MM-245
Installation, Operation and Maintenance Instructions
®
METAL DETECTOR MA3600 Series
ERIEZ MAGNETICS
HEADQUARTERS: 2200 ASBURY ASBURY ROAD, P.O. BOX 10608, ERIE, PA 16514–0608
U.S.A.
WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC, VIBRATORY and INSPECTION APPLICATIONS
1
Introduction This manual details the proper steps for installing, operating and maintaining the Eriez ® Metal Detector models identified on the cover. Careful attention to these requirements will assure the most efficient and dependable performance of this equipment. If there are any questions or comments about the manual, please call Eriez at 814/835-6000 for Metal Detector assistance.
CAUTION: Safety labels must be affixed to this product. Should the the safety label(s) label(s) be damaged, damaged, dislodged or removed, contact Eriez for replacement. replacement.
©
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2009 ERIEZ MAGNETICS
ALL RIGHTS RESERVED
Table of Contents ERIEZ METAL DETECTOR - MA3600 SERIES INTRODUCTIO INTRODUCTION N .......................... ....................................... .......................... .......................... ......................... ......................... ...................... ......... 5 INSTALLA INSTALLATION TION ....................... ........... ....................... ...................... ...................... ...................... ....................... ....................... ...................... ............. 6 Control Control Unit.......................... ....................................... ......................... ......................... .......................... .......................... ........................ ........... 6 Gland Plate .......................... ....................................... ......................... ......................... .......................... .......................... ........................ ........... 7 DIN Rail Components Components......................... ...................................... .......................... ......................... ......................... ...................... ......... 8 Power Supply Connection ...................... ........... ...................... ...................... ....................... ....................... ..................... .......... 9 'Clip-On' 'Clip-On' Ferrites Ferrites ......................... ...................................... .......................... .......................... .......................... ..........................10 .............10 Search Coil Mounting ...................... ........... ....................... ....................... ...................... ...................... ...................... ................ ..... 11 MA3600 HAWK Search Coil ...................... ........... ...................... ...................... ...................... ....................... .................. ...... 11 MA3600 EAGLE Search Coil ....................... ........... ....................... ...................... ...................... ...................... ................ ..... 15 Transmitter & Receiver Cables...................... .......... ....................... ...................... ...................... ...................... .............. ... 16 PCB CONTROLS & CONNECTIONS CONNECTIONS ...................... ........... ...................... ....................... ....................... ..................... .......... 17 Connector Descriptions ...................... ........... ...................... ....................... ....................... ...................... ...................... ............. 19 PCB Controls Controls ......................... ...................................... .......................... .......................... ......................... ......................... .................... ....... 21 WIRING TO THE CONVEYOR MOTOR MOTOR CONTACTOR CONTACTOR ..................... .......... ....................... .................. ...... 25 Auxiliary Relay Wiring...................... ........... ....................... ....................... ...................... ...................... ...................... ................ ..... 25 BELT BELT CLIP DETECTOR OPTION ....................... ........... ....................... ...................... ...................... ...................... ................ ..... 26 Single Belt Clip Sensor...................... ........... ....................... ....................... ...................... ...................... ...................... .............. ... 27 Dual Belt Clip Sensors ...................... ........... ....................... ....................... ...................... ...................... ...................... .............. ... 29 Earthing of Associated Equipment when Frequency Inverter Speed Speed Controls are are being used ..................... .......... ...................... .............. ... 31 TROUBLESHOO TROUBLESHOOTING TING ........................ ..................................... .......................... .......................... .......................... ..........................33 .............33 SUGGESTIONS FOR TROULBE SHOOTING ENVIRONMENTAL ENVIRONMENTAL INTERFERENCE INTERFERENCE ......................... ...................................... .......................... .......................... ......................... ......................... .................... ....... 33 Movement Movement of Metal.............. Metal........................... ......................... ......................... .......................... .......................... ...................... ......... 33 Intermittent Loops of Metal Surrounding Surrounding The Sensor ...................... ........... ..................... .......... 33 Excessive Line Voltage Fluctuations ....................... ............ ...................... ...................... ...................... .............. ... 34 Proximity of Severe RF Radiation Source ...................... ........... ...................... ....................... .................. ...... 34 PARTS LIST ........................ ..................................... .......................... .......................... .......................... .......................... .......................... ............... .. 35 MA3600 Electronic Assembly Parts List............ ....................... ........... ....................... ................... ........ 36 MA3600 PCB Change Change ......................... ...................................... .......................... ......................... ......................... .................... ....... 37 TECHNICAL DAT DATA ..................... .......... ...................... ....................... ....................... ...................... ...................... ...................... ................ ..... 38 CONTROL PANEL DIMENSIONS ....................... ........... ....................... ...................... ...................... ...................... .............. ... 39 DECLARATION DECLARATION OF CONFORMITY ...................... ........... ....................... ....................... ...................... ...................... ............. 40
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Safety Notice • This system is inte nded for permanent connection and can only be completely isolated when mains power is disconnected from the unit. unit. This equipment is not fitted with an isolator or switch to disconnect the mains power supply. • To ensure that the installation conforms to electrical safety regulations, a switch or circuit breaker must be fitted to the mains power supply prior prior to the control unit. It should be in close proximity to the equipment and within easy reach of the operator. operator. It should also be marked as the disconnecting device for the equipment. • Extreme care must be taken when the control panel door is opened if power has not been disconnect ed. Ensure mains power is disconnected from the unit before wiring to any terminals inside the control panel.
WARNING Do not rely on the latched mode to inhibit a reject device or conveyor belt. The latched mode could be reset by a spike on the mains supply or other event (i.e. lightning). Disconnect the mains supply to the metal detector and reject device before working in, on or around the reject device. Also disconnect any air or hydraulic lines and relieve any remaining pressure in the lines before servicing the reject device.
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• The usual setup procedure does not require the operator to remove the internal panel. However, However, if instructed to do so, ensure only the specified part is handled handled using the correct tool. tool. Always switch the mains power off if instructed to insert a link on the printed circuit board, or changing any component within the control panel. • When lifting this unit without mechanical aid, please ensure that all relevant health & safety measures are followed with regard to safe working practices and all other manual handling operations regulations. • To comply with regulations, please make sure that the ‘clip-on’ ferrites are fitted to the cables as instructed in this document.
LONG TERM STORAGE • There are no implications for keeping the system in long term storage. However, it is strongly recommended that the system is kept in vacuum sealed bags to prevent any moisture ingress due to varying ambient temperatures. • Note that the diagrams used within this document are for illustration purposes only and actual installation environments may differ from those shown.
Observe all safety and warning labels.
Introduction BAG DROPPER (OPTIONAL ACCESSORY)
MA3600 HAWK SENSOR COIL
MA3600 CONTROL UNIT WITH OPTIONAL HORN/BEACON WARNING DEVICE FITTED
EXAMPLE CONVEYOR SYSTEM
FIGURE 1
The METALARM (MA)3600 Metal Detector , consists of a control unit (in a NEMA 4 enclosure), one or more sensor coils (dependent upon the application) and optional accessories such as a bag dropper. The optional QUARRYMASTER version for the control is constructed from stainless steel and fitted with an anti-condensation heater for frost protection.
IMPORTANT: When
a detect signal is sent from the MA3600 Metal Detector, there may be more than one piece of metal contamination within the product stream. Always search the product thoroughly in between the point where the conveyor belt stops and the leading edge of the sensor coil assembly.
The following instructions pertain to the installation and operation of the Model 3600 Metal Detector and Control. The MA3600 is used to detect all types of metals within the product stream that are conveyed through it. The size of metal that can be detected can be adjusted via user controls in the control panel, though it is also a function of the size of the aperture opening of the sensor coil assembly; a coil with a small aperture or coil spacing is capable of detecting smaller pieces of metal than a system with a larger coil aperture or coil spacing.
