Thermo Electron Ramsey ORETRONIC III, Operating And Service Manual

Page 1: ...Operating and Service Manual Ramsey ORETRONIC Tramp Metal Detector Rec 4105 Rev E Part No 060298 ...

Page 2: ...ORETRONIC Tramp Metal Detector ...

Page 3: ...also may seek to protect this work as an unpublished copyright In the event of either inadvertent or deliberate publication Thermo Electron intends to enforce its rights to this work under the copyright laws as a published work Those having access to this work may not copy use or disclose the information in this work unless expressly authorized by Thermo Electron All registered and unregistered tr...

Page 4: ...s revision documents version 1 04 of the ORETRONIC III Tramp Metal Detector software Manual revised to add information about Electronically Simulated Tramp EST optional system and UL updates Revision D November 2002 This revision documents changes for software version 1 05 Maximum clips delay extended to 30 feet Revision E August 2003 ECO 3497 This revision documents changes for software version 1...

Page 5: ... Panel 1 8 1 4 3 Synchronization of Transmitter Pulses 1 8 1 4 4 Speed Sensor 1 8 1 4 5 Clip Detector 1 8 1 4 6 High Pile Detector 1 8 1 4 7 Timed Delay Marker 1 8 1 5 System Requirements 1 8 1 6 Technical Specifications 1 9 Chapter 2 Installing the TMD 2 15 2 1 Overview 2 15 2 2 Installation Considerations 2 15 2 2 1 Mounting Location 2 15 2 2 2 Electrical Specifications 2 16 2 2 3 Input Power Re...

Page 6: ...ER Key 3 4 3 2 2 4 RESET Key 3 5 3 2 3 Front Panel LED Indicators 3 5 3 2 3 1 NORMAL 3 5 3 2 3 2 ALARM 3 5 3 2 3 3 BYPASS 3 5 3 2 3 4 CALIB 3 5 3 2 3 5 Bar Graph 3 5 3 2 4 Front Panel Displays 3 6 3 2 4 1 Run Screen 3 6 3 2 4 2 Password Protection Screen 3 7 3 2 4 3 Calibration Screens 3 8 3 2 4 3 1 Coil Balance 3 8 3 2 4 3 2 Calibrate for Metal 3 8 3 2 4 3 3 Calibrate for Clip 3 9 3 2 4 3 4 EST C...

Page 7: ...g the Material Type Code to Adjust Sensitivity 4 17 4 5 3 Testing for Coil or Junction Box Damage 4 18 4 5 3 1 Testing the Transmitter Coil 4 20 4 5 3 2 Testing the Receiver Coil 4 20 4 5 4 Determining TMD Malfunction 4 21 4 6 Passing Bars or Rods Undetected 4 24 4 7 Installing Default Values 4 25 4 8 Error Messages 4 26 4 8 1 Error Conditions 4 26 4 8 2 Fault Conditions 4 26 Chapter 5 Chapter Ser...

Page 8: ... Setting up and Operating the Remote Front Panel B 9 B 10 Parts List B 9 Appendix C Electronically Simulated Tramp EST C 1 C 1 Overview C 1 C 2 Theory of Operation C 1 C 3 Mechanical Installation C 1 C 4 Electrical Installation C 2 C 5 Calibration and Setup C 2 C 6 Interval Setup C 2 C 6 1 Last EST EST Last C 3 C 6 2 EST Test EST Test C 3 Appendix D Engineering Drawings D 1 Index A ...

Page 9: ... Settings 2 27 Table 2 3 Comm Switch SW4 Settings 2 27 Table 3 1 Error Messages 3 14 Table 3 2 Fault Messages 3 14 Table 4 1 Error Messages 4 26 Table 4 2 Fault Messages 4 27 Table A 1 TMD Exception Responses A 3 Table A 2 TMD Holding Registers Continued A 5 Table B 3 Comm Switch Settings B 9 ...

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Page 11: ... 5 Figure 1 7 TMD System Components Under Belt Single Coil 1 6 Figure 1 8 ORETRONIC III Control Unit 1 7 Figure 2 1 Control Unit Mounting Dimensions 2 19 Figure 2 2 Control Unit Enclosure Bottom View 2 21 Figure 2 3 Terminal Block Locations on the CPU Board 2 22 Figure 2 4 Switch Locations on the CPU Board 2 26 Figure 3 1 Tramp Metal Detector Front Panel 3 2 Figure 3 2 TMD Menu Tree 3 3 Figure 4 1...

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Page 13: ... Manual This manual is organized into five chapters and four appendixes Chapter 1 Introduction to the ORETRONIC III Tramp Metal Detector gives you an overview of the device s capabilities describes its functions and lists its technical specifications Chapter 2 Installing the TMD provides information about installing the detector including procedures for mounting wiring and configuring the ORETRONI...

Page 14: ... information Italic type is used for references to other sections of the manual Italic is also used to introduce new terms and for emphasis The names of setup and calibration displays and variables are shown in FULL CAPITALS The names of keys on the TMD are shown in BOLD CAPITALS Safety Messages Instructions in this manual may require special precautions to ensure the safety of the personnel perfo...

Page 15: ...safe installation and servicing procedures could result in death or serious injury Make sure only qualified personnel perform installation and maintenance procedures in accordance with the instructions in this manual Allow only qualified electricians to open and work in the electronics cabinest power supply cabinest control cabinets or switch boxes Covers over the electronics and rotatingpartsmust...

