control unit msg 3 - sigma equipment msg3.4k-ba-cu-en-2114.docx operating instructions control unit...

1 MSG3.4K-BA-CU-EN-2114.docx

Operating Instructions

Control Unit

MSG 3.4K

We reserve the right to change the con-tents due to product innovation or tech-nical improvement.

Please state type of equipment and se-rial number when contacting us.

Please read these instructions and keep the manual safe! Please observe and follow the safety notes! S+S Separation and Sorting Technology GmbH Regener Straße 130 * D-94513 Schönberg Telephone: +49 8554 308-0 * Fax: +49 8554 2606 E-mail: [email protected] Internet: http://www.sesotec.com Service: Telephone: +49 8554 308-180

http://www.sesotec.com/

2 MSG3.4K-BA-CU-EN-2114.docx

Manufacturer: S+S Separation and Sorting Technology GmbH D-94513 Schönberg, Germany

Contact: S+S Separation and Sorting Technology GmbH Regener Straße 130 D-94513 Schönberg, Germany Tel.: +49 (0) 8554 3080 Fax.: +49 (0) 8554 2606 E-mail: [email protected] Internet: www.sesotec.com

Represented by:

Contents

3

Contents

1 General information 5

1.1 Introduction 5

1.2 Fields of application 5

1.3 Application reasons 5

1.4 System identification 5

1.5 Symbols used 5

1.6 EC DECLARATION OF CONFORMITY 5

1.7 Overview with functional elements 6

1.8 Combination possibilities of the Control Unit 6

2 Design and method of operation 7

2.1 Functional principle 7

2.2 Functional and control elements 8

3 Dimensions and technical data 10

3.1 Technical data sheet, see annex 10

3.2 Supply connections, see technical data sheet in the annex 10

3.3 Environmental conditions for operation, storage, and transport 10

3.4 Noise levels 10

4 Safety 11

4.1 Intended use 11

4.2 Safety signs 11

4.3 Dangers arising from non-compliance with safety notes 11

4.4 Safety information for operators 11

4.5 Safety information for operation, maintenance and cleaning 12

4.6 Safety information for commissioning 12

4.7 Safety information for storage and transport 12

4.8 Notes on residual risks 12

4.9 Notes on stable standing requirements 12

4.10 Consequences of unauthorised modification 12

4.11 Improper use 12

5 Commissioning 13

5.1 Mechanical Installation 13

5.2 Connecting the equipment 13 5.2.1 Pin configuration 13 5.2.2 Electrical connections 13 5.2.3 Performance data - connectors 14 5.2.4 Electrical connection of the equipment 14 5.2.5 Connection examples 15 5.2.6 Mains supply 17 5.2.7 Mains supply via safety socket 17 5.2.8 Mains supply via terminal box 17 5.2.9 Behaviour of machine at start-up 18

Contents

4

5.2.10 Relays – operating status 18

6 Setting machine parameters 19

6.1 DIP switches 19

6.2 Hex-switch 20

7 Operation 21

7.1 Settings on the board 21 7.1.1 Setting of Sensitivity 21 7.1.2 Setting of interference suppression 22 7.1.3 Setting of eject duration 22

7.2 Replacing a defective fuse 23

8 Errors and fault remedying 24

8.1 Error messages 24 8.1.1 Faults at solenoid valve MV1 24 8.1.2 Faults at the search coil 24 8.1.3 Compressed air monitor 25 8.1.4 Level monitoring 25

8.2 Undefined activation of switching outputs 25

8.3 Special notes on separators 26

8.4 Replacement of electronic boards 26

9 Maintenance and cleaning 28

9.1 Maintenance 28

9.2 Cleaning 28 9.2.1 Hints for cleaning 28 9.2.2 Cleaning instructions 28

10 Spare parts 29

10.1 Spare parts drawing 29

10.2 Spare parts list 29

11 Shipping, preservation, waste disposal, transport, storage 30

11.1 Shipping, preservation, waste disposal 30

11.2 Transport 31

11.3 Storage 31

12 Annex 32

1. General information

5

1 General information

1.1 Introduction

The texts and illustrations in this instruction manual are for the exclusive purpose of explaining how to operate and handle the control unit. The manufacturer accepts no responsibility for damage resulting from the use or misuse of this equipment. All appropriate safety rules and regulations for the use of this equipment must be adhered to. If you have any questions with regard to the installation and operation of this equipment please do not hesitate to contact us. This instruction manual may not be copied, saved on computer or otherwise reproduced without the prior permission of the manufacturer. Nor may any extract of this instruction manual be similarly repro-duced.

1.2 Fields of application

The MSG3.4K Control Unit is the evaluation and control electronics unit for metal detectors of type RMS and 3E. It operates with proven analog technology. As a rule the Control Unit (operator panel) is installed a few metres away from the actual search coil.