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Installation Control Unit
The control panel should be mounted to a wall or rigid frame (not provided).
MOUNTING STUDS FOR OPTIONAL ALARM
Locate the control unit no closer than 10 ft. (3 meters) to the sensor coil and no more than the supplied sensor cable length away. Preplan routing of cables before deciding where to mount control. Route receiver and transmitter cables so that they are spaced at least 6 inches apart and can be secured to a frame or run in conduit for protection.
CONTROL WEIGHT 22LBS (10KG)
The MA3600 control unit is supplied with insulating mounting brackets. DO NOT remove or replace the mounting brackets, as these are provided to electrically isolate the control unit from the metal conveyor framework. Similarly no other metal work should be in contact with the metal of the control unit case. Hole diameter is 0.433 inch (11mm)
GLAND PLATE
POWER/FAULT INDICATOR (GREEN)
The control unit has an external electrical earth point which is required in certain environments.
EXTERNAL EARTH STUD
DETECT INDICATOR RESET BUTTON (RED)
Allow adequate clearance below the control unit enclosure for cable entry and exit.
EXAMPLE MOUNTING FRAME
SECURE TO FLOOR
FIGURE 2
Failure to comply with the above mounting procedures will invalidate the 'CE' certificate covering the EMC regulations.
6
Installation
(cont.)
Gland Plate
The MA3600 control panel has a gland plate through which all cable interconnections are made. It is pre-fitted with four cable glands (comprising of one 0.787 inch (M20) and three 0.629 inch (M16) sized glands) and an M16 blanking plug.
If it is necessary to add more glands, then undo the screws & remove the plate before drilling.
POWER CABLE GLAND
Do not terminate the shield protection of any cables to the control box; always leave a 0.5 in.(12mm) air gap between the two. This also applies to electrical conduit.
Do not remove bungs from unused glands - to maintain ingress protection level.
BLANKING PLUG
RX CABLE GLAND
0.5 IN. (12MM) AIR GAP
GLAND COVER (SECTION VIEW)
CABLE SHIELD
MAINS POWER CABLE 115/230VAC
FIGURE 4 TX CABLE GLAND
RX CABLE TX CABLE Remove bungs to use cable glands.
Turn gland shell in a clockwise direction to tighten against the cable.
FIGURE 3
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Installation
(cont.)
DIN Rail Components
Connections required for the power supply to the MA3600 metal detector and the standard ‘detect’ & ‘fault’ output signals are made via terminals and devices mounted on a DIN rail inside the control panel.
DETECT RELAY
FAULT RELAY
END STOP
Note: Pre-wired connections are not shown for clarity.
POWER INDICATOR NORMALLY CLOSED CONTACTS
DIN RAIL
NORMALLY OPEN CONTACTS COMMON CONTACTS
EARTH TERMINAL (GREEN/YELLOW)
FUSED LIVE (L1) INPUT TERMINAL (BEIGE)
NEUTRAL (L2) TERMINAL (BLUE)
FIGURE 5
NC 12 COM 11
NO 14 NC 22
COM 21 NO 24
Note: Any supplies connected to external equipment via the relay contacts must be appropriately rated and independently fused. DO NOT connect the power supply for the metal detector to the relay contacts.
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PSU MODULE 100-240VAC 1.0A
The ‘Detect’ & ‘Fault’ relays have two sets of voltfree contacts each. These can be used as part of a belt stop function or to activate another piece of equipment in the process. They can be configured to activate under certain conditions other than just their own respective signals. See PCB controls. TERMINAL
DESCRIPTION
11/21 14/24 12/22
COMMON NORMALLY OPEN NORMALLY CLOSED
CONTACT RATING: 8A, 250VAC
Installation Power Supply Connection
The connection of the power supply to the metal detector is made via the terminals located on the left hand side of the DIN rail.
(cont.)
In option 2, the live (L1) connection is made to the beige colored terminal, and as can be seen, there is an extra fused terminal (F4) for the heater and an additional neutral (L2) terminal (blue).
There are two configurations of the PSU connection terminals available dependant on whether the control unit is fitted with an anti condensation heater. In option 1, the live (L1) connection is made directly to the fused terminal (F3). To access the fuse, lift up the lever arm as shown. The fuse is rated at 1amp. See Spare Parts List for description.
(F4) FUSE FOR HEATER
(F4) FUSE FOR PSU MODULE
(F3) FUSED LIVE (L1) INPUT TERMINAL (BEIGE)
EARTH TERMINAL (GREEN/YELLOW)
EARTH TERMINAL (GREEN/YELLOW)
LIVE (L1) INPUT TERMINAL (BEIGE) NEUTRAL (L2) TERMINAL (BLUE)
LIFT LEVER FOR FUSE ACCESS.
LIFT LEVER FOR FUSE ACCESS. NEUTRAL (L2) TERMINAL (BLUE)
FIGURE 7 DIN TERMINALS OPTION 2 WITH HEATER FITTED
FIGURE 6 DIN RAIL TERMINALS OPTONS 1 (DEFAULT) NO HEATER FITTED
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Installation This equipment is intended for permanent connection and is not fitted with an isolator or switch to disconnect the mains power supply. To ensure that the installation conforms to electrical safety regulations a switch or circuit breaker must be fitted. It should be in close proximity to the equipment and within easy reach of the operator. It should also be marked as the disconnecting device for the equiment.
(cont.)
‘Clip-on’ Ferrites
To ensure that the system complies with EMC regulations, clip on ferrites must be fitted to the sensor & power cables. To fit the ferrites supplied with the metal detector, follow the steps outlined below. See section 2.2.3 ‘Transmitter & Receiver cables’ for the required locations of the ferrites on the cables. FIGURE 9
OPEN THE FERRITE CASE BY INSERTING THE KEY INTO THE SLOTS AS SHOWN
FIT FERRITES TO CABLES - BELOW GLANDS
POWER SUPPLY CABLE TO DETECTOR
LOOP THE CABLE THROUGH BOTH HALVES OF THE FERRITE CORE
NAME PLATE ISOLATOR SWITCH (REQUIRED, CUSTOMER SUPPLIED)
FIGURE 8
OPTIONAL MAINS FILTER
The diagram shows the control panel connected to the incoming mains power supply via an optional filter unit.
10
CLOSE THE CASING UNTIL IT LOCKS INTO POSITION
Installation
(cont.)
Search Coil Mounting
The following instructions give details of how to install the ‘Hawk’ and ‘Eagle’ search coils supplied as part of the Metalarm Metal Detector.
REMOVE THE METAL COVERS
While the ‘Hawk’ search coil is used for illustration purposes, the installation guidelines below apply to both types of search coil and must be rigorously adhered to ensure correct and trouble free operation.
REPLACE GUARD RAIL WITH NONMETALLIC
REMOVE HEAVY DUTY CABLING AWAY FROM DETECTOR
FIGURE 10 MA3600 HAWK Search Coil
A) Locate a suitable position in the conveyor mid way between two idler sets where: 1. Any metal covers or base plates can be removed or replaced by non metallic alternatives for the entire metal free area required by the detector. 2. There is not a joint in the conveyor frame. 3. Metal, when detected can easily be removed from the conveyor belt. 4. The search coil should be mounted on the conveyor frame so that the coil connector is on the opposite side of the conveyor frame from any mains cables. 5. There is no moving metal in the vicinity.
7. The total distance required between adjacent idler sets can be calculated from D+2xH. Where H is the aperture height and D is the depth of the search coil. If this distance becomes too great for the belt to span without significant sagging, then it may be necessary to install nonmetallic carry idler sets. The detector requires a completely metal free area of D+H. Metal is allowed outside of this zone in the ‘non-moving metal area’ but it must be secured in position and unable to move. Note that there are different minimum metal free areas for the HAWK & EAGLE types of search coil. Use the minimum specified distance when the calculated distance is less than this figure.