Page 16: ...the seller unless they are manufactured pursuant to seller s design but shall apply to the workmanship incorporated in the installation of such items in the complete equipment To the extent purchased parts or accessories are covered by the manufacturer s warranty seller shall extend such warranty to buyer Seller s obligation under said warranty is conditioned upon the return of the defective equip...

Page 17: ... BREACH OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT AND THE CORRECTION OF ANY DEFECT IN WORKMANSHIP IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Purchaser agrees to underwrite the cost of any labor required for replacement including time travel and li...

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Page 19: ...rden can be product such as iron pellets minerals aggregates coal or coke The ORETRONIC III TMD can be installed on conveyors with speeds up to 1 200 ft min 6 1 m s In addition because it is insensitive to materials with high magnetic permeability and electrical conductivity this detector can be used in applications where conventional metal detectors produce an unacceptable false alarm rate The OR...

Page 20: ...uces a secondary magnetic field The two magnetic fields can be distinguished from each other by observing their decay times The better the conductivity characteristics of the material the longer the decay time As the magnetic field decays the output signal strength decreases see Figure 1 2 Figure 1 2 How Conductivity Affects Decay Time S i g na l St re ngt h Time A90224 Poor Condition Material Goo...

Page 21: ... at which it reads the output signal only after the magnetic field from the material on the conveyor has decayed and before the tramp s decay has ended see Figure 1 4 Using this measurement window timing helps prevent both false trips and passed tramp metal Figure 1 4 Measurement Window Timing The ORETRONIC III TMD allows you to adjust both the sensitivity of the device to output signals and the l...

Page 22: ...e two models of the ORETRONIC III TMD dual coil and under belt single coil The standard dual coil TMD has a transmitter coil mounted above the belt and a receiver coil mounted under the belt The under belt single coil TMD is physically different but functionally similar to a stan dard model On an under belt single coil TMD the transmitter and receiver coils are together in a coil assembly mounted ...

Page 23: ...05 1 5 Figure 1 6 TMD System Components Dual Coil A90225 Flag Drop Marker Liquid Spray Marker Optional Beacon and Horn Optional Coil Support Transmitter Receiver Coil Clip Detector High Pile Detector Optional Clip Detector Optional Control ...

Page 24: ... and receiver coils are together in a coil assembly mounted under the belt The coil support struc ture does not extend above belt height see Figure 1 7 Coils are made of impact resistant polyvinyl chloride PVC and are designed to withstand stresses up to 10 times gravity The transmitter coil transmits the pulsed electrical energy to the conveyor burden The receiver coil receives the electrical ene...

Page 25: ...ONIC III Control Unit 1 4 Features and Options The ORETRONIC III TMD includes a number of standard features and available options that enhance its performance in a conveyor system 1 4 1 Simplified Operator Interface The operator interface to the TMD is a front panel on the control unit The front panel is composed of a touch panel keypad LED indicators an eight character alphanumeric display and a ...

Page 26: ...Speed input provides for accurate belt coast determi nation and other speed dependent operations The speed sensor output must not exceed 2 KHz 1 4 5 Clip Detector An optional belt clip detector is used with conveyor belts having metallic splices or repair clips The detector momentarily reduces the sensitivity of the TMD while metal fasteners traverse the detection zone Larger tramp metal will stil...

Page 27: ...ual coil and under belt single coil models unless otherwise noted Belt Speed 5 1 200 ft min 1 366 m min Construction Coils and Support Assembly FRP reinforced support assembly Coils sealed in PVC Size Dual Coil Model typical for 42 in belt width Support Frame 54 in x 39 75 in x 24 in H X W X D 1 371 6 mm x 1009 6 mm x 609 6 mm Transmitter Coil Flat 43 in x 9 in x 0 75 in L x W x D 1 092 2 mm x 228...

Page 28: ...ental Conditions Location Indoor outdoor Storage Temperature 67 to 158 F 55 to 70 C ambient Operating Temperature 40 to 122 F 40 to 50 C Humidity 10 to 95 relative humidity non condensing Altitude 6 561 ft 2000 m Pollution Degree Pollution Degree 2 Power Requirements Nominal Line Voltage 115 230 VAC selectable Operating Range 10 15 Nominal Frequency 50 60 Hz Operating Range 48 62 Hz Fusing L1 side...

Page 29: ...green for NORMAL yellow for BYPASS Calibrate LED Indicates the detector is in calibrate mode Keypad Mounted on the enclosure door Cutouts for viewing display status LEDs and bar graph Inputs All isolated inputs have same commons connected to isolated supply voltage common with the exception of the receiver coil Clip Detector Isolated supply voltage provided Configured for two clip detectors on sam...

Page 30: ...age provided 24 V open circuit 7 mA short circuit and 3 mA threshold Isolated Supply 24 VDC 150 mA Outputs Alarm Relay One NO and one NC contact Dry contact 5 A 250 VAC Fail safe Bypass switch provided Time Delay Relay Dry contact 5 A 250 VAC Duration selectable in 0 1 second increments 0 1 0 9 seconds Delay adjustable in 0 1 second increments 0 1 9 9 seconds SYNC Out RS 485 driver Transmitter Coi...

Page 31: ...t 5 A 250 VAC Power On Indicator Dry contact 5 A 250 VAC Option Dry contact 5 A 250 VAC Communications One RS 485 port standard in every detector 2 wire or 4 wire selectable Baud Rates 600 19200 baud Odd Even No parity Isolation Yes Function Communications or remote display ...

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Page 33: ...and understood this entire chapter The precautions and procedures presented in this chapter must be followed carefully to prevent equipment damage and protect the operator from possible injury WARNING Failure to follow safe installation and servicing proce dures could result in death or serious injury Make sure only qualified personnel perform installation and maintenance procedures in accordance ...

