PCE Instruments PCE-MWM 2 Series User manual

Moisture Sensor PCE-MWM 2xx
Manual
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Last change: 27 March 2018
v1.41
English

Manual
Table of Contents
1Introduction .....................................................................................................................5
2Safety notes.....................................................................................................................5
3Scope of delivery.............................................................................................................5
4Specifications..................................................................................................................6
5Mechanical installation ...................................................................................................7
5.1 PCE-MWM 210 ........................................................................................................7
5.1.1 Flange...........................................................................................................8
5.1.2 Installation.....................................................................................................9
5.1.3 Sensor Coverage........................................................................................10
5.2 PCE-MWM 240A....................................................................................................11
5.2.1 Dimensions of the base plate of the sensor.................................................11
5.2.2 Installation with welds .................................................................................12
5.2.3 Installation with screws ...............................................................................13
5.2.4 Installation with flange.................................................................................14
5.2.5 Installation on curved surfaces....................................................................15
5.2.6 Sensor coverage.........................................................................................16
5.3 PCE-MWM 240B....................................................................................................17
5.3.1 Sensor coverage.........................................................................................19
6Electrical installation.....................................................................................................20
6.1Cabling..................................................................................................................20
6.1.1 General properties......................................................................................20
6.1.2 Power supply ..............................................................................................20
6.1.3 Communication...........................................................................................23
6.2 Analog output.......................................................................................................25
6.2.1 Connection..................................................................................................25
6.3 RS-485 interface...................................................................................................26
6.3.1 Connection..................................................................................................26
6.3.2 Protocol.......................................................................................................26
7PCE-MWM Manager.......................................................................................................28
7.1 Introduction..........................................................................................................28
7.2 Overview PCE-MWM Manager.............................................................................29
7.3 Connection electronic unit ..................................................................................30
7.4 Initial calibration .............................................................................................31
7.5 Calibration .....................................................................33
7.5.1 Create new calibration ...........................................................................33
7.5.2 Calibration table..........................................................................................33
7.5.3 Evaluate calibration.....................................................................................37
7.5.4 Finish calibration.........................................................................................38

Manual
7.6 Transfer calibration to / from electronic unit ............................................38
7.7 Export / import calibration in .csv-file ......................................................40
7.8 Select calibration in electronic unit ...............................................................40
7.9 Establish / close connection .....................................................................40
7.10 Test .............................................................................................................40
7.11 Settings ...........................................................................................................40
7.12 Configuration electronic unit .........................................................................41
7.13 Language ........................................................................................................41
8Appendix........................................................................................................................42
8.1 Notes for gathering and handling of samples....................................................42
8.2 Determining moisture content of samples .........................................................42
8.2.1 Drying oven.................................................................................................42
8.2.2 Moisture analyzer........................................................................................43
9Contact...........................................................................................................................44