6. There will not be a return idler or cross piece beneath the search coil. 11
Installation MINIMUM
METAL FREE AREA
NON-MOVING METAL AREA
HAWK
D+600mm (24”)
D+900mm (36”)
EAGLE
D+1000mm (40”)
D+1200mm (48”)
CARRY IDLER
NON-MOVING METAL AREA ½H
METAL FREE AREA = D + H
(cont.)
NON-MOVING METAL AREA ½H
CARRY IDLER
D H
C L
REMOVE RETURN IDLER
FIGURE 11
TRANSMITTER COIL FLAT HEAD BOLT (M10X50)
Assemble the lower coil on the side supports & place on the conveyor frame at the chosen position. WARNING: Before drilling into coil structure, make sure there are no wires or coil connections on the opposite side of the drilling surface.
SIDE SUPPORT
Hardware supplied with metal detector. END SUPPORT
FIGURE 12
12
Installation
(cont.)
PRODUCT/BURDEN
CONVEYOR BELT
MINIMUM AIR GAP
CUT OUT INDICATED AREAS TO LOWER THE COIL IF NECESSARY
MOUNTING BRACKETS
FIGURE 13
C. There should be an absolute minimum of 1 inch (25mm) gap between the underneath of the (fully loaded) conveyor belt and the top of the bottom coil. If not, cut out notches in the bottom of the search coil at all four corners to lower the search coil within the conveyor frame, while making sure that the burden does not collide with the top coil (HAWK ONLY).
D) Brackets to hold the search coil to the conveyor frame (not supplied) should be fitted to the coil to secure it to the conveyor stringers. E) Fit top search coil section and bolt down.
TOP COIL ASSEMBLY
CONVEYOR STRINGER
FIGURE 14
13
Installation
(cont.)
F) The adjacent idler sets on either side of the search coil should be tack welded, ¼˝ wide, once at each of the four corners to the conveyor frame. WELD
WELD
FIGURE 15 WELD
WELD
METAL FLOOR
WELD
FIGURE 16
Also weld all other metal-metal joints in the conveyor structure around the detector search coil. This will eliminate the possibility of false detection signals due to intermittent earth loop contacts around the sensor coil.
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Important: Make sure both search coils are disconnected & the control panel switched off before carrying out any welding on the conveyor structure. The metal detector is a sensitive electronic device which may become damaged if this advice is not followed.
Installation MA3600 EAGLE Search Coil
(cont.)
Once the vertical supports are in position, then fix the transmitter (upper) coil into position.
To prepare the chosen location for the search coil on the conveyor, please follow the instructions for the ‘Hawk’ search coil as described in the previous section.
Important: Do not adjust or remove any of the parts that are already present on the transmitter coil assembly, as this could affect the performance of the detector.
To assemble the ‘Eagle’ search coil, using the provided components, clamp the four vertical support bars into position on the receiver (lower) coil assembly.
Note: Depending on the location of the search coil, it may be necessary to position the receiver coil assembly on to the conveyor before attaching the vertical support bars.
TRANSMITTER COIL ASSEMBLY DO NOT REMOVE ANY PARTS
NUT
LOCK WASHER PLAIN WASHER
FIGURE 17 RECEIVER COIL ASSEMBLY VERTICAL SUPPORT BAR
NUT LOCK WASHER PLAIN WASHER PLAIN WASHER BOLT ASSEMBLED EAGLE SENSOR COIL
FIGURE 18 INSULATED MOUTING FEET (DO NOT REMOVE) MOUNTING HOLE IS 0.375" (10)MM
15
Installation
(cont.)
Transmitter & Receiver Cables
The transmitter & receiver coil cables should not touch each other & should be separated by at least 1˝ (25mm) along their length. They should also be secured so that they can not move. FIT CLIP-ON FERRITE BELOW CONNECTOR
SECURE CABLE
They must be run separately away from any power cables or transmission lines and must not be spliced, joined or extended. FIT CLIP-0N FERRITES BELOW CABLE GLANDS
RX CONNECTOR (HAWK) TWIST TO SECURE IN SOCKET
TX CONNECTOR (HAWK) TWIST TO SECURE IN SOCKET
NO OTHER CABLES IN PROXIMITY TO TX/RX CABLES
FIGURE 19
FIT CLIP-ON FERRITE BELOW CONNECTOR
MAKE SURE THAT TX & RX CABLES ARE SEPARATED & SECURED ALONG THEIR LENGTH
TX CONNECTOR (EAGLE) TWIST TO SECURE IN SOCKET. FIT CLIP-ON FERRITE BEHIND CONNECTOR
SECURE CABLE
RX CONNECTOR (EAGLE) TWIST TO SECURE IN SOCKET. FIT CLIP-ON FERRITE BEHIND CONNECTOR
FIGURE 20 16
PCB Controls & Connections The majority of the controls for the MA3600 Metal Detector are found on the PCB inside the control panel enclosure. Some connections are also made directly to the PCB. To gain access to the controls mounted on the PCB, undo the quick release fasteners holding the face panel, then slide forwards over the controls. QUICK RELEASE FASTENERS FACE PANEL OPERATIONAL STATUS INDICATOR LEDS METAL SIGNAL LEVEL DISPLAY
SW3 RESET MODE SELECTOR
EARTH TAB TB1 TRANSMITTER COIL CONNECTOR TB7 DOOR MOUNTED CONTROLS CONNECTOR
TB2 DC POWER INPUT F1 FUSE 315mA CON1 OPTIONAL ACCESSORY TERMINAL CONNECTOR F2 FUSE 315mA
SW2 SW1 FINE SENSITIVITY CONTROLS
TB3 RELAY CONNECTOR TB4 EXTERNAL RESET & ALARM CONNECTOR TB5 SENSOR COIL TUNING CARD CONNECTOR TB6 RECEIVER COIL CONNECTOR
FIGURE 22
17
PCB Controls & Connections J6 SINGLE/TWIN PEAK DETECTION MODE SELECTOR SW8 RELAY FUNCTION SELECTOR SW7 BELT SPEED SELECTOR
ANALOG GUARD TP12 VTRIP
S W 2 POT1, 2 OUTPUT TIMING CONTROLS
S W 5
SW9.1, 2 RELAY OUTPUT POLARITY SELECTOR
S W 1 S W 4
SW9.3 SWING TOP COIL OR HIGH BURDEN DETECTOR OPTION SELECTOR
POT4 FILTER CLOCK CONTROL POT3 THRESHOLD VTRIP ADJUSTMENT COARSE SENSITIVITY CONTROLS
U2, U22 MICROCONTROLLERS SW6 FREQUENCY PROGRAM SELECTOR
FIGURE 23
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Connector Descriptions NAME DESCRIPTION
NAME DESCRIPTION
EARTH TAB PCB Connection to control panel star point.
TB6
TB1
Pin 1 Pin 2 Pin 3 TB2
Transmitter Coil (see Figure 24) transmitter cable connection. C1 (center conducter 1) Brown Cable shield Black C2 (center conducter 2) White
Pin 1 Pin 2
DC power input from PSU module (pre-wired). (See Figure 24) ‘-‘ 0VDC Black ‘+’ 15VDC Red
TB3 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6
Relay connector. 12VDC DETECT RELAY Red 0VDC COMMON Black 12VDC FAULT RELAY Red 0VDC COMMON Black 12VDC HEALTHY RELAY (option) Red 0VDC COMMON (option) Black
TB4
External reset & alarm connector. (See Figure 25)
Pin 1 Pin 2 Pin 3
Search coil receiver cable connection. (See Figure 25) C1 (center conductor 1) Cable shield C2 (center conductor 2)
TB7
Door mounted controls connector. Pin 1 POWER LED 12VDC CORE (1) Pin 2 0VDC COMMON CORE (2) Pin 3 DETECT LED 12VDC CORE (3) Pin 4 0VDC COMMON CORE (4) Pin 5 12VDC RESET BUTTON CORE (5) Pin 6 SIGNAL RESET BUTTON CORE (6) Pin 7 Not connected Pin 8 counter module (option) 12VDC Pin 9 counter module backlight (option) 12VDC Pin 10 Counter reset (option) Pin 11 Counter detect input (option) Pin 12 0VDC COMMON
FIGURE 24 PIN 1
If required, a ‘volt-free’ contact can be connected to reset the metal detector from a remote location. Contact factory for maximum cable length.
