USER MANUAL

S300 Series Dust Monitors

Models S303 and S304
Document information
Revision 5
Publication date: 2020-11-12
Device series: S300
Applicable products: S303, S304
Original language: en-US

Trademarks
Modbus is a registered trademark of Schneider Electric USA Inc.

Legal disclaimer
Seller hereby disclaims any and all warranties and representations (express or implied, oral or written),
including any and all implied warranties of merchantability or fitness for any purpose whether or not
seller knows, or has reason to know, has been advised, or is otherwise in fact aware of any such purpose,
whether alleged to arise by law, by reason of custom or usage in the trade, or by course of dealing or
performance.

Purchaser understands and agrees that it shall be purchaser’s sole responsibility to ensure that all
products obtained from seller shall adhere to applicable laws, codes and standards within the territory
of use. Purchaser absolves and holds seller harmless for any alleged violations of such local laws, codes,
and standards within the territory of use.

Copyright
Subject to change without notice.
All rights reserved. ©2020 Sintrol.

©2020 Sintrol.
All rights reserved. 2 (116) Revision 5
Contents
1 About this manual ............................................................................................................................ 7
1.1 Description of symbols ......................................................................................................................... 7
1.2 Abbreviations ....................................................................................................................................... 8
2 Safety............................................................................................................................................... 9
2.1 Warnings .............................................................................................................................................. 9
2.2 Intended use ...................................................................................................................................... 10
2.3 Use in potentially explosive atmospheres ......................................................................................... 11
2.4 Conformity to standards and directives ............................................................................................ 11
3 Product overview ........................................................................................................................... 12
3.1 Product description ............................................................................................................................ 12
3.1.1 Key properties ............................................................................................................................. 12
3.1.2 Commissioning ............................................................................................................................ 12
3.1.3 Installation................................................................................................................................... 13
3.1.4 Settings and parameters ............................................................................................................. 13
3.2 Design drawings ................................................................................................................................. 13
3.2.1 Dimension drawings .................................................................................................................... 15
3.2.2 Identification ............................................................................................................................... 17
3.3 Scope of delivery ................................................................................................................................ 18
3.4 Features and accessories ................................................................................................................... 19
3.4.1 Standard features........................................................................................................................ 19
3.4.2 Optional features and accessories .............................................................................................. 19
3.5 Operating principle ............................................................................................................................ 23
3.5.1 Inductive Electrification Unit....................................................................................................... 23
3.5.2 Potential influences on measurement results ............................................................................ 23
4 Storage .......................................................................................................................................... 28
5 Mechanical installation .................................................................................................................. 29
5.1 Unpacking and inspection .................................................................................................................. 29
5.1.1 Unpacking.................................................................................................................................... 29
5.1.2 Inspection .................................................................................................................................... 29
5.2 Selecting installation location ............................................................................................................ 29
5.2.1 Ambient environment ................................................................................................................. 30

©2020 Sintrol.
All rights reserved. 3 (116) Revision 5
 5.2.2 Vibration ..................................................................................................................................... 30
5.2.3 Location....................................................................................................................................... 30
5.2.4 Orientation .................................................................................................................................. 31
5.2.5 Probe length................................................................................................................................ 31
5.2.6 Position ....................................................................................................................................... 32
5.2.7 Duct pressure .............................................................................................................................. 33
5.2.8 Process temperature .................................................................................................................. 34
5.3 Installing sensor ................................................................................................................................. 34
5.3.1 Safety precautions ...................................................................................................................... 34
5.3.2 Installation .................................................................................................................................. 35
6 Electrical installation....................................................................................................................... 40
6.1 Electrical safety .................................................................................................................................. 40
6.2 Cable types ......................................................................................................................................... 41
6.3 Electrical connections ........................................................................................................................ 42
6.3.1 Main board.................................................................................................................................. 42
6.3.2 Terminal blocks ........................................................................................................................... 43
6.3.3 Grounding ................................................................................................................................... 43
6.3.4 Power supply............................................................................................................................... 48
6.3.5 Relays .......................................................................................................................................... 52
6.3.6 Analog mA output ....................................................................................................................... 55
6.3.7 RS-485 buses ............................................................................................................................... 59
6.3.8 Connecting with USB................................................................................................................... 66
6.3.9 Analog mA input ......................................................................................................................... 67
7 DustTool ......................................................................................................................................... 71
7.1 Overview ............................................................................................................................................ 71
7.2 System requirements ......................................................................................................................... 71
7.3 Main view ........................................................................................................................................... 71
8 Commissioning and system setup.................................................................................................... 73
8.1 Auto setup .......................................................................................................................................... 73
8.1.1 Overview ..................................................................................................................................... 73
8.1.2 Operation statuses ...................................................................................................................... 73
8.1.3 Performing Auto Setup ............................................................................................................... 75
8.2 Changing parameters ......................................................................................................................... 76

©2020 Sintrol.
All rights reserved. 4 (116) Revision 5
 8.2.1 Main interface ............................................................................................................................. 76
8.2.2 DustTool software ....................................................................................................................... 77
8.2.3 Modbus RTU and Sintrol Network protocol ............................................................................... 77
8.2.4 Wireless connection .................................................................................................................... 78
8.3 Setting up device network ................................................................................................................. 78
8.3.1 Naming devices ........................................................................................................................... 79
8.3.2 Wired device network ................................................................................................................. 79
8.3.3 Wireless device network ............................................................................................................. 81
8.3.4 Combining wired and wireless connections in a network .......................................................... 83
9 Operation ...................................................................................................................................... 84
9.1 Main interface .................................................................................................................................... 84
9.2 Relay, LED and display functional logic .............................................................................................. 85
9.2.1 Operation statuses ...................................................................................................................... 85
9.2.2 Relay logic ................................................................................................................................... 85
9.2.3 LED and display logic ................................................................................................................... 87
9.3 Parameters ......................................................................................................................................... 87
9.3.1 Overview ..................................................................................................................................... 87
9.3.2 Parameter 1: Display unit............................................................................................................ 89
9.3.3 Parameter 2: Signal averaging time ............................................................................................ 89
9.3.4 Parameter 3: Measurement range ............................................................................................. 89
9.3.5 Parameter 4: ALERT threshold .................................................................................................... 90
9.3.6 Parameter 5: ALARM threshold .................................................................................................. 91
9.3.7 Parameter 6: Alarm delay time ................................................................................................... 92
9.3.8 Parameters 7 and 8: Flow speed compensation......................................................................... 92
9.3.9 Parameter 9: Zero/span check interval....................................................................................... 93
9.3.10 Parameter 10: Command parameter ........................................................................................ 93
9.3.11 Parameters 11 to 14: Displaying measurement results in mg/m3............................................ 95
9.3.12 Parameters 15 and 16: IEU to 20 mA scaling ............................................................................ 97
9.3.13 Parameter 17: Firmware version .............................................................................................. 98
9.4 Troubleshooting ................................................................................................................................. 99
9.4.1 Error codes in FAULT mode......................................................................................................... 99
9.4.2 Display indicates “- -.- -“............................................................................................................ 101
9.4.3 Display indicates “[n] - - -” ........................................................................................................ 102

©2020 Sintrol.
All rights reserved. 5 (116) Revision 5
 9.4.4 No output signal........................................................................................................................ 102
9.4.5 No response after Auto Setup .................................................................................................. 102
9.4.6 Device lid does not open .......................................................................................................... 103
10 Maintenance and inspection ....................................................................................................... 104
10.1 Safety precautions ......................................................................................................................... 104
10.2 Maintenance and inspection interval ............................................................................................ 105
10.3 Maintenance and inspection ......................................................................................................... 105
10.3.1 Removing device from the process ........................................................................................ 106
10.3.2 Cleaning supplies .................................................................................................................... 108
10.3.3 Maintenance of Teflon-coated probe..................................................................................... 108
10.4 Returns ........................................................................................................................................... 108
11 Recycling and disposal ................................................................................................................ 109
11.1 Packaging ....................................................................................................................................... 109
11.2 Device ............................................................................................................................................. 109
12 Specifications.............................................................................................................................. 110
Appendix A: ISO 9001 certificate ...................................................................................................... 112
Appendix B: Modbus RTU registers .................................................................................................. 113
Notes .............................................................................................................................................. 115

©2020 Sintrol.
All rights reserved. 6 (116) Revision 5
1 About this manual
This user manual contains the installation, commissioning, operating and maintenance instructions for
S300 series dust monitor models S303 and S304. Read this manual carefully before using the device. This
manual is an important part of the product, and it must always be available for reference to all
personnel installing, commissioning, operating or performing maintenance on the device. In case the
manual is lost or damaged, request a new copy from the manufacturer or an authorized distributor.

1.1 Description of symbols

These symbols are used to alert you to any potential personal injury hazards, and to provide information
on how to avoid them. Obey all safety messages that use these symbols to avoid possible injury or
death. Symbols that provide additional information about using and handling the product are also
described here.
Symbol Description

General warning symbol.

Hot surface.

Electric hazard.

Toxic hazard.

Explosion hazard.

Important or useful information related to installing, maintaining or operating the device.

Read the user manual before doing a procedure or operating the device.

Wear protective gloves.

©2020 Sintrol.
All rights reserved. 7 (116) Revision 5
Symbol Description

Wear protective glasses.

Wear protective overalls.

Wear a welding mask.

Wear respiratory protection.

CE marking indicates that the device has been designed and manufactured to meet all
applicable health, safety and environmental protection standards required for products
sold in the European Union.
Electronic devices that are marked with this symbol must not be disposed of with general
waste. If a defective or broken-down device cannot be repaired, it must be recycled and
disposed of in accordance with WEEE directive (2012/19/EU) or other applicable local
regulations.

This symbol indicates waste material that must be recycled.

1.2 Abbreviations
Abbreviation Explanation
ESP Electrostatic precipitator
ID Inside diameter
IEU Inductive electrification unit
MB Modbus
OD Outside diameter
RF Radio frequency
RH Relative humidity
SNT Sintrol Network
SPDT Single pole double throw
TSP Total suspended particles

©2020 Sintrol.
All rights reserved. 8 (116) Revision 5
2 Safety
Read this chapter carefully before handling the device in any way.
In addition, read all safety notes before work steps and other instructions.

Only trained and qualified personnel can install, commission, operate and perform maintenance on the
device. All personnel must read and understand this manual and follow its instructions accurately.
Failure to follow the safety instructions and safety precautions could result in serious injury or death.
If you encounter any unexpected situations during the intended use of the device that are not described
in this manual, contact the manufacturer or an authorized distributor.
In addition to the safety instructions described in this manual, the personnel using the device must
follow all applicable country- and industry-specific safety standards and regulations.

2.1 Warnings
DANGER!
“DANGER” indicates a hazard with a high level of risk, which will result in death or
serious injury if not avoided.

WARNING!
“WARNING” indicates a hazard with a medium level of risk, which can result in death
or serious injury if not avoided.

CAUTION!
“CAUTION” indicates a hazard with a low level of risk, which can result in minor or
moderate injury if not avoided.

NOTICE
“NOTICE” indicates a situation with a risk of equipment damage.

©2020 Sintrol.
All rights reserved. 9 (116) Revision 5
2.2 Intended use
This device is designed for measuring total suspended particles (TSP) in the airflow inside conductive
pipes and ducts. The intended use is as described in this user manual. Any other use is considered
improper and can result in injury or equipment damage.

The manufacturer or distributor cannot be held liable for any damage, injury or financial
loss resulting from improper use.

The device must not be modified or repaired in any way that is not specifically described in this manual.
Do not perform any mechanical or electrical repairs without contacting the manufacturer or an
authorized distributor.
Only original Sintrol parts can be used for repairs. If third-party spare parts are used, the manufacturer
cannot guarantee safe operation of the device.
Before installing and commissioning the device, carefully inspect it for any damage or defects. Do not
use the device if it is damaged, or if the power supply is defective. Return damaged device to the
manufacturer or an authorized distributor.
Non-compliance with any of these conditions immediately voids the warranty, and the manufacturer’s
responsibility no longer applies.

Wear appropriate protective gloves at all times when installing the device.

DANGER!
Explosion hazard
The device is not UL/CSA or IECEx/ATEX certified. Do not use the device in potentially
explosive atmospheres.

WARNING!
Use in critical applications
Improper use in critical applications can lead to hazardous situations or have severe
adverse health effects. Such critical applications include, but are not limited to:
• Health protection
• Emission monitoring
• Process control
• Fire and explosion prevention

©2020 Sintrol.
All rights reserved. 10 (116) Revision 5
Many factors can affect the operation of the dust monitoring system. These factors can include, for
example, dust particle size, dust material, the design of the pipes or ducts that the dust monitor is
installed on, and operator error. Because of this, an industry specialist must evaluate and approve the
suitability of Sintrol products for any given dust monitoring system. This is particularly true when the
instruments are only a component in a larger monitoring system, or when they are used in critical
applications.

2.3 Use in potentially explosive atmospheres

DANGER!
Explosion hazard
The device is not UL/CSA or IECEx/ATEX certified. Do not use the device in potentially
explosive atmospheres.

An ATEX-certified model of the device is available. Only ATEX-certified models can be used in potentially
explosive atmospheres.

If you have ordered ATEX-certified device, read the supplementary ATEX safety
instructions carefully before installing, commissioning, operating or performing
maintenance on the device.

2.4 Conformity to standards and directives

This device has been designed and manufactured to comply with the requirements of ISO 9001:2015
standard related to quality management. See Appendix A for ISO 9001 certificate.
This device has been designed and manufactured to comply with the following standards and directives:

• EN 61010-1:2010
• EN 61326-1:2012
• ROHS Directive 2011/65/EU (RoHS II)

©2020 Sintrol.
All rights reserved. 11 (116) Revision 5
3 Product overview
3.1 Product description
The device is designed to measure the concentration of dust particles inside a pipe or duct. It is an ideal
solution for industrial applications like filter leak detection, air circulation control and emission
monitoring.
The operating principle is based on inductive electrification technology, where particles interacting with
an isolated probe induce a signal that is transmitted to the monitoring system. The normal dust level is
determined during commissioning, and the signal generated by the sensor is then scaled in proportion to
this baseline level when the dust level fluctuates.

The device is intended for use in non-condensing environments. The sensor does not
distinguish liquid droplets from dust particles. If the measured airflow contains liquid
droplets, the measurement results are inaccurate.

The device has a local user interface with four keys and a 7-segment display with four digits for local
setup, status indication and changing parameters.
For detailed technical data, see chapter Specifications.

3.1.1 Key properties

Table 1: Key properties of a standard device

Enclosure: Aluminum
Probe length: 500 mm (19.68 in)
Probe material: Stainless steel (316L)
Insulation material: Polyphenylene sulfide (Ryton R-4)
Output signal: 4 ... 20 mA
Max. temperature: 300 °C (572 °F)
Max. pressure: 600 kPa (87.02 psi)
Flow speed: Min. 3 m/s (9.84 ft/s), max. tested 40 m/s (131.23 ft/s)

3.1.2 Commissioning
Commissioning is easy with Auto Setup feature, which determines the baseline dust level and sets up
two alarm thresholds that are proportional to the baseline. An alarm is triggered when the dust
concentration exceeds a configured threshold.

©2020 Sintrol.
All rights reserved. 12 (116) Revision 5
3.1.3 Installation
For installation, the device is equipped with a quick-clamp connector between the instrument and the
weld-on process connection.

