Thermo Scientific DSP2 Owner's manual

DSP2
Metal Detector
Conveyor, Gravity, Pipeline Applications
REC 4283 Rev B Part Number 96230

Revision History
Revision Number Date Released ECO Number Release Specifics
Revision A Original Release of the documents, see specific
documents for details
Revision B May 2007 1441 Updated to Thermo Fisher Scientific and
combined conveyor, pipeline and gravity
machines into one document.

©2005 Thermo Fisher Scientific. All rights reserved.
This document is confidential and is the property of Thermo Fisher Scientific (Thermo Scientific). It
may not be copied or reproduced in any way without the express written consent of Thermo Scientific.
This document also is an unpublished work of Thermo Scientific. Thermo Scientific intends to, and is
maintaining the work as confidential information. Thermo Scientific also may seek to protect this work
as an unpublished copyright. In the event of either inadvertent or deliberate publication, Thermo
Scientific intends to enforce its rights to this work under the copyright laws as a published work. Those
having access to this work may not copy, use, or disclose the information in this work unless expressly
authorized by Thermo Scientific.
“Microsoft” and “Windows” are either registered trademarks or trademarks of Microsoft Corporation
in the united States and/or other countries.
All other trademarks are the property of Thermo Fisher Scientific and its subsidiaries.
Software Program Licence Terms
The Software Program is licensed, not sold. Thermo Fisher Scientific, grants you a license for the
Software Program only in the country where you acquired the Equipment, as defined below. You
obtain no rights other than those granted you under this license.
The term “Equipment” means the equipment with which the Software Program is used. The term
“Software Program” means the original and all whole or partial copies of the Software Program used
in connection with Equipment sold by Thermo Fisher Scientific to the user, including modified copies
or portions of the Software Program. Thermo Scientific retains title to the Software Program, as well as
all improvements, modifications and enhancements to the Software Program, whether made by
Thermo Scientific or any other party. Thermo Scientific owns, or has licensed from the owner,
copyrights in the Software Program.
You are responsible for the selection of the Equipment.
Following the commissioning of the Equipment, any change made by the user to the Software
Program will terminate all warranties with respect to the Equipment and Software Program.
All other trademarks are the property of Thermo Fisher Scientific and its subsidiaries.
License
Under this license, you may:
1. Use the Software Program on only one piece of equipment at any one time, unless the license
information specifies otherwise;
2. Copy the Software Program for backup or in order to modify it;
3. Modify the Software Program and/or merge it into another Software Program; and
4. Subject to the following limitations, transfer the possession of the Software Program to another
party, but only in connection with a transfer of the Equipment.

If you transfer the Software Program, you must transfer a copy of these License Terms, all other
documentation and at least one complete, unaltered copy of the Software Program to the other party.
Unless you have other copies of the Software Program to be used in connection with other Equipment
purchased from Thermo Scientific, or one of its divisions, you must, at the same time, either transfer
all your other copies of the Software Program to the transferee of the Equipment or destroy them.
Your license is then terminated. The other party agrees to these terms and conditions by its first use of
the Software Program.
You must reproduce the copyright notices(s) on each copy of the Software Program.
You may not:
1. Use, copy, modify, merge, or transfer copies of the Software Program except as provided in this
license;
2. Reverse engineer, decompile, or disassemble the Software Program; or
3. Sub-license, rent, lease, or assign the Software Program.
Limitation of Remedies
Thermo Scientifics’ entire liability under this license is the following:
Thermo Scientific will: (a) replace defective media, or (b) make a warranted Software Program operate
or (c) replace the Software Program with a functionally equivalent Software Program, as warranted.
For any claim (including breach), in any form, related in any way to this license, Thermo Scientifics
liability will be for the actual value of the Software Program.
Thermo Scientific will not be liable for any lost profits, lost savings, any incidental damages, or other
economic consequential damages, even if Thermo Scientific, or its authorized supplier, has been
advised of the possibility of such damages. Thermo Scientific will not be liable for any damages
claimed by you based on any third party claim.
General
Thermo Scientific may terminate your license if you fail to comply with the terms and conditions of
this license. In such event, you must destroy all your copies of the Software Program. You are
responsible for payment of any taxes, including personal property taxes, resulting from this license.
Occupational Safety and Health Act (OSHA)
The Occupational Safety and Health Act clearly places the burden of compliance on the user of the
equipment and the act is generalized to the extent that determination of compliance is a judgment
decision on the part of the local inspection. Hence, Thermo Scientific will not be responsible for
meeting the full requirements of OSHA in respect to the equipment supplied or for any penalty
assessed for failure to meet the requirements, in respect to the equipment supplied, of the Occupational
Safety and Health Act, as interpreted by an authorized inspector. Thermo Scientific will use their best
efforts to remedy such violation at a reasonable cost to the buyer.

