Endress+Hauser silopilot FMM 460 User manual

BA 049 F/OO/e/04.92
Part No. 015602-1000
silopilot
FMM 4601460 Z
Level Measurement
Montage-und Betriebsanleitung
Installation and Operating Instructions
Endress + Hauser
Nothing beats know-how

Silopilot FMM 4601460 Z Contents
Contents
Application
Function
Instrument versions
Sensing weight for the FMM 460, FMM 460
Z
Installation
Selectingthe measuring point
Preparingthe measuring point
Mountingthe Silopilot
Electrical connections
Operating
Technical Data
Maintenance
Repair
Re~lacingthe max. switch
Replacingthe slack tape switch
Replacingthe gear motor
Replacingthe tape roll
Replacingthe counting pipe
Circuit diagrams
Spare parts listfor the Silopilot FMM 460

Contents Silopilot FMM 4601460 Z

Silopilot FMM 4601460 Z Application
Application
The SILOPILOT FMM 460 is an electromechanical levelmeasurementsystem.
(See Fig 1
).
The sensing weight which touches the material determinesthe application.
Differenttypes of sensing weight are usedfor measuringthe levelof materials in
bunkers and silos. These can be powdery,fine or coarse-grainedsolids.
Depending on the version and equipment, the SILOPILOT FMM460 is used
for measurementin silosor tanks with operating temperatures up to 60 OC or
pressuresup to
2 bar.
The FMM 460 Z version of the SILOPILOTcan also be used in flammable dusts
designated as explosion-hazardousarea, Zone 10 and 1
1.
The referencesmade in the following text to "bunker","silo"or "vessel"
are identical:
the vessel in which material is measured.
A complete measuring system consists of:
SILOPILOT
FMM 460 with sensing
weight
start buttonor timer
e the electromechanical counter
ZCD 155or ZCD 151
andlor a digitallanalogue converter +
memory ZAD 184
Function
A measuring tape with a sensing weight
attached to the end is lowered into a
bunker. When the weight touches the
surface of the material,the tape
slackens and the motor reverses.
The weight then
returnsto its original position.
While the weight is being lowered,the
SILOPILOT emits pulses corresponding
tothe length of the extended tape.
The pulses are recordedon an
electromechanical counter or the
digitallanalogue converter +
ZAD 184 memory.
The measurement is stored until the
next measuring cycle.
This is initiated bythe start button or
timer.
ZAD Contactor
timer counter
Fig. I
FMM 460
Connections

Function Silopilot
FMM 4601460 Z
Instrumentversions
The ~useof various options enables combinations of both electrical arld mechanical
modular comporlents to be selected specific to the application.
KLOPILOTFMM 460
Certificates,Assessments
R Standard (non-certified)
Y others
Countingsteps I Measuringtape
1 dmlstainless steel
2 dmlnylon
3 1/10foot/stainless sreel.
4 1/10footlnylon
9 others
Instrument heating
A none
B heating 220V, 50160Hz 40 W
C heating 11OV, 50160Hz 40 W
Y others
Minimumfail-safefunction
0 no presetting
1 setting at
xx, X meter
2 setting at
xx, X feet
9 other
Signal function
A non signal function
B signal of upper position
C signal of tape breakage (with 220V only)
D signal of upper position
+ tape breakage (with 220V)
1 Y other
Sun protectivecovea
0 no sun cover
1 with sun cover
9 other
Power supply
J AC 240V, 50160Hz
H AC 230V, 50160Hz
A AC 220V, 50160Hz
G AC 127V,50160Hz
F AC 115V,50160Hz
B AC 110V,50160Hz
D AC 24V,50/60Hz
Y others
Sensingweight
0 nowe~ght
1 (PVC(red),sensing weight
2 PE (white),sensingweight
3 PA (black),sensing weight
4 Umbrella PEIsail cloth
5 Umbrella PAlsa~lcloth
9 others
For connecting to
A ZCD 155or ZCD :51, /= 42 V
B ZCD 155or ZCD 151,34V
C digitallanalog memoryZAD 184
Y others

