The SiloPatrol® SE Inventory Management
System is the second edition of the industry-leading cable-based
smart sensor system that is designed to handle some of the
harshest and most dynamic conditions. The SiloPatrol SE system
incorporates state-of-the-art sensors, a wide choice of operator
interfaces, auxiliary outputs and displays, as well as unique
remote/vendor managed inventory solutions.
The introduction of SiloPatrol several years ago delivered
the first truly robust sensor design, providing reliable
and high value solutions for a wide variety of applications
and industries worldwide. The second edition SiloPatrol SE
incorporates significant advances in this field-proven approach
to reliably monitoring the level of material in bins, silos
and tanks up to 150ft (45.7m) in height. The SiloPatrol SE
sensor technology is suitable for use with a multiplicity
of powders, granules, slurries and liquids, even in the most
harsh and dynamic conditions.
The heart of the SiloPatrol SE system is the sensor itself.
The second edition sensor, Model SMU (Silo Monitoring Unit),
incorporates technological advancements (Patent Pending),
requires no field adjustments and its robust design provides
virtually maintenance-free operation. The SMU is suited for
most any application and can be equipped with a variety of
mounting flanges and plumb bobs.
The SiloPatrol SE system also offers the most sensor interface
choices:
• RS485 “smart” communications output
• 4-20mA analog output
• AC/DC Pulse output
The “smart” RS485 output version SMU can be
connected with either the multi-functional Human Machine
Interface (HMI) or with SiloTrack™ PC-based Inventory
Management Software that provides a flexible graphical interface
for up to 128 sensors.
If a standalone sensor with analog output and no operator
interface display is what you are looking for, the SMU is
available in this type of configuration at a low purchase
price. The second edition SMU is available as a truly standalone
analog output transmitter, including automatic measurement
initiation and a relay output.
The SMU pulse output sensor is typically used for connecting
into older Monitor Technologies inventory systems. This output
version retrofits and replaces the older CM3A/CM4 sensors
and uses the AC pulse output to connect to the old system
console. The DC pulse output also included with the second
edition SMU pulse output version can be used to connect into
existing PLC systems.
Once a measurement cycle is initiated, the SiloPatrol® SE
sensor (SMU) “smart” motor system controls the
descent of a plumb bob, attached to a heavy-duty stainless
steel cable, into the vessel. The SMU measures the amount of
cable dispensed via its unique optical sensing system. The
SMU’s optic system is completely sealed from the internal
environment of the electronics compartment, which is isolated
and sealed from material ingress in the mechanical compartment,
to ensure long-term reliable operation.
The descent of the bob is maintained at an optimal speed by
the “smart” motor control system, contributing
to the elimination of cable slack and maximizing the motor
life. In conjunction with the unique dual optical sensing system,
the “smart” motor control system guarantees that
the bob will stop when it contacts the material surface and
eliminates the need for a mechanical brake. When the bob reaches
the material surface, the SMU reverses the direction of the
motor and transmits the distance value.
During the ascent of the bob, the SMU measures the amount
of cable gathered and controls the speed of ascent. This ensures
proper cable wrapping in the patented storage reel and tangle-free
operation.
The second edition SMU also includes a patent pending Hall
effect sensor array that monitors the movement and position
of the swing-arm that controls the absorption of slack in the
cable system during descent and ascent. The second edition
SMU is smarter than ever and uses this technology to control
the cable and plumb bob travel to ensure reliability of the
measurement cycle, even with harsh changing conditions in the
most severe applications.
The standalone versions of the SMU generate their respective
4-20mA or Pulse output in response to a measurement query,
or automatically with the analog output version. The standard “smart” RS485
SMU communicates with the operator interface chosen for the
system (HMI or SiloTrack™ PC software).
These operator interfaces can perform calculations and conversions
to display the data in the format desired. The SiloPatrol SE
system, if so equipped, will also generate auxiliary analog
and/or relay outputs. RS485 communications
can be accomplished via hardwiring or with wireless transceivers.
