SWR ENGINEERING SOLIDFLOW Manual de usuario
EN
SolidFlow
Monitoring of solids
Operating Instructions
2
CONTENTS Page
1. System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 4
3.1 Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3.2 Identification of Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Technical Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Mounting and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Delivery Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.3 Mounting of the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Mounting of the Evaluation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Overview of the Optional Use of the C-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Use in Ex Hazard Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7. Menu Structure of SolidFlow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8. Menu Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9. Connection Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1 Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 Impulse Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10. Additional Information for the Use of FME 300 Unit with a C3-Box . . . . . . . . . . . . . . . . . . . . . . . . . 26
11. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
13. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15. Quick Start Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operating Instructions
3
Sensor
1. System Overview
Overview of the measuring system:
Fig. 3: Coupling and reflection of the microwaves.
and evaluation unit
2. Function
•SolidFlow is a measuring system especially developed for measuring the flow rate of conveyed solids in
metallic ducts.
•The SolidFlow sensor is based on the newest microwave technology. The sensor is usable in metal
ducts. Through the coupling of the microwave in the duct it is created a homogenous measured field.
•The microwave energy is being reflected by the solid particles and received by the sensor. These signals
are evaluated in frequency and amplitude.
•Because of the selective frequency evaluation only moving particles are measured.
•The measuring signal is independent of pressure and temperature in the duct. A measuring unit
consists of one sensor and the evaluation unit.
Operating Instructions
4
3. Safety
The measuring system SolidFlow was designed, built and tested to be safe and was shipped in safe conditions.
Nevertheless persons or objects may be endangered by components of the system if these are operated in an
inexpert manner. Therefore the operational instructions must be read completely and the safety notes must be
followed.
In case of inexpert or irregular use, the manufacturer will refuse any liability or guarantee.
3.1 Regular Use
•The measuring system must be installed for measuring the flow rate in metallic ducts only.
Other usage and modifications of the measuring system are not permitted.
•Only original spare parts and accessories of 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 supply voltage for all maintenance, cleaning or inspection works on the tubes or on
components of the SolidFlow. Follow the notes of the chapter maintenance.
•Before hot-work the sensor must be removed from the piping.
•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
•The manufacturer reserves the right to adapt technical data to the technical progress without particular
advance notice. If you have any questions, SWR engineering will be pleased to inform you on possible
changes and extensions of the operating instructions.
Operating Instructions
5
4. Mounting and Installation
4.1 Delivery Range
•Evaluation unit in the housing
•Weld on sensor accommodation
•Sensor (union nut, distance washers, seal-ring for adjustment)
•Operating instructions
•C-Box (optional)
4.2 Auxiliary
•Drill Ø 20 mm for steel
•32 mm wrench for union nut
•Pliers for circlips (Ø 20 mm) for adjusting the wall thickness at the sensor
4.3 Mounting of the Sensor
The sensor is to be mounted as follows:
•Determine the place of mounting on the duct. On horizontal or inclined ducts the sensor should be
mounted from top.
•In case of duct diameters greater than Ø 200 mm or a special application one has to install up to three
sensors which are located 120 mm apart from each other and moved by 120° towards each other.
•The distances are valid for the vertical and horizontal installation position.
•Follow the necessary distances of valves, bows, fans or cellular wheel sluices etc. and also other
measurement devices like temperature and pressure etc. to the sensor. (see fig. 4)
Fig 4: Minimal distances of the sensor to duct bends and baffles.
•With free fall applications (e. g. after screw feeders or rotary valves) a free fall height of at least 300 mm
would be perfect.
Operating Instructions
6
•Weld the sensor accommodation on to the duct.
•Drill the Ø 20 mm hole into the duct. Please use your own drill as there are different shafts available.
Take care that the hole is in line and rectangular to the surface to avoid trouble by inserting the sensor.
Warning!
