SICK DUSTHUNTER T User manual

OPERATING INSTRUCTIONS
DUSTHUNTER T
Dust Measuring System
Installation
Operation
Maintenance

2 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Subject to change without notice
Document Information
Described Product
Product name: DUSTHUNTER T
Variants: DUSTHUNTER T50
DUSTHUNTER T100
DUSTHUNTER T200
Document ID
Title: Operating Instructions DUSTHUNTER T
Part No.: 8012428
Version: 2.2
Release: 2014-04
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Place of Manufacture
SICK Engineering GmbH
Bergener Ring 27 · D-01458 Ottendorf-Okrilla · Germany
Trademarks
Windows is a Microsoft Corporation trademark.
Other product names used in this document may also be trade-
marks and are only used for identification purposes.
Original Documents
The English edition 8012428 of this document is an original
document from SICK AG.
SICK AG assumes no liability for the correctness of an
unauthorized translation.
Please contact SICK AG or your local representative in case of
doubt.
Legal Information
Subject to change without notice.
© SICK AG. All rights reserved.

DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 3
Subject to change without notice
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
Important technical information for this product
Supplementary information
Link to information at another place

Contents
4 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Subject to change without notice
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Main hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.1 Hazards from hot and/or aggressive gases and/or high pressure. . . . . . . . . . . . . . . 8
1.1.2 Hazards through electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 Safety information and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Measuring principle, measured variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 Response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Device components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.1 Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.2 Reflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.3 Flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.4 MCU control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.5 Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.6 Installation accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2.7 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.8 Device check accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Device features and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.1 Device features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.2 Device configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 Assembly and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1 Project planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.1 Fitting the flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.2 Fitting the MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.2.3 Fitting the optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.2.4 Fitting the weatherproof cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2.5 Installing fail-safe shutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.2.6 Installing optional components for hall air monitoring . . . . . . . . . . . . . . . . . . . . . . . . 43

Contents
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 5
Subject to change without notice
3.3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.1 General information, prerequisites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3.2 Connecting/starting the optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . 44
3.3.3 Installing the purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.3.4 Connecting the MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3.5 Connecting the reflector on DUSTHUNTER T200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3.6 Fitting and connecting optional Interface and I/O modules . . . . . . . . . . . . . . . . . . . . 50
4 Start-up and Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1.2 Installing the operating and parameter program SOPAS ET . . . . . . . . . . . . . . . . . . . . 52
4.1.3 Connecting to the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.3.1 Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1.3.2 Configuring the interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1.3.3 Connecting using the "Network Scan Assistant" tab . . . . . . . . . . . . . . . . . . . . . . . 57
4.1.3.4 Create a connection using menu "Connection Wizard" (as from SOPAS ET
Version 02.32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.1.3.5 Select device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1.4 Information on using the program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1.5 Online help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.2 Application specific settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2.1 Preparatory work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2.2 Focussing the sender light beam for transmission measurement . . . . . . . . . . . . . . 65
4.2.3 Scaling the measuring system for transmission measurement. . . . . . . . . . . . . . . . . 68
4.2.4 Entering application-specific parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.3 Installing the sender/receiver unit and reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3.1 Connecting the sender/receiver unit and reflector to the purge air supply . . . . . . 72
4.3.2 Fitting and connecting the sender/receiver unit and reflector on the duct . . . . . . 72
4.4 Setting standard parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4.1 Assigning the MCU to the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.4.2 Factory settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.4.3 Determining the function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.4.4 Setting the analog outputs parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.4.5 Setting the analog inputs parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4.6 Setting the response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.4.7 Calibrating for dust concentration measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.4.8 Data backup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.4.9 Starting normal measuring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.5 Setting the Interface module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.5.2 Setting the Ethernet module parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Contents
6 DUSTHUNTER T · Operating Instructions · 8012428 V 2.2 · © SICK AG
Subject to change without notice
4.6 Operating/setting parameters via the optional LC-Display . . . . . . . . . . . . . . . . . . . . . . . 93
4.6.1 General information on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.6.2 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.6.3 Setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.6.3.1 MCU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.6.3.2 Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.6.4 Using SOPAS ET to modify display settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.2 Maintenance on the sender/receiver unit and reflector . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2.1 Maintenance on the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2.2 Maintenance on the reflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.3 Maintenance on the purge air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.3.1 Control unit with integrated purge air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.3.2 Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5.4 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.2 Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.3 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.2 Dimensions, Part Nos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.2.1 Sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.2.2 Reflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.2.3 Flange with tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.2.3.1 Flange with tube (standard version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.2.3.2 Flange with tube for fitting the fail-safe shutter . . . . . . . . . . . . . . . . . . . . . . . . . . 131
7.2.4 MCU control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.2.5 Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.2.6 Weatherproof covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
7.2.7 Optional components for hall air monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.3 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.1 Connection cable, sender/receiver unit - MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.2 Connection cable, sender/receiver unit - reflector. . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.3 Purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.4 Assembly parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.5 Device check accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.6 Options for MCU control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.3.7 Misc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.4 Expendable parts for 2 years of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.4.1 Sender/receiver unit and reflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.4.2 Control unit MCU with integrated purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.4.3 Optional external purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.5 Password. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Important Information
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 7
Subject to change without notice
DUSTHUNTER T
1Important Information
Main hazards
Intended use
Responsibility of user

