THS – FI022GB2K8v3 i
Industrial Metal Detector THS Serial number: ......
Program Version: THSV3.390 ALMV1060 Rev.: FI 022 GB 2K8 v3 Date: 2004-10-26 II- INSTALLAZIONE Instructions THIS MANUAL IS TO BE READ BY THE FOLLOWING PERSONS: - OWNER - OPERATOR - MAINTENANCE TECHNICIAN
Read this manual carefully before installing, operating or carrying out maintenance on the device. Keep the manual in a safe place for future reference, and in perfect condition. This manual must accompany the device described therein in the case of change of ownership, and until the device is broken up. • Follow the instructions contained in this manual for all • The device must be connected to a power supply circuit operations relating to installation, use and maintenance of fitted with a switch or other device which allows the power the device. to be cut off. CEIA cannot be held responsible for any damage resulting • Ensure that replacement fuses are of the correct rating and from procedures which are not expressly indicated in this of the prescribed type. Makeshift fuses and short-circuiting manual, or from any lack of attention, either partial or total, of the fuse boards are strictly forbidden. of the procedures described therein . • If the device is to be powered via an external • Whenever there is any suggestion that the level of autotransformer to regulate the voltage, ensure that the protection has been reduced, the device should be taken common terminal of the autotransformer is connected to out of service and secured against any possibility of the neutral of the power-supply circuit. unintentional use, and authorised service technicians • The power-supply plug must only be inserted into a socket should be called. fitted with an earth/ground connection. The level of protection is considered to have been reduced Any break in the safety conductor, either inside or outside when: the device, or disconnection of the earth/ground safety - the device shows visible signs of wear and tear; terminal, will render the device dangerous. Intentional - the device does not operate correctly; cutting or disconnection is strictly forbidden. - the device has been stored for long periods in sub- optimal conditions; • To avoid damage due to lightning, disconnect the power- - the device has suffered severe stress during transport; supply cable during storms. - the device has come into contact with liquids. • This device contains electrical and electronic components, and may therefore be susceptible to fire. Do not install in • The final user is responsible for selecting the explosive atmosphere or in contact with inflammable appropriate sensitivity for their application. After this material, Do not use water or foam in the case of fire when selection has been made, and programming has been the device is powered up. adjusted accordingly, it is also the final user's • The device must be disconnected from all power sources responsibility to verify calibration using the test before undergoing any maintenance or cleaning, and object(s) appropriate to the level of security selected. before being moved. Additionally, this test should be carried out periodically to insure no changes have occurred in the • Do not wash the device with liquid detergents or chemical equipment. substances. Any cleaning should be done using a slightly-damp, non-abrasive cloth. • Handle the device with care and without excessive force during installation, use and maintenance. • Read the chapter on “Maintenance” carefully before calling the service centre. • After installation the device should be stable, and not Whatever the problem, only specialised service personnel subject to vibration or accidental movement. All connecting authorised to work with CEIA equipment should be called. cables should be properly fastened down, in order to avoid knocks and accidental damage and to obtain optimum • Any damaged parts of the device should be replaced with performance. original components only. • Position the device as far as possible from sources of • Any maintenance or repair of the device while open and electromagnetic interference, such as transformers or energised should be avoided, and in any case should only motors. be carried out by trained personnel who are fully aware of the risks which the operation entails, following the • Before connecting the device to the power supply, ensure instructions given in the “Maintenance” section. that the power supply voltage corresponds to that indicated on the plate affixed to the device. • Disposal of parts with environmental impact: follow the The device should be connected to the mains voltage only regulations in force in the country where the device is after all connections required for full installation have been being used (refer to the “Maintenance” section). carried out.
SYMBOLS The equipment is marked with this symbol wherever the user should refer to this manual in order to avoid possible damage. The same symbol appears in the manual at points where warnings or particularly important instructions, essential for safe, correct operation of the device, are given. The equipment is marked with this symbol in the areas where there is dangerous voltage. Only trained maintenance personnel should carry out work in these areas.
Warranty conditions The Warranty on all CEIA equipment relates to goods delivered from our factory, under our general and specific conditions of sale. THS – FI022GB2K8v3 iii Contents INSTRUCTIONS ...... II SYMBOLS ...... II WARRANTY CONDITIONS ...... II CONTENTS ...... III DESCRIPTION...... 1 GENERAL INFORMATION ...... 1 POWER-SUPPLY AND CONTROL UNIT ...... 3 Control Power Box...... 3 Conveyor Control System ...... 4 METAL DETECTOR ...... 5 Models available ...... 5 Options ...... 9 THS-FB Conveyor Belt ...... 9 Features ...... 9 THS-FB conveyor belt options...... 10 Other optionals for THS metal detectors...... 11 THS metal detector accessories ...... 12 TECHNICAL CHARACTERISTICS ...... 13 INSTALLATION...... 15 GUIDE TO THE APPLICABLE INSTALLATION OPERATIONS ...... 16 General guidelines for mechanical installation ...... 16 GENERAL GUIDELINES FOR ELECTRICAL INSTALLATION...... 17 INSTALLATION OF A CEIA THS-FB INTEGRATED SYSTEM WITH CONVEYOR BELT...... 19 Mechanical installation of THS-FB integrated system with conveyor belt...... 19 Positioning the conveyor belt ...... 19 Ejector: mounting the safety shield ...... 19 Assembling the buzzer/flasher...... 19 Adjusting the height of the belt...... 19 ELECTRICAL INSTALLATION - GENERAL NOTES ...... 20 Connecting to the mains power supply ...... 20 Connection to the ground ...... 20 Control Power Box...... 20 Conveyor Control System ...... 20 Selection of the power supply voltage for the metal detector only - Control Power Box Power Supply Unit...... 21 CONNECTION OF THE COMPRESSED AIR SUPPLY...... 21 NON-INTEGRATED THS SYSTEM SUPPLIED WITHOUT CONVEYOR BELT: DETAILED CONSTRUCTION NOTES AND SELECTION OF OPERATING PARAMETERS ...... 22 Mechanical Installation...... 22 Controls ...... 22 Mechanical installation of the metal detector ...... 22 Mechanical installation of the power supply unit ...... 22 Mechanical installation of the THS/G probe...... 22 Proximity limits around the THS/G probe...... 22 THS/G : mounting the power supply unit ...... 23 Conveyor belt...... 24 Inserting the conveyor belt on the THS/A model...... 26 Transit speed ...... 27 Accessory devices ...... 29 Photocell – General rules ...... 29 Photocell self-diagnosis...... 29 Ejector – General rules ...... 29 THS/M – Specific instructions for ejector ...... 30 Applications at high speed (belt speeds greater than 60 m/min)...... 31 Programming used in a few common types of installation...... 31 Mechanical installation of a bar code reader...... 32 Safety precautions...... 32 Barcode reader kit ...... 32 Distance between the reader and the metal detector probe and distance between packs...... 33 Position of the reader and the label in transit...... 33 Reading features ...... 34 Step-Ladder mode...... 34 Picket-Fence mode...... 34 Kit installation procedure ...... 35 ELECTRICAL INSTALLATION: DETAILED NOTES ...... 36 ALM card electrical connections ...... 39 Conveyor Control System: Power-supply and motor connections...... 41 MDT card...... 41 MDL card ( ATTENTION: 230V 1~ only! )...... 42 Operation of the relays (J15 and J19 connectors) ...... 43 Ejector relay (Eject relay):...... 43 Alarm relay ...... 43 Malfunction relay (Fault relay)...... 43 Upstream belt authorisation relay (Preceding conveyor relay) ...... 43 Auxiliary relay for signalling when periodic test is due (TEST LAMP relay)...... 43 Timing...... 43 Belt blocking with manual alarm reset (EM=B) ...... 43 Conveyor Control System power supply unit ...... 43 Control Power Box power supply unit ...... 43 Belt blocking with photocell synchronisation and manual alarm reset (EM=SB) ...... 43 Conveyor Control System power supply unit ...... 44 Control Power Box power supply unit ...... 44 Automatic ejection with alarm synchronisation (EM=F)...... 44 Automatic ejection with photocell synchronisation (EM=S) ...... 45 Serial line connection (J3 and J4 connectors)...... 46 Inputs...... 47 Bar-code reader...... 47 Downstream belt authorisation (Following conveyor - Conveyor Control System only)...... 47 Photocell...... 47 II- INSTALLAZIONE
Ejection confirmation (Eject confirmation)...... 47 Container full (Full bin)...... 47 Impulse encoder (Encoder)...... 47 Alarm reset (Reset)...... 47 Inhibition ...... 47 Air pressure sensor...... 47 Container absent (Bin absent) ...... 47 OPERATING INSTRUCTIONS ...... 48 LIST OF PRELIMINARY CHECKS...... 48 OPERATIONS DURING USE AND AREAS OF COMPETENCE ...... 48 CONTROLS AND INDICATORS...... 49 Power switch...... 49 Control panel of the probe/electronics unit...... 49 Acoustical indicators...... 49 Controls ...... 50 Conveyor Control System power supply unit control panel ...... 50 Visible/audible alarm signalling device...... 51 SWITCHING ON THE METAL DETECTOR...... 51 Checking the safety features ...... 51 Signals at power-up ...... 52 SIGNALS GIVEN DURING USE ...... 52 Indication of the received signal...... 52 Checking for environmental electromagnetic interference...... 53 Display Messages...... 53 DISPLAY OF THE STATUS OF THE METAL DETECTOR...... 54 USE OF THE CONVEYOR BELT ...... 54 Starting/stopping the conveyor belt...... 54 Adjustment of the belt speed ...... 54 Emergency button...... 55 Automatic stop ...... 55 ALARM RESET...... 55 AUTOMATIC OPERATION USING A BAR-CODE READER ...... 55 PHOTOCELL SELF-DIAGNOSIS...... 56 PROGRAMMING THE METAL DETECTOR ACCORDING TO THE KIND OF PRODUCT...... 56 Procedure for minimising the "product effect" ...... 56 ANALYSIS MODE SELECTION CRITERIA ...... 58 SENSITIVITY CHECK WITH REFERENCE SAMPLE ...... 59 Test using a sample defined by the customer...... 59 Test using a CEIA sample ...... 59 Periodic test management ...... 59 Test procedure ...... 59 PROGRAMMING...... 61 GENERAL POINTS ON PROGRAMMING...... 61 PROGRAMMING INSTRUCTION ...... 63 Products menu...... 63 Autolearn menu ...... 64 Detection menu...... 65 Ejection menu ...... 66 Ejection time menu ...... 67 Counters menu ...... 68 Barcode reader menu ...... 68 THS Configuration menu...... 70 Date settings menu...... 72 Change Password menu...... 73 ALM Configuration menu ...... 73 I/O Status menu...... 77 MD Test menu ...... 77 Print menu ...... 78 Print report menu...... 79 Quality Control menu (Q.C.Report)...... 80 Test Sensitivity menu (Test sensitiv.)...... 80 Commands accessible only in Remote Programming...... 81 REMOTE PROGRAMMING VIA SERIAL LINK...... 82 Communication parameter settings: ...... 82 Entering remote programming ...... 82 Connecting to a metal detector (via RS 232) ...... 82 Long-distance connection to a single metal detector (via RS 485) ...... 82 Network connection (via RS 485)...... 82 Connecting to a metal detector in a network...... 83 3.13.3 - Displaying a parameter setting ...... 83 3.13.4 - Changing a parameter setting...... 83 3.13.5 - Executing a function ...... 83 MAINTENANCE...... 84 PERIODIC MAINTENANCE...... 84 SELF-DIAGNOSIS...... 85 STORAGE ...... 86 TRANSPORT AND MOVEMENT OF THE CONVEYOR BELT...... 86 ADJUSTMENT OF CONVEYOR BELT TENSION ...... 86 Replacing the belt ...... 87 DISPOSAL OF THE DEVICE AND OF CONSUMABLES WITH ENVIRONMENTAL IMPACT ...... 87 FUSES...... 87 TROUBLESHOOTING ...... 87 Self-resetting protections ...... 87 Replacing Card SCD...... 89 Procedure ...... 89 CHECKING ENVIRONMENTAL ELECTROMAGNETIC INTERFERENCE...... 90 APPENDICES...... 91 DECLARATION OF CONFORMITY CE ...... 91 SPARE PARTS, OPTIONS AND ACCESSORIES...... 92 Ordering spare parts...... 92 THS standard model / THS/3F...... 92 THS /A ...... 92 THS – FI022GB2K8v3 v
THS/SL ...... 93 THS/MN...... 93 THS/PH...... 94 THS/G...... 95 THS-FB...... 95 THS Accessories - Test pieces...... 99 THS Accessories - MD CAD - 27185 ...... 100
CEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and optionals, to the prices and conditions of sale.