Applications
The SiloPatrol® SE Inventory Management
System can be used in a wide variety of applications. These
include, but are not limited to, simple inventory monitoring
with a standalone HMI display to Remote and Vendor managed
inventory solutions using SiloTrack™ server and client
software to manage inventories at multiple facilities while
providing access to a virtually unlimited number of users.
Materials being monitored include a broad list of powders
and bulk solids, as well as a wide range of liquids and slurries.
These include coarse/fine granular solids, powders, liquids,
foodstuffs and even some sticky or corrosive substances. The
nature of second edition SMU sensor electronics also makes
it ideal for environments with temperature extremes and ambient
temperature variations.
Typical
Applications include, but are not limited to:
Feeds
Bulk
Chemicals
Cement
Plastic
Pellets
Rocks
Coal
Limestone
Liquids
Sand
Powders
Plastic
Regrind
Oils
Grains
REMOTE INVENTORY MONITORING
If material levels need to be monitored at one or many
locations (i.e. your facility, a location down the
street, or a plant on the other side of the world)
the SiloPatrol® SE system can provide accurate
and reliable measurements. Using SiloTrack™ Version
3.5 software, inventory monitoring from remote locations
has never been easier.
WIRELESS
SENSOR COMMUNICATION INTERFACE
While using the SiloPatrol® SE “smart” sensor
is the most economical approach available for inventory
monitoring, using the available wireless interface
in your application may help you reduce the installed
cost of your SiloTrack™ / SiloPatrol SE system
even further.
The wireless transceivers use frequency-hopping spread-spectrum
wireless technology and operate in the FCC license-free
900MHz band. This provides the longest range and most
reliable wireless communications available.
Working in conjunction with SiloTrack™ PC-Based
inventory management software, the wireless transceivers
provide the most functional and economical inventory
management system available today.
Refer to Bulletin 343D for additional information
and contact our technical support personnel today to
see if your application can benefit from the a wireless
communications solution.
Electronic Features
Industry-exclusive use
of magnetic Hall effect sensor technology (patent pending)
monitors swing-arm movement and improves overall application
reliability and performance, even with the most difficult
dynamic conditions
Microcontroller technology
provides “smart” motor control, high resolution/accuracy
and consistent performance under the most challenging
and dynamic conditions
Lock-out input on all
models to restrict sensor from initiating a measurement
cycle (used to disable measurement during filling operations)
Industry-exclusive
electronics certified to international CE 1010 standard ensures compliance in shock hazard protection,
electromagnetic noise interference and generation
Complete electrical
isolation between inputs/outputs and earth ground
eliminates ground loops and ensures proper long-term
operation and data communication
Superior resolution
of 0.01ft (0.12”; 3mm)
Unique optical measuring
system uses an amplification circuit to maximize signal-to-noise performance
Relay output standard
on analog output version provides contact closure based on user set level, sensor failure or measurement
cycle operating
Mechanical
Features
Split-compartment enclosure
completely isolates electronics from mechanical section
of sensor
Industry-exclusive compartment
seals optical sensors from internal SMU environment completely eliminating problems created by contamination,
even from conduits
Industry-first direct-drive
motor and heavy-duty cable system deliver unsurpassed
pull strength
Process seal (wiper seal
mechanism) easily replaced without removing or cutting
cable
Freeze-resistant flange
can eliminate problems in applications where changing
environmental conditions and condensation are present
Patented storage reel
incorporates a "step" to ensure non-tangling
cable wrap
Cable pathway and storage
reel are completely captive, eliminating cable-jump
Wide variety of plumb
bobs available including cast aluminum or SS, standard
plumb bob, SS inverted cone, Teflon coated and digestible
SMU Model Selection
OUTPUT
TYPES Standard "Smart": The SMU communicates
with the HMI or SiloTrack™ PC-based Inventory Management
Software via a RS-485 proprietary
protocol. This type of system can also be equipped with
auxiliary relay and/or analog outputs and remote displays.
Analog
4-20mA: This SMU sensor is a standalone transmitter
version providing a direct analog signal for each measurement
update. Measurements are initiated automatically as setup
within the sensor or in response to a remotely activated
contact closure. This sensor version is provided with a relay
output that can be set to activate when a user established
level is reached, upon detection of a sensor error or when
a measurement cycle is in process.
