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Control Unit
PRIMUS
We reserve the right to change the contents due to product innovation or technical
improvement.
Please state type of equipment and serial
number when contacting us.
Please read these instructions and keep
the manual safe!
Please observe and follow the safety notes!
S+S Separation and Sorting Technology GmbH
Regener Strae 130
* D-94513 Schnberg
Telephone: +49 (0) 8554 308-0 * Fax: +49 (0) 8554 2606
E-mail: info@sesotec.com
Internet: http://www.sesotec.com
Service: Telephone: +49 (0) 8554 308-180
PRIMUS-BA-CU-EN-3123.docx
Manufacturer:
S+S Separation and Sorting Technology GmbH
D-94513 Schnberg, Germany
Contact:
S+S Separation and Sorting Technology GmbH
Regener Strae 130
D-94513 Schnberg, Germany
Tel.:
Fax.:
E-mail:
Internet:
Represented by:
PRIMUS-BA-CU-EN-3123.docx
Contents
Contents
1
General information
1.1
Introduction
1.2
Field of application
1.3
Application reasons
1.4
System identification
1.5
Symbols used
1.6
EC DECLARATION OF CONFORMITY
1.7
General view
2.1
Functional principle
2.2
7
7
8
3.1
9
9
3.2
3.3
3.4
Noise levels
Safety
10
4.1
Intended use
10
4.2
Safety signs
10
4.3
10
4.4
10
4.5
11
4.6
11
4.7
11
4.8
11
4.9
11
12
12
Commissioning
13
5.1
Mechanical Installation
13
5.2
13
13
13
14
14
16
17
17
Contents
10
11
12
18
6.1
DIP switches
18
6.2
Amplification jumper
19
Operation
20
7.1
20
20
20
20
20
7.2
Operation board
22
23
8.1
Error messages
8.1.1 Faults on magnetic valves MV1 and MV2
8.1.2 Transmitter faulty
8.1.3 Flap position monitoring
8.1.4 External error input
8.1.5 Level monitoring
8.1.6 Receiver voltage too high
8.1.7 Receiver connection
8.1.8 Parameter memory
8.1.9 Transmitter connection
23
23
23
23
24
24
24
24
25
25
8.2
25
8.3
26
8.4
26
28
9.1
Maintenance
28
9.2
Cleaning
9.2.1 Hints for cleaning
9.2.2 Cleaning instructions
9.2.3 Care advice for stainless steel
28
28
28
28
Spare parts
29
29
29
30
30
31
31
11.2 Transport
32
11.3 Storage
32
Annex
33
1. General information
General information
1.1 Introduction
The texts and illustrations in this instruction manual are for the exclusive purpose of explaining how to
operate and handle the control unit. The manufacturer accepts no responsibility for damage resulting
from the use or misuse of this equipment. All appropriate safety rules and regulations for the use of this
equipment must be adhered to. If you have any questions with regard to the installation and operation
of this equipment please do not hesitate to contact us.
This instruction manual may not be copied, saved on computer or otherwise reproduced without the
prior permission of the manufacturer. Nor may any extract of this instruction manual be similarly reproduced.
Product liability
ISO 9000
TQM (Total Quality Management)
Protection of machines and quality assurance
Signal
word
Meaning
Danger
Danger
The lightning symbol is an explicit warning that there is danger from electric current.
