EN

Paddy
Screen break detection
Operating Instructions

SWR engineering Messtechnik GmbH enveaTM a trademark of Environnement S.A Group

CONTENTS Page
1. System overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Identification of dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Safety at work and operational safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Technical progress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 Typical components of the measurement point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Required equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Sensor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Mounting the transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.5 Use in hazardous areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5. Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 DIN Rail terminal layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Field housing terminal layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 C3-Box terminal layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6. Operator interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Differences between the DIN Rail and field housing transmitters . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 PC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.4 Menu structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Basic start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 Data logger function in the software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Adjusting the measurement values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8. Error signalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
11. Fault clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11.1 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12. Connection examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
13. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2
1. System overview
A measuring point consists of the following components:
•• Transmitter (in the DIN Rail housing or field housing)
•• Sensor mount for welding to the pipeline
•• Reference microwave particle sensor
•• Measurement microwave particle sensor
•• C3-Box
•• Installation instructions

Sensors C3-Box Transmitter

C3-Box Transmitter
1 (+ 24 V)
2 (GND)
Sensor 3 (A)
4 (B)
Shield

Sensor

max. 300 m

Fig. 1: Overview of electrical connection with the transmitter in the field housing

Sensors C3-Box Transmitter

C3-Box Transmitter
16 (+ 24 V)
15 (GND)
14 (A)
13 (B)

max. 300 m

Fig. 2: Overview of electrical connection with the transmitter in the DIN Rail version

3
2. Function
•• Use in free fall after screening or grinding.

•• The sensor uses the latest microwave technology. It is only used in metallic pipelines.

•• The microwave radiation in the pipeline is reflected by the solid particles and received by the sensor.
The frequency of the received signals is analysed.

•• Due to the arrangement of two baffle plates in the drop, sedimentation causes differences in fall speed.

•• The frequency-selected evaluation system ensures that only moving particles are measured and
deposits are ignored.

•• The frequency spectrum of the backscattered microwave signal contains information about the speed
of the particles.

v2
v2 > v1

v1

Fig. 3: Integration and reflection of microwaves

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3. Safety
The Paddy measuring system has been designed, built and tested using state-of-the-art, reliable technology, and
was found to be in a perfectly safe condition when it left the factory. Nevertheless, the system components may
present dangers to personnel and items if they are not operated correctly.
Therefore, the operating manual must be read in full and the safety instructions followed to the letter.
If the device is not used correctly for its intended purpose the manufacturer's liability and warranty will be void.

3.1 Normal use

•• The measuring system may only be installed in metallic pipes to measure the particle passing through
them.
It is not suitable for any other use or measuring system modifications.
•• Only genuine spare parts and accessories from envea™ - SWR engineering may be used.

3.2 Identification of dangers

•• Possible dangers when using the measuring system are highlighted in the operating manual with the
following symbols:

Warning.
•• This symbol is used in the operating manual to denote actions which, if not performed correctly may
result in death or injury.

Important.
•• This symbol is used in the operating manual to denote actions which may result in danger to property.

3.3 Safety at work and operational safety

•• The measuring system may only be installed by trained, authorised personnel.
•• During all maintenance, cleaning and inspection work on the pipelines or Paddy components, make
sure that the system is in an unpressurised state.
•• Switch off the power supply before performing any maintenance work, cleaning work or inspections on
the pipelines or the Paddy's components. See the instructions in the section entitled Maintenance and
care.
•• The sensor must be taken out of the pipeline before any welding work is performed.
•• The components and electrical connections must be inspected for damage at regular intervals.
If any signs of damage are found, they must be rectified before the devices are used again.

3.4 Technical progress

•• The manufacturer reserves the right to adjust technical data concerning technical developments without
notice. envea™ - SWR engineering will be delighted to provide information about the current version of
the operating manual and any relevant amendments.

5
4. Mounting and installation
4.1 Typical components of the measurement point:
•• 1 x microwave particle sensor (reference sensor)
•• 1 x microwave particle sensor (measuring sensor)
•• 1 x C3-Box
•• 1 x transmitter in the DIN Rail housing or field housing
•• 2 x sensor mount for welding to the pipeline
•• 1 x installation instructions

4.2 Required equipment

•• Ø 20 mm twist drill bit
•• 32 mm open-ended spanner for union nut
•• Locking ring pliers (Ø 20 mm) to adjust the sensor to the wall thickness

4.3 Sensor installation

Proceed as follows to install the sensor:
•• Decide on the installation position on the pipe.
•• Ensure that the measurement point is at an adequate distance from valves, manifolds, blowers and
rotary valve or other measurement ports such as those used for pressure and temperature sensors, etc.
•• The minimum distance of 100 mm between the weld-on sockets must be adhered to.
•• The baffle plates must be installed in accordance with the instructions issued by envea™ -
SWR engineering, so that the material flow is made uniform.