Manual
Table of figures
Fig. 1 Installation of PCE-MWM 210.................................................................................................................................7
Fig. 2 Welding flange ........................................................................................................................................................8
Fig. 3 Clamping ring..........................................................................................................................................................8
Fig. 4 Sensor fixed in ring-assembly.................................................................................................................................9
Fig. 5 Ring-assembly ........................................................................................................................................................9
Fig. 6 Distance of PCE-MWM 210 to metallic components............................................................................................10
Fig. 7 Dimensions of the base plate of the moisture sensor PCE-MWM 240A ..............................................................11
Fig. 8 Dimensions of the rectangular cut-out ..................................................................................................................12
Fig. 9 Installation with welds ...........................................................................................................................................12
Fig. 10 Dimensions of the rectangular cut-out ................................................................................................................13
Fig. 11 Installation with screws .......................................................................................................................................13
Fig. 12 Dimensions of the rectangular cut-out ................................................................................................................14
Fig. 13 Dimensions of the flange for installation of the moisture sensor PCE-MWM 240A............................................14
Fig. 14 Installation on a curved surface ..........................................................................................................................15
Fig. 15 Sufficient material coverage of the moisture sensor PCE-MWM 240A..............................................................16
Fig. 16 Insufficient material coverage of the moisture sensor PCE-MWM 240A............................................................16
Fig. 17 Components of the moisture sensor PCE-MWM 240B ......................................................................................17
Fig. 18 Dimensions of the welding flanges .....................................................................................................................17
Fig. 19 Installation of the moisture sensor PCE-MWM 240B..........................................................................................18
Fig. 20 Sufficient material coverage of the moisture sensor PCE-MWM 240B..............................................................19
Fig. 21 Insufficient material coverage of the moisture sensor PCE-MWM 240B............................................................19
Fig. 22 M12 connector ....................................................................................................................................................21
Fig. 23 Wiring diagram....................................................................................................................................................21
Fig. 24 Pin assignment....................................................................................................................................................21
Fig. 25 Core identification code.......................................................................................................................................22
Fig. 26 Pin assignment for power supply........................................................................................................................22
Fig. 27 M12 connector ....................................................................................................................................................23
Fig. 28 Wiring diagram....................................................................................................................................................23
Fig. 29 Pin assignment....................................................................................................................................................24
Fig. 30 Core identification code.......................................................................................................................................24
Fig. 31 Pin assignment for signal output.........................................................................................................................24
Fig. 32 Pin assignment for analog output .......................................................................................................................25
Fig. 33 Pin assignment for serial port RS-485 ................................................................................................................26
Fig. 34 Calibration curves for different material ..............................................................................................................28
Fig. 35 PCE-MWM Manager main window.....................................................................................................................29
Fig. 36 Configuring RS-485 converter ............................................................................................................................30
Fig. 37 Settings ...............................................................................................................................................................31
Fig. 38 Successful connection ........................................................................................................................................31
Fig. 39 Message about missing initial calibration............................................................................................................31
Fig. 40 Configuration electronic unit ...............................................................................................................................32
Fig. 41 Dialog for initial calibration..................................................................................................................................32
Fig. 42 Initial calibration successful ................................................................................................................................32
Fig. 43 Tree view of calibrations .....................................................................................................................................33
Fig. 44 Window for new calibration.................................................................................................................................33
Fig. 45 Calibration table ..................................................................................................................................................34
Fig. 46 Warning if measured temperature of recorded date exceeds threshold.............................................................34
Fig. 47 Calibration table with first entry...........................................................................................................................35
Fig. 48 Assign moisture to sensor data...........................................................................................................................35
Fig. 49 Calibration table with multiple measurements ....................................................................................................36
Fig. 50 Calibration with high accuracy ............................................................................................................................37
Fig. 51 Calibration with reduced accuracy......................................................................................................................37
Fig. 52 Flawed calibration...............................................................................................................................................38
Fig. 53 Transfer calibration to electronic unit..................................................................................................................38
Fig. 54 Transfer best-fit line from electronic unit.............................................................................................................39
Fig. 55 Imported best-fit line from electronic unit displayed in the tree view ..................................................................39
Fig. 56 Currently selected calibration in the electronic unit ............................................................................................40
Fig. 57 Status bar for Test...............................................................................................................................................40

5
1 Introduction
This manual as well as the technical description is both intended to introduce the user to the operating principle,
installation and calibration of the moisture sensor. The manufacturer reserves the right to change the design and
circuitry of the moisture sensor.
2 Safety notes
Please read this manual carefully and completely before you attempt to use the device for the first time. The device
may only be used by qualified personnel and repaired by PCE Instruments personnel. Damages or injuries caused by
non-observance of this manual are not covered by warranty.
Only use the moisture sensor PCE-MWM 200 Series when the 24 V power supply is grounded
Do not use the moisture sensor if the electronic unit cover has been removed
Only open the cover of the electronic unit after the power supply was disconnected
Do not open the sensor case
All types of maintenance, repair and installation including disconnection, swapping wires as well as
dismounting, should only be done when the device is disconnected from the power supply
Do not operate the moisture sensor if the cables, plugs or the power supply are damaged
Operation of the sensor system is only permitted in the approved temperature range
Technical changes of the device are prohibited
The sensor system should only be cleaned with a damp cloth and only ph-neutral cleaners may be used
This manual is published by PCE Instruments without any guarantee.
We explicitly refer to our general warranty terms which can be found in our general terms of business.
Please contact PCE instruments if you have any questions.
3 Scope of delivery
1 x PCE-MWM 2xx sensor
2 x 5 m cables
1 x CD (PC software, manual)
1 x RS-485 / USB converter