3.1.4 Settings and parameters

You can access and change the device settings and parameters with the local display that has four keys
and a 7-segment display with four digits. Additionally, you can connect the device to a computer using
USB, RS-485 bus or an optional radio frequency (RF) communication protocol, and change the
parameters using complementary DustTool software. You can download DustTool free of charge at
https://sintrol.com/product/dusttool/.

3.2 Design drawings

1 2 3 4 5 6

Figure 1: Main components of the dust monitor

① Threaded lid with a window ⑤ Sensor probe

② Main board and interface ⑥ Process connection
③ Aluminum enclosure ⑦ External ground connection
④ Quick-clamp connector ⑧ PG11 cable glands

©2020 Sintrol.
All rights reserved. 13 (116) Revision 5
 1

14
2

13
3
12

4
11

5
10

7 8 9
Figure 2: Main interface and electrical connections of the dust monitor

① Status LED ⑧ Micro-B USB port

② Analog mA output ⑨ Navigation keys
③ RS-485 bus (Modbus RTU) ⑩ 24 V DC power supply terminal
④ RS-485 terminator switch ⑪ 7-segment displays
⑤ RS-485 bus (Sintrol Network) ⑫ 100 ... 240 V AC power supply terminal
⑥ Analog mA input* ⑬ Relay terminals
⑦ Internal ground connection ⑭ Auto Setup key
* Only functional in model S304.

©2020 Sintrol.
All rights reserved. 14 (116) Revision 5
3.2.1 Dimension drawings
Dust monitor side view
500.00 mm [19.69 in ] 155.5 mm [6.12 in ]

Figure 3: Side view dimensions of the enclosure and probe

Dust monitor front view

168 mm [6.61 in]
163.3 mm [6.43 in]
175.1 mm [6.89 in]

Figure 4: Front view dimensions of the enclosure

©2020 Sintrol.
All rights reserved. 15 (116) Revision 5
Process connection side view
70 mm [2.76 in]

37.7 mm [1.48 in]

50 mm [1.97 in]
34 mm [1.33 in]
Figure 5: Process connection dimensions

Optional accessories
For part numbers and additional details about optional accessories, see section Optional features and
accessories.
60.00mm [2.36 in]

G1/4 [0.52 in]

50.00mm [1.97 in]

37.70mm [1.48 in]

30.00mm [1.18 in]

Figure 6: Air purge adapter dimensions

©2020 Sintrol.
All rights reserved. 16 (116) Revision 5
 260mm [10.24 in]
30mm [1.18 in]

50mm [1.97 in]

38mm [1.5 in]

26mm [1.02 in]

G1/4 [0.52 in]

Figure 7: High-temperature process connection dimensions

3.2.2 Identification
Identification label is located on the backside of the device, under the sensor probe.

Figure 8: Identification label

① Manufacturer details ⑤ IP rating

Power supply specifications and power
② CE marking ⑥
consumption
③ Device model ⑦ Serial number
④ Production date

©2020 Sintrol.
All rights reserved. 17 (116) Revision 5
3.3 Scope of delivery
A standard delivery includes the following components:

1 2 3 4

Figure 9: Components included in a standard delivery

Weld-on process connection
① Dust monitor ④
Part number: MC900229
Quick-clamp connector End cap for process connection
② ⑤
Part number: MC900034 Part number: MC900033
Quick-clamp gasket
③
Part number: OC900007

When delivered, the device is already assembled with the process connection secured to the sensor
probe with the quick-clamp connector. Disconnect the sensor from the process connection before
installation.
End cap is used to seal the process connection when the device is removed from the process for
inspection and maintenance.

©2020 Sintrol.
All rights reserved. 18 (116) Revision 5
3.4 Features and accessories
3.4.1 Standard features
A standard delivery includes the following features:
Table 2: Comparison of standard features between dust monitor models

Feature ✓=Standard ✕=Not available ⚪=Optional S303 S304

Rugged IP66-rated pressure-casted aluminum enclosure ✓ ✓
Weld-on process connection and quick-clamp for easy installation ✓ ✓
Green, yellow* and red LEDs for status indication ✓ ✓
Auto Setup function for easy commissioning ✓ ✓
Two dry-contact relays to indicate dust alert and dust alarm ✓ ✓
Inputs for 24 V DC and 240 V AC power supply ✓ ✓
USB interface ✓ ✓
DustTool software for easy calibration and setup ✓ ✓
RS-485 bus (MB) for integration into existing control systems using Modbus RTU, and
for connecting multiple devices in parallel using Modbus RTU or Sintrol Network ✓ ✓
protocol
RS-485 bus (SNT) for single-device communication using Sintrol Network protocol ✓ ✓
Main interface with four keys and a 7-segment display with four digits for local setup
and status indication ✓ ✓
Active and isolated 4 ... 20 mA output in accordance with NAMUR NE43 ✓ ✓
Zero/span check with automatic drift compensation ✓ ✓
Possibility to program the display to show dust concentrations in mg/m3 ✕ ✓
Flow speed compensation using an external flowmeter ✕ ✓
Wireless network capability to reduce cabling costs** ⚪ ⚪
* When green and red LEDs are ON at the same time, the color appears yellow or orange
** Requires radio frequency (RF) model. RF antenna cannot be retrofitted to non-RF models.

3.4.2 Optional features and accessories

The device can be customized to meet the specific requirements for various applications and process
conditions.

Probe coating
The sensor probe can be equipped with a protective coating. The standard probe has no protective
coating, and it can be used in process temperatures up to 300 °C (572 °F). Optional coatings for the
sensor probe are:

©2020 Sintrol.
All rights reserved. 19 (116) Revision 5
 Teflon For wet conditions with up to 250 °C (482 °F) process temperature in
non­hazardous areas.
Diamond For abrasive and dry processes.
Salocote enamel For wet conditions with up to 700 °C (1292 °F) process temperature.
Maximum length 500 mm (19.69 in).
For processes with temperatures over 300 °C (572 °F), the device must be equipped with a high-
temperature process connection that protects the probe insulation from heat damage.

Probe length
Standard probe length is 500 mm, and it can be extended in 250 mm increments up to 1500 mm. Probe
length can also be customized more accurately according to client specifications. Contact the
manufacturer or an authorized distributor for details about non-standard probe lengths for coated
probes.
The recommended minimum probe length depends on the measuring conditions and environment. If
the probe is too short compared to the duct diameter, the measurement results are inaccurate.
Recommended probe lengths are as follows:

• For indicative monitoring, a minimum probe length of one fourth (1⁄4) of the duct diameter is
recommended.
• For demanding and critical applications with varying flow speed, a minimum probe length of
one third (1⁄3) of the duct diameter is recommended.

Air purge adapter

Part number: MC900203
Air purge is an additional feature for applications where adhesive or conductive dust buildup can cause
interference on the measurement results. The air purge adapter is installed between the standard probe
and process connection, and secured in place with an additional quick-clamp.

Figure 10: Air purge adapter with 1⁄4-inch G-thread connection

Equipping the device with the air purge adapter is recommended in the following operating conditions:

• Extremely high dust concentrations. Dust buildup on the sensor probe will influence the
measurement results.

©2020 Sintrol.
All rights reserved. 20 (116) Revision 5
 • Unstable process temperature. A drop in the process temperature can cause condensation on
the sensor probe, which will influence the measurement results.
• High relative humidity. High humidity can cause condensation on the base of the sensor, which
will influence the measurement results.
Air purge creates a continuous airflow around the probe that ensures that the base of the probe stays
clean of dust buildup, and that it can provide accurate measurement results. The recommended air
supply uses clean, dry and oil-free instrument air. Recommended airflow is 50 l/min ±10%, and the
required air pressure depends on the flow resistance and process pressure. Adjust the airflow in the
actual application.
The air purge adapter has a 1⁄4­inch G­thread connection for connecting an inlet air hose that has a
1⁄ ­inch R­thread connector. Devices ordered with the air purge option are delivered with an additional
4
quick-clamp and quick-clamp gasket.

Incorrectly installed or configured air purge adapter can cause interference on the
measurement response. This can result in incorrect measurement results or, in the
worst case, interrupt the operation of the device.

For air purge dimensions, see section Dimension drawings.

High-temperature process connection

Part number: MC901165
A standard probe can be used in process temperatures up to 300 °C (572 °F). Optionally, the dust
monitor can be equipped with a probe that can withstand process temperatures of up to 700 °C
(1292 °F).
For processes with temperatures over 300 °C (572 °F), the device must be equipped with a high-
temperature process connection that protects the probe insulation from heat damage.

Figure 11: High-temperature process connection

High-temperature process connection is longer than the standard process connection, which increases
the distance between the probe insulation and the heat source. This helps protect the probe insulation
and the device from heat damage.
Additionally, high temperature process connection has a 1⁄4­inch G­thread connection for connecting an
inlet air hose that has a 1⁄4­inch R­thread connector. This connection is used for air purge function, which
helps keep the base of the probe clean of dust buildup and cools down the probe. The recommended air
supply uses clean, dry and oil-free instrument air. Recommended airflow is at least 50 l/min ±10%, and

©2020 Sintrol.
All rights reserved. 21 (116) Revision 5
the required air pressure depends on the flow resistance and process pressure. Adjust the airflow in the
actual application.

NOTICE
Maximum process pressure with a high-temperature process connection is 300 kPa (43.51 psi).

For dimensions, see section Dimension drawings.

Flange connection
The standard installation with the weld-on process connection is suitable for all conditions where the
device can be used. However, the device can be ordered with an optional flange connection.
Flange connection only changes the way that the device is connected to the process. The device is
secured to the flange connection with the quick-clamp, and the receiving pipe or duct must have a
suitable counter flange.
The flange connection is available in different sizes and configurations according to client specifications.

Wireless communication
A standard device communicates with a monitoring system or PC with signals that are transmitted
through physical wires. The device can be equipped with a radio frequency (RF) antenna to enable
wireless communication.

The device must be ordered with RF capability. Non-RF models cannot be retrofitted
with the RF antenna after delivery.

Accessories
The device can be ordered with the following optional accessories:

RS-485 to USB converter for connecting the device to a

computer using Sintrol Network protocol.
Part number: EC900041

Network Router for setting up device chains and networks.

Part number: PC900091

©2020 Sintrol.
All rights reserved. 22 (116) Revision 5
 Wireless Router for setting up wireless device networks.
Part number: PC900090

DustLog 10 reporting software for additional data logging and

reporting options.

3.5 Operating principle

The device is designed for measuring total suspended particles (TSP) in the airflow inside conductive
pipes and ducts. A complete installation consists of an isolated probe that is inserted inside a duct,
perpendicular to the airflow.
When dust particles moving inside the duct pass or hit the sensor probe, a signal is induced. This signal is
then transferred to a monitoring system, for example a computer running a monitoring software. The
underlying technology is called “inductive electrification”. This technology is very sensitive, and it
minimizes the influence that sensor contamination, changes in process temperature and flow speed
have on the measurement results.
Inductive electrification technology enables a detection limit of as low as 0.01 mg/m3.

3.5.1 Inductive Electrification Unit

The signal level generated by the device is measured in Inductive Electrification Units (IEU), and the IEU
value is converted to mA output signal that the device uses to communicate the dust level to the
monitoring system. The IEU value can be anything from a few hundred up to several million units, which
allows the relation between the IEU value and mA signal to be set very accurately.
The relation between the IEU value and mA output signal is established automatically with the Auto
Setup function. With model S304, it is also possible to display the measurement results in mg/m3.
However, in this case the IEU value and output signal must be calibrated against a reference, for
example the results of gravimetric analysis.

3.5.2 Potential influences on measurement results

With the inductive electrification technology, the signal level shows the following behavior over the
measuring range:

©2020 Sintrol.
All rights reserved. 23 (116) Revision 5
 • Linear range: Signal level increases linearly from the detection limit 0.01 mg/m3 to several
hundred mg/m3.
• Nonlinear range: From linear range up to several g/m3.
• Saturation: After non-linear range. The signal level reaches saturation and no longer increases.

Saturation

Figure 12: Uncalibrated measuring behavior

Many factors can affect the measuring range and behavior of the device. These factors include dust
material, particle size, flow speed and installation environment.

If it is necessary to measure concentrations that are higher than 200 mg/m3 and having
linear behavior is critical, it is recommended to perform reference measurement at the
desired concentration and to add additional calibration points using DustTool software.

Probe length
The recommended minimum probe length depends on the measuring conditions and environment. For
example, in vertical ducts, the dust particles will concentrate in the middle of the duct with high flow
speed. In horizontal ducts, large particles will concentrate on the lower part of the duct with low flow
speed.
If the probe is too short compared to the duct diameter, the measurement results are inaccurate. The
standard probe length is 500 mm (19.68 in).
Recommended probe lengths are:

• For indicative monitoring, a minimum probe length of one fourth (1⁄4) of the duct diameter is
recommended.
• For demanding and critical applications with varying flow speed, a minimum probe length of
one third (1⁄3) of the duct diameter is recommended.

©2020 Sintrol.
All rights reserved. 24 (116) Revision 5
 The sensor probe must not touch the opposite surface inside the duct, because it
distorts the measurement results.

Particle material
Different materials can have different amounts of electrostatic charge. This means that the signals
transmitted by dust particles can vary significantly from one material to another:

• Metals (inorganic, electroconductive) generate the lowest signals.

• Cement and minerals (inorganic, dielectric) generate average signals.
• Wood and flour (organic, dielectric) generate the highest signals.
As a result, different types of dust generate a different output signal at the same concentration.

Certain heavy metal dusts generate extremely low signals For measuring such dusts, the
device must be tested with a dust sample before delivery.

Common dust particle materials include:

• Grains • Ceramics • Minerals

• Sugar • Textiles • Ores
• Coal • Wood and paper • Cement
• Cosmetics • Soap • Plastics
• Dyes • Metals and metal oxides • Chemicals
Particle size
The minimum particle size that the device can detect is 0.3 µm. The optimal detection range is from 1 to
200 µm.

Relative humidity
The device is intended for use in non-condensing environments in both indoor and outdoor applications.
The relative humidity (RH) has an insignificant effect on the measurement results. However, the sensor
does not distinguish liquid droplets from dust particles. This means that the measured airflow must not
contain condensation. If the measured airflow contains condensed liquid droplets, it is possible that the
device does not produce output signal at all, or the output signal can be too high.

©2020 Sintrol.
All rights reserved. 25 (116) Revision 5
Ambient temperature
Ambient temperature only has a very minor effect on the output signal.

Influence of ambient temperature

5,0
4,9
4,8
Output signal (mA)

4,7
4,6
4,5
4,4
4,3
4,2 4,06 4,06 4,05 4,05 4,05 4,04 4,04 4,03
4,1
4,0
−20 −10 0 10 20 30 40 50

Ambient temperature (°C)

Figure 13: Influence of ambient temperature on the output signal

Flow speed

Recommended minimum flow speed is 3 m/s (9.84 ft/s).

Maximum tested flow speed is 40 m/s (131.23 ft/s).

An increase in flow speed also increases the output signal level. Dust material, particle size, temperature
and installation environment can all affect output signal level.

