Eriez E-Z TEC IV, E-Z TEC V Installation, Operation And Maintenance Instructions

Installation, Operation and Maintenance Instructions

MM-235F

E-Z Tec Metal Detectors Models IV & V

ERIEZ MAGNETICS HEADQUARTERS: 2200 ASBURY ROAD, P.O. BOX 10608, ERIE, PA 16514–0608 U.S.A.

WORLD AUTHORITY IN ADV ANCED TECHNOLOGY FOR MAGNETIC, VIBRA TOR Y and MET AL DETECTION APPLICA TIONS

Introduction

This manual details the proper steps for installing the Eriez E-Z Tec® Model IV and V Metal Detectors.

Careful attention to these Installation Requirements will assure the most efficient and dependable performance of this equipment.

If there are any questions or comments about the manual, please call the factory at 814/835-6000 for E-Z Tec

Metal

Detector assistance.

CAUTION - ELECTROMAGNETIC FIELDS

• Metal Detectors emit electromagnetic fields. Contact the American Conference of Governmental Industrial Hygenists, Cincinnati, Ohio, U.S.A., (www.acgih.org) for additional information.

• If you use a medical implant or similar device, you must never approach the equipment because your device may malfunction in the electromagnetic field, with consequences up to and including death.

Contact Eriez if you have a question regarding these precautions.

Handling Instructions

PLEASE LEAVE THESE INSTRUCTIONS ATTACHED

TO THE EQUIPMENT UNTIL INSTALLATION IS COMPLETE

1. DO NOT LIFT THE METAL DETECTOR BY INSERTING ANYTHING INTO OR THROUGH THE APERTURE. The inner surface of the aperture is delicate and is surrounded by a precisely tuned electronic circuit that must not be disturbed. Any damage to this surface or any aperture distortion caused by handling will invalidate Eriez’ warranty.

2. HANDLE THE SHIPPING PALLET NOT THE DETECTOR. Keep the metal detector on its shipping pallet as long as possible.

3. When you must remove the detector from the shipping pallet, LIFT ONLY ON DETECTOR HOUSING SERVICES THAT INCLUDE SUPPORTING “FEET” OR T APPED LUGS, as supplied by Eriez.

4. LIFT BY HAND IF POSSIBLE, or by using a crane and soft nylon slings running under the entire detector housing - NOT THROUGH THE APERTURE. Block the slings to prevent rubbing on the remainder of the detector housing.

5. The metal detector is heavy. Use care when handling to avoid injury to personnel or damage to property.

6. Never weld any attachment to the detector housing. Do not attempt to drill and/or tap the metal detector housing for lifting or mounting attachments.

7. Never lift with a crane or fork lift under the “chin” of the control housing that juts out from the metal detector housing. Make certain that lifting straps and other handling equipment do not contact the control housing.

8. If handling with eye-bolts threaded into pretapped holes supplied by Eriez:

a. Make sure that eye-bolts are strong enough

for the loads that will be applied

b. Never apply loads perpendicular to the

shank of the eye-bolts; they will break.

Table of ContentsTable of Contents

ERIEZ E-Z TEC METAL DETECTORS - MODELS IV AND V

GENERAL ...........................................................................................................12

PRINCIPLE OF OPERATION .............................................................................12

SPECIFICATIONS ..............................................................................................13

DETECT MODES................................................................................................15

Mode 1 ..........................................................................................................15

Mode 2 ..........................................................................................................15

INSTALLATION CAUTION!! ................................................................................16

MECHANICAL INSTALLATION...........................................................................16

Introduction ...................................................................................................16

Handling ........................................................................................................16

Location of Sensing Head .............................................................................16

Metal Free Area.............................................................................................17

Electrical Current Loops................................................................................17

Insulating the Conveyor Shafts .....................................................................17

Permanent Loops..........................................................................................18

Mounting Base ..............................................................................................18

Belt Splices ...................................................................................................19

Conveyor Slider Bed .....................................................................................19

Product Position ............................................................................................19

Reject Proximity Switch.................................................................................19

ELECTRICAL INSTALLATION............................................................................20

Introduction ...................................................................................................20

Choice of Input Power Source ......................................................................20

Power Supply ................................................................................................20

Relays ...........................................................................................................21

Direct Relay.............................................................................................21

Timed Relay ............................................................................................21

Fault Relay ..............................................................................................21

AC SSR ...................................................................................................21

DC SSR...................................................................................................21

Relay Notes.............................................................................................22

Table of Contents (cont.)

Inputs ...........................................................................................................22

Tachometer Input (TACH)........................................................................22

Proximity Switch (PROX SW)..................................................................22

Reject Confirmation (REJ CON)..............................................................22

Reject Reset (REJ RESET).....................................................................23

Host Computer Port (MPC

Printer Port (MPC only) ...........................................................................23

Conduit..........................................................................................................23

Initial Test (Analog Unit) ................................................................................23

Initial Test (MPC Unit)....................................................................................24

ANALOG CONTROLS AND DISPLAYS .............................................................25

Large Rectangular Status LED’S ..................................................................25

Detect (Red) ............................................................................................25

Fault (Yellow)...........................................................................................25

only) ............................................................23

Monitor Display .............................................................................................25

Sensitivity Control .........................................................................................25

Phase Control ...............................................................................................25

Analog Output Controls.................................................................................25

Travel Time..............................................................................................25

Reject Time .............................................................................................25

Standard Reject Time..............................................................................25

Indexed Reject Time................................................................................25

Programming Switches ...........................................................................26

Fault Indicator..........................................................................................26

Balance LED ...........................................................................................26

Reject LED ..............................................................................................26

Relay Status LEDs ..................................................................................26

Direct .......................................................................................................26

Timed.......................................................................................................26

ACSSR ....................................................................................................26

DCSSR....................................................................................................26

Fault ........................................................................................................26

Table of Contents (cont.)

Analog Output Controls (cont.)......................................................................26

Window LED............................................................................................26

Index In LED............................................................................................26

Confirm LED............................................................................................26

Clock LED ...............................................................................................27

Detect LED ..............................................................................................27

Analog Circuit Board Switch Programming ...................................................27

SW1-1 .....................................................................................................27

SW1-2 .....................................................................................................27

SW1-3 through SW1-8 ............................................................................27

SW1-9 .....................................................................................................27

SW2-1 .....................................................................................................27

SW2-2 .....................................................................................................27

SW2-3 .....................................................................................................27

SW2-4 .....................................................................................................27

JP1 ..........................................................................................................28

JP2 ..........................................................................................................28

JP3 ..........................................................................................................28

Switch Charts ..........................................................................................28

MPC CONTROLS AND DISPLAYS ....................................................................30

MPC Control Panel .......................................................................................30

LED Bar Graph........................................................................................30

Switch Keys.............................................................................................30

LCD .........................................................................................................30

MPC Software ...............................................................................................30

Flowchart.................................................................................................30

General MPC Operation................................................................................30

Monitor ....................................................................................................30

Reject Reports.........................................................................................31

Product Setup..........................................................................................31

Options ....................................................................................................31

Passwords.....................................................................................................31

Detect / Reject Display..................................................................................31

Table of Contents (cont.)

Controlling the MPC Display .........................................................................32

Travel Between Menus............................................................................32

Changing Variables .................................................................................32

Detailed MPC Menu Description ...................................................................32

Power Up Display....................................................................................32

Monitor Display........................................................................................32

Change Product Menu ............................................................................33

Identification Display ...............................................................................33

Main Menu...............................................................................................33

Product Setup Menu................................................................................33

Sensitivity ..........................................................................................33

Detect Mode ......................................................................................33

Phase ................................................................................................33

Gain...................................................................................................33

Filter...................................................................................................33

Configure Rejects..............................................................................34

Detailed MPC Menu Description (cont.)........................................................34

Product Description ...........................................................................34

Auto Phase........................................................................................34

Reject Setup............................................................................................34

Detect On Power Up?........................................................................34

Timed Reject .....................................................................................34

Timed Reject, Index Device is not Used............................................34

Timed Reject, Index Device Used .....................................................35

Direct Reject............................................................................................36

Product Description .................................................................................36

Auto Phase..............................................................................................36

Reject Reports.........................................................................................36

Erase All Reports..................................................................................... 37

Fault ........................................................................................................37

Reject Confirmation Fault..................................................................38

Balance Fault ....................................................................................38

Self-Check Fault................................................................................38

Calibration Fault ................................................................................38

Table of Contents (cont.)

