Instruction Manual MSG 3200

Chapter

0

1 Introduction: Construction and working principle of ELMED metal detectors 2 Items delivered, Transport, handling and storage 2.1 Items delivered 2.2 Transport, handling and storage 3 Fitting the equipment to the conveyor 3.1 Installation location 3.1.1 Weather and temperature 3.1.2 Metal-free zone 3.1.3 Effects of surroundings 3.2 Installation, general notes 4 Electrical connection 4.1 Connecting detector coil to the electronics 4.2 Interfacing with external controls 4.2.1 External clock (X8.1 to X8.4) 4.2.2 Sensitivity override (X8.5 to X8.8) 4.2.3 Remote controlled sensitivity selection (X8.11 to X8.16) 4.2.4 RS-232 interface 4.2.5 Pushbutton reset of metal output 4.2.6 Time-delayed enable of detector 4.3 Relay outputs 4.3.1 Metal present (DPDT, X4.x and X5.x) 4.3.2 Detector ready (SPDT X6.x) 4.4 Mains supply and control cables 4.5 Balancing of the detector 4.5.1 Mechanical adjustments 4.5.2 Checking the auto-balancing circuitry 5 Operating 5.1 Requirements 5.2 Front panel 5.2.1 Operator-Menu 5.2.2 Setup-Menu 6 Faultfinding: checklist of possible causes and remedies 6.1 General 6.2 False alarms for mechanical reasons 6.3 False alarms for electrical reasons 6.3.1 Fault analysis specitic to the control unit MSG 3200 7 Technical data 8 Accessories and spare parts 9 After-Sales Service 10 Guarantee 11 Appendices 11.1 Technical drawings 11.2 Circuit diagrams

2 3 3 3 4 4 4 4 5 6 7 7 8 8 9 9 9 9 9 9 9 9 10 10 10 11 12 12 12 12 17 24 25 25 26 27 28 30 31 32 33 33 33

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Instruction Manual MSG 3200
1 Introduction: Construction and working principle of ELMED metal detectors

Chapter

1

Purpose ELMED metal detectors of the MSG range serve to detect metallic foreign bodies in any electrically non conductive or slightly conductive material. Benefit This can protect high-value processing machines against damage or destruction. It also protects your finished product against metal contamination, and protects the consumer against adverse health effects due to undesired metal parts. Construction The ELMED metal detector MSG 3200 consists of the detector coil, and signal processing unit which is housed in a separate electronics cabinet. Since the specification of a metal detector equipment can vary widely according to the application, the search coil is designed specifically to the customer's requirement. Working principle The device indicates the presence of metal when the metal disturbs an electromagnetic field generated in the search coil. As a metal part in the material being monitored passes through the coil, it disturbs the "balanced" field (compensated differential circuit). The electronic signal processing unit recognises this disturbance and displays a message. The signal processing unit is the same for any type of detector coil. It consists of five plug-in Eurostandard cards in a rack module, which together with operator controls and terminal strip is mounted in an electronics cabinet with good servicing access (for drawing see appendix) For your benefit Please remember that the metal detector equipment you have purchased is a highly sensitive measuring instrument, even if it perhaps does not look like one! Your justified expectations in terms of reliability and sensitivity will only be met if the equipment is installed and operated in compliance with some basic conditions. Only if these are fulfilled we can guarantee that the equipment will function properly.

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Instruction Manual MSG 3200
2 Items delivered, Transport, handling and storage 2.1 Items delivered

Chapter

2

Upon delivery you should receive the following items: • • • • Search coil (for drawing see appendix), Control unit (for drawing see appendix), Shielded cable (usually 2 x 10m) for the connection of search coil and control unit, Shock absorbers, either already mounted under the search coil or loose strips that must be placed below the search coil, • Operating manual in the appropiate language.

Please check the delivery for completeness !

!

Attention:

The shock absorbing strips are no packaging material and must be placed below the search coil.

!

2.2 Transport, handling and storage Every metal detector leaves our factory in packing which is specially designed for transportation and storage of the unit until it is finally installed. If the metal detector is stored outdoors, suitable protection from the weather is needed. Depending on the type and size of detector coil, the coil may be supplied ready fitted, or dismantled in a separate crate or pallet. The electronics cabinet and all accessories are packed in a rugged corrugated cardboard carton, also on a pallet. Until reaching the location for final installation, the detector coil and the electronics cabinet should be left in this packing.

!

During transport, handling and during installation, no force must be exerted on the plastic panels covering the highly sensitive measurement system.
This applies especially when lifting the equipment by fork-lift truck or crane. (For instance, do not travel lift forks into the detector coil opening!)

!

