Related Manuals for Safeline STANDARD SERIES
Summary of Contents for Safeline STANDARD SERIES
- Page 1 Reference number : 4618 - 007 STANDARD SERIES METALDETECTORS INSTRUCTION MANUAL FIRMWARE 2.01 TO 2.49 Supplied by: SAFELINE LTD MONTFORD ST, SALFORD, ENGLAND Tel: 44 (0)161 848 8636 Fax: 44 (0)161 888 2292...
- Page 2 NOTE. An upgrade service is available from Safeline, at a fee, that will upgrade older detectors to the latest specification, where possible. Please contact your supplier’s technical departments for information on this service.
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Page 3: Amendments
For further information or to order copies of this document contact Safeline Ltd. at the address shown on the title page of this document, quoting the reference number given on the title page. - Page 4 Warnings and Cautions WARNING THE ABOVE CAPTION IDENTIFIES AN OPERATING PROCEDURE OR PRACTICE THAT COULD RESULT IN PERSONAL INJURY OR DEATH. CAUTION The above caption identifies an operating procedure or practice that could result in damage, or destruction, of the detector, the process or its surroundings. The above caption is used to draw the readers attention to a note of extra importance.
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Page 5: Handling Instructions
CORRECT INCORRECT Safeline does not recommend the lifting or supporting of the detector by a person. Always use suitable lifting or supporting apparatus. Safeline will accept no liability for personal injury caused by attempting to lift or move the detector without the aid of a mechanical apparatus. - Page 6 The equipment should only be used in accordance with the instructions given herein. Failure to comply with these instructions may lead to the protection provided by the equipment becoming impaired. Safeline will not be liable for incidental or consequential damage if the equipment is not installed in accordance with the instructions given.
- Page 7 Detector Precautions CAUTION During installation and operation of the detector the following points must be considered. Failure to do so may result in difficulties of operation, degradation in the performance or damage occurring to your detector. Electric Arc Welding Electric Arc Welding must not be carried out on the detector or on any part of the attached conveyor system.
- Page 8 Avoiding aperture damage At all times ensure that the product does not come in contact with, or impact onto the detector aperture or aperture lining. Handling and lifting When transporting and handling the detector damage may result if the lifting equipment (e.g. sling, cable assembly or by hand) passes through the aperture of the detector.
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Page 9: Table Of Contents
Warnings and Cautions ..............................iv Handling instructions ..............................v CONTENTS ..................................IX LIST OF ILLUSTRATIONS ............................10 SPECIFICATION - STANDARD SERIES DETECTORS....................1 BASIC TECHNOLOGY ..............................1 INSTALLATION ................................5 REJECT TIMERS – GENERAL ..........................19 PROGRAMING THE DETECTOR ..........................30 APPENDIX A................................ -
Page 10: List Of Illustrations
Detector coil system signals ......................Effect of phase control ........................Effect of phase control adjustment ....................Metal Free Zone Guidelines - Standard Series Detectors ............... Layout of Components and Terminals for P/S Connection PCB issues - 6 and 7 ......Power connections........................... - Page 12 Safeline would greatly appreciate being informed of them. The above notwithstanding, Safeline can assume no responsibility for error in this manual or their consequences. No part of this document may be photogated, reproduced, or translated to...
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Page 13: Specification - Standard Series Detectors
SPECIFICATION - STANDARD SERIES DETECTORS Product speed BASIC TECHNOLOGY Selectable high and low from the control panel, High frequency low power electromagnetic coil low - x 1, high - x 3 system. Low - 0.05 to 2.5 metres / min. / mm. of aperture... - Page 14 Spherical Sensitivity RS232 Communication Dependent on aperture size, and frequency of Two communication ports COM1 and COM2 both operation, all sensitivity information is expressed in accessible from the P/S Connection PCB within the diameters of spherical samples. Power Unit Enclosure. Non spherical objects such as wires will exhibit an Both communication ports are typically + 9 V levels orientation effect, ie.
- Page 15 Great care is taken in the design and manufacture reduces the signals from vibration or product effect of the Safeline detectors to minimise the effect of with minimal effect on the metallic signals. vibration on the performance of the detectors.
- Page 16 This is similar to the phase discrimination circuit, however the phase discrimination circuit in the Safeline metal detector is very much more selective. Signals from the detector coil system can also be represented as shown in Fig 2.
