SESOTEC PRIMUS+ Operating Instructions Manual

Operating Instructions

We reserve the right to change the contents
due to product innovation or technical im­provement.

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

Please read these instructions and keep the
manual safe!

Please observe and follow the safety notes!

Sesotec GmbH
Regener Straße 130 * D-94513 Schönberg
Telephone: [phone] * Fax: [phone]
E-mail: [e-mail]
Internet: http://www.sesotec.com
Service: Telephone: [phone]

Control Unit

PRIMUS+

1 PRIMUS-PLUS-BA-CU-EN-5136.docx

Manufacturer:

Sesotec GmbH
D-94513 Schönberg, Germany

Contact:

Sesotec GmbH
Regener Straße 130
D-94513 Schönberg, Germany

Tel.: [phone]
Fax.: [phone]
E-mail: [e-mail]
Internet: www.sesotec.com

Represented by:

2 PRIMUS-PLUS-BA-CU-EN-5136.docx

Contents

Contents
1 General information 6

1.1 Introduction 6

1.2 Field of application 6

1.3 Application reasons 6

1.4 System identification 6

1.5 Symbols used 6

1.6 EC DECLARATION OF CONFORMITY 6

1.7 Overview 7

2 Design and method of operation 8

2.1 Functional principle 8

2.2 Functional and control elements 9

2.2.1 Operating module with LCD graphic display 9

2.2.2 Cable glands 9

2.2.3 PRIMUS+ / IO electronics board 10

2.2.4 PRIMUS+ / CU electronics board 12

3 Dimensions and technical data 13

3.1 Technical data sheet, see annex 13

3.2 Supply connections, see technical data sheet in the annex 13

3.3 Environmental conditions for operation, storage, and transport 13

3.4 Noise levels 13

4 Safety 14

4.1 Intended use 14

4.2 Safety signs 14

4.3 Dangers arising from non-compliance with safety notes 14

4.4 Safety information for operators 14

4.5 Safety information for operation, maintenance and cleaning 15

4.6 Safety information for commissioning 15

4.7 Safety information for storage and transport 15

4.8 Notes on residual risks 15

4.9 Notes on stable standing requirements 15

4.10 Consequences of unauthorised modification 15

4.11 Improper use 16

5 Commissioning 17

5.1 Mechanical mounting 17

5.2 Connection of the equipment 17

5.2.1 PRIMUS+ / IO electronics board (control electronics board) 18

5.2.2 Electrical connections 18

5.2.3 PRIMUS+ / CU electronics board (evaluation electronics board) 19

5.2.4 Electrical performance 20

5.2.5 Drawing of input / output connections 20

5.2.6 Electrical connection of the equipment 21

5.2.6.1 Mains supply via safety socket 21

5.2.6.2 Mains supply via terminal box 21

5.2.7 Behaviour of machine at start up 22

5.2.8 Relays – operating status 23

6 Menu / Operation PRIMUS+ 24

6.1 General Operation 24

3

Contents

6.2 Quick Start 25

6.2.1 Language Selection 25

6.3 Menu Structure 26

6.3.1 Main menu 26

6.3.2 Function menu items 26

6.3.3 Settings menu items 26

6.3.4 Output menu 27

6.3.5 Setup menu 28

6.3.6 Operating mask 32

6.3.7 Change product 33

6.3.8 Auto-Set 34

6.3.9 Product parameter 35

6.3.10 Conveying speed 35

6.3.11 Output 36

6.3.11.1 Output adjust 36

6.3.11.2 Output lock 37

6.3.11.3 Monitoring 37

6.3.11.4 Output Level 37

6.3.11.5 Output options 38

6.3.12 Setup 38

6.3.12.1 Logbook 39

6.3.12.2 Clear logbook (Menu item requires login) 41

6.3.12.3 Show counter 41

6.3.12.4 Device-Info 42

6.3.12.5 Revision 42

6.3.12.6 Change password (menu item requires login) 43

6.3.12.7 Language 43

6.3.12.8 Clock/Date (menu item requires login) 43

6.3.12.9 Setup options (menu item requires login) 44

6.3.12.10 Units (menu item requires login) 44

6.3.12.11 Frequency deviation (menu item requires login) 44

6.3.12.12 Factory settings (menu item requires login) 45

6.3.12.13 Login 45

6.3.12.14 Logout 45

6.3.12.15 Air pressure monitoring (option) (menu item requires login) 45

6.3.12.16 Flap monitoring (option) (menu item requires login) 46

6.3.12.17 External error (option) (menu item requires login) 46

6.3.12.18 Ejection monitoring (option) (menu item requires login) 46

7 Errors and error remedying 47

7.1 Error messages 47

7.1.1 Receiver voltage too high 47

7.1.2 Receiver faulty 47

7.1.3 Transmitter faulty 47

7.1.4 Transmitter over temperature 47

