Titelseite

MAINTENANCE MANUAL

FW101
Maintenance Manual

Preventive Maintenance

This Manual is intended exclusively for trained users.

Unauthorized intervention voids the manufacturer's
warranty.

Analyzers and Process Instrumentation

 Document Information
Document ID
Title: Maintenance Manual
Order No.: 8012462
Version: 1.0
Release: 2008-01

Product
Product name: FW101
Versions: All
Software: Version 1.0

Manufacturer
SICK MAIHAK GmbH
Nimburger Str. 11 · D-79276 Reute · Germany
Phone: +49 7641 469-0
Fax: +49 7641 469 1149
E-Mail: [email protected]

Editor
SICK MAIHAK GmbH
Nimburger Str. 11 · D-79276 Reute · Germany
Phone: +49 7641 469-0
Fax: +49 7641 469 1149
E-Mail: [email protected]

trademarks
It is possible that product designations in this Manual are trade-
marks used here only for identification purposes.

Guarantee Information
This manual is intended only for internal use.
No guarantee claims shall be derived from the specified product
characteristics and technical data as well as the described work
sequences and conclusions.
Subject to technical modifications.

© SICK MAIHAK GmbH. All rights reserved.

2 FW101 Maintenance Manual 8012462/2008-01 (V 1.0) © SICK MAIHAK GmbH

Warning Symbols Information Symbols

Hazard (general) Important technical information for this device

Important technical information on electrical or electro-

Hazard by voltage
nic functions

Hazard by explosive substances/mixtures Important additional information

Hazard by corrosive substances Supplementary information

Hazard by poisonous substances Link to information at another place

Hazard by unhealthy substances

Hazard by high temperature or hot surface

Signal words
DANGER
Immediate hazard which will result in severe personal injury or
death.

WARNING
Risk or hazardous situation which could result in severe personal
injury or death.

CAUTION
Hazard or unsafe practice which could result in less severe or
minor injuries and/or property damage.

FW101 Maintenance Manual 8012462/2008-01 (V 1.0) © SICK MAIHAK GmbH 3

4 FW101 Maintenance Manual 8012462/2008-01 (V 1.0) © SICK MAIHAK GmbH
 1 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Target group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Special hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2 Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Consumables and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1.1 Special tools and auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.1.2 Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

3.1 Regular Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1.1 Activating the maintenance mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1.2 Switching back to the measurement mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2 Maintaining the purge-air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.2.1 Connection unit with integrated purge-air supply . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.3 Maintaining the external purge-air unit (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3.1 Replacing the filter insert, part No. 5306091 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.3.2 Checking the purge-air hoses and hose clamps . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3.3 Checking the noise of the blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.3.4 Checking the under-pressure monitor and differential pressure monitor (option).19
3.4 Maintaining the sender/receiver unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.1 Cleaning of the sender/receiver unit (externally). . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.4.2 Cleaning the optical boundary surfaces, part No. 4003353 . . . . . . . . . . . . . . . . .20
3.5 Check functions of Control Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.5.1 Manual start of a control cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.6 Log files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

FW101 Maintenance Manual 8012462/2008-01 (V 1.0) © SICK MAIHAK GmbH 5

6 FW101 Maintenance Manual 8012462/2008-01 (V 1.0) © SICK MAIHAK GmbH
About this Manual

FW101

1 About this Manual

Target group
Special hazards
Purpose of this Manual

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 7

 About this Manual

1.1 Target group

The tasks and measures described in this Manual must only be carried out by skilled users
who have been trained and are appropriately qualified to perform the respective tasks on
the FW101.

Intervention in the FW101 by persons who have not been trained voids the
SICK MAIHAK GmbH warranty.

WARNING: Damage as a result of improper working

Improper working can damage health and equipment and affect the accuracy
of measurements.

1. 2 Special hazards
WARNING: Toxic and caustic substances in parts in contact with sample
gas.
Depending on sample gas composition, FW101 parts in contact with the
sample gas as well as the upstream gas path can contain toxic and caustic
substances.
‡ Before performing any work on the gas path obtain information concerning
the gases that have been fed to the FW101.
‡ Obtain information as to whether, and then how, the FW101 gas path has
been cleaned.
‡ If necessary, clean the gas path with a suitable method.
‡ In case of doubt, take appropriate protective measures before working on
the gas path: Ensure adequate ventilation at the workplace or work under a
vent. Wear protective goggles or a safety mask, protective gloves and acid-
proof protective clothes.

1. 3 Purpose of this Manual

This Manual provides instructions concerning the preventive maintenance of the FW101.
The technical layout of the FW101 in question can differ from the layout described in this
Manual due to changes made by the manufacturer or customer.

