Manual MSG3200

Instruction Manual MSG 3200

Chapter

0

1 Introduction: Construction and working principle of ELMED metal detectors 2 Items delivered, Transport, handling and storage 2.1 Items delivered 2.2 Transport, handling and storage 3 Fitting the equipment to the conveyor 3.1 Installation location 3.1.1 Weather and temperature 3.1.2 Metal-free zone 3.1.3 Effects of surroundings 3.2 Installation, general notes 4 Electrical connection 4.1 Connecting detector coil to the electronics 4.2 Interfacing with external controls 4.2.1 External clock (X8.1 to X8.4) 4.2.2 Sensitivity override (X8.5 to X8.8) 4.2.3 Remote controlled sensitivity selection (X8.11 to X8.16) 4.2.4 RS-232 interface 4.2.5 Pushbutton reset of metal output 4.2.6 Time-delayed enable of detector 4.3 Relay outputs 4.3.1 Metal present (DPDT, X4.x and X5.x) 4.3.2 Detector ready (SPDT X6.x) 4.4 Mains supply and control cables 4.5 Balancing of the detector 4.5.1 Mechanical adjustments 4.5.2 Checking the auto-balancing circuitry 5 Operating 5.1 Requirements 5.2 Front panel 5.2.1 Operator-Menu 5.2.2 Setup-Menu 6 Faultfinding: checklist of possible causes and remedies 6.1 General 6.2 False alarms for mechanical reasons 6.3 False alarms for electrical reasons 6.3.1 Fault analysis specitic to the control unit MSG 3200 7 Technical data 8 Accessories and spare parts 9 After-Sales Service 10 Guarantee 11 Appendices 11.1 Technical drawings 11.2 Circuit diagrams

2 3 3 3 4 4 4 4 5 6 7 7 8 8 9 9 9 9 9 9 9 9 10 10 10 11 12 12 12 12 17 24 25 25 26 27 28 30 31 32 33 33 33

C:\Dokumente und Einstellungen\af.ELMED\Desktop\Manual_MSG3200.DOC (10.04.12 10:29)

Page 1

Instruction Manual MSG 32001 Introduction: Construction and working principle of ELMED metal detectors

Chapter

1

Purpose ELMED metal detectors of the MSG range serve to detect metallic foreign bodies in any electrically non conductive or slightly conductive material. Benefit This can protect high-value processing machines against damage or destruction. It also protects your finished product against metal contamination, and protects the consumer against adverse health effects due to undesired metal parts. Construction The ELMED metal detector MSG 3200 consists of the detector coil, and signal processing unit which is housed in a separate electronics cabinet. Since the specification of a metal detector equipment can vary widely according to the application, the search coil is designed specifically to the customer's requirement. Working principle The device indicates the presence of metal when the metal disturbs an electromagnetic field generated in the search coil. As a metal part in the material being monitored passes through the coil, it disturbs the "balanced" field (compensated differential circuit). The electronic signal processing unit recognises this disturbance and displays a message. The signal processing unit is the same for any type of detector coil. It consists of five plug-in Eurostandard cards in a rack module, which together with operator controls and terminal strip is mounted in an electronics cabinet with good servicing access (for drawing see appendix) For your benefit Please remember that the metal detector equipment you have purchased is a highly sensitive measuring instrument, even if it perhaps does not look like one! Your justified expectations in terms of reliability and sensitivity will only be met if the equipment is installed and operated in compliance with some basic conditions. Only if these are fulfilled we can guarantee that the equipment will function properly.


Page 2

Instruction Manual MSG 32002 Items delivered, Transport, handling and storage 2.1 Items delivered

Chapter

2

Upon delivery you should receive the following items: Search coil (for drawing see appendix), Control unit (for drawing see appendix), Shielded cable (usually 2 x 10m) for the connection of search coil and control unit, Shock absorbers, either already mounted under the search coil or loose strips that must be placed below the search coil, Operating manual in the appropiate language.

Please check the delivery for completeness !

!

Attention:

The shock absorbing strips are no packaging material and must be placed below the search coil.

!

2.2 Transport, handling and storage Every metal detector leaves our factory in packing which is specially designed for transportation and storage of the unit until it is finally installed. If the metal detector is stored outdoors, suitable protection from the weather is needed. Depending on the type and size of detector coil, the coil may be supplied ready fitted, or dismantled in a separate crate or pallet. The electronics cabinet and all accessories are packed in a rugged corrugated cardboard carton, also on a pallet. Until reaching the location for final installation, the detector coil and the electronics cabinet should be left in this packing.

!

During transport, handling and during installation, no force must be exerted on the plastic panels covering the highly sensitive measurement system.This applies especially when lifting the equipment by fork-lift truck or crane. (For instance, do not travel lift forks into the detector coil opening!)

!


