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Appendix D Engineering Drawings

This Appendix contains the engineering drawings for your Oretronic III
Tramp Metal Detector system. The following drawings are included:

Field Wiring Diagram

(D07344A-E001)

Field Wiring Diagram

(D07344A-E002)

Field Wiring Diagram

(D07344A-E031)

Field Wiring Diagram

(D07344B-E010)

Field Wiring Diagram

(D07344B-E012)

Under Belt Single Coil Assembly Stand

(D07328C-A110-XX)

Under Belt Single Coil Final Assembly

(D07328C-A101)

Under Belt Single Coil Installation Placement

(D07328C-A102)

Final Assembly, Standard System

(D07328C-A001)

Installation Placement, Standard System

(D07328C-A002)

Summary of Contents for Oretronic III

Page 1: ...Oretronic III Tramp Metal Dector Operating Service Manual REC 4105 Rev L Part Number 060298 English...

Page 2: ...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 3497 This revision documents cha...

Page 3: ...Scientific also may seek to protect this work as an unpublished copyright In the event of either inadvertent or deliberate publication Thermo Scientific intends to enforce its rights to this work unde...

Page 4: ......

Page 5: ...operating or maintaining this machine Instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations Potential safety issues are indicated...

Page 6: ...ne s power OFF Replace all covers before resuming operation During maintenance a safety tag not supplied by the factory is to be displayed in the ON OFF switch areas instructing others not to operate...

Page 7: ...parts CAUTION Do not place or store objects of any kind on the machine CAUTION This machine should not be operated at more than the production rate stated on your Equipment Specification sheet or use...

Page 8: ......

Page 9: ...nsiderations 2 1 Mounting Location 2 2 Electrical Specifications 2 2 Input Power Requirements 2 2 Safety Precautions 2 3 Equipment Handling 2 4 Inspection and Unpacking 2 4 Inspection and Unpacking 2...

Page 10: ...nel LED Indicators 3 5 NORMAL 3 5 ALARM 3 5 BYPASS 3 5 CALIB 3 5 Bar Graph 3 5 Front Panel Displays 3 6 Run Screen 3 6 Password Protection Screen 3 7 Calibration Screens 3 8 Coil Balance 3 8 Calibrate...

Page 11: ...2 Adjusting for Clip Belt Splice Detection 4 13 Passing Tramp Undetected 4 17 Adjusting Metal Sensitivity 4 17 Changing the Material Type Code to Adjust Sensitivity 4 19 Testing for Coil or Junction B...

Page 12: ...ring the Remote Front Panel B 6 Input Power Requirements B 6 Critical Wiring Conditions B 6 Field Wiring Procedure B 7 Setting the Comm Switches B 9 Setting up and Operating the Remote Front Panel B 9...

Page 13: ...Unit Enclosure Bottom View 2 8 Figure 2 3 Terminal Block Locations on the CPU Board 2 10 Figure 2 4 Switch Locations on the CPU Board 2 14 Figure 3 1 Tramp Metal Detector Front Panel 3 2 Figure 3 2 T...

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Page 15: ...e 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 mate...

Page 16: ...e 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 de...

Page 17: ...ramp Metal Decay Time Comparison The Oretronic III TMD is designed to take advantage of the difference in decay time by activating its measurement window the point at which it reads the output signal...

Page 18: ...wo 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 be...

Page 19: ...Introduction Thermo Fisher Scientific Introduction 1 5 REC 4105 Rev L Figure 1 6 TMD System Components Dual Coil Optional Optional...

Page 20: ...ed under the belt On an under belt single coil TMD the transmitter and receiver coils are together in a coil assembly mounted under the belt The coil support structure does not extend above belt heigh...

Page 21: ...D system It uses lighted displays and touch panel keys simplifying calibration and operations Figure 1 8 shows the Oretronic III control unit enclosure Figure 1 8 Oretronic III Control Unit The Oretro...

Page 22: ...each other the SYNC input feature allows for the synchronization of transmitter pulses This prevents the detectors from mistaking a transmitter pulse from another detector for a metal signal To set u...

Page 23: ...tify the location of tramp metal on the conveyor you can specify a timed delay that indicates to the TMD how long it takes for the detected tramp to move from the coils to the marking device This help...

