Endres+Hauser Solitrend MMP60 Operating instructions

Brand: Endres+Hauser

Model: Solitrend MMP60

Type: Operating instructions

This manual is also suitable for

MMP60 SONO GS

Products Solutions Services

Operating Instructions

MMP60 SONO GS

Moisture measurement

BA01946M/00/EN/01.18

71418832

2018-10-29

MMP60 SONO GS

2 Endress+Hauser

Order code:

Ext. ord. cd.:

Ser. no.:

www.endress.com/deviceviewer Endress+Hauser

Operations App

XXXXXXXXXXXX

XXXXX-XXXXXX

XXX.XXXX.XX

Serial number

A0023555

MMP60 SONO GS1

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Table of contents

1. Introduction ........................................................................................................... 5

1.1. Area of application ........................................................................................................... 5

1.2. Your benefits ..................................................................................................................... 5

2. Documentation ....................................................................................................... 6

2.1. Standard documentation .................................................................................................. 6

2.2. Supplementary documentation ....................................................................................... 6

3. Basic safety instructions ........................................................................................ 7

3.1. Requirements for personnel ............................................................................................ 7

3.2. Designated use .................................................................................................................. 7

3.3. Workplace safety .............................................................................................................. 8

3.4. Operational safety ............................................................................................................ 8

3.5. Product safety ................................................................................................................... 8

3.5.1. CE mark ...................................................................................................................... 8

4. Incoming acceptance and product identification ................................................... 9

4.1. Incoming acceptance ........................................................................................................ 9

4.2. Product identification ....................................................................................................... 9

4.3. Manufacturer's address .................................................................................................... 9

5. Product lifecycle ................................................................................................... 10

6. Measuring principle ............................................................................................. 11

7. Input ..................................................................................................................... 12

8. Output .................................................................................................................. 13

9. Electrical connection ............................................................................................ 14

10. Performance characteristics ................................................................................ 16

11. Operation and connectivity to SONO probes ........................................................ 18

11.1. Wiring diagram for connection to SONO-VIEW and the PLC .................................. 18

12. SONO-GS1 installation and mechanical construction .......................................... 20

12.1. Installation of the SONO-GS1 under a conveyor belt ............................................... 21

12.2. Installation of the SONO-GS1 in a screw conveyor ................................................... 22

13. Protection of MIL probe connector against abrasion ........................................... 23

14. What to do in the event of suboptimal material flow........................................... 24

15. Calibration curves Cal1 to Cal15 .......................................................................... 25

16. Special functions .................................................................................................. 27

16.1.1. Determination of the mineral concentration ..................................................... 27

16.1.2. Material temperature measurement .................................................................. 27

16.1.3. Temperature compensation when used at elevated temperatures .................. 27

16.1.4. Temperature compensation of internal SONO electronics ............................... 27

16.1.5. Compensation of the temperature of the material being measured ............... 27

16.2. The analog outputs for outputting the measured values ......................................... 28

16.3. The SONO probe serial interface ................................................................................ 29

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16.3.1. Error output and error messages ........................................................................ 29

17. Setting the right operating mode for the probe ................................................... 30

MMP60 SONO GS1

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1. Introduction

MMP60 SONO GS1, TDR material moisture sensor with a large measuring field for different bulk

solids

1.1. Area of application

• IP68 protection towards medium when correctly installed

• Measuring range: 0% to 50% water content

• Material conductivity range: max. 12mS/cm

• Process temperature: 0 to 70°C

• Process pressure: -1 to 3bar, depending on installation

• Accuracy: up to +-0.1%

1.2. Your benefits

High-tech measurement of the moisture content of hard-to-measure materials at the speed of

light at the best possible installation location, with the following performance characteristics:

• Moisture probe with a large measuring field for low-density materials such as grain,

pellets, wood chips and sawdust.

• Ability to install the SONO-GS1 under a conveyor belt enables the moisture measurement

of material which tends to stick and cause heavy buildup without direct contact with the

material being measured.