•• The measuring and reference sensor must be

installed in such a way that the material flow is
detected from the rear.
•• It is imperative that there are no mechanical
or electrical interference sources below the
measuring point.
•• Weld the sensor mount to the pipe.
•• Drill through the pipe through the sensor plug
(Ø 20 mm).
Ensure that the borehole is not angled so that the
sensor can be installed precisely at a later stage.

Fig. 4: Assembly overview

6
 Attention!
•• After drilling, it is essential to check whether the drill bit has caused any burrs on the borehole edges.
Any burrs on the pipe must be removed using a suitable tool. If the burrs are not removed they may
affect the sensor's calibration.
•• If the sensor is not installed immediately insert a plug until it is installed (see also Fig. 5). The plug must
be inserted together with the seal, two sealing rings and the locking ring, and secured using the union
nut.
Use a 32 mm open-ended spanner to tighten the union nut.

Spacer ring 1 mm
Locking ring

Spacer ring 1 mm

O-ring seal 20 x 3

Plug

Sensor mount

Union nut

Fig. 5: Installing the sealing plug in the sensor holder

•• Remove the sealing plug to insert the sensor.

•• The union nut, spacer rings, seal and the locking ring for the sealing plug are required for installation of
the sensor. The locking ring must be set so that the sensor is flush with the inner wall. If necessary, the
wall thickness must be remeasured using a depth gauge. The weld-on socket is 93 mm long.
It is important that the sensor does not project into the pipe. The sensor may be up to 1 mm inside the
pipe wall without this causing a measurement error.

Wall thickness (mm) Position on the sensor neck Number of spacer rings
3.0 1 2
4.0 1 1
5.5 2 2
6.5 2 1
8.0 3 2
9.0 3 1
10.5 4 2
11.5 4 1
13.0 5 2
14.0 5 1

7
 •• Now insert the sensor into the sensor hold as shown in the figure ...

Sensor

Union nut
Überwurfmutter

Spacer ring 11mm

Distanzring mm

Locking ring
Sicherungsring

Spacer ring 11mm

Distanzring mm

O-ring
O-Ringseal
20 x20
3 x3

Sensor mount
Sensoraufnahme

Fig. 6: Installing the sensor in the sensor holder

•• ... and align it lengthwise to the pipe axis in accordance with the polarisation sticker (fig. 7).
Then screw the measuring point tight with the union nut.

Fig. 7: Installing the sensor in the pipe

8
4.4 Mounting the transmitter
The transmitter can be installed at a maximum distance of 300 m from the sensor.
A cable of the type "Ölflex Classic 110 CY" is recommended. The cable should be four-core, twisted in pairs
and shielded. A minimum cross section of 0.75 mm² should be maintained. For distances longer than 150 m,
the cross-section should be increased.

23 118

1 2 3 4

5 6 7 8

PWR
RUN
35
90

USB

9 10 11 12

13 14 15 16

Fig. 8: Dimensions of the transmitter in the DIN Rail housing

Fig. 9: Dimensions of the transmitter in the field housing (front view)

9
Fig. 10: Dimensions of the transmitter in the field housing (side view)

175 mm

57 mm
23,5 mm
35 mm 35 mm 35 mm

163 mm

5 mm
80 mm
52 mm

m
5m

max. max. max. max.

10 mm 10 mm 10 mm 10 mm

Fig. 11: C3-Box dimensions

Fig. 12: Sensor dimensions

10
4.5 Use in hazardous areas
Hazardous area identification: II 1/2D Ex tD IP 65 T84 °C
Zone 20: 0 °C <
_ Tprocess <
_ 80 °C
Zone 21: -1 °C < _ Tamb < 60 °C

- Equipment group 2
- Equipment category: 1/2
Waveguide window zone 20 / housing zone 21
- For explosive mixtures of air and combustible dust
- IP code 65
- Maximum surface temperature 84 °C at Ta = 60 °C

Gas explosion zone identification: II 1/2D Ex tD A20/21 IP 65 T84 °C

II 2G Ex d IIC T5/T3

- Equipment group 2
- Equipment category: 2
- Zone 1
- For explosive mixtures of air and combustible gases
- IP code 65
- Permitted process temperature 0 to 150 °C
- Temperature class T3
- Maximum surface temperature 84 °C at Ta = 60 °C

Ex hazard array No Ex hazard array

DustEx zone 20 Zone 21/22
GasEx zone 1 Zone 1/2

Sensoren

C3-Ex-Box

Fig. 13: Use of sensors in an ATEX zone

11
5. Electrical connection
5.1 DIN Rail terminal layout

1 Current output 2 Current output 3 Input 4 Input

- 4 ... 20 mA + 4 ... 20 mA Power supply Power supply
0 V DC + 24 V DC

5 Not used 6 Alarm relay 7 Alarm relay 8 Alarm relay

NC (break contact) C NO (make contact)

