MICROWAVE MOISTURE SENSOR WITH WIRELESS DATA TRANSMISSION FL-WAPP

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- 1 MICROWAVE MOISTURE SENSOR WITH WIRELESS DATA TRANSMISSION FL-WAPP INDEX General Function Description P. 2 Technical Data P. 2 1. Software Installation P. 3 2.

1 - 1 MICROWAVE MOISTURE SENSOR WITH WIRELESS DATA TRANSMISSION FL-WAPP INDEX General Function Description P. 2 Technical Data P Software Installation P System Integration P Sensor as an Access Point (Server) P Sensor in a Network P Sensor Connection P Clamp Connection / Clamp Box P Operation Software P Start Page P Measured Value Recording P Service Page P Measurement P Limit Values P Filtering P Analog Outputs P Configuration Assistant P Calibration Page P Calibration Procedure P Favorites List P Recalibration P Navigation Bar P Writing and Reading of the Sensor P Saving the settings on a data carrier P Error Detection P Sensor Checking P Connection Problems P Parameterization via Internet browser P Sensor Installation P Sensor Installation - Mixer Measurement P Sensor Installation - Aggregate Measurement P. 18

2 - 2 GENERAL FUNCTION DESCRIPTION The FL-WAPP sensor is a microwave moisture and temperature sensor using WIRELESS data transmission. Transmission of measured values as well as configuration of the sensor are enabled by wireless, manufacturerindependent devices. Measured values displaying and parameterization can be set using the LUDWIG-evaluation software for PC with WINDOWS operating system or any web browser. The sensor supports two analog outputs as an additional possibility for measured value output. An average value can be formed over certain time-limited measurement processes using a start input. The measuring signals are processed by internal filtering algorithms. TECHNICAL DATA Power Supply 12 24V DC Measuring Value Outputs 0-20 ma (4-20 ma) (moisture) / 4-20 ma (temperature) Input 1 x Start Input 12 24V DC Measuring Range 0-15,0% / 0-XX,X% (depending to the material to measure) / 0-80 C Accuracy Depending to the measured medium (approx. ± 0,3%) Power Consumption 2 VA Wireless data transmission WLAN / APP (by UDP-Protocol) Temperature Range 0-80 C Connecting Cable 5x0,25 mm 2 shielded (foil screen), Length 2 meters, with Miniature Round Connector 5-pole Dimensions Ø: 75 mm, Length: 100 mm Weight 1,8 kg Cover Stainless Steel, IP 68

- 3 1. SOFTWARE INSTALLATION Execute setup.exe at the delivered data carrier and follow the instructions. Usually the program is listed on the exception list of WINDOWS firewall when installing.

1 SENSOR AS AN ACCESS-POINT (SERVER) The sensor is running as access point when delivered. After installation the software is even in this operation mode.

3 SOFTWARE INSTALLATION Execute setup.exe at the delivered data carrier and follow the instructions. Usually the program is listed on the exception list of WINDOWS firewall when installing. If you are using another firewall or the security rules of your operating system do not allow an installation, you have to save the FLWAPP.exe manually in the exception list. 2. SYSTEM INTEGRATION 2.1 SENSOR AS AN ACCESS-POINT (SERVER) The sensor is running as access point when delivered. After installation the software is even in this operation mode. First, make a WLAN connection to the probe for configuration. The probe s network name is FL-WAPP xxxxx. xxxxx and depends to the 5-digit serial number of the sensor. Password for WLAN network is ludwig123. Important: The computer connected to the sensor must not be part of another network. The sensor only accepts one incoming connection. Open the software now. A functioning connection is marked with a blue logo. Additionally, the version and the connected sensor number is shown in the status bar. If no connection is possible, the logo stays red. In this case, please check the following: - Is the WLAN connection to the probe active? - Computer is operating with another network connection (LAN cable)? - Software is listed at the exception list of the firewall? - Software is set as Sensor as Access Point? If the sensor should furthermore operate as access point, please skip the following steps.

4 SENSOR IN A NETWORK For access to a router select in the menu: Probe configure router access. Password

- 5 Enter the requested data of your router and the specification of the probe on the page IP configuration.

Change the operation function of the software from The probe works as an access point to The probe(s) is/are connected to a router.

5 - 5 Enter the requested data of your router and the specification of the probe on the page IP configuration. We recommend a static allocation of the IP addresses, not DHCP. The address release can even be set as fix after the IP allocation through the router. Confirm your inputs with Apply. At the site Edit profiles you can create now a profile with the access data of your router. Even here, all inputs are to confirm with Apply. Change the operation function of the software from The probe works as an access point to The probe(s) is/are connected to a router. Finally, insert the probe into your software list at WAPP access. You can assign a free name to the probe s IP address which will be shown in the selection list on the main window. at tab Settings : In the main window the following drop-down-list is appearing To accept the changes to the sensor, it has to be re-set once. Than the probe is logging itself into the router.

