Manual MSG3200

Instruction Manual MSG 3200 Chapter 0

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

1 Introduction: Construction and working principle of ELMED metal detectors 2

2 Items delivered, Transport, handling and storage 32.1 Items delivered 32.2 Transport, handling and storage 3

3 Fitting the equipment to the conveyor 43.1 Installation location 43.1.1 Weather and temperature 43.1.2 Metal-free zone 43.1.3 Effects of surroundings 53.2 Installation, general notes 6

4 Electrical connection 74.1 Connecting detector coil to the electronics 74.2 Interfacing with external controls 84.2.1 External clock (X8.1 to X8.4) 84.2.2 Sensitivity override (X8.5 to X8.8) 94.2.3 Remote controlled sensitivity selection (X8.11 to X8.16) 94.2.4 RS-232 interface 94.2.5 Pushbutton reset of metal output 94.2.6 Time-delayed enable of detector 94.3 Relay outputs 94.3.1 Metal present (DPDT, X4.x and X5.x) 94.3.2 Detector ready (SPDT X6.x) 94.4 Mains supply and control cables 104.5 Balancing of the detector 104.5.1 Mechanical adjustments 104.5.2 Checking the auto-balancing circuitry 11

5 Operating 125.1 Requirements 125.2 Front panel 125.2.1 Operator-Menu 125.2.2 Setup-Menu 17

6 Faultfinding: checklist of possible causes and remedies 246.1 General 256.2 False alarms for mechanical reasons 256.3 False alarms for electrical reasons 266.3.1 Fault analysis specitic to the control unit MSG 3200 27

7 Technical data 28

8 Accessories and spare parts 30

9 After-Sales Service 31

10 Guarantee 32

11 Appendices 3311.1 Technical drawings 3311.2 Circuit diagrams 33



1 Introduction: Construction and working principle of ELMED metal detectors

PurposeELMED metal detectors of the MSG range serve to detect metallic foreign bodies in any electricallynon conductive or slightly conductive material.

BenefitThis can protect high-value processing machines against damage or destruction. It also protects yourfinished product against metal contamination, and protects the consumer against adverse health ef-fects due to undesired metal parts.

ConstructionThe ELMED metal detector MSG 3200 consists of the detector coil, and signal processing unit whichis housed in a separate electronics cabinet.

Since the specification of a metal detector equipment can vary widely according to the application, thesearch coil is designed specifically to the customer's requirement.

Working principleThe device indicates the presence of metal when the metal disturbs an electromagnetic field gener-ated in the search coil. As a metal part in the material being monitored passes through the coil, itdisturbs the "balanced" field (compensated differential circuit). The electronic signal processing unitrecognises 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 Euro-standard cards in a rack module, which together with operator controls and terminal strip is mountedin an electronics cabinet with good servicing access (for drawing see appendix)

For your benefitPlease remember that the metal detector equipment you have purchased is a highly sensitive meas-uring instrument, even if it perhaps does not look like one! Your justified expectations in terms of reli-ability and sensitivity will only be met if the equipment is installed and operated in compliance withsome basic conditions. Only if these are fulfilled we can guarantee that the equipment will functionproperly.



2 Items delivered, Transport, handling and storage

2.1 Items delivered

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 beplaced below the search coil,

• Operating manual in the appropiate language.

Please check the delivery for completeness !

! Attention: The shock absorbing strips are nopackaging material and must beplaced below the search coil.

!2.2 Transport, handling and storage

Every metal detector leaves our factory in packing which is specially designed for transportation andstorage 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 dismantledin a separate crate or pallet. The electronics cabinet and all accessories are packed in a ruggedcorrugated cardboard carton, also on a pallet.

Until reaching the location for final installation, the detector coil and the electronics cabinet should beleft in this packing.

! During transport, handling and during installation,no force must be exerted on the plastic panelscovering the highly sensitive measurement sys-tem.

This applies especially when lifting the equipment by fork-lift truckor crane. (For instance, do not travel lift forks into the detectorcoil opening!)

!