Silopilot FMM 4601460 Z Function
SlLOPlLOTFMM 460 Z
Certificates, Assessments
D BVS approvaldust-Ex Zone
Y others
Countingsteps ! Measuringtape
1 dm/stainless steel
3 1/10foot/stainless steel
9 others
Instrumentheating
A none
B heating 220V, 50160Hz
C heating 11OV, 50160Hz
Y others
Minimumfail-safefunction
0 no presetting
1 setting at xx, X meter
2 setting at xx, X foot
9 others
Signal function
A no signal function
B signal of upper position
C signal of tape breakage (with 220V only)
D signal of upper position + tape breakage (with 220V only)
Y others
Sun protectivecover
0 nosun cover
1 with sun cover
9 other
J AC 240V, 50160Hz
H AC 230V, 50/60Hm
A AC 220V, 50160Hz
G AC 127V, 50160Hz
F AC 1 15V,50/60Hz
B AC l l OV, 50/60Hz
D AC 24V, 50160Hz
Sensingweight
0 without weight
3 PA (black),sensing weight
5 umbrella, PA
l sailcloth
.For connection to
A ZCD 155or ZCD 151, /= 42V
B ZCD 155orZCD 151,24V
I/analoguememory ZAD 184

Sensingweights for the FMM 460, FMM 460 Z
Silopilot FMM 4601460 Z
Sensing weights for the FMM 460, FMM 460 Z
Standardweight in PVC Application:
or PE for the FMM460
With light bulk solids, mainly fine-grained,with powdery characteristics,
e.g.fodder.
For foodstuffs,e.g.salad oil, the PE weight must be used.
(notsuitablefor dust explosion hazardous area, Zone 10).
Weight:920 g
Standardweight for the The sta.ndardweight for the FMM 460 Z isof PA (Vestamid R) with R. 5 109 Cl
FMM 460 Z
Weight:920 g
Fig. 2
FMM 460
Standardweight
Fig,
3
FMM 460
Umbrella weighf
Umbrella weight in PA/PE for the FMM 460, FMM 460 Z
1
connection
distance accorcding
#
to height of
mounting flange
Square umbrha
L spoke in stainless steel
in sail cloth spring
4310
length of edge 250
*on delivew: 180 mm
l I
Application:
For very light, loose solids such as flour, coal dust etc. an umbrella weight in PA only
may be used with the FMM 460 Z
(Ex Zone 10111 l).
The FMM 460 may be used with either a PA or PE weignt.
The umbrellaweight has a large square surface areato prevent it sinking into the
material being measured,It can De folded so that
it fits through the DN 100
flange.

Silopilot FMM 460f460 Z Installation
Installation
Selecting the installation site
Select an installation positionon the silo
roof where inflowing or falling material
cannot damage the measuring tape.
Take intoconsideration the shape and
position of the inflow cone and the
outflow .funnelin the vessel.
See Fig.
4 and Fig. 5
The sensing pathshould not cross
internalfixtures which may touch the
tape when the weight
swings.
Preparing the installation
The SILOPILOT FMM460
DN 100 PN 16 DW 2501 is mounted on
a counter flange or a flange of the same
dimensions. This flange must be
mounted exactly horizontaland the pipe
onto which it is welded should be
exactly vertical. The pipe should be as
Fig. 4
FMM 460
short as possible.
installation withmaterial buikd-up
Installing a plastic pipe with throat and
pipe flange is recommended with an
especially thick silo roof and long pipes
(Fig. 6). This prevents damage tothe
sensing weight or to the tape caused
bythe sharp edges of the roof.
Inthis particular case the buffer cone
must be removed when using an
umbrella weight.
(Fig.
3)
If the instrument is in direct sunlight,
then a protective cover should beused
either in the form of
a sun roof (Fig. 7) or
as a protective sun hood.
Incountries with generally high
temperatures, (by the equator, in the
desert), a protective sun cover is
recommended as shown in Fig.
7.
If high condensation is present,then
installing a thermostatically controlled
electrical heating system for the
housing is recommended. See
instrumentversions, Pages 4
+ 5.
FI~. 5
FMM 460
lnstallation
Takingaccount of the filing cone