1 2 3 4

5 6 7 8

PWR
RUN

USB

9 10 11 12

13 14 15 16

Fig. 14: Electrical connection for the DIN Rail transmitter

9 Digital 10 Digital 11 RS 485- 12 RS 485-

pulse output (-) pulse output (+) Interface Interface
Data B Data A

13 Sensor connection 14 Sensor connection 15 Sensor connection 16 Sensor connection

Cable 4 Cable 3 Cable 2 Cable 1
RS 485 RS 485 Power supply Power suply
Data B Data A 0V + 24 V

12
5.2 Field housing terminal layout

L N PE + - + - + - + - NO C NC + - A B GND + - + - + - A B Shield
I-in 1 I-out 1 I-out 2 I-out 3 Alarm Relay D-out RS 485 D-in 1 D-in 2 Sensor

Fig. 15: Electrical connection for transmitter in the field housing

Transmitter
Terminal no. Connection
Power supply connection
L / +24 V Input power supply 230 V / 50 Hz, 110 V / 60 Hz (optional 24 V DC)
N/0V Input power supply 230 V / 50 Hz, 110 V / 60 Hz (optional 24 V DC)
PE Earth
Connections
+ Current input +
I-in1
- Current input –
+ Current output +
I-out1
- Current output –
Na Not used
Na Not used
Na Not used
Na Not used
Min. / NO Floating change-over contact NO (make contact)
Max. C Floating change-over contact C (common conductor)
relay NC Floating change-over contact NC (break contact)
+ Digital pulse output +
D-out
- Digital pulse output –
A RS 485 interface data A
RS 485 B RS 485 interface data B
GND RS 485 interface ground
+ Digital interface 1 (+)
D-in1
- Digital interface 1 (–)
+ Digital interface 2 (+)
D-in2
- Digital interface 2 (–)
+ Power supply + 24 V Cable no. 1
GND Power supply 0 V Cable no. 2
Sensor A RS 485 data A Cable no. 3
B RS 485 data B Cable no. 4
Shield Shield

13
5.3 C3-Box terminal layout

Transmitter Sensor 1 Sensor 2 Sensor 3

Fig. 16: Electrical connection for the C3-Box

14
6. Operator interface
The transmitter is a multi-sensor transmitter. It is therefore strongly recommended to check whether the correct
sensor is selected in the System menu item before commissioning.
The operator interface differs depending on the system design:
•• DIN Rail housing without display, operation via PC software
•• Field housing with display, alternative operation via PC software
•• Two-sensor system
First of all, the different system versions are described below. In the following, the basic operation of the Paddy
measurement system is described without repeating details about the differences between the various versions.

6.1 Differences between the DIN Rail and field housing analysis units
The transmitter in the DIN Rail housing is only a part of the functions available in the field housing.
The following overview clarifies the differences between the two versions.

Function Field housing DIN Rail

Menu system

•• via PC software yes yes

•• via display yes no
Measurement value display current output yes yes
Pulse output to control solenoid valves yes yes
or output the measured value
Alarm system relay output yes yes
Remote control digital input yes no
Autocorrect analogue input yes no
Error output
•• on current output yes yes
•• at relay yes yes
•• via PC software yes yes
•• via display yes no
•• At status LED no yes

The transmitter in the DIN Rail housing can only be configured via a USB connection and PC software
program. On the transmitter in the field housing, all functions can be configured by menu via the touch-
sensitive display.
The field housing transmitter can also be configured by PC.
The menu items on the display and in the PC software are numbered in a uniform manner so that
they can be referred to later on.

15
6.2 Display
If just the display is used, all the main functions can be controlled via the display. The display is touch-
sensitive and available keys are displayed directly in context.
The start page display the following values:
Paddy I •• Name “Paddy”, freely selectable text which describes
the material or the measuring point

41.23 % ÜK •• Measured value, here in % oversize [ % ÜK ]

•• [ I ] key for info

To access the main menu, press and hold any area of the
Main menu 6.xx # display for several seconds. The sub-menu selection appears:
1. Measurement range
2. Calibration
$ In the menus and input fields, the displayed keys can be
used to browse, select, edit or reject:
3. Alarm E •• [ Arrow ]: Scroll down the page, Select an option,
4. Analogue output Select a position in the input text
€ 8 •• [ E ] for ESC: Interrupt the function without making any
changes
•• [ 8 ]: Select the function or confirm the input
•• [ C ] for Clear: Delete a symbol or number.

The [ I ] key can be used to call up an information window,

Sensor status in which the raw value, temperature and status of the
Temp Raw value Stat sensors can be checked.
S1 63.0 0.000123 OK
S2 63.0 0.000213 OK

If any data has been changed, the change will only be taken
into account when you exit the complete menu structure and
Save changes? answer [ Yes ] when asked if you wish to save the changes.
For reasons of simplicity, a further display menu screen
has been dispensed with.
Y N The display screens are directly derived from the menu
structure in section 6.4.

Protection against unauthorised use:

If a password has been entered in menu 7. System in
7.6 Password, which is different to the “0000” default
setting, you will be asked to enter a password when
attempting to access the menus. After the password has
been successfully entered, the menus will be unlocked for
approx. 5 minutes (from the last menu entry).

