Ampeon AMP-2000V5 User manual

.
AMP-2000V5 type
Metal & spark diverter
User manual
Jiangsu Ampeon Electronic Engineering Co., Ltd
http://www.ampeon.cn

P r e l u d e
Thanks for using new models AMP series of high performance metal & spark diverter produced
by Jiangsu Ampeon Electronic Engineering Co., Ltd. AMP series products are manufactured with
high quality units, materials and with the utilization of latest microcomputer technology. Jiangsu
Ampeon Electronic Engineering Co., Ltd. continuously practices the design and innovation of the
product and provides excellent products with professional attitude. Furthermore, it responds to the
customers with professional service and benefits each other with the customers.
The manual provides cautions about the installing, parameter setting, troubleshooting and daily
maintenance of metal & spark diverter to the user. In order to assure the proper installing and usage
of the product, please read this manual in detail before installing. Please keep the manual well and
give it to the operator of the machine.
Welcome to visit the website of Jiangsu Ampeon Electronic Engineering Co., Ltd. ：
www.ampeon.cn. The website provides the download of the operation instructions and technical BBS
service.
The following are the cautions that need special attention:
▲Caution！
1. First please carry out the delivery inspection and check whether there is damage caused by
transportation process.
2. After unpacking, please compare with the packing list and check the type, specification and
components of the product. If it does not conform to your order documents or if you have any
questions regarding the product, please contact to the dealer or the service office of our
company.
3. Jiangsu Ampeon Electronic Engineering Co., Ltd. provides services of the three guarantee
period 18 months from the delivery date.
4. Troubles due to lightening strike, water invasion and obvious artificial miss or damage etc.
are not in the range of repair guarantee.
5. Metal & spark diverter series products are important products of the fore-spinning procedure
in cotton spinning mill. But the users in cotton spinning mill should also take integrated
measures in fire protection equipments, selection of material, management regulations etc. to
assure the safety production.
▲Caution！
1. The power supply must first be shut down before the electric wiring.
2. Wiring, repairing & maintenance of the machine should be carried out by electric
professionals.
3. Do not carry out compression test toward the inner components because the semiconductor
units are easy to be broken down by the high voltage and are easy to damage.
4. The circuit board CMOS integrated circuit is apt to static electricity damage. So you should
take the static electricity prevention measure before touching the circuit board with hand.
5. As the machine is installed to the pipe in high place, installing personnel should take safety
measures. Suspending or bracket should be solid to prevent the machine from dropping down.
6. Select safety area to install the equipment, prevent the high temperature & direct shinning and
avoid humidity and splashing of the water drops.

Contents
A. Overview.........................................................................................................................................1
1. Use and structural characteristics.............................................................................................. 1
2. Explanation of the principle...................................................................................................... 2
2.1 Spark diverter................................................................................................................... 2
2.2 Metal diverter................................................................................................................... 2
2.3 Diverter.............................................................................................................................3
3. External dimensions and names of the parts............................................................................. 3
4. Technical parameter...................................................................................................................5
B. Electric wiring and installing........................................................................................................5
1. Electric wiring diagram............................................................................................................. 5
1.1 Explanation of main terminal-X1 electric wiring.............................................................6
1.2 The connection of metal diverter’s signal cable...............................................................7
1.3 Ear-thing and safety..........................................................................................................8
2. Installing....................................................................................................................................8
2.1 Install requirements.......................................................................................................... 8
2.2 The installing of control box.......................................................................................... 10
2.3 The installing of metal detector......................................................................................11
2.4 The installing of diverter................................................................................................ 12
C. Debugging and usage maintenance............................................................................................13
1. Indicative and adjustable parameter of the control panel........................................................13
1.1 Spark inspection unit AMP-TIME SET......................................................................... 13
1.2 Metal diverting unit APU-02..........................................................................................15
2. Fire alarm simulation test........................................................................................................ 19
3. Metal diverting function test and adjustment.......................................................................... 19
D.RS-232 communication................................................................................................................ 21
1. Function of RS-232 communication connector.......................................................................21
2. Special APU-01 human-machine interface............................................................................. 22
E. Troubleshooting........................................................................................................................... 23
F. Appendix....................................................................................................................................... 28
Appendix 1: Diagram showing wiring principle of AMP-2000V5 metal & spark diverter........28
Appendix 2:Diagram of AMP-2000V5 metal & spark diverter installing.................................. 29
Appendix 3:The practice of blowing and carding line fire alarm............................................... 31

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A. Overview
1. Use and structural characteristics
AMP-2000V5 type metal & spark diverter is a new type of textile security
product developed and designed by Jiangsu Ampeon Electron Engineering Co., Ltd.,
which is used in the fore-spinning line and can be directly installed on the conducting
duct of blow room machinery, it can automatically detect and remove the metal
material, sparks and combusting scraps in the fiber fabrics. It is an important
equipment to assure the safety production in the blowing-carding joint production
line or lapping production line. The product has more complete function comparing
with the previous models, and is more prominent in metal & spark diverting
performance. It may find expression in the following points:
a. It has high sensitivity and detection ability toward the metal particles and
sparkle.
b. It has excellent resistance toward the interference from the power supply and
electromagnetism.
c. Automatic calibration and equilibrium electric circuit make the inspection
sensitivity free of drift and difference, and the intelligentized program make it
capable of adapting to different install environment and maintains the best working
condition.
d. The design of automatic sensitivity parameters ranks makes the parameter
programming more simple and efficient.
e. LED of the parameter setting unit has increased to 3 digits. So not only the
metal counting maximum value has reached 999, but the delayed parameter setting
precision has also increased to 0.01 second, and the diverter can be controlled more
accurately.
f. The straight duct that the installing of rapid response diverter needs is very
short and has high efficiency of diverting. So it can assure that the volume of noil
dropping with metal substance is the lowest.
g. Design the collect box to enlarge the noil storage volume and improve the
collect valve, so that the executive structure becomes more reliable.
h. The mesh clapboard of the collect box assures the reliable separation of the
dropped noil and makes the diverter adapt to various scutching procedure of positive

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and negative pressure.
i. The whole machine is convenient and simple, easy to install and debug, and it
does not need special maintenance and care.
j. It has RS-232communication connector and it can communicate with special
APU-01 human-machine and adapt to the computer network management and remote
control of the workshop.
Figure1: Diagram of safety equipment layout in blowing-carding joint
production line
2. Explanation of the principle
2.1 Spark diverter
When the beater of a bale plucker strikes metal material or the spindle end of the
beater is tangled with fiber, it may generate sparks, and the sparks can mix in the
fiber and move into the conducting duct under the action of the wind. When the
cotton fiber mixed with sparkles moves through the high sensitive infrared probe
detecting area, the controlling program will immediately make the fire alarm with
sound and light. Furthermore, while stopping the running of related equipments such
as blower fan etc., the cotton flow with sparkle and combusting scraps are discharged
into collect box to assure that the sparkle will not enter the next procedure and
eliminate the hidden trouble of fire.
2.2 Metal diverter
In cotton noil, there are generally metal sundries such as iron wire scraps, screw,
washer, metal reed and so on. While mixed with fibers, they are transported through
the detecting area of metal probe, the metal probe circuit will drive the diverter after
distinguishing, and then discharge the cotton flow with sundries into the collect box
to prevent the metal sundries from entering the blower equipments in the next
procedure to cause the hidden trouble of fire and the damage of machinery such as

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carding cloth.
2.3 Diverter
Executing structure is composed of A201type rapid diverter and collect box.
A201diverter utilizes three-way air rocking plate type valve structure and has rapid
response speed and small wind pressure loss. The collect box has mesh clapboard to
assure the smooth passing of the air flow and reliable separating of the material that
includes sundries. In the procedure of both positive and negative pressure, this
diverter executive structure can work effectively and it is applicable in the parallel
use of reciprocate bale plucker and disc bale plucker.
3. External dimensions and names of the parts
This equipment is mainly composed of three parts: spark detection control box
(figure2), metal detector (figure3) and diverter (figure4).
Figure 2：Diagram of the control box
Type
Remark
A
(mm)
B
(mm)
C
(mm)
D
(mm)
Weight
（KG）
300
Applicable toΦ300mm pipe
300
560
380
260
19
350
Applicable toΦ350mm pipe
350
600
430
260
21
Table 1：Dimension table of control box

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Figure 3：Diagram of the metal detector
Type
Remark
E
(mm)
F
(mm)
G
(mm)
H
(mm)
I
(mm)
J
(mm)
Weight
（KG）
300
Applicable toΦ300mm pipe
325
540
620
415
310
355
45
350
Applicable toΦ350mm pipe
380
580
660
415
335
350
47
Table 2：Dimension table of detector
Figure 4：Diagram of the diverter
Type
Remark
K
(mm)
L
(mm)
M
(mm)
N
(mm)
0
(mm)
P
(mm)
Q
(mm)
R
(mm)
Weight
（KG）
300
Applicable toΦ
300mm and
Φ350mm pipe
585
355
355
505
290
335
290
1480
68
350
Table 3: Dimension of diverter

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4. Technical parameter
a. Sensitivity Metal detection: can detect the steel ball not less than Φ3mm
Spark detection: not less than Φ1mm spark(visual angle not less
than 90 degree)
b. Response time: ≤0.2second
c. Power supply: AC220V±10% ,50HZ（Electromagnetic interference conforms
to related standard of our country）
d. pressure range: 6~8kgf/cm2
e. Sound level of alarm: ＞120db
f. Power: ＜100VA
g. Relay contact output: 10A/240VAC/28VDC
h. Requirement of the environment: temperature -10℃-40℃; relative humidity
（20-75）%RH
B. Electric wiring and installing
In order to reach the best performance of AMP-2000V5 type metal & spark
diverter, proper electric wiring and installing is the most important approach. Before
the installing, please read the following carefully and make further measurement and
evaluation properly with respect to installing environment and condition on the site.
1. Electric wiring diagram
a. Diagram of the front part in control b. Diagram of the hinder part in
box (after the door opens) control box (after the hinder cover
is removed)

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c. Section diagram of control box
Figure 5：Diagram of the inner units in control box
1.1 Explanation of main terminal-X1 electric wiring
Figure 6：Diagram of the main terminal-X1 wiring
a. The connectors 2# and 3# are the incoming line of power supply AC220V. We
should avoid the share of power supply with other equipments that may produce
interference radiation. If possible, please supply the electricity separately. It is
necessary to pay special attention to avoid the phenomenon that on the time of spark
alarm stopping, the power supply of instrument itself cannot be shut down. As the
equipment is installed to the metal pipe, it is recommended that you use the wire over
RVV 1.5mm2.
b. The connectors 4# and 5# can output AC220Vpower supply. It is connected to
the electromagnetic valve coil of the correlated diverter. As the equipment is installed
to the metal pipe, it is recommended that you use the wire over RVV 1.5mm2.
c. The connectors 6# and 7# can provide passive normally closed relay contact
and provide the input circuit to PLC in the control box of the control equipment. With
this, the system can stop when the fire alarm happens. Through the use of 7# and 8#
normally open contacts and with the transformation of intermediate relay, the blower
fan contactor can be directly controlled and the rapid stopping in case of fire alarm

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can be realized.(refer to figure 7). If you use the normally closed contacts 6# and 7#
to connect to the related equipment AC circuit, the rapid stopping can also be realized.
However, it’s not recommended, for the AC circuit may affect the normal working of
the metal detector.
Figure 7: Control the blower fan through the conversion of relay KA1
（recommended）
1.2 The connection of metal diverter’s signal cable
Figure 8：The connection diagram of metal signal cable
1.3 Ear-thing and safety
a. You should earth properly according to the safety standard of local

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government. This equipment needs to be separately earthed. It is suggested that
the ear-thing wire be as short as possible and it is prohibited to earth it together
with other equipments.
b. While overhauling, please shut down the power supply first, and the
temperature of the radiator is very high, so don’t touch it to avoid burn.
c. After the spark alarm, you should shut down the general power supply of
the procedure and then put out the fire.
d. The spark test or repairing work that needs climbing should be carried out
by more than two people.
2. Installing
2.1 Install requirements
The detailed requirements of installing are as follows:
a. Enough length of straight duct must be reserved within the installed route. In
the ordinary course of events, if the length of the straight duct is over 4.5m, it can be
installed according to figure 9. The metal detector and diverter must be installed to
the straight duct (refer to figure 9a).
b. The control box of AMP-2000V5 diverter should also be installed to the
straight duct together with metal detector and diverter for it contains spark detectors.
But for the limitation of the straight duct’s distance, if the straight duct was just about
3m, the control box could be installed to the other side of the bent duct of the cotton
intake (figure 9.b).
Figure 9.a

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Figure 9.b Figure 9.c
Figure 9: The diagram of several AMP-2000V5regular pipes installing (vertical view)
c. If a bent pipe is installed between metal detector and diverter, the diverting rate
will not reach the ideal effect (refer to figure 9c).So we don’t recommend the
installing method of figure 9c.
d. The center-to-center distance L2of the metal detector to the diverter is the most
important parameter that needs to be confirmed before the installing. The
determination method in detail is as the following table (table 4). L2 directly relates
to the diverting rate.
e. Before the installing, it is necessary to prepare the metal slingers, metal bracket
and wire & cable for the installing.
Air speed ν（m/sec）
Install distance ‘L2’ ( m )
ν＜10
2m
10＜ν＜20
2 m～3.5 m
ν＞20 (high wind speed)
≥4m （Adjust according to the actual
situation）
Table 4: The install distance from metal detector to the diverter
▲Caution!
a) During the installing, the center distance between the metal detector and
diverter L2 is the most important parameter of the installing process. If the install
distance L2 is too long, the metal diverter rate will obviously decrease. The most near
distance that satisfies the simulation experiment L2 is most ideal.
b) After finishing the installing, if you can’t get ideal diverting effect through the

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adjustment of parameters in the parameter unit, you must confirm through tests and
adjust the L2 distance.
2.2 The installing of control box
a. The control box is directly connected to the pipe. It can be hung to the two
sides of the metal pipe connected to it (figure 10.a) and it can also be directly hung to
the installing screw in the two sides of the control box (figure 10.b). Or otherwise
under the special condition that installed straight pipe distance is limited, the control
box can also be horizontally installed to the vertical pipe (figure 10.c).
b. The connecting pipe with observing window is directly connected to the
control box (figure 10). The connecting pipe with observing window is designed for
the convenience of the test of spark inspection function.
Figure 10.a Figure 10.b
Figure 10.c
Figure 10: Diagram of control box installin
▲Caution！
The control box installing control panel should face the direction that is easy to
operate and control. The foreside and backside should not be close to the wall for the
convenience of maintenance and repair. The observing window should also face the

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direction that is easy to inspect and observe.
2.3 The installing of metal detector
a. Metal detector can be hung by metal bar to get installed. Please refer to figure
11.a. If metal detector is near the wall, it can be installed with metal bracket to
support and get installed. Please refer to figure 11.b.
b. While installing, don’t let metal substance like screw, spanner etc. remain
inside the metal detector. These things should be hung or supported by holder or
hanging tool, and they should be made of metal, so there should be an insulation
distance between the detector and the supporter.
Figure 11.a Figure 11.b
Figure 11.c Figure 11.d
c. Metal detector should be firmly installed to avoid misacting when the detector
vibrates during usage. The metal detector should be firmly installed to prevent the
misoperation caused by the vibration of the detector. The non- metal duct dispatched
on delivery go through to the inner cavity of the metal detector and should avoid the
collision, furthermore a distance of 5mm should be maintained with the inner cavity.
Please see figure 11.c.

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d. Metal detector should be far away from the things that generate the
electromagnetic radiation such as electric motor, transformer and daylight lamp etc.
Furthermore, it should be far away from moving or vibrating metal substance, for
example, fan etc. The cables with big current shall also keep a distance from the
detector. Please refer to figure 11.d.
Figure 11.e
e. The location that the metal detector is installed is very sensitive to the
electromagnetic interference. For example, in the workshop, there is air conditioner
and a big power inverter is used (over 15KW) and it is within 25m, it may cause the
misoperation. So please install RFI filter to the main connecting wire. The nearer the
install position to the AC motor driver the better it is. And if you adjust the inverter’s
PWM wave carrying frequency, the interference would also relatively decrease.
Please see figure 11.e.
2.4 The installing of diverter
The executive structure is composed of two parts: diverter and collect box(refer to
figure 12). The collect box is installed under the diverter and be careful not to
reversely installed and assure that the collect valve can act flexibly.
The diverter is connected with square joint pipe to the conduct duct. The install
method is the use of hanger. Please pay attention to the direction of cotton incoming
and output. The diverter utilizes rapid response gas driving structure, so it is
necessary to provide clean and stable 6-8kgf/cm2gas supply.
The collect box has noil control valve, if the diverter is installed to the high place,
you can tie ropes to the handle of the door. As for the install position, you should
avoid the problem that cotton containing sundries dropped to the hopper or other
machines when the collect door opens.

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Figure 12: Diagram of diverter installing
C. Debugging and usage maintenance
1. Indicative and adjustable parameter of the control panel
After completing the installing, first carry out the energizing test. If the displayer
shows normally after the energizing, the following procedure is the understanding
and the setting of the parameters.
1.1 Spark inspection unit AMP-TIME SET
Figure 13: The diagram of parameter panel in spark inspection unit
a. The explanation of the messages in LCD
11:11:08 indicates the real-time now is 11:11:08a.m.
♬03 indicates there are 3 alarm messages
AMPEON indicates Logo of Ampeon Electron Co., Ltd.

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The above is the main display information of the main page while working, that
red LED on indicates that AMP01 spark inspection control main-board works in
normal state while Green LED on indicates that there is new alarm information. After
reading the alarm records, it returns to the original state.
b. The search of alarm record
When you push the alarm record button, you can enter the page of the latest alarm.
LCD displays the time of year, month, date, hour and minute.
Then you push △key, you can turn to the previous alarm history. You can
continuously turn to the front page. When “NO RECORD” is shown, it shows that
there is no record and the system will automatically return to main page.
When we push ESC/DELETE key , it exits to the alarm history page. If there is
no instruction in the alarm history page, it can also exit to the main page after 10
second.
▲Caution!
This computer can store 20 alarm messages. If the number exceeds 20, the
history record would be automatically cleared and displays"♬01". That is to say,
it can only store the 21st message, the original 20 messages would be
automatically cleared.
c. Operation in case of alarm
In case of the alarm, the instrument sends the sound and light alarm signals and
shuts down automatically, at the time, the displaying clock in LCD main page stops.
After pushing RESET ALARM key, the alarm status will be eliminated and the
instrument returns to the normal working status. The main page of LCD returns to the
normal time (During the alarm, though the displaying clock stops, the inner is still
timing, so it would automatically enter to the correct time after elimination of the
alarm.) and the message number of alarm will be increased by one.
d. The deletion of alarm record
On the main displaying page of LCD, when you push ESC/DELETE key, the
latest alarm record will be deleted. The function is mainly used in the fire alarm
inspection by maintenance personnel for deleting automatic alarm record while doing
inspection test.
e. Time setting
The time has been set when delivered, in the ordinary course of event, it is not

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necessary to adjust.
If you need to calibrate the time, you can push TIME SET key to enter the time
setting page. Then push the key in turn to switch among the year, month, date, hour,
minute. The adjusted data is in the twinkling status, through pushing the △key, we
can change the value of the data. After finishing the setting of the time, push TIME
SET key to return to the main page and automatically save the time after the change.
In the time setting page, push ESC/DELETE key to return to the main page, but
you can not save the change.
In the time setting page, if there was no more new operation within 4 minutes, it
would return to the main page without saving anything.
▲Caution！
While changing the time, you should operate patiently, please confirm carefully
after saving the changing to prevent the error.
1.2 Metal diverting unit APU-02
Figure 14: Diagram of APU-02 panel
a. Use of counting function
COUNT/CLR
a) The data displayed in LED is the times of the metal diverter’s action. If you
want to restart the counting, you can push COUNT/CLR key. After the count
reaches 999, the counter will automatically reset and restart the counting.
b) Users can understand the times of metal detecting machine’s action and judge
the rate of metal inclusion in the raw material. And we can also compare it with the
calculating value to check the dropped metal substances.
b. Parameter setting
a) DATE SET key is used to transform among the following 5 cycling mode:

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‘working status’→ ‘sensitivity’→ ‘activation delay’→ ‘reset delay’→ ‘fan halt delay’.
Each time you push DATE SET (parameter setting) key, it in turn changes to next
mode. If there was no more operation within 30S, it would automatically return to the
working status.
b) △,▽key can increase or decrease the value in the parameter setting.
c) The five LEDs on the right of the nixie duct indicates the displayed content of
the working nixie duct. They are in turn operation (red), sensitivity (green), activation
delay (green), reset delay (green) and fan halt delay. After finishing of parameter
setting and resume of working status, the changed parameter is automatically written
into the storage devise EEPROM.
c. Parameter setting range and explanation
Parameter
Range of setting
Setting value on delivery
Sensitivity SU
A0, A1, A2 Automatic level
A1
1~99 Manual level
Activation delay T1
0.00S~3.00S
0.00S
Reset delay T2
1.00S~3.00S
1.50S
Fan halt delay T3
0.00S~3.00S
0.00S
Table 5: Parameter setting table
a) Sensitivity SU
Automatic mode of sensitivity (3 levels): A2 (automatic high sensitivity),
A1(automatic medium sensitivity),A0(automatic low sensitivity).
Manual mode of sensitivity, 99 levels: parameter range1-99, the lowest 1, the
highest 99.
We recommend the A0, A1, A2 Automatic mode of sensitivity. A0 and A1
sensitivity levels can satisfy most of the users in spinning mills. In automatic mode,
CPU can adapt itself to different working conditions and make the metal diverter
maintain the best sensitivity status.
1~99 is the manual setting mode of sensitivity, users can set the sensitivity
parameter according to the actual requirement. The values in the range 69-85 can
satisfy most of the users in spinning mills.
▲Caution！
Under the working condition that the magnetic interference is big, if you set the
sensitivity parameter too high, the disoperation of diverter will happen. Under the
condition of bad electromagnetic environment, we can decrease the use of sensitivity

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parameter.
b) Activation delay T1
Action delay refers to the parameter of software delayed time from the time the
detector detects the metal to the time diverter acts. The action delay time parameter
should be set according to the actual wind speed and the install distance from metal
detector to diverter. The setting precision of the action delay parameter is 0.01S and
the setting range is 0.00S-3.00S. As for the adjusting method in detail, refer to this
section 3. Metal diverting function experiment and adjustment. It is suggested that
if the install distance is satisfactory, software delay is not used. The action delay
parameter is set to 0.00S。
c) Reset delay T2
Reset delay refers to the time from the flap of the diverter opens to the time it
resets. The parameter should be confirmed through the experiment. We must assure
that cotton including metal substances can drop to the collect box and in the
meantime, we must assure that the dropping volume is the minimum and it has
minimum influence to the gas flow of normal production. The reset delay parameter’s
setting precision is 0.01S. Adjust △, ▽ and set the reset delay parameter in the
range of 1.00S to 3.00S.
▲Caution!
If the parameter T2 is set too low, this may cause the condition that material
including the metal cannot be discharged .If it is too big, the discharged material may
become excessive. In general course of event, the value between 1.00S to 2.00S can
satisfy the needs. When the instrument detects special big metal substance, reset
delay T2 will automatically prolong and increase the dropping time of the cotton
batting.
d) Fan halt delay T3
Stop delay 0.00S refers to the condition of stopping immediately after the fire
alarm happens. If it is set to 0.50S, then the blower fan or other machine will stop
0.50S after the fire alarm。Adjust △,▽and fan halt delay parameter can be set in the
range between 0.00S and 3.00S.
▲Caution!
Fan halt delay parameter is used in the situation that after the fire alarm, the stop
of running blower fan is delayed to assure that the material can dropped to the collect