METTLER TOLEDO PowerPhase Technical Training Manual

SAFELINE
Metal Detection Metal Detection & X-ray Inspection
PowerPhase
technical training manual
Table of Contents
TABLE OF CONTENTS
Section 1: Detector System Overview ................................................1 - 2 J
Section 2: Detector Theory ............................................................3 - 13 J
Section 3: Software Levels ..........................................................14 - 24 J
Section 4: User Settings and Adjustments ....................................25 - 72 J
Section 5: Troubleshooting ..........................................................73 - 85 J
Section 6: Notes ........................................................................86 - 88 J
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DETECTOR SYSTEMS OVERVIEW
Section 1
1.1 TERMINOLOGY
A. Detector Search Head

I. Detector Aperture II. Aperture Liner III. Former IV. Three Coil System
DETECTOR SYSTEM OVERVIEW

B. Control Module
I. Keypad II. Bar Graph Display III. Detection LED IV. LCD Display
C. Power Supply
I. Top Connection Circuit Board II. Digital Switchmode Power Supply
D. Interconnection Board
I. EEPROM Memory II. Ribbon Connection Cable
1
1.2 SYSTEM CONFIGURATIONS
Section 4
A. Standard Systems
I. The Control Module is mounted directly to the II. The power supply is housed in a separate
detector search head. enclosure (i.e. the motor control enclosure).
USER SETTINGS AND ADJUSTMENTS
B. Remote Systems
I. The Control Module and power supply are II. The detector search head is connected to the
combined together in a separate remote system electronics enclosure by way of two
electronics enclosure. remote connecting cables.
2
DETECTOR THEORY
Section 2
2.1 SEARCH HEAD CONSTRUCTION
A. Case Construction and Finish
1. Painted White
DETECTOR THEORY
I. Used for mild environments II. Wipe down cleaning ONLY III. Powerphase Systems use
"Super-Drive" Modules
2. Stainless Steel
I. Used for harsh environments II. Frequent / Heavy Washdown III. Powerphase Systems use
Applications (NEMA 4X) non "Super-Drive" Modules
3. Polished Chrome
I. Used for mild environments II. Wipe down cleaning ONLY III. Frequently used with
Pharmaceutical Systems
B. Solid Potting
I. Minimizes the effects of Vibration II. Secures the Former firmly in place
C. Former
Rectangular or Square
I. Made of the phenolic material "Trespar" II. Selected for its rigid characteristics
Round
I. Made of Fiberglass II. Can be rigidly formed for circular apertures
Detector Search Head (cut-away view)
3
2.2 THREE COIL SYSTEM
Section 2
A. Description Ra Tx Rb
Beneath the liner in the aperture, lies RECEIVING COIL TRANSMITTER RECEIVING COIL
or
the former assembly. Embedded in wound around former in
clockwise rotation EXCITATION COIL
wound around former in
clockwise rotation
the former assembly are (3) solid
copper wires that are wrapped
DETECTOR THEORY
around the former. The former/3 coil

system surrounds the product as it
passes through the detector aperture. The center coil is referred to as the "excitation", or transmitter
coil. On either side of the transmitter coil, are the (2) receiving coils. The two receiving coils are
wound around the former assembly in opposite directions to one another.
B. Excitation Coil (TX)

A high frequency, low power amplifier located in the
Control Module, applies a signal to the excitation
coil. This causes the coil to transmit an
electromagnetic field outward in all directions.
C. Receiving Coils (Ra & Rb) Ra Tx Rb

When the high frequency electromagnetic Signal Signal Signal
field radiates past the two receiving coils, a
signal is induced into the coils.
Due to the reverse winding relationship of the

two receiving coils, one of the coils receives
the transmitter signal "in phase" with the
transmitter signal, while the opposite
Ra
receiving coil receives the signal as a mirror Signal
image of the transmitter signal or "180
degrees out of phase". Rb + = 0 Volts
Signal
The two signals from the receiving coil are

then processed and added together. Because the two signals are 180 degrees phase shifted, when
these two signals combine, they will cancel each other out and produce a 0-volt condition.
4
2.3 METAL FREE ZONE
Section 2
A. Description
The aperture opening of the detector allows some of the electromagnetic field generated by the
transmitter to extend beyond the case. Any external metal must be kept at a distance from this point.
This area or "zone" is referred to as the metal free zone of the detector. An approximation formula
DETECTOR THEORY
can be used to calculate the required distance of the zone and is based on the height of the aperture
dimension.
B. Zero Peripheral Metal Free Zone Detector (ZPMFZ)

This specially designed detector allows for a tighter field pattern
that restricts the field very close to the aperture opening. This
design permits metal to be positioned much closer to the peripheral
of the aperture. Typical applications include vertical form fill
bagging.
2.4 SENSITIVITY
A. Definition
The sensitivity of a metal detector is stated as the smallest diameter metal sphere that is consistently
detectable in the center of the detector aperture. Many factors can have an influence on a detectors
sensitivity. The following list contains some of the primary influencing factors:
1. Type of metal 6. Operating frequency

2. Shape of metal 7. Product effect
3. Orientation of metal 8. Environmental conditions
4. Position of the metal in the aperture 9. Electromagnetic ground loops
5. Aperture dimensions 10. Detector settings mis-adjustment
5
B. Signal Generation
Section 2
A. Description
A metal sphere approaching the aperture begins to

influence the first receiving coil by inducing a voltage. This
conduction imbalances the normal "zero output condition"
DETECTOR THEORY
and a voltage signal begins to develop.
When the sphere reaches a position directly beneath the

first receiving coil, the maximum conduction occurs, and a
peak positive voltage is output.
As the sphere moves away from the first receiving coil, a

decrease in conduction begins to occur. The output voltage
begins to drop off.
When the sphere reaches the center coil, a momentary state

of balance is achieved since the sphere's influence is equal
to both receiving coils. The output voltage drops
momentarily to 0 Volts.
As the sphere approaches the second receiving coil,

conduction begins to induce and output voltage. The
polarity of this signal is opposite that of the first coil due
to the reverse coil winding relationship.
When the sphere is positioned directly beneath the second

receiving coil, a maximum negative output voltage is
reached.
As the sphere exits the aperture, the voltage drops back to

the original 0 Volt output condition.
6
C. Amplitude Detection
Section 2
The signal generated as a result of the metal sphere passing through the metal detector aperture in
then processed by the system electronics. The signal is referenced to a fixed positive and negative
threshold. If the maximum peak signal is large enough to exceed either the positive or negative
threshold points, then a detection will be registered. This method of signal detection is referred to as
"amplitude detection".
DETECTOR THEORY
+vth +vth
–vth –vth
Signal generated is too small Signal generated is sufficient in size

Metal not detected Metal is detected
D. Operating Frequency
The operating frequency of a detector is the electromagnetic wave frequency that the transmitter
operates at (typically this in the Kilohertz range). If two metal detectors have the same aperture
dimensions, the same maximum sensitivity settings, and no product phase applied, the detector with
the highest operating frequency will have the best metal finding capabilities. A metal detectors
chosen operating frequency is determined by testing the product to be run on that unit. Often times,
the product will be the determining factor as to which frequency will yield the best product set-up and
overall metal finding capabilities.
COMMON METAL DETECTOR OPERATING FREQUENCIES

STANDARD PHARMACEUTICAL POWERPHASE
25Khz 600Khz 25Khz / 100Khz
100Khz 800Khz 100Khz / 300Khz
300Khz 300Khz / 800Khz
7
E. Aperture Dimensions
Section 2
The aperture opening size is another factor that effects sensitivity. Typically, the detectors aperture
size is selected based on the maximum product size to be passed. If two detectors have similar
operating frequency, the same maximum settings and no product phase, the detector with the
smallest aperture will have the best metal sensitivities. This is primarily due to the coil system being
positioned closer to the metal. As the aperture size increases, the signal generated diminishes.
DETECTOR THEORY
Sensitivity = 199 Product Phase = 0 Sensitivity = 199 Product Phase = 0
Minimum detectable ferrous sphere in the center Minimum detectable ferrous sphere in the center
of the aperture is 1.5mm. of the aperture is 0.7mm.
F. Aperture Position
The strength of the high frequency electromagnetic field is less in the direct center of the detector
aperture. This is due to the former/coil assembly being positioned around the circumference of the
aperture opening. Moving from the center aperture position in any direction toward the aperture liner,
the sensitivity increases. The typical sensitivity gradient is less than two diameters. This is the
difference in sensitivity measured at the center of the detector aperture and the sensitivity at any other
point in the aperture not closer than 10mm to the liner surface.
8
G. Metal Types
Section 2
Different types of metals have an effect on a detectors sensitivity. The primary reasons for this are the
physical structure of the metal, the electrical and magnetic characteristics, and the percentage of
elements present, (this is most important in the consideration of the various grades of stainless
steel). This hierarchy of the different types of metal is similar for all forms of coil based metal
detectors.
DETECTOR THEORY
Metal Type(s) Category Permeability Conductivity Ease of Detection
Iron Ferrous Excellent Good Very Easy
Copper Non-Ferrous Good Good To Excellent Relatively Easy
Aluminum
Brass
Lead
Zinc
Various Grades of Non-Ferrous Usually Poor Usually Poor Relatively Difficult
Stainless Steel
Spherical Metal Samples and Spiral Contamination Equivalents
9
H. Orientation Effect
Section 2
When testing the metal detector, it is common to use calibrated test spheres. The reason for this is
that a sphere has the same cross-sectional area regardless of how it is turned. Typically, most metal
contamination is in some elongated, irregular form. Depending on the type of metal, and its
orientation relative to entering the detectors aperture, the metal may be easy or difficult for the detector
to detect.
This phenomenon is referred to as "orientation effect", and is inherent to all coil based metal
DETECTOR THEORY
detectors.
Orientation effect is only evident when the metal contamination's cross-sectional area is smaller than
the detectors minimum spherical capabilities for that same type of metal.
If the metal contamination's diameter is smaller than the detectors capabilities for that same metal
type, it maybe detectable if the metals overall length is sufficient. If the metal contamination is less
than 1/3 the detectors minimum capabilities for that same type of metal, it may not be detected
regardless of how long it is.
Orientation effect as a function of spherical sensitivity
10
2.5 PHASE
Section 2
A. Phase Relations
When objects pass through the aperture of
the metal detector, they interact with the
DETECTOR THEORY
electromagnetic field generated by the high
frequency transmitter coil. Depending on the
composition of the substance(s), a phase
shift can occur.
Comparing the signal of the receiving coils

with the original signal generated by the
transmitter coil, it is noted that the signals
are not in phase.
B. Phase Vectors
To express the phase shift
variations that occur, it is
common to plot the angle as a
function of an X-Y vector.
The example shows some of
the common metal types and
the phase shifts that occur, and
how they would be plotted on
the X-Y graph.
11
C. Vibration
Section 2
Mechanical vibration introduced into the Former/Coil assembly vibrates the assembly and self
induces a voltage back into the receiving coils that is processed.
Since the signal was not reflected back to the system by a material or
substance, no phase shift occurs, and the resulting plotted vector is
horizontal.
DETECTOR THEORY
D. Reference Phase
One of the primary machine settings for the metal detector is the
Reference Phase. It is important that this parameter be properly set to
ensure optimum detector performance.
The system electronics has the ability to generate and control an
electronic phase envelope that can be swept through a 180-
degree range.
Any signal vector that is "captured" within the adjustable

electronic envelope has the effect of reducing or "nulling"
that particular signal.
Setting the Reference Phase aligns the electronic phase
envelope to capture the horizontal signal from vibration,
thus minimizing the effect of mechanical vibration.
Once the Reference Phase has been properly established for the metal
detector, it then provides a "base line" point by which all user product
phase angles will be referenced.
12
E. Product Phase
Section 2
Some products generate strong signals as they pass through the detector. They interact with the high
frequency electromagnetic field in the same way the metals interact. This is commonly referred to as
"Product Effect" signals.
Typically, signals from product are categorized into two general classifications:
DETECTOR THEORY
DRY:
1). VERY LOW MOISTURE CONTENT
2). SIGNAL PRODUCED IS VERY SMALL
3). CONTAINS LITTLE OR NO CONDUCTIVE PROPERTIES
WET:
1). VERY HIGH MOISTURE CONTENT
2). SIGNAL PRODUCED IS VERY LARGE
3). MAY CONTAIN HIGHLY CONDUCTIVE PROPERTIES
Usually, dry product does not require the use of Product Phase. Simple adjustment of the sensitivity
control is all that is required.
Products that are wet and/or conductive require a more controlled set-up to avoid the metal detector
from rejecting them as they pass through the coils. Simply reducing the sensitivity control may not
completely eliminate the strong signal. What is required is a more selective method to "null" out the
product signal, while still allowing for the best metal finding capabilities. The solution to this is the
usage of the Product Phase Control.
Just as the Phase Envelope could capture and "null" the signal produced by vibration, the Product
Phase Control can be user adjusted to capture and "null" the strong product effect signal.
Adjustment of the Product Phase Control aligns the envelope to the product signal instead of the
vibration signal.
Note that while the product signal is now reduced, the movement of the envelope off the vibration
signal now exposes the vibration vector and hence the detector is now more sensitive to the effects of
mechanical vibration.
13
SYSTEM SOFTWARE LEVELS
Section 3
3.1 KEYPAD FUNCTIONS
A. Detection LED
SOFTWARE LEVELS
The detection LED will illuminate each time the bar graph
display crosses from the last green segment to the first red
segment. It will remain illuminated until the red segments
cross back into the green again. The detection LED also serves
as a fault indicator in the event of a fault condition.
B. Bar Graph Display

