logika HMD-SM Operator's Manual

Scanning Hot Metal Detector

HMD-SM Operator’s Manual

Revision 2.1

Logika Technologies Inc. Model HMD-SM Operator’s Manual Rev 2.1 Dec­13

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Contents

1. Introduction ........................................................................................................................... 2

2. Description ........................................................................................................................... 2

2.1 Model Nomenclature ...................................................................................................... 2

2.2 Specifications .................................................................................................................. 3

2.3 Operating Principle ......................................................................................................... 3

2.4 Automatic Threshold Level Adjustment ......................................................................... 5

2.5 Other Features ................................................................................................................. 5

3. Location and Mounting ......................................................................................................... 6

3.1 Sensor Location .............................................................................................................. 6

3.2 Sensor Mounting ............................................................................................................. 7

4. Utility Connections .............................................................................................................. 7

4.1 Electrical Connections .................................................................................................... 7

4.2 Cooling Water Connection ............................................................................................. 9

4.3 Purge Air Connection ................................................................................................... 10

5. Operation............................................................................................................................ 10

5.1 Control Panel ................................................................................................................ 10

5.2 Automatic Threshold Level Description ....................................................................... 11

5.3 Remote Threshold Sensitivity ....................................................................................... 12

5.4 Test Function ................................................................................................................ 13

5.5 Troubleshooting ............................................................................................................ 13

6. Maintenance ....................................................................................................................... 14

6.1 Regular Maintenance .................................................................................................... 14

6.2 Returns of the HMD-SM .............................................................................................. 15

7. Accessories- Hot Metal Simulation Test Bar..................................................................... 15

8. HMD-SM Enclosure Dimensions ...................................................................................... 17

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1. Introduction

The Logika Technologies scanning mode hot metal detector, Model HMD-SM, is
designed for the automation of steel, aluminum and other metal mill production lines. It
includes a rugged enclosure, protecting state-of-the-art electronics and will withstand
the harsh ambient conditions present in heavy industrial environments. The HMD-SM is
used to detect hot metal in a range of temperatures, shapes and sizes of wire, bar, strip,
thin plate, thick plate, billet, and slab production facilities.

The scanning mode feature allows the HMD to detect hot metal across the entire width
of a production line. It also enables the HMD to be installed remotely from the hot
metal target, further protecting the electronics and extending the life of the sensor.

2. Description

2.1 Model Nomenclature

HMD - SM - _Scan angle - Power Input__ - R

Base Model Scan angle Power Input R(Relay)

HMD-SM

10: 10 Degree 110: 110 VAC

1 Normal Open
1 Normal Close

30: 30 Degree 220: 220 VAC
50: 50 Degree 24: 24 VDC

Table 1

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2.2 Specifications

Operating temp

No water cooling:

0˚C to +50˚C (32˚F to 120

˚F)

With water cooling: 0˚C to 120˚C (32˚F to 250˚F)

Detect Range

0.2-8m

LED Indicators

Green = power on, Red = target detect, Orange=

Detector signal

saturation or dirty lens, Off=Alarm

Output

Relay

NO/NC 250VAC

@ 1A,or 24VDC

@ 1A, closing: 7.5ms, opening: 3ms

DC 24V PNP,NPN Transistor output: max 100mA
Diagnostic outputs: control, alarm, signal amplitude

Power Input

24 VDC, 110VAC, 220VAC @ 30VA

Cable

16 wires multi

-

conductor TEFLON cable with

9 x 20Ga

and 7 x 24Ga

Insulation 20MΩ, 500VDC, ≥500˚C (930˚F)

Housing

Hermetically sealed cast aluminum enclosure rated IP66, includes cooling

water connections and air purge.

Size

Enclosure;

315 mm L x 11

0 mm W x 264

mm H (with mounting bracket)

(12.4”L x 4.3”W x 10.4”H)

Weight

7kg

or 15 lb

Min Target Temp

250oC (480

o

F)

S

canning Angle

10˚, 30˚, 50˚

Water Cooling

25˚C, 4 bars pressure (60 psi), 1-2L/min (0.26 to 0.52 USG),
¼” flexible tube

Air Purging

50 to 200 g/cm

2

(0.7 to 2.8 psi), 4-16L/min (0.14 to 0.56 cfm)

¼” compression fitting

Table 2

2.3 Operating Principle

Detector- The HMD-SM uses a Lead Sulfide (PbS) photocell, which is characterized by a very

strong signal output for the range of infrared energy emitted by steel, compared with other
detector materials. The high signal-to-noise ratio from this detector virtually eliminates
detection errors. Figure 2.1 shows the various types of photocell spectrums and the
infrared emission spectrum of steel in 250˚C and 1000˚C.