- 6 3. SENSOR CONNECTION Connection without clamp box Connection via clamp box Wire color: Meaning: White +12.

+outputs Green Moisture / 0-20 ma (4-20 ma) Shield/Screen PE The supply voltage must have the same GND as the analog input card.

XX,X%) is free selectable at the parameterizing software.

4-20 ma Moisture Output 0-20 ma (4-20 ma) Power supply +12V +24V DC!!! For absolute attention!

6 SENSOR CONNECTION Connection without clamp box Connection via clamp box Wire color: Meaning: White V DC Power supply Brown Output Temp. / 4-20 ma Red Start / V DC Black GND Power suppl.+outputs Green Moisture / 0-20 ma (4-20 ma) Shield/Screen PE The supply voltage must have the same GND as the analog input card. The scale of the temperature signal is fix scaled: (4 20 ma 0 80 C) The setting of the moisture output (0 20 ma (4-20 ma) 0 XX,X%) is free selectable at the parameterizing software. Pin assignment of the sensor connector Shield/Screen/PE Start Input 12V 24V DC GND Power supply and Outputs Temperature Output 4-20 ma Moisture Output 0-20 ma (4-20 ma) Power supply +12V +24V DC!!! For absolute attention!!! The power consumption 24VDC for the probe(s) has to correspond to the EMV guidelines. If not, the power consumption has to be guaranteed via separate power supply through an interference suppression filter. The probe cable should not be laid together with load carrying cables.

- 7 4. OPERATION SOFTWARE 4.1 START PAGE In the upper half of the program display the current measured values are shown.

Current measured values: Values are corresponding to the direct unfiltered measured value at the sensor.

7 OPERATION SOFTWARE 4.1 START PAGE In the upper half of the program display the current measured values are shown. In the lower half the course of the raw values (red) and the filtered values (blue) are shown in a period of approx. 4 minutes. Current measured values: Values are corresponding to the direct unfiltered measured value at the sensor. Filtered values: Here, the value is displayed which is given out at the analog output of the sensor. Even with the measuring mode hardware contact the measured result is displayed when given out at the analog output. If the hardware contact is closed, the measuring window is colored green during this time. Temperature: Probe value: Language: Current configuration: Manually start/stop: Displaying of the current temperature at the sensor s measuring surface. This value enables to check the function of the probe and is helpful for our technicians in case of a probable error analysis. Select the requested display language. Depends to the system setting for a certain installation situation. Simulation of a start/stop operation, which is otherwise carried out via an external hardware contact.

- 8 4.2 MESURED VALUE RECORDING The measured value recording enables the protocolling of the filtered and unfiltered measure signals during the time of 15 minutes.

Start of recording: Start recording: Start recording: Playback of recording: By pressing Start capture. By pressing Stop capture.

8 MESURED VALUE RECORDING The measured value recording enables the protocolling of the filtered and unfiltered measure signals during the time of 15 minutes. If the maximum recording time is topped, the oldest measured values are automatically overwritten through the actual measured values. The recording rate is approx.. 2 measurements per second. Start of recording: Start recording: Start recording: Playback of recording: By pressing Start capture. By pressing Stop capture. After the recording is stopped, a dialog field is opening automatically to choose the location to save. The measured values are saved in a CSV file and can be opened again through an EXCEL program or others. When clicking INSERT and LINE, the recording can be displayed as a diagram. Data series in a CSV file: Data series A mentions the unfiltered raw values of the sensor Data series B mentions the filtered raw values of the sensor Data series C mentions the calculated % moisture value (*) (*) In START/STOPP mode (see 5.1 MEASUREMENT ), data series C mentions the % moisture value evaluated through the START/STOP cycle. A positive data series peak shows a positive edge at the start input (START), a negative peak shows a falling edge at (STOP).

