Thermo Scientific Oretronic III Instruction and safety manual

Oretronic III
Tramp Metal Dector
Operating & Service Manual
REC 4105, Rev. L Part Number 060298-English

Revision History
Revision Number Date Released ECO Number Release Specifics
Revision A July 2000 Manual released. This revision documents
version 1..01 of the Oretronic III Tramp Metal
Detector Software
Revision B October 2000 Manual revised to add information about the
underbelt single coil model and remote front
panel.
Revision C January 2002 This revision documents version 1.04 of the
Oretronic III Tramp Metal Detector software.
Manual revised to add information about
Electronically Simulated Tramp (EST) optional
system and UL updates.
Revision D November 2002 This revision documents changes for software
version 1.05. Maximum clips delay extended to
30 feet.
Revision E August 2003 3497 This revision documents changes for software
version 1.06 Auto Zero or F5 disabled after
control alarms on tramp, or if in calibrate mode.
F5 can be disabled by turning on SW1-7.
Revision F January 2005 0516 Revise errors
Revision G June 2005 0641 Revise errors
Revision H May 2007 1392 This revision makes name changes to Thermo
Fisher Scientific.
Revision J December 2009 2180 Rebrand and upgrade format
Revision K August 2010 2383 Graphics of figure 2-4 & 4-1 and update wiring
diagrams attached to manual
Revision L March 2011 2408 Revise errors

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All other trademarks are the property of Thermo Fisher Scientific and its subsidiaries.

About this Manual
This manual provides the information you need to install, operate, and
maintain the Oretronic III Tramp Metal Detector (TMD). This revision
documents version 1.06 of TMD software.
Read this manual before working with the system. For personal and
system safety, and for the best product performance, make sure you
thoroughly understand the manual before installing, operating, or
maintaining this machine.
Instructions in this manual may require special precautions to ensure the
safety of the personnel performing the operations.
Potential safety issues are indicated by this symbol:
Please read the safety information before performing any operation
preceded by this symbol.
There are two levels of safety messages: warnings and cautions. The
distinction between the two is as follows:
WARNING
Failure to observe could result in death or
serious injury.
CAUTION
Failure to observe may cause minor injury or
damage the equipment
Safety
Messages

Do not install, operate, or perform any maintenance procedures until you
have read the safety precautions presented below.
General
Precaution
WARNING
Failure to follow safe installation and servicing
procedures could result in death or serious injury.
Make sure only qualified personnel perform
installation and maintenance procedures in
accordance with the instructions in this manual.
Allow only qualified electricians to open and work in
the electronics cabinest, power supply cabinest,
control cabinets, or switch boxes.
Covers over the electronics and rotatingpartsmust
always remain in place during normalooperation
Remove only for maintenance, with the machine’s
power OFF. Replace all covers before resuming
operation.
During maintenance, a safety tag (not supplied by the
factory) is to be displayed in the ON/OFF switch
areas instructing others not to operate the unit
(ANSI:B157.1).
WARNING
Use only the procedures and new parts specifically ref-
erenced in this manual to ensure specification perfor-
mance and certification compliance. Unauthorized
procedures or parts can render the instrument dangerous
to life, limb, or property.
WARNING
High voltage that may be present on leads could cause
electrical shock.
All switches must be OFF when checking input AC
electrical connections, removing or inserting printed
circuit boards, or attaching voltmeters to the system.
Use extreme caution when testing in, on, or around
the electronics cabinet, PC boards, or modules. There
are voltages in excess of 115 V or 230 V in these
areas.

CAUTION
Keep hands and clothing away from all moving or
rotating parts.
CAUTION
Do not place or store objects of any kind on the
machine.
CAUTION
This machine should not be operated at more than the
production rate stated on your Equipment Specification
sheet or used in applications other than those stated in
the original order.