1.3 Application reasons

Product liability

ISO 9000

TQM (Total Quality Management)

Protection of machines and operators

1.4 System identification

The information in this instruction manual only applies to the MSG3.4K control unit. A label with the re-spective data is attached at every system.

1.5 Symbols used

Symbol Signal

word

Meaning

Danger Warning: Possibility of severe or even fatal personal injuries.

The lightning symbol is an explicit warning that there is danger from elec-tric current.

Warning Warning: Possibility of minor personal injuries or property damage.

Caution Warning: Possibility of defects or destruction of the equipment.

Important

information

Indicates important information for the function.

Important

hint

Indicates an important hint for the function.

1.6 EC DECLARATION OF CONFORMITY

(see annex – EC DECLARATION OF CONFORMITY)

1. General information

6

1.7 Overview with functional elements

Electronics housing

Illuminated push button

Mains cable

Cable for solenoid valve

Cable for coil connection

1.8 Combination possibilities of the Control Unit

1

2

3 4 5

A3 area metal detector

RMS tunnel metal detector

Control Unit

2. Design and method of operation

7

2 Design and method of operation

2.1 Functional principle

Inside the coil the material to be conveyed is penetrated by a high-frequency field. Any metal contamina-tion disturbs this field. This disturbance is evaluated by the electronic unit and converted into a switching pulse. Both a DC switching output and a potential-free relay output are available.

Block diagram:

P

Ejectduration

Interferencesuppression

Senstivity

DCSwitching

output

Output“Metal”

Output“Fault”

Relay“Metal”

Relay“Fault”

Driver

Mainsconnection

Micro controller

DIP-switch

Reset

Oscilator ControlAmplifier

AmplifierConnection“Search coil”

Air pressure monitorFull indicator

Control Unit


8

2.2 Functional and control elements

The drawing below shows the position of the key components and the arrangement of the connectors.

Please note: After redesign, please insert a new component mounting diagram, (description F2 and F3)

Fuse Description Type

F1 Mains supply 1,6A slow-blowing 1500A @ 250VAC 5x20mm

F2 Mains supply IC1 1,6A slow-blowing 35A @ 250VAC TR5

F3 Mains supply IC2 1,6A slow-blowing 35A @ 250VAC TR5

Connectors and termi-

nals:

(1) "Mains": Control unit power supply (2) "Metal": Potential-free change-over contact "Relay metal" (3) "Fault": Potential-free change-over contact "Relay error" (4) "Valve": Solenoid valve connector (5) "Option" Inputs/Outputs (6) "Coil": Search coil connector

Elements connected to

mains voltage

(1) "Mains” connector (7) Mains fuse total (28) Mains fuse single

Elements connected to

external voltage:

(2) "Metal” connector (3) "Fault” connector

LEDs / indicators: (8) Status indicator for solenoid valve 1 (MV1)

(9) Indicator LED for supply voltage +5 V (10) Indicator LED for supply voltage +15 V (11) Indicator LED for supply voltage -15 V (12) 7-segment display for parameters, faults, time functions and user program


9

Potentiometers: (13) Reject duration potentiometer (14) Interference suppression potentiometer (15) Sensitivity potentiometer (16) Potentiometers not used

Switches: (17) DIP switch machine parameters (18) BCD switch user program (19) Reset button

Jumper: (20) Enable user program setting

Test points: (21) Supply voltage +5 V (22) Metal signal (23) Metal threshold (24) Common ground for digital signals (DGND) (25) Common ground for 24 V (GNS-24 V) (26) Supply voltage +24 V (27) Common ground for analog signals (AGND)

3. Dimensions and technical data

10

3 Dimensions and technical data

3.1 Technical data sheet, see annex

3.2 Supply connections, see technical data sheet in the annex

3.3 Environmental conditions for operation, storage, and transport

The environment of the control unit should be free of any chemical vapours such as softeners, chlo-rine, or similar substances. The control unit must not be exposed to direct sunlight or to other environ-mental influences (rain, snow, and storm). For ambient temperature conditions for operation, storage, and transport please refer to the technical data sheet in the annex.

3.4 Noise levels

Sound pressure level measurements (in acc. with DIN 45 635) Peak value of sound pressure level at a distance of 1m from the machine surface and 1.60m above the floor, LpA, 1m, max.

Result: Idling: < 70 dB(A) Activated: < 90 dB(A)

Measurement results for accessories and options: see annex.

We reserve the right to change the contents due to product innovation or technical improve-

ment.

4. Safety

11

4 Safety Our equipment conforms to all official technical safety regulations. However, as a manufacturer we be-lieve it is our duty to make you aware of the following information.

The following safety and danger notes are intended for your protection, for the protection of third parties, and for the protection of the equipment. The safety notes therefore should always be observed!

4.1 Intended use

The equipment is to be used in the following applications only with the appropriate detection coil: Vacuum / pressure conveying, free-fall and conveyor applications. The ambient tempera-ture of the machine must not exceed 50 °C. Ensure that the installation area is free from steam, plasticizers or other materials that may damage the PVC cable sheathing.

4.2 Safety signs

Symbol Signal word Location Meaning

Mains volt-

age

Cover of the electronics housing

This symbol indicates that mains voltage is used in the elec-tronics housing, and that any connected external circuits (e.g. at the metal relay) also may be energised. There is danger of electric shocks due to the presence of mains volt-age. Connection symbols:

"Mains" (1)

"Metal" (2) and "Fault" (3)

If the covering has to be removed during maintenance and repair works take notice of the references in 4.5.

4.3 Dangers arising from non-compliance with safety notes

Any non-observance of safety notes constitutes a danger for life and health.

4.4 Safety information for operators

The control unit may only be operated in the intended purpose and in a perfect functioning condition, especially the cover of the electronic housing has to be closed during operation. En-tered moisture has to be removed! All fixed warning signs on the equipment may not be re-moved and have to be in a well recognizable condition. The operating instructions always have to be in a legible condition and complete available. The operator may only appoint quali-fied personnel for operation, maintenance and repair work. When inspecting materials which are likely to explode follow the appropriate regulations.

Emitted interference Test report according to the provisions of:

BGV B11:2001-06 Regulations of the professional association for safety and health at work. Accident prevention regulations for electromagnetic fields.

E DIN VDE 0848-3-1: 05-2002 Safety in electrical, magnetic, and electromagnetic fields, part 3-1: Protection of persons with active implants in the frequen-cy range of 0Hz to 300 GHz.

In the area where the operating personnel is working the electromagnetic field of the metal de-tector or separator does not exceed the limits stated in the provisions. Therefore there are no health impairments due to electromagnetic fields in this area for persons and for wearers of medical implants such as cardiac pacemakers. Inside the coil of round or closed tunnel coils,

4. Safety

12

or on the surface of flat coils, the limits may be exceeded depending on design and system version. If work is to be performed inside or at the search coil, persons and wearers of medi-cal implants such as cardiac pacemakers may only enter the equipment when it is turned off, provided that size and design allow this.

4.5 Safety information for operation, maintenance and cleaning

Because of energised components in the electronics housing there is a risk of injuries due to electric shock or burns. During operation the cover of the electronics housing must be kept closed. Only qualified personnel may operate and clean the equipment. If the electronics housing must be opened for maintenance or cleaning purposes, remove any dirt and moisture from the electronics housing, so that no larger amounts may get into the interior. Always disconnect the power supply and any connected external circuits before opening the cover. Any moisture that has penetrated into the interior must be removed from the electronics housing. If system parameters have to be changed while the system is energised, such work may only be performed by a qualified electrician under strict observation of the attached warning labels and with due regard to standard approved rules of electrical engineering.

4.6 Safety information for commissioning

To avoid any injuries due to energised parts in the electronics housing, the information in 5.1 and 5.2 must always be observed.

4.7 Safety information for storage and transport

Always observe the information in paragraph 11 to avoid any transport damage and personal injuries.

4.8 Notes on residual risks

Electrical circuits may still be live even after having been isolated from the mains. Switch off immediately if a fault occurs.

4.9 Notes on stable standing requirements

To avoid any loss of stable standing, the information for transport, commissioning and opera-tion must always be observed. Always make sure that the fastening screws of the control unit are tight during operation. When storing or transporting the control unit, place it on the closed rear panel of the housing.

4.10 Consequences of unauthorised modification

Unauthorised modification or repair will invalidate all manufacturer declarations and guaran-tees.

4.11 Improper use

For other applications as enumerated in 4.1 the control unit intended for – that is regarded as inadmissible operation. Improper use also includes operating the equipment with excessive mechanical, static or dynamic loads (e.g. heavy machine parts or strong vibration). It is fur-thermore not permitted to inspect any aggressive materials on the conveyor, such as materi-als containing lyes, acids, and solvents, or materials that react to electromagnetic fields, or living persons or animals. The standard version of the control unit must not be operated in Ex-areas. Operation in Ex-areas only is permissible with the special Atex-version of the control unit, which is described separately.

5. Commissioning

13

5 Commissioning

5.1 Mechanical Installation

Ensure that the equipment is securely installed and vibration-free. Installation under cover. Do not install in an environment where there is risk of explosion.

Do not install in the vicinity of interference fields (e.g. near large electric motors or frequency invert-ers). The safe distance depends on the power of the motor or frequency inverter (approx. 5 m).

Fix the control unit cabinet to a wall or frame using the screw holes provided (check the drawing for dimensions). Ensure that it is securely fixed to support the weight of the control unit (approx. 4 kg).

The control unit must be installed in its own cabinet. On no account install it in other switchgear cab-inets as there is a high risk of interference.

Always discuss with manufacturer prior to altering cable lengths between the electronic unit and the detection coil. Always use original cables supplied with the machine. These connector cables must be laid separately from other cables (use fixing clips or lay them in separate cable ducting).

When using several metal detection systems, the distance between the individual search coils must not be less than 0.5 to 1 m (depending on the coil size), if these coils are positioned side by side.

Do not install the equipment in such a way that operation of the mains cut-off switch is hindered in any way!

5.2 Connecting the equipment

To conform to CE standards all cables external to the electronics and electrical control housings must be shielded. The shielding must be earthed immediately after the cable gland.

HousingShield

Cable

5.2.1 Pin configuration

Netz Metall

L 42 N 41PE 44

Fehler

323134 2 1 4 3 6 5 8 7 10 9 1211 1413

Ventil Option Spule

5.2.2 Electrical connections

Designation Type of connection Function "Mains” Connector for mains supply PE / N / L: Electronics power supply

"Metal” Potential-free relay contact Normal operation: Contacts 41 and 42 closed On metal detection: Contacts 41 and 44 closed

"Fault” Potential-free relay contact Normal operation: Contacts 31 and 34 closed In case of fault: Contacts 31 and 32 closed

5. Commissioning

14

Designation Type of connection Function

"Valve" 24 V valve output 1, 2 switching output solenoid valve

"Option" Switching inputs and outputs

3, 4 Operation 5, 6 Pulse counter 7, 8 Test 9 Manual 10 Reset 11, 12 Compressed-air monitor / Full indicator

"Coil” Connection for search coil

13 Signal search coil 14 Reference ground for search coil

1 2 3 4 5 6 7 8 9 10 11 12 13 14

+2

4V

GN

D2

4V

GN

D2

4V

+2

4V

GN

D2

4V

GN

D

24

V-V

alv

eo

utp

ut

Op

era

tio

n

Puls

e c

oun

ter

Test

Ma

nu

al

Re

se

t

Co

mp

resse

d-a

irm

on

ito

r /

Full in

dic

ato

r

Co

il

5.2.3 Performance data - connectors

Potential-free relay contacts 250VAC / 3A 120VDC / 3A

Switching output Maximum current load: 400 mA

Switching inputs Connection of ’make contacts’ against GND-24V or 24V

Switching elements (contactors, relays etc.) may only be connected to the potential-free contacts if interference is suppressed.

Relay connection for machine protection: For the conveyor system to stop both when metal is detected and when there is a fault, the relays ”Metal” and ”Fault” must be con-nected in series (see drawing on the right).

44 3441 31

Metal 1

Wire jumper

Connection contacts

Fault

42 32

5.2.4 Electrical connection of the equipment

Maximum cable length for external components, switches and sen-

sors is 15 m.

Only shielded cables should be used. The shields must be attached directly to the electronics housing.

HousingShield

Cable

5. Commissioning

15

5.2.5 Connection examples

a) Connection of a load at the "24V-valve output (e.g. solenoid valve)

1 = GND-24 2 = DC 24 V-valve output (400mA) In "metal-reset mode = manual" the 24 V-valve output is reset with the reset button In "metal-reset mode = automatic" the 24 V-valve output is reset by the electronic unit

b) Connection of a load at the "operation" output (e.g. indicator lamp)

3 = "Operation" output (OC 30mA) 4 = +24 V

c) Connection of an external pulse counter

Pulsecounter

5 = GND-24 V 6 = "Pulse counter" output (24 V, optically decoupled)

d) Connection of an external button at the test input

7 = +24 V 8 = "Test" input (optically decoupled) With the test button the function of the electronic evaluation unit in case of metal detection can be checked.

5. Commissioning

16

e) Connection of an external button for manual ejection

7 = +24 V 9 = "Manual" input (optically decoupled) The diverter flap stays in eject position as long as the button is pressed.

f) Connection of an external reset button

7 = +24 V 10 = "Reset" input (optically decoupled)

g) Air pressure monitor or full indicator (Selectable by DIP-switch (see page 19))

- Air pressure monitor Connection of external air pressure monitor

Air pressuremonitor

11 = GND-24 V 12 = "Air pressure monitor" input (optically decoupled)

- Full indicator Connection of external full indicator for the reject box

Full indicator

11 = GND-24 V 12 = "Full indicator" input (optically decoupled) (Full indicator: make contact, NPN)

5. Commissioning

17

h) Connection "Search coil"

13 14

GN

D

13 = Signal output 14 = GND

Switching elements (contactors, relays, etc.) may only be connected to the poten-

tial-free relay outputs in interference-suppressed condition.

ATTENTION: EXTERNAL VOLTAGE !

The potential-free relay outputs may still be energized, even after the mains supply

has been turned off !

5.2.6 Mains supply

The Control-Unit MSG3.4K may only be connected via a fused mains supply line (16A cir-cuit breaker), irrespective of whether connection is made by way of a terminal box or a safety socket.

5.2.7 Mains supply via safety socket

1. Connect the cable with mains plug to an existing socket.

2. After approximately 5 seconds the machine is ready for operation.

5.2.8 Mains supply via terminal box

The following procedures should only be undertaken by qualified personnel. Before re-moving cover plates etc. make sure the equipment is isolated from mains or external volt-age.

If the mains plug is removed, a terminal box and a suitable mains disconnector switch with corresponding labelling/marking must be installed! This disconnector switch must be easily accessible and must disconnect all poles from the mains.

Do not remove either the mains cable or the protective gland as these are essential parts of the EMC configuration. The main cable is a special EMC protected cable and should not be replaced by any other cable.

1. Remove the mains plug. 2. Strip 5 cm length of insulation from the cable and 1 cm from the leads and attach wire end ferrules.

Mains cable:

1 2

345

1 Shield wire

2 Conductor

3 PVC insulation

4 Shield

5 PVC covering

5. Commissioning

18

3. Insert the cable into the terminal box and connect it to the mains supply according to the diagram below.

Prior to this, always make sure that the mains supply to the terminal box is switched off.

Use a suitable shutdown unit i.e. emergency switch.

LNPE

5

7

3

2

1

6

8

4

1 Terminal box

2 3 pin terminal

3 Control unit mains cable

4 Mains supply

5 Conductor L (brown) To terminal L

6 Conductor N (blue) To terminal N

7 Conductor PE (yellow/green) To terminal PE

8 Shield wire To terminal PE

IMPORTANT! Connect the shield wire to PE

4. Close the terminal box. 5. The unit is ready for operation approximately 5 seconds after switching it on.

5.2.9 Behaviour of machine at start-up

Behaviour of switching outputs during the start-up phase:

Output Contact status

Metal relay Contacts 41 and 44 closed (consistent with metal alarm)

Fault relay Contacts 31 and 32 closed (consistent with fault status)

MV1 switching output As programmed High-active or low-active

Behaviour of switching outputs after the start-up phase (approx. 5. seconds):

Output Contact status

Metal relay Contacts 41 and 42 closed

Fault relay Contacts 31 and 34 closed

MV1 switching output As programmed High-active or low-active

5.2.10 Relays – operating status

Metall

424144

Fehler

323134

Without power

Metall

424144

Fehler

323134

Operating

Metall

424144

Fehler

323134

Fault

Metall

424144

Fehler

323134

Metal

6. Setting machine parameters

19

6 Setting machine parameters

6.1 DIP switches

System parameters may only be changed by qualified and skilled persons! Always make sure that the control unit is isolated from the mains voltage and from any ex-ternal voltage before you open the housing!

Various machine parameters can be set by means of the 10 pin DIP switch (see page 8-9, item 17)

Switch 1: Sensitivity High Low

Switch 2: Metal-reset Auto Manual

Switch 3: MV1 active Low-Active High-Active

Switch 4: Processing speed HS LS

Switch 5: not used --- ---

Switch 6: Air pressure monitor / full indicator Air pressure Level





Switch 1: The electronics can be set to max. sensitivity or to reduced sensitivity.

Switch 2: Determines whether the metal signal is reset automatically after an adjustable eject du-ration, or is reset by means of a reset button.

Switch 3: This sets the switch status of magnetic valve connector 1 when metal is detected.

Low-Active: Normal output 24 V, on metal detected 0 V High-Active: Normal output 0 V, on metal detected 24 V

Switch 4: This switch is used for setting the conveying speed (High-Speed / Low-Speed).

Switch 5: Not used.

Switch 6: Level monitoring in the reject container by way of a sensor (low-active) at terminal "Option" 11-12 11-GND-24 V 12-Full indicator Active signal Alarm relay: active Alarm LED: active Operation LED: flash Metal detection is maintained. The status can be acknowledged by pressing the reset

button.

6. Setting machine parameters

20

Description of modes

High-speed: In this mode the equipment operates for pressure and suction conveyor systems and free-fall applica-tions up to a speed of 35 m/s.

Low-speed: In this mode the equipment operates for slow conveyor belt applications to free-fall use (4 cm/s - 2 m/s).

Standard configuration (operating mode) HS („High Speed“) LS („Low Speed“)

Combined with coil or device type RMS 3E

Indicator lamp/contactor:

Indicator lamp (operation / error) X X

Test button X

Reset button X

“Manual ejection” button

Additionally available switching outputs:

Reset X

Manual ejection X X

Air pressure monitor or full indicator X X

Test button X

Additionally available switching outputs:

Potential-free switchover contact 250V/3A (er-ror, metal detection)

X

X

Optically decoupled switching output 24V (metal detection) X X

Switching output 24V DC, 400 mA (for solenoid valve) X X

Conveying speeds:

2.0 to 36.0 m/sec. X

0.04 to 2.0 m/sec. X

0.04 to 2.0 m/sec. (option for „static operation“) X

Adjuster for noise suppression X

6.2 Hex-switch


1 2 3

1 2 3

When the jumper (see page 8-9, item 20) is changed from position 2 – 3 to 1 – 2, the current parameter is shown on the 7-segment displays (see page 8, item 12). Parameter "0" or "1" must be set for the Control Unit.

0

The respective user program can be set with the Hex-switch (see page 8-9, item 18).

Position 0: Program 0 Control Unit without valve output monitoring Position 1: Program 1 Control Unit with valve output monitoring

The selected program is shown on the 7-segment display.

7. Operation

21

7 Operation

7.1 Settings on the board


At the Control Unit the following settings can be performed with three of the five potentiometers (see page 8-9, item 13, 14, 15):

7.1.1 Setting of Sensitivity

The scanning sensitivity can be adjusted with the "sensitivity" potentiometer (see page 8-9, item 15 for potentiometer location).

Correction of the sensitivity: Select the value at which metal impurities are just detected. Reason: If the sensitivity setting is too high, external interferences or certain products may cause spurious triggering.

How the sensitivity depends on the passage cross-section: At the centre of the passage cross-section the sensitivity is lower than at the edges. Therefore the fac-tory-given sensitivity data always refer to the coil centre.

How the sensitivity depends on the shape and composition of the metal impurities: Detection of the metal impurities depends on the geometric shape and on the composition (alloys). This must be taken into consideration when choosing a suitable test piece.

For perfect operation in highest sensitivity ranges optimum installation is an im-

portant prerequisite.

Convey a suitable test piece through the centre of the passage opening

Set optimum sensitivity at potentiometer "sensitivity" (test piece is just detected)

sensitivity

-

When the potentiometer is turned, the current value is shown on the 7-segment displays (page 8-9, item 12). "00." = lowest sensitivity "9.9" = highest sensitivity

7. Operation

22

7.1.2 Setting of interference suppression

The interference suppression can be adjusted with the "interference suppression" potentiometer (see page 8-9, item 14 for potentiometer location).

Interference causes: Vibrations of the conveyor systems are transferred to the search coil. This

may lead to disturbing pulses - and consequently to spurious operation. Interference suppression: A high-quality interference filter guarantees reliable operation of the

metal detector even under "rough" production conditions. Any interference with a frequency that is higher than that of metal signals is suppressed.

Send a suitable test piece through the centre of the passage opening or over the flat coil

Turn the "interference suppression" potentiometer clockwise in steps and repeat point

until the test piece is no longer detected. I n t e r f e r e n c e

s u p p r e s s i o n

-

When the potentiometer is turned, the current value is shown on the 7-segment displays (page 8-9, item 12). "00." = lowest interference suppression "9.9" = highest interference suppression

Then turn the "interference suppression" potentiometer back again until the test piece is

reliably detected again.

The interference suppression is now optimally set.

In HS-mode this potentiometer has no influence.

7.1.3 Setting of eject duration

The eject duration can be adjusted with the "eject duration" potentiometer (see page 8-9, item 13 for potentiometer location).

Definition: The "Eject duration" is the length of the switching pulse that is provided at the switching outputs after metal detection. This switching pulse activates the diverter flap.

rejectduration

-

When the potentiometer is turned, the current value is shown on the 7-segment displays (page 8-9, item 12). "05." = 0.05 s, shortest eject duration "29" = 29 s, longest eject duration

7. Operation

23

Convey test material that contains impurities Good material with test piece

Setting of the optimal eject duration (test pieces are safely separated out with lowest pos-

sible material loss)

If necessary, repeat and

7.2 Replacing a defective fuse

Always make sure that the control unit is isolated from the mains voltage and from any ex-ternal voltage before you open the housing!

Open the cover of the electronics housing

Replace the blown fuse on the electronics board (see page 8-9, item 7 for fuse location).

Reassemble in reverse order

8. Errors and fault remedying

24

8 Errors and fault remedying

If you should have any questions, or if there should be any malfunctions, please

contact the manufacturer.

If you have any questions, please state the equipment type and serial number!

Service telephone: +49 (0) 85 54 - 30 8-180

8.1 Error messages

Errors are indicated by a flashing of the illuminated pushbutton at the housing cover, and by a drop of the fault relay. The appropriate fault status is shown on the 7-segment display (see page 8-9, item 12). Example: The letter F and the fault number flash up alternately.

8.1.1 Faults at solenoid valve MV1

This message is displayed if there is a short circuit or break in the solenoid valve switching output.

Error messages Possible causes Action

F 01 Short circuit to solenoid valve. Check valve cable for breaks and renew if

necessary. Check valve cable plug and socket connec-tions, remove and reinsert if necessary.

Please note: The solenoid output only is monitored in program 1 (see page 18).

8.1.2 Faults at the search coil

This error message is displayed if the connection to the search coil is interrupted.


F 03

Cable between control unit and search coil has a short circuit or is broken.

Disconnect cable at the search coil (triax ca-ble) and measure with Ohm meter: replace if necessary.


25

8.1.3 Compressed air monitor

A compressed air monitor is connected to "Option” terminals 11-12

These message is displayed when there is no air pressure or the air pressure is too low.


F 05

No air pressure or air pipe broken Check air supply

Operating threshold of pressure monitor is set too high.

Adjust pressure monitor

After discharge of compressed air, pres-sure monitor should be disregarded for a certain time. This error may appear if the time interval is too short.

Increase time interval

8.1.4 Level monitoring

Level monitoring connected to "Option", terminals 11-12


F 08

The container is full. Empty container

The sensor is faulty. Change sensor

Sensor is not connected or connection cable is broken.

Check sensor connection

8.2 Undefined activation of switching outputs

Possible causes Action

Machine incorrectly installed See "Assembly”

Conveyor belt systems: Intermittent contacts on the conveyor frame, for example due to:

Loose guide plates

Loose screw connections at the frame parts

Changing contact resistance at the tension and deflection roller bearings or at the drive roller

Certain parts of the conveyor belt are conductive:

Contaminated with metal (welding spatter, metal chips, abraded material….)

Belt junction causing metal alarm to signal even when no product on moving conveyor

Check and tighten all screw connections If necessary weld frame parts.

Insulate cross connections or tension and deflec-tion rollers on one side.

Clean conveyor belt of all residue. If necessary replace conveyor belt.

Circular coils: Mechanical contact between scanning pipe and detection coil.

Observe a minimum distance of 10 mm between pipe and coil. If necessary use a scanning pipe with smaller diameter.

Sensitivity setting too high Repeat product teach-in procedure, if necessary reduces sensitivity manually.

Metal particles hard to identify due to corrosion or encapsulation

Check processed material carefully, if necessary pass through detector again.

Loose contact at the detector cables Check connections

Material or conveyor statically charged (cracking sound heard at the detection coil).

Prevent static by additional earthing (please con-sult manufacturer) or by using ion spraying devic-es.


26

8.3 Special notes on separators

Metal is detected but is not rejected despite activation of the reject unit

Possible causes Action

Mechanism too slow Check air pressure (5 bar minimum)

Replace air hoses that are too thin and too long with hoses that are as short as possible and have a large diameter

Check the reject flap for jammed product

Attention! Risk of accident Disconnect compressed air supply be-

forehand

Reject duration too short Increase reject duration

8.4 Replacement of electronic boards

1 2 3

1. Disconnect mains supply and external circuits and open cover of electronics housing 2. Remove connectors (1) and remove fastening screws (2) 3. Remove evaluation electronics board (3)

4. Install the new board in reverse order but do not connect to mains power supply!


27

Transferring all settings:

A

B

(A) New control unit

(B) Old control unit Procedure:

All the system settings (Dip-switch and Hex-switch), and all the potentiometer settings must be transferred to the new control unit.

9. Maintenance and cleaning

28

9 Maintenance and cleaning

Prior to cleaning turn off the system with the master switch and disconnect the system from the mains voltage.

9.1 Maintenance

The control unit is maintenance-free, yet it is still appropriate to inspect the equipment in regular inter-vals:

- Are all the fastening screws tight?

- Is the housing sealing in perfect condition, and does it provide proper sealing?

- Also check all the cables for possible damage (e.g. at the cable sheath).

