Milltronics ILE-37 User manual

ILE-37 SENSING HEAD
June 2001
ILE-37 SEINSIING HEAD
Instruction Manual PL-374
33453740
Rev. 1.4

© Siemens M illtronics Process Instruments Inc. 2001
Safety Guidelines
Warning notices must be observed to ensure personal safety as w ell as that of others, and to
protect the product and the connected equipment. These w arning notices are accompanied
by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction w ith this manual.
Qualified personnel are only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance w ith specifications.
Copyright Siemens M illtronics Process
Instruments Inc. 2000. All Rights Reserved
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instrumentation described, variations
remain possible. Thus we cannot
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contents of this manual are regularly
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Technical data subject to change.
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7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 1
Ta bl e of Cont e nt s
ILE-37 Sensing Head: Introduction ..................................................................................2
Specifications ......................................................................................................................3
Installation ........................................................................................................................... 6
Side Mount................................................................................................................................................ 6
Base Mount ..............................................................................................................................................7
Sensing Plate ...........................................................................................................................................7
Viscous Damper .......................................................................................................................................8
Interconnection ........................................................................................................................................8
Non-Hazardous Unit without LVDT Conditioner Card.......................................................... 8
Non-Hazardous Unit with Sensing Head Mounted LVDT Conditioner Card.................. 9
Non-Hazardous Unit with Remote-Located LVDT Conditioner Card .............................10
Calibration.......................................................................................................................... 11
LVDT Output ............................................................................................................................................11
Zero Adjustment (if required) ...................................................................................................11
Span Test .......................................................................................................................................12
Sensing Head Level Test ...........................................................................................................13
Integrator Calibration .................................................................................................................14
Zero Calibration ...........................................................................................................................14
Span Calibration ..........................................................................................................................14
M aintenance and Spare Parts ........................................................................................ 15
Maintenance ..........................................................................................................................................15
Typical Maintenance Program ...........................................................................................................15
Spare Parts .............................................................................................................................................15
Range Springs ................................................................................................................... 16
Range Spring Removal ........................................................................................................................16
Range Spring Replacement ................................................................................................................16
Flowmeter Recalibration .....................................................................................................................16
Troubleshooting ................................................................................................................. 17
Linearity .............................................................................................................................. 18
ILE - 37 Side M ount Outline and M ounting .................................................................19
FIG. 1 .............................................................................................................................................19
ILE - 37 Base M ount Outline and M ounting ................................................................20
FIG. 2 .............................................................................................................................................20
ILE - 37 Part Identification Diagram .............................................................................21
FIG. 3A ..........................................................................................................................................21
ILE - 37 Part Identification Table ..................................................................................22
FIG. 3B ..........................................................................................................................................22
FIG. 3C ..........................................................................................................................................23

Page 2 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
ILE-37 Sensing Head: Introduction
The Milltronics ILE-37 Sensing Head is used for continuous in-line weighing of powdered
or granular dry bulk solid materials. The material is directed toward the sensing plate.
The horizontal impact force of the material, deflecting the sensing plate, displaces the
core of the sensing head LVDT (linear variable differential transformer). The LVDT output
signal is proportional to material flowrate. A viscous fluid damper prevents oscillation of
the mechanism and provides mechanical damping of pulsating material flow.
The ILE-37 sensing head is used with Milltronics E-40 (general purpose), C-40 (coal scale),
A-40 (aerated gravity conveyor), and V-40 (vertical material drop) dry solids flowmeters.
LVDT
Moving Beam travel
Sensing Plate
Impact force
E-40 A-40 V40 C-40

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 3
Specifications
ILE-37 Sensing Head
Operating Range
• 0 to 0.5 TPH min., 0 to 40 TPH max.
Product
• fine powder to 13 mm (1/2")
Product Temperature
• –40 to 232 °C (–40 to 450 °F)
Ambient Temperature
• –40 to 60 °C (–40 to 140 °F)
Accuracy
• 1% of full scale
Repeatability
•0.2%
Construction
• dust-tight cast aluminum frame with fiberglass rear cover
M ounting
• side mount or base mount (to suit application)
Sensor Type
• LVDT (linear variable differential transformer)