• Can be installed on the floor of mixers, on containers, hoppers, flanges, silos, conveyor

belts and screw conveyors.

• No additional evaluation units are required.

• Commissioning and maintenance via the serial interface of the moisture probe: on the PC

using the SM-USB module, or alternatively using the SONO-VIEW display and operating

module.

• 2 × 0(4) to 20mA analog output for moisture and conductivity/temperature.

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2. Documentation

The following types of documentation are available in the Download area of the Endress+Hauser

website (www.endress.com/downloads):

For an overview of the Technical Documentation pertaining to the device, please refer to the

following:

• W@M Device Viewer (www.endress.com/deviceviewer): enter the serial number on the

nameplate

• Endress+Hauser Operations App: enter the serial number on the nameplate or

scan the 2D matrix code (QR code) on the nameplate

2.1. Standard documentation

BA01944M

Operating Instructions for MMP42 SONO LD

2.2. Supplementary documentation

SD02334M

Application Manual MMP40, MMP41, MMP42, MMP60

SD02332M

SM-USB

Connection and configuration of SONO and TRIME probes on a PC with Windows

via the SM-USB module

SD02333M

SONO-VIEW

Stand-alone display and configuration unit for reliable process control with SONO

or TRIME moisture probes

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3. Basic safety instructions

3.1. Requirements for personnel

Personnel must meet the following requirements for the tasks they perform:

• Trained specialist staff. Have a relevant qualification for their specific role and task.

• Are authorized by the plant owner/operator.

• Are familiar with federal/national regulations.

• Prior to commencing work: Read and understand the instructions in the manual and

supplementary documentation as well as in the certificates (depending on the application).

• Follow instructions and comply with general policies and conditions.

3.2. Designated use

Application and media

The measuring device described in this manual is intended for the continuous moisture

measurement of a wide variety of materials. With an operating frequency of approx. 1 GHz and

a maximum pulse power of … mW, the device can also be used outside of closed metal containers.

If the device is operated outside of closed containers, it must be mounted as specified in the

instructions in the "Installation" section. The operation of the devices does not present any health

risk.

In compliance with the limit values specified in the "Technical Data" and the conditions listed in

the manual

and supplementary documentation, the measuring device may be used for the following

measurements only:

• Measured process variables: moisture, conductivity and temperature

To ensure that the measuring device remains in proper operating condition throughout the

service period:

• Only use the measuring device for media to which the process-wetted materials are

adequately resistant.

• Observe limit values specified in the "Technical Data".

Incorrect use

The manufacturer is not liable for damage caused by improper or non-designated use.

Clarification of borderline cases:

• With regard to special fluids and media used for cleaning: The manufacturer is glad to assist

in clarifying the corrosion resistance of materials in contact with the fluid but does not accept

any warranty or liability.

Remaining risks

Due to the transfer of heat from the process and power dissipation of the electronics, the

temperature of the electronics housing and the assemblies contained therein can increase to up

to 80°C (176°F). The sensor may reach a temperature close to the medium temperature during

operation.

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Possible burn hazard from touching surfaces!

• In the event of high medium temperatures: Ensure protection against contact to prevent

burns.

3.3. Workplace safety

When working on and with the device:

• Wear the required personal protective equipment according to federal/national regulations.

3.4. Operational safety

Risk of injury!

• Only operate the device if it is in proper technical condition, free from errors and faults.

• The operator is responsible for the interference-free operation of the device.

Modifications to the device

Unauthorized modifications to the device are not permitted and can lead to unforeseeable

dangers:

• If modifications are nevertheless necessary, consult with the manufacturer.

Repairs

To ensure continued operational safety and reliability:

• Carry out repairs on the device only if they are expressly permitted.

• Observe federal/national regulations pertaining to the repair of an electrical device.

• Only use original spare parts and accessories from the manufacturer.

