Pulsotronic Mesep va digital 50 User manual

METAL SEPARATOR

MESEP® VAdigital 50/ 70

Manual

Project Name

Order / Project No.

Metal separator type MESEP VA digital70

The final outlookofthe units depends onthe different

features we offer.

1Contents

1CONTENTS..................................................................................................................................2

2GENERAL....................................................................................................................................3

2.1 INSTRUCTIONS FOR USE OFTHIS MANUAL..............................................................................3

2.2 GENERAL SAFETY INSTRUCTIONS...........................................................................................4

2.2.1 Explanation of the Symbols Used......................................................................................4

2.2.1 BASIC SAFETY MEASURES......................................................................................................5

3APPLICATION AND QUALIFICATION................................................................................6

3.1 USE FOR INTENDED PURPOSE..................................................................................................6

3.2 EXAMPLES OF APPLICATION ...................................................................................................7

3.3 OPERATING PRINCIPLE............................................................................................................7

3.3 MISUSE...................................................................................................................................7

3.4 OWNERS DUTY OF CARE.........................................................................................................8

3.5 FUNCTION .....................................................................................................................................8

3.5.1 Keypad...................................................................................................................................8

3.5.2 Key Functions......................................................................................................................10

3.5.3 Selection of Operation Variants..........................................................................................11

3.6 SENSITIVITY TABLE.....................................................................................................................12

3.7 THESEPARATINGDRUM ..............................................................................................................13

4OPERATING INSTRUCTIONS FOR THE METAL SEPARATORS................................14

4.1 Erection Instructions.......................................................................................................14

4.2 Connection Instructions..................................................................................................14

4.3 Operation Instructions....................................................................................................15

4.4 Failure Protection of the Metal Separator......................................................................15

5TECHNICAL CHARACTERISTICS......................................................................................16

6TECHNICAL DESCRIPTION.................................................................................................17

6.1 FRONT PLATE........................................................................................................................17

6.2 SELECTION OF OPERATION VARIANTS..................................................................................18

6.3 NOTES FOR THE VALUES OFSENSITIVITY ..............................................................................19

6.4 SORTING GATE .....................................................................................................................19

6.5 FUNCTION AND LIMITATIONS ................................................................................................19

6.5 PRODUCT EFFECTS - DISTURBING PRODUCT PROPERTIES.....................................................20

7. TRANSPORT.............................................................................................................................22

7.2 SAFETY INSTRUCTIONS FOR TRANSPORT AND ERECTION ......................................................22

8INSTRUCTIONS FOR ERECTION........................................................................................22

8.1 ERECTION AIDS ....................................................................................................................22

8.2 CONNECTORS........................................................................................................................23

8.3 SAMPLE OFAPPLICATION ......................................................................................................24

8.4 ELECTRICAL CONNECTION....................................................................................................25

8.5 PRINTED CIRCUIT BOARD .....................................................................................................28

8.6 FACTORY SETUP ...................................................................................................................29

8.7 QUICK REFERENCE ...............................................................................................................29

9. MAINTENANCE.......................................................................................................................30

9.1. GENERAL MAINTENANCE .....................................................................................................30

9.1.1 Repairs and Wearing parts - Important Notice...................................................................31

9.1.2 Removal of the Laminated-Paper Protective Tube..............................................................32

9.2 REGULAR INSPECTIONS.........................................................................................................32

10 TROUBLESHOOTING........................................................................................................33

11 ACCESSORIES.....................................................................................................................34

12 SPARE PARTS......................................................................................................................35

13. ANNEX...................................................................................................................................35

2General

2.1Instructions for Use of this Manual

This manual applies toMESEP® VA digital50/70

Manufacturer:

Pulsotronic GmbH& Co.KG

Neue Schichtstr. 14

09366 Niederdorf

Phone: 03 7296 / 930100

Fax: 03 7296/ 930 180

Edition: October 2004, v. 1.2

This manual contains all information required for operation of the equipment.

Prior to the first use ofthe metal detector, this manual must havebeen read

and understood byall people workingat or with the metal separator.