Page 34: ...ional installation considerations 2 2 2 Electrical Specifications 115 230 VAC 10 15 50 60 Hz Single phase 30 VA 0 25 A 2 2 3 Input Power Requirements Switch selectable 115 VAC or 230 VAC Fusing 115 VAC F1 3 8 A 250 VAC SB Type T 230 VAC F1 3 16 A 250 VAC SB Type T 2 2 4 Safety Precautions WARNING High voltage that may be present on leads could cause electrical shock Disconnect incoming power at ma...

Page 35: ...ifting this equipment to avoid damage to the coil s The TMD control unit is normally packaged sealed in foam which is then placed in a cardboard carton This carton should be handled manually Lift the carton observing the This Side Up labels Do not use hooks Use extreme caution when handling this equipment because the electronics are extremely delicate 2 4 Inspection and Unpacking The Tramp Metal D...

Page 36: ...he swing arm feature allows high loads to pass without damage If the transmitter coil is mounted too high the system s sensitivity is reduced 3 Set the receiver coil located under the belt 1 2 in 25 4 50 8 mm below the belt line The belt must not rub on the receiver coil 4 Mount the coils across the conveyor on the centerline between the two idlers Idler spacing at the coil location must be greate...

Page 37: ...ptional system devices such as clip or high pile detectors spray or flag drop markers and alarm beacons or horns may need to be assembled and installed on your conveyor Refer to the appropriate drawings in Appendix D for information about installing optional system devices for your TMD model The Installation Placement drawings and Final Assembly drawings show where optional devices are to be place...

Page 38: ...s to the line power terminals 3 Bolt the enclosure to a flat vertical surface using the 2 position mounting feet on the back of the enclosure see 4 5 6 7 Figure 2 1 8 Punch the required conduit holes in the bottom of the enclosure for the power supply cable coil cables control wiring communications cable s and any additional signal wires and conduit Locate the holes in the appropriate areas of the...

Page 39: ...hrough the same conduit with power cables or any large source of electrical noise 2 6 5 1 Critical Wiring Conditions Be sure to observe the following critical wiring conditions to ensure proper connection of your detector Ensure main power is OFF High voltage 30 V and low voltage 30 V cables must be routed through different areas of the control unit enclosure see Figure 2 2 Earth ground all enclos...

Page 40: ...ng device for the equipment All conduit should enter the bottom of the enclosure Do not run conduit through the top or sides of the enclosure 2 6 5 2 Field Wiring Procedure Follow all cable number specifications on the Field Wiring Diagram D07328C E201 when connecting wiring to the CPU board Figure 2 3 shows the locations of the terminal blocks Figure 2 3 Terminal Block Locations on the CPU Board ...

Page 41: ...ire section Improper connection may result in damage to your detector Verify that the input voltage is correct with a voltmeter before you connect it to the unit The red tag attached to the machine specifies the correct input voltage for your particular unit Earth ground must be provided to the unit Do not use conduit to provide this ground Follow your local electrical codes and regulations for mi...

Page 42: ...ORETRONIC Tramp Metal Detector REC 4105 2 24 sufficient 4 Connect the GROUND wire to the safety ground terminal located on the right inside of the chassis ...

Page 43: ...asure units and cold start are set at the hardware level because these parameters are generally set once and not changed The settings of these switches can be viewed on the TMD front panel after the system is operational Refer to Switch Settings on page 42 Table 2 1 describes the functions of the DIP Switch settings on SW1 Table 2 1 SW1 DIP Switch Settings POS FUNCTION ON OFF 1 Password protection...

Page 44: ...ut for the TMD If RS 485 communication is supported a fifth switch must also be set Figure 2 4 shows the locations of the switches on the CPU board Table 2 2 and Table 2 3 describe the functions of the switch settings Figure 2 4 Switch Locations on the CPU Board A90504 SW3 Electroni cs SW6 Powe r SW4 Comm Switches SW2 Relay Outputs SW5 Line Voltag e TB5 EST ...

Page 45: ...eed sensor use this procedure to calibrate it The procedure is written as though you are familiar with the operator interface to the ORETRONIC III TMD If you are not familiar with the operator inter face please read the detailed descriptions of the front panel keys indicators and displays in Chapter 3 of this manual before beginning this procedure 1 Run the conveyor belt at normal production speed...

Page 46: ...ng a speed sensor Clip delay if you are using a clip detector Timed delay if you are using a marking device To take these measurements you must first place a timing mark on the conveyor belt using the following procedure CAUTION Keep hands and clothing away from all moving or rotating parts Empty the conveyor belt of all material Stop the conveyor belt 3 Place a mark on the belt that will be visib...

Page 47: ...t takes for the splice to travel this distance If a belt clip detector is not used this value should be 0 in setup 2 11 3 Determining Timed Delay If your system uses a marking device you will need to know how long it takes for tramp metal to move from the coils to the marking device This value is the timed delay It is used to allow enough time for detected tramp to get to the marking device so tha...

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Page 49: ...of remote control uses Modbus protocol for reading and writing detector registers The TMD is a dual language instrument All measure units can be either English units or Metric units as selected by the SW1 DIP Switch This chapter uses English units If you change your units selection after the TMD is set up and calibrated you must redo the calibrations and setup using the new units the TMD will not ...

