Safeline Signature User manual

SAFELINE INC
Safeline Business Center
6005 Benjamin Road
Tampa, Florida 33634 USA
Tel: [phone]
Fax: [phone]
Web Site: www.metaldetection.com
Email: [email protected]
[email protected]
[email protected]

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ii 4618–021
Copyright ©Safeline limited, 1996, 1997 2000
No part of this document may be reproduced, or translated, in any form, electronic or otherwise
without the prior written consent of Safeline limited.
Neither Safeline nor its Agents will be liable for incidental or consequential damage in connection
with the use of this document.
Safeline reserve the right to change the contents or form of this manual at any time without prior
notice having been given.
This detector must only be used for the express purposes as advertised by Safeline and as
referred to in this and other Safeline approved literature.
Aims of this manual.
This manual is intended to help those customers who need to:
1) Install the detector
2) Commission the detector subsequent to replacement or installation.
3) Operate the detector on a day to day basis.
4) Change some of the product dependent and installation dependent parameters.
5) Communicate with the detector using serial communications.
6) Arrange a maintenance schedule using the printer option.
This manual is NOT intended as either-
1) A Service Manual, (although some fundamental diagnosis is included in this manual).
2) A Workshop Manual - No detailed technical analysis, either mechanical, electrical or electronic is contained in
this manual.
3) Commercial information - for example sales literature or publicity information.
Safeline technical publications are designed to be backwardly compatible with all previous versions of detectors in
the family. This means that the later issues of manuals will be fully compatible with older equipment, however the
older equipment may not have all of the features of later manuals.
NOTE.
An upgrade service is available from Safeline, at a fee, that will upgrade older detectors to the latest specification,
where possible. Please contact your supplier’s technical departments for information on this service. Remember to
have your serial number ready when making the call.
Published in England

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4618–021 iii
Amendments
Safeline have a policy of updating manuals to include new features, correct erratum, or incorporate customers
requests. The Amendment Record below is provided for the express purpose of the customer, or supplier, to record
any amendments that may have been included in this document.
For further information or to order copies of this document contact Safeline Ltd. at the address shown on the title
page of this document, quoting the reference number given on the title page.
If the document was purchased directly from Safeline, or the supplier is unavailable at the supplier address given,
then contact Safeline directly via the address given on the title page of this document.
If the owner of the manual has any comments or suggestions as to the form, content or presentation of this manual
then they should write their suggestions and send them to the Technical Department at the Safeline address given
on the title page.
Amendment Record
If you receive an update for this manual then:
1. Attach the update sheet(s) to the rear of the manual.
2. In the row whose 'Amendment’ number matches that of the received amendment:-
a) Print your name in the 'Incorporated By’ box.
b) Print the 'Date' box with the date you updated the manual.
AMENDMENT INCORPORATED BY DATE
1. Issue 1 Safeline January 1997
2. Issue 2 Safeline September 1997
3. Issue 3 Safeline January 2000
4. Issue 4 Safeline October 2002
5. Issue 5 Safeline December 2002
6. Issue 6 Safeline March 2003
7. Issue 7 Safeline July 2003
8. Issue 8 Safeline July 2003
9. Issue 9 Safeline December 2003
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

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iv 4618–021
Warnings and Cautions
WARNIN
G
THE ABOVE CAPTION IDENTIFIES AN OPERATING PROCEDURE OR PRACTICE THAT COULD RESULT IN
PERSONAL INJURY OR DEATH.
!
CAUTION
The above caption identifies an operating procedure or practice that could result in damage, or destruction,
of the detector, the process or its surroundings.
The above caption is used to draw the readers attention to a note of extra importance.
!
CAUTION
This manual is regarded as an integral part of the detector.
This manual must always be kept with the detector for the whole of its operating life.
WARNIN
G
WHEN THIS CAPTION IS SHOWN ON THE EQUIPMENT IT IS USED TO INDICATE THE POSSIBILITY OF
ELECTRIC SHOCK.
!
CAUTION
WHEN THIS CAPTION IS SHOWN ON THE EQUIPMENT IT IS USED TO INDICATE THAT THE MANUAL MUST
BE CONSULTED BEFORE PROCEEDING.

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4618–021 v
Handling instructions
The detector does not contain any exposed noxious or dangerous substances.
When transporting and handling the detector damage may result if the lifting equipment (i.e. sling, cable assembly or
by hand) passes through the aperture of the detector. The diagrams below show the incorrect way and the correct
way to lift and support the detector during transportation.
CORRECT INCORRECT
Safeline does not recommend the lifting or supporting of the detector by a person. Always use suitable lifting or
supporting apparatus. Safeline will accept no liability for personal injury caused by attempting to lift or move the
detector without the aid of a mechanical apparatus.
If supporting the detector in a sling or other lifting apparatus always ensure that the detector is securely held and is
not likely to unbalance during lifting.