Hazardous area

To eliminate danger to persons or the installation when the device is used in the hazardous area

(e.g. explosion protection, pressure equipment safety):

• Check the nameplate to verify whether the ordered device can be put to its intended use in

the hazardous area.

• Observe the specifications in the separate supplementary documentation, which is an

integral part of this manual.

3.5. Product safety

This state-of-the-art measuring device is designed in accordance with good engineering practice

to meet operational safety standards, has been tested, and left the factory in a condition in which

it is safe to operate. It meets the general safety requirements and legal requirements.

3.5.1. CE mark

The measuring system meets the legal requirements of the applicable EC Directives.

These are listed in the corresponding EC Declaration of Conformity along with the standards

applied.

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4. Incoming acceptance and product identification

4.1. Incoming acceptance

On receipt of the goods, check the following:

• Are the order codes on the delivery note and the product label identical?

• Are the goods free from damage?

• Do the data on the nameplate match the order specifications on the delivery note?

• Where applicable (see nameplate): are Safety Instructions (XA) provided with the device?

If you can answer "no" to one of these questions, please contact your

Endress+Hauser Sales Office.

4.2. Product identification

The device can be identified in the following ways:

• Specifications on the nameplate

• Extended order code with a breakdown of the device features

on the delivery note

• Enter the serial number on the nameplate in W@M Device Viewer

(www.endress.com/deviceviewer): all the information about the device is displayed.

• Enter the serial number on the nameplate into the Endress+Hauser Operations App or scan

the 2-D matrix code (QR code) on the nameplate with the Endress+Hauser Operations App:

all the information about the device is displayed.

4.3. Manufacturer's address

Endress+Hauser SE+Co. KG

Hauptstraße 1

79689 Maulburg, Germany

Address of the manufacturing plant: see nameplate.

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5. Product lifecycle

Engineering

• Time-tested and precise TDR moisture measuring technology for the non-hazardous area

• Measurement of the material moisture and material conductivity of bulk solids, emulsions

and liquids up to a maximum conductivity range of 50mS/cm

• Different probe housing versions available for different applications

• In addition, the material temperature can also be measured in certain ranges and to

certain accuracy levels.

• IP68 protection towards the measured medium with correct leak-tight sensor installation.

The MIL connector with cable has IP67 protection.

• A special version without a MIL connector and with an IP68 cable entry and a special

cable can be ordered on request.

Procurement

• Best value-for-money moisture probe

Installation

• Can be installed on containers, flanges, screw conveyors, mixer floors, scrapers

and pipes

Commissioning

• Commissioning and maintenance via the serial interface with the SONO-VIEW display

module or alternatively on a PC with Windows using the SM-USB module

Operation

• Continuous self-monitoring

• Auto-correction, the probe recalibrates automatically in event of abrasion

• No additional evaluation units are required.

• Measured value display via optional SONO-VIEW operating and display module

Maintenance

• No maintenance is necessary

• Technical experts available on demand at the manufacturer's facility

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6. Measuring principle

Time-domain reflectometry, or TDR, is a radar-based

dielectric measurement method where the transit time of

electromagnetic pulses is determined to measure the

dielectric constant, and therefore the water content.

The SONO moisture probes feature a stainless steel

housing with a ceramic window. A TRIME TDR

transmitter is integrated in the housing. The high-

frequency TDR pulse (1GHz) generated in the TRIME®

transmitter travels along wave guides, creating an

electromagnetic field around these guides and therefore

also in the material around the probe. Using a patented

measurement method, the transit time of this pulse is

measured with a resolution of one picosecond (1×10-12)

in order to determine the moisture and conductivity.

In contrast to capacitance or microwave measurement methods, TRIME® technology

(Time-Domain-Reflectometry with Intelligent Micromodule Elements) is not only able to

measure the moisture content, but is also able to provide information about the

composition of the material, such as the mineral concentration, for instance. This

increases the level of certainty and reliability in the production of fresh concrete and other

media, for example, as it is possible to check whether the mineral concentration of a

concrete formulation has been adhered to correctly.

