Eriez E-Z TEC IV Manual

Installation, Operation
and Maintenance
Instructions
ERIEZ MAGNETICS HEADQUARTERS: 2200 ASBURY ROAD, P.O. BOX 10608, ERIE, PA 16514–0608 U.S.A.
WORLDAUTHORITY INADVANCED TECHNOLOGYFOR MAGNETIC, VIBRATORY and METAL DETECTIONAPPLICATIONS
®
MM-235F
E-Z Tec®
Metal Detectors
Models IV & V

®
2
Introduction
This manual details the proper steps for installing the Eriez
E-Z Tec®Model IV and V Metal Detectors.
Careful attention to these Installation Requirements will
assure the most efficient and dependable performance of
this equipment.
If there are any questions or comments about the manual,
please call the factory at 814/835-6000 for E-Z Tec®Metal
Detector assistance.
©2005 ERIEZ MAGNETICS ALL RIGHTS RESERVED
CAUTION - ELECTROMAGNETIC FIELDS
• Metal Detectors emit electromagnetic fields. Contact the American
Conference of Governmental Industrial Hygenists, Cincinnati,Ohio,
U.S.A., (www.acgih.org) for additional information.
• If you use a medical implant or similar device, you must never
approach the equipment because your device may malfunction in
the electromagnetic field, with consequences up to and including
death.
Contact Eriez if you have a question regarding these precautions.

®
3
Handling Instructions
PLEASE LEAVE THESE INSTRUCTIONS ATTACHED
TOTHE EQUIPMENT UNTIL INSTALLATION IS COMPLETE
1. DO NOT LIFT THE METAL DETECTOR BY
INSERTINGANYTHINGINTOORTHROUGH
THE APERTURE. The inner surface of the
aperture is delicate and is surrounded by a
precisely tuned electronic circuit that must not
be disturbed. Any damage to this surface or
anyaperturedistortioncausedbyhandlingwill
invalidate Eriez’ warranty.
2. HANDLE THE SHIPPING PALLET NOT THE
DETECTOR. Keep the metal detector on its
shipping pallet as long as possible.
3. When you must remove the detector from the
shipping pallet, LIFT ONLY ON DETECTOR
HOUSING SERVICES THAT INCLUDE
SUPPORTING“FEET”ORTAPPEDLUGS,as
supplied by Eriez.
4. LIFT BY HAND IF POSSIBLE, or by using
a crane and soft nylon slings running under
the entire detector housing - NOT
THROUGH THE APERTURE. Block the
slings to prevent rubbing on the remainder
of the detector housing.
5. The metal detector is heavy. Use care
when handling to avoid injury to personnel
or damage to property.
6. Never weld any attachment to the detector
housing. Do not attempt to drill and/or tap
the metal detector housing for lifting or
mounting attachments.
7. Neverliftwitha craneorforklift underthe“chin”
of the control housing that juts out from the
metal detector housing. Make certain that
lifting straps and other handling equipment do
not contact the control housing.
8. If handling with eye-bolts threaded into pre-
tapped holes supplied by Eriez:
a. Makesurethateye-boltsarestrong enough
for the loads that will be applied
b. Never apply loads perpendicular to the
shank of the eye-bolts; they will break.

®
4
Table of ContentsTable of Contents
GENERAL ...........................................................................................................12
PRINCIPLE OF OPERATION .............................................................................12
SPECIFICATIONS ..............................................................................................13
DETECT MODES................................................................................................15
Mode 1 ..........................................................................................................15
Mode 2 ..........................................................................................................15
INSTALLATION CAUTION!!................................................................................16
MECHANICAL INSTALLATION...........................................................................16
Introduction ...................................................................................................16
Handling ........................................................................................................16
Location of Sensing Head .............................................................................16
Metal Free Area.............................................................................................17
Electrical Current Loops................................................................................17
Insulating the Conveyor Shafts .....................................................................17
Permanent Loops..........................................................................................18
Mounting Base ..............................................................................................18
Belt Splices ...................................................................................................19
Conveyor Slider Bed .....................................................................................19
Product Position ............................................................................................19
Reject Proximity Switch.................................................................................19
ELECTRICAL INSTALLATION ............................................................................20
Introduction ...................................................................................................20
Choice of Input Power Source ......................................................................20
Power Supply ................................................................................................20
Relays ...........................................................................................................21
Direct Relay.............................................................................................21
Timed Relay ............................................................................................21
Fault Relay ..............................................................................................21
AC SSR ...................................................................................................21
DC SSR...................................................................................................21
Relay Notes.............................................................................................22
ERIEZ E-ZTEC METAL DETECTORS - MODELS IV AND V