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vi 4618–021
Safety Instructions
Most companies have a code of practice for their employees which is designed to ensure their safety in the working
environment. When new equipment is introduced it is important that operators, maintenance engineers and
supervisors are aware of the potential hazards.
The following guidelines must be followed by any person concerned with the operation, installation or handling of the
detector to ensure correct operation and to avoid any damage to the detector or to the person concerned.
WARNIN
G
The equipment should only be used in accordance with the instructions given herein. Failure to comply with
these instructions may lead to the protection provided by the equipment becoming impaired.
Safeline will not be liable for incidental or consequential damage if the equipment is not installed in
accordance with the instructions given.
WARNIN
G
On no account should any of the electrical panels of your detector be opened by anyone other than a
qualified electrical engineer. Voltages in excess of 30 volts rms or 50 volts DC. can, in certain
circumstances be lethal. When working on electrical or electronic equipment always follow current health
and safety practices and observe all other applicable regulations.
!
CAUTION
For correct operation and to prevent any damage to the detector follow the instructions given in this
document under the heading 'Installation'.
!
CAUTION
In accordance with EN 61010-1:1993 this equipment has been designed to be safe at least under the following
conditions:
Indoor use.
Altitude up to 2000m.
Storage temperature: -10 °C to +50 °C (15 °F to 120 °F)
Operating temperature: -10 °C to +40 °C (15 °F to 110 °F)
Maximum relative humidity 93% for temperatures up to 45°C.
For connection to TN (EN60950:1992) power distribution systems only, for connections to other power distribution
systems please contact your supplier.
Mains supply voltage fluctuations not to exceed +10%/-15% of the nominal voltage.
Transient overvoltages according to INSTALLATION CATEGORY III.
Pollution degree 2 in accordance with IEC 664.

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4618–021 vii
Detector Precautions
!
CAUTIO
N
During installation and operation of the detector the following points must be considered. Failure to do so may result
in difficulties of operation, degradation in the performance or damage occurring to your detector.
1. Electric Arc Welding
Electric Arc Welding must not be carried out on the detector or on any part of the attached conveyor system.
If Electric Arc Welding must be carried out on any attached systems, disconnect and remove the detector
head and detector power supply box prior to welding.
2. Power Source
It is recommended that the power source should be taken from a source which supplies only low power
equipment.
It is recommended that the detector should not be connected to power sources which are supplying varying
current loads, e.g. Invertors, variable-speed drives etc.
It is recommended that the power source for the detector should be connected via an independent spur.
The power source for the detector should be fitted with an isolation switch and the appropriate circuit breaker
and/or fuse.
3. Electromagnetic Interference
It is recommended that the detector should not be installed in close proximity to any devices which may emit
electromagnetic interference e.g. Radio transmitters.
Ensure all Invertors and variable-speed drives in the proximity of the detector are installed in full accordance
with their manufacturers instructions.
Where possible avoid placing any cables from Invertors, variable-speed drives etc. in close proximity to the
detector or the detector cables.
In particular take care to avoid placing the detector in the proximity of any equipment that generates
electromagnetic interference in the same frequency range as the detector.
4. Magnetic Fields (Ferrous Detectors Only)
It is recommended that this type of detector should not be installed in close proximity to any potential source of
magnetic fields.
5. Metal Free Zone (M.F.Z.)
To achieve the optimum detector performance, an area surrounding the aperture of the detector known as the
Metal Free Zone (M.F.Z.) must be kept free of metal.
The size of this zone will be dependant upon the type of detector, the detector’s aperture height and the
detector’s operating sensitivity.
Stationary metal may be positioned closer to the detector than moving metal.
Typical values of M.F.Z for standard metal detectors are:
M.F.Z. = 1.5 x aperture-height for stationary metal
M.F.Z. = 2.0 x aperture-height for moving metal.
Typical values of M.F.Z for Ferrous detectors are:
M.F.Z. = 1.5 x aperture-height for stationary non-Ferrous metal
M.F.Z. = 2.0 x aperture-height for moving non-Ferrous metal.
M.F.Z. = 2.0 x aperture-height for stationary Ferrous metal
M.F.Z. = 3.0 x aperture-height for moving Ferrous metal.

