1 FW300 Dust Concentration Monitor Operating Instruction

O p e r a ti n g i n s t r u ctio n s
FW300
Dust Concentration Monitor
In-situ Dust Measurement and Output of
Transmission, Opacity, Extinction and
Dust Concentration
Analyzers and Process Instrumentation
FW300
Operating Instructions
Contents
Notes on this Document ....................................................................................................7
1 Safety Instructions...............................................................................................................8
1.1
Intended Use .............................................................................................................................8
1.2
Authorized Personnel..............................................................................................................8
1.3
Safety Information and Protection Measures.................................................................8

1.3.1
Danger from Electrical Equipment ................................................................................................. 9
1.3.2
Danger Due to Hot, Corrosive, or Pressurized Gases ........................................................... 9
1.3.3
Purge-Air Failure .................................................................................................................................... 9
1.3.4
Detecting and Preventing Malfunctions ....................................................................................... 9
2 Product Description.......................................................................................................... 11
2.1
Features and Applications ................................................................................................. 13
2.2
Operating Principle and Measured Variables .............................................................. 14
2.3
8 010 038 / 08-2006
2.2.1
Operating Principle ............................................................................................................................ 14
2.2.2
Calculating Transmission, Opacity, and Extinction ................................................................. 14
2.2.3
Determining the Dust Concentration .......................................................................................... 15
2.2.4
Response time .................................................................................................................................. 16
2.2.5
Check Cycle.......................................................................................................................................... 17
Device Components............................................................................................................. 18
2.3.1
Transmitter/Receiver Unit .............................................................................................................. 18
2.3.2
Reflector................................................................................................................................................. 20
2.3.3
Device Attachment ............................................................................................................................ 21
2.3.4
Flange with Pipe ................................................................................................................................. 22
2.3.5
Connection Unit ................................................................................................................................. 22
2.3.6
External Purge-Air Unit (Optional) ................................................................................................ 24
2.3.7
Data Acquisition, Communication, Measured Value Output, and Display Options.... 24
2.3.8
Optional Components for Monitoring Air in Workshops ...................................................... 25
2.3.9
Optional Components for Higher Internal Duct Pressures ................................................. 26
2.3.10
Accessories for Testing the Device............................................................................................. 26
2.4
Device Configuration ........................................................................................................... 27
2.5
Technical Data ...................................................................................................................... 28
SICK MAIHAK GmbH Germany All rights reserved
FW300
2.6
Dimensions and Order Numbers....................................................................................... 30

2.6.1
Transmitter/Receiver Unit .............................................................................................................. 30
2.6.2
Reflector................................................................................................................................................. 30
2.6.3
Device Attachment ............................................................................................................................ 31
2.6.4
Flange with Pipe ................................................................................................................................. 31
2.6.5
Connection Unit................................................................................................................................... 32
2.6.6
External Purge-Air Unit (Optional) ................................................................................................ 33
2.6.7
Weatherproof Cover For Transmitter/Receiver Unit and Rotating Reflector ............... 34
2.6.8
Optional Components for Monitoring Air in Workshops ...................................................... 35
3 Assembly and Installation...............................................................................................37

3.1
Project Planning .................................................................................................................... 39
3.2
Assembly ................................................................................................................................. 40
3.3
3.2.1
Installing the Flanges with Pipe .................................................................................................... 40
3.2.2
Installing the Connection Unit ....................................................................................................... 42
3.2.3
Installing the Optional External Purge-Air Unit ........................................................................ 43
3.2.4
Fitting the Weatherproof Covers .................................................................................................. 44
3.2.6
Installing optional Components for Monitoring Air in Workshops .................................... 45
Installation............................................................................................................................... 46
3.3.1
General Instructions and Prerequisites .................................................................................... 46
3.3.2
Connection Unit .................................................................................................................................. 46
3.3.3
Connecting/Commissioning the Optional External Purge-Air Unit ................................... 48
3.3.4
Mounting the Device Attachments .............................................................................................. 49
3.3.5
Installing the Purge-Air Supply ....................................................................................................... 50
3.3.6
Connecting optional Devices ........................................................................................................ 51
4 Commissioning and Parameterization ........................................................................55

4.1
4.2
Basics ....................................................................................................................................... 57
4.1.1
General Notes .................................................................................................................................... 57
4.1.2
Prerequisites ....................................................................................................................................... 57
Normalization.......................................................................................................................... 58
4.2.1
Basics .................................................................................................................................................... 58
4.2.2
Focusing the Transmitter Light Beam......................................................................................... 59
4.2.3
Normalization ....................................................................................................................................... 60
4.3
Installing and Connecting the Transmitter/Receiver Unit and Reflector ........... 62
4.4
Parameterization ................................................................................................................... 63
4.4.1
Customer-Specific Parameterization........................................................................................... 63
4.4.2
Parameterization for Dust Concentration Measurement .................................................... 65
4.4.3
Data backup ........................................................................................................................................ 66
4.4.4
Starting Standard Measuring Mode ............................................................................................ 67
8 010 038 / 08-2006
FW300
4.5
Parameterizing Optional Devices ................................................................................... 68

4.5.1
Data Memory / Event Memory ..................................................................................................... 68
4.5.2
CAN Module ......................................................................................................................................... 71
4.5.2
Second Analog Output ..................................................................................................................... 72
4.5.3
LCD .......................................................................................................................................................... 72
5 Maintenance....................................................................................................................... 73
5.1
General ..................................................................................................................................... 75
5.2
Maintaining the Transmitter/Receiver Unit and Reflector ...................................... 76
5.3
Maintaining the Purge-Air Supply .................................................................................... 77
5.4
5.3.1
Connection Unit with Integrated Purge-Air Supply ................................................................. 78
5.3.2
External Purge-Air Unit (Optional) ................................................................................................. 79
Removal from Service.......................................................................................................... 80
6 Troubleshooting ................................................................................................................. 81
6.1
No Indication .......................................................................................................................... 83
6.2
Warnings and Malfunction Messages .......................................................................... 84
6.3
6.2.1
Malfunction Messages ..................................................................................................................... 84
6.2.2
Warnings ................................................................................................................................................ 86
6.2.3
Other Malfunctions and Abnormal Behavior ............................................................................ 86
Test and Diagnosis Options............................................................................................... 88

6.3.1
Testing the Signal Output ................................................................................................................ 88
6.3.2
Check Cycle.......................................................................................................................................... 88
6.3.3
Linearity Check.................................................................................................................................... 89
7 Repairs.................................................................................................................................. 91
7.1
Transmitter/Receiver Unit.................................................................................................. 93
7.1.1
7.2
7.3
8 010 038 / 08-2006
Replacing the LP Processor ........................................................................................................... 94
7.1..2
Replacing the Optics Holder with Receiver Electronics ....................................................... 94
7.1.3
Replacing the Entire T/R Unit Connector................................................................................... 95
7.1.4
Replacing the FW300SE Housing................................................................................................ 95
7.1.5
Checking/Replacing the Battery for the Transmitter/Receiver Unit ................................ 96
Rotating Reflector ................................................................................................................ 97

7.2.1
Replacing the Reflector.................................................................................................................... 97
7.2.2
Replacing the Front Window with the Holder........................................................................... 98
7.2.3
Replacing the Housing for the Rotating Reflector.................................................................. 98
Connection Unit..................................................................................................................... 99
7.3.1
Connection Unit Without Purge-Air Supply................................................................................ 99
7.3.2
Connection Unit with Integrated Purge-Air Supply ...............................................................101
FW300
8 Parts Overview................................................................................................................. 105

8.1
8.2
8.3
8.4
Standard Components.......................................................................................................107
8.1.1
Transmitter/Receiver Units .......................................................................................................... 107
8.1..2
Reflectors ........................................................................................................................................... 107
8.1.3
Device Attachments ....................................................................................................................... 108
8.1.4
Flanges with Pipe............................................................................................................................. 108
8.1.5
Connection Units.............................................................................................................................. 108
8.1.6
External Purge-Air Units (Optional) ........................................................................................... 108
8.1.7
Purge-Air Hoses ............................................................................................................................... 109
8.1.8
Power Supply Cables for the Rotating Reflectors ............................................................... 109
8.1.9
Miscellaneous .................................................................................................................................. 109
Options ...................................................................................................................................110
8.2.1
Transmitter/Receiver Units .......................................................................................................... 110
8.2..2
Connection Units.............................................................................................................................. 110
8.2.3
Device Attachments ....................................................................................................................... 111
8.2.4
Purge-air Connection...................................................................................................................... 111
8.2.5
Weatherproof Covers ................................................................................................................... 111
8.2.6
Optional Components for Monitoring Air in Workshops ................................................... 112
8.2.7
Optional Components for Higher Internal Duct Pressures .............................................. 112
8.2.8
Accessories for Testing the Device.......................................................................................... 112
8.2.9
Miscellaneous .................................................................................................................................. 112
Consumable Parts for 2-Year Operation......................................................................113

8.3.1
Connection Unit with Internal Purge-Air Supply.................................................................... 113
8.3.2
External Purge-Air Unit (Optional) .............................................................................................. 113
Spare Parts............................................................................................................................114
8.4.1
Transmitter/Receiver Unit ............................................................................................................ 114
8.4.2
Reflector.............................................................................................................................................. 115
8.4.3
Device Attachment ......................................................................................................................... 115
8.4.4
Connection Unit................................................................................................................................ 115
8.4.5
Miscellaneous .................................................................................................................................. 115
9 Appendix............................................................................................................................ 117
9.1
Standard Settings for the FW300..................................................................................119
9.2
Password ...............................................................................................................................120
8 010 038 / 08-2006
Notes On This Document
FW300
Notes On This Document

These operating instructions describe the functioning of the FW300 dust measuring system.
They contain general information on planning, assembly, installation, commissioning,
maintenance, and troubleshooting. The description of the available device components is
intended to help you during the planning phase to determine the optimum configuration for
the particular application.
These operating instructions only cover standard applications that conform to the technical
data listed. Your SICK representative will be glad to provide you with additional information
and support for special applications. We strongly advise that you contact a SICK specialist
for consultation on special applications.
Note
Always read these operating instructions carefully before commencing work. The safety
instructions and warnings must be followed at all times.
Some system components (such as the side-channel compressor of the purge-air units)
are supplied with separate user information. This information must also be read carefully.
Symbols used in this document

For quick access and reasons of clarity, important safety information is specially highlighted
in these operating instructions. They are provided at the relevant points in the chapters.
Note
Provides information on the features of the device or system, along with additional tips.
Important
Indicates a risk of damage to the device or system components and potential functional
impairments.
ATTENTION
Warning
DANGER
Identifies potential danger for personnel, particularly due to electrical equipment or as a

result of incorrect handling of the device or system components. These warnings are
intended to protect you from (fatal) injuries.
Always read warnings carefully and follow them at all times!
8 010 038 / 08-2006
Safety Instructions
FW300
Safety Instructions
1.1 Intended Use
The FW300 measuring system measures transmission, opacity, and dust concentration. It
must only be operated in the manner intended by the manufacturer and in accordance with
the following information. In particular, it is important that:
The system is operated in accordance with the technical data and specifications
regarding assembly, connection, ambient, and operating conditions (see the
documentation supplied, the order documents, device documents, and rating plates)
All of the measures required to maintain the device, for example, for maintenance and
inspection requirements, are provided.
1.2 Authorized Personnel

Those responsible for personal safety must ensure that:
All work on the measuring system is carried out by qualified personnel and checked by
the experts responsible.
These persons must be qualified by virtue of their expertise (training, education,
experience) or understanding of the relevant standards, specifications, accident
prevention regulations, and properties of the system. It is crucial that these persons be
able to identify and avoid potential hazards in good time.
Technical experts are those persons defined in DIN VDE 0105, IEC 364, or other directly
equivalent standards.
These persons must be familiar with the hazards posed during operation, such as those
caused by hot, toxic, or pressurized gases, gas/liquid mixtures, or other media, and must
have received special training on how to operate the measuring system.
1.3
General Safety Information and Protection Measures

Handling or using the device incorrectly can result in personal injury or material damage.
Read this chapter carefully and ensure that you observe the safety precautions for the
FW300 at all times. Always observe the warnings provided in these operating instructions.
The following applies at all times:
The relevant legal stipulations and associated technical regulations must be observed
when preparing and carrying out work on the installation.
All work must be carried out in accordance with the local, system-specific conditions and
with due consideration paid to the operating dangers and specifications.
The operating instructions for the measuring system and plant documentation must be
available on site. The instructions for preventing danger and damage contained in these
documents must be observed at all times.
Suitable safety equipment and personal protection measures must be available in
accordance with the potential hazard and must be used by the personnel.
1.3.1
Danger from Electrical Equipment

The FW300 measuring system is an item of electrical equipment designed for use in
industrial power installations. When working on power connections or on live components,
make sure that the power supply is switched off. If necessary, replace shock protection
measures before reconnecting the power supply.
8 010 038 / 08-2006
Safety Instructions
FW300
1.3.2
Danger Due to Hot, Corrosive, or Pressurized Gases

The transmitter/receiver unit and reflector are mounted directly on the gas-carrying duct. In
installations with a low hazard potential (no risk of injury, ambient pressure, low
temperatures, no risk of explosion), these units can be installed and removed while the
installation is in operation, provided that the applicable specifications and safety regulations
for the installation are adhered to and all necessary and suitable protective measures are
taken.
Warning
Installations with toxic gases, high temperatures, high pressure, or risk of explosion must be
shutdown before these components are installed or removed!
DANGER
1.3.3
Danger Due to Laser Beam

The FW300 uses a laser with protection class 2. To prevent blinding:
Never look directly into the laser beam.
Do not direct the FW300 laser beam towards people.
WARNING
1.3.4
Take into account reflections of the laser beam.

Purge-Air Failure
The purge-air supply protects the components fitted in the duct against hot or corrosive
gases. It must remain switched on when the plant is shut down. A purge-air supply failure
can quickly destroy the transmitter/receiver unit and reflector. For this reason, the operator
must ensure that:
The purge-air supply operates reliably and without interruption.
A failure is detected immediately (for example, by using pressure monitors).
ATTENTION
8 010 038 / 08-2006
The transmitter/receiver unit and reflector are removed from the duct in the event of a
purge-air failure and the duct openings are covered (for example, with a flange cover).
Safety Instructions
FW300
1.3.5
Detecting and Preventing Malfunctions

Any deviations from normal operation must be regarded as a serious indication of a
functional impairment. These include:
Significant drifts in the measurement results
A rise in power consumption
A rise in system component temperature
Triggering of monitoring devices
Unusually strong vibrations / unusual operating noise from a purge-air fan
Smoke or unusual odors
1.3.6
Shutdown, Removal from Service, and Storing System Components

The FW300 measuring system must remain switched on when the plant is shut down. The
purge-air supply must never be switched off.
If the FW300 operating voltage is switched off for a prolonged period (more than 3 days),
all the device components must be disassembled and stored in a dry, dust-free location.
10
8 010 038 / 08-2006
FW300
Product Description
Features and Applications

Operating Principle and Measured Variables
Device Components
Device Configuration
Technical Data
Product Description
FW300
Product Description
2.1
Features and Applications

The FW300 measuring system from SICK AG is a two-step direct transmissiometer. It
enables continuous, instantaneous in-situ measurement and can output the following
measured variables:
Transmission
Opacity
Extinction
Dust concentration in mg/m in the operating status (in accordance with gravimetric
comparison measurement)
Features and benefits
Very long measuring path (0.5 m to 15 m)
Modular design
Depending on the application conditions, the FW300 can be assembled using individual
components in such a way that it can fulfill a wide range of requirements and can thus be
used in many different applications.
Integrated measurement of the dust content across the duct diameter, independent of
the flow velocity, humidity, and particle burden.
Digital processing of the measurement values ensures a high level of accuracy and low
susceptibility to interference.
No fittings in the gas flow, which means that device components do not come into direct
contact with the medium to be measured.
Straightforward installation and commissioning
Simple operation and configuration with user-friendly software
Minimum maintenance requirements
Applications
Monitoring emissions from industrial plants to ensure that they remain within limits.
Monitoring filter installations to ensure that they are in working order.
Measuring the dust concentration in flue and exhaust gas ducts.
Monitoring dust burdens in workshops.
Measuring dust emissions on slag heaps, as well as in quarries and mills.
8 010 038 / 08-2006
13
Product Description
FW300
2.2
Operating Principle and Measured Variables
2.2.1
Operating Principle
The FW300 uses the transmissiometry measuring principle. An LED (for measuring paths of
up to 2 m) or a laser diode (for measuring paths of up to 15 m) acts as a light source. The
light in the visible range (wavelength: approx. 650 nm) is sent to the reflector across the
particle-laden measuring path and reflected to the receiver (see Fig. 2.1). When the light
passes through the measuring path twice, it is attenuated by the particles and captured by
the measuring detector (photo-diode). Its reception signal is amplified as an electrical signal
and fed to the measuring channel of a micro-processor, which is a central component of the
measurement, control, and analysis systems.
The transmitter power of the transmitter diode is continuously monitored and maintained at
a steady level. A beam-splitting mirror in front of the transmitter/receiver unit outlet diverts
part of the beam to the monitor detector. Its reception signal is also amplified and then fed
to the monitor duct of the micro-processor. This enables even the smallest changes in the
brightness of the light beam to be detected and taken into account when the output signal
is determined.
Monitor detector
(reference)
Transmitter
diode
Reflector
Measuring
detector
Measuring path
Fig. 2.1: FW300 measuring principle
2.2.2
Calculating Transmission, Opacity, and Extinction