EARTH TAB
The optional factory fitted 12VDC siren/beacon is connected to this terminal block also.
WHITE
Pin 1 Pin 2 Pin 3 Pin 4
External reset connection 1 (volt-free) External reset connection 2 (volt free) ‘+’ 12VDC ALARM (option) ‘-‘ 0VDC COMMON
TB5
Sensor coil tuning card connector (RX PCB). (See Figure 25)
A small PCB required to calibrate the sensor may be fitted in this location. Do not remove except when replacing the electronic assembly.
Brown Black White
TB1
TB2
BROWN BLACK
TX CABLE
TB4
TB5
TB6
FIGURE 25 BROWN BLACK WHITE RX CABLE
19
Connector Descriptions
(cont.)
CON1 Optional Accessory Connector
In the event auxiliary devices are connected to the metal detector, the option terminal block will be fitted to the DIN rail. This is connected to the detector PCB via a ribbon cable to CON1.
RIBBON CABLE TO CON1
It is required for the connection of the Belt Clip Sensor, High Burden Detector, Swing Away Coil, Bag Dropper, Metal Location Indicator (MLI) & shaft encoder accessories. Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12
Active 24VDC output ‘+’ Fused +24VDC Fused +24VDC +12VDC 0VDC common 0VDC common +12VDC MLI reset ‘-‘ Active 24VDC output ‘-’ Belt clip input 0V (24VDC GND) Shaft encoder signal (Pulse generator, max 16 ppr) Pin 13 Halt input (Bag out/low ink signal) Pin 14 Hi burden/swing coil signal Pin 15 MLI reset ‘+’ See the instructions supplied with the optional accessories for full wiring information. In addition to the connection of auxiliary equipment, if the 24VDC option card is fitted to the main PCB, the terminal block has a 24VDC active output, which may be used to activate suitably rated devices directly instead of using the Detect Relay. The connection of certain accessories will require changing the standard two pole detect relay to a four pole version. These devices may need additional contacts to operate.
20
PIN 1
FIGURE 26
OPTION TERMINAL BLOCK
PCB Controls NAME DESCRIPTION SW1
SIGNAL
FINE sensitivity control.
SW2
BELT CLIP (option)
FINE sensitivity control.
SW4
SIGNAL
COARSE sensitivity control.
SW5
BELT CLIP (option )
COARSE sensitivity control.
The sensitivity of the metal detector can be adjusted up or down using the FINE sensitivity control switch SW1. The switch has 12 positions where position 1 is the lowest sensitivity setting & position 12 is the highest. If further adjustment range is required, then the COARSE sensitivity control switch, SW4, can also be adjusted up or down. This switch has 8 positions, where position 1 is the lowest setting & position 7 is the highest. Note that the 8th position is an OFF position, which will prevent metal from being detected. This setting is only used to assist in the setup of the detector or for diagnostic purposes. SW9
RELAY OUTPUT POLARITY SELECTOR
SW9.1
(BROWN) DETECT RELAY STANDARD/FAILSAFE mode
SW9.2
(RED) FAULT RELAY STANDARD/FAILSAFE mode.
SW9.3
(ORANGE) ‘Swing away’ top coil or ‘high burden’ detector selector (option).
The Detect & Fault relays, mounted on the DIN rail below the PCB can be individually configured to operate in a ‘standard’ or ‘failsafe’ mode using sections 1 & 2 of switch SW9 respectively. In the standard mode (down position), the relay only changes state when a detect or fault signal occurs. In the failsafe mode the relay is energised as soon as power is applied to the control panel. As a result of this, the polarity of the contacts of the relay become reversed. This means that the relay changes state when a detect or fault signal is issued and also if there is a power failure to the control panel. So, in the event of a power failure to the metal detector control panel only, a detect signal will be issued to the conveyor belt control circuit (if connected). This will stop the conveyor belt and prevent any unchecked material from passing beyond the metal detector and will protect any equipment further downstream until the power is restored. If the metal detector system has been supplied with a swing away top coil or high burden detector option, then SW9.3 is used to select the appropriate option. When ‘SWING COIL’ (UP) is selected, and a burden depth, which exceeds the aperture height of the sensor coil pushes the top coil out of its path, the HI BURDEN LED will illuminate and there will be no metal detection for the period when the top coil is out of position. Once the top coil has returned to its normal position, the HI BURDEN LED will extinguish & metal detection will resume. When ‘HI BURDEN’ is selected and a burden depth, which exceeds the aperture height of the sensor coil activates the high burden detection sensor system, the HI BURDEN & EXT. FAULT LEDs will illuminate & the Fault Relay will be activated. This signal should be used to stop the conveyor belt so that the excessive burden can be leveled or removed to prevent damage to the sensor coil.
FIGURE 27
21
PCB Controls SW3
RESET MODE SELECTOR (see Figure 28)
UP
TIMED AUTOMATIC RESET
MIDDLE
LATCH/MANUAL RESET
DOWN
TIMED LATCH/DELAYED MANUAL RESET
When metal has been detected, the operating mode of the Detect Relay can be controlled using SW3. RELAY CONTROL TIMED AUTO RESET LATCH TIMED LATCH
FIGURE 28 TIMED AUTOMATIC RESET Using the TIMER controls, the operation of the Detect Relay is controlled to change state only after a prescribed amount of time has elapsed, and will automatically reset itself after a set period of time.
The initial ‘DELAY’ period is adjusted by using control POT1, and the ‘ACTIVE’ period before the system resets is controlled using POT2. POT1 POT2
Delay timer Active timer
0.5 – 47.5 seconds 0.5 – 47.5 seconds
When the timers are in operation the DELAY (amber) & ACTIVE (green) LEDs will illuminate in turn to indicate the respective periods of time. This option would be used to control an automatic reject system to remove metal instead of stopping the conveyor belt. LATCH MODE/MANUAL RESET In this mode, the Detect Relay will change state as soon as metal has been detected. Once the metal contamination has been located & removed, the detector can be reset by pressing the ‘DETECT/ RESET’ button on the door of the control panel. This will cause the Detect Relay to return to its normal state, which should allow the conveyor belt or process to be restarted.
22
(cont.)
TIMED LATCH/DELAYED MANUAL RESET Using the DELAY TIMER control, the operation of the Detect Relay is controlled to change state only after a prescribed amount of time has elapsed, however, the detector will NOT automatically reset itself. Once the metal contamination has been located & removed, the detector can be reset by pressing the ‘DETECT/RESET’ button on the door of the control panel. This will cause the Detect Relay to return to its normal state, which should allow the conveyor belt or process to be restarted. This option might be used to stop the conveyor belt in a specific location to enable an operator to easily remove the metal contaminant . IMPORTANT: After switching SW3 from one position to another, ALWAYS press the reset button on the front of the control panel door. SW8
1
2
RELAY FUNCTION SELECTOR (OFF DOWN, ON UP)
Using SW8, the Detect & Fault Relay can be programmed to be activated by their own respective signals only, to be inactive or be activated by both signals. SW8
1
2
DETECT SIGNAL FAULT SIGNAL
0
OFF OFF
DETECT RELAY ONLY FAULT RELAY ONLY
1
OFF ON
DETECT RELAY ONLY FAULT RELAY OFF
2
ON OFF
DETECT RELAY ONLY DETECT & FAULT RELAYS (DEFAULT)
3
ON
DETECT RELAY OFF FAULT RELAY OFF
ON
Warning: Do not rely on the latched mode to inhibit a reject device or conveyor belt. The latched mode could be reset by a spike on the mains supply or other event (i.e. lightning). Disconnect the mains supply to the metal detector and reject device before working in, on or around the reject device. Also disconnect any air or hydraulic lines and relieve any remaining pressure in the lines before servicing the reject device.