3 Fitting the equipment to the conveyor

3.1 Installation location

3.1.1 Weather and temperature

Regarding the installation location, the following factors need to be considered to give optimum sensi-tivity and highest reliability.

a) Neither the detector coil nor the electronics cabinet must be installed outdoors unpro-tected from the weather. If necessary, an enclosed shelter must be built to protect thecoil from the weather. Under no circumstances must moisture get into the calibra-

tion shaft1, junction box, or under the plastic cover panels. If moisture does enter,the equipment may not work properly.

b) The metal detector equipment and in particular the detector coil should not be exposed todirect sunlight, since this can cause mechanical stresses in the sheet steel housing of thedetector coil which could bring it out of electrical adjustment.

c) 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 longbreaks, in order to prevent condensation forming in the electronics cabinet.

d) Please ask our service department before installing the electronics cabinet of the metaldetector together with other devices in the same cabinet.

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 Type5, 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 detectiondirection. Not only the space between detector and belt or material must be free of metal, but also thespace above belt or material. Please observe for instance, chain conveyors or the like running abovethe 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 withinthe 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 besure to contact our servicing department in case of any questions or doubts.

1 Only present at some types.2 For extra high sensitivity or if aperture heights greater than 1m use factor 6 instead of 43 Dimension of search coil in the direction of material travel.



3.1.3 Effects of surroundings

This term covers all factors having a direct or indirect effect on the electromagnetic field of the detec-tor 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 theneighbourhood 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 fittedwith interference suppressors. The same applies to other electrical or electronic controls located inthe region near the detector coil.

Mains supply interference due to switching of high power machines or motors can also affect thefunctioning of the metal detector equipment. In this case, the power supply for the detector equipmentshould be taken from the lighting circuit instead of the power circuit, or a stabiliser must be insertedin the supply line.

The cables connecting the detector coil to the electronics cabinet should not be laid beside powercables or control cables to high power machines.If high detector sensitivity is required, the transmit and receive cables should be screened by laying insteel conduit.



3.2 Installation, general notes

Mounting the detector coil

Every metal detector equipment is provided with rubber vibration mountings. The number and typevary according to the detector coil type, size, and installed location. The purpose of the rubber vibra-tion 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 adhesive-fixed 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 separatesupporting structure for the detector coil is recommended. Installation on a separate foundationhas been found to work well. Under these requirements a direct mechanical connection of the detectorcoil 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 detectorcoil without touching it, under all operating conditions.

Depending on the type of detector coil, this is achieved by slide boards and side cladding panelsleading through the coil. The minimum clear distance between material (or belt) and the coil must notbe less than 5 - 10 mm, depending on the material being conveyed (weight!), under the most unfa-vourable production conditions. If the material being tested is tree-trunk timber, the minimum distanceis 40 mm.

! The detector coil is clad with plastic panels.

No force or pressure whatever must be exerted on these panelsby 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 slideboards 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 theslide boards. For constructing gutters and chutes in the region near the detector coil, glass fibre rein-forced polyester can for instance be used.



4 Electrical connection

4.1 Connecting detector coil to the electronics

! 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 thedoor of the control unit.

Then connect each numbered terminal in the detector coil junction box to the correspondingly num-bered 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: Connect to control unit using 5-core screened cable.Receive coil: 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.



4.2 Interfacing with external controls

4.2.1 External clock (X8.1 to X8.4)

The metal detector requires an external clock, that is synchronised with the movement of the con-veyor. 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 8,2kΩ.

Higher rates can be divided by the integrated prescaler that has to be adjusted accordingly. Theprescaler can be adjusted for division factors between 1:1 and 99:1.

The LED CLOCK will be on at HIGH on the CLOCK input.

