envea M-Sens WR3 User manual

OPERATING INSTRUCTIONS
M-Sens WR3
ONLINE EXTENDED MOISTURE MEASUREMENT FOR SOLIDS
ENVEA Process GmbH - Gutedelstraße 31 – 79418 Schliengen - GERMANY
Tel.: [phone] / [e-mail] / www.envea.global

The display is touch-sensitive. Available keys are displayed directly in context. When the measuring
system is rst started, a query is initiated to select the language and sensor.
Initialization screen when the Evaluation unit in the eld housing
started rst time.
Selection of the menu language: Deutsch, English, Français.
If a language has been selected, the sensor to be used must be
selected. To be available:
SolidFlow 2.0, Paddy, PicoFlow, MaxxFlow HTC, DensFlow,
SpeedFlow 2.0, SlideControl 2.0, ProSens, M-Sens 2, M-Sens 3,
M-Sens WR3, AirFlow P.
If any data has been changed, the change will only be taken
into account when you exit the complete menu structure and
answer [Yes] when asked if you wish to save the changes.
Afterwards the start page appears.
If you want to communicate with our sensor using our dedicated software, you need to download the
latest version on our website and install it.
 https://www.envea.global/solutions/process-optimization/dahs-software/
It might also be necessary to install drivers, also available on our website.
1st start note
For the 1st use of the sensor, correct sensor type should be selected via the screen or the software.
Software must be installed if needed.
1. SOFTWARE INSTALLATION
2. MSE 300-FH (WITH SCREEN)
Select Language
D E F
E
#
$
8
Sensor
SolidFlow
Save changings?
J N

1st start note
Our dedicated software must be used to connect to the sensor evaluation unit.
Select software language
Right click on „Sprache/Language/
Langue“ and select desired language.
Connect to sensor
Select the correct COM port and
connect to the device using the „read
device“ button.
Select correct sensor
In the menu „System“, under „Sensor“
(8.2.5 or 7.2.5), the correct sensor must
be selected.
After selecting the sensor, check the
box „Overwrite measurement calib.“
and conrm with the button „Device
program“.
For more informations and details, ple-
ase refer to the user manual of the sen-
sor.
3. MSE 300-DR / -DR2 (NO SCREEN)

2
CONTENTS Page
1. System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Regular use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Identication of dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Technical progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Montage and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Delivery parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Mounting of the sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.4 Mounting of the Evaluation unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 DIN Rail housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Field housing terminal layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Terminal layout C-Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7. Menu structure of M-Sens WR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Differences between the DIN Rail and eld housing Evaluation unit . . . . . . . . 27
8.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3 PC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9. Wiring example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13. Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
14. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3
max. 300 m
C1-box
MSE 300-DRSensor
1
2
3
4
1
2
3
4
16 (+ 24 V)
15 (GND)
14 (A)
13 (B)
2 m cable converted
fixed at the sensor
up to 300 m with
correct cablediameter
1. System overview
A complete M-Sens WR3 unit consists of the following components:
•Flange (mounting in screw, hopper)
•1 to 3 sensors with 2 m connecting cable
•Evaluation unit MSE 300
•Optional: C1-box for connecting of sensor and Evaluation unit
The sensor is connected by a shielded, 4-wired cable to the Evaluation unit; the maximal
distance between these devices can be at most 300 m.
Fig. 1: Overview with C1-box and MSE 300-DR
Fig. 2: Overview with C1-box and MSE 300-FH
up to 300 m with
correct cablediameter
max. 300 m
MSE 300-FH
1
2
3
4
S
1
2
3
4
S
1 (+ 24 V)
2 (GND)
3 (A)
4 (B)
Shield
2 m cable converted
fixed at the sensor
Sensor
C1-box

4
Evaluation unitC3-Box
2 m max. 300 m
1 (+ 24 V)
2 (GND)
3 (A)
4 (B)
Shield
Sensor +
Trimmer box
Sensor +
Trimmer box
Sensor +
Trimmer box
Fig. 3: Overview with C3-Box and MSE 300-FH
Fig. 4: Overview with C3-Box and MSE 300-DR
Evaluation unit
C3-Box
2 m max. 300 m
16 (+ 24 V)
15 (GND)
14 (A)
13 (B)
Sensor +
Trimmer box
Sensor +
Trimmer box
Sensor +
Trimmer box
The system can be equipped with up to three sensors. Different C-Boxes (C1, C3) are used accordingly.

