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Metal DetectionSystems
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1994 SciTronics. All rights reserved. Printed in the U.S.A.
No part of this publication may be reproduced, translated into any language, stored in a retrieval system, or transmitted in anyform by any means without the prior written permission of SciTronics.
Model 1080
Metal Detection System
Product Manual
4630 Churchill, Suite 2
Shoreview, MN 55106
Phone: (612) 415-9690
Fax: (612) 415-9691
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Table of Contents
i
Table of Contents
Warranty ................................................................................................................ iii
SciTronics Quality Control Standards ................................................................... iv
Section 1 IntroductionUsing This Manual .............................................................................................. 1-1
System Overview................................................................................................. 1-2
Standard Components.................................................................................... 1-3
Theory of Operation ...................................................................................... 1-4
Section 2 System OptionsOverview ............................................................................................................. 2-1Splice Detector .................................................................................................... 2-1
Metal Markers (Tramp Metal Locator)................................................................ 2-1
Flag Drop Solenoid Operated ........................................................................ 2-1
Liquid Spray Pneumatic Operated................................................................. 2-2
Coast Alarm ......................................................................................................... 2-2
Long Bar Detector ............................................................................................... 2-2
Shift Register ....................................................................................................... 2-2
Remote Reset ....................................................................................................... 2-2
Rotating Alarm Beacon ....................................................................................... 2-3
Controller/Sensor Connecting Cable ................................................................... 2-3Single-Unit Coil System...................................................................................... 2-3
Backlit LCD Trip Counter ................................................................................... 2-4
Section 3 InstallationOverview ............................................................................................................. 3-1
Unpacking the Metal Detection System .............................................................. 3-1
Detection Coils Station ........................................................................................ 3-1
Selecting an Installation Location ................................................................. 3-1
Assembling the Coils ..................................................................................... 3-2
Dual Coil System..................................................................................... 3-2Mounting the Structure .................................................................................. 3-3
Controller Enclosure ............................................................................................ 3-3
Mounting ....................................................................................................... 3-3
Wiring ............................................................................................................ 3-3
Options
Single Unit Coil System ................................................................................ 3-6
Splice Detector .............................................................................................. 3-6
Flag Drop Marker .......................................................................................... 3-7
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Liquid Spray Marker ..................................................................................... 3-7
Rotating Alarm Beacon ................................................................................. 3-8
Remote Reset ................................................................................................. 3-8
Section 4 OperationOverview ............................................................................................................. 4-1
Startup.................................................................................................................. 4-1
Operation of the Failsafe Circuitry Option .......................................................... 4-1
Shutdown ............................................................................................................. 4-2
System Calibration .............................................................................................. 4-2
Sensitivity Control ......................................................................................... 4-2
Splice Detector .............................................................................................. 4-3
Alarm Delay .................................................................................................. 4-4
Alarm Duration.............................................................................................. 4-4
Flag Drop Marker Option .............................................................................. 4-5
Liquid Spray Marker Option ......................................................................... 4-5
Long Bar Detector Option ............................................................................. 4-5
LED Indicator Lights........................................................................................... 4-6
Section 5 Maintenance and TroubleshootingOverview ............................................................................................................. 5-1
Maintenance......................................................................................................... 5-1
Spare Parts ........................................................................................................... 5-1
Troubleshooting ................................................................................................... 5-1
Gaining Access to the Electronics Modules .................................................. 5-1
Diagnostic LEDs............................................................................................ 5-2
Coil Drive Indicator Light ....................................................................... 5-2
Power A Indicator Light .......................................................................... 5-2
Power B Indicator Light .......................................................................... 5-2
Power C Indicator Light .......................................................................... 5-2
ASP Indicator Light ................................................................................. 5-2
Splice Indicator Light .............................................................................. 5-2
Section 6 System Specifications
Operational Specifications................................................................................... 6-1Electrical Specifications ...................................................................................... 6-1
Physical Specifications ........................................................................................ 6-2
Section 7 DrawingsList of Drawings .................................................................................................. 7-1
Drawings.............................................................................................................. 7-3
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Warranty
iii
Warranty
SciTronics warrants all products of its manufacture to be free from defects in material and
workmanship. This warranty is effective for three years from the date of shipment to theoriginal Purchaser.
Upon notification by the Purchaser, SciTronics will correct any defects in equipment of its
manufacture either by repair in our plant or by supply of replacement parts to the Purchaser.