12345678910

12345678910

321

01

2345

6

7890

1

2345

6

789

Interface

daughter board

(optional)

x10

x1

S1

S2

S3

S4

Sensor

LEDs

Pre-scaler

Figure 1: Controls for the prescaler



4.2.2 Sensitivity override (X8.5 to X8.8)

The sensitivity override input can be used to reduce the sensitivity of the detector temporarily. Forexample 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 (seebelow), 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 Product

S1 1

S2 2

S3 4

S4 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 individualproducts. 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 recordedon 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 metaldetector is enabled a short time after starting the conveyor. This function can only be activated byservice technicians.If the function is activated, the control voltage of the conveyor must be connected to terminals X2.3and 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 po-sition 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 push-button 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 forsmall 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 isready for operation.



4.4 Mains supply and control cables

The mains power supply for the electronics should be taken through a separate cable or from themains lighting circuit, in order to avoid interference spikes from switching of large machines, motorsetc.

The stabilised power supply compensates for voltage fluctuations of +/- 10 %. If there is a risk of largerfluctuations 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 theelectromagnetic field in the search coil.

Large metal objects in the neighbourhood of the detector or extreme temperatures can cause perma-nent changes of the electromagnetic field. The auto-balancing circuitry will automatically adjust theelectromagnetic 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 shouldbe checked (see 4.5.2)

4.5.1 Mechanical adjustments

(applies only to Type 3 search coils)



4.5.2 Checking the auto-balancing circuitry

• Select [Compens] from the Setup Menu.

• The display should look like:

After completion of the auto-balancing process the values for ADC2 and ADC3 show the remainingerror of then detectors balance und must not exceed 0,2 V. During normal operation, the values mayincrease to 1V.

If the values for ADC2 or ADC3 exceed the limit of 1V for more than 30 seconds, the auto-balancingwill start again. During the balancing operation both the output „detector ready“ and the ready indicatoron the front panel will be inactive.

The values for DAC0 and DAC1 correspond to the amount of voltage that is necessary to achieve thebalanced state of the detector. The range is from -3 V to +3 V. Reliable operation will be possible if thethe values for DAC0 and DAC1 lie between -2 V to +2 V. Otherwise the saftey margin for changes inthe 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 compen-sated 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 tolarge metal objects. This should be kept in mind during mechanical compensation (for detectorcoils Type 3 only).

• By pressing the [Start] button, the balancing can be started at any time.



5 Operating

5.1 Requirements

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 alsochapter 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 displayon 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 displayand 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 ofmetal signal, trigger level, detection counter andselected product.

Selection of the product parameters.

Displays the logbook with time, date and wave-form of the last 128 metal detections.

Access to setup menu (security code required).



5.2.1.1 On-line Display

The metal signal is displayed as waveform, similarly to the display of an oscilloscope. The amplituderoughly corresponds to size of the part, the X-axis corresponds to conveyor travel. The display is wellsuited to analyze the signal caused by metal parts and disturbances from the surrounding of the de-tector.


Back to the OPERATOR MENU (F5 is the lowestof the menu buttons)

5.2.1.2 Level

This display contains the following items:

• The level of the metal signal is both shown as nu-meric value (at Peak Level) and as bar-graph (onthe 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. Thevalue shown at Trig. Level depends on the chosenProduct.

Pressing [F5] returns to the OPERATOR MENU.



5.2.1.3 Product

This menu is used to select one out of 16 possible product and sensitivity settings.


X-Y-Display

Save settings and return to OPERATOR MENU.

Cancels changes and returns toOPERATOR MENU

For a detailed description see 5.2.2.2



5.2.1.4 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:


Moves marker up by one position

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:


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 usedto 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 inthe display.



5.2.1.5 Setup

The second set of menus is only accessible after entering the security code. This allows for furtheradjustments that are not required during normal operation.

The setup menu can only be entered after entering the correct security code.


Enters 1.

Enters 2.

Enters 3.

Enters 4.

Back to OPERATOR MENU.



5.2.2 Setup-Menu

The functions of the SETUP MENU are used to adapt the detector to individual working conditions.


Adjustment of the real-time-clock

Adjustments for metal detection and productcompensation

Selection of the current product (see alsoOPERATOR MENU)

Adjustment of the software-prescaler for externalclock 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.