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or under the plastic cover panels. Please ask our service department before installing the electronics cabinet of the metal detector together with other devices in the same cabinet. please be sure to contact our servicing department in case of any questions or doubts. If necessary. an additional metal-free zone above the detector coil must be provided. then it should be insulated on one side from the main conveyor frame. the aperture height is the tube diameter. In case of coil Type 5.DOC (10. C:\Dokumente und Einstellungen\af.1 Weather and temperature Regarding the installation location. a) Neither the detector coil nor the electronics cabinet must be installed outdoors unprotected from the weather. since this can cause mechanical stresses in the sheet steel housing of the detector coil which could bring it out of electrical adjustment. Detector coil Type 5 is used for mounting underneath the conveyor. in order to prevent condensation forming in the electronics cabinet. junction box. like any roller stations within the metal-free zone. then this.Instruction Manual MSG 3200 3 3.12 10:29) Page 4 .1. If a roller station is present just outside the metal-free zone. pointing upwards as detection direction.ELMED\Desktop\Manual_MSG3200.1. the equipment should be left switched on after the end of work or during long breaks. b) c) d) 3.04. For extra high sensitivity or if aperture heights greater than 1m use factor 6 instead of 4 3 Dimension of search coil in the direction of material travel.1 Fitting the equipment to the conveyor Installation location Chapter 3 3. Under no circumstances must moisture get into the calibration shaft1. chain conveyors or the like running above the belt! The above rule-of-thumb formula is a suitable basis for all detector coils operated at normal sensitivity. If this is not possible. In the case of under-belt coil (Type 5). The metal detector equipment and in particular the detector coil should not be exposed to direct sunlight. should be manufactured of plastics. Not only the space between detector and belt or material must be free of metal.2 Metal-free zone The zone to be kept free of metals around the equipment is calculated as follows: MFZ = (aperture height x 42) + (depth of search coil)3 In the case of round opening (Type 1). Please observe for instance. Since the metal-free zone has a great influence on the detector coil sensitivity attainable. If moisture does enter. but also the space above belt or material. an enclosed shelter must be built to protect the coil from the weather. 1 2 Only present at some types. the equipment may not work properly. the following factors need to be considered to give optimum sensitivity and highest reliability. use coil depth instead of aperture height. If the ambient temperature changes by a large amount (> 10oC) within a short time (day/night).

then these devices must be fitted with interference suppressors.) from moving in the neighbourhood of the detector coil. chutes or reversing belts are used to eject the material containing metal. C:\Dokumente und Einstellungen\af. In this case. The cables connecting the detector coil to the electronics cabinet should not be laid beside power cables or control cables to high power machines. The same applies to other electrical or electronic controls located in the region near the detector coil. or a stabiliser must be inserted in the supply line.12 10:29) Page 5 . If high detector sensitivity is required. Also no electromagnetic equipment or equipment producing sparks should be allowed in the neighbourhood of the detector.DOC (10.04. Mains supply interference due to switching of high power machines or motors can also affect the functioning of the metal detector equipment.ELMED\Desktop\Manual_MSG3200. fork-lift trucks etc. the power supply for the detector equipment should be taken from the lighting circuit instead of the power circuit. if control flaps.1.Instruction Manual MSG 3200 3. It is essential to prevent any fairly large metallic parts (machine components. For instance. and these are fitted with thyristor-triac or relay switching devices. the transmit and receive cables should be screened by laying in steel conduit.3 Effects of surroundings Chapter 3 This term covers all factors having a direct or indirect effect on the electromagnetic field of the detector coil (see Working principle).

10 mm. The detector coil is fixed to the supporting structure by means of the rubber vibration mountings. or if the conveyor belt structure is subject to heavy vibrations. size. a separate supporting structure for the detector coil is recommended. The minimum clear distance between material (or belt) and the coil must not be less than 5 . if high sensitivity is required. Regular cleaning is recommended here.04.2 Installation.DOC (10. However. the detector coil is installed on the rails after these have been adhesivefixed to the supporting structure. No force or pressure whatever must be exerted on these panels by the material being tested or the slide boards. Hardwood or anti static plastics have been found suitable for constructing the metal-free zone and the slide boards. ! For any type of coil. ! The detector coil is clad with plastic panels. depending on the material being conveyed (weight!). If the material being tested is tree-trunk timber. Guidance of the material The conveyor belt (or the like) and the material being conveyed must pass through the detector coil without touching it. Installation on a separate foundation has been found to work well. Depending on the type of detector coil. under all operating conditions.Instruction Manual MSG 3200 3.ELMED\Desktop\Manual_MSG3200. this is achieved by slide boards and side cladding panels leading through the coil. the minimum distance is 40 mm.12 10:29) Page 6 . The purpose of the rubber vibration mountings is to prevent vibrations of the supporting structure from affecting the detector coil. For constructing gutters and chutes in the region near the detector coil. general notes Chapter 3 Mounting the detector coil Every metal detector equipment is provided with rubber vibration mountings. no material residues or other dirt must be allowed to deposit between the slide boards and the measurement surfaces of the detector coil. If resilient rails are used. glass fibre reinforced polyester can for instance be used. Otherwise vibration of the slide boards may be transmitted to the detector coil. It is in principle possible to mount the detector coil directly onto the conveyor belt structure. under the most unfavourable production conditions. and installed location. Under these requirements a direct mechanical connection of the detector coil to the conveyor system is allowed. The number and type vary according to the detector coil type. C:\Dokumente und Einstellungen\af.

C:\Dokumente und Einstellungen\af.12 10:29) Page 7 .DOC (10. Then connect each numbered terminal in the detector coil junction box to the correspondingly numbered terminal in the control unit. The junction box of the detector coil is on one side of the coil.Instruction Manual MSG 3200 4 4. Transmit coil: Receive coil: Connect to control unit using 5-core screened cable.04.1 Electrical connection Connecting detector coil to the electronics Chapter 4 ! See also attached circuit diagrams in the appendix ! ! First check that your mains voltage supply is the same voltage as that stated on the rating plate in the door of the control unit. Always use the screened cable supplied with the equipment. The screens are to be connected at one end only to the shielded cable glands on the control unit. Connect to control unit using 5-core screened cable.ELMED\Desktop\Manual_MSG3200.

2.ELMED\Desktop\Manual_MSG3200.DOC (10. Input resistance is about 8.12 10:29) 78 901 23 78 901 23 x10 Prescaler x1 456 456 Page 8 .1 to X8.1 External clock (X8. Higher rates can be divided by the integrated prescaler that has to be adjusted accordingly. The signal is connected to contacts CLOCK and GND (see wiring diagrams). The prescaler can be adjusted for division factors between 1:1 and 99:1.2kΩ. The signal should be a square wave with about 50% duty cycle and levels of +12V to +24 for HIGH and 0V to -24V for LOW. The rate should be 1 impulse per millimetre. LEDs Interface daughter board (optional) S1 S2 S3 3 2 1 1 2 3 4 5 6 7 8 9 10 S4 Sensor Figure 1: Controls for the prescaler C:\Dokumente und Einstellungen\af. that is synchronised with the movement of the conveyor. The LED CLOCK will be on at HIGH on the CLOCK input.4) Chapter 4 The metal detector requires an external clock.2 Interfacing with external controls 4.Instruction Manual MSG 3200 4.04.

