.4 Connecting to the MCU control unit .............................................................70
9.4.1 Connection to the MCU via Ethernet............................................70
9.4.2 Configuring the Interface module of the MCU control unit.........70
9.4.3 Configuring the MCU control unit Ethernet module ....................71
9.5 System configuration ....................................................................................71
9.5.1 Application parameters ................................................................71
9.5.2 Assigning the control unit to the sender/receiver unit ...............72
9.5.3 Factory settings.............................................................................73
9.5.4 Setting the function check ...........................................................73
9.5.5 Setting the analog outputs parameters.......................................74
9.5.6 Setting the analog inputs parameters .........................................76
9.5.7 Setting the response time ............................................................77
9.5.8 Gravimetric comparison measurement / calibration..................77
9.5.9 Changing display settings.............................................................79
9.6 Finding the DUSTHUNTER COM port ............................................................81
10 Operation ..................................................................................................82
10.1 Operating concept.........................................................................................82
10.2 User groups ...................................................................................................82
10.2.1 Changing the password for user groups......................................82
10.3 MCUDH Ex-3K displays and operating elements.........................................82
10.4 MCUDH Ex-3K control unit buttons ..............................................................83
10.5 MCU control unit displays and operating elements.....................................83

Contents
68020216/1JQX/V3-1/2023-05 | SICKO P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
11 Menus........................................................................................................ 84
11.1 MCU and MCUDH Ex-3K control units menu structure ............................... 84
11.1.1 Configuration (Menu) ................................................................... 84
11.1.2 Warning and error messages (Diagnosis) ................................... 85
11.2 Configuring on the control unit display........................................................ 86
11.2.1 Configuring analog outputs and inputs of the control unit......... 86
11.2.2 Assigning the control unit to the sender/receiver unit............... 86
11.2.3 Entering the regression coefficients............................................ 86
12 Maintenance............................................................................................. 87
12.1 Safety information ...................................................................................... 88
12.2 Data backup.................................................................................................. 89
12.2.1 Data backup in SOPAS ET............................................................ 89
12.3 Maintenance plan......................................................................................... 90
12.4 Consumables and spare parts ..................................................................... 90
12.5 Maintenance on the sender/receiver unit................................................... 90
12.5.1 Cleaning the optics of the sender/receiver unit ......................... 91
12.5.2 Checking the contamination value.............................................. 92
12.5.3 Non-return valve........................................................................... 93
12.5.4 Test equipment for linearity test ................................................. 93
12.5.5 Power supply without control unit ............................................... 93
12.6 Maintenance work on the sender/receiver unit.......................................... 94
12.6.1 Checking laser alignment ............................................................ 95
12.6.2 Replacing the protection tube O-ring........................................... 96
12.6.3 Replacing the seal in the cleaning opening ................................ 96
12.6.4 Replacing the sinter filter............................................................. 97
12.6.5 Replacing the flange seal ............................................................ 97
12.6.6 Replacing the potential equalization screw ................................ 98
12.6.7 Replacing the protection tube ..................................................... 98
12.6.8 Replacing the hood ...................................................................... 99
12.6.9 Replacing the copper seal of the non-return valve..................... 99
12.6.10 Exchanging the non-return valve ...............................................100
12.7 Maintenance tasks for MCUDH Ex-3K control unit ...................................101
12.7.1 Replacing the button cell in the control unit.............................101
12.7.2 Replacing the MCUDH Ex-3K power supply unit .......................102
12.7.3 Replacing the RS485 Interface module....................................103
12.8 MCU control unit maintenance work .........................................................104
12.8.1 Replacing the button cell in the control unit.............................104
12.8.2 Replacing the Interface module ................................................104
13 Troubleshooting .....................................................................................105
13.1 Safety information ....................................................................................105
13.2 Monitoring and diagnostic system.............................................................106
13.3 Status display LED and display ..................................................................106