16
6.3 PC interface
With both the DIN Rail and field housing version, communication with a laptop or PC is optionally performed
either at the terminals via an RS 485 or at the front via a USB interface.
✔ The RS 485 connection is attached to the transmitter in the field housing at the ModBus A (+)
and ModBus B (-) terminals. On the DIN Rail version, these connections are no. 12 and 11, accordingly.
RS 485 is a bus connection; the ModBus address and the baud rate can be set on the device.
Upon delivery, the communication parameters are set to:
•• ModBus address 1
•• Baud rate 9600, 8, E,1
An RS 485 to USB adapter can be purchased from envea™ SWR engineering.
✔ A standard USB-A-B cable is supplied for the USB connection to the DIN Rail version.
The USB connection is a point-to-point connection that is BUS-enabled. The ModBus address
and baud rate for the front connections cannot be changed and are always:
•• ModBus address 1 (or the device answers to all addresses)
•• Baud rate 9600, 8, E,1
When connected to the PC for the first time, any interface drivers enclosed with the transmitter must be
installed.
After starting the software, the communication parameters must first be entered accordingly.
These can be found in the top left of the program window. The COM port to be configured is displayed
in the device manager.

Communication is established by clicking on “read device”. The acknowledgement message “Parameter read
in” is displayed. If an error message is displayed instead, check the communication parameters and cable
connections between the PC and the transmitter.

17
The edited data is transmitted to the transmitter via “Program device”.
Critical data concerning the ModBus communication and the calibration must be confirmed before the
parameters are transmitted to the transmitter:
✔ If, when saving the parameters in the transmitter, the system calibration data is changed, this action
must be confirmed by checking “Overwrite calibration”.
✔ If, when saving the parameters in the transmitter, the system interface parameter are changed, this
must be confirmed by checking the selection “Overwrite baud r./address”.
In addition, with the PC software,
•• the parameters of the transmitter can be saved in a file (Save configuration)
•• the parameters of the transmitter can be loaded from a file (Load configuration)
•• the parameters of the transmitter can be printed via the set Windows standard printer (Print
configuration)
•• the measured values can be logged in a data logger file (enter the file name and storage rate, and
activate the data logger on the online display)
The software language can be set by right-clicking the “Sprache/Language/Langue” field in the bottom
program line on “German/English/French”.

Protection against unauthorised use:

The PC interface does not have a password prompt as it is assumed that only authorised personnel will have
access to the PC and the software. The password to operate the display can be read and changed in menu
7. System under 7.6 Password.

18
6.4 Menu structure
The menu structure supports the user when adjusting the measuring range, the calibration, the measurement
values and the choice of additional functions. In this connection, the numbering both on the display and in
the PC interface is identical:

1. Measurement range
Setting all relevant measuring range settings.
1.1 Tag No. Input: Free text (10 characters) Name of the measurement point or product.
1.2 Unit Input: Unit text, e. g. % ÜK Desired display unit.
1.3 Decimal point Selection: Number representation and decimal point
0000, 0.000, 00.00, 000.0 accuracy in the measurement menu.
1.4 Set point low Input: 0 … 9999 Throughput rates under this value will not be
displayed at the current output.
The display is not affected.
1.5 Set point high Input: 0 … 9999 Throughput rates above this value will not be
displayed at the current output.
The display is not affected.
1.6 Filter s Input: 0.0 … 999.9 Filtering of measurement for the indicator
and the output values.

19
2. Calibration
Store the calibration curve.

2.1 Calibration factor Input: 0.01 … 9.99 Factor for the subsequent adjustment of
the actual measurement. All measurements
are measured with this factor.

2.2 Calibration filter s Input: 1 … 9999 Filter time for recording the raw value
during calibration. The raw values already
measured over the set time period are
combined into an average value.
2.3 Calibration points Input: 2 … 5 Number of support points for
a linearisation above the operating range.

2.4 Calibration Calibration submenu

2.4.1 1. Calibration point Input: Output measurement value in the selected

measurement value to be shown mass /
time unit.

(2.4.2) P1 calibration Transfer: Raw value Transfer the current raw value (filtered) from
the mass flow with the key [ ← ].
The value can also be entered manually.
. . . (depending on the number of support points) For additional support points (depending on
[ 2.3 ]), additional value pairs can be set.
2.4.n Pn value Input: Measurement to be displayed
2.4.n Pn calibration Transfer: Current raw value

20
3. Alarm
Setting for the alarm via the relay contacts.

3.1 Alarm type Selection: The relay is activated when the measured
Min / Max / None value exceeds the max. limit or undershoots
the min. limit.

3.2 Alarm value Input: 0 … 999.9 Limit value for monitoring Min. or Max.

3.3 Delay Input: 0.1 … 99.9 s The value must permanently exceed or fall
below the set limit during this time.

3.4 Hysteresis Input: 0.1 … 99.9 % The alarm continues for as long as the
measurement is not smaller or larger than
the limit value plus or minus hysteresis.