5
Material
Base flange
p
Securing ring
Sensor
2. Function
The M-Sens WR3 sensor functionality is based on precise high-frequency measurement and
direct digitalization of measured values, where from results a high resolution. As the material
surface and capillary moisture inuences strongly its specic conductive capacity, the moisture
can be measured exactly by a constant averaged bulk density.
The calibration can be done very simply by the operator by pressing the button and entering
the referenced moisture contents.
In this context it is convenient that measured value uctuations by bulk density variations are
balanced by an internal lter function.
Fig. 5: Injection and reexion of high frequency

6
3. Safety
The measuring system M-Sens WR3 designed and built according the latest technology has been
tested to be safe and was shipped in safe condition. Nevertheless persons or objects may be
endangered by components of the system if these are operated in an inexpert manner.
The operating instructions must therefore be read in its entirety, and the safety instructions must be
adhered to. If the device is used in a way that does not adhere to its intended and/or proper use, any
liability or warranty on the part of the manufacturer is void.
3.1 Regular use
•Only original spare parts and accessories of ENVEA Process must be used.
3.2 Identicationofdangers
•Possible dangers when using the measuring system are marked by the following symbols in
the operating instructions:
Warning!
•This symbol in the operating instructions marks actions, which may represent a danger for
life and limb of persons when carried out in an inexpert manner.
Attention!
•All actions which may endanger objects are marked with this symbol in the operating
instructions.
3.3 Operational safety
•The measuring system must be installed by trained and authorized personnel only.
•Switch of the power supply for all maintenance, cleaning or inspection works on the tubes
or on components of the M-Sens WR3. Follow the notes of the chapter maintenance.
•Sensor must be removed from the installation place before any welding work in the area.
•The components and electrical connections must be checked for damages regularly.
If a damage is found, it is to repaired before further operation of the instruments.
3.4 Technical progress
•ENVEA Process reserves the right to adapt technical data to the technical progress without
particular advance notice. If you have any questions, ENVEA Process will be pleased to
inform you on possible changes and extensions of the operating instructions.

7
4. Montage and installation
4.1 Delivery parts
•MSE 300-DR or FH Evaluation unit
•Sensor
•Operating instructions
•C1-Box (optional)
•Welding ange
4.2 Auxiliary
•Screw driver 2.5 mm
•Allen key 5 mm
4.3 Mounting of the sensor
M-Sens WR3 is designed for continuous moisture measurement. Most important conditions for
correct measurement is the right choice of the mounting place of the sensor. That is, when using
chutes or conveyor belts, it is very important to have a almost even material height in front of
the sensor window.
•The ange is welded without sensor and dummy plate in the opening at determined
mounting place. Sensor and dummy plate are mounting by means of plumbing lubricant.
For applications without over-pressure it is possible to renounce the 2 sealing rings.
Attention!
The ange mustn’t be welded together with the sensor or dummy plate (incl. the sealing rings).
Material
Base flange
p
Securing ring
Sensor

8
APPLICATIONS - PRACTICAL EXAMPLES
•Installation in a screw
The installation of a moisture sensor in screw feeders proved to be very advantageous, since the
material passes by the sensor window in even intervals and with relatively constant bulk density.
•Installation on a conveyor belt
By means of the online moisture measurement of solids on a conveyor belt, the operator
can react in due time if the material is too humid or too dry. In consequence, plugging of
subsequent aggregates can be prevented.
Screw feeder
25,3 %
Moisture
Conveyor belt
42,0 % Moisture
Do not install the sensor under or on the
side of the screw, it must be installed
mid-size from bottom, on the side where
material is pushed up
(depending rotation side of the screw).
(Approximattly 30° from the screw bottom).

9
•Installation in a bin
Another installation alternative is to mount a sensor at a bins outlet. Due to constant bulk
density in case of a lled bin, the sensor nds an almost unchanging measuring eld for
monitoring the residual moisture. Thus, M-Sens WR3 avoids that too damp material reaches
the next production level or arrives into the loading.
•Control of dryer by means of moisture measurement
After the material, lying on the belt, has passed through the dryer tunnel, it gets withdrawn
from the hot air zone. At the end of the belt the dried material falls in a screw conveyor
which transports it to the processing.
The operator queries the following points: Has the material reached really the desired
residual moisture value? That is, has he chosen the right cycle time and temperature?
M-Sens WR3 provides accurate and reliable online moisture values for the process control,
by which constant moisture in close tolerances of the output material can be met.
This process optimization enables the operator to manage high savings and quality
improvements.
Belt dryer
Drying area
Granulating machine
granulated,
dried product
Cooling area
5,3 %
Hopper
Moisture