8 DUSTHUNTER T · Operating Instructions · 8012428 V 2.2 · © SICK AG
Important Information
Subject to change without notice
1.1 Main hazards
1.1.1 Hazards from hot and/or aggressive gases and/or high pressure
The optical subassemblies 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
The DUSTHUNTER T measuring system is operational equipment for use in industrial high-
voltage current plants.
WARNING: Danger from exhaust gas
 On equipment with gases detrimental to health, high pressure or high
temperatures, the sender/receiver units and reflector components fitted on
the duct may only be installed/removed when the equipment is at a
standstill.
WARNING: Danger through power voltage
 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.

Important Information
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 9
Subject to change without notice
1.2 Intended use
Purpose of the device
The DUSTHUNTER T 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 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 T measuring system is not approved for use in potentially explosive
atmospheres.

10 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Important Information
Subject to change without notice
1.3 Responsibility of user
1.3.1 General information
Designated users
The DUSTHUNTER T 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.
Special local conditions
 Observe the valid legal regulations as well as the technical rules deriving from imple-
mentation 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.
1.3.2 Safety information and protective measures
Protection devices
Behavior during purge air failure
The purge air supply serves to protect optical subassemblies fitted on the duct against hot
or aggressive gases. Leave the supply switched on when the equipment is at a standstill.
Optical subassemblies can be severely damaged in a short time if the purge air supply
fails.
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:
 The purge air supply runs reliably and continuously
 Failure of the purge air supply is immediately detected (e.g. by using
pressure monitors)
 Optical subassemblies are removed from the duct if the purge air supply
fails and the duct opening is closed off (e.g. with a flange cover).

Important Information
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 11
Subject to change without notice
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:
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 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.

12 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Important Information
Subject to change without notice

Product Description
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 13
Subject to change without notice
DUSTHUNTER T
2Product Description
Measuring principle, measured variables
Device components
Device features and configuration

14 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Product Description
Subject to change without notice
2.1 Measuring principle, measured variables
2.1.1 Functional principle
A high performance LED sends light in the visible range (white light, wavelength approx.
450 to 700 nm) through the active measuring path containing particles to the reflector
where it is bounced back to the receiver (
 Fig. 1). A highly sensitive measurement receiver
accepts the signal weakened by particles, amplifies the signal electrically and feeds it to
the measuring channel of a microprocessor as central part of the measuring, control and
evaluation electronics.
Continuous monitoring of the sender output (partial beam to monitor receiver) registers the
smallest changes in brightness of the light beam sent which then serves to determine the
measurement signal.
Figure 1 Measuring principle
Measured variables
The measuring system uses transmission (T) as primary optical measured variable. The
other measured variables opacity (O), relative opacity (ROPA), absorption (E) and dust
concentration (c) are derived from this variable.
Transmission, opacity, relative opacity:
Transmission, opacity and relative opacity are usually specified in percent.
Extinction:
LED Reflector
Measurement Monitor
receiver receiver
Active measuring path
(gas flowing through, free path)
Concave mirror
TN
Imeas
Imon
------------
=
O1T–=
ROPA 1 e
EDDo
2D
meas