Page 3

Instruction Manual MSG 32003 3.1 Fitting the equipment to the conveyor Installation location

Chapter

3

3.1.1 Weather and temperature Regarding the installation location, the following factors need to be considered to give optimum sensitivity and highest reliability. a) Neither the detector coil nor the electronics cabinet must be installed outdoors unprotected from the weather. If necessary, an enclosed shelter must be built to protect the coil from the weather. Under no circumstances must moisture get into the calibration shaft1, junction box, or under the plastic cover panels. If moisture does enter, the equipment may not work properly. The metal detector equipment and in particular the detector coil should not be exposed to direct sunlight, since this can cause mechanical stresses in the sheet steel housing of the detector coil which could bring it out of electrical adjustment. If the ambient temperature changes by a large amount (> 10oC) within a short time (day/night), the equipment should be left switched on after the end of work or during long breaks, in order to prevent condensation forming in the electronics cabinet. Please ask our service department before installing the electronics cabinet of the metal detector together with other devices in the same cabinet.

b)

c)

d)

3.1.2 Metal-free zone The zone to be kept free of metals around the equipment is calculated as follows:

MFZ = (aperture height x 42) + (depth of search coil)3

In the case of round opening (Type 1), the aperture height is the tube diameter. In the case of under-belt coil (Type 5), use coil depth instead of aperture height. In case of coil Type 5, an additional metal-free zone above the detector coil must be provided. Detector coil Type 5 is used for mounting underneath the conveyor, pointing upwards as detection direction. Not only the space between detector and belt or material must be free of metal, but also the space above belt or material. Please observe for instance, chain conveyors or the like running above the belt! The above rule-of-thumb formula is a suitable basis for all detector coils operated at normal sensitivity. If a roller station is present just outside the metal-free zone, then this, like any roller stations within the metal-free zone, should be manufactured of plastics. If this is not possible, then it should be insulated on one side from the main conveyor frame. Since the metal-free zone has a great influence on the detector coil sensitivity attainable, please be sure to contact our servicing department in case of any questions or doubts.

1 2

Only present at some types. For extra high sensitivity or if aperture heights greater than 1m use factor 6 instead of 4 3 Dimension of search coil in the direction of material travel.C:\Dokumente und Einstellungen\af.ELMED\Desktop\Manual_MSG3200.DOC (10.04.12 10:29)

Page 4

Instruction Manual MSG 32003.1.3 Effects of surroundings

Chapter

3

This term covers all factors having a direct or indirect effect on the electromagnetic field of the detector coil (see Working principle). It is essential to prevent any fairly large metallic parts (machine components, fork-lift trucks etc.) from moving in the neighbourhood of the detector coil. Also no electromagnetic equipment or equipment producing sparks should be allowed in the neighbourhood of the detector. For instance, if control flaps, chutes or reversing belts are used to eject the material containing metal, and these are fitted with thyristor-triac or relay switching devices, then these devices must be fitted with interference suppressors. The same applies to other electrical or electronic controls located in the region near the detector coil. Mains supply interference due to switching of high power machines or motors can also affect the functioning of the metal detector equipment. In this case, the power supply for the detector equipment should be taken from the lighting circuit instead of the power circuit, or a stabiliser must be inserted in the supply line. The cables connecting the detector coil to the electronics cabinet should not be laid beside power cables or control cables to high power machines. If high detector sensitivity is required, the transmit and receive cables should be screened by laying in steel conduit.


Page 5

Instruction Manual MSG 32003.2 Installation, general notes

Chapter

3

Mounting the detector coil Every metal detector equipment is provided with rubber vibration mountings. The number and type vary according to the detector coil type, size, and installed location. The purpose of the rubber vibration mountings is to prevent vibrations of the supporting structure from affecting the detector coil. The detector coil is fixed to the supporting structure by means of the rubber vibration mountings. If resilient rails are used, the detector coil is installed on the rails after these have been adhesivefixed to the supporting structure. It is in principle possible to mount the detector coil directly onto the conveyor belt structure. However, if high sensitivity is required, or if the conveyor belt structure is subject to heavy vibrations, a separate supporting structure for the detector coil is recommended. Installation on a separate foundation has been found to work well. Under these requirements a direct mechanical connection of the detector coil to the conveyor system is allowed. Guidance of the material The conveyor belt (or the like) and the material being conveyed must pass through the detector coil without touching it, under all operating conditions. Depending on the type of detector coil, this is achieved by slide boards and side cladding panels leading through the coil. The minimum clear distance between material (or belt) and the coil must not be less than 5 - 10 mm, depending on the material being conveyed (weight!), under the most unfavourable production conditions. If the material being tested is tree-trunk timber, the minimum distance is 40 mm.

!

The detector coil is clad with plastic panels.No force or pressure whatever must be exerted on these panels by the material being tested or the slide boards.

!

For any type of coil, no material residues or other dirt must be allowed to deposit between the slide boards and the measurement surfaces of the detector coil. Otherwise vibration of the slide boards may be transmitted to the detector coil. Regular cleaning is recommended here. Hardwood or anti static plastics have been found suitable for constructing the metal-free zone and the slide boards. For constructing gutters and chutes in the region near the detector coil, glass fibre reinforced polyester can for instance be used.


Page 6

Instruction Manual MSG 32004 4.1 Electrical connection Connecting detector coil to the electronics

Chapter

4

!

See also attached circuit diagrams in the appendix !

!

First check that your mains voltage supply is the same voltage as that stated on the rating plate in the door of the control unit. Then connect each numbered terminal in the detector coil junction box to the correspondingly numbered terminal in the control unit. The junction box of the detector coil is on one side of the coil. Always use the screened cable supplied with the equipment. Transmit coil: Receive coil: Connect to control unit using 5-core screened cable. Connect to control unit using 5-core screened cable.