SciTronics must decide to its own satisfaction that the equipment is defective and has not
developed malfunctions as a result of misuse, modification, abnormal conditions of
operation, or attempted service not authorized by SciTronics.
SciTronics will not accept any product returned for refund or approve any backcharge for
labor, materials, or other costs incurred by the Purchaser or others in modification,
adjustment, service, or repair of SciTronics equipment unless such return or backcharge hasbeen authorized in writing to the Purchaser.
Any special test or requirement placed upon SciTronics products or products of other
manufacture used in SciTronics systems must be mutually agreed upon in writing by
SciTronics and the Purchaser prior to the date of shipment.
SciTronics reserves the right to make changes in design or construction of its products at any
time without incurring any obligation to make any changes whatsoever on units previously
purchased.
This warranty is expressly made by SciTronics and accepted by the Purchaser in lieu of all
other warranties, including warranties of merchantability and fitness for particular purpose,
whether written, oral, express, implied, or statutory. SciTronics shall not be liable for normal
wear and tear nor for any contingent, incidental, or consequential damage or expense due to
partial or complete inoperability of its products for any reason whatsoever. In no event shall
SciTronics liability exceed the original purchase price of the equipment.
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iv
SciTronics Quality Control Standards
SciTronics visually inspects all incoming goods and then assembles them according to
the best electronics shop standards.
SciTronics powers and tests each circuit to exacting operating specifications, observing
the correct function of each component.
When the unit is complete, the entire operating system is assembled and tested to meet or
exceed factory and customer specifications.
After a substantial burn-in period of up to 100 hours, the system is rechecked to the
original specifications. Only then is the system ready for shipment.
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Section 1 Introduction
1-1
Section 1 Introduction
This manual contains the installation, operation, and maintenance
instructions for your SciTronics Metal Detection System.
NOTEThe warranty for your SciTronics Metal Detection
System is on page iii in this manual. Be sure to read it
so you are aware of its provisions and exclusions.
This manual is arranged in the following sections so that you can
find the information you need quickly and easily:
Section 1 Introduction
describes the organization of this manual as well as the
features and general operation of the metal detection system.
Section 2 System Options
describes the options that are available from SciTronics for
the metal detection system.
Section 3 Installation
provides instructions for unpacking and installing the metal
detection system and options.
Section 4 Operation
contains startup, shutdown, and calibration procedures for the
metal detection system and describes the function of the LED
indicator lights during normal operation of the system.
Section 5 Maintenance and Troubleshooting
explains how to fix minor problems that may occur with the
metal detection system, such as detecting damaged coils,
cables, and connectors.
Section 6 System Specificationsprovides the specification data for the metal detection system.
Section 7 Drawings
includes the drawings for your specific metal detection
system.
Using This Manual
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The SciTronics Metal Detection System is designed to detect tramp
while scanning products such as highly mineralized or magnetic
ores (including magnetite and pyrites, even when conveyed on steel
cable belts) as well as copper, nickel, aluminum, aggregates, coal,rubber, wood chips, sinter, and tar sands. It can also be used in
recycling plants to detect tramp while scanning plastics, glass, or
paper.
The metal detection system has the following features:
The latest electronic design, utilizing all solid-state ICs to
ensure long operating life and trouble-free operation.
Pulsed field operation, which requires no balancing or tuning
and is not affected by temperature and humidity.
A resident diagnostic monitor using LEDs to indicate the
operational status of the circuit.
Programming at the front panel for Alarm Delay, Alarm
Duration, Sensitivity Scale Factor, and Splice Detector
Duration and Threshold.
Automatic spike (interference) protection (ASP) circuitry.
Dual primary (120/240 V) electrostatic-shielded power
transformer and additional RFI-EMI filter for maximum
electrical isolation.
Field-replaceable relays and circuit modules.
Swing-away coil protection.
Conveyor velocity from 6 ft/min to 1,200 ft/min (1.83 m/min
to 365.76 m/min).
The SciTronics Metal Detection System is carefully engineered and
constructed to your specifications. SciTronics uses only the highest
quality components and materials available. With proper installation
and maintenance, your system will provide years of satisfactory
service.
System Overview
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Section 1 Introduction
1-3
The following components are included on all metal detection
systems
Externally located (mounted on the door):
Indicator LightsGreen normal light.
Red alarm light.
Trip Counter
Reset Switch
Internally located within the enclosure:
Sensitivity ControlAdjusts the level of detection.
