Sintrol S304 User manual

Distributor
S304 and S305 Dust Emission Monitors
User Manual
Version 6.6
11.07.2013

2
Table of Contents
1. INTRODUCTION.............................................................................................3
1.1 Safety ............................................................................................................3
1.2 Product overview.........................................................................................4
1.3 Principle of operation..................................................................................4
2. INSTALLATION ..............................................................................................5
2.1 Selecting the installation location..............................................................5
2.2 Installing the sensor....................................................................................7
3. WIRING OF POWER AND OUTPUT CIRCUITS ....................................10
3.1 AC or DC- power connectors (X3)..........................................................10
3.2 Signal connector (X5) ...............................................................................11
4. TECHNICAL SPECIFICATION ..................................................................12
5. DIMENSIONS ................................................................................................13
6. OPERATION..................................................................................................14
6.1 Operation of the monitor ..........................................................................14
6.2 Front panel .................................................................................................15
6.3 Service mode (S305)................................................................................16
6.4 Relay connections.....................................................................................17
6.5 How to change parameter values...........................................................19
6.5.1 Parameter 1 alarm relay 1 threshold.....................................................21
6.5.2 Parameter 2 alarm relay 2 threshold.....................................................21
6.5.3 Parameter 3 Analog output zero adjustment .......................................21
6.5.4 Parameter 4 Analog output span adjustment ......................................21
6.5.5 Parameter 5 Alarm Relay delay time .....................................................21
6.5.6 Parameter 6 Analog output damping.......................................................21
6.5.7 Parameter 7 Percent level of full range during autosetup .................21
6.5.8 Parameter 8 Reference check interval (S305) .....................................22
6.5.9 Parameter 9................................................................................................22
6.5.10 Parameter 10 Output scale .....................................................................22
6.5.11 Parameter 11 Output zero adjustment ..................................................22
6.5.12 Parameter 12 PIN code (S305)..............................................................22
6.6 Automatic setup.........................................................................................23
6.7 The manual range (MR) setup (Only S304)..........................................24
6.8 Self diagnostics: Self Zero check and Span check..............................25
6.9 Calibrating to mg/m3.................................................................................26
7. MAINTENANCE ............................................................................................28
8. TROUBLESHOOTING.................................................................................28
NOTES........................................................................................................................29

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1. INTRODUCTION
This manual describes how to install and use SINTROL digital
triboelectric dust emission monitors S304 and S305.
Sintrol shall not be held liable for any loss or damage whatsoever arising
from omissions or errors in this manual, or any misuse of the product.
1.1 Safety
Model LV requires a 115 VAC, 50/60 Hz power supply and model HV a 230
VAC, 50/60 Hz power supply. In both cases, the power supply must be
considered as potentially lethal and all suitable precautions must be taken
whenever the cover of the unit is removed.
S300 Series dust monitors are virtually maintenance free. Under no
circumstances should the user attempt to replace any components or the PC
board. If, for some reason the monitor fails to operate, contact your local
distributor or the manufacturer.
Take appropriate precautions when installing the monitor:
Unless the process conditions are known to be entirely safe,
suitable precautions must be taken before any entry is made into
the duct for installation or maintenance purposes.
The unit may be installed in ducting, containing particulate, hazardous to
health.
The particulate may be inflammable, explosive or toxic
The gas can be hot and pressurised
The S300 Series dust monitors do not have an internal circuit breaker. The
customer has to install a separate circuit breaker to the power cable to ensure
that the power can be isolated. Electrical installations must be carried out in a
manner to satisfy all applicable, local regulations.
It is essential that the unit is correctly grounded!
(see section 3.1)


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1.2 Product overview
Models S304/S305 are linear emission monitors. They are microprocessor-
based, self-adjusting devices equipped with two alarm relays, one 4-20 mA
signal output and RS422 Serial communication.
Their main use is for dust emission monitoring. The units are compact with the
sensor and control units built into an IP65 enclosure, which has been
specifically designed for easy installation and operation. The standard model is
designed for applications at up to 2 bar and 300 °C. A high-temperature (HT)
model is available for temperatures up to 700 °C.
1.3 Principle of operation
The models S304/S305 use proven and reliable triboelectric technology where
the interaction of particles with the sensor rod causes a small electrical charge
to pass between the particulate and sensor.
It is this small electric charge that provides the signal monitored by the
electronics, the signal generated is proportional to the dust level even if
particles accumulate on the sensor. Experience has shown that this method of
monitoring dust level in gasses, offers accurate results with minimum
maintenance.