Contents
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8020216/1JQX/V3-1/2023-05 | SICK O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
13.4 Sender/receiver unit malfunctions ........................................................... 107
13.4.1 Malfunctions .............................................................................. 107
13.4.2 Warning and malfunction messages ........................................ 107
13.5 Control unit malfunctions .......................................................................... 109
13.5.1 Malfunctions .............................................................................. 109
13.5.2 Warning and malfunction messages ........................................ 109
13.6 Sender/receiver unit troubleshooting measures ..................................... 111
13.6.1 Setting the laser alignment ....................................................... 111
13.6.2 Checking the laser beam for free passage............................... 112
13.7 MCUDH Ex-3K control unit troubleshooting measures ............................ 113
13.7.1 Replacing the fuse..................................................................... 113
13.8 MCU control unit troubleshooting measures ............................................ 114
13.8.1 Replacing the fuse..................................................................... 114
13.9 Sending in devices ..................................................................................... 114
14 Decommissioning ................................................................................. 115
14.1 Switch-off states......................................................................................... 115
14.2 Switching off and dismantling ................................................................... 115
14.3 Return delivery ........................................................................................... 116
14.4 Disposal...................................................................................................... 116
15 Technical data ...................................................................................... 117
15.1 Dimensional drawings and part numbers................................................. 122
15.1.1 DHSP100 Ex-3K sender/receiver unit ..................................... 122
15.1.2 Flange with tube ........................................................................ 123
15.1.3 MCUDH Ex-3K control unit ........................................................ 124
15.1.4 MCU control unit ....................................................................... 125
16 Spare parts ............................................................................................ 127
16.1 Consumable parts...................................................................................... 127
16.1.1 Consumable parts DUSTHUNTER SP100 Ex-3K....................... 127
16.1.2 Consumable parts, MCUDH Ex-3K / MCU control unit............. 128
16.2 Spare parts................................................................................................. 128
16.2.1 Spare parts DUSTHUNTER SP100 Ex-3K.................................. 128
16.2.2 Spare parts, control unit............................................................ 128
17 Accessories............................................................................................ 129
17.1 Weather protection hood ........................................................................... 129
17.2 Connection technology .............................................................................. 129
17.2.1 Sender/receiver - control unit cable ......................................... 129
17.3 Fastening technology ................................................................................. 129
17.4 Optional accessories.................................................................................. 130
17.4.1 Options for MCUDH Ex-3K control unit ..................................... 130
17.4.2 Options for MCU control unit..................................................... 130
17.5 Other accessories ...................................................................................... 130
17.5.1 Device check accessories ......................................................... 130

Contents
88020216/1JQX/V3-1/2023-05 | SICKO P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
18 Annex.......................................................................................................131
18.1 Compliances ...............................................................................................131
18.2 Electrical protection....................................................................................131
18.3 Approvals ....................................................................................................131
18.4 Licenses ......................................................................................................132

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8020216/1JQX/V3-1/2023-05| SICK O P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
ABOUT THIS DOCUMENT 1
1Aboutthisdocument
1.1 Function of this document
These Operating Instructions describe:
●Device components
●Installation
●Operation
●Maintenance tasks necessary for safe operation
1.2 Scope of application
These Operating Instructions apply exclusively to the measuring system described in the
product identification (see “Product identification”, page 20).
The Operating Instructions are not applicable for other SICK measuring devices.
The standards mentioned in the Operating Instructions must be observed in their currently
valid version.
1.3 Target groups
This Manual is intended for persons who install, operate and maintain the device.
Operation
The device may only be operated by authorized persons who, based on their device-specific
training as well as knowledge of the relevant regulations, can assess the tasks given and
recognize the hazards involved.
Installation and maintenance
Installation and maintenance may only be carried out by trained specialists familiar with
the installation conditions.
Observe the information at the beginning of the respective Sections.
1.4 Further information
Observe the enclosed data medium for the product, as well as other supplied documents.
Further information on the internet under: sick.com

10 8020216/1JQX/V3-1/2023-05| SICKO P E R A T I N G I N S T R U C T I O N S | DUSTHUNTER SP100 Ex-3K
Subject to change without notice
1ABOUT THIS DOCUMENT
1.5 Symbols and document conventions
1.5.1 Warning symbols
Table 1: Warning symbols
1.5.2 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.
Note
Hints.
Symbol Significance
Hazard (general)
Hazard by voltage
Hazard by laser radiation
Hazard in potentially explosive atmospheres
Hazard for environment and organisms