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 resetto 00

Cancels changes and returns to SETUP MENU



5.2.2.2 Metal detection and product compensation

The metal detector can be adapted to the working conditions under two aspects

• metal detection sensitivity

• product compensation

The first menu is used to select one of 16 different product (and sensitivity) settings and to inspect thecorresponding parameters.

The display shows both product ID (Product#) and detection parameters.

• Product# Product ID (int=internal control / ext=external control).

• Metal level Trigger level for metal detection

• Product level Trigger level at product phase angle

• Product angle Phase angle of the signal caused by the product


Selects sequentially one of the 16 product set-tings (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 indicatedby “ext“ behind the product number, otherwise “int“ will be shown. External control can be used toswitch between different product settings under control of an external PLC.



5.2.2.2.1 X-Y-Display

During X-Y-display both channels (ferrous and non-ferrous) are show in an two-dimensional coordi-nate system. Phase (or angle) caused by different products and metals will cause the dots on the dis-play to move into different directions.


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 theproduct 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 productangle.

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.


Increases current parameter

Decreases current parameter

Selects current parameter

Save settings and leave menu

Discard changes and leave menu.



The following example is used to illustrate the meaning of the parameters:

Figure 1 shows an idealized example for the signals causeby metal that should be detected and product that should besuppressed: The product causes a signal of about 2V at anangle of 30°. The metal causes a signal with an amplitudeof only 1V at an angle of about 120°. The product effect canbe compensated by putting a detection envelope around thesignal that has the shape of an rotated ellipse.

The long radius of the ellipse corresponds to the prod-uct level, the short radius to the metal level, the rotationof the ellipse to the product phase.

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

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

Furthermore, only the horizontal axis has been scaled (parameter:product level) to reduce the product effect, avoiding metal alarmscaused by the product.

Because the scale of the vertical axis (metal level) has not beenchanged, the metal signal still can trigger the metal alarm.

Figure 3 illustrates the need to verify the effect of the pa-rameters using the X-Y-display: Because the phase differ-ence between metal signal and product effect is less than90°, the metal signal stays within the detection envelope.Metal signals that exceed the trigger level only by a smallaount won’t trigger the metal alarm.

As an consequence the settings always should be verifiedusing sample parts.

ProduktMetall

30°

Fig 1

Produkt

Metall

Figure 2

Produkt

Metall 30°

Figure 3



5.2.2.2.3 Teach-Mode

Main element of the teach mode is an integrated wizard that leads you through the steps that are nec-cessary to adjust the detector to your need.

First, an metal sample has to pass the detector. The wizard records the signal an calculates suitableparameters for metal detection.

Second, product sample have to be passed through the detector. Again the wizard records the signalan 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 tobe performed in the following order:

• Press the [Start] button.

• Feed the sample through the detector.


Start the measurement of the amplitude causedby the metallic sample.

Abort and return to the SETUP MENU.



Step 2:

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


Reset measurement.

Use current measurement and advance toproduct 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 compensatedthrough the search coil.

• Press the [Start] button.

• Feed the sample through the detector.


Starts the measurement




Step 4:

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


Reset measurement.

Use current measurement and advance to finalmenu.


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 theauto-balancing circuit. The display shows the fol-lowing items:

• ADC2 and ADC3: Deviation from optimum bal-anced state. Must be between -1 V and +1 V.

• DAC0 and DAC1: Actual value of the compen-sating voltage. Should stay between -2 V and+2 V, operation is possible as long as value isbetween -2,9 V and +2,9 V.

For the unlikely case, that the values for DAC0 andDAC1 exceed +/-2,5 Volt, mechanical recalibrationof the coil is necessary. Please contact factory fordetails.

If automatic balancing should become impossible,the green indicator [Ready] on the front panel andthe Ready-Output will be deactivated.

The lowest button [F5] returns to the OPERATOR MENU.



5.2.2.4 Clock ratio, Output Delay and On-Time


Increase value by 1

Decrease value by 1

Advance marker (>) to the next field to bechanged.

Permanently stores the parameters that havebeen modified.

Aborts changes and returns to the SETUP MENU

SpeedIf no external clock is present, the metal detector will work at this default value.