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viii 4618–021
6. Avoiding aperture damage
At all times ensure that the product does not come in contact with, or impact onto the detector aperture or
aperture lining.
7. Handling and lifting
When transporting and handling the detector damage may result if the lifting equipment (e.g. sling, cable
assembly or by hand) passes through the aperture of the detector.
Never pass any lifting or supporting equipment through the detector aperture.
Always observe best practices for handling heavy items when lifting or moving the detector.
8. Detector support structures
Avoid supporting the detector on vibrating structures and/or machines subject to mechanical shock.
No part of the supporting structure should rely on the detector for structural integrity.
No part of the supporting structure should be attached to the detector other than through the detector
mounting blocks supplied.
9. Belt maintenance
Certain substances (e.g. metal fragments, liquids etc.) which can be detected by the metal detector are likely
to cause unexpected detections (often giving the appearance of erratic/incorrect operation) if they adhere to
the conveyor belt.
To minimise the chance of this occurring:
a) Avoid any operations that may cause metal fragments to come into contact with the conveyor belt e.g.
welding, metal drilling or cutting in the vicinity of the conveyor belt.
b) Clean the conveyor belt regularly.
10. Orientation of contaminants
Metal detector sensitivity is expressed as the diameter of the smallest spherical object which can be detected.
(i.e. diameter of a ball).
Sensitivity to non-spherical objects of the same material (e.g. wire fragments) will vary according to the
orientation of the object as it passes through the detector aperture. If the diameter of the object is less than the
stated spherical sensitivity the object may not be detected.
11. Product packaging materials
To achieve the optimum detector performance in applications where the product being inspected is packaged
- ensure that the packaging materials used are free from metal contamination.
12. Continuous maintenance and testing
It is recommended that at regular intervals testing with an appropriate test sample is performed to ensure the
detector and any attached reject mechanism is functioning correctly.
It is recommended that inspection and cleaning of the detector system should be carried out at regular
intervals.
13. Static Precautions.
Where a metal detector is to be fitted on a conveyor or otherwise it necessary to bond the metal work
to ground.

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4618–021 ix
Contents
PRELIMINARY PAGES
Aims of this manual. ................................................................................................................................................. ii
Amendments............................................................................................................................................................ iii
Warnings and Cautions ........................................................................................................................................... iv
Handling instructions ................................................................................................................................................v
Detector Precautions .............................................................................................................................................. vii
INDEX .....................................................................................................................................................................xiii
LIST OF ILLUSTRATIONS .......................................................................................................................................XIV
Features of your Metal Detector ...............................................................................................................................3
Product Numbers......................................................................................................................................................3
Timer Groups............................................................................................................................................................3
Timer Types..............................................................................................................................................................3
Product Signal Cancellation (PSC) (option) .............................................................................................................3
Automatic Tracking (option)......................................................................................................................................3
Inverse Detection......................................................................................................................................................3
QUALITY ASSURANCE SUPPORT (OPTION)............................................................................................................4
TECHNICAL SPECIFICATION .....................................................................................................................................5
Technology ...............................................................................................................................................................5
Frequency of Operation of Coil.................................................................................................................................5
Product throughput speed ........................................................................................................................................5
Power Input...............................................................................................................................................................5
Internal Battery..........................................................................................................................................................5
Environmental Protection..........................................................................................................................................5
Switched Power Output ............................................................................................................................................5
Reject Relay..............................................................................................................................................................5
Detect Signal.............................................................................................................................................................6
Q.A. Due/Overdue Output ........................................................................................................................................6
Pack Sensor Requirements ......................................................................................................................................6
Speed Sensor Requirements....................................................................................................................................6
Reject Confirmation Sensor Requirements ..............................................................................................................6
RS232 Serial Communications.................................................................................................................................6
Internal Counters ......................................................................................................................................................7
Spherical Sensitivity..................................................................................................................................................7
Sensitivity Gradient...................................................................................................................................................7
Timer Ranges ...........................................................................................................................................................7
GENERAL......................................................................................................................................................................8
MECHANICAL INSTALLATION ...................................................................................................................................8
Metal Free Zone (MFZ).............................................................................................................................................8
Figure 4 Metal Free Zone Guidelines .................................................................... Error! Bookmark not defined.
Construction of the Detector Installation...................................................................................................................9
Positioning the Detector Head..................................................................................................................................9
Electrical Connections ..............................................................................................................................................9
ELECTRICAL INSTALLATION...................................................................................................................................12
General ...................................................................................................................................................................12
Location and Layout of the Detector Terminals......................................................................................................12
Removing the Power Supply Box Lid .....................................................................................................................12
INTRODUCTION .........................................................................................................................................................16
The Touch Keys Explained.....................................................................................................................................17
Changing Numeric Values......................................................................................................................................19
Universal Settings Guide ........................................................................................................................................21
RUNNING MODE ........................................................................................................................................................32