THS – FI022GB2K8v3 --- I -DESCRIPTION 1
DESCRIPTION
General Information
The THS is an extremely compact metal detector with very high sensitivity, controlled by a microprocessor and designed for industrial use. The device is made up of:
the Metal Detector probe, complete with electronic control unit.
a power-supply and control unit, for connecting the device to mains power and to the external supports (photocell, ejector, etc.)
1 1 probe- Metal Detector 2 power supply unit with conveyor belt control 4 (Control Power Box) 5 3 connecting cable 4 tunnel 5 control panel
2
Fig. I-1a - THS system (probe-electronics unit + Control Power Box power supply unit) installed on a 3 CEIA conveyor belt.
1 probe- Metal Detector 2 power supply unit with conveyor belt control (Conveyor Control System) 1 3 conveyor belt load-bearing structure 4 conveyor belt control panel 5 idler 5 6 motor roller
2 6 Fig. I-1b - THS system (probe- Metal Detector + Conveyor Control System power supply unit) 4 installed on a CEIA THS-FB conveyor belt.
3 2 THS – FI022GB2K8v3 --- I - DESCRIPTION
Product alarm set-aside ejection Air Probe-Metal Detector transit ejector full confirm pressure photocell sensor sensor sensor malfunction
Power supply unit Alarm reset THS-Control contact Power Box (Control Power Box) Computer Inhibition or printer contact
Encoder to measure belt movement buzzer/flashing light
bar-code Flashing light reader indicating test due Conveyor Belt
Fig I-2a - Block diagram of the system CEIA THS-Control Power Box system
Product set-aside ejection Air transit ejector full confirm pressure alarm Probe-Metal Detector photocell sensor sensor sensor
malfunction
THS-Conveyor Inhibition upstream Power supply unit Control System contact belt (Conveyor Control System) Alarm reset authorisation Motor driver card motor downstream belt author- isation Encoder Computer to measure belt buzzer/flashing light movement or printer bar-code Flashing light indicating reader Conveyor test due Belt
Fig I-2b - Block diagram of the system CEIA THS-Conveyor Control System.
Conveyor Belt THS-FB/1 THS-FB/2 CEIA THS-FB/3 Product set-aside ejection Air transit ejector full confirm presssure photocell sensor sensor sensor THS-FB/1 Probe-Metal Detector Flashing light indicating test due upstream belt authorisation Power supply unit Alarm reset downstream (Conveyor Control System)
THS-FB/2 belt author- MDL inverter card motor isation Inhibition buzzer/flashing light contact Computer or printer
THS-FB/3 bar-code malfunction alarm reader
Fig I-2c - Block diagram of a CEIA THS-FB integrated system including the conveyor belt, the THS unit, the Conveyor Control System power supply unit and the sensors and actuators needed for operation.
THS – FI022GB2K8v3 --- I -DESCRIPTION 3
Power-supply and control unit The power-supply and control unit is housed in a watertight box in stainless steel which is designed to be attached by means of four screws and through which pass the connecting cables. The power supply unit is available in two versions:
Control Power Box , containing the metal detector power supply section and designed to allow connection of external sensors and slave devices
Conveyor Control System, with the same functions as the Control Power Box, but with the addition of a conveyor belt motor driver/control section
Control Power Box
Fig. I-3a - Control Power Box in Fig. I-3b – Internal view of the ALM Fig. I-3c - Control Power Box with stainless steel casing card RCU remote control panel (model THS/G or other models on request)
The module contains only the electronics needed for supplying power to the probe and the connection terminals for external sensors and slave devices. The card inside (card ALM), allows connections to be made to the following: • metal detector probe • mains power supply • product transit photocell • external activators and sensors • personal computer
Fig. I-4 Control Power Box: rear and side views 4 THS – FI022GB2K8v3 --- I - DESCRIPTION Conveyor Control System In addition to the functions provided by the Control Power Box, this includes a module to drive the conveyor belt motor. This module is available in two versions: • Card MDT, for fixed-speed applications; in this case, a three-phase input power supply (230V or 400V) is required; • Card MDL, for variable-speed applications; in this case, a single-phase input power supply is required, as the card incorporates an inverter with three-phase outputs.
The versions available, therefore, are the following:
Version Application Input Voltage Maximum Output voltage Maximum power (motor power power of absorbed supply) * motor Conveyor Control System/MDT Fixed speed 230V -18% / +10%, three-phase 1250VA 230V -18% / +10%, 750W with MDT module for 230V power supply without neutral, 48-62Hz three-phase 48-62Hz Conveyor Control System/MDT Fixed speed 400V -18% / +10%, three-phase 2500VA 400V -18% / +10%, 1500W with MDT module for 400V power supply with neutral, 48-62Hz three-phase 48-62Hz Conveyor Control System/MDL Variable 230V ± 10% single-phase 48- 1000VA 230V three-phase 750W with MDL module speed 62Hz 20-60Hz * three-phase asynchronous motor , delta connection
N.B.: if the device is to be mounted on the customer’s own conveyor belt, please specify the power supply voltage in the order.
The unit also incorporates the main switch, the controls for activating the belt and the LED indicators needed for operation (STC card).
ALM card MDT MDL card card
1
2
STC card ALM card
1 On/Off switch Fig. I-4b: Internal view of the Conveyor Fig. I-4c: Internal view of the 2 control panel Control System-MDT Conveyor Control System-MDL
Fig. I-4a: View of the Conveyor Control System
Fig. I-5 Conveyor Control System: rear and side views THS – FI022GB2K8v3 --- I -DESCRIPTION 5
Metal detector The metal detector is enclosed in an extremely robust metal casing, in a tunnel shape (see fig. below), which is designed to be mounted on the conveyor belt or other feed system. The unit contains the sensitive antenna and the control panel. A cable leads from the unit (on the side of the control panel) to connect up with the power supply unit.
Models available
Application THS/STD Model for universal use, for mounting on a conveyor belt
Power-supply and control unit • Power Control Box • Conveyor Control System
Fig. I-7
Order code: 2204 THS-DWxDH (see table I-3) Fig. I-8
TABLE I - 3 . THS/STD & THS/3F * Model DW DH TH DL FHLTP FHP FHW DC TW (opening) Series A 200, 250, ..., 1000 100, 125, 395 290 190 105 TP+10 DW-20 205 DW+420 150,175 TP-30** DW+60** Series B 350, 400, ..., 800 200, 225, ..,275 545 390 290 160 TP+10 DW-20 280 DW+520 Series C 450, 500, ..., 1000 300, 325, 350 635 490 390 210 TP+10 DW-20 320 DW+620 Series D 500, 600, ..., 1300 400, 450, 500 905 490 390 260 TP+10 DW-20 455 DW+720 * For customised versions with different dimensions, see the configuration card at the end of the booklet. ** The position of the support depends on the shape of the load-bearing structure.
Application THS/3F multi-frequency model for mounting on a conveyor belt , for use with a variety of products with significant chemico-physical differences (variable conductivity and so on)
Application examples • Semi-frozen products in aluminised packaging • Products preserved in vinegar or oil, meat, fish etc.
Power-supply and control unit • Power Control Box • Conveyor Control System Fig. I-9
Order code: Dimensions THS/3F-DWxDH (see table I-3) As for the THS/STD model
6 THS – FI022GB2K8v3 --- I - DESCRIPTION
Application THS/MN model for mounting on a conveyor belt, with high discrimination between contaminating ferromagnetic metal and product, which can also be used with product packed in non-magnetic metal containers
Application examples • Products in packaging with a high aluminium content
Power-supply and control unit The power supply group comprises two units: a standard power supply unit (PCB or CCS) and a probe power-supply unit. Fig. I-10 • Power Control Box • Conveyor Control System • Probe power-supply unit
Order code: THS/MN-DWxDH (see table I-4)
pm2071ab Fig.I-11
TABLE I - 4 .THS/M * Model (opening) DW DH TH FHW TW 150 350, 550 150 570 DW+60 DW+620 200 350, 550 200 620 DW+60 DW+620 * For customised versions with different dimensions, see the configuration card at the end of the booklet.
Application THS/SL SLIM LINE model for mounting on a conveyor belt , with extremely reduced dimensions in the direction of transit
Application example • Weighing machines
Power-supply and control unit • Power Control Box • Conveyor Control System
Fig. I-12
Order code: THS/SL-DWxDH (see table I-5)
Fig. I-13 – Drawing M2202D
TABLE I - 5 .THS Slim Line* Model opening) DW DH TH DL FHL TP FHP FHW TW Series A 125, 150, ..., 450 100, 125 330 175 90 105 TP+10 DW- 20 DW+400 Series B 150, 200, ..., 450 150, 175, 200 405 175 90 105 TP+10 DW- 20 DW+400 * For customised versions with different dimensions, see the configuration card at the end of the booklet. THS – FI022GB2K8v3 --- I -DESCRIPTION 7
Application THS/A model for universal use, with a tunnel that can be opened if the conveyor belt can not be interrupted for installation purposes
Application examples • Plastic recycling, quarries, mines etc.
Power-supply and control unit • Power Control Box • Conveyor Control System
Fig. I-14
Order code: THS/A-DWxDH (see table I-6)
m2205 Fig.I-15
TABLE I - 6 . THS/A* Model DW DH TH DL DP FHL RW DS FHW TW (opening) 50 285 290 100 Family A 250, 300, ..., 1500 100 335 290 DS+35 DL+50 30 100 DW-20 DW+150 150 385 290 100 200 535 390 150 250 585 500 30 150 DW+150 300 735 500 30 200 DW+150 350 785 600 50 200 DW+170 400 935 600 50 250 DW+170 Family B 500, 550, ..., 1500 450 985 600 DS+35 DL+50 50 250 DW-20 DW+170 500 1035 600 50 250 DW+170 550 1185 750 50 300 DW+170 600 1235 750 50 300 DW+170 650 1385 750 50 350 DW+170 * For customised versions with different dimensions, see the configuration card at the end of the booklet..
Application THS/G model with circular tunnel for products transported in tubing In the case of the THS/G model, the probe is designed to be fixed, generally, in an inaccessible position. The detector controls are therefore incorporated into the power supply unit, on the RCU card fixed to the casing cover.
Application examples • Installation between multi-head weighing machines and packaging machines • Gravitational and pneumatic product transport in general: powders, granulated products, liquids etc.
Power supply unit • Power Control Box
Fig.I-19 Order code: THS/G-T (see table I-7) 8 THS – FI022GB2K8v3 --- I - DESCRIPTION
Product set-aside ejection Air Probe-Metal Detector transit ejector full confirm pressure photocell sensor o sensor sensor
ALM Alarm reset contact
RCU Power supply unit Inhibition (Control Power Box) contact Buzzer/flashing light THS/G Flashing light indicating test due
alarm
malfunction
Computer or printer Fig. I-20a - Model THS/G: ALM & RCU cards Fig. I-20b - Model THS/G: Block diagram
Fig. I-21 THS/G : probe dimensions (Drawing PM2581F)
TABLE I - 7 THS/G* Model (opening) T TW DH VL HL THS/G-50 50 380 250 205 226 THS/G-100 100 380 250 205 226 THS/G-150 150 430 300 255 276 THS/G-200 200 480 350 305 326 THS/G-250 250 530 400 355 376 * For customised versions with different dimensions, see the configuration card at the end of the booklet.
THS – FI022GB2K8v3 --- I -DESCRIPTION 9
Options
THS-FB Conveyor Belt Belt with speed adjustment, robustly built and with simplified maintenance, available in several versions
Features • Belt available in PVC approved for food handling. • Adjustable speed: 19...58m/'. • Electrical characteristics: see Conveyor Control System unit. • Compressed air supply: pressure: 200-1000 kPa; airflow: 50 litres/min (piston ejector), 600 litres/min (airblow ejector, optional) • Dimensions: see figures below.
