SANDVIK MOBILE CRUSHERS AND SCREENS

PREMIUM RANGE: METAL DETECTOR TESTING

Rev 2 – 01-10-18
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PREMIUM RANGE: METAL DETECTOR TESTING
MANUAL METAL DETECTOR POWER UP

For test proposes the Metal detector can be powered up manually from tech mode without engine running.
Enter tech-mode
pages and enter
code 1234
Flip to page 5

Power up Metal
detector manually

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PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS
• The metal detector uses pulse induction technology to detect
metallic objects in the feed material passing through the bridge
coil assembly.

• A transmitting coil is used to transmit a pulsed signal

(frequency) through the material which is then received by the
receiver coil, any metallic objects within its path will induct the
signal causing it to alter.

• Any alteration to the emitted frequency will cause the control

system to detect and trip the fault.

• Sensitivity can be adjusted to limit the amount of signal

deviation that the system will respond to.

• External frequency caused by loose components around the

metal detector can cause intermittent false faults.
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS

• Sensitivity control set to 5 (Adjustable)

Adjusts the gain and therefore fine adjustment to detect.
The sensitivity setting should be able to detect a steel test block
40mm³ and not be tripped by smaller metal objects.

• Relay control set to Latch.

This setting ensures that once material is detected the system
will hold the fault until reset.

• Set Zero adjustment. (Important)

Adjust using the control knob unit the green indicator LED is
illuminated, calibrating the unit.

This is to calibrate the metal detector to surrounding frame

structure and minimize external effects. Note if this calibration
cannot be performed, external effects will need to be controlled.
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS
• SW6 switch,
Set to the off position (fully down) = High Speed

• SW2 switch,
Brown switch fully up (enable reset if metal within field)
Red Switch fully down (Fail Safe activated)

• SW4 switch,
Set to position 2 (fully right) = 2 Coil Setting
Determines the amount of coils used and therefore the
expected response.

• VR10 – Trip level set to 180mV +/- 5mV.

(measure across TP0 = 0v & TP19 = 180mV +/- 5mV)
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS

TP0 is the ground reference point.

TP1 – TP5 are the control boards power supply’s.

PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS

The twin coil systems installed on Sandvik QH units are MA3000CE(24VDC_HP) + BR(TX/RX_HP). These are high power
systems and as such the settings listed will be used.

These systems are setup in the factory using the below settings;

Sensitivity (VR9) = Max

– This is an operator control used to fine tune the sensitivity
Trip level (TP19) = 180mV
– This can be adjusted with VR10 to adjust the sensitivity further but in most cases should be left factory set.
Operating Frequency (TP6) = 38.8KHz (12-25-4000 to fit QH332 559mm aperture between coils)
= 52.5KHz (MA2021 to fit QH441 495mm aperture between coils)
– This can be adjusted with VR1 to adjust the sensitivity further but in most cases should be left factory set.

Using the above settings, the system has been tested and proven to ensure they can detect 40mm Ferrous cube between
the Tx & Rx coils prior to shipping. Note settings are different for QH/S332 and QH/S441 units.
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS

TP6 is the operating frequency which can be adjusted with VR1.

The system sensitivity can be increased by reducing the frequency. Depending upon the age of
the unit, the frequency settings will differ. On newer (current build) systems the frequency is set
to 38.5KHz or 52.5KHz depending upon the machine type.
Note: If the frequency is higher than 40KHz then the 38.8KHz system, the system will become
unstable.
QH332 Build (559mm Aperture); QH441 Build (495mm Aperture);

38.8KHz 80us VR2 52.5KHz 50us VR2

40.0KHz

Increase Sensitivity Reduce Sensitivity Increase Sensitivity Reduce Sensitivity

Anti-Clockwise Clockwise Anti-Clockwise Clockwise

Increase Frequency Decrease Frequency Increase Frequency Decrease Frequency
VR1 VR1

If a replacement control board is required, the system will need to be matched to original settings.
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS
VR2 potentiometer is used to set the transmitter pulse time in Milliseconds, the larger coil aperture height, the lower the
sensitivity becomes and will require a larger transmission pulse to compensate.

QH332 units use a larger coil aperture height than the QH441 units hence the setting of VR2 will be different. This time
setting can be difficult to view on site as the engineer will need the use of an oscilloscope, but VR2 is marked with an arrow
which can be used as reference based on two specific set points. (50us or 80us)

QH332 Build (559mm Aperture); QH441 Build (495mm Aperture);

80us Setting 38.8KHz 50us Setting 52.5KHz

VR2 VR1 Setting VR2 VR1 Setting
10 O'clock 5 O'clock

Note: VR2 is pre-set and covered in anti tamper paint, this should only be adjusted as instructed.
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR SETTINGS

TP19 is the trip level which can be adjusted with VR10. By increasing the trip level you can reduce the sensitivity.
Voltage reading on TP19 should be set to 180mV +/-5mV
Note:TP19 should never be below 150mV otherwise the system will become unstable.

Trip Level Setting:

150mV 180mV
Increase Sensitivity Reduce Sensitivity

Anti-Clockwise Clockwise

VR10

VR5 “coil zero” control is used to zero out metal surrounding the coil, this should always be set such that the
green LED is illuminated.
PREMIUM RANGE: METAL DETECTOR TESTING
COIL POSITIONING & CONNECTION • The metal detector system consists of
one coil fitted above and one below
the feeder belt.

Receiver (RX) • Check coil positioning is correct.

(RX top, TX bottom).

• Test coil by measuring the resistance.

Expected range
RX Coil – 8 to 10 Ohms
TX Coil – 0.6 to 1.2 Ohms

• Test coil connection cable resistance

• Check connection points at TB4.

TB4-1 = Top Coil Shield (RX)
TB4-2 = Top Coil Core (RX)
TB4-3 = Bottom Coil Shield (TX)
TB4-4 = Bottom Coil Core (TX)
Transmitter (TX)
PREMIUM RANGE: METAL DETECTOR TESTING
COIL POSITIONING & CONNECTION

Probably the biggest issue is incorrect wiring of the Tx/Rx coils.

If they are connected the wrong way around the system may appear to work but will cause intermittent problems.
See below for correct wiring.

It will be useful to know that if the Tx coil is disconnected then the fault & detect LED will illuminate on the control board.
Whereas if the Rx coil is disconnected then a fault condition will not occur. This can be used to check if the coils are wired
the correct way around – unplug the bottom coil and if the fault LED illuminates then the Tx/Rx are connected the correct
way around.
PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR RELAY CONNECTIONS
TB2 are connected through the detect relay. These contacts switch when a detection occurs.

If SW2-2 (red) is in the down position (fail safe) then the NO/NC contacts are reversed. When SW2-2 is in fail safe then the
relay will switch if the control board loses power. Note that when the control board is in a fault condition, the detect circuit is
also activated which will cause the detect relay to switch which will show as ‘metal detected’ on your PLC display.

If ‘metal detected’ keeps showing and will not reset then check to see if the MD is in a fault condition.

Signal received by the machine

control system should be high (24v)
when the system is healthy.

Metal Detector will be energized Not

when the crusher is activated. used

Signal lost = Fault

PREMIUM RANGE: METAL DETECTOR TESTING
METAL DETECTOR FAULT DISPLAY

Fault Lamp
Used to signal a system fault

Detect Lamp
Used to signal material has been detected

Fault Banner
Fault 20 shown on
screen to signal material
has been detected
PREMIUM RANGE: METAL DETECTOR TESTING
TEST SHEET

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