Particular attention hasto be paid to the SafetyInstructions.

The users manual is part ofthe metal separatorand has to be keptin such a

waythat is alwaysaccessible to the authorized personnel. In no case, parts of

this manual maybe removed. Amissingmanual or parts ofit, especiallythe

section onsafetyinstructions, must be replaced immediately.

Notice:

Pulsotronic GmbH &Co. KG does not grant implied warrantyforcommercial

qualityand suitabilityfor a particular purpose of application.

This document containscopyrighted information. WithoutPulsotronic GmbH &

Co. KGsprior permission, it mayneither becopied nor duplicated,translated or

digitallystored.

This documentation is not included in Pulsotronic GmbH &Co. KGs update

service. All rights includingthat ofmodificationofthis documentation are

reserved.

2.2General SafetyInstructions

2.2.1 Explanation of the Symbols Used

The followingsafetysymbols are used in this manual. Theyare to direct the

readersattentiontotheaccompanyingtext.

Danger!

This symbolindicates danger for life and health, or that

an important technical fact has to betaken into

consideration.

Danger!

This symbolindicates danger for life and health due to

electrical voltage.

2.2.1Basic SafetyMeasures

• Do not put your hand into theopenings of the metal separator. Mechanical forces

which maycause heavy injuries occur on switching of thepneumatic gate.

• Prior to anymaintenanceworks, disconnect theequipment from compressed air

and power. Make surethat nobodycanreconnect compressedair andpower

during themaintenance works.

• Never put the metalseparator intooperation without the supplied safetydevices.

This isof particular significance for the protective gridabove themovable

components.

• Instantlyshut-off theequipment if safetydevices are not functioningproperlyor

are damaged.

• In caseof failures duetowearingor ageing, their reasons have to beeliminated

immediately.

• Schedule sufficient regular maintenanceintervals.

• Always observe thesafetyinstructionsfixed totheequipment. Theyhelp toavoid

hazards. Innocase, these instructionsmaybe removed.

• Do not put themetal separator intooperation if

• not havingreceived complete instruction bythe owner,

• you have not studied thismanual completely,

• have not understoodthismanual completely

• Errorsin operation maylead toseriousdamageof healthand property.

Danger!

Avoid touching the electronic p. c. board

Prior to wiring the electronic with peripheral equipment, disconnect the

unit from compressed air and power supply.This will helpyou to avoid

short circuits.

Static charges must be discharged before starting working.

3Application and Qualification

3.1Use for Intended Purpose

The MESEP® VA digital removes metallic contaminations from bulkmaterials.

These materials, for example, can be plastic granules, drypowder, rice or similar

productsfrom different industries.

Free-fall metal separation:

The unit is integrated inthe existingconveying system. To guaranteereliable

separation, the material must not bedroppedinto the device fromaheight ofmore

than 600mm.

Duringthe separation process,it happens that also aminor quantityof the good

material is discharged.

To guarantee the units reliable work,anumber asecondaryandoperating

conditions haveto be observed. This manual deals with those subjects. That is the

reason why it is strictly requiredto studythis manual to guarantee perfectand

reliable operation.

Metal separators are used everywhere where metallic contamination must be

removed fromfreelyfallingbulkmaterials in the product flow.With highsensitivity

and reliability, our type 8217 metal separators react to andseparatemetals like

steel / high-grade steel

iron

aluminium

copper

zinc

brass

nonmagneticpreciousmetals

Material-coated metallic particles are detected safelyseparated, aswell.

This resultsin awide application range for themost different industries:

plastics industry

foodstuff industry

animal feedindustry

pharmaceutical industry

semi-finished and finished products industries

etc.

The 8217 type metal separators are used amongstothers at places where long

equipmentrunningtimes are required. The highsensitivityofthe separators

guarantees shortestpossible machine downtimes and metal-free final products

accordingto nominal sensitivity.Especiallythere where the final products cost

effectiveness comesfrom the quantity, the unit pays for itselfwithin short time.