Models * Application Features Models THS Type (width x belt THS THS/M THS/3F length) THS/SL 300 x 1500mm packaged or Conveyor belt with block. loose product 500 x 1500mm Devices included: • • • • photocell • buzzer/flashing light • two auxiliary emergency buttons THS-FB/1 300 x 1500mm packaged Conveyor belt with piston ejector. product 500 x 1500mm Devices included: • • • • as THS-FB type 1 • piston ejector
THS-FB/2 300 x 1500mm packaged Conveyor belt with piston ejector and product 500 x 1500mm accessory devices. Devices included: • • • • as THS-FB type 2 • ejection confirmation sensor THS-FB/3 • full set-aside container sensor • insufficient air-pressure sensor • blue flashing light to indicate test due
“Supermarket compliant" system * N.B.: the conveyor belt is available only for probes belonging to the A and B Series.
A
B
Fig. I-22a Photocell (A) and Fig. I-22b buzzer/flashing light Fig. I-22c auxiliary emergency Fig. I-22d ejector unit retroreflector (B) button A A B
B
Fig. I-22e detail of ejector Fig. I-22f ejection confirmation Fig. I-22g insufficient air Fig. I-22h blue flashing light to piston sensor (A) and full set-aside pressure sensor indicate test due container sensor (B)
10 THS – FI022GB2K8v3 --- I - DESCRIPTION
Fig. I-24a conveyor belt with THS probe from Family A
THS-FB conveyor belt options
Fig. I-23a - Product- Fig. I-23b – Castor Fig. I-23c - Foot containment panels Code: 21548 Code: 21525 Code: 21533
Fig. I-23d – Mounting kit for bar-code readers (both types)
Code: 21613
Fig. I-23f – Airblow ejector
Characteristics: Max. weight of pack (for pack with low sliding friction): 1 kg; Compressed air supply: pressure 200-1000 kPa; min. airflow 600 litres/min
Code: 22477
Fig. I-24b conveyor belt with THS probe from Family B
THS – FI022GB2K8v3 --- I -DESCRIPTION 11
Other optionals for THS metal detectors Models THS
Option THS/STD THS/SLSL THS/M THS/G THS/3F Connecting cable between power supply unit and probe of non-standard length (max. 40m)
•••• Order code: 19992
RS485 interface, required for: • network connection of several metal detectors • connection of one or more metal detectors over long distances
Order code: 17828 • • • •
Management of Picket-Fence barcode reader.
N.B.: the bar-code reader application is an alternative to use of the remote
control unit • • •
Order code: 18701 Management of Step-Ladder barcode reader.
N.B.: the bar-code reader application is an alternative to use of the remote
control unit • • •
Order code: 19012 Remote control unit on Control Power Box (for probes located in inaccessible positions). Cable length: 2.5m
N.B.: the remote control unit application is an alternative to use of the bar-
code reader • • • Order code: 21560
Remote control unit on Conveyor Control System (for probes located in inaccessible positions) Cable length: 2.5m
N.B.: the remote control unit application is an alternative to use of the bar- • • • code reader Order code: 21559 Power supply transformer unit
115/230V~ transformer unit, to be used to power a THS fitted with an MDL module at 115V~. Order code: 23181 • • •
400/230V~ transformer unit, to be used to power a THS, whether fitted with an MDL module or not, at 400V~. Order code: 23182 • • • •
12 THS – FI022GB2K8v3 --- I - DESCRIPTION
THS metal detector accessories Set of quality control test samples
Available in the following versions:
Code Samples in ferrous Samples in stainless Samples in non-ferrous metal AISI 420 steel AISI 316 metal 18711 ø0.8mm ... ø2.5mm sphere ø1.0mm ... ø3.5mm sphere ---
22605 ø3.0mm ... ø5.5mm sphere ø4.0mm ... ø6.5mm sphere --- 22606 ø3.0mm ... ø5.5mm sphere --- ø4.0mm ... ø6.5mm sphere 22607 ø0.8mm ... ø2.5mm sphere --- ø1.0mm ... ø3.5mm sphere
MD Scope program Remote control and programming with oscilloscope function
Order code: 26894
THS – FI022GB2K8v3 --- I -DESCRIPTION 13
Technical Characteristics
Control Power Box In watertight casing (grade of protection: IP65) Standard power supply Dimensions: 250x150x300mm (wxdxh) unit Power supply voltage: 115/230 V~ (+10 / -22%), single phase - 48/62 Hz Maximum power absorbed: 60 VA (THS/MN: 200VA)
Conveyor Control In watertight casing (grade of protection: IP65) System Dimensions: 250x180x300mm (wxdxh) Power supply unit with inverter card Models available
Version Application Input Voltage Maximum Output voltage Maximum power (motor power supply) power of absorbed * motor Conveyor Control System/MDT Fixed speed 230V -18% / +10%, 1250VA 230V -18% / +10%, 750W with MDT module for 230V power three-phase without three-phase 48-62Hz supply neutral, 48-62Hz Conveyor Control System/MDT Fixed speed 400V -18% / +10%, 2500VA 400V -18% / +10%, 1500W with MDT module for 400V power three-phase with three-phase 48-62Hz supply neutral, 48-62Hz Conveyor Control System/MDL Variable speed 230V ± 10% single- 1000VA 230V three-phase 750W with MDL module phase 48-62Hz 20-60Hz * three-phase asynchronous motor , delta connection
Probe-electronics unit Tunnel-shaped metal structure containing the sensitive antenna and the control panel Dimensions: see preceding pages.
Special features • Ultra-high sensitivity • High immunity to environmental interference • LCD display (4 lines of 20 characters each) to show data • Remote or direct programming of the operating parameters (type of product, immunity level, speed of transit, processing of signal, control over external actuators, etc.) by means of keyboard • Audio and visual detection indicators. • Display of the signal level by means of bar-graph. • Statistical analysis of the number of inspected and contaminated products • ISO 9001 product quality control • THS/A model: model with tunnel that can be opened • Model THS/SL (Slim Line): extremely compact probe • Model THS/3F: detector for magnetic and non-magnetic metals, for use with different types of product thanks to selection of the operating frequency • Model THS/PH: model especially designed for the pharmaceutical industry • Model THS/M: detection of ferromagnetic metals when considerable quantities of aluminium or other non-magnetic metals are present • Model THS/G: probe with circular opening for checking material transported in tubing.
Password 6 levels: operator / supervisor /engineer/ quality control operator / head of quality control / remote programming
Stored sets of 250 sets of parameter settings may be stored, corresponding to 250 possible different products parameters
14 THS – FI022GB2K8v3 --- I - DESCRIPTION
Control inputs Connector for link-up to • photocell • manual reset button • downstream belt authorisation • ejection confirmation • set-aside contained full sensor • encoder to detect the belt speed • emergency button • barcode reader (on demand) • compressed air pressure sensor (for ejection) Serial interface RS232 Serial interface RS485 (on request)
Outputs 5 programmable relays (250Vac - 3A) to activate the external support units •alarm relay •malfunction relay •ejector relay •upstream belt authorisation relay •auxiliary relay
Ejection The system can use the following types of ejector: •compressed air jet •piston •retractable belt Power: compressed air (200-1000 kPa), pressure: 600 litres/min (airblow ejector); 50 litres/min (piston ejector); 100 litres/min (retractable belt ejector).
Alarm signalling Visual: by means of indicator light on central electronics unit Audio: by means of buzzer on central electronics unit By means of output relays
Environmental Working temperature: 0-50°C conditions Humidity: 5-90%, without condensation
System including Belt available in PVC approved for food handling on request., conveyor belt Dimensions, weight and accessories: see the configuration sheet at the end of the manual.
THS – FI022GB2K8v3 --- V - MAINTENANCE 15 INSTALLATION
Observe current regulations regarding electrical and personal safety for both the operator and the installer when installing the device.
BEFORE INSTALLING THE DEVICE READ THE SECTIONS "General guidelines for mechanical installation" and " General guidelines for electrical installation " CAREFULLY. These sections contain some important information regarding sources of electromagnetic interference which may exist in the installation environment.
THEN MOVE ON TO INSTALL THE DETECTOR ACCORDING TO THE FOLLOWING SECTIONS, WHICH DESCRIBE:
• OPERATIONS RELATING TO A CEIA INTEGRATED SYSTEM: models mounted on a CEIA conveyor belt or models that do not need any accessories to operate, such as the THS/PH.
• DETAILED OPERATIONS RELATING TO A NON-INTEGRATED SYSTEM, CREATED BY THE CUSTOMER AROUND THE THS DETECTOR (METAL DETECTOR + POWER-SUPPLY UNIT), with guidelines on the location of accessory devices and their programming. Reading of point 1 is nevertheless recommended in this case as well.
FINAL CHECKS ON INSTALLATION AND PROGRAMMING For the installation checks you need to be able to switch on the system, understand the signals given during use and set the applicable operating parameters. These operations are described in the first part of the “USE” section.
In order to carry out installation operations properly, refer to the information contained in the " Guide to the applicable installation operations " on the next page.
16 THS – FI022GB2K8v3 --- V - MAINTENANCE
Guide to the applicable installation operations
Operation Section / Paragraph to read
CEIA integrated system with Non-integrated THS system, without conveyor belt conveyor belt
Unpacking the device and checking that the various _ components of the system are all there. Reading the installation INSTALLATION SECTION INSTALLATION SECTION instructions • General guidelines for mechanical • General guidelines for mechanical installation installation • General guidelines for electrical • General guidelines for electrical installation installation • Installation of a CEIA THS integrated • Mechanical installation of the model system with conveyor belt THS/PH • Electrical installation - General notes • Electrical installation - General notes • Non-integrated THS system supplied without conveyor belt: detailed construction notes and selection of operating parameters • Electrical installation: detailed notes Switching on and checking the OPERATING INSTRUCTIONS SECTION OPERATING INSTRUCTIONS SECTION safety devices • Controls and indicators • Controls and indicators • Switching on the metal detector • Switching on the metal detector Preliminary operating checks: OPERATING INSTRUCTIONS SECTION INSTALLATION SECTION Setting the applicable installation • Automatic operation using a bar-code • Non-integrated THS system supplied parameters reader without conveyor belt: detailed construction notes and selection of PROGRAMMING SECTION operating parameters • Programming instructions Menus - Ejection PROGRAMMING SECTION - THS Configuration • Programming instructions - ALM Configuration Menus - Ejection - I/O status - THS Configuration - ALM Configuration - I/O status Preliminary operating checks: OPERATING INSTRUCTIONS SECTION Functional check of the slave • Signals given during use devices: motor, ejector, signalling • Use of the conveyor belt devices etc. • Alarm reset
PROGRAMMING SECTION • Programming instructions Menus - Ejection - THS Configuration - ALM Configuration - I/O status
The availability of the various parameters on various models is indicated. If a parameter is specific to the current product it is identified. . Preliminary operating checks: OPERATING INSTRUCTIONS SECTION Checking environmental • Checking for environmental electromagnetic interference interference Preliminary operating checks: OPERATING INSTRUCTIONS SECTION Checking the sensitivity using a • Analysis mode selection criteria sample supplied • Sensitivity check with reference sample
Memorisation of the products OPERATING INSTRUCTIONS SECTION being used with possible use of • Analysis mode selection criteria an autolearn process • Programming the metal detector according to the kind of product
PROGRAMMING SECTION • Programming instructions (Prod. command). • Automatic operation using a bar-code reader
General guidelines for mechanical installation
THS – FI022GB2K8v3 --- V - MAINTENANCE 17
• Load-bearing structure
During assembly the solidity of the load-bearing structure should be borne in mind, in order to ensure that the detector does not oscillate, causing false alarms
• Metal structures surrounding the Metal Detector/conveyor belt system
Fixed metal structures All the fixed metallic structures in proximity to the detector must be securely fastened down with bolts and self-blocking nuts and, if they form intermittent loops, soldered. This is due to the fact that sporadic metallic contacts due to vibrations, resulting in the intermittent short-circuiting of the voltages induced by the probe, may lead to interference with subsequent false alarms in the device.
