WAMGROUP TOREX ILV User manual
2
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www.torex.it
TOREX S.p.A.
Via Canaletto, 139/A
I-41030 S. Prospero s/S
(MO) - Italy
Manual No. TOR.056.--.M.EN Issue: A1
Latest update: September 2016
ORIGINAL INSTRUCTIONS IN ENGLISH
ILV
VIBRATING LEVEL INDICATOR
EN
ASSEMBLY AND
MAIN INSTRUCTIONS
FOR USE AND
MAINTENANCE
All the products described in this catalogue are manufactured according to TOREX S.p.A. Quality System procedures.
The Company’s Quality System, certied according to ISO 9001-2008 guarantees that the entire production process, from the
customer’s order to the after sales service, can full the product quality standard.
This publication cancels and replaces any previous edition and revision.
We reserve the right to implement modications without notice.
This catalogue cannot be reproduced, even partially, without prior written consent by the Manufacturer.
INDEX
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TABLE OF CONTENTS
1.0 GENERAL INFORMATION ......................................................................................................................1
1.1 Scope of the Manual .........................................................................................................................1
1.2 Symbols ............................................................................................................................................2
1.3 Glossary and terminology .................................................................................................................4
1.4 Manufacturer’s data and identication of device............................................................................... 5
1.5 Request for assistance......................................................................................................................6
1.6 Warranty............................................................................................................................................6
1.7 Exclusion of responsibility .................................................................................................................6
2.0 INFORMATION REGARDING SAFETY...................................................................................................7
2.1 General safety prescriptions .............................................................................................................7
2.2 Safety prescriptions for installation ...................................................................................................7
2.3 Safety prescriptions for use and operation........................................................................................8
2.4 Safety prescriptions for maintenance and replacement of components ...........................................8
3.0 TECHNICAL INFORMATION ...................................................................................................................9
3.1 General description of device............................................................................................................9
3.2 Main components............................................................................................................................10
3.3 Operating principle .......................................................................................................................... 11
3.4 Noise level....................................................................................................................................... 11
3.5 Environmental operating limits ........................................................................................................ 11
3.6 Safety and information signs...........................................................................................................13
3.7 Residual risks..................................................................................................................................13
4.0 INFORMATION REGARDING HANDLING AND TRANSPORT............................................................. 14
4.1 Type of packaging ...........................................................................................................................14
4.2 Unpacking .......................................................................................................................................14
4.3 Dimensions and weights .................................................................................................................14
4.4 Disposal ..........................................................................................................................................15
4.5 Reception of goods .........................................................................................................................15
4.6 Lifting and unloading methods ........................................................................................................16
5.0 INSTALLATION AND FIXING.................................................................................................................17
5.1 Safety prescriptions for installation .................................................................................................17
5.2 Assembling instructions.................................................................................................................. 18
5.3 Instructions for ATEX IIIC Da/Db zone ........................................................................................... 21
5.4 Mechanical connections..................................................................................................................22
5.5 Electrical connections .....................................................................................................................23
5.6 Adjusting the indicator .................................................................................................................25
6.0 INFORMATION REGARDING USE .......................................................................................................28
6.1 Production Start-up .........................................................................................................................28
6.2 Machine shut-down at the end of the work cycle ............................................................................28
6.3 Reuse after long shut-down ............................................................................................................28
6.4 Storage of the device for extended period ......................................................................................28
INDEX
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7.0 INFORMATION REGARDING USE .......................................................................................................29
7.1 Cleaning the device.........................................................................................................................29
8.0 REPLACEMENT OF PARTS..................................................................................................................30
8.1 Safety recommendations for replacement ......................................................................................30
8.2 Replacing the electric module .........................................................................................................30
8.3 Returning the device .......................................................................................................................32
8.4 Dismantling and disposal ................................................................................................................32
10.0 TECHNICAL DATA .................................................................................................................................33
10.1 Overall dimensions........................................................................................................................33
AATTACHMENTS.....................................................................................................................................35
A1 Declaration of Incorporation ............................................................................................................35
1.0 GENERAL INFORMATION
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1.1 Scope of the Manual
This Manual has been prepared by the Manufacturer to provide the operating technical information for instal-
lation, operation and maintenance of the device concerned.