Influence of uncompensated flow speed at 10 mg/m3

30%
23% 24%
25%
20%
Output signal (%)

20% 16%
15% 13%

10%

5%

0%
4 8 12 16 20

Flow speed (m/s)

Figure 14: Influence of uncompensated flow speed on the output signal

Model S304 has an option to compensate the changes in flow speed by connecting the mA output of an
external flowmeter to the analog mA input on the main board of the device. Figure 15 illustrates how
compensating with an external flowmeter affects the measurement results. The data used for flow
speed compensation has been gathered over various laboratory tests.

©2020 Sintrol.
All rights reserved. 26 (116) Revision 5
 Influence of compensated flow speed at 10 mg/m3
30%

25% 21% 21% 21%

Output signal (%)

19% 18%
20%

15%
Compensated
10%
Uncompensated
5%

0%
4 8 12 16 20

Flow speed (m/s)

Figure 15: Influence of compensated flow speed on the output signal

For information on how to connect an external flowmeter to model S304, see section Analog mA input
in chapter Electrical connections.
For information on how to set the flow speed compensation with parameters 7 and 8, see chapter
Parameters.

©2020 Sintrol.
All rights reserved. 27 (116) Revision 5
4 Storage
NOTICE
Improper storage can damage the equipment.

When storing the device:

• Select a dry, dust-free location.

• Store the device in its original packaging.
• Do not place any heavy objects on the device.
• Storage temperature must be within range −40 ... 60 °C (−40 ... 140 °F).
Retain the original packaging in case the device is ever transported or returned. For instructions on how
to return a damaged or defective device for repair or replacement, see section Returns in chapter
Maintenance and inspection.

©2020 Sintrol.
All rights reserved. 28 (116) Revision 5
5 Mechanical installation
Read chapter “Safety” carefully before installing the device.

5.1 Unpacking and inspection

5.1.1 Unpacking
NOTICE
Improper handling during unpacking can damage the equipment.

When unpacking the device:

• If you use a knife or scissors to open the package, be careful not to damage the device or its
parts.
• Handle the device and its components with care when taking them out of the package.
• Do not drop the device or subject it to blows.

5.1.2 Inspection
After unpacking the device:

• Check that the device and all its standard and optional parts are included in the delivery.
• Inspect the device and its individual parts for any defects, or damage that may have occurred
during delivery.
For instructions on how to return a damaged or defective device for repair or replacement, see section
Returns in chapter Maintenance and inspection.

5.2 Selecting installation location

Any information given in this user manual regarding the installation location or
suitability for a specific application does not replace careful functionality checks and
necessary approvals from an industry specialist.

Do not install the device close to large motors, cables carrying high voltages, or other
potential sources of interference. These can distort the measurement results.

©2020 Sintrol.
All rights reserved. 29 (116) Revision 5
5.2.1 Ambient environment
NOTICE
If there are any structures that radiate heat near the device, you must insulate the heat source.
Very high temperatures will damage the device.

To minimize the effect that the environment has on the measurement results, install the device in a
suitable location. Table 3 shows the suitable ambient conditions for the device.
Table 3: Ambient conditions of the installation location

Ambient temperature: −40 ... 60 °C (−40 ... 140 °F)

Relative humidity: Max. 95 % RH (non-condensing)

The device is intended for use in non-condensing environments. The sensor does not
distinguish liquid droplets from dust particles. If the measured airflow contains liquid
droplets, the measurement results are inaccurate.

If the device is installed on the side of the duct in a location with occasional condensation, it is
recommended to install the sensor probe with a 5° downward tilt. This helps prevent liquid from
accumulating on the insulation.

5.2.2 Vibration
Probe lengths of less than 1 meter are not affected by vibration. However, the device must be installed
in a location where the vibration level is below 5 m/s2.

5.2.3 Location
An optimal location for installation is in a section of pipe or duct where the dust particles are evenly
distributed in the airflow, and the flow is as laminar as possible. This ensures that the sensor probe
comes into contact with an amount of particles that represents the actual dust concentration in the
airflow.
Install the device in a straight section of pipe or duct that has no bends, valves, dampers or other
obstacles in its vicinity. The recommended minimum distance to any obstacle is 5× the duct diameter if
the obstacle is located upstream from the device, and 3× the duct diameter if the obstacle is located
downstream from the device.

©2020 Sintrol.
All rights reserved. 30 (116) Revision 5
 3xD 5xD

D
Figure 16: Recommended distance to obstacles (D = Duct diameter)
If the device is installed downstream from an electrostatic precipitator (ESP), the distance to ESP must
be at least 40 m (131.23 ft). An ESP creates an electric field that can distort the measurement results.

If installing the sensor in a suboptimal location cannot be avoided, make sure that the
location meets most of the requirements. Installation location must always meet these
recommendations as closely as possible.

5.2.4 Orientation
The device must be installed perpendicular to the airflow, so that dust particles pass the sensor probe at
a 90° angle.

If the device is installed on the side of the duct in a location with occasional
condensation, it is recommended to install the sensor rod with 5° downward tilt. This
helps prevent liquid from accumulating on the device insulation.

RF communication
If multiple devices are connected using a wireless RF connection, make sure that the devices are
oriented the same way with RF antennas pointing in the same direction. This helps prevent polarization
losses in the wireless communication.

5.2.5 Probe length

In vertical ducts, the dust particles will concentrate in the middle of the duct with high flow speed. In
horizontal ducts, large particles will concentrate on the lower part of the duct with low flow speed. This
means that the probe length must be suitable for the installation location.
If the probe is too short compared to the duct diameter, the measurement results are inaccurate. The
standard probe length is 500 mm.
Recommended probe lengths are:

• For indicative monitoring, a minimum probe length of one fourth (1⁄4) of the duct diameter is
recommended.

©2020 Sintrol.
All rights reserved. 31 (116) Revision 5
 • For demanding and critical applications with varying flow speed, a minimum probe length of
one third (1⁄3) of the duct diameter is recommended.

The sensor probe must not touch the opposite surface inside the duct, because it
distorts the measurement results.

5.2.6 Position
Information in this section mostly applies to horizontal pipes and ducts. On vertical
pipes and ducts, the requirements for the installation position are not as strict.
However, never install the device on a corner of a pipe or duct.

Square ducts
When installing on a square duct, the device can be placed either on the top of the duct, or to the side:

• When installing on the top, the device must be positioned in the middle of the duct.
• When installing on the side, the device must be positioned in the middle, or in the lower part of
the duct. Recommended position is between 1⁄2 and 2⁄3 of the duct height measured from the
top.
Permitted installation locations on square ducts are highlighted in green in Figure 17.

Figure 17: Approved installation positions on a square duct (W = Duct width)

©2020 Sintrol.
All rights reserved. 32 (116) Revision 5
You can always install the device on top of the duct if the installation location is within the specified
ambient temperature range (−40 ... 60 °C [−40 ... 140 °F]). However, if there is significant heat transfer
from the process, the device must be installed on the side of the duct.
The device must not be installed on the bottom or corners of the duct. Installing on the bottom or
corners can result in inaccurate measurement results.

Round ducts
When installing on a round duct, the device can be positioned anywhere on the top half of the duct,
between 9 o’clock and 3 o’clock positions. Permitted installation locations on round ducts are
highlighted in green in Figure 18:

Figure 18: Approved installation positions on a round duct

You can always install the device on top of the duct if the installation location is within the specified
ambient temperature range (−40 ... 60 °C [−40 ... 140 °F]). However, if there is significant heat transfer
from the process, the device must be installed on the side of the duct.
The device must not be installed on the bottom half of the duct. Installing on the bottom can result in
inaccurate measurement results.

5.2.7 Duct pressure

If possible, install the device in a location where the duct pressure is lower than the surrounding
environment. This prevents the process gases from being released or minimizes the amount of gas that
is released from the duct during installation.

©2020 Sintrol.
All rights reserved. 33 (116) Revision 5
If the duct pressure is higher than the surrounding environment, there is a risk that process gases are
released from the duct.

5.2.8 Process temperature

NOTICE
If the device must be installed on a pipe or duct carrying hot gas, you must use a high-temperature
process connection. High temperatures will damage the device and the probe insulation.

5.3 Installing sensor

5.3.1 Safety precautions
DANGER!
Poisonous and hot gas hazard
When installing or removing the device, poisonous and hot gas can be released from
the duct.
Wear appropriate respiratory and eye protection gear when installing or removing the
device. Follow all applicable local and plant-specific safety codes before proceeding.

WARNING!
Risk of burns due to hot components
When installing or removing equipment, the device or the installation surface can be
hot.
Wear appropriate heat-resistant gloves and follow all applicable local and plant-specific
safety codes before proceeding.

©2020 Sintrol.
All rights reserved. 34 (116) Revision 5
 WARNING!
Risk of losing eyesight
Risk of burns
Welding arcs and flames emit intense heat and light that will damage eyesight and
burn unprotected skin.
When welding, wear a welding mask and appropriate heat resistant gloves and
clothing.

5.3.2 Installation
For mechanical installation, you need:

A tool that is suitable for making an opening to the duct or pipe

Welding equipment
Protective gear for welding
To install the device:
1. Determine if the process that the device is installed on must be shut down before installation.
• If the duct pressure is lower than the surrounding environment and the process does not
produce any hot or dangerous gases, you can leave the process running.
• If the duct pressure is higher than the surrounding environment and the process produces hot
or dangerous gases, consider shutting the process down before installation.

It is the responsibility of the plant operator to decide whether a process can be running
when the device is installed. Always follow the local and plant-specific safety standards
when installing the device.

2. Make sure that the process connection is not attached to the device.

©2020 Sintrol.
All rights reserved. 35 (116) Revision 5
NOTICE
Do not install the process connection with the device fully assembled. If you weld the
process connection in place with the device attached, you can damage the sensor.

3. Cut an opening to the duct or pipe.

Diameter of the opening depends on the shape and radius of the installation surface.
• If the installation surface is even or it has a large radius:
Cut an opening that is 36 mm (1.42 in) in diameter. This is slightly smaller than the outside
diameter (OD) of the process connection (37.70 mm [1.48 in]) but larger than its inside
diameter (ID) (34 mm [1.33 in]).

• If the installation surface is curved or uneven or it has a small radius:

Cut an opening that is 39 mm (1.54 in) in diameter. This is slightly larger than the outside
diameter (OD) of the process connection (37.70 mm [1.48 in]).
4. Place the process connection over the opening or insert it slightly through the opening, depending
on its diameter.

• If the diameter of the opening is smaller

than the OD of the process connection,
place the process connection on the
installation surface, over the opening.

• If the diameter of the opening is larger

than the OD of the process connection,
insert the process connection slightly
through the opening.

Do not push the process connection all the way through the opening.

©2020 Sintrol.
All rights reserved. 36 (116) Revision 5
5. Make sure that the process connection is in the right position and correctly aligned.
The socket must be perpendicular to the airflow inside the duct.

6. Weld the process connection to the duct or pipe.

Make sure that the welding joint is airtight

7. Fit the quick-clamp gasket on the sensor end of the process connection.

©2020 Sintrol.
All rights reserved. 37 (116) Revision 5
8. Insert the sensor probe through the process connection.

The sensor probe must not touch the opposite surface inside the duct, because it
distorts the measurement results.

9. Secure the sensor in place with the quick-clamp connector.

©2020 Sintrol.
All rights reserved. 38 (116) Revision 5
Note about Teflon-coated probes
A Teflon-coated probe consists of two parts. It has a translucent, outer Teflon sleeve and an inner black
Teflon layer. The inner layer is the actual insulating coating of the probe, and the outer sleeve protects
the coating from scratches and dirt.

1 2

Figure 19: Parts of Teflon-coated probe

① Inner insulating Teflon layer

② Outer translucent protective Teflon sleeve

NOTICE
If your device is equipped with a Teflon-coated probe, do not remove the outer Teflon sleeve during
installation. The outer sleeve is an integral part of the probe and must always be kept on to ensure
proper operation.

©2020 Sintrol.
All rights reserved. 39 (116) Revision 5
6 Electrical installation
Read chapter “Safety” carefully before making any electrical connections to the device.

6.1 Electrical safety

Wear protective glasses when making electrical connections on the device.

WARNING!
Electric shock hazard
Faulty electrical installations, too high line voltage or incorrect operation of the device
can result in an electric shock. Only trained and qualified personnel can install,
commission, operate and perform maintenance on the device.

To ensure safe installation of electrical connections:

• Power down the device when you are making electrical connections, when you intend to perform
maintenance on it, or in the event of malfunction.
• Connect the device to line voltage only if the power supply specifications correspond to the data
on the identification label of the device.
• Make sure that all equipment is properly grounded.
• Stand on an insulating pad and check components only with one hand.
• Never work alone on electrical connections.
When connecting cables, give them enough extra length. This allows the device to be removed from the
mechanical installation for inspection and maintenance without disconnecting the cables.

Cables must be installed in accordance with all applicable local safety codes.

©2020 Sintrol.
All rights reserved. 40 (116) Revision 5
6.2 Cable types
Make sure that the cables are suitable for the environment and industrial application
where the device is used. The cables must meet and be installed according to all
applicable local safety standards.

When choosing cables, consider the following:

• Use a shielded cable if possible. Connect the cable shield to ground on one end only.
• Minimum required conductor size is 0.3 mm2 or 22 AWG.
• The cables must withstand up to 75 °C (167 °F) continuous temperature.
The device uses screw-type wire-to-board terminal blocks for electrical connections. See Table 4 in
section Terminal blocks for specifications.

©2020 Sintrol.
All rights reserved. 41 (116) Revision 5
6.3 Electrical connections
6.3.1 Main board
1

16
2

15
3
14
4
13

5
12

7
8 9 10 7 11

Figure 20: Main board and electrical connections of the dust monitor

① Status LED ⑨ External ground connection

② Analog mA output ⑩ Micro-B USB port
③ RS-485 bus (Modbus RTU) ⑪ Navigation keys
④ RS-485 terminator switch ⑫ 24 V DC power supply terminal
⑤ RS-485 bus (Sintrol Network) ⑬ 7-segment displays
⑥ Analog mA input* ⑭ 100 ... 240 V AC power supply terminal
⑦ PG11 cable glands ⑮ Relay terminals
⑧ Internal ground connection ⑯ Auto Setup key
* Only functional in model S304.

©2020 Sintrol.
All rights reserved. 42 (116) Revision 5
6.3.2 Terminal blocks
The device uses screw-type wire-to-board terminal blocks for electrical connections. See Table 4 for
specifications:
Table 4: Specifications of the terminal blocks

Connection method: M3 slotted screw

Tightening torque: 0.5 ... 0.6 Nm (4.425 ... 5.310 in-lb)
Insulation stripping length: 8 mm (0.31 in)
Pitch: 5.08 mm (0.20 in)
Connection angle: 55°
Solid Flexible AWG
Conductor size:
0.2 ... 4 mm2 0.2 ... 2.5 mm2 24 ... 12

Terminal blocks are compatible with smaller conductor sizes than the minimum
conductor size that is recommended for the device. Do not use a conductor size that is
smaller than 0.3 mm2 / 22 AWG to make electrical connections on the device.

6.3.3 Grounding
WARNING!
Risk of injury
If the dust monitor is not grounded properly, it can display false measurement results.
In the worst case, this can result in severe health impacts to workers, or even a failure
of an explosion prevention system.

For proper and safe operation, it is critical that the device is properly connected to ground. The
enclosure is equipped with two ground connections. One ground connection is located inside the
enclosure, and one on the outside (Figure 21).

