MoistScan Op Manual CL - V103. Rev. 1.2

Scan® Se
MoistS eries III On-Lin

ne Moistture An alysers
s
Op
perattion Man
M ual
for
Conveyor M
Mounted
d Analy
ysers
For So
oftware CL
L_V103
on 1.2, Sept’ 2015
Versio
MA
A-500, MA-50
00 HD, MA-6
600, MA-600 HD,
Contaact Details
Real Time
T Instrumments Pty Ltd
d Phone +61 7 49 5555 966
PO Boox 9117 Fax +61 7 49 6577 099
Slade Point QLD 44740 support@
@realtimegrpp.com
Austra
alia wwww.realtimegrp
p.com
MOISTSCAN SER
RIES III OPE ANUAL (CL_
ERATION MA _V103) – Verrsion 1.2 (Sep
pt’ 2015) Pa
age 1
ment №:
Docum M
MS.OpMan-500HD.S3-CLL_V103.0 Reev. 1.2
MOISTSCAN SER
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Table
e of Con
ntents
1 INTRODUC
I CTION / General
G Infformation 5
1
1.1 Moissture Measurrement 5
1
1.2 Microwave Meassurement Tec
chnique 5
1
1.3 Heallth and Safetty 5
2 SYSTEM
S D
DESCRIPT
TION 6
2
2.1 Com
mponent Iden ntification & Location
L 6
2
2.2 Ante
enna Assemb bly 6
2
2.3 Conttrol Cabinet 6
3 INSTALLA
I ATION 8
3
3.1 Loca ation 8
3
3.2 Environment 9
3
3.3 Stora age, Preservvation, & Han
ndling of Insttrument 9
3
3.4 Liftin
ng of the Ana alysers 9
3
3.5 Instaallation Sequ uence 10
3
3.6 Speccialised Tool & Labour fo or Installation
n 10
3
3.7 Mechanical Insta allation 11
3
3.8 Elecctrical Installa
ation 12
3
3.9 Systtem Healthy Relay 12
3
3.10 Com mmunicationss 12
3
3.11 Modem 13
3
3.12 Calibbration Switcching 13
4 INSTALLA
I ATION DIA
AGRAMS & Pre-Com
mmissioning 14
4
4.1 Mechanical Insta allation Diagrram 14
4
4.2 Elecctrical Installa
ation Diagramm 14
4
4.3 Pre-Commission ning Instructio
ons & Checkklist 14
5 COMMISS
C SIONING AND
A CALIB
BRATION 15
References
R Material 15
5
5.1 Pow
wer-Up Checkks 15
5
5.2 Emppty Belt Configuration 16
5
5.3 Onlin
ne Calibratio
on 16
5
5.4 Sendding data to Real Time In
nstruments 17
5
5.5 Ente
ering a Calibrration 17
6 G7
G HUMA
AN MACHIN
NE INTERFACE (HM
MI) 18
6
6.1 Operation 18
6
6.2 Tren
nds 20
6
6.3 Calib
brate 23
6
6.4 Setu
up 26
7 General
G S
Secification
n – MoistS
Scan, MA--500HD.S3
3 37
8 MAINTENA
M ANCE 39
8
8.1 Physsical Maintennance 39
8
8.2 Isola
ating the Anaalyser 39
8
8.3 Remmoving the An nalyser from the conveyo
or line 39
8
8.4 Fault Indicators 40
8
8.5 Trouuble Shootingg 41
8
8.6 Prevventative Maintenance 42
8
8.7 bration Verification
Calib 42
8
8.8 Reca alibration 42
8
8.9 Sparre Parts 42
8
8.10 Servvice Plans 44
9 Contact
C A
Address & Details 44
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10 APPENDIX
A X 45
1
10.1 Microwave Emission Informa
ation 45
1
10.2 Emppty Belt Value
es 46
1
10.3 Calib
bration 47
1
10.4 Typical Results 48
1
10.5 Pre – Commissio oning 49
Mois
stScan® P
Pre-Commissioning Instructio
ons 49
Pre-C
Commissiioning Checklist 53
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1 INTRODUCTIO
ON / GENERAL
L INFOR
RMATION
1.1 Mo
oisture Measurem
M ment
Moisture has alwayys been an importan nt processs paramete
er that is usually deetermined using
laboratoryy techniquees on infre
equently o btained sa
amples. Th
his methodd of analyssis is expe
ensive
and consu umes valua able time and
a labourr. Most of all, ory analysis are
a the results from thhe laborato
too old to confidentlyy act upon
n.
The MoisstScan® Se eries 3 ra

ange of M Moisture An nalysers provides
p aaccurate measureme
m ent of
moisture in real tim
me, this ins
stantly ava
ailable moisture data a allows foor confiden
nt and proa
active
process ccontrol, pro
oviding manny benefitss for the pla
ant operato
ors and owwners:
 Metalluurgical/pro
ocess accoounting
 Proteccting vulnerrable downnstream prrocesses frrom excessively moisst material
 Feed fforward/ba ack control to dryer ci rcuits
 Feed fforward/ba ack control to dust co ntrol circuits
 Net weeight monittoring for quality
q conttrol purposses
 Moistuure specificcation compliance
Features: Benefits:
Full Transsmission te
echnique Highly rep
presentativ
ve, more acccurate
Advanced
d microwavve process
sing Simultane
eous measurement oof multiple parameters
p s
Non-intrussive measu
urement Non-destrructive, low
w maintenaance
Rapid rea
al time resu
ults Relevant data,
d proactive proceess controll
Automaticc operation
n Low cost, simpler logistics, no operator intervention
n
Australian
n design an
nd manufacture High quality instrument, excell ent technic
cal supporrt
1.2 Microwave
e Measurrement T
Techniqu
ue
The MoisttScan Analysers’ res sults for mo
oisture conntent are deetermined by measuring the ch hange
in a micro
owave signnal that hass passed th
hrough the e subject material.
m Thhis signal is
s emitted frrom a
transmittin
ng antennaa located immediatelly under th he rubber conveyor
c bbelt and is passed thrrough
the belt annd processs material above, andd is then detected
d by
y a receivinng antenna a located above
a
the materrial on the conveyor. The micro owave sign nal interac
cts with anyy moisturee in the proocess
between the two ante
material b ennas. Thee degree of interactioon is meas ured and used
u to derive a
value for tthe amounnt of moistu
ure presen t. This valu
ue is then corrected ffor the amount of ma aterial
in the ana
alysis zone
e to producce a percenntage mois sture value.
1.3 He
ealth and
d Safety
The MoisttScan® Se eries 3 Moisture Ana alyser is de
esigned to use low leevel microowave radiation.
The micro owave pow wer emitteed from thhe lower antenna
a is less thann 10 mW (10 dBm).. This
n directly between the two anntennas, which
radiation level is restricted to the region w is typ
pically
inaccessibble. Microowave em missions aare virtuallly undetec ctable furt
rther than 1m from m the
MoistScan n® Series 3 Moisture e Analyserr. For more e details on the micrrowave emmissions, please
p
refer to Se
ection 10.11 Microwav ve Emissio
on Informattion on pag ge 43.
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2 SYSTE
EM DESC
CRIPTIO
ON
The MoistScan® Se eries III Mo
oisture An alyser On--Belt Moisture Analyyser comprises two major
componen nts, the “CC” Frame Antenna A Assembly and the Control
C Caabinet. The
e functionss and
operationss of these units are described
d iin this chap
pter.
2.1 Co
omponen
nt Identiffication & Locatio
on
2.2 An
ntenna Assembly
A y
The “C” FFrame Anteenna Assembly housses the me easuremennt system ccomprisingg the micro
owave
transmit a
and receive
e antennass, and in m
most cases an ultraso onic level ssensor and
d/or temperrature
sensor. The measurement sys stem is acccurately aligned during the maanufacturinng processs, and
does not require any specific adjustmen nt prior to operation.
o The Antennna Assem mbly is designed
to meet IP
P66 standaard for dust and moissture intrus
sion.
2.3 Co
ontrol Ca
abinet
The Contrrol Cabine
et may be directly
d atttached to the
t “C” Fra ame, or maay also be mounted some
distance a
away. The control caabinet mayy be supplied indepen ndent of thhe “C” Fram
me (the su upport
/ mounting
g frame) foor more co
onvenient l ocation as
s required by the useer, when thhis is the case a
small enclosure will be mounte
ed on the ““C” Frame to house the
t Microw wave electrronics.
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In the stan
ndard conffiguration the
t interiorr of the cab
binet norma
ally comprrises of the
e following:
1.
1 Prograammable Logic
L Controller
2.
2 +24V Power Sup pply Unit
3.
3 Systemm Healthy Relay (See Section 3.9) 11
4.
4 Microwwave Term minal Strip
5.
5 Circuitt Breaker/R
Residual Current
C Devvice 7
8 9
6.
6 Main TTerminal Strip
S
7.
7 Microwwave Enclo osure
8.
8 AnyBuus Communications Adaptor
A
9.
9 “3G” W
Wireless Modem
10.
1 Analog gue Signall Isolators
3 1
11.
1 3G Anntenna connection
4
5
10
0
6
2
Figure
e A: Internaals of Conttrol Cabine
et
Warning: Do not reemove the e batteries from the Central Prrocessing Unit when n the unit is
i not
powered. This will result in lloss of sto
ored variab
bles whichh may requ uire manu ual re-
entry. The
e batteries
s are rated for severa
al years an
nd should oonly be rep
placed wheen the
processor is powere ed.
The RTI H
Human to Machine In nterface (H
HMI)
is mountted in thee door off the Con ntrol
Cabinet fo
or easy an
nd instant access too the
12
complete range of data.
d
12.
1 Location
n of the Se
ecure Digital ‘SD’ Ca rd
1 Commss cable to the Processor Unit
13.
17 15
14.
1 Commss Port A. RS485 (spa are) 20
15.
1 ModBuss to the AnnyBus Adaptor 13
16.
1 Programmming Porrt RS232 (Spare)
(
17.
1 Etherneet connection to the 3G
3 Modem m 19 18 16 14
1
18.
1 USB Ho ost Ports A & B (sparre)
19.
1 USB coonnection Type
T B (spare)
20.
2 Power cconnectionn to the HMMI Figure
F B: R
Rear View of
o HMI
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Figure C: HMI Com
mmunicatiion Ports Options
The underside of thee rear of th
he HMI revveals a range of conn
nection porrts, as indic
cated on th
he
previous ppage; the photo
p abov ve more cleearly show
ws these po
orts. Somee ports serv ve a speciffic
function a
and others provide co ommunicattion optionss.
3 INSTAL
LLATION
The MoisttScan® tecchnology has simple, yet strict, installation guidelinees that muust be followed
®
to ensuree the mostt reliable performanc
p ce of the system.
s Thhe MoistSccan syste em also ha as a
broad arrray of connectivity options
o tha
at may be used to transmit daata in a co onvenient and
robust fasshion. Thesse issues should
s be considered in partne ership withh the Pre-C
Commissioning
Checklist..
3.1 Lo
ocation
The location of the instrumen nt should bbe determined after considerattion of thre
ee factors,, the
importancce of each of these fa
actors will vvary from application
a n to applicaation.
 Objecttive
 Consider the relevance of the mo isture mea asurement to processs control decisions
 Forr feed-backk control th
he instrume ent should
d be immeddiately dow
wnstream ofo the unit
ope
eration
 Forr feed-forw
ward controol, the instrrument shoould be imm
mediately uupstream of
o the unit
ope
eration
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 Calibraation Samp pling
 Consider the installation n location relative to any sampling points
 Effe ective, rep
presentative e samplingg is the ultimate controlling facttor of the accuracy
a off the
instrument
 Alw ways aim to o install the
e instrume ent immedia ately upstrream of a ssampling point
p
 Auxilia
ary Inputs
 Consider the installation n location relative to any other instrumentts that prov vide
neccessary/usseful signalls
 Imp portant auxxiliary signals are typpically eithe
er mass/vo olume throuughput sen nsors (e.g.
belt scales orr flow mete ers) or prop
perty senso ors (e.g. te
emperaturee probes or density
gau uges)
 Accesss to the Annalyser
 It iss necessarry to have access to the analys ser to comp plete the coommissionning and
calibration of the analys ser.
3.2 En
nvironme
ent
MoistScan n® technology has been dessigned to operate in some oof the harshest nattural
environme ents. The following
f data
d is for a standard d, unmodified instrum
ment. Broadder rangess are
available ffor speciallised applic
cations.
 Ambie ent Temperrature 0°C to 45°C C, out of dirrect sunlight
 Relativve Humiditty Non-conden
N nsing*
 Ingress Protectio on IPP 65
*The onlyy measurab ble impactt from hum midity is thee accumulation of coondensatioon on surfa
aces
between tthe transm mitter and receiver a antennas. In large th hroughput application
ns (>100 tph),
t
even cond densation would
w not be a meassurable dis sturbance.
3.3 Sto
orage, Preservattion, & H andling of Instru
ument
Site Stora age:
Short term: - (1 to 12 week ks) for thiss period of time out off doors stoorage is acceptable and a
there are no add ditional req
quirementss other than n that prov
vided by th e shipping g crate.
Long term: - (> 12 weeks) If possible e it is recom
mmended that storagge be indoors to redu uce
deterioration of componen nts due to e extremes in temperature and coondensatio on.
Preservation:
The M Moisture An nalyser will be packe ed with Silic
ca Gel inside the conntrol cabine et to reducce
the hu umidity within the cab binet conta aining the electronics
e s.
It is re
ecommend ded that thee Silica Ge el be replacced after 12 months of storage.
Handling:
The u usual care in handling g to ensure e the analy yser is not dropped iss recomme ended. Lifting
and m moving the analyser priorp to insttallation sh
hould be do one with thhe unit still crated. Att the
time o of installatio
on the ana alyser can be lifted us sing slings around thhe upper arrm of the “C C”.
3.4 Liffting of the Analy