8 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Maintenance Interval

FW101

2 Maintenance Interval

Check/list
Intervals

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 9

 Maintenance Interval

2 .1 Consumables and spare parts

SICK suggests the following amount of spares and wear and tear parts for 18 months of
operation. These have to be available at any time in the plant.
1.5 yd
Required spare parts Qty.1 q1 order no.
(18 month)
Optics cloth 1 x 3 4003353
– Screen cleaner (0.2 l 1 x 1
spray bottle)
– or isopropanol, high
purity (for optics), if
necessary
– or water with little alcohol
Seal K100;
1 x 2 7047036
for FW101 NL435/735 mm
Seal K150;
for FW101 length >1035/ 1 x 2 7047937
1335 mm
Filter Insert C1140;
for connection unit with inter- 1 x 3 7047560
grated purge-air supply
Filter Insert C11 100;
1 x 3 5306091
for external purge-air supply
1 No. per maintenance interval (q = quarterly, yd= 18 month)

At normal use and regular maintenance no spare parts have to be held up in a period of
18 months for connection unit with intergrated purge-air supply.

2.1.1 Special tools and auxiliary equipment

Special tools / auxiliary equipment Required for
Brush for cleaning air purge filter
for cleaning optical boundary
cloth, cotton bud
surfaces
Compressed air (dust and oil free; e.g. compressed air in
200 to 500 ml spray cans),

Auxiliary equipment required Order No. Required to

Fuse 6004305
air purge hose 5 m 4022766
clamp for hose 5700520
Jumper; approx. 10 mm length for initiating check cycle
Spanner, size 7, 17 mm for probe cover mounting

10 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Maintenance Interval

2.1.2 Maintenance Intervals

Maintenance items refer to w1 q1
Visual inspection
Check if measured values are plausible in the control room x x
Check if control cycle is (zero/span) valid (control room or
x x
recorder)
Check if there is any error message (control room) x x
Check mechanical damage x
Check attachments and conditions x
Connection unit with integrated purge air supply
Cleaning or replace the filter insert and housing of the purge air
→ S. 16, § 3.2.1 x
supply, part no. 5306091
External purge air unit (option)
Check the hoses and ring nozzles → S. 19, § 3.3.2 x
Replace the filter insert and check housing of the purge air sup-
→ S. 17, § 3.3.1 x
ply, part no. 5306091
Check function of filter and differential pressure monitor
→ S. 19, § 3.3.4 x
(option)
Probe
Clean probe → S. 19, § 3.4 x
Check the probe surface for sign of corrosion → S. 19, § 3.4 x
Check and if necessary replace the sealing; latest every 12
→ S. 19, § 3.4 x
months; part no. 7047036
Optical unit
Clean housing → S. 19, § 3.4.1 x
Clean the surface of the optical parts and the probe; part no.
→ S. 20, § 3.4.2 x
4003353
Check function of control cycle → S. 22, § 3.5 x
Check if control cycle (zero, span) is valid at the analog output
→ S. 22, § 3.5 x
on the connection unit (terminal block inside)
1 w = weekly, m = monthly, q = quarterly

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 11

 Maintenance Interval

12 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance

FW101

3 Preventive Maintenance

Detailed description

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 13

 Preventive Maintenance

3 .1 Regular Maintenance
3.1.1 Activating the maintenance mode
Before carrying out maintenance activities, the maintenance mode of the FW101 device is
to be activated. The FW101 offers 2 possibilities to do this:
● Using the MEPA-FW software delivered with the device (
or
● manually, as described below.

‡ Install a jumper (maintenance switch) on the FW101 connectio unit

Figure 1 Maintenance switch (jumper) – installed at the the connection unit

Jumper (maintenance switch) to install

between terminal 4 and 9

The now activated Maintenance mode is indicated on the display on front of connection unit
and is output on the relay output 3. See → P. 15, Figure 2.

14 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance

Figure 2 Display of the activated maintenance mode on the connection unit

3.1.2 Switching back to the measurement mode

When you have completed the maintenance activities, switch the system back to measur-
ing mode:
‡ Uninstall the jumper again on the connection unit.
The display indicates „concentration“ again, and the relay output 3 is deactivated.
● When the maintenance switch is set, warning and fault messages are sup-
pressed. The live zero value is given out at the analog output.
● If the FW101 was set into "Maintenance" mode via MEPA-FW („Software
maintenance“), this status is reset at a voltage loss (in this case the FW101
switch automatically into „Measurement“ after the operating voltage is swit-
ched on).
● If „Maintenance“ is set by an external switch, the FW101 remains in this
status as long as the contact is closed at the terminals 4, 9 (refer to the
FW100 operating instruction manual).

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.

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 15

 Preventive Maintenance

3.2 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 in
short intervalls (approx.2 weeks) after commissioning. The maintenance intervals can then
be optimized accordingly.
● If the purge-air supply is not maintained at regular intervals or maintenance
is not thorough enough, it can fail and destroy the sender/receiver unit.
● You must ensure that the purge-air supply is functioning properly when the
sender/receiver unit is installed. When replacing a damaged purge-air hose,
you must remove the sender/receiver unit beforehand

Inspection
‡ Check the running noise of the fan at regular intervals; an increased noise level can indi-
cate 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..

You must not switch off the purge-air supply when cleaning the filter housing or
replacing the filter insert, which means that the sender/receiver unit do not
have to be removed from the duct.

3.2.1 Connection unit with integrated purge-air supply

Cleaning or replacing the filter insert, part no. 7047560
‡ 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). Refer to → P. 18, Figure 4.
‡ 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.

You must only use a cloth soaked in water to wet-clean the components. Make
sure that you dry the components thoroughly.

16 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance

‡ 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.

Figure 3 Changing the filter insert for the connection unit with purge-air supply

Clamping tape

Filter housing

Filter housing cover 2

Intake hose

3.3 Maintaining the purge-air unit

Maintaining the purge-air unit essentially involves cleaning the filter housing and replacing
the filter insert.
WARNING: Keep the purge-air unit operating!
Never operate the device without purge-air as long as the pressure of the flue
gas duct is not permanently below the ambient pressure.

3.3.1 Replacing the filter insert, part No. 5306091

VORSICHT: Do not switch off the purge-air unit during maintenance!

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 17

 Preventive Maintenance

Figure 4 Purge-air unit – components to be checked

Under-pressure monitor Air filter

Snap locks

Hose clamps

Purge-air fan

Purge-air
hose

Procedure
‡ Make sure to have the new filter ready to be inserted.
‡ To avoid drawing in dust while cleaning the filter housing, disconnect the hose from the
filter outlet.
‡ Remove dust from the outside of the filter housing.

Figure 5 Maintenance activities on the air filter

Filter housing Filter housing cover

Filter insert

Snap locks

‡ Remove the filter housing cover by applying pressure to the snap locks to unlock it.
‡ Twist the filter insert counter-clockwise to remove it.
‡ Clean the filter housing and housing cover with a cloth and brush.

You must only use a cloth soaked in water to wet-clean the components.
Dry thoroughly.

‡ Insert the new filter insert by turning it clockwisewhile applying pressure.

‡ Mount the filter housing cover and make sure that it is correctly aligned with the hous-
ing.

18 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance

‡ Make sure the snap locks snap into position.

‡ Reattach the filter outlet hose and make certain it is secure.

3.3.2 Checking the purge-air hoses and hose clamps

‡ Check the purge-air hoses by hand to ensure that they are sufficiently elastic and are
not leaking. Replace them if they are leaking.
‡ Check the purge-air hoses to ensure that the connection points are secure.
‡ Replace defective hose clamps.
‡ Check the seals on the housing by hand. Proceed with care if the purge-air attachment
is hot.
‡ Replace defective seals.

3.3.3 Checking the noise of the blower

‡ Check on the if the blower is running smoothly and quiet.

3.3.4 Checking the under-pressure monitor and differential pressure monitor (option)
‡ Check the under-pressure monitor on the purge-air unit filter to ensure that it works
properly.
‡ To do this activate the under-pressure monitor by holding the filter intake glands
shut for a short time.
‡ If installed, check the differential pressure monitor at the purge-air gland of the GM31
purge-air attachment.
‡ When the purge-air supply is interrupted for a short time, the differential pressure moni-
tor should be activated.
‡ Replace defective monitors.

3.4 Maintaining the sender/receiver unit

WARNING: Damage as a result of improper working
● Make sure that none of the components or accessories of the FW101 are
damaged when performing maintenance work on.
● The purge-air supply must not be interrupted.

3.4.1 Cleaning of the sender/receiver unit (externally)

Clean the outside of the FW101 sender/receiver unit (particularly the measuring probe) at
regular intervals. Remove deposits with water or suitable mechanical aids.
To clean the sender/receiver unit remove it from the duct in the following way:
‡ For FW 101 loosen the securing nuts on the mounting flange.
‡ After cleaning the sender/receiver unit install it in the duct. (see FW100 operation
instruction manual)

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 19

 Preventive Maintenance

3.4.2 Cleaning the optical boundary surfaces, part No. 4003353

The "optical boundary surface" is the surface of the optics or glass that faces the duct.
The optical boundary surfaces of the SR unit only require cleaning if they are visibly dirty or
if the current degree of contamination is reached and is monitored by FW 101; limit 50%
for warning, 70% for malfunction).
‡ Remove the sender/receiver unit from the duct.
WARNING: Hot device parts can cause injuries!
Take care when handling with the FW101 probe, especially when replacing the
probe cover.

Cleaning on the sender/receiver side

Figure 6 FW101 unmounted from the duct

Opening for cleaning the sender/ Protection tube
receiver optics

Probe cover
Cap

‡ Unscrew the cap (black) on the cleaning opening

‡ Clean the optics carefully with cotton cloth for example

Figure 7 Optical boundary surface – sender/receiver side

Cotton cloth

20 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance

Cleaning on the probe end (probe cover)

‡ Remove the probe cover from the probe end:
– Loosen and remove the 2 screw nuts using a spanner (7 mm spanner size).

Figure 8 Removing the probe cover

Light trap

Probe opening

Receiver optics

‡ Clean the receiver optics, the light trap and the probe opening carefully with a cotton
cloth.

Figure 9 Cleaning the optics on the probe end

Light trap

Cotton cloth Receiver optics Light trap

‡ Reassemble all device components correctly

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 21

 Preventive Maintenance

3.5 Check functions of Control Cycle

In order to control the cleaning works it is necessary to carry out a comtrol cycle. The
FW101 device performs an automatical control cycle every 2 hrs.

3.5.1 Manual start of a control cycle

‡ To initiate the control cycle manually remove the jumper from terminal 4 and 9 on the
connection unit; refer to → P. 14, Figure 1.
Now the FW101 switches back to the measurement mode. Refer to → S. 15, §3.1.2.
‡ Connect a amperemeter to the analog output on terminal 5 and 6.

Figure 10 Connection of a amperemeter on the analog output of the FW101 connection unit

Ampere-
meter

Analog output
(terminal 5, 6)

22 FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance

‡ Check the indicated current values on the amperemeter:

– Zero point: 4.00 mA
– Span point: 15.20 mA
– Contamination: > 4 mA to 12 mA max.
If the contamination is higher than 12 mA, the malfunction message „contamination
too high“ will occur.
‡ If your indicated values are correct, the maintenance activities were successful. Now
install the device onto the duct again.
We recommend to check the the laser beam alignment in connection with
cleaning of the optical boundary surfaces (refer to the FW100 operating
instruction manual).

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 23

24
3.6

Figure 11
LOG FILE Weekly

Preventive Maintenance Tasks and Work Allocation Year: Month:

Log files

SICK MAIHAK FW 101 Serial no: Location:

Log file weekly

1. Week 2. Week 3. Week 4. Week 5. Week

Plant operating status

visual inspection
☐ Check if measured values are plausible in the
control room
☐ Check if control cycle is (zero/span) valid (control
room or recorder)

☐ Check reading in the control room Dust reading Dust reading Dust reading Dust reading Dust reading

Dust reading, measured values

Control cycle, Zero point values in mA

Control cycle, Span value in mA

☐ Check if there is any error message

Remarks:

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH

Preventive Maintenance
Preventive Maintenance

Figure 12 Log file quarterly

Preventive Maintenance Tasks and Work Allocation Year: Quarter:

SICK MAIHAK FW 101 Serial no: Location:

Plant operating status:

visual inspection
☐ Check if measured values are plausible in the control room

☐ Check if there is any error message:

☐ Check LED reading at the evaluation unit and analog output Before check After check
☐ Dust reading, measured values in the Control room mg/m mg/m

☐ Dust reading, measured values mA mA

☐ Check if there is any error message

See operating manual page 69 - 75

Purging air unit Status OK Status not OK,

☐ Check the hoses and hose clamps

☐ Replace the filter insert and check fílter housing of the purge-air supply. Part
no: 7047560 or 5306091

☐ Check function of filter and differential pressure monitor (options)

Probe Status OK Status not OK,

☐ Clean probe

☐ Checking the probe surfaces for sign of corrosion

☐ Check and if necessary replace the sealing, latest each 12 month. Part no
7047036 or 7047937

Optical unit Status OK Status not OK,

☐ Clean housing

☐ Cleaning the surfaces of the optical parts and the probe. part no. 4003353

☐ Check function of control cycle

☐ Check if control cycle is (zero/span) valid in the evaluation unit

Control cycle, Zero point values after control cycle mA

Control cycle, Span value after control cycle mA

Date:

Name:

Remarks:

25.07.2007Log file_Quarterly_FW 101_Holcim.xls

FW101 Maintenance Manual 8012462/2007-07 (V 1.0) © SICK MAIHAK GmbH 25

 FW101

SICK MAIHAK worldwide

8012462/2007-07 (V1.0)

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 | [email protected] Analyzers and Process Instrumentation