Fuse, Power Switch, and Operate/By-Pass Switch
Alarm DelayDelays relay contact transfer and is also used for timing for
downstream removal of tramp by a flopgate or diverter belt.
Alarm DurationFor timing the active interval of the metal marker, flopgate, or
diverter mechanism.
ASP (automatic spike detector)An internal monitor that detects electrical noise interference
and discards it from the signal flow path before it can cause a
false trip. Typical noise interference includes communication
radio transmission, lightning, and startup of SCR-controlled
equipment.
Status and Diagnostic LEDsFive standard LEDs and one optional LED (for the splice
detector) on the front panel indicate the operational status of
the following functions:
Generator coil continuity and drive
P-1: Power Logic A
P-2: Power Logic B P-3: Power Logic C
ASP operation
Splice
Standard Components
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Theory of Operation The SciTronics Metal Detection System measures the electricalconductivity of material conveyed through the sensor area by
detecting the variations in a pulsed electromagnetic field.
The magnetic properties of a material are completely independent of
conductivity. Even highly mineralized ore has a much lower
conductivity than refined metal. Therefore, both magnetic and
nonmagnetic metals are efficiently detected while so-called product
effects are virtually eliminated.
The pulsed induction technique intensifies the generated
electromagnetic field for very short time intervals. Measurements
taken many hundred times every second during the concentrated
energy pulse provide a very high signal-to-noise ratio without the
heating and stress of the conventional continuous wave method.
A multicoil sensor system, mounted above and below the conveyed
material, causes a more uniform field, providing better detection
sensitivity throughout the burden cross-section. By generating a
configured field pattern, the desired tramp metal signals are
reinforced and extraneous electrical field signals are cancelled.
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Section 2 System Options
2-1
Section 2 System Options
This section describes the options that are available from SciTronics
for your metal detection system.
Splice Detector (Model 2055) or (Model 2050)
lowers the detection sensitivity, allowing splice/repair areas to pass the
sensor without tripping the alarm. The splice detector is mounted
adjacent to the main sensors, minimizing the splice signal duration
time. The splice detector includes a splice threshold that provides an
adjustable threshold of sensitivity or override. Large tramp may be
detected even though the splice/repair area is traversing the detectionstation coils. The splice detector senses the belt splice before it passes
through the detector coil. The coil is desensitized for an instant while
the splice passes through.
The Model 2055 splice detector is recommended as the standard
application splice detector because it provides outstanding performance
in the less demanding application areas and is very cost efficient.
The Model 2050 splice detector is the proprietary coil. It utilizes the
same generator field and signal processing characteristics as the
main coils. This model is recommended for heavy-duty applicationswith conductive magnetic ores and steel cable conveyor belts.
Single-Flag Drop (Model #2075)orMulti-Flag Dropfor two flags
(Model #2075-2) or three flags (Model #2075-3)
accurately indicates the location of tramp metal on the conveyor.Detector reset is locked out until the flag is retrieved. This flag drop
marker consists of a solenoid, armature/flag assembly, and a lockout
circuit. A normally open contact connected to the active power line
causes the solenoid to operate upon metal alarm. The armature flag
assembly is released and drops on the conveyer. A switch operated by
the armature locks out the metal detector reset until the flag assembly is
retrieved and replaced. A length of chain is used on the flag so that it
does not bounce as it falls onto the moving conveyor. The flag drop
metal markers are available at 120 V or 240 V ac.
Overview
Splice Detector
Metal Markers(Tramp MetalLocator)
Flag Drop SolenoidOperated
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Backlit LCD Trip Counter (Model #4095)
most useful in environments where the lighting is poor, such as
underground mining installations, tunnels, etc.
Backlit LCD TripCounter
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Section 3 Installation
3-1
Section 3 Installation
Overview This section provides instructions for unpacking and installing themetal detection system and options.
1. Place the shipping containers on a stable surface and open
them, taking care not to damage the contents.
2. Carefully remove the metal detection system from the
shipping containers.
3. Inspect the contents and report any shipping damage or
missing parts to the carrier as soon as possible (most carriers
will not consider a claim unless notified within 15 days of
delivery).
NOTEThe bill of lading for this shipment is an acknowledg-
ment by the carrier of the receipt of the equipment in
good condition. SciTronics is not responsible for any
loss or damage incurred during shipment. Note any
damaged or missing parts on the carriers delivery re-
ceipt. Sign the notation and have the carriers driveralso sign it. The consignee is responsible for initiating
claims against the carrier.