Thermo Scientific Warranty
The seller agrees, represents, and warrants that the equipment delivered hereunder shall be free from
defects in material and workmanship. Such warranty shall not apply to accessories, parts, or material
purchased by the seller unless they are manufactured pursuant to seller's design, but shall apply to the
workmanship incorporated in the installation of such items in the complete equipment. To the extent
purchased parts or accessories are covered by the manufacturer's warranty, seller shall extend such
warranty to buyer.
Seller's obligation under said warranty is conditioned upon the return of the defective equipment,
transportation charges prepaid, to the seller's factory in Minneapolis, Minnesota, and the submission of
reasonable proof to seller prior to return of the equipment that the defect is due to a matter embraced
within seller's warranty hereunder. Any such defect in material and workmanship shall be presented to
seller as soon as such alleged errors or defects are discovered by purchaser and seller is given
opportunity to investigate and correct alleged errors or defects and in all cases, buyer must have
notified seller thereof within one (1) year after delivery, or one (1) year after installation if the
installation was accomplished by the seller.
Said warranty shall not apply if the equipment shall not have been operated and maintained in
accordance with seller's written instructions applicable to such equipment, or if such equipment shall
have been repaired or altered or modified without seller's approval; provided, however, that the
foregoing limitation of warranty insofar as it relates to repairs, alterations, or modifications, shall not
be applicable to routine preventive and corrective maintenance which normally occur in the operation
of the equipment.
“EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN, SELLER
DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT
DELIVERED HEREUNDER, INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR USE. THE SOLE LIABILITY OF SELLER ARISING
OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO
BREACH OF THOSE WARRANTIES. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH
OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR
REPLACEMENT OF ANY DEFECTIVE ACCESSORY, PART OR MATERIAL WITH A
SIMILAR ITEM FREE FROM DEFECT, AND THE CORRECTION OF ANY DEFECT IN
WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES.”
Purchaser agrees to underwrite the cost of any labor required for replacement; including time, travel,
and living expenses of a Thermo Scientific Field Service Engineer at the closest factory base.
Thermo Fisher Scientific
501 90th Ave. NW
Minneapolis, MN 55433
Phone: [phone]
Fax: [phone]

Disclaimer
Though the information provided herein is believed to be accurate, be advised that the information
contained herein is not a guarantee for satisfactory results. Specifically, this information is neither a
warranty nor guarantee, expressed or implied, regarding performance, merchantability, fitness, or any
other matter with respect to the products, and recommendation for use of the product/process
information in conflict with any patent. Please note that Thermo Scientific reserves the right to change
and/or improve the product design and specifications without notice.

Preface Section
Thermo Fisher Scientific no longer manufactures the DSP2 metal
detector. This manual is designed for support of the machinery.
As part of this document you will find:
• DSP2 Conveyor Installation and Operation
• DSP2 Gravity Installation and Operation
• DSP2 Pipeline Installation and Operation
• Service Repair and Replacement Parts
Thermo Electron Corporation Title Page i

This page left blank intentionally

Model DSP2
Installation and Operation
Conveyor Applications

This page left blank intentionally

5
Preliminary Inspection
Equipment
Model DSP 2 metal detector consists of four (4) major components:
1) Search Head
The Search Head, which contains the inspection coils, through which the
product to be monitored is passed.
2) Control Unit
The Control Unit, which contains the user interface controls, and main
board electronics.
The Control Unit may be ordered directly mounted to the Search Head or
remotely mounted. In the latter case, the correct length of cable is supplied
with the Search Head.
3) Power Supply
The Power Supply Unit, which houses the power supplies, input/output devices and connection terminal strip.
4) Photo Eye
The Photo Eye. When inspecting discrete products a photo eye is needed to indicate the location of each package.
Preliminary Inspection
Check the contents of crate or crates against the order and/or packing slip. Look specifically for any reject device which might
have been ordered with the equipment. Some reject devices (e.g.: an air-jet solenoid) are quite small and may get discarded with
the packing. Check the equipment for any signs of damage in shipment.
Included with each metal detector are the following;
•Installation and Operation Manual
•Nylon Foot Mount and Nylon Bushings ( 4 of each )
•Metal Test Samples
NOTE:
If there are any signs of external damage to the crate, notify the transport company and do not discard the crate, it may have to
be inspected by an insurance inspector.
A = Aperture Width
B = Aperture Height
C = Through Dimension
X = Aperture Border
Power Supply
Search Head
Remote Control Box
( Optional )
Figure 1
X + 1/2”
B
X + 1/2”
X
A
X + 2 1/2”
C
Nylon
Bushing
Nylon Foot
Mount
Figure 2