Please contact service dept. 5.2 Detector ready (SPDT X6. 4. product #0 will be selected.3 Relay outputs All contacts are floating with a contact rating of 250V AC/5 A max. Input S1 S2 S3 S4 Product 1 2 4 8 • If none of the inputs is activated. The signal level is 12V to 24V.2.2. X4.3).2.3 and X2. • If more than one input is activated.8) Chapter 4 The sensitivity override input can be used to reduce the sensitivity of the detector temporarily.x) This contact will be activated immediately after self-calibration is completed and the metal detector is ready for operation. External control must be enabled from the product menu. The contacts will be activated longer (in terms of conveyor travel) for big parts and shorter for small parts. Product #0 will be selected. 4.2. 5.2 Sensitivity override (X8. Using the setup menus a time delay can be added to the reject interval (see Setup Menus. If the function is activated.3.x and X5. for further information 4.5 to X8. signals from the metal detector can be recorded on the harddisk of an external PC.2.4 RS-232 interface If the optional interface daughter-board is installed.3).x) These contacts switch upon detection of metal. but only if external product selection is selected from the product menu.2.Instruction Manual MSG 3200 4.1 Metal present (DPDT. the effective product corresponds to the sum of the individual products.2. Depending on the configuration. 4. the control voltage of the conveyor must be connected to terminals X2.3.16) These inputs can be activated from an PLC to select different product settings according to the table. The distance between search coil an reject position can be adjusted over a wide range (see Setup Menu. 4.12 10:29) Page 9 . the contacts will stay switched until reset by an external pushbutton switch or will switch back automatically after some travel of the conveyor belt.3 Remote controlled sensitivity selection (X8. This function can only be activated by service technicians.11 to X8. For example the signal can be generated by a diffuse-reflection sensor.2. by activating inputs S1 and S3 product #5 will be selected. regardless of the remote controlled sensitivity selection (see below). C:\Dokumente und Einstellungen\af.DOC (10.1 Metal output 4.ELMED\Desktop\Manual_MSG3200.6 Time-delayed enable of detector False alarms that are caused by vibrations when starting the conveyor can be suppressed if the metal detector is enabled a short time after starting the conveyor. 4.2. If the control voltage (12V to 24V) is present.3.2.04.5 Pushbutton reset of metal output see 4. For example.

2) 4.1 Mechanical adjustments (applies only to Type 3 search coils) C:\Dokumente und Einstellungen\af. If there is a risk of larger fluctuations than this in the supply voltage.DOC (10.ELMED\Desktop\Manual_MSG3200. The auto-balancing circuitry will automatically adjust the electromagnetic field to a neutral state under normal operation conditions. in order to avoid interference spikes from switching of large machines. The stabilised power supply compensates for voltage fluctuations of +/. 4.Instruction Manual MSG 3200 4.4 Mains supply and control cables Chapter 4 The mains power supply for the electronics should be taken through a separate cable or from the mains lighting circuit.04.5.12 10:29) Page 10 .5 Balancing of the detector The working principle of the detector is based on the detection of extremely small changes of the electromagnetic field in the search coil. When the metal detector is operated for the first time.5. then a voltage stabiliser should be provided. Large metal objects in the neighbourhood of the detector or extreme temperatures can cause permanent changes of the electromagnetic field. motors etc.10 %. the state of the auto-balancing circuitry should be checked (see 4.

Instruction Manual MSG 3200 4. This should be kept in mind during mechanical compensation (for detector coils Type 3 only). C:\Dokumente und Einstellungen\af. • By pressing the [Start] button.DOC (10. During normal operation. The range is from -3 V to +3 V.5. Otherwise. If the values for DAC0 and DAC1 lie above +2 V or below -2 V. the values may increase to 1V. the auto-balancing will start again. • Further balancing will start only after an delay time of 30 seconds to avoid unwanted reactions to large metal objects. • The display should look like: Chapter 4 After completion of the auto-balancing process the values for ADC2 and ADC3 show the remaining error of then detectors balance und must not exceed 0.04. Otherwise the saftey margin for changes in the balance during normal operation will become to small.2 Checking the auto-balancing circuitry • Select [Compens] from the Setup Menu. During the balancing operation both the output „detector ready“ and the ready indicator on the front panel will be inactive.2 V. Under normal working conditions this is very unlikely to become neccesary. the detector coil has to be compensated mechanically. please contact factory for instructions. The values for DAC0 and DAC1 correspond to the amount of voltage that is necessary to achieve the balanced state of the detector. Attention ! • Automatic balancing will start immediately after switching on the metal detector.12 10:29) Page 11 . the balancing can be started at any time.ELMED\Desktop\Manual_MSG3200. Reliable operation will be possible if the the values for DAC0 and DAC1 lie between -2 V to +2 V. If the values for ADC2 or ADC3 exceed the limit of 1V for more than 30 seconds.

etc. outputs.2 Front panel All control functions of the detector are menu driven. Selection of the product parameters. the appropriate menu appears on the right-hand side of the display and can be easily associated with the buttons.DOC (10. C:\Dokumente und Einstellungen\af. provide access to the menu selections. electrical connections).2.04.ELMED\Desktop\Manual_MSG3200.1 Operator-Menu Functions described in this chapter are accessible without entering the security code.1 Requirements Chapter 5 Before the metal detector is operated for the first time the following requirements have to been met: • Transmitter and receiver of the detector coil must be connected to the control unit. (See also chapter 4. located beneath the display on the front panel of the control unit. detection counter and selected product. 5. Function of menu button Displays the waveform of the metal signal.12 10:29) Page 12 . date and waveform of the last 128 metal detections.Instruction Manual MSG 3200 5 Operating 5. Five menu buttons. Combined numeric and bar-graph display of metal signal. trigger level. Access to setup menu (security code required). 5.). • Connections with external controls must be completely wired (external clock. Depending on the operating mode. Displays the logbook with time. This section contains brief descriptions of all menus. • The mains voltage must be connected and present.