The bar graph display is a 30-segment display consisting of
10 green segments and 20 red segments. Only signals that
cross into the red section are considered detection. The bar
graph provides the user with an accurate visual indication of
signal size.
C. LCD Display
The LCD display provides the visual information about the
system and performance parameters while viewing the various
screens of the software program modes.
D. Soft Function Keys

Four soft keys are located adjacent to each corner of the LCD
display. These keys permit access to the various adjustments
in the program. If a particular parameter is user adjustable, an
arrow will appear indicating adjustment is permitted.
14
E. Security Key
Section 3
The Security key allows access to the detectors program.
Once the program has been edited, pressing the key again
will exit the program and return to the running mode
display.
SOFTWARE LEVELS
F. RECALL Key
The RECALL key provides system information when
depressed from the running mode display. It also functions
to step backwards when in the various program modes.
G. Cursor Move Key

The cursor move key controls the movement of the cursor
when editing a digital value. The cursor move key always
moves the cursor from right to left.
H. UP / DOWN Arrow Keys

The up / down arrow keys increase or decrease digital
values that appear in the LCD display.
I. ENTER Key
The ENTER Key is used to enter changes into the system
memory. If the enter key is not pressed after a digital value
has been changed, the value will automatically default
back to it's original value.
15
3.2 STANDARD USER LEVELS
Section 3
POWERPHASE Systems User Program Modes

SOFTWARE LEVELS
Program Mode Name Default Security Access Code
1. Running Mode Display No Access Code Required
2. Operators Mode 0001
3. Supervisor Mode 0002
4. Engineer Mode 0003
5. QA Inspector Mode 0004
6. QA Operator Mode 1000 through 9000
7. Viewing Mode 0005
(Note: These sections refer to the POWERPHASE Operating and Instruction Manual)
16
3.3 DIAGNOSTIC LEVEL
Section 3
A. Description
Within each detector system is a diagnostic level that is frequently used by the factory technicians to
aid them in system configuration, setup, and troubleshooting. This level is reserved only for trained
personnel and should not be entered by anyone who is not trained and familiar with the detector
SOFTWARE LEVELS
system. Failure to adhere to this could result in a serious mis-adjustment of the detector rendering it
ineffective.
B. Diagnostic Level Access

Press the program / exit key. Key in the following sequence:
1. With the cursor positioned under the zero in the thousandth's position, increment to the number 1
and press the "ENTER" key.
2. The thousandth's digit will turn to an asterisk, and the cursor will automatically position under the
zero in the hundred's position. Increment to the number 2 and press "ENTER".
3. An asterisk will appear in the hundred's position, and the cursor will move to the ten's position.
Increment to the number 3 and press "ENTER".
4. An asterisk will appear in the ten's position and the cursor will move to the one's position.
Increment to the number 4 and press the "ENTER" key three times. (NOTE: This must be done in
immediate succession or the program will cycle back to the running mode display).
Once the above sequence is completed, the second level of security screen appears.
5. The microprocessor will generate a random four-digit
number that will change each time this level is
5734
reached. 0000
The objective is to enter in values that when
subtracted will equal (4, 3, 2, and 1).
Using the example above, the numbers that would need entered are: (1, 4, 1, and 3). These
numbers when subtracted from the example would yield the desired (4, 3, 2, 1).
NOTE: If the number you are trying to subtract is equal to or larger than the number generated
enter 0 and continue to the next number.
In this example, some of the values generated are too 9206

0000
small to subtract. The entered sequence would be:
(5, enter, enter, and 5).
When the second security level is completed, the main diagnostic menu will be displayed.
CALIBRATE SETTINGS
AGENT CONFIG.
Powerphase Main Diagnostic Menu
17
3.5 Powerphase Diagnostic Menu
Section 3
A. Agent
1). COM 1
Configures COM 1 port for the correct printer type.
COM 1 -- DOT MATRIX
Selectable for: DOT MATRIX or TML60II. ETC.
SOFTWARE LEVELS
2). COM 2
Configures COM 2 port (RS-232). Selectable for:
COM 2 -- SAFELINE PCI
SAFELINE PCI or SNP (Safenet Plus). ETC.
3). AUTO SETUP REJECT INHIBIT

Enables / disables reject inhibit during auto setup
A.S.REJ. INHIBIT IN/OUT
routine. ETC.
4). PERFORMANCE CHECK

Enables / disables the QA Inspectors level. If
PERF. CHECK IN/OUT
disabled, the QA Inspectors level will not be ETC.
accessible.
5). AUTO-TRACKING
Enables / disables auto-tracking feature. Feature is
AUTO. TRACKING IN/OUT
available for special limited applications ETC.
6). AUXILIARY 1 OUTPUT

Configures the AUX 1 output port. Selectable for
AUX 1 OUTPUT FAULT
alarm output if a system fault occurs, or continuous ETC. DETECTOR -- ACTIVE
output if the detector is active (powered ON).
7). DIMENSIONS
Configures unit of measurement for calculations.
DIMENSIONS IMPERIAL
Selectable for metric or imperial ETC.
8). RESET TO DEFAULTS

Resets the system memory to default values.
RESET TO DEFAULTS
Consult with Safeline before initiating a reset. ETC.
18
B. Calibrate
Section 3
1). SWITCHED FREQUENCY
Selectable for single or dual frequency operation. If
SWITCHED FREQ. YES/NO
single frequency operation is selected, the detector will ETC.
default to the "HIGH" operating frequency.
SOFTWARE LEVELS
2). FREQUENCY GROUP AND FREQ. STAGGER
Selects the proper operating frequency group for the
FREQ. GROUP 30/80
detector. It is very important to ensure the frequency ETC. FREQ. STAGGER 3
group is correct for proper detector operation. The
Frequency Stagger indicates the proper coding
number for the crystal installed in the Control Module.
3). COIL PITCH

This is the distance between the coils. It is factory
COIL PITCH 100mm
preset for each detector. ETC.
4). L.F. OFFSET

A real time voltage being read from the LF Amp board.
L.F. OFFSET +000mV
A trimmer potentiometer on the back of the Control ETC.
Module allows adjustment. Tolerance is plus or
minus 010mv.
5). POWER DRIVE

Provides adjustment of the power drive voltage. The
POWER DRIVE (44.00) 100
number in parenthesis is a real time readout of the ETC. AT FREQ. 800Khz
power drive voltage. Selectable for both frequencies.
6). REFERENCE PHASE

Allows for adjustment of the reference phase.
Sensitivity control is provided for signal level during
800KhzREF. SENS. 199
ETC. REF.PHASE. -01.06º
adjustment. Selectable for both operating frequencies.
7). FERROUS PHASE

Provides minor adjustment to the reference phase to
FE PHASE 167.00º
enhance sensitivities to ferrous metal. ETC.
8). SENSITIVITY LIMIT

Limits the maximum sensitivity the detector will setup
SENSITIVITY LIMIT 100
to during an auto setup routine if the phase is at the ETC. AT FREQ. 800Khz
worst vibration position (90.00 degrees). Selectable
for both operating frequencies.
19
C. Configuration
Section 3
1). SERIAL NUMBER

Allows programming of the search heads serial
SERIAL NUMBER --00000
number. ETC.
SOFTWARE LEVELS
2). PEAK DISPLAYS

Enables / disables the peak displays. This provides
PEAK DISPLAYSON/OFF
a numerical readout of the peak level signals from ETC.
the detector.
D. Settings
1). NAME & PRODUCT NUMBER
Allows user to name product numbers.
NAME..............PROD. 00
Up to 14 characters long for the 21 product ETC.
numbers.
2). SENSITIVITY & PRODUCT PHASE

Allows adjustment of the detector sensitivity and
SENS. 199
product phase. ETC. PHASE 000.00º
3). OPERATING FREQUENCY

Switches the detectors operating frequency.
OPERATING FREQ. HIGH
ETC. LOW
4). POWER DRIVE

Adjusts power level to search head.
POWER DRIVE HIGH
HIGH = maximum power drive level ETC. LOW
LOW = reduces to 1/5 of the maximum power drive
level
5). TIMERS
Accesses the timer sub-routine. Allows user to
program the timer parameters. Selectable for 5
A SELECT TIMER B
ETC. GROUP C
timer types.
Any timer can be assigned to one of the three timer
groups (A, B, or C).
20
6). INVERSE DETECTION
Section 3
Switches inverse detection option on / off.)
INVERSE DETECT YES
ETC. NO
7). REJECT COUNT
SOFTWARE LEVELS
Resets the reject count.
REJECT COUNT 0
Maximum count level is 9999 ETC. RESET
8). PACK COUNT

Resets the pack count.
PACK COUNT 0
Maximum level is 16,777,214. ETC. RESET
9). REJECT INHIBIT

Disables the reject device. A visual indicator alerts
REJECT INHIBIT YES
the user to the feature being engaged. ETC. NO
10). VIBRATION SETUP

Selection initiates the vibration setup sub-routine.
VIBRATION SET-UP
ETC.
11). REFERENCE PHASE &

REFERENCE SENSITIVITY
Ref. SENS. 150
Adjustment of the reference phase. A reference ETC.Ref. PHASE +01.82º
sensitivity control is provided to control signal levels
during the adjustment of the reference phase. Any
adjustment to the reference phase in this screen only
effects the operating frequency the detector is currently in.
12). SENSITIVITY LIMIT

Sets the maximum sensitivity level that will occur
SENSITIVITY LIMIT 100
during an auto setup routine if the phase is at its ETC. AUTO.ADJUST
worst position (90.00 degrees). An auto adjust
feature is provided for automatic setting. Best
performed on-site where all ambient vibration is
present.
21
13). PACK SENSOR SETUP
Section 3
Selection initiates pack sensor setup sub-routine. This

PACK SENSOR SETUP
must be setup if using a photo-gated timer.
ETC.
14). PACK SENSOR FITTED

SOFTWARE LEVELS
Configures system for photo-gated operation.

PACK SENSOR FITTED YES
Selectable for enable / disable. ETC. NO
15). PACK SENSOR DISTANCE

Establishes the pack sensors distance. Measures
SENSOR DISTANCE 003in
from the leading edge of the detector case to the ETC.
sensor. Maximum distance is 400 inches.
16). PACK SENSOR CALIBRATE

Calibrates the pack sensor. If the pack sensor fitted
PACK SENSOR CALIBRATE
screen was selected to "yes", the system will proceed ETC.
with the automatic calibration.
17). SECURITY SETUP

Selection initiates security setup sub-routine.
SECURITY SETUP
ETC.
18). OPERATOR ACCESS

Restricts access to operators. Full access permits
OPERATOR ACCESS -- FULL
adjustment of product number, sensitivity, and phase. ETC. LIMITED
Limited permits only access to the product number.
19). CHANGE CODE (OPERATOR)

Programs a custom four-digit security code for
CHANGE CODE -- OPERATOR
operator access. ETC.
20). CHANGE CODE (SUPERVISOR)

Programs a custom four digit security code for
CHANGE CODE -- SUPERVISOR
supervisor access. ETC.
22
21). CHANGE CODE (ENGINEER)
Section 3
Programs a custom four digit security code for
CHANGE CODE -- ENGINEER
engineer access. ETC.
22). CHANGE CODE (VIEWING)
SOFTWARE LEVELS
Programs a custom four digit security code for the
CHANGE CODE -- VIEWING
viewing mode. ETC.
23). SPEED SETUP

Selection initiates speed setup sub-routine. Feature
SPEED SETUP
limited to fixed speed conveyor systems. ETC.
24). SPEED RANGE

Configures the detector for one of three speed ranges.
SPEED RANGE -- NORMAL
Selection enables / disables the dynamic filter feature. ETC.
The three selections are:
NORMAL: Selection activates the dynamic filter. This
speed range selection is limited to fixed speed conveyors.
VARIABLE: Selection disengages the dynamic filter. Selected for variable speed conveyors.
FAST: Selection disengages the dynamic filter. Selected for gravity fall applications.
25). PRODUCT SPEED

Used with the (NORMAL) speed range selection to
PROD. SPEED 100FT/MIN
provide the detector with the exact product speed. ETC. MIN
It is highly recommended to use a tachometer to
establish the precise belt speed and manually enter
this value.
26). DETECTION BUZZER

Enables/disables the internal piezo audio indicator
DETECTION BUZZER -- ON
within the Control Module. ETC. OFF
27). REJECT CONFIRMATION

Turns reject confirmation on or off. For this screen to
REJECT CONFIRM. -- YES
appear in the menu, it must first be selected in the ETC. NO
agent level. Requires additional hardware to function.
23
28). REJECT CONFIRMATION EXTENSION TIME
Section 3
If reject confirmation is selected, allows adjustment of

REJECT CONFIRM.
the extension time. The interval is the "wait period" ETC. EXTN. TIME 2.00S
that the circuit must hold for after a detection to
register a rejection cycle.
SOFTWARE LEVELS
29). BOOST MODE

If selected in the agent mode, this screen will appear
BOOST MODE YES
in the Engineering menu. Boost enhances sensitivity ETC. NO
by re-scaling the bar graph display. Limited
applications.
30). BOOST WINDOW & THRESHOLD

If boost is selected, parameters support the boost
BOOST WINDOW 0200mS
mode. ETC. THRESHOLD 040
31). LANGUAGE
Selects different languages. Selections include:
LANGUAGE ENGLISH
English French German Spanish Dutch Italian ETC.
Swedish Danish Japanese Polish
32). SET THE DATE AND TIME

Sets the date and time (24-hr. clock format).
SET DATE
ETC. SET TIME
24
Section 4
4.1 PRODUCT SETUP
A. Description

