logika HMD-SM User manual

Scanning Hot Metal Detector
HMD-SM Operator’s Manual
Revision 2.1

Logika Technologies Inc. Model HMD-SM Operator’s Manual Rev 2. Dec-
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Contents
1. Introduction........................................................................................................................... 2
2. Description........................................................................................................................... 2
2.1 Model Nomenclature ...................................................................................................... 2
2.2 Specifications.................................................................................................................. 3
2.3 Operating Principle ......................................................................................................... 3
2.4 Automatic Threshold Level Adjustment......................................................................... 5
2.5 Other Features................................................................................................................. 5
3. Location and Mounting......................................................................................................... 6
3.1 Sensor Location .............................................................................................................. 6
3.2 Sensor Mounting............................................................................................................. 7
4. Utility Connections .............................................................................................................. 7
4.1 Electrical Connections .................................................................................................... 7
4.2 Cooling Water Connection ............................................................................................. 9
4.3 Purge Air Connection ................................................................................................... 10
5. Operation............................................................................................................................ 10
5.1 Control Panel ................................................................................................................ 10
5.2 Automatic Threshold Level Description....................................................................... 11
5.3 Remote Threshold Sensitivity....................................................................................... 12
5.4 Test Function ................................................................................................................ 13
5.5 Troubleshooting ............................................................................................................ 13
6. Maintenance....................................................................................................................... 14
6.1 Regular Maintenance .................................................................................................... 14
6.2 Returns of the HMD-SM .............................................................................................. 15
7. Accessories- Hot Metal Simulation Test Bar..................................................................... 15
8. HMD-SM Enclosure Dimensions ...................................................................................... 17

Logika Technologies Inc. Model HMD-SM Operator’s Manual Rev 2. Dec-
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1. Introduction
The Logika Technologies scanning mode hot metal detector, Model HMD-SM, is
designed for the automation of steel, aluminum and other metal mill production lines. It
includes a rugged enclosure, protecting state-of-the-art electronics and will withstand
the harsh ambient conditions present in heavy industrial environments. The HMD-SM is
used to detect hot metal in a range of temperatures, shapes and sizes of wire, bar, strip,
thin plate, thick plate, billet, and slab production facilities.
The scanning mode feature allows the HMD to detect hot metal across the entire width
of a production line. It also enables the HMD to be installed remotely from the hot
metal target, further protecting the electronics and extending the life of the sensor.
2. Description
2.1 Model Nomenclature
HMD - SM - _Scan angle - Power Input__ - R
Base Model Scan angle Power Input R(Relay)
HMD-SM
0: 0 Degree 0: 0 VAC Normal Open
Normal Close
30: 30 Degree 220: 220 VAC
50: 50 Degree 24: 24 VDC
able 1

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2.2 Specifications
Operating temp
No water cooling:
0˚C to +50˚C (32˚F to 20
˚F)
With water cooling: 0˚C to 20˚C (32˚F to 250˚F)
Detect Range
0.2
-
8m
LED Indicators
Green = power on, Red = target detect, Orange= Detector signal
saturation or dirty lens, Off=Alarm
Output
Relay
NO/NC 250VAC
@
A,
or 24VDC
@
A
,
closing: 7.5ms, opening: 3ms
DC 24V PNP,NPN Transistor output: max 00mA
Diagnostic outputs: control, alarm, signal amplitude
Power Input
24 VDC, 0VAC, 220VAC @ 30VA
Cable
6 wires multi
-
conductor TEFLON cable with
9 x 20Ga
and
7 x 24Ga
Insulation 20MΩ, 500VDC, ≥500˚C (930˚F)
Housing
Hermetically sealed cast aluminum enclosure rated IP66, includes cooling
water connections and air purge.
Size
Enclosure;
3 5
mm L x
0
mm
W
x
2
64
mm H (with mounting bracket)
( 2.4”L x 4.3”W x 0.4”H)
Weight
7
kg
or 5 lb
Min arget emp
250
o
C (480
o
F)
S
canning Angle
0˚, 30˚, 50˚
Water Cooling 25
˚ C, 4 bars pressure (60 psi), -2L/min (0.26 to 0.52 USG),
¼” flexible tube
Air Purging 50 to 200 g/cm
2
(0.7 to 2.8 psi), 4- 6L/min (0. 4 to 0.56 cfm)
¼” compression fitting
able 2
2.3 Operating Principle
Detector- The HMD-SM uses a Lead Sulfide (PbS) photocell, which is characterized by a very
strong signal output for the range of infrared energy emitted by steel, compared with other
detector materials. The high signal-to-noise ratio from this detector virtually eliminates
detection errors. Figure 2. shows the various types of photocell spectrums and the
infrared emission spectrum of steel in 250 ˚ C and 000 ˚ C.