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4 Specifications
PCE-MWM
200/230/240A/
240B
PCE-MWM 220
PCE-MWM 210
Sensor
Measuring range
0 … 100 %
Absolute error of moisture
measurement
see Table 1
Calibration temperature range
+5 … +80 °C
Measuring range temperature
-20 … +145 °C
Measuring interval
1 second
Dimensions
Length 240B:
200 … 1500 mm
Length x Width:
270 x 290 mm
Length x Ø:
103 x 108 mm
Weight
Ca. 9 kg
Protection class
IP67, GOST 14254-96
Cable length
1.5 … 4 m
Electronic unit
Dimensions (L x W x H)
255 x 170 x 60 mm
Weight
2 kg
Protection class
IP54, GOST 14254-96
Operating temperature
+5 … +60 °C
Output interface
Serial interface: RS-485 MODBUS RTU
Current loop: 4 … 20 mA
Power supply
Nominal voltage: 24 V
Permissible voltage: 18 … 36 V
Current draw
Max. 200 mA
Max. length of cable
RS-485 to external control device
(controller / computer)
1000 m
Max. length of cable
4 … 20 mA analog signal from
electronic unit to external display
100 m
Average life
10 years
Inline measurement (PCE-MWM 220 only)
Nominal size of pipe
DN50, DN80, DN125
Max. overpressure
10 MPa
PCE-MWM 200/230/240A/240B
PCE-MWM 220
PCE-MWM 210
Moisture [%]
Min. error
(absolute) [%]
Moisture [%]
Min. error
(absolute) [%]
Moisture [%]
Min. error
(absolute) [%]
0 … 6
0.3
0 … 0,3
0.03
Up to 10
0.5
6 … 8
0.4
0,3 … 3
0.1
10 … 20
1
8 … 10
0.5
3 … 7
0.2
20 … 50
2.5
10 … 20
1
7 … 10
0.3
50 … 100
5
20 … 50
2.5
10 … 20
0.5
50 … 100
5
20 … 40
1
40 … 100
2.5
Table 1: Minimal error of moisture measurement (absolute)

Manual
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5 Mechanical installation
Note: After the mechanical installation, the sensors must be initialized. For this initial calibration (see 7.4) the
measuring volume of the sensor needs to be empty.
Additionally a device or an opening to extract samples from needs to be in close vicinity to the installation
position in order to calibrate the sensor (see 7.5).
5.1 PCE-MWM 210
The sensor assembly is manufactured from galvanized steel and consists of two rings which are used to install the
sensor to the container/mixer. The first ring is a welding flange which needs to be welded to the surface of the
container/mixer. The second ring is used to clamp, mount and align the sensor unit inside the opening of the
container/mixer wall.
Fig. 1 Installation of PCE-MWM 210
1) Gap between sensor and wall of container/mixer which needs to be filled with an adequate sealant
2) Wall of container/mixer
3) Weld connecting the welding flange with the wall of the container/mixer
4) Welding flange (galvanized steel)
5) Clamping ring (galvanized steel)
6) Sensor unit

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5.1.1 Flange
Fig. 2 Welding flange
Fig. 3 Clamping ring
1) Welding flange
2) Threaded bolt
3) Securing nut
4) Clamping ring
5) Clamping screws
6) Adjusting screws
7) Sensor
8) Through-bore

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5.1.2 Installation
1) In order to install the sensor a hole with a diameter of 125 mm needs to be cut out of the wall of the
container/mixer. Afterwards the welding flange (1) is welded centrally over the 125 mm hole. The welding
flange is manufactured from galvanized steel. While cutting and welding, the sensor (7) must not be installed.
2) Screw three threaded bolts (2) into welding flange (1) and fix them with three securing nuts (3).
3) Fasten clamping ring (4) on the sensor (7) by using two clamping screws (5).
4) Position the assembly consisting of sensor and clamping ring on the welding flange by pushing the threaded
bolts through the through-bores (8).
5) Align the sensor by using the adjusting screws (6). The surface of the sensor must be in line with the inner
wall of the container/mixer.
6) Secure the assembly by screwing three securing nuts (3) on the threaded bolts.
7) After tightening all screws and nuts, check the alignment of the sensor on the inside of the wall of the
container/mixer again. In any case the sensor must not protrude inside of the container/mixer. Otherwise the
sensor may be damaged by mixing blades during the mixing process!
Fig. 4 Sensor fixed in ring-assembly
Fig. 5 Ring-assembly

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5.1.3 Sensor Coverage
A sufficient material coverage is required to receive an accurate measurement of the material moisture. The
measuring volume of the sensor is approximately Ø108 mm x 100 mm. A sufficient material coverage should always
be ensured even in case of minimal material level or flow inside the container or on a conveyor belt. Apart from
sufficient material coverage it is also important to avoid metallic components within the measuring field of the sensor.
The minimum distance to metallic components to the side is 50 mm. All of the above factors have to be taken into
account when choosing the installation position of the sensor.
Fig. 6 Distance of PCE-MWM 210 to metallic components