9.2 Cleaning

9.2.1 Hints for cleaning

- Please ensure you follow the instructions below. - Specific machine components must be cleaned with specific substances. Please use the correct

materials and clean at regular intervals as suggested. - If the building is being cleaned ensure the machines are covered up. The following must not be used for cleaning: - Sharp, hard or pointed objects - Water or steam jet appliances - Compressed air - Hazardous and solvent-containing materials - Cleaning agents that may attack the materials used

9.2.2 Cleaning instructions

For cleaning purposes we recommend that you use warm water with approved cleaning agents for the respective application, and a soft, lint-free cloth. Once every week the coil shaft should be thoroughly cleaned, removing any dirt accumulations and deposits. After cleaning, wipe up any remaining drops of water with a dry, non-fibrous cloth until the coil shaft is dry. From time to time apply oil to the stainless steel framework (e.g. Nirostol 55 cleaning and maintenance oil which meets food industry standards).

10. Spare parts

29

10 Spare parts Please state type of equipment and serial number when contacting us.

Spare parts and wearing parts must always be obtained from the manufacturer of from a supplier that is certified by the manufacturer.

10.1 Spare parts drawing

1

2

3

4

4

4

4

4

10.2 Spare parts list

Item No. Part Part No. Remarks Drawing no.

1 Two- way- key 33002648

1a Lock with seal 33002650

2 Control Unit 44005460

3 Mains cable 1)

04013484 with plug

4 Illuminated push button / "Test" (complete) 44001414

1) In case of order please give cable lengths!

11. Shipping, preservation, waste disposal, transport, storage

30

11 Shipping, preservation, waste disposal, transport, storage

11.1 Shipping, preservation, waste disposal

1. Choose packing that is suitable for the type and size of unit, taking into account whether the shipment is for export by sea or airfreight, or for national or international road transport The packing material must protect the goods from all damage under normal transport conditions.

2. Depending on the size, weight and nature of the goods packing in cardboard boxes, boxed pallets etc. is only suitable for road transport. Use reinforced card, corrugated cardboard, blister packing and shredded paper to fill and protect the goods. Electrostatic sensitive components (electronic boards, electronic modules, etc.) must

be packed in antistatic foil or foil bags prior to packing! ( t h i s i s e s s e n t i a l ! ) Stick additional warning labels on the outside of the packaging e.g. "Attention, elec-tronic equipment, do not drop,” etc. The packing should be sealed with adhesive tape and, where the weight exceeds 50 kg, additionally with wrapping tape.

2a. When packing for international road transport use the instructions above (see point 2). Larger and heavier shipments must also be protected as for export in wooden crates. Care must be taken to ensure that the goods inside the packing are protected against corrosion. Any parts that will corrode easily must be wrapped in oil paper or corrosion-protective foil. Care must be taken to prevent the components moving around within the packag-ing.

2b. International air freight shipments must be packed in wooden crates or on export pal-tainers. Care must be taken that the goods are secure and well-protected inside the packing. Any parts liable to corrode must be wrapped in oil paper, protective foil or sprayed with anti-corrosion spray.

2c. Sea-freight must be packed in seaworthy export crates. These crates can be obtained from specialist suppliers. The crates must be lined with oil paper to make them resistant to sea water and pre-vent corrosion. In addition the goods must be protected against corrosion by use of a spray or be wrapping in protective foil. Care must be taken to ensure that the goods cannot move around inside the crate. After packing the sea-freight crates must be properly closed. The sea crates must also be fastened externally with securing tapes. During loading care must be taken not to damage the external packaging. The carrier must certify that the shipment has been accepted and loaded correctly by detailing this on the bill of lading, loading list etc.

3.

Waste disposal: Observe the national waste disposal regulations.

11. Shipping, preservation, waste disposal, transport, storage

31

11.2 Transport

In order to avoid injury or damage to the unit it must be handled properly. In addition to following the instructions below, general health and safety good practice and specific accident prevention guidelines should be observed.

For correct handling and storage comply with the following symbols:

Protect against moisture

Careful: glass

Up

Centre of gravity

Do not compress the side walls of the unit or any attached parts by pulling obliquely on ropes or chains.

Only remove handling safeguards once all installation work has been completed.

When handling in a loading area make sure the unit cannot topple over or slip.

Damage caused during transportation must always be reported to the manufacturer.

11.3 Storage

If possible the unit should be stored in a closed room until final installation.

If the unit is stored in the open it must be covered over with tarpaulins and open under-neath to allow condensation to drain off.

Avoid any higher temperature fluctuations. It is possible that condensed water that has formed in the packing cannot properly drain and may corrode equipment surfaces. If a formation of condensed water cannot be avoided, suitable desiccants e.g. in the form of bags must be placed in the packing.

If the unit has been packed for transportation by sea the packaging must not be dam-aged or opened during transit and storage.

For storage temperature and permissible air humidity please refer to the technical data sheet.

For correct storage comply with all storage and handling symbols:

Protect against moisture

Careful: glass

Up

12. Annex

32

12 Annex

EC DECLARATION OF CONFORMITY

Technical data sheet

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