• If the ground potential between the power supply and the installation location is the same,
connect the supply ground to the internal ground connection.
• If there is ground potential difference between the power supply and the installation location,
ground the device to the local ductwork using the external ground connection. In this case it is
also recommended to supply power to the device with a DC power supply.

©2020 Sintrol.
All rights reserved. 43 (116) Revision 5
 WARNING!
Risk of malfunction
Different ground potentials between the power supply and installation location can
create ground current loops, which can result in false measurement results. Depending
on the application, this can have severe implications on worker health and safety.
Always make sure that the device is grounded properly.

2
Figure 21: Position of ground connections on the enclosure

① Internal ground connection

② External ground connection

When the device is grounded properly, there is a clear change in the output signal level when you touch
the probe. There must be no change in the output signal level when you touch the enclosure.

©2020 Sintrol.
All rights reserved. 44 (116) Revision 5
Signs of improper grounding
If the device is not grounded properly, it can show the following behavior:

• Base value of the output signal is >3000 IEU when the process is not running.
• The output signal level does not change significantly when you touch the probe.
• The output signal level changes when you touch the enclosure.
• The displays indicate “Err1” with the red status LEDs blinking. This means that the sensor probe is
grounded.

Subpar power supply can cause behavior similar to improper grounding. Only use
NEC Class 2 or equivalent power supply.

Connecting ground wire

To connect the device to ground, you need:

Protective gear for electric work

Phillips-head screwdriver (M5)
Wrench (20 mm [0.7874 in] or adjustable)
Suitable ground wire
To connect the device to ground:
1. Make sure that the device is not connected to the power supply, or that the power supply is
disconnected or isolated.
2. Select the ground connection that you want to use for connecting the device to ground.
3. Connect the ground wire to the device.
• Internal ground connection:
a. Remove the device lid by turning it counterclockwise to access the main board.

©2020 Sintrol.
All rights reserved. 45 (116) Revision 5
 b. Remove the cable gland at the cable entry that is located on the right side of the device
when you are facing the main board. Loosen the cable gland cap by turning it
counterclockwise with a wrench.

c. Slide the cable gland over the incoming ground wire.

d. Insert the ground wire through the cable entry.

e. Loosen the screw on the ground connection with a screwdriver.

©2020 Sintrol.
All rights reserved. 46 (116) Revision 5
 f. Place the ground wire under the screw head on the ground connection and tighten the
screw.

g. If you do not need to make any other electrical connections:

o Push the cable gland back inside the cable entry and tighten the cap with a wrench.

o Attach the device lid by tightening it clockwise.

©2020 Sintrol.
All rights reserved. 47 (116) Revision 5
 • External ground connection:
a. Loosen the screw on the ground connection with a screwdriver.
b. Place the ground wire under the screw head on the ground connection and tighten the
screw.

4. Connect the other end of the ground wire to a location with the same ground potential as the
ductwork that the device is installed on.
6.3.4 Power supply
DANGER!
Electric shock hazard
Before connecting the device to a power supply, make sure that the power supply is
isolated or disconnected. Electric shock from a connected power supply cable can result
in serious injury or death.
When connecting the device to a power supply, wear protective glasses, protective
clothing and insulating rubber gloves.

The device can be connected to either a 24 V DC or 100 ... 240 V AC power supply. Both power inputs are
polarity-free. Only use NEC Class 2 or equivalent power supply.

NOTICE
Connect only one power supply to the device at a time. Connecting both the AC and DC power
supplies can overheat the device and damage internal components.

©2020 Sintrol.
All rights reserved. 48 (116) Revision 5
 When using AC power input, equip the power supply with a disconnect switch that is
compliant with IEC 60947­1 and IEC 60947­3 or equivalent local standards. Make sure
that the switch is easy to access and labeled as the disconnect switch for the device.

Follow all applicable local regulations when selecting the circuit breakers that protect
the cables.

Figure 22: Power supply inputs on the main board

① 100 ... 240 V AC power input

② 24 V DC power input

Connect the sheath of a shielded cable to ground on one end only. Connecting both
ends to ground can create a ground loop.

To connect the power supply, you need:

Protective gear for electric work

Slotted-head screwdriver (M3)
Wrench (20 mm [0.7874 in] or adjustable)
Suitable power cable

©2020 Sintrol.
All rights reserved. 49 (116) Revision 5
To connect the device to power supply:
1. Make sure that the power supply is disconnected or isolated.
2. Remove the device lid by turning it counterclockwise to access the main board.

3. Remove the cable gland at the cable entry that is located on the right side of the device when you
are facing the main board. Loosen the cable gland cap by turning it counterclockwise with a wrench.

4. Slide the cable gland over the incoming power cable.

©2020 Sintrol.
All rights reserved. 50 (116) Revision 5
5. Insert the power cable through the cable entry.

6. Connect the power cable to either the 24 V DC or 100 ... 240 V AC power supply terminal.
Insert the wires to the terminal block and tighten the screws.

7. If you do not need to make any other electrical connections:

• Push the cable gland back inside the cable entry and tighten the cap with a wrench.

©2020 Sintrol.
All rights reserved. 51 (116) Revision 5
 • Attach the device lid by tightening it clockwise.

• Enable or connect the power supply, and power up the device.

6.3.5 Relays
The device has two Single Pole Double Throw (SPDT) relays. The contacts are labeled “A”, “B” and “C”,
with C being the common contact. The relays can be used to control external loads of up to
240 V AC / 5 A or 30 V DC / 5 A.

AC or DC
supply

Load

Figure 23: Relay connections on the main board

Connect the sheath of a shielded cable to ground on one end only. Connecting both
ends to ground can create a ground loop.

©2020 Sintrol.
All rights reserved. 52 (116) Revision 5
To connect a relay, you need:

Protective gear for electric work

Slotted-head screwdriver (M3)
Wrench (20 mm [0.7874 in] or adjustable)
Two suitable 2-wire signal cables
To connect the relays:
1. Make sure that the device is not connected to the power supply, or that the power supply is
disconnected or isolated.
2. Remove the device lid by turning it counterclockwise to access the main board.

3. Remove the cable gland at the cable entry that is located on the right side of the device when you
are facing the main board. Loosen the cable gland cap by turning it counterclockwise with a wrench.

©2020 Sintrol.
All rights reserved. 53 (116) Revision 5
4. Slide the cable gland over both incoming signal cables.

5. Insert both signal cables through the cable entry.

6. Connect the first signal cable to contact C and either contact A or B on RELAY1 output terminal
block.
7. Connect the second signal cable to contact C and either contact A or B on RELAY2 output terminal
block.
8. Connect the other end of each signal cable to the appropriate input terminal on the application that
you want to control with the relays.
9. If you do not need to make any other electrical connections:
• Push the cable gland back inside the cable entry and tighten the cap with a wrench.

©2020 Sintrol.
All rights reserved. 54 (116) Revision 5
 • Attach the device lid by tightening it clockwise.

• Enable or connect the power supply, and power up the device.

When programming the external device to receive the signals from the relays, refer to Table 14 in
section Relay logic in chapter Operation.
6.3.6 Analog mA output
The device has a single active and isolated mA output that uses industry standard 4 ... 20 mA signal
range for indicating status and measurement value. Maximum resistance for the mA loop is 250 Ω. The
mA output is intended to be used as a long-range analog data transfer in industrial applications.
After Auto Setup, the default output signal level is set to 5% of the scale (4.8 mA). This means that 20 mA
output signal indicates a 20× increase in dust concentration. The scale of the mA output can also be
customized according to the specific end-user application.
>22 mA signals are used to indicate sensor fault in accordance with NAMUR NE43.
Table 5: Measurement values corresponding to device status

mA output Status
4 ... 20 mA Normal operation or zero/span self-test
Device failure, for example due to improper grounding or failure of
>22 mA
the internal checks of the device

©2020 Sintrol.
All rights reserved. 55 (116) Revision 5
Connecting mA output

Figure 24: mA output on the main board

To connect the mA output, you need:

Protective gear for electric work

Slotted-head screwdriver (M3)
Wrench (20 mm [0.7874 in] or adjustable)
Suitable signal cable

Connect the sheath of a shielded cable to ground on one end only. Connecting both
ends to ground can create a ground loop.

To connect the mA output of the device:

1. Make sure that the device is not connected to the power supply, or that the power supply is
disconnected or isolated.

©2020 Sintrol.
All rights reserved. 56 (116) Revision 5
2. Remove the device lid by turning it counterclockwise to access the main board.

3. Remove the cable gland at the cable entry that is located on the left side of the device when you are
facing the main board. Loosen the cable gland cap by turning it counterclockwise with a wrench.

4. Slide the cable gland over the incoming signal cable.

5. Insert the signal cable through the cable entry.

©2020 Sintrol.
All rights reserved. 57 (116) Revision 5
6. Connect the signal cable to mA output terminal block.
Insert the wires to the terminal block and tighten the screws.

7. Connect the other end of the signal cable to the device that receives the mA output.
8. If you do not need to make any other electrical connections:
• Push the cable gland back inside the cable entry and tighten the cap with a wrench.

©2020 Sintrol.
All rights reserved. 58 (116) Revision 5
 • Attach the device lid by tightening it clockwise.

• Enable or connect the power supply, and power up the device.

6.3.7 RS-485 buses

The device has two isolated RS-485 buses. The buses can be used to integrate the device into existing
automation systems, and to connect multiple devices in parallel to create a network. They can be used
to read data from the device, and to change device parameters. Buses are labeled “MB” and “SNT”.

• MB bus is designed for connecting multiple devices into a single bus on a master device using
either Modbus RTU or Sintrol Network protocol.
• SNT bus is designed for connecting a single device to a PC running a DustTool software.
The default communication parameters for Modbus RTU are as follows:
Table 6: Modbus RTU communication parameters

Baud rate: 19200

Data bits: 8
Stop bits: 1
Parity: Even

For a quick reference of the register definitions of the Modbus RTU interface, see Appendix B.
For information about setting up device networks, see section Setting up device network in chapter
Commissioning and system setup.

©2020 Sintrol.
All rights reserved. 59 (116) Revision 5
Polarity
Polarity of the RS-485 bus is indicated with labels A and B, where wire A is negative (−) and wire B is
positive (+). Make sure to always connect wires A and B using correct polarity to the device that receives
the signal.

Markings that indicate polarity on the RS-485-to-USB converter supplied by Sintrol are
inverted. When using RS-485-to-USB converter supplied by Sintrol, connect wire A to +
and wire B to −.

Some manufacturers have the RS-485 output signals inverted, and the way signal polarity is labeled can
differ between manufacturers. For example, some manufacturers indicate negative polarity with
TX−/RX− or D− instead of A, and positive polarity with TX+/RX+ or D+ instead of B.

If you are connecting the device into an existing Modbus RTU automation system or if
you are using a third-party RS-485-to-USB converter or cable, read the related user
documentation carefully before connecting the RS-485 output.

Connecting RS-485 bus

Modbus RTU
master or
Sintrol router

Next device in
the network

Figure 25: Modbus RTU bus on the main board

©2020 Sintrol.
All rights reserved. 60 (116) Revision 5
 Connect the sheath of a shielded cable to ground only on one end. Connecting both
ends to ground can create a ground loop.

PC with RS-485-to-USB
DustTool converter

Figure 26: Sintrol Network bus on the main board

To connect a RS-485 bus, you need:

Protective gear for electric work

Slotted-head screwdriver (M3)
Wrench (20 mm [0.7874 in] or adjustable)
Suitable signal cable
To connect a RS-485 bus:
1. Make sure that the device is not connected to the power supply, or that the power supply is
disconnected or isolated.
2. Select whether you want to connect the MB or SNT bus.
• For MB bus, use a 3-wire shielded twisted pair cable.
• For SNT bus, use a RS-485-to-USB cable, or a converter with a suitable 3-wire shielded cable.

©2020 Sintrol.
All rights reserved. 61 (116) Revision 5
3. Remove the device lid by turning it counterclockwise to access the main board.

4. Remove the cable gland at the cable entry that is located on the left side of the device when you are
facing the main board. Loosen the cable gland cap by turning it counterclockwise with a wrench.

5. Slide the cable gland over the incoming signal cable.

©2020 Sintrol.
All rights reserved. 62 (116) Revision 5
6. Insert the signal cable through the cable entry.

7. Connect the signal cable to the RS-485 output terminal block.

• For connecting multiple devices in parallel and controlling them with a Modbus master device
or DustTool software, connect the RS-485 bus labeled “MB”.
• For connecting a single device to PC and controlling it with DustTool software, select the RS-
485 bus labeled “SNT”.

If you connect several devices in parallel with the MB bus, you must adjust the settings
for each device in DustTool according to instructions in section “Wired device network”
in chapter “Commissioning and system setup”.

8. Connect the other end of the signal cable to the application that receives the RS-485 output.

©2020 Sintrol.
All rights reserved. 63 (116) Revision 5
9. If you do not need to make any other electrical connections:
• Push the cable gland back inside the cable entry and tighten the cap with a wrench.

• Attach the device lid by tightening it clockwise.

• Enable or connect the power supply, and power up the device.

©2020 Sintrol.
All rights reserved. 64 (116) Revision 5
Terminator switch
RS-485 bus (MB) allows multiple devices to be connected in parallel to create device chains and networks.
The main board is equipped with a terminator switch for each RS-485 bus, labeled “1” for MB bus and “2” for
SNT bus. The terminator switch must be turned ON or OFF on each device based on their position in the
chain.

The switch must be in ON position only for the last device of the chain. On all other devices, the terminator
switch must be in OFF position.
Table 7: Terminator switch configurations

Device position RS-485 bus Switch position Note

MB A single connected device is always considered

the last in a chain. If a single device is
Single device connected to either RS-485 bus, switch the
corresponding terminator switch to “ON”
1

ON

SNT position.
2

If the device is the first in a chain or in the

MB middle of a chain, make sure that the
terminator switch is in OFF position.
First or middle
in chain
Not applicable to SNT bus is used for connecting single devices
SNT
SNT bus only, so this position does not apply.

If the device is the last in a chain, make sure

MB
that the terminator switch is in OFF position.
Last in chain
Not applicable to SNT bus is used for connecting single devices
SNT
SNT bus only, so this position does not apply.

©2020 Sintrol.
All rights reserved. 65 (116) Revision 5
 The position of the terminator switch is independent of the communication protocol
and must be set according to the RS-485 bus in use. A device network connected with
MB bus can use either Modbus RTU or Sintrol Network protocol for communication.

6.3.8 Connecting with USB

It is possible to connect the device directly to a computer with USB without any additional equipment if
the USB port of the host computer can supply enough power. This connection type can be used to
change the parameters and settings of the device in DustTool.
Table 8: USB specifications

USB type: Micro-B

Max. cable length: 5 m (16.4 ft)

The USB port is located on the bottom-right corner of the main board inside the enclosure.

Do not use the USB connection to operate the device for extended periods of time. The
USB connection does not replace a dedicated industrial power supply, and it is not
intended for extended use in normal operation.

©2020 Sintrol.
All rights reserved. 66 (116) Revision 5
6.3.9 Analog mA input

This feature is only available in model S304.

Model S304 has an option to compensate the changes in flow speed by connecting the mA output of an
external flowmeter to the analog mA input on the main board of the device.

Flowmeter with
mA output

Figure 27: mA input on the main board

Connect the sheath of a shielded cable to ground on one end only. Connecting both
ends to ground can create a ground loop.