The screens are to be connected at one end only to the shielded cable glands on the control unit.


Page 7

Instruction Manual MSG 32004.2 Interfacing with external controls 4.2.1 External clock (X8.1 to X8.4)

Chapter

4

The metal detector requires an external clock, that is synchronised with the movement of the conveyor. The rate should be 1 impulse per millimetre. The signal is connected to contacts CLOCK and GND (see wiring diagrams). The signal should be a square wave with about 50% duty cycle and levels of +12V to +24 for HIGH and 0V to -24V for LOW. Input resistance is about 8,2k. Higher rates can be divided by the integrated prescaler that has to be adjusted accordingly. The prescaler can be adjusted for division factors between 1:1 and 99:1. The LED CLOCK will be on at HIGH on the CLOCK input.

LEDsInterface daughter board (optional)

S1 S2 S33 2 1 1 2 3 4 5 6 7 8 9 10

S4 Sensor

Figure 1: Controls for the prescaler


78

901

23

78

901

23

x10 Prescaler x1

456 456

Page 8

Instruction Manual MSG 32004.2.2 Sensitivity override (X8.5 to X8.8)

Chapter

4

The sensitivity override input can be used to reduce the sensitivity of the detector temporarily. For example the signal can be generated by a diffuse-reflection sensor. If the control voltage (12V to 24V) is present, Product #0 will be selected, regardless of the remote controlled sensitivity selection (see below), but only if external product selection is selected from the product menu. 4.2.3 Remote controlled sensitivity selection (X8.11 to X8.16) These inputs can be activated from an PLC to select different product settings according to the table. External control must be enabled from the product menu. The signal level is 12V to 24V. Input S1 S2 S3 S4 Product 1 2 4 8

If none of the inputs is activated, product #0 will be selected. If more than one input is activated, the effective product corresponds to the sum of the individual products. For example, by activating inputs S1 and S3 product #5 will be selected. 4.2.4 RS-232 interface If the optional interface daughter-board is installed, signals from the metal detector can be recorded on the harddisk of an external PC. Please contact service dept. for further information 4.2.5 Pushbutton reset of metal output see 4.3.1 Metal output 4.2.6 Time-delayed enable of detector False alarms that are caused by vibrations when starting the conveyor can be suppressed if the metal detector is enabled a short time after starting the conveyor. This function can only be activated by service technicians. If the function is activated, the control voltage of the conveyor must be connected to terminals X2.3 and X2.2. 4.3 Relay outputs All contacts are floating with a contact rating of 250V AC/5 A max. 4.3.1 Metal present (DPDT, X4.x and X5.x) These contacts switch upon detection of metal. The distance between search coil an reject position can be adjusted over a wide range (see Setup Menu, 5.2.2.3). Depending on the configuration, the contacts will stay switched until reset by an external pushbutton switch or will switch back automatically after some travel of the conveyor belt. The contacts will be activated longer (in terms of conveyor travel) for big parts and shorter for small parts. Using the setup menus a time delay can be added to the reject interval (see Setup Menus, 5.2.2.3). 4.3.2 Detector ready (SPDT X6.x) This contact will be activated immediately after self-calibration is completed and the metal detector is ready for operation.


Page 9

Instruction Manual MSG 32004.4 Mains supply and control cables

Chapter

4

The mains power supply for the electronics should be taken through a separate cable or from the mains lighting circuit, in order to avoid interference spikes from switching of large machines, motors etc. The stabilised power supply compensates for voltage fluctuations of +/- 10 %. If there is a risk of larger fluctuations than this in the supply voltage, then a voltage stabiliser should be provided.

4.5 Balancing of the detector The working principle of the detector is based on the detection of extremely small changes of the electromagnetic field in the search coil. Large metal objects in the neighbourhood of the detector or extreme temperatures can cause permanent changes of the electromagnetic field. The auto-balancing circuitry will automatically adjust the electromagnetic field to a neutral state under normal operation conditions. When the metal detector is operated for the first time, the state of the auto-balancing circuitry should be checked (see 4.5.2) 4.5.1 Mechanical adjustments (applies only to Type 3 search coils)


Page 10

Instruction Manual MSG 32004.5.2 Checking the auto-balancing circuitry Select [Compens] from the Setup Menu. The display should look like:

Chapter

4

After completion of the auto-balancing process the values for ADC2 and ADC3 show the remaining error of then detectors balance und must not exceed 0,2 V. During normal operation, the values may increase to 1V. If the values for ADC2 or ADC3 exceed the limit of 1V for more than 30 seconds, the auto-balancing will start again. During the balancing operation both the output detector ready and the ready indicator on the front panel will be inactive. The values for DAC0 and DAC1 correspond to the amount of voltage that is necessary to achieve the balanced state of the detector. The range is from -3 V to +3 V. Reliable operation will be possible if the the values for DAC0 and DAC1 lie between -2 V to +2 V. Otherwise the saftey margin for changes in the balance during normal operation will become to small. If the values for DAC0 and DAC1 lie above +2 V or below -2 V, the detector coil has to be compensated mechanically. Under normal working conditions this is very unlikely to become neccesary. Otherwise, please contact factory for instructions.

Attention ! Automatic balancing will start immediately after switching on the metal detector. Further balancing will start only after an delay time of 30 seconds to avoid unwanted reactions to large metal objects. This should be kept in mind during mechanical compensation (for detector coils Type 3 only). By pressing the [Start] button, the balancing can be started at any time.