The TRIME-TDR method operates in the ideal frequency range between 600MHz and

1.2GHz. Depending on the device, capacitance measurement methods (also known as

frequency-domain technology) operate in a frequency range between 5MHz and 40MHz,

which makes them prone to interference from factors such as the temperature and high

mineral content in the material being measured. Microwave measuring systems work

with high frequencies >2GHz. At these frequencies, non-linearities occur which require

very complex compensation. Because of this, microwave measuring systems are more

sensitive to temperature variations and the grain quality of the material being measured.

Thanks to their novel and innovative probe design, SONO probes recalibrate themselves in

the event of abrasion, which translates to longer maintenance cycles and more accurate

measured values. The modular TRIME technology enables special applications with very

little effort and can be adapted to many applications due to the variable probe design.

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7. Input

Measured variables

The measured variable at channel1 is the material moisture or water content in the medium

being measured.

Optionally, the material conductivity and/or the material temperature can be measured in certain

ranges and with a corresponding level of accuracy and output on channel2.

Measuring ranges

The material moisture can be determined with a water content ranging from 0 to max. 100%.

Material conductivity can be determined up to a maximum range of 12mS/cm. It must be noted

that the material conductivity measurement is not calibrated. Calibration is possible in defined or

higher measuring ranges.

Installation requirements

• The sensor must be installed at a point in the process in such a way that ensures a relatively

constant material density, as the material density is directly related to the water content.

Structural measures may be needed at the place of installation to ensure that the material

flow in the system, and therefore the material density, above the sensor is relatively

constant, or a bypass should be created.

• The moisture sensor should be completely surrounded by material. The layer of material

covering the sensor must be at least 40mm deep.

• The flow of material above the surface of the probe should be relatively continuous.

However, the probe electronics offer ways to automatically detect and bridge material gaps in

intervals of seconds. One example here is operation in a concrete mixer with short-term gaps

in material flow above the probe.

• Longer averaging times increase measurement accuracy.

• No material deposits or buildup should form on the sensor surface, as this would falsify

the readings.

Usable measuring range

The SONO GS1 probe series is suitable for applications with heterogeneous, low-density media

where the material moisture content is in the range from approx. 0% to up to 50%. For

applications in the upper moisture range and for higher material conductivity values of up to

100% moisture and 50mS/cm conductivity, the SONO HC or SONO sensor series would be

better suited.

Media groups

Medium

Application

Moisture range

Conductivity

range

Wood chips

Conveyor belt

0% to 15%

Max. 5mS/cm

Sawdust

Conveyor belt

0% to 10%

Max. 5mS/cm

Pellets

Silo, conveyor belt

0% to 5%

Max. 5mS/cm

Ceramic mass

Under the conveyor belt

0% to 30%

Max. 12mS/cm

Sand-lime

Under the conveyor belt

0% to 30%

Max. 12mS/cm

Detergents

Under the conveyor belt

0% to 30%

Max. 12mS/cm

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8. Output

Output signal for channel1 and channel2

0(4) to 20mA

Two analog current interfaces act as the measured value output for the material moisture and

material conductivity. Optionally, the material temperature can be output to channel2.

Digital output

Standard RS485 serial interface and optionally IMP-Bus. The physical IMP-Bus is specifically

designed for the manufacturer to connect the SONO-VIEW operating and display module, and

the SM-USB module (for connecting a SONO GS1 probe to a Windows PC), to enable users to

analyze and optimize a new application, where necessary.

Data transmission rate: 9600 Bit/s

The serial transmission protocol is based on a manufacturer-specific protocol. The protocol

description is available for download on the manufacturer's homepage.

Signal on alarm

A prolonged EMC disturbance is detected during moisture measurement and output as an

interference signal at the analog output with 21mA on channel1.

Linearization

In the sensor, up to 15 different calibration curves can be used for each of the two channels.