PCB Controls SW6 FREQUENCY PROGRAM SELECTOR This setting is a factory preset & should not be ad justed as the sensor coil has been calibrated to be operated at one setting only, and a change could cause unstable results. Only change this setting if advised to do so by qualified service personnel. PROGRAM DESCRIPTION
0 1 2 3 4 5 6 7 8 9 A B C D E F
COIL SYSTEM
1.8% - 2% 18.9KHz EAGLE 1.8% - 2% 18.2KHz EAGLE 1.8% - 2% 17.5KHz EAGLE 1.8% - 2% 16.9KHz EAGLE 5%<4m/s MASTER 5KHz HAWK 5% <4m/s SLAVE 5.3KHz HAWK 5% <1.75m/s MASTER 2.5KHz HAWK 5% <1.75m/s SLAVE 2.6KHz HAWK 10% <4m/s MASTER 2.5KHz HAWK 10% <4m/s SLAVE 2.6KHz HAWK 10%<1.75m/s MASTER 2.5KHz HAWK 10% <1.75m/s SLAVE 2.6KHz HAWK 20% <4m/s 2.5KHz HAWK 20% <1.75m/s 2.5KHz HAWK >20% 1.1KHz HAWK GENERAL PURPOSE (5-10%) 2.5KHz HAWK
SW7 BELT SPEED SELECTOR It is important to check that the correct speed setting for the conveyor belt is selected, as this information is used to determine whether a signal is a true metal detection or interference. For variable speed belts, a shaft encoder option will be necessary for reliable operation. POSITION
0 1 2 3 4 5 6 7 8 9
SPEED RANGE
SHAFT ENCODER INPUT 0.1 – 0.2 m/s 0.2 – 0.5 m/s 0.5 – 1.0 m/s 1.0 – 1.5 m/s 1.5 – 2.0 m/s 2.0 – 2.5 m/s 2.5 – 3.0 m/s 3.0 – 4.0 m/s 4.0 – 5.0 m/s
(cont.)
SIGNAL LEVEL INDICATOR The amount of signal that the sensor coil is receiving can be seen on the signal level indicator. Normally 3 LEDs will be illuminated; the 2 outer ones are the thresholds & the inner moving one is the actual signal indicator.(see Figure 29) When metal enters the aperture of the detector, this will cause the Signal LED to move to one side of the display and then to the other & will return to the center once the metal has passed through the detector. In the default mode of operation, for the metal to be successfully detected, the Signal LED must pass one threshold & then the other, which must be done within a certain time limit. The time that the signal exceeds each individual threshold is also taken into consideration and is related to the speed of product travel, so it is important that SW7 is set correctly. THRESHOLD LED
THRESHOLD LED
SIGNAL LED
FIGURE 29
The threshold levels are factory set, but if necessary, can be adjusted using potentiometer POT3. The closer they are together, the more sensitive the system becomes, and the further apart the less sensitive. The threshold (Vtrip) can be measured with a digital meter between TP0 & TP12. J6 DETECTION MODE OPEN TWIN PEAK (DEFAULT) CLOSED SINGLE PEAK
If jumper J6 is fitted (for single peak operation) this enables the system to give a detect output after the Signal LED crosses just one threshold. This can be done if the size of the signal from the target metal is not sufficient to cross both thresholds.
23
PCB Controls This mode of operation can make the detector prone to false signals, so the installation must be trouble free for this mode to give reliable operation. OPERATIONAL STATUS LEDs The bank of LEDs on the main PCB are used to show the operational condition of the metal detector and some of the optional accessories connected to it.
HEALTHY (Green) The microprocessor continually monitors the system for any internal faults or problems. If any are indicated (as listed below), then the HEALTHY LED will be extinguished, and if the optional HEALTHY relay is fitted, then this will change state also. Note that if the system registers that it is NOT healthy, then the FAULT Relay will also change state. However, if the optional HEALTHY Relay is fitted, this can be used to distinguish whether the fault signal is being generated by an accessory or not as accessories will only trigger the FAULT Relay and not the HEALTHY Relay. When the detector is turned on it indexes through the Fault Status LEDs from POWER through to RX, and checks the operational condition of the detector. Assuming that everything is ok, the HEALTHY LED will then illuminate. If the HEALTHY LED does not illuminate, then the corresponding Fault LED will remain lit to indicate where the problem is. RX (Red) This checks that the signal being received by the detector is within certain limits. If this indicator is on, then check the metal free area & the amount of metal that is surrounding the sensor coil. TX (Red) This checks the condition of the transmitter coil. If this indicator is lit then check the continuity of the transmitter cable and the coil.
(cont.)
DETECT (Red) This is illuminated when metal has been detected and is extinguished when the system is reset. The detect pushbutton on the door of the control panel will illuminate at the same time also. EXT FAULT (Amber) This indicates that one of the optional accessories connected to the HALT input on the option terminal block is signalling a fault condition. For example, the high pile detector has been triggered, the bag has been released from the bag dropper or the ink-jet marker is running out of ink. When this signal is triggered, the fault relay is activated, so this can be used to stop the belt or to distinguish it from a detect condition. If SW8 is set to option 3 (default) then the detect relay will be activated also. BELT CLIP (Amber) This indicates that the belt clip sensor has been activated. While this LED is illuminated, the sensitivity of the system is set by the belt clip sensitivity switch. When the LED extinguishes, the sensitivity control reverts back to the signal sensitivity switch. HI BURDEN (Amber) This indicates that there is an over burden condition with the product on the conveyor belt. If the system is fitted with a swing coil option, then this LED will illuminate while the top coil has been pushed out of position by the burden. During this situation, metal will not be detected. Once the over burden has passed, the coil will return to its normal position, the LED will extinguish & detection will resume. If the system has been supplied with a high pile detector then when this LED illuminates the ext fault LED will illuminate also. DELAY (Amber) This indicates that the delay timer is running.
TIMING (Red) This checks that the frequency controller microprocessor is functioning.
ACTIVE (Green) This indicates that the active timer is running.
POWER (Red) This checks that the onboard power supplies are running.
Note that the Delay & Active LEDs will illuminate when there has been a metal detection signal even if they are not being utilised to control the detect output.
