SWR ENGINEERING envea M-Sens 2 FD User manual

EN
M-Sens 2 FD
Online moisture measurement
with flow detection for solids
Operating Instructions
M-Sens 2 FD
Online moisture measurement
with flow detection for solids
SWR engineering Messtechnik GmbH PART OF THE ENVEA GROUP

2
CONTENTS Page
1. System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Flow detection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Regular use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Identification of dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Operational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Technical progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Delivery range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Mounting of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Mounting of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Use in the explosion hazard area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 DIN Rail housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Field housing terminal layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Terminal layout C-Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Menu structure of M-Sens 2 FD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
8. Operator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1 Differences between the DIN Rail and field housing transmitter. . . . . . . . . . . . . . . . 28
8.2 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.3 PC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
10. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3
1. System overview
A complete M-Sens 2 FD unit consists of the following components:
•1 welding flange per sensor
•1 to 3 sensors with 2 m connecting cable
•Transmitter MSE 300 up to 3 sensors in a DIN Rail housing or a field housing
•C1-Box or C3-Box for connecting sensor(s) and transmitter
The sensor is connected by a shielded, 4-wired cable to the transmitter; the maximal distance between these
devices can be at most 300 m.
max. 300 m
C1-Box
Transmitter
Sensor
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
Fig. 1: Overview with C1-Box and DIN Rail transmitter
Fig. 2: Overview with C1-Box and field housing transmitter
up to 300 m with
correct cablediameter
max. 300 m
C1-Box
Transmitter
(MSE 300)
Sensor
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

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TransmitterC3-Box
Sensor
Sensor
Sensor
2 m max. 300 m
1 (+ 24 V)
2 (GND)
3 (A)
4 (B)
Shield
Fig. 3: Overview with C3-Box and field housing
Fig. 4: Overview with C3-Box and DIN Rail transmitter
Transmitter
C3-Box
2 m max. 300 m
16 (+ 24 V)
15 (GND)
14 (A)
13 (B)
Sensor
Sensor
Sensor
The system can be equipped with up to three sensors. Different C-Boxes (C1, C3) are used accordingly.

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2. Function
The M-Sens 2 FD 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 influences strongly its specific conductive capacity, the moisture can be measured exactly by
a constant averaged bulk density. By way of support, any fluctuations of the measuring value caused by
the bulk density are balanced through an internal filter function. Temperature-related fluctuations of the
measuring value are automatically compensated by the sensor. On the installed system, the calibration is
a matter of pushing a button and entering the moisture reference value.
2.1 Flow detection function
The M-Sens 2 FD is also able to detect if the material in front of the sensor is flowing or not. This function
can help you to validate the accuracy of the moisture measurement and quickly detect process failure such
as a defective screw conveyor.
If activated, the flow detection function will create an alarm via the relay. See “Alarm” menu.
Fig. 5: Coupling and reflection of the high frequency
Material to be measured
Flange
Sensor

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3. Safety
The measuring system M-Sens 2 FD 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 - SWR engineering must be used.
3.2 Identification 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 2 FD. 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 - SWR engineering reserves the right to adapt technical data to the technical progress without
particular advance notice. If you have any questions, ENVEA - SWR engineering will be pleased to
inform you on possible changes and extensions of the operating instructions.

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4. Mounting and installation
4.1 Delivery range
•Evaluation unit in DIN Rail housing or field housing
•Sensor
•Operating instructions
•C1-Box or C3-Box
•Welding flange
4.2 Auxiliary
•Screw driver 2.5 mm
•Allen key 5 mm
4.3 Mounting of the sensor
M-Sens 2 FD 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 flange 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 flange mustn’t be welded together with the sensor or dummy plate (incl. the sealing rings).

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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
13,1
%
Moisture
1,8 %Moisture
Conveyor belt

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•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 filled bin, the sensor finds an almost unchanging measuring field for monitoring the residual
moisture. Thus, M-Sens 2 FD 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 2 FD 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.
5,2 %Moisture
Bin

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•Moisture measurement in a mixer
M-Sens 2 FD 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 2 FD is connected to a PLC or another process control system.
Mixer

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4.4 Mounting of the transmitter
The transmitter can be installed at a maximum distance of 300 m from the sensor. A cable of type “Ölflex
Classic 110 CY” is recommended. The cable should be four wired, twisted and shielded. A minimum cable
cross-section of 0.75 mm² should 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. 12: Dimension of transmitter in DIN Rail housing
Fig. 13: Dimension of transmitter in field housing (front view)
118
35
23
90
1234
567 8
910 11 12
13 14 15 16
USB
PWR
RUN

12
Fig. 15: 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. 14: 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 transmitter.