ysers
For a MA--500HD wiith a standard sized a analyser Aluminium
A “C”
“ Frame (700mm reach, r 600mm
antenna sseparation)) the total weight
w of thhe analyseer includingg a solar shhield is 66 kg and 86 6kg
for the MAA-500HD/R Reflectance e.
CAUTION N: For MA-500HD An nalysers wh hich includ
de a Solar Shield,
S andd have “C”” Frame rea
ach
less than 700mm; th he centre of
o gravity iss behind th
he first set of mountinng feet. Thus when
unsecured d the analyyser will tip
p back to reest on the bottom ed dge of the S Solar Shielld.
For crane e lifts, use the
t upper arma of the “C” Frame e as a slingg tie-off poiint, when securing
s slings
to this arm
m take care e that these slings doo not catchh on the Ulttra-Sonic.
If the anallyser is to be man ha andled then n always ensure
e corrrect lifting pproceduress are
exercised.
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3.5 Ins
stallation
n Sequen
nce
The electrrical powerr supply an

nd data co mmunication cabling g can (and in most ca
ases should
d
be) complleted beforre the physsical installlation of th
he analyserr is undertaaken.
a) Ensure the appropriate lifting equ uipment and level of manpower
m r is available prior to
com mmencement of the procedure .
b) The e profile an
nd sizing ofo the supp port beams s needs to be determ ined to ens sure that thhe
corrrect cleara ance betwe een the lowwer antenn na cover an nd the undderside of the
t conveyyor
bellt is achievved. I.e. 10 to 20 mm with a loaded conve eyor.
c) Should the pllace of insttallation be e on an ele evated conveyor line then the crane c or othher
lifting device must be adequate fo or the lift, and
a qualifie ed operatorrs available.
d) Ensure an ad dequate ex xclusion zo one, with th he correct signage
s annd barrierss has been
esttablished im mmediately below the installation location n.
e) The e operationn of the co onveyor be lt will need d to be isolated and loocked out.
f) Co onveyor belt lifting frames may b be required d for some e applicatioons.
g) On nce all apprropriate an nd specified d safety prrecautions have beenn taken, including tha at of
riskk managem ment proce edures, the en the insta allation cann proceed..
h) If n
necessary lift and sec cure the co onveyor be elt, this of course
c will require thee releasing g of
thee belt tensio on.
i) Acccurately measure
m and drill the mmounting beams
b to suit
s the loccation of the “C” Fram me
mo ounting points. (typica ally a 14 to
o 16mm bo olt holes to suit M12 bbolt) NOTE E: the centre
linee of the antenna cove er needs to o correspo ond with the e crest of tthe materiaal on the belt.
j) Position and fix the cros ss stringerr support beams,
b this
s may requuire the use e of a qualiified
trad des person n if the beaams are to be welded d to the strringers.
k) Pla ace the ana alyser in po osition on the supporrt beams, secure s withh 2 of the four
f bolts in
thee diagonal opposed fe eet.
l) Low wer the conveyor bellt and re-te ension, the en check th he amount of clearance betwee en
thee analyser and the be elt, then deetermine ho ow much packing
p willl be necesssary to
ach hieve the correct
c spaacing. NOT TE: the pac cking may need to bee placed un nder the iddler
frames.
m) Loo osen the twwo existing g mounting g bolts to allow
a packin ng to be pllaced betw ween the C
Fra ame and su upport bea am of the o other two mounting
m points and ssecure with h the
mo ounting bolts, these bolts
b must uuse “Nyloc ck” nuts to prevent th hem vibrating loose.
n) On nce these tw wo mounting points a are tightly secured, remove thee other two o bolts and
plaace the app propriate amount of p packing be etween the mounting feet and supports beaam,
theen replace bolts and tighten.
t
o) Ele ectrical andd data conn nections ca an now be e made to thet control cabinet via the gland d
holles in the bottom
b of th
he control cabinet.
p) If n
not alreadyy done, the gland hole es may ne eed to be drilled to suuit an M20 Gland.
3.6 Sp
pecialised Tool & Labour for Insta
allation
There are
e no specia
al tools or expertise
e re
equired to install a MoistScan
M M
Moisture Analyser.
A
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3.7 Me
echanica
al Installa
ation
Performan nce of all formats off MoistSca an® technology is ma aximised w when the presentatio
p on of
material iss consiste
ent. For ex xample, on n conveyorr belts, this involves material being dresssed
centrally and evenly on the belt, for all feed rates. r In vessels
v annd hopperrs this meeans
consistent presence e of mate erial betwe een the antennas. Issues
I witth materia
al presenta
ation
should bee rectified prior
p Scan® systtem.
to insttallation off the MoistS
Warning: Mechaniccal installa
ation musst always be cond ducted in accordance with local
l
regulation
ns and site
e specific ssafety practices.
Installation on a Conveyor
C r Belt
Mechaniccal installation is sim
mple and requires attention
a to
t only thrree things s: aligning the
measuremment syste em with thee centre off the conve
eyor belt; adjusting
a thhe height of
o the Ante enna
Assemblyy relative to
t the con nveyor be lt; and ad dequately supportingg the totall mass of the
analyser.
Warning: If the proffile of the material
m on
n the convveyor belt is
s not alignned with the
e centre off the
conveyorr belt, the analyser may need d to be reaaligned, pllease consult with Real
R
Time Instruments or o your loccal MoistSScan® representativee if this is the case. For
conveyorr belt appliications, it is critical that there is no morre than 20mm cleara ance
between the underrside of the e loaded conveyor
c belt
b and thhe antenna a cover off the
lower C-FFrame arm m.
The Antennna Assemmbly must be mounte ed and sec cured to suitable suppports as pe
er the diag
gram
in Section
n 4.1 Mech
hanical Insttallation att the end of
o this manual.
 The “C C”-Frame iss typically installed oon a purpos se-built sup pport framee, attachedd to the
conveyyor belt strringers.
 It is recommende ed that the
e mounting frame be adjustable e.
 The “C C”-Frame must
m be aligned in thrree ways:
 The e centreline of the an ntenna covver should be aligned d laterally w
with the conveyor bellt,
andd by extension the flo ow of mate erial.
 Insstallation sh hould be as close to the downs stream idler as possibble, withou ut interferin
ng
with its operaation, to minimise bel t deflection
n.
 Verrtically succh that the clearance between the t fully loa aded conveeyor belt and
a the low wer
anttenna cove er is between 10mm and 20mm m.
 If mate erial flow cannot be aligned
a withh the centrre of the co
onveyor beelt, then thee antenna
cover sshould be aligned with the centtre of the material
m flo
ow. A toleraance of ± 30
3 mm is
accepttable with this
t alignm
ment.
Caution:: Durin ng the phyysical installlation of th