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100%

0

0.25 0.50 0.75 1 1.25 1.50 1.75 2 2.25 2.50 2.75 3 3.25 3.50 3.75

Si Ge

PbS

Steel 1000℃

Steel 250℃

Wave length

(μm)

A

Figure 2.1 Spectrum of steel emission and different photocells

Scanning System- The HMD-SM uses a scanning optical bench that enables hot metal

detection across a broad angle of detection. The optical field is scanned using a rotating
drum of multiple mirror facets that reflect the energy from the hot metal target in the
scanning field to the PbS photocell, see Figure 2.2 for details. The infrared energy is
converted to an electronic signal by the PbS photocell, which is then processed by the
electronic circuit and changed to a logic signal for analysis and control purposes.

Figure 2.2: HMD-SM Scanning System

Vertical Scanning field- The HMD-SM is manufactured with one of three vertical field angles

10, 30 and 50 degrees, selected at the time of purchase. This enables the sensor to cover
the entire process area but not scan beyond the process line where interfering sources of
infrared energy may be present.

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13

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Figure 2.3

For example, if

a hot metal target

with a HMD-SM-

30 detector selected

Horizontal Scanning field- A

manual

horizontal measurement angle

Distance”). For example, if

a shutter width angle

distance, the scanning width

is 8mm. A positive output signal will resul

hot metal is within the 8 mm scanning field.

distance

in section 3.1 for more details.

2.4 Automatic

Threshold Level Adjustment

The HMD-SM includes a

n Automatic

signal when hot metal is detected to prevent detector signal saturation. The user adjusts the

base gain level via a potentiometer mounted on the

and 5.3 for addit

ional details on

signal level upon exit of the hot metal from the scanning detection field. This feature makes

the sensor more stable and significantly reduces detection errors caused by targe

spots or

varying surface temperature as well as

scale.

2.5 Other Features

 Fast response time to

the hot metal target in and out of the

Model HMD-SM Operator’s Manual

-829-5841 Fax: [phone] Email:

[e-mail]

HMS - SM Vertical Scanning Field

is

located 4 meters (13’) from the front of the

, the vertical scanning field is

2.10 meters

adjustable shutter on the shroud

is used

change

from 1 to 3 degrees (see Section 3.1 “Mounting

is set at 1 degree

with a 4 meter

t if any portion of the

For different targets

, see the

Threshold Level Adjustment to decrease the detector

sensor’s control panel (S

the

use of this feature). The detector will return to the base

interference from water vapor and oxide

scanning field

Rev 2.1 Dec-

HMD

or 84 inches.

for the

(13 feet)

mounting

ee Sections 5.2

t black

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 Detects low temperature and low emissivity targets in harsh environments; even with

infrared reflection or roller heat radiation interference.

 Pulse signal treatment circuit design lessens detector power consumption and temperature

drift.

3. Location and Mounting

3.1 Sensor Location

The ideal location should allow the HMD scanning field to cover the entire process line,
protect it from absorbing excessive heat, and be close enough for the detector to get
sufficient infrared energy from the target.

 Mounting Distance- Check the HMD mounting distance listed on table 3 for different

targets. Find the size of the target, select an approximate mounting distance. Use Figure 2.3
for calculating the scanning field and select the ideal scanning angle (10o, 30o, or 50o) to
make sure the sensor’s scanning field covers the entire process area. The vertical scanning
field should be oriented across the width of the process line for best coverage.