Products are typically classified into two groups, dry and
wet.
Most dry products have very little effect when passing
through the detector. Only minor adjustments to the
sensitivity allow these products to run. Examples of dry
product include, unenriched flour, white sugar, some
cereals, baby diapers, baking powder, etc.
The product has little conductive properties, the signal
produced is mostly resistive.
Signals generated in this fashion are often referred to as
"bulk effect" signals.
Wet products usually have high moisture content and

often contain other conductive elements such as water,
salt, acids, high mineral content, etc. Some examples of
these include fresh meats, fresh breads, brown sugar,
cheese, soups, etc.
Wet products require the detector to have more than just
the sensitivity adjusted. What is required is a
combination of frequency selection, sensitivity, and
product phase to enable the product to pass un-detected
while still maintaining a search for metal contamination.
The product has a substantial "product effect" signal due
to its high conductive elements. Both sensitivity and
product phase will be required to allow this product to
pass through the metal detector.
Waveform produced is large
B. Product Setup
1. See page 29-37 of this manual
25
4.2 REJECT TIMER SETUP
Section 4
A. Description
The detector has 5 timer types that are assignable to any of the three timer groups (A), (B), or (C).
The timers can be assigned to any of the 21 product numbers. Theses timers cover all the various
detector configurations and applications.
TM1 - Simplest timer. Actuates reject instantly upon a detection.
TM2 - A delayed reject timer. Used for fixed speed conveyors. Accuracy is subject to the position of
the metal contaminate.
TM2(G) - A delayed timer that requires a photo sensor for package position. Used for fixed speed
conveyors. Highly accurate for discrete package rejection.
TM3 - Similar to TM2, but designed for variable speed conveyor systems.
TM3(G) - Similar to TM2(G), but for variable speed conveyors.
B. Timer Setup
1. See page 38-57 of this manual.
4.3 VIBRATION SETUP
A. Description
This feature configures the sensitivity limit used by auto setup routine
B. Setting and Adjustments

1. Automatic Adjustment (See POWERPHASE Operating and Instruction Manual).
4.4 Pack Sensor Setup
A. Description
This feature configures the detector for a package sensor. Must be preset before proceeding with a
photo-gated timer such as TM2(G) or TM3(G). Pre-calibrating the sensor speeds up photo -gated
timer setups.
B. Setting and Adjustments

1. (See POWERPHASE Operating and Instruction Manual).
26
4.5 SECURITY SETUP
Section 4
A. Description
Allows user to program custom security access codes for each of the different software levels.
Levels and factory default codes include:

1). Operator (0001)
2). Supervisor (0002)
3). Engineer (0003)
4). QA Inspector (0004)
5). Viewing (0005)
4.6 SPEED SETUP
A. Description
This feature configures the detector for correct product speed. Enables enhanced sensitivity
performance utilizing a dynamic filter circuit. Three selectable product speed ranges:
1). normal - Selects dynamic filter. For fixed speed conveyors.

2). variable - Disengages dynamic filter. For variable speed conveyors.
3). fast - Disengages dynamic filter. Used for gravity fall applications.
4.7 AUTOMATIC TRACKING
A. Description
The automatic tracking feature measures the signals from discrete products and adjusts the phase
and sensitivity to compensate for small changes over time. Three parameters are adjustable:
1). Maximum Rate: Sets the maximum rate the phase is allowed to change between two successive
packs.
2). Maximum Span: The maximum phase value that the phase may deviate from the original phase
setting.
3). Damping: determines how quickly the tracking react to changes in sensitivity and phase.
27
Section 4
4.8 Q.A. SETUP
A. Description
The QA-setup configures the detector for the performance validation routine and printing capabilities.
The setup and programming is done through the QA Inspector mode menu. It is important to
remember that this level will only appear if selected in the "Agent" menu of the diagnostic level.
B. QA Setup
4.9 REJECT CONFIRMATION
A. Description
Reject confirmation is an option that confirms the positive operation of the reject mechanism.
Requires additional hardware.
B. Reject Confirmation Setup

4.10 INVERSE DETECTION
A. Description
The inverse detection feature reverses the normal operation of the detector by scanning for the
presence of a metallic premium and rejecting product without metal in it.
Requires the use of a photo-gated timer.
B. Inverse Detection Setup

1. See page 58 of this manual
28
4.11 PRODUCT NUMBERS
Section 4
This section will show the user how to change Product Numbers, which Pass Codes allow access
and how many product numbers are available.
There are 21 product numbers available from 00 to 20. Each product number will hold a complete
set of information connected with a particular product group / package. The idea of selecting product

numbers allows quick and easy change of one product group to another saving the time of line
operators.
Product number selection is pass code protected, the user groups allowed to change the 'product
number' are:
• Operators • Supervisors • Engineers
A. Changing a Product Number

As an example lets say the Operator wishes to change the Product Number from 00 to 10, the first
task is to Enter the Operator pass code, once the code has been entered correctly the display will
change to show...
NAME..................... PROD. 00
ETC.
This display shows that the product number only can be changed as indicated by the arrow next to
the text.
To make an adjustment the soft-key adjacent to the arrow 4 must be pressed, when this is done the
arrow will flip over and a cursor will appear underneath one of the digits, this indicates that this
parameter can be adjusted.
NAME..................... PROD. 00
ETC. Arrow Flipped
Using the cursor move key position the cursor under the first digit of the product number as shown
here:
NAME..................... PROD. 00 Arrow Flipped

ETC. Cursor Moved
Using the “UP key ” press once to increase the digit to 1, press the ENTER key to store this
number. The arrow will now flip back and the cursor will clear.
NAME..................... PROD. 10
ETC. AUTO SETUP
This action has now changed the Product Number to 10, all the information associated with Product
No: 10 has been selected.
Press the PROG/EXIT key to exit and return to the running mode display.
29
4.12 SENSITIVITY CONTROL
Section 4
This section will show an example of the Sensitivity being set too high and as a result good product
being rejected. It will show how the Sensitivity is adjusted and which pass codes allow access.
The Sensitivity can be adjusted from a minimum value of 000 to a maximum value of 199
The Sensitivity is used to control the detection level of the metal detector. If the sensitivity is set too
high then false detection's can occur which result in unwanted product being rejected, if the level is
set too low then metal contaminants may not be detected. The Sensitivity is set to a value that will
easily detect the 'Calibrated Test Samples' but not detect / false trigger off the product itself.
The Sensitivity Control is pass code protected, the user groups allowed to adjust the Sensitivity are:
• Operators (if access is FULL, when set from the Engineering Mode)
• Supervisors
• Engineers
A. Adjusting The Sensitivity Control
Example:
Lets say that the sensitivity has been set too high and quite a lot of good product is being rejected,
but the test samples are being detected easily.
The Sensitivity is set at 199 and needs to be reduced to 190, the SUPERVISOR will make the
adjustment, the first task is to Enter the supervisor pass code.a
The following sections assume that the Supervisor has Entered the
Supervisor Mode using the correct Pass Code.
30
When the code has been set and Entered the display will change to show...
Section 4
NAME..................... PROD. 00
ETC.

The soft key next to ETC is pressed, the display will show
SENS. 199
ETC. PHASE 000.00º
To adjust the sensitivity the soft-key adjacent to SENS is pressed, this will cause the arrow to flip over
and point to the text, also a cursor will appear under the number 9 as shown below:
This arrow has flipped

over and a cursor has
SENS. 199
appeared ETC. PHASE 000.00º
To reduce the number from 199 to 190 the 'DOWN' arrow key is pressed nine times this will reduce
the number to 190 reducing the sensitivity as required, the display will show:
SENS. 190
ETC. PHASE 000.00º
To store this new setting into the computer memory the ENTER key is pressed, this will cause the
arrow to flip back to its original position and the cursor will disappear, the display will show:
SENS. 190
ETC. PHASE 000.00º
Using the test samples, the metal detector is now tested to verify that the adjustment was successful,
if not re-adjustment may be required.
31
4.13 PHASE CONTROL
Section 4
This section will show an example of the Phase being set incorrectly and as a result good product
being rejected. It will show how the Phase is adjusted and which pass codes allow access.
Some products when passed through a metal detector cause a detection to occur resulting in the item
being rejected from the production line. The signal being generated from the product is known as
'Product Effect'.
The Phase setting, which is sometimes referred to as the 'product compensation' control, is used to
control the Product Effect signal.
The Phase setting can be either automatically or manually adjusted from a value of 000.00° to
180.00°.
Typical products that will exhibit this effect are:
• Cheese • Red Meat
• Mint Sauce • Salad Dressing
• Fresh Chicken Breast • Metalized Film Packaging
The above products are sometimes referred to as WET products.

When a WET product is passed through the metal detector with the Phase set to 000.00° the product
effect signal can easily be seen on the bar-graph display.
The object is to set the Phase control until the signal shown on the bar-graph is at
a minimum. For most applications the Phase value will lie between 80.00° and 100.00°.
The Phase control is pass code protected, the user groups allowed to adjust the Phase are:
• Supervisors • Engineers
The following sections assume that the pass code has been Entered and the
Product Number selected by one of the above user groups
Note: The PHASE control is not available in Product Number 00
A) Adjusting The Phase Control

Before the phase is adjusted automatically the conveyor belt must be checked to make sure that it is
free from any contamination. To do this set the product No to '00' and adjust the sensitivity to '199',
now observe the deflection on the bar-graph display first with the belt stopped and again with the belt
running, the deflection should remain the same as shown below...
If the above condition is not met, i.e. there is a clear contamination signal that is seen to be
repeatable, then clean the conveyor belt or replace it.
32
1) Automatic Mode
Section 4
Once it has been decided that a product exhibits a product effect, the next step is to set the Phase
control. Firstly the Pass code is Entered and the display will show:
NAME......................PROD. 01

ETC. AUTO SETUP
NOTE: A sample of the product must be ready

before the next step is carried out.
To begin the automatic set-up the Auto-Setup soft-key is pressed, when this is done the metal
detector will guide the user on the steps to take, on pressing the soft-key the first display will show:
Ensure NO product is
passing through aperture
While this display is shown note that the bar-graph display may flash (if configured) at the far right
Red area indicating that the reject device is inhibited, after approximately six seconds the display will
show:
Please Wait...
After approximately Five seconds the display will change to show:
Pass product through aperture...
The product sample is now passed through the metal detector aperture at the correct speed, position
and orientation.
33
If the signal measured by the metal detector was too large then the display will show:
Section 4
Product signal too large

please wait...
After which it will ask the user to pass the product again. However if the signal was of the required
size then the display will show:
Adjusting
Phase...
Followed by...
Please Wait...
The user will be asked to pass the product again ...
Pass product through aperture...
After approximately Five seconds the display will change to show:
Product signal too large

please wait...
After which it will ask the user to pass the product again. However if the signal was of the required
size then the display will show:
Adjusting Sensitivity...
After approximately Five seconds the display will change to show one of the following messages:
WARNING phase signal

may be in error
This display may appear if the product signal level was very small, if so the Phase will have to be
checked and may require Manual adjustment.
34
The final display will then be shown to indicate that Automatic set-up has been successful.
Section 4
Product Adjustment Completed
The display will return to the Engineer or Supervisor Mode and the bar-graph display will return to

normal.
2) Adjusting The Phase Control - Manual Mode

Firstly the Pass code is Entered and the display will show:
NAME..................... PROD. 00
ETC.
The soft-key next to ETC is pressed, the display will show:
SENS. 199
ETC. PHASE 000.00º
the soft-key next to phase is pressed, the display will show:
SENS. 199
ETC. PHASE 000.00º
Note that the arrow adjacent to PHASE has flipped over to point towards the text and a cursor has
appeared under the ones digit.
The object is to set the Phase Value to obtain the minimum product effect signal as indicated on the
bar-graph display.
Firstly set the Phase value to 90.00° by moving the cursor to the tens digit using the Cursor Move
key, then set the digit to '9' by pressing the UP key nine times, the display will show...
SENS. 199
ETC. PHASE 000.00º
Next take the product sample and pass it through the metal detector aperture at the correct speed and
orientation noting the signal level on the bar-graph display.
The Sensitivity is now adjusted so that the product signal gives approximately half deflection on the
Red segment of the bar-graph, as shown below...
35
From the display shown below select sensitivity by pressing the soft-key next to SENS.
Section 4
SENS 199
ETC. PHASE 000.00º
The Sensitivity is adjusted using the UP/DOWN keys to give the above deflection when the product
sample is passed through the metal detector aperture.