6
Systems
Goring Kerr manufactures various types of metal detectors and metal detector systems. This manual illustrates the installation
requirements of the most common configuration, the belt conveyor system. However, the methods shown within this manual
apply to all of the systems Goring Kerr manufactures. This manual is also available in a Windows Help format. Contact Goring
Kerr on how to receive a your copy.
Model 402 Gravity Feed System
The model 402 system is supplied completely assembled and tested from the factory. The system
you have may vary from that shown here. Four mounting holes are located at the top of the frame to
support this system. The typical mounting method is to suspend the system with threaded rod. The
threaded rod should support the complete load of the system. When securing the threaded rod to
the 402 frame isolation bushings should be used on all four mounting holes. This will electrically
isolate the frame from any support structure. The 402 system is not designed to support piping from
any of the ports. Piping connected to any of the ports should be independently supported. Hanging
piping from the reject value may distort the valve body and cause unreliable rejection.
( See manual NA-DSP2/GRAV )
Model 426 Pipeline System
The model 426 pipeline system is supplied completely assembled and tested from the
factory. Four mounting holes are located in the corners of the support frame. The typical
mounting method is to suspend the system with threadedrod. The threaded rod should
support the complete load of the system. When securing the threaded rod to the 426
frame isolation bushings should be used on all four mounting holes. This will electrically
isolate the frame from any support structure. Any pipes connected to the system should
be independently supported and not supported by the metal detector system.
( See manual NA-DSP2/PIPE )
Model T7 Pharmaceutical System
The model T7 pharmaceutical system is supplied completely assembled and tested
from the factory. The system is ready to use right from the crate. The reject device,
control unit and search head are pre-wired. The mains supply power cord is also pre-
wired.
( See manual NA-DSP2/PHARM )
Model 402
Figure 3
Model 426
Figure 4
Figure 5

7
Metal Detector Principle Of Operation
The DSP 2 model metal detector operates on the balance coil full loop detection system.
Three equally spaced coils surround the aperture or opening through which the product to be inspected passes. The center coil
is connected to an oscillator circuit to produce an electromagnetic field. This signal is received by two coils one on either side of
the oscillator coil. These are the receiving or input coils. (See Figure 6)
Since the receiving coils are equally spaced from the oscillator, they receive equal amounts of signal. The coils are wound in
such a way that their signals oppose each other; therefore, the net signal across the coil is zero.
When a piece of metal enters within the electromagnetic field, it alters the field strength around it. As this metal passes through
the aperture, it changes the balance of the receiving coils so that the net signal is no longer zero.
This error signal is amplified, demodulated and converted to a digital signal to be processed by the Digital Signal Processor or
DSP. The DSP performs all the product compensation, phasing, residual compensation filtering, and produces a reject signal.
A metal detector is a high performance measuring instrument. The quality of the installation will have a direct effect upon
performance and reliability. Please read the installation instructions completely prior to installing the unit and contact Goring
Kerr if you have any questions.
Figure 6