®
5
Table of Contents (cont.)
Inputs ...........................................................................................................22
Tachometer Input (TACH)........................................................................22
Proximity Switch (PROX SW)..................................................................22
Reject Confirmation (REJ CON)..............................................................22
Reject Reset (REJ RESET).....................................................................23
Host Computer Port (MPC®only) ............................................................23
Printer Port (MPC only) ...........................................................................23
Conduit..........................................................................................................23
Initial Test (Analog Unit) ................................................................................23
Initial Test (MPC Unit)....................................................................................24
ANALOG CONTROLS AND DISPLAYS .............................................................25
Large Rectangular Status LED’S ..................................................................25
Detect (Red) ............................................................................................25
Fault (Yellow)...........................................................................................25
Monitor Display .............................................................................................25
Sensitivity Control .........................................................................................25
Phase Control ...............................................................................................25
Analog Output Controls.................................................................................25
Travel Time..............................................................................................25
Reject Time .............................................................................................25
Standard Reject Time..............................................................................25
Indexed Reject Time................................................................................25
Programming Switches ...........................................................................26
Fault Indicator..........................................................................................26
Balance LED ...........................................................................................26
Reject LED ..............................................................................................26
Relay Status LEDs ..................................................................................26
Direct .......................................................................................................26
Timed.......................................................................................................26
ACSSR ....................................................................................................26
DCSSR....................................................................................................26
Fault ........................................................................................................26

®
6
Table of Contents (cont.)
Analog Output Controls (cont.)......................................................................26
Window LED............................................................................................26
Index In LED............................................................................................26
Confirm LED............................................................................................26
Clock LED ...............................................................................................27
Detect LED ..............................................................................................27
Analog Circuit Board Switch Programming ...................................................27
SW1-1 .....................................................................................................27
SW1-2 .....................................................................................................27
SW1-3 through SW1-8 ............................................................................27
SW1-9 .....................................................................................................27
SW2-1 .....................................................................................................27
SW2-2 .....................................................................................................27
SW2-3 .....................................................................................................27
SW2-4 .....................................................................................................27
JP1 ..........................................................................................................28
JP2 ..........................................................................................................28
JP3 ..........................................................................................................28
Switch Charts ..........................................................................................28
MPC CONTROLS AND DISPLAYS ....................................................................30
MPC Control Panel .......................................................................................30
LED Bar Graph........................................................................................30
Switch Keys.............................................................................................30
LCD .........................................................................................................30
MPC Software ...............................................................................................30
Flowchart.................................................................................................30
General MPC Operation................................................................................30
Monitor ....................................................................................................30
Reject Reports.........................................................................................31
Product Setup..........................................................................................31
Options ....................................................................................................31
Passwords.....................................................................................................31
Detect / Reject Display..................................................................................31

®
7
Table of Contents (cont.)
Controlling the MPC Display .........................................................................32
Travel Between Menus............................................................................32
Changing Variables .................................................................................32
Detailed MPC Menu Description ...................................................................32
Power Up Display....................................................................................32
Monitor Display........................................................................................32
Change Product Menu ............................................................................33
Identification Display ...............................................................................33
Main Menu...............................................................................................33
Product Setup Menu................................................................................33
Sensitivity ..........................................................................................33
Detect Mode ......................................................................................33
Phase ................................................................................................33
Gain...................................................................................................33
Filter...................................................................................................33
Configure Rejects..............................................................................34
Detailed MPC Menu Description (cont.)........................................................34
Product Description ...........................................................................34
Auto Phase........................................................................................34
Reject Setup............................................................................................34
Detect On Power Up?........................................................................34
Timed Reject .....................................................................................34
Timed Reject, Index Device is not Used............................................34
Timed Reject, Index Device Used .....................................................35
Direct Reject............................................................................................36
Product Description .................................................................................36
Auto Phase..............................................................................................36
Reject Reports.........................................................................................36
Erase All Reports.....................................................................................37
Fault ........................................................................................................37
Reject Confirmation Fault..................................................................38
Balance Fault ....................................................................................38
Self-Check Fault................................................................................38
Calibration Fault ................................................................................38

®
8
Table of Contents (cont.)
Options ....................................................................................................39
Buzzer ...............................................................................................39
Setup Communication .......................................................................39
Setup Printer .....................................................................................39
Factory...............................................................................................39
Set Time and Date.............................................................................39
Update Passwords ............................................................................39
Print Options............................................................................................39
Diagnostics..............................................................................................39
Troubleshooting.................................................................................39
Self-Check.........................................................................................40
Calibration Check ..............................................................................41
Calibration Check Setup....................................................................41
CONFIGURING ANALOG METAL DETECTOR .................................................42
Analog Adjustment Procedure.......................................................................42
Phasing Out the Product Effect -Analog Units..............................................42
Reject Adjustment - Analog Units..................................................................43
Direct Reject............................................................................................43
Timed Reject ...........................................................................................44
Timed Reject, Index Device Not Used.....................................................45
Timed Reject, Index Device Used ...........................................................46
CONFIGURING MPC METAL DETECTOR ........................................................48
MPC General Options Menu .........................................................................48
MPC Product Setup ......................................................................................48
MPC Reject Adjustment ................................................................................51
Direct Reject............................................................................................51
Timed Reject ...........................................................................................51
Timed Reject, Index Device Not Used.....................................................51
Timed Reject, Index Device Used ...........................................................52
Obtaining MPC Reject Reports .....................................................................53
LCD .........................................................................................................53
Printer......................................................................................................53
Host Computer ........................................................................................53