Page 4 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
LVDT Excitation
• 2.50 Vac @ 2.9 kHz (supplied by Flowmeter Integrator or LVDT Conditioner Card)
LVDT Output
• 0 – 0.75 Vac @ 2.9 kHz
Damping Fluid
• 1 – 100 cm2/s (100 – 10,000 cs) silicone (Dow Corning 200)
Options
• Epoxy, Teflon®, or Tufram frame coating
• Epoxy painted mild steel or stainless steel rear cover
Approvals
• Optional C.S.A. Class I – Groups C & D: Class II – Groups E, F, & G
•CE
Sensing Plate
Construction
• 304 stainless steel
Options
• 316 stainless steel
• UHMW polyurethane or Ceramic Tile lining
• Teflon or plasma coating
LVDT Conditioner Card
Pow er
• ± 5Vdc (typically from an Accumass Integrator)
Ambient Temperature
•–40to50
oC (–40 to 122oF)

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 5
Input
• 0 to 1.0 Vac from LVDT
Output
• 0 to 50 mVdc to Accumass integrator; [maximum 300 m (1000 ft) separation between
Conditioner Card and Integrator]
Approvals
•CE
Enclosure
• NEMA 4 (remote mounted unit)
Cable
For connection betw een LVDT Conditioner Card and Integrator
• Belden 8404, 4 conductor, shielded 20 AWG or equivalent, 150 m (500 ft) maximum
• Belden 9260, 6 conductor, shielded 20 AWG or equivalent, 300 m (1000 ft) maximum
For connection betw een LVDT and remote LVDT Conditioner Card,
or directly betw een LVDT and Integrator
• Belden 8404, 4 conductor, shielded 20 AWG or equivalent, 300 m (1000 ft) maximum

Page 6 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Installation
The ILE-37 Sensing Head is available in two models; side mount and base mount. The
base mount version should be used if the flowmeter will be subjected to excessive
vibration, for flow rates below 1t/h, or if handling product temperatures above 60oC.
The side mount version is factory-installed on Milltronics flowmeters designed for side
mount sensing heads.
Side M ount
1. With the flowmeter housing installed, remove the ILE-37 sensing head cover.
2. Loosen the four ILE-37 mounting bolts.
3. Place a spirit level on the flat top of the ILE-37 frame: adjust the sensing head level
by rotating it, and retighten the mounting bolts.
Mounting
bolts Spirit level

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 7
Base M ount
1. With the flowmeter housing installed, mount the ILE-37 to a rigid support structure.
2. With the outer gasket in place, bolt the ILE-37 to the housing.
3. Adjust the sensing head levelling hardware provided, to establish level in both
horizontal planes.
Sensing Plate
1. Open the flowmeter housing access door.
2. Remove the sensing head cover and insert the sensing plate shaft fully into the
sensing head shaft socket*.
3. Tighten the set screw/hex screw to secure the sensing plate.
Spirit level
Rigid
support
Moving
Beam
Supporting/
Levelling
bolts
Front View Side View
Note: Ensure that the structure used to support the base mount sensing head is
capable of supporting the dynamic material impact forces as well as the static weight
of the sensing head.
*Note: Ensure the slot in the end of the shaft mates with the roll pin in the back of the
socket.
Sensing Plate
Sensing Head
Shaft Roll Pin
Slot
Set Screw or Hex
Head Screw

Page 8 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Viscous Damper
1. Remove the two damper cover shipping screws. The damper cover will be held up
by a spring.
2. If necessary, top up the damper to near overflowing with the damping fluid supplied.
3. Store the damper cover shipping screws, remaining damper fluid, and filler bottle for
future use.
Interconnection
Non-Hazardous Unit w ithout LVDT Conditioner Card
* See note below for Encapsulated (Hazardous-rated) LVDT color codes.
Note: The damper must be full and free of air bubbles, with the damper cover in the
UP position, during flowmeter operation.
Sensing
Head
Damper
Filler Bottle
Shipping
Screws
Damper
Cover
(Check that
there are no
bubbles.)
to LVDT
G
R
N
B
L
K
Y
E
L
B
L
U
R
E
D
S
I
G
–
C
O
M
E
X
C
–
E
X
C
+
To Integrator
Sensing
Head
Terminal
Block
*For Encapsulated LVDT (hazardous)
YEL = WHITE
BLU = ORANGE
GRN = YELLOW
Cable
Clamp
Note: Ground shield at Integrator only.