Linear and non-linear curves with polynomials of up to degree 5 can be used. The calibration

curve can be selected via the SONO-VIEW operating and display module. Optionally, it is

possible to connect the SONO probe to a PC via the SM-USB module to make calibration

settings and other parameter settings in Windows with the SONO-CONFIG software (see the

SONO-CONFIG software).

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9. Electrical connection

The SONO GS1 with integrated TDR electronics is fitted with a 10-pin MIL flange connector with

IP67 protection.

Assignment of the 10-pin MIL connector and cable connection:

Connector PIN

Sensor connections

Wire color

+12V to 24VDC stabilized power supply

Red

0V Power supply

Blue

1st Analog Positive (+) Moisture

Green

1st Analog Return Line (-) Moisture

Yellow

RS485 A (must be activated)

White

RS485 B (must be activated)

Brown

IMP-Bus RT

Gray/Pink

IMP-Bus COM

Blue/Red

2nd Analog Positive (+)

Pink

2nd Analog Return Line (-)

Gray

Shield

(is grounded at the sensor.

The installation must be properly

grounded!)

Transparent

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Power supply/power consumption

An external power supply is required.

+12VDC to max. +24VDC stabilized, 3W

Caution: Do not use unstabilized power units; risk of overvoltage!

Potential matching

The shield is grounded at the sensor.

Start-up time

The first stable measured value is present at the analog output after approx. one second.

Power failure

The configuration is retained in the sensor.

Process connection cable specifications

Connecting cables with a preterminated MIL connector are available in different lengths.

Special versions without a MIL connector and with an IP68 cable entry and a special cable are

available on request. The individual wires are terminated with ferrules at the end of the cable.

Standard lengths are: 4 meters, 10 meters and 25 meters

User-definable lengths up to a total length of 100 meters can be ordered in increments of one

meter.

UNITRONIC PUR CP shielded cable, twisted pairs 6×2×0.25mm2, PUR sheath resistant to oils

and chemicals.

On request: UNITRONIC ROBUST C (TP) shielded cable, twisted pairs 6×2×0.25mm2, for

resistance to weather conditions, ozone and UV light.

Analog output 0 to 10V with shunt resistor

Some older controllers have a 0 to 10V voltage input instead of a 0(4) to 20mA current input.

Using a 500 Ohm shunt resistor (included in the delivery), it is possible to generate a 0 to 10V

voltage signal from a 0 to 20mA current signal. The 500 Ohm shunt resistor should be fitted

at the end of the line or at the input of the controller. The circuitry is illustrated in the diagram

below.

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10. Performance characteristics

Reference operating conditions

Temperature = 24°C (+75°F) +- 5°C (+-9°F)

Moisture measuring range

SONO GS1 moisture probes measure from 0% up to material saturation.

Maximum measured error

The measured error depends on the operating mode of the SONO GS1 moisture probe and on

the flow of material above the moisture probe. The longer the averaging time and the more

stable the material density above the probe, the lower the measured error.

Measured errors of up to max. +-0.1% are possible.

Static measurements with a low measured error are only possible with homogeneous

materials like liquids or emulsions. Heterogeneous materials such as fresh concrete or bulk

solids with different grain size require a continuous flow of material above the surface of the

probe to achieve an acceptable measured error.

Conductivity measuring range

SONO GS1 moisture probes deliver a radar-based conductance (EC-TRIME) in the 0 to

12mS/cm range as the characteristic value. This value is determined depending on the mineral

concentration in the material being measured. The conductivity range is reduced in moisture

measurement ranges >50%. The conductivity value determined is uncalibrated and is

primarily used to characterize the material being measured.

Temperature measuring range

Measuring range: 0°C to 100°C

The temperature is measured 3mm beneath the probe surface in the probe housing and can

be output at analog output 2. As the probe electronics use approx. 1.5W of power, the probe

housing heats up slightly. Therefore the precise measurement of the material temperature is

only possible to a certain degree. The material temperature can be determined following an

external calibration and compensation of the sensor's internal heating.