Fig. II-1 Fixed metal structures THS/M Installation of structures or equipment with ferromagnetic frames in the vicinity of the Metal Detector is not recommended. If this proves unavoidable, they must be placed at least distance D from each side of the probe.
Other THS models Fixed metal structures (frames, metal furniture, etc.) must, in all cases, be located at a distance that is at least equal to the height of the probe (A), on both sides of the probe.
| Model THS/M THS/A Other models | | | | D ≥ 3 DH ≥ 2 DH ≥ DH | | |
Fig. II-2 : Fixed metal structures Moving metal structures Such structures, especially when of a considerable mass (mills, hoppers, etc.), must be located as far away as possible from the probe.
| Model THS/M THS/A Other models | | | | D ≥ 10 DH ≥ 10 DH ≥ 6 DH | | |
Fig. II-3 Moving metal structures
General guidelines for electrical installation Possible sources of electrical interference may be power supply cables (electromagnetic fields generated by alternating currents) or impulsive electromagnetic sources (electrical motors with high start-up absorption of power and their power supply cables, fluorescent lights, emergency generators, remote control devices, etc.) located near the probe.
• Power supply cables to other devices. The route of the conductors must never be allowed to create a large-scale electromagnetic loop. The power supply cables must be distanced as far as possible from the probe and braided with the shortest possible pitch. In general, it is advisable that the power supply cable harnesses be inserted into special insulated channels. In the event that the conductors have to pass near the probe of the metal detector, it is advisable that they be inserted into an iron tube, either electro-welded or drawn, which is at least 2 mm thick and has a suitable diameter. N.B: this solution is only valid if the tube is not subject to vibrations; should it be subject to vibrations this solution could even be counter-productive.
• Grounding. This connection must lead directly to the electrical power supply board and must not be derived from any other electrical devices. 18 THS – FI022GB2K8v3 --- V - MAINTENANCE
M1 MD M2
QE
Fig.II-4. QE: electrical board; M1: machine 1; M2: machine 2; MD: metal detector.
ci • Warning! If metal ducts are used for production line power and control lines, it is advisable not to create an electrical connection between the conveyor belt frame M1 MD M2 and other nearby devices through the same ducts: if this is done, interference due to multiple ground returns
could be produced. Fig. II-5. ci: ducts in insulating material; M1: machine 1; M2: machine 2; MD: metal detector
• Impulsive sources. In general, impulsive sources must be distanced or eliminated. It is therefore recommended that, during installation, the following procedures be carried out:
1 position as far as possible from the probe any motors, electrical power boards or electromagnetic actuators (it is recommended that they be replaced with similar pneumatic devices); position fluorescent lights and their respective reactors at a distance from the metal detector probe; where possible replace fluorescent lights with filament lights.
2 equip electrical motors with special iron screens and mains filters of sufficient capacity. It is recommended that motors running on alternating current be used as opposed to those running on direct current. The table that follows provides some general guidelines for the distances to be placed between the probe and asynchronous motors, depending on their power.
Table II-A Recommended minimum distance between the probe and motors with alternating current (without screening of the motor) Power Minimum distance THS/M & THS/A Other THS models 0,5 CV 5 x DH 3 x DH 1 CV 6 x DH 4 x DH 2 CV 8 x DH 5 x DH 3 CV 10 x DH 6 x DH > 20 CV 15 x DH ( >10 x DH if screened) 10 x DH ( 6 x DH if screened)
2.1 In the immediate proximity of the metal detector, the motors may be screened by means of cylindrical enveloping in iron; such cylinders must have a sufficiently large diameter in order to contain the motors and a thickness of not less than 2 mm. The cylinders must be of the unwelded type.
3 fit the electromagnets, remote controls and continuous current motors with RC muffling nets (ask our technical office for details of the dimensions) and braid the respective power supply cables with as short a pitch as possible.
Fix the cable which connects the probe to the power supply unit so that it can not oscillate or vibrate. If the cable is too long, DO NOT CUT THE CABLE: COIL UP THE EXCESS! THS – FI022GB2K8v3 --- V - MAINTENANCE 19
Installation of a CEIA THS-FB integrated system with conveyor belt
Disconnect the system from the various power sources before carrying out any movement.
Mechanical installation of THS-FB integrated system with conveyor belt
Positioning the conveyor belt Use lift trucks or sling the load-bearing structure, and ensure that the load is balanced during movement. Avoid deforming the structure or its component parts. Keep the packaging materials for possible future transport.
Never attach lifting gear to the Metal Detector probe or the actuators. Fig II-6 Ejector: mounting the safety shield Fix the shield by tightening the knobs provided.
Fig II-7a Fig II-7b Assembling the buzzer/flasher Fit the buzzer/flasher module into the support and rotate clockwise.
Fig II-7c Fig II-7d Adjusting the height of the belt Raise or lower the adjustable feet or castors of the load-bearing structure.
Fig II-8a - Adjusting a foot Fig II-8b - Adjusting a castor
20 THS – FI022GB2K8v3 --- V - MAINTENANCE
Electrical installation - General notes
Observe current regulations regarding electrical and personal safety for both the operator and the installer when installing the device. Connect the apparatus to the mains power supply only after first carrying out all the other connections needed for complete installation.
These instructions for electrical installation apply to both the CEIA INTEGRATED THS SYSTEM, with conveyor belt, and the CEIA NON-INTEGRATED THS SYSTEM, without conveyor belt.
Connecting to the mains power supply
Only make the connections to the internal terminals of the power supply unit when the unit is disconnected from the mains
Connection to the ground
Connect a grounding conductor to the PE terminal ; the size of the conductor should be in line with the safety standards in force.
Fig. II-9a Terminal PE
Control Power Box • Connect directly to terminal board J17 on card ALM. • Conductor section: 1.5 mm2.
PE Put in a magnetothermic switch upstream:
Fig. II-9b Control Power Box Voltage Current 250Vac 2A 115Vac 4A
Conveyor Control System • Connect to S1 main switch input terminals. • Conductor section: 2.5 mm2.
Put in a magnetothermic switch upstream (curves D) : 10A
Fixed-speed Conveyor Control System, with MDT card
IS • The connection is three-phase, and differs according to the voltage.
Check that the voltage corresponds to the voltage on the identification plate (specify the power-supply voltage when ordering).
Fig. II-9c THS – FI022GB2K8v3 --- V - MAINTENANCE 21
Voltage 400V 3~ with neutral conductor voltage 230V 3~ without neutral conductor
N N
PE PE 2200 2199 Fig. II-9d Fig. II-9e
Variable-speed Conveyor Control System with card MDL
IS • Single-phase connection.
• Put in a ground fault interrupter upstream, provided that the trip current is at least 300 mA.
Connect the safety conductor permanently (without intermediate plugs) to terminal PE on the casing.
Fig. II-9f
Selection of the power supply voltage for the metal detector only - Control Power Box Power Supply Unit
Using the I1 switch, it is possible to set the metal detector power supply voltage to 115Vac or 230Vac. In the illustration, the selector is positioned at 220-240Vac. I1 N.B.: the conveyor belt motor must be set up for the power supply voltage of the system: the power supply voltage should therefore be specified at the time of ordering.
Fig.II-10
If the power supply to the device is different from that specified on the plate and/or from that chosen at selector I1, permanent damage may be caused to the device.
CEIA will not be held responsible for damage to people, animals or objects caused by failure to obey this instruction. Verification that the power supply conforms to the values specified above and to the regulations in force is the total responsibility of the customer.
Connection of the compressed air supply Connect any components powered by compressed air to a source which complies with the specifications in the “Technical characteristics” section, or otherwise specified in the configuration sheet enclosed with this manual.
22 THS – FI022GB2K8v3 --- V - MAINTENANCE
Non-integrated THS system supplied without conveyor belt: detailed construction notes and selection of operating parameters The following notes provide additional instructions necessary for installing the detector on a conveyor belt or other transport system set up by the customer. For the installation checks you need to be able to switch on the system, understand the signals given during use and set the applicable operating parameters. These operations are described in the first part of the “USE” section.
Mechanical Installation
Controls According to regulation EN60204-1, the main switch and the other controls to be used by the operator must be at a height ranging from 600mm to 1,800mm from the flooring. If it proves impossible to comply with this measurement due to the configuration of the system, an additional control unit which complies with the regulations must be set up.
Mechanical installation of the metal detector Mount and fix the probe onto the structure of the conveyor belt (use the four holes located on the base-plates. N.B.: on some models the base-plates can be fixed in two different positions to adapt to the shape of the load-bearing structure). The belt must pass through the tunnel.
The structure must be stable and not subject to vibrations.
Mechanical installation of the power supply unit The power supply unit must be firmly attached to the load-bearing structure by means of four screws; it must be close to the central electronics unit and to the external subsidiary devices connected to the unit (photocell, ejector, etc.).
Mechanical installation of the THS/G probe Mount the probe on the pipe carrying the material to be inspected and fix it with screws and plastic spacers, using the holes provided on underside ( see Fig. "Dimensions of the probe", dimension FHW).
Fix the control unit in a convenient position for use, within the limit set by the length of the probe connecting cable.
Fix the cable which connects the probe to the power supply unit so that it can not oscillate or vibrate. If the cable is too long, DO NOT CUT THE CABLE: COIL UP THE EXCESS!
Proximity limits around the THS/G probe The distance between the probe and fixed or moving masses depends on the sensitivity selected and on the size of the masses. The figure below shows: • the minimum distance D between the probe S and the support plate P • the minimum distance H between the probe S and the deflector f, based on a sensitivity setting of 280 and a flap- type deflector in stainless steel. If the sensitivity or the type of deflector is changed, this minimum distance may decrease: using the procedure for checking environmental interference (see “Maintenance” section), check that activation of the deflector does not influence operation of the metal detector. THS – FI022GB2K8v3 --- V - MAINTENANCE 23
D: distance between probe S and support plate P d: rigid plastic spacer; f: steel flap deflector (dim. 290x200x2mm); H: distance between probe S and deflector f p: stainless steel support plate; S: probe. T: diameter of the probe. t: plastic pipe
Fig. II-12 – fixing the THS/G probe
THS/G : mounting the power supply unit The power supply unit must be firmly fixed to the supporting structure with four screws, near the electronics unit and the slave devices connected to the power supply unit (photocell, ejector etc.). For the location of the holes provided for fixing the unit, see Figure I-14a. 24 THS – FI022GB2K8v3 --- V - MAINTENANCE
Conveyor belt
The distances quoted below are indicative only, and subject to variation according to the sensitivity required and to the type of probe. When installation has been completed, therefore, correct operation should be checked.
Load-bearing structure of the conveyor belt
The load-bearing structures of the conveyor belt must be stable and not subject to detectable vibration during movement of the belt.
THS/M The structure of the belt must be in non-magnetic steel (e.g. non-magnetic AISI 304).
Fig. II-13 Load-bearing structure Rollers of the conveyor belt In general, it is advisable that any rollers located near the antenna be of insulating material. In which case, there must be an electrical connection on only one side of the roller, in order to allow the discharge of any electrostatic charges.
DH | Model THS/M THS/A Other models | | | | D ≥ 3 DH * ≥ 3 DH * ≥ 1,5 DH ** | D | |
* use nonmagnetic steel bearings. I C ** plastic roller with fixed nonmagnetic steel axle and nonmagnetic steel bearings. B N.B.: the bearings must be placed at the ends of the rollers, never in the middle. Fig. II-14. Rollers in insulating material with metallic bearings I: insulated support C: non-insulated support; B: bearing Metal rollers , pulling or free, must be located at a distance D, to both sides of the antenna. Such rollers must also be insulated on a single supporting piece in
order to avoid forming electromagnetic coils and allow the discharge of any DH electrostatic charges. D
I
C | Model THS/M THS/A Other models | Fig. II-15a. Free metal rollers | | I: insulated support C: non- | D ≥ 6 DH ≥ 4 DH * ≥ 2 DH | insulated support | |
DH
C: non-insulated support I: insulated support D S: screening I
S
C Fig. II-15b. Pulling metal rollers
Metal rollers must be perfectly concentric.
YES! NO! Fig. II-16 THS – FI022GB2K8v3 --- V - MAINTENANCE 25
The motors must be located at a distance D from the antenna, adopting measures identical to those described for the rollers above.