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 9
Non-Hazardous Unit w ith Sensing Head M ounted LVDT
Conditioner Card
• Not applicable to Hazardous-rated units
• LVDT to LVDT Conditioner Card connections are made by Milltronics
*Where separation between the integrator and LVDT conditioner exceeds 150 m (500 ft):
• Remove the jumpers SF500 terminal 11/12 and 13/14
• Run additional conductors:
- from SF500 terminal 12 to conditioner terminal block marked "Integrator +EXC"
- from SF500 terminal 13 to conditioner terminal block marked "Integrator –EXC"
For further connection information on specific LVDTs, consult Milltronics.
11 14 12
111
6
122
7
133
8
14
15
16
17
4
9
5
10
18
V+
S+
S-
V-
SHLD
-LOAD CELL-
EXCITATION
LCA+
LCA-
LCB+
LCB-
SHLD
LCC+ SIG
LCC- COM
LCD+ CNST
LCD-
SHLD
-LOAD CELL INPUTS-
E
X
C
+
E
X
C
+
E
X
C
-
E
X
C
-
C
O
M
S
I
G
/
C
O
M
C.
T.
S
I
G
-
S
H
L
D
S
H
L
D
S
I
G
+
LV D T I N T EG R AT O R
RED
BLUE
YELLOW
BLACK
GREEN
SF500
Integrator
Milltronics LVDT Conditioner Card
*
LVDT
♦Note: Shields are common, but not grounded to chassis. Run cable shields through
SHLD terminals and ground at Integrator only.

Page 10 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Non-Hazardous Unit w ith Remote-Located LVDT
Conditioner Card
*Where separation between the Integrator and LVDT conditioner exceeds 150 m (500 ft):
• Remove the jumpers SF500 terminal 11/12 and 13/14
• Run additional conductors:
- from SF500 terminal 12 to conditioner terminal block marked "Integrator +EXC"
- from SF500 terminal 13 to conditioner terminal block marked "Integrator –EXC"
For further connection information on specific LVDTs, consult Milltronics.
11 14 12
111
6
122
7
133
8
14
15
16
17
4
9
5
10
18
V+
S+
S-
V-
SHLD
-LOAD CELL-
EXCITATION
LCA+
LCA-
LCB+
LCB-
SHLD
LCC+ SIG
LCC- COM
LCD+ CNST
LCD-
SHLD
-LOAD CELL INPUTS-
E
X
C
+
E
X
C
+
E
X
C
-
E
X
C
-
C
O
M
S
I
G
/
C
O
M
C.
T.
S
I
G
-
S
H
L
D
S
H
L
D
S
I
G
+
LV D T I NT EG R AT OR
RED
BLUE
YELLOW
GREEN
SF500
Integrator
Milltronics LVDT Conditioner Card
*
**For Encapsulated LVDT (hazardous)
YEL = WHITE
BLU = ORANGE
GRN = YELLOW
**Junction box included with hazardous-rated unit.
*LVDT
**
♦Note: Shields are common, but not grounded to chassis. Run cable shields through
SHLD terminals and ground at Integrator only.

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 11
Calibration
A Test Weight is a calibration reference used to simulate a material impact force (Test
Rate) on the flowmeter sensing plate during the integrator Span calibration. The test
weight is also used to perform a test to verify that the flowmeter sensing head is level.
The Test Rate should be 60 to 80% of the system Design Rate.
To determine the Test Rate produced by a specific Test Weight, calculate:
Test Rate (TPH) = Test Weight (grams)
651grams/TPH
Alternatively, to determine the Test Weight required for a specific Test Rate, calculate:
Test Weight = 651grams/TPH x Test Rate (in TPH)
e.g. If the Test Weight used with an E-40 flowmeter is 500 grams:
Test Rate = 500 grams
65 grams/TPH
= 7.65 TPH
LVDT Output
Zero Adjustment (if required)
1. Connect a voltmeter across the LVDT green and yellow (or yellow and white;
hazardous LVDT) wires.
2. With no load applied to the sensing plate, observe the Vac reading on the voltmeter.
If the LVDT output is 0.10 ± 0.05 Vac, skip toSpan Test, otherwise, proceed as follows:
a. Loosen the locknut on the LVDT threaded core.
b. Turn the core in/out of the LVDT until 0.10 ± 0.05 Vac is obtained.
c. Tighten the locknut, ensuring the measured value is maintained.
1. Use 80 grams for A-40 flowmeters.
Note: Use metric tons per hour (t/h) or short tons per hour (STPH) as applicable for
TPH.
± 0.05
± 0.05
0.100
LVDTLVDT Core
Moving Beam
Locknut
Increase Decrease
To Int egrator
LVDT EXC.
or LVDT
Conditioner Card
Note: Ensure the new position of the LVDT core allows free movement within the
LVDT bore.