The Phase value will now be adjusted so that the deflection observed on the bar-graph is reduced to
a minimum. From the following display select PHASE.
SENS. 180
ETC. PHASE 090.00º
The arrow adjacent to Phase will flip over and the cursor will re-appear under the right hand digit
indicating that the Phase control can be adjusted.
Now pass the product through the metal detector aperture and observe the deflection on the bar-graph
display - note this deflection. Using the UP arrow key increase Phase value to 91.00° and pass the
product through the aperture again, observe and note the deflection on the bar-graph.
If the deflection signal has reduced then increase the Phase value to 92.00°, pass the product again
and observe the deflection on the bar-graph.
If the deflection signal has increased then reduce the Phase value to 89.00°, pass the product again
and observe the deflection on the bar-graph.
Repeat this procedure until the deflection signal reduces to a minimum, if the Phase value is adjusted
from this point then it will be seen that the deflection on the bar-graph will also increase. This
minimum value is known as the 'null' point.
As an example say that the minimum product effect signal has occurred at 91.00° and starts to
increase again at 90.00°
At this stage the product effect signal observed on the bar-graph is quite small. To obtain a more
precise Phase setting increase the Sensitivity value to obtain a larger signal indicated on the bar-
graph display.
By the use of the 'Tenths' digit increase the Phase value (e.g.: 91.00°, 91.10°, 91.20° etc.) until
the product effect signal has reduced to a minimum and then just starts to increase again. Using the
Tenths digit adjust the Phase value UP and DOWN until the minimum signal is found - this is the
'NULL' point.
36
The Phase value is now aligned to the product signal, next adjust the Sensitivity so that the product
Section 4
gives a deflection of 2 to 3 Green Bars maximum on the bar-graph display, as shown below....
Bar-Graph Normal Display

Bar-Graph with Product
showing 2 Bar deflection
The final test is to check the metal detector will not detect/trigger due vibration caused by shock -
this is done by tapping the outer case of the metal detector and by operation of the reject device
while observing the bar-graph, if this is unacceptable the Sensitivity is reduced to an acceptable level.
The Enter key is pressed to store the settings in the computer memory.
Using the metal test samples with the sample product check that a detection occurs with metal test
samples but no detection occurs on the product itself.
37
4.14 REJECT TIMERS
Section 4
Once the metal detector has detected a metal contaminant the normal action is to reject the infected
product from the production line. There are many ways to reject contaminated products using various
reject devices, the metal detector has a wide choice of reject timers to control a variety of reject
devices.
The timer types are:

tm1 ..............basic reject timer without a delay.
tm2 ..............has a delay timer and a reject timer.
tm2[G] ..........has a delay timer, a reject timer and a photo-gated pack detector .
tm3 ..............has a delay timer and reject timer which are externally controlled from a speed /
movement sensor.
tm3[G] ..........has a delay timer, reject timer and a photo-gated pack detector which are externally
controlled from a speed / movement sensor.
The timers are pass code protected and are only available to the Engineer via the Engineering pass
code.
38
A) TIMER tm1: Simple Reject Timer without Delay Time.
Section 4
This reject timer is used when on detection of metal the reject device must operate immediately and
stay in the reject position for a period of time until the metal contaminant has been rejected.
Typical Applications:

Conveyor Stop on detection with timed aud ible alarm. The conveyor would STOP immediately on
detection of metal and an audible alarm would sound for a period of time set by the reject timer.
Diverter rejecters used on Gravity Fall and Pharmaceutical systems. The reject diverter would
operate immediately on the detection of metal and stay in the reject position for a period of time set
by the reject timer.
Timed Aud ible Alarms. Used when product is passing through the metal detector on a chute with no
reject device. On detection of metal an audible alarm would sound to indicate to the operator that a
contaminant has been detected, this alarm would operate for a period of time set by the reject timer.
1) Setting and Adjusting Timer tm1

Once the Engineer has entered the Engineering pass code the display will show...
NAME..................... PROD. 00
ETC.
Next the Sensitivity must be checked to make sure that the signal generated by the metal test sample
causes a maximum of Two Red bar deflection on the bar-graph as show below...
Adjust the Sensitivity so that this condition is met, the metal detector timer must only be adjusted to
the smallest detectable metal test sample otherwise it may be possible to miss rejecting metal
contaminants even though they were detected.
39
Once the Sensitivity has been adjusted, press the ETC soft-key to move down the menu system, the
Section 4
until display shows...
A (Select Timer) B
ETC. C
Now select one of the timer locations A, B or C, for this exercise select A by pressing the soft-key next
to A. The display will change to show...
Timer “A” type YES

tm XX UPDATE NO
As the object is to adjust this timer the soft-key next to YES is pressed, the display will change to
show...
tm1 (TIMER tm2 (G)

ETC. type) tm3 (G)
Next select timer type, as we are working with timer tm1 press the soft-key next to tm1, the display
will change to show...
tm1 REJECT TIME 1.00s
This display will show the Reject Time set value for timer tm1, in this example it is set to 1 second
(1.00s)
Using a test sample adjust the Reject Time until the sample is rejected correctly or the audible
sounder is heard.
To do this press the soft-key next to REJECT TIME, this will cause the arrow to flip over and a cursor
will appear under the reject time value indicating that this figure can be changed, the display will
show...
In the case of a Gravity Fall or Pharmaceutical system, drop the metal test sample through the metal
detector aperture and observe the operation of the reject device.
The reject device should operate immediately upon detection, stay in the reject position until the
contaminant has been rejected then return to the normal accept position.
Example: The Reject Time is too short and the contaminant is not being rejected correctly, the value
needs to be increased to 1.50 seconds to make sure that it is rejected correctly.
40
To adjust the Reject Time value from 1.00s to 1.50s move the cursor to the second digit and using
Section 4
the 'Up' arrow key change the digit to 5 by pressing the key Five times, the display will show...

Using the test sample check that the reject device now operates for the correct time and the sample is
rejected correctly.
Now press the ENTER key to store this value, this will cause the arrow to flip over and the cursor will
disappear.
Press the ENTER key again to allocate this timer to the product number, the display will show...
Timer “A” type tm1

set / updated
This display will appear for approximately 5 seconds after which it will return to display the [Select
Timer] menu.
Press the PROG / EXIT key to return to the running display.
41
B. TIMER tm2 (G): Delay Time, Reject Time and photo-gated Pack Detector.
Section 4
This reject timer is used when the reject device is positioned some distance from the metal detector,
usually on conveyor systems. This application requires a DELAYED REJECT TIMER, upon detection of
a metal contaminant the reject device will not operate until the contaminated product reaches the
reject area, at this time the reject device will operate for the period of time controlled by the Reject
Time.
The following drawing shows a typical metal detector conveyor system incorporating a pusher reject
system, note that the rejecter is positioned a distance from the metal detector and that 'good product'
is between the metal detector and the rejecter. The object is to reject the contaminated product and
accept the 'good' product.
Metal Detector
42
Timer tm2[G] can be used with or without a photo-gated pack detector, the pack detector is used to
Section 4
identify the position of the contaminated package to give pin-point accuracy for rejection.
tm2 (G)

Timer Number 2 Gated
TIMER tm2 - NON GATED MODE
1.) Setting and Adjusting Timer tm2

NAME..................... PROD. 00
ETC.
Next the Sensitivity must be checked to make sure that the signal generated by the metal test sample
causes a maximum of Two Red bar deflection on the bar-graph as show below...
43
Section 4
Once the Sensitivity has been adjusted, press the ETC soft-key to move down the menu system, until
the display shows...
A (Select Timer) B
ETC. C
Now select one of the timer locations A, B or C, for this exercise select B by pressing the soft-key
next to B. The display may change to show...
TIMER “B”, TYPE YES

tm1 UPDATE? NO
show...
tm1 (Timer tm2 (G)

ETC. type) tm3 (G)
Next select timer type, as we are working with timer tm2 press the soft-key next to tm2[G], the
display may show...
Gated timer still YES

required ? NO
If this display is shown press the NO soft-key, the display will change to show...
tm1 SIGNAL DELAY 1.00s

This display shows the Signal Delay Time set value and the Reject Time set value for timer tm2, in
this example they are both set to 1 second (1.00s).
Using the prepared test packet, pass the pack through the metal detector aperture at the correct speed
and orientation with the sample positioned at the rear / trailing edge of the pack, note the operation
of the reject device.
On individual products the reject device must operate just as the Front Leading Edge of the pack
reaches the reject device, from this test it was observed that the reject device operated too early
therefore the Signal Delay needs to be increased.
For this example the Signal Delay has to be increased to 3 seconds.
From this display press the soft-key next to SIGNAL DELAY, this will cause the arrow to flip and a
cursor will appear under the right hand digit indicating that this value can be adjusted. The display
will show...
44
Section 4
REJECT TIME 1.00s
Next use the Cursor Move Key to position the cursor under the right hand digit, now press the UP
arrow key Three times to change the Signal Delay to 3.00s, the display will show...

REJECT TIME 1.00s
Use the test pack to make sure that the adjustment made causes the rejecter to operate just before the
front leading edge of the packet, if not re-adjust the Signal Delay.
Press the ENTER key to store this new value in memory.
Now the Reject time will be adjusted to a time long enough to reject the package, but not too long as
to reject multiple packs.
As an example say that the Reject time was too long at 1.00 second and needs to be reduced to
500ms (500 milli-second = 0.5 second), so the reject time has to be reduced.
Press the soft-key next to REJECT TIME this will cause the arrow to flip over and a cursor will appear
under the right hand digit indicating that this figure can be adjusted, the display will show...

REJECT TIME 1.00s
Using the cursor move key position the cursor under the second digit and using the 'down key' adjust
to read 0.50s (500ms).
Pass the packet containing the metal test sample at the rear / trailing edge and check that the reject
device operates at the correct time and for long enough to cleanly reject the pack.
Press the ENTER key to store this new setting into memory, the display will show...

REJECT TIME 0.50s
Press the ENTER key again, the display will show...
tm2 Gated ? YES

NO
As this section is for the Non-gated Mode of operation press the soft-key next to NO, the display will
show...
Timer “B” type tm2

set / updated
This display will be shown for approximately 5 seconds after which the user will be returned to the
main menu.
Press the PROG/EXIT key to return to running display.
45
C) TIMER tm2[G] - GATED MODE
Section 4
Typical Applications:
Punch or Pusher rejecters On the detection of a contaminant after the Delay Time a Punch will
knock the package off the production line, to give accurate rejection a pack detector is used to 'gate'
the position of the product.
Drop or Lift Flap Reject Mechanisms On the detection of a contaminant after the Delay Time the
Reject device will operate, this action causes a gap in the production line and product will fall
through this gap, to give accurate rejection a pack detector is used to 'gate' the position of the
product.
1) Setting and Adjusting Timer tm2[G] - Gated Mode

NAME..................... PROD. 00
ETC.
As an example let us say that the reject system is an 'punch or pusher' and the product is a box of
Corn Flakes weighing 750g.
Firstly attach the test sample to the Rear / Trailing Edge of the packet and test the Sensitivity to make
sure that the test packet causes a detection and that the deflection on the bar-graph is a maximum of
Two Red segments, if not re-adjust the Sensitivity to give the deflection as shown below...
the smallest detectable metal test sample otherwise it may be possible to miss metal contaminants
even though they were detected.
A (Select Timer) B
ETC. C
Now select one of the timer locations A, B or C, for this exercise select B by pressing the soft-key next
to B. The display may change to show...

tm1 UPDATE? NO
46
Section 4
show...
tm1 (Timer tm2 (G)

ETC. type) tm3 (G)
Next select timer type, as we are working with timer tm2[G] press the soft-key next to tm2[G], the

display may show...

required ? NO

REJECT TIME 1.00s
The previous display shows the Signal Delay Time set value and the Reject Time set value for timer
tm2, in this example they are both set to 1 second (1.00s).
Using the prepared test packet of Corn Flakes, pass the pack through the metal detector aperture at
the correct speed and orientation with the sample positioned at the rear / trailing edge of the pack,
note the operation of the reject device.
The reject device must operate just as the Front Leading Edge of the pack reaches the reject device,
from this test it was observed that the reject device operated too early therefore the Signal Delay
needs to be increased.
For this example the Signal Delay has to be increased to 3 seconds.

REJECT TIME 1.00s
From this display press the soft-key next to SIGNAL DELAY, this will cause the arrow to flip and a
will show...

REJECT TIME 1.00s
Next use the Cursor Move Key to position the cursor under the right hand digit, now press the UP
arrow key Three times to change the Signal Delay to 3.00s, the display will show...

REJECT TIME 1.00s
Use the test pack to make sure that the adjustment made causes the rejecter to operate just before the
front leading edge of the packet, if not re-adjust the Signal Delay.
47
Section 4
Now the Reject time will be adjusted to a time long enough to reject the package if it was positioned
correctly, but not too long as to reject multiple packs. We are not attempting to reject the box at this
stage
As an example say that the Reject time was too long at 1.00 second and needs to be reduced to
500ms (500 milli-second = 0.5 second), so the reject time has to be reduced.

REJECT TIME 1.00s
Using the cursor move key position the cursor under the second digit and using the 'down key' adjust
to read 0.50s (500ms).

REJECT TIME 0.50s
tm2 Gated ? YES

NO
As this section is for the Gated Mode of operation press the soft-key next to YES, the display will
show...
tm2G SYNC. DELAY 100ms

ETC. Window Time 100ms
Important:
• To set the following parameters it must be ensured that the photo-gating device is clear of any
obstruction, i.e. no product passing and breaking the beam.
• A metal test sample is not required to set these parameters.
• Always set the WINDOW TIME before the SYNC. DELAY.
Make sure that a sample box is ready for the next stage in the set-up.
From the above display press the soft-key next to Window Time the display will change to show...

ETC. Window Time -CAL-
The word -CAL- will appear, do not pass the sample box yet as a calibration process is being carried
out, after about 5 seconds the display will change to -RUN- as shown below...
48
Section 4
ETC. Window Time -RUN-
When the display changes to show -RUN- pass the sample box along the system in the correct
orientation typical of the actual line conditions, if it has a slight skew then present it with a skew.

The metal detector will automatically set the Window Time as soon as the pack has passed the
photo-cell.
Note the window time, now pass the box again by firstly pressing the soft key next to CAL and wait
for the word RUN to appear, this is to ensure that the window time is repeatable.
As an example say that the window time calculated was 400ms (milli-seconds) the display will
show...

Next press the soft-key adjacent to SYNC. DELAY, when this is pressed the detect indicator will light and the
detection buzzer will sound, the arrow will flip over and a cursor will appear under the Sync. Delay time.
Pass the sample box and adjust the SYNC. DELAY time using the cursor move key and the up/down keys
until the pack is rejected accurately and consistently. Press the ENTER key to store this new setting in
memory.
As an example the Sync. Delay was adjusted to 600ms, the display will now show...