Pulse (retrofit):
This SMU version generates AC or DC pulses in response to
a request for a measurement from a contact input. This output
can be used to provide direct input into a PLC or to integrate
into an older Monitor Technologies Model CM console when replacing
the old Model CM-3A or CM-4 sensors. The SMU provides only
a 1/10’ or dm pulse output. This sensor version is provided
with a relay output that indicates when a measurement cycle
is in process.
APPROVALS
The SiloPatrol® SE Model SMU sensor is available certified
for either Ordinary or Hazardous locations. The SMU also
carries the CE Mark. Consult the Specifications section for
further information.
FREEZE-RESISTANT MOUNTING
FLANGES
SMU sensors can be provided with either the standard flat
mounting flange or one of the angled flanges (5° and 10° available)
for adapting to sloped roofs. Each of these standard flanges
has a unique design that resists freezing of the plumb bob
to the underside of the flange. This is especially important
in very cold climate conditions where moisture from condensation
within the silo can form and create ice on the underside of
the silo roof, usually due to cycling above and below freezing
temperature in an outdoor installation. In these applications
the freeze-resistant flange may eliminate the need for standpipe
or flange heating. Contact the factory for modified ANSI/DIN
flanges (not “freeze resistant”).
SMU Accessories
Dimensions
are shown in inches with millimeter equivalent in brackets
Standard
Cast Aluminum - Most SMU sensors are shipped
with this plumb bob assembled to the unit. For use
with bulk solids with a bulk density greater than
20lbs/ft3 (320kg/m3). A Teflon® coated version
is also available for sticky materials.
316
Stainless Steel - For use with corrosive solids
and foodstuffs with bulk densities greater than 20lbs/ft3
(320kg/m3). This plumb bob is typically shipped as
a separate item, but can be assembled to the SMU at
the factory upon request.
316
SS Inverted Cone - For use with light bulk
solids and foodstuffs with bulk densities greater
than 5lbs/ft3 (80kg/m3). Teflon®-coated also
available for corrosive or sticky materials. This
is shipped as a separate line item and must be attached
to the cable in the field.
6 in
(152 mm) Diameter 316 SS Ball Float: For
use with liquids with a minimum specific gravity of
0.85. A Teflon®-coated version is also available
for corrosive or sticky materials. This plumb bob is
shipped as a separate line item and must be attached
to the cable in the field.
HMI Features
Multi-functional HMI controls
SMU “smart” output sensor operation,
auxiliary output activation (if equipped), displays measured
and calculated data and performs/displays system and
sensor diagnostic messages
Industry-exclusive electronics
certified to stringent international CE 1010 standards
to ensure worldwide compliance in shock hazard protection, electromagnetic noise interference and generation
Unique back-lit display
ensures visibility in any environment
Environmentally hardened
NEMA 4 enclosure with ambient temperature limits down to –4°F/-20°C
Automatic, Manual or Auto/Manual
operating modes
With data input from the
user, HMI can calculate and display values for level, volume,
weight and percent (See "Use of Volume/Weight Calculations")
Flexible display of data
in English or Metric units including feet, meters, pounds,
kilograms, cubic feet, cubic meters, U.S./British bushels,
gallons, liters, tons, metric tonnes
Displays 12-character alphanumeric
name for vessel contents
HMI Operating Modes
MANUAL
MODE
The HMI is easily programmed to display calculated level, volume,
weight or percent in addition to the basic distance measurement.
Manual readings are taken by depressing the MEAS button, followed
by the channel number, followed by ENTER.
AUTOMATIC
MODE
The HMI can also be programmed to operate the SMU “smart” output
sensors automatically. Menu options allow the user to select
days of operation (such as Mon.-Fri.), time window (such as
7 a.m.-3 p.m.) and measurement interval (minimum 30 minutes).
HMI Model Selections
APPROVALS
The HMI is designed for Ordinary Locations. The HMI also carries
the CE Mark.
NUMBER
OF CHANNELS
The HMI is available in 2-, 8- or 16-channel configurations.