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Page 17: Installation
MFZ guidelines for standard series detectors are as shown in fig 5. Please consult the product data sheet for MFZ of other types of metal detector. Fig. 5 Metal Free Zone Guidelines - Standard Series Detectors Page 5... - Page 18 It is important these items are used to mount the detector to its support framework. A typical installation could be a standard series detector mounted on a metallic conveyor frame with When installed correctly the detector head should rollers positioned across the frame, page 60.
- Page 19 connections and the position and rating of the recommended circuit breaker are shown in Fig. 6B. These instructions are for connection to TN (EN60950:1992) power distribution systems only. For connections to other power distribution systems Arrangement gland assemblies please contact your supplier. connecting the power cable to the power unit box are shown in Fig.
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Page 20: Layout Of Components And Terminals
FUSE F1: 3.15A (T) (ON POWER SUPPLY MODULE UNDERNEATH THE CONNECTIONS BOARD) NOT A USER SERVICABLE PART OPTIONAL REJECT CONFIRMATION UNIT CIRCUIT BOARD FUSE: F2: 1.0A (T) 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 ELECTRONIC FUSE CONCLAMP AND GLAND FITTING (SEE FIG. - Page 21 RATINGS RECOMMENDED POWER LEAD AREA 0.75 mm CONSTRUCTION 24 x 0.2 mm CURRENT RATING 6 AMP. COLOURS BROWN-LIVE, BLUE-NEUTRAL, GREEN/YELLOW-EARTH. a) RECOMMENDED CIRCUIT BREAKER DOUBLE POLE, CURRENT RATING 3 AMP OR 4 AMP, TYPE C CIRCUIT BREAKER TO BE MOUNTED CLOSE TO EQUIPMENT.
- Page 22 Figure 6C Cable Gland Assemblies for Power Supply Unit Page 9A...
- Page 23 Figure 7 Roller Shaft Insulation (one end only) Figure 8 Bearing Block Insulation Page 9B...
- Page 24 THIS PAGE IS LEFT BLANK INTENTIONALLY Page 9C...
- Page 25 Page 10...
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Page 27: The Control Panel
To obtain optimum metal detection perfor- mance for each product the Safeline metal detector With the help of the two colour bar graph display may be programmed to memorise the required the user may observe the signals generated by setting for up to 21 different products. - Page 28 OPERATING THE DISPLAY AND ACCESS MODES AND TOUCH KEY FUNCTIONS Running Mode Liquid Crystal Display (LCD) This represents the normal running display of Used to display the information in the metal the metal detector. In this mode information detector’s computer. may be observed but the display values cannot be changed.
- Page 29 THE PAGE DISPLAY SYSTEM OPERATING AND ACCESS MODES - Continued There is a requirement to display more Supervisor Access Mode informa- tion than the LCD can display at any The supervisor may change the following one time. para- meters. To expand the display capabilities a page display menu system is used.
- Page 30 ENTERING THE ACCESS CODES USING THE TOUCH KEYS Cursor Move Key All Safeline metal detectors are shipped from This key is used to control the movement of the factory with the following access codes. the cursor bar when changing the setting of a Code 0001 = Operator Access digital value.
- Page 31 CHANGING DIGITAL VALUES PROGRAMMABLE SETTINGS Various settings in the progamme are stored General as digital values, eg product number, Twenty one presettable programmes can be sensitivity, phase etc. stored in the computers memory. Each pro- Digital values can only be adjusted if a gramme is identified by a product number.
- Page 32 PROGRAMMABLE SETTlNGS – continued Inverse Detection (Inverse Detect Yes/No) This feature allows the action of the reject timer to be reversed, such that product containing no metal contamination is rejected whilst metal contaminated product is not rejected. This feature is often used to verify that a product contains a metallic premium.
- Page 33 CONFIGURING THE DETECTOR DETECTOR SPEED Various operating characteristics of the detector are Hi/Lo - select to suit product throughput speed. See programmable and may be altered or configured to specification for speed range. Will normally be set suit the particular requirements of the application. to Lo for most conveyor applications and Hi for free The configuration process should be performed by fall applications.
- Page 34 SET TIME - Firmware 2.21 or less Allows the setting of HOUR and MINUTE. The clock uses the 24 hour format. Refer to ’Changing Digital Values’ for adjustment. PRINTER HANDSHAKE - Firmware 2.10 or greater HW/SW controls the handshaking mode the Module uses with Local Printer Unit (LPU).