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x4618–021
Introduction .............................................................................................................................................................32
Pack Count and Reject Count ................................................................................................................................33
Time ........................................................................................................................................................................33
OPERATOR MODE.....................................................................................................................................................35
Introduction .............................................................................................................................................................35
Product Number, Auto Setup and Name ................................................................................................................35
Sensitivity and Phase..............................................................................................................................................35
SUPERVISOR MODE..................................................................................................................................................37
Introduction .............................................................................................................................................................37
Product Number, Auto Setup and Name ................................................................................................................37
Sensitivity and Phase..............................................................................................................................................37
Operating Frequency ..............................................................................................................................................38
Select Timer Group.................................................................................................................................................38
Reject Count ...........................................................................................................................................................38
Pack Count .............................................................................................................................................................38
ENGINEER MODE.......................................................................................................................................................40
Introduction .............................................................................................................................................................40
Product Number, Auto Setup and Name ................................................................................................................40
Sensitivity and Phase..............................................................................................................................................40
Operating Frequency ..............................................................................................................................................41
Power Drive ............................................................................................................................................................41
Select and Update Timer ........................................................................................................................................42
Inverse Detection....................................................................................................................................................42
Automatic Tracking (option)....................................................................................................................................43
Reject Count ...........................................................................................................................................................43
Pack Count .............................................................................................................................................................43
Pack Sensor Setup .................................................................................................................................................44
Security Setup.........................................................................................................................................................44
Speed setup............................................................................................................................................................45
Auto. tracking setup ................................................................................................................................................45
Detection Buzzer.....................................................................................................................................................45
Reject inhibit (Versions XT1.00 and XT1.01 only)..................................................................................................45
Boost Mode.............................................................................................................................................................46
Language ................................................................................................................................................................46
Set Date and Time (Option)....................................................................................................................................47
Printer Handshake (Option) ....................................................................................................................................47
AUTOMATIC SETUP...................................................................................................................................................48
Introduction .............................................................................................................................................................48
Product Signal Cancellation....................................................................................................................................50
VIBRATION SETUP................................................................................................................................................54
Introduction .............................................................................................................................................................54
NOTE ......................................................................................................................................................................54
Sensitivity limit ........................................................................................................................................................54
PACK SENSOR SETUP..............................................................................................................................................56
Introduction .............................................................................................................................................................56
Gating .....................................................................................................................................................................56
Pack Sensor Fitted..................................................................................................................................................56
Sensor distance ......................................................................................................................................................56
Pack Sensor Calibration .........................................................................................................................................57
SECURITY SETUP......................................................................................................................................................59
Introduction .............................................................................................................................................................59
SPEED SETUP............................................................................................................................................................62
Introduction .............................................................................................................................................................62
Speed range ...........................................................................................................................................................62
Automatic tracking maximum rate ..........................................................................................................................64