-----------------------

–=
N = scaling constant
Imeas = light received
Imon =monitorsignal
DDo = stack diameter at the top end
Dmeas= active measuring path
E1
T
---


log=

Product Description
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 15
Subject to change without notice
Dust concentration:
Based on the Beer-Lambert law, the dust concentration is derived from the extinction as
follows:
Extinction is directly proportional to dust concentration for constant particle size and
uniform dust distribution.
Particle size, dust density and dust distribution during differing load states influence
transmission and extinction values and therefore the measuring system must be calibrated
using a gravimetric comparison measurement for exact dust concentration measurement.
The calibration coefficient determined can be entered directly in the measuring system as
c = cc2 ·E² + cc1 ·E + cc0
(Entry
 p. 82, §4.4.7; standard factory setting: cc2 = 0, cc1 = 1, cc0 = 0).
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.
Figure 2 Response time
2.1.3 Function check
A function check can be triggered at fixed intervals as from a definable starting timepoint
for an automatic function check of the measuring system. The setting can be made using
the SOPAS ET operating program (
 p. 76, §4.4.3). Any unallowed deviations from normal
behavior that may occur are signaled as errors. A function check triggered manually can
help localize possible error causes should a device malfunction occur.
c231E
kL
---------------------KE== k = extinction constant
L = 2x active measuring path (due to double beam path)
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 %
Further information Service Manual

16 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Product Description
Subject to change without notice
The function check comprises:
●Approx. 30 s measurement of contamination of optical interfaces (not for DUSTHUNTER
T50), zero and control value
The measuring time depends on the increase in contamination value (change > 0.5% →
measurement is repeated up to 2 times).
●Every 90 s (standard value), output of values determined (duration parameter can be
modified
 p. 76, §4.4.3).
Figure 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.
●The analog output must be activated to output control values on the analog
output (
 p. 77, §4.4.4).
●The value measured last is output on the analog output during control
value determination.
●If the control values are not output on the analog output, the current
measured value is output when control value determination has completed.
●During a function check, relay 3 (
 p. 48, Fig. 29) is activated and the green
LED in the control window of the sender/receiver unit flashes (
 p. 19,
Fig. 7).
●A function check is not started automatically when the measuring system is
in "Maintenance" mode.
●"Function check" is displayed on the display during the function check when
using a control unit with the optional Display module.
●If the start timepoint or cycle interval are changed, a control cycle timed
between parameter setting and new start timepoint is still carried out.
●Changes to the interval time are first effective after the next start
timepoint.
Contamination degree
(Live Zero = 0%,
20 mA = X *)
Contamination output
Control value output
(70%-value, span)
Zero value output (Live Zero)
*: X = 30% for
DUSTUHUNTER T100
and 40% for
DUSTHUNTER T200
Function check
start
Control value
determination
Paper feed
Function check
end

Product Description
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 17
Subject to change without notice
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 fault message is
cleared again when the next functional check runs successfully. The control value is
determined with high precision through statistical evaluation of a high number of intensity
changes.
Contamination measurement (not on DUSTHUNTER T50)
The glass panes positioned in the sender beam during normal measurement are swiveled
away during contamination determination. The measured value determined and the value
defined during scaling are used to calculate a correction factor
 p. 68, §4.2.3. This fully
compensates any contamination that occurs.
Contamination is determined on one side on the DUSTHUNTER T100 (pivoted shutter only
on the sender/receiver unit) and on both sides on the DUSTHUNTER T200 (pivoted shutter
also on the reflector).
Figure 4 Contamination measurement principle (on both sides)
An analog value between live zero and 20 mA proportional to contamination is output
during the check cycle for contamination values < 30%, (DUSTHUNTER T100) or 40%
(DUSTHUNTER T200); when this value is exceeded, the "Malfunction" status is output (for
the fault current set on the analog output for this case;
 p. 75, §4.4.2,  p. 77, §4.4.4).
Figure 5 Pivoted shutter settings on the sender/receiver unit
Sender/receiver unit Reflector
Pivoted shutter
Measuring position Contamination measurement
Glass pane
Control
reflector
(only on the
sender side)
Pivoted
shutter