3.2Examplesof Application

Metal separatorsareused

at the endof a cyclone separator

at the endof a downpipe

at the outlet of a granulatingcrusher

at all material dumpingplaces

as aportable equipmentto feed multiple machines (onlyone unit formore

than onemachine)

3.3Operating Principle

The material to bechecked flowfrom aunit hopper, aflanged pipeline or afeeder

into the metal separator. The separator includes metal detectingcoil, followed bythe

sortinggate. Thesorting gate includes apneumatic valve.

As longas metallic particles are not detected, the material flowsalmost vertically

throughtheseparator via theOKduct for further processing(fig. 1).

Ifthe ring sensor detects metal, the valvein the sortinggate changestothe NOT

OK ductand separatesin this waythe contaminated material fromthe good one.

The separating time is adjustable (potentiometer on the electronic circuit board) from

200 milliseconds to one second, depending on themetallic participle portion and the

flowspeed of the material.

3.3Misuse

It is a misuse to use theMESEP© digital metalseparatorforotherpurposes

than described in section3. Especially, the following is prohibited:

• modifyingor removing of themetal separators safetydevices

• usingthe metal separator for unapproved purposes

• modifyingthe metal separator without permission byPulsotronic SKS GmbH

&Co. KG to fortheuse for other purposes. Consider that aftera

modification you mayberegardedas manufacturer ofthemetal separator-

with all guarantyconsequences.

3.4OwnersDutyof Care

The MESEP© digital metal separator was designed and producedaccordingto

harmonized digitals. It is in accordance with the latest state oftechnology, and it

provided maximum safety.However, duringoperation this safetycan onlybe

achieved if all required measureshad been taken. It is within the owners dutyof

care to determine these measures, and to checktheir implementation.

• In particular, the owner must guaranteethefollowing:

• the metal separator must onlybe used for itsintended purpose(refer to 3.1,

APPLICATION AND QUALIFICATION

• the metal separator mayonlybe used in properlyfunctioningcondition, and

particularlyits safetydevices must becheckedregularlyfor functioning,

• the operatingmanual must always be available in legible and completecondition,

• operation, maintenance and repairsareonlybe carried out byqualified and

authorized personnel,

• prior to the first puttinginto operation andthenin regular intervals, the personnel

must be instructedabout labour safetyandenvironmental protection, and has to

knowthis manual andthe safetyinstruction contained therein.

• all safetyand warning instructions fixed to the equipment maynot be removed

and must bekept in clearlylegible condition.

3.5 Function

This section informs about design and function of themetal separator.

TheMESEPdigital consistsof three functional sections:

• keypad (refer tochapter 5.1)

• ring detector with transmitter and receiver coils

• a pneumatic operatingseparating drum (refer tochapter 5.3)

3.5.1 Keypad

Thekeypad is at the outer side of theblue control box. Bymeans of it,

disturbancesareindicated byLEDs, andthesensitivitysetup is shown. All

important settings are made bykey-pressing. The keypad includes among

othersfour verticallyarrangedLEDs which showthe followingoperationstates.

• GreenLED OPERATION

the MESEP digital workswithout problems.

• Red LED „VALVE FAULT“

After thelast metal detection theseparatingdrum did not reach theend

position. TheMESEP digital can not separatethedetectedmaterial. As soon as

the separating drum switches perfect again after a further metal detection, the

error report goesout automatically.

Elimination of “VALVE FAULT“

• Put thereset key

• Check thecompressedair supplyand compressed air height

• Check separatingdrum on swinging

• Red LED RING FAULT

Indicatesa fault of ringcoil or evaluation electronics. After elimination of the fault,

the LED goesout automatically, and the device isreadyfor operationagain.

Elimination of “RING FAULT”

• Remove power conducting matters being trappedin theringcoil.

• Check electrical connections of thecircuit board.

• Inspect the metal separator visually.

• Press the reset key.

• Red LED PRESSURE FAULT

Indicates afault ofthe compressed-air supply.This is anextended function and not

implementedin thebasicvariant.

Elimination of PRESSURE FAULT

• Check thecompressed-air supply.