Consider the following factors when selecting a location for the
detection coils station on the conveyor: Allow accessibility for tramp removal.
Do not place near large metal machinery that may move or
rotate within the range of the coils field.
Do not place near high voltage and current power cables for
SCR-controlled drive and crushing equipment.
Unpacking the MetalDetection System
Detection CoilsStation
Selecting an Installation
Location
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Be sure that the return idler is not within 4 ft (1.22 m) up or
downstream of the coils location.
There should be a minimum of crossbracing beneath the
coils.
The tramp should not coast over the head pulley.
Remove the metal conveyor deck plate and top cover between the
idlers. If a cover is needed, replace it with wood or plastic. The
spacing between idlers should be 36 in. (914.4 mm) or greater.
Remove the metal skirting approximately 3 ft (.91 m) from the coils.
Replace it with wood or plastic if desired.
Assemble the coils by doing the following:
1. The field generator is the top coil, identified by the four-pin
connector. Position the connector facing up through the
fiberglass support member, away from the belt.
2. The receiver coil looks like the top coil but has a three-pin
connector. Position the connector facing down through the
fiberglass support members, away from the belt. The
connector should face the side of the conveyor closest to thecontroller.
3. Referring to Drawing 1080-200-02, secure the two coils to the
support members using the nylon bolts and nuts that are
included.
Arrange the coils connectors on the same side of the support frame
(the side of the support frame that will provide the most direct route
to the controller enclosure).
Since the frame has a swing-away support for generator coilprotection, mount the frame on the conveyor so the hinge
arrangement for the top coil swings in the direction of belt travel.
The coils support members are drilled so the connector end of the
coils can be placed on either side of the conveyor; mount the coils
connectors on the same side of the conveyor as the controller.
Assembling the Coils
Dual Coil System
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Section 3 Installation
3-3
Mounting the Structure The coils frame has a 2-in. x 2-in. x 18-in. (50.8-mm x 50.8-mm x3.2-mm) angle iron footing that sits directly on the conveyor
stringers. Bolt or weld it into position. Refer to Drawing 1080-200-
02 for the completed assembly details.
NOTEThe frame may be shipped partially assembled.
Position the frame on the conveyor stringer so that the angle-iron
footing is centered between the idler sets (equal distance from the
upstream and downstream idler sets). Refer to Drawing 1080-200-
011. Be sure that the belt does not rub or touch the receiver (bottom)
coil. A 1- 12-in. (38.1 mm) clearance is recommended; a clearance of
more than 2 in. (50.8 mm) is not recommended. Adjustment holesare provided, allowing the clearance of the generator coil above the
belt to be changed.
Mount the controller enclosure within 25 ft (7.62 m) of the coils
cables supplied. When using additional cable, you may mount the
enclosure up to 300 ft (91.44 m) from the coils cables.
Mount the junction box (if provided) on the coils connector side of
the conveyor.
Mount the controllers of synchronized pairs of detectors (for
operation on adjacent conveyors) within range of the required
interconnected 10-ft (3.05-m) synchronizing cable.
Power and process control wiring is not supplied. Two customer-
supplied electric cables are required:
One 110 V, 60 Hz, electric cable to supply power to the
detector, which is approximately 40 W.
One cable to connect the process control relay to the
conveyor and feed system.
Controller Enclosure
Mounting
Wiring
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NOTEOnly 110 V power should be controlled by the relay.
Do not run 480 V lines into the controller enclosure.
Wire the controller enclosure by doing the following:
1. Make openings in the enclosure for coils and process control
and power cables on site in the bottom of the controller box.
The holes may be placed elsewhere in the controller box if
necessary.
CAUTIONDo not allow metal chips or drill turnings from the
openings to enter the detector circuitry. Although thecircuit boards are vertically mounted to minimize the
collection of debris, it is still possible for a conductive
chip to lodge between component leads, which could
destroy the electronics when power is applied.
Cleanliness and caution in this area is strongly
recommended.
2. Route the power and process control wiring through or near
the bottom of the hinge side of the enclosure.
