Siemens milltronics ILE-37 User manual

Instruction Manual September 2003
ILE-37
milltronics

© Siemens MilltronicsProcessInstruments Inc. 2003
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning 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 with 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 with specifications.
Copyright Siemens Milltronics Process
Instruments Inc.2003.AllRights ReservedDisclaimer of Liability
This document is available in bound version and in
electronic version. We encourage users to
purchase authorized bound manuals, or to view
electronic versions as designed and authored by
Siemens Milltronics Process Instruments Inc.
Siemens Milltronics Process Instruments Inc. will
not be responsible for the contents of partial or
whole reproductions of either bound or electronic
versions.
While we have verified the contents of
this manual for agreement with the
instrumentation described, variations
remain possible. Thus we cannot
guarantee full agreement. The
contents of this manual are regularly
reviewed and corrections are included
in subsequent editions. We welcome
all suggestions for improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPI Technical Publications at the following address:
Technical Publications
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [e-mail]
For the libraryof SMPI instruction manuals, visitour Web site: www.siemens-milltronics.com

i
Table of Contents
Milltronics ILE-37 Sensing Head ......................................................................................1
Specifications ......................................................................................................................2
Installation ...........................................................................................................................4
Side Mount................................................................................................................................................ 4
Base Mount .............................................................................................................................................. 4
Sensing Plate............................................................................................................................................ 5
Viscous Damper....................................................................................................................................... 5
Interconnection........................................................................................................................................ 6
Non-Hazardous Unit without LVDT Conditioner Card ..........................................................6
Non-Hazardous Unit with Sensing Head Mounted LVDT Conditioner Card ..................7
Non-Hazardous Unit with Remote-Located LVDT Conditioner Card ...............................8
Calibration ............................................................................................................................9
LVDT Output.............................................................................................................................................. 9
Zero Adjustment (if required) .....................................................................................................9
Span Test .......................................................................................................................................10
Sensing Head Level Test ...........................................................................................................10
Integrator Calibration .................................................................................................................11
Zero Calibration ...........................................................................................................................11
Span Calibration ..........................................................................................................................11
Maintenance and Spare Parts ........................................................................................12
Maintenance .......................................................................................................................................... 12
Typical Maintenance Program........................................................................................................... 12
Spare Parts ............................................................................................................................................. 12
Unit Repair and Excluded Liability ..........................................................................................12
Range Springs ...................................................................................................................13
Range Spring Removal......................................................................................................................... 13
Range Spring Replacement................................................................................................................ 13
Flowmeter Recalibration ..................................................................................................................... 13
Troubleshooting .................................................................................................................14
Linearity ..............................................................................................................................15

ii

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 1
Milltronics ILE-37 Sensing Head
The Milltronics ILE-37 sensing head is an out-of-process sensing element for A, E, V, and
C series solids flowmeters. It 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 V-40 C-40

Page 2 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
Specifications
Operating Range
• 0 to 0.2 t/h (0 to 0.2 STPH) min., 0 to 40 t/h (0 to 44 STPH) max.
Particle Size
• fine powder to 13 mm (0.5")
Product Temperature
• –40 to 232 °C (–40 to 450 °F)
Ambient Temperature
• –40 to 60 °C (–40 to 140 °F)
• –40 to 50 °C (–40 to 122 °F) with optionally internally mounted LVDT card
Accuracy
• ± 1 % of full scale, higher accuracy with linearizing function of integrator
Repeatability
•±0.2%
Construction
• dust-tight cast aluminum frame with fiberglass rear cover
Mounting
• side mount or base mount (to suit application)
Sensor Type
• LVDT (linear variable differential transformer)
LVDT Excitation
• 2.50 V AC @ 2.9 kHz (supplied byintegrator or LVDT conditioner card)
LVDT Output
• 0 – 0.75 V AC @ 2.9 kHz
Damping Fluid
• 1 – 100 cm2/s (100 – 10,000 cs) silicone (Dow Corning 200 recommended)
Options
• Epoxy paint, synergistic polymer, or PFA coating of external aluminum casting surfaces
• Epoxy painted mild steel or stainless steel rear cover
Approvals
•CE
• Optional CSA. Class I, Groups C and D; Class II, Groups E, F, and G

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 3
Sensing Plate
Construction
• 304 (1.4306) stainless steel
Options
• 316 (1.4404) stainless steel
• UHMW polyurethane or Ceramic Tile abrasion resistant lining
• Synergistic polymer or PFA coating for low cohesion and low friction
LVDT Conditioner Card
Power
• ± 5 V DC (typically from a Siemens Milltronics Integrator)
Ambient Temperature
• –40 to 50 °C (–40 to 122 °F)
Input
• 0 to 1.0 V AC from LVDT
Output
• 0 to 50 mV DC to Siemens Milltronics integrator; [maximum 300 m (1000 ft) separation
between conditioner card and integrator]
Approvals
•CE
Enclosure
• NEMA 4 (remote mounted unit)
Cable
For connection between LVDT Conditioner Card and Integrator
•Belden®
18404, 4 conductor, shielded 20 AWG (0.5 mm2) or equivalent, 150 m (500 ft)
maximum
• Belden 9260, 6 conductor, shielded 20 AWG (0.5 mm2) or equivalent, 300 m (1000 ft)
maximum
For connection between LVDT and remote LVDT Conditioner Card,
or directly between LVDT and Integrator
• Belden 8404, 4 conductor, shielded 20 AWG (0.5 mm2) or equivalent, 300 m (1000 ft)
maximum
1. Belden is a registered trademark of Belden Wire & Cable Company.