Clocks/cmThe detector requires an external clock that is synchronized with the movement of the conveyor. Thenominal value is 10 clocks per centimeter. The actual rate can be adjusted with the setting ofClocks/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 percentimeter.

• The Clocks/cm setting is used by the Digital Signal Processor to divide the signal from theprescaler further down to 1 impulse per centimeter.

Output DelayThe signal that is given upon detection of metal can be delayed if required. The sophisticated signalprocessing software always evaluates the signals recorded over about 1,28 cm of travel of the con-veyor. This results in a delayed output signal that will become active about 64 cm after the object haspassed the center of the search coil. As a consequence, the minimum value for Output Delay is 65cm. The Output Delay can be adjusted to any practical value, therefore in many applications an addi-tional PLC used for controlling the reject device can be saved.

On TimeThe duration of the output signal (corresponding to conveyor travel), depends on the size of the de-tected object.The duration can be extended by the setting On Time.

Joint DelayThe travel of the forming belt by which the deactivation of the sensitivity override will be delayed. Usedto avoid false switching due to small defects in the marking on the forming belt that controls the diffusereflection 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 en-gineers. If you have the answers to the items on this checklist, then most types of fault can easily beremedied. (The desirable condition, yes or no, is underlined.)



6.1 General

YES NOHas anything changed recently in respect of system requirements or pro-duction conditions?

If false-alarm signals are occurring, when do they occur?

YES NOwhen 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 maximumsensitivity attainable and increase the probability of false alarms.

YES NOIs 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 vi-bration is being transmitted to the coil?

Have any dirt or material residues (chips etc.) deposited between the de-tector coil and the slide board?

It is absolutely essential for the detector coil to be completely free-standing, with no contact to any partof the conveyor structure at any point (minimum distance 10 mm).



Does 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

YES NOAre 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.

Metal grids on catwalk: Either weld them to the iron joist structure, or underlay with electrically insu-lating 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 thestructure 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-lifttruck 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 NOIs your mains power supply subject to faults, interference or fluctuating volt-age ?

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) Check the cable connection between detector coil and electronics cabinet (cables maybeconfused)

b) Check that all the circuit boards are firmly seated in their sockets.

YES NOHave any other large machines started operation recently which mightcause interference with the metal detector equipment?

How near is the control unit of the metal detector equipment toother electrical cabinets?

________ m



YES NOIs 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 NOIs the sensitivity adequate?

For what sensitivity requirement was the metal detectorequipment originally designed ?

Nut M________

Ball ∅ ________ mm

and for what belt speed?________ mm/s

6.3.1 Fault analysis specitic to the control unit MSG 3200

YES NOAre 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 abovethe transformer).

YES NOIs 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 thetransmit 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 NOWhen an iron part passes through the detector coil, does the red LED on the2nd 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 follow-ing reasons:

Problem Solution

iron part is too small increase the sensitivity, or use a larger part

the metal detector operates for the wrong speed. check the speed reading (see Level Display,5.2.1.2) and the hardware and sofware prescalersettings (see External Clock, 4.2.1, and TimingSetup, 5.2.2.4)



7 Technical data

Electronic enclosure Combination of extruded aluminium profile with board guidesand in cast aluminium connection compartment. Mountingbrackets for wall mouting.

Surface protectionColourDimensionsWeight completeProtection classification

resin stove-enamelled finishlight-grey (RAL 7035)/ stone-grey (RAL 7030),W X H X D (306 x 241 x 262 ) mm20 kg approx.IP - 65

PC boards(From left to right)

5 plug-in boards for easy service.

1.2.3.4.5.

input amplifierDSP (Digital Signal Processor)Interface boardtransmit sectionstabilised power supply unit

Mains supply voltage 230 V / 50 Hz, alternatives on request

The stabilised power supply compensates voltage fluctuationsup to +/- 10 %.

A stable voltage supply is essential for proper functioning ofthe metal detector equipment.

