Apex Metal Detector · Revision History Revision Number Date Released ECO Number Release Specifics...

Apex Metal Detector

Service Guide

REC 4258 Rev C Part # 087929

Revision History Revision Number Date Released ECO Number Release Specifics Revision A March, 2007 1369 Official First Release Revision B May 2007 1442 Added DSP3 to APEX upgrade

instructions, Chapter 11. Revision C July 2007 1516 Added procedures to APEX software

upgrades.

©2006 Thermo Fisher Scientific. All rights reserved.

This document is confidential and is the property of Thermo Fisher Scientific (Thermo Scientific). It may not be copied or reproduced in any way without the express written consent of Thermo Scientific. This document also is an unpublished work of Thermo Scientific. Thermo Scientific intends to, and is maintaining the work as confidential information. Thermo Scientific also may seek to protect this work as an unpublished copyright. In the event of either inadvertent or deliberate publication, Thermo Scientific intends to enforce its rights to this work under the copyright laws as a published work. Those having access to this work may not copy, use, or disclose the information in this work unless expressly authorized by Thermo Scientific.

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All other trademarks are the property of Thermo Fisher Scientific and its subsidiaries.

Software Program License Terms

The Software Program is licensed, not sold. Thermo Fisher Scientific, grants you a license for the Software Program only in the country where you acquired the Equipment, as defined below. You obtain no rights other than those granted you under this license.

The term “Equipment” means the equipment with which the Software Program is used. The term “Software Program” means the original and all whole or partial copies of the Software Program used in connection with Equipment sold by Thermo Fisher Scientific to the user, including modified copies or portions of the Software Program. Thermo Scientific retains title to the Software Program, as well as all improvements, modifications and enhancements to the Software Program, whether made by Thermo Scientific or any other party. Thermo Scientific owns, or has licensed from the owner, copyrights in the Software Program.

You are responsible for the selection of the Equipment.

Following the commissioning of the Equipment, any change made by the user to the Software Program will terminate all warranties with respect to the Equipment and Software Program.

All other trademarks are the property of Thermo Fisher Scientific and its subsidiaries.

License

Under this license, you may:

1. Use the Software Program on only one piece of equipment at any one time, unless the license information specifies otherwise;

2. Copy the Software Program for backup or in order to modify it; 3. Modify the Software Program and/or merge it into another Software Program; and 4. Subject to the following limitations, transfer the possession of the Software Program to another party, but

only in connection with a transfer of the Equipment.

If you transfer the Software Program, you must transfer a copy of these License Terms, all other documentation and at least one complete, unaltered copy of the Software Program to the other party. Unless you have other copies of the Software Program to be used in connection with other Equipment purchased from Thermo Scientific , or one of its divisions, you must, at the same time, either transfer all your other copies of the Software Program to the transferee of the Equipment or destroy them. Your license is then terminated. The other party agrees to these terms and conditions by its first use of the Software Program.

You must reproduce the copyright notices(s) on each copy of the Software Program.

You may not:

1. Use, copy, modify, merge, or transfer copies of the Software Program except as provided in this license; 2. Reverse engineer, decompile, or disassemble the Software Program; or 3. Sub-license, rent, lease, or assign the Software Program.

Limitation of Remedies

Thermo Scientifics’ entire liability under this license is the following:

Thermo Scientific will: (a) replace defective media, or (b) make a warranted Software Program operate or (c) replace the Software Program with a functionally equivalent Software Program, as warranted.

For any claim (including breach), in any form, related in any way to this license, Thermo Scientifics’ liability will be for the actual value of the Software Program.

Thermo Scientific will not be liable for any lost profits, lost savings, any incidental damages, or other economic consequential damages, even if Thermo Scientific, or its authorized supplier, has been advised of the possibility of such damages. Thermo Scientific will not be liable for any damages claimed by you based on any third party claim.

General

Thermo Scientific may terminate your license if you fail to comply with the terms and conditions of this license. In such event, you must destroy all your copies of the Software Program. You are responsible for payment of any taxes, including personal property taxes, resulting from this license.

Thermo Scientific Warranty

The seller agrees, represents, and warrants that the equipment delivered hereunder shall be free from defects in material and workmanship. Such warranty shall not apply to accessories, parts, or material purchased by the seller unless they are manufactured pursuant to seller's design, but shall apply to the workmanship incorporated in the installation of such items in the complete equipment. To the extent, purchased parts or accessories are covered by the manufacturer’s warranty; seller shall extend such warranty to buyer.

Seller's obligation under said warranty is conditioned upon the return of the defective equipment, transportation charges prepaid, to the seller's factory in Minneapolis, Minnesota, and the submission of reasonable proof to seller prior to return of the equipment that the defect is due to a matter embraced within seller's warranty hereunder. Any such defect in material and workmanship shall be presented to seller as soon as such alleged errors or defects are discovered by purchaser and seller is given opportunity to investigate and correct alleged errors or defects and in all cases, buyer must have notified seller thereof within one (1) year after delivery, or one (1) year after installation if the installation was accomplished by the seller.

Said warranty shall not apply if the equipment shall not have been operated and maintained in accordance with seller's written instructions applicable to such equipment, or if such equipment shall have been repaired or altered or modified without seller's approval; provided, however, that the foregoing limitation of warranty insofar as it relates to repairs, alterations, or modifications, shall not be applicable to routine preventive and corrective maintenance which normally occur in the operation of the equipment.

“EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN, SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT DELIVERED HEREUNDER, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE. THE SOLE LIABILITY OF SELLER ARISING OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO BREACH OF THOSE WARRANTIES. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY, PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT, AND THE CORRECTION OF ANY DEFECT IN WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.”

Purchaser agrees to underwrite the cost of any labor required for replacement; including time, travel, and living expenses of a Thermo Scientific Field Service Engineer at the closest factory base.

Thermo Fisher Scientific

501 90th Ave. NW

Minneapolis, MN 55433

Phone: (800) 227-8891

Fax: (763) 783-2525

Disclaimer

Though the information provided herein is believed to be accurate, be advised that the information contained herein is not a guarantee for satisfactory results. Specifically, this information is neither a warranty nor guarantee, expressed or implied, regarding performance, merchantability, fitness, or any other matter with respect to the products, and recommendation for use of the product/process information in conflict with any patent. Please note that Thermo Scientific reserves the right to change and/or improve the product design and specifications without notice.

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Thermo Fisher Scientific Contents i REC 4258 Rev C

Contents

Contents................................................................................................................... i

Figures .................................................................................................................... v

About this Manual..............................................................................................vii Organization of this Guide....................................................................vii

Chapter 1 .............................................................................................................1-1

Search Head PCBA Head Setup .....................................................................1-1 APEX Frequency Limitations .............................................................. 1-1 Safety .................................................................................................. 1-1 Search Head PCB................................................................................ 1-2

Oscillator Transformer Ratio ........................................................... 1-2 Oscillator Frequency ........................................................................ 1-3 Oscillator Amplitude........................................................................ 1-4 Input Tuning ................................................................................... 1-5 Electronic Balance............................................................................ 1-7

Search Head Screen........................................................................... 1-11 Auto Balance..................................................................................... 1-11 Search Head PCP Layout .................................................................. 1-13 Fine Tuning the System .................................................................... 1-14

Parts Required................................................................................ 1-14

Chapter 2 .............................................................................................................2-1

APEX I/O and PSU Connections......................................................................2-1 Wiring AC Power into the PSU PCBA ............................................ 2-2 Input Power Consumption .............................................................. 2-2 Wiring Outputs from the PSU PCBA (Not recommended) ............ 2-2 Wiring Inputs into the PSU PCBA .................................................. 2-3 Inputs .............................................................................................. 2-4

Overview of connections on Relay PCBA............................................ 2-4 Relay outputs ...................................................................................... 2-5 Communication Output ..................................................................... 2-5

Contents

ii Contents Thermo Fisher Scientific REC 4258 Rev C

Chapter 3 .............................................................................................................3-1

Control Panel Assembly...................................................................................3-1 How Too Upgrade the APEX Software............................................... 3-1

PN 090896 - APEX CPU Programming Cable – C07387M-E007.. 3-1 Upgrade Method 1 – MS-DOS boot floppy .................................... 3-2 Upgrade Method 2 – Upgrading in Windows .................................. 3-3

APEX error codes ................................................................................ 3-5 Enable Passwords ................................................................................ 3-7

Assigning/Changing Passwords ........................................................ 3-8 Setup................................................................................................... 3-9

Chapter 4 .............................................................................................................4-1

Maintenance and Troubleshooting ...............................................................4-1 Cleaning.............................................................................................. 4-1

Check for Corrosion ........................................................................ 4-2 Fault Finding ...................................................................................... 4-2

Search Head Faults........................................................................... 4-2 Reject Confirm Fault ....................................................................... 4-2 Battery Low Fault............................................................................. 4-3 Product Memory Fault..................................................................... 4-3 Photo Reject Fault – Conveyor Systems ........................................... 4-3 Shaft Encoder Fault – Conveyor Systems ......................................... 4-3 QA Test Response Fault................................................................... 4-3 QA Test Result Fault ....................................................................... 4-4 Excess Reject Fault ........................................................................... 4-4 Phase Limit Fault ............................................................................. 4-4 Photo-eye Block Fault ...................................................................... 4-4 AuditCheck Fault............................................................................. 4-5 Recommended Testing Procedures................................................... 4-5 Testing Schedule .............................................................................. 4-6 Record Keeping................................................................................ 4-7 Rejected Product Examination ......................................................... 4-7 QA Test Request.............................................................................. 4-7

Service Repair and Replacement Parts ................................................. 4-7 Parts Ordering Information............................................................ 4-11 Parts............................................................................................... 4-12 Phone/Fax Contacts for Thermo Scientific Offices......................... 4-13 Battery Replacement ........................................................................ 4-1 Disposal of Hazardous Waste ........................................................... 4-2

Contents

Thermo Fisher Scientific Contents iii REC 4258 Rev C

Chapter 5 .............................................................................................................5-1

Part & Drawing Numbers ................................................................................5-1 Printed Circuit Board Assemblies ........................................................ 5-1 Control Panel Assemblies .................................................................... 5-1 Cable Assemblies................................................................................. 5-2

Chapter 6 .............................................................................................................6-1

Reference Material...........................................................................................6-1 DSP3/APEX Differences..................................................................... 6-1

DSP3 Sensitivity Control VS APEX Detection Level Control .......... 6-1 DSP3 PCNR VS APEX PNR .......................................................... 6-1 Loss of DSP3 VNX.......................................................................... 6-2 APEX DSV Filter............................................................................. 6-2 APEX DAG Method........................................................................ 6-3 APEX Display Size ........................................................................... 6-3 Plastic Control Box – Will it Shield RF? .......................................... 6-3 Aperture Size Programming on CPU ............................................... 6-4 APEX BNC Connector .................................................................... 6-4

APEX Quick Start Documentation ..................................................... 6-4 Product Speed and Filtering the Signal............................................. 6-5 Rejecting the Product....................................................................... 6-5 Reject Duration................................................................................ 6-5 Rejecting the Product More Accurately ............................................ 6-6 Packs that are to close to each other ................................................. 6-6 Failsafe Operation ............................................................................ 6-6 Recapping so far............................................................................... 6-6 Product Effect .................................................................................. 6-7 Wet and Dry Product....................................................................... 6-7 Phase Tracking................................................................................. 6-7 Recap +1 .......................................................................................... 6-8 Detection Level ................................................................................ 6-8 Effects of Vibration and Mechanical Shock ...................................... 6-9 Metal Free zone................................................................................ 6-9

APEX signal Improvement Algorithms.............................................. 6-10 QNR.............................................................................................. 6-10 PNR............................................................................................... 6-10 CLX............................................................................................... 6-10 Phase Tracking............................................................................... 6-11

Balance Correction Switch Settings on Search Head PCB................. 6-12 To recap, SW1 effectiveness is due to: -.......................................... 6-12

Contents

iv Contents Thermo Fisher Scientific REC 4258 Rev C

Chapter 7 .............................................................................................................7-1

AuditCheck™......................................................................................................7-1 Theory of Operation ........................................................................... 7-1 Operation ........................................................................................... 7-3

Setup – Speed Shuttle Calibration.................................................... 7-3 Software Setup ................................................................................. 7-4 Manual AuditCheck Test ................................................................. 7-7 Faults and Alarms............................................................................. 7-7

AuditCheck Patented Sensitivity Test System ..................................... 7-8 AUDITCHECK THEORY OF OPERATION ............................ 7-11 SUMMARY................................................................................... 7-17

Chapter 8 .............................................................................................................8-1

Using the APEX Oscilloscope.........................................................................8-1

Chapter 9 .............................................................................................................9-1

Cold Start.............................................................................................................9-1

Chapter 10 .........................................................................................................10-1

Oscillator...........................................................................................................10-1

Chapter 11 .........................................................................................................11-1

DSP3 to APEX Upgrade Instructions............................................................11-1 DSP3 Parts...................................................................................... 11-18

Chapter 12 .........................................................................................................12-1

APEX Software Update...................................................................................12-1 Upgrade Method 1 – MS-DOS Boot Floppy .................................... 12-2 Upgrade Method 2 – Upgrading in Windows ................................... 12-3 Troubleshooting................................................................................ 12-6

Update not Starting........................................................................ 12-6 Transfers Timing Out .................................................................... 12-6

Chapter 13 .........................................................................................................13-1

Engineering Drawings....................................................................................13-1

Contents

Thermo Fisher Scientific Contents v REC 4258 Rev C

Figures

Figure 1–1. Oscillator Transformer Ratio .....................................................1-2 Figure 1–2. Oscillator Amplitude....................................................................1-4 Figure 1–3. 90 degree input phase shift ........................................................1-5 Figure 1–4. Input Tuning...................................................................................1-6 Figure 1–5. Electronic Balance Correction (HF)..........................................1-8 Figure 1–6. Electronic Balance Correction (LF) ........................................1-10 Figure 1–7. Auto Balance...............................................................................1-12 Figure 1–8. Search Head PCB Layout ..........................................................1-13 Figure 2–1. PSU PCBA connections...............................................................2-1 Figure 3–1. Password Screen 1 ......................................................................3-7 Figure 3–2. Password Entry Screen...............................................................3-7 Figure 3–3. Password Screen 2 – Assigning Passwords (Level 3 access only.......................................................................................................................3-8 Figure 3–4. Password Entry Screen...............................................................3-8 Figure 3–5. Password Confirmation Screen ................................................3-9 Figure 7–1. Cross section of the search head on a conveyor system.....7-2 Figure 7–2. AuditCheck Screen 1 ...................................................................7-4 Figure 7–3. AuditCheck Screen 3 ...................................................................7-6 Figure 7–4. Head Sensitivity............................................................................7-9 Figure 7–5. AuditCheck Sensitivity..............................................................7-12 Figure 7–6. AuditCheck Elements ................................................................7-14 Figure 7–7. Amplitude of the Signal.............................................................7-15 Figure 11–1. Integral Conversion Kit............................................................11-2 Figure 11–2. Integral Conversion Kit Front View.......................................11-2 Figure 11–3. Integral Conversion Kit Back View ......................................11-3 Figure 11–4. DSP3 Unit to be Upgraded ......................................................11-3 Figure 12–1. APEX CPU Programming Cable .............................................12-1

Contents

vi Contents Thermo Fisher Scientific REC 4258 Rev C

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Thermo Fisher Scientific About this Manual vii REC 4258 Rev C

About this Manual

The APEX Service Guide is a learning resource and reference for use by Thermo Scientific Service Engineers and those adequately trained by Thermo Scientific to perform installation, customer training, product commissioning, and parts replacement.

It is an introduction to the product and a theoretical outline for the instrument and its operation.

Full Service Repair

Install Maintenance Troubleshooting

Service People

Distributor Trained Customer

X X

This guide is organized into 12 chapters. Other good resource for APEX operations are REC 4248, APEX Metal Detector User Guide and REC-58 Quick Start Guide that can be obtained by contacting Thermo Scientific .

Chapter 1: Search Head PCBA Head Setup

Chapter 2: APEX I/O and PSU Connections

Chapter 3: Control Panel Assembly

Chapter 4: Maintenance and Troubleshooting

Chapter 5: Part & Drawing Numbers

Chapter 6: Reference Material

Chapter 7: AuditCheck™ (Not Available on APEX 100)

Chapter 8: Using the APEX Oscilloscope

Chapter 9: Cold Start

Chapter 10: Oscillator

Chapter 11: DSP3 to APEX Upgrade Instructions

Chapter 12: Engineering Drawings

Organizationof this Guide

About this Manual

viii About this Manual Thermo Fisher Scientific REC 4258 Rev C

Instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations.

Please read the safety information before performing any operation.

There are two levels of safety messages: warnings and cautions. The distinction between the two is as follows:

WARNING. Failure to follow safe installation and servicing procedures could result in death or serious injury. ▲

CAUTION. Failure to observe may cause minor injury or damage to equipment. ▲

Do not install, operate, or perform any maintenance procedures until you have read the safety precautions presented.

WARNING. Failure to follow safe installation and servicing procedures could result in death or serious injury. ▲

Make sure only qualified personnel perform installation and maintenance procedures in accordance with the instruction in this manual.

Allow only qualified electricians to open and work in the electronics cabinets, power supply cabinet, control cabinet, or switch boxes.

Covers over the electronics and rotating parts must always remain in place during normal operation. Remove only for maintenance, with the machine’s power OFF. Replace all covers before resuming operation.

During maintenance, a safety tag (not supplied by the factory) to be displayed in the ON/OFF switch areas instructing others not to operate the unit (ANSI:B157.1).

Safety Messages

GeneralPrecautions

About this Manual

Thermo Fisher Scientific About this Manual ix REC 4258 Rev C

WARNING. High voltage that may be present on leads could cause electrical shock. ▲

All switches must be OFF when checking input AC electrical connections, removing or inserting printed circuit boards, or attaching voltmeters to the system.

Use extreme caution when testing in, on, or around the electronics cabinet, PC boards, or modules. There are voltages in excess of 115 V or 230 V in these areas.

WARNING. Use only the procedures and new parts specifically referenced in this manual to ensure specification performance and certification compliance. Unauthorized procedures or parts can render the instrument dangerous to life, limb, or property. ▲

WARNING. Keep hands and clothing away from all moving or rotating parts. ▲

WARNING. Do not place or store objects of any kind on the machine. ▲

WARNING. This machine should not be operated at more than the production rate stated on your Equipment Specification sheet, used in applications other than those stated in the original order, or in a manner not specified by Thermo Scientific . To do so may impair the protection provided by the machine. ▲

About this Manual

x About this Manual Thermo Fisher Scientific REC 4258 Rev C

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Thermo Fisher Scientific Search Head PCBA Head Setup 1-1 REC 4258 Rev C

Chapter 1 Search Head PCBA Head Setup

High frequency operating range: 100 kHz – 500 kHz[g1]

Low frequency operating range: 30 kHz – 150 kHz

Minimum frequency ratio 2:1

Maximum frequency ratio 4:1

Pharmaceutical detector: Single frequency only - 700 kHz

Note. While it is possible to set the APEX to any operating frequency in the ranges listed above, there is the following operating frequency limitations on all integral heads due to the switching PSU (132Khz switching frequency) mounted in close proximity to the search head. Remote mount heads are not affected ▲

DO NOT SET OPERATING FREQUENCY ON INTEGRAL HEADS WITH IN THE FOLLOWING RANGES.

132Khz (+/- 10Khz)

264Khz (+/- 10Khz)

396Khz (+/- 10Khz)

Note. Search head aperture size acts as a restriction to operating frequency; it may not be possible to achieve the lowest frequencies on some smaller heads. ▲

APEX power supply has been designed to produce safe voltage outputs under single fault conditions, which means the search head, can be tested without special procedures. Testing when the Power Supply is fed from AC voltages should only be done by trained personnel.

APEX FrequencyLimitations

Safety

Search Head PCBA Head Setup

1-2 Search Head PCBA Head Setup Thermo Fisher Scientific REC 4258 Rev C

Before fitting replacement PCB, check the position of solder jumper JP14. Change position if necessary (solder link from bottom of PCB). Position to suit high/low frequency option.

A96843 Figure 1–1. Oscillator Transformer Ratio Table 1–1. JP14 Frequency Options Solder Link (2+3) Ratio 2:1

Solder Link (1+2) Ratio 4:1

500kHz/150kHz 500kHz/50kHz



300kHz/100kHz

200kHz/100kHz

150kHz/50kHz

100kHz/50kHz

Search HeadPCB

OscillatorTransformer

Ratio

JP14 3 JP14 1 3

Earth Strap JP1

JP14 Screen



1. Remove the search head screen and fit PCBA, rotate the top of Nylatch to secure.

2. Solder Oscillator and input coil connections, ensure the solder flows fully around the joint.

3. Fasten the earth strap to the body of the head. 4. Refit the search head screen.

This section outlines the steps to set the oscillator frequency

1. Remove the search head screen. 2. Connect 24Vdc power supply to connector block. (Positive to

JP1_12 and negative to JP1_11) (Refer to Figure 1 or Figure 2, this step is for manufacturing ONLY).

3. Solder nominal capacitance value across CL1-CL10 (120nF) and CH1-CH10 (120nF).

4. Connect scope earth to earth point, monitor tp122 [Oscillator o/p]. 5. Set JP6 [frequency select] to high frequency operation. 6. Adjust VR3 [amplitude control] for minimum (fully clockwise). 7. Set JP7 [FET current] to low. 8. Turn power on and check oscillation begins. 9. Add tuning capacitors across CH1-CH10 to set high frequency

+/- 5kHz (1200nF max). 10. Set JP6 [frequency select] to Low Frequency operation. 11. Add tuning capacitors across CL1-CL10 to set low frequency

+/- 3kHz (600nF max).

OscillatorFrequency

1

1

1



This section outlines the steps to set the oscillator amplitude.

1. Set JP6 [frequency select] to high frequency operation. 2. Adjust VR3 [amplitude control] to voltage indicated by graph (see

Chapter 2), if this cannot be achieved set to max un-distorted (do not exceed 40V).

3. Tolerance: 100-150 kHz = +/- 2V, 200-500 kHz = +/- 4V. 4. If signal becomes unstable during adjustment, set JP7 [FET

current] to medium. 5. If instability persists, set JP7 [FET current] to High. 6. Set JP6 [frequency select] to Low frequency operation. 7. Check signal is clean sine wave, if distortion is visible adjust VR3

[amplitude control] to max amplitude with no distortion. If signal is unstable, increase current using JP7 (FET current). Compare to voltage indicated by graph (see Chapter 2), if this cannot be achieved check solder jumper JP14. Tolerance: 50 kHz = +/- 2V, 100-150 kHz = +/- 3V.

8. Reduce power supply to 22Vdc. Check oscillator remains stable at both frequencies (CAUTION. For manufacturing purposes ONLY).

A96843

Figure 1–2. Oscillator Amplitude

OscillatorAmplitude 1

11

1

JP7 FET current

JP1 JP6 (frequency select)

Search Head

CL1 – CL10 (low frequency)

VR3 (amplitude control)

TP122 (oscillator o/p)

CH1 – CH10 (high frequency)



1. Set gain select jumpers for CPU control, JP5. 2. And JP9. 3. Solder nominal capacitance value across CIL1-CIL6 (22nF) and

CIH1-CIH7 (1n0). 4. Set JP6 [Frequency select] to High frequency operation. 5. Set JP8 [Autobalance] to off. 6. Monitor tp 122 [Oscillator o/p] with scope lead 1, position trace

such that peak is in the center of the screen. 7. Set T2 [High Frequency trimmer] flush to top of core.