Page 50: ...Run mode you can display all setup and calibration variables but you cannot change them Setup Calibrate mode allows you to make changes to the device setup and calibrate the TMD for specific metal In Setup Calibrate mode both the BYPASS and CALIB LEDS are lit The display indicates which variable is shown in the counter the counter shows the current value of that variable 3 2 2 Menu Structure The o...

Page 51: ... 0 999 CLP CORS 0 7 CLIP FINE 0 999 AUD CAL 0 24 AUD LAST AUD TEST TEST EXIT SETUP N Y If Y parameters can be changed CLIP DLY 0 10 0 BAR SENS 0 9 BAR LEN 1 0 10 0 BELT SPD 1 1 2H TIME DLY 0 1 9 9 TIME DUR 0 1 0 9 AUDIT INT 1 24 MAT CODE 0 7 TIME CON 1 999 FILTER 0 3 OP FREQ 0 3 REMOTE N Y MODBUS N Y ADDRESS 1 247 BAUD 1 2 2 4 4 8 9 6 19 2 PSW PRT SPEED SYNC BELT REV ENGLISH METRIC LAMP N Y KEY N ...

Page 52: ...e up and down VALUE arrow keys change the value of the displayed variable when the TMD is in Setup Calibrate mode Pressing the up arrow increases the value Pressing the down arrow decreases the value Values increase or decrease only within the range for the individual variable Changed values are not entered into memory until you press the ENTER key and they flash in the counter until you press it ...

Page 53: ... The BYPASS LED yellow indicates that the alarm output relay is disabled by the SW2 SW3 switch settings on the CPU board see Section 2 8 2 CPU Board Switch Settings or by remote bypass input Alarm output is also disabled and the BYPASS LED lit when the TMD is in Setup Calibrate mode CALIB LED lit This allows you to set up and calibrate the detector without generating alarms during the process BYPA...

Page 54: ...access the variables use the scroll keys to move the display up and down the scroll Change variables by pressing the VALUE keys You must press the ENTER key to apply a new value When the value of a variable has been changed but not entered the value of the variable flashes The remainder of this section describes the display screens in the order they appear in the scroll 3 2 4 1 Run Screen The firs...

Page 55: ... password protection The Y will be flashing 2 Press ENTER 3 Press the SCROLL down key The display changes to PSWD The counter shows 000 and the first digit will be flashing 4 Press the VALUE keys to scroll through the range 0 9 5 When the digit you want is showing press ENTER The next digit in the counter will be flashing 6 Repeat the process of scrolling the counter and entering the digit until y...

Page 56: ...his screen shows coil balance which is an indication of how well the gen erating and receiving coils are aligned The screen is for viewing only you cannot make changes to it The display shows COIL BAL The counter indicates how much of the range of the electronic balance is being used from 0 to 999 The current balance condition is indicated on the bar graph with the middle LED in the bar being the ...

Page 57: ...s The first screen adjusts the coarse sensitivity of the clip signal The second screen adjusts the fine sensitivity When you SCROLL to the first clip calibration screen the display shows CLP CORS The counter shows the current coarse sensitivity setting between 0 and 7 You can change the coarse clip sensitivity setting manually using the VALUE keys and the ENTER key You can start auto calibration b...

Page 58: ...s The values of these variables determine how the TMD will function in your application environment The first setup screen enables or disables changes to setup parameters When you SCROLL to the screen the display shows SETUP N To change setup parameters press the down VALUE key to change the display to SETUP Y then press ENTER This puts the TMD into Setup mode Leaving the display on SETUP N and pr...

Page 59: ...r is used refer to Section 2 8 1 DIP Switch Settings If speed sensor input is disabled this screen is used to set the belt speed in feet minute If speed sensor input is enabled this screen shows the actual belt speed The display shows BELT SPD The counter shows the value from 1 to 1 200 feet minute If the belt speed is greater than 999 feet minute it will be shown in thousand feet minute with a de...

Page 60: ...vity to tramp metal but filter less electrical noise The display shows FILTER The counter shows the filter number from 0 to 3 3 2 4 4 11 Operating Frequency This screen is used to specify the operating frequency of the TMD The dis play shows OP FREQ The counter shows one of the following settings from 0 to 3 0 900 Hz 1 780 Hz 2 660 Hz 3 1020 Hz The usual setting is 0 900 Hz 3 2 4 4 12 Remote Front...

Page 61: ...TER tests the indicators by lighting each LED on the front panel individually The bar graph segments light from the bottom up and the counter counts up from 000 to 999 This test completes automatically The second test screen is KEY N Changing this to KEY Y and pressing ENTER initiates the key test When you press ENTER the display shows ENTER When you press the up VALUE key the display shows V UP a...

Page 62: ... reset disable input is open This input is used for the optional marker feature You cannot reset the detector until the input is closed by resetting the marker This prevents you from restarting the belt without the marker in place 3 2 4 5 2 Fault Conditions Faults indicate that the TMD found a failure in the electronics or a setting that does not allow the detector to operate When a fault occurs t...

Page 63: ...ration of your ORETRONIC III TMD Once the TMD is set up correctly few or no changes to the settings are required 3 3 1 Before You Begin Before you begin setting up and calibrating the TMD for your application be sure that The TMD has been installed both mechanically and electrically in accordance with the procedures in Chapter 2 Installing the TMD and the installation and field wiring drawings You...

Page 64: ...croll does not wrap 3 3 3 Entering Values The up and down VALUE arrow keys change the value of the variable shown in the counter Pressing the up arrow increases the value Pressing the down arrow decreases the value Values increase or decrease only within the range for the individual variable To change a variable press a VALUE arrow key until the value you want is displayed in the counter You must ...

