Dust Sensors
Dust Sensors for Process and Compliance
Dynamic baghouse leak detection, built for MACT compliance.
What it does: Continuous particulate monitoring for broken bag leak detection (BLD), filter performance, and plant-wide dust trends- delivered as fully digital data to your PLC/DCS.
How it works: Our sensors use Dynamic Induction™ (DI) to measure the AC signal generated by particles, with advanced filtering to reject noise giving you higher fidelity data across four independent ranges for maximum resolution and the largest operating range. Each sensor calculates up to three rolling averages plus instantaneous dust and verifies input channel status.
Key features:
- Digital comms: Modbus RTU/TCP; PLC/DCS integration
- Automated Electronic Drift Check (EDC) & Patented Rod Isolation Check (RIC)
- 24 VDC power, NEMA 4/4X, local/remote probe mounting
- Optional hazardous zoning/high-temp builds; custom active/inactive rod lengths
Compliance: Meets U.S. EPA MACT requirements for Bag Leak Detectors (BLD).
Whether you are monitoring for compliance or process improvement. We have the best options to get easily get you the right data where you need it.
Contact us today about a free demonstration.
Dynamic Induction
Our Dynamic Induction™ technology utilizes a specific frequency range from the induced AC voltage signal to represent the dust concentration in the gas stream. There are benefits of using the AC portion of the dust signal versus the DC portion, triboelectric effect, of the signnal. The monitoring zone is much larger with the AC signal. We know from internal testing that we can sense dust 12 to 18 inches either side of the rod. The AC signal is not affect by build-up on the rod, which can change the charge transfer rate of the DC signal.
Dynamic Induction provides a more representative indication of your process conditions and is easier to maintain.
Rod Isolation Check
Our patented rod isolation check (RIC) is an automated feature that actually measures the amount of build-up between the sensor's rod and the process wall. When the build-up becomes too much and the resistance is low, the dust signal will take the path of least resistance and by-pass the sensor. But having a method that actually measures the build-up means that the sensor can tell you when it needs to be cleaned.
The RIC is not required for US EPA MACT applications, but the amount of time it can save you by eliminating unnecessary inspections and maintenance trips is important.
Electronic Drift Check
Under the current US EPA BLD guidance, electronic zero and span checks are required monthly. Both the Atlas and Titan sensors allow users to automate this process and the most recent results are stored in local registers so they can be logged. Both the Titan and Atlas sensors have the options of conducting a zero/span check or a linearity check. The linearity check conducts the zero and span checks along with 3 other points within the monitoring range. This eliminates the need for an external signal generator to conduct more details system checks.
Titan Dust Sensor
The Titan sensor is the most advanced dust sensor on the market. It has two (2) RS485 ports for Modbus RTU communications and an Ethernet port (RJ-45) for Modbus TCP communications. The Titan also operates a real-time clock which allows it to track and time-stamp events in real-time. The Titan sensor also calculates three (3) independent rolling average period as well as the alarming on each. These capabilities virtually eliminates the need for reprogramming your PLC/DCS. With optional advanced features such as electronic drift check (EDC) and rod isolation check (RIC), the Titan can handle it all.
Atlas Dust Sensor
The Atlas sensor does not have a real-time clock, but still has the same resolution of dust sensing as the Titan sensor. It has one (1) RS485 port for Modbus RTU communications and calculates one (1) rolling average dust channel and handles alarming status, including any alarm delays. The Atlas eliminates the need for reprogramming your PLC/DCS. All you have to do is read the data and status registers. With optional advanced features such as electronic drift check (EDC) and rod isolation check (RIC), the Atlas can handle all of your dust monitoring needs.
Scout Dust Sensor
When it comes to dust sensing, the Scout maintains the same high dust sensing capability as the Titan and Atlas sensors. The Scout simultaneously outputs both 0 - 10 vdc and 4 - 20 mA signals. Through the dip switches, the sensor can be configured to output a rolling average signal. All scaling and alarming must be handled in the plant's PLC/DCS. Due to the Scout's design, advanced features such as electronic drift check (EDC) and rod isolation check (RIC) are not available.
Sentinel 1 Controller
The Sentinel 1 Controller is a local user interface which handles all of the real-time communications with a Titan or Atlas sensor. The Sentinel provides local data logging and event tracking. All information is logged to internal memory and backed up to USB drives. The Sentinel allows users to easily configure the connected sensor. It provides an analog output as well as alarm relays for status indications.
eSentry 4 Interface
The eSentry 4 is a process interface that can communicate up to four (4) Titan and/or Atlas dust sensors using an RS485 communication interface. All data from the sensors can be read via the Ethernet port using Modbus TCP. We are hoping to introduce an Ethernet/IP interface in 2024. And options HMI is available so users can easily configure the attached sensors and the eSentry unit.
Dust Sensor Applications
Broken bag leak detectors is the most common application for dust sensors, however they can be used is any application where dust or droplets are contained in an air stream. Normally droplets create a problem for charge-based sensors, but some applications are monitoring to water or oil droplets. We have installed sensors in bagging operations to detect bags that did not seal properly before they are stacked on a pallet. We also welcome the opportunity to address any custom needs.
Features
| Parameter | Scout | Atlas | Titan |
|---|---|---|---|
| Measurement Principle | Dynamic Induction | ||
| Detection Limit | < 0.1 mg/m3 | ||
| Maximum Range | Several g/m3, depending on conditions | ||
| Enclosure | Stainless Steel (IP65 / Nema 4X) | ||
| Comm Ports RS485 Ports Ethernet | 0 0 | 1 0 | 2 1 |
| Protocols Modbus RTU Modbus TCP | NA NA | Y Y | Y Y |
| Analog Output 4-10 mA 0-10 vdc | Y * Y * |
Requires Sentinel or eSentry Unit |
|
| Dust Channels Instant Average | C C | 1 1 | 1 3 |
| Alarm Monitoring Alarm Limits Alarm Delay | NA NA | Y Y | Y Y |
| Auto QA Checks EDC RIC | N N | O O | O O |
| O - Optional * - Outputs both analog signals simultaneously C - Choose between Instant or Rolling Average EDC - Electronic Drift Check, includes both zero/span and linearity RIC - Rod Isolation Check (US Patent 9482706B2) |
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Specifications
| Parameter | Scout | Atlas | Titan |
|---|---|---|---|
| Measurement Range | Detection Limit < 0.1 mg/m3 Max Several g/m3, depending on conditions | ||
| Enclosure | Stainless Steel (IP65 / Nema 4X) | ||
| Weight | 7.0 lbs (3.2 kg) (without rod) | ||
| Dimensions (W x H x D) |
7" x 11" x 5" 178mm x 280mm x 127mm (without rod) | ||
| Probe Length + | STD - 36" Active, 45" -Total | ||
| Probe Type + | STD - Local, Remote Probe Optional | ||
| Ambient Temperature | -40 C to +60 C (-40 F to 140 F) | ||
| Power Supply | 24 VDC | ||
| Power Consumption | Less than 5 Watts | ||
| Process Temperature + | Default 200 C (392 F) Optionally up to 1600 F (871 C) |
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| Process Pressure | Default 3000 psi (20684 kPa) | ||
| Process Humidity | Max 95% RH (non-condensing) | ||
| Optional QA Checks | Electronic Drift Check (EDC) Rod Isolation Check (RIC) |
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| + - Custom options available | |||