The display is well suited to analyze the signal caused by metal parts and disturbances from the surrounding of the detector. • The current speed of the conveyor (at Speed). Function of menu button Back to the OPERATOR MENU (F5 is the lowest of the menu buttons) 5.ELMED\Desktop\Manual_MSG3200.Instruction Manual MSG 3200 5. if Peak Level exceeds Trig.1. Level). Level.1 On-line Display Chapter 5 The metal signal is displayed as waveform.DOC (10. Level depends on the chosen Product. Metal will be detected. • Number of detections since power-on (at Counter). The Counter counts these detections. Pressing [F5] returns to the OPERATOR MENU.2.12 10:29) Page 13 .1. the X-axis corresponds to conveyor travel.2 Level This display contains the following items: • The level of the metal signal is both shown as numeric value (at Peak Level) and as bar-graph (on the left side of the display). • Trigger level (at Trig. The value shown at Trig.2. C:\Dokumente und Einstellungen\af. • Product chosen (at Product).04. similarly to the display of an oscilloscope. The amplitude roughly corresponds to size of the part.

04. Function of menu button Chapter 5 X-Y-Display Save settings and return to OPERATOR MENU. Cancels changes and returns to OPERATOR MENU For a detailed description see 5.2.1.3 Product This menu is used to select one out of 16 possible product and sensitivity settings.2.Instruction Manual MSG 3200 5.DOC (10.2.ELMED\Desktop\Manual_MSG3200.2 C:\Dokumente und Einstellungen\af.12 10:29) Page 14 .

The active resolution is underlined in the display. C:\Dokumente und Einstellungen\af. Pressing [F2] switches between +/. After selecting the detection. Button [F1] is used to selected one of the channels.ELMED\Desktop\Manual_MSG3200. Return to OPERATOR MENU The metal detector uses separe channels for ferrous and non-ferrous (VA) metals. the waveforms the led to the metal detection can be viewed: Function of menu button Moves marker up by one position Chapter 5 Moves marker down by one position Advances to the next page Displays the waveform Return to OPERATOR MENU After pressing [View] the display shows the waveform: Function of menu button Toggles between ferrous and non-ferrous (VA) channel.1.DOC (10. Toggles resolution between 1V and 3V full scale.Instruction Manual MSG 3200 5. which is especially usefull for small signals.1V and +/.04. date an waveform of the last 128 metal detections.2.12 10:29) Page 15 .3V full scale an vice versa. The resolution of the display can be increased. The currently selected channel is underlined in the display.4 Logbook The logbook contains time..

C:\Dokumente und Einstellungen\af. Enters 3.ELMED\Desktop\Manual_MSG3200.Instruction Manual MSG 3200 5. Enters 4.2. Back to OPERATOR MENU.12 10:29) Page 16 . Function of menu button Enters 1. This allows for further adjustments that are not required during normal operation. The setup menu can only be entered after entering the correct security code.04.5 Setup Chapter 5 The second set of menus is only accessible after entering the security code.DOC (10. Enters 2.1.

DOC (10.1 Set Time Adjustment of the integrated real-time-clock. Function of menu button Adjustment of the real-time-clock Adjustments for metal detection and product compensation Selection of the current product (see also OPERATOR MENU) Adjustment of the software-prescaler for external clock and timing of output signals Returns to the OPERATOR MENU 5. The marker (>) selects the field to be modified.04.Instruction Manual MSG 3200 5.2 Setup-Menu Chapter 5 The functions of the SETUP MENU are used to adapt the detector to individual working conditions. Seconds will be reset to 00 Cancels changes and returns to SETUP MENU C:\Dokumente und Einstellungen\af.2.2. Set new date and time. Function of menu button Increase value by 1 Decrease value by 1 Advance marker to the next field to be changed.2.12 10:29) Page 17 .ELMED\Desktop\Manual_MSG3200.

C:\Dokumente und Einstellungen\af.Diplay of the metal signal Activates the parameter editor.04.2 Metal detection and product compensation The metal detector can be adapted to the working conditions under two aspects • metal detection sensitivity • product compensation Chapter 5 The first menu is used to select one of 16 different product (and sensitivity) settings and to inspect the corresponding parameters.2.. Trigger level for metal detection Trigger level at product phase angle Phase angle of the signal caused by the product Function of menu button Selects sequentially one of the 16 product settings (0. otherwise “int“ will be shown.15) or external control.Instruction Manual MSG 3200 5.ELMED\Desktop\Manual_MSG3200. (available only during internal control) Leaves the product menu. External control can be used to switch between different product settings under control of an external PLC. • • • • Product# Metal level Product level Product angle Product ID (int=internal control / ext=external control).12 10:29) Page 18 . The [+]-button sequentially selects product #0 to 15 and external control. Activates the Teach-Mode (see below) (available only during internal control) X-Y . External control is indicated by “ext“ behind the product number. The display shows both product ID (Product#) and detection parameters.DOC (10.2.