The individually addressable SMU “smart” output
sensors are wired to the HMI using a single RS-485 network
cable. Multiple SMU “smart” output sensors (up
to a maximum of 16) can be connected to the HMI using a single
RS-485 network cable.
PC-Based Inventory Management Software
SiloTrack™ Version
3.5 Inventory Management Software provides users with
an unsurpassed, flexible graphical interface for SiloPatrol® SE “smart” output
sensors. Together, SiloTrack Server and Client software
can provide inventory monitoring and management to a
virtually unlimited number of users, both internal and
external to your facility. This allows easy implementation
of remote monitoring and vendor managed inventory programs.
SiloTrack capabilities
include:
Monitor up to 128 sensors/with up to
5 sensors per vessel
Easy
to setup and use
Network
capable
Remote
monitoring via LAN, Internet/WAN or dial-up
The SiloPatrol® SE Model SMU sensor makes
a direct measurement of the distance between the sensor and
the material surface. This equipment does not measure the volume
or weight of the material within the vessel. The HMI and SiloTrack™ PC-based
software, when used with a SiloPatrol
SE “smart” output sensor, may be able to perform
calculations to display the volume and weight of the material.
These calculations are based upon the distance measurement
and the vessel dimensions and material bulk density entered
by the user during setup.
Note: The calculated volume and weight values should be considered "estimates".
Monitor Technologies LLC accepts no responsibility for the
accuracy of the calculated and displayed volume and weight
values. The accuracy (not stated or warranted) of the volume/weight
calculations are effected by the fluctuation and accuracy of
various factors. These factors include, but may not be limited
to, actual vessel dimensions, sensor mounting location, angle
of repose (negative and positive), material bulk density, material
flow properties (ratholes, bridging, etc.), material inlet/discharge
locations and material packing. Please consult the factory
to discuss applications where volume/weight is of critical
importance.
System Accessories
AUXILIARY
OUTPUT ENCLOSURES (AOE)
A unique feature of the SiloPatrol® SE Inventory
Management System is the ability to incorporate both relay
and analog outputs with a standard "smart" output
sensor system. These auxiliary relay and/or analog outputs
are provided in Auxiliary Output Enclosures (AOE) and are
programmed and controlled by either the HMI or SiloTrack™ PC-based
Inventory Management Software.
One analog output and up to four relays (two for HMI;
four for SiloTrack) can be assigned to each of the “smart” output
sensors. These can be used to tie the Inventory Management
System into remote control systems, sound alarms and for
local control functions.
Up to 16 analog outputs or 32 relays can be provided within
a single enclosure. Up to four AOE’s can be connected
on a single network. The AOE can be located close to the
point of hardwiring termination minimizing wiring and installation
costs.
2-Card
AOE
REMOTE
DISPLAY UNIT (RDU)
SiloPatrol® SE
systems using the standard "smart" SMU can
be provided with Remote Display Units (RDU). These units
have the same display capability as the HMI. They, however,
can not be used to initiate any measurements. They are
identical to the HMI in specification and appearance.
User setup is required in order to view the data in the
desired units of measure. A maximum combination of four
AOE’s and RDU’s can be connected on each
network.
Specifications
SILO MONITORING UNIT
(SMU)
Power Requirements:
115 VAC or 230 VAC, 50/60 Hz
Power Consumption:
6 VA continuous, 50 VA intermittent
Altitude:
6562ft (2000m) maximum
Installation Category:
II
Pollution Degree:
4 (reduced to 2 via enclosure), Suitable for
indoor/outdoor use
Process Temperature:
-40° F to 300° F (-40° C to 149° C)
Ambient Operating Temperature:
-40° to +150°F (-40° to
65°C)
Maximum Internal
Bin Temperature:
Up to 300°F (149°C) with
use of bare stainless steel cable
Up to 200°F (93°C) with use of stainless steel jacketed cables
Measurement Range:
150 feet maximum (45.7 m)
Measurement Rate:
1.0 ft./sec. (typical) (0.3 m/s)
Accuracy:
+/- 0.25% of distance reading
Repeatability:
0.1 ft. (30 mm)
Resolution:
1/100 ft. (0.12 inch; 3mm)
Mounting:
Freeze-Resistant "K" flange, 8" dia.
