User Manual
Contents
1. gran olf NI I No Neb Figure 8 Automatic setup button and operation indicator led 20 udi AUTOMATIC SETUP Ensure that the process is in normal conditions 2 Make sure that the monitor has been powered for at least 15 minutes in order to warm up and stabilise 3 Press the AUTOMATIC SETUP BUTTON the white button on lower printed circuit board 4 Make sure that green LED indicator turns red Mount the cover of enclosure and tighten it and wait for about 45 minutes until the LED turns green indicating that the Automatic Setup sequence has finished 6 The unit is ready to use 21 udi 8 MAINTENANCE 5303 Dust Monitor needs very little maintenance achieve maximum reliable operation the recommended maintenance interval is 2 months Maintenance is done by removing the unit from the socket and cleaning the probe to prevent signal leakage to ground If the particles in the gas are sticky and tend to build up use air purge adaptor and compressed clean and dry process air to keep the sensor base clean Inside enclosure maintenance is not needed 9 TROUBLESHOOTING The Monitor is not giving output signal 1 Check the power and signal wiring is right connected 2 Check there is power on and three2. CIE aa 22 The Monitor is not giving output 22 The Monitor is giving 4 mA or 20 mA continuously after auto setup sms e tt a td tul la al a a atata i 22 T 23 JX SINTROL For Good Measure 1 INTRODUCTION This manual describes how to install and use SINTROLs digital triboelectric dust monitor 5303 This manual is intended as a guide to the use and installation of the product Sintrol shall not be liable for any loss or damage whatsoever arising from use of any information or details therein or omission or error 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 DC model requires 24 VDC power supply S300 Series dust monitors are virtually maintenance free Under no circumstances should the user attempt to replace any components or the PC board lf 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
3. 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 924 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 HS 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 X5 Signal connector terminal SERIAL RELAY 2 RELAY 1 SIO JS CIA a SHIELD GROUND USED ONLY WITH SERIAL CO
4. M8 Figure 3b Monitor installation with HT or HT MP sensor 1 Probe 5 Enclosure 2 Fixing screw 6 Duct 3 Cooling extender 4 Cover JL SINTROL For Good Measure WRONG SOCKET INSTALLATION Figure 3b Wrong socket installation THE DIAMETER OF THE HOLE MUST BE MINIMUM 38 MM iib 3 WIRING OF POWER AND OUTPUT CIRCUITS 3 1 AC power connectors Voltage 230 20V or 115VAC 10V or 24 VDC Frequency 45 Hz 65 Hz AC models Power cable 1 5 mm 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 9 5 O 9 x3 12 GROUND ERMINAL ii 1 Itt tii Ti i 5 8 e Figure 4 Wiring 10 JX SINTROL For Good Measure
5. 300 seconds with 10 seconds increment Parameter 7 Normal process operation point If the customer wants to change the normal process operation point Factory default value for parameter 7 is 20 96 of monitor amp full range The normal operation point percentage of full range can be adjusted from 10 to 50 18 udi 6 4 Parameter 8 Manual range option Parameter 8 changes the manual range By pressing key B or C desired range can be selected Parameter 8 value 0 means normal mode and auto setup is needed to do All fixed ranges values from 1 to 5 do not need auto setup on commissioning because range settings are set at factory nu uu all auto setup is concentration concentration 100x ied Moderate dust NOT NEEDED concentration 1000x fixed Low dust NOT NEEDED concentration Very low dust 10000x fixed Very low dust NOT NEEDED 6 5 Parameter 9 i Save parameters Parameter number 9 saves all the parameters SP in the display Press button B or C to save parameter changes The dust monitor goes to the normal measuring mode after pressing B or C 19 udi 7 AUTOMATIC SETUP To be able to detect variations in dust flow and to set the alarm so that it will go off if there is excessive dust flow you must determine the typical dust flow in the application when the process is operating normally The unit has an AUTOMATIC SETUP function With this you can set the measuring range of the dust monitor so that
6. PARAMETER CHANGE TABLE DISPLAY KEY EFFECT KEY EFFECT FACTORY PARAMETER NUMBER RANGE KEY B KEY DEFAULT con si Relay 1 trig value Current filter time constant Percent level of full Range n wie o mm ue Table 1 Parameter change table Relay 2 trig value 2 add 1096 add 196 60 increase decrease 4 mA trim 3 aren set to 4 mA increase decrease 20 mA trim 4 currani emeni set to 20 mA JX SINTROL For Good Measure Parameter 1 and 2 Alarm relay 1 and Alarm relay 2 threshold Threshold for alarm relay 1 and relay 2 can be selected as a percentage of the output range You may increase or decrease the trig value by pressing the keys The percentage is displayed by the two rightmost display digits Parameter 3 Analog output zero adjustment If needed output zero can be adjusted to 4 mA Allow 30 minutes warm up time before trimming the mA output Parameter 4 Analog output span adjustment If needed output span can be adjusted to 20 mA Allow 30 minutes warm up time before trimming the mA output Parameter 5 Alarm Relay delay time Time delay for the two alarm relays can be set between 0 and 180 seconds with 10 seconds increment The time set is common for both alarm relays Parameter 6 Analog output damping If the dust reading is oscillating the analog mA output can be averaged by the filler time constant the filter time can be set between and