2 Parameter Editor Using the parameter editor the product settings can be adjusted according to the operation conditions.12 10:29) Page 19 .2.2. C:\Dokumente und Einstellungen\af. every sample from metal signal is shown as a small dot.DOC (10.ELMED\Desktop\Manual_MSG3200.04.2.Instruction Manual MSG 3200 5. Dots outside of the circle cause metal alarm. Function of menu button Clears the display Leaves X-Y-display The circle around the center of the display corresponds to the current trigger level. The direction of dots caused by metal depends from the kind of metal and the setting of the product angle.. During operation. Function of menu button Increases current parameter Decreases current parameter Selects current parameter Save settings and leave menu Discard changes and leave menu.2.2. 5. dots caused by the product should always stay within the circle along the horizontal axis. Phase (or angle) caused by different products and metals will cause the dots on the display to move into different directions.1 X-Y-Display Chapter 5 During X-Y-display both channels (ferrous and non-ferrous) are show in an two-dimensional coordinate system. Using appropriate parameters for metal sensitivity and product compensation. The X-Y-display allows quick verification of the results.2.

avoiding metal alarms caused by the product.Instruction Manual MSG 3200 The following example is used to illustrate the meaning of the parameters: Chapter 5 Metall 30° Figure 1 shows an idealized example for the signals cause by metal that should be detected and product that should be Produkt suppressed: The product causes a signal of about 2V at an angle of 30° The metal causes a signal with an amplitude .ELMED\Desktop\Manual_MSG3200.DOC (10. the X-Y-display looks like shown in figure 2: The phase of both signal has been rotated 30° counterclockwise in order to align the product effect with the horizontal axis (parameter: product phase). Because the scale of the vertical axis (metal level) has not been changed. be compensated by putting a detection envelope around the signal that has the shape of an rotated ellipse.12 10:29) Page 20 . Metal signals that exceed the trigger level only by a small aount won’t trigger the metal alarm. the rotation of the ellipse to the product phase. Fig 1 Products with similar phase will be suppressed equally well because of the smooth shape of the detection envelope. of only 1V at an angle of about 120° The product effect can . As an consequence the settings always should be verified using sample parts. the short radius to the metal level. Produkt Furthermore. The long radius of the ellipse corresponds to the product level.04. Metall For the example illustrated above. only the horizontal axis has been scaled (parameter: product level) to reduce the product effect. Figure 3 C:\Dokumente und Einstellungen\af. Figure 2 Metall 30° Figure 3 illustrates the need to verify the effect of the parameters using the X-Y-display: Because the phase differProdukt ence between metal signal and product effect is less than 90° the metal signal stays within the detection envelope. the metal signal still can trigger the metal alarm. .

04. • Feed the sample through the detector. Function of menu button Start the measurement of the amplitude caused by the metallic sample.ELMED\Desktop\Manual_MSG3200. The wizard records the signal an calculates suitable parameters for metal detection. an metal sample has to pass the detector. C:\Dokumente und Einstellungen\af.DOC (10. Again the wizard records the signal an calculates suitable parameters for product compensation.2.2. The steps have to be performed in the following order: • Press the [Start] button.2.3 Teach-Mode Chapter 5 Main element of the teach mode is an integrated wizard that leads you through the steps that are neccessary to adjust the detector to your need. Second. product sample have to be passed through the detector.12 10:29) Page 21 .Instruction Manual MSG 3200 5. Step 1: In step 1 the operator is asked to feed the metallic sample through the search coil. First. Abort and return to the SETUP MENU.

Aborts and return to the SETUP MENU Step 3: During step 3 the operator is asked to pass a sample of the product that should be compensated through the search coil. Function of menu button Reset measurement. • Feed the sample through the detector. • Press the [Start] button.ELMED\Desktop\Manual_MSG3200.04. The last measurement taken is kept and displayed until the [Reset] button is pressed or a higher amplitude is measured.DOC (10.Instruction Manual MSG 3200 Step 2: Chapter 5 During step 2 the amplitude caused by the metallic part is displayed. The process should be repeated some times to ensure. Use current measurement and advance to product compensation.12 10:29) Page 22 . Function of menu button Starts the measurement Aborts and return to the SETUP MENU C:\Dokumente und Einstellungen\af. that the measurement is reproducible.

The lowest button [F5] returns to the OPERATOR MENU. mechanical recalibration of the coil is necessary.ELMED\Desktop\Manual_MSG3200.12 10:29) Page 23 . • DAC0 and DAC1: Actual value of the compensating voltage.5 Volt. the parameters can be changed using the parameter editor. Must be between -1 V and +1 V. the process should be repeated some times to ensure that the measurement is reproducible. Function of menu button Reset measurement. C:\Dokumente und Einstellungen\af. Should stay between -2 V and +2 V. Use current measurement and advance to final menu.04. during step 4 the amplitude caused by the product sample is displayed. If automatic balancing should become impossible. Please contact factory for details.9 V and +2. For the unlikely case. Aborts and return to the SETUP MENU After completing the teach-mode the parameters will be displayed. Again. If neccessary. using the X-Y-display.9 V. The last measurement taken is kept and displayed until the [Reset] button is pressed or a higher amplitude is measured. the green indicator [Ready] on the front panel and the Ready-Output will be deactivated. it should be verified that • the desired detection sensitivity for metal detection is achieved • the product effect does not cause metal alarms.2.3 Compensation This menu is used to check the condition of the auto-balancing circuit. 5. operation is possible as long as value is between -2. that the values for DAC0 and DAC1 exceed +/-2. The display shows the following items: • ADC2 and ADC3: Deviation from optimum balanced state. Then.DOC (10.Instruction Manual MSG 3200 Step 4: Chapter 5 Similar to step 2.2.