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Page 35: Reject Timers – General
REJECT TIMERS – GENERAL the reject solenoid, and the reject mechanism may TlMER TYPES need to be taken into account. RECOMMENDED APPLICATIONS A wide range of timer types and settings are available to the engineer. Five different timer types, each with variable settings can be pro- grammed Listed below are various types of reject for use within the metal detector. - Page 36 tm1 – TIMER 6) Enter required value The tm1 reject timer is useful for applications 7) Press enter twice: display reads: requiring instantaneous reject action with zero delay time. Typical applications would be gravity fall Timer A,B,C reject mechanism or simple stop alarm conveyor system.
- Page 37 tm2[G] TIMER – NON GATED MODE device to reject contaminated product. The mini- mum value will be the operate time of the reject device. The tm2[G] timer used in the non-gated mode is an ideal delayed reject timer for use with loose product where the reject device is a reasonable distance from the detector head.
- Page 38 Select ’No’, display now reads: tests using larger metal samples. Signal Delay # # # #sec If product is loose test reject operation using large and small samples, also check using two metal samples Reject Time # # # #sec spaced at different distances apart on belt.
- Page 39 tm2[G] TIMER – GATED MODE Sync Delay The tm2(G) photogated reject timer gives precise operation of the reject device where individual products, Sync delay is the time taken for the pack to travel from eg cartoned products, individual chocolate bars etc are the photo beam to the optimum reject position.
- Page 40 such that the pack/product breaks the beam before 6) Select ’Yes’ display now reads reaching the reject device. The beam may be positioned either side of the detector. Ensure the sensors do not Timer type tm1/tm2(G)/tm3(G effect the operation of the metal detector itself by infringing the metal free zone limitations.
- Page 41 the front or rear edge on the conveyor belt and allow it to b) A metal test piece is not required to set these pass through the detector without skewing or slippage. two parameters Press the ’Reject Time’ soft key and adjust the reject time until the metal contaminated pack is cleanly rejected.
- Page 42 tm3[G] TIMER Setting Up Timer Type tm3[G] – Non Gated The tm3[G] is a variable speed version of the tm2[G) Mode timer, To set up the timer use the following procedure: The tm2[G] timer has four time clock controlled functions that will provide an accurate reject action on a fixed speed conveyor.
- Page 43 Setting Up Timer Type tm3[G] – Gated Mode Select ’No’ display now reads Signal Shift # # # To set up the timer use the following procedure: Reject Shift # # # Prepare a sample pack containing a small metal contaminant positioned at the rear/trailing edge.
- Page 44 keys such that the reject mechanism operates just Shows CAL for 5 seconds after which ‘RUN’ as the front/leading edge of the pack reaches the Appears. centre of the reject device. With run displayed pass a pack of the correct size When set –...
- Page 45 When a satisfactory setting has been achieved. Press ENTER once. The Reject Time should now be adjusted. 14) Press the ’Etc’ soft key the display now reads Signal Shift 4## Reject Time ####sec Place the sample pack with metal contaminant in the front or rear edge on the conveyor belt and allow it to pass through the detector without skewing or slippage.
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Page 46: Programing The Detector
The Safeline detector has the ability to store settings for 21 different product numbers. Each product number represents NON PRODUCT EFFECT APPLlCATIONS... -
Page 47: Product Effect Applications
signal of 2 to 3 green segments on the bar graph PRODUCT EFFECT APPLICATIONS display. 6) Test the detection sensitivity with metal samples. Wet/moist product, ie meat, cheese, soups etc generate product signals when passed through the detector. At setting Phase 0000 the signal will be Minimising Product Effect Signal By Manually clearly visible on the LED Bar graph display. - Page 48 2) Enter access code. phase setting up and down until minimum signal ie. the null point is found. 3) Select lowest available product number (01 to 20). 11) The phase discriminator is now aligned to the product signal, next adjust the sensitivity so that the product 4) Manually set phase to 0000.
- Page 49 When asked to pass product through aperture SELECTING INVERSE DETECTION ensure the product is passed in the same orientation and position each time. When the auto-setup routine has finished it will The action of the reject timer can be reversed such that display the message ”Product adjustment completed’.
- Page 50 General Accessing The PVR The performance validation routine (PVR) helps All Safeline metal detectors are shipped from the users comply with ISO 9000 and BS5750 by factory with the following PVR access codes ensuring that the metal detector system is tested...
- Page 51 Test Samples (FERROUS – #.#mm / NONE Setting the time to 0 00 disables timed shift reports. FERROUS – #.#mm / STAINLESS STEEL 0.#mm) Shift Report Start Time (Shift Report Start H.## / This allows the user to setup test sample materials and sizes which will be prompted for during the M W) –...