10
•Moisture measurement in a mixer
M-Sens WR3 can be installed, even later on, in all types of mixers. The measuring values
logging is done by within the moving material during the mixer procedure.
With the measured moisture value of the material in the dryer process parameters like
detention time and dosage quantity can be controlled.
For this purpose M-Sens WR3 is connected to a PLC or another process control system.
•Moisture measurement in free fall pipe / slide
To be able to measure in free fall pipes or inclined pipes (chutes) with the M-Sens WR3,
it is possible to gather material in front of the probe in the short term, for the duration
the measurement, with a catching mechanism. After the measurement, the flap will open
again and allows the gathered material to continue to drop. The measuring process can be
permanently repeated in short or long intervals according to requirements.
Mixer

11
4.4 Mounting of the Evaluation unit
The Evaluation unit can be installed at a maximum distance of 300 m from the sensor. A cable
of type “Ölex Classic 110 CY” is recommended. The cable should be four wired, twisted and
shielded. A minimum cable cross-section of 0.75 mm²should be observed. For distances more
than 150 m the cable cross-section should be adjusted.
The housing is prepared for DIN Rail mounting according to DIN EN 60715 TH35.
Fig. 6: Dimension of the MSE 300-DR
Fig. 7: Dimension of the MSE 300-FH (front)
118
35
23
90

12
Fig. 9: Field housing for the C3-Box
5 mm
175 mm
35 mm 35 mm 35 mm
163 mm
23,5 mm
57 mm
52 mm
80 mm
max.
13 mm
max.
13 mm
max.
13 mm
max.
13 mm
5 mm
Fig. 8: Field housing for the C1-Box
max.
13 mm
max.
13 mm
50 mm
125 mm
113 mm
52 mm
80 mm
57 mm
4,8 mm
4,8 mm
The C1-Box and C3-Box contain fuses and resistances in order to guarantee the communication by
the ModBus between sensor and Evaluation unit.

13
Fig. 10: Electrical connection of the MSE 300-DR
5. Electrical connection
5.1 DIN Rail housing

14
5.2 Field housing terminal layout
Fig. 11: Electrical connection
L N PE
I-in 1 I-out 1
+ -
I-out 2 I-out 3
Alarm Relay
NO C NC
D-out RS 485
A B
GND
D-in 1 D-in 2 Sensor
+ - A B
Shield
+ - + - + - + -
+ -
+ -
Evaluation unit
Terminal No. Connection
Power supply connection
L / +24 V Input power supply 230 V / 50 Hz, 110 V / 60 Hz (optional 24 V DC)
N / 0 V Input power supply 230 V / 50 Hz, 110 V / 60 Hz (optional 24 V DC)
PE Earth
Connections
I-in1 +Current input +
-Current input -
I-out1 +Current output +
-Current output -
Na Not used
Na Not used
Na Not used
Na Not used
Min. /
Max.-
Relay
NO Floating change-over contact NO (make contact)
CFloating change-over contact C (common conductor)
NC Floating change-over contact NC (break contact)
D-out +Digital pulse output +
-Digital pulse output -
RS 485
ARS 485 interface data A
BRS 485 interface data B
GND RS 485 interface ground
D-in1 +Digital interface 1 (+)
-Digital interface 1 (-)
D-in2 +Digital interface 2 (+)
-Digital interface 2 (-)
Sensor
+Power supply + 24 V Cable no. 1
GND Power supply 0 V Cable no. 2
ARS 485 data A Cable no. 3
BRS 485 data B Cable no. 4
Shield Shield

15
5.3 Terminal layout C-Boxes
Evaluation unit Sensor 1 Sensor 2 Sensor 3
M20 M20
Fig. 12: Electrical connection for the C3-Box
Fig. 13: Electrical connection for the C1-Box
Cable gland
M 20 x 1.5
Sensor 1Evaluation unit