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Explosion hazard area
DustEx zone 20
GasEx zone 0
Non-explosion hazard area
Tmax =
80 °C Tmax = 80 °C
4.5 Use in the explosion hazard area
DustEx labelling: II 1D Ex maD iaD 20 T120 °C
- Group of equipment 2
- Equipment category: 1
- Zone 20
- For explosive mixtures of air and flammable dust
- Permissible process temperature 0 ... 80 °C
- Maximum surface temperature 135 °C with Ta = 60 °C
GasEx labelling: II 1G Ex ma ia CII T4
- Group of equipment 2
- Equipment category: 1
- Zone 0
- For explosive mixtures of air and flammable gases
- Permissible process temperature 0 ... 80 °C
- Maximum surface temperature 135 °C with Ta = 60 °C

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Fig. 18: Electrical connection of the C1-box
Sensor Transmitter
Fig. 17: Electrical connection of the transmitter
1234
567 8
910 11 12
13 14 15 16
USB
PWR
RUN
Current output
- 4 ... 20 mA
Current output
+ 4 ... 20 mA
Input
Power supply
0 V DC
Input
Power supply
+ 24 V DC
Not used Alarm relay
NC (break contact)
Alarm relay
C
Alarm relay
NO (make contact)
1 2 3 4
5 6 7 8
Digital
pulse output (-)
Digital
pulse output (+)
RS 485
Interface
Data B
RS 485
Interface
Data A
Sensor connection
Cable 4
RS 485
Data B
Sensor connection
Cable 3
RS 485
Data A
Sensor connection
Cable 2
Power
supply 0 V
Sensor connection
Cable 1
Power
supply + 24 V
9 10 11 12
13 14 15 16
5. Electrical connection
5.1 DIN Rail housing

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5.2 Field housing terminal layout
Fig. 19: 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
+ - + - + - + -
+ -
+ -
Transmitter
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)
C Floating change-over contact C (common conductor)
NC Floating change-over contact NC (break contact)
D-out + Digital pulse output +
- Digital pulse output -
RS 485
A RS 485 interface data A
B RS 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
A RS 485 data A Cable no. 3
B RS 485 data B Cable no. 4
Shield Shield

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5.3 Terminal layout C-Boxes
Transmitter Sensor 1 Sensor 2 Sensor 3
M20 M20
Fig. 20: Electrical connection for the C3-Box
Fig. 21: Electrical connection for the C1-Box
Cable gland
M 20 x 1.5
Sensor 1Transmitter

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6. Commissioning
At the first commissioning of the M-Sens 2 FD it is necessary to calibrate the sensor.
Please consider:
•Correct connection between sensor, C1-box and evaluation unit.
•Correct installation of the sensor in the process.
In case of negative results in spite of consideration of the points as stated above, please contact SWR.
Commissioning of the M-Sens 2 FD
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 (fieldhousing unit only) – See Operator Interface
Basic function For the measurement using the sensor, at least 2 measuring points should be
calibrated 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 fluctuations and corresponding fluctuations 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 etc.
Alarms The user can select operation modes “None”, “Min”, “Max” or “FLOW” 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).
The Flow Detection function is available by choosing “FLOW” in the alarm menu.
This alarm will trigger when selected “Noise” value is reached.
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 output is modified in menu 4 and can be adjusted to user requirements here
(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 defined 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 and 4.6 and 4.7. This operation require the use of a calibrated multimeter.
The measuring range filter makes it possible to adapt to slower recording
devices or continuous output at the analogue output (power output).
Calibration points The measurement can be checked for linearity based on varying moisture
values. 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 specified in menus
2.4.1 etc. (a minimum of 2 during first 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 changes After changes are made, they can be saved using the menu item program
device. The change is carried out once Overwrite calibration is confirmed.
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.

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7. Menu structure of M-Sens 2 FD
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: free text (10 characters) Name of the measurement point or product.
1.2 Unit Input: unit text, e. g. kg Required mass flow unit.
1.3 Decimal point Selection: 0000, 0.000, 00.00, 000.0 Number representation and decimal point-
accuracy in the measurement menu.
1.4 Set point low Input: 0 … 9999 Throughput rates under this value will
not be displayed at the current output.
This does not concern the display indicator,
totaliser or pulse output.
1.5 Set point high Input: 0 … 9999 Throughput rates above this value
will not be displayed at the current output.
This does not concern the display indicator,
totaliser or pulse output.
1.6 Filter Input: 0.1 s … 99.9 s Filtering of measurement for the indicator
and the output values.
1.7 Filter buffer Input: 0.0 …
1.8 High pass filter Input: 0 … 100

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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 filter 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 (filtered) from
the mass flow 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

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3. Alarm
Setting for the alarm via the relay contacts.
3.1 Alarm type Selection: The relay is activated when the measured
None / Min / Max / Flow value exceeds the max. limit or undershoots
the min. limit.
“Flow” alarm is activated when measured
noise value exceeds the setup limit.
3.2 Alarm value Input: 0 … 999.9 Limit value for monitoring Min. or Max.
3.3 Delay Input: 0.1 … 99.9 s The value must permanently exceed or fall
below the set limit during this time.
3.4 Hysteresis Input: 0.1 … 99.9 % The alarm continues for as long as the
measurement is not smaller or larger than
the limit value plus or minus hysteresis.
3.5 Operation mode Selection: NC: the relay is closed, current principle as
NC / NO no alarm is active.
NO: the relay is closed, if there is an alarm.
3.6 Sensor alarm Selection: Off: Sensor or process indicators are
OFF /ERR / PROC not displayed at the relay.
ERR: Serious internal sensor errors trigger
an alarm at the relay.
PROC: Serious internal sensor errors and
process indicators trigger an alarm at the
relay. Further information on the signalling
levels ERR or PROC can in section entitled
Troubleshooting.