The Manual, which is an integral part of the device concerned, must be preserved throughout the life of the
device in a known easily accessible place, available for consultation whenever required.
If the Manual is lost, damaged or becomes illegible, contact the Manufacturer for a copy specifying the serial
number of the device.
If the device concerned changes ownership, the Manual has to be handed over to the new owner as part of
the device supply.
The Manual is meant for specialist technical personnel appointed and authorized by the Manufacturer, owner
and installer to act on the device concerned for which specic technical skills in the sector concerned are nec-
essary (electrical, mechanical, etc.).
The illustrations may differ from the actual structure of the device concerned but do not interfere with the ex-
planation of the operations.
In case of doubt, contact the Manufacturer for explanations.
The Manufacturer reserves the right to make changes to the Manual without the obligation to provide prior The
Manufacturer reserves the right to make changes to the Manual without the obligation to provide prior com-
munication.
The technical information included in this Instruction Manual is the property of the Manufacturer and therefore
has to be considered as condential.
It is forbidden to use the Manual for purposes other than those strictly linked to the operation and maintenance
of the device.
This information is provided by the Manufacturer in the original language (English) and can be translated into
other languages to satisfy legislative and/or commercial requirements.
1.0 GENERAL INFORMATION
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To highlight certain parts of the text, for purposes of safety, or to indicate important information, certain symbols
are used, the meaning of which is described below.
It is important to comply with and scrupulously follow the information highlighted by the symbols.
Danger - Warning
Indicates situations of serious danger which, if ignored, can be risky for the health and safety of per-
sons.
Caution
Indicates that appropriate behaviour must be adopted to avoid posing risk for the health and safety of
persons and avoid causing economic damage.
Important
Indicates particularly important technical information which must not be ignored.
1.2 Symbols
1.0 GENERAL INFORMATION
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Symbol
representation Symbol description
Danger sign: indicates danger of electric shock caused by the presence of pow-
ered components inside the junction box or control panel.
Obligation: read this Manual before carrying out any action on the device con-
cerned.
Forbidden: indicates that it is forbidden to lubricate or adjust moving parts.
Forbidden: indicates it is forbidden to introduce hands into the equipment.
List of safety and information symbols
1.0 GENERAL INFORMATION
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Operator: person appropriately trained and authorized by the Production Manager for setting up the device
concerned and carrying out routine maintenance.
Installer: organization with specialized technicians and appropriate equipment for carrying out risk-free instal-
lation and extraordinary maintenance.
Specialist technician: person responsible for and authorized by the Manufacturer, owner or installer to act
on the device; must have specic technical skills depending on the sector concerned (electrical, mechanical
etc.). The specialist technician, in addition to being familiar with the working of the device concerned, must be
familiar with the working of the plant or equipment on which the device concerned is installed.
Routine maintenance: includes all the actions necessary to keep the device in good working conditions, to
ensure greater operating durability and to keep the safety requisites constant.
Extraordinary maintenance: all the actions meant to keep the device in perfect working order.
Setting in safety conditions: all the precautions the authorized personnel must adopt before acting on
the device concerned.
The precautions are listed below.
- Ensure that the device concerned is disconnected from all the mains and use suitable devices to
prevent the possibility of the power sources being activated accidentally.
- Ensure that all the moving parts of the device have come to a complete stop.
- Ensure the temperature of the device concerned is such that it does not burn.
- Provide appropriate lighting in the area around the operations.
- Wait for the material to be handled inside the device or machine concerned to settle down com-
pletely.
1.3 Glossary and terminology
1.0 GENERAL INFORMATION
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Important
Do not change the data on the identication plate.
Keep the ID plates clean, intact and legible as regards the data they contain.
If the ID plate is damaged or is no longer legible (even just one informative element on it) contact the
Manufacturer for a new ID plate and replace it.
The ID plates shown identify the device concerned and its main components.
The plates show the reference necessary for operating safety.
1.4 Manufacturer’s data and identication of device
Identication plate of the ILV indicator
1) Manufacturer’s name and address
2) Serial No.