Page 11

Instruction Manual MSG 32005 Operating 5.1 Requirements

Chapter

5

Before the metal detector is operated for the first time the following requirements have to been met: Transmitter and receiver of the detector coil must be connected to the control unit. (See also chapter 4, electrical connections). Connections with external controls must be completely wired (external clock, outputs, etc.). The mains voltage must be connected and present. 5.2 Front panel All control functions of the detector are menu driven. Five menu buttons, located beneath the display on the front panel of the control unit, provide access to the menu selections. Depending on the operating mode, the appropriate menu appears on the right-hand side of the display and can be easily associated with the buttons. This section contains brief descriptions of all menus.

5.2.1 Operator-Menu Functions described in this chapter are accessible without entering the security code. Function of menu button Displays the waveform of the metal signal. Combined numeric and bar-graph display of metal signal, trigger level, detection counter and selected product. Selection of the product parameters.

Displays the logbook with time, date and waveform of the last 128 metal detections. Access to setup menu (security code required).


Page 12

Instruction Manual MSG 32005.2.1.1 On-line Display

Chapter

5

The metal signal is displayed as waveform, similarly to the display of an oscilloscope. The amplitude roughly corresponds to size of the part, the X-axis corresponds to conveyor travel. The display is well suited to analyze the signal caused by metal parts and disturbances from the surrounding of the detector. Function of menu button

Back to the OPERATOR MENU (F5 is the lowest of the menu buttons)

5.2.1.2 Level This display contains the following items: The level of the metal signal is both shown as numeric value (at Peak Level) and as bar-graph (on the left side of the display). Trigger level (at Trig. Level). Number of detections since power-on (at Counter). The current speed of the conveyor (at Speed). Product chosen (at Product). Metal will be detected, if Peak Level exceeds Trig. Level. The Counter counts these detections. The value shown at Trig. Level depends on the chosen Product. Pressing [F5] returns to the OPERATOR MENU.


Page 13

Instruction Manual MSG 32005.2.1.3 Product This menu is used to select one out of 16 possible product and sensitivity settings. Function of menu button

Chapter

5

X-Y-Display

Save settings and return to OPERATOR MENU.

Cancels changes and returns to OPERATOR MENU

For a detailed description see 5.2.2.2


Page 14

Instruction Manual MSG 32005.2.1.4 Logbook The logbook contains time, date an waveform of the last 128 metal detections.. After selecting the detection, the waveforms the led to the metal detection can be viewed: Function of menu button Moves marker up by one position

Chapter

5

Moves marker down by one position

Advances to the next page

Displays the waveform

Return to OPERATOR MENU

After pressing [View] the display shows the waveform: Function of menu button Toggles between ferrous and non-ferrous (VA) channel. Toggles resolution between 1V and 3V full scale.

Return to OPERATOR MENU

The metal detector uses separe channels for ferrous and non-ferrous (VA) metals. Button [F1] is used to selected one of the channels. The currently selected channel is underlined in the display. The resolution of the display can be increased, which is especially usefull for small signals. Pressing [F2] switches between +/- 1V and +/- 3V full scale an vice versa. The active resolution is underlined in the display.


Page 15

Instruction Manual MSG 32005.2.1.5 Setup

Chapter

5

The second set of menus is only accessible after entering the security code. This allows for further adjustments that are not required during normal operation. The setup menu can only be entered after entering the correct security code. Function of menu button Enters 1.

Enters 2.

Enters 3.

Enters 4.

Back to OPERATOR MENU.


Page 16

Instruction Manual MSG 32005.2.2 Setup-Menu

Chapter

5

The functions of the SETUP MENU are used to adapt the detector to individual working conditions. Function of menu button Adjustment of the real-time-clock

Adjustments for metal detection and product compensation Selection of the current product (see also OPERATOR MENU) Adjustment of the software-prescaler for external clock and timing of output signals Returns to the OPERATOR MENU

5.2.2.1 Set Time Adjustment of the integrated real-time-clock. The marker (>) selects the field to be modified. Function of menu button Increase value by 1

Decrease value by 1

Advance marker to the next field to be changed.

Set new date and time. Seconds will be reset to 00 Cancels changes and returns to SETUP MENU


Page 17

Instruction Manual MSG 32005.2.2.2 Metal detection and product compensation The metal detector can be adapted to the working conditions under two aspects metal detection sensitivity product compensation

Chapter

5

The first menu is used to select one of 16 different product (and sensitivity) settings and to inspect the corresponding parameters. The display shows both product ID (Product#) and detection parameters. Product# Metal level Product level Product angle Product ID (int=internal control / ext=external control). Trigger level for metal detection Trigger level at product phase angle Phase angle of the signal caused by the product Function of menu button Selects sequentially one of the 16 product settings (0..15) or external control. Activates the Teach-Mode (see below) (available only during internal control) X-Y - Diplay of the metal signal

Activates the parameter editor. (available only during internal control) Leaves the product menu.

The [+]-button sequentially selects product #0 to 15 and external control. External control is indicated by ext behind the product number, otherwise int will be shown. External control can be used to switch between different product settings under control of an external PLC.