Target

HMD

Distance

Target

HMD

Distance

Wire rod, 5 -12 mm 0.2 - 3.0 m Steel Strip 0.6 - 2m

Bar, 10x10-40x40 mm 0.2 - 4.0 m Thin Plate 1.0 - 6.0m

Square Billet 0.5 - 6.0 m Thick Plate 1.0 - 8.0m

Large Billet(Bloom) >2.0 m Slab >2.0m

Table 3

 Interference- Reduce or eliminate background infrared radiation sources, such as other hot

processes behind the target and reflected sunlight:

1. Select the appropriate scanning angle when originally placing order to avoid “over­scanning”.

2. Gradually reduce the sensitivity adjustment on the HMD-SM’s control panel until the
background interference is not detected (when no target metal is within the scanning field).
See the “Operation” chapter in this manual for additional details.

3. In occasional severe environments, install a heat proof enclosure around the HMD to
protect it from overheating and use ventilation to drive away particulate and vapor.

 Other considerations for installation

1. Locate the HMD to reduce interfering infrared sources and choose a detection field that
minimizes the presence of dirt, smoke and water vapor or other infrared absorbing
chemicals.

2. Only part of the target needs to be in the sensor’s scanning field to trigger a hot metal
output signal.

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3.2 Sensor Mounting

 Mounting Foot- The HMD-SM has an adjustable mounting foot designed to allow easy

rotation through horizontal and vertical axes. The HMD is secured to the mounting foot with
one 18mm bolt and can be installed onto a support bracket. The support must be
sufficiently rigid to absorb any excessive site vibrations that can affect the output of the
detector.

 Purge Air, Cooling Water- The HMD-SM has a water-cooling jacket to cool down sensor

temperature and an air-purged shroud for protection of lens; allowing the sensor to be used
in harsh environments with high temperatures, steam, dust and smoke. Please see Section

4.2 Plumbing Connection and Section 4.3 Air-Purge Connection for further details on
installation.

 High Heat Option- If the ambient temperature is more than 250oC (480oF), we recommend

HMD-FOC, Fiber Optical Hot Metal detector. The lens is separate from the detector and
connected by fiber optical cable which can bear high temperatures.

 Caution- For installation environments that contains excessive water vapor or smoke,

additional ventilation such as air curtains or fans should be used to clear the area so the
sensor can “see” the hot metal target.

4. Utility Connections

4.1 Electrical Connections

 Electrical Overview- All electrical connections (power and signal) to the HMD-SM are made

via a 15 pin male Harting connector, a supplied 2-meter long cable with quick fitting on one
end and terminal pins on the other end for junction box connections. Other cable lengths
are available from Logika Technologies Inc. upon request.

 Cable Specification-

• 16 conductors cable, color coded, with 9 conductors 20 AWG unshielded (9 x 0.6 mm²), 7
conductors 24 AWG shielded (7 x O.34 mm²)

• Teflon insulation for high temperature applications.

• Outer metallic braided for mechanical protection.

• Overall diameter of 9 mm.

• Minimum bending radius of 30 mm.

 Junction Box Wiring- Please see Figure 4.1 for the sensor wiring diagram. The supplied

cable should be connected directly to the terminals of a junction box. The shield should be
connected to ground to eliminate electrical noise which may trigger false detection signals.
Any unused output wires must have insulation protection or be connected to free terminals
in the junction box.



Power Connections- Power Input (please specify power input at time of order).

See the Figure 4.1 for detail wirings for different power supply input

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 Static Transistor Output-

• PNP: Terminal 4B White, 24VDC on detect, maximum current 100 mA

• NPN: Terminal 4A Black, 0VDC on detect, maximum current 100mA

• Output Response time:

o HMD-SM-10: 1ms
o HMD-SM-30: 2ms
o HMD-SM-50: 4ms

 Relay Output- Single pole double throw contacts, contact capacity rating 250VAC/1A or

24VDC/1A, relay closes time 7.5ms, relay releases time 3ms.

• Terminal 5C White/Orange: NC, Open = detect

• Terminal 5B White/Blue: NO, Closed = detect

• Terminal 5A White/Purple: COM

 Sensor Diagnostics Outputs- Relay and voltage signals to indicate sensor conditions. All the

outputs voltages are referred to 0VDC (Figure 4.1, Terminal 3B).