3.5 Operation mode Selection: NC: the relay is closed, current principle as
NC / NO no alarm is active.
NO: the relay is closed, if there is an alarm.

3.6 Sensor alarm Selection: Off: Sensor or process indicators are

OFF /ERR / PROC not displayed at the relay.
ERR: Serious internal sensor errors trigger
an alarm at the relay.
PROC: Serious internal sensor errors and
process indicators trigger an alarm at the
relay. Further information on the signalling
levels ERR or PROC can in section entitled
Troubleshooting.

21
4. Analog output
Setting and calibrating the analogue output.
4.1 Lower limit Input: 0 … 22 mA Standard setting: 4 mA
4.2 Upper limit Input: 0 … 22 mA Standard setting: 20 mA
4.3 Alarm value Input: 0 … 22 mA Value to be output at pending alarm
(Standard setting 2 mA)
4.4 Alarm mode Selection: Alarm: Alarm is output
Hold alarm / output measurement value drops to 0, or current
measurement value.
Hold output: Last measurement value
remains pending until fault rectification at
the output signal.
4.5 Analog output 1 Submenu

4.5.1 Calibration 4 mA Selection: Key functions can be used to set the current
Setting the output current and equalise it to the receiver side
4.5.2 Calibration 20 mA Selection: Key functions can be used to set the current
Setting the output current and equalise it to the receiver side
4.6 Analog output 2 Submenu

4.6.1 Calibration 4 mA Selection: Key functions can be used to set the current
Setting the output current and equalise it to the receiver side
4.6.2 Calibration 20 mA Selection: Key functions can be used to set the current
Setting the output current and equalise it to the receiver side

22
4.7 Analogue output 3 Submenu

4.7.1 Calibration 4 mA Selection: Key functions can be used to set the current
Setting the output current and equalise it to the receiver side
4.7.2 Calibration 20 mA Selection: Key functions can be used to set the current
Setting the output current and equalise it to the receiver side

The current output can be calibrated so that the zero point (output of 4 mA) is set to the background
noise of the measuring point. If the background noise decreases due to process changes, sensor wear or
other ageing effects, a signal of less than 4 mA can be output at the analogue output. In this way, a zero
offset can be detected (zero point drift).
If this function is not desired for process engineering reasons, the zero point must be specified for the
calibration to a raw value of zero and/or the 4.1 MIN limit set to 4 mA.
If the settings of the 4 mA or 20 mA signal are changed, the checkbox Overwrite calibration must be set.
If the checkbox is set the changed parameters can be sent to the transmitter by clicking on Program device.

23
5. Pulse output
Passive signal for pulse cleaning.
5.1 Function Selection: OFF / Cleaning
OFF: No pulse output
Cleaning: Option for actuation of a solenoid
value for pneumatic air flushing.

5.2 Pulse period Input: 1 s … 600 s Duration between two pulses

5.3 Pulse length Input: 1 s … 60 s Length of the pulse

24
6. Current input
Option for auto-correction by external current signal.
The signal is not electrically isolated.
If the connection is incorrect, the CPU of the transmitter may be destroyed.
An external, galvanic isolation by means of a current disconnector or similar must be provided.

6.1 Input calib. 4 mA Selection:

Set input current The 4 mA signal must be read in via key
functions.

6.2 Input calib. 20 mA Selection:

Set input current The 20 mA signal must be read in via key
functions.

6.3 Correction Selection: ON / OFF

ON: Activation of the correction.
OFF: Deactivation of the correction.

6.4 P1 input Input: 4 mA … 20 mA Input the current that

is to be used for the correction.

6.5 P1 factor Input: 0.01 … 10 Factor for subsequent adjustment of the

actual measurement value.

6.n Pn input Input: 4 mA … 20 mA Option for further entry of current value and
correction factors.

6.n Pn factor Input: 0.01 … 10

25
7. System
Basic settings of the system and the transmitter.
7.1 Language Selection: D / E / F Selection of the language on the display
of the transmitter
7.2 Sensors Submenu
7.2.1 Sensor 1 Selection: ON Sensor 1 cannot be switched off, since at least
one sensor is required for a measurement.
7.2.2 Sensor 2 Selection: ON / OFF ON: Sensor is evaluated
OFF: Sensor is ignored
7.2.3 Sensor Selection:
SolidFlow 2.0 / PicoFlow /
ProSens / SpeedFlow
Paddy / MaxxFlow HTC The transmitter checks whether the
connected sensor corresponds to the set
sensor.
The measurement values are calculated and
potential errors are displayed based on the
set sensor.
Incorrect sensor selection leads to communi-
cation denial.
7.3 Display Submenu
7.3.1 Sensor info Selection: ON /OFF ON: The key for querying sensor information
is shown on the display.
OFF: The key for querying sensor information
is hidden on the display.

26
7.3.2 Process indicator Selection: ON /OFF ON: Process indicators are shown on the
display and indicated on the DIN Rail by
flashing twice.
OFF: Process indicators are not output.