Options ....................................................................................................39

Buzzer ...............................................................................................39

Setup Communication .......................................................................39

Setup Printer .....................................................................................39

Factory...............................................................................................39

Set Time and Date.............................................................................39

Update Passwords ............................................................................39

Print Options............................................................................................39

Diagnostics..............................................................................................39

Troubleshooting.................................................................................39

Self-Check.........................................................................................40

Calibration Check ..............................................................................41

Calibration Check Setup....................................................................41

CONFIGURING ANALOG METAL DETECTOR .................................................42

Analog Adjustment Procedure.......................................................................42

Phasing Out the Product Effect - Analog Units..............................................42

Reject Adjustment - Analog Units ..................................................................43

Direct Reject............................................................................................43

Timed Reject ...........................................................................................44

Timed Reject, Index Device Not Used.....................................................45

Timed Reject, Index Device Used ...........................................................46

CONFIGURING MPC METAL DETECTOR ........................................................48

MPC General Options Menu .........................................................................48

MPC Product Setup ......................................................................................48

MPC Reject Adjustment ................................................................................51

Direct Reject............................................................................................51

Timed Reject ...........................................................................................51

Timed Reject, Index Device Not Used.....................................................51

Timed Reject, Index Device Used ...........................................................52

Obtaining MPC Reject Reports .....................................................................53

LCD .........................................................................................................53

Printer......................................................................................................53

Host Computer ........................................................................................53

Table of Contents (cont.)

MAINTENANCE ..................................................................................................54

SPARE PARTS....................................................................................................54

Analog Unit Spare Parts................................................................................54

MPC Unit Spare Parts................................................................................... 55

FIGURES ...........................................................................................................56

APPENDIX A - PRINTER OPERATION (MPC ONLY) ........................................77

Introduction ...................................................................................................77

General Description ......................................................................................77

Detailed Description ......................................................................................77

Connector Pinout.....................................................................................77

MPC Printer Setup ..................................................................................77

Data Bits..................................................................................................77

Parity .......................................................................................................77

Transmit Mode.........................................................................................77

End Line With ..........................................................................................78

Baud Rate ...............................................................................................78

Printing Options.............................................................................................78

Printing A Single Report ..........................................................................78

Printing Multiple Reports .........................................................................78

Operating Instructions ...................................................................................78

Configuring Printer Cable ........................................................................78

Setting Up MPC Printer Serial Port .........................................................79

Printing a Single Report Using Manual Mode .........................................79

Printing Reports Automatically ................................................................79

Printing All Stored Reports ......................................................................80

Canceling Print All Reports......................................................................80

APPENDIX B - VARIABLE SPEED TACHOMETER ...........................................81

Tachometer System Design ..........................................................................81

Tachometer Wiring Connections .............................................................82

Table of Contents (cont.)

APPENDIX C - VARIABLE REJECT UNITS .......................................................83

Introduction ...................................................................................................83

Mechanical ....................................................................................................83

Electrical........................................................................................................84

APPENDIX D - SLIM TEC SINGLE SURFACE UNITS.......................................86

Introduction ...................................................................................................86

Mechanical ....................................................................................................86

Electrical........................................................................................................87

APPENDIX E - SLIM TEC APERTURE UNITS...................................................90

Introduction ...................................................................................................90

Mechanical ....................................................................................................90

Electrical........................................................................................................91

APPENDIX F - VFS PACKAGING MACHINE METAL DETECTORS .................94

Introduction ...................................................................................................94

Mechanical ....................................................................................................94

Electrical........................................................................................................95

General

The Eriez Magnetics E-Z Tec IV and V Metal Detectors are state of the art electronic devices for detecting fine particles of metal in non-metallic product streams. They are designed for accuracy , sensitivity, reliability and simplicity of operation. Two variants are available: the analog version (Figure 1) and the MicroProcessor Controlled (MPC®) version (Figure 2). The performance, controls, and outputs of the analog version are ideal for most standalone industrial applications where a simple detect-reject process is required and the product stream has consistent characteristics from day to day. For applications where the detect-reject procedure may require more frequent changes, the record keeping requirements may be more stringent, or a centrally controlled network of detectors is required, Eriez provides the MPC versions of the E-Z Tec IV and V.

This manual covers both the analog and MPC versions of the E-Z Tec IV and V. Much of the discussion herein is relevant to either version.

This manual provides all information necessary to use both the E-Z Tec IV/V Metal Detector (analog version) and the E-Z Tec IV/V MPC Metal Detector as standalone systems. For networked or remotely controlled installations of MPC detectors refer also to the E-Z Tec III/IV/V MPC Communications Manual MM-237

NOTE: Throughout this manual, information specific to the analog version of the metal detector is set off with a gray border.

Information specific to the MPC version of the metal detector is set off with a gray background.

Generic information—applicable to both analog and MPC versions—is neither bordered nor shaded.

Principle of Operation

The E-Z Tec IV/V Metal Detector uses a differential transformer to detect pieces of metal. Three coils encircle the detection aperture. The signal voltage in the primary coil is driven by an oscillator. Two secondary coils, on a common axis with the primary , are coupled into the field of the primary coil in such a manner that the system is in balance and the induced voltages in the two secondary coils cancel.

A piece of metal introduced into the detection aperture will distort the primary field and cause a difference in induced voltages in the two secondary coils. This voltage difference constitutes a signal

that is amplified and manipulated to extract the amplitude and phase angle with respect to the oscillator input signal. This information is used to decide whether the signal represents metal or the user’s product. If it represents the user’s product it is ignored. If it represents metal, and if the signal exceeds a pre-set level, the metal detector generates a detection signal. The detection signal is manipulated to provide various timing functions for creating reject actions.

Figures 3 and 4 illustrate conveyor installations of E-Z Tec analog and MPC metal detectors respectively.

Separation of P o wer and Signal Wiring

This information is being distributed to assemblers and electricians about the importance of proper methods for wiring of controls. These methods are revised and updated from time to time as we (Eriez Magnetics) perceive necessary . This information will cover distances from various categories of cables and Eriez Metal Detector wiring standards. The cable categories are:

Use separate machine entry holes for category 1, 2 and 3 cables.

When Eriez Metal Detectors are being installed in plants using VFC drives, the following precautions are recommended:

1. Route VFC wiring and Eriez Metal Detector wiring in to separate metallic conduits.

1. AC power cables

2. DC distribution (thermocouple, power supplies)

3. Signal and Logic a. Analog (low level) b. Digital logic

Category 1 cables are to be routed along frame members and panels. A void open space hanging.

Category 2 cables are routed as in Category 1 but separate from 1.

Category 3 cables are routed separately from Categories 1 and 2. Category 3b cables are to be spaced 25 cm (1") from Category 1 for each meter of run.

2. Separate power sources should be used for VFC drive and Eriez Metal Detectors.

3. The use of a Harmonic Neutralized Constant Voltage Transformer for the Eriez Metal Detector power is recommended. Use separate conduits for in and out wiring.

4. Twist AC common circuit run wires tegether to minimize electromagnetic field interference.

5. Follow cable category separations as detailed above.

Specifications

POWER SOURCE REQUIREMENTS (TWO RANGES)

105 to 125 VAC 50 to 60 Hz. Max. surges of 150 V RMS for a period of 2 seconds. OR 210 to 230 VAC 50 to 60 Hz. Max. surges of 300 V RMS for a period of 2 seconds. Maximum demand 60 VA (Excluding externally connected loads).