7.1.5 Hardware CU 48

7.1.6 Hardware IO 48

7.1.7 Communication IO 48

7.1.8 Watchdog 48

7.1.9 Memory error 48

7.1.10 Short circuit MV 48

7.1.11 Connection MV 48

7.1.12 Air pressure 49

7.1.13 Diverter position 49

7.1.14 Sensor 1 faulty 49

7.1.15 Sensor 2 faulty 49

7.1.16 Filling level 49

7.1.17 External error 50

7.2 Undefinable activation of the switching outputs 50

7.3 Replacing the backup battery 51

4

Contents

7.4 Replacement of electronic boards 52

7.4.1 Replacing the CU electronics board PRIMUS+ 52

7.4.2 Replacing the IO electronics board PRIMUS+ 53

7.4.3 Replacing the display board 53

8 Maintenance and cleaning 54

8.1 Maintenance 54

8.2 Cleaning 54

8.2.1 Hints for cleaning 54

8.2.2 Cleaning instructions 54

8.2.3 Care advice for stainless steel 54

9 Spare parts 55

9.1 Spare parts view 55

9.2 Spare parts list 56

10 Shipping, preservation, waste disposal, transport, storage 57

10.1 Shipping, preservation, waste disposal 57

10.2 Transport 58

10.3 Storage 58

11 Annex 59

5

1. General information

Symbol

Signal word

Meaning

Danger

Warning: Possibility of severe or even fatal personal injuries.

Danger

The lightning symbol is an explicit warning that there is danger from
electric current.

Warning

Warning: Possibility of minor personal injuries or property damage.

Caution

Warning: Possibility of defects or destruction of the equipment.

Important in-

formation

Indicates an important information for the function.

Important

hint

Indicates an important hint for the function.

1 General information

1.1 Introduction

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

1.2 Field of application

The PRIMUS+ control unit is used in combination with Sesotec metal detectors and separators in the
plastics, wood, food, chemical, and in a special version also in the pharmaceutical industry. Depending
on the respective version, these systems inspect packed, unpacked, or piece products, and bulk mate­rials for magnetic and non-magnetic metal contaminations.
Of course they also are suitable for similar applications in other branches of industry.

1.3 Application reasons

 Product liability
 ISO 9000
 TQM (Total Quality Management)
 Protection of machines and quality assurance

1.4 System identification

The information in this instruction manual only applies to the PRIMUS+ control unit. A label with the
respective data is attached at every system.

1.5 Symbols used

1.6 EC DECLARATION OF CONFORMITY

(See annex – EC DECLARATION OF CONFORMITY)

6

1. General information

PRIMUS+ Control Unit

Graphic display

1.7 Overview

7

2. Design and method of operation

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i

v

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r

T

r

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s

m

i

t

t

e

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R

e

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e

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Detection coil

Signal amplifier

Analog/digital

converter

LCD graphic

display

Memory for

10 products

CU elec tronics

IO electr onics

Power
supply

CPU

Relay

I/O in terface

Oscillator

Control Unit PRIMUS+

Control panel

Logbook

real time clock

CP U

Monitorin g

For reasons of the employed technology it is not possible to guarantee 100% metal
detection.

2 Design and method of operation

2.1 Functional principle

The metal detector works with the so-called "balanced coil" principle:
The transmitter winding in the search coil creates a high-frequency electromagnetic field, which is re­ceived by symmetrical placed receiver windings. The windings are connected against each other;
when undisturbed, the system is in balance.

An electrically conductible object within the detection area disrupts this balance and the electronic cre­ates a switch signal.

A "teach in process” allows to suppress the conductivity of the product itself. Deviations from the

taught-in product are usually caused by metal contaminants, which are detected by the device with
high precision.

