SWR Envea M-Sens 2 User manual

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

2
CONTENTS Page
1. System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Regular use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Identification of dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Technical progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Delivery range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Mounting of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Mounting of the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.5 Use in the explosion hazard area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. Menu structure of M-Sens 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8. Menu parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
10. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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1. System overview
A complete M-Sens 2 unit consists of the following components:
•1 welding flange per sensor
•1 to 3 sensors with 2 m connecting cable
•Transmitter MME 300 up to 3 sensors in a DIN rail housing
•C1-box for connecting of sensor 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

4
2. Function
The M-Sens 2 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. The calibration of the system can easily be carried out
by the operator. On the installed system, the calibration is a matter of pushing a button and entering the
humidity reference value.
Fig. 2: 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 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 authorised 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. Follow the notes of the chapter maintenance.
•Before hot-work the sensor must be removed from the installation place.
•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
•Transmitter in DIN rail housing
•Sensor
•Operating instructions
•C1-box
•Welding flange
4.2 Auxiliary
•Screw driver 2.5 mm
•Allen key 5 mm
4.3 Mounting of the sensor
M-Sens 2 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 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 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 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 is connected to a PLC or another process control system.
Mixer

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4.4 Mounting of the transmitter
The whole electronic equipment can be installed at a maximum distance of 300 m from the sensor.
For assembly in the switching cabinet, the housing is prepared on a top-hat rail in accordance with
DIN EN60715 TH35a.
Fig. 9: DIN-Rail housing for the transmitter
1234
1234
Sensor Transmitter
98
86
36
64
Fig. 10: Field housing for the C1-box
The C1-box contains fuses and resistances in order to guarantee the communication by the ModBus between
sensor and transmitter.
118
35
23
90
1234
567 8
910 11 12
13 14 15 16
USB
PWR
RUN

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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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5. Electrical connection
Fig. 13: Electrical connection of the C1-box
Sensor Transmitter
Current output
- 4 ... 20 mA
Current output
+ 4 ... 20 mA
Input
power supply
0 V DC
Input
power supply
+ 24 V DC
Not available Alarm relay
NC (Opener)
Alarm relay
C
Alarm relay
NO (Closer)
1 2 3 4
5 6 7 8
Not available Not available 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
Fig. 12: Electrical connection of the transmitter
910 11 12
13 14 15 16
1234
567 8
910 11 12
13 14 15 16
USB
PWR
RUN

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6. Commissioning
At the first commissioning of the M-Sens 2 it is necessary to calibrate the sensor.
Please consider:
•Correct connection between sensor, C1-box and transmitter.
•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 SWR.
Commissioning of the M-Sens 2
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:
Put the installation CD in the computer and follow the installation menu. The program is compatible with
Windows operating systems 98, NT, XP, Vista, Win 7, Win 8 and Win 10. The connection can take place via
the USB interface on the front plate, using the supplied cable, or via the integrated RS 485 interface (bus-
compatible) on the screw terminals 11 and 12. By allocating different addresses to the analysis unit, the
devices can be addressed individually in the bus using the ModBus protocol. A brief introduction follows to
serve as an overview.
All changed values are adopted by leaving the menu level and confirming the save function.
Entering the After starting the M-Sens 2 configuration program, the COM1 to COM8
menu interface must be selected on the separate PC.
Set baud rate to 9600 Bd as a fixed value. Set address of the analysis unit
(standard = 1).
Basic function For the measurement using the sensor, at least 2 measuring points should be
calibrated as a reference point and the corresponding humidity 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
humidity content determined in the lab. While the material is conveyed (in the
loading state), the 2nd point is set to a known humidity value and the calibration
is also carried out. If only one material humidity value is available, then minor
humidity fluctuations and corresponding fluctuations in the humidity 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., sub-menu items 1 to 3 are available in menu 1.
Alarms The user can select operation modes “Fault” or “Alarm” in the menu Alarms (2).
A shortfall or exceeding of an adjustable measuring value can be output via the
alarm relay as “open” or “close”.

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Analog output is modified in menu 5 and can be adjusted to user requirements here
(e. g. 0… 20 mA).
The calibration of the starting value takes place in menu items 5.7 and 5.8.
Standard MIN = 4 mA MAX = 20 mA
The measuring range filter makes it possible to adapt to slower recording
devices or continuous output at the analogue output (power output).
Support points The measurement can be checked for linearity based on varying humidity
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
1.4.2 / 2.4.2 / 3.4.2 / 4.4.2 (a minimum of 2 during first commissioning),
a correction value can now be entered for the actual humidity 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.

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In the following there is the menu structure:
7. Menu structure of M-Sens 2
1. Products Products 1 to 4
1.1 Measuring range
1.1.1 Product name Adjust material (8 digits)
1.1.2 Unit Adjust text, e. g. % H2O / % TS
1.1.3 Decimal point Decimal place position
1.1.4 Beginning of measuring range Range 0 ... 999
1.1.5 End of measuring range Range 0 ... 999
1.1.6 Filter value Range 0.1 ... 99.9 s
1.2 Alarm 1
1.2.1 Alarm type Choose: MIN / MAX
1.2.2 Alarm value Range 0 ... 100 % in phys. units
1.2.3 Alarm dead time Range 0.1 ... 99.9 s
1.2.4 Alarm hysteresis Range 0.1 ... 99.9 %
1.2.5 Operation mode Choose: Open or
closed current principle