WARNING. T2 the high frequency trimmer is a delicate adjustment. Care should be taken not to over tighten or damage results. ▲

8. Monitor tp 162 [Low RF gain] with scope lead 2, place ferrite in aperture to generate offset between 110-500 mV.

Note. DO NOT use ferrous metal. ▲

9. Add tuning capacitors across CIH1-CIH7 until 90° phase shift is achieved (signal crosses zero directly at reference peak).

Figure 1–3. 90 degree input phase shift 10. Adjust T2 [High frequency trimmer] for fine adjustment, ensure

trimmer is not at end of travel. If trimmer is would fully in, add capacitance across CIH1-CIH7.

11. Set JP6 [Frequency select] to Low Frequency operation.

Input Tuning1

1

11

1

Input signal

Oscillator signal



12. Monitor tp 122 [Oscillator o/p] with scope lead 1, position trace such that peak is in the center of the screen.

13. Monitor tp 162 [Low RF gain] with scope lead 2, place ferrite in aperture to generate offset between 100-500 mV.


14. Add tuning capacitors across CIL1-CIL6 until 90° phase shift is achieved (signal crosses zero directly at reference peak.

15. Remove ferrite from aperture.

A96843 Figure 1–4. Input Tuning

JP1 JP6 (Frequency select)

TP122 (Oscillator o/p)

JP8 (A/B on/off)

CIH1-CIH7 (High

frequency)

TP162 (Low RF)

T2 (High frequency

trimmer)

CIL1-CIL6 (Low

frequency)

JP5 (Gain select No. JP9

(Gain select No.



The electronic balance circuit can be set for two balance ranges (High/Low) using JP3.

Low Range = (Fine step adjustment).

High Range = (Coarse adjustment).

Thermo Scientific recommends using Low balance range when possible. If balance cannot be achieved set JP3 for High Balance range.

1. Disable Auto Balance JP8. 2. Set JP6 [Frequency select] to High Frequency operation. 3. Set SW1, SW2 [HFX, HFR] to setting zero. 4. Monitor tp 162 [Low RF], adjust VR5 [HFX] and VR4 [HFR] for

minimum signal. 5. Once balanced monitor tp 13 [High RF], adjust VR5 and VR4 for

zero (typically 100 mV). 6. If balance cannot be achieved proceed below.

1. If balance cannot be achieved using VR5 [HFX], return to middle of travel and adjust SW1 [HFX].

2. If adjustment of SW1 [HFX] increases balance signal, change jumper position JP10 [receive coil 1/receive coil 2].

3. If balance cannot be achieved using VR4 [HFR], return to middle of travel and adjust SW2 [HFR].

4. If adjustment of SW2 [HFR] increases balance signal, change jumper position JP11 [receive coil 1/receive coil 2].

ElectronicBalance

Electronic ManualBalance (HF)

Electronic Balance Correction (HF)

1

1

1



A96843

Figure 1–5. Electronic Balance Correction (HF)

SW2 SW1

VR4 VR5 JP10

JP3

Balance components (HF)

JP11

JP6 (Frequency select)

JP1

JP3 (Balance range

TP13 (High RF)

TP162 (Low RF)



1. Set JP6 [Frequency select] to low frequency operation. 2. Set SW3, SW4 [LFX, LFR] to setting zero. 3. Monitor tp 162 [Low RF], adjust VR7 [LFX] and VR6 [LFR] for

minimum signal. 4. Once balanced monitor tp 13 [High RF], adjust VR7 and VR6 for

zero (typically 100 mV). 5. If balance cannot be achieved proceed below. 1. If balance cannot be achieved using VR7 [LFX], return to middle

of travel and adjust SW3 [LFX]. 2. If adjustment of SW3 [LFX] increases balance signal, change

jumper position JP12 [receive coil1/receive coil 2]. 3. If balance cannot be achieved using VR6 [LFR], return to middle

of travel and adjust SW4 [LFR]. 4. If adjustment of SW4 [LFR] increases balance signal, change

jumper position JP13 [receive coil1/receive coil 2].

Electronic ManualBalance (LF)

Electronic BalanceCorrection (LF)

1



A96843

Figure 1–6. Electronic Balance Correction (LF)

JP1

JP3 (Balance range high/low

TP13 (High RF)

TP162 (Low RF)

JP6 (Frequency select)

VR6

SW4 SW3

JP13 VR7

JP12



1. Once balance is achieved at both frequencies, fit search head screen, rotate top of Nylatch to secure.

2. Monitor tp 13 [High RF], adjust VR7 [LFX] and VR6 [LFR] for minimum signal.

3. Set JP6 [Frequency select to High frequency operation. 4. Adjust VR5 [HFX] and VR4 [HFR] for minimum signal.

Once manually balanced (TP13 = 200 mV or less), the Auto-Balance circuit can be enabled and tested.

1. Monitor TP13 [High RF], place ferrite in aperture to generate offset signal 4 V pk-pk (approximately).

2. Set JP8 [A/B on/off] to auto balance on.

3. Check signal is automatically reduced by Auto Balance circuit (typically less than 250 mV).

4. Remove ferrite from aperture.

5. Set JP6 [Frequency select] to Auto frequency operation.

6. Turn power supply off and disconnect.

Search HeadScreen

Auto Balance

1

1



A96844 Figure 1–7. Auto Balance

TP13 (high RF) Access for VR4, VR5, VR6, VR7

balance adjustment

JP6 (Frequency Select)

TP8 (A/B on/off)

Access for T2 (high frequencytrimmer)



Search head Board 079073 is laid out as displayed below.

A96843

Figure 1–8. Search Head PCB Layout

Note. The diagram in Figure 1-7 shows JP3 – JP13 in factory default positions. ▲

Search HeadPCP Layout

JP14 (T1 ratio

l t)

CL1-CL10

CH1-CH10 JP6 (Frequency

JP1JP9 (Gain select No.

JP5 (Gain select No.

Earth strap

CIL1-CIL6

T2(High frequency

trimmer)

TP162(low RF)

CIH1-CIH7

Screen

JP8 (A/B

TP13 (High RF)

Manualbalancecontrols

TP122 (Oscillator

VR3 (Amplitude control)

JP7 (FET current)



• Cable assembly, search head signal cable (refer to Chapter 5 for part numbers).

• Front panel assembly (complete).

1. Fit search head signal cable between CPU motherboard [J2} and Search head board [JP1].

2. Connect PSU cable to CPU motherboard [J6]. 3. Connect power to PSU [J1] 85-264 Vac/single phase 50/60 Hz. 4. Turn power on, check PSU 7v, 12v, 24v and 5v LED’s are all

illuminated. 5. Set [Product No. 1]

• FREQUENCY: [HIGH] • NAME : to suit frequency i.e. [300kHz] • PHASE [90°] • DETECT LEVEL [30] • GAIN [HIGH]

6. Set [Product No. 2] • FREQUENCY: [LOW] • NAME : to suit frequency i.e. [50kHz] • PHASE [90°] • DETECT LEVEL [30] • GAIN [HIGH]

7. Run [Product No. 1], wait several seconds for fast balance to finish (greed LED is off)

8. Learn the resistive (R) reactive (X) thresholds

Fine Tuningthe System

Parts Required



9. Pass ferrite test sample through the aperture, check green LED

illuminates and red LED does not.


10. If green LED fails to illuminate increase test ferrite size, if red LED illuminates reduce test ferrite size.

11. Select [CAL PHASE], pass ferrite sample through aperture and check for 900 +/- 1 (Adjust T2 trimmer if necessary).

WARNING. T2 the high frequency trimmer is a delicate adjustment. Care should be taken not to over tighten or damage results. ▲

12. Run [PRODUCT NO. 2], wait several seconds for fast balance to finish (green LED is off).

13. Learn the resistive (R) and reactive (X) thresholds. 14. Pass ferrite test sample through aperture, check green LED

illuminates and red LED does not. 15. If green LED fails to illuminate increase test ferrite size, if red

LED illuminates reduce test ferrite size. 16. Select [CAL PHASE], pass ferrite sample through aperture and

check for 90 +/- 10 . (Add/subtract capacitance from CIL1-CIL6 if necessary).

Note. Large adjustment may affect both frequencies; re-check phasing from Product No. 1 and No. 2. ▲



******


*********

Thermo Fisher Scientific APEX I/O and PSU Connections 2-1 REC 4258 Rev C

Chapter 2 APEX I/O and PSU Connections

Overview of the connections on PSU PCBA

A79073

A96850

Figure 2–1. PSU PCBA connections

APEX I/O and PSU Connections

2-2 APEX I/O and PSU Connections Thermo Fisher Scientific REC 4258 Rev C

J1, shown above (top left) has a removable receptacle. Remove and connect AC power (voltage range 85vac to 264vac). Please ensure that a good earth is also connected to J1. It is recommended that you use an AC power source that is not connected to heavy duty loads or loads that might cause interference or drop-outs in the supply. Thermo Scientific does not recommend sharing an AC power source that feeds powerful motor invertors because they can cause interference problems. We recommend using a lighting circuit. We also recommend supplying the metal detector via an isolator switch.

Electrical Supply 85 to 260 Vac, 47 to 65 Hz, 100 watts maximum

There are 6 open collector outputs provided on this PCB and these can be connected to solenoids powered from DC voltages not exceeding 24v DC nominal. It is not recommended that these outputs be used unless you have specialized knowledge of how to use them.

If you need volt-free Relay outputs, please use the PCBA that piggy-backs on the PSU. It is detailed later on in this document.

WARNING. DO NOT use the 24 V onboard power supply for an external power supply, it is used exclusively by the search head board. ▲

Wiring AC Powerinto the PSU

PCBA

Input PowerConsumption

Wiring Outputsfrom the PSU PCBA(Not recommended)



Typically the types of inputs used are photo-eyes, micro switches, or keylocks. Displayed above are J3 and J4 (top/middle/right). There are 6 inputs: Table 2. Wiring Inputs into the PSU PCBA

Connector Name Application

J3 pin 1 12v 12v feed to power a photo-eye

J3 pin 2 Input 2 Input, internal pull-up – connect to 0v to activate

J3 pin 3 0v Ground/ return connection for Photo-eye













J4 pin 4 5v 5v feed to speed sensor LED incorporating current limit

J4 pin 5 LED Current limited feed to speed sensor LED only

J4 pin 6 Input 1 Speed sensor input – exclusively used on this input

J4 pin 7 0v Ground/ return connection for speed sensor

CAUTION. Do not use these inputs for connection to any system or unit having signal voltages outside of the range ground to 12v. Damage may occur. If in doubt contact Thermo Scientific. ▲

Wiring Inputsinto the PSU

PCBA



• Input 1 - Speed sensor

• Input 2 - Infeed photo eye

• Input 3 – Reject confirm/Bin full

• Input 4 – Not assigned



Inputs can also be assigned to Bin Full, Product Select 1, Product Select 2, Keylock, and Reject Suppression.

This PCB piggy-backs on the PSU PCB described elsewhere. When removing this PCB or refitting it (service action), please ensure connectors J4 and J5 correctly line up with their mating halves on the PSU PCB.

A96850b

Inputs

Overview ofconnections on

Relay PCBA



There are 6 changeover contacts provided on this PCB and these can be connected to AC powered devices such as solenoids and other relays. Each relay output provides normally open and normally closed contacts.

• RL1 = NO or NC

• RL2 – RL6 = NO only

Reject 1 Reject 2 AuditCheck QA lamp Fault Warning Alarm

Each relay is protected by a 2A fuse – please ensure replacements are rated at 2A at 250vAC.

RS232 and RS485 interfaces are provided. Only one can be used at once. JP2 (as shown above) is currently set for RS232. If RS485 is required swap the shorting strap into the other position on the three pin header, JP2.

JP1 default setting (as above) provides no data inversion on received data. Sometimes, particularly on RS485 communication, the receive lines are inadvertently swapped and JP1 can be quickly set into the invert position – swap the shorting strap and all received data is inverted.

RS485 is a multi-drop system and requires that the cable ends are terminated. S1 is a 4 position switch and the two left-hand switches, when on, provide an RS485 termination.

Sometimes RS485 requires bias current to make it work correctly. Operating the two right-hand switches on S1 apply 5v and ground via 1kohm resistors to the receive inputs.

Relay outputs

CommunicationOutput



******


*********

Thermo Fisher Scientific Control Panel Assembly 3-1 REC 4258 Rev C

Chapter 3 Control Panel Assembly

The APEX metal detector uses a pair of microprocessors or CPU's to perform its tasks. One, called the DSP, performs the signal processing of the signals from the head and detects the metal. The other, called the MMI, takes care of the user interface.

To program an APEX, one needs a special cable to put each of the two CPU's into the bootstrap mode so we can upload a new program to it. This is done by connecting to ground one of two pins on the DB9 connector on the back of the CPU-Motherboard. This is done using a special cable with a switch that can select which of the two CPU's is to be programmed.

Leave the other pins on the APEX DB9 connector unconnected.

Only one of the two switches that select a CPU to program can be closed at one time.

The DB9 connector used to program the APEX CPU’s is located on the motherboard, it is labeled J8 and is located toward the bottom of the front panel, below the power supply connector. To access this connector, the front panel needs to be removed and remain connected to the power supply. Below the connecter are a pair of buttons that will reset the two CPU’s.

To transfer the new software to the APEX, we use a utility called Flash166. Flash166 was written in the days of MS-DOS, so to run it in Windows requires some special treatment. One can choose to use Windows and the supplied files, or one can use an MS-DOS boot floppy. Both methods will be described here.

How TooUpgrade the

APEX Software

PN 090896 -APEX CPU

ProgrammingCable –

C07387M-E007

Control Panel Assembly

3-2 Control Panel Assembly Thermo Fisher Scientific REC 4258 Rev C

If your PC is equipped with a floppy disk drive, this may be the simplest way to upgrade an APEX, as you won’t need to be concerned with running a DOS 16-bit program in Windows.

1. Create a boot-able floppy disk. 2. Copy these files to the disk

Flash166.exe Flash166.ini Flash166.ovl ApexDSP.bat ApexMMI.bat DSP.bin (the new APEX DSP software) MMI.bin (the new APEX MMI software)

3. Boot the PC using the boot floppy you just created. 4. Using the APEX CPU programming cable, connect the APEX to

the PC. 5. Close the switch that selects the APEX DSP CPU 6. Power up the APEX. There will be little if any indication on the

APEX that a CPU is in the bootstrap mode. 7. At the DOS prompt, enter APEXDSP and press Enter. The update

process will begin and the progress will be shown on the screen. At some point, you will be prompted to press a key to continue, do so and then the new software will be transferred to the APEX. When the transfer is complete, about 2 minutes or so, you’ll be prompted again to press a key, do so until the DOS prompt returns.

8. Now Close the switch that selects the APEX MMI CPU and open the APEX DSP switch.

9. Cycle power to the APEX or press both of the CPU reset buttons. 10. At the DOS prompt, enter APEXMMI and press Enter. This

updates the APEX MMI CPU. When prompted to press a key, do so just like how the APEX DSP CPU was done.

11. Remove the cable from the APEX. 12. Cycle power to the APEX and confirm on the splash screen that

the version number is the new one.

Upgrade Method1 – MS-DOS boot

floppy



The Flash166 utility used to upgrade the APEX CPU was written to run in MS-DOS. As such, it directly accesses the serial port hardware on a PC and Windows doesn’t really like this. We must work around this by running it from within it’s own special DOS window defined in *.pif file. They call the same batch files used in the MS-DOS boot floppy method inside a specially configured command prompt window.

1. Create a directory called APEX on a hard drive on your PC. 2. Copy these files into it.

Flash166.exe Flash166.ini Flash166.ovl ApexDSP.bat ApexMMI.bat ProgramApexDSP.pif (If copying from Windows Explorer, the

*.pif extension will not be visible.) ProgramApexMMI.pif DSP.bin (the new APEX DSP software) MMI.bin (the new APEX MMI software)

3. Using the APEX CPU programming cable, connect the APEX to the PC

4. Close the switch that selects the APEX DSP CPU 5. Power up the APEX. There will be little if any indication on the

APEX that a CPU is in the bootstrap mode. 6. From the directory you just created, start the Program ApexDSP

by double clicking it. A command prompt window will open and the update process will begin with the progress being shown on the screen. At some point, you will be prompted to press a key to continue, do so and then the new software will be transferred to the APEX. When the transfer is complete, about 2 minutes or so, you’ll be prompted again to press a key, do so until the DOS prompt returns.

7. Now Close the switch that selects the APEX MMI CPU and open the APEX DSP switch.

8. Cycle power to the APEX or press both of the CPU reset buttons. 9. Start Program Apex MMI by double clicking it. A command

prompt window will open, starting the update to the Apex MMI CPU. When prompted to press a key, do so just like how the APEX DSP CPU was done.

10. Remove the cable from the APEX.

Upgrade Method2 – Upgrading in

Windows



11. Cycle power to the APEX and confirm on the splash screen that the version number is the new one.

NOTE 1:

The utility Flash166 uses COM1 by default. If you want to use a serial port other than COM1, edit the batch files and add one of these command flags to select the appropriate port to the Flash166 command line: /COM2 or /COM3 or /COM4, it would look like this in ApexDSP.bat:

flash166 /P dsp.bin /BAUD=19200 /COM2

NOTE 2:

If something else in your Windows system is using COM1, or is running that sometimes can use COM1, such as ActiveSync, you’ll get a system error message stating that the com port could not be opened. Either stop the program or use a different com port.

NOTE 3:

The people who created Flash166 also recommend a change to this Windows registry key:

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet\Control\PriorityControl\

Win32PrioritySeparation

Change the parameter Win32PrioritySeparation to the value 20 (decimal) or 0x14 (hex). This change gives the foreground window a higher priority. This recommendation is from 2002, it may not be necessary on newer, faster PC’s. If the update process starts, but runs into trouble during the transfer with timeouts, you may want to try making this change to the registry.

• Update not starting:

The most common problems are encountered when initially starting the update process when the Flash166 utility is establishing communications with the APEX CPU. Most of the time resetting the APEX and retrying the update will work fine.

• Transfers timing out:

Often this is a one-time occurrence, so restart the update. If this is a chronic problem, it can have many causes, from a bad cable to Windows not giving Flash166 enough time to run. These are possible solutions:

Confirm that the programming cable is securely plugged in on both ends.

Troubleshooting:



Check the cable, make sure the unused pins on the APEX side are not connected, or can make contact with another pin.

If running in Windows close any other program that may be running.

If running in Windows, make the registry change described in Note 3.

The following table lists the MMI and DSP error codes which will be generated and displayed in case of a fatal or non-fatal error during the execution of the software code. Error codes are independent of any alarms or faults.

MMI errors start at 300 while DSP errors start at 500 and refer to both fatal and runtime errors.

A fatal errors is an event that the system cannot recover from. It causes the system to halt and a power cycle is required to restore operation.

A runtime error indicates a severe event that the system can recover from. It causes a pop window to be displayed and operations continue.

MMI Errors

Token Code Type Description

RC_MMI_ASSERT_FAILURE 300 FATAL A code integrity check has failed; see note 1.

RC_MMI_NON_MASKABLE_INTERRUPT 301 FATAL A non-maskable interrupt has occurred.

RC_MMI_STACK_OVERFLOW_INTERRUPT 302 FATAL The internal stack has overflowed.

RC_MMI_STACK_UNDERFLOW_INTERRUPT 303 FATAL The internal stack has under-flowed.

RC_MMI_CLASS_B_HARDWARE_TRAP 304 FATAL There has been a class B hardware trap; see note 2.

RC_MMI_NVRAM_ERROR 305 FATAL A fault was detected with the NVRAM, one or more CRC's did not verify.

RC_MMI_RTC_ERROR 306 FATAL Failed to initialize Real Time Clock.

RC_MMI_KEYPAD_ERROR 307 FATAL Failed to initialize keypad chip or communication has been lost.

RC_MMI_CAN_NO_REPLY_ERROR 308 FATAL There was no reply to a CAN message sent by the MMI processor when one was expected.

RC_MMI_DSP_MISSING 309 FATAL The MMI has lost it link with the DSP.

RC_MMI_POWER_FAIL_ERROR 310 FATAL The power fail line has been low for 5 seconds; something must be wrong with power fail circuit.

RC_MMI_PERIPHERIAL_BUS_LOCKED 311 RUNTIME Peripheral Bus in use by DSP when MMI tried to access it.

RC_MMI_SOFTWARE_VERSION_MISMATCH 312 FATAL MMI and DSP versions do not match.

RC_MMI_TEXT_STRING_ERROR 313 FATAL Problem with help text strings.

APEX errorcodes



DSP Errors Token Code Type Description

RC_DSP_ASSERT_FAILURE 500 FATAL A code integrity check has failed; see note 1

RC_DSP_NON_MASKABLE_INTERRUPT 501 FATAL A non-maskable interrupt has occurred.

RC_DSP_STACK_OVERFLOW_INTERRUPT 502 FATAL The internal stack has overflowed.

RC_DSP_STACK_UNDERFLOW_INTERRUPT 503 FATAL The internal stack has overflowed.

RC_DSP_CLASS_B_HARDWARE_TRAP 504 FATAL There has been a class B hardware trap; see note 2.

RC_DSP_CAN_NO_REPLY_ERROR 505 FATAL There was no reply to a CAN message sent by the DSP processor when one was expected.

RC_DSP_NVRAM_ACCESS_ERROR 506 FATAL DSP failed to gain access to NVRAM.

RC_DSP_CONFIG_ERROR 507 FATAL CRC error when DSP loaded its configuration from NVRAM.

RC_DSP_PRODUCT_ERROR 508 FATAL CRC error when DSP loaded product details from NVRAM.

RC_DSP_INVALID_PRODUCT_NUMBER 509 FATAL DSP has received an invalid product number to load from NVRAM.

RC_DSP_REJECT_MISSED 510 RUNTIME Reject point missed.

RC_DSP_PACK_LIST_FULL 511 RUNTIME Pack list has become full.

RC_DSP_CONTAMINANT_LIST_FULL 512 RUNTIME Contaminate list has become full, i.e. contaminants not identified to fall within pack.

RC_DSP_CORE_SYNC_OVERRUN 513 FATAL The core processing has interrupting a section of critical code in main loop.

NOTE 1:

Will only occur with debug build software and not production software.

There are various assertion statements in the code which specify a condition that is expected to hold true at some particular point in the code.

If that condition does not hold true, the assertion fails, execution of the codes in interrupted, and the Assertion Failed message appears.

NOTE 2:

List of Class B Hardware Traps:

• Undefined Opcode

• Protected Instruction Fault

• Illegal Word Operand Access



Path: Main Menu

When the machine is first started, you might want to set the passwords for all security levels. The APEX has passwords disabled by default. Use the following steps to enable passwords.

Figure 3–1. Password Screen 1

1. Select the PASSWORD ENTRY SCREEN displays

Figure 3–2. Password Entry Screen

2. Use the arrow keys to navigate to each letter and enter the default Level 3 password “SUPE”

3. Select and APEX enters password mode (Level 3)

The following screen displays

Enable Passwords



Figure 3–3. Password Screen 2 – Assigning Passwords (Level 3 access only.

