GTS SWR ENGINEERING ProSens Bedienungsanleitung
EN
ProSens
Dust Measurement
Operating Instructions
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Operating Instructions
2
CONTENTS Page
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Selection of the Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 7
3.1 Normal Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3.2 Identification of Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Technical Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Sensor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 PME Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 DIN Rail Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Use in Ex Hazardous Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 PME Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 DIN Rail Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.1 Basic Operation of the PME-Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.2 Basics for PC Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.1 Alarm relay does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9.2 No measured value, even so after calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Operating Instructions
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1. Introduction
1.1 Safety
ProSens sensor is powered from the transmitter.
DIN Rail Transmitter requires 24 ±10 % V DC power.
Caution:
The duct has to be exposed to a clean atmosphere during installation.
As such, the following should be considered:
• The gas flows or dust can be hazardous.
• Those flow can be inflammable, explosive, etc.
• The gases can be hot or under pressure.
1.2 Product Overview
The ProSens dust measurement systems are microprocessor-based and are pre-adjusted instruments for
measuring dust burdens in an airstream. ProSens is designed to monitor the clean air section behind filter
components and for measuring dust concentration in exhaust air ducts.
It is a compact unit consisting of a sensor and transmitter, enclosed in an IP 66 enclosure, which has been
specifically designed for easy installation and operation.
The standard transmitter is enclosed in the IP 65 housing and incorporates a touchscreen.
A DIN Rail Transmitter is also available, which is configured using the PC software.
The PME provides USB and RS 485 interfaces for PC configuration, the DIN Rail version can communicate
via RS 232 or RS 485 interfaces.
The PC software allows for configuration and calibration, which included the setting of internal parameters
like filter time, alarm hold time, etc.
With the software it is possible to monitor signal trends and to log protocol files.
ProSens is designed process pressures up to 2 bars and process temperature up to 250 °C.
An optional version is to be used in EX-zones category 1/2 gas & dust.
The sensor is connected to the transmitter using a 4 wire cable.
1.3 Mode of Operation
ProSens utilises tribo-electric technology whereby the interaction of dust particles with the sensor rod causes
a small electric charge, when the particles pass or hit by the sensor rod.
This small electric charge generates a signal proportional to the dust level even with an accumulation
of particles on the sensor rod. Experience has shown that this method of sensing dust level in gases offers
accurate results with a minimum of maintenance.
With power applied the unit is ready-to operate using factory setting and can be configured and calibrated
using the PME or PC software. For DIN Rail versions a PC is required for commissioning. Programmable
maximum & minimum alarm outputs are available. If the relay is used as “normally closed” (NC), the sensor is
also monitored for power failures. Also any other failure will be activated.
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Operating Instructions
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The transmitter has a 4 ... 20 mA output proportional to the trend of the dust burden.
If there is an error found by internal system checks the output is set to 2 mA.
2. Installation
2.1 Selection of the Sensor Location
Fig. 1
3 x DN 3 x DN
3 x DN 3 x DN
3 x DN
3 x DN
3 x DN
3 x DN
Fig. 2: Recommended distances to bends (DN = duct diameter)
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The best location for installation of the ProSens is in a duct section where there is even laminar flow
distribution.
The optimal position would be in a horizontal or vertical section of the duct. There should not be bends,
valves, dampers or other obstructions, either upstream or downstream, for a distance of at least 5 times the
pipe/duct parameters. (See figure 2)
Operating Instructions
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In some applications a compromise has to be made and the sensor will have to be fitted in a position that
satisfies the majority of above requirements.
The sensor has to be attached to metal ductwork so that it will be electrically shielded from interference and
be provided with good grounding. For non-metal ducts, a section of the duct, a minimum of 5 x diameters in
length, should be covered with a metallic foil or fine-mesh on the periphery of the duct.
Caution, ensure good grounding practice are adhered to.
1. The unit should be installed in a position, where the gas flow passes the sensor rod at an angle of 90°.
2. In round cross-section ducts the unit can be installed in any position above the horizontal axis
(between 9 and 3 o’clock). (See figure 2a)
3. 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. (See figure 2b)
4. Although the sensor is not affected by vibration, very high vibration levels should be avoided.
5. The units should not be installed in direct sunlight or in areas where the ambient temperature is above
60 °C.
6. The sensor rod must not contact the opposite duct wall or any other obstacle inside the duct!
The sensor can be shortened to a minimum length of 70 mm. Be careful not to damage the plastic cap
when doing this.
• The recommended length of the antenna is the pipe diameter minus 10 mm, ensuring there is no
contact with the opposite wall.
• The minimum length of the antenna is 1/3 of the pipe diameter, the smaller the dust burden, the
longer the antenna should be.
7. When monitoring an electrical filter system, the minimum distance from the filter is 20 m.
Although vibration does affect the measurement, the sensor should not be subjected to excessive
vibration for long periods of time.