16
6. Commissioning
At the rst commissioning of the M-Sens WR3 it is necessary to calibrate the sensor.
Please consider:
•Correct connection between sensor, optional C1-box and MSE 300.
•Correct installation of the sensor in respect to the wall thickness.
In case of negative results in spite of consideration of the points as stated above, please contact
ENVEA Process.
Commissioning of the M-Sens WR3
After the delivery the sensor is not calibrated to the product(s), so each calibration and
parameterization has to be executed during the commissioning. Therefore it is necessary to
assign the measured moisture to the desired display and to the initial value. The menu functions
are very self-explanatory. In the following a short introduction to the menu overview:
Menu are accessible via PC software or the touch screen (eldhousing unit only) – See Operator Interface
Basic For the measurement using the sensor, at least 2 measuring points should be calibrated
function as a reference point and the corresponding moisture value should be entered.
To do this, the reference point measurement is started in the calibration. After
the measurement, the analysis device expects the input of the moisture content
determined in the lab. While the material is conveyed (in the loading state), the
2nd point is set to a known moisture value and the calibration is also carried out. If
only one material moisture value is available, then minor moisture uctuations and
corresponding uctuations in the moisture values determined in the lab can be used
to save at least 2 calibration points.
Adjustment For the adjustment of user requirements with regard to material, measuring units
alarms etc. the user can select operation modes “None”, “Min”, ”Max” in the menu Alarms
(3.1). A shortfall or exceeding of an adjustable measuring value can be output via the
alarm relay as “open” or “close” (3.5).
In menu Sensor Alarm (3.6), the user can select “OFF” “ERR” or “Proc”. by choosing
“ERR”, alarm will be on in case of sensor error, by selecting “PROC”, alarm will be on
in case of fatal sensor errors/failure and process indicators.
Analog is modied in menu 4 and can be adjusted to user requirements here
output (e. g. 0 ... 20 mA). The setting of the minimum and maximum output current can be
setup on 4.1 and 4.2. The alarm value can be dened on 4.3 and alarm type on 4.4.
The exact calibration of the 4 mA and 20 mA value are done via menu 4.5, 4.6, 4.7,
4.8 and 4.9. This operation require the use of a calibrated multimeter.
The measuring range lter makes it possible to adapt to slower recording devices or
continuous output at the analog output (power output).
Calibration The measurement can be checked for linearity based on varying moisture values.
points To improve accuracy, these should be determined respectively. In case of deviations,
the non-linearity can be corrected through a table of support points. Based on the
points that are selected and specied in menus 2.4.1 etc. (a minimum of 2 during rst
commissioning), a correction value can now be entered for the actual moisture value.
(This value can be changed later.) A maximum of 5 support points are available.
Saving After changes are made, they can be saved using the menu item program device.
changes The change is carried out once Overwrite calibration is conrmed.
C1-Box Is only used when the distance between sensor and analysis unit exceeds 2 m.
C3-Box Is only used when 2 or 3 sensors are connected.

17
7. Menu structure of M-Sens WR3
This software is available for download on our website:
https://www.envea.global/solutions/process-optimization/dahs-software/
The menu structure supports the user when adjusting the measuring range, the calibration, the
measurement values and the choice of additional functions. In this connection, the numbering
both on the display and in the PC interface is identical:
1. Measuring range
Set all relevant measuring range settings
1.1 Tag No. Input: Name of the measurement point or
free text (10 characters) product.
1.2 Unit Input: unit text, e. g. kg Required mass ow unit.
1.3 Decimal point Selection: Number representation and decimal
0000, 0.000, 00.00, 000.0 point-accuracy in the measurement menu.
1.4 Set point low Input: 0 … 9999 Throughput rates under this value will not
not be displayed at the current output.
This does not concern the display indicator,
totaliser or pulse output (= 4mA).
1.5 Set point high Input: 0 … 9999 Throughput rates above this value will not
will not be displayed at the current output.
This does not concern the display indicator,
totaliser or pulse output (= 20mA).
1.6 Filter Input: 0.1 s … 99.9 s Filtering of measurement for the indicator
and the output values.

18
2. Calibration
Store the calibration curve.
2.1 Calibration factor Input: 0.01 … 9.99 Factor for the subsequent adjustment of
the actual measurement. All measurements
are measured with this factor.
2.2 Calibration lter s Input: 1 … 9999 Filter time for recording the raw value
during calibration. The raw values already
measured over the set time period are
combined into an average value.
2.3 Calibration points Input: 2 … 5 Number of support points for
a linearisation above the operating range.
2.4 Calibration Calibration submenu
2.4.1 1. Calibration point Input: Output measurement value in the
selected measurement value to be shown
mass / time unit.
(2.4.2) P1 calibration Transfer: Raw value Transfer the current raw value (ltered)
from the mass ow with the key [ ←].
The value can also be entered manually.
. . . (depending on the number of support points) For additional support points (depending
on [ 2.3 ]), additional value pairs can be set.
2.4.n Pn value Input: Measurement to be displayed
2.4.n Pn calibration Transfer:Current raw value