The metal detector is equipped with comprehensive test and analysis software to ensure fault-free op­eration and retracing of product errors.

8

2. Design and method of operation

1

Graphic display

LCD module

Display of operating and input masks

2

Operator keys

+ , - , , Esc

For operation and machine setting

3

Function key

Reset

Reset to restore the unit after metal or fault signal

4

Function key

Test

Test function for metal detectors

5

Metal LED

Metal

Lights red when metal detected

6

Operating / Fault LED

Operating

Lights green in normal operating mode, metal detec­tion active

6

Operating / Fault LED

Fault

Lights red in case of fault and error

11

98 10 127

Ope rating/ Fault Metal

Esc Test

Reset

(7) Cable gland for the mains cable

(8), (9), (11) Cable gland for option
(10) Cable gland for free use
(12) Cable gland for connecting the detector coil

2.2 Functional and control elements

2.2.1 Operating module with LCD graphic display

2.2.2 Cable glands

9

2. Design and method of operation

Connectors and termi­nals:

(1) "Mains/Option" L/N: Control unit power supply

O1/O2: Optional 24V module power supply
(2) "Relay metal" Potential free change over contact
(3) "Relay fault" Potential free change over contact
(4) "Switching outputs" J5, connector, magnetic valves, signal combi., etc.
(5) "Switching inputs" J6, connector, sensors, switches, etc.
(12) "MV voltage external" J13, connector 24V external (option)
(18) "CU connection" J10, plug connection to CU electronics

Elements connected to
mains voltage:

(1) "Connector, Mains/Option"
(10) "Mains fuses

Elements connected to
external voltage:

(2) "Connector, relay metal"
(3) "Connector, relay fault"

Vorsicht
Fremd­spannung

Light diodes:

(7) "Monitor LED, MV1-3" LD 10, magnetic valve (MV1)
LD 9, magnetic valve (MV2)
LD 8, magnetic valve (MV3)
(9) "Monitor LED, relay" LD 11, relay fault (84, 81, 82)
LD 12, relay metal (74, 71, 72)
(17) "Monitor LED, Vcc” LD 1, +24V
LD 2, +10V
LD 3, +3.3V

9

25 26 27 28 29 30 31 32

1

17 18 19 20 21 22 23 24

10211312413514615716

8

8171N 8474L 8272O1 O2

TP2

JP9

F1

JP10

LD10

LD9

LD8

LD11

LD12

J8

J10

J14

J13

LD1

LD2

LD3

TP1

1

J5 J6

JP3

3
2
1

3

8

1

4
6

2

5
7

J11

11 3 5

2 4 6

2

3

4

5

6

7

8

9

14

13

3

11

15

(GND)

(GND_24V)

2

17

10

16

12

18

2.2.3 PRIMUS+ / IO electronics board

10

2. Design and method of operation

Jumper:

(6) "MV connection monitor" JP10, 1-2, MV1
JP10, 3-4, MV2
JP10, 5-6, MV3
(11) "MV voltage supply" JP3, 2-1 external 24V (connector J13 +/-)
JP3, 2-3 internal, 24V (default)
(15) "Service jumper" J8, 5-6, plugged, enable, program update

Test points:

(8) "GND_24V” TP2, magnetic valves (MV1- MV3)

(16) "GND" TP1, IO electronics

Interface/plug connectors:

(14) "Program update" J11, mini USB, (only for trained staff)
JP9, USB selection (jumper plugged)

(13) "Data backup" J14, USB interface (system / product data)
JP9, USB selection (jumper open)

Fuse

Description

Type

F1

Mains supply

1.6A slow-blowing 1500A @ 250VAC 5x20mm

11

2. Design and method of operation

Connectors and terminals:

(1) "Receiver" J10, input signal from the detection coil
(2) "Transmitter" J7, output signal to the detection coil
(9) "Service interface" J11, diagnostics interface
(11) "FFC connector" J5, ribbon cable connector to the display module
(12) "Memory" J4, system / product data

Test points:

(3) "Transmitter signal" TP7, sine signal ( 25Vss) to the detection coil
(6) "GND" TP8, TP19, reference ground for all signals

Jumper:

(8) "Service jumper" J2, 5-6, plugged, enable, program update

Interface/plug connectors:

