Sintrol S101 / S103 Filter Monitor | Broken Bag Detector

Sintrol S101 / S103 Filter Monitor | Broken Bag Detector

The Sintrol S101 / S103 filter monitor is a fast-response dust detector engineered to identify broken bags and filter leaks in small duct systems under 80 cm. By detecting any particulates in the airflow and responding rapidly to dust breakthrough, the S101 / S103 helps plant operators catch filtration failures the moment they occur — minimising product loss, protecting downstream equipment, and supporting emissions compliance.

Furthermore, both models are available as S101 Ex and S103 Ex variants, which add ATEX and IECEx certification for use in dust hazardous areas. As a result, the S101 / S103 suits both standard small-duct filter monitoring and classified hazardous environments across mining, grain handling, food, timber, and powder processing facilities.

 

How the Sintrol S101 / S103 Works

The Sintrol S101 / S103 is built around Inductive Electrification Technology, a refined evolution of traditional triboelectric sensing. When dust particles pass nearby or strike the insulated stainless steel probe mounted inside the duct, the particles induce a signal on the probe. This signal is then processed through Sintrol’s advanced algorithms to filter out background noise and deliver a fast, reliable indication of dust breakthrough.

In contrast to classic triboelectric sensors that rely solely on the DC contact signal, Inductive Electrification uses the AC component of the signal. Consequently, the technology is:

• More sensitive to fine particles
• Less affected by sensor contamination over time
• More stable across temperature changes
• Less sensitive to variations in gas velocity
• Capable of a detection limit of 0.1 mg/m³

 

S101 or S103 – Which Output Do You Need?

The Sintrol S101 and S103 share the same body, probe, and measurement principle. Therefore, choosing between them depends entirely on the output signal your application requires.

• S101 — Filter leak detection and broken bag alarms using two adjustable solid-state relays (max. 30 V DC / 200 mA). Ideal for plants that need cost-effective, alarm-based filter protection.
• S103 — Adds an active isolated 4–20 mA output (max. loop resistance 500 Ω) for continuous trend monitoring of filter performance. Ideal for plants that want to track filter degradation over time or integrate trend data into a SCADA or PLC system.

In practice, the S101 suits straightforward alarm points, while the S103 suits applications where ongoing trend visibility helps optimise maintenance and pulse cleaning.

 

Built for Small Duct Filter Monitoring

Unlike the larger S201 and S203 dust monitors, which are designed for ducts up to 7000 mm, the S101 / S103 is purpose-built for smaller ducts under 80 cm. Therefore, it is the ideal choice for compact filtration systems, individual bag house outlets, and branch ducts where a full-scale dust monitor would be oversized.

In addition, the compact S100-series design delivers several practical advantages:

• Low 1 W power consumption
• Lightweight 0.7 kg aluminium enclosure
• 250 mm probe that can be shortened by the user to suit the duct
• Simple weld-on or quick-clamp process connection
• Cost-effective protection for smaller filtration assets

 

Fast, Selectable Response Modes

Because different processes demand different reaction speeds, the S101 / S103 offers selectable FAST, MEDIUM, and SLOW response modes. As a result, operators can tune the monitor to react instantly to sudden dust spikes, or to smooth out short-term fluctuations for more stable trend signals.

Combined with the self-teaching Auto Setup function, this flexibility allows the S101 / S103 to be matched precisely to each measurement point — whether the priority is catching rapid filter breakage or monitoring gradual filter wear.

 

Sintrol’s Self-Teaching Auto Setup Function

To simplify commissioning, the Sintrol S101 / S103 includes a unique self-teaching Auto Setup function that automatically adapts the instrument to the actual process conditions. During the Auto Setup procedure, performed under normal operating conditions, the monitor establishes its measuring range and alarm thresholds without any manual configuration.

Consequently, commissioning is fast and straightforward, removing the most common source of misconfiguration in dust monitoring installations. Visible green, yellow, and red status LEDs then provide clear, at-a-glance indication of dust levels for anyone on the factory floor.

 

Hazardous Area Certification (S101 Ex / S103 Ex)

For dust hazardous area applications, the Sintrol S101 Ex and S103 Ex are certified under both ATEX and IECEx schemes. Therefore, they can be installed in classified dust zones without requiring secondary protection systems.

Certifications include:

• ATEX: II 3D Ex tc IIIC T80 °C Dc, −30 °C ≤ Ta ≤ +60 °C
• IECEx: Ex tc IIIC T80 °C Dc, −30 °C ≤ Ta ≤ +60 °C
• CE and RoHS 3 compliant

In Australia and New Zealand, the IECEx scheme is the primary recognised certification under the AS/NZS 60079 series for hazardous area equipment.

 

DustTool Parametrisation Software

Every Sintrol S101 / S103 filter monitor can be managed using the DustTool PC software, which provides a convenient platform for setup, parameter adjustment, and live measurement viewing. Using the optional RS-485 to USB converter, simply connect the monitor to a PC — DustTool then detects the interface and connects to the device.

Furthermore, DustTool supports:

• Live measurement viewing
• Auto Setup initiation and parameter review
• Response mode and alarm threshold configuration
• Diagnostic data extraction
• Network monitoring across multiple S100-series instruments

 

Communication and Integration

To integrate seamlessly with plant control systems, the S101 / S103 offers several communication options:

• S101: Two adjustable solid-state relays (max. 30 V DC / 200 mA) for ALERT and ALARM signals
• S103: Active isolated 4–20 mA output (max. loop resistance 500 Ω) for continuous trend signalling
• RS-485 serial communication with Modbus RTU protocol for control system integration
• Sintrol network protocol for multi-instrument monitoring

 

The Specs at a Glance

Below are the key specifications for the Sintrol S101 / S103 and Ex variants:

Typical Applications

Across Australia, New Zealand, and internationally, the Sintrol S101 / S103 filter monitor is widely deployed for broken bag detection, filter leak detection, and small-duct dust monitoring in:

• Grain, flour, and feed handling
• Mining and minerals processing
• Timber, wood pellet, and biomass facilities
• Cement and lime production
• Food and beverage production
• Pharmaceutical and chemical manufacturing
• Recycling and waste handling
• Bulk and powder handling facilities

 

Proven Technology Since 1993

Sintrol has become a globally recognised dust monitoring supplier with over 20,000 installations across more than 50 countries. Furthermore, the inductive electrification measuring principle has been independently tested across a wide range of dust types, evolving into a proven standard for reliable dust monitoring in demanding industrial environments.

 

Reliable Filter Monitoring from ProDetec

As the Australian and New Zealand partner for Sintrol dust monitoring equipment, ProDetec delivers the S101, S103, and Ex variants with full local technical support, installation guidance, commissioning, and ongoing service. Whether you need fast broken bag detection on a single small duct, alarm-based filter protection, or continuous trend monitoring with a 4–20 mA output, the Sintrol S101 / S103 provides the rapid, reliable filter leak detection your operation requires.