Assigning and changing password requires the user to be signed in with Level 3 (supervisor) access. The default passwords are:

OPER – operator – change products (1)

ENGI – Engineer – change everything but passwords (2)

SUPE – Supervisor – full access (3)

1. From PASSWORD SCREEN 2 (Figure 3–3) select 2. Choose the password level to be changed 1, 2, or 3, the following

screen displays:

Figure 3–4. Password Entry Screen 3. Use the arrow keys to navigate to the letters/numbers to be used

for the password. Remember to press (the enter key) to save each letter.

4. Select when finished and the NEW PASSWORD

CONFIRMATION screen displays. It looks almost the same as the password entry screen except there is now a double key symbol on the left side of the screen.

Assigning/ChangingPasswords



Figure 3–5. Password Confirmation Screen 5. Enter the new password again and to save the new password 6. Follow the same steps above to assign/change passwords for each

level.

Note. To cancel assigning/changing a password, press the key at any time. ▲

To get the best performance from your APEX metal detector, several items need to be setup correctly. The following table indicates those parameters. P in the table indicates the parameter is product specific, Sys indicates the parameter is a system setting. Table 3–1. Setup Parameters

Parameter Application type

Parameter name Type Conveyor *Pipeline *Gravity *Pharm

Product Name P Y Y Y Y

Product Speed P Y Y Y Y

Pack Length (packaged only) P Y

Pack Gap (packaged only) P Y

Detection, No-pack Distance (packaged only) P Y

Reject Distance (Delay) P Y Y Y Y

Reject Duration P Y Y Y Y

Photo-eye-Registration (packaged only) P Y

Infeed PE Distance (packaged only) Sys Y

Belt Speed-Sensor P Y

Operating Frequency P Y Y Y Y

Operating Gain P Y Y Y Y

Learning the Product P Y Y Y Y

Learning the Phase Thresholds P Y Y Y Y

Phase Tracking P Y

Setup

Note the doublekey symbol.



Parameter Application type

Parameter name Type Conveyor *Pipeline *Gravity *Pharm

Inputs and Outputs Sys Y Y Y Y

Warnings, Alarms and Faults Sys Y Y Y Y

Quality Test P Y Y Y Y

AuditCheck P Y Y Y Y

Reject Confirm and Bin full P Y Y Y Y

Passwords Sys Y Y Y Y

Product Selection Sys Y Y Y Y

Units Sys Y Y Y Y

Filters (DSV, QNR, PNR, CLX) P Y Y Y Y

P = Product specific parameter. Must be set up for each different product

SYS = System specific parameter. If it is changed for one product, it will be changed for all products. *Future applications.

Thermo Fisher Scientific Maintenance and Troubleshooting 4-1 REC 4258 Rev C

Chapter 4 Maintenance and Troubleshooting

Regular cleaning procedures must be maintained if reliable, trouble-free operation is to be expected. If there are any questions on cleaning procedures, contact Thermo Scientific for further assistance. It should be noted that certain cleaning agents could affect the integrity and appearance of plastics used on the metal detector head. Ensure cleaning agents do not adversely affect Polycarbonate and Polyester plastic materials.

WARNING. To guarantee personal safety, care must be taken when working on or around conveyors, reject mechanisms, or product tubes. As with all such devices the main supplies (electrical and air) to the system must be locked off when performing repair or maintenance work. After disconnecting the air supply to the system, cycle any reject mechanisms to evacuate any air left in the system. Then switch off and lock the electrical supply.

Ensure that cleaning methods do not leave residues on APEX’s surfaces that might attract dust particles. It is recommended that after cleaning, surfaces be adequately dried. See also note on humidity.

Cleaning agents permitted and their dilution levels are the same as those recommended when cleaning conveyor belts and other equipment on your line. Please consult with your cleaning agent supplier to ensure cleaning materials are suitable and dilutions levels are as recommended.

Do not use high-pressure hose techniques as these may damage APEX or cause breaches of the integrity of the unit that may lead to contamination problems or compromise safety.

Cleaning

Maintenance and Troubleshooting

4-2 Maintenance and Troubleshooting Thermo Fisher Scientific REC 4258 Rev C

Although APEX is made from corrosive resistant materials, there are circumstances, which can lead to corrosion. Stainless steel prevents surface corrosion by rapidly producing a strong and inert oxide layer. Damage to this protective oxide layer can be caused by resting iron objects on APEX’s surfaces. Ensure that signs of corrosion are regularly checked for and preventative methods are employed. Any sign of corrosion should be investigated. Report any incidents of corrosion to Thermo Scientific.

If APEX senses a system fault the fault LED turns on, the fault relay will change state and a fault message is displayed. The section contains descriptions of the type and source of faults that may occur.

Cause Fix

Search head cable connection has been broken

Examine the cable connections at both ends to make sure all wires are connected correctly.

Search head balance may be out of range

All metal detectors are sensitive instruments and after they have been shipped or moved, Thermo Scientific recommends they be re-commissioned by a suitably qualified engineer.

Contact Thermo Scientific or further assistance in troubleshooting Search Head Faults.

Results when reject confirm has been enabled and the confirmation signal has failed to return within the prescribed time.

Cause Fix

Reject device failure

Slow reject action

Reject confirm device (i.e. switch failure)

Check the reject device action; make sure the reject confirm switch is operating properly. It may be necessary to adjust the reject confirm time window.

Check forCorrosion

Fault Finding

Search HeadFaults

Reject ConfirmFault



Cause Fix

The battery powering the memory when power is off is becoming discharged.

Replace Battery and/or control panel as necessary. Note: This does not affect the unit operation as long as power is maintained.

This fault indicates the product memory has been lost or damaged.

Cause Fix

Low battery could cause memory to be lost when the unit is not powered

Check the battery

Detector has been subjected to high static discharges or lightning

Erase the memory

Cause Fix

This fault occurs if photo reject has been enabled and detection has taken place when the photo-eye did not detect a product.

Check the photo-eye alignment, make sure the product is breaking the beam, and check for reasons for false triggering such as metal in the belt. Perform a complete test of the detector including the reject device.

Cause Fix

This fault refers to applications using variable speed timing and an external shaft encoder. If detection occurs, but external clock pulses are missing, the detector will assume a fault has occurred.

Retest detector with a test sample and the belt running. This may clear the fault.

Cause Fix

The QA test light has been ignored and the interval timer has expired.

Perform a QA test

Battery Low Fault

Product MemoryFault

Photo RejectFault – Conveyor

Systems

Shaft EncoderFault – Conveyor

Systems

QA Test Response Fault



Cause Fix

Occurs if during a QA test the required number of detections of specific peak size did not occur.

Enter QA test mode and repeat the test to achieve the required number of detections.

Cause Fix

Occurs only if the excess reject fault has been turned on and the excess reject parameters programmed. The fault indicates an excessive amount of rejects have occurred within the specified time window.

Press CLEAR FAULT Note: This fault may be caused by excessive contamination in the product. The rejected product should be examined to confirm this and appropriate action taken.

Cause Fix

Occurs if a phase limit has been reached during a learn phase or automatic phase period. May be caused by contaminated product or metal elsewhere in the system.

If necessary, check and adjust the phase limits.

Cause Fix

This fault indicates an excessive block time for the photo-eye, which is probably due to photo-eye misalignment.

Check the photo-eye for proper operation.

QA Test ResultFault

Excess RejectFault

Phase Limit Fault

Photo-eye BlockFault



This fault only occurs if you have AuditCheck™ installed as an option on your metal detector.

Cause Fix

During an AuditCheck timed calibration check, the signal produced by the AuditCheck metal ball passing through the search head (with a product) is incorrect, a fault is produced

Check that the fault limits set for AuditCheck are set up for expected variations in the product. Check also that the Alarm limit and Fault limit have not been inadvertently misapplied.

A complete and thorough test of the metal detector system must be done upon installation or whenever a major component of the system has been changed or altered (i.e. reject device repair, etc.). A complete check of the metal detector must include the reject device. Any test procedure designed for your application should take into account the following:

1. The metal detector’s least sensitive point in the aperture is along the centerline of the opening. Any testing should be done so that the test sample passes approximately through the centerline of the opening. If the test sample is run at the side of the aperture or product tube, this will produce a larger signal than through the centerline. The test procedure should consider this for consistent results.

2. Sensitivity capabilities of different detectors used in different applications will vary. Smaller aperture is capable of detecting smaller pieces of metal. Product effect may also interfere with the detection capability. It is inadvisable to rely on a corporate standard to determine and test the detector’s operation. Ideally, each detector should have it is own standards of operation and a corporate outline should be used only as a maximum allowable guide. Sample sizes should be selected so that they are clearly detectable when compared to the signal produced by the product or other interfering signals. If samples are established which are very close to the product signal, frustration on the part of operators can lead to a lack of confidence in the detector’s operation.

AuditCheck Fault

RecommendedTesting

Procedures



3. The detector should be tested at its normal operating speed. Test samples should be placed on conveyors so that they will pass through the detector at normal speed. On pipelines, test samples should be inserted so that they travel through the search-head at the product’s normal flow. On gravity and tablet/pharmaceutical applications, test samples should be placed so they fall from same point as the product.

4. The detector is not equally sensitive to all types of metal. Depending on the type of product and application there can be three typical metal groups which will produce three different levels of detection: Ferrous - any iron derivative Non-Ferrous - any good electrical conducting metals such as

aluminum, copper and brass, etc. Stainless Steel - 300 series stainless steels, which are non-

magnetic, tend to be the most difficult metals to detect.

If a single test sample is to be used for regular testing, it should be a stainless steel sample. This ensures other metal types are detected to this same level or better (smaller).

5. Test samples used should contain spherical metal contaminants. Any other shape produces a different size signal depending on its orientation as it passes through the detector. This can lead to inconsistent results.

6. Any test procedure established must allow the test product to be completely rejected by the reject device. The reject device tends to be the most likely point of failure in any detector system.

7. Care must be taken so if the detector or reject device fails to operate correctly the test sample can be recovered safely. If there are any questions on safety, contact Thermo Scientific for assistance.

The user must decide how often the detector should be tested. If the test procedure can be designed to be simple, it helps ensure the test is performed more frequently. As a guide it must be decided how much product would have to be put on hold for re-inspection if a detector fails the test. Typically, the minimum frequency is once per shift.

Testing Schedule



All detector tests should be documented. A sample Metal Detector Test Sheet is provided for customer convenience.

METAL DETECTOR TEST SHEET

SHIFT 1 SHIFT 2 SHIFT 3

LINE: 15 PERIOD 1 PERIOD 2 PERIOD 3 PERIOD 1 PERIOD 2 PERIOD 3 PERIOD 1 PERIOD 2 PERIOD 3

DATE: 96/08/08 PASSED PASSED PASSED PASSED PASSED PASSED PASSED PASSED PASSED

NOTES /ACTION

If possible, product, which has been rejected by the detector during production, should be examined to establish the source and type of contamination. This may lead to an improvement in the process equipment upstream from the detector.

This detector can be configured to request a test procedure be performed at given intervals or on demand.

This chapter provides information about service, repair, and replacement parts for your Thermo Scientific product. It includes the telephone numbers for various departments at Thermo Scientific, the procedure for ordering replacement parts, a Return Material Authorization Form, and the parts list for the product are also included in this chapter.

The maintenance information in this manual is designed to meet your service needs. If you should encounter a problem that requires technical assistance, you may call Thermo Scientific Product Service at (800) 227-8891.

Thermo Scientific also provides on-site service technicians to assist customers with installation, setup, initial calibration, customer training, maintenance, and repair. Contact the Thermo Scientific Field Service department at the number given below for current rates and scheduling.

Thermo Scientific has repair centers located at the plant in Minneapolis, Minnesota. Products that need system checkout or repair can be returned to the plant with the Return Material Authorization (RMA) Form or the Foreign Customer Repair Authorization form.

Record Keeping

Rejected ProductExamination

QA Test Request

Service Repairand

ReplacementParts



Contact our Repair and Return department (800) 227-8891 to get an RMA number to use on the form.

Note: Have your machine model number and serial number available when you call.

Main Switchboard (800) 227-8891 FAX (763) 783-2525 Service (800) 227-8891 Return Material Authorization & Repair (800) 227-8891

24 x 7 phone support

Or any local Thermo Scientific office.


Return Material Authorization 501 90th Avenue N.W. Minneapolis MN 800-227-8891 RMA -

(This RMA Number Must Be Marked On All Paperwork And On Outside Of Package) Req’d. By: Date: Return, Freight Prepaid To: Customer Thermo Fisher Scientific Contact: 501 90th Avenue N.W. Phone: ( ) Minneapolis, MN 55433 Area Code Bill To Customer #: Ship To

Returned From: Return To:

Description Of Material Being Returned:

Describe Equipment Malfunction Or Defect, If Any; Symptoms:

Minimum Charge Informed Customer of Inspection Charge Per Item

Service Requested:

Repair & Return Estimate

RequiredP.O. No.:

Return for Credit Original P.O. or Thermo

Scientific Order No.:

Warranty Repair or Replacement Serial No:

Return Warranty/Exchange Unit Shipped on Thermo Scientific Order No.:

Other:

Disposition/Comments: (Thermo Scientific Internal Use Only)



501 90th Avenue NW Minneapolis, MN 55433 Foreign Customer Repair Authorization (763) 783-2500 Fax (763) 780-1537 Please complete the following regarding equipment that will be returned for repair

Contact Name: Telephone 011- (country code) (telephone number)

Company Name:

Fax011- - E-mail (country code) (fax number)

Billing Address:

Purchase Order No.(required):

Equipment Type: Serial No.

Description of problem:

Shipping Method (Please check one option):

Thermo Scientific sends good direct to customer. Thermo Scientific determines shipping method and carrier. Charges will be prepaid by Thermo Scientific and customer will be invoiced for charges. Truck and/or air freight will always be utilized unless customer arranges shipment

Thermo Scientific sends goods to customer’s designated freight forwarder. Charges for inland freight to U.S. port will be prepaid by Thermo Scientific and customer will be invoiced for charges.

Shipping Address: Freight forwarder? Yes No

Atn: Telephone

Copies of shipping documents should be sent to the following individual via e-mail or fax. Originals will be sent to the billing address above via regular mail

Contact Name:

Fax 011- - E-mail:

(country code) (telephone number)

Important Notice: Shipment requests will be processed according to this document, which must be fully completed prior to issuance of a Return Material Authorization (RMA) number. Shipping documents will be sent as requested to the individual above upon shipment of goods from Thermo Scientifics plant in Minneapolis, MN. Thereafter, Thermo Scientific bears no responsibility for charges associated with customs clearance or warehouse charges due to customer failure to liberate goods from customs.

This completed form should be faxed to: Attn: Customer Service fax (763) 780-1537


4-11 Maintenance and Troubleshooting Parts Thermo Fisher Scientific REC 4258 Rev C

For the fastest service when ordering parts, telephone or FAX the Thermo Scientific Parts Department at the numbers given below. Your regional field service representative can also assist you with parts orders.

The recommended procedure for ordering parts is:

Determine the broken or faulty part.

1. Locate the part in the Parts List. 2. Find the part number(s) for the item(s) you need. 3. Before you contact Thermo Scientific for your parts, make sure

you have the following information: Machine model and serial number Purchase Order number Date Required Preferred shipping method Part number(s), description, and quantity needed. Telephone or FAX:

Thermo Fisher Scientific Customer Service Department 501 90th Ave. NW Minneapolis, MN 55433 FAX: (763) 783-2525 Phone: (800) 227-8891 Return Material Authorization and Repair: (800) 227-8891

WARNING. Modifications and repairs should only be performed under supervision of a Thermo Scientific Service Engineer and with written consent from Thermo Scientific. ▲

Parts OrderingInformation



Please only use spare parts as directed by Thermo Scientific or their agent. Specifically PCB’s must only be sourced from Thermo Scientific. Fuses can be sourced from any reputable supplier providing their rating is identical:

F1 (PSU PCB) – 250 v AC, 3.15 A, 35 A breaking capacity. Typically, following types are recommended:

Bussmann 3.15 A Radial lead micro fuse BK/ETF type

Bussmann 3.15 A Fast acting BK/EFF type

Wickmann 3.15 A Anti-surge TR5 type

Wickmann 3.15 A Fast acting TR5 type

Bussmann PC-Tron 3A type

F1 to F6 (Relay PCB) 250v AC, 2A typically

Parts



Argentina +54 (0) 11 4 334 3827 +54 (0) 11 4 334 9159 fax Australia +61 (0) 8 8150-5300 +61 (0) 8 8234-5882 fax Canada +1 (905) 888-8808 +1 (905) 888-8828 fax Chile +56 (0) 2-335-3388 +56 (0) 2-335-1590 fax China +86 (0) 21 5465 7588 +86 (0) 21 6445 7830 fax France +33 (0) 1 60 92 48 00 +33 (0) 1 60 92 49 00 fax Germany +49 (0) 208-824930 +49 (0) 208-852310 fax India +91 (0) 20-4011245 +91 (0) 20-26125739 fax Italy +39 02-959514-1 +39 02-953200-15 fax Malaysia +60 (0) 3 2300 1626 +60 (0) 3 2300 1636 fax Mexico +52 (01) 55 5638 0237 +52 (01) 55 5639 2227 fax

Netherlands +31 (0) 33-454-9000 +31 (0) 33-454-9009 fax Poland +48 (0) 22848 3708 phone and fax South Africa +27 (0) 11-609-3101 +27 (0) 11-609-3110 fax Spain +34 91-484-5949 +34 91-661-5572 fax United Kingdom +44 (0) 1788-820300 +44 (0) 1788-820301 fax United States +1 (877) 290-7422 +1 (763) 783-2525 fax

Phone/FaxContacts for

Thermo ScientificOffices


4-1 Maintenance and Troubleshooting Parts Thermo Fisher Scientific REC 4258 Rev C

APEX uses a battery for maintaining product settings and date/time in the absence of AC power. The battery may need replacing after approximately 6 years of normal use. Extended periods of no AC power and operation at lower temperatures for extended periods may reduce the life of the battery. Use the following steps to replace the battery.

1. Ensure power is disconnected from the machine. 2. Undo the captive bolts holding the front plate to the rest of the

search head. 3. Carefully unplug the cables attached to the circuit board in the front

plate (CPU motherboard). 4. Locate the battery in the middle of the PCB. 5. Remove the PCB in a facility suitable for handling printed circuit

boards. 6. Ensure J7’s link is in the left hand position or removed. 7. Remove the PCB and unsolder the 3 connections to the battery. 8. Apply heat to each connection gradually pulling the battery away

from the PCB. 9. Perform the removal very carefully to avoid damage to the plated

holes on the circuit board. 10. Ensure the 3 holes are clear of solder blockages, fit and solder the

battery replacement. 11. Reconnect J7’s link and replace the PCB into the front plate. 12. Reconnect the ribbon cable from the keypad PCB (beneath the CPU

motherboard). 13. Replace the front cover and reattach cables.

APEX’s battery is an approved type according to table 3 of IEC 60086-1 type E. The battery type is Sonnenschein SL-350 PCRN. The nominal voltage is 3.6v. The electrochemical system used in the battery is Lithium Thionyl-Chloride and the rated capacity is 1000 mA-hours.

Battery Replacement



Disposal of lithium batteries and soldered printed circuit boards must be in accordance with your local Hazardous Waste Policy.

As an alternative product supplied by Thermo Scientific may be returned freight pre-paid, for disposal. Contact the Repair Department for a Return Material Authorization Number before shipping any product for disposal.

Disposal ofHazardous Waste



******


*********

Thermo Fisher Scientific Part & Drawing Numbers 5-1 REC 4258 Rev C

Chapter 5 Part & Drawing Numbers

DESCRIPTION PART NUMBER DRAWING NUMBER

Search head PCBA 079073 114-6500

CPU Motherboard PCBA 268391 114-6908

CPU Microcontroller (2) 249005 XSA0006/01

CPU Microcontroller, DSP 092753 C07387M-V003

CPU Microcontroller, MMI 500 092754 C07387M-V004

CPU Microcontroller, MMI 100 092755 C07387M-V005

Display LCD 088362 Buy out

Keypad LED PCBA 268390 114-6910

Keypad 267932 114-6912

PSU PCBA 268392 114-6904

Relay PCBA 268393 114-6906

Anybus Network PCBA TBD TBD


Control panel assembly, APEX 700

TBD TBD

Control panel assembly, APEX 500 089275 B07387M-A003-01

Control panel assembly, APEX100 090586 B07387M-A003-02

Control panel assembly, APEX Upgrade

091813 B07387M-A003-03

Remote cover assembly, APEX 500

089977 B07387M-A012

Printed CircuitBoard

Assemblies

Control PanelAssemblies

Part & Drawing Numbers

5-2 Part & Drawing Numbers Thermo Fisher Scientific REC 4258 Rev C


PSU to CPU Motherboard 268264 B07387M-E001

CPU to Search head (Integral) 268265 B07387M-E002

CPU to Search head (Remote) SEE DRAWING (length specific)

B07387M-E003-XX

APEX programming cable assembly

090896 C07387M-E007

Cable Assemblies

Thermo Fisher Scientific Reference Material 6-1 REC 4258 Rev C

Chapter 6 Reference Material

This chapter contains information that may be useful during service procedures.

DSP3 has a fixed detection level of 100. To make DSP3 more (or less) sensitive to metal it has a sensitivity control that can increase (or decrease) search head signals. APEX does not have a control like this; search head signal amplification is fixed and to increase (or decrease) ability to detect metal, detection level is lowered (or raised).

In short, neither method offers any technical advantage one way or the other. In fact, DSP3 internal signal processing works exactly like APEX; it is only DSP3’s user interface that pretends to have a fixed detect level with variable sensitivity control.

If a customer prefers to have a DSP3 type presentation of peak signal and variable sensitivity then it is likely because they believe it offers superior performance. This is category

PCNR is a non-linear filter that attenuates small signals whilst leaving bigger signals the same. To define where a small signal starts and ends, DSP3’s PCNR has an associated threshold setting which can be raised (or lowered) in factors of two. In short PCNR is a noise gate i.e. it shuts out noise below a certain threshold point.

APEX’s PNR is exactly the same except its noise threshold is determined by the detect level and not by a manual control as on DSP3. Many, many experiments on this led me to conclude that APEX’s PNR (and its automatic threshold determination) is superior to DSP3’s PCNR. Other than the automation of the noise threshold it works exactly the same as DSP3.

DSP3/APEXDifferences

DSP3 SensitivityControl VS APEX

Detection LevelControl

DSP3 PCNR VSAPEX PNR

Reference Material

6-2 Reference Material Thermo Fisher Scientific REC 4258 Rev C

If you want to use a high value of threshold to attenuate moderate to large interference or noise then set the detect level higher and PNR will do the rest. You won’t see any problems and it’s easier to use.

VNX is a technique to totally attenuate a signal having a phase angle between two particular limits. In this respect it is very similar to PCNR except PCNR applies a progressive attenuation rather than step attenuation. Having PCNR and VNX gives the user the ability to set two independent phase points and of course this could be an advantage. However, VNX’s implementation on DSP3 was faulty and I always advised people not to use it.

In the medium/longer term, VNX will be back on APEX but will be significantly more important and usable than DSP3’s implementation of VNX. It is intended for APEX’s VNX to be a complete phase map with definable attenuation across the whole spectrum of phases.