Page 65: ...r to Section 2 11 3 Range 0 1 9 9 seconds Default 1 0 5 Scroll to the TIME DUR display and enter the duration of the timed marking output in tenths of a second Range 0 1 0 9 seconds Default 0 9 6 If your system uses a belt clip detector scroll to the CLIP DLY display and enter the distance in feet from the clip detector to a point six inches past the receiver coil If no speed sensor is used enter ...

Page 66: ... calibration has started 11 Slide the piece of tramp metal completely through the detection area that is between the transmitter and receiver coils in the center of the belt at least three times in the direction of normal travel then press ENTER The display flashes QUIK BAL while the system rebalances and then returns to the COARSE display The counter shows the new coarse sensitivity setting Range...

Page 67: ...nge 0 999 20 Scroll down to the EXIT display and press ENTER Scroll to the high level setup menu and put the TMD in back into Setup mode SETUP Y If your system uses bar rod detection go on to Step If you do not use bar rod detection make sure the counter value for the BAR SENS display is 0 this turns off bar rod detection and go to Step 21 Scroll to the BAR SENS display and enter the sensitivity o...

Page 68: ...24 Scroll to the EXIT display and press ENTER This puts the TMD in normal Run mode and saves the setup values in system memory The display shows COUNT counter shows total NORMAL LED is lit You may want to scroll through all of the Setup and Calibration displays again and record the values ...

Page 69: ...uires minimal maintenance 4 2 Routine Maintenance Keep the area around the TMD free from rocks and material build up The TMD system can be washed down with water and meets NEMA Type 4X standards Do not add harsh chemicals caustics or disinfectants to the wash down solution The control unit enclosure can be wiped clean with a damp cloth and if necessary a mild detergent Never use abrasive cleaners ...

Page 70: ...djustments you can make to the TMD device setup and calibration settings to make it work better First you must determine what is causing the problem and what you can do to correct it 4 3 1 Visual Inspection If you are experiencing operational problems with the TMD a quick visual inspection may reveal the source of the problem Check the following items before proceeding to more specific troubleshoo...

Page 71: ...e the TMD for a day or two before changing the device setup or calibration settings There are two basic types of problems you could be having with the TMD false tripping or passing tramp undetected Both of these problems are costly False trips stop the conveyor and interrupt the process flow Unde tected tramp damages process machinery Common reasons for false tripping include Coil imbalance Sensit...

Page 72: ...he most common problem is a sensitivity set ting that is too high for the amount of background noise present This makes it difficult for the TMD to distinguish between the signal produced by tramp metal and the background signal Another common problem is coil imbalance which can cause the receiver coil to generate output signals when there is no tramp passing If your TMD is false tripping use the ...

Page 73: ...ng sides from top to bottom and visa versa If five or more LEDs are lit you need to manually balance the coils If the coil imbalance exceeds the ability of the TMD to self balance the ALARM indicator lights and the BALANCE fault message appears in the display Press ENTER to clear the message and proceed with Step 7 7 Adjust the coil position for your TMD model as follows For a dual coil TMD Use th...

Page 74: ...AL display and observe the bar graph again The bar graph may be noisier than it was in Step 6 there may be more LEDs lit This is because the sensitivity is set higher 10 Repeat Steps 7 and 8 increasing the coarse sensitivity value each time 11 When you are satisfied with the coil balance scroll to the COARSE display and return the value to the as found value you recorded in Step 5 4 4 2 Finding th...

Page 75: ... of LEDs lit should not change If the noise level number of LEDs lit increases with the conveyor belt running the noise could be caused by mechanical vibrations or electrical disturbances 6 With the conveyor belt still running empty check the area in the immediate vicinity of the coils for possible sources of mechanical vibration The larger the size and surface area of the metal the less the vibra...

Page 76: ...wiring correct it CAUTION The coil wiring must be run in a separate conduit from any power wiring If the system appears to be installed and wired correctly and there is still a high level of noise when the conveyor is run other electrical systems may be generating the noise 8 With the conveyor running empty turn off other systems near the TMD one at a time while observing the bar graph Turning off...

Page 77: ...ll to the FINE display and return the value to the as found value recorded in Step 2 4 4 3 Adjusting for High Product Noise Mineral Ores With some highly conductive ores the default measurement window for detecting metal will cause false tripping similar to high electrical noise when the ore is conveyed The typical indication of this situation is a low noise level when the conveyor is run empty an...

Page 78: ...ugh the coils Observe the noise level on the bar graph The noise level should have decreased fewer LEDs lit If it did use this material type code If the noise level increased the problem is not caused by the type of material conveyed Go to Step 5 4 If the noise level from the ore is still too high scroll to the MAT CODE display increase the value by one and repeat Steps 2 and 3 The valid numbers f...

Page 79: ...ion is not active If any number other than zero appears in the counter the option is active The larger the number from 1 to 9 the more sensitive the TMD to both bar rod and noise If you suspect the bar rod option may be causing false trips follow this procedure 1 Reset the TMD press the RESET key and wait for a false trip 2 Check the display to see if it shows LONG BAR If it does the bar rod optio...

Page 80: ...etector saw the clip 1 Reset the TMD press the RESET key and wait for a false trip 2 Check the display to see if it shows CLIP 3 If the display does not show CLIP scroll to the CLIP DLY display and check the value shown in the counter If the value is 0 clip detection is not active 4 Determine the correct clip delay refer to Determining Clip Delay on page 2 29 and enter the value 5 Repeat Steps 1 a...