Page 12 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Span Test
1. Gently push the sensing head Moving Beam to the right. The LVDT output should
steadily increase until a level of 0.75 to 1.0 Vac is achieved.
2. Gently push the sensing head Moving Beam to the left. The LVDT output should
steadily decrease until zero is reached and then start increasing again to 0.015 to
0.5 Vac.
3. Ensure the LVDT output always returns to 0.10 ± 0.05 Vac, (to the right side of zero)
when pressure on the Moving Beam is released.
Note:
• The LVDT core must not contact the inside of the LVDT over the range of core travel.
• The actual LVDT core travel during this procedure is less than 3 mm (1/8").
0.050
0.150
0.015
0.500
to
0.750
1.000
to

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 13
Sensing Head Level Test
1. With the voltmeter still connected to the LVDT output, hang the test weight directly
off the sensing plate.
2. Check to ensure that the LVDT output does not change by more than 0.01 Vac.
Note:
• If the change is greater than 0.01 Vac, adjust the sensing head level, (refer to
“Installation” on page 6) until the change with and without the test weight on the
sensing plate is less than 0.01 Vac.
• Remove the test weight and readjust the LVDT Output Zero, if necessary. If the level
test is performed after the integrator has been calibrated, a new integrator Zero
and Span calibration, Span Adjust, and Factoring, should be performed.
Sensing
Plate Changes < 0.01 Vac
Test We ight
Voltmeter

Page 14 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Integrator Calibration
Refer to the Flowmeter Integrator Instruction Manual for Integrator Calibration
instructions.
Zero Calibration
Refer to the Flowmeter Integrator Instruction Manual for Zero Calibration instructions.
Span Calibration
After a successful Zero Calibration, apply the Test Weight for the Span Calibration:
1. Attach one end of a string (monofilament fishing line or fine flexible cable) to the
Test We ig ht.
2. Route the other end of the string over the calibration pulley.
3. Attach the free end of the string to the string fixing bolt. Ensure the string rests in the
groove of the bolt.
Note:
• Ensure there is no material flow during Zero and Span Calibrations
• Ensure the Test Weight is suspended free of any obstructions.
•Accuratecalibrationisnotassureduntilmaterial testsanda Manual Span
Adjustment have been performed, as outlined in the Integrator Instruction Manual.
String Fixing Bolt
Calibration Pulley
String
Test Wei ght

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 15
M aintenance and Spare Parts
M aintenance
Establish a program of routine maintenance to ensure the highest achievable level of
performance. Follow good housekeeping practices in the area of the flowmeter.
Typical M aintenance Program
Spare Parts
Milltronics recommends the following spare parts be kept on hand:
• sensing head inner gasket
• sensing head outer gasket (base mount version only)
• damping fluid
•sensingplate
Contact Milltronics or your distributor for spare parts ordering information. The Siemens
Milltronics Web site is: www.milltronics.com
Frequency
M aintenance Description Regular M onthly Semi-
Annual Annual
Clean area around flowmeter !! ! !
Check sensing plate surface1
1. Remove any material buildup in the impact area of the sensing plate.
!! ! !
Check damping fluid !!!
Check sensing head inner gasket !!!
Check sensing plate wear !!!
Check test weight Rate display !!
Test flowmeter linearity !