Page 18

Instruction Manual MSG 32005.2.2.2.1 X-Y-Display

Chapter

5

During X-Y-display both channels (ferrous and non-ferrous) are show in an two-dimensional coordinate system. Phase (or angle) caused by different products and metals will cause the dots on the display to move into different directions. Function of menu button Clears the display

Leaves X-Y-display

The circle around the center of the display corresponds to the current trigger level. During operation, every sample from metal signal is shown as a small dot. Dots outside of the circle cause metal alarm.. Using appropriate parameters for metal sensitivity and product compensation, dots caused by the product should always stay within the circle along the horizontal axis. The direction of dots caused by metal depends from the kind of metal and the setting of the product angle.

5.2.2.2.2 Parameter Editor Using the parameter editor the product settings can be adjusted according to the operation conditions. The X-Y-display allows quick verification of the results. Function of menu button Increases current parameter

Decreases current parameter

Selects current parameter

Save settings and leave menu

Discard changes and leave menu.


Page 19

Instruction Manual MSG 3200The following example is used to illustrate the meaning of the parameters:

Chapter

5

Metall 30

Figure 1 shows an idealized example for the signals cause by metal that should be detected and product that should be Produkt suppressed: The product causes a signal of about 2V at an angle of 30 The metal causes a signal with an amplitude . of only 1V at an angle of about 120 The product effect can . be compensated by putting a detection envelope around the signal that has the shape of an rotated ellipse. The long radius of the ellipse corresponds to the product level, the short radius to the metal level, the rotation of the ellipse to the product phase.

Fig 1

Products with similar phase will be suppressed equally well because of the smooth shape of the detection envelope.

Metall

For the example illustrated above, the X-Y-display looks like shown in figure 2: The phase of both signal has been rotated 30 counterclockwise in order to align the product effect with the horizontal axis (parameter: product phase).

Produkt Furthermore, only the horizontal axis has been scaled (parameter:product level) to reduce the product effect, avoiding metal alarms caused by the product. Because the scale of the vertical axis (metal level) has not been changed, the metal signal still can trigger the metal alarm. Figure 2

Metall

30

Figure 3 illustrates the need to verify the effect of the parameters using the X-Y-display: Because the phase differProdukt ence between metal signal and product effect is less than 90 the metal signal stays within the detection envelope. , Metal signals that exceed the trigger level only by a small aount wont trigger the metal alarm. As an consequence the settings always should be verified using sample parts.

Figure 3


Page 20

Instruction Manual MSG 32005.2.2.2.3 Teach-Mode

Chapter

5

Main element of the teach mode is an integrated wizard that leads you through the steps that are neccessary to adjust the detector to your need. First, an metal sample has to pass the detector. The wizard records the signal an calculates suitable parameters for metal detection. Second, product sample have to be passed through the detector. Again the wizard records the signal an calculates suitable parameters for product compensation. Step 1: In step 1 the operator is asked to feed the metallic sample through the search coil. The steps have to be performed in the following order: Press the [Start] button. Feed the sample through the detector. Function of menu button

Start the measurement of the amplitude caused by the metallic sample. Abort and return to the SETUP MENU.


Page 21

Instruction Manual MSG 3200Step 2:

Chapter

5

During step 2 the amplitude caused by the metallic part is displayed. The process should be repeated some times to ensure, that the measurement is reproducible. The last measurement taken is kept and displayed until the [Reset] button is pressed or a higher amplitude is measured. Function of menu button

Reset measurement.

Use current measurement and advance to product compensation. Aborts and return to the SETUP MENU

Step 3: During step 3 the operator is asked to pass a sample of the product that should be compensated through the search coil. Press the [Start] button. Feed the sample through the detector. Function of menu button

Starts the measurement

Aborts and return to the SETUP MENU


Page 22

Instruction Manual MSG 3200Step 4:

Chapter

5

Similar to step 2, during step 4 the amplitude caused by the product sample is displayed. Again, the process should be repeated some times to ensure that the measurement is reproducible. The last measurement taken is kept and displayed until the [Reset] button is pressed or a higher amplitude is measured. Function of menu button

Reset measurement.

Use current measurement and advance to final menu. Aborts and return to the SETUP MENU

After completing the teach-mode the parameters will be displayed. Then, using the X-Y-display, it should be verified that the desired detection sensitivity for metal detection is achieved the product effect does not cause metal alarms. If neccessary, the parameters can be changed using the parameter editor.

5.2.2.3 Compensation This menu is used to check the condition of the auto-balancing circuit. The display shows the following items: ADC2 and ADC3: Deviation from optimum balanced state. Must be between -1 V and +1 V. DAC0 and DAC1: Actual value of the compensating voltage. Should stay between -2 V and +2 V, operation is possible as long as value is between -2,9 V and +2,9 V. For the unlikely case, that the values for DAC0 and DAC1 exceed +/-2,5 Volt, mechanical recalibration of the coil is necessary. Please contact factory for details. If automatic balancing should become impossible, the green indicator [Ready] on the front panel and the Ready-Output will be deactivated. The lowest button [F5] returns to the OPERATOR MENU.