12 10:29) Page 24 . then most types of fault can easily be remedied. The Output Delay can be adjusted to any practical value. Permanently stores the parameters that have been modified. yes or no.2.Instruction Manual MSG 3200 5. Aborts changes and returns to the SETUP MENU Speed If no external clock is present.4 Clock ratio. If you have the answers to the items on this checklist. the metal detector will work at this default value. (The desirable condition. On Time The duration of the output signal (corresponding to conveyor travel).ELMED\Desktop\Manual_MSG3200. therefore in many applications an additional PLC used for controlling the reject device can be saved. Clocks/cm The detector requires an external clock that is synchronized with the movement of the conveyor. The duration can be extended by the setting On Time. • The Clocks/cm setting is used by the Digital Signal Processor to divide the signal from the prescaler further down to 1 impulse per centimeter. And in case of more difficult faults.DOC (10. 6 Faultfinding: checklist of possible causes and remedies The following checklist is to help you find and remedy simple faults yourself. Used to avoid false switching due to small defects in the marking on the forming belt that controls the diffuse reflection sensor. Attention: Care should be taken not to mix up the different settings used to adapt the clock source: • The prescaler located on the interface board divides the incoming clock down to 10 impulses per centimeter. The nominal value is 10 clocks per centimeter. Joint Delay The travel of the forming belt by which the deactivation of the sensitivity override will be delayed. Output Delay The signal that is given upon detection of metal can be delayed if required. the minimum value for Output Delay is 65 cm. depends on the size of the detected object. is underlined. This results in a delayed output signal that will become active about 64 cm after the object has passed the center of the search coil.04. The actual rate can be adjusted with the setting of Clocks/cm.2.) C:\Dokumente und Einstellungen\af. Output Delay and On-Time Function of menu button Increase value by 1 Chapter 6 Decrease value by 1 Advance marker (>) to the next field to be changed. this is a helpful preparation before discussion with our service engineers. As a consequence. The sophisticated signal processing software always evaluates the signals recorded over about 1.28 cm of travel of the conveyor.

when do they occur? YES when the belt starts up or stops when the belt is being loaded when the chopper is overloaded dependent on temperature sporadically 6. so that vibration is being transmitted to the coil? Have any dirt or material residues (chips etc. YES Is the detector coil mounted on a separate support structure? The support structure must not have any connection to the conveyor structure.Instruction Manual MSG 3200 Chapter 6 6. with no contact to any part of the conveyor structure at any point (minimum distance 10 mm).12 10:29) Page 25 .04.2 False alarms for mechanical reasons In general: Vibrations or impact loads transmitted to the detector coil from its surroundings reduce the maximum sensitivity attainable and increase the probability of false alarms. Is the detector coil mounted on the rubber vibration mounts supplied? Are all screws tightly tightened (especially for Type 3 coil)? Are the slide boards coming into contact with the detector coil.1 General YES Has anything changed recently in respect of system requirements or production conditions? If false-alarm signals are occurring.DOC (10.) deposited between the detector coil and the slide board? It is absolutely essential for the detector coil to be completely free-standing. NO NO NO C:\Dokumente und Einstellungen\af.ELMED\Desktop\Manual_MSG3200.

please first read again Section 4. Insulate from the structure by laying electrically insulating material at the load bearing points supporting the catwalk. or underlay with electrically insulating material (rubber. Are the two LED's on the junction box on the detector coil both alight ? If only one or neither of the LED's is alight: a) b) Check the cable connection between detector coil and electronics cabinet (cables maybe confused) Check that all the circuit boards are firmly seated in their sockets.3 False alarms for electrical reasons If faults occur. Catwalk over the conveyor belt: Install as far away from the detector coil as possible. NO Metal grids on catwalk: Either weld them to the iron joist structure.DOC (10. YES Have any other large machines started operation recently which might cause interference with the metal detector equipment? How near is the control unit of the metal detector equipment to other electrical cabinets? C:\Dokumente und Einstellungen\af. YES Is your mains power supply subject to faults. wood. catwalk over the belt Remedy in this case: Handrails: Make handrails of wood or plastic near the detector.Instruction Manual MSG 3200 Does the conveyor belt itself contain any metallic impurities? Please check whether the detection signal is always given at the same point of the belt. handrails. metal grid platform. Note: the impurity may be very small.12 10:29) NO NO ________ m Page 26 .ELMED\Desktop\Manual_MSG3200. please check the following points. and may be on or underneath the belt Chapter 6 YES Are there any iron or steel parts near the detector coil which can move? e. by walking) no contact is made with the supporting structure. see preceding paragraph. 6. interference or fluctuating voltage ? Is the control unit of the detector exposed to vibration? Has the customer altered any of the factory settings on the circuit boards? Is the mains supply voltage constant? After connecting the correct mains supply as per rating plate.g.0 Electrical connections. If the detector is set for high sensitivity. PVC etc.) so that when there is a load on the surface (e. also large moving metal objects such as a crane or fork-lift truck moving past may cause false alarms.04.g.

or use a larger part check the speed reading (see Level Display.2. and Timing Setup. 5. • the fuses on the main board (3 fuses with transparent cover near the mains terminals.2.3. The brightness depends on the transmit power level set in our factory.1 Fault analysis specitic to the control unit MSG 3200 YES Are all LED's on the 5th circuit board from the left alight? If some or all of these LED's are not alight.Instruction Manual MSG 3200 Chapter 6 YES Is any electric-arc welding being performed near the detector equipment? Are radiotelephone (walkie-talkie radio) sets in use in your factory? . does the red LED on the 2nd board from the left briefly light? If the system does not detect the part (red LED does not light briefly). 5. The following questions and answers can also be relevant for diagnosing faults: YES Is the sensitivity adequate? For what sensitivity requirement was the metal detector equipment originally designed ? and for what belt speed? NO NO Nut Ball ∅ M________ ________ mm ________ mm/s 6.12 10:29) Page 27 . please check • all circuit boards firmly seated in their sockets • cable connection between detector coil and electronics cabinet (cables maybe confused?).4) NO NO NO C:\Dokumente und Einstellungen\af. YES Is the red LED on the 4th circuit board from the left alight? The red LED on this board normally lights less brightly than the others. If the LED does not light at all.2.DOC (10.2.1. check: • that all circuit boards are firmly seated in their sockets.1. Solution increase the sensitivity.2) and the hardware and sofware prescaler settings (see External Clock. 1 fuse above the transformer).04. 4. then this may be for the following reasons: Problem iron part is too small the metal detector operates for the wrong speed. YES When an iron part passes through the detector coil.ELMED\Desktop\Manual_MSG3200.