3) Device type
4) Range limits
5) Output signal range
6) Cable or tape length
7) Application limits
WAM GROUP
TOREX SpA
®
I-41030 S.Prospero (MO)
www.torex.it
SN 1010001111 1.1.2012 ILV
Supply : 230 VAC 50-60 Hz
Outputs: 4-20 mA
L: 30m (100 ft)
Enclosure IP66
thread R 11
2"
Conduit entry M25x1.5;M20x1.5
T(amb) -20°C ...+60°C
T(process) -40°C ...+80°C
P(process) : -2...+2 bar
See instruction manual for proper operation
1
3
2
4
5
6
7
1.0 GENERAL INFORMATION
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1.5 Request for assistance
1.6 Warranty
1.7 Exclusion of responsibility
For all technical assistance, contact the Manufacturer’s service network.
For all requests, provide the device identication data, the type of problem encountered and all other informa-
tion which could be useful for identifying the problem.
The conditions for validity and applicability of the warranty are specied in the sales contract.
The device is delivered according to the specications indicated by the Buyer in the order and the conditions
valid at the time of purchase.
The Manufacturer shall not accept responsibility for safety of persons or objects and operation failure of the
device if the loading/unloading operations from trucks, transport, positioning at the site, use, repairs, mainte-
nance etc. have not been carried out in compliance with the warnings described in this Manual, and in accord-
ance with the national legislation in force.
Likewise, the Manufacturer shall not accept any responsibility if the device concerned is used:
- improperly;
- by unauthorized persons and/or persons not sufciently trained for installation, operation and maintenance;
- with modications made to the original conguration without the Manufacturer’s permission;
- with spare parts that are not original or are not specic for the model;
- without maintenance;
- non-pursuant to the regulatory standards and national or local legislation on the matter of occupational
safety;
- non-pursuant to the regulatory standards and national or local legislation on the matter of occupational
safety.
2.0 INFORMATION REGARDING SAFETY
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2.1 General safety prescriptions
Read the Instruction Manual carefully and strictly follow the instructions it includes, especially those
regarding safety.
Most accidents at the workplace are caused by negligence, failure to follow the most elementary safety
regulations and incorrect or improper use of tools and equipment.
Accidents can be prevented and avoided by taking due care, using suitable equipment and adopting
adequate preventive measures.
Apply and comply with the standards in force regarding workplace hygiene and safety.
The personnel trained for and authorized for the operations has to have the psychological/physical
requisites, experience in the sector concerned and the necessary technical skills for carrying out the
operations assigned to them.
All workers involved in any kind of operation must be prepared, trained and informed as regards the
risks and the behaviour to be adopted.
Pay attention to the meaning of the notices applied on the device, keep these legible and respect the
information indicated.
Use instruments, equipment and tools that have been approved and are intrinsically safe, and cannot
alter the safety level of the operations or damage the device during installation, use and maintenance.
Modications to the device components should not be made for any reason whatsoever, without the
Manufacturer’s permission.
2.2 Safety prescriptions for installation
Before starting with installation, a “Safety Plan” must be implemented to safeguard the personnel di-
rectly involved and those who carry out operations in the surrounding area.
All the laws must be strictly applied, especially those concerning workplace safety.
Before proceeding with installation operations, mark off the work area to prevent access by unauthor-
ized persons.
The electrical connections must be made in compliance with the standards and laws in force.
The person in charge of making the electrical connections has to ensure that the required standards
and laws are respected before testing.
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2.4 Safety prescriptions for maintenance and replacement of components
Danger - Warning
Before carrying out any operation on the device concerned, ensure it is switched off and disconnected
from all mains and use suitable devices to prevent the possibility of the power sources being activated
accidentally.
Maintain the device concerned in the conditions of utmost efciency compliant with the maintenance
plan provided by the Manufacturer.
Good maintenance apart from preserving the functional features and essential safety features over
time, will also allow extending the working life of the device concerned and achieving the best possible
performance.
Strictly follow the procedures indicated in the Manual, especially those concerning safety.
Ensure that all the safety devices are active and working properly.
Mark off the work area in such a manner as to prevent the access of unauthorized persons.
Replace the worn and damaged components exclusively with original spare parts, whose safety, reli-
ability and interchangeability have been undoubtedly established.
Apart from invalidation of the warranty, the Manufacturer declines all responsibility for damage to
objects and harm to persons deriving from the use of non-original spare parts or due to modications
made during repairs without express written authorization.