Contents
Chapter 1 Introduction..........................................................1-1
Overview ..............................................................................1-1
Theory of Operation..............................................................1-1
System Components............................................................1-4
Support Structure & Coils ..................................................1-6
Control Unit........................................................................1-7
Features and Options...........................................................1-7
Simplified Operator Interface.............................................1-7
Remote Front Panel...........................................................1-8
Synchronization of Transmitter Pulses...............................1-8
Speed Sensor....................................................................1-8
Clip Detector......................................................................1-8
High Pile Detector..............................................................1-9
Timed Delay Marker ..........................................................1-9
System Requirements..........................................................1-9
Technical Specifications.....................................................1-10
Chapter 2 Installing the TMD................................................2-1
Overview ..............................................................................2-1
Installation Considerations ...................................................2-1
Mounting Location................................................................2-2
Electrical Specifications........................................................2-2
Input Power Requirements...................................................2-2
Safety Precautions ...............................................................2-3
Equipment Handling.............................................................2-4
Inspection and Unpacking....................................................2-4
Inspection and Unpacking....................................................2-4
Installing the TMD.................................................................2-4
Installing the Coil Support Structure and Coils for a
Dual Coil TMD ...................................................................2-4
Installing the Coil Support Structure and Coil for an
Under Belt Single Coil TMD...............................................2-5
Installing System Devices..................................................2-6
Mounting the Control Unit..................................................2-7
Field Wiring the TMD.........................................................2-9
Critical Wiring Conditions................................................2-9
Field Wiring Procedure..................................................2-10
Connecting Incoming Power...............................................2-11
Configuring the TMD ..........................................................2-12
DIP Switch Settings .........................................................2-12
CPU Board Switch Settings.............................................2-13
Initial Power On..................................................................2-15

Calibrating the Speed Sensor ............................................2-16
Determining Values to Use for Initial Setup........................2-16
Determining Belt Speed...................................................2-17
Determining Clip Delay....................................................2-17
Determining Timed Delay................................................2-17
Chapter 3 Operating the TMD ..............................................3-1
Overview..............................................................................3-1
Operator Interface................................................................3-1
Operating Modes...............................................................3-2
Menu Structure.....................................................................3-2
Front Panel Keypad...........................................................3-4
SCROLL Keys ................................................................3-4
VALUE Keys...................................................................3-4
ENTER Key ....................................................................3-4
RESET Key.....................................................................3-5
Front Panel LED Indicators ...............................................3-5
NORMAL ........................................................................3-5
ALARM ...........................................................................3-5
BYPASS .........................................................................3-5
CALIB .............................................................................3-5
Bar Graph.......................................................................3-5
Front Panel Displays .........................................................3-6
Run Screen.....................................................................3-6
Password Protection Screen...........................................3-7
Calibration Screens ........................................................3-8
Coil Balance....................................................................3-8
Calibrate for Metal ..........................................................3-9
Calibrate for Clip.............................................................3-9
EST Cal ........................................................................3-10
Test...............................................................................3-10
Exit................................................................................3-11
Setup Screens..............................................................3-11
Clip Delay .....................................................................3-11
Bar/Rod Sensitivity .......................................................3-11
Bar/Rod Length.............................................................3-12
Belt Speed....................................................................3-12
Timed Delay..................................................................3-12
Timed Duration.............................................................3-12
Audit Int.........................................................................3-12
Material Code ...............................................................3-12
Time Constant ..............................................................3-12
Filter..............................................................................3-13
Operating Frequency....................................................3-13
Remote Front Panel......................................................3-13
Modbus Communications .............................................3-13
Switch Settings.............................................................3-13

Front Panel Tests..........................................................3-14
Software Version...........................................................3-14
Exit................................................................................3-14
Error Messages.............................................................3-14
Error Conditions............................................................3-14
Fault Conditions............................................................3-15
Setting up the TMD.............................................................3-16
Before You Begin.............................................................3-16
Using the Display Scroll...................................................3-17
Entering Values ...............................................................3-17
Initial Setup Procedure.....................................................3-17
Chapter 4 Maintaining & Troubleshooting..........................4-1
Overview ..............................................................................4-1
Routine Maintenance............................................................4-1
Troubleshooting....................................................................4-2
Visual Inspection................................................................4-2
Diagnosing and Correcting Problems ................................4-3
False Tripping.......................................................................4-4
Correcting Coil Imbalance..................................................4-4
Finding the Source of Mechanical or Electrical Noise........4-7
Adjusting for High Product Noise (Mineral Ores).............4-10
Adjusting for Bar/Rod Detection.......................................4-12
Adjusting for Clip (Belt Splice) Detection .........................4-13
Passing Tramp Undetected................................................4-17
Adjusting Metal Sensitivity...............................................4-17
Changing the Material Type Code to Adjust Sensitivity ...4-19
Testing for Coil or Junction Box Damage.........................4-20
Testing the Transmitter Coil..........................................4-22
Testing the Receiver Coil..............................................4-22
Determining TMD Malfunction .........................................4-23
Passing Bars or Rods Undetected......................................4-27
Installing Default Values.....................................................4-28
Error Messages..................................................................4-29
Error Conditions...............................................................4-29
Fault Conditions...............................................................4-30
Chapter 5 Service, Repair, & Replacement Parts...............5-1
Service and Repair Information............................................5-1
Parts Ordering Information...................................................5-2
Parts Lists.............................................................................5-3
Disposal of Hazardous Waste .......................................... 5-5-3
Appendix A - TMD Modbus Interface ....................................A-1
Overview of TMD Communications.......................................... A-1
Modbus Message Types Supported by the TMD................... A-1
Example: Read Holding Registers ........................................ A-2
Example: Preset Multiple Registers...................................... A-2