3. Referring to Drawings 1080-101-01 and 1080-101-02,connect power and process control wires to TS-2.
4. The coils station cables may be run in 34-in. (19.1-mm)
conduit for permanent installation. Coils station cable
connections are shown on Drawing 1080-100-011 and
identified on the instrument front panel. Connect coils cables
to TS-1: G = top coil = generator
R = receiver coils = junction box
S = splice coil
CAUTIONSharing coils cable conduit with any other lines or
cables may result in interference.
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Section 3 Installation
3-5
5. Extra cable may be coiled within the enclosure. Since the coil
cables look similar, keep them identified for pulling through
the conduit.
NOTEThe metal detection system is designed for operation
from an ac power source with neutral at or near earth
potential. The system is not designed for operation from
two phases of a multi-phase system or across the legs
of a single-phase, three-wire system.
CAUTIONCheck the polarity of the power mains. Many conduits
and outlets have incorrect identification or connections.
An incorrect ground may cause major electrical damage
within the instrument when power is applied.
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Refer to Section 2 - System Options for more information on the
splice detector option.
Install the splice detector by doing the following:
1. Referring to Drawing 1080-200-03, place the rectangular
inductance splice coil at the edge of the belt between the coils
station and the upstream idler set.
2. Position the supporting angle iron so the top of the coil is as
high as the end of the troughing idler roller.
3. Weld or bolt the support angle to the stringer approximately 8
to 12 in. (203.2 to 304.8 mm) upstream from the edge of the
adjacent receiver coil for a dual coil. Mounting distance for a
single unit coil system is 6 to 8 in. (152.4 to 203.2 mm).
4. Secure the support pipe to the angle bracket with hose
clamps.
5. Mount the coil with the connector facing down, away from
the bottom of the belt in the direction of the belt edge.
6. Adjust the clearance between the face of the coil and belt by
sliding the support pipe either up or down on the angle
bracket.
7. Set the clearance to approximately 1 in. (25.4 mm) andtighten the clamps.
Options
Single Unit Coil System
Splice Detector
Refer to Section 2 - System Options for more information on the
single unit coil system option.
The single unit coil system is shipped fully assembled and ready for
installation on the conveyor. Refer to Drawing 1080-200-011B for
dimensional information.
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Refer to Section 2 - System Options for more information on the
rotating alarm beacon option.
Install the rotating alarm beacon on a flat surface or a
1
2
-in. (12.7-mm) pipe. Any convenient distance from the controller is
acceptable. The mounting conduit and connecting wire for the alarm
beacon are not supplied by the factory.
Refer to Section 2 - System Options for more information on the
remote reset option.
Wire the remote reset to the controller enclosure by doing the
following (refer to Drawing 1080-101-02):
1. Remove the jumper on TS-2 between terminals 10 and 11.
2. Connect wires WHITE on the remote reset to terminal 10 on
the controller enclosure and BLACK on the remote reset to
terminal 11 on the controller enclosure.
3. Connect the shield wire to earth ground at terminal 1 or to a
chassis ground.
The detector may now be reset after an alarm by either pressing the
pushbutton on the controller enclosure door or by pressing the
pushbutton on the remote enclosure.
Remote Reset
Rotating Alarm Beacon
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Section 4 Operation
4-1
Section 4 Operation
Overview This section contains the startup, shutdown, and calibrationprocedures for the metal detection system and describes the function
of the LED indicator lights during normal operation of the system.
1. Be sure that power is connected to TS-2 terminals 1, 2, and 3.
2. Turn the contacts switch to BYPASSED to prevent
inadvertent shutdown of the conveyor.
3. Turn the power on at the control panel.
NOTEIf the red light is on at the control panel, press the
RESET switch to put the system into its normal
operating mode.
The failsafe circuitry operates on relay K4 (refer to Drawing 1080-
101-01). The contacts are held in the normal operating position by
the detector power supply. If the line power fails or the detectorpower supply malfunctions, these process control contacts will
change to the alarm state.
A BYPASSED/OPERATE contacts switch enables you to restore
the contacts to normal regardless of the alarm condition of the
detector. This allows you to perform setup and calibration
procedures without stopping the conveyor or dropping the marker
flag.
NOTEThe failsafe circuitry is supplied as a no-charge option
by customer request only.
Startup
Operation of the
Failsafe CircuitryOption
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1. Turn the contacts switch to BYPASSED so the conveyor will
continue operation.
2. Turn the power off at the control panel.
NOTEIf you do not turn the contacts switch to BYPASSED,
the conveyor is turned off also.