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4618–021 xi
QA INSPECTOR MODE (OPTION) ............................................................................................................................67
Introduction .............................................................................................................................................................67
Printer .....................................................................................................................................................................67
Configuring the Performance Validation Routine ...................................................................................................68
Line Identification....................................................................................................................................................68
Printer Fitted ...........................................................................................................................................................68
Printer Fixed/Portable .............................................................................................................................................68
Test Samples..........................................................................................................................................................69
Shift Report Options ...............................................................................................................................................69
Shift Report Interval ................................................................................................................................................70
Shift Report Start Time ...........................................................................................................................................70
Test Interval ............................................................................................................................................................71
Overdue Period.......................................................................................................................................................71
Alarm If Overdue.....................................................................................................................................................72
Change QA Operator Code ....................................................................................................................................72
QA OPERATOR MODE ..............................................................................................................................................74
Introduction .............................................................................................................................................................74
QA Operator Security Codes..................................................................................................................................74
Carrying Out a Performance Check .......................................................................................................................74
Notes on the Test Sample ......................................................................................................................................74
Select Test Material ................................................................................................................................................74
VIEWING MODE..........................................................................................................................................................77
Introduction .............................................................................................................................................................77
REJECT TIMERS INTRODUCTION ...........................................................................................................................78
Recommended Applications ...................................................................................................................................78
Timer Groups A, B or C ..........................................................................................................................................78
Sample size selection .............................................................................................................................................78
tm1 TIMER...................................................................................................................................................................81
tm2[G] TIMER - NON GATED MODE ........................................................................................................................84
Introduction .............................................................................................................................................................84
tm2 settings.............................................................................................................................................................84
tm2G TIMER - GATED MODE....................................................................................................................................88
tm3[G] TIMER - NON GATED MODE ........................................................................................................................94
Setting up Timer Type tm3 .....................................................................................................................................94
tm3[G] TIMER - GATED MODE..................................................................................................................................99
Setting up timer type tm3G in gated mode ...........................................................................................................100
SPEED SENSOR FOR THE TM3 AND TM3[G] TIMERS ........................................................................................109
Speed Sensor Requirements................................................................................................................................109
Speed Sensor Electrical Connections ..................................................................................................................109
Producing A Rotary Encoder Using A Proximity or Photo-electric Sensor...........................................................109
Disc Construction..................................................................................................................................................110
Determining The Required Shift Distance Of The Speed Sensor ........................................................................110
SETTING UP AND CONNECTING A PRINTER TO THE METAL DETECTOR......................................................112
General .................................................................................................................................................................112
Requirements Of Your Serial Printer ....................................................................................................................112
Connection of Printer to Detector .........................................................................................................................113
SAMPLE PRINTED REPORTS.................................................................................................................................114
METAL DETECTOR SERIAL COMMUNICATIONS LINK.......................................................................................118
Introduction ...........................................................................................................................................................118
Host computer or intelligent equipment ................................................................................................................118

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xii 4618–021
Specification of the serial link. ..............................................................................................................................118
Physical layer specification (OSI layer 1) .............................................................................................................118
Data-link layer specification (OSI layer 2).............................................................................................................118
Valid message identifiers......................................................................................................................................120
Commands the host can transmit.........................................................................................................................128
Commands the metal detector may transmit........................................................................................................128
Command Identifier - ‘E’ Error Codes...............................................................................................................130
Command Identifier - ‘Q’ QA Lists and Displays...............................................................................................132
QA Operator commands.......................................................................................................................................132
QA Inspector commands ......................................................................................................................................132
EMULATION MODE..................................................................................................................................................136
Objective ...............................................................................................................................................................136
Principal of operation ............................................................................................................................................136
CRC GENERATION ..................................................................................................................................................142
Method ..................................................................................................................................................................142
C Program.............................................................................................................................................................143
TIMING DIAGRAMS FOR SERIAL COMMUNICATIONS........................................................................................144
MAGNETIC LOOPS ..................................................................................................................................................147
RECOMMENDATIONS FOR THE USE OF INVERTERS ........................................................................................150
ATEX DIRECTIVE ............................................................................................ERROR! BOOKMARK NOT DEFINED.
ATEX system label................................................................................................................................................152
ATEX Static warning label ....................................................................................................................................152
ATEX Enclosure warning label ............................................................................................................................152