Exception Responses.............................................................. A-3
Master/Slave Timing Considerations.................................... A-3
TMD Holding Registers........................................................... A-3
Appendix B - Remote Front Panel........................................ B-1
Overview........................................................................................B-1
Routine Maintenance...................................................................B-1
Technical Specifications..............................................................B-2
Installing the Remote Front Panel.............................................B-3
Mounting the Remote Front Panel ............................................B-4
Field Wiring the Remote Front Panel .............................................B-6
Input Power Requirements......................................................B-6
Critical Wiring Conditions.........................................................B-6
Field Wiring Procedure................................................................B-7
Setting the Comm Switches .......................................................B-9
Setting up and Operating the Remote Front Panel ................B-9
Parts List......................................................................................B-10
Appendix C - Electronically Simulated Tramp (EST)........... C-1
Theory of Operation........................................................................C-1
Mechanical Installation................................................................C-1
Electrical Installation....................................................................C-2
Calibration and Setup..................................................................C-2
Interval Setup................................................................................C-2
Last EST (EST Last).................................................................C-3
EST Test (EST Test) ................................................................C-3
Appendix D Engineering Drawings...................................... D-1

List of Figures
Figure 1–1. Magnetic Fields Generated by the TMD .............................1-2
Figure 1–2. How Conductivity Affects Decay Time..............................1-2
Figure 1–3. Ore/Tramp Metal Decay Time Comparison........................1-3
Figure 1–4. Measurement Window Timing............................................1-3
Figure 1–5. Signal Sensitivity/Measurement Timing Adjustment .........1-4
Figure 1–6. TMD System Components: Dual Coil ................................1-5
Figure 1–7. TMD System Components: Under Belt Single Coil ...........1-6
Figure 1–8. Oretronic III Control Unit ...................................................1-7
Figure 2–1. Control Unit Mounting Dimensions....................................2-7
Figure 2–2. Control Unit Enclosure - Bottom View...............................2-8
Figure 2–3. Terminal Block Locations on the CPU Board...................2-10
Figure 2–4. Switch Locations on the CPU Board.................................2-14
Figure 3–1. Tramp Metal Detector Front Panel......................................3-2
Figure 3–2. TMD Menu Tree..................................................................3-3
Figure 4–1. Terminals on the CPU Board ............................................4-21
Figure B–1. Remote Front Panel Dimensions ....................................... B-5
Figure B–2. Interior of the Remote Front Panel Enclosure ................... B-7
List of Tables
Table 2–1. SW1 DIP Switch Settings...................................................2-13
Table 2–2. CPU Board Switch Settings................................................2-15
Table 2–3. Comm Switch SW4 Settings...............................................2-15
Table 3–1. Error Messages ...................................................................3-15
Table 3–2. Fault Messages....................................................................3-16
Table 4–1. Error Messages ...................................................................4-30
Table 4–2. Fault Messages....................................................................4-31
Table A–1. TMD Exception Responses.................................................A-3
Table B–1. Comm Switch Settings........................................................ B-9