To connect the mA input, you need:

Protective gear for electric work

Slotted-head screwdriver (M3)
Wrench (20 mm [0.7874 in] or adjustable)
Suitable signal cable
To connect the mA output from an external flowmeter to the mA input of the device:
1. Make sure that the device is not connected to the power supply, or that the power supply is
disconnected or isolated.

©2020 Sintrol.
All rights reserved. 67 (116) Revision 5
2. Remove the device lid by turning it counterclockwise to access the main board.

3. Remove the cable gland at the cable entry that is located on the left side of the device when you are
facing the main board. Loosen the cable gland cap by turning it counterclockwise with a wrench.

4. Slide the cable gland over the incoming signal cable.

©2020 Sintrol.
All rights reserved. 68 (116) Revision 5
5. Insert the signal cable through the cable entry.

6. Connect the signal cable to mA input terminal block.

Insert the wires to the terminal block and tighten the screws.

7. Connect the other end of the signal cable to the mA output of the external flowmeter.
8. If you do not need to make any other electrical connections:
• Push the cable gland back inside the cable entry and tighten the cap with a wrench.

©2020 Sintrol.
All rights reserved. 69 (116) Revision 5
 • Attach the device lid by tightening it clockwise.

• Enable or connect the power supply, and power up the device.

©2020 Sintrol.
All rights reserved. 70 (116) Revision 5
7 DustTool
7.1 Overview
DustTool is a complementary software that can be used to control the parameters and features of the
device with a Windows computer. The device can be connected to a computer running DustTool directly
with USB or using RS­485­to­USB converter, Sintrol Router or Wireless Router.

To enable communication using RS-485 protocol, the device must have firmware version
3.0.2 or later, and the host computer must have DustTool version 1.2.1701101750 or
later installed. You can check the firmware version in DustTool on PROPERTIES tab.

If you enable Lock Password feature in DustTool, it is no longer possible to run

Auto Setup or change the device parameters. If you forget the password, you must
contact Sintrol support to unlock the device with a device-specific master password.

You can download DustTool free of charge at https://sintrol.com/product/dusttool/.

DustTool is developed to set up and manage the device parameters and properties. If
you need to save measurement data, create additional alarms, generate reports or
access measurement history, monitoring software DustLog 10 is required.

7.2 System requirements

DustTool is developed for Windows operating system. See Table 9 for system requirements.
Table 9: System requirements for DustTool

Minimum Recommended
Operating system: Windows XP Operating system: Windows 10
Display: 1024×768 Display: 1920×1080
RAM: 512 MB RAM: 4 GB

7.3 Main view

When you launch DustTool, it looks up any connected Sintrol devices. The software automatically
detects the interface that is used for communication and connects to the device. Connected devices
appear on the main view of the software, where you can manage them.
Figure 28 shows the main view that opens each time DustTool is launched.

©2020 Sintrol.
All rights reserved. 71 (116) Revision 5
 Figure 28: DustTool main view
List of currently connected products. Connection type is displayed with a small icon next to
①
the device name.
② Description of the selected product with the model name, serial number and picture.
Tabs help navigate the software, and manage device features related to calibration,
③ parameters, Auto Setup, and commands. Monitor view provides a visualization of the
current process conditions.
Info area on the bottom of the window displays information about the fields and items on
④
the screen when you hover the mouse cursor over them.
Help view provides direct access to documentation related to the connected devices.
⑤
In order to access user documentation, network access must be enabled.
⑥ Settings give you full control over software properties, like updates and network access.

©2020 Sintrol.
All rights reserved. 72 (116) Revision 5
8 Commissioning and system setup
The device requires minimal setup to establish regular operating condition. For basic trend monitoring
applications, it is enough to only run the Auto Setup procedure. After commissioning and setting up the
device, you can adjust parameter settings and alarm thresholds manually.

8.1 Auto setup

8.1.1 Overview

Parameters of the Auto Setup feature can be modified with DustTool software. This
section only describes the default Auto Setup with factory settings.

In normal operation, the device continuously monitors the dust concentration in the airflow. During
Auto Setup, the device analyzes the present measurement signal, determines an average signal level and
establishes normal process conditions that are used as a baseline for future measurements.
Auto Setup also sets up two alarm thresholds (ALERT and ALARM) that are proportional to the normal
dust level. An alarm is triggered when the dust concentration exceeds the configured dust level
threshold.
Auto Setup is performed during normal operating conditions after the device is installed, and the process
that the device monitors is running.

Make sure that Auto Setup is performed during normal operating conditions and usual
dust levels. Performing Auto Setup during irregular conditions can result in false
measurement results.

During Auto Setup, the device always uses the default settings for signal averaging time (50 seconds) and
alarm delay time (30 seconds). Signal averaging time determines the period from which the device
calculates the average signal level, and alarm delay time determines how long the dust level must be
above the configured ALERT or ALARM threshold before the relays switch position and trigger the
alarms.
Auto Setup takes 500 seconds (approximately 8 minutes) to complete. After Auto Setup is completed or
cancelled, signal averaging time and alarm delay time automatically revert to their user-set values.

8.1.2 Operation statuses

Table 10 shows the default signal levels for each operation status after Auto Setup:
Table 10: Default signal levels after Auto Setup

Status Output signal Description

Normal: 4 ... 20 mA Normal operation range
No dust present: 4 mA Minimum value during normal operation

©2020 Sintrol.
All rights reserved. 73 (116) Revision 5
 Status Output signal Description
Measurement baseline: 4.8 mA 5% of signal range
• 5× increase in dust concentration
ALERT: ≥8 mA • 25% of signal range
• Relay 1 switches position
• 20× increase in dust concentration
ALARM: 20 mA • 100% of signal range
• Relay 2 switches position

For further information on operation statuses and relay logic, see section Relay, LED and display
functional logic in chapter Operation.
Figure 29 further illustrates the relation between Auto Setup baseline and the alarm thresholds:

Figure 29: Relation between the output signal baseline and alarm thresholds after Auto Setup
Average output signal. Dust concentration baseline in the example is 10 mg/m3. Output
①
signal is around 4.8 mA, which represents 5% of measurement range.
Dust ALERT threshold at 25% of measurement range. ALERT is triggered when there is a 5×
② increase in dust level compared to the baseline. In the example this corresponds to an
output signal of 8 mA and a dust concentration of 50 mg/m3.
Dust ALARM threshold at 100% of measurement range. ALARM is triggered when there is a
③ 20× increase in dust level compared to the baseline. In the example this corresponds to an
output signal of 20 mA and a dust concentration of 200 mg/m3.

The actual dust concentration at the baseline depends on the location of the measurement point. If the
measurement point is located before a filtration system, the baseline can be several g/m3. If the
measurement point is located after a filtration system, the baseline can be only a few mg/m3. In both
cases, no manual range setup is necessary.

©2020 Sintrol.
All rights reserved. 74 (116) Revision 5
8.1.3 Performing Auto Setup
The easiest way to perform Auto Setup is to start it manually on the main interface of the device. Only
two keys, K0 (+) and AUTOSETUP, are required to perform Auto Setup. The keys are highlighted in
Figure 30:

Figure 30: Main interface of the device with K0 (+) and AUTOSETUP keys highlighted
To perform Auto Setup:
1. Press K0 (+) key to enter MAINTENANCE mode. LEDs on both sides of the display start to blink,
alternating between green and red.
2. Press AUTOSETUP key for 1 second. During Auto Setup:
• The display shows the remaining time in seconds.
• Both green LEDs continue to blink.
3. Auto Setup is completed when the counter reaches 0. The device resumes normal operation.
Auto Setup takes 500 seconds (approximately 8 minutes) to complete.

If you want to cancel Auto Setup, press AUTOSETUP key again for 1 second.

For a more detailed description of the main interface of the device, see section Main interface in
chapter Operation.

©2020 Sintrol.
All rights reserved. 75 (116) Revision 5
8.2 Changing parameters
8.2.1 Main interface
You can change parameters manually with the main interface of the device.

Figure 31: Main interface of the device

To change a parameter with the main interface:

1. Press K0 (+) key to enter MAINTENANCE mode.

• LEDs on both sides of the display blink, alternating between green and red.
• The cursor position is indicated with a blinking digit.
2. Select the parameter you want to edit.
• The selected parameter is displayed in display position D0.
• Press K0 (+) key to select the next parameter.
• Value of the selected parameter is displayed in positions D1 ... D3.
3. Select the value you want to change by pressing K1 (→) key.
• Pressing K1 (→) key moves the cursor one step to the right.
• If the cursor reaches position D3 and you press the key again, the cursor returns to position
D0.
4. Press K0 (+) key to increase the blinking value by 1. If the value reaches 9 and you press the key
again, the value returns to 0.
5. Press K2 (↩) key to save the new parameter value. After saving, the new parameter value comes
into effect immediately, and the cursor returns to position D0.
6. Press K3 (←) key to exit MAINTENANCE mode and return to normal operation.

©2020 Sintrol.
All rights reserved. 76 (116) Revision 5
 If you do not press any key on the main interface for 10 seconds, MAINTENANCE mode
times out and the device returns to normal operation.

For detailed information on the device parameters, see section Parameters in chapter Operation.

Setting negative values

Some parameters allow you to set negative values. To set a negative value, simply press K0 (+) key until
a minus sign appears on the display. Minus sign is always set in display position D1, so for parameter
value “−8” the displays D1 … D3 must indicate “− 0 8”.

8.2.2 DustTool software

You can modify the operating parameters of the connected device in DustTool.
To change the device parameters in DustTool:
1. Launch DustTool.
2. Connect the device to a Windows computer with USB or RS-485 interface.
• The software automatically detects the interface that is used for communication and connects
to the device.
• If multiple devices are connected to the same computer, you must select the device you want
to control from the list on the left side of the main view.
• When connecting with USB, no external power is needed. If you use RS-485, first connect the
device to a power supply.
3. Find the parameter that you want to edit.
Parameter settings are located on tabs PARAMETERS, CALIBRATION and COMMANDS.
4. Edit the parameter value.
5. Click the SAVE button on the bottom of the screen to store the changes in the device memory.

If you do not click the SAVE button, the changes to the parameter values are lost when
you close the program or disconnect the device.

6. Click the READ button to view the parameter values that are currently stored in the device memory.
For a more detailed overview of the DustTool software, see chapter DustTool.

8.2.3 Modbus RTU and Sintrol Network protocol

You can edit the device parameters using RS-485 buses. The device has two isolated RS-485 buses. Buses
are labeled “MB” and “SNT”.

©2020 Sintrol.
All rights reserved. 77 (116) Revision 5
Modbus RTU
You can use Modbus RTU protocol to control the device parameters with an automation control system
or any Modbus master device. To enable communication through Modbus RTU, connect the device to
the master device with the RS-485 bus labeled MB.
For information on how to control slave devices, refer to the user documentation of your Modbus
master device or control system.
For a quick reference of the register definitions of the Modbus RTU interface, see Appendix B.
For information on how to connect the RS-485 bus, see section Connecting RS-485 bus in chapter
Electrical installation.

Sintrol Network
You can use Sintrol Network protocol to connect the device to a computer running DustTool software.
To control the device parameters using Sintrol Network:
1. Connect the device to the computer with the RS-485 bus labeled SNT.
Use a RS-485-to-USB cable, or a converter with a suitable 3-wire shielded cable.
2. Use DustTool software to change the device parameters.
For information on how to change the device parameters using DustTool, see section DustTool software
in this chapter. For a more detailed overview of the DustTool software, see chapter DustTool.
For information on how to connect the RS-485 bus, see section Connecting RS-485 bus in chapter
Electrical installation.

8.2.4 Wireless connection

If your device is equipped with the optional RF antenna, you can use DustTool to remotely control the
settings and parameters of devices that are part of a wireless network.
For information on how to change the device parameters using DustTool, see section DustTool software
in this chapter. For a more detailed overview of the DustTool software, see chapter DustTool.
For information on how to enable wireless communication for the device, see section Establishing
wireless communication in this chapter.

8.3 Setting up device network

RS-485 buses allow multiple devices to be connected in parallel to create a device network. This makes it
possible to communicate with several devices at the same time with minimum wiring. Wired
connections can use either Modbus RTU or Sintrol Network protocol for communication. Wireless
communication, and combination of wired and wireless connections require the use of Sintrol Network
protocol.

©2020 Sintrol.
All rights reserved. 78 (116) Revision 5
A complete measurement system that is based on Sintrol Network protocol can consist of up to 254
devices connected to a single network. These can be connected either wirelessly, with the RS-485 bus
labeled MB, or with a combination of the two.

8.3.1 Naming devices

It is recommended to assign each device in the network a unique name before installation. Because the
network is created automatically when Sintrol Network protocol is used, naming the individual devices
makes it easier to identify them.
To assign a name to a device:
1. Launch DustTool.
2. Connect the device to a Windows computer with USB, or with RS-485 using the SNT bus.
• The software automatically detects the interface that is used for communication and connects
to the device.
• If multiple devices are connected to the same computer, select the device you want to assign
a name to from the list on the left side of the main view.

When connecting with USB, no external power is needed.

If you use RS-485, first connect the device to a power supply.

3. Navigate to PARAMETERS tab and assign an individual name for the device in the Device Name field.

4. Click the SAVE button to store the new device name in the device memory.

5. Disconnect the device.

8.3.2 Wired device network

The device has two isolated RS-485 buses. Buses are labeled “MB” and “SNT”.

• MB bus is designed for connecting multiple devices into a single bus using either Modbus RTU or
Sintrol Network protocol.
• SNT bus is designed for connecting a single device to a PC running DustTool software.
For creating a device network, you must use the bus labeled MB.

©2020 Sintrol.
All rights reserved. 79 (116) Revision 5
 RS-485 bus: RS-485 bus: RS-485 bus:
MB MB MB

AB G AB G AB G

RS-485 bus
Modbus RTU A terminator switch
master or B “ON”
Sintrol router G

Figure 32: A device network created with RS-485 connections

To create a wired device network, you need:

• Communication base station

o Modbus master device for Modbus RTU protocol
o Network Router or Wireless Router for Sintrol Network protocol
• Suitable 3-wire shielded cable
• DustTool software
To set up a wired network, all devices in the chain must first be installed according to the instructions in
chapters Mechanical installation and Electrical installation.
After the devices have been installed, the settings for each individual device must be adjusted in
DustTool. To adjust the device settings in DustTool:
1. Connect the device to a computer with USB.
2. Launch DustTool and navigate to PROPERTIES tab.

3. Adjust the settings for the RS-485 protocol as necessary:

• To use Modbus RTU protocol and to control the device network with Modbus master device,
select the option “Modbus Slave” and assign an appropriate unique slave ID. “Modbus Slave”
is selected by default.

©2020 Sintrol.
All rights reserved. 80 (116) Revision 5
 • To use Sintrol Network protocol and to control the device network with DustTool software and
Network Router or Wireless Router, select the option “SNT Slave”.

4. Click the SAVE button to store the new settings in the device memory.

5. Disconnect the device.

6. Repeat steps 1 to 4 for each individual device in the network.
After you have adjusted the settings for each individual device according to the selected communication
protocol:
7. Switch the terminator switch 1 to ON position on the last device of the chain.
1

ON
2

8. Connect the first device of the chain to the communication base station.
• If your device chain communicates through Modbus RTU protocol, the first device in the chain
must be connected to a Modbus master device.
• If your device chain communicates through Sintrol Network protocol, the first device in the
chain must be connected to Sintrol Router or Network Router. The router device in turn must
be connected to a host computer.
The device network is now operational, and you can use the master device to control the devices.