Page 81: ...replaced If you have determined that the clip detector is functional but still not working properly it is not seeing the clips on the belt This may be because the clip detector is too far from the clip and is out of the detection range or because the clip is too small to detect Note The clip detector is to be mounted 3 to 4 inches away from the first idler toward the tail pulley and the coil suppo...

Page 82: ...est clip the old CLP CORS value was incorrect the new value should be used Note The number of LEDs displayed for the clip s may vary slightly as the clip passes through from one time to the next This is caused by a slight non linearity in the electromagnetic field near the receiver coils and will not cause any problem 8 Compare the old and new CLP FINE values If they are within 50 of each other or...

Page 83: ...TMD may pass tramp undetected The detector may be incorrectly wired or installed the metal sensitivity number may be too low the size of the tramp may be too small for the coil size and separation the coils or junction box may be damaged or the TMD may be malfunctioning Tramp may also pass undetected if your system uses clip detection and the size of the clip s is large compared to the size of the...

Page 84: ...D in Run mode and pass the test tramp through the coils in the normal direction of travel If the TMD does not trip observe the bar graph If the LED level on the bar graph does not increase when the tramp is passed through the coils there is a more serious problem than a low sensitivity setting Go on to Testing for Coil or Junction Box Damage on page 68 or Determining TMD Malfunction on page 71 If ...

Page 85: ...s and check for a trip If the sensitivity is still not correct for your system repeat Steps 7 12 of this procedure until it is If this procedure does not increase the sensitivity enough try the procedures in Finding the Source of Mechanical or Electrical Noise on page 4 6 For a dual coil TMD you can also try lowering the transmitter coil to the minimum height possible refer to Outline Mounting and...

Page 86: ...oning properly at this material type code and the sensitivity will be greater that it was with the previous material type code Note The lower the material type code number the greater the sensitivity to conductive materials other than tramp metal In most instances this will not be a problem If a problem should occur refer Adjusting for High Product Noise Mineral Ores on page 4 9 If more than 5 LED...

Page 87: ...e electronics cabinets power supply cabinets control cabinets or switch boxes WARNING High voltage that may be present on leads could cause electrical shock All switches must be OFF when checking input AC electrical connections removing or inserting printed circuit boards or attaching voltmeters to the system Use extreme caution when testing in on or around the electronics cabinet PC boards or mod...

Page 88: ...rom field terminals 4 and 5 3 Measure the resistance of the coil If the transmitter coil resistance is approximately 2 3 ohms the transmitter coil it is wiring and its portion of the CPU board is all right Check the receiver coil 4 If the ohm meter does not show 2 3 ohms on the transmitter coil wires measure terminals 24 and 25 at the junction box If 24 25 at the junction box are 2 3 ohms the cabl...

Page 89: ...ms the wiring to the junction box or the junction box circuit is bad 4 5 4 Determining TMD Malfunction If the TMD is not functioning correctly follow the test procedures in this section to help determine the problem WARNING Failure to follow safe installation and servicing procedures could result in death or serious injury Make sure only qualified personnel perform installation and maintenance pro...

Page 90: ...must be replaced If the fuse tested bad in the first procedure 1 Replace the fuse with the correct sized fuse 2 Turn the power switch back on 3 If the displays do not light turn the power switch off 4 Test the fuse again If the fuse tests good follow Steps 8 10 in the first test procedure If the fuse tests bad continue with this procedure 5 Disconnect all wiring to the CPU board except the power o...

Page 91: ... go on to the next procedure for checking the TMD configuration 5 Turn on power to the control unit SW6 6 Place the TMD in Setup Calibrate mode 7 Scroll to the MAT CODE display 1 The value shown in the counter should be 3 8 If the MAT CODE value is not 3 change it to 3 and press ENTER If you changed the value rebalance the coils using the procedure in Correcting Coil Imbalance on page 4 4 9 Scroll...

Page 92: ... help determine the cause The procedure is written as though you are familiar with using the operator interface If you are not familiar with the operator interface please read the detailed descriptions of the front panel keys indicators and displays in Chapter 3 of this manual before beginning the procedures 1 Check the coil balance using the procedure in Correcting Coil Imbalance on page 4 4 2 Pl...

Page 93: ... start on power up Refer to DIP Switch Settings on page 2 25 3 Turn on power to the control unit SW6 and wait 4 seconds Default values will be installed on power up 4 Set DIP Switch position 8 on SW1 back to OFF Note It is very important that you set the DIP Switch to OFF so you do not accidentally install default values if the machine is power cycled The factory default values are as follows PARA...

Page 94: ...tart DIP Switch is set to ON Table Memory checksum problem E2 RESETDIS The reset disable input is open This input is used for the optional marker feature You cannot reset the detector until the input is closed by resetting the marker This prevents you from restarting the belt without the marker in place 4 8 2 Fault Conditions Faults indicate that the TMD found a failure in the electronics or a set...

Page 95: ...al fault condition F2 SELFTEST Indicates a microprocessor problem F3 BALANCE The coil imbalance exceeds the ability of the detector to electronically self balance See section 4 4 1 F4 HIGHPILE The high pile input was not reset within 4 seconds after tripping F5 OVERLOAD The input circuitry is saturated Reduce gain mechanically balance coils per 4 4 1 or remove the cause of the overload F6 EST Not ...

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Page 97: ...nter located at our plant in Minneapolis Minnesota Products that need system checkout or repair can be returned to the plant with the Return Material Authorization RMA form found on page 5 3 Contact our Repair and Returns department at 763 783 2774 to get an RMA number to use on the form Note Have your machine model number and serial number available when you call Main Switchboard 763 783 2500 FAX...