Thermo Fisher Scientific Introduction 1-1
REC-4105 Rev L
Chapter 1 Introduction
This chapter introduces the Oretronic III Tramp Metal Detector (TMD).
It gives an overview of the device’s capabilities, describes its basic
functionality, and lists its technical specifications.
The Oretronic III Tramp Metal Detector (TMD) detects the presence of
tramp metal in bulk material being transported on a conveyor belt.
Detected tramp metal can then be removed from the process stream
manually or automatically by mechanical means. Removing the tramp
metal protects crushers, material handlers, and process equipment from
the damage it may cause.
This highly reliable system detects all types of tramp metal that could be
found in bulk material on belt conveyors even when it is buried in wet,
conductive materials. Tramp metal could include such things as bucket
teeth, manganese steel mantles, bore crowns, bar scrap, chains, and
tools. The bulk material (or burden) can be product such as iron pellets,
minerals, aggregates, coal, or coke.
The Oretronic III TMD can be installed on conveyors with speeds up to
1,200 ft/min (6.1 m/s). In addition, because it is insensitive to materials
with high magnetic permeability and electrical conductivity, this
detector can be used in applications where conventional metal detectors
produce an unacceptable false alarm rate.
The Oretronic III TMD has a microprocessor-based control unit that
automates system setup and calibration. The operator interface provides
easy-to-read indicators, a touch panel keypad designed to simplify
setting up, and maintaining the system.
The TMD operates by generating a pulsed magnetic field (the primary
magnetic field) that is radiated from its transmitter coil. This field
generates an output signal in the receiver coil (see Figure 1-1).
When the pulse is turned off, eddy currents induced in tramp metal pro-
duce a secondary magnetic field. This new field also generates an
output signal in the receiver coil. The detector measures the effect of
this secondary magnetic field only during the time the primary field is
inoperative.
Overvie
w
Theory o
f
Operation

Introduction
1-2 Introduction Thermo Fisher Scientific
REC-4105 Rev L
Figure 1–1. Magnetic Fields Generated by the TMD
The material on the conveyor belt also produces a secondary magnetic
field. The two magnetic fields can be distinguished from each other
by observing their decay times. The better the conductivity
characteristics of the material, the longer the decay time. As the
magnetic field decays, the output signal strength decreases (see Figure
1-2).
Figure 1–2. How Conductivity Affects Decay Time
RECEIVER
COIL
TRANSMITTER
COIL
PRIMARY
MAGNETIC
FIELD
TRAMP
METAL
SECONDARY
MAGNETIC
FIELD

Introduction
Thermo Fisher Scientific Introduction 1-3
REC-4105 Rev L
Coal, aggregate, and mineral ores have conductivity characteristics
considerably poorer than tramp metal, which means their magnetic field
decays more quickly (see Figure 1-3).
Figure 1–3. Ore/Tramp Metal Decay Time Comparison
The Oretronic III TMD is designed to take advantage of the difference in
decay time by activating its measurement window (the point at which it
reads the output signal) only after the magnetic field from the material
on the conveyor has decayed and before the tramp's decay has ended
(see Figure 1-4. Using this measurement window timing helps prevent
both false trips and passed tramp metal.
Figure 1–4. Measurement Window Timing

Introduction
1-4 Introduction Thermo Fisher Scientific
REC-4105 Rev L
The Oretronic III TMD allows you to adjust both the sensitivity of the
device to output signals and the location of the measurement window
in the decay time. Signal strength is adjusted by a sensitivity factor;
the measurement-timing window is adjusted based on a material type
code factor. (See Figure 1-5).
Figure 1–5. Signal Sensitivity/Measurement Timing Adjustment
There are two models of the Oretronic III TMD: dual coil and under
belt single coil. The “standard” dual coil TMD has a transmitter coil
mounted above the belt and a receiver coil mounted under the belt.
The under belt single coil TMD is physically different but functionally
similar to a standard model. On an under belt single coil TMD, the
transmitter and receiver coils are together in a coil assembly mounted
under the belt.
This section describes the major components of a TMD system.
Figure 1-6 shows the components and system options for a dual coil
TMD. Figure 1-7 shows the components and system options for an
under belt single coil TMD.
System
Components

Introduction
Thermo Fisher Scientific Introduction 1-5
REC-4105 Rev L
Figure 1–6. TMD System Components: Dual Coil
(Optional)
(Optional)

Introduction
1-6 Introduction Thermo Fisher Scientific
REC-4105 Rev L
Figure 1–7. TMD System Components: Under Belt Single Coil
The coils (or coil) are mounted on a rugged support structure made of
non-conducting fiberglass material. On a dual coil TMD, the transmitter
coil is swing-mounted above the belt to protect the coil and support from
being damaged by oversized material. The receiver coil is mounted
under the belt.
On an under belt single coil TMD, the transmitter and receiver coils are
together in a coil assembly mounted under the belt. The coil support
structure does not extend above belt height (see Figure 1-7).
Coils are made of impact-resistant polyvinyl chloride (PVC) and are
designed to withstand stresses up to 10 times gravity.
The transmitter coil transmits the pulsed electrical energy to the
conveyor burden. The receiver coil receives the electrical energy signal
from the conveyor burden. Within this signal is the eddy current when
tramp metal is present.
Support Structure &
Coils
(Optional)