9 SERVICE PAGE Tab service shows the setting possibilities of the measuring behavior of the sensor. The access to this site is secured with a password use password MEASUREMENT Measuring mode: permanent: Start/Stop: Start delay: Dosing time: Time for measuring mode: The measurement is carried out continuously; the filtered measured value is continuously given out at the analog output. Measurement takes place in mode hardware contact. Measured values between the rising and falling edge are averaged arithmetically and given out at the analog output after the measurement is completed. Measurement is proceeded the same as Start/Stop, only difference is that a delay time is running after the rising edge before the measured values are collected. If the falling edge is effected during delay time, no measurement is proceeded. After an impulse of a hardware contact, a measurement takes place for the pre-set time range. Measured value is given out at the analog output. When the contact is closed over the dosing time, a new measurement is started, over the pre-set dosing time. If the contact is falling during the 2 nd or one of the following dosing times, current measurement is stopped and the last correctly measured result is shown at the analog output. Depending to the measuring mode, the start delay time and the dosing time can be set. 5.2 LIMIT VALUES Min. moisture: Max. moisture: Minimal moisture value (%) is shown in the display field Moisture or is given out from the moisture value output at an analog output or serial interface. Smaller moisture values are limited to Min. moisture. Analog to the above, a maximum moisture value can be set which cannot be topped when displaying nor with the measured value output.

10 FILTERING Filtering mode: Raw values: Measured values are processed only via low-pass filters. P-Detection: Between both low-pass filters the highest value evaluated during the pre-set time is taken for further processing. Average: Median: Measured values are continuously averaged during the pre-set time. Median is passed from the pre-set range to the second filter from the temporal window. Duration filtering mode: Refuse min. values: Refuse max. values: Filter 1: Filter 2: Here, time range for the selected filter mode is set. The time range is dynamic, it follows every new measured value. Maximum setting is 30 seconds. This setting is only used at mode Median. Here, the time range is set, that way, that the lowest measured values are not processed when forming the median. Even this setting is only valid in mode Median. Here, the time range is set so that the highest measured values are not processed when forming the median. Setting of limit frequency of first low-pass filter. This filter damps the signal before transmitting to the filter mode. The lower the value is set, the higher is the damping. Second low-pass filter damps the signal extracted from the filter mode furthermore. 5.4 ANALOG OUTPUTS The analog temperature output is fix to 4 20 ma. 4 ma depends to a temperature of 0 C and 20 ma to a temperature of 80 C. Output mode: Output current/moisture 1: Output current/moisture 2: Select between 0 20 ma and 4 20 ma. Setting, at which moisture the analog output is giving out a certain voltage. 2nd point for determination, at which moisture the analog output is giving out a certain voltage. Using these two points, the analog output for the moisture is free selectable. Even an anti-proportional setting is possible, e.g. for actuating a control valve. Please pay attention: All changes on the service page are only confirmed when touching Probe > Write or confirmed when leaving the service page and activated in the probe!

11 CONFIGURATION ASSISTANT With the configuration assistant, the service settings can be adjusted to certain installation situations of the sensor; all parameters are then set to the depending (correct) settings. Active selection is marked with a green arrow. If no selection is marked, one or more parameters on the service page are different from the selection possibilities. Mixer High measured signal filtering Aggregates, continuously (e.g. on belts) Slight filtering, short measuring window for the averaging Aggregates, charge wise, control No filtering, control is proceeding the average value evaluation during the dosing Aggregates, charge wise, start/stop Automatically averaging via hardware contact supported by the control Please pay attention: If the selection is changed, all current settings on the service page and the probe are overwritten!

- 12 6. CALIBRATION PAGE With the tab Calibration, the calibration curves are stored the measured values of the microwave moisture sensor are adapted to the product features.

12 CALIBRATION PAGE With the tab Calibration, the calibration curves are stored the measured values of the microwave moisture sensor are adapted to the product features. Possibility of taking a material specific calibration (see 6.1) or to use a pre-calibrated curve from the FAVORITES LIST (see 6.2). 6.1 CALIBRATION PROCEDURE Example: Enter the material name at the page CALIBRATION / product name. Take a sample of the material to be measured from the process flow, e.g. 5 kg. Determine the moisture of the material with the DARR method, e.g. 2%. Moist the dried material during the following calibration process in 2 steps again, corresponding to the complete moisture range of the material (e.g. 2%, 6%). Remove the sensor from its fixation and turn it while rotating it slightly into the prepared material sample (2%). Select quotient value 1 through touching the upper measuring field and enter the moisture 1 (here:2%). Raise the moisture of the material sample to 6 %. Example: 1. Moisture 2 % assumed sample quantity: 5 kg 2. Moisture 6 % difference 4 % Water quantity to add: (5000 g / 100) x 4 = 200 g Add now the 200 g water to the material sample and homogenize it well to receive 6% material moisture. Press the sensor again by slightly turns into the sample and note down quotient value 2 by touching the lower measuring field and enter the moisture 2 (here 6%). You receive e.g.: Quotient 1: 1,843 Moisture 1: 2 % Quotient 2: 3,686 Moisture 2: 6 % Activate the curve through Probe > Write or take over the curve when changing to FAVORITES LIST and select the ADD -button. Re-install the sensor into the fixation and start a usual measurement. When receiving measured value deviations please do a RECALIBRATION (see 6.3).

- 13 6.2 FAVORITES LIST To ease starting-up, it is possible to use standard calibration curves to avoid a specific calibration process.

Material specific curves you have calibrated on your own can be added to the listing with Add >>. Curves can be deleted with Delete from list. You return to the CALIBRATION page with cancel.

13 FAVORITES LIST To ease starting-up, it is possible to use standard calibration curves to avoid a specific calibration process. Calibration curves of some common materials are already pre-set in the favorites list. Select first the requested material and then << Replace. Material specific curves you have calibrated on your own can be added to the listing with Add >>. Curves can be deleted with Delete from list. You return to the CALIBRATION page with cancel. To correct measuring variations please use RECALIBRATION (see 6.3). 6.3 RECALIBRATION If the measured moisture value is varying from the real moisture value after the calibration or the selection of a curve from the favorites list, the curve has to be corrected by recalibration. Example: Drying (real): 4 % Display in software: 3 % Curve has to be moved by 1 %. Klick on Parallel movement, enter 3% at the field Display and 4% at the field Drying. With OK, the parallel movement of the complete curve is carried out now.

- 14 7. NAVIGATION BAR 7.1 WRITING AND READING OF THE SENSOR In general, all data are red out of the sensor when a new connection made.

2 SAVING THE SETTINGS ON A DATA CARRIER At menu point File, you can save the current configuration including all logged calibration curves to a file.

14 NAVIGATION BAR 7.1 WRITING AND READING OF THE SENSOR In general, all data are red out of the sensor when a new connection made. When leaving a tab or when closing the software you will be reminded to save probable changes. Certainly, the sensor can be written or read out manually using the menu point Probe. 7.2 SAVING THE SETTINGS ON A DATA CARRIER At menu point File, you can save the current configuration including all logged calibration curves to a file. These data can be reload to the sensor upon request. Data sending has to be carried out manually or after the security check. 8. ERROR DETECTION 8.1. SENSOR CHECKING At the upper side the current raw measured value of the sensor is displayed at Probe value. For a correct function of the probe the following values should be shown: Probe value Sensor clean and dry Sensor covered with hand Should the values of your probe are out of this range, please contact one of our technicians for further steps. 8.2 CONNECTION PROBLEMS If the name of the sensor is listed in the network of your computer, but no connection can be made: - make sure that no other end device (PC, Smartphone) is connected with the sensor If the software s connection displaying is showing that no data exchange is proceeded: Red Logo: Data exchange interrupted Blue Logo: Data exchange OK - check if you are connected to the sensor at the network of your computer - shorten the distance between computer and sensor or change your position - make sure the computer is not connected to another network (e.g. through LAN) - is the sensor listed in the exception list of the firewall? - is the software in the sensor set on probe as access point?

15 PARAMETERIZATION VIA INTERNET BROWSER Independently from the LUDWIG operation software the possibility of displaying of the measured values and parameter entering is enabled by any internet browser. First, make a WLAN connection to the sensor as described at 2.1. Open the internet browser of your computer and enter fl-wapp.net at the address line. At the 3 following menus Start, Systemdata and Calibration now parameters can be changed. The menus are only available in English. Special functions as Recalibration, measure in the calibration menu or the favorites list are not available when using the internet browser. The parameter changing is saved in the probe when touching the APPLY button at the end of the page. Change is confirmed when the button is turning green.

- 16 10. SENSOR INSTALLATION 10.1 SENSOR INSTALLATION MIXER MEASRUREMENT Only one microwave moisture probe is needed, independent from mixer type and size.

INSTALLATION IN THE MIXER BOTTOM OF PLANETARY / ANNULAR PAN MIXERS - Choose an installation place which is cleaned sufficiently every time (e.g. on the highest point of uneven mixer bottoms).