Page 24: ...Transmitter Coil Flat 43 in x 9 in x 0 75 in L x W x D 1 092 2 mm x 228 6 mm x 19 0 mm Receiver Coil Flat 43 in x 15 5 in x 0 75 in L x W x D 1 092 2 mm x 393 7 mm x 19 0 mm Size Under Belt Single Co...

Page 25: ...bient 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 Volta...

Page 26: ...low 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...

Page 27: ...eceiver Receiver Coil 10 ft 3 m maximum distance 1 V max Remote Reset Isolated supply voltage provided 24 V open circuit 7 mA short circuit and 3 mA threshold Isolated Supply 24 VDC 150 mA Outputs Ala...

Page 28: ...osite states they are opposite contacts of the same Form C relay Bypass Indicator Dry contact 5 A 250 VAC Power On Indicator Dry contact 5 A 250 VAC Option Dry contact 5 A 250 VAC Communications One R...

Page 29: ...tion equipment and perform work at the installation site A customer service representative is available to assist with installation and verify operation as well as train personnel assigned to operate...

Page 30: ...either side of the coil support structure must be removed or replaced with non metallic parts Metal chutes of feed points should be at least 8 ft 2 4 m away from the coil support structure Magnets mu...

Page 31: ...ower OFF Replace all covers before resuming operation Safety Precautions WARNING Use only the procedures and new parts specifically referenced in this manual to ensure specification performance and ce...

Page 32: ...ged components The Tramp Metal Detector and associated equipment can be safely stored with the cover secured and hole plugs installed in ambient temperatures between 67 and 158 F 55 to 70 C The contro...

Page 33: ...distance may be reduced by using rubber impact type idlers 7 Remove all deck plates cross bracing and return idlers located within 4 ft 1 2 m of the receiver coil The coil support structure is shipped...

Page 34: ...g and return idlers located within 4 ft 1 2m of the coil Optional 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...

Page 35: ...it should be mounted in a vibration free area less than 10 ft 3 m from the coils Mount the control unit enclosure to a rigid flat vertical surface using the 2 position mounting feet on the back of the...

Page 36: ...ee Figure 2 1 4 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...

Page 37: ...required Stranded rather than solid wire should be used This wiring should be long enough and routed to allow the chassis to be removed from the front for servicing Connect the shields only where sho...

Page 38: ...c REC 4105 Rev L Follow all cable number specifications on the Field Wiring Diagram D07344A E001 when connecting wiring to the CPU board Figure 2 3 shows the locations of the terminal blocks Figure 2...

Page 39: ...nications cables to the appropriate terminals on TB2 and TB3 see Figure 2 3 Follow this procedure to connect incoming power to the control unit See Figure 2 3 for the locations of the terminals 1 Dete...

Page 40: ...re the chassis cover is closed before applying power This section describes the switches that can be set in the field to adapt the TMD to your environment SW1 DIP Switches are located on the display b...

Page 41: ...isabled Required setting on the master 4 Belt direction Reversed Normal 5 Factory test Normal operation Required setting 6 Units selection Metric English 7 F5 Enable F5 error alarm Disables F5 8 Cold...

Page 42: ...Installing the TMD 2 14 Installing the TMD Thermo Fisher Scientific REC 4105 Rev L Figure 2 4 Switch Locations on the CPU Board...

Page 43: ...RMAL BYPASS In NORMAL position alarm output is enabled If both SW2 and SW3 are in BYPASS position alarm output is disabled and BYPASS indicator is ON SW4 Communication switches See Figure 2 3 SW5 Sets...

Page 44: ...The next digit in the counter will be flashing 7 Repeat Steps 4 and 5 to enter each digit of the belt speed When the last digit is entered the entire counter flashes indicating that calibration is in...

Page 45: ...you will need to know the distance between the clip detector and a point six inches past the receiver coil This value is the clip delay It is used to desensitize the TMD so that belt clips and splice...

Page 46: ...ermo Fisher Scientific REC 4105 Rev L To determine timed delay clock the time in seconds that it takes for the mark on the belt to move from the receiver coil to the marking device This value will be...

Page 47: ...MD This method 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...

Page 48: ...ystem tripped or while the belt was coasting to a stop if any When the TMD is in Run mode you can display all setup and calibration variables but you cannot change them Setup Calibrate mode allows you...