1. Control Output (Figure 4.1, Terminal 2A Green):

Normal Output: 24VDC
Diagnostic Alarm Output: 0VDC, indicated if one or more occurs:

• Dust or vapor interference on glass

• Target temperature drop

• Signal saturation

2. Alarm Output (Figure 4.1, Terminal 4C):

Normal Output: 24VDC
Alarm output: 0VDC indicated if one or more occurs:

• Power input loss

• Scanning motor runs abnormally

• The temperature inside the enclosure is higher than 55oC (130oF)

3. Signal Amplitude Output (Figure 4.1, Terminal 3C): 0-13.5 VDC analog output, proportional
to the photocell output signal. This signal may indicate that the sensor’s protective lens
glass needs to be cleaned or the sensor’s sensitivity needs to be increased. Signal amplitude
output is influenced by:

• Sensor installation environment and location

• Target size

• Target temperature

• Distance between the sensor and the target

• Vapor in the field

• Dust on the Lens

• Sensitivity Adjustment Setting

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After the installation and setup are done, the sensor runs normally. Measure the signal
amplitude output voltage for later maintenance reference.

White/Black
White/Brown
White/Red

White/Yellow
White/Green

Green
Orange

Blue
Brown

Red
White
Black

White/Orange
White/Blue
White/Purple

Yellow/Green

Test
Sensitivity Select
Control

Signal Amplitude
0VDC

Remote Sensitivity
Alarm

PNP

Normal Close

Normal Open
Common

Ground

NPN

220VAC

220VAC220VAC

220VAC

110VAC

110VAC110VAC

110VAC

24VDC

24VDC24VDC

24VDC

++++

----

Shielding

Figure 4.1: HMD-SM Wiring Diagram

4.2 Cooling Water Connection

 Description- When the ambient temperature is higher than 50oC (120oF), cooling water

system is required to protect the electronics inside the enclosure. Two Φ10mm OD barbed
fittings are available beside the electrical connector for cooling water to circulate inside the
enclosure, the direction is not necessary.

 Cooling Water Requirements

• Clean industrial water

• Maximum water inlet temperature 25oC (77 oF).

• Maximum water pressure 4 bars (60 PSI)

• Water flow rate of 1 to 2 L/min (0.035 to 0.71 ft3/min)

Connection- Use Φ10mm ID or 3/8” ID hose for connections

One fitting is connected to plant’s water supply
The other one is connected to drain
Both fittings should be secured with hose clamps
Setup the cooling water flow rate by Figure 4.2

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

Ambient Temperaature

60

80

100

120

140

160

°C

Water

0.3

0.5

1.0

1.5

2.0 L/M

8 °C

20 °C

25°C

Figure 4.2 Ambient Temperature vs. Water Flow Rate

4.3 Purge Air Connection

 Description- Compressed plant air can be used to protect the lens from dust and vapor.

Purge air cleans the lens, reduces maintenance times, and prolongs sensor life where dust
or corrosive vapor is present.

 Purge Air Requirements

• Must be clean, dry instrument air, no oil, dust and contaminants included. Poor air quality
will result in dirty lens and decrease detector performance. If the quality of compressed air
can’t be guaranteed, it is better not connect it to the sensor to avoid the lens
contaminated and affect the sensor’s performance.

• Air filtration prior to the inlet fitting is recommended to improve the quality of purge air

•

Air Pressure range from 50 to 200 g/cm2 (0.7 psi to 2.8 psi)

• Air Flow rate from 4 to 16 L/min (0.14 to 0.56 ft3/min)



Connection- Connect the plant air source to the purge air barbed fitting on the sensor’s
lens shroud with Φ10mm ID (or 3/8” ID) hose. Purge air flows out of the sensor shroud
and dissipates into the ambient environment.

5. Operation

5.1 Control Panel

The HMD-SM Sensor’s Control Panel is located at the rear of the enclosure. The following
functions are available on the Control Panel, see Figure 5.1.

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LED= Process Status Indicator
Green: No target detected, standby mode.
Red: Target detected.
Orange: Sensor signal saturation or dirty lens.
Off: Alarm

Push Button= Test Button, turns on internal sensor test signal, at the same time activates
visible laser positioning beam for easy target aiming when the button is pressed.

N= Normal Sensitivity Threshold Level Adjustment Potentiometers. When adjust to

maximum sensitivity (7), detect target temperature 400 oC (752 oF) or higher.