DSV is a linear signal filter attenuating signals at low and high frequencies whilst leaving signals in the “pass-band” unaffected. It has no thresholds it acts the same irrespective of signal amplitude.

DSP3 has DNR filters; APEX has DSV. DSV or DNR is by far the most important means of improving sensitivity i.e. it filters out and discards unwanted signals. When metal passes thru the aperture it does so at a fixed speed1 . This means that the signal it produces has a characteristic point in the frequency spectrum.

For instance, at 100 ft/min, a piece of metal is characterized at a frequency of about 3Hz – this also depends on coil spacing – the wider the coils the smaller the frequency for a particular speed.

APEX’s DSV filter is superior to DSP3’s DNR filter in every respect; it out-performs it at all levels and in all situations. For instance, if the belt speed were manually changed from 100ft/min to 95ft/min, then DSV would recalculate its parameters and optimize itself for this new belt speed.

1 On drop thru’s there is some acceleration but the chage in velocity through the head is insignificant.

Loss of DSP3VNX

APEX DSV Filter

Reference Material


On the other hand DSP3 has four separate filters that are fixed and unchangeable. Each DNR filter has to cover a range of belt speeds and that is there very downfall; they have to be slack and allow possibly unwanted signals to be un-attenuated in case that signal was from metal at a different belt speed. They do not recalculate their parameters on the fly – they can’t. On variable speed applications they are truly compromised and don’t perform well at all over significant ranges of speeds.

APEX’s DAG is offering significant performance improvement over DSP3 and IP+ in wet applications. It is the right approach and will pay dividends. Not using DAG wires is the key and therefore we can’t use them and nobody can measure the DAG resistance. On DSP3, most apertures are protected with a PVC chute and maybe this has let water in causing the DAG to ultimately cause problems. APEX’s protection is resin and we’re confident that this will prevent DAG problems.

In the experience of DAG problems, measuring the resistance tells you little; to be able to determine that a DAG has gone noisy, you are looking for spurious and minute changes in DAG resistance in the order of micro-ohms.

APEX display has exactly the same height as DSP3 but only half the width. Any written characters have the same height as DSP3. APEX’s display is brighter, operates over a significantly greater ambient temperature and has an internal contrast control that can save the day in very extreme climatic temperatures.

DSP2 needed a metal control panel for two reasons – it produced such radiated filth from its CPU board and its search head PCBs were as vulnerable as a flower in the wind.

DSP3 CPU produces significantly less radiated filth (but still needs the supplementary protection of a metal cover). DSP3’s search head board is nowhere near as susceptible to RF as DSP2 and this is primarily down to the transformer coupled input.

Remember that DSP1, 2, 3 and APEX are metal detectors and they are very sensitive to radiation in the 50 kHz to 1 MHz band but that sensitive area is in the aperture not on the front of the control panel.

APEX DAGMethod

APEX DisplaySize

Plastic ControlBox – Will it Shield RF?

Reference Material


DSP3 (as mentioned under APEX DSV filter) uses a filter called DNR. This has 4 settings; DNR 1 thru 4. I’ve already mentioned the limitations of this basic idea but I’ll add one more and that is when slow belt speeds are required.

DNR1 (on DSP3) uses the past 128 samples of data (data rate is 240 per second) to construct the filtered output. Using only 128 samples (each with a hefty numerical process to perform) means that below certain speeds it cannot filter properly. So what DSP3 does to overcome this fallibility is throw away samples of data so that is can use (say) 256 points of data but with only 128 numerical processes. As speed gets lower still it throws away even more data.

At very slow speeds the response time of the CPU to button presses becomes obviously slow and this of course is undesirable. Please don’t regard the selection or de-selection of sample rate as something positive; it is not and never was – it was a tool to make DSP3 work at slow belt speeds and offers only problems.

OK, back to Aperture size programming on DSP3. There is a relationship between coil spacing and minimum aperture distance. Coil spacing and the belt speed determine DSP3’s DNR1-4 and/or sampling rate. APEX has the DSV filter and to get the optimum point you learn the filter by passing metal thru the aperture. You do it once and that’s it forever. If the belt speed changes, APEX tracks this change and applies the precise filtering regime.

It will be used, in the future, with a small test lead, to measure oscillator frequency. It will also be used for measuring oscillator operating voltage.

Reliably detecting small metal contaminates in foodstuffs means getting the best performance from your machine. This is achieved by optimizing the machine performance for your particular application.

Aperture SizeProgramming on

CPU

APEX BNCConnector

APEX QuickStart

Documentation

Reference Material


The product may be fed on a conveyor belt at a particular speed. The metal detector needs to know the speed so it can “recognize” signals generated by metal. Metal signals can be very small and it is important to have the metal detector set up to filter-out unwanted signals leaving only the metal signal.

APEX uses a digital filter to help it detect metal signals. The filter is linked to belt speed and is initially calibrated (or learnt) by passing a metal test-stick through the aperture on the conveyor belt. Once calibrated, the filter tracks any adjustments to the entered belt speed automatically.

APEX works with variable speed machines. You fit a speed sensor (delivering electrical pulses when rotated) to the conveyor. The pulses connect to an input and when actual belt speed changes, APEX maintains its filter at the optimum setting for detecting metal.

A metal detector must detect metal and reject the product containing metal into a quarantine container further down the line. For conveyor applications, belt speed influences when the product is rejected and so it is important that this is accurately entered on the main menu. Various hand-held devices can be used to determine belt speed.

Assuming belt speed (and filter) is calibrated; enter the reject distance (middle of reject arm to metal detector). Both belt speed and reject distance determine when a contaminated product is ejected into the reject bin.

Alternatively, you can enter the reject time and tweak this value until it is correct. APEX allows you to do this and in some applications this may be more appropriate then a distance measurement i.e. vertical drop machines dealing with bulk flowing product.

APEX automatically adjusts reject time/distance values for conveyor applications if a belt-speed sensor is applied.

The length of time that the reject operates for is application dependant. Most conveyor applications should be set so that the reject effectively extends and returns in the shortest possible time. Other applications demand longer times to guarantee successful metal rejection because of product flow variations.

Product Speedand Filtering the

Signal

Rejecting theProduct

Reject Duration

Reference Material


Conveyed products travel quite fast with small gaps and it is important to accurately reject the pack. This means recognizing the pack position not the metal contaminate position. The metal contaminate could be anywhere in the pack but it is the pack that must be rejected and this can only be done accurately by using a photo-eye on the infeed side of the detector.

Belt speed, reject delay and infeed sensor position determine when to push a contaminated pack into the reject container. This is called Photo-registration.

If two packs are butted-up to each other, the infeed sensor cannot distinguish them and so it is important to enter the nominal pack length into APEX so it can recognize when two packs become “adjoined”.

Due to finite errors when sensing a pack’s position it is important to recognize that a pack contaminated with metal along its trailing edge can, under certain conditions cause the detector to “see” the metal in a 2nd pack that is following close behind the first pack. However APEX will “reject” both packs and does this by measuring the distance between 1st and 2nd packs.

If “detection” occurs within a certain distance of both pack edges, both packs are rejected. You need to enter a value that corresponds to a percentage of the nominal pack length to set up this feature. This is called pack-zone.

• We have discussed the need to set up (or learn) the filter so that the best sensitivity can be achieved.

• We have discussed using a belt-speed sensor so that the filter can track the product speed and keep sensitivity optimized.

• We have discussed setting up the reject distance so that contaminated product can be pushed into the reject container.

• We have discussed that the speed sensor (when fitted) automatically adjusts the reject timing if the belt speed varies.

• We have discussed the need to use an infeed photo-eye to more accurately identify and reject the correct contaminated pack.

• We have discussed the two packs being very close to each other and the need to enter the pack-length and pack-zone into APEX.

Rejecting theProduct More

Accurately

Packs that are toclose to each

other

Failsafe Operation

Recapping so far

Reference Material


A product may create signals larger than the metal that may be contained within it. This is called product effect. APEX uses a technique called “phasing-out” to eradicate the product effect. APEX learns the product’s characteristic signal and subsequently ignores it when looking for metal.

Sometimes, product signals can be so large that the electronics is swamped and phasing-out is ineffective. APEX can operate in what is known as “low-gain” to avoid the swamping effect of the product. It may also be necessary to operate in what is known as “low-frequency”.

A product, depending on its effect is grouped into either of two categories called wet and dry. Foodstuffs such as meat, bread or some liquids typify wet products. These have the highest product effect and APEX will phase-out these products in the range –45 degrees to +45 degrees. Wet products create a large “resistive” signal compared to their “reactive” signal.

Dry products are the opposite; they produce a reactive signal that is bigger than their resistive signal. They have a phase angle in the range +45 degrees to +135 degrees. In fact products with no measurable characteristic signal are often grouped into the dry product category,

Although there are subtle differences in the way that wet and dry product signals are handled, for the APEX user, distinguishing between wet and dry is a matter of convenience only and not important for either calibrating the machine or using it.

Most products exhibit a constant phase angle characteristic meaning that once learnt the phase-angle hardly ever varies over the life of the product. However, not all products are like this. Bread for instance when being baked in a bakery is subject to a wide range of local ambient temperature changes throughout the day and this changes the phase angle.

Many products benefit from APEX’s ability to “track” the small phase angle changes ensuring that clean product does not begin to be falsely rejected as the temperature of the product (or ambient temperature) changes.

Product Effect

Wet and Dry Product

Phase Tracking

Reference Material


Setting up requires activation of two control values. The first (track range) has units in degrees. The default value is 1.00 degree meaning a pack can have a phase angle that is 1 degree different to the previous pack and phase will track. If the 2nd pack has a phase angle greater than 1 degree different to the 1st pack, tracking remains at the 1st pack angle. This means contaminated packs will not be tracked.

The 2nd control value (called track limit) is a check to see that the overall phase angle doesn’t track beyond “warning” values. The default for this is 10.00 degrees.

To allow phase tracking to operate successfully, signals produced by conveyor noise or background noise must not cause the phase tracking to move. There are two more control values that must be set to prevent irrelevant small signals activating a track. These are the reactive (X) and resistive (R) thresholds.

• Many Products create their own signal and this is called product effect

• Product effect can be eliminated by phasing-out

• Large product effects may mean lower gain, lower frequency or both

• Definition of wet and dry products

• Phase tracking can help with problem packs.

Once the product effect has been learnt, the final part of the main story is to set the detection level. This means that any signals exceeding the detection level will be regarded as emanating from metal in the product. A high level usually means that there is a lot of residual signal from the product that can’t be adequately phased out and in turn this means the sensitivity to smaller pieces of metal will be reduced. A low detection level usually means that the product effect is easily controlled or very small.

APEX uses a special detection algorithm to look for the correct shape of signal coming from metal to avoid early onset of false detections and rejection. The algorithm avoids problems of metal signals cancelling each other out when two adjacent packs contain similar sized pieces of metal.

Recap +1

Detection Level

Reference Material


The metal case screens the magnetic field of the search head avoiding false detections from nearby moving metallic objects. Obviously this ensures reliable operation. However, the case is metal and can produce signals that may cause false detection.

When product effect is negligible, APEX eradicates case effects because they have a phase angle characteristic like most products and can be learnt by lightly vibrating the case. The phase angle from the case is usually about 89 degrees.

When phasing a wet product, the dominant signal to be eradicated is the product itself, which is typically around 0 degrees. This is totally at-odds with the signal from the case and traditionally, you can’t phase out a product and simultaneously phase out the vibration effects of the metal case.

What you may find in many wet applications are search heads that can be prone to the effects of vibration. Obviously the product effect needs to be eradicated to achieve best performance but this leaves the effects from the case largely unchecked.

APEX recognizes this problem and for many wet applications, vibration or shock to the case will not be a problem. The characteristic of case vibration or shock is that it usually produces a high initial impulse signal that APEX removes before it can be detected.

By applying APEX’s new impulse reduction system, most applications dogged by vibration problems are fixed. This feature is not in DSP3.

Previously it was mentioned that the case screens the search head magnetic field to prevent false detections. In truth the aperture openings remain unscreened i.e. the magnetic field extends beyond aperture openings and can be affected by metallic reject arms when they operate. This will cause a false detection and fire the reject arm after the delay and the cycle repeats.

This sort of problem has affected a few systems in the past but APEX’s new impulse reduction system should fix this in most applications allowing the search head to operate at lower detection thresholds.

Effects ofVibration and

MechanicalShock

Metal Free zone

Reference Material


When you first check your machine QNR is inactive. To activate it proceed to the phase learn screen and go to page 2. It has no other parameters to be set or changed. QNR is generally a useful feature to have activated on all applications. It reduces the background noise levels in many applications and helps prevent false detections in wet mode. It can be used in conjunction with PNR. QNR should be tested both on and off to determine the effect on sensitivity

When you first check your machine PNR is active. To deactivate it proceed to the phase learn screen and go to page 2. It has no other parameters to be set or changed. PNR is generally a useful feature to have activated on all applications. It reduces the background noise levels in all applications and helps prevent false detections. It can be used in conjunction with QNR. It should be active for most applications.

When you first check your machine CLX is inactive. To activate it proceed to the phase learn screen and go to page 2. It can be activated at level 1X, 2X or 3X. 0X means deactivated. It is recommended that 2X level is chosen when activating CLX. It has no other parameters to be set or changed. CLX is generally a useful feature to have activated on most wet applications. It reduces the background noise levels in and helps prevent false detections. It can be used in conjunction with PNR and QNR.

APEX signalImprovement

Algorithms

QNR

PNR

CLX

Reference Material


When you first check your machine Phase tracking is inactive. To activate it proceed to the phase learn screen. It is on page 1. Phase tracking is used when the signal from your product (product effect) can vary. Firstly, you need to learn the product effect (or phase angle) of a clean product. If your product does not have variations in product effect this is all you have to do.

For products whose effect varies with time, we recommend that tracking is activated. Once the product is learnt and tracking activated you will see that the displayed phase angle will vary each time a product is passed thru the aperture. This is normal and it indicates that there are small variations in the product effect and that these are being “tracked” by APEX.

There are two parameters associated with phase tracking. The first parameter is at the bottom of the screen and is associated with a caution symbol. This is the fault limit when tracking. If a product tracks from the original learnt value by more than the upper or lower limit then a fault is generated that will activate a relay that can be wired to stop the conveyor or sound an alarm. The default value is +/- 10.00 degrees.

The other parameter is called the track-limit and it prevents tracking from moving too quickly from one product to the next. It is highly recommended that a tight limit is chosen as this will also improve the ability to detect contaminated product. Default value is +/- 0.30 degrees.

Phase Tracking

Reference Material


SW1 and SW2 are used to manually correct magnetic imbalances. They do this by applying a compensating electrical signal onto the input circuits of the search head PCB. SW1 corrects reactive imbalances and SW2 corrects resistive imbalances.

The compensating signal is derived from the oscillator voltage via JP3. With JP3 in the low (default) position, the oscillator voltage is reduced to one-third meaning that SW1 and SW2 are much finer in their adjustment range. JP10 & JP11 direct compensation to the left or the right input soldered connection i.e. these jumpers are compensation signal invertors or non-invertors.

Compensation “strength” is due to the oscillator voltage, JP3 position and the actual setting on SW1 and 2. It is also affected by oscillator frequency and the input tuning capacitance. If the imbalance is purely reactive and the oscillator was changed from 300 kHz to 200 kHz, SW1’s correction would attenuate about 3.4 times.

Two heads with coil inductance ratios of 2:1 require a 2:1 difference in SW1 to compensate for the same imbalance. The smaller head requires a setting that is twice as high as the larger head – this is because the smaller head has twice the input capacitance and this means reactive compensation is only half as effective.

• Oscillator voltage (half voltage means half effectiveness of control)

• Oscillator frequency (2/3 frequency means 2/3 cubed (8/27) effectiveness)

• JP3 position (Low is one-third as effective as high)

• SW1 position (16:1 change dependent on setting)

• Head size (see below – approximately 3:1 difference across range)

BalanceCorrection

Switch Settings on

Search HeadPCB

To recap, SW1effectiveness is

due to: -

Reference Material


Input tuning affects the reactive (SW1) compensation and across a wide range of typical heads, SW1’s effectiveness may be reduced by up to 3:1: -

Because also, on small heads the oscillator voltage is not as great, the effectiveness is even further reduced; A 200x75 might only have 30vp-p drive whilst a normal sized head (350x150) will have a drive voltage of 40vp-p. Miniteks only have a 20vp-p drive voltage which means that the effectiveness of SW1 and 2 is halved.

If frequency were factored in (say 200 kHz), the numbers in the above table would all reduce by 3.375 (1.5 cubed). If the frequency were lowered to 150 kHz, the effectiveness of SW1 would reduce by 8:1.

At this point I want to concentrate on SW1’s setting – this is the reactive manual compensation control and it is the most likely to cause noise problems when set too high. The noise appears to be equally possible at any phase angle and just because the head may be operating low gain doesn’t mean that this helps. The following tables of numbers are guidelines for limiting the maximum setting for SW1 in high gain: -

300kHz 200 250 300 350 400 450 500 550 650 750 850 950 105040vp-p (8") (10") (12") (14") (16") (18") (20") (22") (26") (30") (34") (38") (42")50 (2") 0.60 0.60 0.70 0.75 0.85 0.85 0.90 1 1.10 1.20 1.40 1.40 1.6075 (3") 0.65 0.65 0.75 0.80 0.85 0.90 1 1.10 1.20 1.20 1.40 1.50 1.60100 (4") 0.70 0.75 0.80 0.85 0.90 1 1.10 1.10 1.20 1.30 1.50 1.60 1.70125 (5") 0.75 0.80 0.85 0.90 0.90 1 1.20 1.20 1.30 1.40 1.60 1.70 1.80150 (6") 0.80 0.85 0.90 1 1 1.10 1.20 1.20 1.40 1.50 1.60 1.80 1.90175 (7") 0.80 0.85 0.90 1 1.10 1.20 1.20 1.30 1.40 1.60 1.70 1.90 2.00200 (8") 0.85 0.90 1 1.10 1.20 1.20 1.30 1.40 1.50 1.60 1.80 2.00 2.10250 (10") 0.90 1 1.10 1.20 1.20 1.30 1.40 1.40 1.60 1.70 1.90 2.10 2.20300 (12") 0.90 1 1.10 1.20 1.30 1.50 1.50 1.50 1.70 1.80 2.00 2.20350 (14") 1 1.10 1.20 1.30 1.40 1.60 1.60 1.60 1.80 1.90 2.20400 (16") 1.10 1.20 1.20 1.40 1.60 1.70 1.70 1.70 1.90 2.20

Reference Material


300kHz 200 250 300 350 400 450 500 550 650 750 850 950 105040vp-p (8") (10") (12") (14") (16") (18") (20") (22") (26") (30") (34") (38") (42")50 (2") 13L 13L 11L 11L 9L 9L 9L 8L 7L 7L 6L 6L 5L75 (3") 12L 12L 11L 10L 9L 9L 8L 7L 7L 7L 6L 5L 5L100 (4") 11L 11L 10L 9L 9L 8L 7L 7L 7L 6L 5L 5L 5L125 (5") 11L 10L 9L 9L 9L 8L 7L 7L 6L 6L 5L 5L 4L150 (6") 10L 9L 9L 8L 8L 7L 7L 7L 6L 5L 5L 4L 4L175 (7") 10L 9L 9L 8L 7L 7L 7L 6L 6L 5L 5L 4L 4L200 (8") 9L 9L 8L 7L 7L 7L 6L 6L 5L 5L 4L 4L 4L250 (10") 9L 8L 7L 7L 7L 6L 6L 6L 5L 5L 4L 4L 4L300 (12") 9L 8L 7L 7L 6L 5L 5L 5L 5L 4L 4L 4L350 (14") 8L 7L 7L 6L 6L 5L 5L 5L 4L 4L 4L 400 (16") 7L 7L 7L 6L 5L 5L 5L 5L 4L 4L

500kHz 200 250 300 350 400 450 500 550 650 750 850 950 105040vp-p (8") (10") (12") (14") (16") (18") (20") (22") (26") (30") (34") (38") (42")50 (2") 3L 3L 2L 2L 2L 2L 2L 2L 2L 2L 1L 1L 1L75 (3") 3L 3L 2L 2L 2L 2L 2L 2L 2L 2L 1L 1L 1L100 (4") 2L 2L 2L 2L 2L 2L 2L 2L 2L 1L 1L 1L 1L125 (5") 2L 2L 2L 2L 2L 2L 2L 2L 1L 1L 1L 1L 1L150 (6") 2L 2L 2L 2L 2L 2L 2L 2L 1L 1L 1L 1L 1L175 (7") 2L 2L 2L 2L 2L 2L 2L 1L 1L 1L 1L 1L 1L200 (8") 2L 2L 2L 2L 2L 2L 1L 1L 1L 1L 1L 1L 1L250 (10") 2L 2L 2L 2L 2L 1L 1L 1L 1L 1L 1L 1L 1L300 (12") 2L 2L 2L 2L 1L 1L 1L 1L 1L 1L 1L 1L350 (14") 2L 2L 2L 1L 1L 1L 1L 1L 1L 1L 1L 400 (16") 2L 2L 2L 1L 1L 1L 1L 1L 1L 1L

200kHz 200 250 300 350 400 450 500 550 650 750 850 950 105040vp-p (8") (10") (12") (14") (16") (18") (20") (22") (26") (30") (34") (38") (42")50 (2") 15H 15H 13H 13H 10H 10H 10H 9H 8H 8H 7H 7H 6H75 (3") 14H 14H 13H 11H 10H 10H 9H 8H 8H 8H 7H 6H 6H100 (4") 13H 13H 11H 10H 10H 9H 8H 8H 8H 7H 6H 6H 6H125 (5") 13H 11H 10H 10H 10H 9H 8H 8H 7H 7H 6H 6H 5H150 (6") 11H 10H 10H 9H 9H 8H 8H 8H 7H 6H 6H 5H 5H175 (7") 11H 10H 10H 9H 8H 8H 8H 7H 7H 6H 6H 5H 5H200 (8") 10H 10H 9H 8H 8H 8H 7H 7H 6H 6H 5H 5H 5H250 (10") 10H 9H 8H 8H 8H 7H 7H 7H 6H 6H 5H 5H 5H300 (12") 10H 9H 8H 8H 7H 6H 6H 6H 6H 5H 5H 5H350 (14") 9H 8H 8H 7H 7H 6H 6H 6H 5H 5H 5H 400 (16") 8H 8H 8H 7H 6H 6H 6H 6H 5H 5H

Reference Material


“H” means JP3 is in the high position. “L” means JP3 in low position.

Numbers are not expressed in hexadecimals for convenience. A=10, B=11, C=12, D=13, E=14 & F=15

These numbers are just guidelines. Higher settings may not produce noise. Indeed lower settings on some heads may still produce some noticeable levels of noise. It is recommended that SW1’s position be kept as low as possible by effective balance correction techniques during production.

Reference Material


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Thermo Fisher Scientific AuditCheck™ 7-1 REC 4258 Rev C

Chapter 7 AuditCheck™

Thermo Scientific AuditCheck™ is an optional system that, if not installed at the factory, can be easily installed in the APEX. It is an automatic means of checking the calibration of both sensitivity and phase angle. AuditCheck simulates the presence of a metal contaminant in the product by “firing” a metal ball through the search head coinciding with a product passing. The metal ball does not come into contact with the product. It is fired through a part of the search head that is segregated from the main aperture.