Page 16 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Range Springs
The Range Spring establishes the range of sensing head Moving Beam travel for a given
range of material flow. This spring is installed in the flowmeter sensing head at the
factory. The spring is selected according to the specified Design Rate of the application.
For best operation, the range spring should provide 0.75 to 2.4 mm (0.030 to 0.094") of
Moving Beam travel from the static zero to the Design Rate operation position. The
Moving Beam travel may be inferred from the value of the LVDT output, as measured
between the LVDT green and yellow wires (or yellow and white wires in the case of a
hazardous-rated LVDT unit).
With the 2.5 Vac, 2.9 kHz LVDT excitation supplied:
• 0.75 mm of Moving Beam movement = 0.188 Vac output
• 2.40 mm of Moving Beam movement = 0.600 Vac output
Should the Design Rate of the flowmeter application change, it may be necessary to
select and install another range spring to obtain the optimum Moving Beam travel (LVDT
output) range.
Range Spring Removal
1. Loosen the range spring locknut.
2. Remove the range spring mounting bolt and three flange mounting bolts.
3. Remove the range spring from the range spring assembly.
Range Spring Replacement
1. Install the new range spring in the range spring assembly.
2. Mount the range spring assembly by the three flange mounting bolts.
3. With the Moving Beam in the static zero position, thread the range spring until the
base just touches the static beam and then turn one complete revolution more.
4. Install the range spring mounting bolt and tighten the range spring locknut.
Flow meter Recalibration
After you have removed and replaced the range spring, recalibrate the flowmeter and
integrator. (See the Integrator Manual, CALIBRATION section, for details.)
1. Perform the LVDT output Zero procedure.
2. Perform an integrator Zero and Span calibration.
3. Perform a Span Adjust and Factoring as required.

7ML19981CW01 ILE-37 Sensing Head – INSTRUCTION MANUAL Page 17
Troubleshooting
Every Milltronics ILE-37 Sensing Head is subjected to extensive quality assurance
procedures to ensure the highest possible degree of quality, reliability, and performance
is achieved.
The following listing indicates the probable cause, and proper course of action to be
taken should the specified fault symptom occur.
Symptom Cause Action
Integrator Rate display doesn’t
change when sensing plate is
moved.
Wrong or bad integrator
connection.
Refer to INSTALLATION/
Interconnection
Viscous damper cover in
shipping position.
Refer to INSTALLATION/
Viscous Damper.
Integrator not prepared for
operation.
Program and Calibrate the
integrator.
Span adjustment does not have
enough range.
Range spring not suited to
application
Refer to RANGE SPRINGS.
Measurement results are not
repeatable.
Sensing head not level. Refer to INSTALLATION and
CALIBRATION/Sensing Head
Level Test
Moving Beam travel is
mechanically limited.
Ensure Moving Beam does
not hit travel stops between –
20% and 150% flowrates.
Leaf springs are damaged. Replace leaf springs, re-
calibrate Flowmeter and
Integrator.
Material flow patterns vary. Refer to the Flowmeter
instruction manual
APPLICATIONS section.
Accuracy varies with material
flowrate.
Non-linear operation Refer to LINEARITY.

Page 18 ILE-37 Sensing Head – INSTRUCTION MANUAL 7ML19981CW01
Linearity
To test linearity, at least three test weights are used. Each test weight represents a
different Test Rate. Record the integrator Rate display value associated with each test
weight applied to the flowmeter.
If all the recorded display values are accurate, the Flowmeter measurement is linear.
e.g. For an E-40 Flowmeter Design Rate of 12TPH, the following three test weights could
be used:
• 780 g (1.72 lb) = 100% Design Rate = 12.0 TPH
• 585 g (1.29 lb) = 75% Design Rate = 9.0 TPH
• 390 g (0.86 lb) = 50% Design Rate = 6.0 TPH
If non-linear results are obtained, ensure:
• at no flow, the Moving Beam does not rest on the zero stop bolt
• at 150% Design Rate, the Moving Beam does not reach the full flow stop nut
• at 150% Design Rate, the LVDT output does not exceed 1.0 Vac.
• the damper piston does not touch the damper cylinder wall at any flow rate
• the LVDT core does not touch the inside of the LVDT at any flow rate
• the viscous damper fluid is free of large air bubbles and the fluid level is correct
• the range spring operates in compression from 0 - 100% flow rate
• the sensing head leaf springs are in good condition
If the test weight linearity test is successful, yet actual material test results are non-
linear, ensure there is no air circulation in the housing sensing plate area. If there is no
significant air circulation in the flowmeter housing while you are running material, the
material flow pattern is probably non-linear.
Non-linear material flow patterns can often be corrected by minor modifications to the
material infeed, or upstream piping. Some integrators are equipped with a linearization
function to compensate for non-linear material flow patterns. Stand-alone linearizing
devices are also available for this purpose.
Electronic linearization should not be used to correct non-linear test weight results.