H= High Sensitivity Threshold Level Adjustment Potentiometers. When adjust to maximum

sensitivity (7), detect target temperature 250 oC (482 oF) or higher.

Adjust sensitivity of the detector within each range, 1 to 7 refers low to high

Toggle Switch = Sensitivity range selection, N (normal) or H (high), use corresponding
potentiometer for the sensitivity adjustment.

!!!!!Note: Improve the sensitivity may trigger fault detection signal

N

H

1

7

TEST

1

7

LED

Figure 5.1: HMD-SM Control Panel

5.2 Automatic Threshold Level Description

 Definition- The HMD-SM includes an Automatic Threshold Level Adjustment. The sensor’s

built in circuit will automatically adjust the signal output when hot metal enters scanning
field to prevent detect signal from saturation. According to different field applications, base
threshold signal level is determined on installation. Follow “Base Threshold Level
Adjustment Procedure” in this section to setup the right threshold level.



Sensitivity- Flip sensitivity toggle switch to N (or H), Tune the corresponding threshold level

potentiometer clockwise will increase the sensitivity leveled from 1 to 7 in its range. The

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lower the potentiometer setting, the hotter the target should be and the more interfering
background radiation will be eliminated.

N: Normal sensitivity, for steel target temperature higher than 400oC (752oF)
H: High sensitivity, for steel target temperature from 250oC - 400oC (480oF-750oF).

 Base Threshold Level Adjustment Procedure

1. Align the HMD to the target or put Logika Hot Metal Simulation Test Bar in the HMD-SM’s
scanning field.

2. Normal (N) Sensitivity

• Flip the sensitivity toggle switch to N

• Tune normal threshold level potentiometer to 3 (middle position).

• Adjust the potentiometer until the LED color changes from green to red.

• This is the lowest threshold setting for this application. Turn potentiometer one unit

higher (clockwise) as the operating base threshold level setup.

3. High (H) Sensitivity

• Flip the sensitivity toggle switch toward H

• Tune high threshold level potentiometer to 3 (middle position)

• Adjust the potentiometer until the LED color changes from green to red.

• This is the lowest threshold setting for this application. Turn the potentiometer one

unit higher (clockwise) as the operating base threshold level setup.

4. If the LED does not change from green to red with hot metal in HMD scanning field, first
make sure the sensor is aligned properly and the target metal temperature is over 250 oC
(480 oF), then adjust the shutter width in front of the shroud(Section 3.2 Horizontal
Scanning field). The sensor will receive more infrared radiation energy from target. Go back
to the above steps to reset the threshold level.

Caution- After long time operation, the temperature of rollers will increase similarly to the
target temperature. To avoid false signal triggered by hot rollers, the HMD’s scanning field

must be set at the gap between the two rollers.

5.3 Remote Threshold Sensitivity

On the control panel
Turn both POTs to level 1, flip the toggle switch to N
On the control room, use a 10k POT and a toggle switch for remote sensitivity setup.

See Figure 5.2 for detail wirings.

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W hit e/ Gr ee n

2 B

B lu e

B r o wn

10 K

1

7

H Clo se -H igh se nsit iv ity
N O pe n- L o w s en sit ivit y

H M D H ar tin g Co nn ec to r

C o nt ro l Ro om

3 B

3 A

S e n siti v ity

S e n siti vit y Se le ct

0V DC

R e m o te S en si t iv ity

Figure 5.2 HMD Remote Sensitivity Setup and Wiring Diagram

5.4 Test Function

To test the electrical integrity of the HMD-SM sensor, follow the steps below:



Connect power supply to the HMD-SM, make sure the green LED is ON.



Press and hold the “TEST” button when no target in the scanning field of view.

•

The LED turns to red

•

The relay clicks

•

Pin 4B (white, High=Detect) changes to 24VDC from 0VDC (compare to Pin 3B, Blue)

•

Pin 4A (Black, low=Detect) changes to 0VDC from 24VDC (compare to Pin 3B, Blue)



Release the test button to return to normal operation and end the test function.

 Remote test function

: See the Figure5.3 for reference, it has the same function as the test

button on control panel.