he analyseer, particulaarly when the “C” Fra
rame
is being mman handle ed, care shhould be taaken not to o use the Ultra-Sonicc as a purrchase poin nt or
subject it to any forcce as the unit
u is not d designed to o withstand
d any subsstantial forc
ce.
Other Installation
ns
For inform mation on other type es of insta allations su
uch as, Ho
opper, screew feederss, vertical disc
filters, and
d horizonta
al belt filterrs or in pip
pe analysers consult with your R
RTI repres
sentative. Real
R
Time Instrruments is able to cu ustom desig gn the MoistScan® to
o suit manyy unusual situations.
s
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3.8 Ele
ectrical Installati
I on
The MoistScan® tecchnology uses
u compponents that require a high quuality powe er supply. It is
strongly re
ecommend he power s upply to th
ded that th ent be filterred power, preferablyy on
he instrume
UPS. The e following data corre
esponds to a standard d, unmodiffied instrum
ment.
 Supplyy Voltage 110 to 240 V AC S
Single Phas
se ( can ac
ccept 90 – 260VAC)
 Frequeency 50/60 Hzz
 Curren
nt Draw 300 W max
m
Instrumen
nts may be
e alternative
ely supplie
ed with 24 or 48 V DC
C power suupplies.
Warning: The MoisstScan® Se eries 3 Mooisture An
nalyser req
quires a ssingle phas se instrum
ment-
quality po
ower supplly. Damag ge caused to the insttrument byy inferior po
ower suppply is
not coverred by the warranty.
The signa al for the measured moisture is output using two 4-20mA ssource po owered currrent
®
loops in tthe standa ard configu uration. Th
he MoistSc can Seriees 3 Moistture Analy yser also uses
u
digital inputs and ouutputs. The e System HHealthy staatus is outp
put using a digital sig
gnal for con
ntrol
purposes;; this is a ‘Dry Co ontact’. Thhe operatio us of the conveyor belt and the
onal statu
availabilityy of materiial on the conveyor
c b
belt are inp
put using digital signaals. These two inputss act
to engage e or disenngage the analyser in order to prevent it from ggenerating g unnecessary
measurem ments.
Warning: The MoisstScan® Se eries 3 Moiisture Anallyser Conttrol Cabineet containss 110/240V V AC
terminals. Electricall installatio
on must always be conducted
c in accorda
ance with local
l
regulation
ns. Site sppecific pro ocedures for
fo isolating
g 110/2400V equipment should d be
performedd before working
w onn the analy
yser poweer circuit. O
Only qualiffied personnel
should peerform worrk inside th he Control Cabinet.
Please reffer to Secttion 4.2 Ele
ectrical Insstallation on
o page 14
4 for a scheematic diag
gram.
3.9 Sy
ystem He
ealthy Re
elay
The Syste em Healthyy Relay is normally o open (NO) in a de-en nergised o r fault state. The relaay is
energisedd when the e CPU outp puts the “S
System He ealthy” condition, indiicated by the
t green LED
L
on the relaay. Continuity exists between S SH1 and SH2
S on the terminal bblock when n the system is
When any of the ana
healthy. W alogue inpuuts to the Central
C Pro
ocessing U Unit (CPU) move outtside
their pre--set limits, this de-a
activates t he relay, opening thet circuit to produce a “Sysstem
Unhealthyy” condition n. For morre informattion see Se
ection 4.2 Electrical
E I nstallation at the rea
ar of
this manuual.
3.10 Co
ommunic
cations
Warning: Electricall installation must alwways be co
onducted in
n accordannce with loc
cal regulattions
and site specific
s saffety practicces.
 Analog
gue Inputs
 AI.1 Sparre; marked AI1+/- on terminal strip. Typica
ally used foor a belt sc
cale input.
(Intternal Analogue Inpuuts to Proce essor) AI.2
2 - MW1: AI.3
A - MW22: AI.4 - MW W3: &
AI.55 - LS (Levvel Sensorr / ultrason ic) where fitted,
f otherwise not cconnected
 Digital Inputs
 DI.1 Convveyor Runn
ning
 DI.2 Average Resett
 DI3 3 Tonn
nage Pulsee
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 Analog gue Outputs
 AO O1 Average Moistu ure 1
 AO O2 Average Moistu ure 2 or an
ny Analoguue Input paass-throughh
 Digital Outputs
 DO O1 Systeem Healthyy
 DO O2 Feedd OK
 RS-23 32 (two porrts)
 RS-42 22/RS-485 (shared po ort)
 TCP/IP P
 Fieldbus Interfacce through the AnyBu us converte
er (optiona
al) can be pprovided; this
t gives a
seamle ess connection to the
e plant with
h most com
mmunicatio on protocools accomm modated.
 DivviceNet, PrrofiBus DP, CANopen n, etc.
3.11 Mo
odem
The provission of a modem
m with
h the Mois tScan Ana alyser provides a signnificant ben nefit to the
end user a as it allowss for a rangge of servi ces withou ut the cost of a techn ician trave
elling to site
e;
(1) Remotte Diagnosstics, (2) Remote
R Datta Analysiss, (3) Remo ote Calibraation Mainttenance an nd
Verificatio
on, (4) Softtware Upda ates and U Upgrades, (5) Remote e Product S Support Se ervice.
PLEASE NOTE: It iss the respo onsibility o er to maintaain a valid data packkage
of the clientt / end use
for the moodem conn nection to the
t analyse er.
3.12 Ca
alibration
n Switching
Some app plications require thee MoistSc an® system m to meas sure differeent produccts or material
blends on n the sam me conveyo or. In thesse instancces, it may y be neceessary to apply spe ecific
calibration
n equation ns for eachh product o or mixture. By defau ult, the MooistScan® system
s comes
with the capacity to t store 161 separa ate calibrattions, but this can be easily y extended d to
accommo odate more e calibratio
on settings . There aree two optioons availa ble to the user to sw
witch
between ccalibrationss:
 Manua ally, wheree the operaator sets whhich calibra
ation to ap
pply from thhe MoistSccan® HMI Cal
C
page 11.
 Via Co ommunicattions Proto ocol, wheree the plant DCS links to the Mo istScan® via digital
communications protocol (e.g. RS-23 32, RS-422 2, RS-485 or TCP/IP)).
Each calib
bration equ
uation has the followiing associa
ated param
meters:
 Number
 Na ame
 Offfset
 “A”” slope
 “B”” Slope
 Emmpty Belt foor each inp
put
These pa arameters may be edited on t he HMI, however
h if there aree multiple equations
e it is
easier to save the parameter
p s using th e “Save Settings“
S fu
unction, i.ee. found by
y selecting
g the
‘Set-Up’ m
main-menu u, then thee ‘HMI’ sub b-menu, and
a the ‘Sa
ave/Recall’’ page from the Pop p-Up
menu, theen edit the csv text file and relo ad.
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4 INSTAL
LLATION DRAW
WINGS & PRE-COMMIISSIONIING
Please reffer to the A3
A format drawings
d a
at the back
k of the Manual.
4.1 Me
echanica
al Installa
ation Dra
awing
Figurre 4-1 Mech anical Insta
allation Diagram
NOTE: Thee standard “C”
“ Fame le
engths are, 5
500, 700, & 900mm,
9 cus
stom sized fframes are available
a at
minimal ad
dditional cos
st.
4.2 Ele
ectrical Installati
I on Draw
wing
Figu
ure 4-2 Electtrical Installlation Diagram
4.3 Pre
e-Comm
missioning Instruc
ctions & Checklist
See Appendix
A 1
10.5 at the
e rear of this manual
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5 COMMISSIONING AN
ND CALIIBRATIO
ON
The MoisttScan® Series 3 Moisture Anallyser is tun ned and te ested as p art of the manufactu uring
process; hhowever different applications require sppecific calibbration setttings. Once the analyyser
has been installed, arrangeme
a ents should
d be made e for an RTI Instrumeents engine eer to carryy out
commissio oning and calibration atively, if competent site staff with
n procedurres. Alterna w instrum ment
experiencce are avaiilable, then
n a remote
e calibration process as outlineed in this manual
m mayy be
followed.
NOTE: Acccess to th he MoistScan Analyse er needs to
o be availaable to faciilitate the commissio
c ning
& calibration of the analyser. This
T proceedure requires access to loggedd data from m the SD card
c
(see Section 2.3 Co net for the location off the SD Card,
ontrol Cabin C on paage 5)
Refe
erences Ma
aterial
ISO 13909:2001
1 – Hard Coals and Cok ke – Mecha anical Samppling; particularly Part 77: Methods for determining
the prrecision of ssampling, sample prep paration andd testing.
ISO 589:2008
5 – Hard coal determinatio
d on of total m
moisture
ISO 15239:2005
1 5: Solid mineeral fuels, Evaluation
E o
of measuremment performance of oon line analy ysers.
5.1 Po
ower-Up Checks
 Apply po ower to the e MoistSca an® Series III Moisture e Analyserr, observingg all regulaatory and site-
s
specific ssafety prottocols.
 Check fo or the gree en LED on the 24V po ower supply (if prese ent).
 Check th he 0V and 24V rails on o the term minal strip to
t ensure that
t the pootential betw
ween themm is
24V±10% %. (See Figure 4-2 Electrical
E In
nstallation Diagram).
 Check fo or the gree en LEDs on n the CPU that corres sponds to RUN and T TX2, RX2.
 The RUN N LED sho ould be solid.
 The LED D should be e flickering
g.
 Check th he Red LED on the Microwave
M Enclosure e.
 LED on – The heater circuit is engaged d.
 LED off – The heater circuit is disengag ged.
 For the ffirst 15 to 20
2 minutes s after powwering up th he system, the LED sshould be solid s as the
e
Microwa ave Enclosu ure is being heated u up to the set point tem mperature (45°C).
 After thiss initial hea
ating period d, the LED D should sttart flashing g as the MMicrowave Enclosure’
E s
temperature is bein ng controlled at the sset point.
 Touch th he Microwa ave Enclos sure to con nfirm that itt is being controlled
c aat approxim
mately 45°CC
 Check th hat the Blue LED in the lower ccentre frontt of the HM MI is on.
 Blue LED D indicatess the SD CardC is corrrectly insta
alled.
 Check th hat values appear on n the G7 HM MI display when the “Inputs” toouch panel is pressed d.
Found via the ‘Ressults’ main menu, and d the ‘Inpuuts’ sub-me enu.
 IN1: shoould be a dimensionle ess value b between 0 and 1000..
 IN3: shoould read dimensionle ess value b between 0 and 1000
 IN4: shoould read accurately
a in Enginee ering Units,, e.g. mm, t/hr., °C (iff connected).
 IN5: shoould be a dimensionle ess value b between 0 and 1000
 Squircle: should be e a dimens sionless va alue between 0 and 10,000.
1
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5.2 Em
mpty Beltt Configu
uration
For conve eyor belt application
a ns it will be
e necessa ary to dete
ermine ‘Emmpty Belt’ values forr the
measured d inputs. Depending
D on the inpput type, th
his may be e as simplle as determining a tare
value. How wever, cerrtain inputs
s need to bbe determined by exttrapolation over a rannge of proccess
conditionss, such as the micro owave para ameters (INN1 and IN2). Note: E Empty belt configuraation
may not b be required, or even me configurations of the MoistS
n applicabl e, for som Scan Analyser
(i.e. MA-7
700, MA-80 00 and MA A-900).
The data is conven niently log
gged onto the SD Card C (earlie
er model may have e a CF Ca ard),
allowing tthe commissioning engineer
e to
o focus onn ensuring that the innstrument is exposeed to
the necesssary proceess conditions.
After ensuuring that the SD Ca
ard is corrrectly inserrted and lo
ogging datta, the follo
owing proccess
conditionss need to be
b arranged:
 Run a clean, empty belt forr at least twwo comple ete revolutions of the belt. For belts
b that have
excesssively long periods (e e.g. overlannd convey yors), then the belt shhould be ru un empty foor at
least 115 minutess.
 Ramp up the thro oughput off material o
on the beltt until a norrmal level iis reachedd. This should
be perrformed gra adually ove
er approximmately halff an hour or o at least sseveral belt cycles.
If this ccannot be done graddually, thenn try to do iti in increm
ments of a ssimilar size
e.
 Record d the date and time of
o these prrocess con nditions, ac ccording to the HMI clock.
c
This data is used byy the comm
missioning engineer tot determin
ne the Emppty belt and d minimumm
depth valu
ues. The procedure
p used
u is desscribed in more detail in Appenndix 10.2 Empty
E Belt
Values.
5.3 On
nline Calibration
Before coommencing g the online
e calibratioon proceduure, it is im
mportant to arrange fo or a laboraatory
to analyse the sam mples in a consiste nt, accura ate and tim mely mannner. Simila arly, it is also
important to arrange e for plant conditionss to be alte
ered in orde er to collecct a suite of
o samples that
covers thee broad ra ange of mo oisture con tent seen in the matterial. For m most proce esses, it iss not
sufficient to artificially increase the moissture of the e material by runningg a water hose overr the
material bbefore the analyser. It is criticcally important that the samplles also re eflect the total
range of mmoisture co ontent thatt will be pre
esent durin
ng normal operationss.
The objecctive of sam mpling is to collect thhe most reepresentative samplees possible e. The loca ation
®
of the Mo oistScan Moisture Analyser
A a
and the design of the processs will greatly affect the
sampling options (se ee Sectionn 3.1 Locattion on pag ge 7).
Warning: Online sa
ampling mu ust always be conduccted in acc
cordance wwith local re
egulations and
site speccific safety
y practice
es. Typicallly, online samplingg involves s collection
n of
material from a livve, un-isollated proc
cess. If appplicable ssafety prottocols prevent
online sampling, then a stop belt samp pling procedure (with or without isolation)) will
be require
ed.
It is important to un
nderstand the
t transie ent nature of moisturre content,, and the ease
e by which
w
samples m may becom me unreprresentative e of the orriginal mate
erial stream s than other
m. More so
propertiees (particlee size, chemical ccomposition, etc.) the t moistture conttent of most
m
materialss is subjec ct to relattively rapiid changee. There are a numb ber of me
echanisms s by
which the e moisturre contentt of a sam mple can increase or o decreasse, the prrimary way to
avoid this is to en nsure thatt the sam ple is sea aled in an air-tight containerr immediaately
after colle
ection.
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The followwing simp ple guidelines shou uld be rigoorously followed to improve the t likelihood
that yourr samples will provide you wiith a high quality ins strument calibration:
 Preferably collecct samples downstrea am of the MoistScan
M ®
Analyserr.
 Samplle size sho ould be manageable
m e in terms of handlin ng and labboratory analysis,
a w
whilst
being large enough to ensure they remain re epresentative. Typicaally a sam mple should d be
severaal kilograms in mass.
 Austra alian Standdards specify the in nitial samp
ple cut sh hould be oof a width h, 3 times the
maximmum particle size
 When primary sa ample cuts s are crushhed or furtther subdiv vision takees place then some work w
needs to be done e to define
e the amou unt of moistture loss thhat happenns in these e processes.
 Samples shoulld be effe ectively se ealed imm mediately after col lection, and a shouldd be
analyssed by the laboratory as soon a as possiblee (within 2 hours
h of coollection).
 Carefu ully calcula
ate the transition tim
me of the material
m fro
om the loccation of th he analyseer to
that off the sampple collectio
on point; th
his must be
b done to the seconnd so the lab results can
be corrrectly assigned to the Analyserrs readings s. I.e. both results aree for the saame materrial.
Whateverr the scena ario, every effort musst be made to elimina ate as manyy errors as s possible.
Once a ssatisfactoryy sampling g procedurre has been developed, the ffollowing data d collecction
proceduree should bee followed::
 Ensure e that the SD
S Card is s correctly inserted and data is being loggged.
 Data for the sampling
s period
p can be recorde ed to a sepparate file oon the SD Card, sele ect
the e’ main menu, then th
e ‘Calibrate he ‘Samplin ng’ sub-me enu and th en select the
t ‘Loggin ng
ONN’ option too start data logging.
 Collecct a series of
o samples s (recomm ended min nimum 30),, recordingg the follow wing:
 Sta art date/tim
me (to the second)
s of the sampling interva al, accordinng to the HMI.
 Fin nish date/tim
me (to the second) o of the samp pling interv
val, accord ing to the HMI.
H
 Ma aterial Tran
nsit Time (in secondss) between the instrum ment and tthe sampling location n.
 Anyy details about the sa ample thatt may acco ount for discrepanciess between the
Mo oistScan® reeading and d the laborratory result. E.g. Material layerring, surfacce water.
 Send tthe sample es to the la
aboratory foor prompt moisture analysis.
a
 Eacch sample should be e carefully ddivided into at least 2 portions and each portion sho ould
be independe ently analyysed.
 If ppossible, annalyse the samples u using the same
s technnique that wwill be use
ed to verify the
perrformance of the MoistScan® syystem.
5.4 Se
ending da
ata to Re
eal Time Instruments
The SD C Card should
d have noww logged thhe Empty Belt
B Config guration annd Online Calibration
C
The follow
wing inform
mation shou
uld now bee emailed to
t an engin
neer at Reaal Time Insstruments,
(support@@realtimeg n® representative’s e mail addre
grp.com or your local MoistScan ess):
 Detailss of the pro
ocedure for taking the
e samples
 SD Caard data for the appro opriate dat es & times
s (see Secttion 6).
 Accura ate dates & times, correspond
c ding to the periods of
o empty bbelt, materiial ramping
g-up
and caalibration sample
s collections.
 Labora atory moistture results
s.
5.5 En
ntering a Calibrattion
The final step in the
e calibratio
on procedu ure is the entering
e of the calibraation detaiils provided
d by
the RTI ccalibration techniciann. These p parameters s may be accessed and modiified using the
HMI by ussing the ‘C alibrate’ main menu to the left of the scre
Calibration’ page, sel ect the ‘Ca een,
then the ‘Calibrate’ sub-men nu along tthe bottom m of the screen
s to arrive at the ‘Calib brate
Moisture’ page. Sele nd use the pop-up panel to inpuut the appro
ect the input field, an opriate vallue.
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6 G7 HUM
MAN MA
ACHINE
E INTER
RFACE (HMI)
(
6.1 Op
peration
The RedL Lion G7 HMI is desig gned to prresent up to date da ata as welll as allow adjustmen nt of
calibration
n settings and systeem parame eters. Para
ameters arre monitoreed and mo odified via
a the
touch screeen on thee front pane
el, allowing
g the Contrrol Cabinett to remainn closed.
Figure 1: G7 HMI Fro

ont Panel
Navigating
g through the various screens and pages s on the RedLion
R HMMI is performed by using
the four m
main-menu u buttons (virtual) onn the left hand side, and subb-menu buttton along the
bottom eddge of the HMI scree en. The HM MI features h a pop-up key
s touch scrreen technnology with
pad appeaaring whenn a field requiring an input is se
elected.
The RedL Lion G7 HM MI featuress a data lo
ogging faciility, where eby per-seccond meas surement data
d
and per-cchange setttings data a is stored
d to a SD Card. Thiis card typpe is a rea adily available
standard, and whilee there is no
n propriettary formatt in use, it is importaant that on nly high-qu
uality
SD Cardss be used in the device. A narrrow blue LEDL in the lower cen tre front fa
ace of the HMI
indicates the status of the card
d. This LED
D will be so
olid if the card
c is inseerted corre
ectly.
Tip: Thhe RTI HMII only write es to the ca ard every even
e minutte (e.g. 10::34:00, 10::36:00,
10:38:00, etcc.). Hence, to ensure that an ev vent is prop
perly captuured and lo
ogged onto o the
SDD Card, it iss important to wait un ntil after the next eveen minute hhas passed d before
remmoving thee card (acc cording to tthe HMI clo ock, top rig
ght hand coorner). Thee write actiion
willl appear as a brief fliicker of the
e blue LED D.
To the rig
ght of the narrow
n Blu
ue LED is a bright Green
G Hom
me Icon, thhis is a tou uch button that
returns the screen back
b to the home pag ge. This is useful wheen navigatting from th he HMI Scrreen
Calibration page. Thhe Analyse er is supplieed with its’’ SD Card, & additionnal ones arre available
e.
The SD C Card is acccessible frrom the re ear of the HMI, on the t right-hhand side. The card has
enough sstorage capacity for at least 2 months of compre ehensive loogging. Th he system will
automaticcally delete
e the oldest files in orrder to mak ke space available
a foor new files
s.
Warning: If yo
ou remove or insert the Secu ure Digital (SD) Carrd while th he G7 HM MI is
attempting o write to it, you riskk corrupting the data
g to read or a stored onn the card. To avoid this,
you shoulld disconne ect the 24V
V power to o the RedL Lion HMI before remooving or inserting thee SD
Card. The e 24V pow wer is prov
vided by a moulded plug p that can
c be saffely removed withoutt the
need for ttools.
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The files are stored d on the caard in a CSSV format (comma-s separated variables), that is eaasily
opened inn any spre ead sheet applicatio n (e.g. Microsoft Exxcel). In orrder to retrieve the data
d
from the SSecure Dig gital (SD) Card
C you w
will require a compatible card reeader. The
ese are reaadily
available from electrronics and office suppply stores and are ty
ypically a U
USB device e that requ
uires
no softwaare installattion.
The log filles are org

ganised into
o four folde
ers under the
t Logs directory
d onn the SD Card
C as perr the
graphic be elow:
CALIB – Calibratio
on
SAMPLE
E
SETTINGS
S
TRENDS
SQUIRC
CLE
Below are
e details off informatio
on recorded
d in each log file:
Calib – RRaw and 1sec
1 data for each analyser input
i (IN1--6) and thhe 2 smoo othed moissture
values as per the Results scre
een. This d
data is reco
orded everry 1 secon d with a ne
ew file crea
ated
every eigh
ht hours.
Sample – Same data as ‘Calib’ but a also includ c analoguee outputs and individual
ding 1 sec
system he
ealthy inpu
ut status. This
T file is o
only create e ‘Samplinng’ option is
ed when the s selected.
Settings – This file is created every 30 m

minutes an
nd records all key anaalyser para
ameters.
Trends – This file iss used to create

c puts and inputs
the analyser trrend plots and recordds all outp
in ‘Raw’ fo
ormat.
Squircle – This file is used to

o create the
e Squircle value, it co
ontains all the raw values requ
uired
to set-up tthe Squircle
Each log file is nam

med accord ding to the
e date and time that it was creaated. The format for this
naming syystem is ass follows:
YYMMDD
DHH.CSV
 YY is tthe year (12 for 2012
2)
 MM is the month h (01 to 12))
 DD is tthe day (01 to 31)
 HH is tthe hour th
hat logging
g commencced (typica
ally 00, 08 or
o 16)
6.1.1 HMI / Plant