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4618–021 xiii
INDEX
A
Amendments, iii
Aperture height, 9
Automatic setup, 3, 37,39, 43, 52
Automatic tracking, 3, 46, 48, 68
B
Battery, 5
Bearing blocks, 12
Belt joint, 12
Boost mode, 49
Buzzer, 48
C
Cable Gland Assemblies, 16
Cautions, iv
Communications, 4, 6,125
Conclamp, 15
Contents, vii
Control Panel, 17
Conveyor, 11
Counters, 6, 7
CRC generation, 143
D
Date, setting, 50
Detect signal, 6
Detector heads positioning, 10
Detector terminals, 13
Due alarm, 6, 76
E
Electrical connections, 10
Engineer Mode, 42
Environmental protection, 5
F
Fault output, 6.
G
Gated timers, 3, 83
Guides, 21
H
Handling instructions, v
How to ..., 21, 25, 26, 27
I
Installation, 9
Inverse detection,3 ,45
L
Language, 49
LCD, 17
Line identification, 72
M
Manually Setting the Detector, 28
Magnetic loops, 149
Metal free zone, 9
N
Name, 37, 39, 43
Next QA test, 34
Numeric Values, 20
O
Operator Access, 63
Operator mode, 37
Operating Frequency, 40, 44
Overdue
alarm at, 6, 76
output, 6
period, 75
P
Pack counter, 7, 34, 40, 46
Pack sensor
Calibration, 60
distance, 59
requirements, 6
setup, 47, 59
Page Display System, 18
Performance check, 25, 78
Performance Validation Guide, 25
Phase
control, 1
setting, 28, 37, 39, 43
Position of the detector,10
Power drive, 43.
Power supply
connections, 14
specification, 5
Printer
setup, 72
handshake, 50
connections, 119
specification, 119
Printouts, 26, 77
samples,121
Product effect, 1
Product name, 37, 39, 42
Product number
introduction, 3
setting,37, 39, 42
setting guide, 24
Product signal cancellation, 3, 46, 53
Product speed, 27, 47, 66
Product Throughput Speed, 5
P.V.R., 4
Q
Q.A. Inspector Mode, 71
Q.A. Due/ Overdue, 6, 34
Q.A. Operator
mode, 78
security codes, 76, 78
Q.A. Support, 4
Q.A. test time, 34
R
RC sensor, 110
RCU Settings, 49, 110
Reject counter, 6
reading, 32, 40, 46
resetting, 40, 46
Reject confirmation, 49, 110
Reject confirmation unit, 110
Reject inhibit, 47, 48
Reject relay, 5
Reject timers, 82
Running mode, 33
S
Security, 19, 47, 63
Sensitivity
gradient, 7
limit, 57
spherical, 7
Sensitivity
setting, 37, 39, 43
Serial number, 33
Shifts, (Q.A.)
printouts, 71, 76, 77
report interval, 74
report options, 73
report start time, 74
Shift distance, 99, 104, 116
Soft keys, 18
Speed Change Guide, 27
Speed sensor connections, 6, 14
Speed sensor disk construction, 115
Speed sensor requirements, 6, 115
Speed setup, 66
Supervisor Mode, 39
Switched Power Output, 5
System Fault Relay, 5
T
Technical specification, 5
Temperature
operating, 5
storage, vi
Test interval, 71, 75
Test sample calibration, 73
Time
display, 34
setting, 50
Timers
groups, 3, 40, 45, 82
group selection, 40, 45, 82
introduction, 3, 82
ranges, 7
tm1 setting, 85
tm2, setting, 89
tm2G, setting,93
tm3 setting, 99
tm3G setting, 104
types, 3
Touch Keys, 18
U
Universal Settings Guide, 22
V
Vibration setup, 47, 57
Vibration signals, 1
Viewing Mode, 81
W
Warnings, iv.
Warm up time, 5

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xiv 4618–021
LIST OF ILLUSTRATIONS
Figure Page
Fig 1 Phase/Amplitude...................................................................................................................................................2
Fig 2 Effect of Phase Control .........................................................................................................................................2
Fig 3 Effects of Unwanted Signals .................................................................................................................................2
Fig 4 Metal Free Zone Guidelines..................................................................................................................................8
Fig 5 Typical Metal Detector Conveyor........................................................................................................................10
Fig 6 Bearing Block And Mounting Foot Insulation......................................................................................................11
Fig 7 Belt Joints............................................................................................................................................................11
Fig 8 Layout of components and Terminals.................................................................................................................13
Fig 9 Power Connections to the Detector ....................................................................................................................14
Fig 10 Cable Gland Assemblies for Power Supply Unit...............................................................................................15
Fig 11 Control Panel ....................................................................................................................................................16
Fig 12 Running Mode Flow Chart ................................................................................................................................31
Fig 13 Operator Mode Flow Chart ...............................................................................................................................34
Fig 14 Supervisor Mode Flow Chart ............................................................................................................................36
Fig 15 Engineer Mode Flow Chart ...............................................................................................................................39
Fig 16 Pack Sensor Mode Flow Chart .........................................................................................................................55
Fig 17 Security Setup Flow Chart ................................................................................................................................58
Fig 18 QA Inspector And Operator Flow Chart............................................................................................................66
Fig 19 Viewing Mode Flow Chart.................................................................................................................................76
Fig 20 Viewing Mode Flow Chart cont.. .......................................................................................................................77
Fig 21 Tm1 Timer Flow Chart ......................................................................................................................................80
Fig 22 Tm2 Timer Flow Chart ......................................................................................................................................83
Fig 23 Tm3 Timer Flow Chart .......................................................................................................................................93
Fig 24 Rotary Encoder ...............................................................................................................................................109
Fig 25 Disc Construction............................................................................................................................................110
Fig 26 Determining The Required Shift Distance ......................................................................................................110
Fig 27 D-1 Host Query of Detector ............................................................................................................................144
Fig 28 D-2 Host Command type 1, (causes change in value of detector variable) ...................................................144
Fig 29 D-3 Host Command type 2, (causes NO change in value of detector variable).............................................144
Fig 30 D-4 Event Occurence inside detector .............................................................................................................145
Fig 31 Event driven message interrupting normal ack/nak response to the host......................................................146

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4618–021 xv
LIST OF ABBREVIATIONS
A Ampere
AC Alternating current
AH Aperture height
CRC Cyclic redundancy check
D.C. Direct current
Fe Ferrous
ft foot
Hz Hertz
kKilo(10
3)
kHz KiloHertz
kV Kilovolt
kΩKiloOhm
LCD Liquid crystal display
LED, led Light emitting diode
mmetre
mA milliampere
MFZ Metal free zone
MHz MegaHertz
min minute
mm millimetre
ms millisecond
non-Fe Non-ferrous
NPN Negative-positive-negative (type of transistor)
PNP Positive-negative-positive (type of transistor)
PSC Product signal cancellation
PVR Performance validation routines
QA Quality assurance
RMS Root Mean Square
VVolt
VA Volt amps
WWatt
0C Degree Celsius
0F Degree Fahrenheit

4618-021 1
Principles of Operation for the Metal Detector
Safeline detectors utilise a low power, high frequency,
magnetic field coil system which has the ability to
sense minute disturbances created by metal particles.
A metal particle passing through the aperture of the
detector will create changes in the magnetic field
inside the detector.
The changes in the magnetic field will generate
electrical signals in the coil system which can be
characterised by the parameters Phase and
Amplitude.
The amplitude/size of the signal is related to the size
of the metal particle passing through the field, the
larger the metal particle the greater the amplitude of
the signal.
Different types of metal generate signals which differ
in phase angle. The term phase angle is a
comparative term and is a measurement of phase
relationship relative to some reference
Vibration Signals
Great care is taken in the design and manufacture of
the Safeline detectors to minimise the effect of
vibration on the performance of the detectors.
However mechanical disturbances do create vibration
signals from the coil system.
Vibration signals can be represented in the same way
as signals generated by metal particles i.e. a signal
with amplitude and phase.
The vibration signal is used as a reference when
comparing the phase angle of signals from the coil
system. For example, if we say stainless steel has a
particular value of phase angle, the phase angle is the
angle relative to vibration. Reasons for selecting
vibration as the reference phase will become
apparent.
Product Effect
Metal detectors are used to inspect all types of
products e.g. food pharmaceuticals, plastics,
chemicals and many others.
Some products exhibit a ‘product effect’ i.e. the
product itself generates a signal in the same way as a
metal particle. This results from the bulk conductivity
of the product at high frequency.
For most products, usually dry products, the product
effect is negligible. Wet or moist products, e.g. meat,
sauces, soups etc. generate a large product effect
signal which will influence the effective operating
sensitivity of the detector.
Product effect signals can be represented
diagramatically as a signal with amplitude and phase
in the same manner as the signals from metallic
particles.
Phase Control
The Safeline metal detector contains a phase control
circuit which discriminates between the wanted
signals from metal particles and the unwanted signals
from vibration and product effect, i.e. it maximises the
detectors response to metal particles whilst
minimising the effects of the unwanted signals.
Probably the simplest way of reducing the vibration or
product effect signals would be to adjust the
sensitivity control. However, the sensitivity control
would reduce the sensitivity to all signals, metallic
signals, vibration and product signals alike.
What is required is a more selective adjustment that
will discriminate between different signals. The phase
control does this, it selectively reduces the signals
from vibration and product effect with minimal effect
on the metallic signals.
A comparison can be made with a domestic Hi-Fi
system. The volume control of the Hi-Fi increases or
decreases the amplitude of all signals just like the
metal detector sensitivity control. The bass control of
the Hi-Fi selectively controls the low frequency notes
only. This is similar to the phase control circuit,
however the phase control circuit in a Safeline metal
detector is very much more selective.
Signals from the detector coil system can be
represented as shown in Fig 1

PRINCIPLES OF OPERATION
24618 - 021
PHASE VALUE
0
0
20
0
40
0
60
0
80
0
90
0
100
0
120
0
140
0
160
0
AMPLITUDE
STAINLESS
STEEL
FERROUS NON-FERROUS
VIBRATION
180
0
VIBRATION
Fig 1 Phase/Amplitude
The characteristic of the phase control circuit is as
shown in Fig 2. This shows the position of the phase
control aligned to minimise the unwanted vibration
signal. All signals which break through the phase
control characteristic (the shaded area) will trigger the
detector. From this it can be seen that the amplitude
of the unwanted vibration signal would have to be
increased to trigger the detector.
It can be seen from Fig 2 that the phase control
characteristic masks off some of the ferrous signal
and has a minimal effect on the Non
Ferrous/Stainless Steel signals
PHASE VALUE
0
0
20
0
40
0
60
0
80
0
90
0
100
0
120
0
140
0
160
0
A
MPLITUDE
STAINLESS
STEEL
FERROUS NON-FERROUS
VIBRATION
180
0
VIBRATION
Fig 2 Effect of Phase Control
The phase control is used to minimise unwanted
product effect signals. Fig 3 shows a typical example.
It can be seen from Fig 3 that the phase control
characteristic masks off some of the Stainless Steel
signals and has a minimal effect on the Ferrous
signal. The detectors phase setting may be adjusted
to align the phase control over any unwanted product
effect signal.
PHASE VALUE
0
0
20
0
40
0
60
0
80
0
90
0
100
0
120
0
140
0
160
0
A
MPLITUDE
STAINLESS
STEEL
FERROUS
NON-FERROUS
VIBRATION
180
0
VIBRATION
PRODUCT
SIGNAL
Fig 3 Effects of Unwanted Signals
In general if operating the detector with any product
which exhibits a product effect the Non
Ferrous/Stainless Steel sensitivity will decrease.

FEATURES
4618 - 021 3
Features of your Metal Detector
Product Numbers
When installed on a product line there may be many
different types of product passing through the metal
detector at different times.
To get the maximum performance from your metal
detector these different products may require different
settings for sensitivity and the phase control. For this
purpose Safeline metal detectors can store settings
for up to 21 products. These settings may then be
recalled by the operator, as required, by selecting a
specific ‘product number’ for each product name in
the detector.
Timer Groups
Experience has shown that although there may be a
need for up to 21 product settings for the sensitivity
and phase control, the type of reject mechanism used
by the 21 products falls into one of a few groups.
Safeline metal detectors allow the engineer to set up
a reject mechanism/timer type once and associate
this with a timer group.
Individual product numbers can then be assigned to
one of these timer groups.
This means that the reject timers do not have to be
set 21 times - just once for each group.
In general, only one timer type and setting will be
required for most applications.
Timer Types
A wide range of timer types and settings are available
to the engineer.
Five different timer types are supported by Safeline
metal detectors, each type has programmable
settings.
Each timer group may be set as either of the following
timer types:
Timer tm1 is a simple reject timer without any delay
time.
Timer tm2 is a delayed reject timer for use in fixed
speed applications.
Timer tm2G is a gated version of tm2 allowing for
more accurate rejection of discrete product.
Timer tm3 is a variable speed version of tm2
Timer tm3G is a variable speed version of tm2G
Automatic Setup
This is a feature that allows phase control and
sensitivity, and frequency of operation (multi-
frequency option only) of the metal detector to be set
up automatically.
Product Signal Cancellation (PSC)
(option)
Phasing out a product effect signal whether manually
or automatically very often does not eliminate the
product signal entirely. The remaining signal normally
means that the detector’s sensitivity must be reduced
to eliminate the product signal entirely, and this in turn
leads to reduced performance.
Product signal cancellation aims to eliminate any
remaining product effect signal without the need for
running at reduced sensitivity.
A pack sensor must be fitted for this option.
Automatic Tracking (option)
Some products have characteristics that may vary
with time or temperature, for example, this feature will
minimise this effect by adjusting its preset settings
automatically in order to maintain optimum spherical
performance.
A pack sensor must be fitted for this option.
Inverse Detection
This feature is used in applications where the
absence of a metal contaminant, rather than the
presence of one, needs to be detected.
A gated timer must be used with this feature.

FEATURES
44618 - 021
QUALITY ASSURANCE SUPPORT (OPTION)
(Performance Validation Routines -PVR
Two modes of detector operation, (QA Inspector mode
and QA Operator mode) help the user comply with
ISO 9000 and BS5750, by ensuring that the metal
detector system is tested and operating to the user's
specified quality assurance standards of performance.
Information may be transferred directly from the metal
detector to paper by using a printer. Refer to
Appendix C for sample printouts.
Timed requests for a check of the metal detector can
be set.
Logging of rejects and logging of changes in the
detectors settings can be set and these can be printed
out on a timed basis e.g. for companies operating 8
hour shifts - once every 8 hours.
Serial Communications
The metal detector has a serial communication port.
The link is a two wire serial connection to allow
information to be transferred to and from the metal
detector. Refer to Appendix D for more information