®
9
Table of Contents (cont.)
MAINTENANCE ..................................................................................................54
SPARE PARTS....................................................................................................54
Analog Unit Spare Parts................................................................................54
MPC Unit Spare Parts...................................................................................55
FIGURES ...........................................................................................................56
APPENDIX A - PRINTER OPERATION (MPC ONLY) ........................................77
Introduction ...................................................................................................77
General Description ......................................................................................77
Detailed Description ......................................................................................77
Connector Pinout.....................................................................................77
MPC Printer Setup ..................................................................................77
Data Bits..................................................................................................77
Parity .......................................................................................................77
Transmit Mode.........................................................................................77
End Line With ..........................................................................................78
Baud Rate ...............................................................................................78
Printing Options.............................................................................................78
Printing A Single Report ..........................................................................78
Printing Multiple Reports .........................................................................78
Operating Instructions ...................................................................................78
Configuring Printer Cable ........................................................................78
Setting Up MPC Printer Serial Port .........................................................79
Printing a Single Report Using Manual Mode .........................................79
Printing Reports Automatically ................................................................79
Printing All Stored Reports ......................................................................80
Canceling Print All Reports......................................................................80
APPENDIX B - VARIABLE SPEED TACHOMETER ...........................................81
Tachometer System Design ..........................................................................81
Tachometer Wiring Connections .............................................................82

®
10
Table of Contents (cont.)
APPENDIX C - VARIABLE REJECT UNITS .......................................................83
Introduction ...................................................................................................83
Mechanical ....................................................................................................83
Electrical........................................................................................................84
APPENDIX D - SLIM TEC SINGLE SURFACE UNITS.......................................86
Introduction ...................................................................................................86
Mechanical ....................................................................................................86
Electrical........................................................................................................87
APPENDIX E - SLIM TECAPERTURE UNITS...................................................90
Introduction ...................................................................................................90
Mechanical ....................................................................................................90
Electrical........................................................................................................91
APPENDIX F - VFS PACKAGING MACHINE METAL DETECTORS .................94
Introduction ...................................................................................................94
Mechanical ....................................................................................................94
Electrical........................................................................................................95

®
11
The Eriez Magnetics E-Z Tec IV and V Metal
Detectors are state of the art electronic devices
for detecting fine particles of metal in non-metallic
product streams. They are designed for accuracy,
sensitivity, reliability and simplicity of operation.
Two variants are available: the analog version
(Figure 1) and the MicroProcessor Controlled
(MPC®) version (Figure 2). The performance,
controls, and outputs of the analog version are
ideal for most standalone industrial applications
where a simple detect-reject process is required
and the product stream has consistent
characteristics from day to day. For applications
where the detect-reject procedure may require
more frequent changes, the record keeping
requirements may be more stringent, or a
centrally controlled network of detectors is
required, Eriez provides the MPC versions of the
E-Z Tec IV and V.
General
This manual covers both the analog and MPC
versions of the E-Z Tec IV and V. Much of the
discussion herein is relevant to either version.
This manual provides all information necessary to
use both the E-Z Tec IV/V Metal Detector (analog
version) and the E-Z Tec IV/V MPC Metal Detector
as standalone systems. For networked or remotely
controlled installations of MPC detectors refer also
to the E-Z Tec III/IV/V MPC Communications
Manual MM-237
NOTE: Throughout this manual, information spe-
cific to the analog version of the metal detector is
set off with a gray border.
Informationspecific to theMPC version ofthe metal
detector is set off with a gray background.
Genericinformation—applicable toboth analogand
MPC versions—is neither bordered nor shaded.

®
12
Principle of Operation
The E-Z Tec IV/V Metal Detector uses a
differential transformer to detect pieces of metal.
Three coils encircle the detection aperture. The
signal voltage in the primary coil is driven by an
oscillator.Two secondary coils, on a common axis
with the primary, are coupled into the field of the
primary coil in such a manner that the system is
in balance and the induced voltages in the two
secondary coils cancel.
A piece of metal introduced into the detection
aperture will distort the primary field and cause a
differencein inducedvoltages in the two secondary
coils. This voltage difference constitutes a signal
that is amplified and manipulated to extract the
amplitude and phase angle with respect to the
oscillator input signal. This information is used to
decide whether the signal represents metal or the
user’s product. If it represents the user’s product it
is ignored. If it represents metal, and if the signal
exceeds a pre-set level, the metal detector
generates a detection signal. The detection signal
is manipulated to provide various timing functions
for creating reject actions.
Figures 3 and 4 illustrate conveyor installations
of E-Z Tec analog and MPC metal detectors
respectively.
Separation of Power and SignalWiring
This information is being distributed to
assemblers and electricians about the importance
of proper methods for wiring of controls. These
methods are revised and updated from time to
time as we (Eriez Magnetics) perceive necessary.
This information will cover distances from various
categories of cables and Eriez Metal Detector
wiring standards. The cable categories are:
1. AC power cables
2. DCdistribution (thermocouple,power supplies)
3. Signal and Logic
a. Analog (low level)
b. Digital logic
Category 1 cables are to be routed along frame
members and panels. Avoid open space hanging.
Category 2 cables are routed as in Category 1
but separate from 1.
Category 3 cables are routed separately from
Categories 1 and 2. Category 3b cables are to
be spaced 25 cm (1") from Category 1 for each
meter of run.
Use separate machine entry holes for category
1, 2 and 3 cables.
When Eriez Metal Detectors are being installed
in plants using VFC drives, the following
precautions are recommended:
1. Route VFC wiring and Eriez Metal Detector
wiring in to separate metallic conduits.
2. Separate power sources should be used for
VFC drive and Eriez Metal Detectors.
3. The use of a Harmonic Neutralized Constant
Voltage Transformer for the Eriez Metal De-
tector power is recommended. Use separate
conduits for in and out wiring.
4. TwistAC common circuit run wires tegether to
minimize electromagnetic field interference.
5. Follow cable category separations as detailed
above.