Installation Silopilot FMM 4601460 Z
Installingthe SILOPILOT
Put a gasketon the flange (especially if there is pressure in the silo). Carefully insert
the sensingweight intothe flange and pipe. Placethe SILOPILOT on the flange and
tighten usingthe
4 bolts.
Note the positionof the cable glands for electrical connections.
When using an l~mbrellaweight, fold it up and then pass it through the
DN 100flange.
(also see Fig.
8)
Mountingon a collar
Removethe housingcover (seePage 10).
with a narrow entrance
Turn the fan wheel until the sensingweight can be pulled away from the FMM to a
(e.g. Fig. 6)
distance of 0.5m. Separate the measuringtape above the buffer cone.
Passthe tape through the entranceand then fasten the umbrellaweight to it with
a
knot.
to DIN 2633
Fig. 6
Mountingin higher silo
roofs

Silopilot FMM 4601460 Z Installation
cover fastening
housingin
castaluminium
cable gland
PG 16
flange DN
100 PN 16
for counterflange
to DIN 2633
weight
920 g
Fig. 7
Sunprotective cover for the
FMM 460
Fig. 8
Dimensions ofthe FMM 460

ElectricalConnections Silopilot
FMM 4601460 Z
Electrical Connections
max. 10 A
connection
start block:
switch open,start blocked
switch closed,start activated
L
ext.start button
or timer
Open the cover with an Allen key (5 AF)
and remove.
Remove transport packing (foam
plastic).
Electricalconnections are carried out
according to the connection diagram
(Fig. g), using the terminal strip facing
the housingwall.
Notethe voltage and frequency ratings
on the nameplateand adhesive label
Fuse protectionof the power cabling
ismaximum 10
A.
Before connecting the
electro-mechanicalcounter, ensure that
all externalvoltages are turned off,
the drive used for the counter is cor-
rect, i.e. the voltage rating indicated
by a cross (Fig. 10).
The externalstart button or the contact
of the timer is connected to Terminals
8
and 9.
Fig. 9
Connectingdiagramfor counter 1 I Warning: An AC voltage of 220 V is
present between these terminals.
L
I I I
as example
Fig.
10
Ratingplate showing the voltage
of the counterunit
The connecting cables should beas short as possible.
It is possible that the programmerof the
FMM 460 Z can be activated by the AC
current flowing through the cabling capacitance alone
if the total cable length is
greater than 250 m.By connecting
a 4.7 kOhm, l0 W resistorto Terminals 4 and 5,
the maximum permitted cable length can be extended to 3000 m.
(Wire cross section 1.5mm2)
Note: Terminals 4 and 5 are already connected by internalwiring.
Please ensure that these are not loosened when connecting the
resistor.
The counter and
ZAD 184are not to beconnected in parallel to Terminals 10to 12
(special version on request.

Silopilot FMM 4601460 Z
Electrical Connections
Connectingdiagramfor the counter
ZCD 155
connectedinternally zero contact
powersupply
max. 500 m, 1.5 mm2
10 12 11
I I
Connectionto the Silopilot
FMM460
FMM460 Z
Fig. 11
Connectingdiagram of theZCD
155 counter
l
Counter ZCD 151
power
supply
FMM 460
FMM 4602
5)-----
1: (connected
l~~~ti~~ntactover OOOOO ) 1
21 20 22
-------
internally) 2
G
I
I I max.
See Tech. documentation
08.78.0112Cand 11.73.04/2efor further information
Connecting diagram for the
ZAD 184,see TI 11.73.14b
Fig. 12
Connecting diagram of theZCD
151 counter
Connecting diagram for the Timer ZS 421 see TI 013 F/OO/e.

Operation Silopilot FMM 460/460 Z
Fig. 13
Operatingelements
in the Silopilot
Fig.
14
Viewof dustcompartment
Fig.
15
Sampling cycle as a function of
ambient temperature andmeasu-
rhg height
Operation
Sliding switch for the power
c On (1) \
-.+ off id)
Connecting
terminals
3 Cable gla~
PG 16
I
bore hole
\ / tape loop
dust
compartment
ambient tem~erature operating
'C
time of motor
at measuring
5m 15m 30m 30m -height
min. cvcle
minutes
Turning on the power
Set the sliding power switch to the off
position (0).Switch on the power supply
for the counters, timer, Silopilot etc.
Startingthe measuring cycle
Briefly press the white start
button (see Fig. 13).As the weight
descends, the red
LED flashes and,
when a counter is connected, also
shows the counting steps.
Calibrating the minimum level
A defined minimum level or distance to
the vessel floor can be calibrated as
follows.
The sensing weight is lowered into an
empty vessel by pressing the start
button. When the weight reaches either
the minimum level selected or the floor,
switch off the unit by means of the
sliding switch (Fig. 13)."Onis visible.
Lift up the measuring tape a little
distance untila tape loop can be put
through one of the two boreholes which
are displaced by 1
80° (Fig. 14)on .the
edgeof the tape spool. Fastenthis loop
under the bolt near the borehole.This
preventsthe weight entering the outlet
cone.
Switch on the instrument using the
sliding switch ("I"is visible). The sensing
weight is raised.