Fit electrical motors with special iron screens and mains filters of sufficient DH capacity. It is recommended that motors running on alternating current be used rather than those running on continuous current. The table that follows provides some general guidelines for the distances to be placed between the probe and asynchronous motors, depending on their power D
Minimum distance advisable between the probe and motors with alternating I current (without motor screening)
| Models THS/M THS/A Other models | S | | | D 0,5 CV ≥ 5 DH ≥ 5 DH ≥ 3 DH | | 1 CV ≥ 6 DH ≥ 6 DH ≥ 4 DH | | | C
• In the immediate proximity of the metal detector, the motors may be screened Fig. II-17. motors by means of cylindrical enveloping in iron; such cylinders must have a sufficiently large diameter to contain the motors and a thickness of not less C: non-insulated support than 2 mm. The cylinders must be of the unwelded type I: insulated support • The table indicates distance measurements corresponding to a high S: screening sensitivity level; for lower sensitivity levels, distance D may be reduced. Attention: Rollers for V-shaped belts, if attached to the frame on one side only, do not require the insulation of the pin.
As in the preceding case, their distance from the probe must be at least equal to DH D, to both sides of the antenna
| Models THS/M THS/A Other models | D | | | D ≥ 9 DH ≥ 6 DH ≥ 3 DH | | | C Fig. II-18. Metal rollers for V- shaped belts C: non-insulated support Examples of roller insulation I R
Insulation of the pin of a roller.
I: ferrule in insulating material; P: side bulkhead of the belt frame; R: roller. P
Fig. II-19a I R Insulation of the pin support of a roller.
I: bearing support in insulating material; P: side bulkhead of the belt frame; R: roller. P Fig. II-19b
Insulation of the bearing support of a roller pin.
I: ferrule and spacer in insulating material. I
Fig. II-19c
26 THS – FI022GB2K8v3 --- V - MAINTENANCE
Position of the conveyor belt inside the probe • The conveyor belt must pass as close as possible to the lower surface of the tunnel. In order to prevent it from accidentally rubbing against the probe it is advisable that it be supported within the probe by means of a sheet of insulating material , which is thick enough to support the weight of the material being transported (approximately 5-20 mm). It is necessary pi n to take this measure when the belt is of considerable length and must
therefore be supported, while at the same time prevented from vibrating. DH The sheet must not touch the probe (in the illustration an intervening D distance of 5-10 mm is shown); if it were to touch the probe it could send vibrations to the antenna. In any event, if there is a supporting metal layer for the belt, when it arrives at the probe, it must be interrupted for a pm distance D, to both sides of the antenna.
n | Models THS/M THS/A Other models | | | | D ≥ 4 DH ≥ 3 DH ≥ 2 DH | | |
pi
N.B.: THS/M Model: if the product is contained in an aluminium tray, the Fig. II-20. Position of the conveyor optimum distance between the bottom of the tray and the surface of the belt inside the probe tunnel is 20-30mm. pi: sheet of insulating material; pm: N.B.: In the standard structure, the conveyor belt passes through the probe in layer of metal material; n: belt both directions to avoid having to cut and rejoin it if the probe is replaced. If necessary, carry out the join as described in the “Maintenance” section.
Side panels to contain the material in transit • Near the probe, such edges must be made of insulating material (plastic, wood, etc.).
Fig. II-21 Side panels for containing the material in transit
Inserting the conveyor belt on the THS/A model The THS/A model allows the installation of one side of the conveyor belt through the probe, without cutting S the belt itself. The probe has a short section on its A side which can be removed to insert the belt.
Procedure • Remove screws S. • Remove section A. B • Move the belt into the probe, or the probe over the belt, depending on the requirements of the structure. • Fix section A in place again using screws S.
Fig. II-22
THS – FI022GB2K8v3 --- V - MAINTENANCE 27
Transit speed
Programming Generally-applied setting Meaning parameters THS/STD THS/SL THS/3F THS/M THS/G THS/PH Transit speed BS 2 - 250m/’ 2 - 250m /’ 2 - 250m /’ 20 - 70m/’ 2 - 250m /’ 2 - 250m /’
Minimum transit speed BL 2 m/’ 2 m/’ 2 m/’ 20 m/’ 2 m/’ 20 m/’
Maximum transit speed BM 250 m/’ 250 m/’ 250 m/’ 70 m/’ 250 m/’ 250 m/’
transmission constant of KT = transit speed . KT _ _ the motor reducer unit motor driver frequency DI = ø roller + 2 x (thickness of belt) DI Diameter of roller _ _
Encoder constant KE 0-1000 impulses per revolution _ _ (impulses per revolution) Maximum motor MI 60-100 (Hz) - - operating frequency Maximum motor current CU 0.000 - 7.000 A - - consumption
The programming parameters must be properly defined depending on the type of installation.
Fixed-speed application, BS should be assigned the true value of the transit speed. without inverter card, without encoder (KT=0.000, KE=0)
V
Fixed-speed application, BS should be assigned the true value of the transit speed. with MDT card but with encoder (KT=F, KE=0)
V
Variable-speed application, speed detected by the encoder. The speed limits (BL e BM) must be selected. with encoder, without The KT parameter is 0.000. inverter card Assign to the KE parameter the number of pulses per revolution of the encoder. Assign to the DI parameter the value of the diameter of the motor roller (see V table above)
28 THS – FI022GB2K8v3 --- V - MAINTENANCE
Variable-speed application • BS should be assigned the desired value of the transit speed (the current speed is detected by the system based on the working location of the with inverter card, with inverter, or via an encoder if fitted). encoder • Assign to the KE parameter the number of pulses per revolution of the encoder. V • Assign to the DI parameter the value of the diameter of the motor roller (see table) • Assign the maximum motor operating frequency to parameter MI. • Assign the maximum motor current consumption to parameter CU.
Variable-speed application with inverter card, without Some structural relationships must be observed: encoder BL ≤ BS ≤ BM BL ≥ 20 x KT V BM ≤ 60 x KT
The parameter KT depends on the system configuration, and can be determined using the following procedure (it is necessary to obtain a transit speed measurement device):
1. set KT=1.000 2. set BS=50 3. activate the motor and measure the speed of transit Vn 4. calculate KT = Vn/50
By changing the value of BS, the speed can vary between 40% and (2 x MI)% of the nominal value of the motor (corresponding to operation at 50Hz).
N.B.: by modifying the value of KT, the parameters BL and BM are automatically set to nominal values, respectively 20 x KT and MI x KT. BL and BM can also be modified manually.
Example: Motor: operating frequency 50Hz ; maximum frequency 60Hz; maximum current 3A; Encoder 100 impulses/rev.; Roller diameter 60mm, belt thickness 2mm; Desired speed 45m/', minimum 25m/', maximum 50 m/'.
• Set: MI=60, CU=3.000, DI=60+(2x2)=64 • Determine KT via the procedure described above: KT=1.000, BS=50 measured Vn =55 m/' KT=55/50=1.100 • Set BL=25 (correct value to give 20KT=22) • Set BM=50 (correct value to give MI x KT=66) • Set desired speed BS=45
N.B.: The BS parameter is memorised individually for each type of product defined. If required, several speed parameters may be set for the same material by defining an equal number of product types.
THS – FI022GB2K8v3 --- V - MAINTENANCE 29
Accessory devices
Photocell – General rules
Programming Meaning Generally applied setting parameters THS/STD THS/SL THS/3F THS/G THS/M THS/PH PD Distance between metal At the entrance to the probe: 0-2000 mm 50-2000 _ detector and photocell At the exit from the probe: see table II-C mm PH Position of the photocell IN : installed at the entrance to the probe IN _ relative to the probe OUT: installed at the exit from the probe IP Type of “Photocell” input NC,NO _
The photocell should naturally be placed at a height whereby it can have a clear view of the objects on the conveyor belt.
Photocell installed at the entrance to the probe When installed at the entrance to the probe, the photocell distance should be within the range 50mm to PD 2 m S
F N
Photocell installed at the exit from the probe When installed at the exit from the probe, the photocell PD distance (PD in the figure) depends on the belt speed, but should not in any case be less than that indicated in the S following table:
F Table II-C N Belt speed (metres/min) Minimum distance photocell- electronics unit (mm) < 20 50 20 50 Fig.II-24. N: conveyor belt; S: electronics unit; F: photocell; 30 60 d: distance photocell- electronics unit 40 100 50 130 60 160 70 190 80 230 90 260 >100 290
Photocell self-diagnosis If the photocell is in a continuously active state for a long period, this is interpreted as a malfunction of the sensor by the self-diagnosis system. There are many possible causes (wrong position, short-circuited wiring etc.). The self-diagnosis message may appear: - in the case of a conveyor belt without encoder or with Power Control Box, with the belt stopped or moving - in the case of a conveyor belt without encoder or with Conveyor Control System, with the belt moving.
The system is not designed to signal a pack which is stuck for some reason in front of the photocell. For this reason, when the system can detect whether or not the conveyor belt is moving (i.e. when it is equipped with an encoder or with the Conveyor Control System power supply unit), the self-diagnosis function gives an alarm only if the photocell is in a state of malfunction when the belt is moving. On systems without encoder or with the Control Power Box, it is the installer’s and operator’s responsibility to ensure that material does not remain in front of the photocell when the belt is stopped: if it does, the photocell will be continuously active even though it is not malfunctioning. If the foregoing situation can not be avoided, it is advisable to disable photocell self-diagnosis (Parameter PA) Ejector – General rules
30 THS – FI022GB2K8v3 --- V - MAINTENANCE
Programming Meaning Generally applied setting parameters THS/STD THS/SL THS/3F THS/G THS/M THS/PH PL Length of _ 5-80cm _ product pack EM Ejection mo Mode B: halting of the production line and manual elimination of the contaminated material Mode F: automatic set-aside of contaminated material with alarm _ synchronisation Mode S: automatic set-aside of contaminated material with photocell synchronisation Mode SB: halting of the production line with photocell synchronisation and manual elimination of the contaminated material ED Distance of 0-6000mm ejector from probe or Application with photocell: set Dfe parameter (see the following figures) photocell Application without photocell: set Dse parameter ET Ejection relay activation time 0-3200 hundredths of a second The programming parameters which relate to the ejector are CE, CT, EJ, IE, IL and LF (see Programming section).
Position the ejector E at the exit point of the central electronics unit. In general, the ejector position is constrained by the following formulas:
S Dp Dfe ≤ 20 x ( PL + Dp) F E N Dse > 0.5 x (L + PL) PL L Fig.II-25: synchronisation with photocell at the entrance to Dse the probe Dfe
S Dp
F E Dfe ≥ 0.5 x PL N Dse ≤ 20 x ( PL + Dp) PL L Dfe Fig.II-26: synchronisation with photocell at the exit from the Dse probe
S Dp Dse ≤ 20 x ( PL + Dp) E Dse > 0.5 x (L + PL) N PL Fig.II-27 synchronisation with Metal Detector L Dse
S probe/electronics unit of the metal detector L length of probe N conveyor belt Dfe distance photocell-ejector F photocell Dse distance probe-ejector PL length of package Dp distance between packs E ejector
The ejection time ET must be determined by experimentation, as it depends on the type of ejector
To minimise the number of packs rejected at each alarm, it is recommended that Dp is longer than L, so that only one pack is ejected each time the ejector is activated.
THS/M – Specific instructions for ejector Rule Note BS BS: transit speed, in m/min Dse ≥ PL + 0,5xL + 60 x (ejector response time)
For accurate analysis, the previous product must have left Dp = 1,2 x (PL + L) the tunnel before the next one passes through
THS – FI022GB2K8v3 --- V - MAINTENANCE 31 Applications at high speed (belt speeds greater than 60 m/min) In this case, the response times of the photocell, metal detector and ejector can not be ignored. We would generally advise users to check operation of the ejector experimentally, changing its position and adjusting parameter ED.