Page 98: ... p m Central Time 5 3 Parts Lists The list below provides part numbers and descriptions of the replaceable parts for the ORETRONIC III TMD control unit All other replaceable parts for the ORETRONIC III TMD are shown on the engineering drawings in Appendix D The drawings help you accurately identify the part s you need and the parts lists on the drawings provide part numbers and descriptions ITEM D...

Page 99: ...polis MN 55433 Area Code Bill To C Ship To Returned From Return To Description Of Material Being Returned Describe Equipment Malfunction Or Defect If Any Symptoms Minimum Charge Informed Customer of Inspection Charge Per Item Service Requested Repair Return Estimate Required P O No Return for Original P O or Thermo Warranty Repair or Replacement Serial No Original P O Original Order Job Return War...

Page 100: ...ircuit boards must be disposed of in accordance with your local Hazardous Waste policy As an alternative you may return product supplied by Thermo Electron with an RMA form freight prepaid for disposal Contact our Repair and Returns department at 763 783 2774 to get an RMA number to use on the form ...

Page 101: ...act as a Modbus master device Baud rates supported are 1200 2400 4800 9600 19200 The default is 9600 bps A 2 Modbus Message Types Supported by the TMD The TMD provides normal Modbus responses only for the functions listed below all other functions and diagnostic requests will return Exception 01 Illegal Function Function 03 Read Holding Registers Function 06 Preset Single Register Function 16 Pres...

Page 102: ...lding registers 40003 4005 from slave device 5 QUERY RESPONSE Field Name Contents Hex Field Name Contents Hex Slave Address 05 Slave Address 05 Function 03 Function 03 Starting Address Hi 00 Byte Count 06 Starting Address Lo 02 Data Hi Reg 40003 02 No of Registers Hi 00 Data Lo Reg 40003 2B No of Registers Lo 03 Data Hi Reg 40004 00 Error Check 16 bit CRC Data Lo Reg 40004 00 Data Hi Reg 40005 00 ...

Page 103: ...ror Check 16 bit CRC Data Hi 00 Data Lo 0A Data Hi 01 Data Lo 02 Error Check 16 bit CRC A 2 3 Exception Responses When the TMD is unable to respond normally to a Modbus query it will return an appropriate exception response to the host Table A 1 shows the two digit code and the meaning of each exception response Table A 1 TMD Exception Responses EXCEPTION CODE MEANING Illegal Function 01 The funct...

Page 104: ...devices not addressed by the query must also process and discard the response message sent by the slave device that was addressed The slave device ID slave address for each individual TMD is assigned in setup and can be from 1 to 247 On a multidrop line each address must be unique A 2 5 TMD Holding Registers The TMD uses Modbus holding registers 4xxxx designation to implement the register set The ...

Page 105: ... Write I Bar length Maximum length of the bar rod 40009 Read Write I Belt speed Entered belt speed if no speed input is present It is the actual belt speed if a speed sensor is present The units are feet minute or meters minute depending on the units implied by the operator during automatic calibration 40010 Read Write I Timed delay in seconds The number stored in this register is divided by 10 40...

Page 106: ... Read Only I THERMO ELECTRON USE ONLY 40020 Read Only P MSB 0x20 ASCII code for a space LSB ASCII code for character 0 left most character of the text display 40021 Read Only P MSB 0x20 ASCII code for a space LSB ASCII code for character 1 of the text display 40022 Read Only P MSB 0x20 ASCII code for a space LSB ASCII code for character 2 of the text display 40023 Read Only P MSB 0x20 ASCII code f...

Page 107: ...Reversed Bit 6 Measure units are Metric Bits 7 15 Unused 40047 40099 Not used 40100 Read Only THERMO ELECTRON USE ONLY 40101 Read Only THERMO ELECTRON USE ONLY 40031 Read Only P General purpose status register which is used for diagnostic purposes If set 1 the bits have the following meanings otherwise bits are 0 Bit 0 NORMAL LED is on Bit 1 ALARM LED is on Bit 2 CALIB LED is on Bit 3 BYPASS LED i...

Page 108: ...nt Example LSB 3 indicates that seven bars below the center are lit This means 7 40033 Read Write I Audit fine sensitivity if Audit Check is active 40034 Read Write I Audit coarse sensitivity if Audit Check is active 40035 Read Write I Audit interval Time in hours between Audit Checks 40036 Read Write I Filter The noise filter used on the TMD 0 Filter emphasizes middle of response curve 1 Filter e...

Page 109: ...3 If left most digit has a decimal point MSB ASCII code for a If left most digit does not have a decimal point MSB 0x20 ASCII code for a space LSB ASCII code for middle digit Integer 2 Right most digit Reg 40044 If middle digit has a decimal point MSB ASCII code for a If middle digit does not have a decimal point MSB 0x20 ASCII code for a space LSB ASCII code for right most digit 40045 Read Only I...

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Page 111: ...cludes a separate power supply and has a distance limitation of 4 000 ft 1 219 m from the main TMD control unit The remote front panel is identical to the front panel on the control unit in both appearance and operation B 2 Routine Maintenance Keep the area around the TMD free from rocks and material build up The TMD system can be washed down with water and meets NEMA Type 4X standards Do not add ...