- Page 52 Alarm If Overdue Carrying out a performance check; (Alarm If Overdue – YES/NQ) If Reject Confirmation hardware is fitted this option can The test sample(s) should be passed though the metal be selected to operate the system fault relay (See ’Power detector with the product.
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Page 53: Print-Outs/Data Collection
Settings printout PRINT-OUTS / DATA COLLECTION This printout contains all the Engineer and QA settings. Enter QA Inspector access code. 2) Press ’PRINT’ soft key the display reads. Information (or data) being transmitted by the metal detector may be transferred directly to paper by using a PRINT ALL SETTINGS PRINT SHIFT REPORT local printer unit (LPU). -
Page 54: Appendix A
APPENDIX A A Rotary Encoder Used As A Speed Sensor For The tm3[G] Timer Speed Sensor Requirements Speed Sensor Electrical Connections The speed sensor may be: Refer to the Installation section. a) a purpose bought item, known as a Rotary Connect the sensor to the terminals labelled Speed Encoder, or Sensor. -
Page 55: Disc Construction
Both proximity and photo-electric devices are (see Figure A-3 below), follow these steps. available in a slot sensor type construction, which can be mounted to sit astride the disk. If this technique is used the disk should be slotted rather than drilled. Disc Construction The disk diameter and number of holes/slots can be determined when the required shift distance of the... - Page 56 If your maximum conveyor speed exceeds this limit then choose the next point up, where in our example the shift distance is 19 mm. At this point distance d still lies within limits, and we have an improved maximum conveyor speed at the expense of a larger shift distance.
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Page 57: Appendix B
APPENDIX B Hardware Failure Numbers, Variable Error Numbers Circuit Fault Numbers And Warning Numbers. GENERAL The flashing segments of the bar graph are cleared by The metal detector carries out various test functions to powering down and back up again with no Variable ensure that it is operating correctly. - Page 58 WARNING NO’S OTHER FAULT MESSAGES During power-up the firmware checks the module memory and the detector head memory for validity, any errors are displayed as Warning Numbers. BALANCE FAULT CONTACT SUPPLIER If Warning 1 occurs it will be followed by the question: This message on the LCD prevents the metal detector Maintain Module YES>...
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Page 59: Appendix C
APPENDIX C Setting Up And Connecting A Printer To The Metal Detector GENERAL Connecting Your Printer Information (or data) being transmitted by the metal detector may be transferred directly to paper by using a The metal detector has two serial communication ports printer. -
Page 60: Connection Of Printer To Detector
CONNECTION OF PRINTER TO DETECTOR NOTES Many printers do not require CTS, DSR or DCD to be at active levels. However it is accepted good practice to connect these signals together as shown. The printer pin numbers shown are for an RS232 25-way D-type connector - if your printer uses a 9 way D-type connector consult the printer manual for the correct pin numbers. -
Page 61: Appendix D
APPENDIX D Sample Printed Reports Showing Format And Contents Metal Detector Current Settings Note: Individual printouts will vary according to the settings stored in the detector ** SETTINGS** Date Time Timer Group 01 Jan 1998 13:41:47 Type ; TM1 Reject ;... - Page 62 QA Settings Printout Shift Report Printout ** SHIFT REPORT START ** * QA Settings * Date Time 01 Jan 1998 10:30:15 Line ID ; 0205 Printer ; YES Relay Rpt ; YES *Reject Relay Operated* Settings Rpt ; YES Report Int ;...
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Page 63: Performance Check
Shift Report Printout - continued Performance Check Date Time * Performance Check * 01 Jan 1998 09:01:15 Date Time 01 Jan 1998 10:45:00 Prod No ; 02 Sens ; 185 Line ID ; 0205 Timer Operator ; QA INSPECTOR Ref Phase ;... - Page 64 APPENDIX E Firmware Versions 2.13, 2.15 and Higher Product Signal Cancellation loose or variable product pipe line systems Phasing out a product effect signal whether manually or automatically very often does not gravity fall systems eliminate the product signal entirely. The remaining signal normally means that the variable speed systems (unless PSC is metal detectors sensitivity must be reduced to...
- Page 65 If not, it will mean the sensitivity setting can not be improved upon and cancellation will be Once PSC is setup and working, if required ineffective. SENS can be manually adjusted but PHASE cannot. If PHASE is adjusted PSC will stop v) Select YES working and the 'P' in PHASE will stop flashing (Firmware Version 2.15 or greater).
- Page 66 DRAWING LIST Page 49 Flow Chart – Running Mode Page 50 Flow Chart – Operator Mode Page 51 Flow Chart - Supervisors Mode Page 52 Flow Chart – Engineers Mode Page 54 Flow Chart – QA Operator Mode Page 55 Flow Chart –...