8.3.3 Wireless device network

It is possible for multiple devices to communicate with each other using the optional radio frequency
(RF) communication protocol. The wireless connection operates on the Sintrol Network protocol, which
takes care of automatically forming the network. The measurement data is always transmitted using the
strongest available connection.

If you want to use the wireless connections, you must have a RF-enabled version of the
device. RF antenna cannot be retrofitted to non-RF models.

The network operates within the ISM radio bands, which do not require any permits or licenses to use.

©2020 Sintrol.
All rights reserved. 81 (116) Revision 5
 Table 11: ISM frequency bands that the device uses

Frequency band Geographical availability

868 MHz Europe
915 MHz North and South America, Australia

It is the responsibility of the end user to verify the available frequency bands and
potential licensing needs in their area.

Sintrol Network protocol has a built-in support for wireless communication. This means that RF-enabled
devices can operate seamlessly within the RS-485 network.

Establishing wireless communication

To establish a wireless connection, you need:

• A device equipped with the optional RF antenna

• Wireless Router
• DustTool software
To enable wireless connection:
1. Install the RF-enabled device as instructed in chapter Mechanical installation.
2. Install Wireless Router and connect it to the host computer as instructed in the related user manual.
3. Launch DustTool and select the router device from the list of connected devices.
4. Navigate to NETWORK tab.

5. NETWORK tab contains a graphical view of the device network. Right-click the icon of the router and
select “Scan Network”. The software automatically identifies the devices in the network and allows
you to control their settings and parameters.

6. Close DustTool.

©2020 Sintrol.
All rights reserved. 82 (116) Revision 5
8.3.4 Combining wired and wireless connections in a network
Sintrol Network protocol supports communication using both the RS-485 bus and wireless RF
connection. This means that it is possible to build a device network that uses both the wired and wireless
connections.
To enable wireless communication in an existing device network that uses wired connections, at least
one device in a device chain must be equipped with the RF capability. This device acts as a
communication station that converts the physical signal from the other devices to radio frequencies. The
communication station also converts radio frequencies from the host application to physical signals and
passes them to the other devices in the network.
To manage the device network with a computer, connect a Wireless Router to a computer running
DustTool. This router act as a base station for all communication between the control software and the
device network. Figure 33 shows an example of a device network that uses both connection types:

Figure 33: An example of a device network using Sintrol Network protocol with wired and wireless connections

©2020 Sintrol.
All rights reserved. 83 (116) Revision 5
9 Operation
9.1 Main interface
The main interface of the device is equipped with a 7-segment display with four digits, and five keys that
are used to operate the device manually. In normal operation, the display shows the measurement
result as a percentage of total range (0 ... 100%) or as a measurement value in mA or mg/m3.
You can change the display unit with Parameter 1. See section Parameters for more information.

Figure 34: The main interface of the device

① AUTOSETUP key. Performs Auto Setup.

7-segment display with four digits.*
• In normal operation, indicates the measurement value.
② • In MAINTENANCE mode:
o Position D0 indicates the active parameter number.
o Positions D1 ... D3 indicate the parameter value.
③ Green and red status LEDs.
K0** (+) key.
④ • Enters MAINTENANCE mode.
• Increases the value of the selected, blinking digit by 1.
⑤ K1 (→) key. Moves the cursor one step to the right.
⑥ K2 (↩) key. Saves the active parameter value.
⑦ K3 (←) key. Exits and returns the device to normal operation.
* Display position labels D0 ... D3 are included in this manual for reference purposes only. They are not printed on the device.
** Key labels K0 ... K3 are included in this manual for reference purposes only. They are not printed on the device.

©2020 Sintrol.
All rights reserved. 84 (116) Revision 5
9.2 Relay, LED and display functional logic
The device has various operation statuses that are indicated to the user with a combination of LEDs, two
relays and a 7­segment display with four digits.

9.2.1 Operation statuses

The operation statuses are described in Table 12:
Table 12: Operation statuses and their descriptions

Device status Description

• The device operates normally according to the initial setup and
generates a valid output signal.
NORMAL OPERATION
• The output signal is below the configured thresholds for ALERT and
ALARM statuses.
• The device operates normally according to the initial setup and
generates a valid output signal.
ALERT • The output signal is above the configured threshold for ALERT status.
• The output signal is below the configured threshold for ALARM
status.
• The device operates normally according to the initial setup and
generates a valid output signal.
ALARM
• The output signal is above the configured threshold for ALARM
status.
• The device analyzes and establishes normal process conditions that
AUTO SETUP are used as a baseline for future measurements.
• The device does not generate a valid output signal.
• The device has been manually set into MAINTENANCE mode.
MAINTENANCE
• The device does not generate a valid output signal.
• The device performs zero/span check automatically at a certain
interval, when the measurement range settings are changed, and
after each time Auto Setup is performed.
• Measurement drift is automatically corrected if it is >3% but <10% of
ZERO/SPAN CHECK
the measurement range. If the drift is >10% or if the device is unable
to correct the drift, the device enters FAULT mode.
• The device generates an output signal according to pre-determined
test values.
• The device has detected a fault in the operation.
FAULT
• The device does not generate a valid output signal.

9.2.2 Relay logic

The device has two Single Pole Double Throw (SPDT) relays. The contacts are labeled A, B and C, with C
being the common contact. The relays can be used to control external loads of up to 240 V AC / 5 A or
30 V DC / 5 A.

©2020 Sintrol.
All rights reserved. 85 (116) Revision 5
 Figure 35: Relay terminals on the device main board
Both relays are energized during normal operation, which means that voltage is applied to the
electromagnetic coils. When the dust level exceeds the configured alarm thresholds, the voltage is no
longer supplied, and the relays are relaxed.
Table 13: Relay statuses

Relay status Relay contacts

B
C-A: open
Energized
C-B: closed C
A
B
C-A: closed
Relaxed
C-B: open C
A
The operation logic of the relays is described in Table 14:
Table 14: Operation logic of the relays

RELAY1 RELAY1 RELAY2 RELAY2

Device status Analog signal (mA)
status contacts status contacts
NORMAL C-A: open C-A: open
Energized Energized According to dust level
OPERATION C-B: closed C-B: closed
C-A: closed C-A: open
ALERT Relaxed Energized According to dust level
C-B: open C-B: closed
C-A: closed C-A: closed
ALARM Relaxed Relaxed According to dust level
C-B: open C-B: open
C-A: open C-A: closed
AUTO SETUP Energized Relaxed >22 mA
C-B: closed C-B: open
C-A: open C-A: closed
MAINTENANCE Energized Relaxed According to dust level
C-B: closed C-B: open
4 mA for Zero check,
ZERO/SPAN C-A: open C-A: closed
Energized Relaxed approx. 16.8 mA for
CHECK C-B: closed C-B: open
Span check
C-A: closed C-A: closed
FAULT Relaxed Relaxed >22 mA
C-B: open C-B: open

©2020 Sintrol.
All rights reserved. 86 (116) Revision 5
9.2.3 LED and display logic
The main interface of the device is equipped with a 7-segment display with four digits, and green and
red LEDs on each side of the display. The LEDs are mirrored, and their function is the same regardless of
their location on the main interface.
The operation logic of the display and LEDs is described in Table 15:
Table 15: Operation logic of the LEDs and display

Device status Green LED Red LED Display

Displays current
NORMAL OPERATION ON OFF
dust level
Displays current
ALERT ON* ON*
dust level
Displays current
ALARM OFF ON
dust level
AUTO SETUP Blinks OFF Countdown (sec)
Blinks between green and Blinks between red and Number and value
MAINTENANCE
red with 500 ms interval green with 500 ms interval of active parameter
Blinks between green and Blinks between red and
ZERO/SPAN CHECK Output signal
red with 500 ms interval green with 500 ms interval
Blinks between left and
FAULT OFF Error code
right with 500 ms interval
* With both red and green LEDs ON, the color appears orange.

To test that the display and LEDs are operating normally, press K0 (+) and K3 (←) keys at the same time.
All four displays are activated, displaying “8.8.8.8.”, and status LEDs on each side of the display are
illuminated. This indicates that the display and LEDs are operating as intended.
For descriptions of error codes, see section Error codes in FAULT mode.

9.3 Parameters
For instructions on how to change the device parameters, see section Changing parameters in chapter
Commissioning and system setup.

9.3.1 Overview
You can control how the device operates and reacts to changes in dust levels by adjusting the device
parameters. To change parameter values on the main display, enter MAINTENANCE mode by pressing K0
(+) key. The device indicates the parameter number on the display position D0, and parameter values
on positions D1 ... D3.
Because only one display position is reserved for the parameter number, 2-digit parameters are
indicated in an abbreviated form. Parameter 10 is indicated as 0, and parameters 11 to 17 as 1., 2., 3.
and so on, with a single digit followed by a period.

©2020 Sintrol.
All rights reserved. 87 (116) Revision 5
See Table 16 for information on the device parameters and their availability on different device models:
Table 16: The device parameters

No. Parameter Value ✓=Available ✕=Not available S303 S304

Displays measurement range in %.
000:
Default value. ✓ ✓
1 Display unit 001: Displays output signal level in mA. ✓ ✓
Displays dust concentration in mg/m3.
002:
Displays - -.- - if mg/m3 is disabled. ✕ ✓
000 ... 300
2 Signal averaging time (sec)
Default = 50 sec ✓ ✓
000 ... 999
3 Measurement range (%) Default = 100% (20× the baseline value calibrated ✓ ✓
during Auto Setup)
ALERT threshold 000 ... 100
4
(% of range) Default = 25% (8 mA) ✓ ✓
ALARM threshold 000 ... 100
5
(% of range) Default = 100% (20 mA) ✓ ✓
000 ... 180
6 Alarm delay time (sec)
Default = 30 sec ✓ ✓
Flow speed compensation 000 ... 99.9
7
at 4 mA (m/s) Default = 0 m/s (no compensation) ✕ ✓
Flow speed compensation 000 ... 99.9
8
at 20 mA (m/s) Default = 0 m/s (no compensation) ✕ ✓
Zero/span check interval 000 ... 999
9
(hours) Default = 0 hours (no check) ✕ ✓
001: Reset to factory default ✓ ✓
✕ ✓
0
Command parameter 002: Enable mg/m3 calibration
(10)
003: Disable mg/m3 calibration ✕ ✓
Integer part of −99 ... 099
✕ ✓
1.
(11) x­intercept 𝜶𝜶 Default = 0 mg/m3
Decimal part of 000 ... 999
✕ ✓
2.
(12) x­intercept 𝜶𝜶 Default = 0 mg/m3
000 ... 999
✕ ✓
3.
Integer part of slope 𝜷𝜷
(13) Default = 0 mg/m3 per mA
000 ... 999
✕ ✓
4.
Decimal part of slope 𝜷𝜷
(14) Default = 0 mg/m3 per mA
20 mA scaling ×
✕ ✓
5.
000 ... 999
(15) 1 000 000 IEU

✕ ✓
6.
20 mA scaling × 1000 IEU 000 ... 999
(16)

✓ ✓
7.
Firmware version Displays current firmware version.
(17)

©2020 Sintrol.
All rights reserved. 88 (116) Revision 5
9.3.2 Parameter 1: Display unit
Parameter 1 is used to determine the unit that the device uses when it displays the measurement signal
level. See Table 17 for descriptions of the parameter values:
Table 17: Parameter 1 values

Value Description Display

Displays measurement range in %. 0.0 ... 100.0 (%),
000
Default value. fixed decimal point
04.00 ... 20.00 (mA),
001 Displays output signal level in mA.
fixed decimal point
00.01 ... 999.9 ... 9999 (mg/m3),
002* Displays dust concentration in mg/m3.
floating decimal point
* Only available in model S304.

If the mA output is not properly connected and parameter value 001 is selected, the
display indicates “OL” for “Open Loop”. This means that the 4 ... 20 mA loop is not
closed.

The device indicates the currently selected measurement unit every 8 seconds by showing it on the
display for 2 seconds. For parameter value 000 the device displays “%”, for parameter value 001 it
displays “mA” and for 002 it displays “mg”.

9.3.3 Parameter 2: Signal averaging time

Signal averaging time refers to the period from which the device calculates the average signal level. For
example, with the default value of 50, the displayed measurement result is the moving average of the
past 50 seconds.
Parameter value corresponds to the signal averaging time in seconds.
Table 18: Parameter 2 values

Value range (sec) Description Default

Determines the signal averaging time in
000 ... 300 50
seconds.

When adjusting the parameter value locally with the device main interface, the maximum signal
averaging time is 300 seconds. However, with DustTool you can set the signal averaging time to up to
6000 seconds.

9.3.4 Parameter 3: Measurement range

Parameter 3 value controls the maximum measurement range in relation to the baseline value that is
determined during Auto Setup. You can control the maximum dust concentration that the device can
detect before reaching the maximum output signal of 20 mA by changing the parameter value. This
scales the whole measurement range to the standard 4 ... 20 mA signal range.

©2020 Sintrol.
All rights reserved. 89 (116) Revision 5
 If Auto Setup has not been performed, the display indicates “3 - - -” when this
parameter is selected.

Table 19: Parameter 3 values

Value range (%) Description Default

Increases or decreases the maximum dust
000 ... 999 100
concentration at 20 mA output signal.

With the default value, the device can detect a 20× increase in the dust level in relation to the baseline
before reaching 20 mA signal level. This represents 100% of the default measurement range.

The maximum range determined with parameter 3 is always calculated from the
baseline value. In practice, parameter 3 value sets a multiplier for how much the dust
concentration can increase before the output signal reaches 20 mA.

See Table 20 for examples on how changing the parameter value affects the measurement range:
Table 20: Examples of adjusting the measurement range with parameter 3

Value (%) Description Dust level at 20 mA

050 Halves the measurement range 10× baseline
100 Default value 20× baseline
200 Doubles the measurement range 40× baseline

After adjusting the measurement range, the device automatically performs

zero/span check.

Adjusting the measurement range does not change the dust concentrations required to
trigger ALERT and ALARM statuses. Instead, it adjusts parameter 4 and 5 values in
relation to the new maximum range. For example, doubling the measurement range
with parameter 3 halves the values of parameters 4 and 5.

For detailed information on the default measurement range and signal levels, see section Auto setup in
chapter Commissioning and system setup.

9.3.5 Parameter 4: ALERT threshold

Parameter 4 controls the relation between the maximum measurement range (adjusted with
parameter 3) and the ALERT status threshold. Parameter value corresponds to the signal level required
to trigger the ALERT status.

©2020 Sintrol.
All rights reserved. 90 (116) Revision 5
 Table 21: Parameter 4 values

Value range (%) Description Default

Increases or decreases the signal level required
000 ... 100 025
to trigger the ALERT status.

See Table 22 for examples on how the parameter value affects the signal level required to trigger the
ALERT status.
Table 22: Examples of adjusting ALERT threshold with parameter 4

Value (%) Description

012 Halves the default signal level. ALERT triggers at 12% of maximum range.
025 Default value. ALERT triggers at 25% of maximum range.
050 Doubles the default signal level. ALERT triggers at 50% of maximum range.