NOTECalibration can be performed with the contacts in
bypassed mode. Refer to Operation of Failsafe
Circuitryin this section of the manual.
Adjust the metal detection system for the desired detection
sensitivity by doing the following:
NOTE
You can make this adjustment with the belt stopped ifdesired. Move the test tramp by hand through the
detection coils at approximately the same rate as the
actual belt speed.
1. Select a round or cube shape piece of tramp approximately
the size of the smallest piece of metal to be detected.
NOTEA round or cube shape piece of tramp produces the
most uniform calibration results.
2. Transfer the metal through the coils at approximately the
speed of the belt.
Shutdown
System Calibration
Sensitivity Control
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Section 4 Operation
4-3
3. Adjust the tramp sensitivity control to a value that causes an
alarm each time the metal travels through the coils. Moving
the control knob clockwise increases the sensitivity to detect
the smaller sizes of tramp. Moving the control knobcounterclockwise decreases the sensitivity, causing the
system to detect only larger tramp.
4. If the value needed to attain the desired sensitivity is greater
than 8 or less than 3, change the scale factor by doing the
following:
1) Locate the control recessed behind the panel.
2) Using a screwdriver, turn the screw counterclockwise to
shift the scale to lower the sensitivity and clockwise to
shift the scale to increase the sensitivity. By adjusting the
scale factor control, you can achieve the desired
sensitivity within the sensitivity control range of 8 and 3.
NOTEIf the test tramp is elevated above the bottom of the
belt during adjustment to simulate riding on top of the
burden, a smaller piece of tramp will cause alarm if it
passes through the coils on the bottom of the belt. This
is normal because even multicoil detection systems are
less sensitive near the center of the aperture.
Calibrate the splice detector by doing the following:
NOTES1. Follow steps 15 for the Model 2050 and steps 1,
4, and 5 for the Model 2055.
2. Before calibrating the splice detector, be sure that
you have already calibrated the sensitivity control
by following the procedure in Sensitivity Controlin this section of the manual and set the threshold
control to 10.
1. Turn the conveyor on so the belt is running and turn the
contacts switch to BYPASSED so the conveyor operation will
not be interrupted if the detector alarms on the splice.
Splice Detector
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2. Set the splice sensitivity dial to 2.
3. Adjust the splice scale control (screwdriver slot) so that the
splice indicator light turns on each time the splice clamps
traverse the coil. Increase the splice sensitivity setting to 7.
4. Adjust the DURATION control so the splice just clears the
detection coils without alarm. Increase the setting slightly to
provide a margin for normal operational variations in speed
and loading.
NOTERepair patches must be marked with four or more pilot
clips, which should be mounted starting at the edge of
the belt that is scanned by the splice coil. Align them
with the leading edge of the clamp repaired area.
5. Decrease the threshold setting incrementally from 10 until the
splice just causes alarm after passing through the coils. Then
increase the setting by a value of 1 to allow for minor
variations caused by conveyor loading, etc.
NOTEBecause the variations in the above procedure depend
on the individual characteristics of each conveyor belt,
the margin required for reliable operation varies andmust be determined on site.
The alarm delay control can be used to calibrate a metal marking
device or to stop the conveyor at a more accessible location for
removing tramp. Otherwise set it to zero.
The alarm duration control can be used to time the duration of a
spray-type metal marker or diverter gate for automatic trampremoval. Otherwise set it to zero.
Alarm Delay
Alarm Duration
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Section 4 Operation
4-5
Use the alarm delay control to calibrate the flag marker. Adjust the
control to provide a sufficient delay for the flag to land on the tramp
location. This method allows the marker to be located any
convenient distance from the coils sensing station.
CAUTIONTo minimize the possibility of losing the flag marker
or causing an inadvertent shutdown of the conveyor,
always turn the contacts switch to BYPASSED when
adjusting the metal detection system or turning the
power either on or off.
Calibrate the liquid spray marker by doing the following:
1. Be sure the conveyor is traveling at its rated speed and that
the metal detector is turned on.
2. Place a piece of tramp metal on the belt.
3. Observe the actuation of the marker as the tramp passes
through the sensor coils station.
4. Adjust the alarm delay control until consistent spotting of the
tramp is achieved.
5. Adjust the alarm duration control to increase or decrease theduration of the spray, as desired.
6. The spray gun on the support rod can be rotated for finer
calibration control while using the minimum alarm delay
time.