Page 49: ...required Calib N Y If Y settings can be changed COIL BAL COARSE 0 7 FINE 0 999 CLP CORS 0 7 CLIP FINES 0 999 AUD CAL 0 24 AUD LAST AUD TEST TEST EXIT SETUP N Y If Y parameters can be changed CLIP DLY...

Page 50: ...do not wrap The 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 decrea...

Page 51: ...lt or error is present It is never on when the NORMAL LED is on The BYPASS LED yellow indicates that the alarm output relay is disabled by the SW2 SW3 switch settings on the CPU board see Section CPU...

Page 52: ...the coast counter to zero If the display is anywhere else in the scroll the counter shows the current value of the displayed variable To access the variables use the scroll keys to move the display u...

Page 53: ...procedure begins at the PSWD N display 1 Press a value key then press ENTER The display changes from PSWD N to PSWD Y indicating that you want password protection The Y will be flashing 2 Press ENTER...

Page 54: ...Leaving the display on CALIB N and pressing ENTER allows you to scroll through the calibration screens and view all settings but not change them To return the TMD to normal Run mode after making chang...

Page 55: ...he second metal calibration screen the display shows FINE The counter shows the current fine sensitivity setting between 0 and 999 You can change the fine sensitivity setting manually using the VALUE...

Page 56: ...nd the display flashes AUTO CLP When the calibration is complete press ENTER again The display shows CLP DONE The counter shows the new fine clip setting To abort the auto calibration SCROLL up or dow...

Page 57: ...e after making changes or viewing settings SCROLL up to the Run screen or SCROLL down to the EXIT screen and press ENTER This screen is used to set the length of belt to let pass the detection area so...

Page 58: ...an H following the number For example 1 1H is 1 100 feet minute This screen is used to set the delay after detection for the timed marking output The display shows TIME DLY The counter shows the timed...

Page 59: ...ontrol unit The display shows REMOTE Y or REMOTE N This screen indicates whether the system is controlled by a PLC connected to the control unit over a serial communications line The display shows MOD...

Page 60: ...ESET This screen shows the version of TMD software installed The display shows V XX XX where XX XX is the version number This screen allows you to exit the setup screens and return to Run mode without...

Page 61: ...ndicate that the TMD found a failure in the electronics or a setting that does not allow the detector to operate When a fault occurs the ALARM LED lights and the alarm output relay is activated If the...

Page 62: ...ken the required measurements refer to Section Determining Values to Use for Initial Setup You have a timing mark on your conveyor belt You have a piece of tramp metal the average size to be detected...

Page 63: ...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 press the ENTER key to use the...

Page 64: ...efault 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...

Page 65: ...ALIB Y 9 Scroll to the COIL BAL display and press ENTER to do a quick electronic balance of the TMD The display flashes QUIK BAL while the TMD balances 10 Scroll to the COARSE display and press ENTER...

Page 66: ...ithout changing the value to start the coarse clip sensitivity auto calibration The counter shows A2 and the display flashes AUTO CLP to indicate that the calibration has started 17 Wait for the timin...

Page 67: ...Undetected Range 0 9 Default 0 22 Scroll to the BAR LEN display and enter the maximum length in feet of bar or rod to detect Range 1 0 50 0 Default 10 0 23 This completes the initial setup procedure...

Page 68: ......

Page 69: ...e and as such requires minimal 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 h...

Page 70: ...there are adjustments 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 If yo...

Page 71: ...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 thes...

Page 72: ...any of these procedures Coil imbalance can result from the transmitter and receiving coils not being aligned well It can also result from different amounts of metal in the conveyor structure on each s...

Page 73: ...the middle of the bar graph The LEDs may be going on and off and changing 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 imbala...

Page 74: ...e improves significantly proceed with Step 8 to fine tune the coil balance Retighten the plastic bolts holding the coil to the frame If adjusting the coil does not affect the bar graph significantly a...

Page 75: ...or the wiring from the motor may also produce noise that interferes with TMD operations Even other electrical systems near the TMD may be generating the noise Follow this procedure to find the source...

Page 76: ...d to cause problems The coil support structure should not vibrate or sway The coil s should be firmly bolted to the structure and should not vibrate There should be no conveyor idlers or other moving...

Page 77: ...orrect 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 co...

Page 78: ...e TMD Go on to Step 14 If the number of LEDs lit does not decrease try each value If the number still does not decrease change the filter back to 0 and go on 11 Scroll to the FINE display and return t...