Notice: Apart of the inscription of thekeypad isexchangeable. Cautiouslyuse

tweezers to find thesmall gapat theright side of the keypad. Widenthe gap a little

and remove thelabel.

Everyunit comes with labels in German, English and French. Theunit is supplied

with labels in German. The labels in other languagesarein theoperatingmanual.

3.5.2 KeyFunctions

TheMESEP digital is set up byfour keys. It is not required to adjust potentiometers.

Therefore, putting theunit into operationis verysimple.

Thekeyfunctions are asfollows:

TEST

• Short manipulation effects metal indication. The separatingdrum switches brief

into theejection position. The functionserves to test the metal separator by key-

pressing. At thesametime, thefour LEDsshowthe currentlyselected sensitivity

value as a LED combination.

• Do holdingthe key. The separatingdrum switches into theejection position as

longasthekeyis beingpressed. This enablestakingof material samples from

the conveyingflow. Inthis way, dischargeof a dosingunit or mixer mounted on

the metal separator can be performed bykeypressing.

F1+

Short manipulation shows thecurrentlyselectedsensitivities for 5sec. (refer to

sensitivitytable, chapter 5.2). Longer pressingof F1+ increases the sensitivity

unless maximum sensitivitywas reached.

F2-

Short manipulation shows thecurrentlyselectedsensitivities for 5sec. (refer to

sensitivitytable, chapter 6.3). Longer pressingof F2- reduces the sensitivityunless

minimum sensitivitywas reached.

RESET

This keyis used to clear an indicated fault after elimination of itsreason.

3.5.3 Selection of Operation Variants

TheelectronicP.C. board includes four DIP switches. Theseswitches serve to

activate or deactivate some basicoperation variants. Duringnormaloperation, a

changeof theDIPswitch positions isnot required.

DIP1: In thecase that two metal separatorsareoperatedin close proximityto each

other, two different working frequencies must beselected. This helps toavoid that

theydisturbone another.

DIP2 : Switch on or switch off of the valve control.

DIP3: In the ON-Position thefault status signal remains after the first metal

detection. Onlyafter pressingof theReset keythesignalis deleted.The metal

separator is still working normallyafter thefirst metal detection, i.e. after each

metaldetection, thecontaminated material is discharged bymeans of the

separation drum.

In this wayit is possible to activate the device in such a manner that after the

first metaldetection apermanent signal isgiven out until theoperator

acknowledgesit bypressingthe reset key.

DIP4: Locking / unlocking thekeyboard

Funktion ON OFF

DIP 1 Workingfrequencyof

detector coil 295 kHz290 kHz

DIP 2 Valve control ON OFF

DIP 3 Save Reset ON OFF

DIP 4 KeylockON OFF

3.6 SensitivityTable

The currentlyselected sensitivityis indicated bymeans ofthe four horizontally

arrangedyellowLEDs at thefront plate.

Example: After pressing of F1+ or F2- buttonsthe diodes 3and 4light for

approximately5 seconds. The actual values of responsesensitivityis 2.5mm.

This corresponds to stage 6, i.e. veryinsensitive.

A metallic particle isdischarged onlyifit is greater or equal the currentlyselected

value.

Hence, the four LEDs serve for fine adjustment of sensitivityand as help for

orientation. (Refer totable below.)

As described in chapter 5.1.1,the sensitivityis indicated or changed bypressing

F1+ or F2-, ifthe keys are not locked.

Thesensitivities applyto themost insensitive section of thedetector which, for this

system, is in the centre. Thesensitivityincreases towards the edge.

X = Ledlights

Sensitivity

stage FE-ST37 bullet

diameter

(mm)

50model/70model

LED 1

LED 2

LED 3

LED 4

1(most sensitive)

from 0.5 / 0,7 X

2 from 0.6 / 0,8 XX

3 from 0.7 / 1,1 X

4 from 0.9 / 1,5 XX

5 from 1.2 / 1,8 X

6 from 1.6 / 2,5 XX

7(most insensitive)

from 2.0 / 3,2 X

Notice:

Beingcoated with material is insignificant for thedetection accuracy.

Nonmagnetic metals influence thering coil’s magnetic field lessthanmagnetic ones.

Hence, reduced response sensitivityhas tobe expected for suchmetals.

For non-ferrousmetals applies: The FE St37 value from thetablemultiplied by1.3 is

the approximate response sensitivityof a non-ferrous metal bullet.

For non-magnetic high-grade steel applies: The FE St37 value from thetable,

multiplied by1.5, is the approximate response sensitivityofahigh-gradesteel bullet.

Notes for the values of sensitivity

Notice:

The sensitivityvalues applyto the centreof thedetection ring, because, for technical

reasons, thereis the lowest sensitivity.The measuringmethod analyses not only

height andwidth, but also the depth ofthe metallic particle. This leadsto afact

which applies to all conventional, metal-separating systems:

Not the weight, but the sizeof the particle is decisive for the detection accuracy. The

bigger the particle size, the greater is the detection current. The detectioncurrent is

a referencevalue for themetal detection.

Notice: Being coated with material is insignificant for the detectionaccuracy.

Nonmagnetic metals influence the ringcoils magnetic field less than magnetic ones.

Hence, reduced response sensitivityhas tobe expected for suchmetals.

For non-ferrousmetals applies: The FE St37 value fromthe table,multiplied by1.3,

is the approximate response sensitivityof anon-ferrousmetal bullet.

For non-magnetic high-grade steel applies: TheFE St37value fromthe table,

multiplied by1.5, is the approximate response sensitivityofahigh-gradesteel bullet.

Far highersensitivities are achieved byour SHARK® products with digitalevalution

electronics and producteffectcompensation. Please contact us for more detailed

information.

3.7 Theseparating drum

Theseparating drum is arrangedin thealuminium enclosureunderneath the blue

metal ring detector. First byscrewingoff the blue round cover plateof theenclosure

the separating drum becomes visible. The separating drum isdesigned sothat

standing or freefalling bulkmaterials areguided alternativelyon the Okor Not ok

discharge. If nometal is detectedthematerial flow goes vertical from the inlet

throughtheseparatingdrum totheOkdischarge. The material does not makeany

diversion.

If metal is detected, theseparatingdrum guids thematerial flowontotheNot ok

discharge.

In order tomakesure that also bigger metallic particles have sufficient time toleave

the separator drum, theseparatingtimeis adapted automatically. Indepence on the

size of themetal the separatingdrum staylonger or shorter in the Not ok position.

Theadvantageof this

activation is thereliable separation of metallic particles of anysize. A stickingof the

separatingunit will be prevent. The material discharge is reducedtoa minimum by

this newtechnology.

At theendof thisvariable timetheseparatingdrum switches back again to theOk

position. If there isa newmetal detection within the separating event, theseparating

drum stays in theNot ok position for alonger time.

4Operating Instructions for the Metal Separators

Smooth and safe operation ofthe MESEP® VA digital is only possible ifthe

followinginstructionsareobserved

4.1 Erection Instructions

• Fixthe unit in such awaythat screws or other fastening elements cannot get

loose unintendedly.

• Theunit must not bedisassembled for erection. It must be erected asacomplete

unit.

• In nocase, weldingcurrent mayflowthroughthemetal separator enclosure. This

would destroythemetal separator.

4.2 Connection Instructions

• Observe the permissible mains voltage.

• Installation andconnection maybe executedonlybyauthorized personnel.

• Observe the general installation instructions for erection and operation of electric

equipment (VDE 0100).

• Do not perform anyworks at theswitched-on metal separator!

• Protective measuresfor personnel and equipment have tobe inaccordance with

the local situation andregulations.

• Observe the power-handlingcapacityof the outlet contacts.

• Provide proper grounding of themetal separator (neutral; avoid end loops;

provide shortest connection tomain grounding).

4.3 Operation Instructions

• Themetal separator should be permanentlyon. This will provide maximum

lifetime of the electroniccircuits.

4.4 Failure Protection of the Metal Separator

Themetal separators mains inlet is protected against disturbinginfluences.

Increased operation safetyand additionalprotection against failures is reached

applyingthe followingmeasures:

• Use of mainsfilters if themainsvoltage isaffected byconnection of large

consumers (compensation systems, weldingequipment, HF furnaces, solenoid

valves etc).

• Protection of inductive loads (solenoid valves, contactors, electromagnets) byRC

members. On switching-off of inductive loads, high voltage peaks mayoccur.

Thesevoltagepeaksareshortened byRC members.

5Technical Characteristics

Articlenumber MESEP VA digital 50

MESEP VA digital 70

Optional with connection control*

Operation voltage 85V – 264 V AC

Mains frequency 47Hz - 440Hz oder DC

Power drain < 40Watts

Permissible operation temperature 0°C –60°C

Permissible product temperature max. 80°C

Free passage of the ring detector ∅70 mm

Maximum material throughput depended on the tricklingabilityof the bulk

material

AndsensitivitiesMESEP VA50 approx... max. <4.500 l/h

0,5 Ferrous ball in the center ofring FE-St37

MESEP VA70 approx. max. <8.800l/h

0,7 Ferrous ball in the center ofring FE-St37

Weight ca. 20 kg

Sensitivityranges 7

Operation pressure 4-6 bar, filtered, water andoil free

Coupler with ¼” thread

Partsin contact with material laminatedpaper or aluminium

Relay contacts metal detection (floatingtwo-wayswitch) 250V /

failure (floating two-wayswitch) 250V / 5A

Semi-conductor output signalsmetal detection 24V/20mA, short-circuit

resistant

24V / 100mA, short-circuit resistant

*Connection monitoring Units withthis functionhave anadditional solenoid valve and a

return spring in the pneumatic cylinder. In case ofcompressed-air failure,thereturn spring

brings thesorting gate into the NOTOK position. The second, additionalsolenoidvalve acts

onlyifmain voltageis available. Ifthis is the case, thecompressed air is connected to the

pneumatic cylinder. In case ofpower failure, thecompressed air is disconnected the

pneumatic cylinder. In this case, the sortinggate changes to the NOTOK position.

6Technical Description

This section informs about design and function of themetal separator.

TheMESEP® VAdigital consistsof three functional sections:

• front plate(refer to chapter 6.1)

• ring detector for creation ofanelectromagnetic field (refer to chapter 6.2)

• pneumaticsorting gate (refer tochapter 6.4)

6.1Front Plate

The Test Button

Pressing thetestbuttonsimulates ametal detection. For ashort time, the

sortinggate mustchange to the separatingposition. This canbe seen from a

position change of the pneumaticcylinder. Am impact soundcan beheard.

Never put you hand into a gate openingduringthis test.

In this way,the buttonserves for instantfunctiontestofthe device. However,

this is not areliable sensitivity test. This must be performed usingan

appropriatetest bullet.

6.2Selection of Operation Variants

Theprintedcircuit boardbehind the front plate includes a potentiometer. It is used to

adjust theseparation time after metal detection.

Atsupply,thedeviceis adjustedfor anaverage

separation time of approx. 1 sec.

The separation time should be adjusted accordingto qualityand flowspeed ofthe

material tobe handled.

Once metal was detected, thesortinggate -dependingon the potentiometer

position -remains in dischargeposition for1to 5.0 sec before beingreturned to the

OK position. (see chapter 8.5)

In case oftoo short separation time (see above) and slowlymovingmaterial, it may

happen thatthe sortinggatehas returned to thestartingposition (conveying

position) before the detected metallic particle passes the gate. Inacaselikethat,

metal separation is not possible.

The longerthe separation time is, the more theloss ofOK material increases. In

case thatthe factorysetting is not the usersmost favourable one, the best setting

has to be determined duringoperation. Otherwise, the factorysettingshould be

kept.

6.3Notes for the values of sensitivity

Notice:

The sensitivityvalues applyto the centreof thedetection ring, because, for technical

reasons, thereis the lowest sensitivity.The measuringmethod analyses not only

height andwidth, but also the depth ofthe metallic particle. This leadsto afact

which applies to all conventional, analogmetal-separatingsystems: