Siemens Milltronics Millpulse 600 Instruction Manual

Instruction Manual September 2006

milltronics

MILLPULSE 600MILLPULSE 600

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.

Unit Repair and Excluded Liability:

• The user is responsible for all changes and repairs made to the device by the user or the user’s
agent.

• All new components are to be provided by Siemens Milltronics Process Instruments Inc.

• Restrict repair to faulty components only.

• Do not reuse faulty components.

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

Disclaimer of Liability

Instruments Inc. 2006. All Rights Reserved

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 a selection of Siemens Milltronics level measurement manuals, go to:
www. siemens.com/processautomation. Under Process Instrumentation, select

Measurement

• For a selection of Siemens Milltronics weighing manuals, go to:
www. siemens.com/processautomation. Under Weighing Technology, select

Weighing Systems

and then go to the manual archive listed under the product family.

and then go to the manual archive listed under the product family.

Level

Continuous

© Siemens Milltronics Process Instruments Inc. 2006

Table of Contents

Safety Notes .............................................................................................................................................1

Safety marking symbols ..............................................................................................................1

The Manual ...............................................................................................................................................1

Milltronics Millpulse 600 ..................................................................................................2

Specifications ................................................... ................................................. ..................3

Installation ...........................................................................................................................5

Environment ..............................................................................................................................................5

Wiring .........................................................................................................................................................5

Interconnection ........................................................................................................................................6

Loading .......................................................................................................................................................7

Operation ......... ................................. ..................................... .................................. .............8

Dimensions ..........................................................................................................................9

Application ...... ......................... ..................... ........................ ..................... ........................10

Bucket Elevators ..........................................................................................................................10

Shafts .............................................................................................................................................10

Belt Conveyors .............................................................................................................................11

Screw Conveyors ......................................................................................................................... 11

Cleaning and Maintenance .............................................................................................12

i

ii

Safety Notes

Special attention must be paid to warnings and notes highlighted from the rest of the text
by grey boxes.

1

WARNING1: means that failure to observe the necessary precautions
can result in death, serious injury, and/or considerable material damage

Note:

means important information about the product or that part of the operating

manual.

Safety marking symbols

In manual On product Description

Protective Conductor Terminal

Both direct and alternating current

The Manual

Notes:

• Please follow the installation and operating procedures for a quick, trouble-free
installation and to ensure the maximum accuracy and reliability of your Millpulse 600.

This manual will help you set up your Millpulse 60 0 for optimum performance. We always
welcome suggestions and comments about manual content, design, and accessibility.
Please direct your comments to [e-mail]

For other Siemens Milltronics process protection manuals, go to:
www.siemens.com/processprotection

.

.

WARNING: Millpulse 600 is to be used on ly in th e ma n ner ou tl in e d in

this manual, otherwise protection provided by the equipment may be
impaired.

1.

This warning symbol is used when there is no corresponding caution symbol on the
product.

7ML19985DG02 Milltronics MillPulse 600 – INSTRUCTION MANUAL Page 1

Milltronics Millpulse 600

Milltronics Millpulse 600 is a heavy-duty 2-wire motion sensor that provides a solid state
switch output to a PLC
reciprocating, or conveying equipment.

Milltronics Millpulse 600 has a circuit card and magnet assembly potted in the probe
body and comes complete with mounting flange and locknut. Milltronics Millpulse 60 0 is
connected in series with the PLC input (or other load) and acts as a switch, opening and
closing as the ferrous targets of the machinery being monitored pass in front of the probe.

1

. It is used primarily for monitoring the speed of rotating,

1.

Milltronics Millpulse 600 is designed to work with Programmable Logic Control­lers (PLC) with input characteristics compatible with the electrical portion of the
CENELEC 50040/36/37/38 standards for two wire proximity sensors.

Page 2 Milltronics MillPulse 600 – INSTRUCTION MANUAL 7ML19985DG02

Specifications

Switching Capability

• voltage: 18 to 48 V AC/DC +/-10%, 50/60 Hz (Jumper In)
60 to 135 V AC/DC +/-10%, 50/60 Hz (Jumper Out)

• current 5 to 400 mA continuous
2 A surge for 20 msec at 1 operation per second

Voltage Drop

•8 V

Residual Current

•1.5 mA

Fuse

• 1A, 250 V, SLO-BLO, 4.5 x 14.5 mm (not operator replaceable)

Swi tch Dur ation

• on: 50 msec minimum

• off: 50 msec minimum

Operating Limit

• 600 pulses per minute maximum

Operating Temperature

• -45 to 60 °C (-45 to 140 °F)

Display

• red LED for switch status

Construction

• probe body: aluminum

• process mounting: 2” NPSL

• connection box: aluminum
3/4” NPT conduit entrance
4 screw terminals for maximum 12 AWG wire size

• gasketing: neoprene

7ML19985DG02 Milltronics MillPulse 600 – INSTRUCTION MANUAL Page 3

Environmental

• location: indoor/ outdoor

• altitude: 2000 m (6 562 ft) max.

• ambient temperature: -45 to 60 °C (-45 to 140 °F)

• max. relative humidity: 80%

• enclosure rating: Type 4/NEMA 4, Type 4X/NEMA 4X, Type 6/NEMA 6, IP67

• installation category: II

• pollution degree: 4

Note:

• The use of approved watertight conduit hubs/glands is required for Type 4/NEMA 4,
Type 4X/NEMA 4X, Type 6/NEMA 6, IP67 (outdoor applications).

Weight

• 2 kg (4.4 lbs.)

Approvals

•CE, CSA

• EMC performance available upon request

(C/US)

Page 4 Milltronics MillPulse 600 – INSTRUCTION MANUAL 7ML19985DG02

Installation

WARNING: The probe is highly magnetic. Keep it away from
magnetosensitive materials such as computer discs an d aud io or
video tapes.

Environment

Milltronics Millpulse 600 should be mounted in an area that is within the temperature
range specified and that is suitable to the housing rating and materials. The cap should
be accessible to allow for wiring and viewing if the status display LED is used.

Milltronics Millpulse 600 should be mounted using the supplied mounting flange, onto a
vibration-free structure. The gap between the face of the Milltronics Millpulse 600 and
the target should be sufficient so there is no danger of the target damaging the unit. Refer
to the chart in the
respect to target velocity.

Operation

Note: In climates where direct sunlight may cause the Milltronics Millpulse 600

temperature to rise above the specified limit, shade the unit by installing a sun shield.

Wiring

Note: All wiring must be done by qualified personnel in accordance with all

governing regulations.

section (page 8) for the maximum allowable gap with

Where possible, the probe should be mounted such that the conduit entry is pointing
down to avoid accumulation of condensation in the casing. Where wiring must be run in
conduit, the use of flexible conduit is suggested for easier removal or adjustment of the
probe.

It is advisable to keep the Milltronics Millpulse 600 away from high voltage or current
runs, contactors and SCR drives.

WARNING: Do not connect Milltronics Mill pu l s e 6 00 direc t ly to
supply.

Ensure that the switching current of the PLC input is above the residual current of the
Milltronics Millpulse 600 and that the load resistance presented by the PLC input is low
enough to ensure that the minimum operating current of the Milltronics Millpulse 600 is
exceeded (see Loading graph). If your PLC does not meet the requirements, a resistor

across the PLC inputs can be used to increase the switching current.

Note:

• The protective earth terminal indicated by must be connected to reliable
ground.

7ML19985DG02 Milltronics MillPulse 600 – INSTRUCTION MANUAL Page 5

Interconnection

Operating Voltage:

jumper in

18 to 48 V AC/DC

jumper out

60 to 135 V AC/DC

jumper

fuse

1

2

3

4

Milltronics

Millpulse

600

PLC

input/load

Notes:

• The protective earth terminal indicated by must be connected to reliable
ground.

• All wiring must be done by qualified personnel in accordance with all governing
regulations.

• The equipment must be protected by a 15A fuse or circuit breaker in the building
installation.

• A circuit breaker or switch in the building installation, marked as the disconnect
switch, shall be in close proximity to the equipment and within easy reach of the
operator.

WARNING : All f ield wir ing m ust h ave in sulati on su itable for a t leas t
135 V.

Page 6 Milltronics MillPulse 600 – INSTRUCTION MANUAL 7ML19985DG02

Loading

7ML19985DG02 Milltronics MillPulse 600 – INSTRUCTION MANUAL Page 7

Operation

Milltronics Millpulse 600 works on the principle of Faraday’s Laws of Electromagnetic
Induction. When a ferromagnetic object (target) enters the probe’s permanent magnetic
field, it distorts the flux causing it to cut the coil windings, thereby generating a voltage.
This voltage is proportional to the speed at which the ferrous target passes through the
flux and is inversely proportional to the square of the distance between the target and
the probe.

Square profile targets work better than round because they present a sharper transition
in ferrous mass. Minimizing the gap is more effective than an increase in target size
beyond 5 cm x 5 cm x 2.5 cm (2” x 2” x 1”), except at very low velocities.

The voltage generated from the probe coil is fed to a processing circuit. The processing
circuit controls a semiconductor switch that opens and closes in response to the
incoming pulses. The switch is normally open (LED off) and closes when a pulse is
generated (LED on). The switch duration times are held to a minimum of 50 msec to give
the PLC sufficient time to read the switch states.

The amplifier has been tuned for a response typical to the range of speed encountered in
industrial applications. This response governs the relationship between target speed and
probe to target gap, as demonstrated in the following chart. The resultant curves indicate
the maximum velocity is about 33 cm/sec. (65 ft/min), and with a velocity of 1 cm/sec.
(2 ft/min), a maximum gap of 3.1 cm (1.25”) is possible.

2"x1"x2"

ferrous target

‘A’

2"x2"x1"

ferrous target

‘B’

2"x1"x1"

ferrous target

‘C’

This graph was plotted from tests using four ferrous blocks set equidistant on a 41 cm
(16”) diameter circle on a non-ferrous disc.

Page 8 Milltronics MillPulse 600 – INSTRUCTION MANUAL 7ML19985DG02

Dimensions

10-32 screw, 4 places. Tighten

screws to 1.1 to 1.7 N-m (10 to

15 in-lb) of torque

terminal

block

LED

earth/ground

screw (min M4)

3/4” NPT conduit

entrance

DETAIL “A”

2” NPSL

o.d.

133 mm

(5.25”)

cap,

aluminum,

with LED

window

casing,
aluminum

cap
gasket,
neoprene

95 mm (3.75”) dia.

probe clearance hole

226 mm

(8.9”)

locknut,
plated

casing gasket,
neoprene
mounting flange,
see detail “A”

aluminum probe

197 mm

(7.75”)

127 mm

(5”)

60mm
(2.38”)

2“ NPSL

MOUNTING

6 mm (0.25”) dia. hole
for 1/4-20 bolt on 114
mm (4.5”) BCD, 4 places

6 mm (0.25”) dia. hole
for 1/4-20 bolt or drill
and tap on 114 mm
(4.5”) BCD, 4 places

Note: Install safety shields where required.

7ML19985DG02 Milltronics MillPulse 600 – INSTRUCTION MANUAL Page 9

Application

Bucket Elevators

ferrous buckets less

than 75 mm (3”)

apart

negligible

side travel

non-ferrous buckets
with ferrous bolts or

buckets greater than

75 mm (3”) apart

Milltronics Millpulse 600 side

mounting

Shafts

Milltronics

Millpulse

600

shaft

paddle

Note: Install safety shields where required.

Milltronics Millpulse 600 front or back

mounting

key or keyway

Milltronics

Millpulse 600

shaft

Page 10 Milltronics MillPulse 600 – INSTRUCTION MANUAL 7ML19985DG02

Belt Conveyors

ferrous blocks or
spoked wheel

Screw Convey ors

idler end

Milltronics

Millpulse 600

clearance and

mounting hole,

Dimensions

See

page 9

,

Milltronics

Millpulse

600

Window Detail

Milltronics

Millpulse

600

Milltronics Millpulse 600

mounting

bracket

Milltronics Millpulse 600
with supplied flange and

locknut

conveyor troughing

bracket

window

plate

Install a non-ferrous window for screw conveyors with troughing over 3 mm (0.125”) thick
or for high temperature applications. The dimensions shown for the plate, window, and
bracket are the minimum recommended. Use series 300 stainless steel, brass, or
aluminum. Milltronics Millpulse 60 0 must not touch the plate if temperatures are in
excess of 60 °C (140 °F).

7ML19985DG02 Milltronics MillPulse 600 – INSTRUCTION MANUAL Page 11

Cleaning and Maintenance

Millpulse 600 can be cleaned by wiping the enclosure exterior with a damp cloth. No
other maintenance is required for this device.

Page 12 Milltronics MillPulse 600 – INSTRUCTION MANUAL 7ML19985DG02

Notes

Notes

www.siemens.com/processautomation

Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, ON, Canada K9J 7B1
Tel: [phone] Fax: [phone]
Email: [e-mail]

Siemens Milltronics Process Instruments Inc. 2006
Subject to change without prior notice

*7ml19985DG02*

Printed in Canada

Rev. 2.0