Page 79: ...btained using material type code 3 CAUTION Keep hands and clothing away from all moving or rotating parts 3 Start the conveyor belt and run material through the coils Observe the noise level on the ba...

Page 80: ...t which the TMD takes its bar rod measurements Any of these parameters may need to be adjusted Before beginning this procedure scroll to the BAR SENS display and check the number shown in the counter...

Page 81: ...asily diagnosed The TMD will trip just as or just after a clip has passed If the conveyor is wired to stop on a trip the clip will generally be the same distance downstream from the coils each time th...

Page 82: ...al 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 modules There ar...

Page 83: ...false tripping on the clips the problem is too high a clip sensitivity Follow this procedure to adjust the clip sensitivity 1 Scroll to the CLP CORS display and record the clip coarse sensitivity valu...

Page 84: ...ater than 500 go to Step 14 9 Scroll to the CLP CORS display 10 Decrease the clip coarse sensitivity value shown in the counter by and press enter 11 Scroll to the clip fine display and press enter wi...

Page 85: ...d descriptions of the front panel keys indicators and displays in Chapter 3 of this manual before beginning any of these procedures The most common cause of undetected tramp is having the metal sensit...

Page 86: ...y Go to Step 7 4 Check the marking on the receiver coil to make sure it is installed correctly Refer to the appropriate Outline Mounting and Assembly Coil Stand drawing 5 If the coil is installed corr...

Page 87: ...ate sensitivity you may need to change the material type code Note Adjusting metal sensitivity is performed the same for both double and single coil detectors Detecting small sized tramp metal especia...

Page 88: ...ensitivity 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 10 If mor...

Page 89: ...e instructions in this manual Allow only qualified electricians to open and work in the electronics cabinets power supply cabinets control cabinets or switch boxes WARNING High voltage that may be pre...

Page 90: ...rocedure to test the transmitter coil 1 Turn off power to the control unit SW6 2 Disconnect the transmitter coil wires from field terminals 4 and 5 3 Measure the resistance of the coil If the transmit...

Page 91: ...approximately 450 500 ohms the receiver coil its wiring and its portion of the CPU board is all right 4 If the receiver coil resistance is all right reconnect the wires to the terminals in the junctio...

Page 92: ...k the connectors on the CPU board and the ribbon cable to the display board for correct mating on boards Re insert any connector that may have come loose during shipping or installation 9 Check for co...

Page 93: ...t the power on TB1 6 Replace the fuse with the correct sized fuse 7 Turn the power switch back on 8 If the displays do not light turn the power switch off 9 Test the fuse again If the fuse tests good...

Page 94: ...ght the fuse is blown The wiring for that component is causing a problem Wire in the components one at a time in the following order Transmitter coil Clip detector A Clip detector B High pile detector...

Page 95: ...d press ENTER If it is not possible to light 5 LEDs decrease the value to 10 10 Place the TMD in Run mode 11 Pass a large piece of tramp or steel 3 inches or more in diameter through the coils while w...

Page 96: ...eed or the actual speed if a speed sensor is being used If the value is incorrect change it 4 Scroll to the BAR LEN display The counter should show the maximum bar rod length for the TMD to detect If...

Page 97: ...ry default values are as follows PARAMETER DEFAULT VALUE Setup Displays CLIP DLY 00 0 BAR SENS 00 0 BAR LEN 01 0 BELT SPD 400 TIME DLY 00 1 TIME DUR 00 1 MAT CODE 003 FILTER 001 OP FREQ 000 REMOTE N M...

Page 98: ...hows the type of fault that occurred refer to Table 4 2 The counter shows the corresponding fault number An F in the first digit of the counter indicates a fault rather than an error condition To clea...

Page 99: ...ue to faulty wiring or actual fault condition F2 SELFTEST Indicates a microprocessor problem F3 BALANCE The coil imbalance exceeds the ability of the detector to electronically self balance See sectio...

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Page 101: ...uct Service at 800 445 3503 Thermo Scientific also provides on site service technicians to assist customers with installation set up initial calibration customer training maintenance and repair Contac...

Page 102: ...termine the broken or faulty part 2 Locate the part on the engineering drawings in Appendix D 3 Find the corresponding part number in the parts list 4 Before you contact Thermo Scientific for your par...