Do not dump polluting material (oil, grease, paint, plastic etc.) in the environment, but carry out waste
separation disposal depending on the chemical composition of the various products in compliance
with the legislation in force.
On completion of maintenance or replacement operations, before resuming production, check that no
foreign bodies (rags, tools etc.) have been left inside the device concerned.
2.3 Safety prescriptions for use and operation
Do not tamper with the device concerned by using any kind of device to obtain performances different
from those designed.
Each unauthorized modication can endanger the health of persons and damage the machine itself.
The operators must wear only protective clothing and personal protection devices suitable to the op-
erations to be carried out required by the safety and work accidents prevention standards.
Before operation make sure all safety devices are installed and working properly.
During operations, prevent access to the work area by unauthorized persons.
Remove all obstacles or sources of danger from the work area.
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3.1 General description of device
Maximum or minimum level indicator with vibrating forks.
The device is used for monitoring the level inside any type of container or silo. It is meant for dust or granular
material with poor tendency to form encrustation or deposits. The food industry is also a wide sector of ap-
plication. The ATEX IIIC Da/Db version of the device is available for use in ein the presence of explosive dust.
Possible applications:
- Industry for building constructions materials for lime, foundry sand, etc;
- Food industry for milk powder, our, salt, etc;
- Plastic materials industry of for plastic granules, etc;
- Timber industry;
- Chemical industry;
- Mechanical constructions, etc.
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3.2 Main components
1
2
3
4
5
6
Item DESCRIPTION Q.ty
1M20x1.5 Cable gland 1
2Cover 1
3ILV Head 1
4Connection thread 1
5Vibrating forks 2
6Nut 1
1. Cable gland: it is used for the passage of electric power supply and signals cables from the level indicator.
2. Cover: protects the electrical connections from dust and water
3. Head: contains the wiring and electronic controller board.
4. Connection thread: it is used for connecting the indicator on the silo or container
5. Vibrating forks: detect the presence of material.
6. Nut: used for the fastening of the level indicator on the silo or container.
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3.3 Operating principle
The ILV oscillating probe is usually screwed to the side wall of the container, near the lling level which is to
be recorded and checked. This probe can also be installed on the upper wall of the container; in this case, an
extension has to be used so as to reach the required level.
The probe can be about 4 m long using an extension tube (ILVB), or 20 m using an extension cable (ILVC).
When stimulated piezoelectrically the oscillating probe vibrates at its mechanical resonance frequency. If the
probe is covered by bulk materials, the damping created is recorded electronically, thereby generating an
output signal. The oscillation of the device constitutes, to some extent, acting as a sort of self-cleaning mecha-
nism.
3.4 Noise level
3.5 Environmental operating limits
OPERATION CONDITIONS
The ILV level indicator emits no noise.
Type ILVA - ILVB ILVC
Ambient Temperature -40°C … +60°C -25°C … +60°C
Operation temperature -40°C … +150°C -25°C … +80°C
Operating pressure -1 … +16 bar -1 … +6 bar
Moisture 0-100%
Altitude max 2000 m
ILV
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MECHANICAL FEATURES
Type ILVA - ILVB ILVC
Casing Body made of RAL5010 gentian blue die-cast aluminium
Housing IP66 in accordance with standard EN 60529
Screw-in item
Material Stainless Steel 304 - 316
Key opening 50 mm
Thread/Flange
1 ½” GAS
1 ½” NPT
DN100 PN6
Vibrating forks
Material Stainless Steel 304 - 316
Total weight 1.7 Kg 4 Kg
Wt. of extensions 2.5 Kg/m 0.5 Kg/m
Type ILVA - ILVB ILVC
Ambient Temperature -40 °C ...+60 °C -25 °C...+60 °C
Operation temperature -40 °C...+150 °C -25 °C...+80 °C
Powder density Max. Min. Max. Min.
30 g/l 150 g/l 20 g/l 75 g/l
Features of bulk material Poor tendency to form deposits
Particle size max. 8 mm Particle size max. 8 mm
Max. lateral load 500 NM 600 NM
Max. torque 250 NM -
Max. traction force - 2 kN
Operating pressure -1 .. +16 bar -1 .. +6 bar
Protection measures in case of high loads: install a protective angular element on the probe top.
ILV
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3.6 Safety and information signs
Danger - Warning
Follow the signs on the plates.