7. entry is made into the duct for installation or maintenance purposes e The unit may be installed in ducting containing particulate hazardous to health e The particulate may be inflammable explosive or toxic e 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 JX SINTROL For Good Measure 1 2 Product overview The 5303 Trend monitor is a microprocessor based self adjusting device equipped with two alarm relays and a 4 20 mA signal output is designed for trend or filter bag leak detection It can also be used to detect blockage or stoppage in pneumatic transport and bulk solids handling It is a compact unit with the sensor and control units built into one IP65 enclosure that has been specifically designed for easy installation and operation The standard model is designed for applications at up to 2 bar and 300 High temperature HT models are available for at up to 700 C 1 3 How does it work The model S303 Trend monitor use proven and reliable triboelectric technology where the interaction of particles with the sensor rod causes a small electrical charge to pass between th
8. JX SINTROL For Good Measure 5303 Dust Monitor User Manual Distributor Version 1 6 11 07 2013 uii Table of Contents 1 nere EE EE EEE REE 3 1 1 rij EEE 3 We Product OV ION 4 t3 TOW dOSS IDOL A anne ee tutte ria ua tubi Diui deed md I pla Dodd Hd 4 2 INSTAELA TION 5 2 1 Selecting the installation 5 2 2 Installing the sensor enne 7 3 WIRING OF POWER AND OUTPUT CIRCUITS 10 3 1 AC power connectors X3 nnne 10 SP NIL CONDECION o MR 11 4 TECHNICAL SPECIFICATION eee e eere eere ene eee 12 5 DIMENSION S e 13 6 OPERATION 14 6 1 Operation of the 14 62 Relay mens erect ente MU POT PN o atata 14 6 3 How to change parameter 16 6 4 Parameter 8 i Manual range 19 6 5 Parameter 9 Save parameters 19 7 AUTOMATIC 20 8 MAINTENANCE 22 9 TROUBLESHOOTING
9. MMUNICATION Figure 5a Signal connector Figure 5b Signal connector X5 wiring 11 4 TECHNICAL SPECIFICATION Measured objects Particle size Measurement range Process Conditions Temperature Pressure Gas velocity Humidity Input surge voltage Measurement principle Output damping time Output signals Ambient conditions Temperature Humidity Vibration Materials Probe Insulation of sensor Enclosure Power Supply Power consumption Wiring connections Weight Range setup options Normal measuring range Extended measuring range Alarm threshold Zero point offset trim oolid particles dust in a gas stream 0 3 um or larger 0 1 mg m to 1 kg m Max 100 C standard 200 350 C optional Max 200 kPa Min 4 m s 95 RH or less non condensing Max 100 V Electrostatic charge detection 10 to 180 seconds Isolated 4 20 mA Relay 5 A 24 V AC or DC 20 to 45 C 95 RH non condensing 5 m s or less oo 316L PEEK 300 Teflon 100 Aluminium alloy 115 VACor 230 VAC or 24 VDC 8 W AC models 3 W 24 VDC model DIN PG11 port for power cables DIN PG11 port for signal cable 2 3 kg automatic based on average measured dust flow option set at factory Adjustable via internal keys or via serial port Automatic This instrument conforms to the following standards E
10. N 61010 1 2001 Safety LVD 61326 1 2005 First Edition C Electromagnetic Compatibility Mechanical tests IEC 60068 2 6 TEST Fc 1995 03 IEC 60068 2 29 TEST Eb 12 db 5 DIMENSIONS 90 Es 5 o 42 ES 56 Ll Q Figure 6 Dimensions and structure of S300 series Dust Monitor enclosure 13 6 OPERATION 6 1 Operation of the monitor The S300 Series Dust Monitor measures the dust level in a gas stream by monitoring electrostatic discharge when charged dust particles hit or pass by the probe It may have a 4 20 mA output 8302 8303 and or two relay contact alarm outputs 5301 5302 and 5303 The signal generated by the electrostatic loaded particles can be averaged with a user selectable time constant to remove the effect of short variations 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 All the user selectable parameters are factory set to default values shown in table 1 on page 16 6 2 Relay connections There are four different setup configurations depending on how the relays ar
11. NTROL For Good Measure 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 Diameter of the hole 9 8 to the stack must be minimum 38 mm 3 to avoid the sensor probe contact to the duct wall Figure 3a Sensor installation 1 Probe Enclosure 2 Fixing screw 6 Duct wall 3 Cables mains and signals 7 Socket 4 Cover 8 Weld JX SINTROL For Good Measure 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 Standard lenght 500 optional by request WM Welding point Locking bolt