Page 23

Instruction Manual MSG 32005.2.2.4 Clock ratio, Output Delay and On-Time Function of menu button Increase value by 1

Chapter

6

Decrease value by 1

Advance marker (>) to the next field to be changed. Permanently stores the parameters that have been modified. Aborts changes and returns to the SETUP MENU

Speed If no external clock is present, the metal detector will work at this default value. Clocks/cm The detector requires an external clock that is synchronized with the movement of the conveyor. The nominal value is 10 clocks per centimeter. The actual rate can be adjusted with the setting of Clocks/cm. Attention: Care should be taken not to mix up the different settings used to adapt the clock source: The prescaler located on the interface board divides the incoming clock down to 10 impulses per centimeter. The Clocks/cm setting is used by the Digital Signal Processor to divide the signal from the prescaler further down to 1 impulse per centimeter. Output Delay The signal that is given upon detection of metal can be delayed if required. The sophisticated signal processing software always evaluates the signals recorded over about 1,28 cm of travel of the conveyor. This results in a delayed output signal that will become active about 64 cm after the object has passed the center of the search coil. As a consequence, the minimum value for Output Delay is 65 cm. The Output Delay can be adjusted to any practical value, therefore in many applications an additional PLC used for controlling the reject device can be saved. On Time The duration of the output signal (corresponding to conveyor travel), depends on the size of the detected object. The duration can be extended by the setting On Time. Joint Delay The travel of the forming belt by which the deactivation of the sensitivity override will be delayed. Used to avoid false switching due to small defects in the marking on the forming belt that controls the diffuse reflection sensor. 6 Faultfinding: checklist of possible causes and remedies The following checklist is to help you find and remedy simple faults yourself. And in case of more difficult faults, this is a helpful preparation before discussion with our service engineers. If you have the answers to the items on this checklist, then most types of fault can easily be remedied. (The desirable condition, yes or no, is underlined.)C:\Dokumente und Einstellungen\af.ELMED\Desktop\Manual_MSG3200.DOC (10.04.12 10:29)

Page 24


Chapter

6

6.1 General YES Has anything changed recently in respect of system requirements or production conditions? If false-alarm signals are occurring, when do they occur? YES when the belt starts up or stops when the belt is being loaded when the chopper is overloaded dependent on temperature sporadically 6.2 False alarms for mechanical reasons In general: Vibrations or impact loads transmitted to the detector coil from its surroundings reduce the maximum sensitivity attainable and increase the probability of false alarms. YES Is the detector coil mounted on a separate support structure? The support structure must not have any connection to the conveyor structure. Is the detector coil mounted on the rubber vibration mounts supplied? Are all screws tightly tightened (especially for Type 3 coil)? Are the slide boards coming into contact with the detector coil, so that vibration is being transmitted to the coil? Have any dirt or material residues (chips etc.) deposited between the detector coil and the slide board? It is absolutely essential for the detector coil to be completely free-standing, with no contact to any part of the conveyor structure at any point (minimum distance 10 mm). NO NO NO


Page 25

Instruction Manual MSG 3200Does the conveyor belt itself contain any metallic impurities? Please check whether the detection signal is always given at the same point of the belt. Note: the impurity may be very small, and may be on or underneath the belt

Chapter

6

YES Are there any iron or steel parts near the detector coil which can move? e.g. handrails, metal grid platform, catwalk over the belt Remedy in this case: Handrails: Make handrails of wood or plastic near the detector.

NO

Metal grids on catwalk: Either weld them to the iron joist structure, or underlay with electrically insulating material (rubber, wood, PVC etc.) so that when there is a load on the surface (e.g. by walking) no contact is made with the supporting structure. Catwalk over the conveyor belt: Install as far away from the detector coil as possible. Insulate from the structure by laying electrically insulating material at the load bearing points supporting the catwalk, see preceding paragraph. If the detector is set for high sensitivity, also large moving metal objects such as a crane or fork-lift truck moving past may cause false alarms. 6.3 False alarms for electrical reasons If faults occur, please first read again Section 4.0 Electrical connections. YES Is your mains power supply subject to faults, interference or fluctuating voltage ? Is the control unit of the detector exposed to vibration? Has the customer altered any of the factory settings on the circuit boards? Is the mains supply voltage constant? After connecting the correct mains supply as per rating plate, please check the following points. Are the two LED's on the junction box on the detector coil both alight ? If only one or neither of the LED's is alight: a) b) Check the cable connection between detector coil and electronics cabinet (cables maybe confused) Check that all the circuit boards are firmly seated in their sockets. YES Have any other large machines started operation recently which might cause interference with the metal detector equipment? How near is the control unit of the metal detector equipment to other electrical cabinets?C:\Dokumente und Einstellungen\af.ELMED\Desktop\Manual_MSG3200.DOC (10.04.12 10:29)

NO

NO

________ m Page 26


Chapter

6

YES Is any electric-arc welding being performed near the detector equipment? Are radiotelephone (walkie-talkie radio) sets in use in your factory? , The following questions and answers can also be relevant for diagnosing faults: YES Is the sensitivity adequate? For what sensitivity requirement was the metal detector equipment originally designed ? and for what belt speed?