To understand the benefits of AuditCheck it is necessary to determine what is meant by sensitivity of a metal detector head. As an example, a common head sensitivity of 1mm ferrous and 1.2mm non-ferrous indicates the head is capable of detecting spherical piece of ferrous material with a diameter of 1.0mm or a spherical piece of non-ferrous material with a diameter of 1.2mm.

All products have their own effect on a metal detector. In some cases, this effect is small (such as products referred to as “dry” products). Other products have a much larger effect (such as products referred to as “wet” products). Any metal detector must be capable of correctly compensating for such product effects so uncontaminated product is not rejected. The AuditCheck system is a true quantitative measurement of sensitivity since it actually passes a test piece through the magnetic field of the head and measures the resultant signal in the presence of product.

The AuditCheck system has been designed to provide the ideal automatic sensitivity test for metal detectors. AuditCheck takes advantage of the fact there is a fixed relationship between the sensitivity at each point in a metal detector field and by firing the ball through the same magnetic field as the product, AuditCheck produces the same effect as if a metal contaminate were in the product.

Figure 7–1 illustrates the essential elements of AuditCheck. A tube is inserted into the metal detector case along the line “AB” that is within the active magnetic field area of the head. A test piece (molded into a plastic shuttle) travels along the line of the conveyor or pipeline from “A” to “B” and returns rapidly from “B” to “A”.

Theory ofOperation

AuditCheck™

7-2 AuditCheck™ Thermo Fisher Scientific REC 4258 Rev C

As part of the automatic setup and calibration the test piece is fired from “A” to “B” simultaneously with the product. The resultant metal detection signal can then be measured in the presence of the product. The test piece rapidly returns from “B” to “A” so its signal is filtered out and does not affect the peak signal measurement.

Figure 7–1. Cross section of the search head on a conveyor system

AuditCheck™


Ensure product calibration (sensitivity and phase) is complete before AuditCheck is enabled.

After initial setup the test sphere is firing synchronized with the product at a regular interval set by the Test interval. The resulting head signal (Current Peak) is then measured and compared with the calibration results (Learnt Peak).

If the signal is outside of tolerance, a fault is generated. This indicates there has been a change in sensitivity and/or phase angle. Such small changes would not typically be detectable using manual methods.

To begin initial setup, the valves on the ends of the AuditCheck tube must now be adjusted for proper passage of the shuttle. The air regulator for AuditCheck should be set at the desired setting. The setting is not critical but must not be changed after AuditCheck has been setup since the change in air pressure affects the speed of the AuditCheck shuttle as it passes through the head.

The AuditCheck shuttle should be adjusted so it moves from position “A” to “B” at the same speed as the product, dwells for a minimum amount of time, then returns to position “A” as rapidly as possible so it is ready for the next operation.

1. Select

2. Use the down arrow to screen 2 of 4 and select If the detector is in bulk mode with no photoeye, the AuditCheck shuttle fires when the RUN MANUAL AUDIT CHECK icon is pressed. If there is a photoeye installed it does not fire until a package passes the photoeye and reaches the head. (It is not necessary to pass a package the infeed photoeye can be blocked with a hand). Observe the shuttle as it emerges from the downstream side of the head after AuditCheck is fired. The shuttle should just reach the O-ring stop and then return. If it does not reach the stop, the valve on the downstream side should be opened up (turned counter clockwise) to allow more airflow through the valve. If it reaches the stop and remains there, the airflow should be restricted by turning the valve clockwise.

Operation

Setup – Speed Shuttle

Calibration

AuditCheck™


Note: The upstream valve (Valve A) should be left wide open so there is no restriction on the return so the shuttle returns as fast as it can. The downstream valve (Valve B) needs to be adjusted so the speed of the shuttle is the same as the speed of the product and the shuttle just reaches Position B and then returns.

If the shuttle does not reach the downstream valve (Position B) open control valve “B”: to increase the airflow. If it reaches the downstream valve and rests there, close the control valve “B” to reduce air flow. (Use a small screwdriver and turn the screw clockwise to restrict the air to slow the shuttle down. Conversely, turn the screw counter clockwise to free the air to speed up the shuttle.)

Any specific product should be setup and learnt prior to AuditCheck software setup. Use the following steps to setup AuditCheck:

Path: Main Menu

AuditCheck has three set-up screens. The first one displays below:

Figure 7–2. AuditCheck Screen 1

Software Setup

AuditCheck Screen 1

Peak and phase averages of the three tests.

AuditCheck™


This is the calibration page.

1. Select Icon #1 to calibrate. The peak and phase results are shown directly below the icon.

2. For best accuracy, calibrate #2 and #3 also. The peak and phase averages of the three tests are shown at the bottom of the screen.

Note. The padlock symbol in the right corner indicates that AuditCheck calibration can be excluded from a main product learn. In the screen above an ‘X’ displays indicating that AuditCheck is included in a main product learn. ▲

The AUDITCHECK screen 2 allows you to set the parameters for the test or run a manual test.

Icon Description Run AuditCheck manually

Time between tests in minutes (timing)

Time to complete test in minutes (timing)

Rejects as a result of the AuditCheck test directed to bin 1 or 2

To set the AuditCheck time and length between tests navigate to the appropriate icon and a pop up screen displays. Use the arrow keys to increase or decrease the times.

AuditCheck Screen 2

AuditCheck Timing

AuditCheck™


This icon is a toggle switch. Select it and choose between off (‘X’) or a bin number (1 or 2).

At SCREEN 3, the tolerances are set. Tolerances set high and low limits for AuditCheck. If the timed calibration signal is outside these limits, a fault/alarm is produced. Be careful not to set the tolerances too small. Small changes in product effect can result in AuditCheck failure. The tolerances should be set high enough to overcome normal product variation, typically between 20% and 50%.

Example: If Audit Check’s learnt peak is 1000, and the tolerance is set to 20% above below that level, any peak value below 800 or above 1200 triggers an alarm/fault.

Note. A 20% difference in signal strength does not mean the detector sensitivity to metal has changed by 20% difference in sphere size. The metal detector’s sensitivity to metal is roughly a cubic function of the signal strength. ▲

Example: When AuditCheck detects 20% change, the sphere size has changed by approximately 6% (1.0 mm to 1.06 mm).

Figure 7–3. AuditCheck Screen 3

Note. If the product is wet, it is recommended that the phase limits be set to zero (off). ▲

AuditCheck Rejects

AuditCheck Screen 3

AuditCheck™


Icon Description

Warning Peak limit of 20%

Warning Phase limit of 2 degrees

Alarm Peak limit of 40%

Alarm Phase limit of 4 degrees

Fault Peak limit of 80%

Fault Phase limit of 8 degrees

To check the calibration a manual AuditCheck can be run at any time. Use the following steps to run a manual AuditCheck.

1. Navigate to AuditCheck screen 2 and press

The results are displayed as shown:

Now that the software has been calibrated, enable the alarms associated with the system. Refer to Chapter 3 of REC 4132 for instructions.

Manual AuditCheck Test

Faults andAlarms

AuditCheck™


AuditCheck is a unique and patented (USA Patent No. 5,160,885) automatic sensitivity test system for Thermo Scientific metal detectors. Not only does the AuditCheck automate the regular testing of metal detection sensitivity, but it also saves time and money and insures product quality. AuditCheck may be used as part of a quality or HACCP system.

In order to fully understand the benefits of AuditCheck it is necessary to consider what is really meant by the sensitivity of a metal detector head. It is common to talk of a head by having a sensitivity of 1 mm ferrous and 1.2 mm non-ferrous. This would indicate that the head is capable of detecting a spherical piece of ferrous material with a diameter or 1.0 mm or a spherical piece of non-ferrous material with a diameter of 1.2 mm.

There are several factors that need to be taken into consideration, however, in order to fully qualify such statement. First, it should be noted that the sensitivity of any metal detector varies across its aperture with the least sensitive point being in the center.

Second, all products will have their own effect on a metal detector. In some cases, this effect is quite small (such products are often referred to as ‘dry’ products). Other products, on the other hand, have a much larger effect (known as ‘wet’ products). Any metal detector must be capable of correctly compensating for such product effects so that uncontaminated product is not rejected. In general terms, as the product effect increases, the achievable sensitivity of the metal detector decreases.

It is apparent that when carrying out checks on the sensitivity of a metal detector, the test piece must be in the same relative position in the aperture and also that the test be carried out in the presence of product. It is often extremely difficult in real production situation to carry out such tests in an accurate and reproducible manner. In order to achieve a reasonable attempt at a representative test, special test packs often need to be made (in the case of many products, fresh for each shift). Production has to be interrupted in many occasions in order to introduce the test package into the line.

AuditCheckPatented

SensitivityTest System

AuditCheck™


After all of these inconveniences, it is still difficult to ensure that the contamination is always traveling along a consistent path. There are applications in which traditional manual testing methods are, for all intent and purposes, impossible to achieve - for example, in the case of hot soup being detected in a pipe line. In many cases inconsistencies may be introduced when the product temperature changes over time, such as frozen product thawing over the course of a production run.

Let us consider what we really mean by the sensitivity of a head with reference to Figure 7–4.

If we were to pass a series of varying metal spheres sizes each through the head, approximately one hundred times each, we could plot a graph of percentage probability of metal detection against relative sphere size. We would then typically produce a curve similar to that indicated by ‘X’. What this curve means is that for very small sizes of contaminate (below a relative size of 0.5) the detector will never see the metal. For large contaminate sizes, (above a relative size of 0.8) the detector will see the contaminate 100% of the time.

Figure 7–4. Head Sensitivity

AuditCheck™


There is a region between these limits where the probability of metal detection will vary from 0% to 100%. For example, there will be a point X2 where if the contaminate is passed 100 times it will only be detected 50 times, there will also be a point X1 where the contaminate will be seen 99.9% of times.

This means in practice that when a metal detector is to be tested using a manual test piece, a size is chosen somewhere on the curve above X1 so that it may reasonably be expected to be seen 100% of times. A typical point might be at ‘A’. Manual testing consists of passing a test piece if size ‘A’ through the head and ensuring that it is detected.

Consider the scenario of the metal detector losing sensitivity such that its sensitivity characteristic is represented by curve Y. Such a loss of sensitivity would not be detected by the manual testing regime, since the test piece would still be seen 100% of the time. Indeed the sensitivity might decrease further, as represented by curve ‘Z’, and the test still be acceptable. The reason for this is that the test piece is now equivalent to point ‘Z2' (the 50% probability point) and, therefore, there is a 50% chance that the test piece will be detected the first time it is passed through the head.

Human nature being what it is, most operators would pass the test sphere a second time, should it fail on the first attempt, and so long as it was detected on the second pass the operator would accept that the detector was operating correctly. The detector sensitivity may need to decrease further before the manual test system shows up an operational problem. One must question why the manual test system is a poor method of tracking the performance of a metal detector’s sensitivity. It is because a manual test system is a qualitative (go/no go) method. What is actually required is a quantitative measurement system?

The ideal sensitivity test system would have the following characteristics:

a. Fully automatic at a user definable frequency

b. Testing carried out in the presence of product

c. Test piece always traveling along the same path in the detector field

d. Testing carried out under normal detecting conditions

e. A true quantitative measurement system

AuditCheck™


Such a system may seem to be a quantum leap from the traditional manual testing methods. Indeed it is, but that is exactly what is offered by the Thermo Scientific AuditCheck.

The AuditCheck system (USA Patent No. 5,160,885) has been designed to provide the ideal automatic sensitivity test system for metal detector systems.

Like all classic designs, the AuditCheck is on the surface an extremely simple device. One might ask the question “Why has it not been developed before?” The simplicity of the device belies the fact that a very significant amount of development effort has been expended to provide a reliable and failsafe device.

The signal measured by a metal detector search head depends on the volume of a metal sample. Consequently, a 10% change in the test sphere diameter will result in approximately a 30% change in measured signal.

Sensitivity is defined as the peak signal at any given point with a given sphere size. The signal strength (peak signal) is used to establish the sensitivity. The center of the aperture is the least sensitive point in the aperture.

The AuditCheck sphere is always at the same point in the field “A”. A test sphere will not always be at the same place. Sometimes it will be at the aperture center “C”, and other times it will be somewhere else, resulting in a different measurement.

See Figure 7–5 below.

AUDITCHECKTHEORY OFOPERATION

AuditCheck™


Figure 7–5. AuditCheck Sensitivity

The AuditCheck system uses the fact that there is a fixed relationship between the sensitivity at each point in a metal detector field. For example, define the sensitivity at the center “C” as “S” and the corresponding sensitivity at another point “A” as “T”. If the sensitivity at point “C” decreases by a factor “Y” to be “S/Y”, then the corresponding sensitivity at “A” will be “T/Y”. If the sensitivity at one point in the field is measured, it may be used as a reference for the sensitivity at all other points within the aperture. This fact is the foundation of the AuditCheck design.

Assume that the peak signal at point “C” for a given sphere = 200 (S) and the peak signal at point “A” for a possibly different sphere = 5000 (T). If the sensitivity decreases by Y, S = 200/Y and T = 5000/Y.

If the overall metal detector sensitivity decreases by 25%, Y = 1/(1-.25) = 1.33. Therefore, the sensitivity at point “C” would be (200/1.33) = 150 and the sensitivity at point “A” would be (5000/1.33) = 3750.

AuditCheck™


If the overall metal detector sensitivity decreases by 50%, Y = 1/(1-.50) = 2. Therefore, the sensitivity at point “C” would be (200/2) = 100 and the sensitivity at point “A” would be (5000/2) = 2500.

If the overall metal detector sensitivity decreases by 75%, Y = 1/(1-.75) = 4. Therefore, the sensitivity at point “C” would be (200/4) = 50 and the sensitivity at point “A” would be (5000/4) = 1250.

Therefore, with the AuditCheck signal at 5000 and the tolerance set to 20%, a warning/fault will be generated when the AuditCheck signal drops below 4000. The test sphere may or may not be detected (peak = 160) because a minimum peak of 180 is needed for 100% detection. The decrease in sensitivity might not be noticed if the test sphere is detected during a manual test because a manual test is usually a go/no-go test, not a quantitative test that carefully checks the actual signal level. The AuditCheck system would detect the decrease in sensitivity before any method of manual testing.

The essential elements of the AuditCheck are shown in Figure 7–6. A tube is cast into the metal detector case within the active field area of the head. A test piece (molded into a plastic shuttle) is able to travel along the line of the conveyor or pipeline from A to B and return from B to A. As part of the automatic product effect calibration and set up procedure, the test piece will be fired from A to B in synchronized with the product. The resultant metal detection signal can then be measured in the presence of the product. The test piece will then be returned under control of the microprocessor from B to A.

AuditCheck™


Figure 7–6. AuditCheck Elements It should be also noted that the path of the test piece is precisely controlled. Another benefit of the design is that it is a failsafe system. If the air supply to the system is defective, the test piece will not travel through the tube and the resultant head signal will not be measured. The result will be an alarm condition. In fact, the microprocessor must detect the precise calibration signal in order for the test to pass.

Figure 7–7 illustrates the graph of the counts representing the amplitude of the signal on the receiving coils of the metal detector for a given head size against relative contaminant size. The calibration counts generated during a product set up is shown at A.

AuditCheck™


Figure 7–7. Amplitude of the Signal

Having calibrated the test system, the test piece will be fired in parallel with the product at a regular interval, approximately once an hour. The resulting signal is then measured and compared with the stored baseline calibration result. If the voltage is outside the limit WL or WU then a warning signal will be generated by the microprocessor. This indicates that there has been a small change in sensitivity. Such small changes would not typically be detectable using manual methods. The cause of such a warning may be a change in product effect, requiring the system to be recalibrated, or it might be caused by excessive product build up on the head.

If the test signal falls outside much broader limits AL or AU (equivalent to the typical results obtainable from manual tests), then an alarm signal will be generated indicating a more serious loss of sensitivity.

This system is a true quantitative measurement of sensitivity since it actually passes a test piece through the head field and measures the resultant head signal in the presence of product. The cost of the AuditCheck will pay for itself in lower operating costs within a few weeks.

AuditCheck™


• Components

The detector must be equipped with an AuditCheck system. This consists of the 5-way valve, the AuditCheck shuttle tube with two adjustable airflow valves, shuttle(s) and test sphere(s), and pneumatic tubing.

• Basic Operation

The basic operation of the system is as follows. The valve is wired to a relay under the control of the microprocessor. The valve input is low pressure air (typically under 30 psi). The two outputs of the valve go to the AuditCheck tube. The pneumatic system is plumbed such that the downstream adjustable valve has air supplied to it. The upstream adjustable valve is not pressurized. The air pressure forces the shuttle (and test sphere) upstream, holding it there against the O-ring stop. When it is time to do an AuditCheck, the 5-way valve is energized, reversing air pressure to the two adjustable valves. The shuttle is then blown through the tube in the downstream direction. The 5-way valve is then deenergized; this returns the shuttle back to the upstream position ready for the next test.

The signals from most products cannot be completely eliminated due to a number of factors affecting conductivity of the product. The important consequence of this fact is the signals from one individual product are different that the signals from another individual product of the same type, size, etc. When the signal from the varying products are added to the signal from the AuditCheck test sphere (the signal from the AuditCheck test sphere is very consistent), the signal the detector “sees” varies as well. The detector is looking for a difference in the AuditCheck signal during the test and the signal it saw during the learn process. There are internal limits on how much the difference between learn and run can be. If the difference is too great, a warning or fault will be issued. Therefore, the signal the detector “sees” from the AuditCheck test sphere must be large enough that the differences in signal from package to package do not appreciably affect the test function.

The AuditCheck test sphere size is not directly correlated to the actual size of the test sphere the detector will detect with product. The primary reason for this is the AuditCheck test sphere is passed through the detector in a location different from where the product test sphere is placed. The AuditCheck system is intended to check the entire system for changes in performance. While there is no direct correlation of the AuditCheck test sphere size with the

SETUP

AuditCheck™


product test sphere size, any change in system performance will be detected by the AuditCheck system. There are two internal limits to the AuditCheck system. The first limit is set to detect any change in signal from the AuditCheck greater than 20 percent. If the AuditCheck signal is greater or less than the expected signal by more or less than this 20 percent, this first warning is issued. The 20 percent difference in signal strength does not mean the detector sensitivity to metal has changed by a 20 percent difference in sphere size. The metal detector’s sensitivity to metal is roughly a cubic function of the signal strength. What this means in sensitivity to metal is the 20 percent change in signal translates to a change in test sphere size of about 6 percent. The second internal warning/fault level is set to detect a difference of 40 percent or more. This translates to approximately a 33 percent difference in sphere diameter.

The size of the AuditCheck test sphere is not critical for evaluating system performance as long as the signal is large enough that it does not cause false failure indications due to the reasons stated before. This is because the sensitivity to metal is scaled; a change in response of the detector to the test metal will translate to the same percentage of difference in signal to actual metal. The size of the AuditCheck test sphere is not without limits, however. If the AuditCheck test sphere is too large, it will over range the detector and will cause the AuditCheck system to indicate a failure. The signal is checked to insure that this does not happen.

AuditCheck is a terrific supplement to manual testing. It can save time and money by increasing the ease and frequency of detector testing thereby insuring top performance.

AuditCheck uses a real metal sample tested in parallel with product in the magnetic field of the detector. The resulting signal characteristics are compared against a stored baseline signal and evaluated.

AuditCheck can be used as part of a quality or HACCP program.

SUMMARY

AuditCheck™


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Thermo Fisher Scientific Using the APEX Oscilloscope 8-1 REC 4258 Rev C

Chapter 8 Using the APEX Oscilloscope

This appendix outlines the use of the oscilloscope associated with the APEX software.

From the TOOLS menu, page 1, use the arrow key to select the SCOPE icon.

Press the ENTER (green key) and the following screen displays:

There should be a vertical dotted line moving across the screen. You should also see a highlighted area below the screen. The highlighted area tells you 4 things:

• The time it takes the vertical line to cross the screen is 2 seconds

Using the APEX Oscilloscope

8-2 Using the APEX Oscilloscope Thermo Fisher Scientific REC 4258 Rev C

• The amplitude of the screen is 100 from center to top or bottom of screen

• Channel 1 is showing the output of the lo-pass filter

• Channel 2 is switched off

Press ENTER (green key) and the following screen displays:

This screen further details the information located at the bottom of the previous screen and adds more selections for the display. Use the following steps to make changes to the display:

1. Use the ARROW keys to move the highlighted area on the screen to any selection. (Offset will be used for this example.)



3. Using the RIGHT arrow press it repeatedly until an offset of +80

displays.

4. Press the CANCEL (red) key to return to the scope display. The

following screen displays:

As displayed, the signal previously running along the horizontal centerline of the display has dropped to 80 points below where it was. This can be a useful feature when examining a stored signal in detail.

5. Return the Offset to 0 and use the select an Amplitude of 25 (using the instructions as listed above) and return to the scope display. The following screen displays:

Notice that there is more activity on the Channel 1 signal. This is because the scope display has been made more sensitive by lowering the amplitude.



Try lowering the amplitude even further and you will see more signal fluctuations.

It is important to understand what signals can be shown on the scope.

• R:INPUT

• X:INPUT

• R:HI-PASS

• X:HI-PASS

• R:CLIPPED

• X:CLIPPED

• PHASED

• QNR

• PNR

• LO-PASS



To make best use of the scope you must understand where each of these signals exist in the signal processing chain of the machine. Below is a diagram to help.

Let’s examine some of the signals.

• Assign Channel 1 to R:INPUT and

• Assign Channel 2 to X:INPUT.

The screen will display as follows:

Notice the amplitude has changed to 200 and running across the screen are the two signals defined at the bottom of the screen. The amplitude has been purposefully changed to 200 because the two inputs shown can have considerable DC offsets associated with them.

As an example, if an amplitude of 100 was chosen both signals would not be visible on the screen. The lower signal (X) would be below the bottom part of the screen and the R signal would be above the top part of the screen.

On many applications, when viewing the X and R inputs together, amplitudes greater than 200 may be necessary. However, when moving on to the next pair of signals we don’t need to worry about this because the DC offsets are removed and both signals appear along the centre of the display.



Displayed are high-pass filtered X and R signals when a metal passes thru the search head. X is larger indicating the metal’s phase angle is closer to 90 than zero degrees. (This signal is equivalent approximately to a piece of ferrous metal about 1.0mm in diameter.)

Displayed below are high-pass filtered R and the Lo-pass signal. Note the amplitude has lowered to 100 for better screen resolution.

It can be seen that the act of low-pass filtering does the following to the signal: -

• The top and bottom peaks are restored symmetrically about the centerline i.e. they have equal magnitude – this can be important for how we detect metal.

• There is a delay between the high-pass R signal and the lo-pass output.



If we examined the background noise by lowering the amplitude even more we would see something like this: -

It can be a little tricky to see but the low-pass trace is largely unaffected by noise – for the most part it runs steady across the centerline of the scope. Note that the amplitude has been dropped to just 6 making the screen very sensitive indeed. The high-pass R signal is very noisy and it is the effect of the low pass filtering that removes this noise as well as making the signal symmetrical and delaying the signal slightly.

You should also examine the effect of the QNR filter and the PNR filter – these both help to reduce the presence of random noise on the signal and in turn allow smaller detect levels to be attained.