Ambient temperature range

SONO GS1 moisture probes: -40 to +70°C

Process temperature

SONO GS1 moisture probes with integrated TDR electronics: 0 to 70°C

Please note that moisture measurement is not possible below 0°C (32°F) as the water content

of ice or frozen water cannot be determined.

Signal outputs

2 x analog output 0(4) to 20mA

Output 1: moisture in % (the measuring range can be individually set in the range from

0 to 100%)

Output 2: conductivity (EC-TRIME) or optionally temperature, or optionally the standard

deviation.

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It is also possible to divide analog output 2 into two ranges, namely the 4 to 11mA range for

temperature and the 12 to 20mA range for conductivity. Analog output 2 then switches

between these two current windows every 5 seconds.

The two analog outputs can be individually adjusted with the SONO-CONFIG software via the

SM-USB module or with the SONO-VIEW operating and display module. A 500R resistor can

be used for a 0-10VDC voltage output.

Calibration

SONO GS1 moisture probes are calibrated upon delivery, in line with the task the probe is to

perform. 15 different calibrations are saved per channel in the probes. Variable calibrations

with polynomials of up to degree 5 are possible for special materials and can be entered in the

probe using the SONO-CONFIG software. The zero point can be adjusted using the SONO-

CONFIG software or the SONO-VIEW display module.

Measured data pre-processing

SONO GS1 moisture probes can be set to different operating modes:

Mode CS: (Cyclic-Successive) For very short measurement processes in the seconds range

(e.g. 5 to 20 seconds) without averaging and with up to 100 measurements per second

internally and a cycle time of 250 milliseconds at the analog output. The CS operating mode is

also used to record raw values without averaging and filtering.

Mode CA: (Cyclic Average Filter) Standard averaging for relatively fast but continuous

measurement processes, with filtering and an accuracy of up to 0.1%.

Mode CF: (Cyclic Floating Average with Filter) Floating average for very slow and continuous

measurement processes, with filtering and an accuracy of up to 0.1%. Suitable for applications

in fluidized bed dryers, on a conveyor belt etc.

Mode CK: (Cyclic with Kalman-Filter) For complex applications.

Mode CC: (Cyclic Cumulated) With automatic totalization of moisture quantity measurements

in one batch process.

Mode CH: (Cyclic Hold) Similar to Mode CC but without totalization

The configuration options are documented in detail in the SM-USB and SONO-View manuals.

Communication

The serial interface enables network operation of the probe. A data bus protocol for the

connection of multiple SONO probes is implemented by default. The description of the serial

data protocol is available for download on the manufacturer homepage.

Measuring field propagation

Approx. 30-40mm, depending on the material and moisture.

Connector plug

SONO GS1 moisture probes are fitted with a rugged 10-pin MIL flange connector. Ready-made

connecting cables are available in cable lengths 4m, 10m or 25m. A special version without a

MIL connector and with an IP68 cable entry and a special cable can be ordered on request.

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11. Operation and connectivity to SONO probes

11.1. Wiring diagram for connection to SONO-VIEW and the PLC

With the help of the free

software SONO-CONFIG,

adjustments to the probe can

be made quickly and easily.

Via the SM-USB module

the SONO probe can be

connected to a PC for

communication.

With the SONO-VIEW

stand-alone display unit,

it is possible to set

suitable configuration

parameters directly

during operation without

having to connect a PC.

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SONO-VIEW allows users to view measured values and configure SONO probes.

The moisture content determined and the conductivity / temperature can either be fed directly

into a PLC via two analog outputs 0(4) to 20mA, or queried via the serial interface.

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12. SONO-GS1 installation and mechanical construction

The SONO-GS1 probe can be installed directly in the floor of a container or in a screw conveyor.

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Endres+Hauser Solitrend MMP60 Operating instructions

Brand: Endres+Hauser

Model: Solitrend MMP60

Type: Operating instructions

This manual is also suitable for

MMP60 SONO GS

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