FUSES

Located in separate NEMA 4(X) enclosure

(See Figure 7).

F1 - Self resetable fuse rated at 200mA DC.

Requires no service.

F2,3,4,5,6 - Bussman GMA-1A 5X20 mm. F7, F8 - Bussman GMC-1A 5X 20 mm.

TACHOMETER INPUT

Used to monitor variable speed conveyors.

See Appendix B.

Voltage

Logic 0 - 0.0 VDC to 0.9 VDC. Logic 1 - 3.15 to 50 VDC . (NPN Open Collector can also be used).

Current

Source N/A. Sink 1 mA min.

Frequency

50 Hz max maximum.

Minimum Pulse Width

Logic 0 - 5 mSec. Logic 1 - 5 mSec.

PROXIMITY SWITCH INPUT

Voltage

Logic 0 - 0.0 VDC to 0.9 VDC. Logic 1 - 3.15 to 50 VDC. (NPN Open Collector can also be used).

Current

Source N/A. Sink 1 mA min.

Frequency

50 Hz max maximum.

Minimum Pulse Width.

Logic 0 - 5 mSec. Logic 1 - 5 mSec.

REJECT CONFIRMATION INPUT

Voltage

Logic 0 - 0.0 VDC to 0.9 VDC. Logic 1 - 3.15 to 50 VDC. (NPN Open Collector can also be used).

Current

Source N/A. Sink 1 mA min.

Frequency

50 Hz max maximum.

Minimum Pulse Width

Logic 0 - 5 mSec. Logic 1 - 5 mSec

REJECT OUTPUTS

Direct Reject

K1 - Mechanical single pole double throw relay rated 1A, 250 VAC or 1A, 30 VDC.

Timed Reject

K2 - Mechanical single pole double throw relay rated 1A, 250 VAC or 1A, 30 VDC.

OPTIONAL SOLID STATE RELAYS

SSR1 - AC solid state relay rated .02 to 1.0 A,

12 to 250 VAC.

SSR2 - DC solid state relay rated .02 to 1.0 A,

5 to 60 VDC.

PRODUCT MEMORY (MPC ONLY)

The MPC is capable of storing all metal detector adjustments and alphanumeric descriptions for 99 separate products.

REJECT TIMERS

Direct Reject

Travel Time 0.00 sec. Reject time 0.05 to 60 sec (these values approximate on analog version).

Timed Reject

Travel Time 0.05 to 60 sec. (approximate on analog version). Reject Time 0.05 to 60 sec. (approximate on analog version).

Shift Register Resolution 1200.

Specifications (cont.)

REJECT COUNTER (MPC ONLY)

The MPC stores a running total of the number of times the Direct Reject output has cycled. This normally provides a very close approximation of the total number of detections while preventing multiple counts of the same piece of tramp metal.

Maximum Count: 9999.

REJECT REPORTS (MPC ONLY)

The MPC stores pertinent data on the most recent 100 rejects. Report Number, Product Number, Time, Date, and Peak Signal Level can be reviewed on the LCD display. The reports can be downloaded to a remote printer. In this case, Travel Time, Timed Reject Time, Sensitivity, Gain, and Product Description are also included in the report. The reports can be downloaded to a remote computer. The computer report contains all information mentioned above plus Phase, Filter Frequency, Detect Mode, Fault Status, Date & Time that any one of the variables was last changed, Direct Reject Time, Window Time, and status of Tach Input, Direct Reject Auto Reset, T imed Reject Auto Reset, Space Between Products, Index Device Used?, and Reject Confirmation.

ENCLOSURE RATING

NEMA-4X/IP66.

PRODUCT VELOCITY

The metal detector can be adjusted to scan products traveling from approximately 2 ft./min. to 7800 ft./min. (.6 m/min. to 2400 m/min.) depending on the size and type of sensing head. The unit is set up at the factory for optimal performance for the customer’s application and requires no further adjustment.

FREQUENCY

The metal detector operating frequency depends on the aperture size and the characteristics of the product to be inspected. It is adjustable but this is normally not required unless another metal detector in the area causes interference. In this case consult the factory for adjustment details.

BATTERY LIFE (MPC ONLY)

Minimum 1.4 years; maximum 5.0 years.

COMMUNICATION (MPC ONLY)

Printer-RS 232 (see Appendix A).

Computer-RS 232/485 (see E-Z Tec MPC Communications Manual MM-237).

ENVIRONMENT

Ambient Temperature 0° C (32° F) to 50° C

(122° F) during operation.

Storage Temperature -10° C (14° F) to 80° C

(176° F).

Relative Humidity 0 to 95%.

NOTE: When stored at or below 0° C for longer than six hours and then moved to a warmer location, the temperature of the unit should be allowed to stabilize long enough to allow drying of moisture which may have accumulated on the electronic components (overnight is recommended). DO NOT APPLY POWER UNTIL ELECTRONIC CIRCUITR Y IS COMPLETELY DRY.

PRODUCT DESCRIPTION (MPC ONLY)

32 alphanumeric characters of description can

be stored for each of 32 separate products.

DIAGNOSTICS (MPC ONLY)

Automatic self-checking for proper operation of the metal detector electronics at user definable intervals

Detector can show Fault condition when userscheduled calibration procedure is missed.

Receiver and transmitter independently controllable for identification and isolation of external electronic noise sources.

Detect Modes

E-Z T ec IV and V metal detectors can operate in either of two detect modes. The most appropriate mode for a given application depends largely upon environmental conditions and upon the likely mix of tramp metal in the product stream. The discussion below provides guidelines on selection of the best detect mode for your operation.

MODE 1

The metal detector control processes an analog signal from the receiver coils of the metal detector. A typical example of a metal signal is shown in Figure 5-A. If the magnitude of the signal rises above a predetermined detection threshold, the metal detector will output a detect signal. Note that the analog signal has a positive and a negative portion. In detect mode 1 the metal detector will detect on both portions of the signal. The detect signal typically begins with the first portion of the signal crossing the detection threshold (at point “A”) and ends after the second portion of the signal returns through the opposite detection threshold (at point “B”). Mode 1 is usually the most sensitive and reliable method of detection and is, therefore, used in most applications.

MODE 2

Occasionally a metal detector is used in an environment where significant interference is experienced. Typical sources of interference are lightning, static electricity , and nearby equipment with inductive loads. These types of interference usually cause analog signals which have only one polarity. Figure 5-B shows typical unipolar noise signals at “D”, “E” and “F”. Each of these signals would cause a metal detector to false detect when operating in Mode 1 because they exceed the detection threshold level.

The metal detector can be adjusted to ignore many of these signal types by using Mode 2 detection. Refer again to the analog signal of Figure 5-A. Notice that the metal signal has both a positive and negative polarity . Mode 2 detection does not detect a unipolar signal. It holds off detection until the second polarity of the signal occurs. For the signal in Figure 5-A the detection would occur at point “C”. It would last a predetermined length of time and reset. The noise signals in Figure 5-B would be ignored because they are unipolar.

In general, Mode 2 detection may be somewhat less sensitive than Mode 1 detection. Also Mode 2 detection may allow metal to pass undetected in certain instances. Figure 5-C shows an analog signal representing a small piece of metal followed by a large piece of metal in the product stream. The beginning of the signal is similar to the beginning of the signal shown in Figure 5-A; but as it moves toward the negative detection threshold, the signal of the small piece of metal is absorbed by the signal of the larger piece of metal following it. The larger piece of metal is detected at “G”. Note that the small piece of metal is not detected. Extremely large pieces of metal will cause larger sections of the product stream to be ignored because the electronics will require more time to recover. Therefore, the probability of missed metal increases with the size of the tramp metal. Normally this area is small because the tramp metal is small. The probability is low that metal will be missed, but the possibility exists and must be considered before one decides to use Mode 2 detection.

