Eriez Xtreme User manual

Reference
Guide
ERIEZ MAGNETICS HEADQUARTERS: 2200 ASBURY ROAD, ERIE, PA 16506–1402 U.S.A.
WORLDAUTHORITYIN SEPARATIONTECHNOLOGIES
2017831A
(sw pkg 3.0.x)

Use this product only in the manner described in this manual. If the
equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
CAUTION
The metal detector is heavy. Do not lift nor support the metal detector
by hand/manually.
To avoid damage or injury, use only the handling and installation
procedures outlined in this reference guide.
CAUTION
Hazardous voltages are present in this equipment when energized. All
power sources must be isolated or disconnected before accessing the
inside of the enclosure.
Failure to follow these precautions may result in serious injury or
death.
WARNING - HAZARDOUS VOLTAGE
If you have a pacemaker or other implanted medical device, please
consult your doctor before using this product. Electromagnetic waves
can interfere with the operation of your pacemaker or other medical
devices.
CAUTION
Metal detectors emit electromagnetic fields, which may interfere with
some pacemakers or other implanted medical devices. The end user
bears the responsibility to determine if the emitted electromagnetic
fields will affect employees with medical devices. If you have an
implanted medical device, please consult your doctor before being in
the vicinity of the metal detector during operation.
CAUTION
1

To avoid injury or damage to the equipment, only qualified service
technicians are to install the metal detector at customer sites in
accordance with local safety codes.
CAUTION
To avoid injury or damage to the equipment, all electrical installations
are to be performed by qualified and competent personnel authorized
by Eriez Manufacturing Company. All electrical installations are to be in
compliance with local safety codes. Ensure that all materials used in
the installation of the equipment are suitable and appropriate for
purpose.
CAUTION
For continued compliance with electrical safety standards, the
protective earth connection from the power source must be connected
directly to the protective terminal on the wall of the enclosure. This is
required to be the FIRST connection to the terminal, and secured with
a star lock washer and nut, independent of any other connections to
the terminal.
CAUTION
An external disconnect switch labeled “Metal Detector” must be
installed near the metal detector to allow the metal detector to be
completely disconnected from the power source during installation and
maintenance. All lock-out tag-out procedures and local safety codes
are to be followed during metal detector installation and maintenance.
The metal detector must not be positioned in a way that makes it
difficult to operate the disconnect switch.
CAUTION
2

Cleaning procedures may cause false trips of the metal detector,
resulting in actuation of any connected reject devices. Ensure
personnel and equipment are clear from the path of the reject devices
at all times. To avoid an unsafe condition or damage to equipment,
remove all power sources (including air supplies) from the metal
detector and reject devices prior to wash down.
CAUTION
To avoid injury or damage to the equipment, all electrical maintenance
on the metal detector is to be performed by qualified and competent
service technicians authorized by Eriez Manufacturing Company.
CAUTION
The XTREME metal detector is not designed nor intended for operation
in environments classified as hazardous locations/zones. Do not
operate the XTREME metal detector in areas where the possibility of
explosions or fires exists.
CAUTION
For installations where the metal detector control screen presents
ergonomic challenges or unsafe viewing conditions, it is recommended
that a remote display be used to eliminate these issues.
CAUTION
The metal detector will start automatically when power is restored after
a power interruption. All external components controlled by relays
within the metal detector control will also complete their cycle when the
metal detector is re-energized. The end user must determine if a
hazard exists and install the proper safety precautions and protocol to
ensure that an injury does not occur in the event of a power
interruption.
CAUTION
3

When cleaning the metal detector surfaces, use appropriate personal
protective equipment (PPE) for any physical/chemical/biological
hazards that may exist due to the end user’s production environment.
Avoid contact with contaminants on or around the metal detector.
Pressure Wash and sanitize metal detector surfaces when
maintenance is required.
CAUTION
EXPLANATION OF SYMBOLS
Cautionary information
Protective Conductor Terminal
Hazardous Voltage – Risk of Electric Shock
Pacemaker warning information
Pinch Point
4

Pg.7
Pg.9
Pg.13
Pg.23
Pg.33
Pg.83
Pg.97
Handling
Basic lifting and moving instructions
Specifications
Basic product specifications and safety information
Mechanical
Mechanical installation instructions
Electrical
Electrical Installation Instructions
User Interface
Every screen explained and easy to use how-to guides.
PLC Interface
PLC interface setup instructions
Maintenance
Maintenance and cleaning
Vertical Metal Detector
with Valve Addendum
Handling, installation and maintenance Pg.99
5