12. a typical dust flow in the application corresponds to 20 of the emission monitor output full scale For AUTOMATIC SETUP you need to know that the process is running with a normal dust flow rate Then remove the cover of the unit and initiate AUTOMATIC SETUP by pressing the small button near the indicator lamp on the lower printed circuit board see Figure 9 NOTE the indicator lamp must be green before you press the key The unit starts collecting dust flow data This takes from about one hour typically 40 60 minutes The three digit display counts down to zero and the indicator lamp remains red as long as data are being collected To avoid interference from background electrical noise you should replace the cover of the unit after having initiated the AUTOMATIC SETUP After an hour the setup is ready and the unit returns to normal operation If your environment is not electrically noisy you may check the indicator lamp It will turn to green when setup is ready MATIC SETUP BUTTON GREEN LED NORMAI PERATION RED LED AUTIDTUNING IN PROGRESS n D C E eL GL O Q ke L u ACI C HUI
13. digit display is showing measurement readings and it is possible to change and save parameters 3 Check the parameter settings If the monitor is not giving any output signal after checks 1 2 and 3 contact your local distributor The Monitor is giving 4 mA or 20 mA continuously after auto setup procedure 1 Checkthat there is normal process going on and during auto setup there were normal operation conditions Check that the dust concentration really is not the zero or over the range 2 Check the power and signal wiring is right connected 3 Check the signal is not leaking to ground Contact between sensor probe and duct wall is not allowed The gas should not be condensing Check the sticky dust does not build up to the base of the sensor and does not make the bridge between sensor probe and duct wall If the dust is bridging the air purge is needed 4 Check the parameter settings 22 JX SINTROL For Good Measure NOTES 23 JX SINTROL For Good Measure Sintrol Oy Ruosilantie 15 Fl 00390 Finland Tel 358 9 5617 360 Fax 358 9 5617 3680 24
14. e connected TT Light bulb indication is ON when relay contact spring is closed e e Light bulb indication is OFF when relay contact spring is open _ Low alarm level and High alarm level are dust levels where relays change state 14 JX SINTROL Setup configuration 1 Both relays connected to Normally Open NO Relay 1 NO Relay 2 NO Relay 2 Dust Measuring High alarm level range concentration Relay 1 Low alarm level Setup configuration 2 Relay 1 Normally Open NO Relay 2 Normally Close NC Relay 1 NO Relay 2 NC Close i Open daro mend g range High alarm level Gi l PS ose RO e Relay1 E concentration Low alarm level d Open 9 Setup configuration 3 Relay 1 Normally Close NC Relay 2 Normally Open NO Relay 1 NC Relay 2 NO Q g Measuring Relay 2 p S TE High alarm level Dust concentration Relay 1 Low alarm level 15 JX SINTROL Setup configuration 4 Both relays connected to Normally Close NC Relay 1 NC Relay 2 NC Open Measuring Relay 2 E E Dust range High alarm level Open concentration Relay 1 Low alarm level Close 6 3 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 8 Indicator leds Automatic setup Green normal operation button wh
15. e mesh outside of the duct The units must not be installed in direct sunlight or in areas where the ambient temperature is above 45 C Please contact your local distributor or Sintrol if you require further advice JX SINTROL For Good Measure Figure 2 5303 Trend 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 lock and 3 oGlock 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 The mounting socket in PTT TEPES the middle of the side or in the middle of the top EET L 8 t L 8 T1 Figure 2a Round cross section duct Figure 2b Square cross section duct JX SI
16. e 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 JX SINTROL For Good Measure 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 5 x DN 3 x DN 1 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 5300 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 fin
17. ite to Red Auto tuning in start auto tuning buttons A B and C Cy MIC ers N u ZA Figure 7 S300 series Dust Monitor front panel 5 On e dro JX SINTROL For Good Measure Press the left key A below the display until the left digit indicates the number of the parameter you wish to change 1 8 see Table 1 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 1 When you have selected all the parameters push the leftmost A key again until the display left digit shows number 8 Push one of the other keys B or C to save all the parameters to 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 Changed parameters should be saved to EEPROM to make sure parameters remain unchanged after power cut
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