P Con
nnection
The MoisttScan Ana alyser – HM MI is typicaally conneccted the plant via ann Ethernet connectionn as
this provid
des the clie
ent with the
e ability to access / mirror
m the HMI
H at the plant control room.
There aree a numberr of options s available , and this should
s be discussed before plaacing the order
o
for your analyser.
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6.2 Tre
ends
6.2.1 Moisturre Trends
s
The moisture trend
d screen provides a ggraphical snapshot
s of
o moisture values forr both of th
he
MoistSca
an analoguue outputs
s. I.e. Moistture 1 and Moisture 2
Figure
F 2: Mo
oisture Tren
nds Display
Figure
F 2.1: M
Moisture Tre
end Display
Figure 2.1 providess the identtification off which colour trend line belonggs to which
h Analogue
e
Output; iin this scre
een shot Red indicate es AO1 & Blue
B indica
ated AO2. To remove e the Sub-
Menus frrom along the bottom m, just toucch the “Treends” menu u again.
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6.2.2 Microw
wave (MW
W) Trend
This scre
een displayys the tren
nd lines forr the Microw
wave signa
als.
Figure 3: Mic
crowave Tre
ends Display
y
To reveaal the Micro
owave tren
nd plot iden
ntification & values, simply
s ends’ main--
toucch the ‘Tre
menu
u button ag
gain.
6.2.1 Depth Trend

T
This scre
een displayys the outp
put from th
he ultrasonic level sensor.
Figure 4: D
Depth Trend
ds Display
To revea
al the Mate
erial Bed Depth
D trendd plot identtification & value, sim ds’
mply touch the ‘Trend
main-meenu button again. Bedd depth is usually allocated to Input 4, IN N4 or AI4.
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6.2.2 Resultss
Output 1 & 2 (rea ad only) Moisture
M 1 & 2 thesse function
ns displayss the value
e for Analo
ogue
Outputs 1 & 2. This can be Moisture 1 or 2 (smo
oothed ove er “Smoothhing 1” or “Smoothinng 2”
periods in second ds), Moistu
ure Wtd, and the weighted
w moisture
m oover a tim
me period, the
material Depth or any
a other variable
v an
nalogue inp
put to the Central
C Proocessing Unit
U (CPU).
Figure
F 5: Mo
oisture Resu
ults Display
6.2.3 Inputs
IN1 (rea
ad only) Min vallue = 0, Ma
ax value = 1000
This Input displayss the meas
sured value
e for the firrst microwa
ave param eter.
ad only)
IN2 (rea Min vallue = 0, Ma
ax value = 1000
sured value
e for the se
econd micrrowave parrameter.
IN3 (rea
ad only) ax value = 1000
Min vallue = 0, Ma
sured value
e for the third input to
o the proceessor
ad only)
IN4 (rea Min
n value = 00mm, Max value = 50 00mm
This Inp
put displayss the mea
asured valuue for the fourth input to the pprocessor. (This inpu
ut is
usually tthe bed de
epth as mea
asured fro m the ultra
asonic leve
el sensor).
IN5 (rea
ad only)
This disp
plays the measured
m value
v for th
he fifth input to the prrocessor.
IN6: (rea
ad only)
This disp
plays the measured
m value
v for th
he sixth inp
put to the processor.
p (This is us
sually a sp
pare
input tha
at is used in special application
a s, temperaature, mateerial flow raate, etc.)
“Squircle”
This is a phase shift
s input which hass been mathematica ally processsed to allow for la
arger
variation
n in the bed
d depth tha
an would n
normally be
e possible.
MOISTSCAN SER
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Figure 6: C
Current Inputs Display
The softtware has been
b writte
en to allow
w maximum m flexibility; with any i nput being
g assignable to
any Inpu
ut number. The follow wing arranggement is thet typical allocation of the Inputs.
IN 1: Microwavve Attenuation Value
IN 2: Microwavve Phase Input (Initia
al phase)
IN 3: Microwavve Phase Input (seco ond phase reading)
IN 4: Ultra-Son
nic Bed Deepth Input
IN 5: Optional Extra Anallogue Inpuut
IN 6: Optional Extra Anallogue Inpuut
“SQUIRC CLE”: A ph
hase meas surement u utilising botth phase innputs to coorrect for phase skipss.
6.3 Calibrate
e
6.3.1 Empty Belt
This pag
ge displayss the fields for enterin
ng the Emp
pty Belt (EB) values rrelating to that particcular
Input number.
Figure
F 7: Em
mpty Belt Se
etup Display
y
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EB IN1 Min value = -11000, Max value = 10 000
This function sets the baseline respon
nse or Empty Belt va
alue for Inpput 1 for the selecte
ed
calibratio
on.
EB IN2
ed
calibratio
on.
EB IN3
ed
on.
calibratio
EB IN4
ed
calibratio
on.
EB IN5
ed
calibratio
on.
EB IN6
ed
calibratio
on.
EB SQU UIRCLE
This function sets the baseline respon pty Belt value for Squuircle for the selecte
nse or Emp ed
calibratio
on.
6.3.2 Sampling
This pag ge is used when MoiistScan® d ata is to be recorded d over a sppecific time period, such
s
as calibrration sammples being g collected
d. The Ana alysers’ rea
adings aree logged to o the SD Card
C
when yo ou select the ‘LOGGING ON N’ option by b touching g the ‘ONN’ of the screen
s sw
witch.
Similarlyy to stop re
ecording to
o the Samp ple file on the SD Carrd, one sim
mply touche es the ‘OFF’ of
the scree en Loggingg switch.
Figu
ure 8: Samp
pling Display
y (Logging Off)
O
LOGGIN
NG OFF (S
Stops recorrding to the
e Sample File
F on the SD Card)
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LOGGIN NG ON (Starts record ding to the Sample File on the SD
S Card)
The ‘ON N’ option wiill start logg n the \LOGS\SAMPLE
ging moistture data in E directory
y from the time
it is selected till the
e time the ‘OFF’ or sttop is selec
cted.
Figu
ure 9: Samp
pling Display
y (Logging On)
O
Calibrattion – Mois
sture
Figure 10 : Calibration
n Display
6.3.3 Calibra
ate
Currentt Calibratioon in Use 1 to 16
This setss which ca
alibration is
s to be app
plied.
Calibrattion beingg edited 1 to 16
This setss which ca
alibration is
s to be editted below.
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Name
Sets a n
name for th he calibration selecte ed. The nam me can be e edited onn the screeen but this is
not veryy user frieendly. For several ccalibrations s it is easier to eddit the parrameter fille
manuallyy and reloa ad. (\paramms.csv on tthe SD carrd)
Offset
This setss the offse
et or ‘y-intercept’ for th
he calibrattion.
“A” Slope
e slope for the first fac
Sets the ctor of the calibration
n, by defauult Microwaave 1 on-de epth
“B” Slope
Sets the
e slope for the second d factor of the calibra
ation, by deefault Squiircle on-depth
Moisturre Equatio on Configu uration
This pag
ge sets up the factors s to be useed in the ca
alibration. It refers to this equattion:
Var 1 Var 3
Mooisture%  Offset n  ASlopee n  BSlope n
Var 2 Var 4
Where V Var1, Var22, Var3 an nd Var4 ca an be any of the se even inputss to the processor or
o
values 1, 10 or 100. By defa ault Var1 iss Input1 (M
MW1), Var3 a Var 2 &
3 is Squirclle (MW2) and
Var4 is Input4 (Depth). It is only
o in rare
e situations
s that this needs
n to bee changed.
6.4 Se etup
6.4.1 Inputs
Figure
e 11: Inputs Menu
Figure 11 shows thee pop-up menu
m whenn the ‘Inputts’ Sub-me
enu is seleccted, one then
t selectts
the Input nnumber wh
hich is to be
b checked
d or adjusteed.
Digital Inp
puts
Conveyor Running g
The ‘Con nveyor Running’ Sig gnal provid des the MoistScan
M system wwith an inddication when
w
material sshould be available
a to analyse.. If there is
s a ‘Conveeyor Runni ng’ digital input supp
plied
to the CP PU then th he MoistSc can will sttop analys sing when the conveeyor is sto opped. This is
particularlly importan
nt if a tonnees weighteed moisture e value is required.
r
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Reset
Mass-weig ghted moissture can be
b calculatted based on the inputs from thhe Ultra-Soonic bed deepth
sensor (In
nput 4) or the 4-20m mA kg/m ou utput of a Belt Scale in close pproximity to
o the moissture
analyser.
To reset ((re-start) th
he weighted average period an input from
m the plant is requiredd. This mayy be
a pulse orr an open oro closed circuit.
c
Figure 12: Digital Inputs Display

Inputs
The Inpu
ut pages also set up the analog
gue inputs to the CPU U. By defa ult Input 1 & Input 2 are
Microwaave 1 & Miccrowave 2 respective
ely. Input 4 is usually Depth from
m the Ultra a-Sonic.
IN1 (2, 3
3, 4, 5, 6 & Squircle)) ‘Connectted’: Yes or No
This nom minates that an inpuut is conneected to th he correspoonding anaalogue inp
put position
n on
the proccessor and that the usser wishess for this input to be used.
u
IN1 (2, 3
3, 4, 5, 6) ‘@ 4mA’
This setss the 4mA scaling fac
ctor for the
e corresponding input to the proocessor.
IN1 (2, 3
3, 4, 5, 6) @ 20mA
This setss the 20mA A scaling fa
actor for th
he correspo
onding inp
put to the pprocessor.
Figure 13
3: Inputs Dis
splay (Input 1 used as example)
e
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Squirc
cle
Figure14: Inputs D isplay (Inpu

ut Squircle Set-Up)
S
Phase 1 Input
Selects w which physsical input (1 through h to 6) is co
onnected to the ‘Phaase 1’ outpu ut of the
microwa ave module e. By defau ult Input 2 oor Input 3.
Phase 2 Input
Selects w which physsical input (1 through h to 6) is co
onnected to the ‘Phaase 2’ outpu ut of the
microwa ave enclosu ure. By deffault Input 3 or Input 2.
Loading g Input
Selects w which physsical input (1 through h to 6) is us
sed for loading comppensation in the
‘Squirclee’ calculatioon. By defa ault Input 4
4.
X Shift
This parrameter is usedu in the
e calculatioon of the Squircle
S me
easuremennt. It is used to correcctly
shift the Squircle in n the X Axis. The corrrect value for this pa arameter iss generated d during QA
Q in
the factoory and sho ould not bee changed except by y commissioning and calibration n engineerrs.
X & Y Norm
This parrameter is usedu in the
e calculatioon of the Squircle
S me
easuremennt. It is used to correcctly
normalizze the Squircle in the e X and Y A Axis. The correct
c valu
ue for this parameterr is generated
during QQA in the fa actory and should no ot be chang ged exceptt by commiissioning and a calibration
engineers.
Skip Po oint X & Y
This valuue specifiees the locattion of the first 360 degree phase skip onn a plot of Squircle
S vss
Depth fo or material of nearly consistent
c material. The
T data to o correctly set this paarameter must
m
be colleccted during g commiss sioning.
Skip Sizze
This valuue specifiees the dista ance betwe een each 3603 degree e phase skkip on a plo ot of Squirccle
vs Depth h for materrial of nearrly consiste ent materia al. The data
a to correcctly set this
s paramete er
must be collected during com mmissionin ng.
Magnitu ude Min & Max
This valuue sets limmits on the acceptable e magnitud de of the Squircle vecctor for corrrect analysis.
By defau ult the limitts are set to 0.5 for th
he minimum m and 1.5 for the maaximum. Th his should be
appropriate for all application
a ns.
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6.4.2 Outputss
Fig
gure 15: Sho
ows the Pop
p-Up Menu fo
or the Outputs sub men
nu
Figure
F 15.1: Digital Outp
puts Display
y
Digital Ou
utput
The ‘Systeem Healthy’ status iss indicatedd by a close
ed circuit on
o the ‘Sysstem Healtthy’ relay. This
is driven b
by the condition of th
he analogu ue inputs to
o the proceessor unit, should any of the inputs
go outsidde their pre-set min nimum or maximum m limit theen the relaay will be e de-activaated
producingg an open circuit. Th hus the outt of range condition in any of these inpu uts indicate
es a
conditionaal change, compone ent failure, errors in the proce essor batteery, or the
e MW1, MW2,
M
Input3, or Input4, Input 5, Inpu
ut 6 or Squ ircle.
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Analogue
e Outputs – (Moistu
ure Analog
gue Outpu
uts page)
AO1 Outp put Moisture
M 1,, Wtd. IN1,, IN2, IN3, IN4, Moistture 2
This seleccts which parameter
p to output o
on Analogu
ue Output 1.
AO1 @ 4m mA Min vaalue = 0, Max
M value = 100
Sets value
e of percen
ntage mois
sture to be output ove
er analogu
ue output 1 at 4mA
AO1 @ 20 0mA Min vaalue = 0, Max
M value = 100
Sets value
e of percen
ntage mois
er analogu
ue output 1 at 20mA
AO2 Outp put Moisture
M 1,, Wtd, IN1,, IN2, IN3, IN4, Moistture 2
This seleccts which parameter
p to output o
on Analogu
ue Output 2.
2
AO2 @ 4m mA Min vaalue = 0, Max
M value = 100
Sets value
e of percen
ntage mois
er analogu
ue output 2 at 4mA
AO2 @ 20 0mA M value = 100
Min vaalue = 0, Max
Sets value
e of percen
ntage mois
er analogu
ue output 2 at 20mA
Weighting Input IN
N1, IN2, IN
N3, IN4, T-Pulse
The “Wtd” option iss used to select
s the weighting parameter for the wweighted moisture
m va
alue.
Any of thee inputs caan be weig
ghted by a throughp put from an
ny of the oother inputts to the CPU.
C
Usually ‘In
nput 4’ (de
epth of ma
aterial) or a 4-20mA tonnage output
o from
m a belt sccale is useed to
provide a mass we eighted mo
oisture ave erage. An input from the plaant will be e required d to
reset the weighted averaging g period.
Smoothin ng 1, (2) iff Low Zero orr Hold
Nominates if the va utput 1 (2) should res
alue for Ou set to zero
o or continnue holding
g after a lo
ower
limit has b
been excee eded for more
m than 1 0 secondss
Smoothin ng 1, (2) iff High Zero orr Hold
Nominate es if the value for Outtput 1 (2) sshould res
set to zero or continuue holding after an up
pper
limit has b
been excee eded for more
m than 1
10 seconds s
Figure 16: An
nalogue Outputs Display
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6.4
4.3 Parame
eters:
When thhe “Parameeters” sub-menu is se
elected, the required page can then be se
elected from
the pop--up menu.
Figu
ure 17: Para
ameters Sub
b-Menu Disp
play
Smoothiing: - Pop-Up-Menu
Smooth hing 1 ax value = 3600
Min vallue = 1, Ma
This setss the analyysis time fo
or “Moisturre 1” in sec
conds.
Smooth hing 2 ax value = 3600
Min vallue = 1, Ma
This setss the analyysis time fo
or “Moisturre 2” in sec
conds.
Figure 18: Sm
moothing Pe
eriod Display
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Parame
eters – coontinued
Limits
Figure 19: Limits Display