ALERT threshold is set in relation to maximum measurement range, which is determined

with parameter 3. These two parameters are not linked and must be set independently.
For example, if you double the maximum measurement range, the default parameter 4
value is decreased from 025 to 012 (25% to 12% of maximum measurement range).

9.3.6 Parameter 5: ALARM threshold

Parameter 5 controls the relation between the maximum measurement range (adjusted with
parameter 3) and the ALARM status threshold. Parameter value corresponds to the signal level required
to trigger the ALARM status.
Table 23: Parameter 5 values

Value range (%) Description Default

Increases or decreases the signal level required
000 ... 100 100
to trigger the ALERT status.

See Table 24 for examples on how the parameter value affects the signal level required to trigger the
ALARM status.
Table 24: Examples of adjusting ALARM threshold with parameter 5

Value (%) Description

050 Halves the default signal level. ALARM triggers at 50% of maximum range.
100 Default value. ALARM triggers at 100% of maximum range.

©2020 Sintrol.
All rights reserved. 91 (116) Revision 5
 ALARM threshold is set in relation to maximum measurement range, which is
determined with parameter 3. These two parameters are not linked and must be set
independently. For example, if you double the maximum measurement range, the
default parameter 5 value is decreased from 100 to 050 (100% to 50% of maximum
measurement range).

9.3.7 Parameter 6: Alarm delay time

Parameter 6 determines how long the average dust level must be above the configured ALERT or ALARM
threshold before an alarm is triggered. This is to avoid false alarms caused by naturally occurring peaks
in dust levels in certain processes.
Parameter value corresponds to the alarm delay time in seconds.
Table 25: Parameter 6 values

Value range (sec) Description Default

000 ... 180 Sets the alarm delay time in seconds. 30

Parameter 6 applies a delay to all relay position switches when the device changes its
operation status. However, in practice this only affects the operation of the device in
relation to ALARM and ALERT statuses.

9.3.8 Parameters 7 and 8: Flow speed compensation

Parameter 7 and 8 are only available in model S304.

Flow speed can have an impact on the measurement results. With model S304 you can compensate the
influence that changes in flow speed have on the signal level by connecting the mA output of an external
flowmeter to the mA input of model S304.
For information on how to connect an external flowmeter to model S304, see section Analog mA input
in chapter Electrical connections.

Parameter 7: Flow speed at 4 mA

Use parameter 7 to set the flow speed value that corresponds to the 4 mA output signal level from the
external flowmeter. Parameter value corresponds to the flow speed in m/s.
Table 26: Parameter 7 values

Value range (m/s) Description Default

Sets the flow speed corresponding to 4 mA
00.0 ... 99.9 00.0
output signal from the external flow meter.

©2020 Sintrol.
All rights reserved. 92 (116) Revision 5
 Parameter value 00.0 means that flow speed compensation is disabled.

Parameter 8: Flow speed at 20 mA

Use parameter 8 to set the flow speed value that corresponds to the 20 mA output signal level from the
external flowmeter. Parameter value corresponds to the flow speed in m/s.
Table 27: Parameter 8 values

Value range (m/s) Description Default

Sets the flow speed corresponding to 20 mA
00.0 ... 99.9 00.0
output signal from the external flow meter.

Parameter value 00.0 means that flow speed compensation is disabled.

9.3.9 Parameter 9: Zero/span check interval

This parameter is only available in model S304.

Zero/span check is an automatic self-diagnostics procedure. During zero/span check, the device
disconnects the sensor probe from the measurement chain and induces a computer-generated signal to
the processing electronics. This is done to ensure that the measurement results match the factory-
calibrated reference values. Parameter 9 controls how often the device performs zero/span check.
Parameter value corresponds to the zero/span check interval in hours.
Table 28: Parameter 9 values

Value range (h) Description Default

000 ... 999 Sets the zero/span check interval in hours. 000

Parameter value 000 means that the automatic zero/span check is disabled. The device
performs zero/span check independently of the parameter 9 value each time you adjust
the range setting with parameter 3, and each time Auto Setup is performed.

9.3.10 Parameter 10: Command parameter

Command parameter 10 can be used to reset the device to the default factory settings. With model S304
it is also possible to enable the device to display the measurement results in mg/m3.
See Table 29 for descriptions of the parameter values:

©2020 Sintrol.
All rights reserved. 93 (116) Revision 5
 Table 29: Parameter 10 values

Value Description
001 Reset all parameters to default factory values.
002* Enable mg/m3 calibration.
003* Disable mg/m3 calibration.
* Only available in model S304.

Reset to default factory values

To reset the device to the default factory settings:

1. Press K0 (+) key to enter MAINTENANCE mode.

2. Navigate to parameter 10.
3. Enter parameter value 001 and press K2 (↩) key to save the value.
4. Press K3 (←) key to exit and return to normal operation.
All device parameters are now overwritten with the default factory values.

Resetting the device to factory settings with command parameter 10 rewrites all
parameter values, including the ones set with Auto Setup.

Enable mg/m3 calibration

To enable displaying the measurement results in mg/m3:

1. Press K0 (+) key to enter MAINTENANCE mode.

2. Enter the values 𝜶𝜶 and 𝜷𝜷 of the calibration equation 𝒚𝒚𝒊𝒊 = 𝜶𝜶 + 𝜷𝜷𝒙𝒙𝒊𝒊 to parameters 11, 12, 13 and 14.
After setting the value for each parameter, save the value by pressing K2 (↩) key.
See section Parameters 11 to 14: Displaying measurement results in mg/m3 for information about
the calibration equation and individual calibration parameters.
3. Navigate to parameter 10.
4. Enter parameter value 002 and press K2 (↩) key to save the value.
5. Navigate to parameter 1.
6. Enter parameter value 002 and press K2 (↩) key to save the value.
7. Press K3 (←) key to exit and return to normal operation.
The measurement results are now displayed in mg/m3.

Disable mg/m3 calibration

To disable displaying the measurement results in mg/m3:

8. Press K0 (+) key to enter MAINTENANCE mode.

©2020 Sintrol.
All rights reserved. 94 (116) Revision 5
9. Navigate to parameter 10.
10. Enter parameter value 003 and press K2 (↩) key to save the value.
11. Navigate to parameter 1.
• Enter parameter value 000 to display the measurement range in %.
• Enter parameter value 001 to display output signal level in mA.

If you do not set a new value for parameter 1, the device alternates between displaying
“- -.- -“ and “mg” in normal operation mode.

12. Press K2 (↩) key to save the value.

13. Press K3 (←) key to exit and return to normal operation.

9.3.11 Parameters 11 to 14: Displaying measurement results in mg/m3

Parameters 11 to 14 are only available in model S304.

To enable the device to display the measurement results in mg/m3, the device must be calibrated by
inserting values from a calibration equation to parameters 11, 12, 13 and 14. These values are calculated
by utilizing a linear regression curve with an equation 𝒚𝒚𝒊𝒊 = 𝜶𝜶 + 𝜷𝜷𝒙𝒙𝒊𝒊 . To determine the parameter values
for parameters 11 to 14, you need to know the values for x-intercept 𝜶𝜶 and slope 𝜷𝜷. The values are
calculated from the results of a reference measurement. A commonly used method is gravimetric
sampling.

This section describes how to perform the calibration using the local display. You can
also use DustTool to calibrate the device to display measurement results in mg/m3.

After setting values for parameters 11 to 14, enable mg/m3 calibration with parameter
10 and set the local display to show measurement results in mg/m3 with parameter 1.

Example parameter values

For setting the parameters, values 𝜶𝜶 and 𝜷𝜷 are split into integer and decimal parts:

• Integer part of value 𝜶𝜶 becomes the value for parameter 11.

• Decimal part of value 𝜶𝜶 becomes the value for parameter 12.
• Integer part of value 𝜷𝜷 becomes the value for parameter 13.
• Decimal part of value 𝜷𝜷 becomes the value for parameter 14.

©2020 Sintrol.
All rights reserved. 95 (116) Revision 5
Table 30 uses example values to show how these values are used to set the parameter values for
calibrating the device to display the measurement results in mg/m3:
Table 30: Example values for parameter 11 to 14

No. Parameter Calibration variable Parameter value

1.
Integer part of x-intercept 𝜶𝜶 𝜶𝜶 = −𝟖𝟖. 625 −08
(11)
2.
Decimal part of x-intercept 𝜶𝜶 𝜶𝜶 = −8. 𝟔𝟔𝟔𝟔𝟔𝟔 625
(12)
3.
Integer part of slope 𝜷𝜷 𝜷𝜷 = 𝟏𝟏. 625 001
(13)
4.
Decimal part of slope 𝜷𝜷 𝜷𝜷 = 1. 𝟔𝟔𝟔𝟔𝟔𝟔 625
(14)

Parameter 11: Integer part of x-intercept 𝜶𝜶

Parameter 11 is used to set the calibration value for the integer part of x-intercept 𝜶𝜶 when the device is
calibrated to display measurement results in mg/m3.
Table 31: Parameter 11 values

Value range (mg/m3) Description Default

−99 ... 099 Value for the integer part of x-intercept 𝜶𝜶. 000

Parameter 12: Decimal part of x-intercept 𝜶𝜶

Parameter 12 is used to set the calibration value for the decimal part of x-intercept 𝜶𝜶 when the device is
calibrated to display measurement results in mg/m3.
Table 32: Parameter 12 values

Value range (mg/m3) Description Default

000 ... 099 Value for the decimal part of x-intercept 𝜶𝜶. 000

Parameter 13: Integer part of slope 𝜷𝜷

Parameter 13 is used to set the calibration value for the integer part of slope 𝜷𝜷 when the device is
calibrated to display measurement results in mg/m3.
Table 33: Parameter 13 values

Value range
Description Default
(mg/m3/mA)
000 ... 099 Value for the integer part of slope 𝜷𝜷. 000

©2020 Sintrol.
All rights reserved. 96 (116) Revision 5
Parameter 14: Decimal part of slope 𝜷𝜷
Parameter 14 is used to set the calibration value for the decimal part of slope 𝜷𝜷 when the device is
calibrated to display measurement results in mg/m3.
Table 34: Parameter 14 values

Value range
Description Default
(mg/m3/mA)
000 ... 099 Value for the decimal part of slope 𝜷𝜷. 000

9.3.12 Parameters 15 and 16: IEU to 20 mA scaling

Parameters 15 and 16 are only available in model S304.

Parameters 15 and 16 control the maximum measurement range by setting an IEU value that
corresponds to the 20 mA output signal. This allows you to set the measurement range more accurately
than with parameter 3, which controls the measurement range by setting a multiplier in relation to the
baseline value.
The IEU scale ranges from 0 to several million units. Because of this, setting the IEU value is done with
two parameters. Parameter 15 sets the IEU value in millions, and parameter 16 in thousands.
Table 35: Parameter 15 and 16 functions

No. Parameter Description

5.
IEU units in millions Parameter value represents × million IEU units
(15)
6.
IEU units in thousands Parameter value represents × thousand IEU unit
(16)

This means that for setting 20 mA to correspond to, for example, 125 020 000 IEU, the parameter values
would be as shown in Table 36:
Table 36: Example parameter values for 125 020 000 IEU

No. Parameter Parameter value

5.
IEU units in millions 125
(15)
6.
IEU units in thousands 020
(16)

Adjusting the measurement range with parameters 15 and 16 overrides the previous
range settings done using parameter 3.

©2020 Sintrol.
All rights reserved. 97 (116) Revision 5
Parameter 15: IEU units in millions
Parameter 15 sets the million part of the IEU value that corresponds to 20 mA output signal. Parameter
value represents × million IEU units.
Table 37: Parameter 15 values

Value range
Description Default
(million IEU)
000 ... 999 Sets the million part of the IEU value n/a

Parameter 16: IEU units in thousands

Parameter 16 sets the thousand part of the IEU value that corresponds to 20 mA output signal.
Parameter value represents × thousand IEU units
Table 38: Parameter 16 values

Value range
Description Default
(thousand IEU)
000 ... 999 Sets the thousand part of the IEU value n/a

9.3.13 Parameter 17: Firmware version

Parameter 17 is a read-only parameter. Navigating to it returns the current firmware version.

The user cannot update the device firmware on-site.

To update firmware version, contact the manufacturer or an authorized distributor.

©2020 Sintrol.
All rights reserved. 98 (116) Revision 5
9.4 Troubleshooting
If performing the checks as instructed in this section does not solve your problem, contact the
manufacturer or an authorized distributor.

9.4.1 Error codes in FAULT mode

When the device enters FAULT mode, an error code is displayed on the local display. See below table for
the error codes and their descriptions.
Table 39: Error codes

Error code Description Solution

Err1 Sensor probe grounded Clean the probe.
Check measurement response and
Err2 Zero/span check failed
return the device for repair.
Verify mA output of the external
Err3* Flow compensation input failed flowmeter and check the device
parameter values.
Run Auto Setup again. If the issue
Err4 Auto Setup failed persists, contact the manufacturer
or an authorized distributor.
Contact the manufacturer or an
Err5 Boot check failed
authorized distributor.
* Only available in model S304.

Err1: Sensor probe grounded

Error code “Err1” indicates that the sensor probe is grounded.

• Check the ground connections, and make sure that the device has been connected to ground
properly.
• Make sure that there is no contact between the sensor probe and the duct or pipe wall.
• Remove the device from the process, clean it with non-abrasive methods, and install it back to
the process.
If the probe is constantly grounded or it gets repeatedly grounded during normal operation, contact an
authorized distributor to have either an air purge adapter or a coated probe installed.
For more information about ground connections, see section Grounding in chapter Electrical
installation.
For more information about cleaning and inspecting the probe, see chapter Maintenance and
inspection.
For more information about optional functions and accessories, see section Features and accessories in
chapter Product overview.

©2020 Sintrol.
All rights reserved. 99 (116) Revision 5
Err2: Zero/span check failed
Error code “Err2” indicates that zero/span check has failed. This happens when the device is unable to
compensate for the drift, or when the drift is >10% after the first zero/span check. There are two
possible causes for this:

• Measurement response is drifting due to faulty components, for example due to heat damage.
• Internal signal generator is damaged.
To determine the cause of zero/span check failure, you can use Reference Signal Generator to check if
the measurement response is within the expected range.

• If the results of the check with Reference Signal Generator are within the expected range, the
internal signal generator of the device is damaged. In this case the measurement results are most
likely accurate, but the device is unable to confirm that there is no drift.
• If the check with Reference Signal Generator fails, the measurement response is drifting due to
component failure. In this case the measurement response no longer corresponds to the actual
dust concentration, and the measurement results are false.
In both cases, return the device to the manufacturer or an authorized distributor for maintenance and
repair.

Err3: Flow compensation input failed

Error code “Err3” is only available in model S304.

Error code “Err3” indicates that the device has failed to read the flow speed measurement from the
external flowmeter when the flowmeter compensation is active.

• Verify that the external flowmeter is transmitting valid output signal.

• Check that the values for parameter 7 and 8 have been set properly and that flow speed
compensation is active.
For more information about flow speed compensation, see section Analog mA input in chapter Electrical
installation and section Parameters 7 and 8: Flow speed compensation in this chapter.

Err4: Auto Setup failed

Error code “Err4” indicates that Auto Setup function has failed.

• Run Auto Setup again.

• If the problem persists, contact the manufacturer or an authorized distributor.
For more information about Auto Setup feature, see section Auto setup in chapter Commissioning and
system setup.