Warning
Caution
1. General information
e iv
er
Control Unit
Tra
nsm
itte
r
Re c
Com puter
Signal amplifier
e iv
er
Data
Analog / digital
c onverter
Data
Digital signal
proc essing
LCD display
Keyboard
Relay
24V outputs
24V inputs
Output
c ontrol
Monitoring
Power
supply
Memory for
8 products
1
F
Empfindlichkeit Produktwechsel
sensitivity
product change
Auto-Set
2
3
1
2
3
4
LED display
Operator keys
LED display
Function key
5
6
7
Function key
Red LED
Red LED
Strung
fault
Metall
metal
8-digits
+,-,F
Navigation / operation
Esc / Reset
Esc / Reset
Test
Strung (fault)
Metall (metal)
Esc
Reset
Test
25
rejec t
duration
rejec t
delay time
14
28
10
23
15
26
MV2 time
27
17
18
19
ON
1
2
3
4
5
6
7
8
9
10
20
16
22
8
21
30
9
11
12
24
(1) Mains/Option:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Metal 1:
Fault:
+24V:
Input/Output
Receiver
Transmitter
Ribbon cable connector
Mains/Option
Mains fuses
Metal 1
Fault
29
(1)
(9)
(2)
(3)
Memory devices:
Light diodes:
Switches:
Jumper:
Test points:
L/N:
Control unit power supply
O1/O2: Optional 24V module power supply
Potential free change over contact
Potential free change over contact
+24V external supply (only for solenoid supply)
24V Inputs/Outputs
Receiver connector
Transmitter connector
Connector for control panel
Elements connected to
mains voltage:
Elements connected to external voltage:
Potentiometer:
28
145
2 3 4 5 6 7 8
F
Empfindlic hkeit Pr oduktwechselAutoS
- et
sensitiv ity
pro ductchange
Esc
Reset
Test
240
Meta l
meta l
315
Str ung
fa ult
All measurements in mm
< 70 dB(A)
< 90 dB(A)
4. Safety
Safety
Our equipment conforms to all official technical safety regulations. However, as a manufacturer we believe it is our duty to make you aware of the following information.
The following safety and danger notes are intended for your protection, for the protection of
third parties, and for the protection of the equipment. The safety notes therefore should always be observed!
Meaning
Mains voltage
This symbol indicates that mains voltage is used in the electronics housing, and that any connected external circuits
(e.g. at the metal relay) also may be energised. There is
danger of electric shocks due to the presence of mains voltage.
Connection symbols:
Cover of
the electronics
housing
"Mains" (1)
"Metal " (3/4) and "Fault" (2)
If the covering have to be removed during maintenance and repair works take notice of the references
in 4.5.
10
4. Safety
Emitted interference
Test report according to the provisions of:
BGV B11:2001-06
Regulations of the professional association for safety and
health at work.
Accident prevention regulations for electromagnetic fields.
E DIN VDE 0848-3-1: 05-2002 Safety in electrical, magnetic, and electromagnetic fields,
part 3-1: Protection of persons with active implants in the
frequency range of 0Hz to 300 GHz.
In the area where the operating personnel is working the electromagnetic field of the metal
detector or separator does not exceed the limits stated in the provisions. Therefore there
are no health impairments due to electromagnetic fields in this area for persons and for
wearers of medical implants such as cardiac pacemakers. Inside the coil of round or
closed tunnel coils, or on the surface of flat coils, the limits may be exceeded depending
on design and system version. If work is to be performed inside or at the search coil, persons and wearers of medical implants such as cardiac pacemakers may only enter the
equipment when it is turned off, provided that size and design allow this.
11
4. Safety
12
5. Commissioning
Commissioning
Housing
Model number
Type of connection
Function
Mains/Option
Metal 1
Voltage free
relay contact
Voltage free
relay contact
+24V external
L/N:
Electronics power supply
O1/O2: Optional 24V module power supply connector
Normal operation:
Contacts 31 and 32 closed
On metal detected
Contacts 31 and 34 closed
Normal operation:
Contacts 21 and 24 closed
In case of fault:
Contacts 21 and 22 closed
Connector external power supply (+24V) Solenoid supply
(MV1 / MV2). Required for solenoids valve with power
consumption >5W
Fault
+24V
13
5. Commissioning
Model number
Type of connection
Function
Input/Output
1,2
3,4
4,5
6,7
7,8
9,10
10,11,12
11,12
12,13,14
15,16
Receiver
Transmitter
1
2
3
4
5
1
2
3
250VAC / 3A
120VDC / 3A
Maximum current load: 200 mA
Connection of make contacts against or 24V, or
PNP-outputs (NPN on request)
Switching elements (contactors, relays etc) may only be connected to the potential-free
contacts if interference is suppressed.