18 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Product Description
Subject to change without notice
2.2 Device components
Measuring system DUSTHUNTER T comprises as standard the components (  Fig. 6):
●Sender/receiver unit DHT-T
●Connection cable to connect the sender/receiver unit to the control unit (lengths 5 m,
10 m)
●Reflector DHT-R
●Connection cable to connect the reflector to the sender/receiver unit (only for DUST-
HUNTER T200, lengths 5 m, 10 m, 20 m, 50 m)
●Flange with tube
●Control unit MCU 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
●Purge air hose for supply by control unit MCU-P
Figure 6 DUSTHUNTER T device components
Communication between sender/receiver unit and MCU
As standard, each sender/receiver unit is connected to one control unit via the connection
cable.
MCU-P
(with purge
air supply)
Optionalexternal
purge air unit
Sender/receiver unit
Purge air hose
Connection
cable
Operating and
parameter
setting program
SOPAS ET
Reflector
Flange with tube
Connection cable
USB 1.1
(RS 232)
Power
supply
Duct
Optional
MCU-N
(without
purge air
supply)
Purge air hose

Product Description
DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG 19
Subject to change without notice
2.2.1 Sender/receiver unit
The sender/receiver unit contains the optical and electronics subassemblies to send and
receive the reflected light beam as well as to process and evaluate the signals. Versions
with contamination measurement are also fitted with swivel mechanisms (
 p. 17, Fig. 5
and
 p. 20, Fig. 8).
Figure 7 Sender/receiver unit DHT-Txx
B
Sender/receiver unit for DUSTHUNTER T100/200
Sender/receiver unit for DUSTHUNTER T50
Purge air connection
Control window
A
A
B
B
Connection for connection cable to reflector (only DUSTHUNTER T200)
Flange
Mounting holes
Knurled screw
Housing with electronics (swivel-mounted)
Handle
Connection for connection cable to MCU
Hinge
Connection for connection cable to MCU
Flange
Purge air connection
Control window
A
A
B
Mounting holes
CAMLOCK clip
Handle
Control window
Status
indicator
Alignment
indicator
Electronics unit
Mounting attachment

20 DUSTHUNTER T · Operating Instructions · 8012428 V2.2 · © SICK AG
Product Description
Subject to change without notice
Data transfer to and power supply (24 V DC) from the control unit run via a shielded cable
with 4 wires and plug-in connector. An RS485 interface is available for service purposes.
Clean air to cool the probe 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 (
 p. 18, Fig. 6).
The alignment of the optical axes as well as the current device state (operation = green
LED, malfunction = red LED, maintenance request = yellow LED;
 p. 19, Fig. 7) are shown at
the control window.
On DUSTHUNTER T100/T200, the housing with fitted sender/receiver unit can be swiveled
to the side after the knurled screws have been loosened. Optics, electronics and
mechanical components can then be easily accessed for maintenance tasks.
Self-alignment functionality (only DUSTHUNTER T200)
The sender module can be moved horizontally and vertically using motors and bevel gears
so that the sender light beam can be adjusted by approximately 2° in all directions.
Tracking is performed using the measurement signal on the 4 quadrants of the
measurement receiver. This allows automatic compensation of optical axis misalignment
caused by, for example, distortion of duct walls due to temperature fluctuations.
Figure 8 Self-alignment principle design
Type code
A type code identifies the special sender/receiver unit version:
(Sender/receiver unit)
Base plate
Retaining
bracket
AA
Drive
Tension spring
Bevel
gear
Sender module
Sender/receiver unit: DHT-TXX
Contamination measurement:
- 0: Without
- 1: With contamination measurement on one side (sender side only)
- 2: With contamination measurement on both sides
Self-alignment:
- 0: Without
- 1: With