NO

NO

Nut Ball

M________________ mm ________ mm/s

6.3.1 Fault analysis specitic to the control unit MSG 3200 YES Are all LED's on the 5th circuit board from the left alight? If some or all of these LED's are not alight, check: that all circuit boards are firmly seated in their sockets, the fuses on the main board (3 fuses with transparent cover near the mains terminals, 1 fuse above the transformer). YES Is the red LED on the 4th circuit board from the left alight? The red LED on this board normally lights less brightly than the others. The brightness depends on the transmit power level set in our factory. If the LED does not light at all, please check all circuit boards firmly seated in their sockets cable connection between detector coil and electronics cabinet (cables maybe confused?). YES When an iron part passes through the detector coil, does the red LED on the 2nd board from the left briefly light? If the system does not detect the part (red LED does not light briefly), then this may be for the following reasons: Problem iron part is too small the metal detector operates for the wrong speed. Solution increase the sensitivity, or use a larger part check the speed reading (see Level Display, 5.2.1.2) and the hardware and sofware prescaler settings (see External Clock, 4.2.1, and Timing Setup, 5.2.2.4) NO NO NO


Page 27

Instruction Manual MSG 32007 Technical data

Chapter

7

Electronic enclosure

Combination of extruded aluminium profile with board guides and in cast aluminium connection compartment. Mounting brackets for wall mouting. resin stove-enamelled finish light-grey (RAL 7035)/ stone-grey (RAL 7030), W X H X D (306 x 241 x 262 ) mm 20 kg approx. IP - 65 5 plug-in boards for easy service.

Surface protection Colour Dimensions Weight complete Protection classification PC boards (From left to right) 1. 2. 3. 4. 5. Mains supply voltage

input amplifier DSP (Digital Signal Processor) Interface board transmit section stabilised power supply unit 230 V / 50 Hz, alternatives on request The stabilised power supply compensates voltage fluctuations up to +/- 10 %. A stable voltage supply is essential for proper functioning of the metal detector equipment. Transient voltage fluctuations exceeding these limits caused for instance by switching high power machines on or off can impair reliability and cause false alarms. For this reason, the electronics should be fed through separate cables or fed from the electric lighting circuit. If this is not possible, a voltage stabiliser with interference filter should be connected in the power supply line, see Sec. 3.1.3 Effect of surroundings.

Power taken Measurement frequency

50 VA approx.16.384 kHz quartz stabilised (standard) If several metal detectors are installed near to each other, including existing detectors, then different frequencies should be used. Please tell us!

Connecting the detector coil The junction boxes for connecting the transmit and receive sections are located on the narrow side of the coil. They must remain accessible for servicing after installation. Transmit coil: Receive coil: 5-core screened cable 0,5 mm 5-core screened cable 0,5 mm


Page 28


Chapter

7

Operator controls Mains switch Control switch Position OFF Detector switched off, Output "Metal present": always active Output "Detector Ready": always inactive Normal operation, Output "Metal present": active on metal detection Output "Detector Ready": active if detector working Standby operation, Output "Metal present": always inactive Output "Detector Ready": always active 2-pole, switch-off

Position

ON

Position

TEST

Indicators Illuminated LC-Display Pilot lights showing functions Power Ready Metal yellow LED green LED red LED Detector switched on Detector ready Metal detected Graphic display for menu control and information display

"Metal detected" Outputs Contact Rating 250 VAC / 5 Amps 250 VAC / 5 Amps No Metal X4.2 X5.2 X4.3 X5.3 Metal detected X4.2 X5.2 X4.1 X5.1

"Detector ready" Outputs Contact Rating 250 VAC / 5 Amps detector ready X6.2 X6.3 detector not ready X6.2 X6.1


Page 29


Chapter

8

Contact assignments for interface signals Direction Input (optional) Input (optional) Input (optional) Output Input Output Output Output Input Output Output (optional) (optional) Output Input Input Input Input Output Output Output Input Input / Output 8 Accessories and spare parts Accessories signal hooter signal lamp reset push-button screened oil-flex cable 5 x 0,50, solderable screen 10 no. fine fuses 5 x 20 - 4 A slow-blow 10 no. fine fuses 5 x 20 - 2 A slow-blow 10 no. fine fuses 5 x 20 - 0,4 A slow-blow 2 no. relays RP 42012 power supply unit transmitter input amplifier switching stage Auto check module circuit board adapter 3 no. lamp holders, green, yellow, red with cap 1 no. incandescent bulb, external control 1 no. mains switch 1 no. reset push-button (internal) 1 no. potentiometer 1 no. moving-coil meter 100 A 1 no. door lock Terminal X2.1 X2.2 X2.3 X8.1 X8.2 X8.3 X8.4 X8.5 X8.6 X8.7 X8.8 X8.9 X8.10 X8.11 X8.12 X8.13 X8.14 X8.15 X8.16 X8.17 X8.18 X8.19 X8.20 Function ext. Control voltage (Mains) : Output Reset 0 V : Common Terminal ext. Control voltage (Mains) : Startup Delay Auxiliary supply 15 VClock from conveyor 0 V- (Ground) PE (Shield) Auxiliary supply 15 VInput for optional diffuse-reflection sensor 0 V- (Masse) PE (Shield) Reserve 1 (not used) Reserve 2 (not used) Auxiliary supply 15 VSensitivity control from PLC (Range 1) Sensitivity control from PLC (Range 2) Sensitivity control from PLC (Range 3) Sensitivity control from PLC (Range 4) 0 V- (Masse) PE (Shield) RS-232 Interface (TX) RS-232 Interface (RX) RS-232 Interface (Masse)

Spare parts Set No. I

Spare parts Set No. II 1 set of modules comprising:

Spare parts Set No. III


Page 30

Instruction Manual MSG 32009 After-Sales Service

Chapter

8

Should you have any further questions on commissioning or malfunctions during operation which cannot be remedied following the enclosed "Troubleshooting Guide" (see chapter 6. "Faultfinding: checklist of possible causes and remedies"), please contact our after-sales service department. When making technical enquiries, please quote the serial number of the unit. This information can be found on the rating plate on the inside of the control cabinet and alongside the terminal boxes on the detection coil.