Calibrate the long bar detector by doing the following:
1. Turn the conveyor on if it is not running.
2. Select a piece of tramp approximately the size to be detected.3. Adjust the tramp sensitivity control to zero so there is no
interference with the bar calibration.
Flag Drop MarkerOption
Long Bar DetectorOption
Liquid Spray MarkerOption
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4. Start with a high sensitivity setting on the long bar detector to
establish that the selected bar tramp is within the detectable
range. Lower the setting, reducing the sensitivity on
subsequent passes of the tramp through the coils station untilthe tramp is just reliably detected.
NOTEThe scale adjustment (screwdriver access) may be set
so the required detection is within midrange of the
sensitivity control.
The LED indicator lights monitor the following: Coil Drive
This light turns on to indicate the correct connection and
operation of the generator (top) coil.
Power A, B, and C
This light turns on to indicate proper functioning of the three
main power blocks of the detector electronics.
ASP
This light indicates operation of the automatic spike
protection circuitry. The light is off or flickers momentarilyduring normal operating conditions. When the light remains
on or flickers continuously, a problem in the receiver coils
(bottom) or cables is indicated.
Splice
This light indicates operation of the splice detector and turns
on when the splice goes through the coils station.
During normal operation, the coil drive and power A, B, and C
lights should turn on. The ASP light should be off and the splice
light should turn on only when the splice passes through the coilsstation.
LED Indicator Lights
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Section 5 Maintenance and Troubleshooting
5-1
Section 5 Maintenance and Troubleshooting
Overview This section explains how to fix minor problems that occur with themetal detection system, such as detecting damaged connectors,
coils, and cables.
NOTEAny repair to the metal detection system should be done
by someone knowledgeable in electronics using a
quality oscilloscope.
No periodic maintenance is either required or recommended.
No spare parts are recommended. Replacement indicator lights,
fuses, and socket-mounted relays and ICs are standard and usually
available locally. The factory maintains an inventory of all
components in case an item is not available in your area.
A problem is indicated when the metal detector does not detect
tramp or when it alarms at random or on a splice/repair area.
The electronics in the metal detector are technically complex.
Therefore, a quality oscilloscope and knowledge of electronics are
required to correctly diagnose an electronic problem. Since the
majority of field problems consists of damaged connectors, severed
or bruised cables, and an occasional IC component failure, a
knowledgeable electrician using a volt-ohmmeter and inexpensive
ICs can correct most of the problems encountered. The information
following addresses these types of problems.
To gain access to the electronics modules, first remove the control
knobs on the cover panels using a 116-in. Allen wrench.
Maintenance
Spare Parts
Troubleshooting
Gaining Access to theElectronics Modules
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SciTronics Model 1080
Diagnostic LEDs
Coil Drive Indicator L ight The coil drive indicator light turns on when the generator coil,
cable, and connectors are operating properly. When the light isnot on, the metal detector will not detect tramp metal. Check the
coil and cable for damage. Using the ohmmeter, check the cable/connector assembly for an open circuit or shorting between wires.
Power A Indicator Light When the power A indicator light is not on, the detector may stillfunction but only at half or less of normal sensitivity. Replace IC
74C221 and IC 74C00.
Power B Indicator Light When the power B indicator light is not on, the detector may stillfunction but only at half or less of normal sensitivity. Replace IC
74C221 and IC 74C00.
Power C Indicator L ight The power C indicator light should be continuously lit. If it is not,the detector may indicate false alarms. Replace IC 74C20 (two).
ASP Indicator Light The ASP indicator light flickers or turns on only whenintercepting potential alarm-causing interference. If the light
is on continuously, there may be a problem in the receiver
coil and cable system. Use the ohmmeter to check for continuity
of the coils and cable. The receiver coil resistance at theconnector with standard 25 foot cable lengths is
approximately 540 ohms 10%
Splice Indicator Light The splice indicator light turns on only when the splice coil sensesmetallic clips. When clips cannot be detected even at maximum
splice sensitivity, check the physical alignment of the coil. The
belt may have traversed out of the detection range of the coil.
5-2
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Section 6 System Specifications
6-1
Tramp Metal Detects both nonmagnetic andmagnetic metals.
Sensitivity Maximum sensitivity is approximately5% of aperture height; stable to 10%
within the same sector of the aperture
location.
Conveyor Velocity Minimum: 6 ft/min (1.83 m/min).Maximum: 1,200 ft/min (365.76
m/min).