Programming used in a few common types of installation
Belt block without ejector Photocell at entrance, with ejector pd ed ed
F
E
parameter description value parameter description value code code EM ejection mode B, BS (belt block) EM ejection mode S (synchronised) BS speed belt speed (m/min) BS speed belt speed (m/min) EJ ejection ON PL pack length length of pack (cm, only for THS/M) ED ejection distance ed (mm) pack stop position IP photocell input NO: normally open /NC: norm. closed ET ejection time ejection time (hundredths of a second) LO input logic N: negative / P: positive EJ ejection ON ED ejection distance ed (mm) PD dist. ph.- metal det. pd (cm) PH photocell position IN
Photocell at exit, with ejector Retractable belt pd ed ed
F
E
parameter description value parameter description value code code EM ejection mode S (synchronised) EM ejection mode F (flap) BS speed belt speed (m/min) BS speed belt speed (m/min) IP photocell input NO: normally open NC: norm. closed ET ejection time ejection time (cs) ET ejection time ejection time (hundredths of a sec) EJ ejection ON LO input logic N: negative / P: positive ED ejection distance ed (mm) EJ ejection ON ED ejection distance ed (mm) PD dist. ph.- metal det. pd (cm) PH photocell position OUT
Fig.II-28 F: photocell E: ejector
32 THS – FI022GB2K8v3 --- V - MAINTENANCE Mechanical installation of a bar code reader
Safety precautions Although the power of the laser beam used in this barcode reader is very low, it can be dangerous to the human eye if stared into for long periods of time. Careful attention must be paid to the warnings on use of the laser. These warnings refer to regulations enforced by local authorities.
IEC regulations Warning labels indicating laser radiation and the reader classification are applied to the body of the reader:
Fig.II-29
The device is classified as a Class 2 laser product according to the rules indicated in IEC publication N. 825-1 (1993).
Turn the power off when opening the reader during maintenance or installation to avoid dangerous laser radiation.
Barcode reader kit The barcode reader can also be installed on the THS system at a later date: a special kit is available for this purpose, and includes an enabling code. The reader is available in two versions: • Picket-Fence, optimised for codes with vertical bars • Step-Ladder, optimised for codes with horizontal bars
1 reader 2 Bar code test chart (PCS 0.9) 3 Mounting kit: - bracket- screws Fig.II-30b dimensions
Fig.II-30a composition of the barcode reader kit
THS – FI022GB2K8v3 --- V - MAINTENANCE 33
Distance between the reader and the metal detector probe and distance between packs The reader is mounted upstream of the probe in order to read a code stamped on the pack. If the code is recognised, the reader sends a command to the metal detector to select the relevant product type. The time required by the THS to process the barcode is usually insignificant, but becomes important if the band is changed due to a modification in the type of product.. When the metal detector receives the signal to change product type, an internal adjustment procedure is activated the length of which determines the minimum distance between two packs with different codes, that is to say containing different products. Model / Event Distance between the Distance between the packs barcode reader and the THS probe Dp THS/3F S with change of band BR (BA parameter) D ≥ L + 3000 mm D ≥ 3000 mm between one product p sbr N and the other sbr L D Dp THS/3F S without change of BR band (BA parameter) D ≥ L + 300 mm D ≥ 300 mm between one product p sbr N and the other Dsbr L Dp S BR Other THS models D ≥ L + 300 mm D ≥ 300 mm p sbr N Dsbr L
S probe/electronics unit of the metal detector L length of probe N conveyor belt Dsbr Distance THS probe-barcode reader BR Barcode reader Dp Distance between the packs of different products Position of the reader and the label in transit
A non-rigid mounting, using anti-vibration supports, should be adopted for the reader.
The two types of reader should be mounted as shown in the figures below. Attention must be paid to the position of the pack in transit, in order to ensure that the barcode can be read (angles P, S and T in the following figures).
D P =˜ 0û D
P =˜ 0û P =˜ 0û P =˜ 0û
D
S = 10 - 30û S = 10 - 30û
S = 10 - 30û S = 10 - 30û S = 10 - 30û
T =˜ 0û T =˜ 0û T =˜ 0û T =˜ 0û
Fig. II-31a Step-Ladder reader: mounting Fig. II-31b Picket-Fence reader: mounting 34 THS – FI022GB2K8v3 --- V - MAINTENANCE
Reading features The number of scans performed on the code by the reader, and therefore its decoding capability, is influenced by the following parameters: • number of scans per second • code motion speed • label dimensions • scan direction in respect to code motion
At least 5 scans during the code passage should be allowed to ensure a successful read.
Step-Ladder mode BCR bar code reader
CMD code motion direction at LS speed
LB laser beam
Fig. II - 32
If scanning is perpendicular to the code motion direction ( “step ladder” mode), the number of effective scans performed by the reader is given by the following formula:
SN = ((LH/LS) * 350) - 2 These symbols signify: SN = number of effective scans LH = label height (in mm) LS = label movement speed (in mm/s)
For example, the reader for a 25 mm high code moving at 500 mm/s performs:
SN = ((25/500) * 350) - 2 = 15 effective scans
Suitable values for LH and LS should therefore be chosen, so that:
LH/LS > 0.02
Picket-Fence mode BCR bar code reader
CMD code motion direction at LS speed
LB laser beam
Fig. II -33 If scanning is parallel to the code motion, (“picket fence” mode), the number of effective scans is given by:
SN = (((FW-LW)/LS) * 350) - 2 These symbols signify: SN = number of effective scans FW = reading field width (in mm) LW = label width (in mm) LS = label movement speed
THS – FI022GB2K8v3 --- V - MAINTENANCE 35
Reading field width depends on the distance between the label and the reader. The following figure gives the reading diagram for the following conditions:: • code = interleaved 2/5 or code 39 • PCS = 0.90 • P angle = 0° • S angle = 10° • T angle = 0°
Reader - label distance
reader axis
Distance of the label from the reader axis Fig. II -34 width of the reading field
For example, for a code 50 mm wide moving through at 1500mm/s at a distance from the reader corresponding to a reading field of 200mm, we get:
SS = (((200-50) /1500) * 350) - 2 = 33 effective scans
The position of the reader must therefore be chosen so that FW is at maximum, based on the reading diagram, and LW e LS should be chosen so that
(FW-LW)/LS > 0.02
Kit installation procedure 1. Mechanical mounting, including determination of: • Distance between reader and metal detector probe • code transit speed • label dimensions 2. Electrical connection to the ALM card 3. Assignment of the CEIA enabling code to parameter BE 4. Selection of parameters from the "barcode reader" menu 5. Selection of the corresponding product type, or creation of a new one if necessary 6. Execution of barcode acquisition procedure (command LC) 7. Repetition of steps 5 and 6 for all products being used
36 THS – FI022GB2K8v3 --- V - MAINTENANCE
Electrical installation: detailed notes
Fig. II -35a : Diagram of model THS connections
THS – FI022GB2K8v3 --- V - MAINTENANCE 37
Fig. II -35c : Diagram of model THS/G connections 38 THS – FI022GB2K8v3 --- V - MAINTENANCE
Fig. II -35d : Diagram of model THS-FB connections THS – FI022GB2K8v3 --- V - MAINTENANCE 39
Observe current regulations regarding electrical and personal safety for both the operator and the installer when installing the device. Connect the apparatus to the mains power supply only after first carrying out all the other connections needed for complete installation.
ALM card electrical connections Table II-D ALM card connections Connector Pin Label Input/ Type Range /Max. value Function Output ALM-J1 - - - - - Reserved ALM-J2 - - - - - Reserved ALM-J3 7-8 - Input N.C. contact - Emergency button ALM-J4 1 NC - NC RS 485 serial connection 2 ISO GND - ground (see next table) 3 RX- Input RX- 4 RX+ Input RX+ N.B.. the ground contact is insulated from the power 5 TX+ Output TX+ supply unit ground, and is provided for connection of 6 TX- Output TX- RS485 cable shielding (if required) ALM-J5 1 -V Output -V 0V Bar-code reader 2 -V Output -V 0V 3 TXD Output TXD - 4 RXD Input RXD - 5 +VB Output +VB 20-26Vcc, 0.15A ALM-J6 2 - Input RXD - RS 232 serial connection 3 - Output TXD - (see next table) 5 - - ground - 6 - Input DTR - ALM-J7 - - - - - reserved ALM-J8 - - - - - reserved ALM-J9 - - - - - reserved ALM-J10 1 +Vin - +V 20-26Vcc, ** +V (high logic level/sensor power supply) 2 lid full Input N.O. contact* 0V... +Vin container full 3 -V - ground - 0V (low logic level/ power supply ground) 4 +Vin - +V 20-26Vcc, ** +V (high logic level/ sensor power supply) 5 eject confirm . Input N.O. contact* 0V... +Vin ejection confirmation 6 -V - ground - 0V (low logic level/ power supply ground) 7 +Vin - +V 20-26Vcc, ** +V (high logic level/ sensor power supply) 8 photocell Input N.O. contact* 0V... +Vin photocell 9 -V - ground - 0V (low logic level/ power supply ground) 10 +Vin - +V 20-26Vcc, ** +V (high logic level/ sensor power supply) 11 follow.conveyor Input N.O. contact 0V... +Vin downstream belt authorisation 12 -V - ground - 0V (low logic level/ power supply ground) ALM-J11 - - - - - reserved ALM-J12 1 +Vin - +V 20-26Vcc, ** +V (high logic level) 2 Inhibition Input N.O. contact 0V... +Vin inhibition 3 -V - ground - 0V (low logic level) 4 +Vin - +V 20-26Vcc, ** +V (high logic level) 5 Reset Input N.O. contact 0V... +Vin alarm reset 6 -V - ground - 0V (low logic level) 7 +Vin - +V 20-26Vcc, ** +V (high logic level/sensor power supply) 8 Encoder Input N.O. contact 0V... +Vin encoder impulses 9 -V - ground - 0V (low logic level/ power supply ground) 10 terra - ground - ground ALM-J14 - - - - - reserved ALM-J15 1 common Output common 250Vca 3A auxiliary relay for test due notification 2 Cont. NC Output N.C. contact 250Vca 3A 3 Cont. NA Output N.O. contact 250Vca 3A 4 common Output common 250Vca 3A authorisation upstream belt relay 5 Cont. NC Output N.C. contact 250Vca 3A 6 Cont. NA Output N.O. contact 250Vca 3A ALM-J16 - - - - - reserved ALM-J17 1 L0 Input - 230Vac ± 10% 48-62Hz mains power supply*** 3 L1 Input - 230Vac ± 10% 48-62Hz 4 PE - ground - safety ground PE **** 40 THS – FI022GB2K8v3 --- V - MAINTENANCE
Connector Pin Label Input/ Type Range /Max. value Function Output ALM-J18 - - - - - reserved ALM-J19 1 terra - ground - ground 2 C1 Output common 250Vca 3A malfunction relay 3 NC1 Output N.C. contact 250Vca 3A 4 NA1 Output N.O. contact 250Vca 3A 5 C2 Output common 250Vca 3A ejector relay 6 NC2 Output N.C. contact 250Vca 3A 7 NA2 Output N.O. contact 250Vca 3A 8 C3 Output common 250Vca 3A alarm relay 9 NC3 Output N.C. contact 250Vca 3A 10 NA3 Output N.O. contact 250Vca 3A ALM-J20 - - - - - reserved ALM-J21 - - - - - reserved (connection of metal detector) ALM-J22 1 +Vo Output +Vo 20-26Vcc, ** reserved 2 +Vo Output +Vo 20-26Vcc, ** reserved 3 -V Output -V 0V ground (external contacts) 4 -V Output -V 0V ground (external contacts) 5 +VDD Output +VDD - reserved 6 -V Output -V 0V ground (external contacts) 7 +VDD2 Output +VDD2 - reserved 8 -V Output -V 0V ground (external contacts) 9 OUT 1 Output OUT 1 18-30Vcc,0..2A motor stop alarm (EM=B) 10 OUT 2 Output OUT 2 18-30Vcc,0..2A reserved 11 PE - ground - safety ground N.C. contact: normally closed contact; N.O. contact: normally open contact
* IE=NO, IL=NO, IP=NO
** The +Vin outputs can provide an overall maximum current of 150mA ; the +Vo outputs can provide an overall maximum current of 150mA
*** On the model with conveyor belt, connect the power supply line to the main switch (see diagram below)
**** IMPORTANT! In the case of the Conveyor Control System , connect the safety conductor permanently (without intermediate plugs) to terminal PE on the casing.
N.B.: the J7, J10 and J12 inputs can be connected to switch contacts or to transistors (in this case the saturation voltage must be < 0,4V). Their logic is determined by the LO parameter (Input logic, see Programming section).