with 7" bolt
circle
2-lines by 20-characters, 0.22"
x 0.12" characters, LCD backlight
Keypad:
20 keys
Indicators:
8 LEDs (function, relay, and error
status)
Enclosure (HxWxD):
Painted aluminum
6.29 x 10.23 x 3.54 in
(160 X 260 X 90 mm)
Enclosure Rating:
NEMA 4; IP66
Approvals:
CE Mark
Teflon® is a registered trademark of Dupont Chemical Co.
Windows® is a registered trademarks of
the Microsoft Corporation
RSView® is a registered trademark of Rockwell Automation
Wonderware® is a registered trademark of Wonderware Corporation
Intellution® is a registered trademark of Intellution,
Inc.
Cimplicity® is a registered trademark of General Electric
Company
Warranty
Monitor Technologies LLC warrants
each SiloPatrol® SE Inventory Management System it manufactures
to be free from defects in material and workmanship under normal
use and service for two (2) years from the date of purchase.
The purchaser must notify Monitor of any defects within the
warranty period, return the product intact, and prepay transportation
charges. The obligation of Monitor Technologies LLC under this
warranty is limited to repair or replacement at its factory.
This warranty does not apply to any product which is repaired
or altered outside of Monitor Technologies’ factory,
or which has been subject to misuse, negligence, accident,
incorrect wiring by others, or improper installation. Monitor
Technologies LLC reserves the right to change the design and/or
specifications without prior notice.
343A.12.1206
Global Flour Processor Uses Flexar® Guided Wave Radar
A large global flour processor and food products company recently began using the Flexar® guided wave radar in a total of eighteen (18) silos and bins to manage their finished product inventory. Readings from these continuous level sensors is reported as being reliable and accurate, even during pneumatic filling, contrary to their previous measuring system. A previous non-performing ultrasonic system was replaced by the Flexar level sensors. Flexar guided wave radar level sensors were chosen as the best for pneumatically filled dust laden flour silos.
Eight (8) Flexar level sensors are installed in load-out silos that fill bulk trucks with processed and finished flour. These silos are 12ft in diameter and 35ft tall. The finished flour is pneumatically conveyed into these silos. During filling the internal environment of the silos is very dusty and turbulent. The finished flour in these silos is used for loading bulk transport trucks for distribution. In addition, ten (10) Flexar level sensors are installed in 40ft high bins that contain bran. This material is also sent by bulk transport to end users.
All of the Flexar level sensors are equipped with an RS485 digital communications output that is connected to a PC with a graphical user interface for inventory management purposes. Monitor’s SiloTrack™ inventory management software is used by the facility to monitor and manage material inventories of both the finished flour and the bran. SiloTrack allows for multiple user viewing and data access via LAN and this is how the facility will be using the software that provides a flexible, graphical user interface, alarms, report generation and history analysis functions.
Guided wave radar is especially well suited to level measurement applications of dusty powder materials even when measuring during pneumatic filling. Flexar guided wave radar utilizes TDR (time domain reflectometry) technology. Radar pulses are continuously transmitted down the sensor’s probe and guided to the material surface where they are reflected back to the electronics along the wave guide. The time-of-flight of the pulses is measured and directly related to the distance to the material surface and its level.
SiloTrack™ Version
3.5 Inventory Management Software provides users with
an unsurpassed, flexible graphical interface for SiloPatrol® SE “smart” output
sensors. Together, SiloTrack Server and Client software
can provide inventory monitoring and management to a
virtually unlimited number of users, both internal and
external to your facility. This allows easy implementation
of remote monitoring and vendor managed inventory programs.
SiloPatrol® SE
systems using the standard "smart" SMU can
be provided with Remote Display Units (RDU). These units
have the same display capability as the HMI. They, however,
can not be used to initiate any measurements. They are
identical to the HMI in specification and appearance.
User setup is required in order to view the data in the
desired units of measure. A maximum combination of four
AOE’s and RDU’s can be connected on each
network.
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