Silopilot FMM 4601460 Z
Technical Data
Finaltouches
Pull the cable glands tight and also seal them if necessary
(open at installation).
Carefully put the cover on the instrumentand screw tightly.
If necessary,fit the protective sun cover and attach springs.
Set timers or adjust the digitallanalogue converter
+ memory. (seeTI 11.73.14b)
Settingthe timer (see TI 02.85.0111)
Set the timer to the required measuringfrequency.
Refer to Fig. 15
Technical Data
Measuringrange:
max.30 m
Measuringerror:
max. 1pulse
Pulseoutput:
one pulse per 10cm or per 1/10foot
Other versions on request
Powersupply:
refer to instrumentversions/power supply
Heatingvoltage:
220V 50160 Hz or 110V50160 Hz
Powerconsumption:
approx. 40 VA
Housingand flange:
Cast aluminium (G-AL)
Measuringtape FMM 460 Z:
Corrosion-resistantsteel tape 01mm
Option (not for Zone 10)
Oil-resistant nylon tape o 1 mm
Materialof sensingweights:
refer to instrumentversionslsensing weight
Max. gauge pressure p,:
2 bar in Silo
Protectionconformingto DIN 40050:
Dust compartment FMM460 IP 55
Dust compartment FMM460
Z lP65
Control compartment IP 55
Permissibletemperature by instrument:
-15O C ... + 50° C (heating required below-10° C)
invessel: -15O C
...+ 60° C
Meantape speed:
approx. 18cmls at 50 Hz (when raisingor lowering)
Liftingforce:
approx. 14 N, automatic motor shut-off with overstraining,automatic cut-in when
strain removed
Mounting:
flange to fit counter flange DN 100, PN 16DIN 2633
Totalweight:
approx. 15 kg

Maintenance SilopilotFMM 460/460 Z
Fig. 16
Taperoll path (Zone 10);
dust-tightseparationbetween Zo-
ne 10andZone
11 as wellas to
electricalmotor andcontrol com-
partment.
Housing cover andspringentry
comply withatleast IP65
maximumsurface temperature
P
" (monitored)
Maintenance
The motor and gear box requirenomaintenanceas these components are greased
for their operating life.
If the material causes build-up, then the sensing weight must occasionally
be cleaned so that the weight on .thetape is not too great.
(A material build-up of 0.5 kg is permissible)
With materialswhich give rise to dust, the dust compartment of the SILOPILOT should
be regularly blownout with compressed air
(< 0.6 bar). With materialscontaining iron,
metal dust inthe dust compartmentcan settle on the magnets used for counting. The
magnets should then be regularly cleaned.
Once dust-Ex instrumentshave beenoverhauledor repaired,a checktest must be
made in accordance with ElexV,
9 Sections 1 and 2. With the FMM 460 unit, this work
can becarried out without check testing.
Section
(1) If an electrical unit, a part of which has explosion protection, has been
repaired or overhauled,it may only then be operated after an authorized specialist
has determined that its design fulfilsthe requirementslaiddown in the regulations
and after he has supplied either a certificate or given the
instrumenta mark of conformity.
Section(2)Section
1 does not apply if a unit isoverhauled or repaired bythe
manufacturer and isthen given a check test whereby the manufacturerthen states
that its design fulfilsthe requirements laid down in the regulations.
electricalcone
housing with protection
lP 54, maximum surface
temperature
<80 C
monitored (not repaired
power supply in
Cleaning the dust compartment
Opening the instrument:
Loosenthe four cover screwswith an Allen key (5 AF) and remove both covers.
(Fig.
8)
One wall of the instrumentcontainsthe tape roll with the rolled up tape, the counting
disk with magnets fixed with screws and the reed switch.
On the other side is the power switch, next to it the internal start button, the terminal
block, behindthis the wiper switch, and the suspended and freely swinging
motor and .finallythe end switch.
Cleaningthe dust
compartment
The frequency of cleaning depends on the type of material it is used with.
Dust deposits are best blownout with compressed air.
Ifthe electrical connecting walls of the instrumentbecome dirty then the PG glands
and the covering gasket should be checked and replaced
if necessary.