The FW300 uses the following measured variables: transmission, opacity, and extinction.
Transmission is the optical variable from which the other measured variables are derived.
Transmission is defined as follows:
I
T=
where:
14
I0
T = transmission,
I = light received
I0 = light emitted
8 010 038 / 08-2006
Product Description
FW300
Provided that the light is not attenuated by particles, the following result is calculated:
I = I0
In other words, the transmission is no more than 1 or 100 %. Since the light received is also
attenuated by device-specific and distance-related influences along the particle-free
measuring path, a normalization constant (N) must also be used to ensure that transmission
really is 1 or 100%.
With the FW300, measuring signal Imeasure is used instead of I and Imon is used instead of I0.
In this way, transmission is calculated on the basis of the constant (N) determined (see
section 4.2) and saved during normalization. The following formula is used:
Imeasure
T = N
Imon
The measured variables 'opacity' and 'extinction' are derived from 'transmission' in
accordance with the following formulas.
Opacity:
O= 1 - T
Extinction:
E = log
(T )
'Transmission' and 'opacity' are normally specified in %; the results of the formulas must
then be multiplied by 100 % accordingly.
2.2.3
Determining the Dust Concentration

The attenuation of a light beam through absorption and particle scattering is described by
the Lambert-Beer law.
I = I0 e
where:
-c k L
c = dust concentration
k = extinction constant
L = double measuring path (due to double transmission; see Fig. 2.1)
Conversion to c results in:

ln
c=
( II )
0
-kL
Using extinction, the result is as follows:

c=
2.31 E
kL
=KE
This means that with a consistent particle size and homogeneous dust distribution,
extinction is directly proportional to the dust concentration in mg/m. Fig. 2.2 shows the
ideal correlation between extinction and dust concentration.
8 010 038 / 08-2006
15
Product Description
FW300
5 m
3 m
2 m
100
90
Particle size
Reference:
Each 80 % under the
specified value
Dust concentration in mg/m
80
70
60
50
Values for fly ash with 2.5

g/m density
and 1 m measuring path
40
30
20
10
Transmission in %
0
100
98
96
92
94
90
88
86
84
82
80
Extinction
0
0,01
0,02
0,03
0,04
0,05
0,06 0,07 0,08 0,09 0,097
Fig. 2.2: Correlation between transmission, extinction, and dust concentration
cc =
cc2:
cc1:
cc0:
calibration coefficient
square
linear
absolute
To take into account the effect that different particle sizes, dust density, and dust distribution
under different load conditions have on transmission and, in turn, extinction values when the
dust concentration is determined, the measuring system must be calibrated by a gravimetric
comparison measurement. During parameterization, the regression coefficients calculated
during this process are entered in the FW300 as follows:
concentration= cc2 Ext + cc1 Ext + cc0
(see section 4.4.2; standard factory setting: cc2 = 0, cc1 = 1, cc0 = 0).
Ext = Extinction
2.2.4
Response Time
The response time (t90) is the time taken by the FW300 to reach 90% of the end value after
a sudden change in the measured value (see Fig. 2.3). The t90 time can be set to any value
between 0.1 and 600 s. Setting a higher t90 time provides better attenuation of transient
fluctuations in the measured value and malfunctions to produce a "smoother" output signal.
Measured
value
in %
100
90 % of the peak
98
96
Measured value with t90 response time
94
Process change
92
90
t90
88
86
t in s
84
10
20
30
40
50
60
70
80
90
100
Fig. 2.3: Response time
16
8 010 038 / 08-2006
Product Description
FW300
2.2.5
Check Cycle
The check cycle is used for automatically checking that the transmitter/receiver and
reflector are functioning properly. Any impermissible deviations from the standard behavior
are signaled as errors. The check cycle can be triggered automatically at fixed intervals
(setting in MEPA-FW, see section 4.4.1) and/or manually (1 min after the power supply has
been connected, or the system has been switched from "Maintenance" to "Measure" in
MEPA-FW).
If a malfunction is present, you can trigger a check cycle manually to locate the cause of the
problem (see Chapter 6).
The check cycle consists of a zero-point check and span test. The system displays the
check values regardless of the set measured variable. The zero point is checked by
switching the system off; the span value (70 % of the set measuring range) is checked by
modulating the light source accordingly. The check values can be output via the analog
output (see section 4.4.1).
Check cycle (automatic)
20 s Determination of the check values
90 s Output at the analog output (70 % value) (provided output is activated)
90 s Output at the analog output (zero value) (provided output is activated)
Zero value
Check value 70 %
Fig. 2.4: Check cycle output on plotter
Notes
When the check values are being determined (duration: approx. 20 s), the value last
measured is output at the analog output.
If the check values are not output at the analog output, the current measured value is
output once the check value has been determined.
The "Maintenance" relay is activated to signal that a check cycle is in process.
With the LCD option, a check cycle is indicated with a plain-text "check cycle" display and
as a status output at relay 6.
Automatic check cycles are carried out periodically from the parameterized time interval,
until the interval setting is changed (or the device is reset). After a device reset (or power
failure), the check cycle begins at the defined time when the device resumes operation.
8 010 038 / 08-2006
17
Product Description
FW300
2.3 Device Components

The FW300 measuring system comprises the following components (see Fig. 2.5):
Transmitter/receiver unit
Reflector
Device attachment
Possible device
configurations
see section 2.4.
Flange with pipe

Connection unit
with integrated purge-air supply (for internal duct pressure -70 ... +2 mbar)
without purge-air supply. The following is, therefore, required:
External purge-air supply (for internal duct pressure -70 ... +30 mbar)
Duct
Flange with pipe

Reflector
Optional
Connection unit with

purge-air supply
Meas. path
Connection
unit without
purge-air
supply
Device attachment
Power supply
External purgeair unit option
RS 232
Purge-air hose
MEPA-FW
operating and
configuration
program
Sensor cable
Power supply for
reflector
Fig. 2.5 Overview of the FW300 components
2.3.1
Transmitter/Receiver Unit
The transmitter/receiver unit contains the optical and electronic modules for transmitting
and receiving the light beam, as well as processing and evaluating signals. An integrated
sight enables you to align the light beam with the center of the reflector. The transmitter/
receiver unit is connected to the connection unit using a 16-pole cable with a connector,
and has a 24 V DC power supply.
It is secured to the device attachment with clamps.
Receiver
lens
Clamp fixing
bracket
Connection for
connection cable
Fig. 2.6: FW300SE transmitter/receiver unit
18
8 010 038 / 08-2006
Product Description
FW300
The transmitter/receiver units are available in two versions:

With light diode (for measuring paths between 0.5 and 2 m)
With laser diode (for measuring paths between 1.5 and 15 m)
The basic version features the following interfaces (on the terminal strip in the connection
unit):
Analog output (1x)
0/2/4 ... 20 mA
Relay outputs
Max. load: 48 V, 1 A
Digital input
RS 232
interface
For outputting the following

measured variables:
Transmission
Opacity
Extinction
Dust concentration
For outputting the

following status signals:
Operation/malfunction
Limit value
Maintenance (check
cycle)
E.g.: for connecting

the maintenance
switch with floating
contact
For parameterization
with the
MEPA-FW operating
program
The operating status is also signaled by two LEDs on the rear of the housing:
(green = operation, red = malfunction).
The basic versions can also be equipped with a data memory/event memory, CAN module,
or a second analog output (see section 2.3.7). The different versions are defined by a type
key:
Transmitter/receiver unit:
Type
- 1:
- 2:
FW3X0XX- XXX-XX
Measuring path: 0.5 ... 2 m; light source: LED

Measuring path: 1.5 ... 15 m; light source: laser diode
Basic version
- SE: Standard
- EX: Protected for use in hazardous locations
Data memory/event memory
- N:
No memory
- M:
Memory
Optional modules
- N:
No module
- A:
Second analog output module
- C:
CAN module
LCD activation (in the connection unit)
- N:
No display activation
- D:
Display activation
Special version
- 00: No extras
- SO: Special design (e.g. stainless steel housing)
Example:
FW320SE-MAD-00
Transmitter/receiver unit type 320, standard, with laser diode and:

Second analog output
LCD activation
No extras
8 010 038 / 08-2006
19
Product Description
FW300
2.3.2
Reflector
A special film attached to a glass substrate reflects the light beam to the receiver in the
transmitter/receiver unit. Two different reflector types are available:
Fixed reflector
Reflector type
Rotating reflector
FW-R-055-F-000
FW-R-055-D-000
FW-R-105-D-000
0.5 m to 2 m
1.5 m to 8 m
6 m to 15 m
Measuring path
Effective diameter of the
active optical surface
55 mm
105 mm
Rotating
Fixed
Optical
axis
Fixing
bracket
Active optical
surface
Power supply
connector
Fig. 2.7: FW300 reflectors
With the rotating reflector, a motor rotates the glass substrate and film around the optical
axis. This reduces the swing sensitivity of the measuring system and increases the accuracy
of the measurements. The reflection surface and drive are installed in a housing unit with
the same external dimensions as the transmitter/receiver unit.
The reflector is also secured to the device attachment with clamps.
Type key for the different versions:
Reflector
FW-R-XXX-X-XXX
Diameter of the active optical surface (055/105)

Version (F=fixed reflector, D=rotating reflector)
Special version (000)
Note
20
Weatherproof covers are available if the transmitter/receiver unit and rotating reflector are
to be installed outdoors (see Fig. 2.22 and Fig. 2.23).
8 010 038 / 08-2006
Product Description
FW300
2.3.3
Device Attachment
The device attachment is used for securing the transmitter/receiver unit and reflector, as
well as purging the optical surfaces with purified ambient air. This protects device
components against contamination, overheating, corrosion, and damage caused by hot,
corrosive gases. A disk assembly can be installed to improve the effect of the purge air.
2nd Purge-air nozzle
at FW-V-105-P-00
Clamp
Purge-air nozzle
Fig. 2.8: Device attachment with purge-air nozzle
A rubber sealing strip ensures that the device attachment and flange with pipe are firmly
sealed.
The device attachments are available in different versions to suit different applications (see
table below).
Device
attachment type
Internal disk For mounting the

diameter
Purge-air
Special
connection version
Standard
FW-V-030-P-000
30 mm
40 mm
none
FW-V-055-P-000
55 mm
Reflector FW-R-055
40 mm
none
FW-V-105-P-000
105 mm
Reflector FW-R-105
40 mm
none
FW-V-030-N-000
30 mm
Reflector FW-R-055
none
none
FW-V-055-N-000
55 mm
Reflector FW-R-055
none
none
FW-V-055-N-H00
55 mm
none
with heater
Options
Type key for the different versions:

Device attachment
FW-V-XXX-X-XXX
Internal disc diameter (030/055/105)

Purge-air nozzle (P=purged/N= not purged)
Special version (000/H00)
8 010 038 / 08-2006
21
FW300
Product Description
2.3.4
Flange with Pipe

The flange with pipe is used for connecting the device attachment to the duct wall and is
available in graded nominal lengths, different steel types, and different sizes. Your choice
depends on the wall and insulation thickness of the duct ( nominal length), reflector type/
device attachment ( size), and duct material (see Fig. 2.9).
Mounting indicator
Material St 37
or 1.4571
TOP
Securing pins
for device
attachment
Fig. 2.9: Flange with pipe
D100 is for device attachments FW-V-030-X-XXX and FW-V-055-X-XXX; D160 is for device
attachment FW-V-105-P-000.
2.3.5
Connection Unit
The connection unit contains the power supply for the transmitter/receiver unit and rotating
reflector, terminals for the network connection and input/output signals, and an RS 232
interface (9-pole Sub-D socket) for connecting a PC/laptop. The connection cable for the
transmitter/receiver unit (16-pole, shielded) is securely attached to the connection unit. The
cable length is 3 m or 10 m.
Two versions are available:
Connection unit without purge-air supply
LCD
Power supply unit
Terminal block
Fig. 2.10: Connection unit without purge-air supply
22
8 010 038 / 08-2006
Product Description
FW300
Connection unit with integrated purge-air supply

This version also has a purge-air fan, air filter, and purge-air nozzle for connecting the purgeair hose for the transmitter/receiver unit and reflector.
LCD
Purge-air fan
Air filter
I/O board with

terminal block
Mounting plate
Purge-air nozzle
Power supply unit

(on rear of
mounting plate)
Fig. 2.11: Connection unit with integrated purge-air supply
The connection units can also be fitted with the LCD module with additional relay outputs
(see section 2.3.7).
The different versions are also defined by a type key:
Connection unit:
AK1-X-XXXX-X-X
Integrated purge-air supply

- P:
With
- N:
Without
Cable length (= length of purge-air hose to
to transmitter/receiver unit for type AK1-P)
- 03:
- 10:
3m
10 m
Supply voltage
- WR: Power supply 100 ... 240 V AC (wide-range power unit)
- 02: 24 V DC
LCD
- N:
- D:
No display
Display
Special version
- 0:
Without
- S:
Special design (e.g. stainless steel housing)
8 010 038 / 08-2006
23
Product Description
FW300
Purge-air hose and power supply for the rotating reflector

The purge-air hoses to the transmitter/receiver unit and reflector, and the cable for
supplying power to the rotating reflector are separate components of the measuring
system. They are available in the standard lengths of 3, 5, 10, and 25 m, which ensures that
the device can be easily configured for a wide range of applications with just a limited range
of options.
The purge-air hoses for the transmitter/receiver unit and reflector can be of different
lengths.
Purge-air distributor
Using the FW-R 105-D-000 rotating reflector we recommend to install the optional purgeair distributor for a better distribution of the purge air inside the FW-V 105-P 000 device attachment (see section 3.3.5 and 8.2.4).
2.3.6
External Purge-Air Unit (Optional)

The connection unit with integrated purge-air supply cannot be used if the internal duct
pressure is greater than +2 mbar or the large FW-R-105-D-000 rotating reflector is used.
In this case, the option with an external purge-air unit must be used. It features a highperformance fan and is suitable for use in pressurized ducts of up to 30 mbar.
Baseplate
Air filter
Fan
(standard type 2BH13)
Purge-air hose
Fig. 2.12: Purge-air unit SLV 1
The different purge-air requirements for the transmitter/receiver unit and reflector can be
distributed using a purge-air aperture (see section 3.3.5).
A weatherproof cover is available if the system is to be used outdoors (see Fig. 2.21).
2.3.7
Data Acquisition, Communication, Measured Value Output, and Display Options
Note
The options described here can only be installed by the manufacturer.

Installed in transmitter/
receiver unit
24
This option enables up to 7,280 measured values and 100 events to be recorded in
continuous operation. The measured values can be saved as mean values over a definable
period (e.g. every half hour) and assigned a time stamp by an integrated real-time clock. All
changes in the device operating status (maintenance, limit value violation, error statuses)
are recorded as events The menu-driven MEPA-FW parameterization program reads or
displays the data (see section 4.5.1).
8 010 038 / 08-2006
Product Description
FW300
CAN module
receiver unit
A separate evaluation unit is available to complement the existing input/output and

connection options (see section 8.2.9). To enable communication with this evaluation unit
via the CAN bus, the transmitter/receiver unit must be equipped with this module. In this
way, up to three FW300 systems can be connected to the connection unit with a data
transfer of up to 1000 m.
receiver unit
Instead of a CAN module, the transmitter/receiver unit can be fitted with a second,
electrically isolated analog output (0/2/4 ... 20 mA). It has the same technical specifications
as the standard output. The measuring range can be parameterized independently (see
section 4.5.3).
Note
If a CAN module or second analog output is installed, you can only install two additional relay
outputs (operation/malfunction and limit value/maintenance; can be parameterized in
MEPA-FW). The following option is recommended here.
LCD
Installed in connection
unit
To display the measured values and status information, a module with a 2-row LCD, two LCD
for signaling "Maintenance" (green) and "Malfunction" (red), and three additional relays for
maintenance, the second limit value, and the check cycle can be integrated in the
connection unit. This module is activated by the transmitter/receiver unit, which must be
configured accordingly, that is, it must be ordered with the LCD (see type key, section 2.3.1).
The LCD shows the following status information (warnings and malfunction messages see
section 6.2):
Indications on the LCD Meaning
Limit1
Limit 1 is exceeded
Limit2 Limit 2 is exceeded
Limit1
Limit2
Soft
Hard (In1)
Soft
8 010 038 / 08-2006
Hard (In1)
Limit 1 and limit 2 are exceeded

Maintenance mode is set via MEPA-FW (Software maintenance)
Maintenance mode is set by using of an external switch (hardware
maintenance; see section 3.3)
Hardware and software maintenance are set
25
Product Description
FW300
2.3.8
Optional Components for Monitoring Air in Workshops

If the transmitter/receiver unit and reflector are to be installed outside (e.g. for monitoring
slag heaps) or in workshops, a light/dust protection tube is available with a suitable bracket
(see Fig. 2.13). This provides a vibration-free installation for instantaneous measurements
over distances of up to 10 m. The light/dust protection tube is available with or without a
heater and insulation cover.
Light/dust protection tube

(without heater and insulation cover)
Transmitter/receiver
unit or reflector
Light/dust protection tube bracket
Fig. 2.13: Light/dust protection tube with bracket
2.3.9
Optional Components for Higher Internal Duct Pressures

Special modules for installing the transmitter/receiver unit and reflector in the duct can be
supplied if the FW300 is to be located in areas where the pressure is between +30 mbar
and +30 bar (see section 8.2.7).
2.3.10 Accessories for Testing the Device

Linearity test equipment
A linearity test can be performed to check that the transmission is being measured correctly
(see section 6.3.3). Absorption filters with defined transmission values are placed in the
beam path and the values are compared with those measured by the FW300. If the results
match and are within the permissible tolerance, the FW300 is functioning correctly. The
absorption filters and bracket are supplied with a case.
Adjustment bracket for normalization
Adjustment brackets are available for checking the transmission measurement on a smokefree section (see section 2.2.2). They are placed at set distances away from the transmitter/
receiver unit and reflector, and must be arranged in such a way that the optical axes are
identical (see section 4.2). The calculated transmission value is set to 100 % and
represents the norm for the measurement in the dust-burdened measuring path.
Zero pipe for normalization
Instead of an adjustment bracket, a pipe with a defined length can be used to normalize the
FW300 (see section 4.2). This enables the transmitter/receiver unit and reflector to be
installed and aligned on a smoke-free section more easily and accurately. When not in use,
the zero pipe is sealed with end caps so that dust cannot enter it. This option is highly
recommended if a dust-free atmosphere cannot be ensured during normalization.
26
8 010 038 / 08-2006
Product Description
FW300
2.4 Device Configuration