Press the ETC key to return to the Reject Time section, the display will show...
tm2G SYNC. DELAY 3.00s

ETC. Window Time 0.50s
Press the soft-key next to REJECT TIME this will cause the arrow to flip over and a cursor will appear under
the right hand digit indicating that this figure can be adjusted.
Pass the sample box along the system with the contaminant at the front or the rear edge and adjust the
Reject time to a value long enough to reject the package accurately but not too long as to hit the next box
on the line.
Press the ENTER key twice to store this new setting in memory.
49
D.) TIMER tm3[G]: Variable Speed with Delay Time, Reject Time and photo-gated
Section 4
Pack Detector.
This reject timer is used for variable speed conveyor applications or for a process were the product
can start and stop on demand. Upon detection of a metal contaminant the reject device will not
operate until the contaminated product reaches the reject area, at this time the reject device will
operate for the period of time controlled by the Reject Time.
The following drawing shows a typical metal detector conveyor system incorporating a pusher reject
system, a speed sensor (or tacho) and a pack detector (photo-cell), note that the rejecter is
positioned a distance from the metal detector and that 'good product' is between the metal detector
and the reject device. The object is to reject the contaminated product and accept the 'good' product.
Timer tm3[G] can be used with or without a photo-gated pack detector, the pack detector is used to
identify the position of the contaminated package to give pin-point accuracy for rejection.
The timer is used with a speed sensor or encoder, this device is used to generate pulses in relation to
the distance travelled by the conveyor belt and hence the product and a possible metal contaminant.
50
Typical Application
Section 4
Retracting Band Rejecter: Used when the conveyor is varied in speed or starts and stops on demand
of the production process, this can be observed on biscuit dough applications were the product is
conveyed to a calendar roller or biscuit press. On the detection of a contaminant after the Delay Time
the conveyor belt will retract, this action causes a gap in the production line and product will fall
through this gap. This system is used for loose product, i.e. peanuts, chocolates, biscuit dough etc.

Air Blast Rejecters: On the detection of a contaminant after the Delay Time a stream of compressed
air will blow the package off the production line.
1) Setting and Adjusting Timer tm3[G] None Gated Mode

NAME..................... PROD. 00
ETC.
Example: Let us say that the reject system is a retracting band/belt and the product is Biscuit Dough.
Important Note: Set the speed of the system to its MID RANGE point
Now place the test sample into the product and test the Sensitivity to make sure that the test sample
causes a detection and that the deflection on the bar-graph is a maximum of Two Red segments, if
not re-adjust the Sensitivity to give the deflection as shown below...
A (Select Timer) B
ETC. C
to 'B'. The display may change to show...
51
Section 4
tm1 UPDATE? NO
show...
tm1 (Timer tm2 (G)

ETC. type) tm3 (G)
Next select timer type, as we are working with timer tm3 press the soft-key next to tm3[G], the
display may show...

required ? NO
tm1 SIGNAL SHIFT 010

REJECT SHIFT 010
This display shows the Signal Shift set value and the Reject Shift set value for timer tm3, in this
example they are both set to 10 pulses.
Place the test sample in the product and let it pass through the metal detector aperture at the MID
RANGE SPEED of the system, note the operation of the reject device.
The reject device must operate just before the test sample reaches the reject area, from this test it was
observed that the reject device operated far too early therefore the Signal Shift needs to be increased.
For this example the Signal Shift has to be increased to 20 pulses (020).

REJECT SHIFT 010
From this display press the soft-key next to SIGNAL SHIFT, this will cause the arrow to flip and a
will show...

REJECT SHIFT 010
52
Next use the Cursor Move Key to position the cursor under the middle digit, now press the UP arrow
Section 4
key once to change the Signal Shift to 020 (20 pulses), the display will show...

REJECT SHIFT 010
Use the test sample again to make sure that the adjustment made causes the rejecter to operate just

before the reject point, if not re-adjust the Signal Shift.
Now the Reject Shift must be adjusted to a time long enough to reject the contaminant, but not too
long as to reject too much product.
As an example say that the Reject Shift Time was too long at 10 pulses and needs to be reduced to
5 pulses (005), so the Reject Shift has to be reduced.
Press the soft-key next to REJECT SHIFT this will cause the arrow to flip over and a cursor will
appear under the right hand digit indicating that this figure can be adjusted, the display will show...

REJECT SHIFT 010
Using the 'down key' press 5 times to read 005 (5 pulses).

Pass the metal test sample again and check that the reject device operates at the correct time and
for long enough to cleanly reject the contaminant.

REJECT SHIFT 005
tm2 Gated ? YES

NO
As this section is for the Non-gated mode of operation press the soft-key next to NO, the display will
show...
TIMER “B”, TYPE tm3

set / update
This display will be shown for approximately 5 seconds after which the user will be returned to the
main menu.
Press the PROG/EXIT key to return to the running mode display.
The system should now be tested at the minimum and maximum speeds of the variable speed
controller to ensure that the metal test sample is rejected over the full range.
It is highly recommended that upper and lower limits are programmed into the variable speed
controller this will prevent the conveyor speed from running at a speed lower than the minimum
through-put rate for the metal detector.
53
E.) TIMER tm3: None Gated Mode
Section 4
Typical Application
Punch or Pusher rejecters: Used when the conveyor system is varied in speed or the conveyer can
be stopped by external equipment. On the detection of a contaminant after the Delay Time a Punch
will knock the package off the production line, to give accurate rejection a pack detector is used to
'gate' the position of the product.
Setting and Adjusting Timer tm3[G] - Gated Mode

Important Note: Set the speed of the system to its MID RANGE point
NAME..................... PROD. 00
ETC.
As an example let us say that the reject system is an 'punch or pusher' and the product is a box of
Corn Flakes weighing 750g.
Firstly attach the test sample to the Rear / Trailing Edge of the packet and test the Sensitivity to make
sure that the test packet causes a detection and that the deflection on the bar-graph is a maximum of
Two Red segments, if not re-adjust the Sensitivity to give the deflection as shown below...
A (Select Timer) B
ETC. C
to B. The display may change to show...

tm1 UPDATE? NO
show...
tm1 (Timer tm2 (G)

ETC. type) tm3 (G)
54
Next select timer type, as we are working with timer tm3[G] press the soft-key next to tm3[G], the
Section 4
display may show...

required ? NO


REJECT SHIFT 010
This display shows the Signal Shift set value and the Reject Shift set value for timer tm3, in this
example they are both set to 10 pulses.
Pass the test packet, with the sample at the rear trailing edge, through the metal detector aperture at
the MID RANGE SPEED of the system, note the operation of the reject device.
The reject device must operate just before the front edge of the test packet reaches the reject device,
from this test it was observed that the reject device operated too early therefore the Signal Shift needs
to be increased.
For this example the Signal Shift has to be increased to 20 pulses (020)

REJECT SHIFT 010
From this display press the soft-key next to SIGNAL SHIFT, this will cause the arrow to flip and a
will show...

REJECT SHIFT 010
Next use the Cursor Move Key to position the cursor under the middle digit, now press the UP arrow
key once to change the Signal Shift to 020 (20 pulses), the display will show...

REJECT SHIFT 010
Use the test packet again to make sure that the adjustment made causes the rejecter to operate just
before the reject device, if not re-adjust the Signal Shift.
55
Now adjust the Reject Shift so that the reject mechanism responds in a way that would reject the
Section 4
pack if it was positioned correctly. We are not attempting to reject the pack at this stage.
As an example say that the Reject Shift Time was too long at 10 pulses and needs to be reduced to 5
pulses (005), so the Reject Shift has to be reduced.
Press the soft-key next to REJECT SHIFT this will cause the arrow to flip over and a cursor will appear

REJECT SHIFT 010
Using the 'down key' press 5 times to read 005 (5 pulses).

Pass the test packet again and check that the reject device operates at the correct time and for long
enough.

REJECT SHIFT 005
tm3 Gated ? YES

NO
Press YES for Gated mode of operation, the display will show...
tm3G SYNC. SHIFT 100

ETC. Window Shift 100
Important:
• To set the following parameters it must be ensured that the photo-gating device is clear of any
obstruction, i.e. no product passing and breaking the beam.
• A metal test sample is not required to set these parameters.
• Always set the WINDOW SHIFT before the SYNC. SHIFT.
Make sure that a sample box is ready for the next stage in the set-up.
From the above display press the soft-key next to Window Shift the display will change to show...

ETC. Window Shift -CAL-
The word -CAL- will appear, do not pass the sample box yet a calibration process is being carried
out, after about 5 seconds the display will change to -RUN- as shown below...

ETC. Window Shift -RUN-
56
When the display changes to show -RUN- pass the sample box along the system in the correct
Section 4
orientation typical of the actual line conditions, if it has a slight skew then present it with a skew.
The metal detector will automatically set the Window Shift as soon as the pack has passed the
photo-cell.
Note the window shift, now pass the box again by firstly pressing the soft key next to CAL and wait
for the word RUN to appear, this is to ensure that the window shift is repeatable.

As an example say that the window shift calculated was 008 pulses the display will show...

Next press the soft-key adjacent to SYNC. SHIFT, when this is pressed the detect indicator will light
and the detection buzzer will sound, the arrow will flip over and a cursor will appear under the Sync.
Shift time.
Pass the sample box and adjust the SYNC. SHIFT time using the cursor move key and the up/down
keys until the pack is rejected accurately and consistently. Press the ENTER key to store this new
setting in memory.
As an example the Sync. Shift was adjusted to 030, the display will now show...

Press the ETC key and note that the Reject Shift has changed to Reject Time, the display will show...
tm3G SIGNAL SHIFT 020

ETC. Reject Time 050ms
under the right hand digit indicating that this figure can be adjusted.
Pass the sample box along the system with the contaminant at the front or the rear edge and adjust
the Reject time to a value long enough to reject the package accurately but not too long as to hit the
next box on the line.
Press the ENTER key twice to store this new setting in memory. The user will be returned to the
running mode display
The system should now be tested at the minimum and maximum speeds of the variable speed
controller to ensure that the metal test sample is rejected over the full range.
It is highly recommended that upper and lower limits are programmed into the variable speed
controller this will prevent the conveyor speed from running at a speed lower than the minimum
through-put rate for the metal detector.
57
4.15: INVERSE DETECTION
Section 4
Inverse detection is used to detect the presence of a metallic premium or free gift within a product
package or box. The metal detector will detect the premium, if the premium is not detected then the
reject device will operate rejecting packs that do not contain the free gift.
The metal detector operates in the normal manner but the action of the reject device is reversed -
metal is accepted, absence of metal is rejected.

Operation of Inverse Detection: Inverse detection is set-up in the usual manner, the factors to be
aware of are:
1. The metallic free gift or insert must be set in a position that allows the metal detector to just detect
it when in the worst orientation for detection. The reject timer is adjusted to this condition.
2. The FAST RECOVERY electronic module must be used.
3. There must be a sufficient gap between consecutive products as to allow the metal detector to
recover after detection of the metallic insert, otherwise a product with the insert missing could be
accepted incorrectly.
The inverse detect option is selected once the above steps have been carried out, as follows...
Selecting Inverse Detection: Note: Inverse detection can only be used when using a photo-gated
timer tm2[G] or tm3[G] as the packet must be photo-gated.
Inverse detection is an option and it is factory set by Safeline when specified by the customer, when
selected it can be switched on or off in the Engineering mode.
Access the Engineering mode using the Engineering pass code, when the code has been entered the
display will show...
NAME..................... PROD. 00

ETC.
From this display press the ETC key until Inverse detection is displayed as shown below...
INVERSE DETECT YES

ETC. NO
To select the function in the chosen product number press the soft key next to the YES arrow, this will
flash the letter 'Y' informing that selection has been successful.
58
4.16: PRODUCT SIGNAL CANCELLATION (P.S.C.)
Section 4
Reduction of a product effect signal by adjustment of the 'phase' control either manually or
automatically very often does not eliminate the product signal completely. Due to this effect the
sensitivity is sometimes reduced which in turn leads to reduced performance.
Product Signal Cancellation (P.S.C. or Product Cancellation) aims to eliminate any remaining

Product Effect Signal without the need to operate at a reduced sensitivity.
System Requirements:
• The conveyor must run at a fixed speed, minimum speed 10 m/min.
• A pack detect photocell must be fitted before and as close to the metal detector as possible.
Product Requirements:
• The maximum pack length must not exceed 1 meter.
• The product effect signal must be consistent and repeatable.
• The minimum space between packs must be 25mm.
• Product presentation must be consistent, product guides may be necessary.
• Up to 5 correctly presented products may be in the aperture at any one time.
If any of the above requirements cannot be met, please consult with a Safeline representative.
Selection of Product Cancellation: Note: Product cancellation can only be used in conjunction with
a photo gated pack detector. Product cancellation is available in products numbered 01 to 05 only.
Product cancellation is an option and is factory set by Safeline when specified by a customer order,
when selected it can be switched on or off in the engineering mode.
To select P.S.C., access the engineering mode using the engineering pass code, when the code has
been entered correctly the display will show...
NAME..................... PROD. 00

ETC.
From this display repeatedly press the ETC soft key until Prod. Cancellation is displayed, as shown
below...
Prod. Cancellation YES

ETC. NO
Press the YES soft key to turn on the function; this will cause the Y to flash indicating that the
selection has been successful.
Press the PROG/EXIT key to return to the running mode display.
Now that P.S.C. has been activated if an improvement can be made in sensitivity on completion of
the automatic set-up routine, the following directions will be given to the operator.
59
After the automatic product adjustment the display will show...
Section 4
Product YES
cancellation NO
If this display is not shown it will mean that an improvement cannot be made using P.S.C.
Press the soft key next to YES to continue with product cancellation, the display will show...
PASS PRODUCT THROUGH

APERTURE...
Pass the product package through the metal detector, the display will show...
OBTAINING PRODUCT
INFORMATION 1...
Followed by...
PLEASE WAIT...
Followed by...

APERTURE...
Pass the product package through the metal detector again, the display will show...
OBTAINING PRODUCT
INFORMATION 2...
Followed by...
PLEASE WAIT...
Followed by...