The next scope trace is shown to help you understand the vertical dotted line crossing the screen. You should note that the time-base setting on the scope has been reduced to 500ms to emphasize what is happening:



Metal has passed thru the aperture and the final part of the signal (to the left of the vertical dotted-line) is about to overwrite the older data on the right hand side of the vertical dotted line. In other words, the dotted line indicates both the beginning of the signal and the end of the signal. It is important to show this so that signal analysis mistakes are not made.

Next is the use of the trigger facility. Go to the Config screen and set it up like below: -

The important point to note is that channel 1 and 2 are set as previous when looking at the delay and symmetry restoration of the low pass filter, the time base is back to 2 seconds and the trigger source is set to detection.

Now press ENTER to return to the scope display. What you’ll see is this:

Note the trigger information contained in the lower right block. Previously it said “FREE” meaning the scope traces were free-running and cycling continuously. Now it indicates that it is waiting for a metal-detection. Pass a piece of metal thru the search head and you will see trigger information registering the detection and then



counting-down to capture several seconds of data. After it has captured the data it will look something like this: -

The trigger information indicates “HOLD” and this mean it has captured all the data. On the configuration screen above you will note that the trigger reference chosen is “CENTRE” and this means that the captured data is split equally as pre-trigger and post-trigger information. In other words you can examine the signal leading up to the detection and also examine what happened afterwards.

Examining the captured signals is achieved, once an event has triggered and the data is held, by pressing the up arrow from the screen above. You will note that the vertical bar to the left of the scope window is now highlighted and steady: -

This indicates that you can use the arrow keys to move around the captured data.

Pressing the green enter key causes the vertical bar to flash – this indicates that the arrow keys change from scroll and page to time base zoom and amplitude zoom. You can revert to scroll/page mode by hitting the red key.

Hitting the red key again returns the highlighted area to the lower left section of the display.



One final bit of information on the use of trigger; a manual trigger is performed by moving highlighting the trigger information and hitting the green enter key.

Digital signals can also be displayed. Below shows the metal signals as before but this time a digital signal is introduced. This digital signal is the infeed photo-eye and is shown at the top of the screen below.

You can also trigger-off the infeed photo-eye and that is exactly what is shown above. The infeed PE was triggered by a dry pack containing a metal contaminate.

Thermo Fisher Scientific Cold Start 9-1 REC 4258 Rev C

Chapter 9 Cold Start

A cold start should only be performed as a last resort when the machine is not performing as expected.

WARNING. Performing a cold start will erase all of the memory in the APEX and it will have to be reprogrammed and recalibrated.

1. Disconnect power from the machine. 2. Remove the front panel. 3. In the center of the large circuit board on the front panel is a battery.

Just below the battery is a jumper across a pair of pins on a 3-pin header (J7). Remove this jumper.

J7

DSP3 to APEX Upgrade Instructions

9-2 Cold Start Thermo Fisher Scientific REC 4258 Rev C

4. Wait 10 seconds to be sure the contents of the battery-backed memory have been discharged.

5. Replace the jumper across the same 2 pins (J7 1 to 2 = ON). 6. Remount the front panel. 7. Restore power. A series of errors will scroll across the screen. These

are NVRAM errors for the system and product parameters that were invalidated and new default ones were created.

8. Disconnect power form the machine again. 9. Restore power to the machine again, this time no errors display and

the machine boots to the MAIN SCREEN.

Thermo Fisher Scientific Oscillator 10-1 REC 4258 Rev C

Chapter 10 Oscillator

This appendix contains an oscillator voltage guide for your convenience.

Thermo Fisher Scientific DSP3 to APEX Upgrade Instructions 11-1 Rec4258 Rev C

Chapter 11 DSP3 to APEX Upgrade Instructions

This chapter documents the procedures for upgrading the DSP3 machine with APEX electronics.

Tools and Equipment Needed

1. 12” adjustable wrench 2. 10 mm nut driver 3. Regular flat screwdriver, ¼” blade 4. Small jewelers screwdriver 5. Integral Conversion Kit Drawing (B07387M-A015)

1

2

3

4


11-2 DSP3 to APEX Upgrade Instructions Thermo Fisher Scientific REC 4258 Rev C

Figure 11–1. Integral Conversion Kit

Figure 11–2. Integral Conversion Kit Front View

Note. Numbers referenced above are the item numbers listed on drawing B07387M-A015. ▲

Note. Power cable shown will not be included as a standard part. ▲

Power Cable

1

15

13

14

2 6

5

5


Thermo Fisher Scientific DSP3 to APEX Upgrade Instructions 11-3 REC 4258 Rev C

Figure 11–3. Integral Conversion Kit Back View

Figure 11–4. DSP3 Unit to be Upgraded



Use the following steps to perform the conversion: 1. Disconnect the power to the power supply unit (PSU) enclosure. 2. Remove the front panel assembly using 10 mm nut driver. Total of

4 bolts.

3. Disconnect the cables from the control panel assembly. Total of 3

connectors.

4. Place the DSP3 front panel assembly aside.



5. Remove the PSU and search head drain wires, 2 Dag ground wires and search head board ground wire from the DSP3 bulkhead using the flat head screwdriver.

6. Unscrew and remove the wires.



7. Remove the search head cable assembly and set aside.

8. Disconnect the connectors from the PSU cable assembly. This is required to remove the PSU cable assembly from the search head. Total of 2 connectors (18 wires).



9. Connectors removed.

10. Remove PSU cable assembly conduit fitting from the search head using 12” adjustable wrench.



11. Remove the PSU cable assembly from the search head and set aside with power supply enclosure.

DSP3 shown ready for integral APEX upgrade.



12. Install APEX upgrade cable assembly through the gland hole in the DSP3 search head.

13. Thread APEX upgrade cable assembly conduit connector into M20

threaded gland of DSP3 search head. 14. Use supplied M20 locking nut if the gland is a through hole and

not a threaded hole.



15. Tighten conduit fitting using 12” adjustable wrench.

16. Insert conduit into conduit fitting. Ensure no tabs of conduit fitting are folded under by the conduit.

17. Hand tighten conduit fitting until conduit is secured.



18. Use the Remote Cable Assembly drawing (B07387M-E003) to wire cable ends to connectors. Total of 12 wires to 10 terminals.

19. Wire connectors and tighten to .5-.6 Nm [4.4-5.3 in-lb] using jewelers flat screw driver.



20. Connect upgrade cable assembly drain wire, 2 dag ground wires and SH PCBA ground wire to bulkhead using ground screw and flat head screwdriver.

21. Tighten to 3-4 Nm [27-35 in-lb].

22. Connect cable assembly PL1 to search head PCBA JP1. Ensure connector is fully engaged.



23. With APEX upgrade cable assembly completely installed, ensure excess cable length is neatly dressed inside of the enclosure.

24. No part of the cable should lay across the search head PCBA.

25. The bottom of the lid assembly has mounting bolts closest to the

edge of the lid. The top of the lid assembly has mounting bolts further from the edge of the lid.

26. Mounting of the lid assembly this way will ensure the top of the APEX electronic enclosure is flush with the top of the lid assembly.

Top



27. Install the lid assembly (B07387M-A013) onto DSP3 front enclosure

28. Tighten the 4 mounting bolts evenly using M10 nut driver. Tighten to 3-4 Nm [27-35 in-lb].

29. Position the APEX upgrade assembly onto the lid assembly for installation.



30. Fasten the APEX upgrade assembly onto the lid assembly using M6 x 12 mounting bolts and flat washers, total of 4.

31. Completely tighten the 4 bolts using M10 nut driver to 3-4 Nm [27-35 in-lb].

32. Apply power to the APEX upgrade search head (reference Field Wiring Diagram D07387N-W001)



33. Verify the APEX upgrade is running and no faults are present 34. Reference REC 4248 – APEX operator manual for full setup

details.

35. Place a 12” adjustable wrench into the aperture to cause the search head fault (caused by a balance error).



36. The Front Panel must issue a search head Fault. RED fault LED flashes and Fault output is active.

37. Remove the 12” adjustable wrench from the aperture; search head fault must clear.

38. Reference Chapter 1 of this manual for detailed information on tuning and balancing of the APEX upgrade search head.

Fault Output

Search Head Fault

Flashing RED fault LED



The parts removed from the DSP3 can remain with the customer if they want to keep them. If the customer does not want them, box them up and ship them back to Thermo Fisher Scientific.

DSP3 Parts

Search head Cable Assembly

PSU Cable Assembly Connectors

Front Panel Assembly

PSU Cable Assembly

PSU Enclosure

Thermo Fisher Scientific DSP3 to APEX Upgrade Instructions 12-1 Rec4258 Rev C

Chapter 12 APEX Software Update

The Apex metal detector uses a pair of microprocessors or CPU’s to perform it’s tasks. One, called the DSP, performs the signal processing of the signals from the head and detects the metal. The other, called the MMI, takes care of the user interface.

To program an Apex, a special cable is needed to put each of the two CPU’s into the bootstrap mode so software upgrades can be uploaded. This is done by connecting to grounds one of the two pins on the DB9 connector on the back of the CPU motherboard. This is done using a special cable with a switch that can select which of the two CPU’s is to be programmed. Figure 12–1. APEX CPU Programming Cable

Leave the other pins on the Apex DB9 connector unconnected.

Only one of the two switches that select a CPU to program can be closed at one time.

The DB9 connector used to program the Apex CPU’s is located on the motherboard, it is labeled J8 and is located toward the bottom of the front panel, below the power supply connector. To access this connector, the front panel needs to be removed and remain connected to the power supply. Below the connecter are a pair of buttons that will reset the two CPU’s.



To transfer the new software to the Apex, we use a utility called Flash166. Flash166 was written in the days of MS-DOS, so to run it in Windows requires some special treatment. One can choose to use Windows and the supplied files, or one can use an MS-DOS boot floppy. Both methods will be described here.

If your PC is equipped with a floppy disk drive, this may be the simplest way to upgrade an APEX, as you won’t need to be concerned with running a DOS 16-bit program in Windows.

1. Create a bootable floppy disk 2. Copy these files to the disk

Flash166.exe Flahs166.ini Flash166.ovl ApexDSP.bat ApexMMI.bat DSP.bin (the new Apex DSP software) MMI.bin (the new ApexMMI software)

3. Boot the PC using the boot floppy you just created 4. Using the Apex CPU programming cable, connect the Apex to the

PC. 5. Close the switch that selects the Apex DSP CPU 6. Power up the Apex. There will be little if any indication on the

Apex that a CPU is in the bootstrap mode. 7. At the DOS prompt, enter ApexDSP and press Enter.

The update process will begin and the progress will be shown on the screen. At some point, you will be prompted to press a key to continue, do so and then the new software will be transferred to the Apex. When the transfer is complete, about 2 minutes or so, you’ll be prompted again to press a key, do so until the DOS prompt returns.

8. Close the switch that selects the Apex MMI CPU and open the Apex DSP switch.

UpgradeMethod 1 –

MS-DOS BootFloppy



9. Cycle power to the Apex or press both of the CPU reset buttons 10. At the DOS prompt, enter ApexMMI and press Enter.

This updates the Apex MMI CPU. When prompted to press a key, do so until the DOS prompt returns.

11. Remove the cable from the Apex 12. Cycle power to the Apex and confirm on the splash screen that the

version number is the new one.

The Flash166 utility used to upgrade the Apex CPU was written to run in MS-DOS. As such, it directly accesses the serial port hardware on a PC and Windows doesn’t really like this. We must work around this by running it from within it’s own special DOS window defined in *.pif file. They call the same batch files used in the MS-DOS boot floppy method inside a specially configured command prompt window.

1. Create a directory called Apex on the hard drive on your PC 2. Copy these files into it

Flash166.exe Flash166.ini Flash166.ovl ApexDSP.bat ApexMMI.bat ProgramApexDSP.pif (If copying from Windows Explorer, the

*.pif extension will not be visible.) ProgramApexMMI.pif DSP.bin (the new ApexDSP software) MMI.bin (the new Apex MMI software) SetPriorityControlTo20.reg

3. Using the Apex CPU programming cable, connect the Apex to the PC

4. Close the switch that selects the Apex DSP CPU 5. Power up the Apex. There will be little if any indication on the

Apex that a CPU is in the bootstrap mode.

UpgradeMethod 2 –

Upgrading inWindows



6. From the directory you just created, start the Program ApexDSP

by double clicking it. A command prompt window will open and the update process will begin with the progress being shown on the screen.

At some point, you will be prompted to press a key to continue, do so and then the new software will be transferred to the Apex. When the transfer is complete, about 2 minutes or so, you will be prompted again to press a key, do so until the DOS prompt returns.

7. Now Close the switch that selects the Apex MMI CPU and open the Apex DSP switch.

8. Cycle power to the Apex or press both of the CPU reset buttons. 9. Start ProgramApex MMI by double clicking it.

A command prompt window will open, starting the update to the Apex MMI CPU. When prompted to press a key, do so just like how the Apex DSP CPU was done.

10. Remove the cable from the Apex. 11. Cycle power to the Apex and confirm on the splash screen that the

version number is the new one.

Note 1

The utility Flash166 uses COM1 by default. If you want to use a serial port other than COM1, edit the batch files and add one of these command flags to select the appropriate port to the Flash166 command line: /COM2 or /COM3 or /COM4, it would look like this in ApexDSP.bat:

flash166 /P dsp.bin /BAUD=19200 /COM2

Note 2

If something else in your Windows system is using COM1, or is running that sometimes can use COM1, such as ActiveSync, you’ll get a system error message stating that the com port could not be opened. Either stop the program or use a different com port.



Note 3

The people who created Flash166 also recommend a change to this Windows registry key:

HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet\Control\PriorityControl\

Win32PrioritySeparation

Change the parameter Win32PrioritySeparation to the value 20 (decimal) or 0x14 (hex). This change gives the foreground window a higher priority. This recommendation is from 2002, it may not be necessary on newer, faster PC’s. If the update process starts, but runs into trouble during the transfer with timeouts, you may want to try making this change to the registry.

To simplify the registry change, a file called SetPriorityControlTo20.reg has been created that will import this change into the Windows registry. Double click on this file and the registry will be updated with the above key.

Note 4:

If you are upgrading an Apex100, there are some additional files needed to program the MMI CPU:

• ApexMMI100.bat

• MMI100.bin (the new Apex100 MMI software)

• ProgramApexMMI100.pif (Not needed if using the MS-DOS method)

When updating an Apex100, follow the instructions above for programming the DSP CPU, but when you program the MMI CPU, use the ProgamApexMMI100.pif (Windows) or ApexMMI100.bat (DOS) file instead.



This section outlines some of the things that could go wrong during the software update and how to handle those issues.

The most common problems are encountered when initially starting the update process when the Flash166 utility is establishing communications with the Apex CPU. Most of the time resetting the Apex and retrying the update will work fine.

Often this is a one-time occurrence, so restart the update. If this is a chronic problem, it can have many causes, from a bad cable to Windows not giving Flash166 enough time to run. These are possible solutions:

• Confirm that the programming cable is securely plugged in on both ends.

• Check the cable, make sure the unused pins on the Apex side are not connected, or can make contact with another pin.

• If running in Windows, close any other program that may be running.

• If running in Windows, make the registry change described in Note 3.

Troubleshooting

Update notStarting

Transfers TimingOut

Thermo Fisher Scientific Engineering Drawings 13-1 REC 4258 Rev C

Chapter 13 Engineering Drawings

Control Panel Assembly, APEX B07387M-A003-XX Assembly, Power Supply/I/O, APEX

B07387M-A004 Tuned Search Head Assembly, APEX 500

B07387M-A007 Electronics GP, APEX 500, Integral

B07387M-A009 Electronics GP, APEX 500, Remote

B07387M-A010-XX Remote Cover Assembly, S/H, SS, APEX

B07387M-A012 Electronics GP, DSP3>APEX upgrade, Integral

B07387M-A015 Search Head Assembly, APEX 100

B07387M-A101 PSU to CPU MB Cable Assembly

B07387M-E001 CPU MB to SH Board Cable Assembly

B07387M-E002 Cable Assembly, SH/Remote CPU, APEX

B07387M-E003 APEX Conversion Kit

D07387M-M018 APEX Software Program Update

D07387M-V001 Field Wiring Diagram, APEX

D07387M-W001


13-2 Engineering Drawings Thermo Fisher Scientific REC 4258 Rev C

******


*********

6

8

9

10

2

7

4

15

3

10

DATE:

3

3

B

A

4

C

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PROJECTION

2

CHECKED BY:

SHARP EDGESPART NUMBER:

ENGINEER:

1

DRAWING NUMBERSIZESCALE

DATE:

SHEETREV

A

C

12

D

DATEAPPBYECO DESCRIPTIONREV

REMOVE ALL BURRS & UNNECESSARY

ALL DIMENSIONS ARE IN MILLIMETERS AND [INCHES]TOLERANCE UNLESS SPECIFIED:

authorized by Thermo.

This document is confidential and is the property of Thermo Fisher Scientific ("Thermo"). It may not be copied or reproduced in any manner without the expressed written consent of Thermo. This document also is an unpublished work of Thermo. Thermo intends to and is maintaining the work as confidential information. Thermo also may seek to protect this work as an unpublished copyright. In the event of either inadvertent or deliberate publication, Thermo intends to enforce it's rights to this work under the copyright laws as a published work. Those having access to this work may not copy, use or disclose the information in this work unless expressly

DATE:

DRAWN BY:

5/5/06

CONTROL PANEL ASSY,APEX ____

Derived From: © 2006, by Thermo Fisher Scientific

DMG

D07387M-A003-XX

1 of 2

DG

DMG

1:31054

5/5/06

DGRELEASED TO PRODUCTIONA

SD&P-KW

SEE TAB7/25/06

B

5/5/06

X .8 [.03]X.X .3 [.01]X.XX .13 [.005]ANGLES .5

C 1338 ADDED TAB -03 AND SHEET 2 DG RLK 3/9/07B 1284 TABULATED (ADDED -02 VERSION) DG RLK 12/21/06

4. PLUG ITEMS 3,4, AND 8 INTO ITEM 2. DO NOT TWIST CABLE ON ITEM 4.

3. PLUG ITEM 7 INTO ITEM 4.

COMPLETELY WITHIN RECESSES. KEYPAD TO BE INSTALLED AGAINST MOLDED ALIGNMENT FEATURES.REMOVE ANY DRIED, CLOUDY FILM OVER WINDOW WITHOUT SCRATCHING IT. LABELS TO RESIDE IF NECESSARY, CLEAN WITH ISOPROPYL ALCOHOL AND A LINT FREE CLOTH, BEING CAREFUL TO

2. ENSURE LABEL AND KEYPAD AREAS ON ITEM 1 ARE CLEAN PRIOR TO INSTALLING ITEMS 5, 6, AND 7.

1. ITEMS 2 AND 4 ARE MOUNTED WITH SCREWS AND TAPERED BUSHINGS SUPPLIED WITH ITEM 1.

NOTES:

095297 CONTROL PANEL ASSY,APEX 300 088719 268325 095294 07387M-M003-05

268391 PCBA, CPU, MOTHER BD, APEX3 2 249005 MICROCONTROLLER, PCB4 1 268390 PCBA, LED KEYPAD, APEX5 1 SEE TAB LABEL,CONTROL PANEL,APEX _00 07387M-M004-XX6 1 SEE TAB LABEL,TS/APEX ____,FRONT SEE TAB7 1 267932 KEYPAD, APEX8 1 088362 DISPLAY PCBA, LCD, MET DET, APEX9 4 088596

SCR, MET, MACH, PNH, M2.5 X 8 SST057789810SPACER, BRS, HEX, F-F, M2.5 X 15

PARTS LISTITEM QTY PART NO DESCRIPTION DRAWING #

1 1 SEE TAB COVER ASSY,CTRL PANEL,APEX _00 07387M-A001-XX2 1

TAB CHARTTAB PART NO DESCRIPTION ITEM 1 P/N ITEM 5 P/N ITEM 6 P/N ITEM 6 DWG #-01 089275 CONTROL PANEL ASSY,APEX 500 088719 268325 088589 07387M-M003-01-02 090586 CONTROL PANEL ASSY,APEX 100 090587 091569 090588 07387M-M003-03-03 091813 CONTROL PANEL ASSY,APEX UPGRD 088719 268325 092187 07387M-M031-01-04

D 1423 ADDED TAB -04 DG RLK 4/24/07

-04-01 -02 -03

3

3

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REMOVE ALL BURRS & UNNECESSARYSHARP EDGES

PART NUMBER:

ENGINEER:

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This document is confidential and is the property of Thermo Fisher Scientific ("Thermo"). It may not be copied or reproduced in any manner without the expressed written consent of Thermo. This document also is an unpublished work of Thermo. Thermo intends to and is maintaining the work as confidential information. Thermo also may seek to protect this work as an unpublished copyright. In the event of either inadvertent or deliberate publication, Thermo intends to enforce it's rights to this work under the copyright laws as a published work. Those having access to this work may not copy, use or disclose the information in this work unless expressly authorized by Thermo.

TOLERANCE UNLESS SPECIFIED:ALL DIMENSIONS ARE IN MILLIMETERS AND [INCHES]

CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A003-XX

CONTROL PANEL ASSY,APEX ____

D 2 of 21:3

DMG 5/5/06

B SEE SHEET 1 FOR REVISION INFORMATION

SD&P-KW

DMG

5/5/06

5/5/06

SEE TAB

© 2006, by Thermo Fisher ScientificDerived From:

X .8 [.03]X.X .3 [.01]X.XX .13 [.005]ANGLES .5

45

1

8

27

6

3

3

3

BOM TABLEITEM QTY PART N0 DESCRIPTION DRAWING NO

1 1 268392 PCBA, PSU, APEX N/A2 1 268393 PCBA, RELAY BD, APEX N/A3 24 021007 WASHER, LOCK, INT TOOTH, #4 SST 4 6 183987 SCR, SET, SCH, CUP, M3 X 16 SST N/A5 6 089972 SPACER,BRS,HEX,M-F,M3 X 10 N/A6 12 088595 SPACER, BRS, HEX, M-F, M3 X 18MM LG N/A7 6 050996 WASHER, MET, FLAT, M3, D125A, SST N/A8 6 050977 NUT, MET, HEX, DIN 934, M3 SST N/A

NOTES:1. THIS IS A PHANTOM ASSEMBLY AND CAN ONLY BE ASSEMBLED ONTO THE NEXT ASSEMBLY. IT CANNOT BE PRE-ASSEMBLED AS A SUBASSEMBLY.

DATE:

3

3

B

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CHECKED BY:

SHARP EDGESPART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D


REMOVE ALL BURRS & UNNECESSARY

ALL DIMENSIONS ARE IN MILLIMETERS AND [INCHES]TOLERANCE UNLESS SPECIFIED:

information in this work unless expressly authorized by Thermo.