Page 103: ...s and descriptions ITEM DESCRIPTION PART NO Control Unit Enclosure NEMA 4X 060095 Chassis Assembly 067169 PCBA CPU 058550 PCBA Display 058547 Relays 6 GP 24 V DC 5 A 2SPST PC 049637 Fuse SloBlo 37 3 8...

Page 104: ...008105118 86 0 2164451101 fax Germany 49 0 208 824930 49 0 208 852310 fax India 91 22 4157 8800 91 22 4157 8801 fax Italy 39 02 959514 1 39 02 953200 15 fax Mexico 52 55 1253 9410 52 55 1253 9424 fax...

Page 105: ...ion The host or PLC must act as a Modbus master device Baud rates supported are 1200 2400 4800 9600 19200 The default is 9600 bps The TMD provides normal Modbus responses only for the functions listed...

Page 106: ...a 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 Data Lo Reg 40005 64 Error Check 16 bit CRC In this example the host write...

Page 107: ...of the idle time between messages The minimum idle time between messages is 3 5 character times at the current serial baud rate However there must be no more that 1 5 character times between character...

Page 108: ...5 Rev L Table A 2 describes each holding register used for Modbus communication with the TMD In the table Type I is a signed integer Type P means that data is packed within the bytes MSB most signific...

Page 109: ...resent 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...

Page 110: ...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 Rea...

Page 111: ...ONLY 40101 Read Only THERMO FISHER SCIENTIFIC 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 b...

Page 112: ...taken is taken into account 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 c...

Page 113: ...t digit Integer 1 Middle digit Reg 40043 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...

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Page 115: ...serial communications can be added to the main TMD control unit The remote front panel includes a separate power supply and has a distance limitation of 4 000 ft 1 219 m from the main TMD control unit...

Page 116: ...n H x W x D 284 5 mm x 234 4 mm x 155 4 mm Weight 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 7 C a...

Page 117: ...aph 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 T...

Page 118: ...when testing in on or around the electronics cabinet PC boards or modules There are voltages in excess of 115 V or 230 V in these areas Covers over the electronics should always remain in place during...

Page 119: ...Scientific B 5 REC 4105 Rev L Figure B 1 Remote Front Panel Dimensions WARNING Make sure the mounting surface is flat so that the fibreglass enclosure does not twist or warp when the mounting bolts a...

Page 120: ...for your system or refer to the Field Wiring Diagram D07344A E001 in Appendix D to connect system wiring to the remote front panel WARNING All wiring must be done in accordance with field wiring diag...

Page 121: ...asy reach of the operator and it must be marked as the disconnecting device for the equipment All conduits should enter the bottom of the enclosure Do not run conduit through the top or sides of the e...

Page 122: ...1 Connecting Incoming Power WARNING Do not apply power until you have read and understood this entire section Improper connection may result in damage to your detector Verify that the input voltage is...

Page 123: ...parameter settings of the main TMD control unit To support the remote front panel the remote parameter in the control unit must be set to y Because the operator interface provided by the remote front...

Page 124: ...he parts list in Chapter 5 and the engineering drawings in Appendix D for other TMD system part numbers The drawings help you accurately identify the part s you need and the parts lists on the drawing...

Page 125: ...ot turn on when a belt 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...

Page 126: ...T horizontally to reposition it 6 Press the ENTER key and run the calibration procedure again Keep moving the EST and running the calibration until your reading displays in the desired 250 500 signal...

Page 127: ...signal reading for the last interval EST test Use the following procedures to display the last EST value 1 At the TMD control panel from the RUN menu scroll to the CALIBRATION menu 2 Press ENTER 3 Sc...

Page 128: ...ION mode only lights the ALARM LED The ALARM LED turns off if either scroll key is pressed Use the following procedure to perform an EST Test in CALIBRATION mode 1 At the TMD control panel from the RU...

Page 129: ...01 Field Wiring Diagram D07344A E002 Field Wiring Diagram D07344A E031 Field Wiring Diagram D07344B E010 Field Wiring Diagram D07344B E012 Under Belt Single Coil Assembly Stand D07328C A110 XX Under B...

Page 130: ...Dimensions Spray Marker D07344B B007 Outline Mounting Dimensions Alarm Horn B07328C B005 Outline Mounting dimensions Rotating Beacon Assembly B07328C B006 Outline Mounting and Installation High Pile D...

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