APERTURE...
Pass the product package through the metal detector again, the display will show...
60
Section 4
ADJUSTING
SENSITIVITY...
Followed by...

PRODUCT ADJUSTMENT
COMPLETED...
If an error has occurred or the PROG/EXIT key was pressed the following display will be shown...
PRODUCT CANCELLATION
NOT OPERATING...
Now the adjustment is complete, the letter 'P' in the word PHASE will flash indicating that P.S.C, is
working.
SENS. 190 PROD. No.01

ETC. PHASE 0000
The letter 'P' will flash.

Note: Manual adjustment cannot be made once PSC is in operation, if a change is made to the
phase setting the PSC option will turn off and stop operating.
61
4.17: REJECT CONFIRMATION
Section 4
Reject confirmation is used to detect that the reject device has operated and rejected a contaminated
product.
When the metal detector has detected a metal contaminant a signal is sent to the Reject confirmation
unit, this unit starts a timer, and this timer is reset by the action of either the reject mechanism
operating or a package being rejected. If the timer is not reset then an alarm signal is given, this
signal can be used to sound an alarm or shut the production line down.
Shown below is a representation of a metal detector and a reject device indicating the position of
both mechanical movement sensors and physical rejection sensors?
Only one sensor is used to reset the reject confirmation unit, the above drawing is indicating were the
sensors would be fitted in an actual application.
62
Setting up Reject Confirmation: Firstly a reject confirmation unit (RCU) must be fitted to the power
Section 4
supply board and a second relay fitted / plugged in location RL2, a detection sensor must be wired
and secured in position.
Reject confirmation is controlled from the engineering mode. First enter the engineering pass code,
when entered correctly the display will show...

NAME..................... PROD. 00
ETC.
Using the ETC soft key move along until 'Reject Confirm' is displayed as shown below...
Reject Confirm. YES

ETC. NO
Press the soft key next to YES to select the function, the letter 'Y' will flash to indicate that the
selection has been made.
Press the ETC key to move forward.
There are two possible displays which are dependent on the timer type being used, these are:
1. Extension Time - used with timer types tm1, tm2 and tm2(G)
2. Window Time - used with timer types tm3 and tm3(G)
1. Extension Time: If Extension Time is used the display will show:
REJECT CONFIRMATION
ETC. extn. time X.XXs
The 'extension time' is the time taken for the external sensor to detect that a contaminated package
has been rejected. If the sensor does not detect the contaminated pack with-in the extension time then
a fault will be given.
The 'extension time' begins after the reject system has operated.
To set the extension time press the soft key next to seconds (s) this will allow the time to be adjusted
or set.
2. Window Time: If window time is used the display will show...
REJECT CONFIRMATION
ETC. extn. time X.XXs
The 'window time' is the time from when the metal detector detects a contaminant to a time after the
sensor has detected and rejected the contaminant.
To set the window time presses the soft key next to seconds (s).
Note:
1. Reject confirmation cannot be used on start / stop applications
2. The window time must be set with the conveyor running at its slowest speed to ensure proper
operation over the rest of its variable speed range.
63
Setting and Testing the Reject Confirmation Unit (RCU): The RCU is fitted with two indicators - a
Section 4
red FAULT indicator and a yellow LED, these indicators are used to aid the setting up procedure.
When using extension time set the time to 100 milli-seconds (ms), pass the metal test sample either
fixed to a package or in the product if not using packaged product. The yellow LED will light just
before the reject device operates and should stay lit until the reject device returns to its normal accept
position and the contaminated product has been rejected. If the yellow LED turns off before this action
the red FAULT indicator will light and a fault will be given. If this happens reset the RCU using the
reset switch and adjust the extension time in steps of 100ms until the above condition is met, then
increase a further 200ms. The ENTER key is then pressed to store this new setting into memory.
Diagram of the RCU
64
When using window time estimate the time taken for the contaminated product to travel from the
Section 4
centre of the metal detector aperture and enter the reject bin. Set the window time to this estimated
value.
Pass a metal test sample through the metal detector aperture making sure the detector triggers.
The Yellow LED will light immediately and at the programmed time the reject device will operate from
its accept position to its reject position.

When the reject mechanism returns to its accept position the reject sensor will detect that the reject
system has operated and the Yellow LED will turn off provid ing that the 'window time' is long
enough. If the Red fault indicator lights re-set the RCU using the reset switch and re-adjust the
'window time' by a further 500ms. Repeat this exercise until the red indicator remains off, then
reduce in steps of 100ms until the red indicator turns on, this is to find the 'switch over' point. When
this point has been found increase the window time by 300ms and press the ENTER key to store this
new value into memory.
Fault Messages: If the reject confirmation unit is not reset by the operation of the sensor then an
alarm will be given and a message will be displayed as shown below...
Reject Confirmation
REJECT FAULT
The alarm output can be used to stop the production line or just give an audible / visual alarm,
connections are made to relay RL2 on the power supply board.
This display will clear when the RCU is reset and the fault is cleared, an external reset switch is fitted
to terminals on the power supply board.
If the metal detector cannot communicate with the RCU the following message will be shown...
REJECT CONFIRMATION
input / Output FAULT
This display will clear when the fault has been cured.
65
4.18: QA INSPECTOR MODE AND PERFORMANCE VALIDATION ROUTINE (P.V.R)
Section 4
The module will discuss the operation of the QA Inspector Mode, it will also demonstrate the use of
the Product Validation Routine.
The Q.A. Inspector mode is part of the Product Validation Routine as the inspector sets the
performance parameters for P.V.R.
P.V.R. helps the user comply with ISO 9000 by ensuring that the metal detector system is tested and
operating to the users specified quality standards of performance.

The quality standards of many users require that the metal detector and its reject system is tested at
specified intervals by authorized Q.A. personnel to validate compliance.
Q.A. personnel may program the metal detector to indicate when testing is required and to give an
alarm if the test is not carried out at the specified time. Individual staff may be given a personal
access code ensuring that the individual charged with testing does so at the required time.
The Q.A. Inspector Mode - setting up P.V.R.: To access this mode enter the QA Inspector code, the
factory setting is 0004 (this code may be changed in the engineering mode). Once the code has
been entered correctly the display will show...
QA SETUP TEST

PRINT
Press QA SET-UP to enter the set-up menu, the display will show...
LINE ID. ####

ETC.
At this point a line identification number can be entered, for example the first two numbers could be a
line number and the other numbers the metal detector number. Press the soft-key next to LINE ID.
and enter the number using the cursor move and
up / down arrow keys.
Press the ETC key to move on, the display will show...
PRINTER - YES
ETC. NO
Press YES if a printer is connected to the metal detector, NO should always be selected when a printer
is not connected, otherwise a printer connect error may be given.
Press the ETC key to move on, the display will show...
STAINLESS STEEL
ETC. #.# mm
66
This display allows a test sample size to be entered which will be prompted for during the
Section 4
performance check. There are three independent settings for each of the 21 product numbers.
Press the soft key next to the material the display will show...
FERROUS
ETC. #.#mm

and again to show.....
NON FERROUS
ETC. #.#mm
To set the sample size press the soft-key next to 'mm' this will cause the arrow to flip over and a
cursor will appear under one of the digits as shown below...
NON FERROUS
ETC. 0.0mm
Enter the sample size value using the up/down keys in conjunction with the cursor move key, when
the value is entered press the memory key. Carry out this procedure for each of the materials -
stainless steel, ferrous and non ferrous.
Press the ETC soft-key to move on, the display will show...
SHIFT REPORT OPTIONS

ETC.
Press SHIFT REPORT OPTIONS soft-key to access this section, the display will show...
Reject Relay Oper’ns IN

ETC. OUT
This section will allow the number of reject relay operations to be included on the print out.
IN means the report will include the date and time of each relay operation.
OUT means the report will not include this information.
Press the required soft-key either IN or OUT, a cursor will flash on the option made.
Press the ETC to move forward, the display will show...
Mod ified Settings IN

ETC. OUT
67
This section will allow the printed report to show when a setting was changed.
Section 4
IN - this will include certain settings which have been changed since the last shift report. The shift
report will include the settings new value and the date and time when it was changed.
The settings which are recorded are:
Product Number
Sensitivity
Phase
Timer Type
Reference Phase
Pack and Reject counter resets
Reject Inhibit
OUT - the function is turned off.
Press the ETC to move forward, the display will show...
Shift report Int. H. xx

ETC. M. xx
The shift report can be printed automatically on a timed basis specified by the user. A time is entered
using the H (hours) and M (minutes) soft keys.
H = hours, can be adjusted to a maximum of 8
M = minutes, can be adjusted to a maximum of 59
This will allow a maximum of 8h:59m between shift reports, setting the time to 0.00 disables this
function.
Press the enter key to move forward the display will show...
Shift report start H. xx

ETC. M. xx
This will allow the start time of the shift report to be set to a specified time.
Press the ETC key to move forward, the display will show...
Test interval - H. x
ETC. M. xx
The test interval is the time period between which the metal detector
system requests the QA personnel to carry out a performance check. The following message will
appear when the test is due...
*REQUEST FOR
PERFORMANCE CHECK*
68
The test interval time is restarted when a performance check has been carried out.
Section 4
This will allow a maximum of 8h : 59m between performance checks, setting the time to 0.00
disables this function.

Overdue Period - H. x
ETC. M. xx
This section is used to set an alarm indicating to the operator that the metal detector is overdue for
the performance test. If this time is reached the display will change from...
*REQUEST FOR
PERFORMANCE CHECK*
to...
*OVERDUE FOR
PERFORMANCE CHECK*
The Bar-graph will flash and the buzzer will sound to attract attention, an output alarm signal is also
available, (see next section).
The maximum overdue period is restricted to half of the test interval time.
Alarm if - DUE
ETC. OVERDUE
The Alarm can be selected for either Due or Overdue conditions.

DUE - means that the alarm is given when the performance test is due.
OVERDUE - means that the alarm is given when the performance test is overdue.
Select the required condition from this section.
Change Code - QA1 xxxx

ETC. ^------
This section allows the QA operator code to be changed, there are nine QA operator codes.
To change the required code press the soft key adjacent to ' ^------ ' until the number is displayed
(i.e. 1-9), then press the soft key next to the four digit code number - this will cause the arrow to flip
over and a cursor will appear under the first digit. Enter the required code then press the ENTER key
to store the new code into memory.
69
Example the new operator is 7 and the code is 5702, the display will show....
Section 4
Change Code - QA7 5702

ETC. ^------
Press the ETC key to return to menu, the display will show...
QA SETUP TEST

ETC.
Carrying out Performance Validation
A performance check may be carried out at any time, the PVR may have been configured to
automatically prompt the user (normally authorized QA personnel) to carry out a performance check.
This will occur at regular intervals determined by the pre-programmed test interval.
The next test time can be checked by pressing the ETC key twice from the normal running display,
when this is done the display will show...
Current Time 10:24

ETC. Next QA Test 11:24
70
Note.: If PVR has been set for timed checks the test interval time will be restarted after the check has
Section 4
been carried out.
Carrying out a test: A metal test sample is required either placed in the product or secured to a
sample package. When passing the test sample try to keep the sample as close to the centre of the
metal detector aperture as possible.
Firstly enter either a QA Inspector code or a QA operator code, if the inspector code is entered the

display will show...
QA SETUP TEST

PRINT
From this display press the TEST soft key, the display will show...
FERROUS NON FERROUS

EXIT STAINLESS STEEL
Press the required material, in this example FERROUS will be tested, press the soft key next to
FERROUS the display will change to show...
Pass X.Xmm FE sample

PASSED FAILED
This display will show the size of test sample to use, if using packaged product attach the sample to
the pack and allow it to pass through the detector on the conveyor belt. Ensure that the test sample is
detected (and rejected if a reject device is fitted).
Enter the result of the test by pressing the PASSED or FAILED soft key, the display will return to the
menu as shown below.
FERROUS NON FERROUS

EXIT STAINLESS STEEL
If other materials are to be tested press the appropriate soft key and pass the test sample associated
with that material.
If the performance check has been completed press the 'EXIT' soft or the 'PROG/EXIT key.
If a printer is connected, the test result will be printed and produce a hard copy as evidence of
completion of the test.
71
Print-Outs / Data Collection: The following assumes that a printer is connected and that
Section 4
the printer option has been selected in the QA inspector set-up, as shown below...
Printer - YES
ETC NO
Once the printer has been selected the metal detector PRINT option can be used, from
the following display accessed from the QA inspector pass code the print soft key can
be pressed.
QA SETUP TEST

PRINT
When the PRINT key has been pressed the display will change to show...
PRINT ALL SETTINGS

ETC PRINT SHIFT REPORT
PRINT ALL SETTINGS will cause the printer to print out all the current settings held with-
in the metal detector headed with the sub-heading **SETTINGS**
PRINT SHIFT REPORT will cause the printer to print out all the current Shift report
information which has compiled from the last shift report print-out, it will be headed by
the sub-heading **SHIFT REPORT START**
72
TROUBLESHOOTING
Section 5
5.1 Introduction
This section is dedicated to assisting the technician in providing a step-by-step method to resolve the
most common service issues. Also included are the detector circuit fault and warning messages.
TROUBLESHOOTING
5.2 Low Sensitivity
In the event of a failed validation test, ensure the detector is still properly set-up. This should include
not only the current product set-up, but also all of the factory parameters.
A. Maximum Sensitivity Testing