24
Wiring To The Conveyor Motor Contactor To stop the conveyor drive motor when metal is detected, connect the normally-closed relay contacts of the Detect Relay (terminals COM and NC) in series with the Fault Relay and the conveyor motor contactor, KM1, as in the diagram below. After removing the metal, if the system is wired as shown, the conveyor will not restart until the control unit is reset AND the conveyor motor start switch is depressed. SIMPLIFIED CONVEYOR START/STOP CIRCUIT Note: If the detect (or fault) relay is operated in ‘failsafe’ mode, then the wire connected to NC should be moved to NO, as the relay will change polarity when power is applied to the control unit. The Fault Relay is connected in series to stop the conveyor if the detector develops a fault and also to prevent the belt from being started until after the power up sequence has been completed when the control unit is initially turned on. Auxiliary relay An auxiliary relay is necessary between the control unit and the motor starter when the motor wiring system is a fully three-phase delta with no star-point and uses a motor starter with a 415VAC coil (see figure 31). The 415VAC motor starter coil exceeds the maximum voltage rating of the detect & fault relay
contacts, which are rated at 250VAC maximum. So, an auxiliary relay or small contactor is required for the 415VAC contacts. An auxiliary relay is also necessary when the plant switchgear is generating electrical interference or brushes are arcing, or when other electrical noise is being created. This interference will propagate through the air and may also travel along the conductors in close proximity to the noise sources. When this occurs, interference will be fed into the control unit along the interconnecting wires, and will cause false triggering. An auxiliary relay in a separate enclosure, external to the metal detector and separate from the main switchgear cabinet, will normally isolate the offending interference. Auxiliary Relay Wiring Diagram Note: If the detect (or fault) relay is operated in ‘failsafe’ mode, then the wire connected to NC should be moved to NO, as the relay will change polarity when power is applied to the control unit. The Fault Relay is connected in series to stop the conveyor if the detector develops a fault and also to prevent the belt from being started until after the power up sequence has been completed when the control unit is initially turned on.
FIGURE 30
FIGURE 31
25
Belt Clip Detector Option In the event that the conveyor belt upon which the metal detector is installed has: • damage that has been repaired using metal clips; • a splice that is joined using metal clips; • a splice in a steel cored conveyor belt that causes a detect indication; Then it will be necessary to install an optional belt clip detector to allow normal operation of the metal detector. The belt clip detector is used to detect the belt clips before they enter the aperture of the main sensor coil and lower the sensitivity setting to allow the clips to pass without causing a detection signal. During this period, the sensitivity of the detector is controlled by switches SW2 and SW5 (belt clip channel). Once the clips have passed the main sensor or coils, the sensitivity is returned to the normal controls (SW1 and SW4) and its previous level (signal channel). NOTE: It is highly recommended that a stainless steel splice be used to minimize the signal generated by it and enable it to be phased out easier. The diagram shows a belt clip sensor fitted to the optional belt clip mounting frame.
BELT CLIP SENSOR
ANGLE ADJUSTMENT
BELT CLIP MUST PASS OVER SENSOR FACE
FIGURE 33
The belt clip sensor should be installed so that the sensing face is no more than 1˝ (25mm) away from the underside of the belt. To ensure that the clip is detected, it may be necessary to reduce this distance. IMPORTANT NOTE: In the instance that the belt clips are fitted in the center of the belt only, then it will be necessary to install an extra clip at the edge so that it passes over the belt clip sensor at the same time as (or just before) those in the center.
LINK PIN
OPTIONAL BELT CLIP MOUNTING FRAME DEPTH ADJUSTMENT HEIGHT ADJUSTMENT
FIGURE 34 FIGURE 32
For correct operation of the belt clip sensors, ensure that a link pin is fitted between sockets P2 & P3 on the PCB as shown in Figure 34.
26
Belt Clip Detector Option (cont.) The belt clip detector option is available in two configurations:
The sensor should be connected to the option connector block, CON1, as shown above.
1. Single belt clip sensor
WIRE DESCRIPTIONTERMINAL BROWN (S1) VCC CON1 PIN 4 BLUE (S1) 0VDC CON1 PIN 5 BLACK (S1) SIGNAL WHITE TERMINAL
2. Dual belt clip sensors
Fixed belt speed installations Var iab le belt speed installations
TIME SETTING WHITE TERMINAL BLOCK
TIME RANGE (SEC, MIN, HR)
CON1
N W O R B
E U L B
K C A L B
TIMER MODE (SET TO R) TIMER RELAY
FIGURE 35
Single belt clip sensor Before beginning the belt clip setup process, ensure that the main sensor coil is setup to detect the required metal type and size. Installation & setup The belt clip sensor should be installed no closer than 12 in. (300mm) to the main sensor so that it is outside of the minimum metal free area.
1. For the belt clip detector setup process it is necessary that the relays do not operate and stop the conveyor belt when a detect signal is given. It is important that the setup process is completed without any product on the conveyor belt to prevent any metal contamination from passing
CLIP DETECTOR SENSOR
through the metal detector. 2. Remove the front panel from the PCB: A: Set SW8 sections 1 & 2 to the ON position; B: SW5 (belt clip coarse sensitivity) to the OFF position; C: Set SW2 (belt clip fine sensitivity) to position 12; D: Set the relay control switch, SW3, to timed auto reset & the delay & active controls to MIN; E: Press the reset button. 3. On the DIN rail mounted timer relay, set the time range control to ‘s-1’ (1 second range)and the time setting control to minimum (fully anti clockwise).
27
Belt Clip Detector Option (cont.) MIN 12 in. (300mm)
DIRECTION OF TRAVEL
FIGURE 36
4. Start the conveyor belt & observe what happens. As the clip passes the sensor, the timer relay will be activated momentarily and the belt clip LED on the PCB will illuminate also for the same period. When the clip reaches the main sensor coil, the bargraph signal LED will move and the Detect LED will illuminate until the clip passes beyond the influence of the detection field. 5. Increase the time setting control on the timer relay. As this control is increased, the timer relay & the Belt Clip LED will remain on for longer. Also, the time that the bargraph signal LED moves and the Detect LED is illuminated will become reduced. 6. Increase the time setting control (in conjunction with the time range control) until the bargraph LED no longer moves & the Detect LED does not illuminate when the clip passes through the main sensor coil. Once this happens, the Timer Relay controls are correctly set and need no further adjustment. 7. Set SW5 to position 7. This should cause the bargraph signal to move and the Detect LED to illuminate again when the clip enters the main sensor coil. If the clip does not cause the bargraph to move or a detect indication, then no further adjustment is necessary. Set SW8 and SW3 back to their original positions and begin normal operations. Otherwise continue to the next step.
28
8. Turn SW5 to the next position below and observe the bargraph and Detect LEDs when the clip enters the main sensor. 9. If the bargraph signal no longer moves, then return SW5 to the previous higher position and then turn SW2 (belt clip fine sensitivity) down by one position and observe. Keep reducing the position of SW2 until the movement of the bargraph signal is minimized when the clip is passing the main sensor coil and does not cause a detection. If the bargraph signal still moves enough to cause a detect indication, then return to step 8 and repeat. Otherwise proceed to step 10. 10. Once the settings of SW5 & SW2 are reached so that the bargraph signal movement is minimized and there is no detect indication, then no further adjustment is necessary. Set SW8 and SW3 back to their original positions and begin normal operations. Note that it is only necessary to minimize the signal from the belt clip and not to reduce it to its lowest possible level (or turn SW5 to the OFF position). This is to ensure that it is still possible to detect other metal contamination that may be entering the main sensor coil at the same moment as the belt clip. However, the detector will not be able to maintain the same level of sensitivity that it achieves during normal operation when the belt clip channel is inactive.