(10) "Program update" J9, mini USB, (only for trained staff)
(JP2, observe jumper position)

Light diodes:

(5) "Monitor LED,s, Vcc" LD 5, +24V
LD 6, +5V
LD 7, -5V
LD 8, +15V
LD 9, -15V
LD 10, 3.3V
(4) "Monitor LED’s" LD 4, green, operating status

LD 3, red, fault status

Memory:

(12) "Memory devices" J4, device and product data
(7) "Battery" BT1, for real-time clock

2.2.4 PRIMUS+ / CU electronics board

12

3. Dimensions and technical data

3 Dimensions and technical data

3.1 Technical data sheet, see annex

3.2 Supply connections, see technical data sheet in the annex

3.3 Environmental conditions for operation, storage, and transport

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

3.4 Noise levels

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

the floor, LpA, 1m, max.
Result:

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

We reserve the right to change the contents due to product innovation or technical improve­ment.

13

4. Safety

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

The equipment is intended for use in the following fields of application and only in combi­nation with a corresponding detection coil of series GLS, C-SCAN DLS, P-SCAN RP: Suc­tion/pressure conveyor applications, free-fall applications, and applications at a conveyor
belt. The equipment can be used in the plastics, food, animal feed, recycling, and chemical
industry. Basically it is possible to also use the system in other applications than the in­tended use stated herein, but such applications always require the prior consultation and
approval of Sesotec GmbH.

Symbol

Signal word

Location

Meaning

Mains volt­age

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

"Mains" (1)

"Metal" (2) und "Fault" (3)

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

The control unit PRIMUS+ may only be operated in the intended purpose and in a perfect func­tioning condition, especially the cover of the electronic housing has to be closed during opera­tion. Entered moisture has to be removed! All fixed warning signs on the equipment may not be
removed and have to be in a well recognizable condition. The operating instructions always
have to be in a legible condition and complete available. Prior to commissioning always make

sure that the applicable accident prevention regulations are observed. If the control unit is
not mounted at the detection coil, it must be properly and firmly fastened by means of the
four screws. The operator must make sure that the equipment is mounted at an ergonomic
height for operation. The operator may only appoint qualified personnel for operation, mainte-

nance and repair work. If potentially explosive materials are examined, the pertinent regula­tions must be observed.

Emitted interference
Test report according to the provisions of:

BGV B11:2001-06

Regulations of the professional association for safety and
health at work.
Accident prevention regulations for electromagnetic fields.

E DIN VDE 0848-3-1: 05-2002

Safety in electrical, magnetic, and electromagnetic fields,
part 3-1: Protection of persons with active implants in the
frequency range of 0Hz to 300 GHz.

In the area where the operating personnel is working the electromagnetic field of the metal

4 Safety

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

4.1 Intended use

4.2 Safety signs

4.3 Dangers arising from non-compliance with safety notes

4.4 Safety information for operators

14

4. Safety

detector or separator does not exceed the limits stated in the provisions. Therefore there
are no health impairments due to electromagnetic fields in this area for persons and for
wearers of medical implants such as cardiac pacemakers. Inside the coil of round or
closed tunnel coils, or on the surface of flat coils, the limits may be exceeded depending
on design and system version. If work is to be performed inside or at the search coil, per­sons and wearers of medical implants such as cardiac pacemakers may only enter the
equipment when it is turned off, provided that size and design allow this.

Because of energised components in the electronics housing there is a risk of injuries due
to electric shock or burns. During operation the cover of the electronics housing must be
kept closed. Only qualified personnel may operate and clean the equipment.

If the electronics housing must be opened for maintenance or cleaning purposes, remove
any dirt and moisture from the electronics housing, so that no larger amounts may get into
the interior. Always disconnect the power supply and any connected external circuits be­fore opening the cover. Any moisture that has penetrated into the interior must be re­moved from the electronics housing. If any maintenance work must be performed in
energised condition, e.g. battery replacement, such work may only be performed by a
qualified electrician under strict observation of the attached warning labels and with due
regard to standard approved rules of electrical engineering.

No safe condition is established when outputs are switched "inactive" (with "Disable Out­puts", "Bypass", or "Output level inactive".
For any maintenance work the compressed-air and power supply of the machine must al­ways be disconnected, and any existing pneumatic cylinders must be vented.