This document is confidential and is the property of Thermo Electron ("Thermo"). It may not be copied or reproduced in any way without the expressed written consent of Thermo. This document also is an unpublished work of Thermo. Thermo intends to and is maintaining the work as confidential information. Thermo also may seek to protect this work as an unpublished copyright. In the event of either inadvertent or deliberate publication, Thermo intends to enforce it's rights to this work under the copyright laws as a published work. Those having access to this work may not copy, use or disclose the

DATE:

DRAWN BY:

07387M-A004Derived From:

ASSY, POWER SUPPLY/I/O, APEX

A 1 of 11:2

DMG 5/10/06

B

Thermo

1054 DG 7/5/06DGRELEASED TO PRODUCTIONA

ELECTRON CORPORATIONSD&P-KW

DMG

5/10/06

5/10/06

089311

© , by Thermo Electron

X .8 [.03]X.X .3 [.01]

X.XX .13 [.005]ANGLES 0 30'

DETAIL A

3

20 21

CASE CUTOUT EDGE

6

8

0.118ALL AROUND3.00

36.02X 1.42

2X 36.0 1.42



CHECKED BY:

DATE:

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DATEAPP

4

DESCRIPTIONECO BY


DATE:

DRAWN BY:

VARIOUS

7/19/06

TUNED SEARCH HEAD ASSY,APEX 500DMG 7/19/06

Derived From:

C1:5 07387M-A007© 2006, by Thermo Fisher Scientific

1 of 3

DMG

1054 DG

7/19/06

DG

B7/21/06RELEASED TO PRODUCTIONA

DMG

X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

RLK 8/28/06

022007 ADHESIVE,GP,CLR (SUPER GLUE)

2

TO PREVENT FOAM ESCAPE DURING FOAMING, USE ITEM 12 TO SEAL GAPS IN SUPPORT CHANNELS INSIDE

2

4 27 A/R 066345 FOAM,URETHANE,RIGID,TWO-PART

DGB 1178 ADDED 3MM APERTURE POTTING DIM (PREVIOUSLY FLUSH)

WICK SUPER GLUE (ITEM 26) UNDER SHOULDER WASHERS TO SECURE IN PLACE.1. PRESS NYLON SHOULDER WASHERS (ITEM 9) INTO HOLES IN CASE (ITEM 1) WITH SHOULDERS INSIDE CASE.

NOTES:

5.

FILL AIR BUBBLES/VOIDS WITH ITEM 22, BUT NOT AFTER THE FINAL POUR.6. POT 4 SIDES OF APERTURE WITH 2-PART EPOXY (ITEMS 20 AND 21), FILLING 3MM BEYOND CUTOUT EDGES.

6

5

FILL CASE WITH 2-PART EXPANDING FOAM (ITEMS 18 AND 19, NOT SHOWN).

4. USE TWO-PART FOAM (ITEM 27) TO SECURE COIL WIRES IN "TUNNEL" AFTER FINAL APERTURE BALANCING.

ARRANGED DIAGONALLY. LEAVE A 3-5 MM [.12-.20 IN] GAP BETWEEN ADJACENT DAG SHEET PIECES.3. USE 2 WASHERS AND SCREWS (ITEMS 13 AND 14) PER PIECE OF DAG SHEET (ITEM 16), ONE SET PER SIDE,

CASE AND ITEM 23 TO SEAL GAPS BETWEEN FRONT CUTOUT IN CASE AND ALUMINUM PLATE (ITEM 3).2.

PARTS LISTITEM QTY PART NO DESCRIPTION DRAWING NO

1 1 VARIOUS CASE,APEX 500,____MMX___MMX___ 07387M-M011-012 1 N/A COIL WINDING ASSY,APEX 500 07387M-A0063 1 089592 ASSY,BULKHEAD PL/GND STUD,APEX 07387M-A0084 1 089312 ASSY,SEARCH HEAD BD MOUNT,APEX 07387M-A0055 1 079073 PCBA,SEARCH HEAD,DSP36 A/R 072294 BUSHING,NYL,.75OD X.63ID X.0627 2 080225 PLUG,HOLE,NYLON,BLACK .7188 2 088590 LABEL,TS/APX500,SIDE,38X200MM 07387M-M003-029 20 088077 WASHER,SHLDR,.250 X .500OD,NYL

10 8 088322 WASHER,SEAL,#12X5/8OD,NPRN/SST11 8 182250 SCR,MET,CAP,BTNHD, M6 X16 SST12 A/R 089564 ADH,ACRYLIC,2-PART,NO-SAG,50ML13 A/R 088611 WASHER,FLAT,.199ID X.06THK,BRS14 A/R 088891 SCR,MET,CAP,FLH,SKT,M4 X 16 SS15 A/R 078538 BOARD,1/8,EPG16 A/R 086930 RESISTIVE MAT,DAG SHT - LARGE 07339M-M31617 A/R 060832 TAPE,COPPER FOIL,CNDCT ADH,1"18 A/R 074267 FOAM,CASTING(A-100)ISOCYANATE19 A/R 074268 FOAM,CASTING(PF6590-7)RESIN20 A/R 089230 EPOXY,CASTING(A-014BL)RESIN21 A/R 055169 EPOXY,CASTING(B-069)HARDENER22 A/R 023378 EPOXY,ALL PURPOSE,TWO PART,CLR23 A/R 036058 EPOXY,ALL PURPOSE,2-PART,FLEX24 A/R 059452 SEALANT,SILICONE,CLR(732) 3 OZ25 3 168236 NUT,KEPS,HEX, M5 SST26 A/R

C 1330 ADDED ITEMS 25, 26, AND 27, CHANGED NOTES 1 AND 4 DG RLK 1/25/07

1

1011

4

5

8

8

7 24

6 12

7

24

25

17

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A007

TUNED SEARCH HEAD ASSY,APEX 500

C 2 of 31:4

DMG 7/19/06


DMG

DMG

7/19/06

7/19/06

VARIOUS


X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

2

3

13

16

14

1

3

3

15

22

23

9 26

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A007

TUNED SEARCH HEAD ASSY,APEX 500

C 3 of 31:4

DMG 7/19/06


DMG

DMG

7/19/06

7/19/06

VARIOUS


X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

INTERNAL COMPONENTS

ANY UNUSED GLANDS. ITEM 7 IS USED FOR LARGER DIAMETER CABLES.

GROUND STUD WITH ITEMS 12 AND 13.

LABEL,SER/MOD,THERMO ELECTRON

3. CABLE GLANDS (ITEM 5) SUPPLIED WITH NUT. INSTALL PLUG (ITEM 6) IN

BAG UNUSED ITEMS 6 AND 7 AND PLACE INSIDE GLAND FRAME (ITEM 9).

045366214NUT,KEPS,HEX, M5 SST

2. ATTACH GROUND WIRE RING TERMINAL OF SEARCH HEAD PCBA TO

NOTES:

1. POWER SUPPLY ASSEMBLY (ITEM 2) CANNOT BE PREASSEMBLED AS A UNIT. IT MUST BE ASSEMBLED ONTO THE SEARCH HEAD.

5. CONNECT ITEM 4 (NOT SHOWN) TO ITEM 1 AND SEARCH HEAD PCBA.

6. TORQUE ITEM 10 TO 7 Nm [62 IN-LB].

7. TORQUE 8 MOUNTING SCREWS OF ITEM 1 TO 3 Nm [27 IN-LB].

4. CONNECT ITEM 3 (NOT SHOWN) TO ITEMS 1 AND 2.

07103C-H001


1 1 089275 CONTROL PANEL ASSY,APEX 500 07387M-A003-012 1 089311 POWER SUPPLY ASSY,I/O,APEX 07387M-A0043 1 268264 PSU TO CPU M/B CABLE 07387M-E0014 1 268265 CPU M/B TO S/H BOARD CABLE 07387M-E0025 6 088605 GLAND,CBL,.20-.35,M20,SM,NYLON6 5 088607 INSERT,GLAND,CABLE,M20,SM,PLUG7 6 088612 INSERT,GLAND,CA,M20,SM,.26-.478 1 088613 LABEL,CERTIFICATION/SPECS,APEX9 1 088720 GLAND FRAME ASSY,APEX 500 07387M-A002-01

10 12 054115 SCR,MET,CAP,SCH, M6 X 25 SST11 12 054246 WASHER,MET,FLAT,M 6,D 125,SST12 1 051053 WASHER,MET,FLAT,M 5,D 125,SST13 1 168236

B 1330 CHANGED QUANTITY OF ITEMS 12 & 13, PICTORIAL UPDATE DG RLK 1/24/07

REVauthorized by Thermo.


CHECKED BY:

DATE:

3

3

B

A

4

C

DESCRIPTION

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D

DATE

D

ECO BY APP


DATE:

DRAWN BY:

A

7/11/06

ELEX GP,APEX 500,INTEGRALDMG

7/11/06

Derived From:

DG07387M-A009

1:4 1 of 2

089595

B© 2006, by Thermo Fisher Scientific

B

DMG 7/11/06

7/24/061054 DG

DMG

RELEASED TO PRODUCTION

X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

3

6

75 7

2

1

(07387M-A007)

6

2

1

9

11

10

2

1312

SEARCH HEAD

SEARCH HEAD PCBA

8

GROUND STUD

14

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A009

ELEX GP,APEX 500,INTEGRAL

B 2 of 21:4

DMG 7/11/06


DMG

DMG

7/11/06

7/11/06

089595


X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

81420.0 0.79

3.5490.0

0.3910.0

20.0 0.79

12

(07387M-A007)

4

6

14

5

83

7

6

13

21

6

11

15

10

GROUND STUD

SEARCH HEAD

SEARCHHEAD PCBA

1

2

3

5

16

7

CHECKED BY:

DATE:

3

3

B

A

4

C

D

4

B

PROJECTION

ALL DIMENSIONS ARE IN MILLIMETERS AND [INCHES]


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D

DATEAPPBYECO DESCRIPTION

2

TOLERANCE UNLESS SPECIFIED:

authorized by Thermo.REV


DATE:

DRAWN BY:

B

ELEX GP,APEX 500,REMOTE,__M

Derived From:

7/25/06

1 of 2

SEE TAB

07387M-A010-XX1:67/25/061054

7/25/06

B

DMG

DG

DMG

DGA

7/25/06DMG

© 2006, by Thermo Fisher Scientific


X 10 [.4]X.X .5 [.02]X.XX 1.00 [.039]ANGLES .5

07387M-A002-01GLAND FRAME ASSY,APEX 5000887201507387M-A012

5 088605 GLAND,CBL,.20-.35,M20,SM,NYLON11 4 088607

054115127

SCR,MET,CAP,SCH, M6 X 25 SST

4. CONNECT ITEM 9 (NOT SHOWN) TO ITEMS 2 AND 3.

5. CONNECT ITEM 1 TO ITEM 2 AND SEARCH HEAD PCBA.

6. TORQUE ITEM 6 AND 4 MOUNTING SCREWS OF ITEM 4 TO 7 Nm [62 IN-LB].

7. TORQUE 8 MOUNTING SCREWS OF ITEM 2 TO 3 Nm [27 IN-LB].

126

089619ELEX GP,APEX 500,REMOTE,30M089607-30089618ELEX GP,APEX 500,REMOTE,25M INSERT,GLAND,CABLE,M20,SM,PLUG

12 5 088612 INSERT,GLAND,CA,M20,SM,.26-.4713 1 088613 LABEL,CERTIFICATION/SPECS,APEX14 1 051053 WASHER,MET,FLAT,M 5,D 125,SST15 1 168236 NUT,KEPS,HEX, M5 SST16 3 045366 LABEL,SER/MOD,THERMO ELECTRON 07103C-H001

1007387M-E001PSU TO CPU M/B CABLE2682641907387M-M010PLATE,REMOTE CONTROL PNL,APEX08922618

WASHER,MET,FLAT,M 6,D 125,SST054246

NOTES:

1. POWER SUPPLY ASSEMBLY (ITEM 3) CANNOT BE PREASSEMBLED AS A UNIT. IT MUST BE ASSEMBLED ONTO ITEM 8.

2. ATTACH GROUND WIRE RING TERMINAL OF SEARCH HEAD PCBA TO GROUND STUD WITH ITEMS 14 AND 15.

3. CABLE GLANDS (ITEM 10) SUPPLIED WITH NUT. INSTALL PLUG (ITEM 11) IN ANY UNUSED GLANDS. ITEM 12 IS USED FOR LARGER DIAMETER CABLES. BAG UNUSED ITEMS 11 AND 12 AND PLACE INSIDE GLAND FRAME (ITEM 5).


1 1 SEE TAB CABLE ASSY,SH/RMT CPU,APEX,__M 07387M-E003-XX2 1 089275 CONTROL PANEL ASSY,APEX 500 07387M-A003-013 1 089311 POWER SUPPLY ASSY,I/O,APEX 07387M-A0044 1 089977 REMOTE COVER ASSY,S/H,SS,APEX

TAB CHARTTAB PART NO DESCRIPTION ITEM 1 P/N-02 089596 ELEX GP,APEX 500,REMOTE, 2M 089608-03 089597 ELEX GP,APEX 500,REMOTE, 3M 089609-04 089598 ELEX GP,APEX 500,REMOTE, 4M 089610-05 089599 ELEX GP,APEX 500,REMOTE, 5M 089611-06 089600 ELEX GP,APEX 500,REMOTE, 6M 089612-08 089601 ELEX GP,APEX 500,REMOTE, 8M 089613-10 089602 ELEX GP,APEX 500,REMOTE,10M 089614-12 089603 ELEX GP,APEX 500,REMOTE,12M 089615-15 089604 ELEX GP,APEX 500,REMOTE,15M 089616-20 089605 ELEX GP,APEX 500,REMOTE,20M 089617-25 089606

B 1330 PICTORIALLY UPDATED DG RLK 1/26/07

1610.0 .3920.0 .79

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A010-XX

ELEX GP,APEX 500,REMOTE,__M

B 2 of 21:4

DMG 7/25/06


DMG

DMG

7/25/06

7/25/06

SEE TAB


X 10 [.4]X.X .5 [.02]X.XX 1.00 [.039]ANGLES .5

10

8

5

2

6

12

7

9

1 4

1

3

112

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

4

REV

A

C

12

D

DATEAPPBYECO DESCRIPTIONREVauthorized by Thermo.


CHECKED BY:

DATE:

3

3

B

A

SHEET

D

C

4


DATE:

DRAWN BY:

BDG

REMOTE COVER ASSY,S/H,SS,APEX

DG 7/21/06A RELEASED TO PRODUCTION

DMG

1:2

7/21/06

DMG

7/21/06

B

089977

Derived From:

7/21/06

07387M-A012

DMG

1054


1 of 1

X .8 [.03]X.X .3 [.01]X.XX .13 [.005]ANGLES .5

8 066099 SCR,MET,SET,SCH, FP, M6X 50 SS

NOTES:

1.PLACE BY WICKING ADHESIVE (ITEM 8) BETWEEN WASHERS AND COVER.

2.

NUT,MET,HEX,DIN 934, M6 SST

PROTRUDE BEYOND REAR PLATE SURFACE. SECURE IN PLACE WITH NUTS (ITEM 11).

PRESS NYLON SHOULDER WASHERS (ITEM 4) INTO HOLES IN COVER (ITEM 1), SHOULDERS INSIDE. SECURE IN

12050978

INSTALL SET SCREWS (ITEM 12) SO THEY CONTACT AND FIRMLY SUPPORT FRONT OF COVER. SCREWS CANNOT


1 1 089974 COVER,S/H BOARD,REMOTE,SS,APEX 07387M-M0212 1 089274 GASKET,GLAND FRAME,REAR,APEX 07387M-M0163 4 055693 SCR,MET,CAP,HEX, M6 X 70 SST4 8 088077 WASHER,SHLDR,.250 X .500OD,NYL5 4 088322 WASHER,SEAL,#12X5/8OD,NPRN/SST6 2 003302 TERM,RING,16-14AWG #10 INSUL7 2.5 FT 164950 WIRE, CSA #14 300V PVC GREEN/Y8 A/R 066851 ADH,RTNG CMPD,PLSTC/RBR(SI30)9 1 024129 WASHER,LOCK,INT TOOTH, #10 SST

10 1 085064 SCR,MET,CAP,HEX, M5 X 10 SST11 8

B 1256 REDUCED QUANTITY OF ITEMS 3, 4, & 5, ADDED ITEMS 11 & 12 DG RLK 1/8/07

5

10 12

6

2

9

15

87

11

1

1

2

3

4

4

5

14

6

CABLE GLANDS (ITEM 10) SUPPLIED WITH NUT. INSTALL PLUG (ITEM 11, NOT SHOWN) 2.IN ANY UNUSED GLANDS. ITEM 12 (NOT SHOWN) IS USED FOR LARGER DIAMETER CABLES. BAG UNUSED ITEMS 11 AND 12 AND PLACE INSIDE GLAND FRAME (ITEM 6).

CONNECT ITEM 13 CABLE (NOT SHOWN) TO POWER SUPPLY ASSEMBLY (ITEM 5) 3.AND CONTROL PANEL ASSEMBLY (ITEM 15).

CONNECT ITEM 14 CABLE TO CONTROL PANEL ASSEMBLY (ITEM 15).4.

BE ASSEMBLED ONTO BACK PLATE (ITEM 2).

NOTES:

POWER SUPPLY ASSEMBLY (ITEM 5) CANNOT BE PREASSEMBLED AS A UNIT. IT MUST 1.

TORQUE ITEM 8 TO 7 Nm [62 IN-LB].5.

TORQUE 8 MOUNTING SCREWS OF CONTROL PANEL (ITEM 15) TO 3 Nm [27 IN-LB].6.


1 1 091748 LID ASSY,DSP3>APEX UPGR,INTGRL 07387M-A0132 1 089226 PLATE,REMOTE CONTROL PNL,APEX 07387M-M0103 4 050998 WASHER,MET,FLAT,M6,D9021,SST4 4 061386 SCR,MET,CAP,HEX, M6 X 12 SST5 1 089311 POWER SUPPLY ASSY,I/O,APEX 07387M-A0046 1 088720 GLAND FRAME ASSY,APEX 500 07387M-A002-017 12 054246 WASHER,MET,FLAT,M 6,D 125,SST8 12 054115 SCR,MET,CAP,SCH, M6 X 25 SST9 1 092189 LABEL,CERT/SPEC,APEX UPGR,MPLS

10 5 088605 GLAND,CBL,.20-.35,M20,SM,NYLON11 4 088607 INSERT,GLAND,CABLE,M20,SM,PLUG12 5 088612 INSERT,GLAND,CA,M20,SM,.26-.4713 1 268264 PSU TO CPU M/B CABLE 07387M-E00114 1 091663 CABLE ASSY,SH/RMT CPU,APEX,.5M 07387M-E003-.515 1 091813 CONTROL PANEL ASSY,APEX UPGRD 07387M-A003-03

DESCRIPTIONREVauthorized by Thermo.


CHECKED BY:

DATE:

3

3

B

A

4

ECO

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D

C

BY APP DATE


DATE:

DGRELEASED TO PRODUCTION

ELEX GP,DSP3>APEX UPGR,INTEGRL

A

DMG

DMG

2/13/07


2/13/07

091814

Derived From:

07387M-A015

1 of 1A1:4

DMG 2/13/07

B1338 RLK 3/9/07

X .8 [.03]X.X .3 [.01]X.XX .13 [.005]ANGLES .5

DRAWN BY:

066345

FOAM,URETHANE,RIGID,TWO-PART

2.

CONNECT ITEM 9 CABLE (NOT SHOWN) TO CONTROL PANEL (ITEM 3) AND SEARCH HEAD PCBA (ITEM 7).9. CONNECT ITEM 8 CABLE (NOT SHOWN) TO CONTROL PANEL (ITEM 3) AND POWER SUPPLY (ITEM 4).

LARGER DIAMETER CABLES. BAG UNUSED GLAND INSERT GROMMETS AND PLACE INSIDE GLAND FRAME (ITEM 2).8. CABLE GLANDS (ITEM 10) SUPPLIED WITH NUT. INSTALL PLUG (ITEM 11) IN ANY UNUSED GLANDS. ITEM 12 IS USED FOR

SHOWN (ITEMS 23 AND 24).7. ATTACH GROUND WIRE RING TERMINAL OF SEARCH HEAD PCBA (ITEM 7) TO GROUND STUD OF ITEM 6 BETWEEN FASTENERS

6. POWER SUPPLY ASSEMBLY (ITEM 4) CANNOT BE PREASSEMBLED AS A UNIT. IT MUST BE BUILT UP ON THE SEARCH HEAD.

BUBBLES/VOIDS IN NON-FINISH POURS WITH ITEM 25.5. POT 4 SIDES OF APERTURE WITH 2-PART EPOXY (ITEMS 33 AND 34), FILLING 3MM BEYOND CUTOUT EDGES. FILL AIR

4. FILL CASE WITH 2-PART EXPANDING FOAM (ITEMS 31 AND 32, NOT SHOWN).

DIAGONALLY. LEAVE A 3-5 MM [.12-.20 IN] GAP BETWEEN ADJACENT DAG SHEET PIECES.3.

TO PREVENT FOAM ESCAPE DURING FOAMING, USE ITEM 27 TO SEAL GAPS IN SUPPORT CHANNELS INSIDE CASE AND ITEM 26 TO SEAL GAPS BETWEEN FRONT CUTOUT IN CASE AND ALUMINUM PLATE (ITEM 6).

USE 2 WASHERS AND SCREWS (ITEMS 19 AND 20) PER PIECE OF DAG SHEET (ITEM 30), ONE SET PER SIDE, ARRANGED

10. TORQUE GLAND FRAME MOUNTING SCREWS (ITEM 21) TO 7 Nm [62 IN-LB].

A/R37ADHESIVE,GP,CLR (SUPER GLUE)022007

GLUE (ITEM 36) UNDER SHOULDER WASHERS TO SECURE IN PLACE.

NOTES:

PRESS NYLON SHOULDER WASHERS (ITEM 16) INTO HOLES IN CASE (ITEM 1) WITH SHOULDERS INSIDE CASE. WICK SUPER 1.

TORQUE 8 MOUNTING SCREWS OF CONTROL PANEL ASSEMBLY (ITEM 3) TO 3 Nm [27 IN-LB].11.

USE TWO-PART FOAM (ITEM 37, NOT SHOWN) TO SECURE COIL WIRES IN "TUNNEL" AFTER FINAL APERTURE BALANCING.12.