Page 112: ... 11 5 lb 5 2 kg Maximum Distance from TMD 4 000 ft 1 219 m Environmental Conditions Location Indoor outdoor Storage Temperature 67 to 158 F 55 to 70 C ambient Operating Temperature 40 to 122 F 40 to 50 C Humidity 10 to 95 relative humidity non condensing Altitude 6 561 ft 2 000 m Pollution Degree Pollution Degree 2 Power Requirements Nominal Line Voltage 115 230 VAC selectable Operating Range 10 1...

Page 113: ...aph B 4 Installing the Remote Front Panel This section provides information about mounting and wiring the remote front panel Do not connect power to the machine or turn on the unit until you have read and understood this entire Appendix The precautions and procedures pre sented in this Appendix must be followed carefully to prevent equipment damage and protect the operator from possible injury WAR...

Page 114: ... covers before resuming operation WARNING Use only the procedures and new parts specifically referenced in this manual to ensure specification performance and certification compliance Unauthorized procedures or parts can render the instrument dangerous to life limb or property WARNING All wiring must be done in accordance with field wiring diagrams applicable sections of the National Electrical Co...

Page 115: ...mp Metal Detector REC 4105 B 5 Figure B 1 Remote Front Panel Dimensions WARNING Make sure the mounting surface is flat so that the fiberglass enclosure does not twist or warp when the mounting bolts are tightened A90514 ...

Page 116: ...ing Diagram D07328C E201 in Appendix D to connect system wiring to the remote front panel WARNING All wiring must be done in accordance with field wiring diagrams the National Electrical Code and all local electrical codes B 6 1 Input Power Requirements Switch selectable 115 VAC or 230 VAC Fusing 115 VAC F1 1 4 A 250 VAC Type T 230 VAC F1 1 8 A 250 VAC Type T B 6 2 Critical Wiring Conditions Be su...

Page 117: ... the remote front panel Figure B 2 shows the locations of the wiring connections Figure B 2 Interior of the Remote Front Panel Enclosure Use this procedure to wire the remote front panel 1 Ensure that the POWER switch on the chassis cover is in the OFF position 19 Route incoming power connections through a conduit hole in the bottom right of the enclosure see Figure B 1 Use 14 AWG stranded copper ...

Page 118: ...er to the remote front panel See Figure B 2 for the locations of the terminals 1 Determine the input power to be supplied to the control unit and set the VOLTAGE switch to the correct voltage see Figure B 2 2 Verify that fuse F1 is correct for the input power 115 VAC 1 4 A 250 VAC Type T 230 VAC 1 8 A 250 VAC Type T 3 Connect the ground wire to the GND terminal 4 Wire the HOT input power to the te...

Page 119: ... the display on the remote front panel will show busy if you try to use it You will not be able to use the remote until 30 seconds after the control unit is no longer in use B 10 Parts List The list below provides part numbers and descriptions of the replaceable parts for the ORETRONIC III TMD remote front panel Refer to the parts list in Chapter 5 and the engineering drawings in Appendix C for ot...

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Page 121: ...t splice is detected but waits until the belt splice is through the coils and then starts the test If the latest EST value measured differs from the reference or learned EST value an alarm is generated This simple yet sophisticated system guarantees the transmitter and receiver on your TMD are working properly C 3 Mechanical Installation Use the following procedures for mechanical electrical insta...

Page 122: ...in the desired 250 500 signal range 29 After the value displays between 250 and 500 securely tighten the nuts on the bolts that run through the cross support beam and the EST plate 30 Run the calibration again to ensure the EST plate did not move while tightening the nuts If the reading is not between 250 and 500 loosen the nuts and start the calibration again beginning with Step 5 C 6 Interval Se...

Page 123: ... can be done in either calculation or normal mode of operation An EST test done on demand in NORMAL operating mode is identical to an EST test done automatically using the EST Time Interval If the test fails the ALARM LED lights and the alarm output is activated The alarm must be cleared before returning to normal operation An EST test failure in the CALIBRATION mode only lights the ALARM LED The ...

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Page 125: ...llation Placement D07328C A102 Under Belt Single Coil Outline and Mounting Under Belt D07328C B101 XX Final Assembly Standard System D07328C A001 Installation Placement Standard System D07328C A002 Outline Mounting and Assembly Coil Stand D07328C A003 Outline Mounting Dimensions Clip Detector D07328C B003 Outline Mounting Dimensions Flag Drop Marker B07328C B004 Outline Mounting Dimensions Alarm H...

Page 126: ...onic III Tramp Metal Detector REC 4105 D 2 Electronically Simulated Tramp EST Assembly Standard Hi Strength D07328C K001 EST Outline and Mounting D07328C B008 EST Under Belt Outline and Mounting D07328C B102 ...

Page 127: ... 26 error conditions 4 26 fault conditions 4 26 fault conditions 3 14 features 1 7 field wiring 2 21 front panel displays 3 6 calibration 3 8 password 3 7 run 3 6 setup screens 3 10 high pile detector 1 8 input power requirements 2 16 installation 2 18 keys enter 3 4 reset 3 5 scroll 3 4 value 3 4 LED indicators 3 5 alarm 3 5 bar graph 3 5 bypass 3 5 calib 3 5 normal 3 5 maintenance 4 1 menus 3 2 ...

Page 128: ... speed sensor 1 8 support structure 1 6 system components 1 4 system requirements 1 9 technical specifications 1 9 theory of operation 1 1 timed delay 2 28 timed delay marker 1 8 troubleshooting 4 1 adjusting metal sensitivity 4 16 bar rod adjustment 3 11 4 11 changing material type code 4 17 coil imbalance 4 4 coil or junction box damage 4 18 diagnostics 4 3 false tripping 4 4 noise mechanical or...

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