6

RF INTERFERENCE
Radio Frequency (RF) emissions have been tested to the requirements of FCC 47CFR
Part 18, and CISPR 11/EN 55011 (Class A, Group 2).
The Eriez Xtreme Metal Detector generates an electromagnetic field which has the
potential to escape. This field may interfere with nearby radio frequency equipment.
If interference becomes a problem you may need to:
1. Move the Metal Detector or interfering equipment
2. Change the frequency on the Metal Detector
3. Call the Factory for further assistance
HANDLING INSTRUCTIONS
DO NOT LIFT THE METAL DETECTOR BY INSERTING ANYTHING INTO OR
THROUGH THE TUNNEL. The inner surface of the tunnel protects the precisely
tuned electronic circuit and internal parts. The tunnel liner also protects the internal
parts against water damage. The integrity of this liner and seal must be maintained.
Any damage or distortion to this surface caused by handling will invalidate the
warranty.
When handling, keep the metal detector on the shipping pallet as long as possible.
When removing the detector from the shipping pallet LIFT ONLY ON THE DETECTOR
HOUSING SURFACES OR SUPPORTING FEET. DO NOT LIFT BY THE CONTROL
HOUSING THAT PROTRUDES FROM THE BODY OF THE METAL DETECTOR.
If possible lift the metal detector by using a crane and soft nylon slings running under
the entire metal detector housing as seen below. See Vertical Metal Detector with
Valve Addendum p99 at the end of this reference guide for information concerning
vertical metal detectors.
7

Larger metal detectors may have eyebolts preinstalled at the factory. When handling
with the eyebolts ensure loads are never applied perpendicular to the shank of the
eyebolts; they will break.
The metal detector is heavy. Do not lift nor support the metal detector
by hand.
To avoid damage or injury, use only the handling and installation
procedures outlined in this reference guide.
CAUTION
Never weld any attachment to the metal detector. Do not attempt to drill and/or tap the
metal detector for lifting or mounting attachments.
8

SPECIFICATIONS
EQUIPMENT DESCRIPTION
The Eriez Xtreme Metal Detector is a balanced coil metal detector used to detect metal
contaminants/foreign objects in material(s) passed through the aperture.
SUPPLY, MAINS, VOLTAGE
The Xtreme Metal Detector will operate from AC supply voltages over the range of 100 to 240
VAC RMS, 50 or 60 Hz.
Mains supply voltage fluctuations shall not exceed ±10% of the nominal value.
EQUIPMENT CLASSIFICATION
The Xtreme Metal Detector is specified for the following categories:
- Class 1 equipment requiring a protective ground conductor.
- Installation Category (Overvoltage Classification) II
- Pollution Degree 2
MAXIMUM DEMAND
The internal electronics require 60 VA to operate. The power available for external loads
(powered from the internal source) is 1250 VA and is limited to 5 amps of current by CB1.
Maximum demand will be 1310 VA.
OUTPUTS
There are nine total outputs, each with one set of contacts.
There are four programmable “Form C” (NO-C-NC) relay outputs rated at 5A (due to PCB trace
width) up to 250 VAC, 30 VDC each.
- Reject (K1)
- Relay 1 (K3)
- Relay 2 (K2)
- Relay 3 (K4)
All four relays are fail-safe wired; if power is lost, the relays will switch to the activated position.
NOTE: If the power at L1B and L2B is used to power the relays, its maximum available current
is 5A, and the voltage will be equal to that applied at L1 and L2 on TB3.
SPECS
9

Power at L1B and L2B passes through the circuit breaker switch located on the left side of the
control housing.
There are five programmable “FormA” (SPST-NO) solid state relay outputs rated at 500mAup
to 40 VDC.
- Out 1 (K9)
- Out 2 (K8)
- Out 3 (K7)
These five outputs can be wired as NPN or PNP. The output can be set to NO or NC under
normal running conditions.
REJECT
Reject (K1) is the primary reject device output. It must run via Reject Timer or OverheadA-B
when used. All reject log information is based on Reject Timer.
RELAY 1-3
Relay 1(K3), Relay 2 (K2), and Relay 3 (K4) are fully programmable and may use any of the
four reject timers. They also may use OverheadA-B or be used as a fault or warning output.
See for details regarding I/0 configuration.
OUT 1-5
Out 1 (K9), Out 2 (K8), Out 3 (K7), Out 4 (K6), and Out 5 (K5) are fully programmable and may
use any of the four reject timers. They also may use OverheadA-B or be used as a fault or
warning output.
TIMERS
There are four independent reject timers. Each reject timer has its own travel (delay) time and
reject (duration) time in the range of 0 to 60 seconds or 0 to 1200 tachometer pulses. Each
reject timer runs off of time or tach for both travel and duration time. Only Reject Timer can use
reject confirmation, a reject index device or be configured for manual reset.
FAULT
All outputs except Reject (K1) can be configured as a fault output.
WARNING
All outputs except Reject (K1) can be configured as a warning output.
- Out 4 (K6)
- Out 5 (K5)
SPECS
p47 p48
10

OVERHEAD A-B
OverheadA-B runs via Reject Timer and is used for an overhead pusher arm. It can be setup
to reject on one or both sides of the conveyor. It can also be setup to always return to the same
side of the conveyor when actuated. The functionality of OverheadA-B is based on the
hardware used. Additional information on how to setup Overhead A-B is located in the wiring
section of this manual.
INPUTS
The Xtreme Metal Detector has eight configurable inputs that can be set to “Active High” or
“Active Low”.
Input Voltage
-“High” = 10 to 30 VDC
-“Low” = 0 to 0.9 VDC
Input Impedance = 2.8kΩ
Current Requirement = 3 to 10 mA
TACHOMETER INPUT
Voltage, Current, and Impedance specifications same as above.
Frequency: 50Hz (determined by number of poles on Tachometer and maximum belt speed)
Minimum pulse width = 0.005 seconds (5 mSec)
OPERATING AMBIENT TEMPERATURE RANGE
Integral Control -10°C (14°F) to 49°C (120°F)
Remote Control -10°C (14°F) to 54°C (130°F)
STORAGE TEMPERATURE
-10°C (14°F) to 80°C (175°F)
SPECS
11

MAXIMUM OPERATING ALTITUDE
2000 meters (6561 feet)
PRODUCT VELOCITY
Minimum: 2 ft/min (0.6 m/min)
Maximum: up to 3000 ft/min (914 m/min)
Note: Actual maximums are dependent on aperture size.
For gravity-fed vertical metal detectors, product velocity is determined by free-fall distance. The
maximum free-fall distance is dependent on the system design, especially the distance between
the sensing head and reject valve. The standard vertical system is designed for a max Drop
Height of 19 in (48 cm) above the sensing head.
ENCLOSURE
The standard enclosure is rated NEMA 4X/PW 12 and IP69K which will withstand the high
pressure wash-down standard of 80° C (176° F) water at 100 bar (1450 psi).
RELATIVE HUMIDITY
0 TO 95%
SPECS
12

MECHANICAL INSTALLATION
Xtreme Metal Detectors are manufactured to very stringent quality 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 these procedures
are important, and must be followed precisely for proper metal detector operation.
Metal detectors are extremely sensitive to very small changes in the electrical and physical
environment. Unstable operation is possible if installed incorrectly. Metal detectors are
sensitive to excessive vibration, and may generate a false reject signal when the conveyor
starts and stops. These problems can be prevented with proper installation techniques.
Please read all instructions prior to using the metal detector. Problems caused by improper
installation techniques are not covered under warranty. Time invested in proper installation will
be worthwhile, and will provide trouble free startup and continued reliable service.
INTRODUCTION
The metal detector contains several components which must be physically mounted to a
conveyor or suitable stand. These include the sensing head, the control (if remote), and other
devices such as a tachometer. Most Xtreme Metal Detectors sensing heads have an integral
control, thus simplifying installation and wiring.
Figure 1
MECH
The sensing head contains the coils and main electronics. The head must be installed so that
the products being inspected can pass through the aperture in a consistent and controllable
manner.
To avoid injury or damage to the equipment, only qualified service
technicians are to install the metal detector at customer sites in
accordance with local safety codes.
CAUTION
13

It is vital that the sensing head be protected from excessive vibration, physical abuse,
electromagnetic interference, static electricity, and corrosive materials. The conveyor belt,
chute, or other conveyance device must not contact the metal detector aperture.
Utilizing the control remotely requires that it be mounted to a convenient surface with minimal
vibration. It should also be easily accessible in the event an adjustment is necessary. The
control enclosure is fitted with mounting tabs that must be isolated to prevent electrical current
loops.
HANDLING
The metal detector must be handled with care during installation. Refer to the Handling
Instructions for more information.
LOCATION OF SENSING HEAD
The location of the metal detector sensing head is extremely important. When selecting a
location, consider the surrounding processing equipment, product velocity, and rejection of
foreign objects. Operator convenience should also be evaluated. Ensure installation guidelines
are followed and met before the final location is selected. If there are any questions, please
contact Eriez for assistance.
METAL FREE AREA
The metal detector monitors an electromagnetic field to detect metal. This field is
predominantly contained within the aperture of the detector. However, some of the
electromagnetic field extends out from the inlet and outlet of the aperture. This extended field
causes the metal detector to be affected by metal in the vicinity of the aperture. Metal that is
not part of the product stream must not be present in this area. The required metal free area
depends on the size of the smaller dimension of the aperture. In most circumstances 1.5 times
the smaller aperture dimension is a sufficient distance for stationary metal and 2.0 times for
moving metal. Testing to determine the metal free distance will help ensure mitigation of false
tripping. Refer to Figure 2.
MECH
For installations where the metal detector control screen presents
ergonomic challenges or unsafe viewing conditions, it is recommended
that a remote display be used to eliminate these issues.
CAUTION
14

H = smaller tunnel
dimension (typically height)
Figure 2
ELECTRICAL CURRENT LOOP
The most frequent problem encountered in metal detector installations is false tripping caused
by intermittent electrical current loops. The electromagnetic field dissipates in strength with
distance to a point that metal outside the “metal free” area will not cause false detections.
Since the field is time varying, it will generate small electrical currents in conductive paths
(metalwork) beyond the metal free area. These currents along with ground currents from
nearby equipment will not cause false tripping as long as they are constant. If the current is
disrupted, the resulting disturbance in the electromagnetic field may cause the metal detector to
false trip.
The schematic diagram shown in Figure 3 provides a simplified view of a typical metal detector
and conveyor. The arrows represent electrical currents. The bearings supporting the pulleys
and idlers turn, causing them to become “make and break” contact points.
MECH
15

Likewise, the cross-members of the conveyor framework represent possible break points. Over
time, these connections can work loose or corrode and cause “make and break” connections
due to vibration. The interruption or change of the current is a source of electromagnetic
interference detectable by the metal detector.
Figure 3
Potential Sources for
“Make and Break”
connections
Metal
Detector
Head
Pulley
Tail
Pulley
Electromagnetic
Field
Bearings
Return
Idler
Welded Frame Cross
Member
Induced/Ground Current
Paths
INSULATING CONVEYOR SHAFTS
A continuous electrical path through pulleys and idlers cannot be assured. As a result, current
changes cannot be prevented in these components. They must be electrically isolated from the
rest of the system by introducing an isolating medium into the conductive path. There are three
common methods to accomplish this task.
MECH
16

The method shown in Figure 4 requires machining the end of the shaft to a smaller diameter to
allow space for a nylon plastic sleeve. 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 4
Pulley or Idler
Nylon Insulator
Figure 5 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 diameter large enough to
accept an insulating shoulder washer. The bearing block should also be insulated from the
conveyor frame with non-metallic insulators extending across the base of the block.
Figure 5
Insulating Shoulder Washer (Nylon) Insulating Shoulder Washer
Insulator Material
(Neoprene or Fiberglass)
Figure 6 shows the method recommended by Eriez; this is also the simplest method. It requires
the bearing block on the end opposite the motor to be replaced with a plastic/non-metallic one.
MECH
17

Figure 6 Non-metallic/Plastic Bearing Block
All three insulating methods are reliable. However, it only takes a small metal shaving or burr to
cut through and short-circuit the insulators. Acheck of the integrity of the insulation with an
ohmmeter will ensure everything is correctly installed. Insulating either end of the shaft will
prevent current loops but will also prevent testing with an ohmmeter. For this reason, isolating
both ends during testing is recommended.
Build-up of a static electric charge on the conveyor belt can also cause false tripping. Astatic
charge can build up on pulleys or idlers that are insulated on both ends. To prevent this build-
up and subsequent false tripping, the insulation must be modified to ensure a ground. After the
integrity of the insulators is checked with an ohmmeter, one end of each shaft should be
electrically reconnected to the conveyor frame. If the sleeve insulating method has been used,
the setscrew of one of the bearings should be extended to make contact with the shaft. This
may require drilling a small hole through the sleeve and inserting a sharp pointed setscrew. If
the bearing block insulating technique has been used, simply remove one of the shoulder
washers on one end of the shaft. If using the plastic bearing block method, the opposite
bearing block is metallic and grounded already. The integrity of the insulators can easily be
rechecked when using any of the three methods.
NOTE:
If a drive pulley is powered by a metal chain, it is not necessary to remove the insulators on
either end of the shaft as described above. The metal drive chain will bleed off any static
charge that may accumulate on the pulley. If a non-metallic belt drive is used, insulate the
conveyor pulley on the side opposite the drive motor.
MECH
18