If the detector is suspect of having lost sensitivity, the following test will assist to confirm factory
specification. It will require the original ferrous test samples supplied with the system.
1. Stop product flow
2. Stop conveyor (if applicable).
3. Ensure no product is in the detectors aperture.
4. Enter the engineer's mode
5. Set the product number to (00)
6. Set the sensitivity to (199)
7. If the system is a conveyor, select a non-metallic package. Ensure no metal contamination is
present in the package.
8. Select the smallest ferrous sample that was originally supplied with the system. Locate the
sample on the rear edge of the empty test package in the direct center of the detectors aperture.
9. Turn the conveyor "on" and pass the test package so the metal sample passes through the center
of the detector aperture.
10.A detection must occur with this sample. Repeat multiple times to ensure detection.
11.If the detector does not see the sample, re-check the factory parameters for the power drive and
reference phase. If all parameters are set correctly, substitute another Control Module and inspect
all module cabling. Repeat the test procedure to confirm proper operation.
12.If after module replacement, unit still does not detect sample, a hardware fault may exist in the
detector system and will need returned to Safeline for repair.
(Call Safeline Technical Support for a Return Authorization Number).
73
5.3 Random Detection
Section 5
A. Definition
The metal detector registers a detection with AND without product regardless of contamination.
CAUTION: DISCONNECT AIR OR POWER FROM REJECT DEVICE TO AVOID INJURY FROM REJECT
OPERATION DURING TROUBLE-SHOOTING.
TROUBLESHOOTING
B. Testing Procedure
1. Set the metal detector to Product number to 00 and Sensitivity to 199.
2. If the system stabilizes, the possible causes of the random detections are:
I. Product Effect: The detector may be sensing the product or the product's package.
II. Electromagnetic Loop: Metal contact points on the support frame may have loosened or come
into contact with other metalwork.
III. Reference Phase: The reference phase may be out of adjustment.
IV. Metal free zone violation: Metal is positioned too close to the detector.
V. Contaminated belting: Contamination will trigger at the contamination points.
With the belt moving, mark the belt with tape to identify the trigger points; remove any metal
contamination or replace belt.
VI. Static Discharge: Usually found on gravity feed systems or high speed conveyor belts.
System needs to be properly earth grounded.
3. If unit continues to random detect then most probable cause are:
I. Module malfunction: Replace with spare module and confirm proper operation.
II. Radio Frequency Interference (RFI) or Electromagnetic Interference (EMI):
(See Section 7.12 for troubleshooting assistance)
III. Detector damage: A component or sub-assembly of the metal detector is damaged.
a. Damaged or delaminated liner.
b. Water intrusion into system.
c. Damaged electronic sub-system. Replace with spare and verify
proper operation.
4 If difficulty is experienced isolating the random detection, try the following:
I. Remove the detector system from the installation and relocate to a quiet area.
II. Repeat the troubleshooting process.
III. If the problem follows the detector system, inspect and isolate to fault.
IV. If the problem does not follow the detector system, then there is a high probability the problem
is in the installation or production environment.
V. Contact Safeline Customer Support for assistance.
74
5.4 Reject Failure
Section 5
A. Definition
The reject device fails to operate after a metal detection.
CAUTION: DISCONNECT POWER AT MAIN BREAKER BEFORE WORKING ON ANY ELECTRICAL
COMPONENTS.
TROUBLESHOOTING
If applicable, refer to wiring schematic that accompany all Safeline manufactured Pipeline and
Conveyors. The schematic is located both in the Power Supply enclosure and the information packet
provided.
B. Testing Procedure
1. Ensure that the correct timer type is selected for the application.
2. Ensure the air pressure is adequate. Safeline systems are engineered for 80 psi.
3. Check the solenoid operation. Most solenoid have a test button to initialize operation.
4. Check the pneumatics system for damaged air hoses, fittings, etc.
5. Check that RL1 is changing states for each detection.
Note: RL1 may not be the reject relay in some systems. RL2 can be the reject relay. Please refer to
the system schematic for details. In some cases RL1 is used as a latching relay for a system alarm
i.e. a beacon or audible alarm.
6. Change the Timer Type to TM1. Cause a detection; RL1 should change states immediately.
If RL1 does not change states:

I. Set TM1 Reject Time to 5 seconds.
II. Check for a voltage change between terminals 40 & 36 at the detector power supply. A voltage
change should occur from 0.6-0.7 VDC to 5 VDC on a detection.
III. Check the detector cable for damages, loose connections at the power supply, or misalignment of
the connector at the Interconnection Board.
IV. Possible Control Module malfunction. Replace the Control Module with spare.
V. Retest for the voltage change. If no voltage change then:
VI. An Interconnection Board failure may exist. Replace the Interconnection Board with spare.
If RL1 changes states:

I. Check the voltage supplied to the terminals of the reject relay for the correct voltage.
(Please refer to the power supply schematic on inside lid of power supply enclosure).
II. A jumper is usually between P/S terminals #1 or #5 to the common terminals #8 and / or #11.
(Note: If RL2 is the reject relay then #15 and / or #17).
III. Check that the voltage is supplied to the reject solenoid during a detection. Inspect the solenoid
for proper operation.
a. Turn the detector OFF at the power supply.
b. Remove the jumper installed between terminals # 20 and # 21 on the power supply.
This is the latch jumper. Once removed and a detection occurs, RL1 latches after changing
states. (Not applicable if RL2 is the reject relay).
IV. Turn the unit on. RL1 will latch during detector self test. If reject does not operate and remain in
the reject position then the device is not receiving power from the power supply.
V. Check wiring for damage.
VI. Check device for water intrusion, corroded lead connections.
VIII.Ensure to replace jumper between #20 and #21 after troubleshooting.
75
5.5 Multiple Rejects
Section 5
A. Definition
Unit rejects several times after detector registers only one reject.
B. Verification of Electronic Function

1. Stop product flow and remove any remaining product from the detector aperture.
TROUBLESHOOTING
2. Select TM1 timer for detector.

3. Disconnect air from reject device or remove RL1 from the power supply.
4. From the running mode, press the ETC soft key to display Pack Count and Reject Count.
5. Trigger the detector ONCE with hand or small metallic object. The displayed Reject Count should
increase by one and only one.
Note: Bi-directional Over-head sweep reject devices require a small "reject time" timer setting than
normal. If set too long the device will sweep both direction which looks similar to the Multiple Reject
symptom.
If the Multiple Rejecting Continues:
a. Replace the Control Module spare.
b. Replace the Interconnection Board with spare.
c. Replace the power supply with spare.
Passed, but still getting multiple rejects from one detect signal with product.
1. Pack Spacing:
a. For a photo-gated reject operation the pack spacing is too small. One reject but the detector is
sensing the next package before the rejected package is out of the detector aperture resulting in
one or more rejections.
b. Increase the belt speed to increase package spacing.
c. Reset the reject timers to reflect the new belt speed.
5.6 Continuous Rejects

A. Definition
The reject device operates, one reject after another without product present.
B. Stopping continuous rejects
1. Disconnect air supply to reject device or turn Reject Inhibit in detector programming "ON" (Note:
The last five(5) red LED's on the right side of the bar graph display will begin flashing stopping
the normal operation of RL1)
2. Pull RL1 from power supply top board. The reject device should deactivate immediately.
C. Find ing the cause
1. Perform a Vibration check. (See SECTION 7.9 VIBRATION)
a. If the detector passes the Vibration check, then possible cause of the continuous rejecting
maybe:
I. RL1 relay is allowing a leakage of voltage backward into the DC voltage of power supply.
Replace RL1 relay with spare.
II. A power surge is returning from the reject device. Install a surge suppressing capacitor
across the terminals at power supply.
2. If the detector fails Vibration check:
a. Possible electromagnetic loop in installation or supporting structure (See SECTION 7.10
ELECTROMAGNETIC LOOPS).
b. Possible Interference (See SECTION 7.12 INTERFERENCE).
c. Possible damaged or delaminated liner (See SECTION 7.3 RANDOM DETECTION).
76
5.7 Voltage / Power Faults
Section 5
A. Definition
Unit fails to power up or is missing one or more system voltages
CAUTION: THE FOLLOWING TEST REQUIRES THE POWER TO BE SUPPLIED AS NORMAL TO THE
DETECTOR. SEVERE INJURY CAN OCCUR IF CARE IS NOT TAKEN WHEN WORKING ON LIVE
TROUBLESHOOTING
ELECTRICAL COMPONENTS.
The detector requires (3) DC Voltages to function during
normal operation. The three voltages can be observed
from the front of the Control Module to indicate when all
power requirements are met.
1. The left most LED signifies the +15 VDC is supplied.
2. The second LED from the left signifies the -15 VDC is
supplied.
3. The liquid crystal display, when lit, signifies the +5
VDC is supplied.
B. Voltage Failure
One or more of the LED's not Illuminated when power is switched "ON."
1. Check the AC voltage supplied at the power supply terminals 1 & 2.
2. Check voltage between terminals 43 & 44 = +15 VDC.
3. Check voltage between terminals 42 & 43 = -15 VDC.
4. Check voltage between terminals 41 & 43 = +5 VDC.
(Note: The +5VDC is fused at the power supply top board).
C. Testing for Fault

1. Switch power OFF at power supply.
2. Disconnect the terminal strip numbered 29 through 44 from the power supply. It is not necessary
to disconnect the individual conductors from the terminal block.
3. Re-test for the terminal voltages as in steps 2, 3, and 4 above. (Use caution to ensure not to
touch the test probes together).
4. If terminal voltages are low or missing then, replace the power supply with spare.
5. If the voltages appear normal, then proceed to inspect the detector head cable for a short or open.
Look for any cuts or pinched areas that have damaged the conductors inside cable.
6. Inspect for a possible connector problem with the cable connector below the Interconnect board
inside the module cavity. This is usually caused by pulling on the detector head cable below the
detector body.
7. Loose or miss aligned module connectors.
8. Replace the Interconnection Board.
9. Replace the Control Module with spare.
77
5.8 CIRCUIT FAULTS and WARNING MESSAGES
Section 5
Message type FAULT

Reason Essential detector operation is jeopardized
TROUBLESHOOTING
Fault output Active

Screen status Message permanently displayed
Detection relay Active
Bar graph status Flashing
Audio indicator Series of short pulses
Message type WARNING

Reason Non-Essential detector features affected
Fault output Active
Screen status Message intermittently displayed
Detection relay Inactive
Bar graph status Normal
Audio indicator No audible alarm
Message type CAUTION

Reason Indicates cautionary message regarding an operation process
Fault output Inactive
Screen status Message briefly displayed
Detection relay Inactive
Bar graph status Normal
Audio indicator No audible alarm
78
Section 5
2. Identification
The chart below identifies the Circuit Fault and Warning messages for both Version
1 and Version 2 systems (STD), and Powerphase systems (PPH)
STD PPH Description Remedy#
TROUBLESHOOTING
Warning 1 Fault 01 Blank Eeprom E-1
Warning 2 Fault 02 Blank Eeprom And Blank Ram E-2
Warning 3 N/A Partial Ram Default E-3
Warning 4 Fault 03 Blank Ram E-4
N/A Fault 05 One Of The Selectable Values Is E-5
Outside Acceptable Limits
N/A Warning 07 Communications Fault E-6
Circuit Fault N/A Cpu Fault (Rom. 1.21) E-7
Circuit Fault 2 Fault 08 Low Level Power Drive Voltage E-8
Circuit Fault 3 Fault 09 Low Or Missing D.C. Reference Voltage E-9
Circuit Fault 4 Warning 02 Faulty Eeprom E-10
Circuit Fault 5 Warning 03 Eeprom Read / Write Error E-11
Circuit Fault 6 Automatic Setup Detector Unable To Complete E-12
Failed An Auto-Setup Routine
N/A Fault 11 ~ 16 Communications Fault E-13
Balance Fault Balance Fault Detector Coils Out Of Balance E-14
Bad Rom Eeprom Checksum Operating Software (Firmware) Fault E-15
Checksum Found Fault
Data Collection Data Collection Request To Print Without Printer E-16
Unit Not Ready Unit Not Ready Configured Or Hardqware Connected
Data Collection Data Collection Request To Print Initiated, But Not E-17
Unit Not Configured Unit Not Configured Selected In The Qa Setup Mode
Reject Confirmation Reject Confirmation Reject Device Failed Or Reject E-18
Reject Fault Reject Error Confirmation Circuit Failed
Reject Confirmation Reject Confirmation Firmware Can'T Locate The Hardware E-19
Input / Output Fault Input / Output Error Or System Power Turned Off And On
Rapidly
79
Remedy# Suggested Troubleshooting Sequence
Section 5
E-1 1. Press any key to clear the first message.

2. A "Maintain Module Settings" message will appear in the display screen:
3. Press "YES" to download module memory into interconnect eeprom.
4. Press "NO" to default both memories (will require re-programming).
E-2 1. Press any key to clear message.

TROUBLESHOOTING
2. Default settings will be automatically loaded (will require re-programming).

2. Confirm both factory and user settings for any corrupted data.
E-4 1. Press any key to upload interconnect eeprom memory to module.

2. If message returns after a power down, the modules back-up battery
may need replaced, or the modules RAM memory is bad.
3. Replace module if necessary.

2. Confirm both factory and user settings for any corrupted data.
3. Replace Interconnection board.
4. Replace Module.
E-6 1. Replace Module.
E-8 1. Ensure detector head and module are the same frequency
(or frequency group).
2. Ensure frequency group is selected correctly (PPH system only).
3. Ensure the power drive cable is connected and not damaged.
4. Inspect frequency switching cable for connection or damage
(PPH system only).
5. On remote systems, inspect remote cables for connection or damage.
6. Replace Module.
8. Replace Power Supply.
E-9 1. If missing first or second green bar on bar graph display,

proceed to Section C.
2. Inspect for cable connections or damage.
3. Replace Module.
E-10 1. Inspect flat grey ribbon cable from Interconnection board

to Module for connection or damage.
3. Replace Module.
E-11 1. Inspect flat grey ribbon cable from Interconnection board
to Module for connection or damage.
3. Replace Module.
80
Section 5
Remedy# Suggested Troubleshooting Sequence
E-12 1. Re-run the auto set-up routine and ensure to follow closely.
2. Switch Power Drive to "LOW" and re-try auto set-up (PPH system only).
3. Ensure the conveyor has no contamination in the belting.
4. Ensure there is no metal free zone violations.
5. Ensure there are no electromagnetic ground loops.
TROUBLESHOOTING
6. Replace Module.
E-14 1. Ensure there is no product built-up in detectors aperture.