8
Mechanical Installation
The power supply unit and control unit (if remote) may be mounted as any other electrical control would be, wherever
convenient. However, the search head must be installed as per the following instructions if correct performance is to be
expected. Please contact Goring Kerr if you have any questions regarding installation requirements and restrictions.
Warning
To insure optimum performance the following considerations should be taken:
•Avoid contaminating the belt with metal fragments, weld splatters, etc. during installation.
•Use belting material designed for metal detectors. Antistatic or colored plastic chain belting may contain pigments
that could affect the performance of the metal detector.
•Variable speed drives, walkie talkies or RF transmitters may affect the performance of the metal detector.
Contact Goring Kerr for assistance.
Safety
To insure personal safety care must be taken when working on or around the metal detector conveyor. As with all such devices
the main supplies ( electrical and air ) to the conveyor must be locked off when performing repair or maintenance work. After
disconnecting the supplies to the conveyor cycle the metal detector reject device to evacuate any air left in the system. Then
switch off and lock the electrical supply to the metal detector.
Search Head Mounting And Isolation
The detector is supplied with four nylon isolation mounts and four nylon washers which should be used to attach the search
head to the conveyor. These mounts ensure a rigid, electrically isolated mounting. Be sure to drill the frame hole large enough
for the shoulder of the isolation bushing. This will isolate the bolt shaft from the frame. Care must be taken to ensure electrical
isolation of the mounting bolt and support frame. (see Figure 7)
Metal Detector
Foot
Nylon Foot
Mount
Mounting Bolt
Nylon Bushing
Figure 7
Mounting Bolt
Nylon Bushing
Nylon Shoulder

9
Metal Free Area
While the detector is shielded above, below and on the sides, metal objects have to be kept from the entrance and exit of the
detector opening as shown below. No metal can be located in this area. Large moving metal should be kept fifty (50) percent
further away or at least two (2) times the smaller aperture dimension. (see Figure 8). There are special models available for
operation in areas which require smaller metal free areas. Contact Goring Kerr for more details.
Aperture Width
A
1.5 * B
1.5 * B
C
Aperture
Height
B
Figure 8
Aperture Clearance
It is important that nothing is allowed to touch any part of the detector's aperture. A slider bed or board is required to support
the load of the product on the belt. This can be any non-metallic material; phenolic is recommended as it is easy to machine,
does not generate static and has good wearing properties. The slider board must be supported outside the search head and
should not rest on any part of the detector. One suggested way of installation is illustrated below. (see Figure 9)
Conveyor BeltSlider board
support
Slider Board Clearance
Figure 9

10
Loop Effect
Besides observing rules for metal-free areas, precautions should be taken to prevent the occurrence of loop effect. Loop effect
is caused by an electrical loop in the conveyor, which is allowed to make intermittent contact (see Figure 10). This loop, when
closed, can produce a large electromagnetic field. When the loop opens, the field collapses very rapidly, causing the detector's
field to be disturbed. This results in false detections. Loops can be caused by rollers whose bearings make intermittent
connection, or any metal which crosses the conveyor frame that is not securely fastened (e.g.: transfer plate, loose cross
member, electrical conduit, retracting reject or flap gate reject).
Metal Free Area Loop Effect Area
Electrical Loop
Roller
Cross Members
Legs
Side Panel
Bearing
Figure 10

11
Roller Isolation
Loop effect is most prominent with detectors having an aperture height ( smaller dimension ‘B’ ) greater than five inches and a
width ( or ‘A’ dimension ) greater than twelve inches. Loops as far as three feet away may affect the operation of the metal
detector. This depends on roller, bearing and frame materials and on the quality of contact.
It is recommended that all cross members and transfer plates, etc., be welded or securely fastened. Rollers, of course, cannot be
secured and, therefore, should be isolated from making electrical contact. Only one side of each roller assembly needs to be
isolated. DO NOT isolate both ends. The materials generally used are plastic and phenolic.
Option 1) Stub Shaft
With this design the roller shaftdoes not continue through the roller. This
separation removes the electrical loop within the roller.
Note: The roller must be non-metallic
Option 2) End Cap
Placing a closed ended plastic cap on one end of the roller shaft will break
the electrical connection between the shaft and bearing assembly.
Option 3) Bearing Isolation
Isolating the bearing assembly requires both isolation of the housing, and the
mounting bolts. An insulating sleeve is used to electrically isolate the bearing
housing from the conveyor frame. Plastic inserts are used to isolate the
mounting bolts from the bearing assembly.
Option 4) Plastic Bearing
The plastic bearing assembly is one of the easiest designs to implement.
Most plastic bearings are available in standard mount designs. However,
some plastic bearings contain a metal sleeve in the mounting holes which is
internally connected to the bearing raceway. With this bearing plastic
inserts would have to be used to create the electrical isolation.
Standard Roller
Design
Figure 11 Stub Shaft
Design
Shaft does not continue
through roller
Non-metalic roller
End Cap
Design
Plastic Cap
Roller
Conveyor Frame
Bearing Assembly
Plastic Inserts
Insulating Sleeve
Isolated Bearing
Design
Roller
Plastic Bearing Housing
Plastic Bearing
Design

12
Vibration
Efforts should be made to reduce excessive vibration, especially if a conductive (wet) product is to be inspected.
Conveyor Separation
If you have a separate conveyor for the metal detector system ( which is preferred ), you must make certain that this conveyor
does not make intermittent contact with the infeed and discharge conveyors. Fastening them with a non-metallic material is the
recommended method as shown below. (see Figure 12)
Non-metallic Strap
Metal Free Area Loop Effect Area
Gap
Figure 12

13
Electrical Installation
When choosing the power supply line for the metal detector, it should be remembered that starting of heavy electrical machinery
creates very considerable (though momentary) voltage drops in the line. Such "spikes" can cause the metal detector to trigger.
Since the power consumption of the detector is very low (approximately twenty-five watts), it is recommended that a lighting
circuit be used for its supply rather than a machinery power circuit. Where this is not possible, and line noise does trigger the
detector, contact Goring Kerr for recommendation of a suitable isolation transformer or power line filter.
a) The metal detector connections are shown in the Power Supply Connections section. If the control unit is mounted on the
search head, the connections from the search head to the control unit are already made.
b) The cable between the power supply unit and control unit is of a specific type. Do not substitute or splice on
extra cable. Likewise, the cable between the control unit and search head (when remote) is of a specific type.
Do not substitute or splice on extra cable. Either cable can be cut to length and they are notsensitive to
movement. Contact Goring Kerr for extra cable or cable information if required.
c) Use waterproof cable glands at all cable entries.
Power Supply Layout
L N E
E N L 1 2 3 4 5 6 7 8 9
F1
F2
F3
F4
F5
F7
F6
SW1
LK2
LK4
LK3
LK5
LK6
LK1
LK1
TP12
TP10
TP9
TP5
TP4
TP11
TP7
TP6
RL4
RL3
RL2
RL1
GORING KERR
DSP 2 POWER SUPPLY
REV:3.0
PL2 PL3
PL4
PL5
PL6
Analog
Secondary Fuse
Digital
Secondary Fuse
115
PL1
LD 3
(7VDC)
LD 6
LD 7
(24VDC)
Figure 13

14
Power Supply Connections
Main connector PL1 Main Connector
Line F1
Neutral
Earth
Earth
Neutral
Line
Reject
Reject F2
Reject
Fault
Fault F3
Input / Output 1
Input / Output 1 F4
Input / Output 2
Input / Output 2 F5
L
N
E
E
N
L
1
2
3
4
5
6
7
8
9
Mains
Supply
Special Function
Input/Output
Devices
Fault Output
Reject Output RL1
RL2
RL3
RL4
Figure 14
Mains Supply
Connect the supply line to, L-Live, N-Neutral, E-Ground (Earth).
Either 110 or 220 volts single phase can be used to power the metal detector. A selection switch ( SW1 )on the power supply
board will switch between voltages. The metal detector can operate on either 50 or 60 Hertz, 55 va.
Fuses
Fuses F1 to F4 are 1 Amp 250 volt fast acting fuses, only use fuses with the same rating for replacements. Secondary fuses F6
and F7 are 2 Amp 250 volt slow blow, use only same rating for replacement.
Reject Output
When metal is detected or detector power is turned off dry contacts 1 and 2 close, 2 and 3 open. Terminal 2 is fused 1 Amp 250
volt fast acting fuses. To supply typical reject device (e.g.: solenoid), connect jumper from L to 2, connect solenoid to 1, N and
E, or 3, N, E, depending on action required.
NOTE: DAMAGEmay occur if wrong voltage is applied to relays !
Solid state relays are available. Check power unit lid for description of relay type. Mechanical relays are AC or DC -
only terminals 2 and 3 are used for reject.
Fault Output
During a fault condition or when power is turned off terminals 4 and 5 will close. These connections can be connected to an
external alarm to indicate a fault condition. Terminal 5 is fused at 1 Amp 250 volt fast acting fuses.
Note: It is advised that the fault output be connected to either a fault alarm e.g. horn, or to the reject device.
Special Function Input / Output Devices
Terminals 6, 7, 8, 9 are for use with special options. Terminals 7 and 9 are fused at 1 Amp 250 volt fast acting fuses.
Note: I/O devices are not normally fitted. DO NOT connect to these terminals if it is unclear of the type or voltage rating of
devices fitted. Permanent damage may occur if incorrect voltage is applied.