Indicators Red alarm light.Green ready light.
Alarm totalizer: electronic LCD
counter, NEMA 4. May be wired to
provide zero set from front of case.
Backlit LCD (option).
Reset Manual pushbutton switch located
between the indicator lights on theenclosure door. Jumper-wire
selectable for automatic reset. Remote
stations available.
Line Power Dual primary power transformer for240/120 V 10%; 50/60 Hz; 40 VA; 1
phase.
Fuse Protection Fuse: 1 A at 120 V: 0.5 A at 240 V.
Timed Output Contacts One single-pole double-throw (SPDT)passive contact set. 120 V at 10 A ac.
Section 6 System Specifications
OperationalSpecifications
ElectricalSpecifications
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SciTronics Model 1080
6-2
Process Control Contacts The alarm activates two sets ofpassive isolated contacts: one set is
wired normally closed and one set is
wired normally open. Specify forother contact arrangements. 120 V at
10 A ac.
Marker Contacts Timed normally open passive contactset. 120 V at 10 A ac.
Beacon/Horn Contacts One passive normally open contactset. 120 V at 10 A ac.
Spare SPDT Contacts One SPDT passive contact set.
Jumper-wire selectable for timedactivation. 120 V at 10 A ac.
Operators Relays, lights, and counter arepowered by a regulated 12 V supply
to ensure long operating life.
Socket plug-in electromechanical
relays with 2P2T and 3P2T contacts.
Relay coils rated for 12 V dc at 0.1 A.
#756 14 V dc bulb.
Controller NEMA 12 enclosureDimensions: 20 in. x 20 in. x 8 in.
(508 mm x 508 mm x 203.2 mm)
Includes lockable latch handle and
drip shield. NEMA 9, 7, and 4
available.
Control instrument and sensors rated
from 30oF to 140oF (34.4oC to
60oC). Specified for outdoor all-
weather use.
Coils Sensor coils constructed frommonolithic, impact-resistant PVC.
PhysicalSpecifications
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Section 6 System Specifications
6-3
Coils Support Structure Fabricated from Extran 500 fiberglassreinforced pultrusions. Fire retardant
Extran 525 available.
Weight Controller: 60 lb (27.21 kg).
Coils Set: 40 lb (18.14 kg), 42-in.
(1,067-mm) size.
Structure: 30 lb (13.61 kg).
Cables: 5 lb (4.54 kg).
Coils Junction Box (if provided): 5 lb
(4.54 kg).
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6-4
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Section 7 Drawings
7-1
This section includes the following drawings for your metal
detection system:
1080-100-01 Wiring Diagram, Coils StationConnections (TS-1) with 3-coil flat
sensor coils
1080-100-01A Wiring Diagram, Coils StationConnections (TS-1) with 2-coil flat
sensor coils
1080-100-01B Wiring Diagram, Coils StationConnections (TS-1) with underbelt
mono coil flat
1080-100-011 Wiring Diagram, Coils StationConnections (TS-1) with 3-coil sensor
coils contoured receiver coils
1080-100-011A Wiring Diagram, Coils StationConnections (TS-1) with 2-coil sensor
coils contoured receiver coils
1080-100-011B Wiring Diagram, Coils StationConnections (TS-1) with underbelt
mono coil contoured
1080-100-011C Wiring Diagram, Coils StationConnections (TS-1) with underbelt
mono coil U-shaped
1080-100-011D Wiring Diagram, Coils Station
Connections (TS-1) with open-endedsearch coil
1080-100-02 Wiring Diagram, Transducer Connections(TS-1) with pipe coil
1080-101-01 Schematic, Power and Process ControlConnections (TS-2)
List of Drawings
Section 7 Drawings
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SciTronics Model 1080
1080-101-02 Wiring Diagram and Process ControlConnections (TS-2)
1080-200-00 NEMA 12 Enclosure
1080-200-000 NEMA 4 Enclosure
1080-200-01 Coil Support Structure 3-coil flatsensor set
1080-200-011 Coil Support Structure 3-coilcontoured sensor set
1080-200-011A Coil Support Structure 3-coil
contoured sensor set
1080-200-02 Coil Support Structure Assembly
1080-200-03 Splice Detector Coil Mounting
1080-200-04 Liquid Spray Metal Marker
1080-200-05 Flag Drop Metal Marker Enclosureand Dimensions
1080-200-07 Flag Drop Metal Marker MountingLocation
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