Transient voltage fluctuations exceeding these limits causedfor instance by switching high power machines on or off canimpair reliability and cause false alarms. For this reason, theelectronics should be fed through separate cables or fed fromthe electric lighting circuit. If this is not possible, a voltagestabiliser with interference filter should be connected in thepower supply line, see Sec. 3.1.3 Effect of surroundings.

Power taken 50 VA approx.

Measurement frequency 16.384 kHz quartz stabilised (standard)

If several metal detectors are installed near to each other,including existing detectors, then different frequencies shouldbe used.

Please tell us!

Connecting the detector coil The junction boxes for connecting the transmit and receivesections are located on the narrow side of the coil. They mustremain accessible for servicing after installation.

Transmit coil: 5-core screened cable 0,5 mm²

Receive coil: 5-core screened cable 0,5 mm²



Operator controls

Mains switch 2-pole, switch-off

Control switch

Position OFF Detector switched off,Output "Metal present": always activeOutput "Detector Ready": always inactive

Position ON Normal operation,Output "Metal present": active on metal detectionOutput "Detector Ready": active if detector working

Position TEST Standby operation,Output "Metal present": always inactiveOutput "Detector Ready": always active

Indicators

Illuminated LC-Display Graphic display for menu control and information display

Pilot lights showing functions

Power yellow LEDReady green LEDMetal red LED

Detector switched onDetector readyMetal detected

"Metal detected" Outputs

Contact Rating No Metal Metal detected

250 VAC / 5 Amps X4.2 X4.3 X4.2 X4.1

250 VAC / 5 Amps X5.2 X5.3 X5.2 X5.1

"Detector ready" Outputs

Contact Rating detector ready detector not ready

250 VAC / 5 Amps X6.2 X6.3 X6.2 X6.1



Contact assignments for interface signals

Direction Terminal Function

Input (optional)Input (optional)Input (optional)

X2.1X2.2X2.3

ext. Control voltage (Mains) : Output Reset

0 V∼ : Common Terminalext. Control voltage (Mains) : Startup Delay

Output X8.1 Auxiliary supply 15 V-Input X8.2 Clock from conveyor

Output X8.3 0 V- (Ground)Output X8.4 PE (Shield)Output X8.5 Auxiliary supply 15 V-

Input X8.6 Input for optional diffuse-reflection sensorOutput X8.7 0 V- (Masse)Output X8.8 PE (Shield)

(optional) X8.9 Reserve 1 (not used)(optional) X8.10 Reserve 2 (not used)

Output X8.11 Auxiliary supply 15 V-Input X8.12 Sensitivity control from PLC (Range 1)Input X8.13 Sensitivity control from PLC (Range 2)Input X8.14 Sensitivity control from PLC (Range 3)Input X8.15 Sensitivity control from PLC (Range 4)

Output X8.16 0 V- (Masse)Output X8.17 PE (Shield)Output X8.18 RS-232 Interface (TX)

Input X8.19 RS-232 Interface (RX)Input / Output X8.20 RS-232 Interface (Masse)

8 Accessories and spare parts

Accessories signal hootersignal lampreset push-buttonscreened oil-flex cable 5 x 0,50, solderable screen

Spare parts Set No. I 10 no. fine fuses 5 x 20 - 4 A slow-blow10 no. fine fuses 5 x 20 - 2 A slow-blow10 no. fine fuses 5 x 20 - 0,4 A slow-blow 2 no. relays RP 42012

Spare parts Set No. II1 set of modules comprising:

power supply unittransmitterinput amplifierswitching stageAuto check modulecircuit board adapter

Spare parts Set No. III 3 no. lamp holders, green, yellow, red with cap1 no. incandescent bulb, external control1 no. mains switch1 no. reset push-button (internal)1 no. potentiometer1 no. moving-coil meter 100 µA1 no. door lock



9 After-Sales Service

Should you have any further questions on commissioning or malfunctions during operation which can-not be remedied following the enclosed "Troubleshooting Guide" (see chapter 6. "Faultfinding: check-list 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 befound on the rating plate on the inside of the control cabinet and alongside the terminal boxes on thedetection coil.