Test W hite/Yellow

2C

0V DC Blue

3B

HM D Hartin g Co nnecto r

Co nt ro l R oom

Push
Button

Figure 5.3 Remote Test Function Wiring Diagram

5.5 Troubleshooting

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 Missed Target-

If the HMD doesn’t act normally when a hot metal target is in the scanning

field, there are two possibilities:

1. The Horizontal Scanning Angle Shutter located in front of the sensor is closed. Manually
adjust the shutter to allow the target’s infrared energy to reach the detector.

2. The threshold sensitivity potentiometer is set too low. Go to Section 5.2, and recalibrate
the Base Threshold Level.

 False Positive Target Detected-

1. The base threshold is set too high. Go to Section 5.2, and recalibrate the Base Threshold
Level.

2. If step 1 does not correct false positives, check for background sources of radiation such as
reflected sunlight or hot processes behind the target line. Correct these conditions as
necessary by adjusting the sensor aiming or by blocking the interfering radiation source.

 Diagnostic Signal Output Detected-

Check the diagnostic signals available and their status
indication (see Section 4.1 Sensor Diagnostic Outputs for details). Correct fault conditions
as necessary. See additional notes below:



Control Output terminals 2A/3B output 0VDC- Check that the sensor wiring connections are
correct, that the connections are secure and tight and that the power supply is proper and
normal.



Alarm Output terminals 4C/3B normally will output a signal of 24VDC. If the output is 0V
following a detected error, the following situation may occur:

1. If the housing temperature is over 55oC (130oF), then water cooling must be used (see
section 4.2). If water cooling is already in use, then check the water’s inlet temperature
and clogged water line.

2. If lens and temperature are fine, and alarm is still there. Measure the signal amplitude
output, 0VDC means the Scanning Error (motor error or circuit error). Please contact
Logika Technologies for resolution.

6. Maintenance

6.1 Regular Maintenance

 Diagnostics-

Usually, the HMD-SM does not need special maintenance. Regular attention to

the following will ensure steady operation of the sensor:

 Lens Cleaning-

periodically check the HMD-SM sensor’s glass for dust or oil residue, like a
month or 2 months depended on the sensor’s environment and purge air quality. Open the
black lens shroud and clean the glass with alcohol and lens paper or soft cloth.

 Detector-

Monitor the Signal Amplitude Output (Terminal 3C, Figure 4.1) for the general

conditions of the photocell and optical system.

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 Adjustments-

The threshold level sensitivity (see Section 5.2) and the shutter may require

adjustment if conditions are changed.

6.2 Returns of the HMD-SM

Contact us at 1-888-856-4452 (1-888-8LOGIKA) with the Serial Number of your HMD­SM before you return our product. If the problem cannot be resolved by telephone or email,
we will provide you with a return authorization number.

Please return to: Logika Technologies Inc.
2-2857 Sherwood Heights Drive,
Oakville, ON, L6J 7J9
Canada

Do not return the HMD-SM without a return authorization number. If the product is out of
warranty, we will provide a repair estimate and then complete the repairs upon your approval.

7. Accessories- Hot Metal Simulation Test Bar



In order to facilitate the installation, use and maintenance of HMD-SM hot metal detector
and other infrared sensors, Logika has developed a hot metal simulation test bar, Model TP-

1. This process simulation tool uses an AC power supply of 110/220V with the maximum
power of 500 W. The power output can be adjusted by the potentiometer on the test bar to
simulate different process temperatures.



When using the TP-1 test bar, please note the following:

•

The power supply should be supplied with a ground.

•

The test bar is made of sensitive electronic components. Use care when handling the unit.

•

Maximum one hour continuous usage, turn the power off when it is not used.

•

The tungsten lamp tube can be replaced if it is burnt.

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Figure 7.1: Hot Metal Simulation Test Bar Drawing

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8. HMD-SM Enclosure Dimensions

All units are in mm

Figure 8.1: HMD-SM Enclosure Side View

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Figure 8.2: HMD-SM Enclosure front View

Figure 8.3: HMD-SM Enclosure top View

Logika Technologies Inc. Model HMD-SM Operator’s Manual Rev 2.1 Dec­13

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Figure 8.2: Junction Box Dimension