The components required for the measuring system depend on the application. The
following table will help you decide which components you need.
Meas.
path [m] Transmitter/
receiver unit
Type FW310
FW310SEXXX-XX
0.5 - 2
1.5 - 8
FW320SEXXX-XX
Type FW320
6 - 15
Purge-air supply
Duct components
Reflector
Device attachment for

T/R unit
Flange with pipe for
Reflector
T/R unit
FW-R-055-F000
FW-V-055-P000
FW-R-055-D- FW-V-030-P000
000
D100
D100
FW-V-105-P000
FW-R-105-D000
D160
Connection and supply components
Measuring
path
[m]
Max. internal duct

pressure: +2 mbar
Max. internal duct

pressure: +30 mbar
0.5 - 8
AK1 -P-XXXX-X-X
AK1 -N-XXXX-X-X
and
external purge-air unit
Permissible
6 - 15
Not permissible
AK1 -N-XXXX-X-X and device attachment

FW-V-055-N-000 or FW-V-055-H00
0.5 - 8
Max. measuring
path
in m
Notes
Reflector
Purge-air hose length in m when component is used

AK1 -P-XXXX-X-X
External purge-air unit (optional)
To T/R unit
To reflector
To T/R unit
To reflector
10
10
10
10
10 (5)
10
10
10
10
10
15
10
25
10
25
The connection cable and purge-air hose to the transmitter/receiver unit and the supply
cable and purge-air hose for the rotating reflector must be the same length.
Depending on the actual installation conditions, you can order the purge-air hoses in the
standard lengths shown in the table below (connection unit with integrated purge-air
supply: x 2; external purge-air unit: x 1). You can also order just one purge-air hose and
divide it accordingly (provided that it is sufficiently long).
8 010 038 / 08-2006
27
Product Description
FW300
2.5
Technical Data
Measured value acquisition

Measured variables
Transmission
Opacity
Extinction
Dust concentration
Measuring range
Any value
between
100 and 0 %
Any value
between
0 and 100 %
Any value
between
0 and 2.5
100 - 80 %
0 - 20 %
0 - 0.1
Depending on the
measuring path and
particle content/size;
see separate table
0.4 %
0.4 %
0,002
Minimum range
Measuring accuracy
1)
Response time
Any value between 0.1 and 600 s
Application data
Measuring path
(upper limits for
instantaneous installation only)
0.5 - 2 m
with FW310SE-XXX-XX
and FW-R-055-F-000
1.5 - 8 m
with FW320SE-XXX-XX
and FW-R-055-D-000
6 - 15 m
with FW320SE-XXX-XX
and FW-R-105-D-000
F/F measurement tolerance 2)

(in % transmission or opacity)
0.8 % at 1 m;
0.8 % at 1 m;
1.5 % at 8 m
1 % at 6 m;
1.5 % at 15 m
1 at 1 m
1 at 1 m; 0.15 at 8 m
0.4 at 6 m; 0.15 at 15 m
Alignment tolerance angle
0 C to 600 C
Gas temp. (above dewpoint)

Internal duct pressure
3)
Ambient temperature
-50 ... +2 mbar

-50 ... +30 mbar
Connection unit with purge-air supply

-20 ... +50 C

-20 ... +45 C
Connection unit with purge-air supply
Purge air intake temperature
Connections
Analog output
Electrically isolated, 0/2/4 ... 20 mA, max. load 750 ; 10 bit, resolution 1 %
Relay outputs
For status signals operation/malfunction, limit value, maintenance;

Load carrying capacity: 48 V, 1 A; floating
Interfaces
RS 232 for laptop/PC (9600, 8, N, 1)
Digital input
Dig in 1 = connection for maintenance switch with floating contact
Options
LCD
2-row display for the measured variables, as well as warning and malfunction messages
With additional relay outputs for maintenance, second limit value, check cycle
Electrically isolated, 0/2/4 ... 20 mA, max. load 750 ; can be parameterized separately
CAN module
For connecting the FW300 to an evaluation unit
For storing and displaying up to 7,280 measured values and 100 events
Power supply
Connection unit
Power supply:
Power consumption:
100...240 V AC, 47...63 Hz; opt. 24 V DC

max. 15 W without purge-air supply
approx. 70 W with purge-air supply
Power supply:
Power consumption:
24 V from connection unit

max. 4 W
Rotating reflector
Power supply:
Power consumption:
24 V from connection unit

1 W in standard operation; max. 12 W

(with fan: 2BH13)
Power supply:
200 ... 240 V/345...415 V at 50 Hz;

220...275 V/380...480 V at 60 Hz
2.6 A/Y 1.5 A
0.37 kW at 50 Hz; 0.45 kW at 60 Hz
Rated current:
Motor rating:
28
1):
Absolute value; instantaneous and between 0 C and 40 C
2):
Within maximum alignment tolerance angle
3):
-50 mbar ... +6 bar / +30 bar with optional components for high internal duct pressure
8 010 038 / 08-2006
Product Description
FW300
Dimensions (W x H x D)
150 mm x 150 mm x 110 mm
Reflector
80 mm x 34 mm
150 mm x 150 mm x 110 mm
Fixed reflector
Rotating reflector
Device attachment
126 mm x 200 mm
179 mm x 300 mm
Type FW-V-030-X-XXX and FW-V-055-X-XXX

Type FW-V-105-P-000
Connection unit
300 mm x 400 mm x 220 mm

200 mm x 200 mm x 130 mm
with purge-air supply

without purge-air supply
550 mm x 550 mm x 258 mm; with weatherproof cover: 605 mm x 550 mm x 350 mm
Weight
2 kg
Reflector
0.4 kg
2.2 kg
Fixed reflector
Rotating reflector
Device attachment
1.4 kg
4.5 kg
Type FW-V-030-X-XXX and FW-V-055-X-XXX

Type FW-V-105-P-000
Connection unit
13.5 kg
3.7 kg
with purge-air supply

without purge-air supply
14 kg
Miscellaneous
Class of protection
Rotating reflector
Connection unit
IP 65
IP 65
IP 65
Signal cable length
3 m, 10 m
other lengths available on request
Length of purge-air hose

and cable for supplying power
to the rotating reflector
3 m, 5 m, 10 m, 25 m
other lengths available on request
Laser
Class of protection 2;
Purge air flow rate
Approx. 30 ... 50 m/h

Approx. 50 ... 100 m/h
Power < 1 mW; wavelength between 640 nm and 660 nm
connection unit with internal purge-air supply

external purge-air unit (optional)
Dust concentration measuring range

The range limits have been defined on the basis of empirical evidence gathered over many
years by SICK. They are used for assessing the area of application and are valid on the
assumption that particle sizes are consistent and evenly distributed.
Precise range limits cannot be specified because conditions may vary from application to
application.
Meas. Average
down particle
stream size
Cloth
filters
3m
Electrostatic
precipitators
5m
Spin
filters
10 m
Meas.
range
Dust concentration in mg/m with measuring path in m

1
10
11
12
13
14
15
190
95
65
48
38
32
27
24
21
19
17
16
15
14
13
maximum 5000 2500 1660 1240 1000 830
710
625
555
500
460
420
390 360 330
minimum
38
34
30
27
24
22
maximum 7000 3500 2350 1750 1400 1170 1000 880
850
770
700
640
51
46
42
38
minimum
minimum
270
460
135
230
90
153
67
115
54
92
45
77
66
58
21
19
18
590 500 470

35
33
31
maximum 12000 6000 4000 3000 2400 2000 1700 1500 1330 1200 1100 1000 920 850 800
8 010 038 / 08-2006
29
Product Description
FW300
2.6
Dimensions and Order Numbers

All dimensions in mm
150
2.6.1
80
150
80
27
Fig. 2.14 FW300 transmitter/receiver unit
Transmitter/
receiver unit type
FW310SE-NNN-00
FW310SE-NND-00
FW310SE-MNN-00
FW310SE-MND-00
FW310SE-NAN-00
FW310SE-NAD-00
FW310SE-MAN-00
FW310SE-MAD-00
FW310SE-NCN-00
FW310SE-NCD-00
FW310SE-MCN-00
FW310SE-MCD-00
FW320SE-NNN-00
FW320SE-NND-00
FW320SE-MNN-00
FW320SE-MND-00
FW320SE-NAN-00
FW320SE-NAD-00
FW320SE-MAN-00
FW320SE-MAD-00
FW320SE-NCN-00
FW320SE-NCD-00
FW320SE-MCN-00
FW320SE-MCD-00
Order no.
7040370
7040371
7040372
7040373
7040374
7040375
7040376
7040377
7040378
7040379
7040380
7040381
7040300
7040301
7040302
7040303
7040304
7040305
7040306
7040307
7040308
7040309
7040310
7040311
(see section 2.3.1 for type key)
2.6.2
Reflector
Rotating reflector
Reflector type
FW-R-055-F-000
FW-R-055-D-000
FW-R-105-D-000
150
80
69
Fixed reflector
Order no.
7040334
7040331
7040332
14
20
27
80
Dim.
D
150
Rotating reflector type
FW-R-055-D-000
FW-R-105-D-000
80
140
Fig. 2.15 FW300 reflectors
30
8 010 038 / 08-2006
Product Description
FW300
2.6.3
Device Attachment
45
Attachment type
FW-V-030-P-000
FW-V-055-P-000
FW-V-105-P-000
FW-V-030-N-000
FW-V-055-N-000
FW-V-055-N-H00
D1
45
Order no.
7040340
7040341
7040342
7040343
7040344
7040345
D2
D3
D4
Dim.
D1
D2
D3
D4
L
40
L
Device attachment type

FW-V-030-X-XXX, FW-V-055-X-XXX
FW-V-105-P-000
76
133
56
101
100
160
126
179
200
300
x: 2nd Purge-air nozzle

only for FW-V-105-P-00
Fig. 2.16 Device attachment
2.6.4
Flange with Pipe

45
45
TOP
D1
D2
D3
Dim.
D1
D2
D3
L
G
Flange with pipe

D100
D160
76
108
100
160
130
180
130, 240, 500
100, 200
M10
M8
Flange with pipe type

D100
Length 130 mm,
St37
Length 240 mm,
St37
Length 500 mm,
St37
Length 130 mm, V4A
Length 240 mm, V4A
Length 500 mm, V4A
D160
Length 100 mm,
St37
Length 200 mm,
St37
Length 100 mm, V4A
Length 200 mm, V4A
Order no.
2017845
2017847
2017849
2017846
2017848
2017850
7040128
7040137
7040138
7040139
Fig. 2.17 Flange with pipe
8 010 038 / 08-2006
31
Product Description
FW300
2.6.5
Connection Unit
Connection unit without purge-air supply
160
Connection unit type
AK1-N-03WR-N-0
AK1-N-10WR-N-0
AK1-N-0302-N-0
AK1-N-1002-N-0
AK1-N-03WR-D-0
AK1-N-10WR-D-0
AK1-N-0302-D-0
AK1-N-1002-D-0
200
220
200
130
Order no.
7040350
7040351
7040352
7040353
7040354
7040355
7040356
7040357
Fig. 2.18 Connection unit without purge-air supply (with LCD)
Connection unit with integrated purge-air supply

AK1-P-03WR-N-0
AK1-P-10WR-N-0
AK1-P-0302-N-0
AK1-P-1002-N-0
AK1-P-03WR-D-0
AK1-P-10WR-D-0
AK1-P-0302-D-0
AK1-P-1002-D-0
400
420
260
Order no.
7040358
7040359
7040360
7040361
7040362
7040363
7040364
7040365
300
220
Fig. 2.19 Connection unit with integrated purge-air supply (with LCD)
32
8 010 038 / 08-2006
Product Description
FW300
2.6.6
Purge-air unit type

Order no.
1012409
SLV4-21112
with fan (2BH13) and
purge-air hose
(length: 10 m)
1012424
SLV4-21111
with fan (2BH13) and
purge-air hose
(length: 5 m)
40
470
550
14
40
128
40
470
258
550
Fig. 2.20 External purge-air unit (optional)
245
550
Component
Weatherproof cover
for purge-air unit
550
Order no.
5306108
350
605
Fig. 2.21 Weatherproof cover for external purge-air unit
8 010 038 / 08-2006
33
Product Description
FW300
2.6.7
Weatherproof Cover for Transmitter/Receiver Unit and Rotating Reflector

Weatherproof cover for transmitter/receiver unit and reflector (incl. device attachment)
360
239
365
492
Component
Weatherproof cover
for analyzer
Order no.
2702407
Cannot be used for rotating

reflector FW-R-105-D-000
Fig. 2.22 Weatherproof cover for analyzer
Weatherproof cover for FW-R-105-D-000 rotating reflector

Outside dimensions like weatherproof cover for analyzer (Fig. 2.22), mounting dimensions according to flange with
pipe D160 (Fig. 2.17).
Order number: 2021457
Weatherproof cover for transmitter/receiver unit and rotating reflector housing (without device attachment)
164
160
157
Component
Weatherproof cover
for housing FWSE/
FWR-D
Order no.
7040394
(Transmitter/receiver unit and rotating reflector housing)

Spacer pin
Fig. 2.23 Weatherproof cover for housing FWSE/FWR-D
34
8 010 038 / 08-2006
Product Description
FW300
2.6.8

Clamp
45
76
45
100
122
250
150
800
Component
Order no.
Light/dust protection 7041168
tube
Light/dust protection 7040233
tube bracket
280
350
Fig. 2.24 Light/dust protection tube (without heater or insulation cover)
240
(230)
21
8
13
8
21
42
Fig. 2.25 Light/dust protection tube bracket
8 010 038 / 08-2006
35
FW300
Product Description
8 010 038 / 08-2006
36
FW300
Assembly and Installation
Project Planning
Assembly
Installation
FW300

3.1 Project Planning
The following table provides an overview of the project planning work you have to carry out
to ensure that the device is correctly installed and fully functional. You can use this table as
a checklist by ticking off all the steps you have carried out.
Task
Requirements
Step
Determine the
measuring and
installation
locations for
the device
components.
Inlet and outlet sections Round and square ducts:

Dh = duct diameter
must be of sufficient
length, each at least 3 x
Rectangular ducts:
"hydraulic diameter" (Dh)
Dh = 4 x cross-section divided by
circumference
Comply with specifications for new

installations; choose the best possible
location for existing installations;
if the inlet/outlet sections are too short:
inlet section > outlet section
Homogeneous flow
distribution
Representative dust
distribution
If possible, no bends, cross-section

If this cannot be ensured, determine the
variations, feed pipes, discharge pipes, flaps, flow profile to VDI 2066 and choose the
or fittings in the inlet and outlet sections.
best possible location.
Mounting position of the Must not be installed vertically on horizontal Choose the best possible location
transmitter/
ducts or ducts positioned at an angle; max.
receiver unit and reflector measurement axis angle to the horizontal:
45
Accessibility, accident
prevention
The device components must be easily and Provide platforms if necessary

safely accessible
Vibration-free installation Accelerations < 1 g
Take appropriate measures

to eliminate/reduce vibrations
Ambient conditions
For limit values, see "Technical data".
If necessary:
Fit weatherproof covers/sun
protection
Cover or insulate the device
components
Up to +2 mbar (connection unit with
Determine the supply type
Choose the
Sufficient purge-air prepurge-air supply pressure (depending on
the internal duct
pressure)
Clean intake air
integrated purge-air supply)

From + 2 mbar to +30 mbar (external
purge-air unit option)
As little dust as possible,
no oil, humidity, corrosive gases
Choose the best possible intake

location
Determine the required purge-air

hose lengths
Choose the
device
components
Plan the
calibration
openings
Measuring distance, duct Transmitter/receiver unit, reflector, device

wall strength with
attachment, flange with pipe or light/dust/
insulation
protection tube with bracket
Choose the components in accordance

with the configuration table in 2.4;
If necessary, plan additional measures
to install the flange with pipe
(see section 3.2.1)
Internal duct pressure
Connection unit and, if necessary, external

purge-air unit (optional) or components for
higher internal duct pressures
Installation locations
Cable and purge-air hose lengths
Accessibility
Easy and safe
Provide platforms/pedestals if
necessary
Distances to the
measurement level
No mutual interference between

calibration probe and FW300
Ensure sufficient distance between the

measurement and calibration level
(distance approx. 500 mm)
See "Technical Data" in section 2.5
Ensure sufficient cable cross-sections

and fuse
Plan the power Operating voltage,

supply
maximum demand
8 010 038 / 08-2006
39
FW300
3.2 Assembly
All of the assembly and installation work has to be carried out by the customer. This includes:
Installing the flanges with pipe (or weld-on flanges for high-pressure versions).
Installing the connection unit
Installing the external purge-air unit (optional).
Fitting the optional components for monitoring the air in workshops or for high internal
duct pressures.
Warning
When carrying out assembly and installation work, observe the relevant safety regulations
and the safety information in Chapter 1!
DANGER
Assembly and installation work on potentially dangerous machinery (hot, corrosive, or

explosive gases, high internal duct pressure) must only be carried out when the
machinery is shut down!
Suitable measures must be taken to protect against local or installation-specific
hazards!
3.2.1
Installing the Flanges with Pipe

Activities
Measure out the mounting locations and mark the mounting location.
Remove the insulation (if present).
Cut out suitable apertures in the duct wall; with brick and concrete ducts, drill suitably
sized holes (for flange pipe diameter, see Fig. 2.17)
Important
Make sure that parts do not fall into the duct!
ATTENTION
Installation in a steel duct

>50
A
Installation in a brick duct
Installation in a thin-walled
duct
30
TOP
Marking for
mounting
Flange with pipe
Duct wall
Armature base plate
Junction plate
Fig. 3.1 Installing the flanges with pipe
Insert the flange with pipe into aperture in such a way that the marking "Top" faces
upwards (see Fig. 3.1)
40
8 010 038 / 08-2006
FW300
Roughly align the flange and pipe and tack into position with a few spot welds (with brick
or concrete ducts, tack onto the armature base plate; with thin-walled ducts, use junction
plates, see Fig. 3.1).
Use a suitable pipe (for smaller ducts) or a SICK alignment device to precisely align it (see
Fig. 3.2); max. axis deviation: 1.
Alignment using the auxiliary pipe
Auxiliary
pipe
Duct wall
Flange with pipe
Alignment using the alignment device

A
The alignment device

(see section 8.2.9)
can also be hired out.
A
Light source
Flange with pipe
Duct wall
Target
optic
Fig. 3.2: Aligning the flanges with pipe
Note
Align the flange with the target optics in such a way that the light spot from the lamp is
visible in the center of the target optics.
Weld on the flange pipes around their circumference, while constantly ensuring that the
alignment is exact (correct if necessary). If you are using the alignment device, you first
have to reposition the flange plate with the light source and flange plate with target optics
before you weld on the second flange pipe.
Once installed, cover the the flange aperture to prevent gas from escaping.
8 010 038 / 08-2006
41
FW300
3.2.2
Installing the Connection Unit

The following points must be taken into account when selecting the mounting location:
The connection unit must be mounted on a level, vertical base at an accessible,
protected location (see Fig. 3.3 for dimensions).
The mounting location must be vibration free.
The ambient temperatures must be within the permissible range (see section 2.5) (take
into account any radiant heat).
The connection unit with the integrated purge-air supply must be mounted at a location
with clean air. If necessary, lay an intake hose or pipe at a location where the conditions
are more favorable.
You must take into account the length not only of the connection cables to the
transmitter/receiver unit and, if used, rotating reflector, but also the purge-air hoses for
the connection unit with integrated purge-air supply.
The connection cable and purge-air hoses must be routed out on the underside.
M6
> 300
c
Clearance for cables
(and purge-air hoses)
Dim.
(All dimensions
in mm)
a
b
c
Clearance for opening

the door

AK1 -N-XXXX-X-X
AK1-P-XXXX-X-X
160
260
220
420
> 350
> 550
Fig. 3.3: Mounting dimensions for the connection unit
Note
42
At the securing points, you are advised to use M6 pins that can be used to attach the
connection unit and secure it with self-locking nuts.
8 010 038 / 08-2006
FW300
3.2.3
Installing the Optional External Purge-Air Unit

The following points must be taken into account when selecting the mounting location:
The purge-air unit must be mounted at a location with clean air. The intake temperature
must match the values specified in the technical data (see section 2.5). If necessary, lay
an intake hose or pipe at a location where the conditions are more favorable.
The mounting location must be easily accessible and fulfill all the applicable safety
requirements.
You must ensure that sufficient space is available for changing the filter insert.
When installing the purge-air unit outdoors, you must ensure that sufficient space is
available for fitting and lifting the weatherproof cover (see Fig. 3.4).
Flange with pipe
> 140
Duct
470
(550)
Clearance for fitting the weatherproof cover
470
Clearance for replacing filter insert
(550)
> 160
Alternative:
retaining bracket
M8
50
50 x 5 steel pipe
DIN 2391
Fig. 3.4: Structure and installation dimensions for the purge-air unit
Installation work
Prepare the bracket as shown in Fig. 3.4.
Secure the purge-air unit with 4 bolts (M8).
Check whether the filter insert is installed in the filter housing (install if necessary).
8 010 038 / 08-2006
43
FW300
3.2.4
Fitting the Weatherproof Covers

Weatherproof cover for analyzer
This weatherproof cover protects the transmitter/receiver unit and reflector, including the
device attachment (see Fig. 2.22). It comprises a baseplate and cover.
Installation:
Mount the baseplate sideways on the flange with pipe and secure it onto the surface of
the flange plate using the threaded pins (see Fig. 3.5).
Mount the cover from above.
Insert the side lock bolts into the counterparts, and rotate them until they latch into place.
> 250
Lifting
clearance
Cover
Baseplate
(239)
(360)
Duct
(365)
(492)
Flange with pipe
Threaded pin
Lock bolt
Fig. 3.5: Fitting the weatherproof cover for the analyzer
Weatherproof cover for FWSE/FWR-D housing

This weatherproof cover is secured directly onto the rear of the transmitter/receiver unit and
reflector housing (see Fig. 2.23).
Installation:
Remove the M6 plastic covers.
Screw the spacer pins into the thread openings on the rear of the housing.
Secure the weatherproof cover onto the spacer pins.
Weatherproof cover for external purge-air unit
The weatherproof cover (see Fig. 2.21) comprises a cover and lock set.
Installation:
Mount the lock parts from the lock set on the baseplate.
Fit the cover from above.
Insert the lock bolts into the counterparts sideways, and rotate them until they latch into
place.
44
8 010 038 / 08-2006
FW300
3.2.5
Installing Optional Components for Monitoring Air in Workshops

The bracket for the light/dust protection tube must be mounted on a level, vibration-free
surface (see Fig. 2.25 and Fig. 3.7 for dimensions). Following the light/dust protection
tubes are to be inserted and secured.
Important
Take into account specifying the mounting locations that the optics of transmitter/receiver
unit and reflector may not be spotlighted directly by light sources (spotlight, sun or other).
ATTENTION
Lamp, spotlight
inferior sun
Fig. 3.6: Inadmissible installation
You can use the alignment device to align the optical axes (see 8.2.9). To do so, proceed
as follows:
Secure the alignment device onto the light/dust protection tube.
Align the bracket for this light/dust protection tube in such a way that the light/dust
protection tube lies centrally in the field of vision.
Secure the alignment device onto the other light/dust protection tube and repeat the
procedure.
Warning!
The transmitter/receiver unit and reflector must not be installed.
ATTENTION
(800)
Opposite light/dust
protection tube
(250)
(350)
max. 10 m in stable,
distortion-free installation
A
Alignment tool
Dimensions in mm
Fig. 3.7: Installing and aligning the optional components for monitoring the air in workshops
8 010 038 / 08-2006
45
FW300
3.3 Installation
3.3.1
General Instructions and Prerequisites

Before you start the installation work, you must have carried out the steps described in
section 3.2.
Unless otherwise agreed with SICK or an authorized SICK representative, all of the
installation work must be carried out by the customer. This includes laying and connecting
the power supply and signal cables, installing circuit-breakers and power fuses, fitting the
device attachments, and connecting the purge-air supply.
Notes
Ensure the cable cross-sections are of sufficient size (see section 2.5, "Technical Data").
The cable ends with the connector for connecting the transmitter/receiver unit and
rotating reflector must be of adequate length.
Warning
All installation work must be carried out in line with the relevant safety regulations and
instructions listed in Chapter 1.
DANGER
3.3.2
46
Suitable measures must be taken to protect against danger.
Connection Unit
The power supply cables (terminals L1, N, and PE, as well as 7 and 8 for the rotating
reflector) and signal cables (analog output, digital inputs/outputs) must be connected to the
terminal strip as shown in Fig. 3.8.
8 010 038 / 08-2006
FW300
RS 232 connection
RS 232
assignment
Brown/Yellow
White/Yellow
Relay 3
Brown/Green
Relay 2
White/Green
Red/Black
Purple
Dig in 1
Gray/Pink
Blue
Blue Gnd
Relay 1
Red
Brown +
RS 232
115/230 V AC; 50/60 Hz
Black
Gray
Green
0...20 mA
Yellow
Gnd
Customer wiring
Gnd
Blue
Brown
Fuse T1A
Signal cable
Brown
5 Gnd
White
5 Gnd
Power
cable
Rxd
3 Txd
Txd
2 Rxd
Yellow/Green
2 Txd
3 Rxd
Terminal strip
Pink
Plug
(9 pole)
PC
Socket
(9 pole)
FW300
Shield
Power supply for rotating reflector (24 V DC)

Maintenance
Analog output
(LiY 2x 0.5 mm (approx.))
Limit value
Digital input (maintenance) (LiY 2x 0.5 mm (approx.))
Malfunction
Connection units with 24 V DC power supply:

Instead of L1
Instead of N
Fig. 3.8: Terminal strip connections for the customer wiring
The power supply cable for the rotating reflector is one of the device components, although
it can be adapted on site if required (open the connector as shown in Fig. 3.9 and connect
the cable accordingly).
Open
Closed
Open
Closed
Connection cable
A -A
Brown (+)
Blue (-)
24 V
Note
To open the connecter, plug it into the plug
on the rotating reflector.
Fig. 3.9: Terminal assignment of the connector for supplying the rotating reflector
8 010 038 / 08-2006
47
FW300
3.3.3
Connecting/Commissioning the Optional External Purge-Air Unit

Activities
Compare the supply voltage and frequency with the specifications on the rating plate of
the purge-air motor.
Important
Do not connect the purge-air unit if the values do not match.
ATTENTION
Connect the power supply cable to the terminals on the purge-air motor (see
supplementary sheet on purge-air motor and cover of motor terminal box; see the
connection arrangement shown in Fig. 3.10).
Connect a protective conductor to the terminal.
If you are in doubt, or if

you are using a special
motor version, the
operating instructions
supplied with the motor
take priority over any
other information.
Set the motor circuit-breakers in accordance with the connection data of the fan (see
technical data of purge-air unit) to a value 10% greater than the rated current.
Check the functioning and running direction of the fan (flow direction of the purge-air unit
must match the arrows at the inlet and outlet openings on the fan). If the direction of
running on 3-phase motors is incorrect, swap power connections L1 and L2.
Connect the (optional) pressure monitor for monitoring the purge-air supply.
Important
Use a fail-safe power supply (emergency power supply, bar with redundant supply).
ATTENTION
The purge-air unit must be fused separately from the other system components. The fuse
type must match the rated current (see technical details of purge-air unit). Fuse each
phase separately. Provide circuit-breakers to protect against a phase failure on one side.
Low-pressure monitor
V1
U2
V1
U1
W2
U2
U1
W1
W2 U2 V2
U1
W1
V2 W2
V2
W2 U2 V2
V1 W1 PE
U1
V1 W1 PE
Power
supply
4 x 1.5 mm2
L1
L2
L3
PE
L1
L2
L3
PE
24 V
Fig. 3.10: Electrical connections for the external purge-air unit
48
8 010 038 / 08-2006
FW300
3.3.4
Mounting the Device Attachments
c
f
1 pair
d
e
g
c
d
e
f
g
Flange with pipe

Disk springs (4 pairs)
Device attachment
Self-locking nuts
Rubber sealing strip
Fig. 3.11: Mounting the device attachments
The device attachments are mounted in accordance with the number sequence in Fig. 3.11
on the flange with pipe (remove any flange covers beforehand).
Important
ATTENTION
When mounting the device attachments, observe the relevant safety information (when
mounting device attachments on potentially hazardous devices, ensure that the device is
switched off; take the appropriate protective measures; see Chapter 1)!
Note
You do not need the disk springs when mounting the device attachment for the reflector.
3.3.5
Installing the Purge-Air Supply

Lay the purge-air hoses without kinks along the shortest path (shorten the purge-air
hoses if necessary). Provide sufficient distance from hot duct walls.
Switch on the connection unit with purge-air supply or optional external purge-air unit
(switch on the power supply) and ensure that the purge air is flowing in the right direction.
Push the purge-air hoses onto the relevant purge-air nozzles and secure them with the
clamping tape.
8 010 038 / 08-2006
49
FW300
Notes
For the connection unit with the integrated purge-air supply, assign the outputs as shown
in Fig. 3.12. The nozzle for the transmitter/receiver unit must be mounted in the shown
way (adjust if necessary).
Purge-air
inlet
Purge-air outlet for the

transmitter/receiver unit
Purge-air outlet for the reflector
Fig. 3.12: Underside of the connection unit with the integrated purge-air supply
If you are using the optional external purge-air unit, the purge-air volume to the
transmitter/receiver unit and reflector must be distributed at a ratio of approx. 1:4. The
purge-air aperture (see section 8.2.4), which is available as an accessory, can also be
used.
Purge-air nozzle
Device attachment for the

transmitter/receiver unit
Purge-air aperture
Hose clamping tape
Purge-air hose
Fig. 3.13: Installing the purge-air aperture
If the FW-V-105-P-000 device attachment is installed, both purge-air nozzles should be

attached to the purge-air supply for a better purge air distribution. You can use for this
the optionally deliverable purge-air distributor (see Section 8.2.4)
(T-piece with hoses
and clamping tapes)
FW-V-105-P-000
device attachment
Clamp
Purge-air hose from

the purge-air supply
50
8 010 038 / 08-2006
FW300
Fig. 3.14: Connection of the purge-air distributor
8 010 038 / 08-2006
51
FW300
3.3.6
Connecting Optional Devices

CAN Module and Second Analog Output
The "Maintenance" relay output (relay 3) is not required when the optional CAN module or
second analog output is installed. The cables to the connection unit for the CAN bus or
analog signal are used instead.
RS 232 connection
RS 232
assignment
Shield
Option CAN module
or 2nd analog
output
Limit value
Analog output
Brown/Yellow
White/Yellow
Brown/Green
Relay 2
White/Green
Gray/Pink
Red/Black
Relay 1
Green
RS 232
115/230 V AC; 50/60 Hz
Black
Yellow
Gnd
Gnd
Purple
Brown
Blue
White
Txd
Customer wiring
Rxd
Yellow/Green
Blue
Brown
Fuse T1A
Dig in 1
5 Gnd
Blue Gnd
5 Gnd
Signal cable
Power
cable
Red
3 Txd
Gray
3 Rxd
Brown +
2 Rxd
0...20 mA
2 Txd
Terminal strip
Pink
Connect
or (9
pin)
PC
Socket
(9 pole)
FW300
Malfunction
Digital input (maintenance) (LiY 2x 0.5 mm (approx.))

Instead of L1
Instead of N
Option
Terminal 15
Terminal 16
CAN module
CAN + high
CAN - low
2nd analog output
Fig. 3.15: Terminal assignment when the optional CAN module or 2nd analog output is installed
Note
Instead of relay 3, which is not required, relay 2 can be used to signal the "Maintenance"
operating status (setting in MEPA-FW, see section 4.5.2).
Important
To ensure that data is transmitted reliably on the CAN bus, you must connect a terminating
resistor to the end of the bus (terminating resistor equal to line impedance value).
ATTENTION
52
8 010 038 / 08-2006
FW300
Evaluation Unit EVU

E
EVU
CAN 1
H L
Terminating resistor of the EVU

(realized by a jumper)
Connect the terminating

resistor in the connection
unit which is removed
from the EVU furthest.
15 16
Connection unit
AK1
15 16
(Connection unit
AK1)
Terminating resistor
(value equal to line impedance)
15 16
(Connection unit
AK1)
EVU in the middle of the bus
CAN 1
H L
Connect the terminating

resistors in the connection
units which are removed
from the EVU furthest
15 16
(Connection unit
AK1)
15 16
Connection unit
AK1
The terminating resistor

of the EVU is not needed
(remove the jumper)
15 16
(Connection unit
AK1)
If only one FW300 is connected to the EVU, the terminating resistors must be connected in the EVU and connection unit.
The terminating resistors in the connection units have to be supplied by the customer.
Fig. 3.16: Connection of the optional EVU
8 010 038 / 08-2006
53
FW300
LCD
If the optional LCD is installed, the terminal strip in the connection unit for the customer
wiring (see Fig. 3.8) is replaced by an additional board with terminals to which the cables
for the analog and status signals are attached as shown in Fig. 3.17.
Connections for the signal cables to the T/R
RS 232 connection
(Assignment as
shown in Fig. 3.8)
Board
Terminal block 2
Connection for shield
115/230 V AC; 50/60 Hz

Relay 6
Relay 5
Relay 4
Relay 2
Relay 1
Dig in 1
Blue Gnd
Brown +
RS 232
0...20 mA
Gnd
Gnd
Txd
Customer wiring
Rxd
Terminal block 1
Shield
Option CAN module

or 2nd analog
output
Check cycle
Analog output
Limit value 1
Limit value 2
Digital input (maintenance)
Malfunction
Maintenance

Instead of L1
Instead of N
Option
Terminal 15
Terminal 16
CAN module
CAN + high
CAN - low
2nd analog output
Screen
White
Brown
Yellow
Green
Pink
Grey
Red
Blue
Purple
Black
Grey/Pink
Red/Black
White/Green
Brown/Green
White/Yellow
Brown/Yellow
Fig. 3.17 Terminal assignment with optional LCD
Signal cable
Board
Fig. 3.18: Connection of the optional EVU
54
8 010 038 / 08-2006
FW300
Commissioning and Parameterization
Basics
Normalization
Installing and Connecting the Transmitter/Receiver Unit and Reflector
Parameterization
Parameterizing Optional Devices
FW300

4.1 Basics
4.1.1
General Notes
Commissioning the FW300 involves the following steps:
Focusing the transmitter light beam.
Normalizing the measuring system for a smoke-free section.
Mounting the transmitter/receiver unit and reflector on the device attachments.
Customer-specific parameterization in accordance with requirements.
If the FW300 is to be implemented for continuously measuring dust content, it must be
calibrated using a gravimetric comparison measurement to ensure accurate measurements
(see Section 4.4).
The process of setting options in accordance with Section 2.3.7 is described in Section 4.5.
The MEPA-FW parameterization program is shipped with the device. The required settings
can be easily configured using the program menus. Other functions (such as data storage
and graphical display functions) are also available.
Certain device functions can only be accessed once you have entered a password (see
appendix). The access rights are assigned in 3 stages:
4.1.2
Level
Password
Access to
"User"
none
Measured value displays, device status query, display/output

parameter log; parameterization not possible
"Authorized
user"
Level 1
Displays, queries, and parameters for commissioning and

customizing.
"Service"
Level 2
Displays, queries, and all parameters.