Fig. 3a: Round cross section
▼
▼
ProSens in the
horizontal axis.
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Operating Instructions
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Fig. 3b: Rectangular ducts
2.2 Sensor Installation
Once the location of the sensor has been selected, the R 1” female thread is welded on the duct wall.
Then the G 1” male thread, of the sensor is screwed in until the connection is tight. Sealing has to be
checked.
Caution:
•Use a correct installation tool (wrench opening = S36) and turn at the G 1“ location. Do not screw in the
sensor manually by turning at the housing. This may lead to a faulty installation and cause damage to the
sensor.
• Warranty will be void if improperly installed.
ProSens mounted in the centres
for top and sides.
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Operating Instructions
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3. Safety
The ProSens was designed, built and tested for safety and is shipped in this condition. Components within the
supplied system could be hazardous if not unpacked, installed, connected and commissioned by authorised
qualified persons. All operating instructions must be read, and understood, before handling the system. Failure to
do so will cause the warranty to be revoked.
3.1 Normal Use
•The measuring system must be installed for measuring dust burden only.
Other usage, or modifications, of the measuring system is not permitted.
•Only original spare parts and accessories of SWR engineering must be used.
3.2 Identification of Hazards
Possible hazards, when using the measuring system, are marked by the following symbols:
Warning!
•This symbolises a situation where personal safety is at risk if used in an improper manner.
Attention!
• This symbolises the possible damage to the system, if used in an improper manner.
3.3 Operational Safety
•The measuring system must be installed by trained and authorised personnel only.
•In case of maintenance-work on the pipe or on components of the ProSens-sensor, make sure that the
piping is in unpressurized condition.
•Switch off the power supply for all maintenance, cleaning or inspection works on the sensor or on
components within the ProSens. Follow the notes of the chapter maintenance.
•Caution, if welding is required on the pipe, remove sensor.
•The components and electrical connections must be checked for damages regularly. If a damage is
found, it is to be repaired before further operation of the instruments.
3.4 Technical Statement
•The manufacturer reserves the right to change any technical data, without prior notice. If any queries
arise, SWR engineering will be happy to informer customers of any possible changes made.
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Operating Instructions
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Connection to PME
Sensor PME
Max. 300 m using
wire of appropriate
cross sectional area
1
2
3
4
1 (+ 24 V)
2 (GND)
3 (A)
4 (B)
It is recommend that shielded, twisted cable be used for noisy environments and for long distances!
Sensor DIN Rail Transmitter
Max. 300 m with
sufficiant wire dimension
1
2
3
4
16 (+ 24 V)
15 (GND)
14 (A)
13 (B)
Connection to DIN Rail Transmitter
Fig. 4: Electrical connection Tab. 1: Sensor connection
Fig. 6: Sensor connection to DIN Rail Transmitter
Fig. 5: Sensor connection to PME
+ 24 V
0 V
RS 485 - A
RS 485 - B
NO
COM
NC
Plug number Signal name
1 V+ (24 V DC)
2 V- (0 V)
3 RS 485 - A
4 RS 485 - B
5 Relay NO
6 Relay C
7 Relay NC
4. Electrical Connection
The ProSens is fit out with an internal wiring box, providing the plugs for different options:
Note: For EX-versions category 1 and 2 the relay contact is only available at the transmitter and not at the sensor.
4.1 Sensor Connection
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Operating Instructions
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L N PE
I-in 1
NA
NA
I-out 1
+ - NA
NA
I-out 2
NA
NA
I-out 3 Relais
No C Nc NA
NA
D-out RS 485
A B
GND
NA
NA
D-in 1
NA
NA
D-in 2 Sensor
+ - A B
Shield
4.2 PME Transmitter
Fig. 7: PME electrical terminal
Transmitter
Terminal No. Connection
Connection of the Power Supply
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 Protective Earth
Connections
I-in 1 NA not available
NA not available
I-out 1 + Current Output +
- Current Output -
I-out 2 NA not available
NA not available
I-out 3 NA not available
NA not available
Alarm
Relay
NO Isolated Relay NO
C Isolated Relay C
NC Isolated Relay NC
D-out 1 NA not available
NA not available
RS 485
A RS 485 Interface Data A (+)
B RS 485 Interface Data B (-)
GND RS 485 Interface Ground
D-in 1 NA not available
NA not available
D-in 2 NA not available
NA not available
Sensor
+ Power Supply 24 V (+) Cable No. 1
- Power Supply 24 V (-) Cable No. 2
A RS 485 Data A Cable No. 3
B RS 485 Data B Cable No. 4
Shield Shield Shield
Tab. 2: Connections PME
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Operating Instructions
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4.3 DIN Rail Transmitter
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
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
Alarm relay
C
Alarm relay
NO
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
9 10 11 12
13 14 15 16
Fig. 8: Terminal DIN Rail Transmitter
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Inhaltsverzeichnis