+Vin +Vin +Vin +Vin
0V 0V 0V 0V
LO=N: contact LO=P: contact LO=N: transistor LO=P: transistor Fig. II-36
Make all connections relating to input lines using screened cable, connecting the shielding only at the THS system end to the contacts marked with the symbol which are provided on the various connectors. Lay the cables at a good distance from power lines.
THS – FI022GB2K8v3 --- V - MAINTENANCE 41
Conveyor Control System: Power-supply and motor connections
MDT card
E2199
N N
PE PE
E2199
Fig. II-37a MDT card connections for 230V power supply Fig. II-37b MDT card connections for 400V power supply
Table II-E: MDT card connections for three-phase 230V power supply Connector Pin Label Input/ Type Range /Max. value Function Output MDT-J23 1 1 - Ground - safety ground PE 2 2 - Neutral - Not used 3 3 Input L3 Phase 230V -18% / +10% , 48-62Hz Power supply 4 4 Input L2 Phase 230V -18% / +10%, 48-62Hz Power supply 5 5 Input L1 Phase 230V -18% / +10%, 48-62Hz Power supply MDT-J24 1 1 Output W Phase Input voltage and frequency, 5A (8A breakaway current) Motor power supply 2 2 Output V Phase Input voltage and frequency, 5A (8A breakaway current) Motor power supply 3 3 Output U Phase Input voltage and frequency, 5A (8A breakaway current) Motor power supply 4 4 - - - Not connected 5 5 - Ground - safety ground MDT-J25 1 1 Input NA Cont. 0 - 26Vcc Normally open motor thermal 2 2 Input NA Cont. 0 - 26Vcc protection contact 3 3 - Shield Shield 4 4 Input NC Cont. 0 - 26Vcc Normally closed motor thermal 5 5 Input NC Cont. 0 - 26Vcc protection contact MDT-J26 1 1 Output L3 Phase 230V -18% / +10% , 48-62Hz ALM card power supply 5 5 Output L2 Phase 230V -18% / +10% , 48-62Hz ALM card power supply
Table II-F: MDT card connections for three-phase +neutral 400V power supply Connector Pin Label Input/ Type Range /Max. value Function Output MDT-J23 1 1 - Ground - safety ground PE 2 2 - Neutral - Neutral 3 3 Input L3 Phase 400V -18% / +10% , 48-62Hz Power supply 4 4 Input L2 Phase 400V -18% / +10%, 48-62Hz Power supply 5 5 Input L1 Phase 400V -18% / +10%, 48-62Hz Power supply MDT-J24 1 1 Output W Phase Input voltage and frequency, 5A (8A breakaway current) Motor power supply 2 2 Output V Phase Input voltage and frequency, 5A (8A breakaway current) Motor power supply 3 3 Output U Phase Input voltage and frequency, 5A (8A breakaway current) Motor power supply 4 4 - - - Not connected 5 5 - Ground - safety ground MDT-J25 1 1 Input NA Cont. 0 - 26Vcc Normally open motor thermal 2 2 Input NA Cont. 0 - 26Vcc protection contact 3 3 - Shield Shield 4 4 Input NC Cont. 0 - 26Vcc Normally closed motor thermal 5 5 Input NC Cont. 0 - 26Vcc protection contact MDT-J26 1 1 Output L3 Phase 230V -18% / +10% , 48-62Hz ALM card power supply 2 2 Output Neutral 230V -18% / +10% , 48-62Hz ALM card power supply
MDT - 400Vac: ALM card power supply: pay attention to the connections at connector J26, illustrated in the figure: power supply to card ALM (230V) uses one input phase and the neutral connection. WARNING! incorrect connection may cause permanent damage to the ALM card.
42 THS – FI022GB2K8v3 --- V - MAINTENANCE
Dimensioning of the motor: the voltage and frequency values of the motor must correspond to the mains voltage available. The current limit values are shown in the table.
Motor overload protection: to safeguard the motor, it must be fitted with a suitable thermic relay or a magnetothermic switch (see the diagram shown in the figure)
Fig. II-37b: motor protection. connection of a normally closed Fig. II-37c: motor protection. connection of a normally open contact contact: note the jumper on contacts 4 and 5 of connector J25.
MDL card ( ATTENTION: 230V 1~ only! )
Fig. II-37e MDL card connections.
Table II-G: MDL card connections Connector Pin Label Input/ Type Range /Max. value Function Output MDL-J6 1 ground - ground - Shield 2 ground - ground - Protection ground PE 3 U Output U phase 230V – 2,7A (6 A max breakaway current) motor power supply 4 V Output V phase 230V – 2,7A (6 A max breakaway current) motor power supply 5 W Output W phase 230V – 2,7A (6 A max breakaway current) motor power supply
The power supply voltage to the Conveyor Control System with ALM card must be within the range 230Vac ± 10%, 48-62Hz .
Motor overload protection: the motor is protected from overload directly by the card software:: select the motor nominal current value for parameter CU (see Programming section).
WARNING! Do not connect the cable shielding at the motor end. THS – FI022GB2K8v3 --- V - MAINTENANCE 43
Operation of the relays (J15 and J19 connectors)
Ejector relay (Eject relay): Programmable relay with delayed action (with respect to the detector alarm); capacity; the programming parameters that relate to the functioning of this relay are ED, EM and ET (see Programming chapter). Alarm relay programmable relay with immediate action (with respect to the detector alarm); capacity; the programming parameter that relates to the functioning of this relay is AT. Malfunction relay (Fault relay) Safety operation relay (contacts NA and C connected in correct operation); capacity; the programming parameter that relates to the functioning of this relay is FR. Malfunction conditions are described in the Maintenance section. N.B.: when the device is switched on, the relay is not activated (malfunction condition) for about 6 seconds. Upstream belt authorisation relay (Preceding conveyor relay) Safety operation relay (contacts NA and C connected in correct operation); capacity 3A. Auxiliary relay for signalling when periodic test is due (TEST LAMP relay) Programmable relay ; 3A current-carrying capacity ; the programming parameters relating to operation of this relay are LB and the parameters of the QA configuration menu (see Programming section).
Timing
Belt blocking with manual alarm reset (EM=B) Operation with halting of the production line, manual elimination of the contaminated material and manual reset by the operator. N.B.: The metal detector does not check if there are any subsequent fragments in the material immediately following: all material under the probe must therefore be eliminated along with the part that caused the alarm. To minimise waste of material it is advisable to select a low setting for the ED parameter. Product: loose or packaged Models: All models except THS/PH
Conveyor Control System power supply unit Signal Waveform Function Preceding conveyor relay Upstr. belt authorisation
Alarm relay Signalling
Ejection relay* Belt block
Stop/start/reset button Alarm reset/Restart
Output OUT1 Buzzer/flashing light
Fig. II-38a *:output not activated if MDT or MDL module is fitted
Control Power Box power supply unit Signal Waveform Function Alarm relay Signalling
Ejection relay Belt block ED/BS Stop/start/reset button Alarm reset
Output OUT1 Buzzer/flashing light
Fig. II-38b N.B.: BS = transit speed
Belt blocking with photocell synchronisation and manual alarm reset (EM=SB) Operation with halting of the production line synchronised by photocell, manual elimination of the contaminated material and manual reset by the operator. Allows precise positioning of the material to be rejected. 44 THS – FI022GB2K8v3 --- V - MAINTENANCE
N.B.: The metal detector does not check if there are any subsequent fragments in the material immediately following: all material under the probe must therefore be eliminated along with the part that caused the alarm. To minimise waste of material it is advisable to select a low setting for the ED parameter. Product: loose or packaged Models: All models except THS/PH
Conveyor Control System power supply unit Signal Waveform Function Preceding conveyor relay Upstr. belt authorisation
Alarm relay Signalling
Ejection relay* Belt block
Stop/start/reset button Alarm reset/Restart
Output OUT1 Buzzer/flashing light
Fig. II-39a N.B.: *: output not activated if MDT or MDL module is fitted
Control Power Box power supply unit Signal Waveform Function Alarm relay Signalling
Ejection relay Belt block
Stop/start/reset button ED/BS Alarm reset
Output OUT1 Buzzer/flashing light
Fig. II-39b N.B.: BS = transit speed
Automatic ejection with alarm synchronisation (EM=F) Operation with automatic set-aside of contaminated material. The set-aside method can vary: an ejector may be used – without halting the production line – or the material can be eliminated by using a retractable belt or by inverting the direction of the belt. This application is typically used for loose material. The mode allows the following settings to be selected: –- alarm relay activation time (AT parameter); – ejection distance (ED parameter); – selection of activation time of the ejection relay (ET parameter).
Product: loose Models: All models except THS/PH
Signal Waveform Function Preceding conveyor relay None
Alarm relay t1 Signalling
Ejection relay Ejection ED/BS t1 ET Output OUT1 Ejection Fig. II-29c N.B.: NOTE: BS = transit speed Parameter AT is set to automatic (AT=A); t1= alarm time, generally corresponding to the transit of the metal mass through the probe.
THS – FI022GB2K8v3 --- V - MAINTENANCE 45
Model THS/PH This model uses a dedicated line (OUT2) instead of the ejection relay. N.B.: standard values for parameters ED and AT are ED=0 and AT=A.
Signal Waveform Function Preceding conveyor relay None
Alarm relay t1 Signalling
Ejection relay Ejection
Output OUT2 Ejection ED/BS t1 ET
Fig. II-29d N.B.: BS = transit speed. t1= alarm time, generally corresponding to the transit of the metal mass through the probe
Automatic ejection with photocell synchronisation (EM=S) Operation with automatic set-aside of contaminated material, synchronised by photocell. Very similar to the above application, this mode can be used for packaged products. The mode allows the following settings to be selected: – alarm relay activation time (AT parameter); – ejection distance (ED parameter); – selection of activation time of the ejection relay (ET parameter); – selection of the distance between metal detector and photocell (PD parameter). – selection of the position of the photocell (PH parameter)
Product: packaged Models: All models except THS/PH
Photocell at entrance Signal Waveform Function Photocell Synchronisation
Alarm relay Signalling AT
Ejection relay Ejection
ED/BS ET Output OUT1 None
Fig. II-29e N.B.: BS = transit speed
Photocell at exit Signal Waveform Function Photocell Synchronisation
Alarm relay Signalling AT
Ejection relay Ejection
ED/BS ET Output OUT1 None
Fig. II-29f N.B.: BS = transit speed
46 THS – FI022GB2K8v3 --- V - MAINTENANCE Serial line connection (J3 and J4 connectors)
Connect the serial communication cable to the terminal board: contacts for both RS485 and RS232 standards are catered for.
The RS 485 connection allows: • long-distance connection of a personal computer to a THS metal detector • connection of a personal computer to several metal detectors linked in a network
The RS 232 connection allows: • connection of a personal computer to a single THS metal detector only • connection of a printer fitted with a serial interface
RS 485 connections RS 232 connections
THS personal computer (25p) RX (SI) 2 2 TX TX(SO) 3 3 RX personal computer THS GND 5 7 GND 6 J6 RX- TX- 5 RX+ TX+ 4 THS personal computer TX+ RX+ 3 (9p) TX- RX- RX (SI) 2 3 TX TX(SO) 3 2 RX 5 5 J4 GND GND J6 Fig. II –40a
Fig. II –41a
personal computer J4 THS 1 6 RX- TX- 5 THS printer RX+ TX+ (25p) 4 TX+ RX+ 3 RX (SI) 2 2 TX TX- RX- TX(SO) 3 3 RX DTR 6 20 DTR GND 5 7 GND J4 THS 2 J6 6 TX- 5 THS printer TX+ 4 (9p) RX+ 3 RX (SI) 2 3 TX RX-+ TX(SO) 3 2 RX DTR 6 4 DTR GND 5 5 GND J6 to the next THS N.B.: Select DTR=H mode on the THS
Fig. II –40b
Fig. II –41b
THS – FI022GB2K8v3 --- V - MAINTENANCE 47
Inputs
Make all connections relating to input lines using screened cable, connecting the shielding only at the THS system end to the contacts marked with the symbol which are provided on the various connectors.
Bar-code reader The bar-code reader is supplied upon request: for connection, follow the indications in the plan on the previous pages. Downstream belt authorisation (Following conveyor - Conveyor Control System only) When active, this input indicates that the downstream belt is operating and can accept the product. Photocell When active, this input indicates the passage of the product in front of the photocell. The input is monitored by the self- diagnosis system. Ejection confirmation (Eject confirmation) When active, this input indicates the passage of the product into the set-aside container. The input is monitored by the self-diagnosis system. Container full (Full bin) When active for at least 5 seconds, this input indicates that the set-aside container is full (the malfunction relay is activated). Impulse encoder (Encoder) This input is used to measure the speed of the conveyor belt if an encoder has been installed. The sensor must provide impulses, the amplitude of which is indicated in the table “Electrical connections”, with a minimum frequency of 2 Hz and a maximum frequency of 1kHz. It may be contact type, open collector (NPN o PNP) or push-pull. For correct operation a coefficient KE must be determined during installation and set-up, as per the procedure described in the para. “ Transit speed “. Alarm reset (Reset) When active, this input forces the Metal Detector to exit from the alarm state (used in the case of operation with belt block and manual reset). Inhibition When active, this input disables the detector: it is generally used to avoid false alarms caused by the start-up of the conveyor belt when it is not possible to adjust the mechanical structure of the belt.
Alarm inhibition when belt is switched on If the start-up of the belt is accompanied by interference which is serious enough to cause a false alarm, the alarm can be inhibited:
• Control Power Box: • connect a contact which is activated at start-up to the inhibition input; • set the IN parameter to a suitable value determined by experiment (see “Programming” section).
• Conveyor Control System: simply set the IN parameter to a suitable value determined by experiment (see “Programming” section).
Air pressure sensor When active, this input indicates that the compressed air pressure is sufficient for the ejector.
Container absent (Bin absent) When active for at least 5 seconds, this input indicates that the set-aside container is not in its place (the malfunction relay is activated). 48 THS – FI022GB2K8v3 --- V - MAINTENANCE
Operating instructions
List of preliminary checks If the equipment is being switched on for the first time, some checks must be carried out and the value of some operating parameters must be set. These operations, which are listed on the first page of the INSTALLATION section, are described in the subsequent paragraphs in this section.
Operations during use and areas of competence The system is designed to be managed by 6 different operators with different areas of competence: • operator • supervisor • engineer • quality-control operator • head of quality control • remote programmer
Access to programming differs between the various types of user (operator, supervisor, etc.) according to the following table (see Programming section).
Operation to be carried out Programming access Parameters or menus used level • Adjustment of sensitivity Operator (if enabled) Sensitivity Parameter
Supervisor Product Menu Engineer
• Choice of product Operator Product Parameter
Supervisor Product Menu Engineer
• Memorisation of new products Supervisor Product Menu • Autolearn Engineer Autolearn Menu • Counter management Counter Menu
• Setting up periodic tests and test Head of quality control MD Test Menu reports QA Configuration Menu
• Carrying out periodic tests Quality-control operator Test MD Menu Head of quality control • Printing test reports Head of quality control Print Menu
• Setting detection and ejection Supervisor Rec. parameters Menu (receiver) parameters Engineer Ejec. parameters Menu (ejector)
• Setting of installation parameters Engineer Barcode reader Menu THS Configuration Menu ALM Configuration Menu
• Checking of status of sensors and Engineer I/O Status Menu actuators * menu available only when a barcode reader is fitted.
N.B.: all the parameters shown in the table are accessible in remote mode
THS – FI022GB2K8v3 --- V - MAINTENANCE 49
Controls and indicators
Power switch On the Conveyor Control System model, the On/Off switch is located on the power supply unit cover; in the case of the Control Power Box, an external switch must be fitted.
Switch
Fig. III-1a - Conveyor Control Fig. III-1b - Control Power Box Fig. III-1b - Control Power Box in the System version for the THS/G
Control panel of the probe/electronics unit The control panel, containing the optical indicators and the metal detector controls, is located on one side of the electronics unit:
a green indicator indicates the A POWER presence of power
a red indicator indicates the metal B ALARM detector alarm (detection of a metal fragment or breakdown)
4 lines, of 20 characters each, Alphanumeric display the messages relating to use, C display programming and self-diagnosis of the device
Control panel
Acoustical indicators In the Power Control Box is included an acoustical indicator that is activated in case of alarm for the detection of metallic fragments, for the signalization of a fault or for the request of an operator intervention. 50 THS – FI022GB2K8v3 --- V - MAINTENANCE
Controls The control of the Metal Detector and the setting of the device parameters are performed through the control panel keyboard, as shown below:
Key Function Access and exit from the programming phase
Return back from the submenus to the main menu Exit from the Metal Detector Status visualization Scroll through the sequence of instructions Choice of the parameters to be changed
Modification of the parameter values
Metal Detector Status visualization
Selection of the selected submenu from the main menu Confirmation of the data entered
Reset of some kinds of fault
Conveyor Control System power supply unit control panel On the power supply unit Conveyor Control System, the container cover incorporates a motor control panel. In the case of operation with stopping of the belt and manual resetting, the motor start/stop button also functions as the alarm reset. The motor speed control keys have different functions depending on the version.
Fixed-speed Conveyor Control System Key Status of motor Motor on Motor off No function Manual advance * No function Manual reverse * * if parameter MM = ON
Variable-speed Conveyor Control System Parameter MM = OFF Parameter MM = ON Key Status of motor Status of motor Motor on Motor off Motor on Motor off Increase in speed No function No function Manual advance Decrease in speed No function No function Manual reverse
SchedaPower MDL indicator Motor on indicator
Motor malfunction Motor off indicator indicator Speed increase button
Speed decrease button
Metal detector alarm indicator detector Motor start/stop and alarm reset button
Fig. III-3: commands and indicators on the power unit with inverter card Conveyor Control System THS – FI022GB2K8v3 --- V - MAINTENANCE 51
Visible/audible alarm signalling device The signalling device comprises a flashing light and a buzzer. The sound volume and the type of sound can be selected via minidips.
1 volume & sound selectors
1
Fig. III-4
Switching on the metal detector
If the device is stored for a long period in temperatures outside the operating range, wait for the temperature of the detector to come back within that range before switching on
Power supply unit There are dangerous voltages inside the power supply unit. Close the cover and keep the key safe so that it is only available for use by trained personnel (Regulation EN 60204)
Conveyor belt motor The motor can reach high temperatures during use: do not touch the motor or bring inflammable materials close to it while it is operating or immediately afterwards. Ensure that the cooling air intakes are not obstructed, and that there is free air circulation WARNING: do not set the motor in motion without the conveyor belt: this may lead to damage due to excess revolutions and consequent overheating.
Checking the safety features Before switching on, check that the safety devices with which the system is fitted are in good condition: 1. rollers: protection crankcase for the pin 2. rollers: lower protection panels 3. ejector: protection panels (if fitted)
Also check operation of the emergency button with the belt in motion.
1 1
1 3 3
2 3 2
Fig. III-5 roller safety protection 52 THS – FI022GB2K8v3 --- V - MAINTENANCE
It is strictly forbidden to start up the system if all safety features are not properly functional. Tampering with the safety features is also forbidden, and voids all responsibility of the manufacturer for any damage caused.
Keep the power supply unit panel closed. The key must always be in the possession of an authorised person.
Fig. III-6
Signals at power-up The detector is designed to be switched on directly from the electrical panel that controls the production line. The power supply unit does however contain an auxiliary switch I2, which is normally in the ON position.
The presence of mains power supply is signalled by the lighting up of the indicator located on the control panel (Conveyor Control System) ...
Fig. III-7a
... or of the green LED L2 located on card ALM, near switch I2 (Control Power Box).
I2 L2 Fig. III-7b
When it is first powered up, the Metal Detector’s configuration includes 5 factory-set passwords (shown in the test card at the end of the manual). It is extremely important that the person in charge of the detector modifies the passwords in order to avoid unauthorised access to programming.
When the device is turned on, the display lights up, as do the indicators located on the front of the electronics unit. More specifically, the display shows, in sequence, the serial number and the version of the software program that drives the power supply unit; after that the following is displayed:
in which: THS identifies the model
THS V3.xxx V3.xxx identifies the software version of the metal detector Product productname
| productname indicates the type of programming, specific to one product, which may be chosen from among 250 stored sets, of which 249 can be defined by the user (see Programming chapter); Fig.III-8 each stored programming set is customised and relates to a specific product to be monitored.
Signals given during use
On models where there is a control panel on both the probe and the power supply unit (because the probe is installed in a position which is inaccessible to the operator), the electronics unit display is disabled (the message “Disabled” appears).
Indication of the received signal On the fourth line of the display the signal being received is displayed by means of a horizontal illuminating bar, subdivided into 20 sections. When the signal increases, the bar extends towards the right. The alarm threshold corresponds to 10 illuminated sections: the sections from 1 to 10 are bars, those from 11 to 20 are asterisks THS – FI022GB2K8v3 --- V - MAINTENANCE 53
THS V3.xxx THS V3.xxx THS V3.xxx Product productname Product productname Product productname
| | | | | | | | | | | | | | | | | | | | | * * * * * Fig.III-9a. Example: signal well below Fig.III-9b. Example: signal just below Fig.III-9c Example: signal above the the threshold level the threshold level threshold level (alarm).
Checking for environmental electromagnetic interference The THS Metal Detector has very high immunity to electromagnetic interference. However, it may happen that electrical devices, usually power devices, cause interference which is strong enough to lead to false alarms. To identify these sources of interference the indication of the signal received from the probe, which the detectors normally shows on the display, can be used. Under normal conditions, the indication on the display should correspond to that in Fig. III-9a.
Display Messages The Metal Detector display shows messages relating to its current mode of operation:
DISPLAY MEANING
Normal functioning The Metal Detector is in normal operating mode: THS V3.xxx On the fourth line of the display the signal being received Product productname is displayed by means of a horizontal illuminating bar, | subdivided into 20 sections. When the signal increases, the bar extends towards the right.
Metallic mass detection The Metal Detector is in normal operating mode: it has THS V3.xxx just detected a metal object and activates connected Product productname slave devices. The alarm threshold corresponds to 10 | | | | | | | | * illuminated sections: the sections from 1 to 10 are bars, those from 11 to 20 are asterisks.
access code Programming access phase
000000 The Metal Detector requests a password to be entered.
Programming Sensitivity 265 <- Products The Metal Detector has been set to programming mode: accessible parameters can be modified.
Test procedure **TEST** The Metal Detector requires an operational test to be Product productname carried out (see “Periodic test management” section in | this manual).
Self diagnosis The device, when a possible functional problem is **BIN FULL** Product productname detected, shows on the display the problem kind and
| utters the alarm signal, asking for the intervention of the operator.
54 THS – FI022GB2K8v3 --- V - MAINTENANCE
Display of the status of the Metal Detector
If the (increase) key is pressed when the display shows normal operation, a list of information relating to the Metal Detector’s status is shown: THS/M
Sensitivity 265 THS/MN V3.xxx Cur Alar. 10 Product productname Cur. Obj. 156 Time 12:34 Date 24/10/97 | Next test 15:00 Fig. III-11a
Other THS models: Sensitivity 265 TX program 0
THS V3.xxx Cur Alar. 10 Product productname Cur. Obj. * 156 Time 12:34 Date 24/10/97 | Next test 15:00 Fig. III-11b * not present on THS/G models
Use of the conveyor belt
Starting/stopping the conveyor belt With the correct power supply and with the motor stopped, check that the LED indicators are on or off as shown in the following table:
Indicator Status mains voltage on
motor on off
motor off on
motor malfunction off ! M metal detector alarm off !
• Press the start/stop button to switch on the motor: check that it starts up, and that the “motor on” indicator comes on and the “motor off” indicator goes off.
• To stop the motor press the start/stop button again: check that it stops, and that the “motor on” indicator goes off and the “motor off” indicator comes on. • Fixed-speed Conveyor Control System: check the manual movement of the motor using the and keys (if parameter MM=ON).
Adjustment of the belt speed The motor speed control keys have different functions according to the value of parameter MM (see Programming section). The speed of the conveyor belt can be adjusted by: • programming the BS parameter on the metal detector • simply pushing the keys located on the Conveyor Control System, if parameter MM=OFF.