To avoid any injuries due to energised parts in the electronics housing, the information in

5.1 and 5.2 must always be observed.

Always observe the information in paragraph 10 to avoid any transport damage and per­sonal injuries.

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

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

Unauthorised modification or repair will invalidate all manufacturer declarations and guar­antees.

4.5 Safety information for operation, maintenance and cleaning

4.6 Safety information for commissioning

4.7 Safety information for storage and transport

4.8 Notes on residual risks

4.9 Notes on stable standing requirements

4.10 Consequences of unauthorised modification

15

4. Safety

For other applications as enumerated in 4.1 the control unit PRIMUS+ intended for – that
is regarded as inadmissible operation. Improper use also includes operating the equip­ment with excessive mechanical, static or dynamic loads (e.g. heavy machine parts or
strong vibration). It is furthermore not permitted to inspect any aggressive materials on the
conveyor, such as materials containing lyes, acids, and solvents, or materials that react to
electromagnetic fields, or living persons or animals, and to operate the system in an Ex
protection area.

4.11 Improper use

16

5. Commissioning

In order to meet CE conformity all cable outside of the housing has
to be shielded. The shields must be grounded immediately after the
cable gland.

Housing

Shield

Cable

5 Commissioning

5.1 Mechanical mounting

 Ensure stable and non-vibrating installation! In house mounting and operation. Do not install the

system in an explosion proof zone.

 Do not install the detection coil and the electronic unit in the vicinity of interference fields (large

electric motors and frequency converters!) The distance depends on the power consumption of the
motor or of the frequency converter (value for orientation: 5 m).

 Mount the control cabinet by using the provided bores. I.e. at a wall or frame (dimensions are shown in

the outline drawings). Pay attention to good stability, as the weight of the control unit is approx. 4 kg.

 Never install the electronic unit in other switchgear cabinets, because this may lead to interference

effects. (E.g. from contactor controls)!

 Cable lengths may only be modified after consultation with "Sesotec". Use only original cables. Lay

the connecting cable in fixed installation apart from other cables (e.g. fix it with nailing clips or lay it
in a cable duct).

 If several metal detector systems are used, the distance of the detection coils must not be less than

2m, if these coils stand side by side. If the coils are arranged opposite to each other, the distance
must not be less than 10 m. These values apply to large systems; for smaller systems the distanc­es may be reduced to 50 cm. If, for reasons of space, these distances cannot be observed, please
contact Sesotec service!

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

any way!

5.2 Connection of the equipment

17

5. Commissioning

Pos.

Connection

Type of connection

Function

(1)

"Mains/Option"

Connector for mains
supply

L/N: Electronics power supply
O1/O2: Optional 24V module power supply connector

(2)

"Relay metal"

Voltage free
relay contact

Normal operation: Contacts 71 and 72 closed
On metal detected Contacts 71 and 74 closed

(3)

"Relay fault"

Voltage free
relay contact

Normal operation: Contacts 81 and 84 closed
In case of fault: Contacts 81 and 82 closed

(4)

"Outputs"

Switching outputs
24V

J5

Switching functions
MV = magnetic valve connection
( =24V to GND or  = 0V to 24V)

1 – 9

, FU: Not assigned

2 – 10

, LM: Lamp metal

3 – 11

, LB: Lamp operation

4 – 12

, LF: Lamp fault

5 – 13

, Mz: Ext. metal counter

6 – 14

 or , MV1, (after system setup)

7 – 15

 or , MV2, (after system setup)

8 – 16

 or , MV3, (after system setup)

(5)

"Inputs"

Switching inputs 24V

J6

Switching functions
24V, NPN or PNP switching

17 – 18 – 25

KÜ: Flap monitoring
PNP or NPN (dep. on application)

19 – 26 – 27

FEX: Fault external
PNP or NPN (dep. on application)

20 – 28

DÜ: Compressed-air monitoring
NPN

21 – 29

TEX: Test external
NPN

22 – 30

REX: Reset external
NPN

23 – 31

MAN: Manual separation
NPN

24 – 32

MD: Deactivate metal detection
NPN

J5J5

J6

5.2.1 PRIMUS+ / IO electronics board (control electronics board)

5.2.2 Electrical connections

18