If the metal detector works reliably using Mode 1 detection, Eriez recommends use of this mode. Some applications are electrically noisy and the number of false trips is high enough that the metal detector cannot be used in Mode 1. In this case one must decide whether to use Mode 2 detection with an increased probability of missing a small percentage of metal. The unit will ignore most noise and still detect the overwhelming majority of the metal. Mode 2 is much better than no protection. However, Eriez recommends its use only when absolutely necessary.

Every unit leaves the factory with an Individual Unit Specifications sheet. This sheet will indicate whether the unit is set for Mode 1 or Mode 2 detection. Most units will be set for Mode 1 detection. If the detection mode of the unit must be changed, use switch SW2-1 on the Output Control panel of an E-Z Tec IV or V analog metal detector (in the Power Supply housing) or use the Detect Mode menu option on an E-Z Tec IV or V MPC metal detector. Detailed instructions for these procedures are given in later sections.

Installation Caution!!

E-Z Tec IV and V metal detectors have been manufactured to very stringent quality control standards to ensure that they will provide years of trouble-free service. To achieve this troublefree service, the installer must follow the installation procedures outlined in this manual.

The details of the procedures are important, and must be followed precisely for proper metal detector operation.

A metal detector is by nature extremely sensitive to very small changes in its electrical and physical environment. Installed incorrectly, it will be very likely to display unstable operation. It will appear

Mechanical Installation

INTRODUCTION

The metal detector contains from one to three components which must be physically mounted to a conveyor or suitable stand: 1) the sensing head,

2) the control (including the MPC in MPC versions) if it is not part of the sensing head, and 3) the power supply which may be integral with the sensinghead and/or this control. See Figure 6.

The sensing head includes the sensing aperture and related electronics. The control is either attached to the sensing head or remote from it. If the control is remote from the sensing head, its enclosure must be mounted to a convenient surface (free of vibration) that is easy to access so that the metal detector can be adjusted. The control enclosure is fitted with plastic mounting feet that must be used to mount it.

The power supply contains all the electrical connections to the metal detector. It is located within a NEMA-4X enclosure (see Figure 7). This enclosure is also fitted with plastic mounting feet that must be used to mount it.

to be extremely sensitive to vibration and/or will false trip (generate a false reject signal) when the conveyor starts and stops. These and other troubles will be prevented by proper installation techniques.

The following installation procedures have been collected over years of experience. Please make use of them! Problems caused by improper installation techniques are not covered by warranty! A little time invested in the installation process will pay for itself many times over by providing a smooth trouble-free startup and continued reliable service.

HANDLING

The metal detector must be handled with care during installation. Follow the specific handling guidelines attached to the detector or included in the shipping materials. For convenience, generic handling guidelines are included in this manual immediately inside the front cover.

LOCATION OF SENSING HEAD

The location of the metal detector sensing head is extremely important. The process of selecting a location must include consideration of the needs of the metal detector, the surrounding processing equipment, and the operator. Product flow including velocity and rejection of contaminants is a major concern. Be certain to read and understand all installation guidelines before the final location is selected.

Mechanical Installation (cont.)

METAL FREE AREA

The metal detector monitors an electromagnetic field to detect metal. This field is predominantly contained within the metal detector sensing aperture but some fringing of the field exists at the entrance and exit openings. The fringing field will allow the metal detector to detect metal in the vicinity of the entrance and exit. For this reason, metal must not be located in this area. The required metal-free area depends on the size of the smaller dimension of the aperture. Normally

1.5 times the smaller aperture dimension is sufficient clearance for non-moving metal. If space allows, a 1.75 multiplier on the smaller aperture dimension should be used. Applications which involve relative movement between the sensing head and adjacent metal should use a 2.0 multiplier. (For example, stationary metal should not be located closer than 6 to 7 inches (150 to 175mm) from either the entrance or exit opening of a metal detector with a 4 x 8 inch aperture. Moving metal should not be closer than 8 inches (200mm) from the entrance or exit of such a detector.) Please refer to Figure 8 for details.

ELECTRICAL CURRENT LOOPS

By far the most frequent trouble experienced with metal detector installations is false tripping caused by electrical current loops. As was explained in the previous section, some electromagnetic field extends from the metal detector aperture. The field dissipates in strength with distance, to a point that metal contained outside the metal-free area defined above will not cause false detections. However, since the field is time-varying, small electrical currents are set up in conveyor conduction paths (i.e. metalwork) quite some distance from the aperture. These currents and others (e.g. ground currents from other nearby equipment) are not harmful as long as they are constant, but if they change, the metal detector will false trip. Figure 9 shows a simplified aerial view of a typical metal detector and conveyor. The arrows located within the conveyor framework, head pulley, tail pulley and return idlers represent electrical currents. The bearings

supporting the pulleys and idlers represent potential switches. As they turn, the bearings make and break contact with their respective races through the lubricant within. Likewise the cross-members of the conveyor framework represent potential switches if they are attached to the conveyor with bolts or rivets. Through time, connections such as these work loose or corrode and make and break electrical connections as a result of normal conveyor vibrations. Potential switches of both these types must be eliminated.

INSULATING THE CONVEY OR SHAFTS

In the case of pulleys and idlers there is no way to make the electrical path constant enough to prevent changes in the currents. These currents must be eliminated by introducing an insulating medium within the conduction path. Figure 10 shows two common methods.

The method shown in Figure 10-A is accomplished by machining the end of the shaft which rides in the bearing to a small diameter and inserting an Ultra-High Molecular Weight (UHMW) plastic sleeve over it. The outside diameter of the sleeve is the same as the inside diameter of the bearing. This sleeve breaks the electrical connection between the bearing and the shaft, thus permanently preventing current flow. WARNING: Do not cut through the sleeve when tightening the bearing set screw.

Figure 10-B shows a method of insulating the complete bearing block from the conveyor frame. This requires drilling the bolt holes through the bearing block to a larger diameter to accept an insulating shoulder washer. The shoulder washer wall thickness should be at least 1/32" (1 mm). Alternatively the shoulder washer can be replaced with a plastic washer and a length of plastic pipe or hose. Insulating the bolt with tape is not recommended. The bearing block is insulated from the conveyor frame with a UHMW insulator extending entirely across the base of the block as shown.

Mechanical Installation (cont.)

Both insulating methods are reliable. However, it takes only a small metal shaving or burr to cut through and short-circuit the insulators. For this reason the insulation should be tested with an ohmmeter after the pulley or idler is installed on the conveyor frame. Obviously insulating either end of the shaft will prevent current loops. However, leaving one end uninsulated will prevent testing with an ohmmeter. For this reason insulating both ends is recommended.

Sometimes when the humidity is low, static electricity will form on the conveyor belt. A charge can build up on pulleys or idlers which are insulated on both ends. This should be prevented because static discharge may cause the metal detector to false trip. After the integrity of the insulators is checked with an ohmmeter, one end of each shaft should be electrically reconnected to the conveyor frame. In the case of the sleeve insulating method the set screw of one of the bearings should be used. This may require drilling a small hole down through the sleeve and inserting a sharp pointed set screw. In the case of the bearing block insulating technique simply remove one of the shoulder washers on one end of the shaft. Note that in both methods if at any future time the integrity of the insulators is in doubt they can be checked again easily.

NOTE: If the conveyor belt drive pulley is driven with a metal chain, do not defeat the insulators on either end of the shaft. The metal drive chain will bleed off any static charge which may accumulate on the pulley.

PERMANENT LOOPS

Permanent conduction paths (such as cross members) associated with the conveyor frame must be welded securely . In this way currents flowing in the loops will remain constant. Bolted construction is not permissible. Any conduction path which is to remain removable or is simply not weldable must be insulated from the conveyor frame.

Figure 11 shows the modified conveyor frame. Note the potential switches no longer exist and the only currents in the conveyor frame are running through welded, permanent connections. They will be consistent and therefore will not cause false detections.