7.3.3 Backlight Input: 0 min … 99 min Display lighting in minutes

0 = Permanent lighting
99 = Time selection for lighting

7.3.4 Contrast Input: 0 … 100 % In the event of an inadequate display, the

contrast can be changed via the PC software,
if necessary.

7.4 Address Input: 1 … 255 ModBus address of transmitter, if this is

operated on a PLC or PC as a ModBus slave
(RS 485 connection).

7.5 Baud rate Selection:

4800 / 9600 / 19200 / 38400 Communication speed of the transmitter if
operated on a PLC or PC as a ModBus slave.

7.6 Password Input: 0 … 9999 0 = No password protection

XXXX = Four digit password that is queried
when calling up the menu on the display.
Automatic locking for five minutes after the
last display input.

27
 8. Service
Display of the sensor status
In menu 8. Service the status of each connected sensor is displayed. FW type, FW version,
temperature, serial number and possible hardware errors are automatically read in and displayed.
In the case of a change of display, the PC software can be used to adjust the contrast, if necessary.
Only after instruction by trained personnel from envea™ SWR engineering:
If a detailed error analysis is necessary, you can use the PC software by clicking on Sensor Dump
to save a copy of all ModBus registers as a text file in the installation folder of the software. This is
possible only with the PC software. In addition, a service program with deeper access to the sensors
can be launched via the PC software.
Only the information on the status of the individual sensors is output on the field housing display.

7. Start-up procedure
7.1 Basic start-up
Upon delivery, the sensor is not calibrated to the product to be measured and must be parametrised when
started up. During the process, the raw values measured by the sensor are assigned the display values and
output quantities required by the user.
The following points must be checked before commissioning:
•• Correct installation of the baffle plates in the transport pipeline as per the information provided by
envea ™ SWR engineering.
•• The correct flush-mounting of the sensor on the internal wall of the transport pipe.
•• The correct electrical connection between the sensor, C3-Box and transmitter.

28
At the beginning of the calibration, it is necessary to check whether the correct sensor is selected via the
System menu item.
If the correct sensor has been selected, the desired measuring range and the physical unit are entered in
1. Measurement range.
The 1.2 Unit is a free text unit, for which 10 characters are available. For the Paddy, we recommend using
the unit: % ÜK (% oversize), since the measuring point is calibrated to a defined oversize allowance.
The system is then calibrated via at least two calibration points in 2. Calibration.
For the calibration it is absolutely necessary to add coarse material to the fine flow. It is recommended to use
the first calibration point for the good condition and the additional calibration points for the addition of coarse
material.
Good condition When the process is running and the material flow is stable, the first calibration
point is read in. To do this, in 2.4.1 - 1. Calibration point a value of "0" is
entered and then assigned to the corresponding raw value (2.4.2 Raw value).
The raw value is entered either by direct read-in or is manually determined via
the data logger function in the PC software.
Calibration point 1 When the process is running, a mass of coarse material of at least 10 % is added
as evenly as possible to the "clean" material flow. Subsequently, in 2.4.n -
2. Calibration point, the added percentage of oversize material is entered
and assigned to the associated raw value. The raw value is entered either by
direct read-in or is manually determined via the data logger function in the
PC software.
Once the calibration points have been saved, the transfer of the calibration parameters must be confirmed.
On the transmitter in the field housing, this is done by a security query when exiting the menu structure.
In the software, a tick must be set next to Overwrite calibration.
If the tick is set, the parameters can be sent to the transmitter by clicking on Program device.
The configuration of the device's basic functions is thus complete and an alarm can be set and
output.
Additional calibration If it is possible to calibrate for different levels of coarse material up to 5 support
points points can be selected in 2.3 Number of calibration points. Each additional
support point is calibrated in the same way as for Calibration point 1.

7.2 Data logger function in the software

To determine the raw values via the data logger function in the PC software, a file path must first be stored.
The file path and file name can be selected after clicking on the folder icon (next to file name). Once the
file path has been stored, it is still possible to change the storage rate. This is recommended for long-term
logging. To determine the raw values for a calibration point, the default setting of 1 (raw value) per second is
recommended.
To start the data logger, the on-line display must be opened. As soon as the tick is set by Data logger
activated in the on-line display, the recording starts and the log file is created in the background.
To evaluate the recorded log file, it must be opened with Excel or a similar program.
The columns in the log file contain the following data sets:
Column A Date
Column B Time
Column C Measurement value
Column D Raw value
In order to determine the appropriate raw value for a calibration point, the mean value must be determined
from the time period of the coarse material addition, or from the stable "clean" material flow. The mean value
can be calculated by Excel using the function =AVERAGE( ). The calculated mean value of the raw value is
then entered in the box next to Raw value in the configuration software.