Ensure the plates are legible; otherwise clean them and replace the damaged ones, applying them in
their original position.
ELECTRICAL FEATURES
Type Relay output PNP Output
Supply voltage 19...230V 50/60Hz +10% /
19...40VDC +10% 18...50VDC +10%
Maximum oscillation 7Vss DC 7Vss
Power absorption Max. 22VA/ 2W Max. 0.5A (ILVA/ILVB)
Max. 1.5W (ILVC)
Cable gland M20x1.5
Signal output
AC Max 250V,8A non inductive
DC Max. 30V, 5A non inductive
(ILVA-ILVB)
Permanent charge max. 0.4 A
protected against short-circuit and
overload. Voltage for protection
against polarity inversion. Output
voltage equal to the input voltage,
voltage drop <2.5V.
AC max. 253V, 4A, 500VA Phi =1
DC Max. 253V, 4A 60W (ILVC)
Signal delay
Uncovered probe covered for approx. 1sec.
Covered probe uncovered for approx 1..2 sec.
Safety operation (FSL, FSH) Can be switched for minimum/maximum safety
Sensitivity Adjustable on two levels
Measuring frequency About 200 Hz (ILVA-ILVB)
About 125 Hz (ILVC)
Insulation Power supply on output signal
and output signal on output signal:
: 2225Vrms
-
Protection class I III
3.7 Residual risks
Perform the connections of the ILV level indicator in accordance with the indications contained in the paragraph
"Electrical connections". The ILV indicator is supplied with no the power cables. When the device is started up,
the operator must connect the cables in the correct manner, by performing the operations in complete safety,
as envisaged by the regulations concerning the use of electricity.
The earthing connection is in charge of the installer.
4.0 INFORMATION REGARDING HANDLING
AND TRANSPORT
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4.1 Type of packaging
The level indicators ILV are packaged separately in cardboard boxes.
Depending on the quantity ordered, the boxes can be secured on pallets covered with lm or shrink-wrap.
4.2 Unpacking
The unpacking operations require the removal of the protection lm (if present).
The indicators in the boxes are not xed in any manner.
4.3 Dimensions and weights
A 130
B200
C 400
dimensions in mm
The dimensions in the table above refer to the standard level indicator ILVA.
The packages may vary depending on the congurations, extensions and/or high temperature versions.
The weights of the vibrating level indicators can differ depending on the conguration type.
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4.4 Disposal
The packaging material has to be disposed off or recycled in compliance with the standards in force. The op-
eration is in charge of the installer.
Type Indicator weight Weight in Kg/m of the extension
ILVA 1.7 Kg -
ILVB 2.3 Kg 1.9 Kg/m
ILVC 4.0 Kg 0.5 Kg/m
E.g. Calculation of weight with 2.5 m long extension.
Considering the weight of the standard indicator equal to 2.3 kg, and multiply the 2.5 m extension by the weight
in meters of the extension.
2.3 kg + (2.5 m x 1.9 kg/m) = 7.05 kg total weight of ILV extension 2.5 m
Important
The data on the rating plate do not include the weight of the complete package (pallets or other) if
present.
4.5 Reception of goods
On receiving the goods, check if type and quantity match the data on the acknowledgement of order.
Possible damage has to be immediately communicated in writing in the space provided to this purpose in the
waybill.
The carrier is obliged to accept the complaint and leave the Customer a copy of the waybill.
If the supply is “free destination” a copy of the waybill and of the complaint shall be sent to the Manufacturer
or to the forwarder.
If the damages are not claimed immediately on receipt of the goods, your request for compensation may not
be accepted.
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AND TRANSPORT
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4.6 Lifting and unloading methods
Danger - Warning
Carry out the lifting and handling operations according to the information indicated on the device and
in the Manufacturer’s Operation Manual.
The person authorized for unloading operations has to make sure all the necessary measures are
adopted to ensure his or her safety and the safety of other persons directly involved.
Use means and accessories (ropes, hooks, shackles etc.) suitable for the load to be lifted.
Pay attention in the lifting phase to balance the load to avoid uncontrolled movements which could
cause work injuries to persons.
Do not stack the packages as they are not sized for that purpose.
Before lifting and handling the load, read the relevant information indicated in the “Information regard-
ing safety” Chapter.
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