For performing all on-site service activities (for example,
diagnosis and troubleshooting).
Prerequisites
Laptop/PC with:
Pin assignment
RS 232
socket in
connection
unit
PC
connector,
9-pin
Pin 2 (txd)
Pin 2 (rxd)
Pin 3 (rxd)
Pin 3 (txd)
Pin 5 (gnd)
Pin 5 (gnd)
Processor: Pentium 2 or higher

VGA graphics card
Serial interface COM 1 or COM 2
Main memory (RAM): minimum 32 MB
Operating system: Microsoft Windows 95 or higher
Interface cable (serial cable; see Options, Section 8.2) for connecting a laptop/PC to the
FW300.
The MEPA-FW operating and parameterization program must be installed on the laptop/
PC. To install the program, insert the disk/CD supplied into your disk/CD drive, call up the
corresponding drive, run the "mepa-fw_setup.exe" file, and follow the instructions.
The power supply must be connected.
8 010 038 / 08-2006
57
FW300
4.2 Normalization
4.2.1
Basics
To eliminate device-specific and distance-related interference with the measurement result,
the FW300 must be normalized on a particle-free section. This section must be identical to
the measuring path (the distances between the optical boundary surfaces of the
transmitter/receiver unit and the reflector must be identical).
Two options are available for mounting the measuring equipment for normalization (see Fig.
4.1):
Adjustment bracket for normalization (see Section 8.2.8)
On-site installation of a "zero pipe" (with suitable diameter and clamps)
When mounting the measuring equipment, you must ensure that the electrical connections
to the connection unit are installed properly (if necessary, use an adapter cable or a
separate power supply (supplied by SICK I MAIHAK on request)).
Normalization with calibration adjustment brackets
A
Reflector
Adjustment bracket for

normalization
Adjustment bracket for

normalization
(order no. 7040131)
(order no. 7040131 for

FW-R-055-F
or FW-R-055-D;
order no. 7040156
for FW-R-105-D)
Normalization with zero pipe
Reflector
Clamp
TL110-A1
(order no. 7045516)
Antiglare
louvre
76.1 x 2
Pipe
D = D1 in Fig. 2.16
A = length of device attachments with mounting kits + distance flange - flange
Fig. 4.1 Possible configuration for normalization
58
8 010 038 / 08-2006
FW300
4.2.2
Focusing the Transmitter Light Beam

The transmitter light beam must be focused to ensure that the light spot on the reflector lies
within the active optical reflection surface. When focusing the beam, you must take into
account the measuring path and permissible swing angle (see Section 2.3.2). The following
guide values apply:
Measuring path
Light spot diameter
Up to 2 m
20 ... 25 mm
Greater than 2 m
12 ... 15 mm
Make the setting as follows:

Check the alignment
(see Section 4.3)
Prepare the measuring path with the transmitter/receiver unit and reflector in accordance
with Fig. 4.1.
Attach a sheet of white paper to the adjustment holder or zero pipe opening as a reflector.
Connect the cable to the connection unit to provide the power supply.
Unscrew the securing bolts on the housing cover of the transmitter/receiver unit and
remove the cover.
Insert a small screwdriver (or other suitable tool) through the focusing aperture in the
processor board and into the hole for the setting wheel. Turn it clockwise or counterclockwise (see Fig. 4.2) until the light spot is the right diameter.
Replace and secure the cover.
Mount the reflector.
Housing
Focusing aperture
Processor
Light spot gets smaller
Light spot gets bigger
Setting wheel
Hole
Fig. 4.2: Setting the light spot
The FW300 must then be normalized.

Important
The FW300 must be re-normalized every time the focus settings are changed!
ATTENTION
8 010 038 / 08-2006
59
FW300
4.2.3
Normalization
Connect the interface cable to the connection unit and laptop/PC.
Start the "MEPA-FW.EXE" operating and parameterization program.
The "Connection" menu appears on the screen.
The type displayed in this

window must be the same
as the connected device.
Fig. 4.3: "Connection" menu
Enter password level 1.

Connect to the FW300.
Choose the serial interface on the PC (e.g. COM 1) and click "Connection". The active
parameter set for the device is then imported to MEPA-FW.
Note
You cannot connect to the device while the system is calculating the check values during
a check cycle (duration approx. 20 s, see section 2.2.5; the information is then displayed
in a separate window).
Once you have successfully connected to the device, the start menu is displayed and
shows a graphical representation of the measured values, system state, and analog
value(s).
Menu bar
Tab page
Desktop
Current measured
Displayed only with 2nd analog output

option
Status bar
Fig. 4.4: "Measured values" tab page
60
8 010 038 / 08-2006
FW300
If necessary, change the language setting under "Options / Language".

Switch the FW300 to "Maintenance" mode (menu: "Operation mode / Maintenance" or
with an external maintenance switch connected at the terminals for Dig in 1; see Fig. 3.8
or Fig. 3.15/3.17).
The status of the device is shown by the "Maintenance" indicator (if configured with
MEPA-FW and with "(SOFT)" specified as the software setting).
Press the "Set reference" button on the "Diagnosis/Test" tab page.
The normalization window is then displayed and shows a graphical representation of the
current transmission values and input fields (see Fig. 4.5).
Fig. 4.5: Normalization window
Allow the FW300 to function without intervention for approximately 20 min (must be in
position for normalization). You can check the status using the graph.
Press the "Distance T/R unit - reflector" button, enter the actual measuring path in mm
(see Fig. 2.5), and save.
Note
If correct, press "OK"
to confirm.
This value enables the distance to reproduced in subsequent normalization processes.

Press the "Set reference" button and wait approximately 50 s (normalization process is
indicated with separate progress bars).
The mean average transmission value that is then displayed must be 100 0.2 %.
If not, repeat the normalization process.
Mount the transmitter/receiver unit and reflector onto the duct in accordance with
Section 4.3.
8 010 038 / 08-2006
61
FW300
4.3 Installing and Connecting the Transmitter/Receiver Unit and Reflector

First ensure that the device attachments have been mounted (see Section 3.3.4) and the
purge-air supply (if available) is in operation (ensure that the flow direction is correct and the
purge-air hoses are securely attached to the connector).
Activity
Place the transmitter/receiver unit and reflector on the appropriate device attachments
and secure with the clamps. The clamps must be closed with reasonable force (approx.
10 to 15 N) (may have to be readjusted).
Connect the cable from the connection unit (screw the connectors tight!).
Align the transmitter light beam in accordance with Fig. 4.6 or Fig. 4.7.
Horizontal
alignment
Transmitter/
receiver unit
Fixed
Vertical alignment
Sight
Device attachment
Tighten the nuts in such a way that the

transmitter light beam is in the center of
the reflection surface of the reflector.
Fig. 4.6: Aligning the transmitter/receiver unit with the device attachment
vertical
Adjustment method
during normalization on
the on-site zero pipe
Carefully adjust the securing pins once you have

removed the housing cover (pre-loading of the
disk springs must be maintained!)
horizontal
Fig. 4.7: Aligning the optical element in the transmitter/receiver unit
Two methods are available for checking the alignment:

With a mounted reflector
If the alignment is correct, a strong reflection is clearly visible in the sight on the rear of
the transmitter/receiver unit housing.
Without reflector
You can check the alignment using a sheet of paper (e.g. white photocopying paper) on
the device attachment for the reflector (light spot must be in the center of the aperture).
62
8 010 038 / 08-2006
FW300
4.4 Parameterization
The FW300 is shipped with default settings. The standard values are enclosed in the
parameter log. You can also view these settings on the "Protocol" tab page in MEPA-FW.
If you do not have to change these settings, you can use the FW300 in your installation
straight away.
If you do have to change the parameters, set the password once the connection to MEPAFW has been established, activate "Maintenance" mode, and choose the "Parameter" tab
page (see Fig. 4.8).
The regression function is only

displayed if you select the
measured variable
'concentration'.
Fig. 4.8: "Parameter tab page
4.4.1
Customer-Specific Parameterization
"Signal calculation" field
Response time t90 (see Section 2.2.4)
Enter a value between 0.1 s and 600 s in the relevant field (in the format: XXX.XX).
Note
8 010 038 / 08-2006
The t90 time setting affects the response behavior of the measured value and the output
of analog values and the limit value relay. If you enter a high t90 time, the limit value relay
does not respond to transient, high measured value peaks. At low t90 times , the
response behavior of the FW300 is extremely quick (noise is greater).
63
FW300
Measured variable (see Section 2.2.2 and 2.2.3)

The measured variable selected in this field (transmission, opacity, extinction,
concentration) is output to the analog output and graphically displayed on the "Measured
values" tab page in MEPA-FW (and on the LCD, if installed). When you choose
"Concentration" (= dust concentration), the system opens an additional window for
entering the regression factors determined in a comparison measurement (see Fig. 4.8).
Important
If the option Data memory / event memory is installed, these memories are deleted at
a change of the measured variable (see also Section 4.5.1).
ATTENTION
"Output" field
The current output and limit value relay is set in this field.
Analog output
Live Zero (LZ)
You can set the zero point to 0.2, or 4 mA.
Recommendation
This value should ideally be set to 2 or 4 mA to differentiate between the measured

value and when the device is switched off or the power supply is interrupted.
Measuring range (MR)
You must enter the lower MR limit for LZ and the upper MR limit for 20 mA.
Limit value
Enter a value below or above which (depending on the selected measured variable) the
limit value relay is to drop out. The limit value relay has a hysteresis equal to 10 % of the
defined limit value.
"Check cycle" field
The check cycle is activated by default and the cycle time is set to 8 hours. You can
deactivate it by deselecting the "Enable" checkbox.
Define the cycle time
In the "Interval" window, enter the time between the start of one check cycle and the next
check cycle (range: between 2 and 24 hours).
Output at analog output
When you activate the "Check values analog output" checkbox, the check values
calculated during the cycle check are output at the analog output (see section 2.2.5).
Notes
Each time you switch on the device, and when the device exits "Maintenance" mode, a
check cycle is triggered after 60 s and the check cycle time begins again.
An automatic check cycle is not triggered if the FW300 is in "Maintenance" mode at the
starting time.
After entering of the parameters these must be transferred to the FW300. To do this, press
the button Write to device. Only after this it can be changed to another tab page.
64
8 010 038 / 08-2006
FW300
4.4.2
Parameterization for Dust Concentration Measurement

To measure the dust concentration exactly, the correlation between the extinction
calculated from the primary 'transmission' measured variable and the actual dust
concentration in the duct must be established. For this purpose, the dust concentration
must be determined by means of a gravimetric measurement to VDI 2066 or ISO 9096 and
compared to the extinction values measured simultaneously by the FW300. To be able to
model the correlation between the extinction and dust concentration as precisely as
possible (see section 2.2.3), a regression function is stored in the FW300 that can be set
as a quadratic or linear function.
Required steps
The steps described here

will help you avoid making
input errors. Comparison
measurements require
special knowledge that
cannot be described in
detail here.
Choose the measured variable 'concentration' in the "Parameter" tab page

("Maintenance" mode and password must be set).
Check whether the regression coefficients correlate with
"Concentration" = 0 Ext + 1 Ext + 0 (see Fig. 4.8)
(if not, correct them accordingly). The dust concentration is thus the same as the
extinction and is directly assigned to the mA value as an mg value at the analog output.
Carry out the gravimetric measurement to VDI 2066 or ISO 9096.
Check the necessary measuring range (see Section 2.5) and enter it in the "Parameter"
tab page (see Fig. 4.8).
Determine the regression coefficients
First, use a regression calculation to calculate the correlation between the gravimetrically
measured dust concentrations and the mA values of the FW300.
c
= K2 Iout + K1 Iout + K0
c
Iout
= dust concentration in mg/m

= current output value in mA
Iout
= LZ + Ext
(1)
20 mA - LZ
(2)
URL
Ext = measured extinction value

LZ = Live Zero
URL = defined upper range limit (entered value for 20 mA;
normally 2.5 x fixed limit value)
You must then use regression coefficients K2, K1, and K0 of function c = f (Iout ) to
determine coefficients cc2, cc1, and cc0 to be entered in the device.
"Concentration = cc2 Ext + cc1 Ext + cc0
(3)
By using (2) in (1), the result is as follows:
c = K2 LZ + Ext
8 010 038 / 08-2006
20 mA - LZ 2
+ K1 LZ + Ext
URL
20 mA - LZ
URL
)+ K0
65
FW300
Using (3), the result is as follows:

cc2 = C2
20 - LZ 2
URL
cc1 = (2 C2 LZ + K1)
20 - LZ
URL
cc0 = C2 LZ2 + C1 LZ + C0
Enter regression coefficients cc2, cc1, and cc0 in the FW300.
Notes
A special program is available for calculating the regression coefficients.

If a data memory / event memory is available, the FW300 measured values can be saved
as a file, from which the coefficients can be determined in MS Excel.
4.4.3
Data Backup
In some cases, you may have to reconfigure the parameter settings. For the sake of
simplicity, we recommend that you save and/or print out the parameter log and keep it with
your device documentation. The parameter log can also be useful for determining the cause
of malfunctions (send the log to SICK I MAIHAK).
To save your parameter settings, choose the "Protocol" tab page and then "Save to file" or
"Print protocol" (see Fig. 4.9).
With the button "Load

from file you can reload a later time again
a stored file, also if
there is no connection
to the FW300 (select
"Connection menu,
interface "Simulation).
Fig. 4.9: Parameter log (example)
Notes
66
The value shown on the field "Status code serves for the evaluation by the manufacturer
in the case of device malfunctions. If you want to analyze the device status, please
change to the "Diagnosis/Test" tab page. Possible messages displayed there and
corrective measures are described in Section 6.2.
8 010 038 / 08-2006
FW300
The device protocol can be changed also into a text file (ASCII format) and then edited
using any editor or text program. To do this, press the button Print protocol and activate
the checkbox Print to text file in the Printer selection menu (see Fig. 4.10).
Fig. 4.10: Printer selection menu
4.4.4
Starting Standard Measuring Mode

Standard measuring mode is started when you switch to "Measure" mode ("Operation
mode / Measure" menu). This completes the standard commissioning procedure. The
measured values are displayed graphically on the "Measured values" tab page in MEPA-FW
and as a current value of the analog output (see Fig. 4.11).
Fig. 4.11: "Measured values" tab page
Notes
You can change the resolution of the displayed measured values in the "Diagram scale"
field by resetting the value in the "Peak auto scale" and entering a value between 1 and
10000 in the "Maximum" field
The device also switches to measuring mode when you close the MEPA-FW operating
and parameterization program. If "Maintenance" mode has been set, the FW300
automatically switches to "Measure".
A check cycle is automatically triggered 1 min after the system has switched to measuring
mode.
8 010 038 / 08-2006
67
FW300
4.5 Parameterizing Optional Devices

This section describes the settings required for the data memory / event memory, CAN
module, second analog output, and LCD options. Before you can enter or change the
parameters, you must switch to "Maintenance" mode and enter the relevant password.
4.5.1
Data Memory / Event Memory

The data is saved by additional hardware in the transmitter/receiver unit and activated by a
release code entered by the manufacturer.
Once the system has been connected, the data memory / event memory is available on the
"Data memory / event memory" tab page in MEPA-FW.
Measured value table