29
7.3 Adjusting the measurement values
The system's additional functions can be set in the following menus:
Alarms Throughput upper/lower limit values can be set in 3. Alarm. A sensor monitoring

alarm can also be activated here.
Analogue output The analogue output values are assigned in 4. Analogue output.
The required measuring range is assigned a corresponding output value here
(4 . . . 20 mA). Upper and lower limits of the permitted power and power in the
event of failure are set here. Power output can also be calibrated here.
Pulse output In 5. Pulse output there is an option to use a cleaning pulse. This impulse may
be for pneumatic cleaning of the sensor (if available).
Current input In 6. Current input different input currents can be stored.
When the current is applied, the corresponding correction factor is applied to the
measured value. The input current can also be equalised here.
System In 7. System functions such as selection of the menu language, the number of
connected sensors and their average, the display screen or ModBus addressing

and speed are summarised.

30
8. Error signalling
To monitor availability, comprehensive system diagnostic functions have been integrated to signal various
errors:
1. Serious errors (ERR):
Serious errors (ERR) always set the current output to the configured alarm value. Technical problems
affecting the sensor or the entire system that require replacement or repair of a component are
displayed:
•• Failure of the communication to a sensor (sensor failure)
•• Failure of a subcomponent of a sensor (temperature monitoring, heater control, memory, data
consistency, etc. on the sensor)
•• Inconsistent signal paths in the sensor (amplifier stages, DC offsets)
2. Process indicators (PROC):
Process indicators (PROC) merely report a violation of set parameters and should be viewed as
information to improve the measurement process.
Process indicators are not output at the current output, however they can be shown on the display (field
housing) or the RUN LED (DIN Rail) and optionally on the relay:
•• Temperature instability in the sensor due to external thermal stress (overtemperature, low
temperature)
•• Overload of the sensor due to material flow (too much, too little)
Process indicators may also only show temporary abnormalities in the process, which can be prevented by
optimising the sensor or delivery parameters.
Process indicators are not sensor errors, but rather provide information about optimisation potential at the
measuring point.

Display Display Run LED Relay Current output

(field housing) (DIN Rail) (optional)
No error Sensor status OK in Single flashing every Normal status 4 ... 20 mA
the information second
display ([I] key)
PROC Display with indi- Double flashing Enabled if relay 4 ... 20 mA
Process cator code in the every second alarm option PROC
indicators bottom display line, is selected
extended informa-
tion via [I] key
ERR Display with error Triple flashing every Enabled if relay 2 mA (or alarm value
Hardware code in the bottom second alarm option PROC set for the current
error display line, extend- or ERR is selected output)
ed information via
[I] key

Error codes: Error and indicator codes are composed of the letter E (ERR = error) or P (PROC = process
indicator) and a three-digit hexadecimal value from “000” to “FFF”. The cause can be determined via the
displayed code.
Error timeout: In order not to complicate the start-up of a processing plant due to process and heating
status errors, non-serious errors are only signalled at the outputs after approx. 5 minutes have elapsed
following a reset of the measuring system. The timeout delay is indicated by a small "t" in the upper-left
corner of the display (field housing only).

31
8.1 Compatibility
For the Paddy system, the software version 6.xx or higher is available for the transmitter and the associated
PC software.
Technical innovations may include the addition of new functions, so that only corresponding
variants of the transmitter and PC software can be operated together.

9. Maintenance
Warning!
•• Switch the power supply off before performing any maintenance or repair work on the measuring
system.
The transport pipe must not be operational when replacing the sensor.
•• Repair and maintenance work may only be carried out by electricians.
•• The system requires no maintenance.

10. Warranty
On condition that the operating conditions are maintained and no intervention has been made on the device and
the components of the system are not damaged or worn, the manufacturer provides a warranty of 1 year from the
date of delivery.

In the event of a defect during the warranty period, envea™ SWR engineering will replace or repair defective
components at its factory free of charge at its discretion. Replaced parts will become the property of envea™
SWR engineering. If the customer requests that parts be repaired or replaced at its site, the customer must pay
the travel expenses for envea™ SWR engineering service personnel.

envea™ SWR engineering cannot accept any liability for damage not caused to the goods themselves, and in
particular envea™ SWR engineering cannot accept liability for loss of profit or other financial damages suffered by
the customer.

32
11. Fault clearance
•• Warning!
The electrical installation may only be inspected by trained personnel.

Error Cause Action

Measuring system does Power supply interrupted. Check the power supply.
not work.
POW LED does not light Cable break. Check the connection cables for a possible cable break.
up. Defective fuse. Replace fuse.
RUN LED does not light Defective device. Notify envea™ SWR engineering and rectify the error as
up. instructed on the telephone.
Measuring system does Microprocessor does not Switch the power supply off and on again.
not work. start. Remove programming cable.
POW LED does not light
up.
RUN LED does not light
up.
Measuring system No sensor communication. Sensor defective.
works. Cable break between sensor and measuring system.
POW LED does not light Sensor connected incorrectly. Check connection cable.
up.
Sensor defective. Replace sensor.
RUN LED flashes twice
Sensor not receiving 24 V Make sure the power supply is connected.
or three times per cycle.
supply.
Excessive voltage drop in the Check cable lengths.
supply cable to the sensor.
Error code available on the Additional error diagnosis by error code.
display.
Measuring system Calibration incorrect. Perform a recalibration.
outputs incorrect values. Calibration shifted by Perform a recalibration.
abrasion on the sensor head.
Switch output relay Hysteresis too low. Increase hysteresis. Check for fault caused by external consumer.
chatters.
The warranty will be rendered void if you open the device.