1 1 VARIOUS CASE,APEX 100, ___MMX___MMX___ 07387M-M011-022 1 090585 GLAND FRAME ASSY,APEX 100 07387M-A002-023 1 090586 CONTROL PANEL ASSY,APEX 100 07387M-A003-024 1 089311 POWER SUPPLY ASSY,I/O,APEX 07387M-A0045 1 089312 ASSY,SEARCH HEAD BD MOUNT,APEX 07387M-A0056 1 089592 ASSY,BULKHEAD PL/GND STUD,APEX 07387M-A0087 1 079073 PCBA,SEARCH HEAD,DSP38 1 268264 PSU TO CPU M/B CABLE 07387M-E0019 1 268265 CPU M/B TO S/H BOARD CABLE 07387M-E002

10 6 088605 GLAND,CBL,.20-.35,M20,SM,NYLON11 A/R 088607 INSERT,GLAND,CABLE,M20,SM,PLUG12 6 088612 INSERT,GLAND,CA,M20,SM,.26-.4713 2 045366 LABEL,SER/MOD,THERMO ELECTRON 07103C-H00114 1 090589 LABEL,CERTIFICATION/SPECS,APX115 2 090590 LABEL,TS/APX100,SIDE,38X200MM 07387M-M003-0416 20 088077 WASHER,SHLDR,.250 X .500OD,NYL17 8 088322 WASHER,SEAL,#12X5/8OD,NPRN/SST18 8 182250 SCR,MET,CAP,BTNHD, M6 X16 SST19 A/R 088611 WASHER,FLAT,.199ID X.06THK,BRS20 A/R 088891 SCR,MET,CAP,FLH,SKT,M4 X 16 SS21 12 054115 SCR,MET,CAP,SCH, M6 X 25 SST22 12 054246 WASHER,MET,FLAT,M 6,D 125,SST23 1 051053 WASHER,MET,FLAT,M 5,D 125,SST24 4 168236 NUT,KEPS,HEX, M5 SST25 A/R 023378 EPOXY,ALL PURPOSE,TWO PART,CLR26 A/R 036058 EPOXY,ALL PURPOSE,2-PART,FLEX27 A/R 089564 ADH,ACRYLIC,2-PART,NO-SAG,50ML28 A/R 060832 TAPE,COPPER FOIL,CNDCT ADH,1"29 A/R 078538 BOARD,1/8,EPG30 A/R 086930 RESISTIVE MAT,DAG SHT - LARGE 07339M-M31631 A/R 074267 FOAM,CASTING(A-100)ISOCYANATE32 A/R 074268 FOAM,CASTING(PF6590-7)RESIN33 A/R 089230 EPOXY,CASTING(A-014BL)RESIN34 A/R 055169 EPOXY,CASTING(B-069)HARDENER35 1 N/A COIL WINDING ASSY,APEX 100 07387M-A10036 A/R

B 1330 ADDED ITEM 37, CHANGED QTY ITEMS 23,24, VISUAL UPDATE DG RLK 1/25/07



CHECKED BY:

DATE:

3

3

B

A

4

C

D

REV

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D

DATEAPP

4

DESCRIPTIONECO BY


DATE:

DRAWN BY:

12/21/06

VARIOUSSEARCH HEAD ASSY,APEX 100

12/21/06


RELEASED TO PRODUCTION 07387M-A101

Derived From:

B 1 of 4

12/21/06

1:5

DMG

B12/21/061284

DMG

DG

DMG

RLKA

X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A101

SEARCH HEAD ASSY,APEX 100

B 2 of 41:3

DMG 12/21/06


DMG

DMG

12/21/06

12/21/06

VARIOUS


X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

15

14

13

A

20.0 0.79

1.4236.02X

1.4236.0

0.7920.0

1.1830.0

2X

112.0 4.41

34

DETAIL A

33

CASE CUTOUT EDGE

5

3.00 0.118ALL AROUND

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A101


B 3 of 41:4

DMG 12/21/06


DMG

DMG

12/21/06

12/21/06

VARIOUS


X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

1

1718

15

15

28

13

14

13

2221

23

24

10

11

12

4

5

7

2

3

8

9

6

89

10

11

24

7

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

D




CHECKED BY:

DATE:

DATE:

DRAWN BY:

07387M-A101


B 4 of 41:4

DMG 12/21/06


DMG

DMG

12/21/06

12/21/06

VARIOUS


X 10 [.4]X.X 5.0 [.20]X.XX 1.00 [.039]ANGLES .5

INTERNAL COMPONENTS

35

619

30

20

1

3

3

25

26

29

16 36

100 20[3.950[2.0] MAX.50[2.0] MAX. .8]

350±20 13.8±.8

4

2. ALL WIRES CAN BE SINGLE PLAIN COLOR OR DIFFERENT PLAIN/BI COLORS.

CPU M/B Pins

19

6. INSTALL BRAIDED SHIELD (ITEM 7) OVER WIRES (ITEM 4). SOLDER GROUND WIRE (ITEM 8) TO

1412

4. ALL WIRE CONNECTIONS ARE ONE-TO-ONE ON THE 'D' TYPE CONNECTOR.

D-TYPE SOCKET PIN OUT VIEW26

1 31610

CPU Motherboard J6

5 6

PSU BOARD J5

9

PSU Board to CPU Motherboard wiring connections Diagram

13

24

178

18

PSU Board Pins

5. THE FOLLOWING PINS ARE NOT USED: 3,7,10,25 & 26. HENCE, TOTAL NUMBER OF WIRES IS 21.

3. SHROUDING ON THE 'D' TYPE CONNECTORS IS NOT REQUIRED.

26-WAY D-TYPE SOCKET 26-WAY D-TYPE SOCKET

20

2

Cable Assembly Diagram

FROM WIRE ENTRY SIDE252221

715

OUTSIDE OF BRAIDED SHIELD AND COVER WITH POLYESTER BRAID (ITEM 5).

11

23

NOTES:

1. ALL WIRES TO BE 7/0.2MM (0.22MM²)[24 AWG (7/32 AWG)].

B 1213 ADDED BRAIDED SHIELD & GROUND WIRE DG GJB 9/28/06

O/P 5

Not used4

3

GND

1

2

PIN No. 10

PIN No. 19

PIN No. 1

Vcc

17

4GND

3

17

18

2

GNDGND55

Not used

24V

O/P 321

24

Not used

O/P 625

26

O/P 4

24V

23

22

CTX

16

O/P 120

19

CRX

I/P 1 (EMU)

Not used

1

O/P 2

I/P 413

I/P 3

I/P 215

14

I/P 5

I/P 612

11

8

7V

7V9

10

GND

Not used7

6

Not used

16

O/P 321

24O/P 6

Not used25

26

O/P 4

O/P 523

22

CTX

O/P 1

O/P 220

19

I/P 1 (EMU)

CRX

Not used

18

Not used

I/P 413

I/P 3

I/P 215

14

I/P 5

I/P 612

11

8

7V9

10

7V

Not used

GND7

6

Vcc

PIN No. 26

1 3 4

658 97

C 1338 CHANGED ITEM 4 SUPPLIER REF. TO ROHS COMPLIANT DG GJB 2/6/06

PARTS LISTITEM PART NO. DESCRIPTION SUPPLIER SUPPLIER REF. QTY.

1 214534 26-WAY, HIGH-DENSITY D-TYPE SOCKET FARNELL 151-214 23 214535 SOCKET CRIMPS FOR D-TYPE CONNECTOR FARNELL 151-225 424 235328 7/0.2mm WIRE SINGLE/ANY COLOR (SEE NOTE 2) FARNELL 1172870 13.7m5 268263 10mm POLYESTER EXPANDABLE BRAIDED SLEEVING FARNELL 322-3073 0.26m6 005738 CABLE TIE, 3.88LG (TY-WRAP) PANDUIT PLT-1M 27 090364 BRAID,TINNED COPPER,FLAT,10AWG ALPHA WIRE 1233/2 .8 FT8 068272 WIRE,UL RCGD,#22(7X30)GRN .6 FT9 017083 TERM,RING,22-18AWG #6 INSUL 1

SHEETREV

A

C

12

D

DATEAPPBYECO DESCRIPTION

DATE:



CHECKED BY:

DATE:

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1

REVSCALE SIZE DRAWING NUMBER


DATE:

SD&P-KW

Derived From:

PSU TO CPU MOTHERBOARDDMG

1054

B

CABLE ASSY.

1 of 1

DMG

5/25/06

A 6/01/06DG


5/25/06

DG

268264

5/25/06

07387M-E001RELEASED TO PRODUCTION

C1:3

X 1 [.04]X.X .5 [.02]X.XX .25 [.010]ANGLES .5

DRAWN BY:

19.7±1.2

30[1.2] MAX.30[1.2] MAX.

500±30

7 .3

PARTS LISTITEM DESCRIPTION PART NO. SUPPLIER SUPPLIER REF. QTY.

1 CONN,TERM BLK,12POS,3.81MM,SOC 268262 FARNELL 370-5079 12 CONN,TERM,BLK,12POS,COMBICOM, 080169 FARNELL 370-5523 13 FERRULE,24AWG,BLU INSUL, 8MM L 200540 RS 157-1200 184 7/0.2mm WIRE SINGLE/ANY COLOR (SEE NOTE 2) 235328 FARNELL 1172870 4.6m5 10mm POLYESTER EXPANDABLE BRAIDED SLEEVING 268263 FARNELL 322-3073 0.45m6 CABLE TIES 100 MM 201899 RS 178-462 2

NOTES:

CHANGED ITEM 2 AND CONNECTIONS DIAGRAM

S/H BOARD PINS 12-WAY FEMALE CONNECTOR

SCALE 4:1

3. TERMINATE ALL WIRES WITH 0.25MM² BOOTLACE FERRULES (ITEM 3).

CPU M/B PINS

CPU Motherboard to Search head board wiring connections Diagram

Cable Assembly Diagram

2. ALL WIRES CAN BE SINGLE PLAIN COLOR OR DIFFERENT PLAIN/BI COLORS.

4. ALL WIRE CONNECTIONS ARE ONE-TO-ONE ON THE CONNECTOR SOCKETS.

5. TOTAL NUMBER OF WIRES IS 9.

B

1. ALL WIRES TO BE 7/0.2MM (0.22MM²) [24 AWG (7/32 AWG)].

9/28/061213 DG

SEARCH HEAD BOARD (JP1)

GJB

CPU MOTHERBOARD (J2)12-WAY FEMALE CONNECTOR

C 1338 CHANGED ITEM 4 SUPPLIER REF. TO ROHS COMPLIANT DG GJB 2/6/06

9

Ground 1

24V11

121

SEARCH HEAD BOARD

PIN 1 JP1

6

11Ground 1

CPU MOTHERBOARD

12

(NOT USED) B1

Search head Freq.

ADC

B210

9

ADX7

8

Search head Gain

Oscillator OK/Fault

3Ground 2

ADR

BEM5

4

7

2

24V

Search head Gain2

Oscillator OK/Fault1

BEM

3 Ground 2

ADR4

ADX6

5

Search head Freq.

ADC10

B2

B1 (NOT USED)8

PIN 1 J2

3

12

64 5

ECO DESCRIPTIONREVauthorized by Thermo.


CHECKED BY:

DATE:

3

3

B

A

BY

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


DATE:

SHEETREV

A

C

12

4

APP DATE

D


DATE:

DG

DMGCPU MOTHERBOARD TO SEARCH

A

268265



Derived From:

07387M-E002

HEAD BOARD CABLE ASSY.

C 1 of 11:3

5/25/06

5/25/06

DMG

1054

5/25/06

6/1/06DG

B

SD&P-KW

X 1 [.01]X.X .5 [.02]X.XX .25 [.010]ANGLES .5

DRAWN BY:

2 [6.56]CABLE ASSY,SH/RMT CPU,APEX,3M

MARK ITEM 18 WITH PART NUMBER AND CURRENT DRAWING REVISION.5.

CONDUIT FITTINGS (ITEM 11) SUPPLIED WITH NUT.6.

16.35 [53.64]-20 089617 CABLE ASSY,SH/RMT CPU,APEX,20M

CABLE ASSY,SH/RMT CPU,APEX,30M089619

C

1.85 [6.07]

-15 089616

9BROWN 12PL1-12

20 [65.62] 21.35 [70.05]

4.ON RING TERMINAL (ITEM 6).

PART NO DESCRIPTION ITEM 1 QTY(A) M [FT]

-10 10 [32.81]CABLE ASSY,SH/RMT CPU,APEX,10M089614

.5 [1.64]CABLE ASSY,SH/RMT CPU,APEX,.5M091663-.5-02 089608 CABLE ASSY,SH/RMT CPU,APEX,2M

31.35 [102.85] +24VDCGREEN

DO NOT ATTACH FERRITE BEAD (ITEM 7), CABLE TIES (ITEM 8), OR CONNECTORS (ITEMS 12 AND 13). PLACE THESE ITEMS IN A PLASTIC BAG 3.AND TIE-WRAP TO CABLE ASSEMBLY.

PULL CONDUCTORS OF ITEM 2 THROUGH SIDE OF BRAIDED SHIELD. TWIST BRAIDED SHIELD, COVER WITH HEAT SHRINK (ITEM 4), AND CRIMP

GJBDG

CABLE ASSY,SH/RMT CPU,APEX,15M 15 [49.21]

11.35 [37.24]-12 089615 CABLE ASSY,SH/RMT CPU,APEX,12M

9/28/06

3.35 [10.99]-03 089609

6.35 [20.83]-06 089612 CABLE ASSY,SH/RMT CPU,APEX,6M 6 [19.69] 7.35 [24.11]-08 089613 CABLE ASSY,SH/RMT CPU,APEX,8M

-30

1338 ADDED -.5 TABULATION DG

TAB

TAB CHART

CABLE ASSY,SH/RMT CPU,APEX,4M

B 1213 REDESIGNED

4 [13.12]-05 089611 CABLE ASSY,SH/RMT CPU,APEX,5M 5 [16.40]

5.35 [17.55]

2/15/07GJB

089610-044.35 [14.27]3 [9.84]

M [FT]ITEM 2 QTY (B)

30 [98.43]26.35 [86.45]

NOTES:

STRIP CONDUCTORS OF ITEM 2, CRIMP ON FERRULES (ITEMS 9 AND 10), AND APPLY MARKING LABELS (ITEM 19, NOT SHOWN) TO WIRES 1.NEAR FERRULES (AROUND BOTH WIRES FOR PINS 3 AND 12).

9.35 [30.68]8 [26.25]

-25 089618 CABLE ASSY,SH/RMT CPU,APEX,25M 25 [82.02]

13.35 [43.80]12 [39.37]

2. APPLY MARKING STRIPS (ITEMS 14-17) TO CONNECTORS (ITEMS 12 AND 13). MARK PL1 AND PL2 AS INDICATED.

CONNECTION CHARTPL2 PIN #(ITEM 13)

PL2 WIRE LABEL(ITEM 19)

# OF WIRES

WIRE COLOR(S) SIGNAL FERRULE

ITEM #PL1 WIRE LABEL

(ITEM 19)PL1 PIN #(ITEM 12)

1 PL2-1 1 RED-BLUE OSC. OK/FAULT 10 PL1-1 12 PL2-2 1 PINK S/H GAIN 10 PL1-2 2

3 PL2-3 2 BLACKRED GROUND 9 PL1-3 3

4 PL2-4 1 WHITE ADR 10 PL1-4 45 PL2-5 1 GREY BEM 10 PL1-5 56 PL2-6 1 VIOLET ADX 10 PL1-6 67 PL2-7 1 BLUE S/H FREQUENCY 10 PL1-7 78 - - - - - - 89 PL2-9 1 YELLOW B2 10 PL1-9 9

10 PL2-10 1 PINK-GREY ADC 10 PL1-10 1011 - - - - - - 11

12 PL2-12 2

D 1423 CHANGED ITEM 12 PART # AND PIN #'S, 75.00 WAS 50 MAX DG GJB 6/6/07


1 SEE TAB 088717 CONDUIT,FLEX,LT,20MM N-MET,RF2 SEE TAB 080174 CABLE,SHLD, 12/C,22AWG4 6.5 IN 006089 INSULATOR,HEATSHRINK,.1885 2 IN 006130 INSULATOR,HEATSHRINK,.3756 1 003302 TERM,RING,16-14AWG #10 INSUL7 1 090307 FERRITE BEAD,1.12ODX.542ID8 2 006156 CABLE TIE, 7.38LG (TY-WRAP)9 4 053285 FERRULE,20AWG,WHITE INSUL

10 16 062216 FERRULE,22AWG,TURQ INSUL11 2 088718 FTG,CONDUIT,LT,STR,N-MET,M2012 1 080169 CONN,TERM,BLK,12POS,COMBICOM,13 1 268262 CONN,TERM BLK,12POS,3.81MM,SOC14 .083 CARD 014588 MARKING STRIP,5.0 CONN,# 1-1015 .071 CARD 014589 MARKING STRIP,5.0 CONN,#11-2016 .071 CARD 071221 MARKING STRIP,3.8 CONN,# 1-1017 .071 CARD 071222 MARKING STRIP,3.8 CONN,#11-2018 2 088669 LABEL,WIRE MKR,VINYL,1.00X1.2519 20 701215 LABEL,WIRE MKR,VINYL, .50X1.00

C

12

D

DATEAPPBYECO DESCRIPTIONREVauthorized by Thermo.

TOLERANCE UNLESS SPECIFIED:

A

CHECKED BY:

DATE:

3

3

B

A

4

C

D

4

B

PROJECTION

2


PART NUMBER:

ENGINEER:

1


ALL DIMENSIONS ARE IN MILLIMETERS AND [INCHES]

REV SHEET

DATE:


DATE:

DRAWN BY:

Derived From:

07387M-E003

CABLE ASSY,SEARCH-HEAD/

D

REMOTE CPU,APEX

1:2 1 of 1

GJB 7/6/06

1054

BDG 7/6/06DGRELEASED TO PRODUCTION

DMG

A

GJB

7/6/06

7/6/06

SEE TAB


X 50 [2.0]X.X 25.0 [.98]X.XX 12.50 [.492]ANGLES .5

"PL1"

63

93

16

10

14

4

9

(JP1)

8

(J2)

5

6

5

1 7MARK

-BOARD CPU PCBA SEARCH HEAD PCBA

"PL2"

13 1

REMOTE CONTROL

6

UNIT MOTHER

3

17186

10

11 55

2

24

1

XXXXXX-X

32

XXXXXX-X

18 11 2

MARK

5

4

121110987

13

12

15

1.00025.40

A

2.95375.00

7503.937

100.00

B

29.525.401.000MAX

2.050

50019.7

123456789

101112

How To Upgrade the APEX Software The Apex metal detector uses a pair of microprocessors or CPU's to perform its tasks. One, called the DSP, performs the signal processing of the signals from the head and detects the metal. The other, called the MMI, takes care of the user interface. To program an Apex, one needs a special cable to put the each of the two CPU's into the bootstrap mode so we can upload a new program to it. This is done by connecting to ground one of two pins on the DB9 connector on the back of the CPU-Motherboard. This is done using a special cable with a switch that can select which of the two CPU's is to be programmed. APEX CPU Programming Cable

Leave the other pins on the Apex DB9 connector unconnected. Only one of the two switches that select a CPU to program can be closed at one time. The DB9 connector used to program the Apex CPU’s is located on the motherboard, it is labeled J8 and is located toward the bottom of the front panel, below the power supply connector. To access this connector, the front panel needs to be removed and remain connected to the power supply. Below the connecter are a pair of buttons that will reset the two CPU’s. To transfer the new software to the Apex, we use a utility called Flash166. Flash166 was written in the days of MS-DOS, so to run it in Windows requires some special treatment. One can choose to use Windows and the supplied files, or one can use an MS-DOS boot floppy. Both methods will be described here. Upgrade Method 1 – MS-DOS boot floppy If your PC is equipped with a floppy disk drive, this may be the simplest way to upgrade an APEX, as you won’t need to be concerned with running a DOS 16-bit program in Windows.

1) Create a boot-able floppy disk. 2) Copy these files to the disk

• Flash166.exe • Flash166.ini • Flash166.ovl • ApexDSP.bat • ApexMMI.bat • DSP.bin (the new ApexDSP software) • MMI.bin (the new Apex MMI software)

3) Boot the PC using the boot floppy you just created.

1) Using the Apex CPU programming cable, connect the Apex to the PC. 2) Close the switch that selects the Apex DSP CPU 3) Power up the Apex. There will be little if any indication on the Apex that a CPU is in the

bootstrap mode. 4) At the DOS prompt, enter ApexDSP and press Enter. The update process will begin and

the progress will be shown on the screen. At some point, you will be prompted to press a key to continue, do so and then the new software will be transferred to the Apex. When the transfer is complete, about 2 minutes or so, you’ll be prompted again to press a key, do so until the DOS prompt returns.

5) Now Close the switch that selects the Apex MMI CPU and open the Apex DSP switch. 6) Cycle power to the Apex or press both of the CPU reset buttons. 7) At the DOS prompt, enter ApexMMI and press Enter. This updates the Apex MMI CPU.

When prompted to press a key, do so just like how the Apex DSP CPU was done. 8) Remove the cable from the Apex. 9) Cycle power to the Apex and confirm on the splash screen that the version number is the

new one. Upgrade Method 2 – Upgrading in Windows The Flash166 utility used to upgrade the Apex CPU was written to run in MS-DOS. As such, it directly accesses the serial port hardware on a PC and Windows doesn’t really like this. We must work around this by running it from within it’s own special DOS window defined in *.pif file. They call the same batch files used in the MS-DOS boot floppy method inside a specially configured command prompt window.

1) Create a directory called Apex on a hard drive on your PC. 2) Copy these files into it.

• Flash166.exe • Flash166.ini • Flash166.ovl • ApexDSP.bat • ApexMMI.bat • ProgramApexDSP.pif (If copying from Windows Explorer, the *.pif extension will

not be visible.) • ProgramApexMMI.pif • DSP.bin (the new ApexDSP software) • MMI.bin (the new Apex MMI software)

3) Using the Apex CPU programming cable, connect the Apex to the PC 4) Close the switch that selects the Apex DSP CPU 5) Power up the Apex. There will be little if any indication on the Apex that a CPU is in the

bootstrap mode. 6) From the directory you just created, start the ProgamApexDSP by double clicking it. A

command prompt window will open and the update process will begin with the progress being shown on the screen. At some point, you will be prompted to press a key to continue, do so and then the new software will be transferred to the Apex. When the transfer is complete, about 2 minutes or so, you’ll be prompted again to press a key, do so until the DOS prompt returns.

7) Now Close the switch that selects the Apex MMI CPU and open the Apex DSP switch. 8) Cycle power to the Apex or press both of the CPU reset buttons. 9) Start ProgramApexMMI by double clicking it. A command prompt window will open,

starting the update to the Apex MMI CPU. When prompted to press a key, do so just like how the Apex DSP CPU was done.

10) Remove the cable from the Apex. 11) Cycle power to the Apex and confirm on the splash screen that the version number is the

new one.

NOTE 1: The utility Flash166 uses COM1 by default. If you want to use a serial port other than COM1, edit the batch files and add one of these command flags to select the appropriate port to the Flash166 command line: /COM2 or /COM3 or /COM4, it would look like this in ApexDSP.bat: flash166 /P dsp.bin /BAUD=19200 /COM2 NOTE 2: If something else in your Windows system is using COM1, or is running that sometimes can use COM1, such as ActiveSync, you’ll get a system error message stating that the com port could not be opened. Either stop the program or use a different com port. NOTE 3: The people who created Flash166 also recommend a change to this Windows registry key: HKEY_LOCAL_MACHINE\SYSTEM\CurrentControlSet\Control\PriorityControl\

Win32PrioritySeparation Change the parameter Win32PrioritySeparation to the value 20 (decimal) or 0x14 (hex). This change gives the foreground window a higher priority. This recommendation is from 2002, it may not be necessary on newer, faster PC’s. If the update process starts, but runs into trouble during the transfer with timeouts, you may want to try making this change to the registry. Troubleshooting: Update not starting: The most common problems are encountered when initially starting the update process when the Flash166 utility is establishing communications with the Apex CPU. Most of the time resetting the Apex and retrying the update will work fine. Transfers timing out: Often this is a one-time occurrence, so restart the update. If this is a chronic problem, it can have many causes, from a bad cable to Windows not giving Flash166 enough time to run. These are possible solutions:

• Confirm that the programming cable is securely plugged in on both ends. • Check the cable, make sure the unused pins on the Apex side are not connected, or can

make contact with another pin. • If running in Windows, close any other program that may be running. • If running in Windows, make the registry change described in Note 3.

Apex Metal Detector · Revision History Revision Number Date Released ECO Number Release Specifics...

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Transcript of Apex Metal Detector · Revision History Revision Number Date Released ECO Number Release Specifics...