Belt Clip Detector Option (cont.) WHITE TERMINAL BLOCK
TIME SETTING TIME RANGE (SEC, MIN, HR)
CON1
N W O R B
E U L B
K C A L B
TIMER MODE (SET TO R) TIMER RELAY
FIGURE 37
CLIP DETECTOR SENSOR SENSOR S1
CLIP DETECTOR SENSOR SENSOR S2
FIGURE 36 Dual belt clip sensors The sensors should be connected to the option connector block, CON1, as shown above. WIRE BROWN (S1)
DESCRIPTION TERMINAL VCC CON1 PIN 4
BROWN (S2) BLUE (S1) BLUE (S2) BLACK (S1) BLACK (S2)
VCC 0VDC 0VDC SIGNAL SIGNAL
CON1 PIN 4 CON1 PIN 5 CON1 PIN 5 WHITE TERMINAL BC RELAY PIN A1
Before beginning the belt clip setup process, ensure that the main sensor coil is setup to detect the required level of metal contamination. Installation & setup Both belt clip sensors should be installed no closer than 12” (300mm) to the main sensor so that they are outside of the minimum metal free area. The dual belt clip sensor configuration allows the detector to be turned to the low sensitivity mode by sensor S1; it is then switched back to normal sensitivity by sensor S2. In the event that the belt
mis-tracks and/or the last clip is missed by sensor S2, then the detector is switched back to normal sensitivity by the timer relay. Clip detector sensor S1 should be installed in front of the leading edge of the main sensor coil. Clip detector sensor S2 should be installed after the trailing edge of the main sensor coil and on the opposite side of the conveyor belt to S1. 1. For the clip detector setup process it is necessary that the relays do not operate and stop the conveyor belt when a detect signal is given. It is important that the setup process is completed without any product on the conveyor belt to prevent any metal contamination passing undetected through the metal detector. 2. Remove the front panel from the PCB: A: Set SW8 sections 1 & 2 to the ON position; B: SW5 (belt clip coarse sensitivity) to the OFF position; C: Set SW2 (belt clip fine sensitivity) to position 12; D: Set the relay control switch, SW3, to timed auto reset & the delay & active controls to MIN; E: Press the reset button.
29
Belt Clip Detector Option (cont.) LOW SENSITIVITY PERIOD CLIP DETECTOR SENSOR S2
MIN 12 in. (300mm)
TRAILING CLIP
DIRECTION OF TRAVEL
REPAIR CLIPS
LEADING CLIP
MIN 12 in. (300mm)
CLIP DETECTOR SENSOR S1
FIGURE 38
3. On the DIN rail mounted timer relay, set the time range control to ‘m-1’ (1 minute range)and the time setting control to maximum (fully clockwise). 4. Start the conveyor belt & observe what happens. As the leading clip passes sensor S1, the timer relay will be activated and the belt clip LED on the PCB will illuminate also for the same period. When the clip reaches the main sensor coil, the bargraph signal LED should not move and there will be no detect indication. When the trailing clip passes sensor S2, the timer relay & the belt clip LED will be turned off and the system will return to normal sensitivity. 5. Set SW5 to position 7. This should cause the bargraph signal to move and the detect LED to illuminate again when the clip enters the main sensor coil. If the clip does not cause the bargraph to move or a detection, then no further adjustment is necessary. Set SW8 and SW3 back to their original positions and begin normal operations. Otherwise continue to the next step. 6. Turn SW5 to the next position below and observe the bargraph and detect LEDs when the clip enters the main sensor. 7. If the bargraph signal no longer moves, then return
30
SW5 to the previous higher position and then turn SW2 (belt clip fine sensitivity) down by one position and observe. Keep reducing the position of SW2 until the movement of the bargraph signal is minimized when the clip is passing the main sensor coil and does not cause a detection. If the bargraph signal still moves enough to cause a detect indication, then return to step 6 and repeat. Otherwise proceed to step 8. 8. Set the conveyor belt speed to its slowest setting that will be used in operation and note the amount of time it takes the belt clips to pass between sensors S1 and S2. Add 20% to this value and then using the appropriate range setting on the timer relay, adjust the time setting control to this value. For example, if the time taken is 5 seconds, then 5 secs + 20% = 6 seconds. So the time range control should be set to s-10 (10 second range) and the time setting control to ‘0.6’. This will ensure that if the trailing belt clip is not detected by sensor S2, the detector does not remain in the lower sensitivity mode during normal operation. It is necessary for the time setting (on the timer relay) to exceed the longest period that it
Earthing of Associated Plant takes the clips to pass between S1 and S2. This is to prevent the main detector sensor being switched back to the normal sensitivity level while the clips are still within the aperture, which will cause a false detection.
Note that it is only necessary to minimize the signal from the belt clip and not to reduce it to its lowest possible level (or turn SW5 to the OFF position). This is to ensure that it is still possible to detect other metal contamination that may be entering the main sensor coil at the same moment as the belt clip. However, the detector will not be able to maintain the same level of sensitivity that it achieves during normal operation when the belt clip channel is inactive.
9. Once the settings of SW5 & SW2 are reached so that the bargraph signal movement has been minimized and there is no detect indication, then no further adjustment is necessary. Set SW8 and SW3 back to their original positions and begin normal operations.
FIGURE 39 EARTHING OF ASSOCIATED PLANT WHEN FREQUENCY INVERTER SPEED CONTROLS ARE BEING USED. Please note that when frequency inverter speed controls are being used in the vicinity of the metal detector, all earth connections must be run independently back to a single star point as shown below:In addition, if filters are being used, they should be mounted and connected as shown below:Because of the complex circuit design used in these filters an Earth Leakage Current of 8 to 80mA may be observed. It is possible that nuisance tripping of extremely sensitive type of ELCBs may occur so this figure should be considered when choosing such a device. It is important to provide well defined paths for the high frequency currents involved so the best results are achieved when both the filter and inverter are mounted securely on the same conducting, earthed backplate and not on rails etc.
Supply Cable The supply cable should be a stranded conductor and not a solid conductor type to achieve proper connection inside the terminal block, also cable lengths inside the wiring cabinet should be kept to a minimum (i.e. cable entry to filter and filter to inverter). This will reduce the effect of radiated emissions back into the input cables.
FIGURE 40A
FIGURE 40B
31
Earthing of Associated Plant (cont.) Motor Cable Since the cable between the inverter and motor is a major source of radiated and conducted interference, it should be a shielded type and kept as short as possible with the shield and safety earth connected directly to the bonded earth post at one end and to the motor earth at the other. Never connect only one end of the shield to earth as this can be detrimental (Pig tail effect). It is strongly recommended that the conducting center (not the earth or shield) are threaded through, or, if possible, wound around an output cable filter choke as shown.
Multiple Inverters Where more than one inverter is used, for effective suppression, it is preferable that a separate filter should be used for each inverter.
OUTPUT FILTER CHOKE SHIELDED
L1 L2 L3 INPUT
Control Cables The control cables to the inverter or any other equipment in the vicinity are obviously highly susceptible to radiated emissions in the same way and should also never be run along side motor output cables.
MOTOR CABLE FILTER
INVERTER
BACKPLATE BONDED TO EARTH
FIGURE 41 Earthing The point here is to clearly define the paths through which high frequency earth currents flow, and thereby minimize their harmful effect on other nearby, sensitive devices. All earthing leads, including filter earth, inverter earth and shielded cable earths, should be as short as possible and securely fastened to the bonded backboard earth post - poor connections and loops of cable will act as aerials and pick up stray radiated emissions.
FIGURE 43A
FIGURE 43B
FIGURE 42A
FIGURE 42B Separation Keep the separation of the input and output cables as great as possible to prevent feedback. Input and motor output cables should never be run together in the same trunking or conduit.