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5.2 PCE-MWM 240A
There are several possibilities of installing the PCE-MWM 240A moisture sensor to a container. The sensor can be
connected to the container wall with welds or screws. The following figures show installation examples since several
different installation setups are possible depending on container dimensions and geometry. The following examples
display a vertical orientation of the sensor. Depending on the application it is also possible to choose a horizontal
orientation as well as any other angle.
5.2.1 Dimensions of the base plate of the sensor
Fig. 7 Dimensions of the base plate of the moisture sensor PCE-MWM 240A

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5.2.2 Installation with welds
Fig. 8 Dimensions of the rectangular cut-out
Fig. 9 Installation with welds
In order to install the base plate of the sensor, a
rectangular cut-out with dimensions of at least 315 x
80 mm needs to be cut from of the container. On
curved surfaces the cut-out dimensions deviate and
need to be calculated individually depending on the
container.
The cutting edges should be smoothed to prevent
material adhering to the inside after installation of the
sensor and to prevent injuries caused by sharp edges.
Note: Please pay attention to the safety instructions
regarding the use of the appropriate cutting tools. Only
persons with appropriate training may carry out the
task.
After the sensor is positioned in the rectangular cut-out, the base plate
can be welded from the outside to the container wall.
Warning: It is prohibited to weld the base plate to the container wall
while the electronic unit is connected to the power supply.
Note: Please pay attention to the safety instructions regarding the use of
the appropriate welding tools. Only persons with appropriate training
may carry out the task.

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5.2.3 Installation with screws
Fig. 10 Dimensions of the rectangular cut-out
Fig. 11 Installation with screws
In order to install the base plate of the sensor, a
rectangular cut-out with dimensions of at least 315 x
80 mm needs to be cut from the container.
Furthermore four holes for the screws have to be
drilled through the container wall with distances of 336
/ 100 mm between. On curved surfaces the cut-out
dimensions deviate and need to be calculated
individually depending on the container.
The cutting edges should be smoothed to prevent
material adhering to the inside after installation of the
sensor and to prevent injuries caused by sharp edges.
Note: Please pay attention to the safety instructions
regarding the use of the appropriate cutting tools.
Only persons with appropriate training may carry out
the task.
After the sensor is positioned in the rectangular cut-out, the base
plate can be screwed from the outside to the container wall.
Warning: It is prohibited to screw the sensor to the container wall
while the electronic unit is connected to the power supply.
Depending on the surface and geometry of the container wall it is
possible that the connection exhibits gaps. In that case especially
fine-grained materials can trickle through the small gaps between
the base plate of the sensor and the container wall. An adequate
sealant should be used to close these gaps.

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5.2.4 Installation with flange
Fig. 12 Dimensions of the rectangular cut-out
Fig. 13 Dimensions of the flange for installation of the moisture sensor PCE-MWM 240A
1) Rectangular cut-out in container wall with
dimensions of at least 360 x 125 mm. Smooth
the edges of the cut-out.
2) Align flange with dimensions as shown in Fig.
13 over the cut-out and weld it to the container
wall from the outside.
3) Screw the sensor with the base plate from the
inside of the container to the flange.
The dimensions of the flange are an example and
exact dimensions may change depending on the
container. Different dimensions or shape of the flange
does not affect the measuring accuracy of the sensor.
Note: Please pay attention to the safety instructions
regarding the use of the appropriate tools. Only
persons with appropriate training may carry out the
task.
Installation with a flange offers two advantages:
1) For maintenance purposes it is easier to remove the
sensor since it is held with screws and is not welded to the
container wall.
2) The base plate of the sensor can be mounted on the same
level as the inside of the container wall. This can help to
reduce material adhesion at the cutting edges and to
improve material flow inside the container.

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5.2.5 Installation on curved surfaces
Fig. 14 Installation on a curved surface
On curved surfaces the rectangular cut-out in the container
wall needs to be individually adjusted to the curvature.
Considering the size of the base plate of 356 x 120 mm a
possible way is to adjust the cut-out in such a way so that
one side is shorter and one side longer than the according
length of the base plate. In this case one edge of the base
plate would “fall” into the container while the other edge
would rest on the cutting edges of the container wall. It is
also possible to individually adjust the geometry of the flange
to a container in order to install the sensor.
Gaps between the container wall and the sensor / flange
should be sealed with a suitable sealant.
Fig. 14 shows the top view of an installation example.