IMPORTANT:

It is risky to accept an installation with bolted conveyor construction, even though tests may show that no metal detector false trips occur when bolted structural members are deliberately shaken or twisted. No matter how good the bolted connections are initially , there is a high likelihood that such connections will eventually degrade or loosen, creating an unstable electrical pathway that interferes with metal detector operation and that may be extremely difficult to locate. Use only welded or insulated construction techniques.

MOUNTING BASE

The base to which the metal detector sensing head is mounted must be strong, rigid, and as free as possible from vibration. Although the metal detector can be set up to be relatively insensitive to vibration, better sensitivity to metal can often be obtained by preventing vibration from reaching the detector head.

Four insulating mounting feet are supplied with the metal detector. They must be used (refer to Figure 12). All four must sit flat on the mounting base. Never draw the feet down to the stand by tightening the mounting bolts. This will put uneven stresses on the sensing head and possibly cause instability. If for any reason the feet do not all sit flat on the mounting base, shim with appropriate washers until all four mounting feet are carrying the same load.

Nothing except the insulating feet and electrical connections may contact the sensing head. Conduit attached to the metal detector shell should utilize plastic fittings (refer to Electrical Installation).

Mechanical Installation (cont.)

BELT SPLICES

The metal detector sensing head cannot be disassembled to be fitted around the conveyor belt. For this reason the conveyor must be designed to return the belt through the aperture, or the belt must be cut and spliced back together. Splicing the belt with lacing or clamps is not recommended because foreign materials tend to collect at the joint, and these eventually cause false detections.

Vulcanized splices are recommended for best reliability. Refer to Figure 13 for typical splice types. If the belt is single-ply, the Finger Splice configuration should be used. If the belt is multiply, a combination of Step/Finger Splice configuration is recommended.

Cold bonding is a popular on-site practice. In this case the splice is usually a Beveled or Step-Lap type. Adhesives are available which are food or non-food grade. In either case the splices should be diagonal rather than straight across the belt. The cold bond splice is adequate for many applications as long as the splice is diagonal but the Vulcanized Finger splice is preferred.

NOTE: During all splicing it is absolutely necessary to ensure that no foreign material (especially metal) is trapped within the splice. If this happens, the metal detector will trip every time the splice passes through the aperture. Since the metal is trapped inside the splice it cannot normally be located and removed without ruining the belt.

CONVEYOR SLIDER BED

The conveyor belt must be supported as it travels through the metal detector. This task is performed by a slider bed, which must be capable of holding the belt off the aperture liner even when fully loaded. The slider bed must not contact the metal detector aperture liner. It should be supported by the conveyor frame. The slider bed should be made of static-resistant non-metallic material. Wood and phenolic are good choices. Plastic should normally not be used because it tends to generate static electricity as the conveyor belt slides across it.

PRODUCT POSITION

The product should always be guided through the center of the aperture, both vertically and horizontally. This is true whether the product travels through the metal detector on a conveyor or flows through a pipe as in a vertical application. If multiple size products will be inspected by the same metal detector, design the system to center the largest product in the aperture.

REJECT PROXIMITY SWITCH

The proximity switch is used to indicate when a package aligns with a reject device. For example, a product in a box may need to align with a reject device, such as a pusher arm, to be rejected reliably. The proximity switch indicates when the alignment is achieved. Normally the proximity switch is positioned just after the reject device so that it is triggered as the product aligns with the reject device. If it is difficult to install a switch in that location, it can be installed upstream from the reject device. In this case the proximity switch must contain a delay timer capable of delaying the output until the product aligns with the reject device. Be certain not to infringe on metal detector metal free areas when choosing the location of the proximity switch.

Electrical Installation

INTRODUCTION

All electrical connections are intended to be made within the NEMA-4X power supply enclosure. Figure 14 shows the enclosure and the electrical connections to the power supply circuit board. There are no user serviceable electronics or electrical connections within the control enclosure. Never attempt to remove the detector control from the control enclosure.

CHOICE OF INPUT PO WER SOURCE

The metal detector is equipped with filtering devices to help eliminate incoming electrical noise. Noise is usually created by inductive loads sharing the same power circuit. Even with the filters there is a limit to what the metal detector can withstand without false tripping.

The best insurance against electrical noise is to run a separate circuit from the main power bus. This circuit should be free of all loads except the metal detector. The power line should be run in its own metal conduit. The conduit must be electrically insulated from the conveyor. This includes any supporting structure for the metal detector. If this is impossible or impractical, reliable operation can often be obtained by powering the metal detector from a “clean” lighting circuit. This circuit must be free of inductive loads such as motors, solenoids, motor starters, variable frequency drives, etc.

If the metal detector must be powered by a less favorable source, false tripping caused by line noise can usually be eliminated through the use of a harmonic neutralized constant voltage transformer.

POWER SUPPLY

Refer to Figure 14 for wiring to the power supply. The metal detector may be powered at either of two voltage ranges described in the specifications section of this manual. Be certain the input power voltage selection switch is in the proper position to accept the power supply. The voltage selection switch is shown in Figure 14 and is labeled SW2 on the circuit board.

CAUTION:

Be careful to distinguish between the input voltage selection switch and the power (off/on) switch. Both are located in the lower left corner of the power supply circuit board. THE VOL TAGE SELECTION SWITCH IS RED, AND IS LABELED WITH THE AVAILABLE VOLTAGES, 115V AND 230V . THE POWER SUPPLY SWITCH IS BLACK, AND IS LABELED WITH 0 AND 1, TO INDICATE OFF AND ON, RESPECTIVELY. INADVERTENT USE OF THE IMPROPER SWITCH COULD LEAD TO CIRCUIT DAMAGE AND/OR PERSONAL INJURY. See Figure 14 for the location of these two switches.

The power source attaches to terminals L1 and L2. If operating in the 115 VAC range, L1 is the active or high side of the line and L2 is the neutral. If operating in the 230 V AC range, connect either supply line to L1 and the other to L2.

Note that L1 and L2 are connected through circuit board traces to other terminals on the circuit board as labeled. They are intended to be conveniently available to the user to power various ancillary equipment. They are not fused on the circuit board. It is the user’s obligation to be certain L1 and L2 lines are adequately fused external to the metal detector, preferably at the power source.

The power source must contain a reliable ground. It must be connected to the “GND” terminal.

NOTE: The metal detector may be grounded at only one point, through the power supply ground wire. No other ground connections are permitted. This includes mounting hardware and conduit.

The metal detector electronics are protected by 1A fuses (GMC-1A). The fuses are located between the POWER SUPPLY L1 and L2 terminals and the metal detector electronics. Note there are no fuses between the POWER SUPPL Y L1 and L2 terminals and the other L1 and L2 terminals on the circuit board.

Electrical Installation (cont.)

RELAYS

The E-Z Tec IV and V provide three standard and two optional relays as follows:

DIRECT RELAY

The Direct Relay is a mechanical SPDT (single pole double throw) relay. The relay contacts are labeled on the circuit board showing the respective terminal connections. The relay is shown energized which is its normal non-reject state (this provides fail-safe relay operation). When Direct Reject occurs, the relay changes to the state opposite that shown (the relay is deenergized which causes the left contacts to close and the right contacts to open). After the reject clears, the relay is again energized switching it back to its original position.

TIMED RELAY

The Timed Relay is a mechanical SPDT (single pole double throw) relay. The relay contacts are labeled on the circuit board showing the respective terminal connections. The relay is shown energized which is its normal non-reject state (this provides fail-safe relay operation). When Timed Reject occurs, the relay changes to the state opposite that shown (the relay is deenergized which causes the left contacts to close and the right contacts to open). After the reject clears, the relay is again energized switching it back to its original position.

FAULT RELAY

The Fault Relay is a mechanical SPDT (single pole double throw) relay. The relay contacts are labeled on the circuit board showing the respective terminal connections. The relay is shown energized which is its normal non-fault state (this provides fail-safe relay operation). If a fault condition occurs, the relay changes to the state opposite that shown (the relay is deenergized which causes the left contacts to close and the right contacts to open). After the fault clears, the relay is again energized switching it back to its original position.