Graphical display of
measured values
Zoom option
Zoom area
Events
Centralized malfunctionIndividual faults
Event table
System mode-dependent
display
Fig. 4.12: "Data memory / Event memory" tab page
Notes
The measured value and event table displays a maximum of 10 values/events along with
their date and time. If more exist, you can go to the required area by scrolling through the
table.
The system displays the measured values for the set measured variables.
In the measured value display, you can activate/deactivate the zoom function in the
center of the screen to choose all of the measured values that have been saved or just
those visible in the measured value table. You can scroll through the zoom area in the
table in the same way.
When you call up this tab page, the column headers in the event table are always
displayed in abbreviated form. You can click the column header to display them in their
full form (column becomes wider), which enables you to see what each column indicates.
The "Erase data memory" and "Erase event memory" buttons are only displayed when
the password is set (inactive display). The system must be in "Maintenance" mode for
active use.
68
8 010 038 / 08-2006
FW300
Data memory
The measured value is averaged over the set period, whereby the current measured value
is totaled every 500 ms and, after the time interval has elapsed, the sum is divided by the
number of times it has been totaled. A prerequisite here is that no faults are present and
the system is not in maintenance mode. The resulting average value is not written to the
data memory, however, until the current measured values have been valid for at least 2/3
of the time interval, that is, the total sum of the times for "Maintenance", "Malfunction", or
check cycle was less than 1/3 of the time interval.
You can set or change the interval period for saving the measured values in the "Option
memory measurement value/save interval" field on the "Parameter" tab page within a
range of 1 s to 2 h (see Fig. 4.13).
Fig. 4.13: Setting the storage intervals
Event memory
The following events are registered in this memory:
When they occur (= 1):
Ger... = Device restart (reset)
Me... = Data memory deletion
Ere... = Event memory deletion
At start ( = 1) and end (= 0)
Nor... = Normalization
Gre... = Limit value violation
Ers... = Reference measuring path activation
War... = Maintenance
S=... = Centralized malfunction
set/reset when one of the following faults is present / no longer present
- S1... = Device temperature > 75 C
- S2... = Span test not successful
- S3... = Monitor signal too low
- S4... = Real-time clock has failed
- S5... = Steady light signal too high
- S6... = Normalization not successful
- S7... = Measured value override
- S8... = EEPROM check sum
- S9... = Communication with display
8 010 038 / 08-2006
69
FW300
Description
Function
Description
"Read data memory"
When you press the "Read data memory" button, the measured values stored in the
connected FW300 are displayed in tabular and graphical form. Up to 7,280 measured values
can be displayed.
The time range starts with the first measured value interval read and ends with the storage
time of the last (current) measuring interval. If (o) (=overflow) appears at the end of the row,
the data memory has overflowed at least once since it was last cleared.
The time information for the measured values in the table always relates to the end of an
averaging interval (the storage time).
If the cyclic backup was interrupted (power off, maintenance), the next measured value is
assigned a new time stamp. In this case, the row may not appear in full in the table.
"Erase data memory"
The data memory is deleted after you have confirmed the system prompt. This function is only
available in "Maintenance" mode after you have entered your password.
Important
The data memory is also cleared if you change the measured variable or the set storage interval
time ("Parameter" tab page).
"Read event memory"
When you press the "Read event memory" button, the events stored in the connected
FW300 are displayed in tabular and graphical form. Up to 100 events can be displayed.
The time range starts with the first event read and ends with the storage time of the last
(current) event.
The time information for the measured values in the table always relates to the the storage
time.
"Erase event memory"
The event memory is cleared after you have confirmed the system prompt. This function is only
available in "Maintenance" mode after you have entered your password.
"Load from file"
You can choose and read a measured value file (*.dat) or event file (*.eve) stored in the system
(separate MEPA format).
"Save to file"
The measured values or events displayed are store in a measured value or event file (separate
MEPA format).
"ASCII export"
The measured values or events displayed can be stored in an ASCII file (*.txt). The data can
then, for example, be processed subsequently for a graphical analysis in a spreadsheet
program (such as Excel) or processed for logging purposes in a word processing program.
Important
The ASCII file cannot be re-read by MEPA-FW!
Note
70
The "Save to file" and "ASCII export" functions can only be used if measured values or
events have already been read.
8 010 038 / 08-2006
FW300
Setting the real-time clock

The FW300 has a battery-buffered real-time clock that is set by the manufacturer before
shipment. If required, this clock can be synchronized with the system time of a connected
PC. Ensure that the clock in the PC has the right date (year numbers from 2000 [00] to
2066 [66] only).
To set the clock, press the "Set with PC time" button in the "Option memory measurement
value" field on the "Parameter" tab page in MEPA-FW (see Fig. 4.14). This sets the deviceinternal clock to the time and date of the connected PC.
Important
Important
Changing the time or date does not automatically reset the data memory / event memory,
which means that time ranges may occur twice or gaps may exist in the relevant memories.
ATTENTION
4.5.2
CAN Module
An address must be assigned to the FW300 so that it can communicate with the evaluation
unit. Enter this in the "Option CAN-Bus" on the "Parameter" tab page (see Fig. 4.14). The
address can be set in a range of 73 to 127.
Only displayed if the option is

installed
Fig. 4.14: Parameterizing optional devices
For communication between FW300 and evaluation unit, only the addresses 73, 74 and 75
are selectable. The assignment to the connected FW300 is displayed on the LCD of the evaluation unit in the following way:
8 010 038 / 08-2006
FW_1:
FW300 with address 73
FW_2:
FW_3:
71
FW300
4.5.3
Second Analog Output

You can set the required measuring range in the "Option measurement range analog output
2" field on the "Parameter" tab page (see Fig. 4.15). The range limits are set in the same
way as for the standard output (see section 4.4.1).
The standard output values apply for live zero.
Since the lines for relay 3 are used for this option (see also section 3.3.6), relay 2 can be
set to signal either maintenance mode or the limit value. You make the assignment in the
"Relay 2 signals field by choosing the appropriate checkbox.
Only displayed if the

option is installed
Fig. 4.15: Parameterizing option 2 (analog output and LCD)
4.5.4
LCD
This option enables you to define a second limit value. Enter the value in the "Option limit
value 2" field on the "Parameter" tab page (see Fig. 4.15).
No further parameterization is required.
72
8 010 038 / 08-2006
FW300
Maintenance
General
Maintaining the Transmitter/Receiver Unit and Reflector
Maintaining the Purge-Air Supply
Removal from Service
Maintenance
FW300
Maintenance
5.1 General
The FW300 is designed for long-term and almost maintenance-free operation. You simply
have to ensure that the optical boundary surfaces are clean and the purge-air supply is
functioning properly.
Maintenance must be carried out, for example, if the transmission values are constantly
decreasing, or opacity and extinction are increasing due to contamination.
Before you carry out these maintenance tasks, you have to set the FW300 to
"Maintenance" mode. You can do this by connecting the digital input Dig in 1 (terminals 4,
9; see Fig. 3.8/Fig. 3.15/Fig. 3.17) externally on the hardware side, or by choosing
"Operating mode / Maintenance" in the MEPA-FW menu on the software side.
Once you have completed these activities, switch the system back to measuring mode
(switch off the external maintenance switch or choose "Measure" in the "Operating mode"
menu).
Note
When the maintenance switch is set, warning and fault messages are suppressed. The live
zero value is output at the analog output.
Maintenance intervals
The plant operator is responsible for defining the maintenance intervals. This will depend on
specific operating parameters, such as dust content and type, gas temperature, plant
operational procedures, and ambient conditions. For this reason, only general
recommendations can be provided here. Maintenance is generally carried out every 2 to 6
weeks. The activities required and their completion must be documented by the operator in
a maintenance log.
Maintenance agreement
Regular maintenance activities can be carried out by the plant operator. These activities
must be carried out by qualified persons (as described in Chapter 1) only. If requested, all
maintenance activities can also be performed by the SICK Service department, or an
authorized service partner. SICK offers a range of economical maintenance and repair
agreements. SICK undertakes all maintenance and servicing work specified in these
agreements. Wherever possible, specialists carry out repairs on site.
8 010 038 / 08-2006
75
Maintenance
FW300
5.2 Maintaining the Transmitter/Receiver Unit and Reflector

The "optical boundary
surface" is the surface of
the optics or glass that faces
the duct.
The optical boundary surfaces should be cleaned at regular intervals. The intervals depend
on the operating conditions, although experience has shown that maintenance is required
every 2 to 6 weeks. At the very latest, they must be cleaned when the maximum permissible
level of contamination has been reached.
Required tools:
Brush, cloth, water, compressed air (dust and oil free; e.g. compressed air in 200 to
500 ml spray cans)
A blind plug for the device attachment (if required)
Warning
When carrying out work on the system, always observe the relevant safety precautions
and instructions provided in Section 1.3 (in particular, in Section 1.3.3).
DANGER
The purge-air supply must not be interrupted.
Procedure
Loosen the clamps on the device attachments and carefully remove the transmitter/
receiver unit and reflector.
Blow off any loose dust on the optical boundary surfaces, wet the SICK optics cloth with
water, and clean the optics. Polish the optics with a dry optics cloth. Blow or brush off any
lint.
Carefully place the transmitter/receiver unit and reflector back onto the device
attachments and secure with the clamps.
Ensure that the optical axes are correctly aligned.
If necessary, re-normalize the FW300 (see Section 4.2).
76
8 010 038 / 08-2006
Maintenance
FW300
5.3 Maintaining the Purge-Air Supply

You must carry out the following maintenance activities:
Inspect the entire purge-air supply
Clean the filter housing
Replace the filter insert (if necessary)
The dust load and wear on the filter insert depend on the degree of contamination of the
ambient air that is drawn in. For this reason, we cannot provide specific recommendations
regarding maintenance intervals, although you are advised to inspect the purge-air unit
every 1 to 2 weeks after commissioning. The maintenance intervals can then be optimized
accordingly.
Important
If the purge-air supply is not maintained at regular intervals or maintenance is not
thorough enough, it can fail and destroy the transmitter/receiver unit and reflector.
ATTENTION
You must ensure that the purge-air supply is functioning properly when the transmitter/
receiver unit and reflector are installed. When replacing damaged purge-air hoses, you
must remove the transmitter/receiver unit and reflector beforehand (see section 5.4).
Inspection
Check the running noise of the fan at regular intervals; an increased noise level can
indicate a fan failure.
Check that all the hoses are secure and free of damage.
Check the filter insert for contamination.
You must replace the filter insert when:
a high degree of contamination is visible on the filter surface
the purge-air quantity is considerably less than during operation with a new filter
Note
8 010 038 / 08-2006
You must not switch off the purge-air supply when cleaning the filter housing or replacing
the filter insert, which means that the transmitter/receiver unit and reflector do not have
to be removed from the duct.
77
Maintenance
FW300
5.3.1
Connection Unit with Integrated Purge-Air Supply

Cleaning or replacing the filter insert
Open the door of the connection unit using the appropriate key.
Remove the clamping tape at the filter output (1) and remove the filter from the gland (2).
Remove the filter housing.
Turn the filter housing cover in the direction of the arrow to "OPEN" and remove it.
Remove the filter insert and replace it with a new one.
Clean the filter housing and housing cover with a cloth and brush.
Important
You must only use a cloth soaked in water to wet-clean the components. Make sure that
you dry the components thoroughly.
ATTENTION
Spare part:
Filter insert C1140,
Order no. 7047560
Insert the new filter insert.

Replace the filter housing cover and turn it against the direction of the arrow until it clicks
into position.
Place the filter housing back into the connection unit.
Clamping tape
Filter housing
Filter housing cover
2
1
Intake hose
Fig. 5.1: Changing the filter insert for the connection unit with purge-air supply
78
8 010 038 / 08-2006
Maintenance
FW300
5.3.2

Important
The purge-air unit must be maintained at the very latest when the low-pressure monitor at
the filter output is activated (see Fig. 5.2).
ATTENTION
Replacing the filter insert

Ensure that you have a new filter insert (2) ready.
Loosen the hose clamp (6) on the purge-air hose (7) and remove the hose. Secure the
hose onto a clean surface.
Important
ATTENTION
Attach the end of the hose in such a way that no foreign bodies can enter it (danger of
destroying the fan), but do not seal it! During this time, the purge-air entering the purgeair glands is unfiltered.
Remove any dust from the outside of the filter housing (1).
Press the two quick-release locks (4) on the filter housing cover (3) to remove it.
Remove the filter insert (2) by turning it counter-clockwise.
Clean the filter housing and housing cover with a cloth and brush.
Important
You must only use a cloth soaked in water to wet-clean the components. Make sure that
you dry the components thoroughly.
ATTENTION
Spare part:
Filter insert Micro-Top
element C11 100,
Order no. 5306091
Insert the new filter insert by turning it clockwise while applying pressure.
Mount the filter housing cover and ensure that it is properly aligned with the housing. Snap
the quick-release locks into position.
Reconnect the purge-air hose to the filter outlet using the hose clamp.
6
8
1
2
3
4
5
Filter housing
Filter insert
Filter housing cover
Quick-release lock
Air intake gland
6
7
8
9
Hose clamp
Purge-air hose
Hose clamp
Low-pressure monitor
Fig. 5.2: Replacing the filter insert
8 010 038 / 08-2006
79
Maintenance
FW300
5.4 Removal from Service

The FW300 must be removed from service:
as soon as the purge-air supply fails
if the plant is shut down for a prolonged period (more than approx. 1 week)
Important
The purge-air supply must never be switched off or interrupted when the FW300 is installed
in the duct!
ATTENTION
Activities
Loosen the cable to the connection unit.
Loosen the clamps and remove the transmitter/receiver unit and reflector from the
device attachments.
Loosen the nuts and remove the device attachments from the flanges with pipe (see Fig.
3.11).
Seal the flange with pipe using a blind plug.
Switch off the purge-air supply.
Loosen the hose clamping bands and detach the purge-air hoses from the glands. Seal
the ends of the hoses to prevent dirt and moisture from entering.
Disconnect the connection unit from the power supply.
Warning
When disassembling the system, observe the relevant safety regulations and
the safety information in Chapter 1!
DANGER
Disassembly work on potentially dangerous machinery (high internal duct pressure, hot,
corrosive, or explosive gases) must only be carried out when the machinery is shut down!
Suitable measures must be taken to protect against danger!
Switches that must not be activated for safety reasons are labeled accordingly and
safeguarded to prevent unintentional activation.
Storage
Store the components in a clean, dry location.
Take suitable measures to protect cable connectors against dirt and moisture.
Ensure that no dirt or moisture can enter the purge-air hoses.
80
8 010 038 / 08-2006
FW300
Troubleshooting
No Indication
Warnings and Malfunction Messages
Test and Diagnosis Options
Troubleshooting
FW300
Troubleshooting
6.1 No Indication
Symptom
Possible cause
Remedy
Transmitter/receiver unit LEDs

do not light up
LEDs on LCD do not light up, no

indication on display
No power supply
Fuse defective
Power supply unit defective
Signal cable defective or not
properly connected
connector defective
LP processor defective
LCD defective
Disconnect the device from the power supply

Open the connection unit cover
Check the fuse (see Section 7.3.1)
Check the power supply after connecting it to terminals N and
L1
Check the 24 V supply in the connection unit at terminals
7 (+) and 8 (Gnd) and in the transmitter/receiver unit at test
point +24 V and ground (e.g. spacer pin) (see Fig. 7.1 and
Fig. 7.2)
Check the plug connection and cable
Important
Always observe the relevant safety regulations when carrying out work on live components!
ATTENTION
8 010 038 / 08-2006
83
Troubleshooting
FW300
6.2 Warnings and Malfunction Messages

6.2.1
Malfunction Messages
Device malfunctions are signaled when the red LED on the rear of the transmitter/receiver
unit lights up and, if the device is connected to MEPA-FW, the status indicator on the
"Measured values" tab page ("System status" field) switches from green ("Operation") to
red ("Malfunction").
If the LCD option is installed, malfunctions are also signaled in the second line of the display
in plain text (English) (see the following table).
Current malfunctions can also be interrogated in MEPA-FW on the "Diagnosis/Test" tab
page (see Fig. 6.1). In the "Malfunctions" field, all malfunctions currently present are
displayed as a short text. Comments are also available for each malfunction message,
although they are only displayed when a message is selected.
To supplement the displays in MEPA-FW, individual malfunction messages are available.
These are explained in detail in the following section.
Short text
Comment field
Short text
Comment field
These are only displayed if

the LCD option is installed
Fig. 6.1: "Diagnosis/Test" tab page
84
8 010 038 / 08-2006
Troubleshooting
FW300
Malfunction messages
Possible cause
Remedy
The last parameters could not be
Reload the device parameters

Switch to the "Protocol" tab page
Press the "Load from file" button (the
parameters must be saved beforehand; see
section 4.4.3)
Press the "Write to device" button (password
level 1 and "Maintenance" operating mode
must be set)
MEPA-FW
LCD
"Checksum
EEPROM"
"Checksum
EEPROM"
"Overflow meas.
value"
"Meas. overflow" The measuring distance has been

shortened without being re-normalized.
saved due to reset or power failure

EEPROM security area violated
Re-normalize the FW300 (see section 4.2.3)
(Value for AN0 > 4.4 V; see "Protocol"

tab page, "Factory settings" field)
"Signal too low
during set
reference"
"Set reference"
Measuring signal < 1 V
Clean the optics

Check the alignment of the optical axes and
readjust if necessary
Repeat normalization
"Constant light
signal too high"
"Constant light"
Direct sunlight or reflections on duct

components
"Real-time clock" "Real-time clock" Real-time clock cannot be addressed

Only with data memory/event memory
option
Control cycle cannot be triggered /
measured values cannot be saved
automatically
"Monitor signal
too low"
"Monitor signal"
"Device
"Temp. > 70
temperature > 75 grdC"
C"
"No display
communication"
Send the device back to the manufacturer for

repair
The laser byte calculated during
Check transmitter current ("Protocol" tab page,
normalization generates a defined

monitor signal
Laser byte 250 digit:
2.8 ... 4.4 V
Laser byte 200 digit:
2.0 ... 4.4 V
Transmitter diode defective
Transmitter diode has been switched
off because temperature is too high
"Factory settings" field)

The value must be between 45 mA and 100
mA (temperature dependent; permissible
range:
+20 ... +70 C)
Send the device back to the manufacturer for
repair
Internal device temperature too high

Temperature sensor defective
Temperature sensor incorrectly
Check installation conditions

Protect transmitter/receiver unit against
calibrated
=> Laser is switched off until the

temperature reaches < 70 C
Take appropriate measures (e.g. choose a

different measuring site, or apply low-reflection
paint)
ambient or radiant heat (insulate)
Check the temperature sensor (comparison

measurement with separate sensor)
"Comm. failure
Defective connection
Waiting for data"
Only if the LCD option is installed.