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2. INSTALLATION
2.1 Selecting the installation location
The best location for installation of the units of the S300 Series is in a section
of duct where the particulate has an even distribution and the flow is laminar.
This is to ensure that the sensor rod comes into contact with a representative
flow of particles.
The ideal position would be in a section of duct that has no bends, valves,
dampers or other obstructions for a distance equal to at least three duct
diameters downstream or upstream (preferable 5 x duct diameter).
Figure 1. Recommended distances to duct bends
In some applications, a compromise must be made and the sensor will have to
be fitted in a position that satisfies the majority of above requirements. The
units of the S300 Series must be attached to metal ductwork so that they will
be electrically shielded from interference and be provided with a ground
reference. For non-metal ducts, a section of the duct, approximately five
diameters in length, should be covered with a metal foil or fine-mesh outside of
the duct.
The units must not be installed in direct sunlight or in areas where the ambient
temperature is above 45oC. Please contact your local distributor or Sintrol if
you require further advice.

6
Figure 2. S305 Emission Monitor
The unit shall be installed in a position, where the gas flow passes the sensor
rod in a 90angel.
In round cross-section ducts, the unit can be installed in any position above the
horizontal axis (between 9 o’clock and 3 o’clock).
For square cross-section ducts, the unit must be positioned in the middle of the
top or in the middle of one of the sides. In all cases, the tip of the sensor rod
must extend at least 1/3 of the diameter of the duct. Depending on the dust
concentration, the probe length could vary from 1/3 to 2/3 of the duct diameter.
As a rule of thumb: the lower the dust concentration the longer the probe.
If possible the unit shall be installed in a position where the duct pressure is
negative.
If installed downstream an electrostatic precipitator (ESP), the distance from
the ESP should be at least 20 m. Although the sensor (lengths less than 1m)
is not affected by vibration, very high vibration levels should be avoided.
Figure 2a. Round cross-section duct Figure 2b. Square cross-section duct
mounting socket in the
middle of the side or top
above horizontal axis

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2.2 Installing the sensor
Once the location of the unit has been selected, the mounting socket must be
welded to the pipe or duct. To do this, first cut a hole in the duct slightly
larger than the OD of the mounting socket, 38 mm. The socket must be
perpendicular to the flow in the duct. Make sure the socket is in the right
position and make an airtight welding. After welding the socket in position,
insert the sensor.
Figure 3a. Sensor installation
1. Probe 5. Enclosure
2. Fixing screw 6. Duct wall
3. Cables (mains and signals) 7. Socket
4. Cover 8. Weld
Diameter of the
hole to the stack
must be
minimum Ø 38
mm. to avoid the
sensor probe
contact to the
duct wall.

8
When installing HT or HT/MP sensor it is important to take care that the
ambient temperature will not increase above 45 degree. The electronics
inside of enclosure is sensitive for temperature.
To do the installation, first cut a hole in the duct slightly larger than the OD
of the mounting socket, 38 mm (HT ) 45 mm (HT/MP). The socket must be
perpendicular to the flow in the duct. Make sure the socket is in the right
position and make an airtight welding. After welding the socket in position,
insert the HT or HT/MP sensor.
Figure 3b. Monitor installation with HT or HT/MP sensor
1. Probe 5. Enclosure
2. Fixing screw 6. Duct
3. Cooling extender
4. Cover

9
38
mm
WRONG SOCKET INSTALLATION
Figure 4. Wrong socket installation,
THE DIAMETER OF THE HOLE MUST BE MINIMUM 38 MM
IMPORTANT
!!
Hole diameter
must be at least
38 mm

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3. WIRING OF POWER AND OUTPUT CIRCUITS
3.1 AC or DC- power connectors (X3)
Voltage: 230 VAC +/- 20 V or 115VAC +/- 10V or 24 VDC
Frequency: 45 Hz … 65 Hz (AC models)
Power cable: 3 x 1,5 mm2
Connect a 115/230 VAC power supply or a 24 VDC power supply to connector
X3 (see Figure 5). Push the connector lever until the connector slot jaw opens.
Insert the power supply lead, then release the lever. Attach the ground wire to
the GND screw.
AC1 - power input (- terminal in 24 VDC model)
AC2 + power input (+ terminal in 24 VDC model)
GND Protective earth terminal.
Figure 5. Wiring

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3.2 Signal connector (X5)
One or more of the following functions are available, depending of the product
model:
Relay output 1: Volt free SPDT contact, max. load 5 A @24 V AC/DC
Relay output 2: Volt free SPDT contact, max. load 5 A @24 V AC/DC
Analogue output: 4-20 mA, active,isolated. Isolation Voltage 500 V.
Serial communication: RS-485 isolation Voltage 500 V.
Connect the signal wires to connector X5 (see Figure 5a and 5b). Push the
connector lever with a screw driver, until the connector slot jaw opens, insert or
remove the wire, then release the lever.
Slot 1 Relay1 normally closed (NC) terminal.
Slot 2 Relay1 common (C) terminal.
Slot 3 Relay1 normally open (NO) terminal.
Slot 4 Relay2 normally closed (NC) terminal.
Slot 5 Relay2 common (C) terminal.
Slot 6 Relay2 normally open (NO) terminal.
Slot 7 4-20 mA (+) more positive terminal, active output.
Slot 8 4-20 mA (-) more negative terminal, active output.
Slot 9 RS 485 output (+) terminal
Slot 10 RS 485 output (-) terminal
Slot 11 RS 485 input (+) terminal (D+/TX+)
Slot 12 RS 485 input (-) terminal (D-/TX-)
Figure 5a. Signal connector Figure 5b. Signal connector X5 wiring
X5
Signal connector
terminal
mA -
mA +
NC
NO
C
C
NC
NO
SERIAL
mA
RELAY
2
RELAY
1
NOT IN USE

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4. TECHNICAL SPECIFICATION
Measured objects: Solid particles (dust) in a gas flow
Particle size: 0.3 m or larger
Measurement range: 0.1 mg/m3to 1 kg/m3
Process Conditions:
Temperature: Max. 300°C (standard) / Max. 700°C
(optional)
Pressure: Max. 200 kPa
Gas velocity: Min. 4 m/s
Humidity: 95 % RH or less (non-condensing)
Input surge voltage: Max. 100 V
Measurement principle: Inductive Electrification
Output damping time: 0 to 300 seconds
Output signals: Isolated 4-20 mA
Relay 5 A , 24 V AC or DC
Ambient conditions:
Temperature: -20 to + 45oC
Humidity: 95% RH (non-condensing)
Vibration: 5 m/s2or less
Materials:
Probe: SS 316L
Insulation of sensor: PEEK (300 oC), Teflon (250 oC)
Enclosure: Aluminium alloy
Power Supply: 115 VAC or 230 VAC or 24 VDC
Power consumption: 8 W AC models, 3 W 24 VDC model
Wiring connections: DIN PG11 port for power cables
DIN PG11 port for signal cable
Weight: 2.3 kg
Protection class: IP 65
Range setup options:
Normal measuring range: -automatic, based on average measured
dust flow
Extended measuring range: - (option) set at factory
Alarm threshold: Adjustable via internal keys or via serial port.
Zero point offset trim: Automatic
This instrument conforms to the following standards
EN 61010-1:2001 Safety, LVD
IEC 61326-1:2005 (First Edition)
Electromagnetic Compatibility EMC
Mechanical tests:
IEC 60068-2-6, TEST Fc(1995-03), IEC 60068-2-29, TEST Eb

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5. DIMENSIONS
Figure 6. Dimensions and construction of the S300 series Dust Monitor

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6. OPERATION
6.1 Operation of the monitor
The S304 Emission Monitor measures the dust level in a gas stream by
monitoring electrostatic discharge when charged dust particles hit or pass by
the probe.
The signal generated by the electrostatic loaded particles is low-pass filtered
with a user selectable time constant to remove the effect of short variations,
and then converted into a current loop output signal. The user can trim the
output of the 4…20 mA signal can be calibrated.
The S304/S305 models include two independent alarm relays. The alarms are
arranged such that Alarm 1 is a low alarm, Alarm 2 is a high alarm. The alarms
can be delayed by means of a common time delay. The time is user selectable
in the range 0 to 180 seconds in 10 seconds increments.
The alarm threshold for each of the two alarms, are adjustable between 1 to
99% of the measuring range.
The relay output(s) change their state when the measured value for the dust
flow exceeds a user selected alarm trigger level. The relay output(s) are also
protected from the effect of short variations in the input signal with a user
selectable time constant common for both relays. Further the relays can also
be used to indicate internal errors during monitoring or to indicate when the
unit is in the service mode.
All the user selectable parameters are factory set to default values shown in
table 2. page 17.

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6.2 Front panel
The front panel consists of the following:
A button for AUTOMATIC SETUP (on the lower printed circuit board)
A red/green AUTOMATIC SETUP indicator led (on the lower printed
circuit board)
A three digit display
Three control keys
Figure 8. Front panel of the monitor

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6.3 Service mode (S305)
Before servicing the model S305 monitor or changing any parameters it is
needed to enter the service mode. To access service mode right PIN code is
required. In service mode the alarm relays will indicate that the
measurement is invalid and shall be ignored by the reporting system.
Selecting the right PIN code to access service mode:
5. Press button A and select first PIN code digit 0..9
6. Press button B and select second PIN code digit 0..9
7. Press button C and select third PIN code digit 0..9
Factory default for PIN code is 1. 1. 1.
There are four different setup configurations depending on how the relays are
connected. After the right PIN code is selected to enter the service mode
simultaneously press and hold down buttons B and C for one second. The dot
in the corner of the right-hand digit on the display panel indicates when unit is
in the service mode. To exit the service mode simultaneously press and hold
down buttons B and C for one second.

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6.4 Relay connections
Light bulb indication is ON when relay contact spring is closed.
Light bulb indication is OFF when relay contact spring is open.
Low alarm level and High alarm level are dust levels where relays change
their state.
Setup configuration 1:
Both relays connected to Normally Open (NO)
Service mode (S305) : Relay 1 contact is open and Relay 2 contact is close.
Relay 2
High alarm level
Relay 1
Low alarm level
Relay 1 (NO)
Relay 2 (NO)
Close
Close
Close
Open
Open
Open
Service mode
Open
Close
Setup configuration 2:
Relay 1 Normally Open (NO), Relay 2 Normally Close (NC),
Service mode (S305) : Relay 1 and Relay 2 contacts are open.
Relay 2
High alarm level
Relay 1
Low alarm level
Relay 1 (NO)
Relay 2 (NC)
Close
Open
Close
Close
Open
Close
Service mode
Open
Open
Dust
concentration
Dust
concentration
Normal
operation
Normal
operation

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Setup configuration 3:
Relay 1 Normally Close (NC), Relay 2 Normally Open (NO),
Service mode (S305) : Relay 1 and Relay 2 contacts are close.
Relay 2
High alarm level
Relay 1
Low alarm level
Relay 1 (NC)
Relay 2 (NO)
Open
Close
Open
Open
Close
Open
Service mode
Close
Close
Setup configuration 4:
Both relays connected to Normally Close (NC)
Service mode (S305) : Relay 1 contact is close and Relay 2 contact is open.
Relay 2
High alarm level
Relay 1
Low alarm level
Relay 1 (NC)
Relay 2 (NC)
Open
Open
Open
Close
Close
Close
Service mode
Close
Open
Dust
concentration
Normal
operation
Dust
concentration
Normal
operation

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6.5 How to change parameter values
Remove the cover of the monitor. You will see the front panel, display unit and
three parameter adjustment keys. (A, B and C, figure 9). Model S305 it is
needed to feed PIN code before you can change parameters (see chapter 6.2).
Model S304 PIN code is not required.
Figure 9. S300 series Dust Monitor front panel
Press the left key (A), below the display, until the left digit indicates the number
of the parameter you wish to change, 1 … 9, tenth parameter left digit indicator
is 0. eleventh 10. and twelfth is first digit of PIN code = 1. if factory default PIN
code value. The last parameter, –SP (save parameters), saves all the
changes you have made. (See Table 2).
The two rightmost display digits now show the parameter values. By pressing
the middle key (B) and right key (C), the value for each parameter can be
altered as indicated in table 2.
Parameter
change
buttons A, B
and C
Automatic
setup button
(white) to
start
autotuning
Indicator leds:
Green: normal operation
Red: Autotuning in
progress

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When parameters have been changed as required, press the left key (A) again
until the display digit shows –SP (Save parameters). Press any of the other
keys (B or C) to save all the parameters into the EEPROM.
NOTE: Change all the required parameters before saving them. If you decide
not to save the parameters you have changed, push the left key (A) again.
PARAMETER CHANGE TABLE
PARAMETER
DISPLAY
LEFT NUMBER
RANGE
KEY
EFFECT
KEY B
KEY EFFECT
KEY C
FACTORY
DEFAULT
Relay 1
threshold
1
1…99%
add 10%
add 1%
5%
Relay 2 threshold
2
1…99%
add 10%
add 1%
60%
4 mA adjustment
3
-
increase
current
decrease
current
set to 4 mA
20 mA
adjustment
4
-
increase
current
decrease
current
set to 20 mA
Alarm delay time
5
0…180s
add 10s
-
0
Analog output
filter
time constant
6
0…300s
add 10s
-
0
Percent level of
full range during
autosetup
7
10-50 %
increase 10
%
decrease 10 %
20 %
Reference check
interval
8
0-99 hour
increase
decrease
0
Reference check
alarm setup
9
0-8min or
continuous
increase
decrease
0
Output scale
0.
1-100 %
increase
decrease
20 %
Output zero point
adjustment
10.
1-99 %
increase
decrease
0 %
*PIN
code/Manual
Range( S304)
1.
000-999
increase
decrease
1.1.1 (S305)
Save parameters
- SP
save all
Save all
*) If you have the model 304, please see also the chapter about the manual range set up
option.
Table 2. Parameter change table