®
13
Specifications
POWER SOURCE REQUIREMENTS
(TWO RANGES)
105 to 125 VAC 50 to 60 Hz.
Max. surges of 150 V RMS for a period
of 2 seconds.
OR
210 to 230 VAC 50 to 60 Hz.
Max. surges of 300 V RMS for a period
of 2 seconds.
Maximum demand 60 VA (Excluding
externally connected loads).
FUSES
Located in separate NEMA 4(X) enclosure
(See Figure 7).
F1 - Self resetable fuse rated at 200mA DC.
Requires no service.
F2,3,4,5,6 - Bussman GMA-1A 5X20 mm.
F7, F8 - Bussman GMC-1A 5X 20 mm.
TACHOMETER INPUT
Used to monitor variable speed conveyors.
See Appendix B.
Voltage
Logic 0 - 0.0 VDC to 0.9 VDC.
Logic 1 - 3.15 to 50 VDC .
(NPN Open Collector can also be used).
Current
Source N/A.
Sink 1 mA min.
Frequency
50 Hz max maximum.
Minimum Pulse Width
Logic 0 - 5 mSec.
Logic 1 - 5 mSec.
PROXIMITY SWITCH INPUT
Voltage
Logic 0 - 0.0 VDC to 0.9 VDC.
Logic 1 - 3.15 to 50 VDC.
(NPN Open Collector can also be used).
Current
Source N/A.
Sink 1 mA min.
Frequency
50 Hz max maximum.
Minimum Pulse Width.
Logic 0 - 5 mSec.
Logic 1 - 5 mSec.
REJECT CONFIRMATION INPUT
Voltage
Logic 0 - 0.0 VDC to 0.9 VDC.
Logic 1 - 3.15 to 50 VDC.
(NPN Open Collector can also be used).
Current
Source N/A.
Sink 1 mA min.
Frequency
50 Hz max maximum.
Minimum Pulse Width
Logic 0 - 5 mSec.
Logic 1 - 5 mSec
REJECT OUTPUTS
Direct Reject
K1 - Mechanical single pole double throw
relay rated 1A, 250 VAC or 1A, 30 VDC.
Timed Reject
K2 - Mechanical single pole double throw
relay rated 1A, 250 VAC or 1A, 30 VDC.
OPTIONAL SOLID STATE RELAYS
SSR1 -AC solid state relay rated .02 to 1.0A,
12 to 250 VAC.
SSR2 - DC solid state relay rated .02 to 1.0A,
5 to 60 VDC.
PRODUCT MEMORY (MPC ONLY)
The MPC is capable of storing all metal
detector adjustments and alphanumeric
descriptions for 99 separate products.
REJECTTIMERS
Direct Reject
Travel Time 0.00 sec.
Reject time 0.05 to 60 sec (these values
approximate on analog version).
Timed Reject
Travel Time 0.05 to 60 sec. (approximate
on analog version).
Reject Time 0.05 to 60 sec. (approximate
on analog version).
Shift Register Resolution 1200.

®
14
REJECT COUNTER (MPC ONLY)
The MPC stores a running total of the number
of times the Direct Reject output has cycled.
This normally provides a very close approxi-
mation of the total number of detections while
preventing multiple counts of the same piece
of tramp metal.
Maximum Count: 9999.
REJECT REPORTS (MPC ONLY)
The MPC stores pertinent data on the most
recent 100 rejects. Report Number, Product
Number, Time, Date, and Peak Signal Level
can be reviewed on the LCD display. The re-
ports can be downloaded to a remote printer.
In this case, Travel Time, Timed Reject Time,
Sensitivity, Gain, and Product Description are
also included in the report. The reports can
be downloaded to a remote computer. The
computer report contains all information men-
tioned above plus Phase, Filter Frequency,
Detect Mode, Fault Status, Date & Time that
any one of the variables was last changed,
Direct Reject Time, Window Time, and status
of Tach Input, Direct RejectAuto Reset, Timed
Reject Auto Reset, Space Between Products,
IndexDevice Used?, and Reject Confirmation.
ENVIRONMENT
Ambient Temperature 0°C (32°F) to 50°C
(122°F) during operation.
Storage Temperature -10°C (14°F) to 80°C
(176°F).
Relative Humidity 0 to 95%.
NOTE: When stored at or below 0 ° C for
longer than six hours and then moved to a
warmer location, the temperature of the unit
should be allowed to stabilize long enough to
allow drying of moisture which may have ac-
cumulatedonthe electronic components(over-
night is recommended). DO NOT APPLY
POWER UNTIL ELECTRONICCIRCUITRY IS
COMPLETELY DRY.
ENCLOSURE RATING
NEMA-4X/IP66.
PRODUCT VELOCITY
The metal detector can be adjusted to scan
productstraveling fromapproximately 2ft./min.
to 7800 ft./min. (.6 m/min. to 2400 m/min.) de-
pending on the size and type of sensing head.
The unit is set up at the factory for optimal
performancefor thecustomer’s applicationand
requires no further adjustment.
FREQUENCY
The metal detector operating frequency de-
pends on the aperture size and the character-
istics of the product to be inspected. It is ad-
justable but this is normally not required un-
less another metal detector in the area causes
interference. In this case consult the factory
for adjustment details.
BATTERY LIFE (MPC ONLY)
Minimum 1.4 years; maximum 5.0 years.
COMMUNICATION (MPC ONLY)
Printer-RS 232 (see Appendix A).
Computer-RS 232/485 (see E-Z Tec MPC
Communications Manual MM-237).
PRODUCT DESCRIPTION (MPC ONLY)
32alphanumeric characters of description can
be stored for each of 32 separate products.
DIAGNOSTICS (MPC ONLY)
Automatic self-checking for proper operation
of the metal detector electronics at user defin-
able intervals
Detector can show Fault condition when user-
scheduled calibration procedure is missed.
Receiver and transmitter independently con-
trollable for identification and isolation of ex-
ternal electronic noise sources.
Specifications (cont.)

®
15
Detect Modes
E-ZTecIVandVmetaldetectorscanoperateineither
of two detect modes. The most appropriate mode for
a given application depends largely upon
environmental conditions and upon the likely mix of
tramp metal in the product stream. The discussion
below provides guidelines on selection of the best
detect mode for your operation.
MODE 1
Themetaldetectorcontrolprocessesananalogsignal
from the receiver coils of the metal detector.Atypical
example of a metal signal is shown in Figure 5-A. If
the magnitude of the signal rises above a
predetermineddetectionthreshold,themetaldetector
willoutputadetectsignal. Notethattheanalogsignal
has a positive and a negative portion. In detect mode
1themetaldetector willdetectonboth portionsofthe
signal. The detect signal typically begins with the first
portion of the signal crossing the detection threshold
(at point “A”) and ends after the second portion of the
signalreturnsthroughtheoppositedetectionthreshold
(at point “B”). Mode 1 is usually the most sensitive
and reliable method of detection and is, therefore,
used in most applications.
MODE 2
Occasionally a metal detector is used in an
environment where significant interference is
experienced. Typical sources of interference are
lightning,staticelectricity,andnearby equipmentwith
inductive loads. These types of interference usually
cause analog signals which have only one polarity.
Figure5-Bshowstypicalunipolarnoisesignalsat“D”,
“E”and“F”.Eachofthesesignalswouldcauseametal
detector to false detect when operating in Mode 1
because they exceed the detection threshold level.
The metal detector can be adjusted to ignore many
ofthesesignaltypesbyusingMode2detection.Refer
again to the analog signal of Figure 5-A. Notice that
the metal signal has both a positive and negative
polarity. Mode 2 detection does not detect a unipolar
signal. It holds off detection until the second polarity
of the signal occurs. For the signal in Figure 5-A the
detection would occur at point “C”. It would last a
predetermined length of time and reset. The noise
signals in Figure 5-B would be ignored because they
are unipolar.
In general, Mode 2 detection may be somewhat
less sensitive than Mode 1 detection.Also Mode 2
detection may allow metal to pass undetected in
certain instances. Figure 5-C shows an analog
signal representing a small piece of metal followed
by a large piece of metal in the product stream.
The beginning of the signal is similar to the
beginning of the signal shown in Figure 5-A; but as
it moves toward the negative detection threshold,
the signal of the small piece of metal is absorbed
by the signal of the larger piece of metal following
it.Thelargerpiece of metal is detected at “G”. Note
that the small piece of metal is not detected.
Extremely large pieces of metal will cause larger
sections of the product stream to be ignored
because the electronics will require more time to
recover. Therefore, the probability of missed metal
increaseswith thesize ofthe trampmetal. Normally
thisarea is small because the tramp metal is small.
The probability is low that metal will be missed, but
thepossibility existsand mustbeconsidered before
one decides to use Mode 2 detection.
If the metal detector works reliably using Mode 1
detection, Eriez recommends use of this mode.
Some applications are electrically noisy and the
number of false trips is high enough that the metal
detector cannot be used in Mode 1. In this case
one must decide whether to use Mode 2 detection
with an increased probability of missing a small
percentageof metal.The unit willignore most noise
and still detect the overwhelming majority of the
metal. Mode 2 is much better than no protection.
However, Eriez recommends its use only when
absolutely necessary.
Everyunit leaves the factory with an Individual Unit
Specifications sheet. This sheet will indicate
whether the unit is set for Mode 1 or Mode 2
detection. Most units will be set for Mode 1
detection. If the detection mode of the unit must be
changed, use switch SW2-1 on the Output Control
panel of an E-Z Tec IV or V analog metal detector
(in the Power Supply housing) or use the Detect
Mode menu option on an E-Z Tec IV or V MPC
metal detector. Detailed instructions for these
procedures are given in later sections.