•After drilling you have to check, if there is a burr resulted at the drilling walls from the drilling. If so, this
burr in the duct must be removed with an appropriate tool. If this burr is not removed, a calibration of
the sensor is not possible!
•If the sensor is not installed immediately, the dummy plug must be put in until the sensor will be
installed (see fig. 5). Use a 32 mm wrench for tightening the union nut.
Fig. 5: Installation of the sensor
accommodation and the dummy plug.
Distance washer 1 mm
O-ring-type sealing
ring 36 x 3
Sensor accommodation
Union nut
Circlips for shafts
Dummy plug
q
q
q
q
q
q
q
•Fig. 5: Installation of the sensor accommodation and the dummy plug.
•It’s important that the sensor does not intrude into the duct because otherwise the front end of the
sensor will be worn by abrasion. If necessary the wall thickness must be checked with a depth gauge.
Then position the circlip in the complying slot. The sensor may be submerged into the duct wall by up to
1 mm without creating an error of measurement.
Wall thickness (mm) Circlip for shafts position Number of distance washers
3,0
4,0
5,5
6,5
8,0
9,0
10,5
11,5
13,0
14,0
1
1
2
2
3
3
4
4
5
5
2
1
2
1
2
1
2
1
2
1
•Now the sensor is put into the sensor accommodation and screwed with the union nut according to
figure 6a.
Operating Instructions
7
•Look at the POLARIZATION - label to adjust the sensor along to the duct, fig. 6b.
Fig. 6a: Installation of
sensor accommodation
and sensor.
Sensor accommodation
O-ring-type sealing ring 36 x 3
Distance washer 1 mm
Circlip for shafts 20 x 1.2
Distance washer 1 mm
Union nut
Sensor
q
q
q
q
q
q
q
1
2
• Lock the sensor with the union nut dust proof and fix the sensor.
Fig. 6b: Adjustment of the sensor.
▼
Flow direction
• Make sure you install a drip loop with the cable anywhere it may get wet to prevent
water flow from reaching the sensor.
Operating Instructions
8
Fig. 7: Field housing evaluation unit.
Fig. 8: Field housing C-Box (optional).
4.4 Mounting of the Evaluation Unit
•The whole electronic equipment can be installed at a maximum distance of 300 m from the sensor.
The housing is prepared for wall mounting.
90 120
244
254
237
Sensor Evaluation Unit
PG11
98
86
36
64
Operating Instructions
9
The C-Box is an useful optional extension, if the distance between the sensor and the evaluation unit exceeds
the given standard length of 2 meters. The C-Box contains additional safety devices and terminal resistors to
guarantee the communication over the ModBus between the sensor and the evaluation unit even over longer
distances.
Sensor C-Box Evaluation Unit
2 m cable
of the sensor
manufactures firmly
up to 300 m,
at sufficient conductor
cross section
4.5 Overview of the Optional Use of the C-Box
Operating Instructions
10
4.6 Use in Ex Hazard Array
Marking DustEx: II 1/2D Ex tD IP 65 T84 °C
Zone 20: 0 °C _< Tprozess _< 80 °C
Zone 21: -10 °C _< Tamb _< 60 °C
- Group of equipment 2
- Equipment category: 1/2
Waveguide window zone 20 / Housing zone 21
- For combustible mixtures from air and inflammable type of dust
- IP-Code 65
- Maximum surface temperature 84 °C with Ta = 60 °C
Marking GasEx: II 1/2D Ex tD A20/21 IP 65 T84 °C
II 2G Ex d IIC T5/T3
- Group of equipment 2
- Equipment category: 2
- Zone 1
- For combustible mixtures from air and inflammable type of gas
- IP-Code 65
- Allowable process temperature 0 to 150 °C
- Class of temperature T3
- Maximum surface temperature 84 °C with Ta = 60 °C
Ex hazard array
DustEx zone 20
GasEx zone 1
Zone 21/22
Zone 1/2
No ex hazard array
Tmax = 60 °C
Tmax =
150 °C
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