Silopilot FMM 460/460 Z Troubleshooting
Troubleshooting
1.) Instrumentdoes not function
a) Check the power source and cabling
b)The power switch is in the "off"position
c) Motor is faulty
- check the thermopiles
Motor spool and therefore cable fuses are burnt out
Max,end switch out of alignment
d) Start lock open (Fig. 9 Terminals 6 + 7)
2.) Sensing weight cannot be raised
a) Weight submerged
b)Weight too heavy, build up of material
3.) Motor operates continuously
a) Tape breakage
b)Spring broken or clamping sleeve loose (intape roll)
4.) Counter does not count or counts inaccurately:
a) Check reed contact (l Ohm) when closed
b)Wiper switch Contact
D is faulty
c) Magnet holder broken off
5.) Tape slips out of tape roll
a) Flange is not horizontal

Repair Silopilot FMM 460/460 Z
Repair
Fig. 17
Position of mau. end switch
Replacing
the max. end switch
To open the housing see Page 16
1. Swivel the motor to the right with approx. 2 mm betweenthe motor housing and
plate spring.
Hold the motor in this position.
2. Slide the loosened max. end switch in order to posi-lionit so that the lever of the
rnicroswitch shows the correct position on the switching gate.
Now adjust the microswitch so that it switches correctly. The connections
0 (red)
and
2 (black) must beopen.
3. Twisting the switching gate activates the microswitch.
Inthe compressed state, the level must still have a play of min.
1 mm.
This ensures that the switch is not under mechanical stress and cannot moveover a
period of time.
4. After adjustment the tops of the retaining screws are to be
sealed with lacquer!

Silopilot FMM 4601460 Z
Replacingthe slack tape switch
Replacingthe slack tape switch
To open the housing see Page 16
Slacktape switch
1. Swivel the motor to the leftwith approx. 5 mm betweenthe motor housing
and wiper.
Hold the motor in this position.
2. Slide the loosenslack tape switch in order to positionit so that the lever of the
microswitch shows the correct positionon the switching gate.
Now adjust the microswitch so that it switches.
The connections
0 (green) and 2 (brown) must beopen.
3. Twisting the switching gate activates the microswitch.
In the compressed state, the lever must still have a playof min. 1 mm.
This ensuresthat the switch is not under mechanicalstress
and cannot move over a period of time.
4. After adjustment, the tops ofthe retainingscrews are to be sealed with lacquer!
U
stop cam
motor housing
Fig. 18
Slack tape switch

Replacing theslack tape switch Silopilot
FMM 4601460 Z
Replacingthe gear motor
To open the housingsee Page 16
1. Disconnect all five cables of the motorfrom the terminal strip,
Fig. 19
Installing themotor
18
Terminal
7 = black
9 = black
13
= red
14 = green
15 = yellow
Thermopile
Motor power supply
2. Removethe tape roll (refer to Replacingthe tape roll)
3. Loosenthe cylindrical screws of the spindle washer and carefully tap out the
gear shaft with a rubber hammer.
With old instrumentsthe spindle washer is within the motor compartment, above
the gears, and fastened by two screws.
4. Lightly grease the spindle of the new motor (e.g. universalgrease BP Energrease
LS
2) and carefully insert it through the bearing;
take care when handlingthe microswitch(mech. damage).
With
Z instruments,both bearings inthe shell must be also packedwith Loctite to
increasesealing characteristics.
Please note that, according to the
Ex regulations,this gland must be checked for air
tightness.
5. Screw on the spindle washer again and connect the motor to the terminal strip.
Orientthe cable so that no looping or pinching occurs. Carry out a trial run.