D
Limits
IN1 Min: Min vallue = 0, Ma
ax value = 1000
Sets the
e minimum limit for IN
N1, the firstt microwav
ve parametter
IN1 Maxx: ax value = 1000
Min vallue = 0, Ma
Sets the
e maximum
m limit for th
he IN1, the
e first micro
owave para
ameter
IN2 Min: Min vallue = 0, Ma
ax value = 1000
Sets the
e minimum limit for the IN2, the second microwave parameter
p
In2 Maxx: Min vallue = 0, Ma
ax value = 1000
Sets the
e maximum
m limit for th
he IN2, the
e second microwave
m parameterr
IN3, IN4
4, IN5, IN6 Min:
ourth, fifth, & sixth inp
e minimum limits for the third, fo
Sets the puts to the processorr
IN3, IN4
4, IN5, & IN
N6 Max:
Sets the
e maximum m limits for the third, fo
fourth, fifth, & sixth inputs to thee processo
or
SQUIRC CLE Min:
Sets the
e minimum limit for the Squircle input to th
he process
sor
SQUIRC CLE Max:
Sets the
e maximum
m limit for th
he Squircle
e input to the process
sor
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Miscellaneous Configu
uration
Threshold 0<x≤1
This sets the ‘fractioon of a seecond’ thatt all inputs
s must be within theiir minimum m or maximmum
limits for the 1 seco ond moistu ure calcula
ation to prooceed. If the
t limits ffor any of the inputss are
exceeded d for longerr than the ‘Threshold ’ period the
en this ave
eraging perriod will no
ot be used..
Feed Timmeout
This sets the time delay
d beforre MoistSccan® resultts are put ‘On
‘ Hold’ ((last true value)
v or go
g to
Zero afterr an input goes
g outsid
de its’ min or max lim
mit.
Cal Type Filttered, Unfililtered
All calibra
ations shou
uld be setu
up to be ‘F
Filtered’, but
b in certa
ain applicaations ‘Unffiltered’ iss the
appropriate choice. This shoulld only be adjusted by
b a commissioning oor calibratioon Enginee er.
Trend Flaags: Mois
sture, MW,, Depth
These paarameters determine
e which inpputs are displayed
d on which trend scre
een. For each
e
screen sim
mply add the
t numbe ers for each
h value tha
at should be
b displayyed and en
nter the sum
m in
the param
meter.
Output 1 = 1 For ex
xample Mooisture Trend flag would
w
Output 2 = 2 norma
ally want tto display Output 1 and
Input 1 = 4 Output 2 so it sshould equual 1 + 2 or 3.
Input 2 = 8 These are setupp during manufacture
m e and
Input 3 = 16 should
d not need to be adju
usted.
Input 4 = 32
Input 5 = 64
Input 6 = 128
Squircle = 256
HMI Vers sion

This displays the pro
ogramme version
v tha
at is curren
ntly installe
ed in the Reed Lion dis
splay.
PLC Verssion
Displays tthe program
m version that is imp
planted in the process
sor
Figure 20: Mis

sc. Configuration Displlay
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6.4
4.4 Human
n Machine
e Interfacce (HMI)
Etherneet
This screeen allowss configuration of the Ethernet interface to
o allow connnection off the HMI to the
local nettwork or a modem. IPP Address:: Network Mask:
M & Gateway IP .
Figure 21
1: IP Addres
ss Display
Screen Cal - (no screen
s sho
ot available
e)
This pagge is to calibrate the screens
s to
ouch response with th he actual toouch pane
els; the ope
erator
must touuch each inndicator sqquare when n it turns re
ed, and com
mplete thee process to calibrate
e the
screen. Note: To navig gate off thiss page sim
mply use the “Home Iccon” at the
e bottom
surroundd of the scrreen.
Screen Setup
Brightne
ess: This sets
s the brrightness o
of the G7 display.
d
Figure 22: Screen Settup Display
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PLC Sta
atus:
Input 1 (2
2, 3, 4, 5, and
a 6) Stattus:
The statuss Indicatess if the Inpu
ut being m easured is
s within an acceptablee level. If the
t input iss
within a co
orrect mea asurement range thiss will displa
ay OK, if no
ot this will ddisplay Errror.
System H Healthy
This Indiccates if all inputs are within
w limitts.
Good Cyc cles
Each seco ond this va alues updaates with th m cycles inn which all the inputs were
he number of program
within thosse limits se
et for each
h input.
Cycles
Each secoond this va
alue update
es with the
e total num
mber of prog
gram cyclees in that second.
Combined d with the ‘Good Cycles’ value, these two
o values are
e useful ass a diagnosstic tool forr the
‘System In
nput Stabillity’.
Figure 23: Status Display
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Save Re
ecall
The HMI allows thhe user to store a prrofile of the
e current configuratio
c on to the SD
S Card. InI the
®
event that the parameters in
n the MoisstScan sys stem beco omes corruupted or lost, these saved
s
parametters may be quickly recalled & rreloaded innto the sys
stem.
Alternatiively, the user

u may also
a recall tthe factory default co
onfigurationn.
Tip: T
The data is stored in files
f namedd \Paramss.csv and \D
Defaults.cssv respectiively. Thesse
te
ext files can be conve
eniently ed
dited on a normal
n commputer if reequired.
Save Setttings
This savves the currrent config
guration pa
arameters to
t the SD card.
c
Load Setttings
This resttores the saved
s conffiguration p
parameters
s from the SD card.
Load Deffaults
This resttores the default
d configuration parameterrs from the SD card.
Figure
F 24: M
Moisture Res
sults Display
MOISTSCAN SER
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7 GENER
RAL SECIFICAT
TION – MoistSc
can, MA
A-500HD
D.S3
Full Transmissioon, or Refle
ectance, Non‐Contact, Continuouss Real‐Time
Operation of Unit
Meaasurement
Sensing Sysstem Microwave Traansmission TType / Microwave Refl ected Signaal Type
Alum
minium Pow wder Coated d Frame, Integrated Trransmitter aand Receiveer
Support/MMounting Fraame Ante
enna. The sstandard “C” Frame sizes (reach) aare 500, 7000, & 900mmm.
(“C” Framee) Fram
me sizes cann be manuffactured to suit conveyyor belts fro
om 600mm tto
2200mm wide.. Optional uupgrade to 316 grade SStainless Ste eel Frame
Ingress Pro
otection Ratting IP65
5/4X
Mass Comp
pensation Via Ultrasonic B
Bed Depth SSensor; or B
Belt Scale 4‐‐20mA inpu
ut to CPU
Typically: MA‐5500 = 30m mm to 350m
mm; materiial dependaant
Bed Depth Range
MA‐5500HD = 50
0mm to 500mm; materrial dependaant
Graphical Trendd Display wwith Touch SScreen activvation of sub
b‐menus an nd
Human Maachine Interrface setting changess. 7” TFT Active Matrixx WVGA, 166M Colour 8 800 x 480
Pixe
el LCD screeen with LED Backlight.
Control Cab
binet (stand
dard) 316 Grade Stai nless Steel; 400wide x 600high x 2200mm dee
ep
Control Cabineet is usually mounted on the end oof the “C” Frrame.
Control Cab
binet Location Alte
ernatively it can be locaated remote
ely to the “CC” Frame, ssome distan
nce
awaay
Data Captu
ure Continuous Datta Logging w
with Interna
al Data Cappture to the SD Card
Moisture R
Range 0 to
o 80% (Mateerial depend
dant)
Measurement/Analysis
50 H
Hz
Frequency
Measurement Techniq
ques Both
h ‘Attenuattion’ and extended range ‘Phase SShift’
Measurement Updatee Time One
e Second
Measurement Smooth hing ; Sele
ectable:
Moisture 11: (M1) M1 ‐ from 1 seccond to 360
00 seconds; typically beetween 10 & 30 seconds
Moisture 22: (M2) M2 – from 1 seecond to 3600 seconds; typically 330 to 1800 sseconds
Optimal Achievvable Instrument Precision ±0.1%
Oveerall operatiional accuraacy; includin
ng typical caalibration e
error is likelyy
Instrumentt precision
to b
be between ± 0.4% & ±0.8% at 1 sttandard devviation, App plication
Deppendent
MOISTSCAN SER
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110/240 VAC, ssingle phase e, 300 Wattt maximum dissipation
Power
(opttional 24 orr 48VDC sup
pply system
m)
Operating TTemperature 0 to
o 50C with protection from directt sunlight (SSolar Shield option
Range avaiilable)
Operating Humidity Raange 0 to
o 95% Relatiive Humiditty (non‐ con
ndensing)
As d
default the MMoistScan h has the capacity to stoore and use 16 different
Calibration
n Settings
calib
bration setttings, but th
his can be easily extendded to more
e if required
d.
2 x 4
4‐20 mA so urce powerred current loops indic ating the ro
olling averagge
Analogue SSignal moisture conntent over aan accumulated time pperiod
of m
(Notte: current loop powerred from an
nalyser)
Digital Sign
nal Relaay indicatingg system he
ealth (Dry C
Contact)
Digital Com
mmunication
ns RS232, RS485, Ethernet (TTCP/IP)
Mod dBus
Default Com
mmunicatio
on
Option ‐ for an y of the mo
ore common
n communiccation protocols, via an
Protocol
AnyyBus Protocool Converteer
Analogue Outpput 1 (AO1/M M1) & Analogue Outpuut 2 (AO2/M M2)
AO11= Time aveeraged percentage moiisture
Analogue SSignal
AO22= Weightedd percentagge moisture e, value can be weighte ed by the
Configuratiion
oughput of aany of the aanalogue inputs to the CPU. I.e. M
thro Moisture 1,
Bed Depth, Tonnnes Input o or Moisture
e 2.
Conveyor Runnning. ‐ Dry C Contact; thiss is not esseential unless a tonnes
weigghted moistture is requ uired.
If a ttonnes weigghted moisture outputt is requiredd then the ffollowing
Standard In
nputs
inpuuts to the M
MoistScan Analyser are also needeed.
1/‐ TTonnes Resset ‐ Digital pulse +2000 millisecondds
2/‐ AAnalogue o utput of Be elt Scale Ton
nnes/hour oor Kg / metrre
54 kkg for a stanndard 700 reach, 600 separation, aaluminium “C” Frame
Analyser neet weight
The same fram me including a Solar Shie
eld = 68.7 kkg
Crated Ship
pping Weigh
ht App
proximately – 165 kg
External Crrate Dimenssions Typically – 14700mm long, x 890mm w
wide, x 12100mm high

MOISTSCAN SER
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8 MAINTENANC
CE
The MoisstScan® Mo oisture Annalyser is a robust and
a reliable system that will provide prrecise
moisture m
measurem ment of the material a nd moisturre range th
hat it has b
been calibra
ated to.
The MoistScan Ana alyser, being a non--contact ty ype analy yser and h having noo moving parts
has a natu
urally low maintenan
m ce require ment. Howwever, like any precission instrum
ment, it req
quires
occasiona
al mainten nance and d recalibraation. Calibration maintenanc
m ce is the main typ pe of
maintenannce requireed by the analyser.
a
8.1 Ph
hysical Maintenan
M nce
The key aaspect of physical ma aintenancee is to visuaally inspect the analyyser, the fiv
ve key area
as to
inspect arre:
(1) The lo
ower antenna cover, check
c for w
wear in cas se the belt has been making co ontact
(2) The uppper antennna cover, check to ssee if material on the belt has b been makin ng contact
(3) The Ultra-Sonic bed depth sensor, ag gain checkk for damag ge from maaterial con ntact
(4) The inside edge of the upright of the “C” Frame e making contact withh the edge of the beltt
(5) Checkk that the control
c cabinet door iss closed firrmly, and has
h not beeen left parttially open..
8.2 Iso
olating th
he Analy
yser
The MoisttScan Analysers’ con ntrol cabineet is usuallly connecteed to a 2400 Volt 50Hz power
supply, whhich is immmediately reduced
r to low voltagge (24 volt)) power su pply for the internal
componen nts. The 24 40 volt sup
pply is term
minated at a Mains Current Breaaker (MCB B/RCD) which is
located beehind a barrier to preevent any a accidental contact to the 240 voolt terminals. There area
no expose ed points oro terminalss within the
e cabinet which
w carry
y 240 voltss. The MCB B/RCD can n be
used as aan isolator for
f mainten nance worrk inside th he control cabinet.
c
Should the MCB/RC CD need re eplacemen nt, then it will
w be nece essary to issolate the 240
2 volt po ower
supply prior to the analysers’
a control
c cabbinet.
If the anallyser is going to be re
emoved fro om its mou unting on the conveyyor stringerrs then it iss also
necessaryy to have the 240 vollt supply be e isolated prior to the
e cabinet.
8.3 Re
emoving the Analyser fro
om the co
onveyor line
For this prrocess it iss essential to first foll ow all site safety preecautions, tthis is likely to include the
isolation oof the powe er supply, isolation off the conve eyor drive, and its loccking off, butb depend ding
on the loccation and positioning g of the an alyser it maym include e other safeety measures.
A typical MMoistScan configurattion will ha ave four (4)) mounting g bolts whicch secure the t lower arm a
of the “C” Frame (th he analyserrs’ mountin ng and sup pport frame e) to a pairr of mounting beams
which spa an between n the conve eyor stringgers.
It is necesssary to gaain access to the area a undernea ath the carrrying convveyor to remove thesse
mounting bolts. Sho ould the conveyor line e be at an incline, it will
w be neceessary to secures the
analyser w with some temporary y ties beforre the bolts s are removed, this iss to preven nt the analyyser
toppling wwhen the la ast bolt is removed.
With a sta andard con nveyor line configurattion it is no ot usually necessary
n to lift the conveyor
c belt to
remove th he analyser, but some configura equire the belt to be lifted. Whe
ation will re en lifting th
he
conveyor belt it is esssential to ensure tha at the mea ans of lifting
g the belt iss secure with
w no
possibilityy of the belt dropping unexpecte edly.
The overa all weight of
o a MoistS Scan analyyser is typic cally betwe een 74 & 9 0 kilogram ms, this is foor
aluminium m “C” Fram me, a 316 grade
g stain less steel “C” Frame adds 20 kkg.
If using a crane or Franna
F to remove the e analyser from an elevated connveyor; slin ngs may be
attached tto the top arm
a of the “C” Frame e as this is designed as a liftingg point.
MOISTSCAN SER
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8.4 Fa
ault Indic
cators
The MoisttScan Moissture Analy yser monittors the inp puts to the processingg unit and provides a
‘System H Healthy’ ouutput to alert the operrator when any of the ese inputs goes outsiide of its’ pre-
p
set limits. See sectio his manuall for more information
on 3.9 of th n on the “S System Healthy” outp put.
Other indiicators with hin the MoistScan An nalyser are e as follows s;
1) 24 Voltt Power Su upply: This Weidmulle er Unit hass a Bright Green
G LEDD on the top left-handd side
which indicates th he 24V sup pply is acti ve.
2) Microw wave Module Temperrature Stab bilisation: th
his is a Red LED whiich is locatted on the top
left of the microwwave module PCB; wh hen the annalyser is first turned on the LED D may be
continu ually on, deepending what
w the ammbient tem mperature is s at the tim
me. The Microwave
Module e is designed to be te emperature e stabilisedd at 45° C, so as the module ap pproached its’
set poin nt temperaature the LED will sta art to blink, and when n at the sett point the LED will fla
ash
at regular intervals.
3) System m Heathy Relay:
R This is a Light Green LED located on o the fronnt of the relay, which
indicate es the relay is energiised. That is the systtem is heallthy.
4) Central Processo or Unit: On the top lefft of the CP PU there is s a group oof LED indicators, the e first
is PWR R, which is a solid Ligght Green L LED indica ating that thhere is pow wer to the CPU, seco ond is
RUN, w which is alsso a solid Light
L Gree n LED indicating that the CPU is cycling through itss
softwarre program mme. Third is ERR orr Error, this s is a solid Red LED, indicating that there e
CPU iss not cycling through its program mme.
Immediately below this grou up of LEDss is a pair that
t relate to the POR RT 1 connection, thiss port
is used d for the CPPU to HMI data conn nection, wh hen the com mmunicatioon cable is s in place and
a
the sysstem is ope erational th
he Light Grreen LEDs marked TX1 & RX1 should be e blinking
rapidly.. This indiccates that the
t CPU iss communicating with h the HMI.
5) HMI – H Human to Machine In nterface: T The HMI ha as a numbe er of indicaator LEDs depending g on
the type e and num mber of com mmunicatio on connecttion are being utilisedd. Typically y the Port B
(RS 23 32) is used for the CP PU to HMI cconnection n; at this poort there iss also a Re
ed & Green n
LED to indicate an a active co ommunicattion link. AlsoA refer to
o sections 2.3 & 6.1 forf further
informa ation on thee HMI unit.
6) Modem m: When su upplied with the MoisstScan Ana alyser, it also has a nnumber of LedL indicattor
lights, tthese being the Powe er Red LE D, indicatin ng that pow wer is beinng suppliedd to the Moodem.
The Sta atus Light Green LED D, indicatin ng the func ctional status of the uunit. The Warn
W Yelloww
LED, in ndicating thhat the unitt is not to b
be powered down or disconneccted while this light iss on.
And the e Error Red LED, ind dicating a fafault within the Modem m.
Description of LED
Ds
Legend: O
On-- Offf-- Blink
k--
Power on Start
S to run
n firmware Begin dial to
o Internet
o internet
Connect to Upgrading
U ffirmware Restore facto
ory default
MOISTSCAN SER
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Signal Sttatus LED Description
--- Signal: 1-9 (bad signal level, route cannot work

k, please check the anteenna and local signal le
evel)
--- S
Signal: 10-19 (Router work
w normallyy under this signal levell)
--- S
Signal: 20-31 (Perfect signal level)
8.5 Tro
ouble Sh
hooting
The first ssteps to takke are the obvious on
nes, visuall inspection
n, fault indiicators and
d input valu
ues.
NOTE:
Trouble sh hooting forr those with
hout a veryy good und derstanding of microw wave beha aviour and
knowledge of the MoistScans’ processin ng of the microwave
m data,
d is lim
mited to tha
at of workinng
through thhe visual in
ndicators, fault
f indica
ators (Mainntenance Section
S 8.4)) and lookiing at the
inputs to tthe central processorr (Section 6 6.2.3 Inputts) to see if they are outside of their usua al
limits. (Se
ection 6.4.3
3 Paramete ers; Limits))
Visual Insspection
1. Ch heck the up pper and loower armss of the ana alyser havee not sustaained dama age.
2. Insspect the antenna
a co
overs to seee if they arre intact, on
o the loweer antenna cover che eck to
se
ee if the belt has wornn through tthe cover.
3. Ch heck that thhe Ultra-Soonic bed d epth senso or has not been dam mage by be eing impactted
byy material on
o the belt.
4. Is the HMI sccreen blan nk?
5. Op pen the control cabin net door, iss there pow wer to the analyser,
a i..e. Green LED
L on the
e
poower supplyy is illumin
nated.
6. Ha as the RCD D switch in the off po
osition, if so
o is there any
a obviou s scorch marks
m on th
he
Miicrowave Module
M PC
CB, or is the ere a burntt wiring sm
mell within tthe cabinet.
7. Is there any sign of the e cabinet door having g been left unlocked?? Look for dust
d or
mo oisture inside the cab
binet.
Fault Indiccators
1. Wo
ork through
h the list off fault indiccators (1 to
o 6) in the Maintenanc
M ce Section
n 8.4
Input Valu
ues
T
These are the analogu
ue input va
alues to the
e CPU; the
ey are a goood indicattion if there
e is a
fault in a p
particular area.
a
1. IN1
1: Microwaave attenuaation value
e. Limits
L = Min
n’ 0 / Max’ 1000
2. IN2
2: Microwaave phase shift
s value 1. Limits
L = Min
n’ 0 / Max’ 1000
3. IN3
3: Microwaave phase shift
s value 2. Limits
L = Min
n’ 0 / Max’ 1000
4. IN4
4: Ultra-Sonic Bed De epth Value
e. Limits
L = Min
n’ 0 / Max’ 500 Default
5. IN5
5: Optionall Extra Ana
alogue Inpuut
6. IN6
6: Optionall Extra Ana
alogue Inpuut
7. IN7
7: Squircle, special Microwave
M value. Limits
L = Min
n’ 0 / Max’ 10,000
MOISTSCAN SER
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8.6 Pre
eventativ
ve Mainttenance
The areass of prevenntative maintenance a are limitedd to keepingg the analyyser clean and not
allowing a build-up of
o material on the topp of the control cabinet. If a Sollar Shield is fitted the
en
check to e
ensure the front vinyll cover and
d its’ retain
ners are in good conddition.
For analyssers older than 5 yea
ars old, the
e cabinet door
d seal should be cchecked for resilience e.
8.7 Ca
alibration
n Verifica
ation
It is recom
mmended that t calibra
ation verificcation be undertaken
u n three (3) months aftter the initial
calibrationn has been n complete ed, and theen again ev very four (44) to six (6)) months after
a that. The
T
calibrationn verificatio
on processs is a simpllified versio
on of a full calibrationn, where only
o about 6
samples a are collecteed and laboratory an nalyser for their moistture valuess. The obje ect here is to
identify if there has been any substantial
s l movemen nt in the annalysers reeadings compared to
those of th he laboratoory analyseed sample es. Should the results s show no m movementt then no
change ne eed be imp plemented, but shoulld there be e a significa
ant discreppancy betw ween the tw wo
sets of vaalues then a more tho orough che eck needs to be unde ertaken. A complete recalibration is
rarely required if thee calibration is mainta ach calibration verificcation.
ained at ea
8.8 Re
ecalibratiion
The syste em may ne eed to be recalibrat ed on an as-needs basis or w when one or more of o the
process vvariables are
a significa antly altere
ed. Typically the effeect of belt wear and electronicss drift
results in an error of
o approxim mately 0.1 tto 0.3% off total moissture over tthe course
e of two to three
months.
Should a calibratio on verification indica ate signific cant devia
ation from the analysers histtorical
results, th
hen the firsst step is to
o investigatte if there has been a change iin the proccess materrial, or
one of thee other varriables, folllowing thiss a recalculation of th
he empty bbelt value, and a cheecking
of the output of the microwave
m e module, aand the ulttra-sonic le
evel sensorr may be necessary.
n
8.9 Sp
pare Partts
Should yo our MoistS Scan® Serie
es 3 Moistture Analysser requiree spare paarts, they may m be ord dered
from RTI or your loccal represe entative. R
RTI maintaiins a stockkholding off all common components
and can usually disspatch witthin 24 ho ours. If your MoistSc can Analyyser is sup pplying pro
ocess
critical data it is recommended d that a se
et of spare
e parts be purchased
p d and kept in reserve e. The
following sspare parts for a MA
A-500HD.S3 3 Analyserr are listed in order oof priority:
Expected
Lead Timme
Desc
cription Part No.
N Manu
ufacturer Annual
Deliverry
Usage
Batteries
B –B
Button Cr 235
54(x2) 0.25 Ex stocck
Pair
P Antenna
a Covers MS-01
126 RTI 0.2 1 weekk
Lower
L Antenna Covers fo
or Reflectanc
ce Analyser MS-01
175 RTI 0.2 1 weekk
Upper
U Antenna Covers fo
or Reflectanc
ce Analyser MS-01
176 RTI 0.1 1 weekk
Power
P Supply 24 V DC MS-00
054 Weidmuller 0.20 Ex Stocck
Microwave
M M
Module–Slimline Series 3 MS-00
007 RTI 0.1 1 weekk
PLC
P - total un
nit, including
g programmin
ng MS-00
025 RTI 0.1 Ex Stocck
Ultrasonic
U Se
ensor- pre prrogrammed ABM300
A MS-00
020 RTI 0.20 Ex Stocck
G7
G Touch Sccreen HMI, pre
p programm
med MS-01
155 RTI 0.17 2 weekks
MOISTSCAN SER
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The follow
wing Partts List contains a description
n of the componennts contained within
n the
MoistScann MA-500HD.S3 & MA-500H D.S3/Refle ectance Analysers. Minor con
nsumable items
have not b
been includ
ded.
Part CURRE ENT MOISTTSCAN MA A500 HD

SUPP
PLIER Qty Unit
Numbeer ARTS LIST - Parts Des cription.
SIII PA
MS0127 NI06042 2/S Cabinet RTI
R 1 ea.
Perspexx isolation barrier RTI
R 1 ea.
MS0039 HMI Weather Shield d RS
R Components 1 ea.
MS0050 RCD/MC CB Clipsal RTI
R 1 ea.
MS0155 HMI G07 7S0000 RTI
R 1 ea.
MS0103 SD Card d RTI
R 1 ea.
MS0054 Power supply 24V DC D Weidmuller
W 1 ea.
MS0164 PLC An nalogue CPU RTI
R 1 ea.
MS0159 PLC Inpput Module RTI
R 1 ea.
MS0161 D2-DSC CBL serial Cable
C RTI
R 1 ea.
MS0162 D2-BAT T-1 Battery RTI
R 1 ea.
MS0171 Isolator SIG-202 4-20 RTI
R 1 ea.
MS0166 Isolator SIG-201 4-20 RTI
R 1 ea.
MS0033 MW-Anttenna WiMo o PA-900R RTI
R 1 pa
air
MS0031 L-Com hyperlink
h RTI
R 1 pa
air
MS-0020
0 Ultrasonnic probe ABBM300 RTI
R 1 ea.
MS0126 Antenna a covers HD D transmissiion RTI
R 1 pa
air
MS0175 Lower Antenna
A Cov ver / Reflecttance RTI
R 1 ea.
MS176 Upper Antenna
A Cov ver / Reflecttance RTI
R 1 ea.
MS0007 Slimline Series III RTI
R 1 ea.
Relays Finder 40.5 51 24V DC RTI
R 1 ea.
Relay baase Finder 95.05 Base e RTI
R 1 ea.
Diode bllocks Finder 990292 20499 RTI
R 1 ea.
MS0056 Aluminiuum MoistSc can frame RTI
R 1 ea.
Reference cable RTI
R 1 ea.
PLC and d HMI softw ware installe
ed RTI
R 1
OPTION NAL COMPO ONENTS

MS0124 Welotecc modem/ro outer Welotec
W Germany 1 ea
ALL082 Wi-Fi an
ntenna ANT406 RTI
R 1
MS0051 RCD/MCB NHP for 110V AC RTI
R 1 ea
a.
MS0088 Thermosstat Stego 0-60deg
0 Element 14 1 ea
a.
MS0089 Heater 60Watts
6 Element 14 1 ea
a.
MS0090 Tempera ature probe
e Calex One-temp
O 1 ea
a.
MOISTSCAN SER
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ervice Pla
8.10 Se ans
‘On Site’ and ‘Rem mote’ Serrvice Plan s are offeered by Real
R Timee Instrume
ents. For more
informatio stScan® sa les represe
on, contactt your Mois entative.
9 CONTA
ACT ADDRESS & DETA
AILS
RTI Pty. L
Ltd. - Head
d Office After-s
sales Reprresentativee
Scott Simpson
S – RTI Gene eral Managger
Real Timee Instruments Direct Ph. + 61 (0) 7 49
9 657 009
Lot J, Macckay Marinna Village, Mobilee Ph. + 61 (0) 428
8 786 761
Mulherin DDrive, Macckay Harboour Email: scott.simppson@rtiau ustralia.com
Queenslaand 4740 Australia
A Technical Servicces
Robin Sheehy – Software / R&D Eng gineer
Phone: +61 (0) 7 49
9 555 944 Phone e: + 61 (0) 7 49
9 555 944
Fax: +61 (0) 7 49
9 657 099 Email: robin.sh eehy@rtia australia.co
om
upport@re
Email: su ealtimegrp.com
MOISTSCAN SER
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10 APPEN
NDIX
10.1 Microwave
e Emissio
on Inform
mation
The MoisstScan MA A-500 Seriees of micro owave moisture analy ysers are ddesigned tot use low level
“non-ionizing” micrrowave rad mination of total moistture within a materiall.
diation for tthe determ
quency range utilized by the Mo
The freq oistScan moisture
m analysers is ffrom 500 MHz
M to 10 GHz.
The micrrowave po ower emitte ed from thee transmiss sion antennna is a maaximum of 1 milliWattt
(mW).
Equipme ent emitting
g microwav ve radiatio
on must conform to th he regulatioons set out by the
national authority, ARPANSA A, or the Au ustralian Radiation
R and
a Nucleaar Safety Authority.
A The
applicab
ble standarrd in this ca
ase is the AAustralia and
a New Ze ealand Staandard AS//NZS 2772 2.1
The 2002 Maximum m Exposurre Levels t o Radiofre

equency Fields - 3 kH
Hz to 300G
GHz, Radia
ation
Protectio
on Series Publication
P n No. 3.
At 500MHz: At 100GHz:
/m rms)
E, Electrric field (V/m 68.6
6 1 37
H, Magnetic field (A A/m rms) 0.182
0 0. 364
P, Power Flux (W/m m2) 12.5
1 550
The
T parameters listed d above arre the highe est levels allowable
a (averaged
( over a 6 minute
m periiod)
fo
or a device
e in a workkplace. The e most app plicable limmit here is the Power Flux, P. Th he output from
2 2
a MoistSca an MA-500 0 or 500HD D is 1.1mW W/m or 0..0011W/m which iss less than n 10,000 times
lo
ower than n what is required
r at 500MHz.. This radia ation level only existss directly between
b thee two
antennas
a a
and in almoost all case
es is inacce essible due e to the co
onveyor be lt. Microwa ave radiatio
on
further than
n 1 metre from
f the annalyser is vvirtually un
ndetectable e.
As
A an exam mple, microowave ovens are legaally allowe
ed to leak radiation off up to 5 milliWatts/cm
m m²,
as
a specified d by the National Health and M
Medical Res search Council 19855. During co ommission ning a
Real
R Time Instruments enginee er can dem
monstrate with
w a simple microwaave leakag ge monitor that
the radiatio
on levels arround the MoistScan
M n MA-500 are
a far less s than whatt is legally required frrom
a commerccial microw wave oven.
For
F a comp
parison the
e energy level is simillar to a low
w power ‘Bluetooth’ ddevice.
Should
S you
u require fu
urther inforrmation, orr a more de
etailed explanation off Microwavve
Transmissi
T on Energie
es, please contact ou ur head offfice on +61 (0)7 49 5555 944 and ask to sp
peak
with
w our Re esearch & Development Officerr, Mr Robin n Sheehy.
MOISTSCAN SER
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10.2 Em
mpty Beltt Values
The follow
wing is the method us
sed to dete
ermine the empty bellt and minim
mum depth values fo
or the
®
MoistScann .
Empty B
Belt Depth
h
 Import the data frrom the RA AW folder on the ‘SD D’ Card into
o a spreadd sheet. Ploot a trend graph
g
of the DDepth, usuually Input 4.
4 Record the minimum value when w the bbelt is know
wn to be empty,
this is input as the
e EB IN4 value.
v
 Correctt the Deptth values in the spre ead sheet for the EBB Depth vaalue then plot Micro owave
(Input 1 or 2) on the
t y axis against
a Be
ed Depth (Input 4) on the x axiss.
 Add a line of bestt fit (Trend line in Miccrosoft® Ex
xcel)
Hint: To
o add a tren nd line in Microsoft®
M Excel, righ
ht-click the
e data seriees on the chart
c and select
s
“Ad
dd Trend liine”. Selec ct the “Optiions” tab, and
a check the box labbelled “Dis splay equaation
on chart”, clicck OK.
 This lin
ne should pass
p throug ave a posittive offset, see “Trend line
gh the mosst data poiints and ha
1” in Figure 9.3. This
T offset (428) can be read frrom the equation of thhe trend lin
ne.
In the plo
ot in Figurre 10-1 Empty Belt Microwav ossible to see that the micro
ve, it is po owave
response does not follow a lin
near trend with bed depth for low bed deepths. In order
o to prrevent
Scan® from
the MoistS m analysingg material in this region, a value
e for the m
minimum be
ed depth should
be set. T
The minimu um bed de epth in Figgure 10-1 is 50mm.. The miniimum bed depth ma ay be
accessed and modiffied from th
he HMI by pressing thet “Limits”” key.
 In this ssituation, it is also ad
dvisable to
o recalculaate the valu
ue for emppty belt mic
crowave byy only
plotting
g the trend line to inc clude data in the line
ear region. From “Treend line 2” in Figure 10-1,
enter EEB MW1 = 360 into th he calibratiion equatio
on.
700
Trend lin
ne 1 y = 1.0331x + 428.58
600
Empty belt
500 microwave
Microwave Response IN 1
Trend line 2 y = 1.45x + 360

400
300
Non linear region
200
100
Minim
mum Bed
depth
0
0 50 100 150 200 250
Bed Dep
pth (mm)
Figure 10-1 Empty Beltt Microwave

e
MOISTSCAN SER
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10.3 Ca
alibration
n
To get a rreliable caalibration fo Scan®, or indeed
or a MoistS i any
y on line aanalyser, a set of sammples
needs to be taken n that can n be corre elated to the analyser microw wave resp ponse. Fo or the
MoistScan n, the microwave sig gnal changge from the empty belt
b value, divided by y the amou unt of
material iss proportio
onal to the percentag ge of moisture in the material, sso the calib
bration equ
uation
is determined by ca arrying outt a linear rregression of the MooistScan reesponse vs. the ana alysed
result.
The calibrration proccedure willl vary greaatly depending on plant condittions and facilities.
f T get
To
the best ccalibration for
f a partic cular produ
uct the follo
owing cond
ditions neeed to be me et.
 Caarefully co o-ordinatee the time es; the material transit time between the t MoistSScan®
loccation and sample co ollection lo
ocation must be accu urately calcculated to ensure tha at the
®
ressult from MoistScan
M and Laborratory relatte to the sa
ame materrial.
 Reepresentativve samplin ng of the m
material on n the belt and
a carefull handling and analyysis to
gett the most accurate laaboratory rresult.
 Samples nee ed to be co
ollected oveer the full range of moisture
m annd material depth, likkely to
be seen durin ng normal operationss.
 Am minimum ofo 30 samples is requ uired to prooduce a staatistically ssignificant result
r
 Takke note off the condition of the e material, e.g., is there any nnoticeable segregation or
diffferences in
n moisture across thee belt or fro
om the top to the botttom of the material.
The most suitable method
m is to use a meechanical sampling system
s takking severa al increments or
cuts over several minutes andd combiningg into one sample. The
T numbeer and mas ss of increm
ments
in each ssample will depend on the va riability within the material
m beeing testedd and therre are
statistical methods and
a standa ards to dete e level of accuracy thhese will prrovide.
ermine the
If a mechanical sam mpling systtem is not available the
t next be est alternaative is stop
p belt sam
mpling.
To make it easier to t co-ordin nate the M MoistScan result
r to th
he sample , it is oftenn convenieent to
drop a ma arker on th
he belt at thhe MoistSccan. When n the belt is
s stopped a full cut should
s be taken
across thee belt of a width equ ual to 3 tim
mes the top
p size of th
he materiall. The cut should takke the
full depth of the matterial on the belt.
When the ere is no other
o altern
native spott samples may be ta aken. Exceept for fine e and extre emely
well mixe ed materia al, spot samples arre not truly representative samples and will have
significantt variation i.e. error; so the caliibration de
etermined in this wayy will also show
s significant
error. Cauution also needs
n to be exerciseed when taking spot samples
s too prevent innjury.
If it is jusst not posssible to sa
ample in a represen ntative manner, thenn contact your
y MoisttScan
representative to disscuss a ‘S Static Sam
mple Calibrration’ meethod. Whaatever the scenario, every
effort musst be made e to eliminaate as man
ny errors as
s possible..
 Set “Sm moothing” to a dura ation at lea ast as long
g as the time taken to collectt a sample
e. For
instancce, if it take
es 5 minuttes to colle
ect a sampple, then set
s “Smootthing 2” to 6 minutess. For
“spot” ssamples sets “Smootthing 1” to between 15 and 20 0 seconds . The “Sm
moothing” period
p
can be set via the HMI, firs st select th
he ‘Setup” main-menu, then thee ‘Parameters’ sub-mmenu,
ed by the ‘S
followe Smoothingg’ pop-up m menu. Thiss will give you the ‘S
Smoothing
g 1 & 2 fields to
input th
he approprriate value..
 Collectt a series of
o samples s (preferab
bly duplicattes), record
ding the Av
Average mo oisture reaadings
he HMI. En
from th nsure that the readin ng taken corresponds to the m material beiing collecte
ed by
conside Scan® to thhe sampling point.
ering the trransit time of the matterial from the MoistS
MOISTSCAN SER
pt’ 2015) Pag
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Docum M
10.4 Ty
ypical Re
esults
The follow
wing data is from a typical
t coa
al wash plant. The fiirst plot, F
Figure 8-2, is a plot of
o the
®
calibrated
d MoistSca an Series 3 Moisturre Analyse er moisturee result aggainst the moisture value
determineed by laboratory ana alysis. The second plot, Figure
e 8-3, is a tracking plot
p of the same
data, plottted against sample number.
n
1
14.0
1
12.0
Moistscan Moisture
1
10.0
8.0
6.0
Standard Error = 0.51%
(This is a measurre of the total error,
4.0
including analyse
er, sampling, prepara ation
and laboratory errror.)
2.0
0.0
0 2 4 6 8 10 12 14
ory Moisture
Laborato
Figure 10-2:
1 MoistScan® Serie
es 3 Moisturre Analyser vs
v laboratorry result
14
12
10
% Moisture
Laboratory
6
Mois tscan®
4 Standard Erroor = 0.51%

(This is a mea
asure of the total errror, including
analyser, sammpling, preparation and
a
2 laboratory errror.)
0
1 2 3 4 5 6 7 8 9 10
0 11 12 13 14 15 16 17 1
18 19
Sample
Figure 10--3: Tracking oistScan® Se

g plot of Mo eries 3 Moisture Analyser vs laboraatory result by sample
A “Pre – Comm missioning Checklis st”