16 SENSOR INSTALLATION 10.1 SENSOR INSTALLATION MIXER MEASRUREMENT Only one microwave moisture probe is needed, independent from mixer type and size. To guarantee optimal measure results, the probe has not to be covered by material anytime and the material to measure has to be sufficiently homogenized. INSTALLATION IN THE MIXER BOTTOM OF PLANETARY / ANNULAR PAN MIXERS - Choose an installation place which is cleaned sufficiently every time (e.g. on the highest point of uneven mixer bottoms). - Place the probe near the view hatch to enable visual controlling without entering the mixer to avoid hazardous injury. Specific: Annual Pan Mixers - If the mixer arms are giving during the dry mix process an unsufficient homogenizing is according on the mixer bottom zone which results in error measurements. - Remedy: Reduce the mixing size or re-adjusting the feathers. INSTALLATION IN A (SINGLE / DOUBLE) SHAFT -MIXERS - We recommend the installation of our wear tile round. - Place the probe near the view hatch to enable visual controlling without entering the mixer to avoid hazardous injury. - The probe sould be installed in a middle distance between both side walls of the mixer pan. (approx. 1m distance to the side wall) Best place: near the opening clap - The probe should be installed at 05:00 approx. (The mixer shares should transport the material upwards on the probe.) - The above mentioned recommends are even to be considered with single shaft mixers. USEFUL TIPS - The probe has to be installed in min. 1 meter distance to electric motors (e.g. mixer drive). - The probe should be installed near an inspection clap. - If the mixer bottom is unevenly used, the probe should be installed on the highest place of the bottom. - The holder surface and the probe s surface have to be installed the same level as the mixer bottom. - The distance of the probe s measure surface (centre) should take 15 cm from the inner side of the outer mixer wall minimum. - The probe cable has not to be layed together with load carrying cables. - Before installing in the holder, the probe should be lubricated with high-performance grease. - Only de-installing without using massive force. Pull out the probe of the holder only from bottom to top. - Welding working in the probe s environment only with uninstalled probe. - The clamp box (screwing and plug mounted face down) should be placed in the lower third of the mixer wall with screws to the mixer cover in a max. distance of 1,5m to the probe.

17 - 17 HOLDER SYSTEMS To protect the probe optimally against wear and electrical interference effects, one of the following holder systems should be used: Wear Tile ROUND

- 18 10.2 SENSOR INSTALLATION AGGREGATE MEASUREMENT To guarantee optimal measure results the probe has to be free of material storage anytime.

- Do not assign the probe s measure surface too high above the silo outlet. - Do not assign the probe s measure surface directly to bracings or steam jets.

INSTALLATION AT A SLIDE ONTO CONVEYER BELT - Fix the installation set absolutely stable and vibration-free.

18 SENSOR INSTALLATION AGGREGATE MEASUREMENT To guarantee optimal measure results the probe has to be free of material storage anytime. INSTALLATION WITH PROTECTION TUBE IN THE SILO OUTLET - The probe s measure surface has to be situated in the current material flow. - Do not assign the probe s measure surface too high above the silo outlet. - Do not assign the probe s measure surface directly to bracings or steam jets. - Pay attention when filling the silo that no material falls from high above onto the probe (do not empty the silo totally). INSTALLATION AT A SLIDE ONTO CONVEYER BELT - Fix the installation set absolutely stable and vibration-free. - Press the slide as deep in the material as the measure surface is covered with the material even when material height variations occur. - Relief: The material flow s height can be optimized to approx cm when affixing deflector or dust plates on the dosing belt. - The angle should be 10 (visual effect skiing ). - Hold a constant conveying speed of the measure medium. - Do not assign the probe directly over a guide roller. INSTALLATION WITH A WEAR PROTECTION TILE UNDERNEATH A SILO OUTLET - The probe s measure surface has to be situated in the middle of the current material flow. - The probe s surface should be totally covered with the material to be measured. Measured value variations result, if the probe s measuring surface is not covered enough. - Evaluation of a reliable measured value requests a sufficient dosing time (2 sec. min.).

- 19 USEFUL TIPS - The probe has to be installed in min.

- The holder surface and the probe s surface have to be installed the same level.

- Before installing in the holder, the probe should be lubricated with

- Welding working in the probe s environment only with uninstalled probe.

the cover in a max. distance of 1,5m to the probe.

19 - 19 USEFUL TIPS - The probe has to be installed in min. 1 meter distance to electric motors (e.g.. mixer drive). - The holder surface and the probe s surface have to be installed the same level. - The probe cable has not to be laid together with load carrying cables. - Before installing in the holder, the probe should be lubricated with high-performance grease. - Welding working in the probe s environment only with uninstalled probe. - The clamp box (screwing and plug mounted face down) should be fixed with screws to the cover in a max. distance of 1,5m to the probe. HOLDER SYSTEMS For protecting the probe optimally against wear and interference effects, one of the following holder systems should be installed: Wear Protection Pipe Slide Wear Protection Tile Installation Microwave Probe with wear protection tile underneath silo outlets

Manufactured by M-Sens 2 Online-Moisture Meter for Solids. Moisture % Product Information.

EN Manufactured by M-Sens 2 Online-Moisture Meter for Solids Product Information Moisture 13.47 % www.onthelevel.com Using M-Sens 2 is specifically designed for continuous moisture measurement of solids.