33
11.1 Error codes

Type Error Flashing Current Cause Action

code RUN LED output
ERR DISC 3 2 mA Sensor not detected or Check supply, communication lines,
wrong sensor detected shielding and software settings

ERR ID 3 2 mA Sensor responds with Check whether selected sensor type

wrong ID matches with connected sensor
ERR E002 3 2 mA Internal data bus defec- Switch off power supply for at least 10 s,
tive if not helpful: replace
ERR E020 3 2 mA Internal data memory Switch off power supply for at least 10 s,
defective if not helpful: replace
ERR E040 3 2 mA Internal temperature Switch off power supply for at least 10 s,
measurement defective if not helpful: replace
ERR E080 3 2 mA Internal parameter mem- Switch off power supply for at least 10 s,
ory defective if not helpful: replace
ERR E100 3 2 mA Parameter table not Switch off power supply for at least 10 s,
readable if not helpful: replace
ERR E200 3 2 mA Parameter table not Switch off power supply for at least 10
described s, reprogram parameters, if not helpful:
replace
ERR E400 3 2 mA Reset request not exe- Switch off power supply for at least 10 s,
cutable if not helpful: replace
ERR E001 3 2 mA Internal amplifier defec- Switch off power supply for at least 10 s,
tive (DC offset) if not helpful: replace
ERR E200 3 2 mA Internal amplifier defec- Switch off power supply for at least 10 s,
tive (channels) if not helpful: replace
ERR UT-K 3 2 mA Critical low temperature, Check heater, observe heating time,
measurement value out- insulate cooling sources
put not possible
ERR OT-K 3 2 mA Critical overtemperature, Insulate heat sources in the vicinity
measurement value out-
put not possible
PROC UT 2 4 … 20 mA Low temperature, warn- Check heater, observe heating time,
ing: unreliable measure- insulate cooling sources
ment value
PROC OT 2 4 … 20 mA Overtemperature, warn- Insulate heat sources in the vicinity
ing: unreliable measure-
ment value
PROC P010 2 4 … 20 mA Low measurement signal Adjust limit value, increase test flow of
material
PROC P040 2 4 … 20 mA Measurement signal too Adjust limit value, decrease test flow of
high material
PROC P000 2 4 … 20 mA Measuring signal indi- Check installation situation and material
cates flow
Quality 0

A detailed error analysis and subsequent troubleshooting can be carried out by trained envea™ SWR
engineering personnel.

34
12. Connection examples

R = (Ub - 0.7 V)/l

Fig. 17: Pulse output

35
13. Technical data
Sensor
Housing material Stainless steel 1.4571
Protection category IP 65, dust explosion zone 20 or gas explosion zone 1 (optional)
Ambient operating temperature Sensor tip: -20 ... + 80°C Optional: -20 ... + 200°C
Sensor element: 0 ... + 60 °C
Max. operating pressure 1 bar, optional 10 bar
Operating frequency K-Band 24.125 GHz, ± 100 MHz
Transmission power Max. 5 mW
Weight 1.3 kg
Dimensions Ø 60, Ø 20, L 271 mm
Measuring accuracy ± 2 ... ± 5% (in the calibrated measuring range)
Field housing transmitter
Power supply 110/230 V, 50 Hz (optional 24 V DC)
Power consumption 20 W / 24 VA
Protection category IP 65 to EN 60 529/10.91
Ambient operating temperature -10 ... +45°C
Dimensions 258 x 237 x 174 (W x H x D)
Weight Approx. 2.5 kg
Interface RS 485 (ModBus RTU) / USB
Cable screw connectors 3 x M16 (4.5 – 10 mm Ø)
Connection terminals cable cross-section 0.2 – 2.5 mm² [AWG 24-14]
Current output 4 ... 20 mA (0 ... 20 mA, load < 500 W
Switch output measurement alarm Relay with switchover contact max. 250 V AC, 1 A
Data backup Flash memory
Pulse output Open collector – max. 30 V, 20 mA
DIN Rail transmitter
Power supply 24 V DC ± 10 %
Power consumption 20 W / 24 VA
Protection category IP 40 to EN 60 529
Ambient operating temperature -10 ... +45°C
Dimensions 23 x 90 x 118 (W x H x D)
Weight Approx. 172 g
Interface RS 485 (ModBus RTU) / USB
DIN Rail fastening DIN 60715 TH35
Connection terminals cable cross-section 0.2 – 2.5 mm² [AWG 24-14]
Current output 4 ... 20 mA (0 ... 20 mA, load < 500 W
Switch output measurement alarm Relay with switchover contact max. 250 V AC, 1 A
Data backup Flash memory

SWR engineering Messtechnik GmbH

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EN 27/06/2018 36