32
Troubleshooting SUGGESTIONS FOR TROUBLE SHOOTING ENVIRONMENTAL INTERFERENCE The metal detector generates a high frequency alternating field within and near the sensor coil. While the field is strongest on the sensor coil face or in the throat of the sensor coil, it is inherent in the sensor coil design that a certain amount of the field exists outside of the sensor coil. Certain environmental conditions may sometimes affect this alternating field causing false and erratic signals. If after installation, the unit does not work properly, check for compliance with the following hook-up and installation details before proceeding to the specific causes of interference. All cable connections should be tight on the terminal blocks in the control unit. The power source cables should be isolated from varying inductive loads and should be run in a separate conduit. The control unit should have a good electrical ground connection. In certain locations more than one problem may exist and the problems may be interrelated. Observing the installation site and the operation of the metal detector for recurring symptoms is very helpful in isolating the causes of the problems. Correlating malfunctioning occurrences is invaluable for environmental interference trouble shooting. Observe whether interference occurs at certain specific times and in conjunction with specific activity. Observe whether interference occurs when operated by certain personnel or only after physical change of the environment. Use the following to help diagnose problems and problem sources and to implement corrective measures. Basically environmental interference may be classified into four types, as described below: Movement of Metal Large masses of metal such as shaker screens, metal deflection plates, vehicles etc. may affect metal detector operation even when at a considerable distance from the sensor coil. Other smaller masses of moving metal when sufficiently close to the search unit may also cause false trips. Interference may exist outside of the room or building and be hidden from operators view, such as
vehicular traffic in an alley next to the building wall or a chain conveyor below or above the floor, or moving metal objects in an adjacent room. Corrective Measures • Secure moving metal objects or remove them altogether, if possible, or replace with a non metallic material. Re-route vehicular traffic. • Place a metal shield securely fastened and stationary between the sensor and the source of interference. Place a shield as close to moving object as possible. The size of the shield will depend on the size of the moving object. • Install the metal detector in another location free from interference sources. Intermittent loops of metal surrounding the sensor (Shorted Turns) A source of interference, which is difficult to recognize, is that of the "shorted turn". A "shorted turn" is formed by metal pieces forming a complete loop in an orientation around or near the sensor. If this loop is intermittent, as in the case of two pieces of conduit occasionally touching together, the detector will trip each time the conduits make or break connections. The intermittence may be caused by physical deflection or vibration of equipment and by expansion or contraction of metal due to temperature changes. The effect of the "shorted turn" is that of a secondary "coil" or "turn" coupled to the metal detector sensor coil. The varying load of this secondary 'coil' when it makes or breaks is reflected to the sensor coil tripping the control unit. The following metal objects may be part of or form a "shorted turn" by themselves: metal framework, pipes, conduit, flexible conduit, guard railing, metal catwalks, conveyor rolls, etc. To determine the existence of a "shorted turn": switch the metal detector off and disconnect the sensor lead at the terminal block. This will disconnect the sensor from the control instrument and there will be no metal detection. Now, turn the control instrument on again and set gain control to maximum. Run operation under normal conditions and observe the signal level indicator. If the indicator is stable at this time, it is most likely that the sensor is picking up a "shorted
33
Troubleshooting (cont.) turn". However, the problem may also be a break on the sensor cable. Check for breaks at this time and replace the cable if necessary. If the cable is in good condition, search for a 'shorted turn' as described in the following paragraph. If the level indicator is not stable at this time, the problem is likely to be due to excessive line voltage fluctuation. To isolate and correct the "shorted turn" problem, reconnect the sensor coil and turn off all surrounding equipment in order to eliminate any vibration. The level indicator should settle down at this time or at least reduce the number of false trips. Proceed by tapping on all metal objects, starting near the sensor coil and working out from there, in order to find where the break point is located. It is suggested that one person watch the level indicator on the control unit in order to observe any movement, while another person is tapping on metal objects around and near the sensor coil. In some cases, this may be several feet from the sensor coil. Sudden level indication movement when a metal object is tapped will indicate the intermittent connection. It may be possible to fix the problem by insulating or permanently securing this metal to metal connection. For example, in the case of a broken weld, re-weld or in the case of a loose pipe or conduit, re-secure the holders. Excessive Line Voltage Fluctuations Electrical interference may be in the form of line voltage "spikes" caused by cycling of inductive loads of electrical equipment on the same power line as the metal detector, or other power lines in close proximity to the supply line for the metal detector. Corrective Measures • Use another power line, (without the varying inductive loads) for the metal detector. • Disconnect electrical equipment causing the large inductive loads. • Connect interfering electrical equipment to another power source. • Re-route the power line to the metal detector. • Install a constant voltage transformer (120VA minimum) between the metal detector and power source. The transformer should be mounted within 3 feet of the metal detector control.
34
Proximity of Severe RF Radiation Sources Electrical or electronic interference can be radiated into the sensor coil or introduced into the metal detector from other energy emitting devices such as arcing motors, arc welders, and arcing relay points. Corrective Measures • Remove or replace equipment causing interference. • Operate welding equipment only at times when metal detector is not required to operate.
Call the factory service department if unable to arrive at a satisfactory solution. View http://www.eriez. com/ to locate your nearest representative. Please have model and serial number available.
MA3600 Case Assembly Parts List FIGURE 44 2
1
6
3/9 5 4/8
10
7.1
7.2 7.3
Ref No Description 1 2 3 4 5 6 7.1 7.2 7.3 8 9 10
Case fully fitted Enclosure (Stainless or powder coated steel) Indicator assembly (POWER). Momentary illuminated switch assembly (DETECT/RESET). Door indicators wiring loom Insulated mounting kit Cable gland .6299 in. (M16) Cable gland .7874 in. (M20) Blanking plug .6299 in. (M16) Red LED module Green LED module Door key
SEARCH COIL CABLES Cable Search Coil - 10 ft (3m) Cable Search Coil - 16 ft (5m) Cable Search Coil - 33 ft (10m) Cable Search Coil - 66 ft (20m)
Eriez Part Number
Qty 1 1 1 1 1 1 3 1 1 1 1 1
2 2 2 2
35
MA3600 Electronic Assembly Parts List FIGURE 45
21
22
29 24 23
25
28 26
Ref No 20 21 22 23 24 25 26 27 28 29
36
Description Electronic Unit Complete CB26 Printed Circuit Board Front Panel MA3600 Quick release hinge F1 Fuse 3.15A radial TR5 slow blow F2 Fuse 315mA radial TR5 slow blow Mains input fuse 5x20mm 1A Power supply module Relay 2PCO RX PCB (quote serial number)
27
Eriez Part Number
Qty 1 1 1 1 1 1 1 1 As required 1
MA3600 PCB Change DISCONNECT ALL CABLES & CONNECTORS FROM THE MAIN PCB. UNDO QUICK RELEASE FASTENERS & TILT PCB FORWARDS
SQUEEZE QUICK RELEASE HINGE MECHANISIM TOGETHER AS SHOWN
IMPORTANT: REMOVE RX PCB FROM ORIGINAL UNIT & FIT TO REPLACEMENT SYSTEM
FIGURE 46
REMOVE PCB FROM CASE. REPLACE WITH NEW PCB BY REVERSE PROCEDURE
FIGURE 47
37
Technical Data CONTROL PANEL: POWER SUPPLY
100 – 240 VAC SWIT CHED MODE POWE R SUPP LY 50/ 60H z (24VDC VERSION AVAILABLE ON REQUEST 2A STARTUP CURRENT CAPACITY REQUIRED)
POWER
50W
FUSE
1A
RELAYS
2X2DPDT VOLT FREE (DRY) 250V/8A MAXIMUM RATING (2KW PER RELAY)
TEMPERATURE
0 TO +50°C (32°F TO +122°F)
IP RATING
IP66 (NEMA 4) POWDER COATED STEEL ENCLOSURE (RAL7032) IP66 (NEMA 4X) STAINLESS STEEL ENCLOSURE
SEARCH COIL:
MATERIALS HAWK
HDPE (HIGH DENSITY POLYETHYLENE) WHITE
RESIN
TEMPERATURE
-40°C TO 76°C (-40°F TO +168.8°F)
EAGLE
HDPE (HIGH DENSITY POLYETHYLENE) WHITE
RESIN POWDER COATED ALUMINIUM TRAY
FIBERGLASS
TEMPERATURE
-40°C TO 65°C (-40°F TO +149°F)
SENSOR CABLE:
TYPE
SHIELDED TWISTED PAIR CABLE (UNITRONIC FD CP (TP) 1x2x1)
TEMPERATURE
-40°C TO 75°C (-40°F TO +167°F)
NOTE: Temperature range ratings shown for standard construction only. High temperature coil designs are available on request
38
Control Panel Dimensions
Control Weight 22 LBS (10 KG)
39