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1.4.6 Calibration point 1 Measurement range start and end
1.4.7 Raw value Record of input value
1.4.8 Calibration point 2
1.4.9 Raw value ... (depends on the number of the
calibration points)
1.4.10 Calibration point N Measurement range init and end
1.4.11 Raw value Record of input value
For 2.1 to 2.4 / 3.1 to 3.4 / 4.1 to 4.4 - same way
1.3. Alarm 2
1.3.1 Alarm type Choose: MIN / MAX
1.3.2 Alarm value Range 0 ... 100 % in phys. units
1.3.3 Alarm dead time Range 0.1 ... 99.9 s
1.3.4 Alarm hysteresis Range 0.1 ... 99.9 %
1.3.5 Operation mode Choose: Open or
closed current principle
1.4 Calibration
1.4.1 Calibration filter Range 0.1 ... 999.9 s
1.4.2 Number of calibration points Range 2 ... 5 base points
When the multisensor function is switched on, up to 3 sensors can be declared!
1.4.3 Calibration factor for sensor 1
Rating of sensor signal with several
sensors used and disconnecting of
1 sensor with 0
1.4.4 Calibration factor for sensor 2
Rating of sensor signal with several
sensors used and disconnecting of
1 sensor with 0
1.4.5 Calibration factor for sensor 3
Rating of sensor signal with several
sensors used and disconnecting of
1 sensor with 0

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5. Analog output
5.1 Beginning of range Range 0 ... 22 mA (Standard 4 mA)
5.2 End of range Range 0 ... 22 mA (Standard 20 mA)
5.3 MIN limit Range 0 ... 22 mA (Standard 3 mA)
5.4 MAX limit Range 0 ... 22 mA (Standard 20 mA)
5.5 Alarm value Range 0 ... 22 mA (Standard 3 mA)
5.6 Filter time Range 0.1 ... 999.9 s (Standard 1 s)
5.7 Calibration: 4 mA Adjust current output
(calibration to 4 mA)
5.8 Calibration: 20 mA Adjust current output
(calibration to 20 mA)
6. No digital inputs present on the top-hat rail device!
7. System
7.1 Baud rate Choose: 4800 / 9600 / 19200 / 38400 Bd
7.2 ModBus-address Range 1 ... 255
7.4 Language Choose: D / F / E

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8. Menu parameters:
1.1 MEASURING RANGE
Product name Freely selectable symbols of the measuring-medium or -place, max. 8 digits.
Unit Selection % H2O or % TS
Decimal point Adjust the digit in the display.
Beginning of
measuring range Enter the respective value of the measuring range you will start with.
End of
measuring range Enter the respective value of the measuring range end.
Filter value Adjustable damping for the display in seconds. Range: 0.1 ... 999.9 s
1.2 ALARM 1 Effect on the relay.
Alarm type Upper and lower limit value.
Alarm value Threshold value
Range 0 ... 100 % of the measuring range in phys. units.
Alarm dead time Threshold value how long the value must be over or under the limit until the
alarm relay reacts . Range: 0.1 ... 99.9 s
Alarm hysteresis Threshold value of the alarm.
Range: 0.1 ... 99.9 % of the specified measuring range.
Operation mode Choice of the contact work or rest
NO (working current) - NC (static current)
1.3 ALARM 2 wie ALARM 1

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1.4 CALIBRATION
Calibration filter Attenuation filter to smooth fluctuating signals during
calibration. (Has no effect on output.) 0.1 to 999.9 s
Number of calibration points Input of number of necessary support points.
Calibration point 1 - measuring value Measuring value to be displayed in physical units.
This is where the actual humidity value is entered as it
was determined in the lab based on a material sample.
Range: Start of the measuring range ... end of the measuring
range.
Calibration point 1 - calibration The sensor signal belonging to a measuring value is recorded
and the entered measuring value is allocated when the 
area is clicked. The value can also be entered numerically.
The additional points are recorded just like the first one.
Calibration point 2 - measuring value Measuring value to be displayed in physical units.
Range: Start of the measuring range ... end of the measuring
range.
Calibration point 2 - calibration Input value is recorded and allocated to the measuring value
to be displayed.
Calibration point N - measuring value Measuring value to be displayed in physical units.
Range: Start of the measuring range ... end of the measuring
range.
Calibration point N - calibration Input value is recorded and allocated to the measuring value
to be displayed.
For 2.1 to 2.4 / 3.1 to 3.4 / 4.1 to 4.4 same as point 1
5 ANALOG OUTPUT
Start of range Value to be set for the current output minimum
(Standard 4 mA) Range 0 ... 22 mA
End of range Value to be set for the current output maximum
(Standard 20 mA) Range 0 ... 22 mA

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MIN limit Minimum current output value to be set
(Standard 3 mA) Range 0 ... 22 mA
MAX limit Maximum current output value to be set
(Standard 20 mA) Range 0 ... 22 mA
MIN limit Minimum current output value to be set
(Standard 3 mA) Range 0 ... 22 mA
Alarm value Output value to be set for alarm (sensor or internal alarm),
at the same time the relay drop.
(Standard 3 mA) Range 0 ... 22 mA
Filter time Filter time to be set for the current output.
(Standard 1 s) Range 0.1 ... 999.9 s
Calibration: 4 mA Setting of the min. starting current. Adjustment to the external
measuring system (in case of deviating display). Adjust the
current output to 4 mA with the < and > buttons.
Calibration: 20 mA Setting of the max. starting current. Adjustment to the external
measuring system (in case of deviating display). Adjust the
current output to 20 mA with the < and > buttons.
9. Maintenance
Warning!
•Electric shock hazard when housing is open!
•Switch off the power supply during all maintenance and repair work on the measuring system.
The system may not be in operation for a sensor exchange.
•Repair and maintenance work may only be carried out by qualified electricians
•The system is maintenance-free.