No interrogation of Dig in1 to Dig in4
and no signaling of the 2nd limit value.
Check the signal cable connections between the

transmitter/receiver unit and connection unit
Check the LCD module connections in the

connection unit
Switch off power supply for approx. 5 s and

switch back on again (PowerOn-Reset)
Ensure that the LCD option is enabled in MEPAFW
8 010 038 / 08-2006
85
Troubleshooting
FW300
6.2.2
Warnings
Since no malfunctions are present when warning messages are output, the "Operation"
status is still displayed (the green LED on the rear of the housing lights up; the status
indicator in MEPA-FW is green ("Operation")).
Warnings are also displayed in MEPA-FW ("Diagnosis/Test"; see Fig. 6.1) and on the LCD
(if installed) in plain text (English).
Warning message
MEPA-FW
Remedy
Displayed for information purposes when

the "Test mode on" checkbox in the "Test
output signals" field is active when the
device is in "Maintenance" mode and the
password has been set.
You have to deactivate the "Test mode on"

checkbox before you exit the "Diagnosis/Test"
tab page or MEPA-FW.
The real-time clock can be addressed, but

does not display a date or time.
Reset the clock (see section 4.5.1)

Check the battery voltage; replace battery if
necessary (see section 7.1.5)
If a warning is still present, send the device
LCD
"Test mode
active"
"Reset real-time
clock"
Possible cause
"Battery low"
Only with data memory/event memory

option
Only time differences can be
measured; absolute times cannot be
specified.
6.2.3
back to the manufacturer for repair
Other Malfunctions and Abnormal Behavior

Severely fluctuating measured values, transmission too low, or opacity/extinction/dust
concentration too high (implausible)
Corrective measures:
Check the normalization.
Check that the optical boundary surfaces are not excessively contaminated.
Check the alignment of the optical axes of the transmitter/receiver unit and reflector
(possible thermal distortion or excessive vibrations); see Section 4.3.
The reflector must be clearly visible from the direction of the transmitter/receiver unit
and must not be partially or completely covered.
If you are using a rotating reflector, check whether the motor rotates (open the cover
of the reflector housing).
Check the flange pipes for deposits in the beam path (remove any deposits).
Ensure that the beam path is unobstructed.
Fittings or objects must not be installed in the beam path inside the duct.
Check optical boundary surfaces for internal damage or contamination.
Ensure that fittings on the transmitter/receiver unit (optics holder, LP processor) and
the rotating reflector are secure and undamaged.
The disk springs for adjusting the optics holder in the transmitter/receiver unit must
have sufficient pre-loading strength.
86
8 010 038 / 08-2006
Troubleshooting
FW300
Check values generated during the check cycle are not output via the analog output or
are outside tolerance ( 2 %).
Check the device status.
Malfunction messages (see Section 6.2.1;): in "Maintenance" mode, "Live Zero" is
output constantly.
Check whether the check value output via the analog output has been deactivated
(MEPA-FW: "Parameters" tab page).
Start the check cycle manually and ensure that it runs correctly ("Maintenance" mode
must not be active).
Switch off power supply for approx. 5 s and switch back on again (PowerOn-Reset); a
check cycle must be triggered after one minute.
Temporary contamination on optical boundary surfaces
Check the purge-air supply (replace filter if necessary); check the hoses for damage
or leakage (replace hoses if necessary).
Check the rubber sealing strip on the transmitter/receiver unit and reflector.
Check the clamps on the transmitter/receiver unit and reflector to ensure that they are
sufficiently and equally secure.
Check the duct pressure for fluctuations or surges.
Check whether the fan power is sufficient (use a more powerful fan if necessary).
If only one component is contaminated (transmitter/receiver unit or reflector), check
the purge-air distribution.
The purge-air volume for the reflector must be greater than that for the transmitter/
receiver unit (see Section 3.3.5).
If you have installed an external purge-air unit, ensure that a constant purge-air supply
is available.
Use a fail-safe power supply and ensure that the motor contactor setting is not too fine
(see Section 3.3.3).
If the filters are heavily contaminated for a temporary period, choose a different intake
location (see Section 3.2.3) or install additional prefilters.
Check the inside of the purge-air hoses for contamination or deposits. Clean or replace
them if necessary, and establish the cause of the contamination or deposits. If very
fine dust is penetrating the filter, install additional fine filters (with a more powerful fan
if necessary).
8 010 038 / 08-2006
87
Troubleshooting
FW300
6.3 Test and Diagnosis Options

You can call up the "Diagnosis/Test" tab page in MEPA-FW to check that the analog output,
relay outputs, digital inputs, and LCD are functioning properly (see Fig. 6.2). To do so, the
device must be connected to MEPA-FW via a laptop or PC, password level 1 must be set,
and the device must be set to "Maintenance" mode.
Fig. 6.2: "Diagnosis/Test" tab page
6.3.1
Testing the Signal Output

After you have activated the "Test mode on" checkbox in the "Test output signals" field, you
can check whether the analog output and relay outputs are functioning correctly by entering
an analog value and setting the radio button for the relays to "ON" or "OFF". To start the test,
click the "Write to device" button.
Important
You have to deactivate test mode again before you exit the "Diagnosis/Test" tab page,
otherwise the measurement cannot be carried out properly.
ATTENTION
6.3.2
Check Cycle
Click the "Check-point verification" button to check the check values (zero and span). Do
not activate the "Test mode on" checkbox. The following message is output if the check was
successful:
Zero point OK
Check point deviation < 2 %
Acknowledge the message by clicking "OK".
88
8 010 038 / 08-2006
Troubleshooting
FW300
6.3.3
Linearity Check
To ensure that the device functions properly, you are advised to check the linearity of the
transmission measurement at regular intervals (e.g. during the annual functional check) to
ensure that the other measured variables are accurate. The linearity test equipment can be
used here. This equipment has been specially designed for the FW300. It comprises an
adapter for integrating special transmission filters and a filter set with different transmission
values.
For a description of the individual steps that have to be carried out in a linearity test, see the
accompanying operating instructions.
If you are using other options, you must ensure that the optical axes of the transmitter/
receiver unit and reflector are exactly aligned with each other, and transmission filters
installed in the beam path allow the beam to pass through twice.
8 010 038 / 08-2006
89
FW300
Troubleshooting
8 010 038 / 08-2006
90
FW300
Repairs
Rotating Reflector
Connection Unit
Repairs
FW300
Repairs
Any repair work on the FW300 is limited to replacing the system components listed under
the spare parts (see Secction 8.4) (e.g. LP processor, housing, fan, power supply unit).
Individual modules can only be repaired at the manufacturer.
Note
Repairs that are not authorized by the manufacturer may render existing warranty claims
invalid.
Required tools:
Socket wrenches: w/s 7 and w/s 13
Spanner: w/s 7
Hexagon socket screw key: w/s 3
Small and medium-sized recessed-head screwdriver
Medium-sized flat screwdriver (for approx. 5 mm slot length)
Medium-sized flat screwdriver (for approx. 3 mm slot length)
Screwdriver TORX 20
8 010 038 / 08-2006
93
Repairs
FW300
7.1 Transmitter/Receiver Unit

7.1.1
The new LP processor
must be compatible with
the transmitter/receiver
unit type (see Section
8.1.1, 8.2.1, and 8.4.1).
Replacing the LP Processor

Unplug the connection cable to the connection unit from the connector on the bottom of
the housing.
Loosen the screws for securing the housing cover and remove the cover.
Loosen the self-locking nuts (see Fig. 7.1) and carefully raise the board.
Remove the socket connectors with the ribbon cable from the connectors on the
underside of the board and remove the LP processor.
Reassemble the transmitter/receiver unit with the new LP processor by following the
above steps in reverse order (connect the socket connectors with the ribbon cable, insert
and screw on the LP processor, and then replace the cover).
Reconnect the connection cable to the connection unit.
Processor board
Self-locking nuts
Ribbon cable
+24 V test point
Connection cable
Fig. 7.1: FW300 transmission/receiver unit (opened)
Note
You may have to refocus the transmitter light beam (see 4.2.2).
7.1.2
Replacing the Optics Holder with Receiver Electronics
Spare part for FW310SE:

optics holder with receiver
electronics for FW310SE
(order no. 7040430)
Remove the LP processor as described above.
Spare part for FW320SE:

optics holder with receiver
electronics for FW320SE
(order no. 7040431)
94
Unscrew the spacer pin (see Fig. 7.2) and remove the optics holder with electronics.
Insert the new module and re-assemble the transmitter/receiver unit by carrying out the
above steps in reverse order.
8 010 038 / 08-2006
Repairs
FW300
Spacer pin
Socket connector
with ribbon cable
Optics holder with
receiver electronics
Spacer pin
Connector
T/R unit
(assembly)
Contact plate
Fig. 7.2: FW300 transmitter/receiver unit without LP processor
Notes
When removing the optics holder with the receiver electronics, you must ensure that
the disk springs and spacer remain attached to the spacer bolts. If these parts fall out,
however, push the spacer onto the spacer bolt and then reattach the disk springs in pairs
(6 pairs; arrangement as in Fig. 3.11 for installing the device attachment).
After the component has been replaced, the optical axis may have shifted due to a different
pre-loading strength of the disk springs. Correct this as described in Section 4.3. This can
also be corrected by opening the housing cover and tightening the spacer pins in the
transmitter/receiver unit to different degrees (see Fig. 4.7).
7.1.3
Spare part:
T/R unit connector
(assembly) (order no.
7040432)
Replacing the Entire T/R Unit Connector

Loosen the spacer pin (see Fig. 7.2) and remove the LP processor with the optics holder
with receiver electronics.
Loosen the screws for securing the connector on the underside of the housing.
Loosen the nuts for securing the contact plate and remove them together with the
washers and spring washers.
Remove the board with the connector and ribbon cable from the housing.
Remove the contact plate and seal (on housing interior) and replace them with new ones
(supplied with the module).
Insert the new board with connector and re-assemble the transmitter/receiver unit by
carrying out the above steps in reverse order.
Note
When removing the modules, ensure you do not damage the disk springs and spacers (if
necessary, reinsert them as described in Section 7.1.2).
7.1.4
Replacing the FW300SE Housing
Spare part:
FW300SE housing
without optics holder or
receiver electronics (order
no. 7040432)
Note
To replace damaged housing or glass on the transmitter/receiver unit, remove the LP

processor and optics holder with the receiver electronics as described in Section 7.1.1 and
7.1.2 from the old housing and install them in the new FW300SE housing.
The transmitter/receiver unit connector (assembly) is supplied in the spare parts module for
the FW300SE housing without the optics holder or receiver electronics.
8 010 038 / 08-2006
95
FW300
Repairs
7.1.5
Checking / Replacing the Battery for the Transmitter/Receiver Unit

The battery is soldered onto the rear of the LP processor in the transmitter/receiver unit.
The rated voltage is 3 to 3.3 V. The service life depends on the operation duration of the
transmitter/receiver unit (constant use: more than 5 years; occasional use: 1 - 2 years).
Voltage check
the housing.
Remove the housing cover of the transmitter/receiver unit.
Connect the digital multimeter to the positions marked + and - in Fig. 7.3 and measure
the voltage.
Battery (soldered
onto the rear)
Transmitter/receiver
unit
Processor board
Fig. 7.3: Battery for the data memory/event memory
If the voltage is less than 2.2 V, the battery must be replaced with battery type BR 2032 V
(vertical installation, capacity: 190 mAh) (can be supplied by SICK on request).
Replacing the battery
Save stored measured values and events to a file (see Section 4.5.1).
Remove the LP processor as described in Section 7.1.1.
Unsolder the battery (see Fig. 7.3).
Solder the new battery on.
Reassemble the transmitter/receiver unit and connect the connection cable to the
connection unit.
Delete the data memory/event memory (see Section 4.5.1).
Set the real-time clock as described in Section 4.5.1.
96
8 010 038 / 08-2006
Repairs
FW300
7.2 Rotating Reflector

7.2.1
Spare part for
FW-R-055-D: reflector
D55 (order no. 7040838)
Replacing the Reflector

the housing.
Loosen the screws for securing the housing cover and remove the cover.
Disconnect the wires from the terminal block (push the terminal with a small screwdriver
and pull the wire out); see.
Spare part for

FW-R-105-D: reflector
D105 (order no.
7040272)
Loosen the securing bolts with the TORX screwdriver (see Fig. 7.4) and remove the
reflector.
Reassemble the rotating reflector by following the above steps in reverse order (insert
the reflector, connect the wires, and replace the cover).
Securing bolts
Red
Blue
Wires
Fig. 7.4: Rotating reflector, opened (type: FW-R-055-D)
8 010 038 / 08-2006
97
Repairs
FW300
7.2.2
Replacing the Front Window with the Holder
Spare part for

FW-R-055-D: holder D55
(order no. 7040814)
Remove the reflector as described in the previous section.
Spare part for

FW-R-105-D: holder
D105 (order no.
7040276)
Secure the new holder onto the housing and re-assemble the rotating reflector by
carrying out the above steps in reverse order.
Loosen the securing bolts (see Fig. 7.5) and remove the holder with the window from the
reflector housing.
Securing bolts
Holder with window
(on the outside of
the housing)
Fig. 7.5: Rotating reflector, opened (type: FW-R-055-D), without reflector
7.2.3
Spare part for
FW-R-055-D: housing
D55 installed (order no.
7040813)
Replacing the Housing for the Rotating Reflector

To replace damaged housing, remove the reflector (D55 or D105) and holder (D55 or
D105) from the old housing (as described in Section 7.2.1 and 7.2.2) and install them in
the new housing.
Spare part for

FW-R-105-D: housing
D105 installed (order no.
7040277)
98
8 010 038 / 08-2006
Repairs
FW300
7.3 Connection Unit

Important
You must disconnect the connection unit from the power supply before carrying out
repairs!
ATTENTION
7.3.1
When carrying out repairs on a connection unit with an integrated purge-air supply, you
must remove the transmitter/receiver unit and reflector from the duct for the duration of
the repair work.
Connection Unit Without Purge-Air Supply

Replacing the fuse
Open the cover of the connection unit.
Fold out the fuse holder and open the cover (see Fig. 7.6).
Remove the defective fuse and install the new one.
Close and secure the fuse holder.
Close the cover and reconnect the power supply.
Fuse holder
Spare fuse
Cover
Fig. 7.6: Replacing the fuse
8 010 038 / 08-2006
99
FW300
Repairs
Replacing the power supply unit

Spare part:
24 V 60 W power supply
unit (order no. 7047557)

Loosen the lock nuts for the mounting bracket (1) (see Fig. 7.7).
Loosen the conduit thread connections and push the connection cable a small distance
into the connection unit.
Remove the mounting bracket with the power supply unit and disconnect the wires.
Loosen the securing bolts for the power supply unit (2).
Power
supply unit
d
c
Mounting
bracket
c
Fig. 7.7: Mounting bracket with power supply unit
Loosen the retaining bolt or nut (3) and remove the power supply unit.
Mounting
bracket
Fig. 7.8: The mounting bracket and power supply unit have been removed from the connection unit
Insert and connect (see Fig. 7.9) the new power supply unit, and reassemble the
connection unit by carrying out the above steps in reverse order.
Close the cover and connect the power supply.
Brown
Red
Blue
Blue
Fig. 7.9: Terminal assignment
100
8 010 038 / 08-2006
Repairs
FW300
7.3.2
Connection Unit with Integrated Purge-Air Supply
Notes
The fuse is replaced as described in Section 7.3.1.

The filter is replaced as described in Section 5.3.1 (order no. 7047560).
Replacing the power supply unit
Spare part:
24 V 60 W power supply
unit (order no. 7047557)

If the LCD is installed, loosen the lock nuts of the I/O board (1) and fold out the board
(see Fig. 7.10).
Loosen the securing bolts for the power supply unit (2).
Loosen the securing bolts for the mounting plate (3).
Loosen the conduit threads and push the connection cable a small distance into the
connection unit.
Fold out the mounting plate and disconnect the wires.
Loosen the retaining bolts (4) (see Fig. 7.11) and remove the power supply unit.
Insert and connect the new power supply unit (see Fig. 7.11) and reassemble the
connection unit by carrying out the above steps in reverse order.
Fuse holder
Mounting plate
d
e
I/O board
Fig. 7.10: Mounting plate with I/O board

Power supply
Mounting plate
Re
Blue
Yellow/
Blue
Black
Fig. 7.11: Power supply unit with mounting plate (rear)
8 010 038 / 08-2006
101
Repairs
FW300
Replacing the Fan

Spare part:
Fan,
Order no. 7047042
Disassemble the filter housing (see Section 5.3.1)

Remove the fan connector and protective conductor (see Fig. 7.12)
Loosen the securing bolts.
Remove the clamping tape and disconnect the purge-air hose.
Connector
Securing bolts
Fan
Protective
conductor
Purge-air hose
Fig. 7.12: Fan in the connection unit with an integrated purge-air supply
Take out the fan and remove the connection plate with the seal from the purge-air outlet
(see Fig. 7.13).
Install and connect the new fan by carrying out the above steps in reverse order.
Important
Do not forget the connection for the protective conductor.
ATTENTION
Install and connect the filter housing.