10 %. 2.12 10:29) Page 28 . A stable voltage supply is essential for proper functioning of the metal detector equipment.5 mm² 5-core screened cable 0. IP .3 Effect of surroundings.DOC (10. 3. 3.ELMED\Desktop\Manual_MSG3200. alternatives on request The stabilised power supply compensates voltage fluctuations up to +/.5 mm² C:\Dokumente und Einstellungen\af.04. a voltage stabiliser with interference filter should be connected in the power supply line.1. Transient voltage fluctuations exceeding these limits caused for instance by switching high power machines on or off can impair reliability and cause false alarms. Surface protection Colour Dimensions Weight complete Protection classification PC boards (From left to right) 1. then different frequencies should be used. the electronics should be fed through separate cables or fed from the electric lighting circuit.65 5 plug-in boards for easy service. W X H X D (306 x 241 x 262 ) mm 20 kg approx.Instruction Manual MSG 3200 7 Technical data Chapter 7 Electronic enclosure Combination of extruded aluminium profile with board guides and in cast aluminium connection compartment. For this reason. see Sec. If this is not possible. 5. They must remain accessible for servicing after installation. Mains supply voltage input amplifier DSP (Digital Signal Processor) Interface board transmit section stabilised power supply unit 230 V / 50 Hz. Transmit coil: Receive coil: 5-core screened cable 0. 16. 4. Please tell us! Connecting the detector coil The junction boxes for connecting the transmit and receive sections are located on the narrow side of the coil. Mounting brackets for wall mouting.384 kHz quartz stabilised (standard) If several metal detectors are installed near to each other. Power taken Measurement frequency 50 VA approx. including existing detectors. resin stove-enamelled finish light-grey (RAL 7035)/ stone-grey (RAL 7030).

2 X4. switch-off Position ON Position TEST Indicators Illuminated LC-Display Pilot lights showing functions Power Ready Metal yellow LED green LED red LED Detector switched on Detector ready Metal detected Graphic display for menu control and information display "Metal detected" Outputs Contact Rating 250 VAC / 5 Amps 250 VAC / 5 Amps No Metal X4. Output "Metal present": always active Output "Detector Ready": always inactive Normal operation.3 Metal detected X4.2 X5.2 X5.DOC (10.12 10:29) Page 29 . Output "Metal present": always inactive Output "Detector Ready": always active 2-pole.1 "Detector ready" Outputs Contact Rating 250 VAC / 5 Amps detector ready X6.1 X5.3 detector not ready X6.2 X6. Output "Metal present": active on metal detection Output "Detector Ready": active if detector working Standby operation.04.1 C:\Dokumente und Einstellungen\af.Instruction Manual MSG 3200 Chapter 7 Operator controls Mains switch Control switch Position OFF Detector switched off.3 X5.2 X4.ELMED\Desktop\Manual_MSG3200.2 X6.

0.DOC (10.3 X8. moving-coil meter 100 µA 1 no. red with cap 1 no. reset push-button (internal) 1 no.17 X8.Instruction Manual MSG 3200 Chapter 8 Contact assignments for interface signals Direction Input (optional) Input (optional) Input (optional) Output Input Output Output Output Input Output Output (optional) (optional) Output Input Input Input Input Output Output Output Input Input / Output 8 Accessories and spare parts Accessories signal hooter signal lamp reset push-button screened oil-flex cable 5 x 0. fine fuses 5 x 20 .1 X8.16 X8. Control voltage (Mains) : Startup Delay Auxiliary supply 15 VClock from conveyor 0 V.2 X2. relays RP 42012 power supply unit transmitter input amplifier switching stage Auto check module circuit board adapter 3 no. mains switch 1 no. fine fuses 5 x 20 . lamp holders.4 A slow-blow 2 no.(Ground) PE (Shield) Auxiliary supply 15 VInput for optional diffuse-reflection sensor 0 V.5 X8.12 X8.4 X8.10 X8. external control 1 no. green.15 X8. fine fuses 5 x 20 .50.1 X2.20 Function ext. potentiometer 1 no.4 A slow-blow 10 no. II 1 set of modules comprising: Spare parts Set No.ELMED\Desktop\Manual_MSG3200.7 X8. III C:\Dokumente und Einstellungen\af. yellow. I Spare parts Set No.04. solderable screen 10 no.19 X8.13 X8. incandescent bulb.2 X8.(Masse) PE (Shield) Reserve 1 (not used) Reserve 2 (not used) Auxiliary supply 15 VSensitivity control from PLC (Range 1) Sensitivity control from PLC (Range 2) Sensitivity control from PLC (Range 3) Sensitivity control from PLC (Range 4) 0 V. door lock Terminal X2.6 X8.8 X8.11 X8.(Masse) PE (Shield) RS-232 Interface (TX) RS-232 Interface (RX) RS-232 Interface (Masse) Spare parts Set No.14 X8.9 X8.2 A slow-blow 10 no.3 X8.12 10:29) Page 30 .18 X8. Control voltage (Mains) : Output Reset 0 V∼ : Common Terminal ext.

