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protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed.
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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.
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Sensing Head ........................................................................................................................................... 4
Spare Parts ............................................................................................................................................. 11
Unit Repair and Excluded Liability ..........................................................................................11
The Milltronics ILE-61 sensing head is an out-of-process sensing element for A, E, and V
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.
LVDT
moving beam travel
impact force
sensing plate
The ILE-61 sensing head is used with Milltronics E-300 (general purpose), A-300 (aerated
gravity conveyor), and V-300 (vertical material drop) dry solids flowmeters.
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 designrate.
To determine the test rate produced by a specific test weight...
Test Rate (TPH) = Test Weight (grams)
45* grams/ TPH
Alternatively, to determine the test weight required for a specific test rate:
Test Weight (grams) = 45* grams x Test Rate (in TPH)
1 TPH
*Use 60 grams for A-300 flowmeters.
e.g. If the test weight used with an E-300 flowmeter is 7000 grams...
Test Rate = 7000 grams
45 grams/TPH
= 155 TPH
Note: Use metric tons per hour (t/h) or short tons per hour (STPH) as applicable for
TPH.
LVDT Output
Zero Adjustment
1.Connect a voltmeter across the LVDT green and yellow (or yellow and white) wires.
2.With no load applied to the sensing plate, observe 0.10 V AC on the voltmeter.
Note: If the LVDT output is 0.10 to 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 to 0.05 V AC is obtained.
c.Tighten the locknut, ensuring the measured value is maintained.
to integrator
LVDT EXC. or
LVD T con dit ion er
card
Page 13
Span Test
1.Gently push the sensing head moving beam to the right. The LVDT output should
increase steadily 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
decrease steadily until zero is reached and then increase to 0.25 to 0.50 V AC.
3.Ensure the LVDT output always returns to 0.10 to 0.05 V AC, (on the right hand 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 . 7 5 0
to
1 . 0 0 0
0 . 0 5 0
to
0 . 1 5 0
Sensing Head Level Test
1.With the voltmeter still connected to the LVDT output, hang the test weight directly
off the sensing plate.
2.Observe the display value does not change by more than 0.01 V AC.
0 . 0 1 5
to
0 . 5 0 0
Note: If the change is greater than 0.01 V AC, adjust the sensing head level 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 this procedure is performed after the integrator is calibrated, a new integrator
zero and span calibration, span adjust, and Factoring (if required) should be
performed.
A program of routine maintenance should be established to ensure the highest
achievable level of performance is maintained. Good housekeeping practices in the area
of the flowmeter are recommended.
Maintenance DescriptionFrequency
RegularMonthlySemi-AnnualAnnual
Clean area around flowmeter
Check sensing place surface*
Check damping fluid
Check sensing head inner gasket
Check sensing plate wear
Check test weight Rate display
Test flowmeter linearity
* Material buildup (if any) in the impact area of the sensing plate should be
removed.
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Spare Parts
Milltronics recommends a spare inner and outer gasket, sensing plate, and spare
damping fluid be kept on hand.
!
Contact 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.
Should it ever be necessary to replace the sensing head inner gasket, refer to the
Installation and Figures sections of this instruction manual prior to performing the
following procedure.
1.Remove the ILE-61 fibreglass cover, (10 bolts).
2.Bolt down the viscous damper cover to the shipping position, (2 bolts).
3.Remove the sensing plate from the sensing head.
4.Remove the inner retaining ring, (6 bolts).
5.Remove the upper and lower hinge block bolts, (4 per block).
6.a. Hazardous versions, remove the LVDT core and LVDT, (3 bolts), or
b. Non Hazardous, remove the LVDT cable TY WRAPs (2) and disconnect LVDT
connections.
7.While supporting the main assembly, remove the secondary static beam bolts (3 per
side).
8.Draw the main assembly away from the main frame.
Note: The main assembly is heavy and awkward to handle; ensure it is
supported well.
9.Remove the outer retaining ring and inner gasket, (8 bolts).
10.Install the new inner gasket and reverse the procedure (steps 1 through 9).
11.Perform the LVDT output zero procedure.
12.Referring to the integrator instruction manual, perform an integrator zero and span
calibration. Perform a span adjust if calibration accuracy appears affected.
The range spring establishes the range of sensing head moving beam travel for a given
range of material flow. This spring installed, is selected and positioned 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 by the value of the LVDT green and yellow (or yellow and
white) wires.
With the 2.5 V AC, 2.9 kHz LVDT excitation supplied:
•0.75 mm of moving beam movement = 0.188 V AC
•2.40 mm of moving beam movement = 0.600 V AC
Should the design rate of the flowmeter application change, it may be necessary to
reposition the original range spring, or select and install another range spring, to obtain
the optimum moving beam travel (LVDT output) range. Moving the range spring to a
location further away from the pivot point leaf spring, increases the maximum flowrate
capacity.
Range Spring Remov al
1.Observe the range spring mounting position. (3 positions are available)
2.Loosen the range spring locknut.
3.Remove the range spring center bolt and 4 flange mounting bolts.
4.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 4 flange mounting bolts.
3.With the moving beam in the static zero position, turn the range spring until the base
just touches the beam, and then turn 1 complete revolution more.
4.Install the range spring center bolt and tighten the range spring locknut.
Flowmeter Recalibration
After removing and replacing the range spring, the flowmeter and integrator should be
recalibrated.
1.Perform the LVDT output zero procedure. Refer to Calibration.
2.Perform an integrator zero and span calibration. Refer to the integrator manual,
Calibration.
3.Perform a span adjust and factoring as required. Refer to the integrator manual,
Calibration.
Every Millltronics ILE-61 sensing head is subjected to extensive quality assurance
procedures to ensure the highest 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.
SymptomCauseAction
Integrator Rate display
doesn’t change when sensing
plate is moved
Span adjustment does not
have enough range
Measurement results are not
repeatable
Accuracy varies with material flowrate
Wrong or bad integrator
connection
Viscous damper lid in shipping position
Integrator not prepared for
operation
Range spring not suited to
application
Sensing head not level
Moving beam is mechanically
limited
Leaf springs are damaged
Material flow patterns vary
Non-linear operationRefer to Linearity
Refer to Installation\Integrator LVDT Interconnection
Refer to Installation/ Viscous
Damper
Program and Calibrate the
integrator
Refer to Range Springs
Refer to Installation and
Calibration/Sensing Head
Level Test
Ensure moving beam does not
hit travel stops between -20 %
and 150 % flowrates
Replace leaf springs,
recalibrate flowmeter, and
integrator
Consult Siemens Milltronics
or your distributor
To test linearity, at least 3 test weights are used. Each 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-300 flowmeter Design Rate of 200 TPH, the following three test weights
could be used:
•9000 g (19.82 lb.) = 100% Design Rate = 200 TPH
•6750 g (14.87 lb.) = 75% Design Rate = 150 TPH
•4500 g (9.91 lb.) = 50% Design Rate = 100 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 bolt.
•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 - 150% 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 nonlinear, ensure there is no air circulation in the housing sensing plate area. If there is no
significant air circulation in the flowmeter housing while 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.
Note: Electronic linearization should not be used to correct non-linear test weight