Is pro
ovided as a separablle portion at dix 10.5 forr the easy oof copying, thus it can be
a the end of Append
made e available
e for multip
ple operatio
ons and un
nits.
MOISTSCAN SER
pt’ 2015) Pag
ge 48
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Docum M
10.5 Pre
e – Commissioning
M
MoistSccan® P
Pre‐Com
mmisssioning Instrruction
ns
This is a separa
able portio
on of the manual so itt can be co
opied for th
he Pre-Com
mmissionin
ng Stage.
The objective
o o
of this docu
ument is to
o:
1. Ensure tthat the MooistScan® is installedd correctly in the mos st appropriiate locatio
on given the
objectivees and con
nstraints.
2. Detail th
he process conditions s and serviices requirred whilst the Commiissioning Engineer
E is on
site to en
nable the analyser
a to
o be effectiively set up
p and calib
brated.
3. Ensure tthat the an
nalyser is fu
unctioning correctly prior
p to the Commisssioning Eng gineer attending
site.
se read thiis document and com
Pleas mmunicate with the nominated RTI Comm
missioning Engineer by
b
comppleting and
d returning the checklist on pag
ges 47 and 48.
Installation
se refer to the manua
Pleas al supplied
d for detailss on Installlation and mechanicaal and elec
ctrical draw
wings.
The following
f sshould be considered
c d prior to in
nstalling the
e MoistSca
an®:
 Locationn
 Environmment
 Mechanical Installa ation
 Electrica
al Installatio
on
 Commun nications
 Calibratiion Switchiing
 Calibratiion Sampling
Location
To de
etermine w
where the analyser
a sh
hould be in
nstalled consider the following:
 Objectivve
o C Consider the relevanc ce of the mmeasureme ent to proce
ess controll decisions s
o For feed-ba ack control the instrum
ment should be imme ediately doownstream m of the unitt
operation
o For feed-forrward control, the insstrument sh hould be im
mmediatelyy upstream m of the unit
operation
 Sampling
o C Consider the installation location n relative to
o any sampling pointts
o E Effective, reepresentatiive samplinng is the ultimate conntrolling facctor of the accuracy of
thhe instrume ent
o A Always aim to install the instrum ment immed stream of a sampling point
diately ups
 Auxiliaryy Inputs
o C Consider the installation location n relative to
o any otheer instrumeents that prrovide
ne ecessary/uuseful signals
o Im mportant auxiliary sig
gnals are tyypically either mass/v volume thrroughput sensors (e.g g.
be elt scales or
o flow meeters) or pro
operty sen nsors (e.g. temperatuure probes or density
ga auges)
MOISTSCAN SER
pt’ 2015) Pag
ge 49
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Docum M
Environmen
nt
The following
f d
data is for a standard, unmodifie
ed MoistSc
can®. Broa
ader rangees are available for
specialised app
plications:
 Ambientt Temperatture 0°C to 40°C
C, out of dirrect sunlight
 Relative Humidity Non-conndensing*
 Ingress Protection IP 65
Notee that the oonly measuurable impa

act from hu
umidity is the accumuulation of ccondensation on surffaces
between the tra ansmitter and
a receive er antennaas. In large throughpu
ut applicatiions (>100
0 tph) it is
unlike
ely that thee presence
e of conden
nsation woould be a measurable
m e disturbannce.
Mec
chanical Installation
Precision is maaximised when
w the prresentation
n of material is consisstent. On conveyor belts,
b this
involv
ves materiial being drressed cen ntrally and evenly on the belt, foor all feed rates. In vessels
v andd
hopppers this means conssistent pres sence of mmaterial bettween the antennas.
a Issues with material
preseentation sh
hould be reectified prio
or to installlation of the MoistSca
an system .
Conv
veyor Belt Installation
n
 The C-F Frame is typically insttalled on a purpose-b built frame,, attached to the conv veyor belt
stringerss
 It is recoommended d that the mounting
m frrame be ad djustable
 The C-F Frame musst be aligne ed in three ways:
o T The centreliine of the antenna
a co over should d be aligneed laterallyy with the conveyor
c belt,
and by exte ension the flow
f of maaterial
o In nstallation should be as close to o the trailin
ng (downsttream) idleer as practical, withou ut
in
nterfering with
w its ope eration, to m minimise belt
b deflection
o V Vertically suuch that thee clearancce between n the loadeed conveyoor and the lower ante enna
coover is bettween 10m mm and 20m mm
o T The above installation n paramete er does nott always ap pply to a “RReflectancce Type
A
Analyser”. The
T clearance distan ce betwee en the lowe er antenna surface an nd the
underside ofo the loade ed conveyo or belt will depend on n the “Set- Up” of the analyser and
a
th
he materiall being ana alysed. In m most cases s the clearrance will bbe the samme as that for
f a
“T
Transmissiion Type Analyser”,
A bbut confirmmation shou uld be sortt from RTI engineerin ng
prior to insta
allation to ensure
e opttimal perfo ormance off the analysser is achieved.
 Should tthe peak off the material flow no ot correspo ond with the centre off the conve eyor, then the
centre linne between the two antennas
a sshould be aligned
a witth the centtral peak of the material
cross se ection.
Hopp
per or Vesssel Installa
ation
 Antenna as should be b installed
d as low ass possible ono the vesssel, to enssure consis
stent prese
ence
of materrial
 Antenna as should be b installed
d such thatt the linearr distance between
b thhem is minimised,
 The fracction of material that will
w pass th hrough thee analysis zone
z shoulld be maximised
 Typicallyy, antennas are insta alled at the narrowestt section off the vesseel
MOISTSCAN SER
pt’ 2015) Pag
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Docum M
Elec
ctrical Ins
stallation
n
Electtrical installlation musst always be
b conducte
ed in acco
ordance witth local reggulations and
a site spe
ecific
safetty practicess.
MoistScan® inccorporatess sensitive microwavee compone ents that re

equire a higgh quality power sup
pply.
The following
f d
data corressponds to the standarrd, unmodified analyser:
 Supply V
Voltage 110 to 240 V AC
 Frequen
ncy 50/60 0 Hz
 Current Draw 300 W max
It is strongly
s reccommende
ed that the
e power sup
pply to the
e instrumen
nt be filtereed power, preferably
p on
UPS. Equipment damage e due to ina
adequate p
power supply is not covered
c unnder warranty.
Instru
uments maay be alternatively su upplied with
h 24 or 48 V DC pow wer suppliees, this sup
pply must be
b of
instru
ument quality, fluctua
ations in vo
oltage greaater than ± 2 volts cannot be to lerated.
Com
mmunica
ations
Moisture and other user-d be relayed to the Pla

defined outputs can b ant DCS viaa a numbe
er of
commmunication
n options. These are:
 4-20mA Analog ou ut
 RS-232 (two ports)
 RS-422//RS-485 (sshared portt)
 TCP/IP
The default
d com
mmunicatioon protoco
ol is Modbu
us. Most co
ommunication protoccols are av
vailable witth an
optio
onal upgrad
de using an
n AnyBus converter:
Calibration S
Switchin
ng
Normmally produ
ucts requiree product-s
specific ca
alibrations. There are several ooptions ava
ailable to
switc
ch betweenn calibratio
ons:
 Manuallyy, where th
he operatoor sets whicch calibratiion to apply from the MoistScann® HMI.
 Via Com
mmunications Protoco ol, where thhe plant DCS links to o MoistScaan® via a se
erial or
Ethernett connectio
on (e.g. RS
S-232, RS--422, RS-4 485 or TCP P/IP).
If botth options aabove are not available switchiing betwee en calibrations can bee done via a digital inp
puts
(2 sp
pare digital inputs ena able switch
hing betweeen up to 4 calibration
ns). This hhowever is not standa ard in
the current
c verssion of softtware. Ple
ease let RT
TI know if you
y require e calibratioon switching via digita
al
inputts.
Site Require
ements fo
or Calibrration
To ca
alibrate the
e MoistSca
an® the following serrvices and operationa
al conditionns are requ
uired whilsst the
commmissioning engineer is on site:
MOISTSCAN SER
pt’ 2015) Pag
ge 51
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Docum M
Emp
pty Belt
 Clean, e
empty belt for at leastt two compplete revolu
utions of th
he belt. Foor belts tha
at have
excessivvely long periods
p (e.g d conveyorrs), then the belt shouuld be run empty for at
g. overland
least 10 minutes.
 Ramp upp the throu

ughput of material
m on
n the belt until a nominal level iss reached. This shou uld be
performe
ed as graddually as po ossible (an
nd practicaal). If gradual increasee is not possible, then
stepped increasess will suffice
e.
Variiation in Moisture
e over fu
ull range moisturre range
 The moisture in the
e material should if p
possible be
e varied so
o that sampples can be e taken ove
er
the norm
mal moisturre range. Ideally 10 samples should
s be taken in duuplicate at low
l moistu
ure,
10 at ave
erage moissture and 10 at high moisture.
presentattive and Duplicatte Samplling

Rep
 Ideally oonline calib
bration requuires that a minimum m of 30 reprresentativee samples over the fuull
moisture e range and in duplicate. Norm mally samp pling is con
nducted ussing the sta
andard site
e
sampling g procedurre.
 If additio
onal samp pling is requ
uired and tthis has to be performmed manuaally site lab
bour will be
e
requiredd.
Laboratory A
Analysis
s
 Collected sampless require prrompt and representa ative analy
ysis. Analyysis technique should d be
consisteent with typ
pical analys
sis proceduures and comply
c with
h any standdards appllicable to thhe
specific material. If this serv
vice is not available, then an ex
xternal labooratory will be used.
se commu
Pleas unicate withh the nomin
nated Commmissioning Engineer to discusss these sitte requirem
ments
and any
a limitatiions that may
m need to o be addre
essed.
MOISTSCAN SER
pt’ 2015) Pag
ge 52
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Docum M
Pre‐Co
ommisssionin
ng Che
ecklistt
Priorr to a Commmissioning g Engineer attending site it is im
mportant that the ana lyser is ins
stalled and set
up coorrectly. A
All instructio
ons in the manual
m an
nd associatted drawings should be followe ed. Details on
the various
v inpu
uts and ou utputs are available
a in
n the manu ual and asssociated ellectrical drrawing.
Pleas
se complette the follo
owing chec
cklist and re
eturn via email
e of fax
x together w
with requested digita
al
photo
os.
Mec
chanical installation
 What
W is the clearance from the top
t of the ttransmitterr cover to th
he bottom of the conveyor belt
when
w the beelt is emptyy?_______
____mm (tthis shouldd be between 10-20m mm)
 What
W is the clearance from the top
t of the a
antenna coover to the bottom of the conveyor belt wh
hen
th
he belt is fu
ully loaded? _______
____mm (tthis should
d be between 10-20m mm)
 How
H is the M
MoistScan® aligned? ?
1 The leveel sensor iss aligned with
w the pea
ak of the material
m
2 The leveel sensor iss aligned with
w the cen
ntre of the conveyor belt
 Does
D the material proffile changee under diffferent proc he peak of the
cess conditions (thatt is does th
material
m mo
ove laterallyy on the be
elt)?
1 YES
2 NO
 Send photos of the fin

nal installattion, clearlyy showing belt cleara
ance and cconveyor alignment,
a t
to
Callidan
C Insstruments.
 Send a photo indicatin t profile of material on the co

ng clearly the onveyor to
su
upport@re
ealtimegrp.com
Elec
ctrical Ins
stallation
n
 The MOIST
TSCAN hass been inte
egrated to tthe site po
ower supply
y and cont rol system.
1 YES
2 NO
 What
W type o
of power su
upply is be
eing used?
1 240V AC C
2 110V AC C
3 24V DC
4 Other __ __________________ ____
MOISTSCAN SER
pt’ 2015) Pag
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ment №:
Docum M
 What
W type o
of commun nications is being use
ed?
1 4-20mA AO1
2 4-20mA AO2
3 RS-232
4 RS-485
5 TCP/IP __.___.___
IP __ _.___ SM ____.___.__
__.___ GW ____.___.___._
___
6 DeviceNNet
7 ProfiBuss DP
8 CANope en
 Has
H the Con
nveyor Running signal been co
onnected (o
optional)
1 YES
2 NO
 Has
H the Sysstem Healtthy signal been
b conn ected (optional)
 If the profile oduct on the belt is errratic then the 4-20m

e of the pro mA signal frrom a belt weigher
lo
ocated closse by on th he same coonveyor co ould be con nnected in place of thhe Ultra So
onic input to the
MoistScan®
M ®
1 YES
2 NO
 Send a photo or copy down from m the HMI ““Inputs” pa

age (Select RESULT TS then INPPUTS on th
he
HMI)
H the va
alues of IN1
1 to IN6 wh
hile the con
nveyor is empty,
e clea
arly showinng the mea
asurements, to
Real
R Time Instrument
IN1 _
______
IN2 _
______
IN3 _
______
IN4 _
______
IN5 _
______
IN6 _
______
Squirrcle _
______
 Send a photo of the HMI

H “Inputs
s” page wh ile the con
nveyor is fu
ully loaded,, clearly sh
howing the
measureme
m ents, to RTTI.
IN1 _
______
IN2 _
______
IN3 _
______
IN4 _
______
IN5 _
______
IN6 _
______
Squirrcle _
______
Pleas
se complete pages 53
5 and 54 and
a send tto your nom
minated Co
ommissionning Engine
eer prior to
o his /
her arrival
a on ssite.
MOISTSCAN SER
pt’ 2015) Pag
ge 54
ment №:
Docum M

MoistScan Op Manual CL - V103. Rev. 1.2

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Scan® Se

MoistS eries III On-Lin

The MoisstScan® Se eries 3 ra

3.4 Liffting of the Analy

The electrrical powerr supply an

Caution:: Durin ng the phyysical installlation of th

Figure 1: G7 HMI Fro

The log filles are org

Settings – This file is created every 30 m

Trends – This file iss used to create

Squircle – This file is used to

Each log file is nam

6.1.1 HMI / Plant

6.2.1 Depth Trend

Figure 12: Digital Inputs Display

Figure14: Inputs D isplay (Inpu

Figure 19: Limits Display

HMI Vers sion

Figure 20: Mis

Figure 22: Screen Settup Display

Figure 23: Status Display

Alternatiively, the user

--- Signal: 1-9 (bad signal level, route cannot work

Part CURRE ENT MOISTTSCAN MA A500 HD

OPTION NAL COMPO ONENTS

The 2002 Maximum m Exposurre Levels t o Radiofre

Trend line 2 y = 1.45x + 360

Figure 10-1 Empty Beltt Microwave

4 Standard Erroor = 0.51%

Figure 10--3: Tracking oistScan® Se

A “Pre – Comm missioning Checklis st”

Notee that the oonly measuurable impa

MoistScan® inccorporatess sensitive microwavee compone ents that re

Moisture and other user-d be relayed to the Pla

 Ramp upp the throu

presentattive and Duplicatte Samplling

 Send photos of the fin

 Send a photo indicatin t profile of material on the co

 If the profile oduct on the belt is errratic then the 4-20m

 Send a photo or copy down from m the HMI ““Inputs” pa

 Send a photo of the HMI

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