2. Ensure there is no metal free zone violation.
3. On remote systems, inspect the remote head cables
for connection or damage.
4. Power down detector.
5. Remove the (4) 13mm bolts that secure the Module to the head
or enclosure.
6.. Unplug the 6 pin in-line connector from the right hand side of the Module.
7. Power system up.
8. Observe Module display, if message remains, replace Module.
9. If message is absent, detector will require re-balancing (Contact Safeline).
E-16 1. Ensure printer is connected and powered "ON".

2. Ensure proper handshaking is selected (see Engineering level menu).
3. Inspect printer port and internal cable harness for connection or damage.
E-17 1. Ensure printer is enabled in Q.A. Level menu.

2. Ensure correct selection of "FIXED" or "PORTABLE" in the Q.A. Level menu.
3. Replace Module.
E-18 1. Ensure air pressure is still being maintained to system.

2. Ensure sensor is still operational (signal at power supply terminal
#45 and #46).
3. Verify correct reject time (selectable in the Engineers Level menu).
4. Verify correct RCU extension time (selectable in the Engineers Level menu).
5. Ensure the jumper on the RCU board is set for correct polarity
(NPN or PNP).
6. Ensure the two position slide switch on the RCU board is set correctly.
7. Replace the RCU board.
8. Replace the Module
9. Replace the Interconnection board.
E-19 1. Power down the detector for approximately 10 seconds.

2. On power up, if message is still present, a hardware fault may exist.
3. Inspect hardware, sensor, and cables for connection or damage.
4. Replace RCU board.
5. Replace Module.
81
5.9 Vibration
Section 5
Mechanical vibration produces signals that make the metal detector unstable and prone to false
detection. Specialized electronic circuits incorporated in the metal detector permit for these signals to
be minimized for maximum performance.
The REFERENCE PHASE is a detector machine setting which reduces signals caused by vibration.
The reference phase is set at the factory and only needs to be adjusted under specific circumstances.
TROUBLESHOOTING
The following procedure verifies that the reference phase setting is correct:
A. Verification of the Reference Phase:
NOTE: Before testing or adjusting the reference phase, ensure that the aperture is free of product,
electromagnetic ground loops are broken, and any metal free zone violations are removed.
1. Set the detector to product number "00" and raise the sensitivity to "199".
2. With a soft rubber mallet or heel of hand, induce vibration into the detector by striking lightly at
the top and sides of the detector to induce vibration. The induced vibration should mimic normal
vibration that occurs during production. Observe the reaction of the detectors bar graph display
a. 1-2 green bars = normal and no adjustment to the reference phase is necessary. The Product
Phase angle for the product may need to be slightly adjusted.
b. 3-5 green bars = OK, if not operating the detector above a sensitivity setting of 180. Adjust
the reference phase by the one's digit to fine tune, see below.
c. More than 5 green bars or detects = Adjusting Reference Phase required.
B. Adjusting the Reference Phase (Version 1 & 2 Systems Only)
1. Enter the Engineers Mode level.
2. Advance to the screen that reads "Adjust Reference Phase".
3. Press the upper right soft key.
(Note: The screen will read: "See OPERATING MANUAL PRIOR TO ADJUSTMENT!" and automatically
advance to the screen where the Reference Phase and the sensitivity setting can be adjusted).
RECORD THIS REFERENCE PHASE NUMBER.
4. Induce vibration as above and observe the bar graph signal. If all the red LED segments light
when vibration is induced, lower the sensitivity setting so the vibration does not register more
than 10 of the available 20 red LED segments.
5. Begin adjusting the reference phase either up or down until the signal on the bar graph is
reduced to a maximum signal level of 0-3 green bars at a sensitivity setting of "199".
6. Press the ENTER key to store the new value.
7. RECORD THE NEW REFERENCE PHASE NUMBER for that detector serial number for future
reference.
8. Exit the Engineering mode level and return to the Running Mode display screen
NOTE: On newer Version 2 systems and all Powerphase systems, the Reference Phase must be set
using a ferrite wand due to the nature of the solid potting material. Please contact Safeline Customer
Service for assistance.
82 82
5.10 Electromagnetic Loops
Section 5
The construction of the metal detector support framework
can influence the performance of the detector. A detector
mounted on an inadequate support structure will exhibit
poor vibration characteristics and be prone to random
false triggering.
TROUBLESHOOTING
Even metalwork positioned outside the metal free zone
can act as an aerial or receiving antenna, making the
entire framework susceptible to electromagnetic loops.
The field generates minute electrical currents that flow
in the surrounding metalwork.
The current flows through the closed path or loop
created by the rollers mounted across the conveyor
frame. Loops can be avoided by opening or closing
the loop in a permanent manner. It is the intermittent
nature of a loop path that causes the random triggering
of the metal detector.
The problem with the rollers on the conveyor can be
overcome by insulating one end of the roller from the
conveyor frame. This may take the form of a plastic
insulation plate and washers on the bearing mounting
block or a plastic bushing at one end of the roller shaft.
By insulating the roller in this way the loop is opened
permanently. The support frame should be of welded construction rather than bolted sections. A
welded construction is an example of a permanently closed loop. Any metallic items bolted to the
conveyor frame, (i.e. guards, conduit, or any metallic objects) potentially create loops. To avoid
difficulty insulate/isolate all items bolted to the frame.
5.11 Metal Free Zone (MFZ)

The aperture opening of the detector allows some of the electromagnetic field generated by the
transmitter to extend beyond the case. Any external metal must be kept at a distance from this
point. This "zone" is referred to as the metal free zone (MFZ) of the detector. A formula can be used
to calculate the required distance of the zone and is based on the height of the aperture dimension.
83
5.12 Interference
Section 5
A. Source Power
1. The power source for the detector should be fitted with an isolation switch and an appropriate
circuit breaker and/or fuse.
2. The mains supply for the detector should be an independent feed.
3. It is recommended that the power source for the detector be taken from a source that supplies
TROUBLESHOOTING
only low power equipment.

4. DO NOT power the detector from sources that supply varying current loads such as inverters,
switching networks, variable speed drives, or heavy current drawing loads. ALWAYS protect the
supply feed to the detector with an approved lightning/surge suppression device.
B. Ground ing
1. ALWAYS properly ground the detector systems electrical supply. Use a low impedance cable and
ensure solid contact at both ends.
2. A chassis or frame ground may also be required depending on the product application. If a
chassis or frame ground is required, a one gauge low impedance cable should be used. Ensure
this cable is as short as possible and terminated to a proper grounding/earth rod (See your local
code for establishing a proper earthing/grounding rod).
C. Power Filtering
Plant power interconnected through several pieces of equipment can allow load fluctuations that the
detector power supply cannot filter out. Line filters, power conditioners, and isolation transformers
are the most cost-effective method to eliminate spikes in supplied power.
Verification:
1. Remove the power from the detector power supply and replace with a separate, independent
power cord from a known low voltage source or utilize input power from a standard computer
UPS system.
2. If the detector operates more effectively, then a dedicated low voltage line feed and /or power filter
or line conditioner may be required.
D. Rad io Frequency Interference (RFI)
Devices such as variable frequency drives (VFD's), two way radios, citizen band (CB) radios,
cellular phones, personal pagers, other metal detectors, etc, emit radio frequencies. These
frequencies can interfere with the metal detector and cause false triggering.
E. Electromagnetic Interference (EMI)
The metal detector generates an electromagnetic field. It is susceptible to other fields generated by
motors, high voltage conduit lines, magnetic separators, audio speakers, and other electromagnetic
devices. The solution is to separate such devices from "close" proximity to the detector or provide a
grounded shield between the device and detector like a metal plate.
Verification:
1. Turn off any other machinery, especially variable frequency drives, two-way radios, and other
metal detectors one at a time.
2. Once the interference source is turned off, the detector will operate normally.
If the equipment is another metal detector, the Control Module will need to have the frequency
staggered. Please call Safeline Customer Support for assistance.
84
F. Shield ing
Section 5
Each component must be grounded to manufacture specifications and all conduit or cable runs must
be properly shielded and grounded.
1. Replace any plastic conduit, junction boxes, cable fittings, etc, with metal.
2. All facets of the system must be linked together using low impedance connections to form a
continuous unbroken shield.
TROUBLESHOOTING
3. Keep all connections as short as physically possible
4. When possible, avoid routing conduit and cabling in close proximity to the metal detector.
5. Use the largest surface area as a good ground conductor, for example a properly grounded
cabinet wall or control panel plate inside a cabinet
G. Variable Frequency Drives (VFD's)
Frequency control devices emit large quantities of RFI into the surrounding area. These frequencies
can be minimized with the following screening and adjustment techniques:
1. The cabinet, conduit or cable, and the motor housing must be connected together to form a single
screen. No interruptions of the screen are permissible.
2. The inverter drive with its switching elements is the main source of the interference. Mounting the
Inverter in a properly shielded and grounded metal enclosure can help to reduce RFI emissions
3. Ensure that the conduit or cabling to the motor is properly grounded. Avoid the usage of
unshielded (rubberized) cables. If cable is used as the conductor to the motor, use a braid-
shielded cable and ground the shield to the panel where the drive is mounted. The best ground
for the braid of the cable is a strap. This strap should fit tight to the braid, and mount to the
ground structure, the panel of the drive. Remember to keep the connection as short as possible.
Expose the braid shield, fit the strap over the exposed area, and fasten securely.
4. Some VFD's have the capability of changing the carrier frequency of the VFD known as the pulse
width modulation (PWM). Read the operations manual for the device in question to determine if
this adjustment is possible. If adjusting this carrier frequency is possible, adjust in small
increments while watching for a reduction in the bar graph display of the detector. While it may
not be possible to completely eliminate the entire interference signal, usually a setting can be
found that results in the best performance of the detector.
H. Multiple Interference Sources
In some cases, the operating environment of the detector is where many VFD's or sources are
discovered. A methodical process of elimination can help to minimize the interference and restore
stability to the metal detector system.
1. Start with the equipment causing the largest signal recognized from the reaction of the detector on
the bar graph display (this will often time be the equipment in closest proximity to the metal
detector).
2. When the first VFD has been adjusted for the best possible performance, then move to the next
source.
3. The first source adjustment may need minor readjustment when working with the second, third, or
fourth source.
85
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87
www.mt.com/safelineus
For more information
Mettler-Toledo Safeline
6005 Benjamin Road, Tampa, FL 33634, USA
Tel: 1-800-447-4439
1-813-889-9500
Fax: 1-813-881-0840
Email: safeline.sales@mt.com
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SAFELINE

Metal Detection Metal Detection & X-ray Inspection

Section 1: Detector System Overview ................................................1 - 2 J

Section 2: Detector Theory ............................................................3 - 13 J

Section 3: Software Levels ..........................................................14 - 24 J

Section 4: User Settings and Adjustments ....................................25 - 72 J

Section 5: Troubleshooting ..........................................................73 - 85 J

Section 6: Notes ........................................................................86 - 88 J

A. Detector Search Head

DETECTOR SYSTEM OVERVIEW

Detector Search Head (cut-away view)

around the former. The former/3 coil

B. Excitation Coil (TX)

C. Receiving Coils (Ra & Rb) Ra Tx Rb

Due to the reverse winding relationship of the

The two signals from the receiving coil are

B. Zero Peripheral Metal Free Zone Detector (ZPMFZ)

1. Type of metal 6. Operating frequency

A metal sphere approaching the aperture begins to

and a voltage signal begins to develop.

When the sphere reaches a position directly beneath the

As the sphere moves away from the first receiving coil, a

When the sphere reaches the center coil, a momentary state

As the sphere approaches the second receiving coil,

When the sphere is positioned directly beneath the second

As the sphere exits the aperture, the voltage drops back to

Signal generated is too small Signal generated is sufficient in size

COMMON METAL DETECTOR OPERATING FREQUENCIES

Sensitivity = 199 Product Phase = 0 Sensitivity = 199 Product Phase = 0

Spherical Metal Samples and Spiral Contamination Equivalents

Orientation effect as a function of spherical sensitivity

Comparing the signal of the receiving coils

Any signal vector that is "captured" within the adjustable

3.1 KEYPAD FUNCTIONS

B. Bar Graph Display

D. Soft Function Keys

G. Cursor Move Key

H. UP / DOWN Arrow Keys

POWERPHASE Systems User Program Modes

Program Mode Name Default Security Access Code

1. Running Mode Display No Access Code Required

2. Operators Mode 0001

3. Supervisor Mode 0002

4. Engineer Mode 0003

5. QA Inspector Mode 0004

6. QA Operator Mode 1000 through 9000

7. Viewing Mode 0005

B. Diagnostic Level Access

In this example, some of the values generated are too 9206

Powerphase Main Diagnostic Menu

3). AUTO SETUP REJECT INHIBIT

4). PERFORMANCE CHECK

6). AUXILIARY 1 OUTPUT

8). RESET TO DEFAULTS

3). COIL PITCH

4). L.F. OFFSET

5). POWER DRIVE

6). REFERENCE PHASE

7). FERROUS PHASE

8). SENSITIVITY LIMIT

NAME..................... PROD. 00 Arrow Flipped