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5.2.6 Sensor coverage
A sufficient material coverage is required to receive an accurate measurement of the material moisture. The
measuring volume of the sensor is approximately 360 x 130 x 100 mm. A sufficient material coverage should always
be ensured even in case of minimal material level or flow inside the container or on a conveyor belt. Apart from
sufficient material coverage it is also important to avoid metallic components within the measuring field of the sensor.
All of the above factors have to be taken into account when choosing the installation position of the sensor.
Fig. 15 Sufficient material coverage of the moisture sensor PCE-MWM 240A
Fig. 16 Insufficient material coverage of the moisture sensor PCE-MWM 240A
Sufficient sensor coverage
Insufficient sensor coverage

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5.3 PCE-MWM 240B
Two welding flanges are used to install the sensor at the measuring location. Therefore the sensor must be
disassembled previous to installation. In order to dismantle the sensor assembly sleeve 3, sleeve 4, welding flange 1
and welding flange 2 must be released and removed from the sensor rod. Sleeve 1 and sleeve 2 can remain on the
rod.
Fig. 17 Components of the moisture sensor PCE-MWM 240B
Fig. 18 Dimensions of the welding flanges
Fig. 18 shows the exact dimensions of the welding flanges. Accordingly the round cut-out for welding flange 1 must be
smaller than 60 mm but not smaller than 52 mm. The round cut-out for welding flange 2 must be smaller than 60 mm
but not smaller than 45 mm.

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Warning: It is not permitted to weld the flanges to the pipe or container while the flanges are connected to the sensor
rod or sleeves. It is also not permitted to install the sensor while the electronic unit is connected to the power supply.
The pipe or container needs to be empty during cutting and welding.
Note: Please pay attention to the safety instructions regarding the use of the appropriate cutting / welding tools. Only
persons with appropriate training may carry out the task.
Fig. 19 Installation of the moisture sensor PCE-MWM 240B
1) After welding the flanges to the pipe/container the sensor can be installed. The sensor rod is inserted from the
left through welding flange 1 and welding flange 2 until sleeve 2 reaches the end position inside welding
flange 1.
2) Sleeve 3 is screwed to the end position inside welding flange 2.
3) The already detached cable which contains the temperature sensor needs to be inserted into the sensor rod
and secured with a temperature-resistant adhesive.
4) Sleeve 1 and sleeve 4 are screwed on the sensor assembly.
5) Gaps between the container wall and the welding flanges should be sealed with a suitable sealant.

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5.3.1 Sensor coverage
A sufficient material coverage is required to receive an accurate measurement of the material moisture. Sufficient
material coverage should always be ensured even in case of minimal material level or flow inside the container or on a
conveyor belt. Apart from sufficient material coverage it is also important to avoid metallic components within the
measuring field of the sensor. All of the above factors have to be taken into account when the installation position of
the sensor is chosen.
Fig. 20 Sufficient material coverage of the moisture sensor PCE-MWM 240B
Fig. 21 Insufficient material coverage of the moisture sensor PCE-MWM 240B
Insufficient sensor coverage
Sufficient sensor coverage

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6 Electrical installation
Always use shielded cables to connect the electronic unit of the moisture sensors to external devices, displays and the
power supply.
6.1 Cabling
PCE Instruments recommends a sensor / actuator cable type M12 (e.g. Lapp Group).
6.1.1 General properties
Coding
A
Protection
IP65 / IP67 / IP68
Insulation resistance
≥100 MΩ
Volume resistance
≤ 5 mΩ
Overvoltage category
II
6.1.2 Power supply
The connector for the power supply needs to be a sensor / actuator cable, 4-pos., PUR black, straight socket M12 on
free conductor end (e.g.: Lapp Group art. no. 22260322).
6.1.2.1 Technical data
Number of contacts
4
Core identification code
brown (1), white (2), blue (3), black (4)
Core insulation, material
PP
Outer sheath
PUR
Outer diameter, cable
4.1 mm
Conductor, cross-sectional area
0.34 mm²
Ambient temperature, fixed installation
-40 °C … +80 °C
Ambient temperature, flexing
-25 °C … +80 °C
Minimum bending radius, fixed installation
5 x cable diameter
Minimum bending radius, flexing
10 x cable diameter
Nominal voltage
≤300 V
Rated current
4 A
Test voltage
≥ 3000 V
Standard / approvals
IEC 61076-2-101, E249137