Metal 1
Fault
34 31 32
24 21 22
Wire jumper
Connection contacts
14
Housing
5. Commissioning
3
1
1
2/3/4
5
15
PVC - sheath
PVC - insulation
Conductor
5. Commissioning
Prior to this, always make sure that the mains supply to the terminal box is switched off.
L
N
PE
Terminal box
3 pole terminal strip
Control unit mains cable
Mains supply
Conductor L (brown)
to terminal L
Conductor N (blue)
to terminal N
Conductor PE (yellow/green) to terminal PE
1
2
3
4
5
6
7
2
4
In p u t/O u tp u t
1
In p u t/O u tp u t
6
10
11
12
13
In p u t/O u t
14
15
16
10
11
123
MV1
Reset Metal
button count
Test
button
Manual
separation
External
error
input
Disable
metal
Sensor1
detection
Potential-free contact
In case of error contact open
16
MV2
Sensor2
12
5. Commissioning
Contact status
illuminates
illuminates
Contacts 31 and 34 closed (consistent with metal alarm)
Contacts 21 and 22 closed (consistent with fault status)
As programmed
High active or Low active
Contact status
off
off
Contacts 31 and 32 closed
Contacts 21 and 24 closed
As programmed
High active or Low active
Without power
Operating
Metal
17
Switch 1:
Reset mode
Hand
Auto
Switch 2:
OFF
ON
Switch 3:
MV1 active
Low Active
High Active
Switch 4:
MV2 active
Low Active
High Active
Switch 5:
Metal on error
OFF
ON
Switch 6:
Frequency deviation P
OFF
ON
Switch 7:
Frequency deviation M
OFF
ON
Switch 8:
OFF
ON
Switch 9:
Spare
OFF
ON
Switch 10:
Monitoring
OFF
ON
Switch 1:
This position determines whether the metal outputs should be reset manually or automatically (after preset reject duration).
Switch 2:
Switch 3:
This sets the switch status of magnetic valve connector 1 when metal is detected.
Low Active:
High Active:
Switch 4:
This sets the switch status of magnetic valve connector 2 when metal is detected.
Low Active:
High Active:
Switch 5:
This sets the switch status of metal relay 1 if the machine is at fault status.
In case that several metal separators are operated close to each other different operating frequencies
have to be set to avoid interferences.
Switch 6:
OFF
ON
OFF (ON)
Switch 7:
OFF
OFF
ON (ON)
no deviation
positive deviation
negative deviation
Switch 8:
Switch 9:
Spare
(special function depending on the applications)
Application "Standard conveyor mode" or
Application "Conveyor belt controller" and ON Failure at metal
Application "PROTECTOR" and ON No ejection when Power ON
Switch 10:
This activates and deactivates the self-monitoring function of the control unit.
18
Low amplification
Medium amplification
High amplification
19
7. Operation
Operation
1 2 3 4
7.1.2
6 7
20
7. Operation
Sensitivity setting
Empfindlichkeit
sensitivity
Product change
Produktwechsel
product change
21
7. Operation
Automatic teach-in process is not possible if vacuum / pressure equipment conveying speeds are > 8 m/sec.
Auto-Set
Shortly press the (F) button three times to change to the AutoSet (product learn) mode.
The Auto-Set LED illuminates.
The product learn process will be automatically activated after
approx. 3 seconds. The display changes and a block of three
LEDs will flash alternately from the left to the right continuously.
(see diagram).
During this time (approx 1 minute) the products must be conveyed through the detector. Press the (F) button again to end
the teach-in process. If the electronics unit identifies a phase
angle, this is set.
If the product effect is too high no phase angle is identified and
the phase angle setting remains unchanged.