Page 4 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
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 1 t/h, or if handling product temperatures above 60 °C.
The side mount version is factory-installed on Siemens Milltronics flowmeters
designed for side mount sensing heads.
Side Mount
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.
Base Mount
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.
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.
mounting
bolts spirit level
spirit level
rigid
support
moving
beam
supporting/
levelling
bolts
front view side view

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 5
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.
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.
*Note:Ensure the slot in the end of the shaft mates with the roll pin in the back of the
socket.
Note: The damper must be full and free of air bubbles, with the damper cover in the
UP position, during flowmeter operation.
sensingplate
sensing head
shaft roll pin
slot
set screw or hex
head screw
sensing
head
damper
filler bottle
shipping
screws
damper
cover
(Check that
there are no
bubbles.)

Page 6 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
Interconnection
Non-Hazardous Unit without LVDT Conditioner Card
* See note below for Encapsulated (Hazardous-rated) LVDT color codes.
Note: Ground shield at Integrator only.
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

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 7
Non-Hazardous Unit with Sensing Head Mounted LVDT
Conditioner Card
• Not applicable to Hazardous-rated units
• LVDT to LVDT Conditioner Card connections are made by Siemens 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 Siemens Milltronics.
♦Note:Shields are common, but not grounded to chassis. Run cable shields through
SHLD terminals and ground at Integrator only.
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 TE G R AT O R
RED
BLUE
YELLOW
BLACK
GREEN
SF500
integrator
Siemens Milltronics LVDT conditioner card
*
LVDT

Page 8 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
Non-Hazardous Unit with 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 Siemens Milltronics.
♦Note:Shields are common, but not grounded to chassis. Run cable shields through
SHLD terminals and ground at Integrator only.
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 TE G R AT OR
RED
BLUE
YELLOW
GREEN
SF500
integrator
Siemens Milltronics LVDT
*
**For Encapsulated LVDT (hazardous)
YEL = WHITE
BLU = ORANGE
GRN = YELLOW
**Junction box included with hazardous-rated unit.
*LVDT
**

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 9
Calibration
A Test Weight is a calibration reference used to simulate a material impact force (test
rate) on the flowmeter sensing plate during the integrato 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 V AC reading on the
voltmeter.
If the LVDT output is 0.10 ± 0.05 V AC, skip to Span 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 V AC 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.
Note: Ensure the new position of the LVDT core allows free movement within the
LVDT bore.
± 0.05
± 0.05
0.100
LVDTLVDT core
moving beam
locknut
increase decrease
To Int egrator
LVDT EXC.
or LVDT
Conditioner Card

Page 10 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
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 V AC 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 V AC.
3. Ensure the LVDT output always returns to 0.10 ± 0.05 V AC, (to the right side of zero)
when pressure on the moving beam is released.
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 V AC.
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").
Note:
• If the change is greater than 0.01 V AC, adjust the sensing head level, (refer to
“Installation” on page 4) until the change with and without the test weight on the
sensing plate is less than 0.01 V AC.
• 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.
0.050
0.150
0.015
0.500
to
0.750
1.000
to
sensing
plate changes < 0.01 V AC
test weight
voltmeter

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 11
IntegratorCalibration
Refer to the Integrator instruction manual for Integrator Calibration instructions.
Zero Calibration
Refer to the 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 weight.
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.
• Accurate calibration is not assured until material tests and a manual span
adjustment have been performed, as outlined in the Integrator instruction manual.
string fixing bolt
calibration pulley
string
test weight

Page 12 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
Maintenance and Spare Parts
Maintenance
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 Maintenance Program
Spare Parts
Siemens Milltronics recommends the following spare parts be kept on hand:
• sensing head inner gasket
• sensing head outer gasket (base mount version only)
• damping fluid
• sensing plate
Contact Siemens Milltronics or your distributor for spare parts ordering information.
Unit Repair and Excluded Liability
All changes and repairs must be done by qualified personnel and applicable safety
regulations must be followed. Please note the following:
• The user is responsible for all changes and repairs made to the device.
• All new components must be provided by Siemens Milltronics Process
Instruments Inc.
• Restrict repair to faulty components only
• Do not re-use faulty components.
Frequency
Maintenance Description Regular Monthly 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 !

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 13
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 V AC, 2.9 kHz LVDT excitation supplied:
• 0.75 mm of moving beam movement = 0.188 V AC output
• 2.40 mm of moving beam movement = 0.600 V AC 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.
Flowmeter 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.

Page 14 Milltronics ILE-37 – INSTRUCTION MANUAL 7ML19985CW01
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.

7ML19985CW01 Milltronics ILE-37 – INSTRUCTION MANUAL Page 15
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 12 TPH, 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 V AC.
• 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.

ILE - 37 Side Mount Outline and Mounting
Notes: 1. Refer to flowmeter drawing for the dimension from the sensing head mounting hole to the flowguide centerline. 2. Ensure that the outer gasket seal to the flowmeter housing wall is dust tight.
see Note 1
outer gasket
as required
250 mm (9.84") B.C.D.
225 mm dia. (8.85")
50o
40o
sensing pate
305 mm
(12")
327 mm (12.88")
fiberglass cover
conduit entry 1/2" NPT (internal)
50o
35o
FIG. 1