AC SSR

The AC SSR is a solid state relay suitable for switching AC loads only. It functions in parallel with the Timed Relay described above. The relay contacts are labeled on the circuit board showing the respective terminal connections. The polarity (e.g. normally open or normally closed) is adjustable using SW1. If the switch is in the right position, the relay is normally closed. When Timed Reject occurs, the relay changes state (the relay is de-energized which causes the relay to open). After the reject clears, the relay is again energized switching it back to its original position. If SW1 is in the left position, the relay operates opposite in polarity to that just described.

NOTE: This relay is optional. This relay is only installed in units where the relay was requested by the customer at the time of manufacture.

DC SSR

The DC SSR is a solid state relay suitable for switching DC loads only. It functions in parallel with the Timed Relay described above. The relay contacts are labeled on the circuit board showing the respective terminal connections. Note the left terminal is positive and the right terminal is negative. The polarity (e.g. normally open or normally closed) is adjustable using SW1. If the switch is in the right position, the relay is normally closed. When Timed Reject occurs, the relay changes state (the relay is de-energized which causes the relay to open). After the reject clears, the relay is again energized switching it back to its original position. If SW1 is in the left position, the relay operates opposite in polarity to that just described.

NOTE: This relay is optional. This relay is only installed in units where the relay was requested by the customer at the time of manufacture.

Electrical Installation (cont.)

RELAY NOTES

As shipped, none of the relays source power. If switched AC power is needed it must be supplied to the appropriate relay through a jumper, such as from one of the L1 or L2 terminals or from an external source. If switched DC power is needed it must be supplied from a remote source or from the +5 TACH terminal (5 volts DC, 100mA max.). All relays are protected by a 1A fuse (GMA-1A).

Solid state relays cannot be tested with most ohmmeters. T est the solid state relays by applying an appropriate power source and load.

INPUTS

The metal detector will accept inputs from external devices of various types. The terminals for these inputs are located at the lower edge of the Power Supply PCB, and are described functionally below.

TACHOMETER INPUT (TACH)

Applications having variable speed product flow and needing automatic reject timing use this input. A tachometer is used to allow the metal detector control to monitor product speed and reject according to the distance the product has traveled rather than elapsed time since detection. (Refer to Appendix B for details.)

The electrical specifications are as follows: Voltage

Logic 0 - 0.0 VDC to 0.9 VDC Logic 1 - 3.15 to 50 VDC (NPN Open Collector can also be used)

Current

Source N/A Sink 1 mA min

Frequency

50 Hz max

Minimum Pulse Width

Logic 0 - 5 mSec Logic 1 - 5 mSec

PROXIMITY SWITCH (PROX SW)

Sometimes the metal detector is used to scan and automatically reject packages. A proximity switch is used to sense the location of the package so it can be rejected reliably. The device can be a mechanical switch, photo-eye, or any other device

which is capable of precisely locating the package. The electrical specifications are as follows:

Voltage

Logic 0 - 0.0 VDC to 0.9 VDC Logic 1 - 3.15 to 50 VDC (NPN Open Collector can also be used)

Current

Source N/A Sink 1 mA min

Frequency

50 Hz max maximum

Minimum Pulse Width

Logic 0 - 5 mSec Logic 1 - 5 mSec

Note the right terminal of this input is ground. Since the metal detector is to be grounded only by the input power supply ground, this terminal must not be grounded by the proximity device.

REJECT CONFIRMATION (REJ CON)

The reject confirmation input is used to monitor the function of the reject device. It is usually a limit switch attached to the reject device which indicates it is functioning. For example, the device may be a switch attached to a pusher bar used to reject a box off a conveyor . The switch is positioned in such a way that it closes as the pusher bar reaches its maximum extension. The electrical specifications are as follows:

Voltage

Logic 0 - 0.0 VDC to 0.9 VDC Logic 1 - 3.15 to 50 VDC (NPN Open Collector can also be used)

Current

Source N/A Sink 1 mA min

Frequency

50 Hz max maximum

Minimum Pulse Width

Logic 0 - 5 mSec

Logic 1 - 5 mSec Note the right terminal of this input is ground. Since the metal detector is to be grounded only by the input power supply ground, this terminal must not be grounded by the limit switch.

Electrical Installation (cont.)

REJECT RESET (REJ RESET)

The metal detector has two reject outputs, Direct and Timed. Either or both can be set to reset manually following a reject. The Reject Reset input can be used to reset the rejects. Normally a momentary close push-button switch is used. The electrical specifications are as follows:

Voltage

5 VDC

Current

20 mA

Note the right terminal of this input is ground. Since the metal detector is to be grounded only by the input power supply ground, this terminal must not be grounded by the switch.

HOST COMPUTER PORT (MPC ONLY)

The MPC version is capable of communicating with one or more host computers (typically PCs) through an RS232 or RS485 link. Please refer to the E-Z Tec MPC Communication Manual MM-237 for further information on the use of this port.

PRINTER PORT (MPC ONLY)

The MPC can drive a remote printer through an RS232 link to print reject reports. This subject is covered in detail in Appendix A, Printer Operation.

support structure. Metallic conduit fittings must not be used to attach conduit to the metal detector housing. Always use a plastic fitting for this purpose. Conduit for "other" equipment must not be run along the metal detector conveyor. Although the conduit serves as shielding, possible interference could occure.

NOTE: The power on/off switch located inside the power supply enclosure is intended to be a service convenience only. It is recommended that the unit remain on continuously . This will provide best metal detector performance and enhance the longevity of the electronic components.

CAUTION:

Be careful to distinguish between the input voltage selection switch and the power (off/on) switch. Both are located in the lower left corner of the power supply circuit board. THE VOLTAGE SELECTION SWITCH IS RED, AND IS LABELED WITH THE AVAILABLE VOLTAGES, 115V AND 230V. THE POWER SUPPLY SWITCH IS BLACK, AND IS LABELED WITH 0 AND 1, TO INDICA TE OFF AND ON, RESPECTIVELY. INADVERTENT USE OF THE IMPROPER SWITCH COULD LEAD TO CIRCUIT DAMAGE AND/OR PERSONAL INJURY. See Figure 14 for the location of these two switches.

CONDUIT

It is always wise to run wiring to and from the metal detector through metal conduit. High voltage wiring for the power supply and reject devices should not be installed in the same conduit as low power sensor wiring (such as wiring for the tachometer and reset switch). Always keep all metal detector wiring separate from cables carrying heavy or switched loads. This is especially true with variable speed motor control wiring. If these guidelines are followed, interference from electrical noise will be greatly decreased.

The use of metal conduit will provide necessary shielding for the wires within; however, metal conduit also represents a potential ground path. Metallic conduit or airlines must be electrically insulated from the associated components of the metal detector, such as conveyor, stand or any other

INITIAL TEST (ANALOG UNIT)

a. After all electrical connections are com-

pleted and checked, turn the power switch, SW4, on. The two center green LED’s in the bar graph of the metal detector control panel (Figure 15) should light.

b. Pass a large piece of metal through the

metal detector aperture. The LED bar graph should respond with positive and negative excursions of the red LED’s.

c. If the above does not occur, check all in-

stallation instructions, fuses, and input power. If the fault cannot be located, contact Eriez Magnetics for assistance.

d. Close and latch the power supply enclo-

sure door.

Electrical Installation (cont.)

INITIAL TEST (MPC UNIT)

a. After all electrical connections are com-

pleted and checked, turn the power switch, SW3, on. The two center green LED’s in the bar graph of the MPC control panel (refer to Figure 18) should light. The LCD alphanumeric display should respond with “ERIEZ MAGNETICS,” address, telephone, and fax numbers. After approximately 10 seconds, the MONITOR display should appear on the LCD screen showing time, date, SENSITIVITY ##, and PHASE ##.

b. Pass a large piece of metal through the

metal detector aperture. The LED bar graph

should respond with positive and negative

excursions of the LED’s. The LCD display

top line should register “REJECT” in the top

left corner and “REJECT” in the top right

corner.

c. If any of the above do not occur, check all

installation instructions, fuses and input

power. If the fault cannot be located, con-

tact Eriez Magnetics for assistance.

d. Close and latch the power supply enclo-

sure door.

Analog Controls and Displays

ANALOG CONTROL PANEL

Figure 15 shows the location of the various front panel controls and indicators on the E-Z Tec Version IV and V analog unit. These controls and indicators are primarily concerned with the detection performance of the unit.

LARGE RECTANGULAR STATUS LED’S

The two large rectangular LED’s (Light Emitting Diodes) in the center of the E-Z Tec control panel indicate the metal detector status as follows:

DETECT (RED)

Used to indicate that metal has been detected. It illuminates as metal is detected and extinguishes soon after detection terminates.

FAULT (YELLOW)

Used to indicate that the coils are unbalanced or that the reject confirmation failed.

MONITOR DISPLAY

This is an LED bar graph display . The center two segments are non-extinguishing green LED’s. They indicate power-on. Red LED excursions to right and left indicate relative signal intensity. All red LED’s are off when no signal is present.

SENSITIVITY CONTROL

The sensitivity control is a 100 position switch. A setting of 99 provides maximum sensitivity. The adjustment is variable in 01 increments down to 00, at which point the metal detector sensitivity is very low, and the unit will detect only extremely large pieces of metal.

PHASE CONTROL

This control is a 1000 position switch. It is used to make the unit more or less responsive to various types of materials passing through the aperture. This control can be used to provide maximum response to a particular type of metal or (more often) minimum response to a particular product. The latter procedure is termed “phasing out the product effect.”

ANALOG OUTPUT CONTROLS

Figure 16 illustrates the output control panel of the E-Z Tec Version IV and V analog metal detector. This panel is located in the power supply housing. The controls and switches on this panel are primarily concerned with the rejection performance of the unit.

TRAVEL TIME

Often contaminated product is automatically eliminated from the product flow by a suitable reject device. The reject signal from the metal detector must be delayed until the contaminated product travels to the reject device. This delay is called Travel Time. It is adjustable using the Travel T ime control knob and the jumper JP2. The control knob has a range of 0 to 10 units, with the value of each unit depending on the setting of JP2. Note that this control is not present in the MPC metal detector because the relevant function is controlled by user input at the front panel (or through the computer interface).

REJECT TIME

The time required for a reject device to perform its function varies widely depending on the particular application. The reject time of the timed relay is controlled by the STANDARD reject adjustment or the INDEXED reject time adjustment depending on the setting of SW2-2. Note that these controls are not present in the MPC metal detector because the relevant functions are controlled by user input at the front panel (or through the computer interface).

STANDARD REJECT

Time The STANDARD REJECT TIME adjustment determines the amount of time that the TIMED RELA Y will remain in the detect state when SW22 is set for the standard reject setting. This interval is adjustable from 0.12 seconds to 9.5 seconds.

INDEXED REJECT TIME

When the INDEXED reject is selected with SW22 the amount of time that the TIMED RELAY will remain in the detect state is set with the INDEXED reject adjust. This interval can be adjusted from

0.12 seconds to 9.0 seconds.

Analog Controls and Displays (cont.)

PROGRAMMING SWITCHES

These switches are located in the power supply housing of the analog metal detector. They are labeled SW1 and SW2. The functions controlled by these switches are detailed in the section “Circuit Board Switch Programming.” Note that these switches are not present in the MPC metal detector because the relevant functions are controlled by user input at the front panel (or through the computer interface).

FAULT INDICATOR

There are two conditions that can cause the FAUL T LED on the analog control panel to illuminate. These two conditions are indicated on the output control panel (in the power supply housing) as BALANCE and REJECT and are explained below.

BALANCE LED

When the BALANCE LED is illuminated it indicates that the coils in the search head are out of balance and the sensitivity of the metal detector may be in question. The coils must be out of balance for approximately two minutes before this is considered a fault condition and the fault relay actuates. The BALANCE LED is reset as soon as the coils are balanced.

REJECT LED

The REJECT LED indicates that there was not a confirmation signal from the reject device when it was to reject metal within the last two minutes. The REJECT LED only indicates a fault condition when SW1-1 is set to enable the reject confirmation.

illuminates as soon as there is no metal being detected and direct relay output has returned to its normal state.

TIMED

The TIMED LED is off when the timed relay output is in a reject state.

ACSSR

The ACSSR LED is off when the AC solid state relays output is off. The AC solid state relay operates at the same time the TIMED RELAY operates. The output of the AC solid state relay may be on or off during reject depending on the setting of SW2-4.

DCSSR

The DCSSR LED is off when the DC solid state relays output is off. The DC solid state relay operates at the same time the TIMED RELAY operates. The output of the AC solid state relay may be on or off during reject depending on the setting of SW2-4.

FAULT

The FAULT LED indicates the status of the FAULT RELAY output. The FAULT LED is normally illuminated and turns off when a fault condition occurs.

WINDOW LED

The Window LED on the analog output control panel is illuminated to indicate the period of time during which a reject can occur when switch SW22 is set to enable INDEXED reject.

RELAY STATUS LEDS

The five RELAY STATUS LED’s on the output control panel in the power supply housing indicate the state of the five relay outputs. The two solid state relays are optional, but the status LED’s will always indicate what their status is even if the solid state relays are not installed.

DIRECT

The DIRECT LED is illuminated when the metal detector is operating properly and no metal is detected. As soon as the metal is detected the DIRECT LED turns off to indicate that the direct relay output has changed states. The DIRECT LED

INDEX IN LED

When a proximity sensor is used to locate the package to be rejected the INDEX IN LED illuminates when a package is detected. If a proximity sensor is not used this LED does not illuminate.

CONFIRM LED

When reject confirmation is used to verify the operation of the reject device, the CONFIRM LED illuminates to indicate a signal from the reject confirmation device was received. If reject confirmation is not used the CONFIRM LED does not illuminate.

Analog Controls and Displays (cont.)

CLOCK LED

The CLOCK LED is used to show the rate at which the timer for the timed relay is operating. When the internal clock is selected with SW2-3 the CLOCK LED flashes at the rate at which the internal clock is running. When SW2-2 is set to select the tachometer input for the clock, the CLOCK LED flashes at the rate at which the pulses from the tachometer are occurring.

DETECT LED

The DETECT LED illuminates when the sensing head sends a signal indicating metal has been detected.

ANALOG CIRCUIT BOARD SWITCH PROGRAMMING

Figure 17 shows the various switch locations on the analog unit output control panel, PSOPT-1. The user programmable switches are listed on Page 23 along with a brief explanation of their function. The discussion below provides a source for quick reference.

SW1-1

When a reject confirmation device is connected to the metal detector, SW1-1 must be set to the UP position for the metal detector to process the signal. If a reject confirmation device is not connected to the metal detector, SW1-1 must be set to the DN position or a fault condition will occur.

SW1-2

When this switch is set to the UP position the output of the TIMED RELAY will not reset after a reject until a signal is received at the REJ RESET input. When SW1-2 is set to the DN position the TIMED RELA Y output will reset automatically. The time for the relay to reset is determined by the ST ANDARD REJECT TIME when SW2-2 is in the UP position or by the INDEXED REJECT TIME when SW2-2 in the DN position.

SW1-3 THROUGH SW1-8

These switches set the length of the shift register. Refer to the SWITCH CHART for switch settings and shift register length. Refer to Appendix B for a discussion of the Shift Register function.

SW1-9

When this switch is set to the UP position the DIRECT RELAY will not reset after a reject until a signal is received at the REJ RESET input. When SW1-9 is set to the DN position the DIRECT RELA Y output will automatically reset after a reject.