®
16
E-Z Tec IV and V metal detectors have been
manufactured to very stringent quality control
standards to ensure that they will provide years
of trouble-free service. To achieve this trouble-
free service, the installer must follow the
installation procedures outlined in this manual.
The details of the procedures are important, and
must be followed precisely for proper metal
detector operation.
A metal detector is by nature extremely sensitive
to very small changes in its electrical and physical
environment. Installed incorrectly, it will be very
likely to display unstable operation. It will appear
to be extremely sensitive to vibration and/or will
false trip (generate a false reject signal) when
the conveyor starts and stops. These and other
troubles will be prevented by proper installation
techniques.
The following installation procedures have been
collected over years of experience. Please make
use of them! Problems caused by improper
installation techniques are not covered by
warranty! A little time invested in the installation
process will pay for itself many times over by
providing a smooth trouble-free startup and
continued reliable service.
Installation Caution!!
Mechanical Installation
INTRODUCTION
The metal detector contains from one to three
components which must be physically mounted to
a conveyor or suitable stand: 1) the sensing head,
2) the control (including the MPC in MPC versions)
ifit is not part ofthe sensing head, and 3)the power
supplywhich may be integral with the sensinghead
and/or this control. See Figure 6.
The sensing head includes the sensing aperture
and related electronics. The control is either
attached to the sensing head or remote from it. If
the control is remote from the sensing head, its
enclosure must be mounted to a convenient
surface (free of vibration) that is easy to access
so that the metal detector can be adjusted. The
control enclosure is fitted with plastic mounting
feet that must be used to mount it.
The power supply contains all the electrical
connections to the metal detector. It is located
within a NEMA-4X enclosure (see Figure 7). This
enclosure is also fitted with plastic mounting feet
that must be used to mount it.
HANDLING
The metal detector must be handled with care
during installation. Follow the specific handling
guidelines attached to the detector or included in
the shipping materials. For convenience, generic
handling guidelines are included in this manual
immediately inside the front cover.
LOCATION OF SENSING HEAD
The location of the metal detector sensing head
is extremely important. The process of selecting
a location must include consideration of the needs
of the metal detector, the surrounding processing
equipment, and the operator. Product flow
including velocity and rejection of contaminants
is a major concern. Be certain to read and
understand all installation guidelines before the
final location is selected.

®
17
METAL FREE AREA
The metal detector monitors an electromagnetic
field to detect metal. This field is predominantly
contained within the metal detector sensing
aperture but some fringing of the field exists at
the entrance and exit openings. The fringing field
will allow the metal detector to detect metal in
the vicinity of the entrance and exit. For this
reason, metal must not be located in this area.
The required metal-free area depends on the size
of the smaller dimension of the aperture. Normally
1.5 times the smaller aperture dimension is
sufficient clearance for non-moving metal. If
space allows, a 1.75 multiplier on the smaller
aperture dimension should be used.Applications
which involve relative movement between the
sensing head and adjacent metal should use a 2.0
multiplier.(For example,stationary metalshould not
belocated closerthan 6 to7 inches (150to 175mm)
from either the entrance or exit opening of a metal
detector with a 4 x 8 inch aperture. Moving metal
should not be closer than 8 inches (200mm) from
theentrance orexit of sucha detector.)Pleaserefer
to Figure 8 for details.
ELECTRICAL CURRENT LOOPS
By far the most frequent trouble experienced with
metal detector installations is false tripping
caused by electrical current loops. As was
explained in the previous section, some
electromagnetic field extends from the metal
detector aperture. The field dissipates in strength
with distance, to a point that metal contained
outside the metal-free area defined above will not
cause false detections. However, since the field
is time-varying, small electrical currents are set
up in conveyor conduction paths (i.e. metalwork)
quite some distance from the aperture. These
currents and others (e.g. ground currents from
other nearby equipment) are not harmful as long
as they are constant, but if they change, the metal
detector will false trip. Figure 9 shows a simplified
aerial view of a typical metal detector and
conveyor. The arrows located within the conveyor
framework, head pulley, tail pulley and return
idlers represent electrical currents. The bearings
supporting the pulleys and idlers represent
potential switches. As they turn, the bearings
make and break contact with their respective
races through the lubricant within. Likewise the
cross-members of the conveyor framework
represent potential switches if they are attached
to the conveyor with bolts or rivets. Through time,
connections such as these work loose or corrode
and make and break electrical connections as a
result of normal conveyor vibrations. Potential
switches of both these types must be eliminated.
INSULATING THE CONVEYOR
SHAFTS
In the case of pulleys and idlers there is no way
to make the electrical path constant enough to
prevent changes in the currents. These currents
must be eliminated by introducing an insulating
medium within the conduction path. Figure 10
shows two common methods.
The method shown in Figure 10-A is
accomplished by machining the end of the shaft
which rides in the bearing to a small diameter
and inserting an Ultra-High Molecular Weight
(UHMW) plastic sleeve over it. The outside
diameter of the sleeve is the same as the inside
diameter of the bearing. This sleeve breaks the
electrical connection between the bearing and the
shaft, thus permanently preventing current flow.
WARNING: Do not cut through the sleeve when
tightening the bearing set screw.
Figure 10-B shows a method of insulating the
complete bearing block from the conveyor frame.
This requires drilling the bolt holes through the
bearing block to a larger diameter to accept an
insulating shoulder washer. The shoulder washer
wall thickness should be at least 1/32" (1 mm).
Alternatively the shoulder washer can be
replaced with a plastic washer and a length of
plastic pipe or hose. Insulating the bolt with
tape is not recommended. The bearing block
is insulated from the conveyor frame with a
UHMW insulator extending entirely across the
base of the block as shown.
Mechanical Installation (cont.)

®
18
Both insulating methods are reliable. However, it
takes only a small metal shaving or burr to cut
through and short-circuit the insulators. For this
reason the insulation should be tested with an
ohmmeter after the pulley or idler is installed on
the conveyor frame. Obviously insulating either
end of the shaft will prevent current loops.
However, leaving one end uninsulated will prevent
testing with an ohmmeter. For this reason
insulating both ends is recommended.
Sometimes when the humidity is low, static
electricity will form on the conveyor belt.Acharge
can build up on pulleys or idlers which are
insulated on both ends. This should be prevented
because static discharge may cause the metal
detector to false trip. After the integrity of the
insulators is checked with an ohmmeter, one end
of each shaft should be electrically reconnected
to the conveyor frame. In the case of the sleeve
insulating method the set screw of one of the
bearings should be used. This may require drilling
a small hole down through the sleeve and
inserting a sharp pointed set screw. In the case
of the bearing block insulating technique simply
remove one of the shoulder washers on one end
of the shaft. Note that in both methods if at any
future time the integrity of the insulators is in doubt
they can be checked again easily.
NOTE: If the conveyor belt drive pulley is driven
with a metal chain, do not defeat the insulators
on either end of the shaft. The metal drive chain
will bleed off any static charge which may accu-
mulate on the pulley.
PERMANENT LOOPS
Permanent conduction paths (such as cross
members)associated withthe conveyorframe must
be welded securely. In this way currents flowing in
the loops will remain constant. Bolted construction
is not permissible.Any conduction path which is to
remain removable or is simply not weldable must
be insulated from the conveyor frame.
Figure 11 shows the modified conveyor frame.
Note the potential switches no longer exist and
the only currents in the conveyor frame are
running through welded, permanent connections.
They will be consistent and therefore will not
cause false detections.
IMPORTANT:
It is risky to accept an installation with bolted
conveyor construction, even though tests may
show that no metal detector false trips occur when
bolted structural members are deliberately
shaken or twisted. No matter how good the bolted
connections are initially, there is a high likelihood
that such connections will eventually degrade or
loosen, creating an unstable electrical pathway
that interferes with metal detector operation and
that may be extremely difficult to locate. Use only
welded or insulated construction techniques.
MOUNTING BASE
The base to which the metal detector sensing
head is mounted must be strong, rigid, and as
free as possible from vibration.Although the metal
detector can be set up to be relatively insensitive
to vibration, better sensitivity to metal can often
be obtained by preventing vibration from reaching
the detector head.
Four insulating mounting feet are supplied with
the metal detector. They must be used (refer to
Figure 12). All four must sit flat on the mounting
base. Never draw the feet down to the stand by
tightening the mounting bolts.This will put uneven
stresses on the sensing head and possibly cause
instability. If for any reason the feet do not all sit
flat on the mounting base, shim with appropriate
washers until all four mounting feet are carrying
the same load.
Nothing except the insulating feet and electrical
connections may contact the sensing head.
Conduit attached to the metal detector shell
should utilize plastic fittings (refer to Electrical
Installation).
Mechanical Installation (cont.)

®
19
BELT SPLICES
The metal detector sensing head cannot be
disassembled to be fitted around the conveyor
belt. For this reason the conveyor must be
designed to return the belt through the aperture,
or the belt must be cut and spliced back together.
Splicing the belt with lacing or clamps is not
recommended because foreign materials tend to
collect at the joint, and these eventually cause
false detections.
Vulcanized splices are recommended for best
reliability. Refer to Figure 13 for typical splice
types. If the belt is single-ply, the Finger Splice
configuration should be used. If the belt is multi-
ply, a combination of Step/Finger Splice
configuration is recommended.
Cold bonding is a popular on-site practice. In this
case the splice is usually a Beveled or Step-Lap
type. Adhesives are available which are food or
non-food grade. In either case the splices should
be diagonal rather than straight across the belt.
The cold bond splice is adequate for many
applications as long as the splice is diagonal but
the Vulcanized Finger splice is preferred.
NOTE: During all splicing it is absolutely neces-
sary to ensure that no foreign material (especially
metal) is trapped within the splice. If this happens,
the metal detector will trip every time the splice
passes through the aperture. Since the metal is
trapped inside the splice it cannot normally be lo-
cated and removed without ruining the belt.
CONVEYOR SLIDER BED
The conveyor belt must be supported as it travels
through the metal detector. This task is performed
by a slider bed, which must be capable of holding
thebeltoffthe apertureliner evenwhen fullyloaded.
The slider bed must not contact the metal detector
aperture liner. It should be supported by the
conveyor frame. The slider bed should be made of
static-resistant non-metallic material. Wood and
phenolicaregood choices. Plastic should normally
not be used because it tends to generate static
electricity as the conveyor belt slides across it.
PRODUCT POSITION
The product should always be guided through the
center of the aperture, both vertically and
horizontally. This is true whether the product
travels through the metal detector on a conveyor
or flows through a pipe as in a vertical application.
If multiple size products will be inspected by the
same metal detector, design the system to center
the largest product in the aperture.
REJECT PROXIMITY SWITCH
The proximity switch is used to indicate when a
package aligns with a reject device. For example,
a product in a box may need to align with a reject
device, such as a pusher arm, to be rejected
reliably. The proximity switch indicates when the
alignment is achieved. Normally the proximity
switch is positioned just after the reject device
so that it is triggered as the product aligns with
the reject device. If it is difficult to install a switch
in that location, it can be installed upstream from
the reject device. In this case the proximity switch
must contain a delay timer capable of delaying
the output until the product aligns with the reject
device. Be certain not to infringe on metal detector
metal free areas when choosing the location of
the proximity switch.
Mechanical Installation (cont.)

®
20
INTRODUCTION
All electrical connections are intended to be made
within the NEMA-4X power supply enclosure.
Figure 14 shows the enclosure and the electrical
connections to the power supply circuit board.
There are no user serviceable electronics or
electrical connections within the control
enclosure. Never attempt to remove the detector
control from the control enclosure.
CHOICE OF INPUT POWER SOURCE
The metal detector is equipped with filtering
devices to help eliminate incoming electrical
noise. Noise is usually created by inductive loads
sharing the same power circuit. Even with the
filters there is a limit to what the metal detector
can withstand without false tripping.
The best insurance against electrical noise is to
run a separate circuit from the main power bus.
This circuit should be free of all loads except the
metal detector. The power line should be run in its
ownmetal conduit.The conduit must be electrically
insulated from the conveyor. This includes any
supporting structure for the metal detector. If this is
impossible or impractical, reliable operation can
often be obtained by powering the metal detector
from a “clean” lighting circuit. This circuit must be
free of inductive loads such as motors, solenoids,
motor starters, variable frequency drives, etc.
If the metal detector must be powered by a less
favorablesource, falsetripping causedby linenoise
can usually be eliminated through the use of a
harmonicneutralized constant voltage transformer.
POWER SUPPLY
Refer to Figure 14 for wiring to the power supply.
The metal detector may be powered at either of
two voltage ranges described in the specifications
section of this manual. Be certain the input power
voltage selection switch is in the proper position to
accept the power supply. The voltage selection
switch is shown in Figure 14 and is labeled SW2
on the circuit board.
Electrical Installation
CAUTION:
Be careful to distinguish between the input
voltage selection switch and the power (off/on)
switch. Both are located in the lower left corner
of the power supply circuit board. THE VOLTAGE
SELECTION SWITCH IS RED,AND IS LABELED
WITH THE AVAILABLE VOLTAGES, 115V AND
230V. THE POWER SUPPLY SWITCH IS BLACK,
AND IS LABELED WITH 0AND 1, TO INDICATE
OFFAND ON, RESPECTIVELY. INADVERTENT
USE OF THE IMPROPER SWITCH COULD
LEAD TO CIRCUIT DAMAGE AND/OR
PERSONAL INJURY. See Figure 14 for the
location of these two switches.
The power source attaches to terminals L1 and
L2. If operating in the 115 VAC range, L1 is the
active or high side of the line and L2 is the neutral.
If operating in the 230 VAC range, connect either
supply line to L1 and the other to L2.
Note that L1 and L2 are connected through circuit
board traces to other terminals on the circuit
board as labeled. They are intended to be
conveniently available to the user to power
various ancillary equipment. They are not fused
on the circuit board. It is the user’s obligation to
be certain L1 and L2 lines are adequately fused
external to the metal detector, preferably at the
power source.
The power source must contain a reliable ground.
It must be connected to the “GND” terminal.
NOTE:The metal detectormaybe grounded at only
one point, through the power supply ground wire.
No other ground connections are permitted. This
includes mounting hardware and conduit.
The metal detector electronics are protected by
1A fuses (GMC-1A). The fuses are located
between the POWER SUPPLY L1 and L2
terminals and the metal detector electronics. Note
there are no fuses between the POWER SUPPLY
L1 and L2 terminals and the other L1 and L2
terminals on the circuit board.