If the (F) button is not pressed, the learn process is automatically cancelled after approx. 1 minute, and all the
product data remain unchanged.
Pressing the (Esc/Reset) button also cancels the learn process, and all the product data remain unchanged.
Auto-Set
If the (F) button is shortly pressed four times (within 3 seconds), the Auto-Set mode is not activated, but the system returns to the normal detection mode.
reject
delay time
MV2 time
22
If you have any questions, please state the equipment type and serial number!
F 01
F 02
Possible causes
Action
Short circuit or connection broken Check valve cable for breaks and renew if
to magnetic valve 1.
necessary.
Check valve cable plug and socket connections, remove and reinsert if necessary.
Short circuit or connection broken Check valve cable and connectors with Ohm
to magnetic valve 2.
meter for short circuit, replace if necessary.
Check magnetic valve resistance which should
be 320...340 (or 100...140 for pusher application).
F 03
Possible causes
Transmitter cable between control unit and detector has a short
circuit or transmitter frequency is
incorrect.
Action
Disconnect transmitter cable at the detector
(triax cable) and measure with Ohm meter: replace if necessary or check transmitter frequency.
F 04
Possible causes
Is the reject mechanism faulty?
No air pressure?
Is the sensor faulty?
23
Action
Check reject mechanism
Check air pressure, pressure?
Change sensor
F 05
Option
Compressed air
monitor
FC monitor
Action
Check air supply
F 08
F 09
Possible causes
Large piece of metal (e.g. aluminium
ladder, screwdriver, hammer, bracelet) directly beside or in the detection
coil. Detection coil installed incorrectly
Detection coil installed incorrectly
Action
Check the coil and its immediate surrounding area. Sometimes pieces of
metal can be lodged inside or underneath the belt.
Check detection coil Operating Instructions Assembly). If the detector is a
DLS model check that the centre sleeve
or locking screws are not loose.
F 10
Possible causes
Break in receiver cable between electronics and coil
24
Action
Check receiver cable for breaks and renew if necessary.
Check connection cable plug and socket
connections, remove and reinsert if necessary.
F 11
Possible causes
EEPROM unavailable or
faulty
Action
Check that EEPROM is properly sited (see page 8
item 10).
If necessary replace EEPROM.
F 12
Possible causes
Break in transmitter cable to
detection coil.
Action
Check transmitter cable for breaks and renew if
necessary.
Check transmitter cable plug and socket connections, remove and reinsert if necessary.
Action
See Assembly
Circular coils:
Mechanical contact between scanning pipe and
detection coil.
Sensitivity setting too high
Metal particles hard to identify due to corrosion or
encapsulation
Loose contact at the detector cables
Material or conveyor statically charged (cracking
sound heard at the detection coil).
25
Action
Check air pressure (5 bar minimum)
Replace air hoses that are too thin and too long
with hoses that are as short as possible and
have a large diameter
Check the reject flap for jammed product
2
3
1
1.
2.
3.
4.
Disconnect mains supply and external circuits and open cover of electronics housing
Remove connectors (1) and remove fastening screws (2)
Remove evaluation electronics board (3)
Install the new board in reverse order but do not connect to mains power supply!
The control unit electronic board is equipped with a memory module which contains all
the equipment settings and product data. If this memory board is transferred to the new
controller board no new settings need to be programmed.
26
(a)
(b)
Procedure:
1. Remove data memory from the new (already installed) controller board (a) and put to one side.
2. Remove data memory from the old controller board (b) and
plug it carefully into the new controller board (a).
Ensure that the clipped corner on the memory device points to
the left.
3. All machine settings (DIP switches), as well as all potentiometer and jumper settings must be transferred to the new board.
4. Switch on power supply. The new board runs with the old parameters.
27
9.1 Maintenance
The PRIMUS control unit is maintenance-free, yet it is still appropriate to inspect the equipment in
regular intervals:
Are all the fastening screws tight?
Is the housing seal in perfect condition, and does it provide proper sealing?