Protective
conductor
connection
Purge-air outlet
Connection plate
Seal
Fig. 7.13: Fan purge-air outlet
102
8 010 038 / 08-2006
Repairs
FW300
Replacing the LCD module

Spare part:
LCD module
order no. 7040434

Remove the connector on the LCD module (see Fig. 7.14).
Loosen the lock nuts on the LCD and remove the module.
Install, secure, and connect the new module.
LCD module
Connector
Lock nut
Fig. 7.14: LCD module
8 010 038 / 08-2006
103
FW300
Repairs
8 010 038 / 08-2006
104
FW300
Parts Overview
Standard Components
Options
Consumable Parts for 2-Year Operation
Spare Parts
Parts Overview
FW300
Parts Overview
8.1 Standard Components
The standard components required for a complete measuring system depend on the
measuring distance and the internal duct pressure. The following table displays the possible
combinations and the quantities required:
Meas.
distance
[m]
Transmitter/
receiver
unit
Reflector
0.5 - 2
1 x FW310SEXXX-XX
1 x FW-R055-F-000
1 x FW320SEXXX-XX
1 x FW-R055-D-000
1 x FW320SEXXX-XX
1 x FW-R105-D-000
1.5 - 8
6 - 15
Device
attachment
1 x FW-V-030P-000
1 x FW-V-055P-000
1 x FW-V-030P-000
1 x FW-V-055P-000
1 x FW-V-030P-000
1 x FW-V-105P-000
Flange
with pipe
Connection unit External

Purge-air
purge-air hose
unit
(optional)
Power supply
cable for
rotating
reflector
AK1-P-XXXX-X-X
x2
AK1-N-XXXX-X-X
x1
x1
AK1-P-XXXX-X-X
x2
x1
AK1-N-XXXX-X-X
x1
x1
x1
1 x D100
AK1-P-XXXX-X-X
x2
x1
1 x D160
AK1-N-XXXX-X-X
x1
x1
x1
2 x D100
2 x D100
The different versions are listed in the following sections. They are defined by abbreviations
in accordance with the type code (see 2.3).
8.1.1
Transmitter/Receiver Units
Name
8.1.2
Transmitter/receiver unit FW310SE-NNN-00

Measuring distance: 0.5 m - 2 m
7040370
Transmitter/receiver unit FW320SE-NNN-00

Measuring distance: 1.5 m 15 m
7040300
Reflectors
Name
8 010 038 / 08-2006
Order number
Order number
Reflector FW-R-055-F-000
7040334
Reflector FW-R-055-D-000
7040331
Reflector FW-R-105-D-000
Measuring distance: 6 m - 15 m
7040332
107
Parts Overview
FW300
8.1.3
Device Attachments
Name
8.1.4
Order number
Device attachment FW-V-030-P-000

With purge-air nozzle, for transmitter/receiver unit
7040340

With purge-air nozzle, for reflectors FW-R-055-F-000 and FW-R-055-D-000
7040341

With purge-air nozzle, for reflector FW-R-105-D-000
7040342
Flanges with Pipe

Name
Order number
D100
Flanges with pipe, diameter = 70.2, length = 130 mm, St37
2017845
2017847
2017849
Flanges with pipe, diameter = 70.2, length = 130 mm, V4A
2017846
2017848
2017850
D160
8.1.5
Flanges with pipe, DN 108, length = 100 mm, St37
7040128
Flanges with pipe, DN 108, length = 200 mm, St37
7040137
Flanges with pipe, DN 108, length = 100 mm, V4A
7040138
Flanges with pipe, DN 108, length = 200 mm, V4A
7040139
Connection Units
Operating voltage: 90 ... 260 V AC, 47 ... 63 Hz
Name
8.1.6
7040350
Connection unit AK1-N-10WR-N-0

Without purge-air supply, signal cable length = 10 m
7040351
Connection unit AK1-P-03WR-N-0

With integrated purge-air supply, signal cable length = 3 m
7040358
Connection unit AK1-P-10WR-N-0

With integrated purge-air supply, signal cable length = 10 m
7040359
External Purge-Air Units (optional)

Name
108
Order number
Connection unit AK1-N-03WR-N-0

Without purge-air supply, signal cable length = 3 m
Order number
Purge-air unit SLV4-21112

With fan 2BH13, 3ph and purge-air hose (length = 10 m)
1012409
Purge-air unit SLV4-21111

With fan 2BH13, 3ph and purge-air hose (length = 5 m)
1012424
8 010 038 / 08-2006
Parts Overview
FW300
8.1.7
Purge-Air Hoses
Name
8.1.8
7040396
Purge-air hose D40/46, length = 5 m
4022766
7040397
7040398
Power Supply Cables for the Rotating Reflectors

Name
8.1.9
Order number
2-core cable, length = 3 m
7040399
7040400
7040401
7040402
Miscellaneous
Name
8 010 038 / 08-2006
Order number
Order number
Flange/analyzer installation set
2018183
Flange/reflector installation set
2018184
109
FW300
Parts Overview
8.2 Options
8.2.1
Transmitter/Receiver Units
Name
Order number

Transmitter/receiver unit FW310SE-NND-00
7040371
Transmitter/receiver unit FW310SE-MNN-00
7040372
Transmitter/receiver unit FW310SE-MND-00
7040373
Transmitter/receiver unit FW310SE-NAN-00
7040374
Transmitter/receiver unit FW310SE-NAD-00
7040375
Transmitter/receiver unit FW310SE-MAN-00
7040376
Transmitter/receiver unit FW310SE-MAD-00
7040377
Transmitter/receiver unit FW310SE-NCN-00
7040378
Transmitter/receiver unit FW310SE-NCD-00
7040379
Transmitter/receiver unit FW310SE-MCN-00
7040380
Transmitter/receiver unit FW310SE-MCD-00
7040381
Measuring distance: 1.5 m -15 m
8.2.2
Transmitter/receiver unit FW320SE-NND-00
7040301
Transmitter/receiver unit FW320SE-MNN-00
7040302
Transmitter/receiver unit FW320SE-MND-00
7040303
Transmitter/receiver unit FW320SE-NAN-00
7040304
Transmitter/receiver unit FW320SE-NAD-00
7040305
Transmitter/receiver unit FW320SE-MAN-00
7040306
Transmitter/receiver unit FW320SE-MAD-00
7040307
Transmitter/receiver unit FW320SE-NCN-00
7040308
Transmitter/receiver unit FW320SE-NCD-00
7040309
Transmitter/receiver unit FW320SE-MCN-00
7040310
Transmitter/receiver unit FW320SE-MCD-00
7040311
Connection Units
Operating voltage: 90 ... 260 V AC, 47 ... 63 Hz
Name
Order number
Without purge-air supply

Connection unit AK1-N-03WR-D-0
With LCD, signal cable length = 3 m
7040354
Connection unit AK1-N-10WR-D-0

7040355
With integrated purge-air supply
110
Connection unit AK1-P-03WR-D-0

7040362
Connection unit AK1-P-10WR-D-0

7040363
8 010 038 / 08-2006
Parts Overview
FW300
Operating voltage 24 V DC
Name
Order number
Without purge-air supply

Connection unit AK1-N-0302-N-0
Without options, signal cable length = 3 m
7040352
Connection unit AK1-N-1002-N-0

7040353
Connection unit AK1-N-0302-D-0

7040356
Connection unit AK1-N-1002-D-0

7040357
With integrated purge-air supply
8.2.3
Connection unit AK1-P-0302-N-0

7040360
Connection unit AK1-P-1002-N-0

7040361
Connection unit AK1-P-0302-D-0

7040364
Connection unit AK1-P-1002-D-0

7040365
Device Attachments
Name
8.2.4
Device attachment FW-V-030-N-000

Without purge-air nozzle, for transmitter/receiver unit
7040343
Device attachment FW-V-055-N-000

Without purge-air nozzle, for reflector FW-R-055-F-000
7040344
Device attachment FW-V-055-N-H00

Without purge-air nozzle, with heating, for reflector FW-R-055-D-000
7040345
Purge-air Connection
Name
8.2.5
Order number
Purge-air aperture
7040403
7041075
Weatherproof Covers
Name
Weatherproof cover for analyzer
8 010 038 / 08-2006
Order number
Order number
2702407
Weatherproof cover for rotating reflector FW-R-105-D-000
2021457
Weatherproof cover for housing FWSE/FWR-D
7040394
Weatherproof cover for purge-air unit
5306108
111
Parts Overview
FW300
8.2.6

Name
8.2.7
Order number
Light/dust protection tube
7041168
Bracket for light/dust protection tube
7040233
Optional Components for Higher Internal Duct Pressures

Name
Order number
Internal duct pressures up to +6 bar

Weld-on flange DN50 PN16 ST37
7040278
Ball valve DN50 PN16
7040281
Purge-air attachment PN60
7040282
Pressure reducer with filter
7040283
Weatherproof cover
7040284
Internal duct pressures up to +30 bar

High-pressure attachment
8.2.8
Accessories for Testing the Device

Name
8.2.9
Order number
Linearity test equipment
7040404
Adjustment bracket for normalization (small)
7040131
Adjustment bracket for normalization (large)
7040156
Miscellaneous
Name
112
7040212
Order number
Evaluation unit for connecting max. 3 x FW100/FW300
7047540
Interface cable (for connecting the evaluation unit to a laptop/PC)
7040012
Optical alignment device for mounting the flange
1700462
Adjustment tool for aligning the light/dust protection tube
7040395
8 010 038 / 08-2006
Parts Overview
FW300
8.3 Consumable Parts for 2-Year Operation

8.3.1
Connection Unit with Internal Purge-Air Supply

Name
8.3.2
Order number
Filter insert C1140
7047560
Optic cleaning cloth
4003353
Quantity
Order number
Filter insert Micro-Topelement C11 100
5306091
Optic cleaning cloth
4003353

Name
8 010 038 / 08-2006
Quantity
113
Parts Overview
FW300
8.4 Spare Parts

8.4.1
Name
Order number
T/R unit connector (assembly)
7040432
Housing FW300SE (without optics holder or receiver electronics)
7040433
FW310SE
LP processor FW310SE-NNN (without options)
7040407
LP processor FW310SE-MNN (with data memory/event memory)
7040408
LP processor FW310SE-NAN (with 2nd analog output)
7040409
LP processor FW310SE-NCN (with CAN module)
7040410
LP processor FW310SE-MAN (with data memory/event memory and

2nd analog output)
7040411
LP processor FW310SE-MCN (with data memory/event memory and

CAN module)
7040412
LP processor FW310SE-NND (with display activation)
7040413
LP processor FW310SE-MND(with data memory/event memory and

display activation)
7040414
LP processor FW310SE-NAD (with 2nd analog output and display

activation)
7040415
LP processor FW310SE-NCD (with CAN module and display activation)
7040416
LP processor FW310SE-MAD (with data memory/event memory, 2nd

analog output and display activation)
7040417
LP processor FW310SE-MCD (with data memory/event memory, CAN

module and display activation)
7040418
Optics holder with receiver electronics (for FW310SE )
7040430
FW320SE
LP processor FW320SE-NNN (without options)
114
7040818
LP processor FW320SE-MNN (with data memory/event memory)
7040419
LP processor FW320SE-NAN (with 2nd analog output)
7040420
LP processor FW320SE-NCN (with CAN module)
7040421
LP processor FW320SE-MAN (with data memory/event memory and

2nd analog output)
7040422
LP processor FW320SE-MCN (with data memory/event memory and

CAN module)
7040423
LP processor FW320SE-NND (with display activation)
7040424
LP processor FW320SE-MND(with data memory/event memory and

display activation)
7040425
LP processor FW320SE-NAD (with 2nd analog output and display

activation)
7040426
LP processor FW320SE-NCD (with CAN module and display activation)
7040427
LP processor FW320SE-MAD (with data memory/event memory, 2nd

analog output and display activation)
7040428
LP processor FW320SE-MCD (with data memory/event memory, CAN

module and display activation)
7040429
Optics holder with receiver electronics (for FW320SE )
7040431
8 010 038 / 08-2006
Parts Overview
FW300
8.4.2
Reflector
Name
8.4.3
7040334
Reflector D55
7040838
Reflector D105
7040272
Holder D55
7040814
Holder D105
7040276
Housing D55 installed
7040813
Housing D105 installed
7040277
Device Attachment
Name
8.4.4
7040346
Louvre insert D55 (for FW-V-055-X-XXX)
7041028
7041032
Connection Unit
Order number
24 V 60 W power supply unit
7047557
Fan (for AK1-P-XXXX-X-XX)
7047042
Filter insert (for AK1-P-XXXX-X-XX)
7047560
LCD module
7040434
Miscellaneous
Name
8 010 038 / 08-2006
Order number
Name
8.4.5
Order number
Reflector FW-R-055-F-000
Order number
7040396
4022766
7040397
7040398
Flange/analyzer installation set
2018183
Flange/reflector installation set
2018184
Filter insert Micro-Topelement C11 100
5306091
115
FW300
Parts Overview
8 010 038 / 08-2006
116
FW300
Appendix
Standard Settings for the FW300

Password
Appendix
FW300
Appendix
9.1 Standard Settings for the FW300
Parameter protocol
31 Aug 2004
13:17:46
------------------------------------------------------------------------------Productinformation
------------------------------------------------------------------------------Type
FW310
Firmware
03031115
Compilation date
May 12 2003
Serialnumber
03158727
Option memory measurement value Option analog output 2
Option CAN-Bus
Device adress
Option display
------------------------------------------------------------------------------Parameter and measured value
------------------------------------------------------------------------------Measure value
Transmission
Coefficients square/lin./abs.
- / - / Response time
30.0
sec
Limit value
80.0
%
Limit value 2
%
Live Zero
4
mA
Range LiveZero...20 mA
30.0 ... 100.0
%
Range2 LiveZero...20 mA
%
Save interval
sec
Check cycle
enable
Check cycle interval
02:00
hh:mm
Analog output checkpoints
enable
Relay 2 used for
Limit value
Laser current
74.21
mA
Distance s/r unit-reflector
800
mm
------------------------------------------------------------------------------Factory settings
------------------------------------------------------------------------------Offset 0
0.040
Burstfrequency
10000
Hz
Number of impulses per Burst
50
Burstcycle
20
msec
Calibration analog output 1
5
Calibration analog output 2
Statuscode
00000200
Fig. 9.1: Standard settings for the FW300 (on delivery)
8 010 038 / 08-2006
119
Appendix
FW300
9.2 Password
Passwort Autorisierter Nutzer

Nach dem Start des mengefhrten Parametrierprogrammes MEPA-FW sind nur die
Programmfunktionen verfgbar, die keinen Einfluss auf die Gertefunktion haben.
Nicht eingewiesenes Personal kann keine nderungen der Parameter vornehmen. Zur
Nutzung des erweiterten Funktionsumfanges wird das
Passwort
SICKOPTIC
bentigt.
Falls zur Eingabe eine falsche Taste gedrckt wird, muss das Fenster geschlossen und
anschlieend die Passworteingabe wiederholt werden.
High level password

After the start of the MEPA-FW parameterization program, the only menus available are
those which have no effect on the functioning of the device.
Untrained personnel cannot alter the device parameters. To access the extended range
of functions the
High level password
SICKOPTIC
must be entered
If a wrong key is pressed when entering the password, the window must be closed and
then the password repeated.
Fig. 9.2: MEPA-FW password
The password is provided with the FW300 on delivery.
120
8 010 038 / 08-2006
8010038/08-2006
(V1.0)
SICK MAIHAK worldwide
You will find our local subsidiary

or agency at:
www.sick-maihak.com.

Your local sales and service partner
SICK MAIHAK GmbH | Analyzers and Process Instrumentation

Nimburger Str. 11 | 79276 Reute | Germany | www.sick-maihak.com
Phone +49 7641 469-0 | Fax +49 7641 469-11 49 | info.sick-maihak@sick.de
analyzers and process Instrumentation

1 FW300 Dust Concentration Monitor Operating Instruction

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

1 FW300 Dust Concentration Monitor Operating Instruction

Enviado por

Direitos autorais:

Formatos disponíveis

O p e r a ti n g i n s t r u ctio n s

Analyzers and Process Instrumentation

Dust Concentration Monitor

Notes on this Document ....................................................................................................7

Intended Use .............................................................................................................................8

Safety Information and Protection Measures.................................................................8

Danger from Electrical Equipment ................................................................................................. 9

Danger Due to Hot, Corrosive, or Pressurized Gases ........................................................... 9

Purge-Air Failure .................................................................................................................................... 9

Detecting and Preventing Malfunctions ....................................................................................... 9

Features and Applications ................................................................................................. 13

Operating Principle and Measured Variables .............................................................. 14

8 010 038 / 08-2006

Operating Principle ............................................................................................................................ 14

Calculating Transmission, Opacity, and Extinction ................................................................. 14

Determining the Dust Concentration .......................................................................................... 15

Response time .................................................................................................................................. 16

Transmitter/Receiver Unit .............................................................................................................. 18

Device Attachment ............................................................................................................................ 21

Flange with Pipe ................................................................................................................................. 22

Connection Unit ................................................................................................................................. 22

External Purge-Air Unit (Optional) ................................................................................................ 24

Data Acquisition, Communication, Measured Value Output, and Display Options.... 24

Optional Components for Monitoring Air in Workshops ...................................................... 25

Optional Components for Higher Internal Duct Pressures ................................................. 26

Accessories for Testing the Device............................................................................................. 26

Device Configuration ........................................................................................................... 27

Technical Data ...................................................................................................................... 28

SICK MAIHAK GmbH Germany All rights reserved

Dust Concentration Monitor

Dimensions and Order Numbers....................................................................................... 30

Transmitter/Receiver Unit .............................................................................................................. 30

Device Attachment ............................................................................................................................ 31

Flange with Pipe ................................................................................................................................. 31

External Purge-Air Unit (Optional) ................................................................................................ 33

Weatherproof Cover For Transmitter/Receiver Unit and Rotating Reflector ............... 34

Optional Components for Monitoring Air in Workshops ...................................................... 35

3 Assembly and Installation...............................................................................................37

Project Planning .................................................................................................................... 39

Installing the Flanges with Pipe .................................................................................................... 40

Installing the Connection Unit ....................................................................................................... 42

Installing the Optional External Purge-Air Unit ........................................................................ 43

Fitting the Weatherproof Covers .................................................................................................. 44

Installing optional Components for Monitoring Air in Workshops .................................... 45

General Instructions and Prerequisites .................................................................................... 46

Connection Unit .................................................................................................................................. 46

Connecting/Commissioning the Optional External Purge-Air Unit ................................... 48

Mounting the Device Attachments .............................................................................................. 49

Installing the Purge-Air Supply ....................................................................................................... 50

Connecting optional Devices ........................................................................................................ 51

4 Commissioning and Parameterization ........................................................................55

General Notes .................................................................................................................................... 57

Focusing the Transmitter Light Beam......................................................................................... 59

Installing and Connecting the Transmitter/Receiver Unit and Reflector ........... 62

Parameterization for Dust Concentration Measurement .................................................... 65

Data backup ........................................................................................................................................ 66

Starting Standard Measuring Mode ............................................................................................ 67

SICK MAIHAK GmbH Germany All rights reserved

8 010 038 / 08-2006

Dust Concentration Monitor

Parameterizing Optional Devices ................................................................................... 68

Data Memory / Event Memory ..................................................................................................... 68

CAN Module ......................................................................................................................................... 71

Second Analog Output ..................................................................................................................... 72