Example of a rating plate:

ELMED GmbH42579 Heiligenhaus Weilenburgstrae 39 Tel.: 02056-2891 Fax: 02056-3467 Typ : MSG Nr. : xxxx 230V/50Hz

2000

Address: ELMED Dr.Ing.Mense GMBH Weilenburgstrae 39 42579 Heiligenhaus Postfach 100211/16 Tel. : (00) 49 2056/2891-92-93 Fax : (00) 49 2056/3467


Page 31

Instruction Manual MSG 320010 Guarantee

Chapter

10

Provided that the installation and operating instructions above have been observed, the following terms of guarantee apply: I. Duration and Start of the Guarantee Period 1.) A guarantee is given for the following period: a) 12 months from the date of commissioning b) but not more than 18 months after the date of the invoice The supply of spare parts or repairs for reasons covered by the guarantee do not constitute a general extension to the original guarantee period. We guarantee the parts replaced under the guarantee for a period of 6 months. II. Preconditions for the Guarantee Messrs ELMED GmbH offer a guarantee for such coils which demonstrably satisfy the following preconditions: 1.) Installation has been performed in accordance with the appropriate guidelines (VDE, DIN) 2.) All commissioning instructions contained in the operating manual have been correctly carried out. In the event of a fault being discovered, the claim for service under guarantee must be made in writing immediately, as otherwise the right to service under guarantee shall be void.

III. Content and Scope 1.) Faults occurring within the guarantee period will be remedied by Messrs ELMED GmbH either by repair or by replacement of the parts concerned. All replaced parts shall become the property of Messrs ELMED GmbH. 2.) In the event of irreparable major faults, Messrs. ELMED GmbH shall have the right to meet the claim for cancellation of the contract by a replacement of the goods free of charge. 3.) For equipment in operation outside Germany, the service under guarantee shall be limited to the supply, free of charge, of spare parts necessary to remedy the fault to the German border. 4.) Further or other claims, in particular claims for damages, shall not be accepted unless they are legally prescribed. IV. Limitations Faults or defects attributable to: a.) Faulty installation, e.g. failure to observe applicable regulations or written commissioning instructions b.) incorrect operation or loading c.) normal wear, d.) other effects, e.g. transport damage, damage due to the effects of the weather, incorrect or inappropriate storage, other natural phenomena, e.) Repairs and modifications performed without the express approval of Messrs. ELMED GmbH, are not covered by the guarantee.

V. Miscellaneous 1.) Venue for all liabilities arising from the obligations under guarantee shall be Heiligenhaus. 2.) If individual clauses of this guarantee obligation should be or become legally invalid or unenforceable for any reason, ths shall not affect the validity of the other clauses.


Page 32

Instruction Manual MSG 320011 Appendices 11.1 Technical drawings 11.2 Circuit diagrams

Chapter

11


Page 33


X8.11 12 13 14 15 16 1 2 3 18 19 20 9 10

5 6 7

X8.1 X8.2 X8.3 X8.4 X8.5 X8.6 X8.7 X8.8 X8.9 X8.10

terminal X8 15 V Ext. trigger 0V PE 15 V Ext. lowering 0V PE NC (option) NC (option)

X8.11 X8.12 X8.13 X8.14 X8.15 X8.16 X8.17 X8.18 X8.19 X8.20

15 V Sens.-range S1 Sens.-range S2 Sens.-range S3 Sens.-range S4 0V PE TX (Seriell Data) RX (Serial Data) 0 V (Serial Data)


X1. 1 2 3 4 5

X2. 1 2 3

X3. 1 2 3 4

X5. X4. 1 2 3 1 2 3

X6. 1 2 3

X7. 1 2

L1 N

-X1.1 -X1.2 -X1.3 -X1.4 -X1.5

-X2.2 -X2.3

-X2.

fused (4 A)

(receipt)

(delay)

fused (4 A)

0 V~

option

floating contacts (potentialfree)CY 5 x 0,5 qmm

L1 N PEe.g. for the junction of the output contacts 3 x 1,5 qmm

W1

W2

metal signal

monitoring

detector coil receiver

external control(terminals X2 and X8)

detector coil transmitter

contact outputs contact rating : 250 V~ / 5 A

power supply voltage

The screenings of wires W1 & W2 have to be connected only at the controller side ! The connection will be given through the screen connectors of the metal screws-type conduit fittings.

Caution! The connection of a detector coil, type MSG2000, is described in table "KAB2E.DOC".

W3Li.

control voltage for X2.1 / X2.3 : power supply voltage

CY 5 x 0,5 qmm

27.10.96

PE

L1

N

MSG 3200wiring plan controller

Chapter

Page 34

11

VERDRAHT\VPLANSTD

E LMED GmbHWeilenburgstr. 39 42579 Heiligenhaus

Manual MSG3200

Documents

Transcript of Manual MSG3200