Also check all the cables for possible damage (e.g. at the cable sheath).
9.2 Cleaning
9.2.1 Hints for cleaning
-
28
10 Spare parts
Please state type of equipment and serial number when contacting us.
Spare parts and wearing parts must always be obtained from the manufacturer of from a
supplier that is certified by the manufacturer.
Part
Part No.
Membrane keypad
33014230
33005970
Electronics housing
Evaluation electronics
44003888
33014114
29
3
10.4 Spare parts list control unit optional version
Item No.
Part
Part No.
33014230
44003638
33002708
Evaluation electronics
44003094
Interface
44003888
33014114
30
Choose packing that is suitable for the type and size of unit, taking into account
whether the shipment is for export by sea or airfreight, or for national or international
road transport The packing material must protect the goods from all damage under
normal transport conditions.
2.
Depending on the size, weight and nature of the goods packing in cardboard boxes,
boxed pallets etc is only suitable for road transport.
Use reinforced card, corrugated cardboard, blister packing and shredded paper to fill
and protect the goods.
Electrostatic sensitive components (electronic boards, electronic modules, etc.) must
be packed in antistatic foil or foil bags prior to packing! ( t h i s i s e s s e n t i a l ! )
Stick additional warning labels on the outside of the packaging e.g. "Attention, electronic equipment, do not drop, etc. The packing should be sealed with adhesive tape
and, where the weight exceeds 50 kg, additionally with wrapping tape..
2a. When packing for international road transport use the instructions above (see point 2).
Larger and heavier shipments must also be protected as for export in wooden crates.
Care must be taken to ensure that the goods inside the packing are protected against
corrosion.
Any parts that will corrode easily must be wrapped in oil paper or corrosion-protective
foil. Care must be taken to prevent the components moving around within the packaging.
2b. International air freight shipments must be packed in wooden crates or on export paltainers.
Care must be taken that the goods are secure and well-protected inside the packing.
Any parts liable to corrode must be wrapped in oil paper, protective foil or sprayed
with anti-corrosion spray.
2c. Sea-freight must be packed in seaworthy export crates. These crates can be obtained
from specialist suppliers.
The crates must be lined with oil paper to make them resistant to sea water and prevent corrosion. In addition the goods must be protected against corrosion by use of a
spray or be wrapping in protective foil.
Care must be taken to ensure that the goods cannot move around inside the crate.
After packing the sea-freight crates must be properly closed.
The sea crates must also be fastened externally with securing tapes.
During loading care must be taken not to damage the external packaging.
The carrier must certify that the shipment has been accepted and loaded correctly by
detailing this on the bill of lading, loading list etc.
3.
31
11.2 Transport
In order to avoid injury or damage to the unit it must be handled properly. In addition to
following the instructions below, general health and safety good practice and specific
accident prevention guidelines should be observed.
For correct handling and storage comply with the following symbols:
Careful: glass
Up
Centre of gravity
Do not compress the side walls of the unit or any attached parts by pulling obliquely on
ropes or chains.
Only remove handling safeguards once all installation work has been completed.
When handling in a loading area make sure the unit cannot topple over or slip.
Damage caused during transportation must always be reported to the manufacturer.
11.3 Storage
If possible the unit should be stored in a closed room until final installation.
If the unit is stored in the open it must be covered over with tarpaulins and open underneath to allow condensation to drain off.
Avoid any higher temperature fluctuations. It is possible that condensed water that has
formed in the packing cannot properly drain and may corrode equipment surfaces. If a
formation of condensed water cannot be avoided, suitable desiccants e.g. in the form of
bags must be placed in the packing.
If the unit has been packed for transportation by sea the packaging must not be damaged or opened during transit and storage.
For storage temperature and permissible air humidity please refer to the technical data
sheet.
For correct storage comply with all storage and handling symbols:
Careful: glass
32
Up
12. Annex
12 Annex
EC DECLARATION OF CONFORMITY
33