©2020 Sintrol.
All rights reserved. 100 (116) Revision 5
Err5: Boot check failed
Error code “Err5” indicates that the device has failed to perform internal functions that are essential to
its operation. In this case, contact the manufacturer or an authorized distributor.

9.4.2 Display indicates “- -.- -“

Four dashes (- -.- -) on the device display indicate that the parameters for displaying the measurement
results are set improperly. The correct procedure to fix this depends which unit of measurement you
want to display the measurement results with.

Displaying measurement results in mA or % of total range

If you want to display the measurement results in mA or as % of total range:

1. Press K0 (+) key to enter MAINTENANCE mode.

2. Navigate to parameter 1.
• Enter parameter value 000 to display the measurement result as % of total range.
or
• Enter parameter value 001 to display the output signal level in mA.
3. Press K2 (↩) key to save the value, and press K3 (←) key to exit and return to normal operation.

Displaying measurement results in mg/m3

If you want to display the measurement results in mg/m3:

1. Press K0 (+) key to enter MAINTENANCE mode.

2. Enter the values 𝜶𝜶 and 𝜷𝜷 of the calibration equation 𝒚𝒚𝒊𝒊 = 𝜶𝜶 + 𝜷𝜷𝒙𝒙𝒊𝒊 to parameters 11, 12, 13 and 14.
After setting the value for each parameter, save the value by pressing K2 (↩) key.
See section Parameters 11 to 14: Displaying measurement results in mg/m3 for information about
the calibration equation and individual calibration parameters.
3. Navigate to parameter 10.
4. Enter parameter value 002 and press K2 (↩) key to save the value.
5. Navigate to parameter 1.
6. Enter parameter value 002 and press K2 (↩) key to save the value.
7. Press K3 (←) key to exit and return to normal operation.

©2020 Sintrol.
All rights reserved. 101 (116) Revision 5
9.4.3 Display indicates “[n] - - -”
When setting parameter values, the display can indicate “[n] - - -“, where [n] is the parameter number
and dashes have replaced the parameters values. This usually means that the device has not been
properly commissioned to accept parameter values. For example, if you attempt to set parameter value
for the measurement range (parameter 3) without running Auto Setup, the displays indicate “3 - - -“.
Make sure that you have commissioned and set up the device according to instructions in chapter
Commissioning and system setup.

9.4.4 No output signal

If the device does not generate a valid output signal during normal operation:

• Make sure that the device is connected to a power source and that all electrical connections are
made correctly.
• Make sure that the power supply is ON.
• Make sure that normal processes are running.
• Perform Auto Setup.

9.4.5 No response after Auto Setup

If the device does not respond after you have performed Auto Setup:

• Make sure that the device is connected to a power source and that all electrical connections are
done correctly.
• Make sure that the power supply is ON.
• Make sure that the signal is not leaking to ground. Possible causes for a signal leak are:
o Contact between the sensor probe and the duct wall.
o Condensed droplets in the gas flow.
o Sticky dust buildup on the sensor base, which can cause bridging between the sensor
probe and the duct wall.
• Make sure that normal processes are running during Auto Setup.

©2020 Sintrol.
All rights reserved. 102 (116) Revision 5
9.4.6 Device lid does not open
The device lid can become stuck if too much dust accumulates between the threads. In this case, you can
use a rod or other suitable tool to force the lid open. To force the lid open:
1. Place a rod or other suitable tool between two opposite slots on the device lid. The lid has four slots.

2. Use the rod to turn the lid counterclockwise. The slots lock the rod in place, allowing you to force
the lid open.

The design of the slots makes the rod slip out if you attempt to use it to turn the lid
clockwise. This prevents you from using a tool to close the lid by force.

©2020 Sintrol.
All rights reserved. 103 (116) Revision 5
10 Maintenance and inspection
10.1 Safety precautions

Read chapter “Safety” carefully before performing maintenance on the device.

The device must not be modified or repaired in any way that is not specifically described in this manual.
Do not perform any mechanical or electrical repairs without contacting the manufacturer or an
authorized distributor.
Only original Sintrol parts can be used for repairs. If third-party spare parts are used, the manufacturer
cannot guarantee safe operation of the device. The manufacturer or distributor cannot be held liable for
any damage, injury or financial loss resulting from improper use.

Wear protective glasses when working on electrical connections.

DANGER!
Poisonous and hot gas hazard
When installing or removing the device, poisonous and hot gas can be released from
the duct.
Wear appropriate respiratory and eye protection gear when installing or removing the
device. Follow all applicable local and plant-specific safety codes before proceeding.

WARNING!
Risk of burns due to hot components
When installing or removing equipment, the device or the installation surface can be
hot.
Wear appropriate heat-resistant gloves and follow all applicable local and plant-specific
safety codes before proceeding.

©2020 Sintrol.
All rights reserved. 104 (116) Revision 5
 WARNING!
Electric shock hazard
Faulty electrical installations, too high line voltage or incorrect operation of the device
can result in an electric shock. Only trained and qualified personnel can install,
commission, operate and perform maintenance on the device.

To ensure that performing maintenance on the device is safe, keep the following points in mind:

• Power down the device when you are making electrical connections, when you intend to perform
maintenance on it, or in the event of malfunction.
• Make sure that all equipment is properly grounded.
• Never perform maintenance on the device alone.

10.2 Maintenance and inspection interval

The recommended inspection and maintenance intervals depend on the operating conditions. The
amount of dust and other possible substances in the measurement air affect how often the sensor must
be inspected and cleaned.
During the first months after installation (up to 6 months), it is recommended to perform maintenance
on the device monthly. If there is no noticeable dust build-up on the sensor probe and the probe is easy
to clean, the maintenance interval can be increased step-by-step.

It is the responsibility of the plant operator to decide what is the appropriate

maintenance interval.

A monthly interval is recommended for the visual inspection of the device and testing of the device
functions.
If you notice that the device is not operating normally, contact the manufacturer or an authorized
distributor. Make sure that an industry specialist inspects and approves the device for use in the
monitoring system that the device is part of, and ensures that its use complies with all local safety
standards and regulations.

10.3 Maintenance and inspection

Do the following inspections monthly:

• Visually inspect the outer parts of the device, its accessories, and cables. Make sure that there is
no obvious visible damage.
• Make sure that the device lid, quick-clamp, cable glands and cables are tightly secured.
• Make sure that the display and LEDs are operating normally.
• Clean the device enclosure, lid and the window.

©2020 Sintrol.
All rights reserved. 105 (116) Revision 5
 • Make sure that the measurement results are within the expected range.
• Make sure that the device is properly grounded by touching the enclosure and the probe. The
device is properly grounded if:
o The output signal does not change when you touch the enclosure.
o The output signal changes when you touch the probe.
• If applicable, make sure that the air supply for the air purge is operating normally, and that the
inlet air connection is tight.
o Recommended airflow is 50 l/min ±10%.
o The required air pressure depends on the flow resistance and process pressure.
In addition, do the following maintenance tasks at regular intervals determined by the plant operator:

• Clean the sensor probe by wiping it with a cloth. If necessary, you can use a brush.
10.3.1 Removing device from the process
For cleaning and testing that the probe reacts properly to being touched and to clean it, the device must
be removed from the process. To remove the device from the process:
1. Loosen the quick-clamp connector that is used to secure the device to the process connection.

©2020 Sintrol.
All rights reserved. 106 (116) Revision 5
2. Remove the device from the process by lifting it out of the process connection. Leave the quick-
clamp gasket in place on the process connection.

3. Fit the end cap on the process connection.

4. Secure the end cap in place with the quick-clamp connector.

5. Do necessary inspections and maintenance on the probe.

6. When you are done, install the sensor again by removing the end cap and securing the sensor in
place with the quick clamp.

©2020 Sintrol.
All rights reserved. 107 (116) Revision 5
10.3.2 Cleaning supplies
Use a cloth or paper towel to clean the device enclosure and probe. If necessary, you can apply mild
detergent or isopropyl alcohol to remove stuck-on dirt.

NOTICE
Do not use any abrasive material or corrosive substances to clean the device enclosure or sensor
probe. It can cause damage to the device or probe and influence the measurement results.

You can use a steel brush to gently clean a standard uncoated steel probe, for example if the probe is
encrusted with burned particles from the process.

10.3.3 Maintenance of Teflon-coated probe

NOTICE
If you have a Teflon-coated probe, only use soft cloth to clean it. If you use other kinds of cleaning
supplies, the Teflon coating can break. Always handle a Teflon-coated probe with care.

If the dust build-up on a Teflon-coated probe is impossible to clean, remove the outer translucent Teflon
sleeve and replace it with a new one. Contact the manufacturer or an authorized distributor for
information on how to order a spare Teflon sleeve for your probe.
The inner black coating of the probe is a second layer of very fine Teflon, which is the actual insulating
part of the probe and must not be scratched.

If you damage the second layer of Teflon, the probe must be replaced. Contact the
manufacturer or an authorized distributor for information on how to have the probe
replaced.

10.4 Returns
If you need to return a defective device for repair, replacement or disposal, contact the manufacturer or
an authorized distributor. Return the device in its original packaging, or in a suitable secure container.
Contact details for the manufacturer’s offices are available on the back cover of this user manual, and
online at https://sintrol.com/contact/.

©2020 Sintrol.
All rights reserved. 108 (116) Revision 5
11 Recycling and disposal
11.1 Packaging
Recycle any paper, cardboard or plastic material used in the product packaging, and sort
them in an appropriate recycling container.
Any non-recyclable packaging material must be disposed of with general waste.

11.2 Device
Electronic devices that are marked with this symbol must not be disposed of with general
or household waste. If a defective or broken-down device cannot be repaired, it must be
recycled and disposed of in accordance with WEEE directive (2012/19/EU) or other
applicable local regulations.

©2020 Sintrol.
All rights reserved. 109 (116) Revision 5
12 Specifications
For dimensions, see section Dimension drawings in chapter Product overview.

General information
Product name: S303, S304
Measured objects: Total suspended particles (TSP)
Measurement principle: Inductive electrification
Detection limit 0.01 mg/m3
Measurement range:
Max. range up to several g/m3 depending on operating conditions
Ingress protection: IP66
24 V DC ±10%
Power supply requirements:
100 ... 240 V AC ±10%, 50 / 60 Hz
Power consumption: Up to 10 W DC / AC
• 2 × Independent SPDT dry contact relays,
max. 30 V DC / 5 A or 240 V AC / 5 A,
Output signals: cos φ = 1
• Isolated active 4 ... 20 mA output loop,
max. loop resistance 250 Ω
• 2 × Serial communication RS-485
Communication interface: • USB
• Radio frequency (RF)*
• Modbus RTU (with RS-485)
Communication protocol:
• Sintrol network (with USB, RF and RS-485)

Physical characteristics
Enclosure: Aluminum
• Probe: Stainless steel (316L)
Wetted parts:
• Insulation: Polyphenylene sulfide (Ryton R-4)
Weight: 1.5 kg (3.3 lb)

Ambient conditions
Temperature: −40 ... 60 °C (−40 ... 140 °F)
Humidity: Max. 95 % relative humidity (non-condensing)
* Requires optional RF antenna

©2020 Sintrol.
All rights reserved. 110 (116) Revision 5
 Process conditions
• Max. 300 °C (572 °F), optionally up to 700 °C (1292 °F)
Temperature:
• Max. 250 °C (482 °F) with Teflon-coated probe
• Max. 600 kPa (87.02 psi) in temperatures
up to 300 °C (572 °F)
Pressure: • Max. 300 kPa (43.51 psi) in temperatures
from 300 °C (572 °F) to 700 °C (1292 °F) when
high­temperature process connection is used
Flow speed: Min. 3 m/s (9.84 ft/s), max. tested 40 m/s (131.23 ft/s)

Wireless communication*
• 868 MHz, 15 channels
Frequency bands:
• 915 MHz (license-free ISM band)
Transmit power: Up to +23 dBm, user-adjustable
Receiver sensitivity: −110 dBm
Communication protocol: Proprietary Sintrol Network protocol
Typical communication range • 868 MHz version
(non-line of sight) • Up to 1000 m (3280 ft) in urban environments**
* Requires optional RF antenna.
** Surrounding structures and other devices using radio frequencies can have significant effect on RF communication range.

©2020 Sintrol.
All rights reserved. 111 (116) Revision 5
Appendix A: ISO 9001 certificate

©2020 Sintrol.
All rights reserved. 112 (116) Revision 5
Appendix B: Modbus RTU registers
Full register definitions available from the manufacturer on request.

Default Modbus communication parameters

Baud rate: 19200
Data bits: 8
Stop bits: 1
Parity: Even

Supported function codes

Input registers (R – Read only)

• 4 – Read Input Registers

Holding registers (R/W – Read and Write)

• 3 – Read Holding Registers

• 6 – Write Single register

©2020 Sintrol.
All rights reserved. 113 (116) Revision 5
Modbus RTU quick reference guide
Register R or
Description Data type Notes
address R/W
First 16 bits of a 32-bit
Unscaled measurement data [IEU] MSB 6 R
integer
Last 16 bits of a 32-bit
Unscaled measurement data [IEU] LSB 7 R
integer
First 16 bits of a 32-bit Value must be divided by 100 to achieve the correct
Calibrated measurement data [mg/m3] MSB 8 R
integer result. For example, value 125 = 1.25 mg/m3.
Last 16 bits of a 32-bit
Calibrated measurement data [mg/m3] LSB 9 R
integer
Auto Setup remaining time 34 R 16-bit unsigned integer Remaining Auto Setup time in seconds
Alarm status of the device: 00000000000000[bit1][bit0]:
Bit 0 Bit 1
No alarm 1 1
ALERT 0 1
Alarm status 50 R 16-bit Boolean values
ALARM 0 0
Maintenance 1 0
Fault 0 0

1 Start Auto Setup

Auto Setup command register 1536 W 16-bit integer
2 Cancel Auto Setup
Measurement moving averaging time in seconds,
Signal averaging time 4096 R/W 16-bit unsigned integer
divided by 10. For example, value 100 = 10.0 seconds.
Save measurement parameters 1538 W 16-bit integer 1 Save parameters

©2020 Sintrol. 114 (116)

All rights reserved. Revision 5
Notes

©2020 Sintrol.
All rights reserved. 115 (116) Revision 5
Contact us
FINLAND RUSSIA UKRAINE INDIA CHINA JAPAN
WORLDWIDE Subsidiary Subsidiary Representative Representative Representative
Head Office Dunaysky Str 13,b.1 Rybalskaya Str 2 Office Office Office
Ruosilantie 15 196158 01011 Kiev city A-2/78 Room 517 Tokyo
00390 Helsinki St.Petersburg Ukraine Safdarjung Enclave Mingliuweilai Tel. +81 90 8585 1301
Russia Tel. +380 44 280 3392 japan@sintrol.com
Finland 110029 New Delhi Building
Tel. +7 812 4486083 ua@sintrol.com
Tel. +358 9 5617 360 India No.18 Jiaomen
Fax. +358 9 5617 3680 spb@sintrol.com Tel. +91 9811676061 Majiapu Xi Road
info@sintrol.com india@sintrol.com
Fengtai District
Beijing
P.R. China
Tel. +86 10 59002256
Fax. +86 10 59002259
china@sintrol.com

https://sintrol.com/
https://sintrol.com/contact/

Subject to change without notice. Revision 5

All rights reserved. © 2020 Sintrol 2020-11-12