Example of a rating plate: Address:

ELMED GmbH42579 HeiligenhausWeilenburgstraße 39Tel.: 02056-2891 Fax: 02056-3467

Typ : MSG 2000Nr. : xxxx230V/50Hz

ELMED Dr.Ing.Mense GMBHWeilenburgstraße 3942579 HeiligenhausPostfach 100211/16Tel. : (00) 49 2056/2891-92-93Fax : (00) 49 2056/3467

Instruction Manual MSG 3200 Chapter

10


10 Guarantee

Provided that the installation and operating instructions above have been observed, the followingterms 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 commissioningb) 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 gen-eral extension to the original guarantee period. We guarantee the parts replaced under the guar-antee for a period of 6 months.

II. Preconditions for the Guarantee

Messrs ELMED GmbH offer a guarantee for such coils which demonstrably satisfy the followingpreconditions:

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 carriedout.

In the event of a fault being discovered, the claim for service under guarantee must be made inwriting 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 eitherby repair or by replacement of the parts concerned. All replaced parts shall become the prop-erty of Messrs ELMED GmbH.

2.) In the event of irreparable major faults, Messrs. ELMED GmbH shall have the right to meet theclaim 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 tothe 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 arelegally prescribed.

IV. Limitations

Faults or defects attributable to:

a.) Faulty installation, e.g. failure to observe applicable regulations or written commissioning in-structions

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 in-appropriate 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 unen-forceable for any reason, ths shall not affect the validity of the other clauses.

Instruction Manual MSG 3200 Chapter

11


11 Appendices

11.1 Technical drawings

11.2 Circuit diagrams

Ins

truc

tion

Ma

nu

al M

SG

32

00

Ch

ap

ter

11

C:\D

oku

me

nte

un

d E

inste

llun

ge

n\a

f.EL

ME

D\D

eskto

p\M

an

ua

l_M

SG

32

00

.DO

C (1

0.0

4.1

2 1

0:2

9)

Pa

ge

34

1 2 3 4 51 1 2 3 1 2 3 4 1 2 31 1 2 3 1 2 3 1 2 L1 N

X3. X5. X7.

X8.

1 2 3 5 6 7 9 10

11 1213 1415 16 18 19 20

-X1.5

-X1.1

-X2

.2

-X2.3

-X2.

W1

-X1.2

-X1.3

-X1.4

PE

L1

NW

3

0 V

~

CY

5 x

0,5

qm

m

3 x

1,5

qm

m

W2

CY

5 x

0,5

qm

m

VERDRAHT\VPLANSTD

Li. MSG 3200

ELMED GmbHWeilenburgstr. 39Weilenburgstr. 39

42579 Heiligenhaus

X6.X1. X4.X2.

L1 N PE

27.10.96

external control(terminals X2 and X8)

detector coil

contact rating :

contact outputs power supply voltagedetector coil

metal signal monitoring

transmitter

250 V~ / 5 A

fuse

d (

4 A

)

fuse

d (

4 A

)

(rece

ipt)

0 V

~

(de

lay)

receiver

floating contacts (potentialfree)of the output contacts

control voltage for X2.1 / X2.3 :

power supply voltage

option

The screenings of wires W1 & W2 have to be connected only at

screen connectors of the metal screws-type conduit fittings.

e.g. for the junction

the controller side ! The connection will be given through the

wiring plan controller

Caution!The connection of a detector coil, type MSG2000,

is described in table "KAB2E.DOC".

terminal X8

X8.1 15 V X8.11 15 V

X8.2 Ext. trigger X8.12 Sens.-range S1

X8.3 0 V X8.13 Sens.-range S2

X8.4 PE X8.14 Sens.-range S3

X8.5 15 V X8.15 Sens.-range S4

X8.6 Ext. lowering X8.16 0 V

X8.7 0 V X8.17 PE

X8.8 PE X8.18 TX (Seriell Data)

X8.9 NC (option) X8.19 RX (Serial Data)

X8.10 NC (option) X8.20 0 V (Serial Data)

Manual MSG3200

Documents

Transcript of Manual MSG3200