04. : (00) 49 2056/2891-92-93 Fax : (00) 49 2056/3467 C:\Dokumente und Einstellungen\af. please contact our after-sales service department. "Faultfinding: checklist of possible causes and remedies").Ing.12 10:29) Page 31 . please quote the serial number of the unit.Mense GMBH Weilenburgstraße 39 42579 Heiligenhaus Postfach 100211/16 Tel.ELMED\Desktop\Manual_MSG3200.DOC (10. This information can be found on the rating plate on the inside of the control cabinet and alongside the terminal boxes on the detection coil. When making technical enquiries.: 02056-2891 Fax: 02056-3467 Typ : MSG Nr. : xxxx 230V/50Hz 2000 Address: ELMED Dr. Example of a rating plate: ELMED GmbH 42579 Heiligenhaus Weilenburgstraße 39 Tel.Instruction Manual MSG 3200 9 After-Sales Service Chapter 8 Should you have any further questions on commissioning or malfunctions during operation which cannot be remedied following the enclosed "Troubleshooting Guide" (see chapter 6.

free of charge. transport damage. We guarantee the parts replaced under the guarantee for a period of 6 months. Content and Scope 1. 4. In the event of a fault being discovered.) Installation has been performed in accordance with the appropriate guidelines (VDE. the service under guarantee shall be limited to the supply. DIN) 2. Miscellaneous 1.DOC (10.) If individual clauses of this guarantee obligation should be or become legally invalid or unenforceable for any reason.Instruction Manual MSG 3200 10 Guarantee Chapter 10 Provided that the installation and operating instructions above have been observed. incorrect or inappropriate storage. Duration and Start of the Guarantee Period 1.ELMED\Desktop\Manual_MSG3200. the following terms of guarantee apply: I. e. Preconditions for the Guarantee Messrs ELMED GmbH offer a guarantee for such coils which demonstrably satisfy the following preconditions: 1. ELMED GmbH. II. III.g. 2. ELMED GmbH shall have the right to meet the claim for cancellation of the contract by a replacement of the goods free of charge.) For equipment in operation outside Germany.12 10:29) Page 32 .) A guarantee is given for the following period: a) 12 months from the date of commissioning b) but not more than 18 months after the date of the invoice The supply of spare parts or repairs for reasons covered by the guarantee do not constitute a general extension to the original guarantee period. 2. d.) incorrect operation or loading c. C:\Dokumente und Einstellungen\af. shall not be accepted unless they are legally prescribed.) Venue for all liabilities arising from the obligations under guarantee shall be Heiligenhaus. damage due to the effects of the weather.) In the event of irreparable major faults. as otherwise the right to service under guarantee shall be void. Messrs.04. IV. ths shall not affect the validity of the other clauses.g. the claim for service under guarantee must be made in writing immediately. 3.) All commissioning instructions contained in the operating manual have been correctly carried out.) Further or other claims. in particular claims for damages. Limitations Faults or defects attributable to: a. e. other natural phenomena. All replaced parts shall become the property of Messrs ELMED GmbH. of spare parts necessary to remedy the fault to the German border. failure to observe applicable regulations or written commissioning instructions b.) other effects. e.) normal wear. are not covered by the guarantee.) Faulty installation.) Repairs and modifications performed without the express approval of Messrs.) Faults occurring within the guarantee period will be remedied by Messrs ELMED GmbH either by repair or by replacement of the parts concerned. V.

04.1 Technical drawings 11.12 10:29) Page 33 .ELMED\Desktop\Manual_MSG3200.2 Circuit diagrams Chapter 11 C:\Dokumente und Einstellungen\af.DOC (10.Instruction Manual MSG 3200 11 Appendices 11.

12 X8.ELMED\Desktop\Manual_MSG3200.DOC". 1 2 3 X3.96 PE L1 N MSG 3200 wiring plan controller Chapter Page 34 11 VERDRAHT\VPLANSTD E LMED GmbH Weilenburgstr. type MSG2000.5 qmm W1 W2 metal signal monitoring detector coil receiver external control (terminals X2 and X8) detector coil transmitter contact outputs contact rating : 250 V~ / 5 A power supply voltage The screenings of wires W1 & W2 have to be connected only at the controller side ! The connection will be given through the screen connectors of the metal screws-type conduit fittings. lowering 0V PE NC (option) NC (option) X8. for the junction of the output contacts 3 x 1.2 -X2.14 X8.-range S4 0V PE TX (Seriell Data) RX (Serial Data) 0 V (Serial Data) Instruction Manual MSG 3200 X1.17 X8.04.18 X8.19 X8.3 -X2.1 X8.5 qmm 27.DOC (10.9 X8.2 X8.3 -X1.11 X8. Caution! The connection of a detector coil.7 X8.10. fused (4 A) (receipt) (delay) fused (4 A) 0 V~ option floating contacts (potentialfree) CY 5 x 0.3 X8. 1 2 L1 N -X1.5 qmm L1 N PE e. is described in table "KAB2E.1 -X1.5 X8. 39 42579 Heiligenhaus .C:\Dokumente und Einstellungen\af. X4.4 -X1.-range S2 Sens. 1 2 3 4 5 X2.2 -X1.3 : power supply voltage CY 5 x 0.6 X8.4 X8.13 X8.1 / X2.16 X8.12 10:29) X8. 1 2 3 4 X5.8 X8. 11 12 13 14 15 16 1 2 3 18 19 20 9 10 5 6 7 X8.g. 1 2 3 1 2 3 X6.15 X8.-range S1 Sens.10 terminal X8 15 V Ext. trigger 0V PE 15 V Ext. control voltage for X2. 1 2 3 X7.-range S3 Sens.5 -X2.20 15 V Sens. W3 Li.