- Page 67 Ver #.# # M/C Model # # # RECALL Product Number 00 SENS. # # # PROD. No.00 < ETC Safeline Ltd. SENS. # # # PROD. No. # # < ETC PHASE # # # Pack Count # # # # # # # # <...
- Page 68 RUNNING CURRENT TIME # # : # # Pack count # # # # # # # # MODE NEXT QA TEST # # : # # Reject count # # # # PROG/EXIT ENTER OPERATOR CODE SENS. # # # >...
- Page 69 CURRENT TIME # # : # # RUNNING Pack count # # # # # # # # MODE Reject count # # # # NEXT QA TEST # # : # # PROG/EXIT ENTER SUPERVISOR - CODE ENTER SENS. # # # >...
- Page 70 CURRENT TIME # # : # # PACK COUNT # # # # # # # # RUNNING MODE NEXT QA TEST # # : # # REJECT COUNT # # # # PROG/EXIT ENTER ENGINEERS MODE ENTER SENS. # # # >...
- Page 71 CONTINUED FROM LAST PAGE DETECTION BUZZER -ON/OFF CHANGE CODE - OPERATORS CHANGE( ..) CODE SUPERVISORS # # # # CHANGE CODE - OPERATORS QA INSPECTOR ENTER NEW (...) CODE # # # # DETECTOR SPEED. - HIGH/LOW REJECT INHIBIT - YES/NO REJECT CONFIRM - YES/NO REJECT CONFIRMATION Extension time becomes...
- Page 72 PACK COUNT # # # # # # # # CURRENT TIME # # : # # RUNNING REJECT COUNT # # # # NEXT QA TEST # # : # # MODE PROG/EXIT EXIT ENTER QA OPERATOR CODE FERROUS > FERROUS >...
- Page 73 CURRENT TIME # # : # # RUNNING PACK COUNT # # # # # # # # NEXT QA TEST # # : # # MODE REJECT COUNT # # # # PROG/EXIT ENTER QA INSPECTOR CODE PRINT ALL SETTINGS > PRINT>...
- Page 74 Entered from Engineer or Supervisor mode. Make sure that no product is passed through Ensure no product is the metal detector when this message is displayed. passing through aperture Please wait Product signal too large Product signal too large Pass product through Please wait.
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Page 75: Timer Sub-Routine
SELECT TIMER A > SELECT TIMER B > SELECT TIMER C > ° A/B/C ° UPDATE < TIMER < TIMER ° A/B/C ° UPDATE TIMER TYPE tm3[g] > See separate sub routine TIMER TYPE tm2[g] > TIMER TYPE tm1[g] > REJECT TIME # # # >... - Page 76 Tm2[G] TIMER SUB-ROUTINE ENGINEER MODE – VERSION 2.01 to 2.49 SELECT TIMER A > SELECT TIMER B > SELECT TIMER C > < TIMER " A/B/C " UPDATE < TIMER " A/B/C " UPDATE See separate sub routine TIMER TYPE tm3[g] >...
- Page 77 tm3[G] TIMER SUB-ROUTINE ENGINEER MODE – VERSION 2.01 to 2.49 SELECT TIMER A > SELECT TIMER B > SELECT TIMER C > < TIMER "A/B/C" UPDATE < TIMER "A/B/C" UPDATE TIMER TYPE tm3[G] > TIMER TYPE tm2[G] > See separate sub routine TIMER TYPE >...
- Page 78 TYPICAL METAL DETECTOR CONVEYOR Page 60...
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Page 79: Recommendations For The Use Of Inverters
Do attempt to install, operate, maintain or inspect the inverter until you have read through the instruction manual supplied with the inverter. Safeline use Mitsubishi as our supplier of inverters, we know this works well with the metal detector and we have carried out extensive tests to meet the requirements of the CE regulations. - Page 80 (Applicable only if ATEX option is ordered) ATEX DIRECTIVE • This product complies with the ATEX Category as stated on the ATEX system label shown below. • A static hazard may exist – Do not clean non-metallic parts with a dry cloth. •...
- Page 81 (Applicable only if ATEX option is ordered) ATEX system label Montford St. Salford METAL DETECTION England System Identifier Year of Manufacture Model IP Rating System Rating 110 120 220 230 240 Voltage/Spannung/ Tension/Voltaje 400 415 440 Phase/Phase/Phase/ Fase Ø Ø Frequency/Frequenz Fréquence/Frecuencia 300 600 1K...
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