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100%
00.25 0.50 0.75 1 1.25 1.50 1.75 2 2.25 2.50 2.75 3 3.25 3.50 3.75
Si Ge PbS
Steel 1000℃
Steel 250℃
Wave length
(μm)
A
Figure 2.1 Spectrum of steel emission and different photocells
Scanning System- The HMD-SM uses a scanning optical bench that enables hot metal
detection across a broad angle of detection. The optical field is scanned using a rotating
drum of multiple mirror facets that reflect the energy from the hot metal target in the
scanning field to the PbS photocell, see Figure 2.2 for details. The infrared energy is
converted to an electronic signal by the PbS photocell, which is then processed by the
electronic circuit and changed to a logic signal for analysis and control purposes.
Figure 2.2: HMD-SM Scanning System
Vertical Scanning field- The HMD-SM is manufactured with one of three vertical field angles
0, 30 and 50 degrees, selected at the time of purchase. This enables the sensor to cover
the entire process area but not scan beyond the process line where interfering sources of
infrared energy may be present.

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Figure 2.3
For example, if
a hot metal target
with a HMD-SM-
30 detector selected
Horizontal Scanning field- A
manual
horizontal measurement angle
Distance”). For example, if
a shutter width angle
distance, the scanning width
is 8mm. A positive output signal will resul
hot metal is within the 8 mm scanning field.
distance
in section 3. for more details.
2.4 Automatic
hreshold Level Adjustment
The HMD-SM includes a
n Automatic
signal when hot metal is detected to prevent detector signal saturation. The user adjusts the
base gain level via a potentiometer mounted on the
and 5.3 for addit
ional details on
signal level upon exit of the hot metal from the scanning detection field. This feature makes
the sensor more stable and significantly reduces detection errors caused by targe
spots or
varying surface temperature as well as
scale.
2.5 Other Features
Fast response time to
the hot metal target in and out of the
Model HMD-SM Operator’s Manual
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[email protected]m
Figure 2.3
HMS - SM Vertical Scanning Field
a hot metal target
is
located 4 meters ( 3’) from the front of the
30 detector selected
, the vertical scanning field is
2. 0 meters
manual
adjustable shutter on the shroud
is used
horizontal measurement angle
change
from to 3 degrees (see Section 3. “Mounting
a shutter width angle
is set at degree
with a 4 meter
is 8mm. A positive output signal will resul
t if any portion of the
hot metal is within the 8 mm scanning field.
For different targets
, see the
in section 3. for more details.
hreshold Level Adjustment
n Automatic
Threshold Level Adjustment to decrease the detector
signal when hot metal is detected to prevent detector signal saturation. The user adjusts the
base gain level via a potentiometer mounted on the
sensor’s control panel (S
ional details on
the
use of this feature). The detector will return to the base
signal level upon exit of the hot metal from the scanning detection field. This feature makes
the sensor more stable and significantly reduces detection errors caused by targe
varying surface temperature as well as
interference from water vapor and oxide
the hot metal target in and out of the
scanning field
Rev 2. Dec-
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located 4 meters ( 3’) from the front of the
HMD
2. 0 meters
or 84 inches.
is used
for the
from to 3 degrees (see Section 3. “Mounting
with a 4 meter
( 3 feet)
t if any portion of the
, see the
mounting
Threshold Level Adjustment to decrease the detector
signal when hot metal is detected to prevent detector signal saturation. The user adjusts the
sensor’s control panel (S
ee Sections 5.2
use of this feature). The detector will return to the base
signal level upon exit of the hot metal from the scanning detection field. This feature makes
the sensor more stable and significantly reduces detection errors caused by targe
t black
interference from water vapor and oxide
scanning field

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Detects low temperature and low emissivity targets in harsh environments; even with
infrared reflection or roller heat radiation interference.
Pulse signal treatment circuit design lessens detector power consumption and temperature
drift.
3. Location and Mounting
3.1 Sensor Location
The ideal location should allow the HMD scanning field to cover the entire process line,
protect it from absorbing excessive heat, and be close enough for the detector to get
sufficient infrared energy from the target.
Mounting Distance- Check the HMD mounting distance listed on table 3 for different
targets. Find the size of the target, select an approximate mounting distance. Use Figure 2.3
for calculating the scanning field and select the ideal scanning angle ( 0
o
, 30
o
, or 50
o
) to
make sure the sensor’s scanning field covers the entire process area. The vertical scanning
field should be oriented across the width of the process line for best coverage.
arget
HMD
Distance
arget
HMD
Distance
Wire rod, 5 - 2 mm 0.2 - 3.0 m Steel Strip 0.6 - 2m
Bar, 0x 0-40x40 mm 0.2 - 4.0 m Thin Plate .0 - 6.0m
Square Billet 0.5 - 6.0 m Thick Plate .0 - 8.0m
Large Billet(Bloom) >2.0 m Slab >2.0m
able 3
Interference- Reduce or eliminate background infrared radiation sources, such as other hot
processes behind the target and reflected sunlight:
. Select the appropriate scanning angle when originally placing order to avoid “over-
scanning”.
2. Gradually reduce the sensitivity adjustment on the HMD-SM’s control panel until the
background interference is not detected (when no target metal is within the scanning field).
See the “Operation” chapter in this manual for additional details.
3. In occasional severe environments, install a heat proof enclosure around the HMD to
protect it from overheating and use ventilation to drive away particulate and vapor.
Other considerations for installation
. Locate the HMD to reduce interfering infrared sources and choose a detection field that
minimizes the presence of dirt, smoke and water vapor or other infrared absorbing
chemicals.
2. Only part of the target needs to be in the sensor’s scanning field to trigger a hot metal
output signal.

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3.2 Sensor Mounting
Mounting Foot- The HMD-SM has an adjustable mounting foot designed to allow easy
rotation through horizontal and vertical axes. The HMD is secured to the mounting foot with
one 8mm bolt and can be installed onto a support bracket. The support must be
sufficiently rigid to absorb any excessive site vibrations that can affect the output of the
detector.
Purge Air, Cooling Water- The HMD-SM has a water-cooling jacket to cool down sensor
temperature and an air-purged shroud for protection of lens; allowing the sensor to be used
in harsh environments with high temperatures, steam, dust and smoke. Please see Section
4.2 Plumbing Connection and Section 4.3 Air-Purge Connection for further details on
installation.
High Heat Option- If the ambient temperature is more than 250
o
C (480
o
F), we recommend
HMD-FOC, Fiber Optical Hot Metal detector. The lens is separate from the detector and
connected by fiber optical cable which can bear high temperatures.
Caution- For installation environments that contains excessive water vapor or smoke,
additional ventilation such as air curtains or fans should be used to clear the area so the
sensor can “see” the hot metal target.
4. Utility Connections
4.1 Electrical Connections
Electrical Overview- All electrical connections (power and signal) to the HMD-SM are made
via a 5 pin male Harting connector, a supplied 2-meter long cable with quick fitting on one
end and terminal pins on the other end for junction box connections. Other cable lengths
are available from Logika Technologies Inc. upon request.
Cable Specification-
•6 conductors cable, color coded, with 9 conductors 20 AWG unshielded (9 x 0.6 mm²), 7
conductors 24 AWG shielded (7 x O.34 mm²)
•Teflon insulation for high temperature applications.
•Outer metallic braided for mechanical protection.
•Overall diameter of 9 mm.
•Minimum bending radius of 30 mm.
Junction Box Wiring- Please see Figure 4. for the sensor wiring diagram. The supplied
cable should be connected directly to the terminals of a junction box. The shield should be
connected to ground to eliminate electrical noise which may trigger false detection signals.
Any unused output wires must have insulation protection or be connected to free terminals
in the junction box.

Power Connections- Power Input (please specify power input at time of order).
See the Figure 4. for detail wirings for different power supply input

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Static ransistor Output-
•PNP: Terminal 4B White, 24VDC on detect, maximum current 00 mA
•NPN: Terminal 4A Black, 0VDC on detect, maximum current 00mA
•Output Response time:
oHMD-SM- 0: ms
oHMD-SM-30: 2ms
oHMD-SM-50: 4ms
Relay Output- Single pole double throw contacts, contact capacity rating 250VAC/ A or
24VDC/ A, relay closes time 7.5ms, relay releases time 3ms.
•Terminal 5C White/Orange: NC, Open = detect
•Terminal 5B White/Blue: NO, Closed = detect
•Terminal 5A White/Purple: COM
Sensor Diagnostics Outputs- Relay and voltage signals to indicate sensor conditions. All the
outputs voltages are referred to 0VDC (Figure 4. , Terminal 3B).
. Control Output (Figure 4. , Terminal 2A Green):
Normal Output: 24VDC
Diagnostic Alarm Output: 0VDC, indicated if one or more occurs:
•Dust or vapor interference on glass
•Target temperature drop
•Signal saturation
2. Alarm Output (Figure 4. , Terminal 4C):
Normal Output: 24VDC
Alarm output: 0VDC indicated if one or more occurs:
•Power input loss
•Scanning motor runs abnormally
•The temperature inside the enclosure is higher than 55
o
C ( 30
o
F)
3. Signal Amplitude Output (Figure 4. , Terminal 3C): 0- 3.5 VDC analog output, proportional
to the photocell output signal. This signal may indicate that the sensor’s protective lens
glass needs to be cleaned or the sensor’s sensitivity needs to be increased. Signal amplitude
output is influenced by:
•Sensor installation environment and location
•Target size
•Target temperature
•Distance between the sensor and the target
•Vapor in the field
•Dust on the Lens
•Sensitivity Adjustment Setting

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After the installation and setup are done, the sensor runs normally. Measure the signal
amplitude output voltage for later maintenance reference.
White/Black
White/Brown
White/Red
White/Yellow
White/Green
Green
Orange
Blue
Brown
Red
White
Black
White/Orange
White/Blue
White/Purple
Yellow/Green
Test
Sensitivity Select
Control
Signal mplitude
0VDC
Remote Sensitivity
larm
PNP
Normal Close
Normal Open
Common
Ground
NPN
220VAC
220VAC220VAC
220VAC
110VAC
110VAC110VAC
110VAC 24VDC
24VDC24VDC
24VDC
+
++
+
-
--
-
Shielding
Figure 4.1: HMD-SM Wiring Diagram
4.2 Cooling Water Connection
Description- When the ambient temperature is higher than 50
o
C ( 20
o
F), cooling water
system is required to protect the electronics inside the enclosure. Two Φ0mm OD barbed
fittings are available beside the electrical connector for cooling water to circulate inside the
enclosure, the direction is not necessary.
Cooling Water Requirements
•Clean industrial water
•Maximum water inlet temperature 25
o
C (77
o
F).
•Maximum water pressure 4 bars (60 PSI)
•Water flow rate of to 2 L/min (0.035 to 0.7 ft
3
/min)
Connection- Use Φ10mm ID or 3/8” ID hose for connections
One fitting is connected to plant’s water supply
The other one is connected to drain
Both fittings should be secured with hose clamps
Setup the cooling water flow rate by Figure 4.2