SW2-1

This switch selects MODE 1 or MODE 2 detection. Refer to the DETECT MODE DESCRIPTION section of this manual for an explanation of MODE 1 and MODE 2. MODE 1 is also referred to as normal detection and is selected when SW2-1 is in the UP position. MODE 2 is also referred to as narrow zone detection and is selected when switch SW2-1 is in the DN position.

SW2-2

This switch selects between INDEXED REJECT and STANDARD REJECT for the TIMED RELAY output. When SW2-2 is in the UP position, INDEXED REJECT is selected and the reject time is adjusted with the INDEXED REJECT TIME. When SW2-2 is in the DN position, STANDARD REJECT is selected and the reject time is adjusted with the STANDARD REJECT TIME.

SW2-3

This switch is used to select an internal clock or a tachometer input for the travel time on the TIMED RELA Y output. When the switch is in the UP position, the source of the clock is from the tachometer input. When the switch is in the DN position the source of the clock is from an internal clock.

SW2-4

This switch is used to determine whether the output of the solid state relays is to be ON during reject or OFF during reject. When the switch is in the UP position the output of the solid state relays turns OFF when a reject occurs. When the switch is in the DN position the output of the solid state relays turns ON when a reject occurs.

Analog Controls and Displays (cont.)

JP1

This jumper is to set up the metal detector when a proximity sensor is used. If there is always a space between packages, then JP1 is OFF (open). When a space between packages cannot be guaranteed, then JP1 is ON (shorted).

JP2

This jumper is used to set the range of adjustment the TRAVEL TIME has. When JP2 is ON (shorted) the TRAVEL TIME has an

Switch Chart A - Output Board PSOPT-1

SWITCHES AND JUMPERS

SWITCH POSITION/SETTING POSITION/SETTING

SW1-1 UP Reject confirmation is OFF DOWN Reject confirmation is ON SW1-2 UP Timed output is manually reset DOWN Timed output is automatically reset

adjustment range of 0.30 seconds to 50 seconds. When JP2 is OFF (open) the TRA VEL TIME adjustment has a range of 0.05 seconds to 10 seconds. JP3 This jumper is used to inhibit the reject during power up. With JP3 ON (shorted the DIRECT RELAY and the TIMED RELAY outputs will not reject until the power to the metal detector has been on for 10 seconds. When JP3 is OFF (open) the DIRECT RELAY and TIMED RELAY will be active as soon as power is turned on.

SW1-3 Sets the length of the Shift Register. See Switch Chart B. SW1-4 Sets the length of the Shift Register. See Switch Chart B. SW1-5 Sets the length of the Shift Register. See Switch Chart B. SW1-6 Sets the length of the Shift Register. See Switch Chart B. SW1-7 Sets the length of the Shift Register. See Switch Chart B. SW1-8 Sets the length of the Shift Register. See Switch Chart B. SW1-9 UP Direct output is manually reset DOWN Direct output is automatically reset SW2-1 UP MODE 1 detection DOWN MODE 2 detection SW2-2 UP Indexed reject DOWN Standard reject SW2-3 UP Tachometer input DOWN Internal clock SW2-4 UP SSR output is normally closed DOWN SSR output is normally open JP1 ON Not always space between packages OFF Always space between packages JP2 ON Travel time (0.30sec - 50sec, ± 10sec) OFF Travel time (0.05sec -10sec, ± 2sec) JP3 ON 10sec reject inhibit at power on OFF Reject enabled at power on

Controls and Displays (cont.)

Switch Chart B

Output Board PSOPT-1

SWITCHES SW1-3 THROUGH SW1-8 U = UP D = DOWN

Shift Shift

Length 3 4 5678Length 345678

0 UU UUUU 32 DUUUUU 1 UU UUUD 33 DUUUUD 2 UU UUDU 34 DUUUDU 3 UU UUDD 35 DUUUDD 4 UU UDUU 36 DUUDUU 5 UU UDUD 37 DUUDUD 6 UU UDDU 38 DUUDDU 7 UU UDDD 39 DUUDDD 8 UU DUUU 40 DUDUUU

9 UU DUUD 41 DUDUUD 10UU DUDU 42 DUDUDU 11UU DUDD 43 DUDUDD 12UU DDUU 44 DUDDUU 13UU DDUD 45 DUDDUD 14UU DDDU 46 DUDDDU 15UU DDDD 47 DUDDDD 16UD UUUU 48 DDUUUU 17UD UUUD 49 DDUUUD 18UD UUDU 50 DDUUDU 19UD UUDD 51 DDUUDD 20UD UDUU 52 DDUDUU 21UD UDUD 53 DDUDUD 22UD UDDU 54 DDUDDU 23UD UDDD 55 DDUDDD 24UD DUUU 56 DDDUUU 25UD DUUD 57 DDDUUD 26UD DUDU 58 DDDUDU 27UD DUDD 59 DDDUDD 28UD DDUU 60 DDDDUU 29UD DDUD 61 DDDDUD 30UD DDDU 62 DDDDDU 31UD DDDD 63 DDDDDD

Switch SW1-

MPC Controls and Displays

MPC CONTROL PANEL

Figure 18 illustrates the E-Z Tec IV and V MPC control panel. The panel consists of a 22 segment LED bar graph, an 8 line x 40 character Liquid Crystal Display (LCD), and nine push-button switch keys. The operator controls the MPC through the interaction of these components.

LED BAR GRAPH

The bar graph monitors all signals entering the metal detector. Its major role is to aid the operator in adjusting for product effect and vibration. More information on this function is presented in the “Metal Detector Adjustment” section.

SWITCH KEYS

The operator commands the MPC to perform all functions with the switch keys. T wo of the keys are labeled Contrast Lighten and Contrast Darken. Their only task is to adjust the contrast of the LCD to suit the operator. The other keys are known as soft keys since their function is controlled by the MPC software program. Each soft key has an arrow pointing to a section of the display. The current function of the key is displayed there.

LCD

The LCD is the medium through which the MPC displays information. This includes all setup parameters, metal detection status, and reports. It is equipped with a backlight to illuminate the display in dark environments. The backlight turns on following any key press and remains on until ten minutes has elapsed with no key activity.

MPC SOFTWARE

The software is a computer program stored in the MPC memory. It tells the microprocessor what to do and how to communicate with the operator. It has been designed to be user friendly. Although a complete discussion of adjustment procedures is provided below, memorization of these should not be necessary because the prompts and help files lead the way through the adjustment routines. A good general understanding of the procedures and parameters are all that should be required to adjust the MPC.

FLOWCHAR T

Figure 19 is a flowchart representing the structure of the portion of the MPC software which communicates with the operator. It is a graphical representation of the flow of the program showing how to move to different sub-menus. Consider it a road map showing how to get from one sub-menu to another.

Each block of the flowchart represents a sub-menu. The arrows between the blocks represent the possible links between sub-menus. Each arrow has a short description indicating how to direct the program along that link.

Example: a. Refer to the “Product Setup” sub-menu in

Fig. 19.

b. This menu is reached via the “Main Menu”

by entering the Product Setup command.

c. The Exit command returns the program to

“Main Menu.”

Each sub-menu fits on one full screen of the LCD display . Since the screen is quite large, each menu provides a variety of information. One advantage of the large screen is to provide directions to guide the operator through adjustments. In addition, multiple parameters are displayed on each menu, so that the number of links in the flowchart is substantially reduced.

GENERAL MPC OPERATION

At first glance the MPC menu flowchart may look somewhat complex. Actually it is extremely simple. The following sections introduce the four major portions of the software flowchart and the General Operation Information. Further information on all of these sub-menus is available in the Detailed Menu Description and Adjustment section of this manual.

MONITOR

Under normal operating conditions the MPC “resides” at the MONITOR MENU. The operator can change products and obtain information necessary to consult the factory for assistance without going through the MAIN MENU. This is provided as a convenience to the operator since changing the product under inspection is the only adjustment normally necessary after the initial unit setup.

+ 70 hidden pages

Eriez E-Z TEC IV, E-Z TEC V Installation, Operation And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual