Certified For Construction OCT 16, 2018 Eriez Magnetics Erie Pennsylvania

128 [3251]
59.00 [1499]
1 to 2 "
VIEW THROUGH APERTURE
CERTIFIED
FOR CONSTRUCTION
12" 47 1/4 [1200] OCT 16, 2018
MINIMUM
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
24 [610]
9.RECOMMEND IDLER SPACING 1200mm MINIMUM.

8.CUSTOMER TO PROVIDE SUPPORT STRUCTURE AND SHIM AS NECESSARY TO PROVIDE PROPER BELT
CLEARANCE.
7.RELOCATE ADJACENT IDLERS TO DIMENSION SPECIFIED WITH ISOLATION KIT. ONE KIT WILL ISOLATE (2) IDLER ASSEMBLIES.
6.REPLACE ANY METALLIC SKIRTING, HOOD OR COVER 30 inches (1M) BOTH SIDES OF DETECTOR CENTERLINE
WITH NONMETALLIC MATERIAL. CUSTOMER TAG:
5.REMOVE ANY METAL DECKING, CROSS BRACING, AND RETURN IDLERS BELOW OR BETWEEN IDLERS ADJACENT
TO ANTENNAS. REPLACE WITH NONMETALLIC STRUCTURE AS NEEDED. 1 [25] T0 2 [51] 2110-ZM-252
4.DISCONNECT LINE POWER GROUND (TB2-3) AND RECEIVER CONNECTION AT TERMINAL BLOCK BEFORE
ARC WELDING WITHIN 100 FT (30M).
3.IF EXPERIENCING AIRBORNE OR ELECTRICAL INTERFERENCE, ELECTRICALLY GROUND CONVEYOR AT
335657
335657
THE HEAD AND TAIL. 11.64 [296]

2.SUGGESTED LOCATION OF METAL DETECTOR: 1) IN LOW VIBRATION AREA, 2) AS FAR AWAY AS POSSIBLE ERIEZ P/N:831971
10/15/2018
9/10/2018
FROM ELECTRICAL AND AIRBORNE INTERFERENCE I.E., RADIO XMTRS, VARIABLE SPEED DRIVES
AND CONTROLLERS.
ESD
ESD
WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

1.ALLOW AT LEAST 6FT(2M) DISTANCE BETWEEN DETECTOR POWER AND SIGNAL LINES,PLANT CONDUIT, VIBRATORY AND METAL DETECTION APPLICATIONS
CABLE AND PIPING RUNS. CLIP DETECTOR WORLD HEADQUARTERS, ERIE, PA, USA
NOTES UNLESS OTHERWISE SPECIFIED BOLT OR WELD TO FRAME TITLE OUTLINE

SHEET TITLE
SEE NOTE 4 1260 METAL DETECTOR 118BW N4X
FOR
ALARM/BEACON, CLIP DETECTOR, FLAG DROP, SWING AWAY
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OCT 16, 2018
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
CUSTOMER TAG:
335657
2110-ZM-252
9/10/2018
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VIBRATORY AND METAL DETECTION APPLICATIONS
WORLD HEADQUARTERS, ERIE, PA, USA
TITLE CONTROL CONNECTION DIAGRAM CCD

SHEET TITLE
1260 METAL DETECTOR 220/50 N4X 15' CABLE
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ITEM QUANTITY DESCRIPTION
1 1 ENCLOSURE - P/N 56055
2 1 GREEN LIGHT ASSEMBLY P/N 56066
3 1 ALARM LIGHT & HORN 115VAC - P/N 55008.11
4 1 ON/OFF SWITCH P/N 56069
5 1 RESET SWITCH P/N 56079

13 3/4 [350]
1 SET FOR EACH METAL DETECTOR
6 3/8 [162]
3 3/4 [95] 5 [127]
6 1/16 [154]
2 3/4 [70]
7 7/8 [200]
4 [102]
15 3/4 [400] 14 3/4 [375]
Ø5/16 [Ø8]
01/2 [13]
335657
335657
335657
07/16 [11]
10/15/2018
4/26/2018
9/10/2018
14 5/8 [371]
ESD
ESD
ESD

CERTIFIED TITLE
SHEET TITLE
OUTLINE
FOR CONSTRUCTION FOR

1200 SERIES METAL DETECTOR CONTROL
N4X CONTROL HOUSING ALARM HORN/BEACON COMBO
OCT 16, 2018 CUSTOMER TAG: DR. BY ESD ORDER #
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2110-ZM-005 DATE 4/21/2018

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INCHES [MILLIMETERS]
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C
A
COUT a2016_0
128 [3251]
(4) BOLT, 3/8 - 16 X 1 C.S.
(4) NUT, 3/8 - 16 C.S. (2) UPRIGHT, 2 in. SQ TUBE FRP
(8) WASHER, FLAT, 3/8 in. C.S.
(2) BOLT, 3/8 - 16 X 3.5 C.S. CROSS BAR, 3 in. C CHANNEL FRP
(4) NUT, 3/8 - 16 C.S.
SWING AWAY ASSY - 9 in. RADIUS
TRANSMITTER ANTENNA (STANDARD)
1 x 6 x 40
(4) BOLT, 1/4 - 20 X 2 C.S.
(4) NUT, 1/4 - 20 C.S.
(4) WASHER, FENDER, 1/4 in. C.S.
59.00 [1499]
ADJUSTABLE HEIGHT RECEIVER
1-1/2 in. INCREMENTS
RECEIVER ANTENNA
1 x 13 x 35
(4) BOLT, 1/4 - 20 X 2 C.S.
(4) NUT, 1/4 - 20
(4) WASHER, FLAT, 1/4 in.
(4) WASHER, FENDER, 1/4 in.
1 to 2 "
(2)MOUNTING FOOT
2 in. RT ANGLE CARBON STL
(6) BOLT, 3/8 - 16 X 3 C.S.
(2) BOLT, 3/8 - 16 X 3.5 C.S.
(8) NUT, 3/8 - 16 C.S.
(8) WASHER, FLAT, 3/8 in. C.S. CERTIFIED
FOR CONSTRUCTION
ELECTRONICS ENCLOSURE
OCT 16, 2018
16 H X 14 X 6.D
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
CUSTOMER TAG:
9.RECOMMEND IDLER SPACING 1200mm MINIMUM. 1 [25] T0 2 [51] 2110-ZM-005

CLEARANCE.
13.60 [345]
WITH NONMETALLIC MATERIAL.
335657
335657
TO ANTENNAS. REPLACE WITH NONMETALLIC STRUCTURE AS NEEDED. ERIEZ P/N:831970

10/15/2018
9/10/2018
ARC WELDING WITHIN 100 FT (30M). CLIP DETECTOR

3.IF EXPERIENCING AIRBORNE OR ELECTRICAL INTERFERENCE, ELECTRICALLY GROUND CONVEYOR AT BOLT OR WELD TO FRAME
THE HEAD AND TAIL.
ESD
ESD

SEE NOTE 4 VIBRATORY AND METAL DETECTION APPLICATIONS
2.SUGGESTED LOCATION OF METAL DETECTOR: 1) IN LOW VIBRATION AREA, 2) AS FAR AWAY AS POSSIBLE
FROM ELECTRICAL AND AIRBORNE INTERFERENCE I.E., RADIO XMTRS, VARIABLE SPEED DRIVES TITLE OUTLINE
SHEET TITLE
AND CONTROLLERS.
1235 METAL DETECTOR 118BW N4X
1.ALLOW AT LEAST 6FT(2M) DISTANCE BETWEEN DETECTOR POWER AND SIGNAL LINES,PLANT CONDUIT, FOR
CABLE AND PIPING RUNS. NEXT
DR. BY ESD ORDER # 335657 1N-201802988
NOTES UNLESS OTHERWISE SPECIFIED ASS'M

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OCT 16, 2018
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
CUSTOMER TAG:
335657
2110-ZM-005
9/10/2018
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SHEET TITLE
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BOLT SIZE BOLT SIZE METRIC WASHER MAJOR WASHER MINOR WASHER ID WASHER L
ITEM QTY DESCRIPTION
IMPERIAL OD OD MAJOR OD
3/4" M20 2.065"(52.4mm) 1.05"(26.7mm) .806"(20.5mm) .5"(12.7mm) 1 16 Shoulder Washer - 0.54" ID (14mm) - Nylon
MINOR OD L
2 16 Shoulder Washer - 0.65" ID (16.5mm) - Nylon
ID
4 16 ISOLATION PAD, Fiberglass 4"X4"X1/4"
CERTIFIED
FOR CONSTRUCTION
OCT 16, 2018
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
IDLER BOLT (EXISTING)
IDLER WASHER (EXISTING)
NYLON SHOULDER WASHER (BY ERIEZ)

IDLER FLANGE (EXISTING)
4" X 4" FRP PAD

(BY ERIEZ)

1, 2, 3
IDLER NUT (EXISTING)

4
INSTALLATION INSTRUCTIONS
1. Remove the adjacent idler on either side of the detector installation location.
2. Select Shoulder Washers that is the closest fit for the existing idler bolt.
3. Position 4 isolation pads under idler feet (two on each side) so they are
centered on the idler foot hole, drill a holes into the four isolation plates large
enough to allow the shoulder washer flange to fit. CUSTOMER TAG:
4. Re-mount the idlers onto the frame so that the isolation plates are in between 2110-ZM-005
2110-ZM-252
the idlers mounting foot and the conveyor frame. Secure the idlers with the
335657
bolt, washers, shoulder washer and nuts. When completed, the idler will be
10/15/2018
electrically isolated from the conveyor frame.

ESD
NOTE: Besure to use a metal flat washer on top of the nylon shoulder washer to VIBRATORY AND METAL DETECTION APPLICATIONS
TITLE OUTLINE
spread the bolt head preasure evenly. SHEET TITLE
FOR IDLER PULLEY ISOLATION W/ TAGGING

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SCALE NTS E.R. # PRIOR REF 201507851

DATE 9/10/2018
UPDATE QTY'S

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DOUTL a2013
1 2 SETS NON-METALLIC FLAG (SET OF 3) P/N 56036
2 30' CABLE, SO8, 18GA - NOT SHOWN - PN 10784

3 1 FDM Back Support PN 40053.21
4 1 Gusset Plate, FDM Frame - PN 40050.4
5 4 Screw, Machine - Philips 1 4-20 X 12" - PN 11235
6 2 Bolt, 3/8-13 x 1.5" PN 10600
7 1 UPRIGHT - 2" FRP Souare tube - 46" Long - PN 40050.2
8 1 HORIZ. SUPPORT - 2" FRP Square tube X 33" - PN 40050.3
9 2 Bolt 3/8-13 x 3" - PN 10599
10 5 Bolt 3/8-13 x 1" - PN 10601
2 1/2 [64]
CERTIFIED
FOR CONSTRUCTION
OCT 16, 2018
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
37 3/16 [945]
CUSTOMER TAG:
2110-ZM-005
2110-ZM-252
335657
10/15/2018
5 5/8 [143]
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TITLE FLAG DROP MARKER

SHEET TITLE
FOR 1235/1260 METAL DETECTORS W/ TAGGING

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2 BRACKET TUBE-1.06 X 10.0/20.0 LG 3/4" SCHED 40 STL PIPE 3 1/8 [80]
3 1/8 [80]
BRACKET TUBE W/PLATE- 3.125 SQ 12 ga C.S.
3 2 PROXIMITY SENSOR
CERTIFIED
4 STRAIN RELIEF
5 2 SWIVEL JOINT FOR CONSTRUCTION 1 11/16 [43] 1 11/16 [43]
6 25' (2) CLIP DETECTOR CABLE
OCT 16, 2018
ERIEZ MAGNETICS
ERIE PENNSYLVANIA
4
3
10 [254]
6
LED STATUS
INDICATORS
2 RED TO 1 WHITE TO 4
NC 2 BLACK TO 3
1
3 4
20 [508]
1 2
1 1/16 [27] 1 1/16 [27]
1 13/16 [46]
FOR BELT WIDTHS OF 90" OR LESS
5
Note:
Green LED for power on ASSEMBLY
Yellow LED for metal detect
1 1/16 [27] 1 1/16 [27]

335657
1 13/16 [46]
ANGLE SWIVEL BRACKET TO MATCH TROUGHING ANGLE
10/15/2018
AND KEEP FLAT PART OF SENSOR PARALLEL TO THE BELT MOUNT 2 [51] AWAY FOR BELT WIDTHS OF 90" OR GREATER
AND ABOUT 1 [25] AWAY FROM BACK OF BELT. FROM ROLLER
POSITION 4 [102] BELOW EDGE OF BELT.
CUSTOMER TAG:
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2110-ZM-005 TITLE OUTLINE

SHEET TITLE
2110-ZM-252
WELD CLIP DETECTOR FOR 1235/1260 BELT CLIP DETECTOR W/ TAGGING
MOUNTING BRACKET BASE
SUPPORT TUBE TO NEXT
DR. BY ESD ORDER # ASS'M
CONVEYOR FRAME
SCALE 1/2 E.R. # PRIOR REF 3R-201200837
DATE 9/10/2018
INSTALLATION
UPDATE QTY'S
REFERENCE
SPENCE GROWTH OPTIONS PROJECT CHKD. BY DRAWING NUMBER REVISION
DISCONNECT LINE POWER GROUND(TB-2,3) AND RECEIVER

CONNECTION @ TERMINAL BLOCK BEFORE ARC WELDING.
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A
COUT a2016_0
Installation, Operation
and Maintenance
PREPARED FOR:
CONSORCIO TNT VIAL Y VIVES
1235 DETECTOR
STYLE NO: 201802988
1260 DETECTOR
STYLE NO: 201802989
SERIAL NO: 335657
Eriez Magnetics
Headquarters
2200 Asbury Road
Erie, PA 16506-1440
PHONE (814) 835-6000
WEB www.eriez.com
TABLE OF CONTENTS
SECTION 1
INSTALLATION, OPERATION AND MAINTENANCE
INSTRUCTIONS FOR METAL DETECTOR MODEL 1235
ANALOG
SECTION 2
INSTALLATION OPERATION AND MAINTENANCE
ANALOG
SECTION 3
SPARE PARTS LIST
SECTION 4
DRAWINGS
SECTION 1

ANALOG
MM-1235-ANALOG-D
and Maintenance
Instructions
Metal
Detector
MODEL 1235 ANALOG
ERIEZ MAGNETICS HEADQUARTERS: 2200 ASBURY ROAD, ERIE, PA 16506–1402 U.S.A.

WORLD AUTHORITY IN SEPARATION TECHNOLOGIES
Introduction
This manual details the proper steps for installing,
operating and maintaining the Eriez Model 1235 Metal Detector.
Careful attention to these requirements will assure the most
efficient and dependable performance of this equipment.
If there are any questions or comments about the manual, please
call Eriez at 814-835-6000 for Model 1235 Metal Detector assistance.
CAUTION
Safety labels must be affixed to this product.
Should the safety label(s) be damaged, dislodged
or removed, contact Eriez for replacement.
© 2016 ERIEZ MAGNETICS ALL RIGHTS RESERVED
2
Table of Contents
ERIEZ MODEL 1235 Metal Detector
SAFETY WARNINGS.......................................................................................................... 5
General ......................................................................................................................... 5
Installation..................................................................................................................... 5
Connections.................................................................................................................. 5
GENERAL INFORMATION.................................................................................................. 5
Standard Warranty........................................................................................................ 5
Installation Assistance................................................................................................... 5
Technical / Application Assistance................................................................................ 5
DESCRIPTION.................................................................................................................... 6
General ......................................................................................................................... 6
Method of Operation..................................................................................................... 6
Physical Description...................................................................................................... 6
Electronic / Interface Modules....................................................................................... 6
Search Coil Assembly................................................................................................... 9
Clip Detector................................................................................................................. 9
INSTALLATION................................................................................................................. 10
Unpacking................................................................................................................... 10
Site Selection & Preparation....................................................................................... 10
Idler Roller Isolation.................................................................................................... 11
Mounting: Search Coil Assembly................................................................................ 13
Mounting: Main Control Enclosure.............................................................................. 13
Swing-Away Switch..................................................................................................... 14
Clip Detector............................................................................................................... 14
Marking Device........................................................................................................... 15
Installation Instructions......................................................................................... 15
Calibration of Marking Device............................................................................... 15
Flag Drop Marker........................................................................................................ 17
Calibration of Flag Drop Marker........................................................................... 18
START UP & CALIBRATION............................................................................................. 20
Start-Up....................................................................................................................... 20
Main Detector Unit: Metal Sensitivity Calibration........................................................ 20
Oversize Threshold..................................................................................................... 20
Non-Magnetic Metal Sensitivity Calibration................................................................ 21
Main Detector Unit: Clip Detector Calibration............................................................. 21
Operation.................................................................................................................... 22
Excessive Electrical Interference................................................................................ 22
ERIEZ Model 1235 Metal Detector
3
Table of Contents (continued)
ERIEZ MODEL 1235 Metal Detector
SYSTEM PROGRAMMING............................................................................................... 23
General ....................................................................................................................... 23
Metal Gain................................................................................................................... 23
Clip Gain..................................................................................................................... 23
Clip Detector Time Delay............................................................................................ 24
Delay Before Alarm..................................................................................................... 24
Time Alarm On............................................................................................................ 24
Standard or Fail - Safe Output Operation................................................................... 25
Manual/Auto Resets.................................................................................................... 25
Reset Override............................................................................................................ 26
Sampling..................................................................................................................... 26
Trip Register................................................................................................................ 26
Fine Frequency Select................................................................................................ 26
TROUBLESHOOTING...................................................................................................... 27
Status Indicators......................................................................................................... 27
Troubleshooting Flow Diagrams................................................................................. 27
Electronic Module Troubleshooting............................................................................. 27
Maintenance Kit.......................................................................................................... 27
Addendum................................................................................................................... 30
Troubleshooting Flow Diagram #1.............................................................................. 31
Troubleshooting Flow Diagram #2.............................................................................. 32
APPENDIX A: CONTROL CONNECTION DIAGRAMS.................. 33

APPENDIX B: SERVICE, PARTS, REPAIRS.................................. 52
MODEL 1235 FRAME ASSEMBLY................................................................................... 53
4
Safety Warnings General Information
This Detector should be installed by Eriez detectors are custom fabricated to suit each
qualified electrical and mechanical user’s particular application. Each detector system is
personnel only. subjected to extensive testing both at the sub-assembly
level and after final assembly to ensure compliance with
General performance and electrical safety standards.
All standard safety procedures should be observed when
working on electrically powered equipment. Standard Warranty
Proper care should be taken when connecting or (Please refer to full warranty information.)
disconnecting the power source. Eriez new metal detectors are warranted against
defects in workmanship and materials for three years.
When connected to a power source, un-insulated, This warranty does not cover failures due to misuse,
dangerous voltage is present within the Detector’s neglect, abuse, improper handling, alteration, improper
electronics enclosure which may constitute a risk of maintenance or accident, and Eriez shall not be liable for
electric shock. any direct, indirect, consequential or incidental damages
from use, results of use or inability to use this product.
Do not allow moisture to collect in the electronics
Repairs by any other than Eriez authorized service
enclosure or near the power connections. Always close
personnel will void this warranty.
the enclosure and secure the locking mechanism after
working with the electronics. Within the warranty period, the product will be repaired
or replaced at Eriez’ option, free of charge; shipping
The user should not attempt to service the Detector.
costs will be paid by Eriez. Except as mentioned above,
All servicing should be referred to certified service
no other warranty, expressed or implied, applies. If
personnel qualified to work on electrical equipment.
Modules are not covered by warranty as mentioned
Installation above, Customer will be billed for the repair and

shipping. Non warranty repairs, Customer must issue a
Do not install this Detector near heat sources such as PO # or Credit Card # prior to any repair.
radiators or air ducts.
Place the Detector in a location with adequate air Installation Assistance
circulation to prevent internal heat buildup. Eriez metal detectors have been designed for installation
by qualified personnel with detailed instructions provided
Connections with each shipment. When required, a Eriez Field
Engineer will supervise or check the installation, activate
As standard, this Detector is set for connection to
115 VAC or 220 VAC. Refer to Appendix A Control the system and provide training on periodic adjustments
Connection Diagram for information about connections and care of the Detector for user maintenance personnel.
and color code hook-up instructions. Please contact Eriez for Field Service rates.
Technical/Application
Assistance
Eriez welcomes your inquiries concerning metal
detectors and their application, installation and servicing.
If technical or application assistance is needed, contact:
Eriez Magnetics
2200 Asbury Road, Erie, PA 16506-1402 USA
Phone: 814-835-6000 • 800-345-4946
Email: eriez@eriez.com
Website: www.eriez.com
5
Description Physical Description
Main Control Enclosure
General This enclosure houses and protects the Electronic and
Interface Modules and also serves as a junction box for
The Model 1235 is specifically designed to differentiate
between magnetic and nonmagnetic metals. This conduit and cables running to and from the Detector.
Detector is typically used in conjunction with a magnetic As standard, the Detector is housed in a steel NEMA 4
separator. The Detector monitors the conveyed material enclosure. Other enclosures are available as options.
for potentially damaging non-magnetic metal, while Visible and accessible on the front panel are: Power On/
magnetic metal is allowed to pass and is removed by the Off Switch, Green Power “ON” Indicator Lamp, Red Trip
magnetic separator further downstream. In addition, the Indicator Lamp that lights when the unit has detected
Model 1235 can be set to trigger on any metal (magnetic metal and a Reset Button. See Figure 1.
or nonmagnetic) too heavy for the magnetic separator to
remove. Consequently, full metal protection is provided.
Electronic/ Interface Modules
The Detector makes use of the latest in solid state All the electronics and controls for the Detector are
technology. The design includes a number of innovative contained in two modules, the Interface Module and the
features: self-test circuits that monitor the performance Electronic Module shown in Figure 2. The Electronic
of the detection circuitry using light emitting diodes Module houses the electronic circuitry and components
(L.E.D.’s) which indicate the status of the test circuits; associated with metal signal processing and analysis.
wide programming capability to custom tailor the Visible on the front panel of the Electronic Module are
Detector to suit specific application requirements; and the “Metal Sensitivity” control knob, “Clip Override”
solid state relays to provide reliable arc-free switching. control knob and L.E.D. status indicators used to monitor
the status of the Detector's self-test circuits. By removing
Method of Operation the front panel of the module, all of the electronics
are exposed for calibration and troubleshooting. All
During normal operation, the transmitter coil is energized
to produce a pulsed electromagnetic signal. These signals connections for the Electronic Module are made through
produce a field that locally permeates the conveyed a 36-pin connector located along the bottom edge of the
material. A piece of metal entering this field absorbs module. When the modules are in place, this connector
energy emitted from the transmitter coil. The metal particle mates with a connector on the Interface Module.
then releases the energy and this change is detected The Interface Module interconnects all external signals
by the receiver coil. This technique provides optimum and power to the Electronic Module. This module houses
discrimination between tramp metal and the conveyed the power transformer, solid state relays and interface
material; product effect is non-existent or minimal. circuit board. Visible on the face of the Interface Module
Having detected metal by a waveform change, the signal are system fuses and two terminal blocks for external
generated is amplified and filtered. The signal is then wiring; all are clearly identified. The right terminal block,
compared to a threshold determined by the size of metal a 13-pin, 3/8" center screw type, connects the Detector's
that must be detected. When the signal exceeds this external transducers and signals. The left terminal
threshold, a “metal signal” is generated. Once this metal block, a 7-pin, 7/16" center screw type, is used for all
signal is generated, a secondary circuit analyzes the connections handling the A.C. line voltage.
metal for its magnetic properties.
If this secondary unit determines that the tramp metal is
magnetic, it is allowed to pass the Detector with no alarm
for subsequent removal by the magnetic separator. If
the secondary circuit determines that the metal is non-
magnetic, the metal signal triggers solid state relays
which in turn switch the line voltage to the output alarm
terminals. In addition, the Detector will activate the alarm
terminals for metal too heavy for the magnetic separator
to remove. Any metal larger than the preset oversize
limit will trigger the alarm regardless of its magnetic
properties. The Detector is influenced only by change.
Therefore, stationary structural members, metal belt
cords, symmetrical idlers and other objects which do not
represent a moving mass to the field are not detected.
6
Type: JIC NEMA
Size: 16" x 14" x 6"
Weight: 33 lbs. (includes all electronics)
ITM QTY DESCRIPTION
1 1 POWER “ON” INDICATOR (GREEN) LAMP
2 1 TRIP INDICATOR (RED) LAMP
3 1 ON/OFF SWITCH (LEVER HANDLE)
4 1 RESET PUSH BUTTON
4. DIMENSIONAL TOLERANCE ±0.060

3. DETAIL DIMENSIONAL TOLERANCE ±0.010
2. DETAIL IS HOFFMAN MINIATURE 4-WAY
1. MATERIAL: RITTAL ENCLOSURE FRONT DOOR
JB161406HC
NOTE UNLESS OTHERWISE SPECIFIED
NOTE: REFBACK PANEL DRAWING 130-015
Figure 1
7
Electronic Module
Size: 10.5" x 8" x 1.5"
Weight: 2.5 lbs
Figure 2a
Interface Module
Size: 11" x 2.5" x 4"
Weight: 4.75 lbs
Figure 2B
8
Search Coil Assembly Size: 3.5" x 3.5" x 2"
Weight: 1.25 lbs.
The Search Coil Assembly includes receiver
and transmitter antennas, mounting frame and
interconnecting cables. Each assembly is custom
designed to suit its particular application. Please refer to
the Frame Assembly Diagram.
Receiver Coil
The receiver coil is typically located under the conveyed
material within 2" of the loaded conveyor belt.
Transmitter Coil
The transmitter coil is located opposite and parallel to
the receiver coil. The distance between the transmitter
and receiver (aperture) is typically 4" greater than the
maximum burden depth of the processed material.
Figure 3
Mounting Frame
The mounting frame supports the antennas on trough and
slider bed conveyors. Special designs are available to
accommodate other types of material handling systems.
The swing-away assembly, shown in Figure 3, protects
the transmitter from oversized conveyed materials.
Interconnecting Cables
Shielded cables connect the receiver and transmitter
to the Main Control Enclosure. 25' of cable between
the frame assembly and the control unit is supplied as
standard. Optimum performance is assured with cable
lengths of 25' or under. However, lengths of up to 100’
are acceptable where Detector sensitivity requirements
are minimal.
Clip Detector
(if applicable)
The clip detector consists of a compact sensor head
and mounting bracket. The clip detector senses the
proximity of repair clips as they pass over the sensor’s
head. Once the clips are detected, the Metal Detector is
desensitized, but not disabled. Any large piece of metal
riding on the clips will still trigger the Detector.
Figure 4
9
Installation Select a site with minimum vibration. High vibration
areas may degrade detector sensitivity and shorten
component life.
PLEASE READ THROUGH COMPLETELY BEFORE
BEGINNING WORK! Locate the Search Coil Assembly away from sources of
airborne electrical interference emitted from variable-
Unpacking speed drives, large motors, ballasts, FM radios,
Upon receipt of the crate(s) containing the Metal induction furnaces and other radio frequency (RF)
Detector System, inspect the contents for physical sources. Because RF energy travels along a straight
damage and missing parts. If anything is broken or line (line-ofsight), position the receiver coil or relocate
missing, please contact the carrier and notify the RF sources so they are out of the direct line-ofsight with
supplier immediately. the top and bottom of the receiver coil. Cables carrying
high voltage or varying loads must be enclosed in steel
Site Selection & Preparation conduit, grounded at both ends and located at least 4'
from the detector antennas.
While each application is unique, the guidelines listed
below apply to most installations. Specific information Position the entire search coil assembly so that the
concerning your installation can be found in the Frame bottom of the coil (usually the receiver) is equally spaced
Assembly and Control Connection Diagrams. Follow between the two adjacent idler rollers. Center the
the steps listed below to choose the best location receiver coil. Do not center the 2" x 2" uprights.
for the detector:
Choose a location for the detector so the material
handling system has ample time to react to tramp metal.
Locate the detector far enough in advance of the head
pulley so the belt can come to a stop before the metal
falls off the end of the belt. If a diverter is used, consider
the reaction time of the system and speed of the
conveyor belt.
Figure 5
10
Idler Roller Isolation
The magnetic field generated by the transmitter coil
induces eddy currents in nearby metal cross bracing,
stairways, handrails and pipes. These eddy currents
may cause false tripping if the current path intermittently
makes contact. Eddy current loops can be broken by
cutting the conductive paths in these structures. Use
non-metallic hardware as required to restore structural
support. If conveyor idlers are used in your application, the
idlers adjacent to the Search Coil Assembly may require
modification or isolation to break eddy current loops. Refer
to the Conveyor Idler Modification Diagram for details.
If the Search Coil Assembly is located where a metal skirt
passes through the coils, it must be replaced with a five-
foot section of non-metallic material (i.e., wood or plastic).
Remove metallic decking, skirt boards, cross bracing
and return idlers below and within 3' of the center line of
the receiver coil (upstream and downstream). Relocate
or tightly secure moving or vibrating pieces of metal such
as cables, conduit and piping within 36" of the Search
Coil Assembly.
Figure 6
11
ITM QTY DESCRIPTION
1 8 SHOULDER WASHER 1/2" ID (12MM)
ISOLATION PAD, FIBERGLASS

4 2
4 X 4 X 1/4 INCH THK. Set of 4.
12
Figure 7
2. Select Shoulder Washers that is the closest fit for the idler bolt.
centered on the idler foot hole, drill a holes into the four isolation plates
large enough to allow the shoulder washer flange to fit.
4. Re-mount the idlers onto the frame so that the isolation plates are in
between the idlers mounting foot and the conveyor frame. Secure the idlers
with the bolt, washers, shoulder washers and nuts. When completed, the
idler will be electrically isolated from the conveyor frame.
Note: Be sure to use a metal flat washer on top of the nylon shoulder
washer to spread the bolt head pressure evenly.
1 NO METAL DECKING, CROSSBRACING, OR RETURN IDLERS BELOW

OR BETWEEN IDLERS ADJACENT TO RECEIVER ANTENNA.
Mounting: Mounting:
Search Coil Assembly Main Control Enclosure
Note the material flow direction arrows, match marks and After installing the Search Coil Assembly, select a
other identification on the Detector components before place to mount the Main Control Enclosure for ease of
beginning work. Please refer to the Frame Assembly operation. Avoid high vibration areas. Note the length of
Diagram for installation. interconnecting cables and the location of the connectors
on the receiver and transmitter coils. Locate the Control
Assemble the top crossbar to the vertical upright Enclosure on the same side of the conveyor frame as
supports using four 3/8" x 1" bolts with washers the connectors for ease in routing the cables.
(provided). Be sure the crossbar is located on the
upstream side of the upright supports and the base of The Enclosure should be positioned so the front panel
the metal mounting feet point in toward the belt. hinge is on the left side and the indicators are on top.
Assemble the top transmitter coil (with swing-away Fabricate and install a sun/rain shade for added
brackets attached) to the upright supports. The height protection over the Enclosure if it is mounted outdoors.
of the transmitter coil should be as low as possible Do not obstruct the natural airflow around the Enclosure.
without being hit by overburden. The nominal height for
the transmitter coil is indicated by dimension “S” on the Familiarize yourself with the type of electrical
Frame Assembly Diagram. Use two 3-1/2" bolts with connections required for this installation and any safety
washers (provided). Each of the two bolts contains four precautions before proceeding. Please refer to the
flat washers and two nuts. Make sure two washers are Control Connection Diagram for information about
located between the swing-away bracket and upright connections and color code hook-up.
support to insure proper spacing and freedom of Use an electrician’s conduit punch or drill to make
movement. The remaining washers are located at the either 1/2" or 3/4" conduit entries on the bottom of the
end of each bolt. Hand tighten each bolt with a nut until Enclosure. The Control Connection Diagram shows
light drag is exerted on the swing-away bracket. Tighten where to position each entry. Remember to remove all
the second nut against the first nut to serve as a jam nut. metal shavings when you are finished. Use caution to
Verify that the swing-away brackets are free to move. not damage the electronics and to ensure that no metal
particles enter the electronics. Do not run metal conduit
CAUTION along the sides or near the Search Coil Assembly.
If the swing-away assembly is not free to move, damage The receiver and transmitter cables must be routed
to the transmitter coil may result if hit by over burden. in a separate conduit. Do not run power wiring near the
transmitter and receiver cables.
Position the upright assembly onto the conveyor frame All line voltage connections terminate at TB2. Install
with the arrow on the transmitter coil pointing in the line voltage cables between devices controlled by the
direction of belt flow. Detector including diverters, auxiliary relays, marking
devices, alarm horns or motor control equipment and
Assemble the receiver coil (mounting brackets attached) to TB2 in the Main Control Enclosure. The direct or timed
the upright supports using four 3/8" x 3-1/2" bolts with washers outputs should not be connected to a Programmable
(provided). Position the height of the receiver coil as close as Logic Controller (PLC) or other low voltage computer
possible to the belt. The nominal height for the receiver coil is interface equipment that may require dry contact
indicated by dimension “R” on the Frame Assembly Diagram. closures. The direct and timed output contacts are
Allow for belt sag under load. Bolt the brackets into place with typically programmed as normally “OFF” at the Factory.
nuts and washers facing in toward the belt. They may be set to normally “ON” if required. Refer to
the System Programming Section for details.
Verify that the search coil assembly is square and all
bolts installed are properly tightened. Connect a 115/220 VAC (50/60 Hz), single phase power
line with at least 10 amp capacity to TB2. Make sure to
Position the entire search coil assembly so the bottom receiver connect an electrical ground to terminal #3. The power
coil is equally spaced from the idler rollers on either side. should be the “cleanest” available and free of significant
Weld or bolt the metal support feet to the conveyor voltage variations or spikes. Do not connect the Detector
frame. Be sure unwanted twists and torques in the frame to a line which is used for operation of motors or motor
assembly are corrected before you weld. A twist in the controls. Proceed with the Start-Up & Calibration Section
frame may cause the swing-away bracket to pull away before applying power.
from the upright support. This may cause the transmitter
coil to bounce from vibration while in operation.
13
It is recommended that the Clip Detector cable running
CAUTION to the Main Control Enclosure be installed in conduit.
The Interface Module is preset at the Factory for 115 The same conduit that houses the transmitter coil cable
or 220 volt (±10%), 50/60 Hz, single phase operation. may be used.
If the voltage source is different, contact the Factory Feed the Clip Detector cable into the conduit from the
for instructions to select the proper voltage source. Clip Detector end to the Main Control Enclosure.
Cut off excess cable. Connect wires to terminal block
(TB1) using the supplied spade lugs. Refer to the
Swing-Away Switch Control Connection Diagram for color code hook-up. Be
certain all wires are attached securely and connected to
(if applicable)
their proper terminals.
The Swing-Away Cutout Switch (Optional) is a pre-wired
switch mounted on the swing-away bracket. Its purpose When metal repair clips are used, two or more clips
is to prevent the Metal Detector from tripping when the close together must pass directly over the Clip Detector
transmitter coil is hit by an overburden of material. Route Sensor in order to activate it. If a small patch of clips is
the free end of this cable in the same conduit as the used on the belt, which would not pass directly over the
transmitter cable to the Main Control Enclosure. Refer to Clip Detector, reference clips are required. Reference
the Control Connection Diagram for hookup. clips are made by installing two or more clips which
will pass directly over the Clip Detector to trip it when a
small patch passes by. Numerous repair and reference
clips on the belt will degrade the Detector's performance
because it will frequently be in a desensitized mode.
Clip Detector
(if applicable)
Refer to Control Connection and Frame Assembly
Diagrams. If there are idlers adjacent to the search coils,
position the Clip Detector Sensor approximately 1" to 3"
upstream of the nearest upstream idler before the Search
Coil Assembly. For slider bed type conveyors, position
the Clip Detector Sensor approximately (but no closer
than) 2' from the center line of the receiver coil on the
upstream side of the Search Coil Assembly. The flat face
of the Clip Detector should be facing toward the belt with
approximately 1/2" to 1" of clearance. This clearance
must be maintained in order to assure proper
operation. The Clip Detector should be a few inches from
the edge of the belt. Do not mount the Sensor too far
from the edge, as tramp metal lying close to the belt may
trigger the sensor and pass through the search coils as a
repair splice.
With the Clip Detector Sensor in the proper position
below the belt, weld the 3/4" support pipe (provided) to
the conveyor frame. The pipe may be cut to the proper
size for an easier fit. The multi-axis swivel joint will
provide adequate movement for proper adjustment.
14
Marking Device Calibration of Marking Device
(if applicable) Refer to the System Programming section “Delay Before
The Marking Device is a pressurized, solenoid activated Alarm” and “Time Alarm On” to set the desired timing for
liquid spray system which pinpoints the location of tramp marking a predetermined location.
metal to eliminate costly search and down time.
Using a sample piece of tramp metal, with the belt
operating at normal load, adjust the Marking Device
Specifications
timing by trial and error.
Tank Pressure Rating: 150 psig (maximum working pressure)
Tank Capacity: 3 Gallons (liquid)
Operational Voltage: 115/220 VAC (50/60 Hz), 15 Watts
Air: Plant air or any source of 100 to 200 psig inert gas
Installation Instructions
Refer to the Frame Assembly Drawing for layout of the
Marking Device on the belt.
Position the solenoid support upright and cross arm as
shown. Distance from the coils should be 3' to 6'. Clamp
in place temporarily.
Position the support bracket of the solenoid spray valve
so that the nozzle is pointed directly on the center of the
conveyor belt. The nozzle may be positioned as shown
or on the opposite side of the arm. Bolt the bottom of the
support frame to the conveyor frame.
The solenoid control cable is connected to the Interface
Module Timed Output (Terminal TB2, Pins 4 & 5). Route
the cable accordingly.
Connect the hose between the tank outlet and the
solenoid valve.
Connect the facility air source to the tank regulator inlet.
Be sure the facility air source is shut off and no pressure
is in the tank.
Remove the top of the spray tank.
The spray solution is supplied by the User. The
recommended mixture is five (5) fluid ounces of colorant,
Chrome Yellow (or other contrasting color) manufactured
by Tenneco Chemical (or equivalent) mixed with a two
(2) gallon solution of water and antifreeze appropriate
for local climate conditions (minimum of 25% antifreeze).
DO NOT USE PAINT. Paint will clog the spray valve.
Mix the solution and pour it into the holding tank.
Replace the cap.
Verify that the pressure regulator valve is closed prior to
turning on the facility air.
Apply the facility air and adjust the pressure regulator
between 60 and 100 psig, as noted on the pressure
gauge on top of the holding tank.
15
16
MARKING DEVICE AND DYE RESERVOIR
Flag Drop Marker
(if applicable)
The Flag Drop Marker is device which drops a tag or flag
onto the belt which pinpoints the location of tramp metal
to eliminate costly search and down time.
Specifications
Plastic NEMA 4X box which holds the electronics and flag
One set of 3 flags
Operational Voltage: 115/220 VAC (50/60 Hz), 15 Watts
VERTICAL SUPPORT
1" SQUARE SOLID FRP
HORIZONTAL SUPPORT
1" SQUARE SOLID FRP
Figure 14
17
Installation Instructions Calibration of Flag
Refer to the Figure 15 for assembly and mounting and
Figure 16 for positioning of the Flag Marking Device on Drop Marker
the conveyor belt. Refer to System Programming section “Delay Before
Alarm” and “Time Alarm On” to set the desired timing for
Attach the upright support to the upright. Position the marking a predetermined location.
frame upright in front of the first downstream idler roller.
Lay the upright support on the top of the C channel and The initial delay time that is set can be calculated using
adjust the upright so that it is straight up and down. Clamp the belt speed and the distance between the center of
in place now drill the a hole in the side of the C channel to the receiver antenna and the flag drop marker flag or use
secure the bottom of the upright and drill a couple of holes a stop watch to time a mark on the belt as it moves from
through the upright support and top of C channel and the center of the receiver antenna to the flag drop maker
secure the support to the conveyor C channel. flag. This is the Delay Before ON time. The ON Time is
preset at the factory to about .05 second. It is easier to
Attach the frame cross bar with gusset to the upright. adjust the timing of the flag marker with an empty belt.
Use a sample piece of tramp metal large enough to
Mount the NEMA box to the cross bar. Position the box
trigger the detector. With the belt up to full speed place
on the cross bar so that the flag will drop on the product
the tramp metal on the belt far enough before the metal
where the edge of the product touches the belt, (if the
detector antennas that the metal has come to rest on the
product comes to the edge of the belt then position the
belt and is not moving relative to the belt. What should
box so the flag is far enough in so that the flag does not
happen is when the piece of metal reaches the flag drop
fall off of the belt).
area the released and will fall to the belt. If the flag lands
Route the power cord across the cross bar and down the before the piece of metal then increase the Delay Before
upright, secure cord with ty-raps. Make connections to the On time. If the flag lands after the metal then reduce the
Metal Detector electronics Ref Appendix A Figure A12. Delay Before On time. The flag should drop and hit the
metal. The delay time for the flag will vary depending on
the distance it has to fall. If the flag is dropped on the
product the distance the flag has to travel between an
empty belt and a full belt will cause the flag to be either
in front of the metal or behind the metal, so when looking
for metal look about 12" on either side of the flag if the
metal is not visible and is buried in the product.
18
Figure 15
Figure 16
19
Start-up & Calibration Oversize Threshold
This adjustment determines the size of metal that will
Start-up trigger the alarm circuitry regardless of its magnetic
properties. It has been preset at the factory for a size
Before turning on the system, locate the switches and lights slightly smaller than the largest piece of magnetic metal
on the door panel and the controls inside the cabinet. that can be removed by the magnetic separator and
The power switch is located on the lower left-hand should not be adjusted unless absolutely necessary.
corner of the door panel. Place it on the “ON” position. If the oversize threshold is not used, set the “Oversize
The green “ON” indicator should light at this time. Threshold” control on the front of the Electronics Module
to a setting of “10”. If the oversize threshold is used,
If the green “ON” does not come on, return the power switch calibration is as follows:
to the “OFF” position and inspect the light bulb and fuses;
also check the power and wiring for proper connections. 1. Pass the larger sample piece of magnetic metal
between the coils at the height of the average
Approximately 5 seconds after power “ON”, the No. 1 burden and at a speed comparable to belt travel. If
status indicator (power supply) located on the front panel the Detector trips on the test sample, skip step 2 and
of the Electronic Module will light (reference Figure 2). proceed with 3. If the Detector does not trip continue
This indicates that the power supply is fully operational with step 2.
and all the electronics are enabled.
2. Reduce the oversize threshold by turning the
If the power supply L.E.D. status indicator or the “ON” “Oversize Threshold” control knob on the face of the
indicator does not light, refer to Troubleshooting Flow Electronic Module counter-clockwise to a smaller
Diagram #1 for instructions. Until the power supply setting. Continue adjusting until the Detector picks
L.E.D. is lit, calibration of the unit cannot begin. up the larger test sample.
Main Detector Unit: 3. Pass the smaller sample piece of magnetic metal
between the coils in the same manner as the larger
Metal Sensitivity Calibration piece. If the unit does not trip when the metal passes
Before proceeding with the calibration procedure, between the coils, the test is complete. If the unit trips,
obtain four samples of tramp metal as listed in the adjust the “Oversize Threshold” until it does not trip.
following reference table. These samples should
4. Repeat steps 2 and 3 until the system accepts the
represent the type of metal most likely found in the
larger piece of metal and rejects the smaller. When the
conveyed material. The clip timer, L.E.D. No. 7, cannot
final setting is made, note the number on the “Oversize
be lit during calibration. This results in erroneous data.
Threshold” control knob for future reference.
During calibration, the test samples must be fully
passed through the detection field. The samples must 5. If the Detector does not respond properly to
be traveling at a uniform rate through the area two feet calibration, refer to the Troubleshooting Flow
ahead and two feet behind the receiver coil in order for Diagrams at the end of this Manual.
the Detector to analyze the magnetic characteristics of
the metal.
Magnetic/
Nonmagnetic Size Example
Smallest size Aluminum,
1 Piece Nonmagnetic that will damage Brass,
crusher. Manganese
Aluminum,
Largest size that will
1 Piece Nonmagnetic Brass,
not damage crusher.
Manganese
Slightly smaller than
1 Piece Magnetic the largest size the Steel
magnet can remove.
Larger than magnet
1 Piece Magnetic Steel
can remove.
20
Non-magnetic Metal Main Detector Unit:
Sensitivity Calibration Clip Detector Calibration
1. Set the “Metal Sensitivity” control knob, located (if applicable)
on the front panel of the Electronic Module, to the Turn the “Clip Override” control knob fully clockwise to
middle of the dial (reading of 5). position 10 on the dial. This knob is located on the front
2. Pass the larger sample piece of non-magnetic panel of the Electronic Module as shown in Figure 2.
metal between the coils at the height of the average Observe the reference clips to see if they are passing
burden, at a speed comparable to belt travel and within 1" of the Clip Sensor Head when the belt is empty.
completely through the search coil assembly. Adjust the Clip Detector if it is not within this distance
making sure that the clips or the belt do not hit the Clip
If the Detector does not trip on the test sample, Detector Sensor Head when the belt is fully loaded.
turn the “Metal Sensitivity” control knob to a higher If the clip is located properly, the Clip Timer, status
sensitivity (in direction of ascending numbers), so indicator No. 7, located on the Electronic Module will
the Detector will trip just as the metal is passed light for approximately 1 second each time the clips pass
between the coils. over the Clip Detector Head.
In the event that the unit doesn't trip with the “Metal
Sensitivity” control knob on 10, check to see if the NOTE
metal signal L.E.D. No. 2 lights as the metal is passed
If the Clip Detector is spaced more than 1" from the
through the field. If the L.E.D. does not light as the
passing clips, erratic performance may occur.
tramp metal is passed through the field, additional
sensitivity may be required. In this case, please refer
to the section System Programming “Metal Gain”. If the Detector is tripping on the clips with a “Clip
Override” setting of 10, refer to the System Programming
3. Pass the smaller sample piece of non-magnetic
section “Clip Gain”, Clip Gain.
metal between the coils in the same manner as
the larger piece. The unit should not trip when the Gradually turn the clip control knob counterclockwise to
smaller piece of metal passes between the coils. a lower setting until the unit trips on the largest set of
If the unit does trip, adjust the “Metal Sensitivity” repair clips on the belt.
control knob until it does not trip on the metal.
Turn the clip control knob clockwise one number higher
4. Repeat steps 2 and 3 until the system accepts the as a safety factor.
larger piece of metal and rejects the smaller. When
the final setting is made, note the number on the
“Metal Sensitivity” control knob for future reference. NOTE
If this number is greater than 8, increase the gain This setting should be periodically checked to
of the Detector as described in the section System compensate for shifting of the conveyor belt. Turn
Programming “Metal Gain”. the control knob to a “0” setting if the clip detector
5. Pass the smaller sample of magnetic metal through is not used.
the sensing area. L.E.D. No.2 should light, indicating
the presence of metal. The Detector should not trip
because the sample is magnetic. If the unit does trip,
the “Oversize Threshold” may require recalibration.
Refer to “Oversize Threshold”.
21
Operation Excessive Electrical
The Detector may be programmed to operate in a
manual or an automatic reset mode; the standard mode Interference
of operation is manual reset. The Metal Detector has a unique circuit that distinguishes
electrical noise from a legitimate metal signal.
Manual Reset When this circuitry “sees” interference that lasts longer
In the manual reset mode, once the unit has tripped, the than .1 second or that interferes more than 25% of the
Detector's Direct Output provides a continuous alarm time, the Detector will turn off L.E.D. status indicator
indication to alert the operator of detected metal and/or No.4 each time the interference occurs. In addition, the
to stop the belt. To reset the unit, the reset button located incoming “noisy” signals are blocked from downstream
on the front panel must be manually depressed. circuitry to reduce the chance of any false tripping.
Automatic Reset If an excessive amount of electrical interference
The Detector may be converted to an “Automatic Reset occurs, the source of the interference must be found
Mode”. In this mode the Detector will momentarily and corrected. Excessive interference will reduce the
signal when tripped then self-reset according to the Detector’s sensitivity and may false trigger the system.
placement of the programming switches. For complete Such interference problems are usually associated with
programming instructions, refer to the System motor phase to ground shorts, severely arcing brushes
Programming section “Manual/Auto Resets”. on motors, poor ground conditions, etc.
Remote Reset
Provisions have been made to externally reset the
Detector from a remote location. Wire a normally open
set of contacts across the remote reset terminals TB1
pins 1 & 2 located on the Interface Module. Upon closure
of the contacts, the unit will reset.
22
System Programming 3. Check that the clip timer, status indicator No. 7, is
not lit during any portion of this test. If the clip timer
is lit, the data will be incorrect.
General 4. Pass the sample piece of tramp metal completely
The Detector provides a wide range of programming
through the coils at a height midway between
capability. The Detector can be individually tailored to
the transmitter and receiver coils and at a speed
the customer’s specific requirements; taking into account
near that of the conveyed material under normal
the type and size of metal to be detected, the type of
operating conditions. Increase or decrease the gain
material being conveyed and the mode and combination
of the system with the rotary switch as needed until
of alarm signals required.
the Detector will trip just as the sample metal is
passed between the coils. The larger numbers on
Removing/Replacing Cover
the gain setting switch correlate to a higher gain, the
To program the Electronic Module, the cover must be
lowest gain being 1 and the highest 0 (representing
removed. Remove the control knobs with the 1/16" Allen
10). If the unit never trips, refer to Troubleshooting
wrench (provided). Unscrew the six screws securing the
Flow Diagram #1.
cover with the 5/64" Allen wrench (provided).
5. If all other functions are properly programmed,
When replacing the cover, it is essential to re-index the
replace the cover and knobs. Re-index the control
control knobs. Before tightening the set screw, line it
knobs as indicated in the “General” section.
up with the flat of the shaft. The knob, when properly
indexed, will indicate 10 in a full clockwise position and 0 6. Recalibrate the "Metal Sensitivity" control knob as
in a full counterclockwise position. instructed in the Start-up & Calibration section “Non-
Magnetic Metal Sensitivity Calibration”.
Metal Gain
When a piece of tramp metal passes over the search Clip Gain
coils, a change in the received signal occurs. This change When belt repair clips are used on a conveyor belt,
is extremely small and must be amplified to produce a the repair clips may represent a stronger metal signal
suitable signal to trigger the relay driver circuitry. than the tramp metal. In this situation, it is necessary
to reduce the gain of the system to allow the clips to
The amount of gain required in the receiver circuitry
pass. Rotary Switch S5, shown in Figure 4, establishes
depends on the following factors:
the gain whenever the clip detector circuit is energized.
• Coil Length In the event that Switch S5 is set higher than S4, the
• Coil Aperture system will choose the smaller gain setting of the two for
• Belt Speed the clip gain.
• Type of Metal to be Detected
For calibration of the clip gain, follow these steps:
• Size, Shape and Orientation of the Metal to the
Search Coil 1. Run the belt at normal running speed and maximum
belt load.
The internal gain of the Detector is adjusted by a rotary
switch, S4, located inside the Electronic Module (refer to 2. Verify that the clip timer, status indicator No. 7, lights
Figure 4). Each step in gain represents an increase over each time a clip passes the sensor head. If it does
the last step. Ideally, the gain is adjusted to pick up the not, adjust the clip sensor head as described in the
desired piece of tramp metal with the “Metal Sensitivity” “Clip Detector” Installation section.
control knob located on the outside of the Electronic
Module set to 5. 3. Record the settings for the “Metal Sensitivity” control
knob and the Clip Override control knob. Adjust the
If the gain must be changed, use a sample of tramp “Clip Override” control knob, shown in Figure 2, to a
metal the same size as the piece to be detected and setting of 5.
follow the procedures listed below:
4. Remove the cover as described in the “General”
1. Remove the control knobs and cover of the Electronic section without changing the setting on the “Clip
Module as indicated in the “General” section. Override” control knob.
2. Set the “Metal Sensitivity”: control knob (R70) to its
rotational midpoint (if the cover was not removed,
the “Metal Sensitivity” would be 5)
23
5. Adjust the Clip Gain, Switch S5 shown in Figure 4,
to the highest gain that does not trip the Detector
Time Alarm On
The timed output can be accurately programmed to remain
when the clips pass. If the unit continues tripping
energized for a timed period once it is switched on. This
even at the minimum clip gain of 1, the desensitized
feature can activate a diverter gate, sound an alarm for a
length of the belt may be too short. In other words,
given period, command a marking device to spray a given
the system is switched back to full sensitivity before
length of the belt, etc. Switches S3-1 through S3-5 control
the clips are completely out of the Detector's field.
this time delay from .01 to 22.0 seconds. Refer to Table 2
To correct, increase the clip detector time delay as
for a tabulation of the delay time versus switch settings and
described in the “Clip Detector Time Delay” section.
Figure 4 for the switch locations.
6. If all other functions are properly programmed,
replace the cover as described in the “General”
section. Return the controls to recorded settings.
7. Calibrate the “Clip Override” as described in
Section Start-up & Calibration section “Clip
Detector Calibration”.
As the repair splice passes through the sensing coils,
the magnetic properties of the clips override the signal
from any small sample of metal riding on the splice.
Consequently, the Detector is designed to trip if the
clip threshold is exceeded, regardless of the magnetic
properties of the detected metal. When properly
calibrated, it takes approximately 20% more metal signal
than is represented by the largest set of repair clips to Table 1
trigger the Detector during the desensitized mode. Clip Time Delay
(Switch S1)
Clip Detector Time Delay
If the clip detector is used, the length of belt desensitized
to permit the clips to pass can be adjusted by properly
programming the clip detector time delay switches S1-
5, 6 & 7. The locations of these switches are shown in
Figure 5. The range of delay times is from .28 seconds to
2.10 seconds as tabulated in Table 1. These switches are
set at the factory according to customer requirements and
should not be adjusted unless absolutely necessary. As
long as the Detector is desensitized, the clip timer, status
indicator No. 7, will remain lit.
Delay Before Alarm

The timed output alarm can be accurately programmed
with a time delay before turn on. This allows the
conveyed material to travel for a programmed period
before the timed output alarm signal is energized.
Typically this feature is used in conjunction with a
marking device or diverter gate to delay the system
until the detected tramp metal has reached the auxiliary
equipment. Switches S2-1 through S2-5 control this
time delay from .01 to 22.0 seconds. Refer to Table 2 for
tabulation of the delay time versus switch settings and
Figure 4 for the switch locations.
Table 2
S2 - Delay Before Alarm
S3 - Time Alarm On
24
Standard or Fail – Safe Manual/Auto Resets
Output Operation Manual Reset
In the manual reset mode, once the unit has tripped, the
As standard, the alarm outputs of the Detector will
energize when tramp metal is detected. In this mode, the Detector’s Direct Output provides a continuous alarm
solid state relay is programmed to operate in a Normally indication to alert the operator of detected metal and/or
“OFF” condition. The outputs will not energize until metal to stop the belt. To reset the unit, the reset button located
is detected. on the front panel must be manually depressed.
Provisions have been made to program the Detector to Automatic Reset

operate in a fail-safe mode. In this mode, the outputs The Detector may be converted to an “Automatic Reset
of the Detector are always energized and de-energize Mode”. In this mode, the Detector will momentarily signal
when tramp metal is detected or when power to the when tripped then self-reset.
Detector is turned off. In the fail-safe mode, the solid
state relay is programmed to operate in a Normally The direct output can be programmed to automatically
“ON” condition. Both outputs can be independently reset by shorting the remote reset terminals TB1 pins 1 &
programmed. The direct output (status indicator No. 9) 2, located on the front of the Interface Module. To “short”,
and timed output (status indicator No. 8) will monitor install a jumper from pin 1 to pin 2. Open Switch S2-7.
the alarm's output condition. If the status indicator is lit, The operating mode of the timed output is governed by
its associated output is energized. Switch S2-6 controls the position of Switch S3-7 as shown in Table 4. With the
the direct output and S3-6, the timed output as shown switch in the open position, the timed output operates in
in Table 3. To operate the solid state relay condition in a the Automatic Reset Mode. When the switch is closed,
Normally “OFF” condition, open the appropriate switch. the timed output will follow the mode programmed on the
Conversely, to operate the relay in a Normally “ON” direct output.
condition, close the switch.
Table 3 Table 4
S2 - Direct Output Normally On/Off Select Timed Output Reset Mode
S3 - Timed Output Normally On/Off Select Switch (S3)
25
Reset Override Trip Register
If required, the Detector can be programmed so the The “Trip Register” is used with the Detector’s timed
system is disabled during the reset period. This means output. The Trip Register accurately tracks up to 128
the Detector is prevented from tripping as long as a reset metal particles concurrently. Each particle’s signal is
signal is provided, either manually on the front panel or released to the timed output terminals consistent with
remotely through a set of external contacts. the programmed “Delay Before Alarm”. This standard
feature is automatically activated when the timed output
With S2-7 in the open position, the reset signal does is used for delayed operation of any device.
not disable the Detector. Closing S2-7 will program the
Detector so it is disabled while a reset signal is applied.
Refer to Table 5. Fine Frequency Select
The Detector is calibrated to operate at an optimally
Sampling selected transmitting frequency when using a 50 or 60
Hz line frequency. This frequency can be fine-tuned
The Detector Sampling Mode is set at the factory to over a 5% range by adjusting potentiometer R90, shown
make the Detector sensitivity selective between various in Figure 4. However, this is not usually necessary as
materials as required for each particular application. all units are calibrated at the factory prior to shipment.
Switches S1-1 through S1-4 inclusive are preset and The operating frequency of the Detector can best be
are not to be adjusted by the user. measured at the zero gate test point “Z”, shown in
Figure 4. The signal switches between 0V and +15V as
referenced to 0V of the system (Test Point 0V). If viewed
on an oscilloscope, this signal would be high one pulse
width and low for seven.
Table 5
Belt Reset Override
(Switch S2)
26
Control Position Function Comment
1
2 Allows the detector to detect metal and ignore conveyed
Sampling Mode
3 product. Factory pre-set; do not adjust.
S1 4
5
Selects how long the detector remains desensitized to metallic
6 Clip Time Delay
repair clips. Refer to Table 1 for position settings and times.
7
1
2 Controls timed output. Selects the time from when metal is
3 Delay Before Alarm detected until timed output is energized. Refer to Table 2 for
4 position settings and times.
S2 5
Sets direct output contacts as normally “ON” or “OFF”.
Direct Output
6 Refer to Table 3 for settings. Be aware of downstream circuit
Normally On/Off Select
effect before operating this switch.
Used to disable metal detection as reset signal is applied.
7 Belt Reset Override
Refer to Table 5 for settings.
1
2
Controls timed output. Selects how long the output remains
3 Time Alarm On
energized. Refer to Table 2 for position settings and times.
4
S3 5
Sets timed output contacts as normally “ON” or “OFF”.
Timed Output
Timed Output Determines if timed output will reset manually or
7
Reset Mode automatically. Refer to Table 4 for settings.
Selects metal signal amplification (gain) without repair clips
S4 Metal Gain
in sensing zone. “1” least gain; “0” most gain.
Attenuates metal signal amplification (gain) when repair
S5 Clip Gain
clips are in sensing zone. “1” most attenuation; “0” least.
Sets metal “trip” threshold level.
R70 Metal Sensitivity
“10” most sensitive, “1” least sensitive
Attenuates (reduces) metal sensitivity to allow repair clips to
R46 Clip Override
pass through detector. “10” most attenuation, “1” least.
R90 Fine Frequency Adjust Permits fine adjustment of detectors operating frequency.
Determines the size of metal (magnetic or not) that will

R86 Oversize Threshold
trigger the alarm circuitry.
Table 6
Programming Controls Summary
27
Figure 4
Programming Controls & Test Point Locations
28
Troubleshooting Electronic Module
Troubleshooting
Status Indicators In the event that the unit does not operate and the
In order to facilitate troubleshooting of the Detector, a
number of self-test circuits have been designed to monitor trouble has been traced to the Electronic Module, further
the condition of the detection circuitry. The results of these troubleshooting of the Module is possible using the test
test circuits are visible to the operator through L.E.D.’s on points provided on the circuit board. Monitoring these
the front panel of the Electronic Module (refer to Figure points requires a VOM, oscilloscope and frequency
2). These L.E.D.’s are referred to as Status Indicators. counter. If this equipment is available, schematics can
For a description of all L.E.D. monitors and their normal be obtained from the factory.
operating condition, refer to the Status Indicator Summary
(Table 7) on the following page. Maintenance Kit
Prior to shipment, a maintenance kit is packed in the
Troubleshooting Flow Main Control Enclosure.
Diagrams This kit contains all parts necessary for basic

maintenance. The items included are as follows:
NOTE (1) 1 Amp Fuse
(1) 10 Amp Fuse
Before working with Troubleshooting Diagrams,
(2) Spare Bulbs
check all terminals, connectors and cables for open
(1) 1/16" Allen Key Wrench
circuits and correct as required.
To aid in troubleshooting the Detector, two easy to follow,

step-by-step, flow diagrams were designed. Troubleshooting
Flow Diagram #1 deals with insufficient metal sensitivity. This
diagram is used if the unit detects metal, but is not sensitive
enough for the required application or if the Detector does
not respond to metal at all. Refer to Troubleshooting Flow
Diagram #2, if the unit continually false trips (triggers with no
metal in the field). When the Detector cannot discriminate
between magnetic and nonmagnetic metal, refer to
Troubleshooting Flow Diagram #3.
LED # Identification Normal Condition Comment

Indicates detector power supply operational; must be lit for unit to detect metal. Will not light
1 Power Supply ON when power supply malfunctions, low line voltage is presents, or optional transmitter swing-
away switch is activated. LED lights approximately 5 seconds after power is turned on.
2 Metal Signal OFF Indicates metal is detected in the sensing zone, regardless of its magnetic properties.
3 Zero
4 Enable Indicates specified internal Electronics Module circuits are functioning normally.
ON
5 - Sample Must be lit for unit to detect metal.
6 + Sample
Indicates repair clip is in proximity of clip detector head. LED remains lit for the
7 Clip Timer ON
period detector was programmed to allow clip to clear sensing zone.
Indicates the condition of the timed alarm output. If the LED is lit, the timed alarm
8 Timed Out OFF*
outputs are energized with the line voltage.
Indicates the condition of the timed alarm output. If the LED is lit, the direct alarm
9 Direct Out OFF*
outputs are energized with the line voltage.
* When programmed to operate in a fail-safe mode (output normally “ON”), the LED's will be normally lit.
Table 7
Electronics Module Status Indicator Summary
29
Addendum
Metal Activation Circuit for Model 1235
The odel 1235 has the ability to discriminate
between magnetic and non magnetic metals. When a
nonmagnetic metal is detected the Direct and Timed
Outputs are activated to send a signal to conveyor
control to stop the belt. Once the belt is stopped an
operator removes the nonmagnetic metal and starts the
conveyor once again.
If magnetic metal is passed between the antennas the
detector will show that the metal was sensed by the
detector but the outputs are not activated and the belt
is not stopped.
A high power electro magnet can remove the magnetic
metal from the belt but keeping the magnet at high
power is not recommended because the magnet will
get hot and as the temperature of the magnet increases
the magnetic pulling force is reduced. There is also an
increased cost of operating the magnet at high powered,
reduced life of the magnet and higher maintenance
costs. Also when conveying magnetic ore the magnet
can not be at high power because too much product
would be removed from the belt.
The Magnetic Activation Circuit was developed
addressed to problem of removing magnetic metal
without stopping the conveyor belt. When magnetic
metal is detected by the metal detector the signal is
sent to the MAC circuit. The magnetic metal signal is
then processed and the MAC output is activated using
a KRPA relay mounted on the white plate under the
Interface Module. The relay provides the output from
the metal detector to the electromagnet magnet control
circuitry. This can be 120vac, 220vac or any level of DC
voltage as long as the contact current of the relay is not
exceeded.
The magnet can be run at low idle current which keeps
the magnet cool allowing maximum flux energy when it
is switched to high current.
The MAC circuit board has one variable potentiometer
that controls how long the output is on. The on time
range can be set between 2.5 seconds and 15 seconds.
If J3 jumper is connected the on time range is reduced to
1.3 seconds to 7.5 second.
30
Disconnect Refer to the
METAL DETECTOR Replace NO Receiver Coil. YES “Metal Sensitivity Check Clip
DOES NOT DETECT electronic Does Status Calibration” Detector Sensor
METAL module Indicator No. 4 section in manual and Cable
Light Up? on excessive
electrical
NO
NO
NO
interference
Are status
Is Status Is Status
IS STATUS YES indicator nos YES Replace
indicator No. 4 Indicator No. 7 YES
INDICATOR NO. 1 LIT 3, 4, 5, 6 Electronic Model 1235
Lit all of the Lit all of the
ALL OF THE TIME? lit all of the Module
time? Time?
time? Troubleshooting
Flow Diagram #1
NO
YES
**********
IS INPUT POWER TO Is Status Disconnect clip
NO Line Voltage YES
METAL DETECTOR Indicator No. 7 detector cable Insufficient
Regulator
ABOVE 100 (210) Lit all of the from interface
Required Metal Sensitivity
VAC? time? module
NO
YES
Check 10 Amp Does Status Does status
NO Fuse, door plug Indicator No. 2 YES indicator No. 9 NO
IS GREEN LIGHT
connection, Flash when metal Light when status
ON ENCLOSURE LIT?
Power switch & is passed through indicator No. 2
Green light search coils? lights?
NO
31
YES
YES
Set Metal
IS 1 AMP FUSE ON YES
Replace Sensitivity Replace interface Contact Factory
INTERFACE MODULE
1 amp fuse control KNob module For Service
BLOWN?
to “0”
NO
YES
Trace Antenna
Does metal Re-calibrate
NO Replace cable. Are cables NO
detector have metal detector Connect Cables to
Electronic connected
a swing-away sensitivity Proper Terminals
Module to proper
cutout switch? control knob
terminals?
NO
YES
YES
YES
Does Status Does status IS THE METAL GAIN

Disconnect swing- Reduce search
Is status Indicator No. 2 NO indicator No. 2 NO SWITCH S4 AT ITS
away cutout coil aperture
indicator Flash when metal flash when metal MAXIMUM SETTING
cable from to minimum safe
No. 1 Lit? is passed through is passed through “0” REPRESENTING
interface module distance
search coils? search coils? “10”
YES

NO
Check Swing-Away Adjust metal gain

Cutout Switch switch S2 to next
and Cable higher setting
Metal Detector Disconnect
Does Detector Is status
False Trip on NO NO transmitter YES YES Verify “clean”
False Trip on Does Unit Still indicator no. 4
Repair Clips on cable from the ground to
Repair Clips on False Trip? lit all of
Return Side of interface module conveyor
Main Side of Belt the time?
Belt? ----------
no. 6 light will
turn off
NO
NO
YES
YES
Remove all
Increase distance Add a Wire Jumper Disconnect
“Possible” metal NO Replace Verify “clean”
between return BEtween TB1-5 & receiver coil does
located near Electronic ground to
belt & Receiver TB1-7 on interface status indicator
the search coil Module detector
Coil module no. 4 light up?
assembly
YES
Install Isolation Refer to the Start-
If unit still false Are adjacent
Kit to adjacent NO Up & Calibration
trips contact idler rollers
idler rollers Section “Excessive
the factory for isolated from
refer to “Idler Electrical
service conveyor frame
Roller Isolation” Interference”
Installation
Section in Manual
YES
reconnect Disconnect
transmitter Contact factory receiver cable
cable to for service from the
interface module interface module
32
YES
Strike the conveyor

frame, cross
Replace bracing, idler
is status NO Electronic rollers, return Is input power to YES Does unit still
indicator Module idlers, conduit metal detector
runs, cat walk, false trip?
no. 7 lit? ---------- “stable”?
Remove Jumper guard screens, in
areas around the
antennas
NO
NO
YES
Check for
Re-calibrate Mark Conveyor electrical
does unit still YES clip gain. Refer Joints which trip Line voltage interference I.E.
false trip on to System the detector regulator arcing contacts,
repair clip? Programming when conveyor is required radio transmission
section “Clip Gain” struck or phase to
ground short
NO
Remove Jumper weld marked
------------- joints to ensure
IS GREEN LIGHT
Place permanent
ON ENCLOSURE LIT?
screwdriver over electrical
clip head connections
Model 1235
Re-calibrate
clip time, refer Troubleshooting
to the System
Check clip if unit still false Flow Diagram #2
Programming YES Is Status NO detector sensor trips, contact
Section “Clip indicator
& Cable for open the factory for **********
Detector Time No. 7 Lit?
circuit service
Delay” in manual False Tripping
APPENDIX A
Control Connection Diagrams
33
Figure A1
Power Input
34
Figure A2
Transmitter and Receiver Antenna
35
Figure A3
Clip Detector
36
Figure A4
Dual Clip Detector
Clip heads need to be modified as shown above. Also J6 & J8 on the electronics Module must be made. Normally Jumpers
J5 and J7 are made for single clip operation. Refer to Figure 16 Programming Controls and Test Point Locations.
37
Figure A5
Synchronization
38
Figure A6
Spray Marker
39
Figure A7
Swing Away Switch
40
Figure A8
Control Unit Extension
41
Figure A9
Auxiliary 2 or 4 Relay Sq D 115 vac or 220 vac
42
Figure A10
Auxiliary Relay KRPA 115 vac or 220 vac
43
Figure A11
Voltage Regulator
44
MODEL 1235 CONNECTIONS
Figure A12
Flag Drop Marker
45
Figure A13
Alarm Horn & Flashing Beacon
46
Figure A14
Alarm Horn
47
Figure A15
Flashing Beacon
48
Figure A16
Remote Reset Switch
49
Figure A17
Automatic Reset
50
Figure A18
Strip Heater 115 VAC or 220 VAC
51
APPENDIX B
Service, Parts, Repairs
52
Model 1235 Frame Assembly
Num. Name
1 Crossbar
2 Upright Pair
3 Mounting Feet Carbon Steel
4 Receiver Bracket Pair
5 Transmitter Bracket Pair
6 Receiver Antenna
7 Transmitter Antenna
8 Roughing Guard
9 Swing-Away Switch
53
Eriez and Eriez Magnetics are registered trademarks of Eriez Manufacturing Co, Erie, PA ©2016 Eriez Magnetics All Rights Reserved
World Authority in Separation Technologies 

Headquarters: 2200 Asbury Road, Erie, PA 16506-1402 U.S.A.
Telephone: 814-835-6000 • 800-345-4946 • Fax: 814-838-4960 • International Fax: 814-833-3348
Web Site: http://www.eriez.com e-mail: eriez@eriez.com
Manufacturing Facilities: AUSTRALIA • BRAZIL • CANADA • CHINA • INDIA • JAPAN • MEXICO • SOUTH AFRICA • UNITED KINGDOM • UNITED STATES
1016-WEB-AHA ERIEZ MANUFACTURING CO ©2016 PRINTED IN USA

SECTION 2

ANALOG
MM-1260-ANALOG
and Maintenance
Instructions
Metal
Detector
MODEL 1260
ANALOG
ERIEZ HEADQUARTERS: 2200 ASBURY ROAD, ERIE, PA 16506–1402 U.S.A.

Introduction
This manual details the proper steps for installing, operating and
maintaining the Eriez Model 1260 Analog Metal Detector.
Careful attention to these requirements will assure the most
efficient and dependable performance of this equipment.
If there are any questions or comments about the manual, please
call Eriez at 814-835-6000 for Model 1260 Metal Detector assistance.
CAUTION
Safety labels must be affixed to this product.
Should the safety label(s) be damaged, dislodged
or removed, contact Eriez for replacement.
2
Table of Contents
ERIEZ Model 1260 ANALOG Metal Detector
SAFETY WARNINGS.......................................................................................................... 5
General ......................................................................................................................... 5
Installation..................................................................................................................... 5
Connections.................................................................................................................. 5
GENERAL INFORMATION.................................................................................................. 5
Standard Warranty........................................................................................................ 5
Installation Assistance................................................................................................... 5
Technical/Application Assistance.................................................................................. 5
DESCRIPTION.................................................................................................................... 6
General ......................................................................................................................... 6
Method of Operation..................................................................................................... 6
Physical Description...................................................................................................... 6
Main Control Enclosure.......................................................................................... 6
Electronic/Interface Modules.................................................................................. 7
Search Coil Assembly................................................................................................... 9
Receiver Coil.......................................................................................................... 9
Transmitter Coil...................................................................................................... 9
Mounting Frame..................................................................................................... 9
Interconnecting Cables........................................................................................... 9
Clip Detector................................................................................................................. 9
INSTALLATION................................................................................................................. 11
Unpacking................................................................................................................... 11
Site Selection & Preparation....................................................................................... 11
Mounting - Search Coil Assembly............................................................................... 14
Mounting - Main Control Enclosure............................................................................. 14
Swing-Away Switch..................................................................................................... 15
Clip Detector............................................................................................................... 16
Spray Marking Device................................................................................................. 18
Specifications....................................................................................................... 18
Calibration of Marking Device............................................................................... 20
Flag Drop Marker........................................................................................................ 21
Specifications....................................................................................................... 21
Calibration of Flag Drop Marker........................................................................... 21
ERIEZ Model 1260 Analog Metal Detector
3
Table of Contents (continued)
ERIEZ Model 1260 ANALOG Metal Detector
START-UP & CALIBRATION............................................................................................. 24

Start-Up....................................................................................................................... 24
Main Detector Unit - Metal Sensitivity Calibration....................................................... 24
Rod Diameter Calibration..................................................................................... 24
Oversize Calibration............................................................................................. 24
Rod Length Calibration......................................................................................... 24
Main Detector Unit - Clip Detector Calibration............................................................ 25
Operation.................................................................................................................... 25
Manual Reset....................................................................................................... 25
Automatic Reset................................................................................................... 25
Remote Reset....................................................................................................... 25
Excessive Electrical Interference................................................................................ 25
SYSTEM PROGRAMMING............................................................................................... 26
General ....................................................................................................................... 26
Removing/Replacing Cover.................................................................................. 26
Metal Gain................................................................................................................... 26
Clip Gain..................................................................................................................... 26
Clip Detector Time Delay............................................................................................ 27
Delay Before Alarm..................................................................................................... 27
Time Alarm On............................................................................................................ 27
Standard or Fail - Safe Output Operation................................................................... 27
Manual/Auto Resets.................................................................................................... 28
Manual Reset....................................................................................................... 28
Automatic Reset................................................................................................... 28
Reset Override............................................................................................................ 29
Sampling..................................................................................................................... 29
Fine Frequency Setting............................................................................................... 29
TROUBLESHOOTING...................................................................................................... 32
Status Indicators......................................................................................................... 32
Troubleshooting Flow Diagrams................................................................................. 32
Electronic Module Troubleshooting............................................................................. 32
Maintenance Kit.......................................................................................................... 32
APPENDIX A: CONTROL CONNECTION DIAGRAMS.................. 36

APPENDIX B: SERVICE, PARTS, REPAIRS................................... 55
4
Safety Warnings General Information
Eriez detectors are custom fabricated to suit each
THIS DETECTOR SHOULD BE INSTALLED BY user’s particular application. Each detector system is
QUALIFIED ELECTRICAL AND MECHANICAL subjected to extensive testing both at the sub-assembly
PERSONNEL ONLY. level and after final assembly to ensure compliance with
performance and electrical safety standards.
General
• All standard safety procedures should be observed
when working on electrically powered equipment.
Standard Warranty
(Please refer to full warranty information)
• Proper care should be taken when connecting or Eriez new metal detectors are warranted against
disconnecting the power source. defects in workmanship and materials for three years.
This warranty does not cover failures due to misuse,
• When connected to a power source, un-insulated,
neglect, abuse, improper handling, alteration, improper
dangerous voltage is present within the Detector’s
maintenance or accident, and Eriez shall not be liable for
electronics enclosure which may constitute a risk
any direct, indirect, consequential or incidental damages
of electric shock.
from use, results of use or inability to use this product.
• Do not allow moisture to collect in the electronics Repairs by any other than Eriez authorized service
enclosure or near the power connections. Always personnel will void this warranty.
close the enclosure and secure the locking
Within the warranty period, the product will be repaired or
mechanism after working with the electronics.
replaced at Eriez’s option, free of charge; shipping costs
• The user should not attempt to service the Detector. will be paid by Eriez. Except as mentioned above, no
All servicing should be referred to certified service other warranty, expressed or implied, applies. If Modules
personnel qualified to work on electrical equipment. are not covered by warranty as mentioned above,
Customer will be billed for the repair and shipping.
Installation Non warranty repairs, Customer must issue a PO #
or Credit Card # prior to any repair.
• Do not install this Detector near heat sources such
as radiators or air ducts.
• Place the Detector in a location with adequate air
Installation Assistance
Eriez detectors have been designed for installation by
circulation to prevent internal heat buildup. qualified personnel with detailed instructions provided with
each shipment. When required, a Eriez Field Engineer will
Connections supervise or check the installation, activate the system
• As standard, this Detector is set for connection to and provide training on periodic adjustments and care
115 VAC. If specifically requested, the Detector can of the Detector for user maintenance personnel. Please
be set for 220 VAC. The Detector must be connected contact Eriez for Field Service rates.
only as supplied.
• The power cable should be routed so that it is not Technical/Application
likely to be walked on or pinched by items placed
upon or against it, paying particular attention to the
Assistance
Eriez welcomes your inquiries concerning metal
point where it exists from the Detector. detectors and their application, installation and servicing.
If technical or application assistance is needed, contact:
Eriez
2200 Asbury Road, Erie, PA 16506-1402 USA
Phone: 814-835-6000 • 800-345-4946
Email: eriez@eriez.com
Website: www.eriez.com
5
Description of the metal signal. Given a constant belt speed, the
length of the piece can be determined. If this circuit
determines that the tramp metal is shorter than
General programmed, it is allowed to pass with no alarm.
The Model 1260, Long Object Detector, is designed to
On the other hand, if the secondary circuit determines that
selectively detect and discriminate between long metal
the metal is sufficiently long, the metal signal is allowed
objects and shorter, bulkier ones. In a typical application,
to trigger the solid state relays at the appropriate time.
this Detector could be used on a conveyor system
These solid state relays in turn switch the line voltage
monitoring the conveyed material for potentially damaging
to the output alarm terminals of the detector. Various
metal rods that could tear a conveyor belt if jammed in a
combinations of alarm horns, belt stop relays, alarm
transfer point.
beacons, etc., can then be actuated by these switched
The Detector may be set to detect a rod of a given alarm outputs.
minimum diameter and length. It will then trip on this
In addition to this protection, the detector will also activate
diameter rod only when the rod is the selected length or
the alarm for any piece of tramp metal considered to be
longer. This trip signal would then be used to stop the
oversized. Such an oversized piece will trigger the alarm
belt and/or sound an alarm. In addition to the rod control,
regardless of its length.
the unit also has and “Oversize” control. This control is
set to trigger on objects larger than the rod diameter, The detector is influenced only by change. Therefore,
independent of length. stationary structural members, metal belt cords,
symmetrical idlers and other objects which do not
To provide the calibration capability for the detection
represent a moving mass to the field are not detected.
selectively described, the Detector has three adjustable
Metal belt repair clips are passed by the unit with an
controls: 1) long object minimum diameter, 2) long object
optional clip detector sensor and inhibitor circuit which
minimum length, and 3) oversize object size.
is properly adjusted to the clip signal.
The Detector makes use of the latest in solid state
technology. The design includes a number of innovative Physical Description
features: self-test circuits that monitor the performance
Main Control Enclosure
of the detection circuitry using light emitting diodes
This enclosure houses and protects the Electronic and
(L.E.D.’s) which indicate the status of the test circuits;
Interface Modules and also serves as a junction box for
wide programming capability to custom tailor the Detector
conduit and cables running to and from the Detector.
to suit specific application requirements; and solid state
As standard, the Detector is housed in a steel NEMA 4
relays to provide reliable arc-free switching.
enclosure. Other enclosures are available as options.
Method of Operation Visible and accessible on the front panel are: Power On/
During normal operation, the transmitter coil is energized Off Switch, Green Power “On” Indicator Lamp, Red Trip
to produce a pulsed electromagnetic signal. These signals Indicator Lamp that lights when the unit has detected
produce a field that locally permeates the conveyed metal and a Reset Button. See Figure 1.
material. A piece of metal entering this field absorbs Type: NEMA
energy emitted from the transmitter coil. The metal particle Size: 16" x 14" x 6"
then releases the energy and this change is detected Weight: 33 Lbs. (Includes All Electronics)
by the receiver coil. This technique provides optimum
discrimination between tramp metal and the conveyed
material; product effect is non-existent or minimal.
Having detected metal by a waveform change, the signal
generated is amplified and filtered through several stages.
The signal is then compared to a set threshold determined
by the size of metal that must be detected. When the
signal exceeds this threshold, a metal signal is generated.
In the 1260, once this metal signal is generated a
secondary circuit is enabled which times the duration
6
Figure 1
Figure 1
Electronic/ Interface Modules The Interface Module interconnects all external signals
All the electronics and controls for the detector are and power to the Electronic Module. This module houses
contained in two modules, the Interface Module and the the power transformer; solid state relays and interface
Electronic Module shown in Figure 2. The Electronic circuit board. Visible on the face of the Interface Module
Module houses the electronic circuitry and components are system fuses and two terminal blocks for external
associated with metal signal processing and analysis. wiring; all are clearly identified.
Visible on the front panel of the Electronic Module are
The left terminal block, a 7-pin, 7/16" center screw type,
the “Oversize Sensitivity” control knob, “Rod Length”
is used for all connections handling the A.C. line voltage.
control knob, “Clip Override” control knob and L.E.D.
The right terminal block, a 13-pin, 3/8" center screw
status indicators used to monitor the status of the
type, connects the Detector’s external transducers
detector's self-test circuits. By removing the front cover
and signals.
of the module, all of the electronics are exposed for
calibration and troubleshooting. All connections for the
Electronic Module are made through a 36-pin connector
located along the bottom edge of the modules.
7
ELECTRONIC MODULE Figure 2
ELECTRONIC MODULE
Size: 10.5” x 9.5” x 1.5” Figure 2
Size:
Weight: 3.25 Lbs. 1.5”
10.5” x 9.5” x
Electronic Module
Weight: 3.25 Lbs.
Size: 10.5" x 9.5" x 1.5"
Weight: 3.25lbs
INTERFACE MODULE
Interface ModuleINTERFACE MODULE
Size: 11” x 2.5” x 4”
Size: 11" x 2.5" x 4"Size: 11”4.75Lbs.
Weight: x 2.5” x 4”
Weight: 4.75lbs Weight: 4.75Lbs.
Figure 2 5
5
8
Shielded cables connect the receiver and transmitter to the Main Control E
cable between the frame assembly and control unit is supplied as stan
Search Coil Assembly performance is assured Clip Detector
with cable lengths of 25’ or under. However, length
(if applicable)
are acceptable
The Search Coil Assembly includes where detector
a pair of receiver sensitivity requirements are minimal.
The clip detector consists of a compact sensor head and
antennas, a transmitter antenna, mounting frame and
interconnecting cables. Each assembly is custom mounting bracket. The clip detector senses the proximity
1.3.4 Clip Detector (if applicable)
designed to suit its particular application. Please refer of repair clips as they pass over the sensor’s head. Once
the clips are detected, the Metal Detector is desensitized,
to the Frame Assembly Diagram, Figure 4.
The clip detector consists but of
not a compact
disabled. sensor
Any large head
piece andriding
of metal mounting
on the bracket. T
Receiver Coil senses the proximity ofclips repair clips
will still asthethey
trigger pass over the sensor's head. On
Detector.
detected, the Metal Detector is desensitized, but not disabled. Any large
The receiver coils are typically located under the
conveyed material within 2" of the loaded conveyor belt.
riding on the clips will still
Size:trigger
3.5" x 3.5" the
x 2"Detector.
Transmitter Coil Weight: 1.25 Lbs.
Sensing Face
The transmitter coil is located opposite and parallel to
the receiver coil. The distance Size:
between3.5”
the xtransmitter
3.5” x 2”
Weight:
and receiver (aperture) is typically 1.25than
4" greater Lbs.
the
maximum burden depth of the processed material.
Mounting Frame
The mounting frame supports the antennas on trough and
slider bed conveyors. Special designs are available to
accommodate other types of material handling systems.
The swing-away assembly, shown in Figure 4, protects
the transmitter from oversized conveyed materials.
Shielded cables connect the receiver and transmitter to
the Main Control Enclosure. 25' of cable between the
frame assembly and control unit is supplied as standard.
Optimum performance is assured with cable lengths of 25'
or under. However, lengths of up to 100' are acceptable
where detector sensitivity requirements are minimal.
Figure
6 3
9
Figure 4
Swing Away Frame Assembly Diagram
7
10
2.2.4 Position the entire search coil assembly so that the bottom of the coil (usually the
receiver) is equally spaced between the two adjacent idler rollers. Center the receiver coils or
transmitter coil using the cable connector as the center line of the antenna. Do not center the
2” x 2” uprights.
Figure 5
Installation
PLEASE READ THROUGH COMPLETELY BEFORE
BEGINNING WORK!
Unpacking
Upon receipt of the crate(s) containing the Metal
Detector System, inspect the contents for physical
damage and missing parts. If anything is broken or
missing, please contact the carrier and notify the
supplier immediately.
Site Selection & Preparation

While each application is unique, the guidelines listed
below apply to most installations. Follow the steps listed
below to choose the best location for the detector:
Choose a location for the detector so the material 2.2.5 The magnetic field generated by Figure 5
the transmitter coil induces eddy currents in nearby
metal cross bracing, stairways, handrails and pipes. These eddy currents may cause false
handling system has ample time to react to tramp metal. The magnetic field generated by the transmitter coil
tripping if the current path intermittently makes contact. Eddy current loops can be broken by
Locate the detector far enough in advance of the head cutting the induces
conductiveeddy currents
paths in nearbyUse
in these structures. metal cross bracing,
non-metallic hardware as required to
stairways,
pulley so the belt can come to a stop before the metal restore structural handrails
support. andonpipes.
Idler rollers These
either side of theeddy
antennacurrents
assembly are one of the
major sources
may of eddy current
cause interference.
false tripping An idler
if the isolation
current pathkitintermittently
is provided see Figure 6.
falls off the end of the belt. If a diverter is used, consider
For instructions on how to install the isolation kit, refer to the Idler Modification Diagram for
the reaction time of the system and speed of the makes
details Figure 7. contact. Eddy current loops can be broken by
conveyor belt. cutting the conductive paths in these structures. Use
2.2.6 If non-metallic hardware
the Search Coil Assembly as required
is located to restore
where a metal structural
skirt passes through the coils, it
Select a site with minimum vibration. High vibration must be replaced
support. withIdler
a five-foot
rollerssection of non-metallic
on either side ofmaterial (i.e., wood or plastic).
the antenna
areas may degrade detector sensitivity and shorten assembly are one of the major sources of eddy current
component life. 2.2.7 Remove metallic decking, skirt boards, cross bracing and return idlers below and
within 3' interference.
of the center line An idler
of the isolation
receiver kit is provided
coil (upstream see Figure
and downstream). Relocate or tightly
Locate the Search Coil Assembly away from sources of secure 6.
movingFor orinstructions
vibrating pieces on
of how
metal to
suchinstall
as the
cables, isolation
conduit and kit,
pipingrefer
within 36" of
the Searchto Coil
the Assembly.
Idler Modification Diagram for details Figure 7.
airborne electrical interference emitted from variable-
speed drives, large motors, ballasts, FM radios, If the Search Coil Assembly is located where a metal
induction furnaces and other radio frequency (RF) skirt passes through the coils, it must be replaced with
sources. Because RF energy travels along a straight line a five-foot section of non-metallic material (i.e., wood
(line-of-sight), position the receiver coil or relocate RF or plastic).
9
sources so they are out of the direct line-of-sight with

the top and bottom of the receiver coil. Cables carrying Remove metallic decking, skirt boards, cross bracing
high voltage or varying loads must be enclosed in steel and return idlers below and within 3' of the center line of
conduit, grounded at both ends and located at least 4' the receiver coil (upstream and downstream). Relocate
from the detector antennas. or tightly secure moving or vibrating pieces of metal such
as cables, conduit and piping within 36" of the Search
Position the entire search coil assembly so that the Coil Assembly.
bottom of the coil (usually the receiver) is equally
spaced between the two adjacent idler rollers. Center
the receiver coils or transmitter coil using the cable
connector as the center line of the antenna. Do not
center the 2" x 2" uprights.
11
Figure 6
Isolation Kit
Isolation Kit contains 8 4"x4" FRP plates, 16 1" diameter

Isolation
flat washers,Kit contains
16 5/8" 8 4”x4”
nuts and FRP5/8"
1 48" long plates, 16 1” diameter flat washers, 16 5/8” nuts and 1 48” long
threaded
5/8”
rod. threaded
Note: rod. Note:
When isolation Whenbyisolation
kit ordered its self thekit ordered by its self the threaded rod may be precut into
threaded
4 piecesrodtomay
aid be
in precut into 4 pieces
packaging. to aidKits
Isolation in supplied with unit orders do not have the threaded rod
packaging. Isolation Kits supplied with unit orders
doprenotcut.
have the threaded rod pre cut.
10
12
Figure 7
Figure
11 7
13
Mounting – Search Weld or bolt the metal support feet to the conveyor
frame. Be sure unwanted twists and torques in the frame
Coil Assembly assembly are corrected before you weld. A twist in the
Note the material flow direction arrows, match marks and frame may cause the swing-away bracket to pull away from
other identification on the Detector components before the upright support. This may cause the transmitter coil to
beginning work. Please refer to the Frame Assembly bounce from vibration while in operation.
Diagram Figure 13 for installation.
Tightly secure or remove any loose metal in the vicinity of
Assemble the top crossbar to the vertical upright supports the coils; such as floor plates, broken or unused brackets,
using four 3/8" x 1" bolts with washers (provided). Be sure etc. Movement of any metal around the coils will appear
the crossbar is located on the upstream side of the upright to be “TRAMP” metal to the detector and will cause false
supports and the base of the metal mounting feet angles trips. Also, remove any cross bracing in the vicinity of the
point in toward the belt. receiver coil.
Assemble the top transmitter coil (with swing-away

brackets attached) to the upright supports. The height of
Mounting – Main
the transmitter coil should be as low as possible without Control Enclosure
being hit by overburden. The nominal height for the After installing the Search Coil Assembly, select a
transmitter coil is indicated by dimension “S” on the Frame place to mount the Main Control Enclosure for ease of
Assembly Diagram. Use two 3-1/2" bolts with washers operation. Avoid high vibration areas. Note the length of
(provided). Each of the two bolts contains four flat washers interconnecting cables and the location of the connectors
and two nuts. Make sure two washers are located between on the coil. Locate the Control Enclosure on the same side
the swing-away bracket and upright support to insure of the conveyor frame as the connectors for ease in routing
proper spacing and freedom of movement. The remaining the cables.
washers are located at the end of each bolt. Hand tighten
each bolt with a nut until light drag is exerted on the swing- The Enclosure should be positioned so the front panel
away bracket. Tighten the second nut against the first nut hinge is on the left side and the indicators are on top.
to serve as a jam nut. Verify that the swing-away brackets Fabricate and install a sun/rain shade for added protection
are free to move. over the Enclosure if it is mounted outdoors. Do not
obstruct the natural airflow around the Enclosure.
Familiarize yourself with the type of electrical connections
CAUTION
required for this installation and any safety precautions
If the swing-away assembly is not free to move, before proceeding. Please refer to Appendix A, Control
damage to the transmitter coil may result if hit Connection Diagram for information about connections
by overburden. and color code hook-up.
Use an electrician's conduit punch or drill to make either
Position the upright assembly onto the conveyor frame with 1/2" or 3/4" conduit entries on the bottom of the Enclosure.
the arrow on the transmitter coil pointing in the direction of The Control Connection Diagram shows where to position
belt flow. each entry. Remember to remove all metal shavings when
you are finished. Use caution to not damage the electronics
Assemble the receiver coil (mounting brackets attached) and to ensure that no metal particles enter the electronics.
to the upright supports using four 3/8" x 3-1/2" bolts with Do not run metal conduit along the sides or near the
washers (provided). Position the height of the receiver to Search Coil Assembly.
allow for 1" distance between the bottom of the belt and
the top of the receiver antenna at maximum belt load. Transmitter and receiver cables should be routed in
Bolt the brackets into place with the nuts and washers conduit. Do not run any power wiring in the same
facing in toward the belt. conduit or near the transmitter and receiver cables.
Verify that the search coil assembly is square and all bolts
installed are properly tightened.
Position the entire search coil assembly so the bottom
receiver coil is equally spaced from the idler rollers on
either side.
14
CAUTION: The Interface Module is preset at the Factory for 115 or 220 volt (±1
50/60 Hz, single phase operation. If the voltage source is different, contact the Facto
instructions to select the proper voltage source.
2.5 Swing-Away Switch (if applicable)

Swing-Away Switch
All line voltage connections terminate at TB2. Install line
voltage cables between devices controlled by the Detector
including diverters, auxiliary relays, marking Cutout (if
devices, alarm
The Swing-Away applicable)
Switch (Optional) Figure 8 is a pre-wired switch in a NEMA 4 ho
horns or motor control equipment and TB2 in the Main The Swing-Away Cutout Switch (Optional) Figure 8 is a
mounted on the swing-away bracket.
pre-wired Its in
switch purpose
a NEMAis 4tohousing
preventmounted
the Metal Detector from tri
on the
Control Enclosure. The direct or timed outputs should not
when the transmitter
be connected to a Programmable Logic Controller (PLC) or
coil is hit by an overburden of material. Route the free
swing-away bracket. Its purpose is to prevent the Metalend of this cable
same conduit as
other low voltage computer interface equipment that may the transmitter
Detector from tripping when the transmitter coil is hit byAppendix A C
cable to the Main Control Enclosure. Refer to
Connection
require dry contact closures. The direct and timedDiagram
output for hookup.
an overburden of material. Route the free end of this
contacts are typically programmed as normally “OFF” at cable in the same conduit as the transmitter cable to the
the Factory. They may be set to normallySwing-Away Switch in NEMA
“ON” if required. 4 Housing
Main Control Enclosure. Refer to Appendix A Control Figure 8
Refer to the System Programming Section for details. Connection Diagram for hookup.
Connect a 115/220 VAC (50/60 Hz), single phase power

line with at least 10 amp capacity to TB2. Make sure to
connect an electrical ground to terminal #3. The power
should be the “cleanest” available and free of significant
voltage variations or spikes. Do not connect the Detector
to a line which is used for operation of motors or motor
controls. Proceed with the Start-Up & Calibration Section
before applying power.
CAUTION
Figure 8
The Interface Module is preset at the Factory for 115 Swing-Away Switch In NEMA 4 Housing
or 220 volt (±10%), 50/60 Hz, single phase operation.
If the voltage source is different, contact the Factory
2.6 Clip Detector (if applicable)
for instructions to select the proper voltage source.
Install the clip detector unit as follows:
2.6.1 Refer to Control Connection Diagram (Appendix A) and Figure 9 for positionin
there are idlers adjacent to the search coils, position the Clip Detector Sensor approxim
2" upstream of the nearest upstream idler before the Search Coil Assembly. For slide
type conveyors, position the Clip Detector Sensor approximately (but no closer than) 2’
the center line of the receiver coil on the upstream side of the Search Coil Assembly. Th
face of the Clip Detector should be facing toward the belt with approximately ½” to
clearance. This clearance must be maintained in order to assure proper operation
Clip Detector should be a few inches from the edge of the belt. Do not mount the Senso
far from the edge, as tramp metal lying close to the belt may trigger the sensor and
through the search coils as a repair splice.
14
15
Clip Detector With the Clip Detector Sensor in the proper position
below the belt, weld the 3/4" support pipe (provided) to
(if applicable) the conveyor frame. The pipe may be cut to the proper
Install the clip detector unit as follows: size for an easier fit. The multi-axis swivel joint will
provide adequate movement for proper adjustment.
Refer to Control Connection Diagram (Appendix A)
and Figure 9 for positioning. If there are idlers adjacent It is recommended that the Clip Detector cable running
to the search coils, position the Clip Detector Sensor to the Main Control Enclosure be installed in conduit.
approximately 2" upstream of the nearest upstream The same conduit that houses the transmitter coil cable
idler before the Search Coil Assembly. For slider bed may be used.
type conveyors, position the Clip Detector Sensor
approximately (but no closer than) 2' from the center line Feed the Clip Detector cable into the conduit from the
of the receiver coil on the upstream side of the Search Clip Detector end to the Main Control Enclosure.
Coil Assembly. The flat face of the Clip Detector should be Cut off excess cable. Connect wires to terminal block
facing toward the belt with approximately 1-1/2" to 1" of (TB1) using the supplied spade lugs. Refer to the
clearance. This clearance must be maintained in order Control Connection Diagram for color code hook-up.
to assure proper operation. The Clip Detector should be Be certain all wires are attached securely and connected
a few inches from the edge of the belt. Do not mount the to their proper terminals.
Sensor too far from the edge, as tramp metal lying close
to the belt may trigger the sensor and pass through the
search coils as a repair splice.
Figure 9
Angle swivel bracket to match trough

angle and keep flat part of sensor
parallel to the belt, about 1" away
from the belt, about 1" away from the
belt. Position 4" below edge of belt.
Conveyor Belt
Weld clip detector mounting base

Conveyor Frame support tube to conveyor frame.
Figure 9
2.6.2 With the Clip Detector Sensor in the proper position below the belt, weld the 3/4
support pipe (provided) to the conveyor frame. The pipe may be cut to the proper size for a
easier fit. The multi-axis swivel joint will provide adequate movement for proper adjustment.
16
2.6.6 When metal repair clips are used, two or more clips close together must pass directly
When metal repair clips are used, two or more clips
closeover the must
together Clip pass
Detector
directlySensor in order
over the to activate it. If a small patch of clips is used on the
Clip Detector
Sensor belt, whichtowould
in order activatenotit. Ifpass directly
a small patchover the Clip Detector, reference clips are required, refer
of clips
is usedto Figure 10. which
on the belt, Reference
wouldclips are made
not pass directlybyover
installing two or more clips which will pass directly
over the Clip Detector to activate it whentoa small patch passes by. Numerous repair and
the Clip Detector, reference clips are required, refer
Figure 10. Reference
reference clips clips
on the arebeltmadewillby degrade
installing the
two Detector's
or performance because it will frequently
more clips which will pass directly over the Clip Detector
be in a desensitized mode. The Clip Delay time must be increased to allow the entire repaired
to activate it when a small patch passes by. Numerous
repairarea
andto pass theclips
reference firstondownstream idler roller.
the belt will degrade the If maximum clip time is not enough to allow the
repaired
Detector's area to pass
performance the down
because stream idler
it will frequently be then additional reference clips must be installed to
retrigger themode.
in a desensitized clip circuitry
The Clip Delayprior to timethemust
endbe of the first clip time cycle. For long repairs it better
to have
increased morethe
to allow reference clips closer
entire repaired area totogether
pass the and shorter clip delay times, this will reduce the
first downstream
length of time idler the
roller. If maximum
detector is inclipcliptime is notfor normal splice and for shorter repaired areas.
mode
enough to allow the repaired area to pass the down
Refer to section 4.4 Clip Detector Time Delay and Figure 16 Programming Controls and Test
stream idler then additional reference clips must be
Point Locations.
installed to retrigger the clip circuitry prior to the end
of the first clip time cycle. For long repairs it better to
have more reference clips closer together and shorter
clip delay times, this will reduce the length of time the
detector is in clip mode for normal splice and for shorter
repaired areas. Refer to Clip Detector Time Delay
section and Figure 16 Programming Controls and Test
Point Locations.
Figure 10
Figure 10
16
17
Spray Marking Device The solenoid control cable is connected to the Interface
Module Timed Output (Terminal TB2, Pins 4 & 5) Refer
(if applicable) to Appendix A Control Connection Diagrams Figure A6.
The Marking Device is a pressurized, solenoid activated
liquid spray system which pinpoints the location of Connect the hose between the tank outlet and the
tramp metal to eliminate costly search and down time. solenoid valve.
The parts included with the spray making system are Connect the facility air source to the tank regulator inlet.
depicted in Figure 11. Colorant is available in a variety Be sure the facility air source is shut off and no pressure
of color, white is supplied. Contact the factory for colors is in the tank.
and pricing.
Remove the top of the spray tank.
Specifications
Tank Pressure Rating: 50 psig (maximum working pressure) The spray solution is supplied by the User. The
Tank Capacity: 2.5 Gallons (liquid) recommended mixture is five (5) fluid ounces of colorant,
Operational Voltage: 115/220 VAC (50/60 Hz), 15 Watts Chrome Yellow (or other contrasting color) manufactured
Air: Plant air or any source of 100 to 200 psig inert gas by Tenneco Chemical (or equivalent) mixed with a two
(2) gallon solution of water and antifreeze appropriate
2.7 Spray Marking Device (if applicable) for local climate conditions (minimum of 25% antifreeze).
Installation Instructions
Refer to the Frame Assembly Antifreeze needs to be added even in areas where there
The MarkingDrawing
Device isfor mounting solenoid
a pressurized, of activated liquid spray system which pinpoints the
the Marking Device on the conveyor
location belt toFigure
of tramp metal 14.costly searchisand
eliminate
no chance of freezing. The antifreeze solution keeps
down time. The parts included with the
the
spray making system are depicted in Figure 11. Colorant colorant from
is available in being
a varietyabsorbed into isthe material it was
of color, white
Position the solenoidsupplied.
supportContact
upright and cross arm as sprayed
the factory for colors and pricing. on so the marked area stays visible. DO NOT
shown. Distance from the coils should be 3' to 6'. Clamp USE PAINT. Paint will clog the spray valve.
in place temporarily.
Mix the solution and pour it into the holding tank.
Adjust the support bracket of the solenoid
2.7.1 Specifications spray valve Replace the cap.
so that the nozzle is pointed directly on the center of the
Tank Pressure
conveyor belt. The nozzle may be Rating: 50 psigas
positioned (maximum
shown working Verify that the pressure regulator valve is closed prior
pressure)
Tank Capacity: 2.5 Gallons (liquid)
or on the opposite side of the arm. Bolt the bottom of the to turning on the facility air.
Operational Voltage:
support frame to the conveyor frame. 115/220 VAC (50/60 Hz), 15 Watts
Apply the facility air and adjust the pressure regulator
Air: Plant air or any source of 100 to 200 psig inert gas
between 60 and 100 psig, as noted on the pressure
gauge on top of the holding tank.
Figure 11
Figure 11
18
17
Figure 12
Figure 12
18
19
Calibration of Spray Marking Device piece of metal reaches the spray area the first time is the
enough to trigger the detector. With the belt up to full speed place the tramp metal on the belt
spray will be just after the piece of metal if it is shorten
The initial delay time that is set can be calculated using
far enough before the metal detector
the belt speed and the distance between the center
antennas that the
the Delayhas
metal Timecome to 10th
a few rest onof a thesecond
belt andandis try it again.
not moving relative to the belt.
of the receiver antenna and the spray nozzle or use a What should happen is when the piece of metal reaches the
The metal should be centered in the in the marked area.
stop watch spray areaa the
to time mark first timebelt
on the is the
as itspray
moves will be just after
from Oncethe thepiece
metalof is metal
centeredif itrepeat
is shorten the
the procedure with
th
the centerDelay
of theTime a few
receiver 10 oftoa the
antenna second
sprayand try it again. aThe
nozzle. metal
full belt to should be metal
see if the centered in the
is still in the
in the marked area.
This is themarked area. Once
Delay Before ON time.the Set
metal
theisONcentered
Time torepeat the procedure
If not adjust the with a full
timing beltmetal
so the to seeis if the
centered in the
1 second.metal is stilltoinadjust
It is easier the marked area.ofIfthe
the timing notspray
adjust the timing
marked so the
area.metal is centered in the marked
marker witharea.
an empty belt. Use a sample piece of tramp
Refer to Sections Delay Before Alarm and Time Alarm
metal large enough to trigger the detector. With the
On to set the desired timing for marking a predetermined
belt up to2.7.3.2
full speed placetothe
Refer tramp 4.5
Section metal
andon4.6
thetobelt
set the desired timing for marking a predetermined
location.
far enough before the metal detector antennas that the
location.
metal has come to rest on the belt and is not moving Figure 13
relative to the belt. What should happen is when the
Figure 13
20
20
Flag Drop Marker Calibration of Flag Drop Marker
Refer to Sections Delay Before Alarm and Time Alarm
(if applicable) On to set the desired timing for marking a predetermined
The Flag Drop Marker is device which drops a tag or flag location.
onto the belt which pinpoints the location of tramp metal The initial delay time that is set can be calculated using
to eliminate costly search and down time. the belt speed and the distance between the center of
the receiver antenna and the flag drop marker flag or use
Specifications a stop watch to time a mark on the belt as it moves from
Plastic NEMA 4X box which holds the electronics and flag the center of the receiver antenna to the flag drop maker
One set of 3 flags flag. This is the Delay Before ON time. The ON Time is
Operational Voltage: 115/220 VAC (50/60 Hz), 15 Watts preset at the factory to about 1/2 second. It is easier to
adjust the timing of the flag marker with an empty belt.
Installation Instructions Use a sample piece of tramp metal large enough to
Refer to the Figures 14 for assembly and mounting and trigger the detector. With the belt up to full speed place
Figure 15 for positioning of the Flag Marking Device on the tramp metal on the belt far enough before the metal
the conveyor belt. detector antennas that the metal has come to rest on the
Attach the upright support to the upright. Position the belt and is not moving relative to the belt. What should
frame upright in front of the first down stream idler roller. happen is when the piece of metal reaches the flag drop
Lay the upright support on the top of the C channel and area the first time is the flag will be just after the piece
adjust the upright so that it is straight up and down. of metal if it is shorten the Delay Time a few 10th of a
Clamp in place now drill the a hole in the side of the second and try it again. The flag should drop and hit the
C channel to secure the bottom of the upright and drill metal. The delay time for the flag will vary depending on
a couple of holes through the upright support and top the distance it has to fall. On an empty belt the flag will
of C channel and secure the support to the conveyor have to travel farther before it hits the metal than on a
C channel. full belt. Because of the distance the flag has to travel
between an empty belt and a full belt will cause the flag
Attach the frame cross bar with gusset to the upright. to be either in front of the metal or behind the metal.
So when looking for metal look about 12" on either side
Mount the NEMA box to the cross bar. Position the box
of the flag if the metal is not visible and is buried in
on the cross bar so that the flag will drop on the product
the product.
where the edge of the product touches the belt, (if the
product comes to the edge of the belt then position the
box so the flag is far enough in so that the flag does not
fall off of the belt).
Route the power cord across the cross bar and down
the upright, secure cord with ty-raps. Make connections
to the Metal Detector electronics Ref Appendix A
Figure A12.
21
Mounting of the flag drop marker Figure 14
Figure22 14
Mounting of the Flag Drop Marker
22
Positioning the flag marker Figure 15
Figure 15
Positioning the Flag Marker
2.8.3 Calibration of Flag Drop Marker
2.8.3.1 Refer to Section 4.5 and 4.6 to set the desired timing for marking a predetermined
location.
2.8.3. The initial delay time that is set can be calculated using the belt speed and the distance
between the center of the receiver antenna and the flag drop marker flag or use a stop watch to
time a mark on the belt as it moves from the center of the receiver antenna to the flag drop
maker flag. This is the Delay Before ON time. The ON Time is preset at the factory to about
½ second. It is easier to adjust the timing of the flag marker with an empty belt. Use a
sample piece of tramp metal large enough to trigger the detector. With the belt up to full
speed place the tramp metal on the belt far enough before the metal detector antennas that the
metal has come to rest on the belt and is not moving relative to the belt. What should happen
is when the piece of metal reaches the flag drop area the first time is the flag will be just after
the piece of metal if it is shorten the Delay Time a few 10th of a second and try it again. The
flag should drop and hit the metal. The delay time for the flag will vary depending on the
distance it has to fall. On an empty belt the flag will have to travel farther before it hits the
metal than on a full belt. Because of the distance the flag has to travel between an empty belt
and a full belt will cause the flag to be either in front of the metal or behind the metal. So
when looking for metal look about 12” on either side of the flag if the metal is not visible and
is buried in the product.
23
23
Start-up & Calibration Before proceeding with the calibration, two points must be
checked. The #2 LED must be out all of the time. Second
the #7 LED must be off except when belt clips are to be
Start-up passed. Do not run a test when either of these two
Before turning on the system, locate the switches and lights LEDs is on.
on the door panel and the controls inside the cabinet.
Rod Diameter Calibration
The power switch is located on the lower left-hand corner Unless specified otherwise by the customer, for maximum
of the door panel. Place it on the “ON” position. The green protection, the rod diameter sensitivity is calibrated to
“ON” indicator should light at this time. detect the smallest diameter rod practical for the antenna
assembly aperture. Remove the Electronic Module cover
If the green “ON” does not come on, return the power
(Refer to section Removing/Replacing Cover) to expose
switch to the “OFF” position and inspect the light bulb
the circuit board. Refer to Figure 16 Programming Controls
and fuses; also check the power and wiring for proper
and Test Points.
connections.
Set the “Oversize Sensitivity” R101 to “0” and “Oversize
Approximately 5 seconds after power “ON”, the No. 1
Gain” to “1”. This sets the oversize to a piece of metal
status indicator (power supply) located on the front panel
much greater than the actual oversize metal needed, but
of the Electronic Module will light (reference Figure 2).
setting the oversize to maximum will assure the unit trips on
This indicates that the power supply is fully operational
the rod diameter and not the oversize signal. Set the Rod
and all the electronics are enabled.
Diameter R187 to “5” and Rod Gain to “0”.
If the power supply L.E.D. status indicator or the “ON”
With the belt stopped, momentarily place the shorter of the
indicator does not light, refer to Troubleshooting Flow
two test rods in the field about half the distance between
Diagram #1 for instructions. Until the power supply L.E.D.
the top antenna and the belt, then remove. The LED #2
is lit, calibration of the unit cannot begin.
light should light and when the rod is removed it should
go out. Turn the Rod Gain down to 9 and repeat the test.
Main Detector Unit – Keep turning the Rod Gain down until the #2 light does not
Metal Sensitivity Calibration light. Turn the Rod Gain back to one higher number. Next
turn R187 Rod Diameter from 5 to 6 and repeat the test.
Before proceeding with the calibration procedure,
obtain four samples of tramp metal as listed below. Keep increasing the Rod Diameter until the rod does not
These samples will be used in the calibration and turn the #2 light on and then move back to the previous
should represent the type of tramp metal most likely number. If the Rod Diameter is turned all the way to 10 and
expected to be found in the conveyed material. the #2 still turns on then reduce the Rod Gain S4 by one
number and then turn the Rod Diameter to a lower number
1. Tramp metal sample smaller than oversize piece where the #2 light consistently turns on every time the rod
to be detected. is placed in the field.
2. Tramp metal sample equal to the oversize piece
to be detected. NOTE
3. Rod correct diameter but shorter than length to If the metal sample is left in the filed too long the
be detected. automatic zeroing circuit will begin to cancel the
signal out.
4. Rod correct diameter and equal in length to
be detected.
Oversize Calibration
NOTE Rod Length Calibration
During all test and calibration, the test samples
must be fully passed through the detection field. In
addition, the samples must be traveling at a uniform
rate through the area two feet ahead and two feet
behind the receiver antenna. This is necessary for
the detector to properly analyze and measure the
length of the rod.
24
Main Detector Unit – Automatic Reset
The Detector may be converted to an “Automatic Reset
Clip Detector Calibration Mode”. In this mode the Detector will momentarily
signal when tripped then self-reset according to the
(if applicable)
placement of the programming switches. For complete
Turn the “Clip Override” control knob fully clockwise to
programming instructions, refer to Manual/Auto Resets.
position 10 on the dial. This knob is located on the front
panel of the Electronic Module as shown in Figure 2.
Remote Reset
Observe the reference clips to see if they are passing Provisions have been made to externally reset the
within 1" of the Clip Sensor Head when the belt is empty. Detector from a remote location. Wire a normally open
Adjust the Clip Detector if it is not within this distance set of contacts across the remote reset terminals TB1
making sure that the clips or the belt do not hit the Clip pins 1 & 2 located on the Interface Module. Upon closure
Detector Sensor Head when the belt is fully loaded. of the contacts, the unit will reset.
If the clip is located properly, the Clip Timer, status
indicator No. 7, located on the Electronic Module will Excessive Electrical
light for approximately 1 second each time the clips pass
over the Clip Detector Head. Interference
The Metal Detector has a unique circuit that
distinguishes electrical noise from a legitimate metal
NOTE signal. When this circuitry “sees” interference that lasts
If the Clip Detector is spaced more than 1" from the longer than .1 second or that interferes more than
passing clips, erratic performance may occur. 25% of the time, the Detector will turn off L.E.D. status
indicator No. 4 each time the interference occurs. In
addition, the incoming “noisy” signals are blocked from
If the Detector is tripping on the clips with a “Clip downstream circuitry to reduce the chance of any
Override” setting of 10, refer to Clip Gain section. false tripping.
Gradually turn the clip control knob counterclockwise to If an excessive amount of electrical interference
a lower setting until the unit trips on the largest set of occurs, the source of the interference must be found
repair clips on the belt. and corrected. Excessive interference will reduce the
Detector’s sensitivity and may false trigger the system.
Turn the clip control knob clockwise one number higher Such interference problems are usually associated with
as a safety factor. motor phase to ground shorts, severely arcing brushes
on motors, poor ground conditions, etc.
NOTE
This setting should be periodically checked to
compensate for shifting of the conveyor belt. Turn
the control knob to a “0” setting if the clip detector
is not used.
Operation
The Detector may be programmed to operate in a
manual or an automatic reset mode; the standard mode
of operation is manual reset.
Manual Reset
In the manual reset mode, once the unit has tripped,
the Detector’s Direct Output provides a continuous alarm
indication to alert the operator of detected metal and/or
to stop the belt. To reset the unit, the reset button located
on the front panel must be manually depressed.
25
System Programming Set the “Metal Sensitivity”: control knob (R56) to its
rotational midpoint (if the cover was not removed, the
“Metal Sensitivity” would be 5)
General Check that the clip timer, status indicator No. 7, is not lit
The Detector provides a wide range of programming
during any portion of this test. If the clip timer is lit, the
capability. The Detector can be individually tailored to
data will be incorrect.
the customer’s specific requirements; taking into account
the type and size of metal to be detected, the type of Pass the sample piece of tramp metal completely
material being conveyed and the mode and combination through the coils at a height midway between the
of alarm signals required. Refer to Programming transmitter and receiver coils and at a speed near
Controls Summary for an overview of switch functions that of the conveyed material under normal operating
Table 6 and Programming Controls & Test Point conditions. Increase or decrease the gain of the system
Locations Figure 16 for component locations. with the rotary switch as needed until the Detector will
trip just as the sample metal is passed between the
Removing/Replacing Cover coils. The larger numbers on the gain setting switch
To program the Electronic Module, the cover must be correlate to a higher gain, the lowest gain being 1 and
removed. Remove the control knobs with the 1/16" Allen the highest 0 (representing 10). If the unit never trips,
wrench (provided). Unscrew the six screws securing the refer to Troubleshooting Flow Diagram #1.
cover with the 5/64" Allen wrench (provided).
If all other functions are properly programmed, replace
When replacing the cover, it is essential to re-index the the cover and knobs. Re-index the control knobs as
control knobs. Before tightening the set screw, line it indicated in Section Removing/Replacing Cover.
up with the flat of the shaft. The knob, when properly
indexed, will indicate 10 in a full clockwise position and Recalibrate the “Metal Sensitivity” control knob as
0 in a full counterclockwise position. instructed in Section Main Detector Unit – Metal
Sensitivity Calibration.
Metal Gain Clip Gain
When a piece of tramp metal passes over the search
coils, a change in the received signal occurs. This change When belt repair clips are used on a conveyor belt, the
is extremely small and must be amplified to produce a repair clips represent a stronger metal signal than the
suitable signal to trigger the relay driver circuitry. tramp metal. In this situation, it is necessary to reduce
the gain of the system to allow the clips to pass. Rotary
The amount of gain required in the receiver circuitry Switch S5, shown in Figure 15, establishes the gain
depends on the following factors: whenever the clip detector circuit is energized. In the
event that Switch S5 is set higher than S4, the system
• Coil Length
will choose the smaller gain setting of the two for the
• Coil Aperture
clip gain.
• Belt Speed
• Type of Metal to be Detected For calibration of the clip gain, follow these steps:
• Size, Shape and Orientation of the Metal
to the Search Coil Run the belt at normal running speed and maximum
belt load.
The internal gain of the Detector is adjusted by a rotary
switch, S4, located inside the Electronic Module (refer to Verify that the clip timer, status indicator No. 7, lights
Figure 13 Programming and Test Point Locations). Each each time a clip passes the sensor head. If it does not,
step in gain represents an increase over the last step. adjust the clip sensor head as described in Section
Ideally, the gain is adjusted to pick up the desired piece Clip Detector.
of tramp metal with the “Metal Sensitivity” control knob Record the settings for the “Metal Sensitivity” control
located on the outside of the Electronic Module set to 5. knob and the Clip Override control knob. Adjust the
If the gain must be changed, use a sample of tramp “Clip Override” control knob, shown in Figure 2,
metal the same size as the piece to be detected and to a setting of 5.
follow the procedures listed below: Remove the cover as described in Section Removing/
Remove the control knobs and cover of the Electronic Replacing Cover without changing the setting on the
Module as indicated in Section Removing/Replacing “Clip Override” control knob.
Cover.
26
mum belt load.
o. 7, lights each time a clip passes the

as described
Adjustinthe
Section 2.6.Switch S5 shown in Figure 15, to
Clip Gain,
the highest gain that does not trip the Detector when
Delay Before Alarm
The timed output alarm can be accurately programmed
the clips pass. If the unit continues tripping even at
y” control knob and
the minimum clipthe
gainClip
of 1, Override
the desensitized length of
with a time delay before turn on. This allows the
conveyed material to travel for a programmed period
, shownthe
in belt
Figure
may2,
betotooa setting
short. In of 5. words, the system
other
before the timed output alarm signal is energized.
is switched back to full sensitivity before the clips
Typically this feature is used in conjunction with a
are completely out of the Detector’s field. To correct,
1.1 without changing the setting on the
increase the clip detector time delay as described in
marking device or diverter gate to delay the system
until the detected tramp metal has reached the auxiliary
Section Clip Detector Time Delay.
equipment. Switches S2-1 through S2-5 control this
If all other functions are properly programmed, replace time delay from .01 to 22.0 seconds. Refer to Table 2 for
ure 15, to
thethe highest
cover gain that
as described does not
in Section Removing/Replacing tabulation of the delay time versus switch settings and
nues tripping even atthethe
Cover. Return minimum
controls clip settings.
to recorded Figure 15 for the switch locations.
too short. In other words, the system is
ompletely
Calibrate
out of
the “Clip
the
Override”
Detector's
as described
field. To
in Section
Main Detector Unit – Clip Detector Calibration.
Time Alarm On
The timed output can be accurately programmed to remain
bed in Section 4.4.
energized for a timed period once it is switched on. This
Clip Detector Time Delay feature can activate a diverter gate, sound an alarm for a
If the clip
med, replace thedetector
cover isasused, the length
described inof belt desensitized given period, command a marking device to spray a given
to permit the clips to pass can be adjusted by properly length of the belt, etc. Switches S3-1 through S3-5 control
. programming the clip detector time delay switches S1- this time delay from .01 to 22.0 seconds. Refer to Table 2
5, 6, 7. The locations of these switches are shown in for a tabulation of the delay time versus switch settings
ction 3.3.
Figure 13. The range of delay times is from .10 seconds and Figure 15 for the switch locations.
to 1.91 seconds as tabulated in Table 1. These switches
are set at the factory according to available information
but further fine tuning can be done on site as needed.
Standard or Fail –
As long as the Detector is desensitized, the status Safe Output Operation
indicator No. 7, will remain lit. No. 7 light should turn on As standard, the alarm outputs of the Detector will
just before the upstream idler roller and turn of just after energize when tramp metal is detected. In this mode, the
the first downstream idler roller after the metal detector solid state relay is programmed to operate in a Normally
antennas assembly. Keep clip time to a minimum. “OFF” condition. The outputs will not energize until metal
itized to permit the is detected.
ng the clip detector Provisions have been made to program the Detector
these switches are to operate in a fail-safe mode. In this mode, the outputs
.10 seconds to 1.91 of the Detector are always energized and de-energize
e set at the factory when tramp metal is detected or when power to the
Detector is turned off. In the fail-safe mode, the solid
ning can be done on state relay is programmed to operate in a Normally
the status indicator “ON” condition.
before the upstream
Both outputs can be independently programmed. The
idler roller after the direct output (status indicator No. 9) and timed output
minimum. (status indicator No. 8) will monitor the alarm's output
condition. If the status indicator is lit, its associated
output is energized. Switch S2-6 controls the direct
output and S3-6, the timed output as shown in Table
3. To operate the solid state relay condition in a
Normally “OFF” condition, open the appropriate switch.
Conversely, to operate the relay in a Normally “ON”
table 1 condition, close the switch.
Clip Time Delay (Switch S1)
27
s used in conjunction with a marking device
ted tramp metal has
hrough S2-5 control
fer to Table 2 for
s and Figure 15 for
Manual/Auto Resets
Manual Reset
In the manual reset mode, once the unit has tripped,
4.5 Delay Before Alarm the Detector's Direct Output provides a continuous alarm
indication to alert the operator of detected metal and/or
to remain energized to stop the belt. To reset the unit, the reset button located
ature can activate a The timed output alarm can be accurately
onprogrammed
the front panelwith
musta be
time delay before
manually turn on.
depressed.
ommand a marking This allows the conveyed material to travel for a programmed period before the timed output
itches
4.7 S3-1 through
(continued) alarm signal is energized. Typically thisAutomatic Reset
feature is used in conjunction with a marking device
The Detector may be converted to an “Automatic Reset
onds. Refer tocan
Both outputs Table or diverter gate to delay the system until
be independently programmed. The direct output (status the detected
Mode”.indicator
tramp
No. the
In this mode, 9)metal
and has
Detector will momentarily signal
settings
imed and (status
output Figure indicatorreached
No. 8)thewill
auxiliary
monitorequipment.
the alarm'sSwitches
output
when S2-1 through
condition.
tripped If the
then S2-5 control
status
self-reset.
this time delay from .01 to 22.0 seconds. Refer to
ndicator is lit, its associated output is energized. Switch S2-6 controls the direct output and Table 2 for
tabulation of the delay time versus The settings
switch direct output
and can be programmed
Figure 15 for to automatically
S3-6, the timed output as shown in Table 3. To operate the solid reset statebyrelay condition
shorting in a reset
the remote terminals TB1 pins
Normally "OFF" condition, the
ut open switch locations. switch. Conversely,
the appropriate 1 &to2,operate
located the relay
on the inofa the Interface Module. To
front
Normally "ON" condition, close the switch. “short”, install a jumper from pin 1 to pin 2, Appendix A
4.6 Time Alarm On Figure A17. Open Switch S2-7, Figure 15.
The operating mode of the timed output is governed by
4.8
will Manual/Auto
energize when Resets the position of Switch S3-7 as shown in Table 4. With the
The timed output can be accurately programmed to remain energized
olid state relay is switch in the open position, the timed output operates in
for a timed period once it is switched on. This feature canMode.
activate a the switch is closed,
ndition. The outputs the Automatic Reset When
4.8.1 Manual Reset diverter gate, sound an alarm for a given period, command a marking
the timed output will follow the mode programmed on
device to spray a given length of the belt, the etc. Switches
direct output. S3-1 through
In thetomanual S3-5 control this time delay from .01 to 22.0 seconds. Refer to Table
made programreset
the mode, 2once the unit has tripped, the Detector's Direct
for alarm
a tabulation of thetodelay
Output provides a continuous indication alerttime
the versus
operatorswitch
of settings and Figure
a fail-safe mode. In 15 for the switch locations.
detected metal and/or
of the Detector are to stop the belt. To reset the unit, the reset button
ocated on the front panel must be manually depressed.
de-energize when
d or when power to 4.7 Standard or Fail – Safe Output
4.8.2 Automatic Reset
off. In the fail-safe Operation
elay is programmed
The Detector
y “ON” may be converted to an "Automatic Reset Mode". In this mode,
condition.
he Detector will momentarilyAssignal
standard,
whenthe alarmthen
tripped outputs of the Detector will energize when
self-reset.
tramp metal is detected. In this mode, the solid state relay is
programmed to to automatically
operate in a Normally table
outputs4
The direct output can be programmed reset by "OFF"
shortingcondition.
the remote Thereset
Timed Output Reset (Switch S3)
will not on
erminals TB1 pins 1 & 2, located energize until
the front ofmetal is detected.
the Interface Module. To "short", install a
umper from pin 1 to pin 2, Appendix tableA Figure
2 A17. Open Switch S2-7, Figure 15.
S2 - Delay Before Alarm Provisions have been made to program the
The operating mode of the timed output is governed byDetector
S3 - Time Alarm On to operate
the position in aS3-7
of Switch fail-safe mode. In
as shown
n Table 4. With the switch in the open position, the timed this mode,
outputthe outputsinofthethe
operates Detector are
Automatic
Reset Mode. When the switch is closed, the timed output alwayswill energized
follow the andmodede-energize
programmed when
on the direct output. tramp metal is detected or when power to
the Detector is turned off. In the fail-safe
mode, the solid state relay is programmed
to operate in a Normally “ON” condition.
4.9 Reset Override
If required, the Detector can be programmed so the system is disabled during
he reset period. This means the Detector
table 3 is prevented from tripping as long
as a reset signal is provided,Timed
eitherOutput
manually
Reseton the front panel or remotely
hrough a set of external contacts.
(Switch S2 & S3)
31
With S2-7 in the open position, the reset signal does not disable the
28 Detector.
Closing S2-7 will program the Detector so it is disabled while a reset signal
e". In this mode,
reset.
eset by shorting the remote reset

face Module. To "short", install a
witch S2-7,
ResetFigure Override
15.
If required, the Detector can be programmed so the
positionsystem
of Switch S3-7 as
is disabled shown
during the reset period. This means
output operates in the
the Detector Automatic
is prevented from tripping as long as a reset
will follow theismode
signal programmed
provided, either manually on the front panel or
remotely through a set of external contacts.
With S2-7 in the open position, the reset signal does
not disable the Detector. Closing S2-7 will program the
Detector so it is disabled while a reset signal is applied.
Refer to Table 5.
s disabled during
tripping as long
anel or remotely
ble the Detector.

ile a reset signal
table 5
Timed Output Reset (Switch S2)
Sampling
The Detector Sampling Mode is set at the factory to
make the Detector sensitivity selective between various
materials as required for each particular application.
Switches S1-1 through S1-4 inclusive are preset
and are not to be adjusted by the user.
Fine Frequency Setting

The Detector is calibrated to operate at an optimally
selected transmitting frequency when using a 50 or 60
Hz line frequency. This frequency can be fine-tuned over
a 5% range by adjusting potentiometer R7, shown in
Figure 16. However, this is not usually necessary as all
units are calibrated at the factory prior to shipment.
The operating frequency of the Detector can best be
measured at the zero gate test point “Z”, shown in
Figure 16. The signal switches between 0V and +15V as
referenced to 0V of the system (Test Point 0V). If viewed
on an oscilloscope, this signal would be high one pulse
width and low for seven.
29
Control Position Function Comment
1
2 Allows the detector to detect metal and ignore conveyed product.
Sampling Mode
3 Factory preset. DO NOT ADJUST.
S1 4
5
Selects the length of time the detector remains desensitized for
6 Clip Time Delay
the clips. Refer to Table 1.
7
1
2 Controls timed output. Selects the time from when metal is
3 Delay Before Alarm detected until timed output is energized. Refer to Table 2 for
4 position settings and times.
S2 5
Sets direct output contacts as normally “ON” or “OFF”.
Direct Output
Normal On/Off Select
Used to disable metal detection as reset signal is applied. Refer
7 Belt Reset Override
to Table 5 for settings and times.
1
2
Controls timed output. Selects how long the output remains
3 Time Alarm On
energized. Refer to Table 2 for position settings and times.
4
S3 5
Sets timed output contacts as normally “ON” or “OFF”.
Timed Output
Timed Output Determines if timed output will reset manually or automatically.
7
Reset Mode Refer to Table 4 for settings.
Course gain adjustment for rods, without repair clips in sensing
S4 Rod Gain
zone. “1” least gain; “0” most gain.
R187 Rod Diameter Rod sensitivity “0” for smaller and “10” for larger metal.
Course gain adjustment for oversize metal, “1” least gain;
S5 Oversize Gain
“0” most gain.
R101 Oversize Metal Oversize sensitivity, “0” for smaller and “10” for larger metal.
R167 Rod Length Sets length of rod the detector will trip on.
Attenuates (reduces) metal sensitivity to allow repair clips to pass
R90 Clip Override
through detector. “10” most attenuation, “1” least attenuation.
R7 Fine Frequency Adjust Permits fine adjustment of Detector’s operating frequency.
Table 6
30
Figure 16
Figure 16
35
31
Troubleshooting Maintenance Kit
Prior to shipment, a maintenance kit is packed
Status Indicators in the Main Control Enclosure.
In order to facilitate troubleshooting of the Detector, a This kit contains all parts necessary for basic
number of self-test circuits have been designed to monitor maintenance. The items included are as follows:
the condition of the detection circuitry. The results of these
(1) 1 Amp Fuse
test circuits are visible to the operator through L.E.D.’s on
(1) 10 Amp Fuse
the front panel of the Electronic Module (refer to Figure
(2) Spare Bulbs
2). These L.E.D.’s are referred to as Status Indicators.
For a description of all L.E.D. monitors and their normal
operating condition, refer to the Status Indicator Summary
(Table 7) on the following page.
Troubleshooting Flow
Diagrams
NOTE
Before working with Troubleshooting Diagrams,
check all terminals, connectors and cables for open
circuits and correct as required.
To aid in troubleshooting the Detector, two easy to follow,

step-by-step, flow diagrams were designed. Troubleshooting
Flow Diagram #1 deals with insufficient metal sensitivity. This
diagram is used if the unit detects metal, but is not sensitive
enough for the required application or if the Detector does
not respond to metal at all.
Refer to Troubleshooting Flow Diagram #2, if the unit
continually false trips (triggers with no metal in the field).
Electronic Module
Troubleshooting
In the event that the unit does not operate and the
trouble has been traced to the Electronic Module, the
equipment may be sent back to the factory for repair.
If the plant can not operate with out a metal detector
for the time it takes to repair the equipment then a
replacement module may be obtained, either purchase
of a new module or a refurbished exchange module,
in either case the module can be shipped overnight,
minimizing down time.
32
L.E.D. Normal
Identification Comments
Number Condition
Indicates detector power supply operational; must be lit for unit to detect
metal. Will not light when power supply malfunctions, low line voltage
1 Power Supply ON
is present or optional transmitter swing away switch is activated. LED
lights approximately 5 seconds after power is turned on.
Indicates signal analyzer output is above the threshold limit, usually
2 Metal Signal OFF
when detectable metal is in sensing zone.
3 Self-Test
4 Self-Test Indicates specified internal Electronic Module circuits are functioning
ON
5 Self-Test normally. Must be lit for unit to detect metal.
6 Self-Test
Indicates repair clip is in proximity of the clip detector head. LED
7 Clip Timer OFF remains lit for the period detector was programmed to allow clips
to clear the sensing zone.
Indicates the condition of the timed alarm output. If the LED is lit,
8* Timed Out OFF
the timed alarm output is energized with the line voltage.
Used to diable metal detection as reset signal is applied.
9* Direct Out OFF
Refer to Table 5 for settings and times.
* When programmed to operate in a fail-safe mode (output normally “ON”), the LED’s will be lit.
Table 7
Electronics Module Status Indicator Summary
33
Metal Disconnect
Replace YES Refer to Section Check Clip
Detector NO Receiver Coil
Electronic on “Excessive Detector Sensor
Does Not Does Status
Module Electrical and Cable
Detect Metal Indicator No. 4 Interference”
Light Up?
NO NO NO
Is Status Are Status

YES YES Is Status Is Status YES
Indicator Indicators Replace
Indicator Indicator
NO. 1 Lit 3, 4, 5 & 6 Electronic
NO. 4 Lit All NO. 7 Lit All
All of Lit All of Module
of the Time? of the Time?
The Time? the Time?
NO YES
Is Input Is Status Disconnect Clip

NO Line Voltage YES Detector Cable
Power To Metal Indicator
Regulator From Interface
Detector Above NO. 7 Lit All
Required Module
100(210) VAC? of the Time?
YES NO
Does Status Does Status

Check 10 AMP Indicator Indicator NO.
Is Green NO Fuse, Door Plug YES NO Contact Factory
NO. 2 Flash 9 Light When
Light On Connection, For Service
When Metal is Status Indicator
Enclosure Lit? Power Switch Passed Through NO. 2 Lights?
and Green Light Search Coils?
YES NO YES YES
34
Trace Antenna
Set Metal Re-Calibrate Cables. Connect Cables
Is 1 AMP Fuse YES Replace NO
Replace Sensitivity Metal Detective Are Cables to Proper
On Interface Interface
1 AMP Fuse Control Knob Sensitivity Connected Terminals
Module Blown? Module
to “0” Control Knob to Proper
Terminals?
NO
Insufficient Metal Sensitivity

YES YES
Does Status Does Status Is the Metal
Does Metal NO Indicator NO Reduce Search Indicator NO Gain Switch S4
Replace Coil Aperture to NO. 2 Flash at its Maximum
Detector Have NO. 2 Flash
Electronic Minimum Safe When Metal is Setting “0”
A Swing-Away When Metal is
Module Distance Passed Through Representing
Cutout Switch? Passed Through
Search Coils? Search Coils? “10”?
YES NO
NO
Model 1260 Trouble Shooting Flow Diagram #1

YES
Disconnect Adjust Metal
Swing-Away Is Status Gain Switch
Cutout Cable Indicator S4 to Next
From Interface NO. 1 Lit? Higher Setting
Module
YES
Check
Swing-Away
Cutout
Switch & Cable
Disconnect
Does Metal Does Detector Transmitter Is Status
Detector False NO False Trip on NO YES Verify “Clean”
Cable From the Does Unit Still Indicator
Trip on Repair Repair Clips on Interface Module False Trip? No. 4 Lit All of Ground to
Clips on Return Main Side No. 6 Light Will the Time? Conveyor
Side of Belt? of Belt? Turn Off
YES YES NO NO
Increase Add a Wire Remove All Disconnect

Distance Jumper Between “Possible” Metal Receiver Coil. NO Replace Verify “Clean”
Between 1B1-5 & TB1-7 Located Near Does Status Electronic Ground to
Return Belt & on Interface the Search Coil Indicator No. 4 Module Detector
Receiver Coil Module Assembly Light Up?
YES
Install Isolation Refer to Disconnect

If Detector Still Are Adjacent
Kit to Adjacent NO “Excessive Receiver
False Trips, Idler Rollers Contact Factory
Idler Rollers Electrical Cable from
Contact Factory Isolated from for Service
Refer to Page 11 Interference” the Interface
For Service Conveyor Frame
in Manual in Manual Module
YES YES
Reconnect Is Input Power YES

Transmitter to Metal Does Unit Still
Cable to Detector False Trip
Interface “Stable”
Module
Replace NO NO
Is Status NO Electronics
35
Indicator Module Strike the Check for
NO. 7 Lit? Conveyor Frame, Line Voltage Electrical
Remove Jumper Cross Bracing, Regulator Interference
Idler Rollers, I.E. Arcing
False Tripping
Required
YES Return Idlers, Contacts, Radio
Conduit Runs, Transmission or
Cat Walk, Guard Phase to Ground
Re-calibrate Screens in Areas Short
Does Unit Still YES Around the
False Trip Clip Gain, Refer
to “Clip Gain” Antennas
on Repair Clips
in Manual
Reconnect
NO Transmitter &
Mark Conveyor Receiver Cables
Joints which to Interface
Remove Jumper Trip the Detector Module
when Conveyor
is Struck
Model 1260 Trouble Shooting Flow Diagram #2

Place
Screwdriver
Over Clip Head
Weld Marked
Joints to Ensure
Re-calibrate Permanent
YES NO Check Clip Electrical
Clip Time, Refer Is Status Detector Sensor Connections
to “Clip Detector Indicator & Cable for
Time Delay” in NO. 7 Lit? Open Circuit
Manual

If Unit Still
False Trips
Contact the
Factory
APPENDIX A
Control Connection Diagrams
36
Power Input Figure A1
Figure a1
Power Input
37
Transmitter and Receiver Antenna Figure A2
Figure a2
Transmitter and Receiver Antenna
38
Clip Detector Figure A3
Figure a3
Clip Detector

43
39
Dual Clip Detector Figure A4
Used on variable speed conveyors
Clip heads need to be modified as shown above. Also J6 & J8 on the Electronics Module must
be made. Normally Jumpers J5 and J7 are made for single clip operation. Refer to Figure 16
Programming Controls and Test Point Locations.
Clip heads need to be modified as shown above. Also J6 & J8 on the Electronics Module must be
made. Normally Jumpers J5 and J7 are made for single clip operation. Refer to Figure 16
Programming Controls and Test Point Locations.
Figure a4
Dual Clip Detector
40
Synchronization Figure A5
Figure a5
Synchronization
41
45
Spray Marker Figure A6
Figure a6
Spray Marker
42
46
Swing Away Switch Figure A7
Figure a7
Swing Away Switch

47
43
Control Unit Extension Figure A8
Figure a8
Control Unit Extension
44
Auxiliary 2 or 4 Relay Sq D 115 vac or 220 vac Figure A9
Figure a9
Auxiliary 2 or 4 Relay Sq D 115 VAC or 220 VAC
49 45
Auxiliary Relay KRPA 115 vac or 220 vac Figure A10
Figure a10
Auxiliary Relay KRPA 115 VAC or 220 VAC
50 46
Voltage Regulator Figure A11
Figure a11
Voltage Regulator
51 ERIEZ Model 1260 Analog Metal Detector
47
Flag Drop Marker Figure A12
52
Figure a12
Flag Drop Marker
48
Alarm Horn & Flashing Beacon Figure A13
Figure a13
Alarm Horn & Flashing Beacon
53
49
Alarm Horn Figure A14
Figure a14
Alarm Horn
50
54
Flashing Beacon Figure A15
Figure a15
Flashing Beacon
55 ERIEZ Model 1260 Analog Metal Detector
51
Remote Reset Switch Figure A16
Figure a16
Remote Reset Switch
52
Automatic Reset Figure A17
Figure a17
Automatic Reset
53
Strip Heater 115 vac or 220 vac Figure A18
58
Figure a18
Strip Heater 115 vac or 220 vac
54
APPENDIX B
Service, Parts, Repairs
55
Search Coil Assembly Swing Away
Model 1260 Frame Assembly
1 Crossbar
2 Upright Pair
3 Mounting Feet Carbon Steel
4 Receiver Bracket Pair
5 Transmitter Bracket Pair
6 Receiver Antenna
7 Transmitter Antenna
8 Roughing Guard
9 Swing-Away Switch
60
World Authority in Separation Technologies

Telephone: 814-835-6000 • 800-345-4946 • Fax: 814-838-4960 • International Fax: 814-833-3348
1116-AHA-WEB ERIEZ MANUFACTURING CO ©2016 PRINTED IN USA

SECTION 3
SPARE PARTS LIST

Serial No. 335657
Style 201802988 (831970)
August 21, 2018
Spare Parts List

Eriez 1235 118" Metal Detector
Description Part No. Quantity
Transmitter Coil 831986 1

Receiver Coil 831987 1
Transmitter Coil Bracket 812284 2
Receiver Coil Bracket 812286 2
Mounting Feet 812288 2 sets
Transmitter Cable 819099 1
*Transmitter Cable Connector 812327 1
Receiver Cable 819098 1
*Receiver Cable Connector 812326 1
Interface Module 800525 1
Electronic Module 812332 1
Clip Detector 812290 1
Flag Drop Marking System 818543 1
Swing Away Circuitry 812240 1
Beacon/Horn Combo 815804 1
* Connectors are already on Transmitter & Receiver Cables

Serial No. 335657
Style 201802989 (831971)
August 21, 2018
Spare Parts List

Eriez 118" 1260 Metal Detector
Description Part No. Quantity
Transmitter Coil 831988 1

Receiver Coil 831989 1
Frame Assembly 812282 1
Transmitter Coil Bracket 812284 2
Receiver Coil Bracket 812286 2
Mounting Feet 812288 2 sets
Transmitter Cable 812322 1
Transmitter Cable Connector 812327 1
Receiver Cable 812324 1
Receiver Cable Connector 812326 1
Interface Module 813582 1
Electronic Module 812331 1
Clip Detector 812290 1
Flag Drop Marking System 818543 1
Swing Away Circuitry 812240 1
Beacon/Horn Combo 815804 1
SECTION 4
DRAWINGS
128 [3251]
(4) BOLT, 3/8 - 16 X 1 C.S.
(4) NUT, 3/8 - 16 C.S. (2) UPRIGHT, 2 in. SQ TUBE FRP
(2) BOLT, 3/8 - 16 X 3.5 C.S. CROSS BAR, 3 in. C CHANNEL FRP
(4) NUT, 3/8 - 16 C.S.
SWING AWAY ASSY - 9 in. RADIUS
TRANSMITTER ANTENNA (STANDARD)
1 x 6 x 40
(4) BOLT, 1/4 - 20 X 2 C.S.
(4) NUT, 1/4 - 20 C.S.
(4) WASHER, FENDER, 1/4 in. C.S.
59.00 [1499]
ADJUSTABLE HEIGHT RECEIVER
1-1/2 in. INCREMENTS
RECEIVER ANTENNA
1 x 13 x 35
(4) BOLT, 1/4 - 20 X 2 C.S.
(4) NUT, 1/4 - 20
(4) WASHER, FLAT, 1/4 in.
(4) WASHER, FENDER, 1/4 in.
1 to 2 "
(2)MOUNTING FOOT
2 in. RT ANGLE CARBON STL
(6) BOLT, 3/8 - 16 X 3 C.S.
(2) BOLT, 3/8 - 16 X 3.5 C.S.
(8) NUT, 3/8 - 16 C.S.
ELECTRONICS ENCLOSURE
16 H X 14 X 6.D
CUSTOMER TAG:
9.RECOMMEND IDLER SPACING 1200mm MINIMUM. 1 [25] T0 2 [51] 2110-ZM-005

CLEARANCE.
13.60 [345]
WITH NONMETALLIC MATERIAL.
335657
335657
TO ANTENNAS. REPLACE WITH NONMETALLIC STRUCTURE AS NEEDED. ERIEZ P/N:831970
ARC WELDING WITHIN 100 FT (30M). CLIP DETECTOR
9/10/2018
10/15/2018
3.IF EXPERIENCING AIRBORNE OR ELECTRICAL INTERFERENCE, ELECTRICALLY GROUND CONVEYOR AT BOLT OR WELD TO FRAME
THE HEAD AND TAIL. WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,
ESD
ESD
SEE NOTE 4 WORLD HEADQUARTERS, ERIE, PA, USA
2.SUGGESTED LOCATION OF METAL DETECTOR: 1) IN LOW VIBRATION AREA, 2) AS FAR AWAY AS POSSIBLE
TITLE OUTLINE
SHEET TITLE
AND CONTROLLERS.
1235 METAL DETECTOR 118BW N4X
1.ALLOW AT LEAST 6FT(2M) DISTANCE BETWEEN DETECTOR POWER AND SIGNAL LINES,PLANT CONDUIT, FOR
CABLE AND PIPING RUNS. NEXT
NOTES UNLESS OTHERWISE SPECIFIED
DATE 4/21/2018
CHKD. BY
ADD TAGGING
UPDATE DIMENSIONS
B
A
B
- DOUT a2016_0
128 [3251]
59.00 [1499]
1 to 2 "
12" 47 1/4 [1200]

MINIMUM
24 [610]
9.RECOMMEND IDLER SPACING 1200mm MINIMUM.

CLEARANCE.
WITH NONMETALLIC MATERIAL. CUSTOMER TAG:
TO ANTENNAS. REPLACE WITH NONMETALLIC STRUCTURE AS NEEDED. 1 [25] T0 2 [51] 2110-ZM-252
ARC WELDING WITHIN 100 FT (30M).
3.IF EXPERIENCING AIRBORNE OR ELECTRICAL INTERFERENCE, ELECTRICALLY GROUND CONVEYOR AT
335657
335657
THE HEAD AND TAIL. 11.64 [296]
2.SUGGESTED LOCATION OF METAL DETECTOR: 1) IN LOW VIBRATION AREA, 2) AS FAR AWAY AS POSSIBLE ERIEZ P/N:831971
9/10/2018
10/15/2018
AND CONTROLLERS.
ESD
ESD
1.ALLOW AT LEAST 6FT(2M) DISTANCE BETWEEN DETECTOR POWER AND SIGNAL LINES,PLANT CONDUIT, VIBRATORY AND METAL DETECTION APPLICATIONS
CLIP DETECTOR WORLD HEADQUARTERS, ERIE, PA, USA
CABLE AND PIPING RUNS.
TITLE OUTLINE
NOTES UNLESS OTHERWISE SPECIFIED BOLT OR WELD TO FRAME
SHEET TITLE
SEE NOTE 4 1260 METAL DETECTOR 118BW N4X
FOR
NEXT
DATE 4/21/2018
CHKD. BY
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UPDATE DIMENSIONS
B
A
B
- DOUT a2016_0
CUSTOMER TAG:
335657
2110-ZM-005
9/10/2018
ESD

SHEET TITLE
FOR
NEXT
DATE 4/21/2018
CHKD. BY
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A
A
- COUT a2016_0
CUSTOMER TAG:
335657
2110-ZM-252
9/10/2018
ESD

SHEET TITLE
FOR
NEXT
DATE 4/21/2018
CHKD. BY
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A
A
- COUT a2016_0
1 1 ENCLOSURE - P/N 56055
2 1 GREEN LIGHT ASSEMBLY P/N 56066
3 1 ALARM LIGHT & HORN 115VAC - P/N 55008.11
4 1 ON/OFF SWITCH P/N 56069
5 1 RESET SWITCH P/N 56079

13 3/4 [350]
1 SET FOR EACH METAL DETECTOR
6 3/8 [162]
3 3/4 [95] 5 [127]
6 1/16 [154]
2 3/4 [70]
7 7/8 [200]
4 [102]
15 3/4 [400] 14 3/4 [375]
Ø5/16 [Ø8]
01/2 [13]
335657
335657
335657
07/16 [11]
4/26/2018
9/10/2018
14 5/8 [371]
10/15/2018
ESD
ESD
ESD
TITLE OUTLINE
SHEET TITLE
1200 SERIES METAL DETECTOR CONTROL
FOR
N4X CONTROL HOUSING ALARM HORN/BEACON COMBO
NEXT
CUSTOMER TAG: DR. BY ESD ORDER # ASS'M
SCALE NTS E.R. # PRIOR REF 3R-201310423
2110-ZM-005 DATE 4/21/2018

CHKD. BY
SPENCE GROWTH OPTIONS PROJECT 2110-ZM-252
UPDATE TITLE BLOCK

ADD TAGGING
UPDATE QTY'S
C
A
B
C
- COUT a2016_0
BOLT SIZE BOLT SIZE METRIC WASHER MAJOR WASHER MINOR WASHER ID WASHER L
ITEM QTY DESCRIPTION
IMPERIAL OD OD MAJOR OD
3/4" M20 2.065"(52.4mm) 1.05"(26.7mm) .806"(20.5mm) .5"(12.7mm) 1 16 Shoulder Washer - 0.54" ID (14mm) - Nylon
MINOR OD L
ID
4 16 ISOLATION PAD, Fiberglass 4"X4"X1/4"
IDLER BOLT (EXISTING)

NYLON SHOULDER WASHER (BY ERIEZ)

IDLER FLANGE (EXISTING)
4" X 4" FRP PAD

(BY ERIEZ)

1, 2, 3
IDLER NUT (EXISTING)

4
2. Select Shoulder Washers that is the closest fit for the existing idler bolt.
centered on the idler foot hole, drill a holes into the four isolation plates large
enough to allow the shoulder washer flange to fit. CUSTOMER TAG:
4. Re-mount the idlers onto the frame so that the isolation plates are in between 2110-ZM-005
2110-ZM-252
335657
the idlers mounting foot and the conveyor frame. Secure the idlers with the
bolt, washers, shoulder washer and nuts. When completed, the idler will be
10/15/2018
electrically isolated from the conveyor frame.
ESD
NOTE: Besure to use a metal flat washer on top of the nylon shoulder washer to WORLD HEADQUARTERS, ERIE, PA, USA
TITLE OUTLINE
spread the bolt head preasure evenly. SHEET TITLE
FOR IDLER PULLEY ISOLATION W/ TAGGING

NEXT
SCALE NTS E.R. # PRIOR REF 201507851

DATE 9/10/2018
CHKD. BY
UPDATE QTY'S
A
A
- DOUTL a2013
2 BRACKET TUBE-1.06 X 10.0/20.0 LG 3/4" SCHED 40 STL PIPE 3 1/8 [80]
3 1/8 [80]
BRACKET TUBE W/PLATE- 3.125 SQ 12 ga C.S.
3 2 PROXIMITY SENSOR
4 STRAIN RELIEF
5 2 SWIVEL JOINT 1 11/16 [43] 1 11/16 [43]
6 25' (2) CLIP DETECTOR CABLE
4
3
10 [254]
6
LED STATUS
INDICATORS
2 RED TO 1 WHITE TO 4
NC 2 BLACK TO 3
1
3 4
20 [508]
1 2
1 1/16 [27] 1 1/16 [27]
1 13/16 [46]
FOR BELT WIDTHS OF 90" OR LESS
5
Note:
Green LED for power on ASSEMBLY
Yellow LED for metal detect
1 1/16 [27] 1 1/16 [27]
335657
1 13/16 [46]
ANGLE SWIVEL BRACKET TO MATCH TROUGHING ANGLE
AND KEEP FLAT PART OF SENSOR PARALLEL TO THE BELT MOUNT 2 [51] AWAY FOR BELT WIDTHS OF 90" OR GREATER
10/15/2018
AND ABOUT 1 [25] AWAY FROM BACK OF BELT. FROM ROLLER
POSITION 4 [102] BELOW EDGE OF BELT.
CUSTOMER TAG: WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,
ESD
TITLE OUTLINE
2110-ZM-005
SHEET TITLE
2110-ZM-252
WELD CLIP DETECTOR FOR 1235/1260 BELT CLIP DETECTOR W/ TAGGING
MOUNTING BRACKET BASE
SUPPORT TUBE TO NEXT
DR. BY ESD ORDER # ASS'M
CONVEYOR FRAME
SCALE 1/2 E.R. # PRIOR REF 3R-201200837
DATE 9/10/2018
INSTALLATION DRAWING NUMBER
SPENCE GROWTH OPTIONS PROJECT CHKD. BY REVISION
REFERENCE
UPDATE QTY'S
DISCONNECT LINE POWER GROUND(TB-2,3) AND RECEIVER INCHES [MILLIMETERS]
A
A
CONNECTION @ TERMINAL BLOCK BEFORE ARC WELDING. - COUT a2016_0
1 2 SETS NON-METALLIC FLAG (SET OF 3) P/N 56036
2 30' CABLE, SO8, 18GA - NOT SHOWN - PN 10784

3 1 FDM Back Support PN 40053.21
4 1 Gusset Plate, FDM Frame - PN 40050.4
5 4 Screw, Machine - Philips 1 4-20 X 12" - PN 11235
6 2 Bolt, 3/8-13 x 1.5" PN 10600
7 1 UPRIGHT - 2" FRP Souare tube - 46" Long - PN 40050.2
8 1 HORIZ. SUPPORT - 2" FRP Square tube X 33" - PN 40050.3
9 2 Bolt 3/8-13 x 3" - PN 10599
10 5 Bolt 3/8-13 x 1" - PN 10601
2 1/2 [64]
37 3/16 [945]
CUSTOMER TAG:
2110-ZM-005
2110-ZM-252
335657
5 5/8 [143]
10/15/2018
ESD
TITLE FLAG DROP MARKER

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SCALE NA E.R. # PRIOR REF
DATE 9/10/2018
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A
A
- COUTL a2013
INHI INLO
INHI INLO
_
_
7FU 8FU
KLDR-4 KLDR-4
CERTIFIED
FOR CONSTRUCTION
OCTOBER 12, 2018
ERIEZ MAGNETICS
335351
335351
1 2 ERIE PENNSYLVANIA
10/11/2018
6/15/2017
JTK
JTK

3 WORLD HEADQUARTERS, ERIE, PA, USA
TITLE SCHEMATIC & OUTLINE STYLE 201802870

SHEET TITLE
FOR
ADD WEIGHT, BOTTOM LAYOUT
4 NEXT
DR. BY JTK ORDER # 335351 201802870
REVISIONS PER ASSEMBLY
ASS'M
SCALE E.R. # PRIOR REF 200704558

DATE 4/27/2018
CHKD. BY
5
- B
A
DOUTL a2012
CERTIFIED
FOR CONSTRUCTION
OCT 08, 2018
ERIEZ MAGNETICS
ERIE PENNSYLVANIA

TITLE OUTLINE
SHEET TITLE
FOR ERIEZ MAGNET LOAD MONITOR CUSTOMER TAGGING
NEXT
DR. BY JTK ORDER # 335351 ASS'M
SCALE E.R. # PRIOR REF 9809500

DATE 10/8/2018
CHKD. BY
- COUTL a2012
SM-323W
and Maintenance
Instructions
Suspended
Electromagnets

Suspended Electromagnets
Introduction
This manual applies to the two basic types of Eriez Magnetics suspended
electromagnets: oil cooled and air‑cooled. The slight differences in installation
and maintenance procedures for these magnets are detailed in the text.
A careful reading of these Installation, Operation and Maintenance Instructions

will assure your magnet’s most efficient and dependable performance.
If there are any questions or comments about the manual, please call
Eriez Manufacturing at 814/835‑6000 for assistance
CAUTION ‑ STRONG MAGNET
This equipment includes one or more extremely powerful magnetic circuits.

The magnetic field may be much stronger than the Earth’s background field
at a distance several times the largest dimension of the equipment.
• If you use a heart pacemaker or similar device you must never approach
the equipment because your device may malfunction in the magnetic
field, with consequences up to and including death.
• To avoid serious pinch‑type injuries caused by objects attracted to the

magnet, keep all steel and iron objects well away from the equipment.
Do not allow hands, fingers, and other body parts to be caught between
the equipment and “workpiece” being lifted.
• Keep credit cards, computer disks, and other magnetic storage devices
away from the equipment because magnetically stored information may
be corrupted by the magnetic field.
• Keep electronic devices, such as computers or monitors, away from

the equipment because exposure to the magnetic field may result in
malfunction or permanent damage to such devices.
Contact Eriez if you have a question regarding these precautions.
CAUTION
Safety labels must be affixed to this product. Should
the safety label(s) be damaged, dislodged or removed,
contact Eriez for replacement.
© 2018 ERIEZ ALL RIGHTS RESERVED
2
Table of Contents
ERIEZ SUSPENDED ELECTROMAGNETS
WARNING.............................................................................................................. 4
DESCRIPTION....................................................................................................... 5
INSTALLATION
General............................................................................................................. 6
Magnet Positions.............................................................................................. 6
Suspension Height........................................................................................... 7
Burden Depth................................................................................................... 7
Guidelines for Magnet Installation.................................................................... 7
Wiring............................................................................................................... 9
OPERATION......................................................................................................... 10
MAINTENANCE
Manual Cleaning Models................................................................................ 10
Self-Cleaning Models..................................................................................... 10
RECTIFIER TROUBLESHOOTING DATA SHEET............................................... 12
TROUBLESHOOTING
General........................................................................................................... 13
Adjustment Guide for Manual Cleaning Units................................................. 14
Adjustment Guide for Self‑Cleaning Units...................................................... 14
Bolt Torque..................................................................................................... 14
Copper Conductor Size Chart........................................................................ 15
3
Warning
Suspended electromagnets with self‑cleaning belts When either a self‑cleaning or a manual cleaning
are normally suspended above conveyor belts away electromagnet is energized, workers should never
from personnel working areas. Eriez has no control extend parts of their bodies into the magnetic field
over this location or adjacent areas. area between the conveyor and the magnet face.
Under certain conditions it may be necessary for the Tramp iron pieces will be attracted suddenly and
user to install additional safety devices to protect unexpectedly to the magnet potentially pinning an
operating personnel. arm etc. with enough force to cause severe injury.
Suspended electromagnets with self‑cleaning belts Warning and Caution plates and decals on the magnet
have pinch points where the belt goes over the must not be removed or painted over. It is important
pulleys. When the belt is running this is a hazardous that these warnings and cautions be legible and that
area. Workers should be instructed not to perform they be followed. Note the magnetic field warning at
duties on this equipment unless it is shut down and the front of this document.
the electric supply source is locked out.
(ALL SIDES)
ELECTRICAL SHOCK
MAGNETIC FIELD HAZARD
HAZARD P/N 442303/456970*
P/N 457034*/442276
HOT LIQUID BURN HAZARD
P/N 443365/456321*
WIRING TYPE
P/N 462339*
(BOTH SIDES) HAZARDOUS VOLTAGE

(BOTH SIDES)
HOT SURFACE HAZARD P/N 442300/456960*
READ INSTRUCTION MANUAL
P/N 456916*/442350
P/N 456858*/442313
Figure 1
Safety decal locations - manual cleaning models
*three language labels
(BOTH SIDES)
READ INSTRUCTION MANUAL
P/N 456858*/442313
(BOTH SIDES) (BOTH SIDES)HAZARD
ELECTRICAL
HOT SURFACE HAZARD P/N 451518/456970*/442302
MAGNETIC FIELD HAZARD
P/N 456916*/442350 P/N 457034*/442276
(SE ONLY) P/N 456970*/442303 (SE ONLY)
BELT AND PULLEY HAZARD

P/N 456901*/442342
BELT AND PULLEY HAZARD ELECTRICAL HAZARD

P/N 456901*/442342 P/N 451518/456970*/442302
Figure 2
Safety decal locations - self-cleaning models
4
Description
Suspended electromagnets are heavy duty DC
powered separators designed for use over a moving
bed of material from which iron is to be removed.
Basically, they are box‑shaped units with coils inside
to generate a powerful magnetic field.
There are two basic types available: oil‑cooled and air
cooled. Both of these types are available as Manual
or Self‑Cleaning units. Each type has two styles,
in‑line and cross‑belt, to accommodate installation
requirements. There is a wide range of sizes available
for each type and style. Figure 3
Typical air-cooled self-cleaning
Manual Cleaning magnets are designed for use where suspended electromagnet
small amounts of tramp iron are suspected. They can
be furnished with an adjustable cable sling designed
for a one‑point suspension or adjustable Jaw & Jaw
turnbuckles for four-point suspension.
With Manual Cleaning magnets it is necessary to
shut off the power periodically to discharge the
accumulated tramp iron. Manual Cleaning Units may
be installed over the head pulley or over the conveyor.
Self‑Cleaning magnets consist of a Manual Cleaning
unit with a short belt conveyor built around it to provide
automatic discharge of tramp iron. These magnets,
typically furnished with turnbuckles for four‑point
suspension, can also be used over the head pulley
or over the conveyor.
Figure 4
Typical oil-cooled manual cleaning
suspended electromagnet
5
Installation
General
Use care in uncrating to avoid damage to the
equipment.
IMPORTANT: Check the area upstream,
downstream, on the sides and underneath the
magnet for carbon steel or other ferrous metals.
Specifically look for carbon steel conveyor belt
idlers, slider beds, side frames or any other Figure 5
metals in the area. All carbon steel or ferrous Manual cleaning position 1
metals within magnetic field of the magnet (up to
3-feet or possibly more for larger size magnets)
will become induced or “magnetized” and will
reduce the separation efficiency of the suspended
electromagnet.
For this reason, replace all carbon steel or other
ferrous metals with 304 or 316 stainless steel,
aluminum, plastic, wood or other non-magnetic
materials in the area of the magnet for the best
magnetic separation efficiency.
For Oil‑Cooled Models: Be sure the magnet is oriented Figure 6
Self-cleaning position 1
properly. In all installations, the external oil expansion
chamber must be at right angles to the direction of separator has adequate room to run properly and that
material flow and on the high side if installed at an provisions have been made to collect the discharged
angle. Magnets with adjustable expansion tanks must tramp iron. A hinged non‑magnetic splitter, adjustable
be positioned so the drain is at 6 o’clock. (See page 9). in length, will be required to prevent extracted tramp
Check the pressure relief valve located on the high end iron from reentering the product.
of the oil expansion chamber to make sure it is free to Position the magnet so that the face of the belt is
operate. This is done by pulling the stem and releasing approximately 2" (50 mm) from the trajectory of the
it. It is spring loaded and will re‑seat itself when material being discharged. The centerline of the
released. magnet should be approximately perpendicular to
the material at that point.
MAGNET POSITIONS
Position 1 (in‑Line) Position 2 (Cross‑belt)
The preferred installation of a suspended magnet is Installation of the separator over the moving bed of
over the trajectory of material discharged from the belt material at right angles to the conveyor is referred to
conveyor. This is referred to as POSITION 1 as POSITION 2 (See Figures 7 and 8). This location
(See Figures 5 and 6). normally presents a more difficult separation problem
For optimum separation in Position 1 installations, than Position 1 and usually requires a stronger
provision must be made to adjust the location of the magnet.
magnet to suit the trajectory of the material. For Position 2 installations, steel conveyor idlers
For Position 1 installations with conveyor belt speeds of cannot be used in the length of the conveyor beneath
less than 350 fpm (107 m/min), greater separation will the separator. Any conveyor idlers beneath the
be achieved by using a nonmagnetic head pulley. separator must be made of rubber, wood, or some
If a Self‑Cleaning unit is being installed, examine the other non‑magnetic material. Both the Manual
area to make sure that the self‑cleaning belt around the Cleaning and the Self‑Cleaning units should be
installed on the centerline of the material conveyor
and parallel to the slope of the conveyor.
6
Specified suspension height should be considered a
maximum and the magnet should be lowered as close
to the actual burden as possible. When lowering the
magnet to the burden, be sure that plowing of material
does not occur. If the unit is a Self--Cleaning magnet,
make sure that the separator belt has room to operate
and discharge tramp iron properly. A clearance of
3" (75 mm) between the magnet or belt and the top
of the burden is typical for Self‑Cleaning units; this
clearance can be reduced to 2" (50 mm) for Manual
Cleaning units.
BURDEN DEPTH
The best separator performance is achieved by
controlling the burden depth. A plow or leveler
Figure 7 positioned above the conveyor and before the
Manual cleaning position 2
magnet will help level high spots or surges in
Position 2 installations. For Position 1 installations,
the recommended installation location is calculated
on expected tonnage. Any variation from this rate
changes the trajectory of the burden with respect
to the working surface of the magnet and may result
in poor separation.
GUIDELINES FOR MAGNET INSTALLATION
Generally, sufficient application data is available
so that we can prepare an installation drawing to
show the magnet location that will provide optimum
tramp iron removal. However, for those instances
where there is not enough information to permit
preparation of a drawing, the guidelines that follow
Figure 8 should be helpful. Observing these guidelines will
Self-cleaning position 2 not necessarily result in an ideal magnet location but
as you approximate these conditions more closely,
performance will be improved. It is important to
SUSPENSION HEIGHT provide for adjustment of the magnet position
Each size magnet is designed for a specific so optimum results can be obtained under actual
suspension height. This distance (See Figure 9) operating conditions.
is measured from the magnet face to the product
conveyor belt. Position 1 mounting ‑ magnet over the conveyor
head pulley.
Determine where the highest point of the material
trajectory occurs and position the magnet so that the
face is 2" (50 mm) for a manual cleaning magnet and
3" (75 mm) if unit is self‑cleaning type, above material
and the magnet center line passes through the high
point of the trajectory. See Figure 10.
Suspension height
Product conveyor belt
Figure 9 Suspended Electromagnets
7
Installation (cont.) Position 2 mounting ‑ magnet across the
conveyor belt.
Position the magnet so that it is centered over the
width of the conveyor and the face (bottom) is parallel
to the slope of the conveyor.
When a self‑cleaning magnet is installed over a
troughed conveyor belt, the magnet must be high
enough so that a piece of iron on the magnet belt will
clear the edge of the conveyor belt. However, caution
must be exercised so that the rated suspension height
of the magnet is not exceeded. See Figure 12.
Figure 10
Suspension Height Clearance
Note: The normal magnet angle with respect to a

horizontal plane will be in the range of 15‑25°. As belt
speeds increase, installation angles tend to decrease.
In cases where belt speeds are slower (usually 350 Figure 12
fpm (107 m/minute) or less) the material trajectory will
not rise higher than the top of the pulley but, rather, For Oil‑Cooled Models:
will follow around the periphery of the pulley and
“fall‑off” the downstream side. For this condition, the CAUTION
magnet centerline should pass through the center of After installation and prior to start‑up, check the
the pulley. Note: A head pulley of non-magnetic oil level at the Oil Level Plug located on the side
material (series 300 stainless steel) is required to corner of the magnet near the expansion tank.
avoid magnetic inducement that would be present If the level is low, add oil of the type specified
with a mild steel pulley. See Figure 11. on the plate attached to the top of the magnet
beside the Oil Fill Plug.
Oil Expansion Tanks are mounted with slotted

brackets allowing adjustment to the tank. Adjustments
are made to keep the relief valve in proper position.
Tanks can be factory adjusted if incline angle is
specified when ordering. Otherwise field adjustment
will be required.
Tanks are properly adjusted when the orientation
arrow is pointing straight down. When hanging a
magnet the tank is turned toward the magnet until
the arrow points down.
Figure 11
8
Procedure Applies to
Sling and Turnbuckle suspension
CAUTION
Orientation Do not attempt to turn the terminal posts
Arrow
themselves. This may result in internal damage.
Tank Slots Install the terminal lugs between the two brass nuts
for Adjustment
provided on the terminal posts. Hold the back nut
Rotate securely in place with a wrench when tightening
Orientation
the front nut.
Arrow
A ground stud is provided in the outlet box for the
ground lug furnished in the kit of terminals. The ground
lug is installed between the two brass nuts on the
stud. The ground wire must be installed to the
ground lug to be a CSA-approved installation.
NOTE: Either wire from the DC power source can
be connected to either terminal post in the outlet box,
Figure 13 unless indicated on the magnet. Do not break the
Oil Expansion Tank Positioning for Oil Cooled Magnets DC leads from the DC power source with a switch
with Slotted Mounting Brackets. or fuses. The energy from the magnet must have a
WIRING (CSA APPROVED) decay path through the power source.
Wiring for Eriez electromagnets is very simple
(see Figure 14). Connect the two DC leads from
the DC power source to the two terminal posts in the
magnet outlet box. A kit of crimp type terminal lugs
is provided for the minimum recommended wire size
for the magnet (refer to Table 5.)
The conductor insulation must be rated for 125°C.
The CSA-Certified lugs are T&B (Thomas and Betts
Co.) or equal and must be crimped with a T&B tool.
A recommend T&B crimping tool is also listed for
each conductor wire size in Table 5. Only use tools
recommended by the terminal lug manufacturer. See
Figure 15 for the routing of wires in the outlet box.
Grounding
connection
Figure 15
Figure 14
9
Operation 2. The oil should be laboratory tested every 12
months for:
START-UP OF SELF-CLEANING UNITS a. Moisture
1. Be sure the frame is visibly square and has not b. Contaminants
been damaged or twisted. c. Dielectric strength (20 KV min.)
Eriez does not perform this service, but it is
2. After installation, momentarily close the AC switch
suggested that inquiries be directed to:
to the belt drive to determine if the belt is running in
a. a reliable testing laboratory
the right direction. The bottom of the belt should be
b. the oil vendor
running toward the motor. Also check to see if the
c. local electric utility
belt tends to wander and, if so, in which direction.
3. Be sure the expansion tank pressure relief valve
3. Belt Adjustment
is free. This should be checked frequently. (See
a. The smaller Suspended Electromagnets page 6 general installation instructions).
utilize a two‑pulley design. The tail pulley has
approximately 6" (150 mm) of take‑up available
CAUTION
for both belt stretch and tracking purposes. To
The relief valve can release hot oil if excessive
track the belt, the tail pulley should be moved
heat causes above‑normal expansion.
in a direction to tighten the belt on the side to
which the belt wanders.
NOTE: Normal external operating temperature
b. The larger magnets have a four‑pulley design
of Eriez oil‑cooled electromagnets is
and have two take‑up adjustments. The bottom
approximately 185°F (85°C); for air‑cooled
tail pulley is initially used to take up the slack
magnets, approximately 160°F (70°C). These
(adjust both sides evenly). Tracking is achieved
temperatures are extremely hot to the touch.
by adjusting the small pulley located on the
same end so that the belt is tightened on the FOR SELF-CLEANING MODELS:
side to which it wanders. 1. Lubricate bearings on a schedule consistent with
other equipment in use with your product and
NOTE: Never start the belt drive and allow it to run
environment. An NGL1 No. 2 lithium‑base grease
continuously until the belt is properly trained.
is recommended.
2. Check V‑belt tension frequently. Adjust by
Maintenance tightening the reducer torque arm as required.
AIR-COOLED MANUAL CLEANING MODELS: 3. For motor and reducer maintenance, refer to the
No maintenance other than periodic removal of tramp manufacturer’s instruction sheets packed with the
iron is required for air‑cooled Manual Cleaning units. shipment.
OIL-COOLED MANUAL CLEANING MODELS: 4. If the separator is to be installed inside a fabricated
1. The oil level should be checked periodically (check enclosure, provisions must be made to maintain
only when magnet is cold). If the oil level is low, fill and adjust moving parts as required.
as required with the same brand and type as noted 5. After initial run in, check all fasteners for proper
on the plate beside the oil fill plug. Do not attempt tightness. Refer to Torque Table on Page 14.
to mix types since many substitutes for the original 6. After 250 hours of running check pulley hubs and
are not compatible. tighten set screws to 17 lb. ft. (23 Nm) torque.
10
7. Proper adjustment for belt tension and tracking is
vital to trouble free operation of the self‑cleaning
system, and should be checked frequently. To
track these belts you should proceed in the
following manner:
The smaller Suspended Electromagnets utilize Belt is too tight
a two‑pulley design. The tail pulley has
approximately 6" (150 mm) of take‑up available for
both belt stretch and tracking purposes. To track
the belt, the tail pulley should be moved in a
direction to tighten the belt on the side to which
the belt wanders.
The larger magnets have a four‑pulley design and
have two take-up adjustments. The bottom tail
pulley is initially used to take up the slack (adjust
both sides evenly). Tracking is achieved by
adjusting the small pulley located on the same
end so that the belt is tightened on the side to
which it wanders.
Belt is too loose
8. Once the belt has been trained, further adjustment
may be required to achieve proper tension.
Excess tension applied in an effort to keep the
belt flat against the face of the magnet can lead
to pulley, shaft or bearing failure. It is normal for
the belt to sag due to its own weight and this
becomes more prevalent on the larger units.
Efficient operation can be achieved without
applying excess tension so the belt should be 1" to 2"
tightened only enough to prevent slipping on the

pulleys when it is conveying iron off the face of the
magnet. Usually a sag of up to 3" (75 mm) is not
detrimental unless it interferes with material flow. Belt should have 1" to 2" gap at magnet corners.
See Figure 16. Larger magnets can have a belt sag in the center
up to 3" (76 mm)
Figure 16
11
Maintenance (cont.)
12
Troubleshooting
GENERAL
On self‑cleaning units, stop the belt before troubleshooting
or performing checks and maintenance. Do not allow the
belt to remain stationary for more than 30 minutes with the
magnet energized; heat may damage the belt.
PROBLEM PROBABLE CAUSE SOLUTION
a. Check power switch and check DC voltage at magnet
terminals; adjust as required
b. Check location of magnet with respect to burden and
confirm that it is within the recommended suspension
a. Magnet is not turned on or the height at the centerline of the magnet
magnet voltage is low c. Check missed tramp iron with small permanent magnet
b. Magnet is not installed at the proper to confirm that it is magnetic
suspension height d. Check area around the separator with a small steel
c. Parts not being attracted are probe to see if the structure or conveyor components
non‑magnetic are themselves acting as a magnet and attracting iron.
Magnet will not
Replace with a non‑magnetic material as required
attract iron d. Induced iron in the area of the
magnet prohibits the extraction e. Check for proper DC voltage at the magnet terminals
of tramp iron and check for proper current. Current should be
approximately 30% lower than nameplate current.
e. Magnet is overheated
Correct voltage. Allow magnet to cool
f. Magnet coils are grounded
f. Take megohm reading between each magnet terminal
g. Magnet coil is shorted or open and ground. 0.5 megohms should be minimum reading
g. Check for rated current at rated voltage at magnet OR
measure DC resistance of cold magnet. The resistance
should equal the nameplate voltage divided by
nameplate amperes
a. Check and repair as required. Magnet may be welded
or patched as required BUT EXTREME CAUTION
MUST BE TAKEN TO PREVENT FIRE DURING ANY
WELDING in hazardous locations (coal dust, etc.). The
welding should be performed by qualified welders using
electric arc welding equipment. Drain the oil from the
magnet into clean containers. Purge the magnet of all
oil fumes by using an inert gas (argon or C02). Purge
for 30 to 45 min. through the drain plug in the magnet
to the relief valve in the expansion tank at 5 pounds
pressure. Continue to purge when welding. Small pin
a. Damaged unit hole leaks can be more easily welded when peened
Oil Leak shut first. A stainless steel plate or angle on a corner
b. Excessive internal pressure
can be continuously welded over a crack if required.
CARE should be taken when welding a magnet
containing transformer oil to prevent igniting the oil in
the magnet or any spilled oil. After welding is completed,
check for leaks at 5 pounds pressure using soapy
water. If no leaks are found, then fill the magnet with
oil. Use a filter (paint filter) when re‑installing oil to
eliminate any ferrous particles to enter the magnet
box which can cause coil failure
b. Check freedom of pressure relief valve and replace
if required
Table 1
General troubleshooting chart
13
Troubleshooting (cont.)
a. Manual Cleaning units ‑ prior to hanging magnet, loosen
Adjusting cable clamps, adjust cable length and tighten clamps.
Suspension b. Self‑Cleaning units ‑ adjust turnbuckle length by turning
the turnbuckle body.
Table 1
General troubleshooting chart (cont.)

a. Examine face of the magnet for build‑up of excessive
quantities of extracted tramp iron. Discharge more
frequently as required.
a. Magnet face is overloaded with
already‑extracted iron. b. Check for proper clearance between the magnet and
Magnet will burden. Adjust for proper gap.
not b. Magnet set too far from burden.
attract iron c. Check for proper clearance between the magnet and
c. Magnet set too close to burden.
the burden. If too close, material surges can occur and
d. Magnet not aligned with belt. the surge may act as a wiper.
d. Position magnet with center above centerline of belt
and edges parallel to edges of belt.
Table 2
Adjustment guide for manual cleaning units.
(All general items also apply)

a. For Self‑Cleaning units in Position 2, check to see that
enough clearance has been allowed between bottom of
Tramp iron a. Not enough clearance for the iron to be magnet and edge of conveyor belt for maximum sizes
re‑entering discharged from the product magnet. to be discharged. Adjust as necessary
the product b. Splitter improperly positioned. b. For Self‑Cleaning units in Position 1, check splitter for
proper location and clearance with respect to the magnet.
Adjust splitter angle and length as required
Table 3
Adjustment guide for self-cleaning units.
PLAIN PLATED
BOLT SIZE
Lb.‑Ft. Newton Meter Lb.‑Ft. Newton Meter
1/4 ‑ 20 8 11 6 8
5/16 ‑ 18 17 23 13 18
3/8 ‑ 16 31 42 23 31
1/2 ‑ 13 76 103 57 77
5/8 - 11 150 203 112 152
3/4 ‑ 10 266 361 200 271
7/8 ‑ 9 430 583 322 437
1‑8 644 873 483 655
These values apply to unlubricated Grade 5 bolts with flat or no washers under the head.
Table 4
Bolt torque
14
Copper Conductor Size for Connection of Magnet to the DC Power Source
Per Canadian Electrical Code,Part I,C22.1-12 Table 2 and Table 16 for 125°C Wire. 4
These Magnets Must Be Wired with 125°C Conductior Insulation.
T&B Hand Kit of

DC DC Mains Wire T&B Ground Wire
MODEL 1 Crimping Terminals
Volts Amperes size AWG Terminal Lug Size AWG. 2
Tool Part No. 3,4
71_0 115 14.3 12 10RC-38X ERG4001 14 2N-201008490
71_5 115 20.9 10 10RC-38X ERG4001 12 2N-201008490
72_0 115 23.1 10 10RC-38X ERG4001 12 2N-201008490
72_5 115 31.3 8 54132 TBM4S 10 2N-201008491
73_0 115 33.1 8 54132 TBM4S 10 2N-201008491
73_3 115 41.7 8 54132 TBM4S 10 2N-201008491
73_5 115 42.8 8 54132 TBM4S 10 2N-201008491
73_8 115 43.8 8 54132 TBM4S 10 2N-201008491
74_2 115 53.7 6 54136 TBM4S 10 2N-201008492
74_5 115 54.9 6 54136 TBM4S 10 2N-201008492
75_0 115 57.2 6 54136 TBM4S 10 2N-201008492
75_5 115 68.4 4 54140 TBM4S 8 2N-201008493
76_0 115 71.1 4 54140 TBM4S 8 2N-201008493
76_5 115 83.5 4 54140 TBM4S 8 2N-201008493
77_0 115 86.5 2 54143 TBM4S 8 2N-201008494
77_2 115 88.2 2 54143 TBM4S 8 2N-201008494
77_5 115 103.3 2 54143 TBM4S 6 2N-201008494
77_7 115 104.9 2 54143 TBM4S 6 2N-201008494
78_0 115 106.6 2 54143 TBM4S 6 2N-201008494
78_5 230 62.8 6 54136 TBM4S 8 2N-201008492
79_0 230 64.4 6 54136 TBM4S 8 2N-201008492
79_5 230 74.6 4 54140 TBM4S 8 2N-201008493
79_8 230 82.6 4 54140 TBM4S 8 2N-201008493
Table 5
Notes:
1. The third digit in the model number denotes in line self cleaning (-1-), cross belt self cleaning (-2-),
or manual cleaning (-3-)
Example: Model 7610 = In-line self-cleaning magnet
Model 7620 = Cross-belt self-cleaning magnet
Model 7630 = Manual clean magnet
2. Use grounding lug supplied in kit of terminal parts.
3. Each kit of terminals includes two listed terminal lugs and one ground lug.
4. Reference CSA C22.2 No. 14- most current edition.
15
Note: Some safety warning labels or guarding may have been removed before photographing this equipment.
Eriez and Eriez Magnetics are registered trademarks of Eriez Manufacturing Co, Erie, PA ©2018 Eriez All Rights Reserved
World Authority in Separation Technologies

Telephone: 814/835-6000 • Fax: 814/838-4960
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16
SM-620P
and Maintenance
Instructions
Powertrol
Silicon Rectifier
Power Supplies

Powertrol Silicon Rectifier Power Supplies

Introduction
This manual details the proper steps for installing, operating and
maintaining the Eriez Powertrol Silicon Rectifier Power Supply.
Careful attention to these requirements will assure the most efficient

and dependable performance of this equipment.
If there are any questions or comments about the manual,

please call Eriez at 814/835-6000 for Powertrol Silicon
Rectifier Power Supply assistance.
CAUTION
Safety labels must be affixed to this product. Should
the safety label(s) be damaged, dislodged or removed,
contact Eriez for replacement.
WARNING!!!
High voltage AC/DC - shock hazard - consult a
qualified electrician.
2
Table of Contents
SUSPENDED PERMANENT MAGNETS
DeSCRIPTION....................................................................................................... 4
INSTALLATION & OPERATION............................................................................. 5
Unpacking......................................................................................................... 5
Location............................................................................................................ 5
Mounting........................................................................................................... 5
Wiring............................................................................................................... 5
Line Voltage Limitations.................................................................................... 5
Operation.......................................................................................................... 5
TROUBLESHOOTING........................................................................................... 7
MAINTENANCE, REPAIR AND ALTERATION....................................................... 7
Long Term Storage of “Powertrol”
Rectifier Power Supplies.................................................................................. 7
3
General Description
Eriez Silicon Rectifiers have been especially
designed for use with various types of electromagnetic
equipment. They are built to the highest electrical
standards and will give years of satisfaction and
trouble‑free operation when properly installed and
operated.
Powertrol Rectifiers feature convection cooling, a full
wave bridge circuit, double wound transformers and
14 gauge steel cabinets for wall mounting. A plainly
marked terminal strip is provided for AC line and DC
load connections. Good voltage regulation is inherent,
and rectifier output is unfiltered with ripple being on
the order of 4%.
4
Installation Install a fused safety switch ahead of the “Powertrol”
for short circuit protection. The fuses should not exceed
Unpacking the capacity of the conductors between the switch
Take care in unpacking so as not to break the pilot and the “Powertrol.” Connect the DC load directly to
light or damage the rectifier housing. Remove the terminals marked M1 and M2 on the panel. On highly
rectifier cover and make a physical inspection of inductive apparatus, such as electromagnets, NO DC
rectifier for shipping damage. If damage has occurred switch should be used when supplying only one piece
in shipping, notify and file a claim with the carrier. of equipment. All on and off switching should be
done in the AC circuit by means of a manual switch
Location or magnetic contactor. For installations where one
The rectifier should be located as you would any rectifier supplies several pieces of equipment, a DC
other electrical equipment. Standard NEMA 12 and switch can be used in each circuit. If DC switching is
NEMA 4 units are designed for operation in ambient necessary, it must be done by switches employing
temperatures less than 100°F (40°C). Avoid direct surge suppressors, (such as those manufactured by
sunlight. If not possible, install a canopy for protection. Cutler‑Hammer, Allen‑Bradley, etc., called automatic
For operation in higher ambient temperatures, derating drop controllers), or by switches specifically designed
is necessary. Consult Eriez for information on derating. to absorb the high transient voltage generated
Mounting upon interruption of a DC line. If remote operation is
When installing the wall mounted unit, be sure the desired, the manual switch must be replaced by an
mounting surface is reasonably flat. Space Rectifier AC magnetic contactor and a stop‑start switch located
Cabinet at least 1.5'' off of wall to ensure proper where desired.
cooling. Line Voltage Limitations
Wiring Line voltage should be within + or ‑5% of
Knockouts are provided in NEMA 1 and NEMA 9 nameplate rating, + 10% being the maximum
cabinets for conduit connection to line and load. Other allowable. Continuously impressed AC voltages
cabinets require knockout punching at installation. higher than 10% above nameplate rating can result
Read the nameplate ratings carefully to determine the in a rectifier failure and should be corrected by the
line voltage. Check the supply line voltage to be sure use of auto transformers.
it corresponds to the nameplate. Make AC line Operation
connections to terminals marked L1, L2, and L3 After wiring is completed and the load connected,
(marked LINE). Take care not to apply the higher line the unit is ready for operation. Close the fused line
voltage to the rectifier when it is connected for the safety switch and then turn the AC switch on. The
lower voltage; this can burn out the transformer and pilot light should go on, indicating the unit is in
destroy the silicon diodes and the pilot light along with operation.
its resistors. Read the AC and DC amps on nameplate
to determine the proper wire size. The wire size should
conform to National Electrical Code or local code for
current carrying capacity.
5
JLS_________
AJT________
6
Troubleshooting Maintenance, Repair
and Alteration
WARNING!!! No scheduled maintenance is necessary or required.
High voltage AC/DC - shock hazard - However improved life can be obtained from the unit
consult a qualified electrician. by keeping it clean and all connections tight.
Repair, alteration or disassembly of this equipment in
Open the manual switch (or safety switch) and check the field, without written authorization and instructions
the wiring, input fuses and output fuses. If fuses are from Eriez, nullifies the responsibility and guarantee
blown, attempt to locate the short circuit by first of the manufacturer.
checking all of the silicon rectifier diodes. To check Longterm Storage of “Powertrol” Rectifier
the diodes isolate the rectifier assembly from the Power Supplies
transformer by removing the 3 output fuses, and Upon receiving the power supply, thoroughly inspect
from the load by disconnecting terminals marked the equipment. Any damage should be reported to
M1 and M2. Then take Ohmmeter readings the carrier, and the supplier should also be
directly across each diode, first with one polarity notified immediately.
and then with reversed polarity. If the diode is good,
The units should be stored indoors in a room where
the resistance will be very high with one polarity and
the temperature is in the range of ‑5°F to 140°F
very low with the reversed polarity. High resistance
(‑20°C to +60°C). For storage up to one year for
readings with both polarities indicate an open diode,
Nema 1 (IP23) type cabinets, a desiccant should
and low readings indicate a shorted diode. Replace
be placed inside and the vents and door should be
the rectifier assembly if a short or open is detected.
sealed with tape and plastic film. Other cabinets,
If fuses and diodes check out good, inspect all wiring such as Nema 12 ‑ 4 (IP55, IP66), etc. require only
for possible short circuits or opens. the placement of a desiccant inside and reclosing
of the cabinet, retightening its latches.
For storage longer than one year, it is recommended
the terminals inside the control be treated with a
corrosion inhibitor spray in addition to the steps
mentioned above. If the storage area is known to be
prone to high humidity and fungus growth, the internal
wiring should be treated with a fungus‑proof coating.
7

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8
SM-419B
and Maintenance
Instructions
Magnet load
monitor
Series FS
Microprocessor
ERIEZ WORLD HEADQUARTERS: 2200 ASBURY ROAD, ERIE, PA 16506–1402 U.S.A.

Description Applications
Magnet Load Monitor Series FS Microprocessor-based The MLM is intended specifically for use with any
sensor for monitoring changes in magnetic fields. suspended electromagnet (SE). It is successful
because of the nature of the design of an SE. The
probe is to be mounted on the vertical side of an SE.
Introduction It is not intended for operation on or below the face of
The Magnet Load Monitor (MLM) was designed to the magnet. The intention is to measure fringe fields
provide a means of monitoring a suspended generated by the reluctance of the magnet circuit. As
electromagnet as it is loaded with ferrous metal. After a magnet is loaded with tramp iron, the reluctance of
adjustment to the magnet field at the probe location, the circuit is reduced with a corresponding change in
a relative change in magnetic field is displayed on an the fringe-magnetic fields. Every magnetic circuit is
LED bar indicator. unique in response to loading. In general, smaller
circuits have greater response. This reluctance effect
does not occur with permanent-magnet circuits,
Features therefore the MLM is not suitable for permanent
The MLM is designed around a microprocessor and magnet applications.
high-sensitivity magnetic sensor. It is packaged in an A typical application is an over-belt installation of a
impact-resistant NEMA 4X polycarbonate housing. manual-cleaning SE. The MLM can be installed and
The magnetic-sensor probe is provided with 25' (7.6 m) set up to trigger an alarm beacon before the magnet
of cable. (Longer cables are optional.) The probe holds has picked up enough tramp iron to cause a problem.
the sensor inside a stainless-steel sleeve. This sleeve At this time, the MLM can trigger an alarm or beacon
is mounted in a fixture, which is attached to the side that is audible or visible to the loader operator or the
of the magnet. This fixture, constructed of aluminum, control room.
allows two-axis rotation of the probe.
The sensor is linear in response to magnetic fields up Installation/Operation
to 600 gauss. An internal temperature- monitoring The MLM needs to be located within 25' (7.6 m) (or as
function maintains the linearity of the magnetic sensor limited by the supplied probe-cable length) of the
as the probe changes temperature. magnet. With the cover properly attached, the NEMA
A series of LED’s provides a display showing the 4X box is suitable for installation in most outdoor
relative change in magnetic field. locations. It should not be attached to the magnet itself.
If it is necessary to move the magnet for cleaning,
A relay (SPDT 8 amps, 250VAC) is provided to drive an consider this before permanently mounting the MLM.
optional or customer-provided alarm device. Stepped-
sensitivity adjustment allows gauss sensitivity per LED The probe must be mounted on the side of the magnet
to vary. This adjustment also allows the user to vary box using the two-axis probe mount. Normally it is
the magnetic-field magnitude that will cause the relay located on the centerline of the magnet near the face
to trigger. The relay trip will occur when the field either or pickup surface. The probe mount may be affixed
increases or decreases. using double-coated tape, epoxy adhesive, or short
self-tapping or drive screws. NOTE: if using screws to
The auto-zero function helps in setting up the MLM for attach the probe mount, be sure they are short enough
operation. Pressing the button located on the face of not to penetrate the magnet coil cavity.
the control will bring the MLM to a zero state within a
few seconds. If the relay is being used to drive a beacon or alarm,
install the wiring to the appropriate relay terminal. Wire
The unit is easily adjustable for international operation the control unit and set the appropriate voltage.
by a front-panel switch. Operation at either 115 VAC or
220 VAC is selected during initial installation.
2
Control Set-Up d. Continue rotation of the probe until the LED
bar display indicates a drop in magnetic field
1. Install the probe into its mount. when the probe is rotated in any direction
2. Place the magnet in position, energized, at from the present position.
normal operating temperature, and with no tramp e. Repeat steps (b) through (d) at higher
iron on the magnet face. sensitivity of 3 or 4. Lock the probe in place
3. The probe and control must now be properly and press zero a final time.
zeroed. Two people best accomplish this. One 4. Load the magnet with a typical amount of tramp
person reports on the LED display and resets metal desired to cause an alarm relay trigger.
the zero position on the MLM. The other rotates, As the magnet is loaded, the LED bar should
holds, and locks in place the probe. move to the left indicating less leakage field. If
a. Set sensitivity at 0, 1, or 2. the load does not cause an alarm relay trigger,
repeat step 3, increasing the sensitivity to a
b. Rotate the probe in two axes to allow the
maximum level of 7. Settings 8 and 9 provide
sensor to be perpendicular to the lines of
the same sensitivity as 7.
magnetic flux.
c. As the probe is rotated, the LED display
indicates higher field strengths. When the Part Numbers
display “maxes out,” push the zero-reset button
PART # DESCRIPTION
to bring the display back to the center position.
The zero reset should be made without 435591 MLM
movement of the probe. Zero reset normally 436334 Probe
takes place in five to 15 seconds. A slow 436335 Mount
flashing of the ‘ON’ LED indicates a zero has
been reached. Table 1
figure 1
Magnet Load Monitor: Series FS Microprocessor
3
figure 2

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518-AHA-Web ERIEZ MANUFACTURING CO ©2018 PRINTED IN USA

2 2
PIC PIC
CG CG
26-8 1 26-8 1
1 26-8 1 26-8
CG C CG
PI PIC
PIC PIC
CG CG
1 26-8 1 26-8
26-8 1 26-8 1
C CG C CG
PI PI
1 1
CG CG 2- 2-
2 2
CG CG
QT QT
P IC
P IC
P IC
P IC
QT QT 2 2
CG CG 2-
1 2-
1
CG CG
CG CG
CG CG
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Proyectos e Ingeniería SpA

EQUIPOS MAGNÉTICOS Los Pamperos 424, Recoleta
Fabricados en Chile bajo licencia de Código Postal 8441517
Casilla 70, Centro de Casillas
Santiago - Chile
 (56-2) 27709000
Fax (56-2) 26218811
polimin@polimin.com
ERIEZ MAGNETICS, USA www.polimin.com
LISTADO COMPLETO DE REPUESTOS RECOMENDADO
A) REPUESTOS PUESTA EN MARCHA (PEM) & y COMISIONAMIENTO
Nº Parte -
ÍTEM CANT DESCRIPCIÓN
POLIMIN
1 1 TRANSFORMADOR DE CONTROL POL-4785-0104
2 1 AUTOMÁTICO 3F POL-4785-0105
3 2 SENSOR INDUCTIVO POL-4785-0106
4 1 RELE DE CONTROL POL-4785-0107
5 1 RELE PROTECCIÓN TÉRMICA POL-4785-0113
B) REPUESTOS PARA 1 (AÑO) DE OPERACIÓN :
Nº Parte -
POLIMIN
1 1 MOTORREDUCTOR (TREN MOTRIZ) POL-4785-0101
2 1 RUEDA MOTRIZ (COMPLETA) POL-4785-0102
3 1 RUEDA CONDUCIDA (COMPLETA) – BOGIE MOTRIZ POL-4785-0103
4 1 TRANSFORM. DE CONTROL POL-4785-0104
7 2 RELE DE CONTROL POL-4785-0107
8 1 SELECTOR POL-4785-0108
9 2 PULSADOR POL-4785-0109
10 2 CONTACTOR POL-4785-0110
11 2 LUZ PILOTO, ROJA POL-4785-0111
12 2 LUZ PILOTO, VERDE POL-4785-0112
13 2 RELÉ DE PROTECCIÓN TÉRMICA POL-4785-0113
Proveedor : POLIMIN LTDA.
LR-4785-01/Rev0: Junio 13-2018 Página 2

Magnetic equipment The Pamperos 424, Recoleta
Manufactured under license in Chile Postal code 8441517 Box 70,
Center Casillas
Santiago, Chile
• (56-2) 27709000 Fax
(56-2) 26218811
polimin@polimin.com
ERIEZ Magnetics, USA www.polimin.com
COMPLETE LIST OF RECOMMENDED SPARES
A) SPARE START (PEM) and COMMISSIONING &
Part No.
ITEM DESCRIPTION QTY
POLIMIN
one one TRANSFORMER CONTROL POL-4785-0104
2 1 AUTOMATIC 3F POL-4785-0105
3 INDUCTIVE SENSOR 2 POL-4785-0106
4 1 CONTROL RELAY POL-4785-0107
5 THERMAL PROTECTION RELAY 1 POL-4785-0113
B) SPARE 1 (YEAR) OPERATING :
Part No.
ITEM DESCRIPTION QTY
POLIMIN
one 1 GEARMOTOR (POWERTRAIN) POL-4785-0101
2 1 Sprocket (FULL) POL-4785-0102
3 1 wheel (FULL) - BOGIE MOTRIZ POL-4785-0103
4 one TRANSFORM. OF CONTROL POL-4785-0104
5 one 3F AUTOMATIC POL-4785-0105
6 2 INDUCTIVE SENSOR POL-4785-0106
7 2 CONTROL RELAY POL-4785-0107
8 one SELECTOR POL-4785-0108
9 2 BUTTON POL-4785-0109
eleven 2 PILOT LIGHT, RED POL-4785-0111
12 2 PILOT LIGHT, GREEN POL-4785-0112
13 2 THERMAL PROTECTION RELAY POL-4785-0113
Supplier: POLIMIN LTDA.
LR-4785-01 / Rev0: June 13-2018 Page 2

Los Pamperos 424, Recoleta
Código Postal 6621361
Santiago - Chile
 (56-2) 27709000
Fax (56-2) 26218811
polimin@polimin.com
www.polimin.com
TyV CHILE LTDA.

OC Nº 16020000140
SPENCE – SGO, CHANCADOR PRIMARIO
MANUAL
INSTALACIÓN, OPERACIÓN Y MANTENCIÓN
P-4785-ME-MO-01
CARRO DE TRASLACIÓN
TROLLEY TROLLMAG MODELO C4-50, PARA SE 12067 MC-1

TAG
TAG 2110-MA-001-01
POLIMIN LTDA.
OT N° 4785
Rev. Por Emitido para Fecha Revisado por Aprobado por
0 S.P.C. INFORMACIÓN 22/10/2018 RAS/MPV/SPC CLIENTE

B S.P.C. APROBACIÓN 22/10/2018 RAS/MPV/SPC POLIMIN
A S.P.C. COORDINACIÓN INTERNA 02/08/2018 RAS/MPV/SPC POLIMIN
Comentarios del Cliente:
Santiago - Chile
 (56-2) 27709000
Fax (56-2) 26218811
polimin@polimin.com
www.polimin.com
CONTENIDO
SECCIÓN A............................................................................................................................................................................ 3
1. INTRODUCCIÓN........................................................................................................................................ 3
2. DESCRIPCIÓN DEL SISTEMA Y EQUIPO ............................................................................................ 4

2.1 DESCRIPCIÓN GENERAL DEL SISTEMA ....................................................................................................... 4
2.2 DESCRIPCIÓN DEL EQUIPO ............................................................................................................................. 5
2.3 DESCRIPCIÓN DE COMPONENTES................................................................................................................. 6
2.4 SISTEMA ELÉCTRICO .......................................................................................................................................10
2.5 SISTEMA DE CONTROL ...................................................................................................................................10
a) OPERACIÓN SISTEMA DE CONTROL...........................................................................................................11
b) SISTEMA DE SEGURIDAD ...............................................................................................................................11
2.6 EQUIPOS Y ELEMENTOS PERIFÉRICOS......................................................................................................12
a) EQUIPOS ELÉCTRICOS (Tableros eléctricos y de control) .................................................................12
b) SENSORES DE POSICIÓN .................................................................................................................................12
c) BALIZA / BOCINA ..............................................................................................................................................13
d) SOPORTE DE CABLES Y CABLES DE FUERZA Y DE CONTROL ............................................................13
e) SISTEMA DE IZAJE ............................................................................................................................................13
3. OPERACIÓN DEL EQUIPO ................................................................................................................... 14

3.1 PRECAUCIONES EN LA OPERACIÓN............................................................................................................14
3.2 DESCRIPCIÓN POSICIONES DE OPERACIÓN ............................................................................................14
3.3 OPERACIÓN TRABAJO .....................................................................................................................................16
3.4 OPERACIÓN DESCARGA / MANTENCIÓN ..................................................................................................16
4. MANTENIMIENTO E INSPECCIÓN .................................................................................................... 17

4.1 COMPONENTES ELÉCTRICOS........................................................................................................................17
4.2 COMPONENTES MECÁNICOS .........................................................................................................................17
5. INSTRUCCIONES DE MONTAJE ......................................................................................................... 18

5.1 TAREAS PREVIAS ..............................................................................................................................................18
5.2 PROCEDIMIENTO DE MONTAJE ...................................................................................................................18
6. INSTRUCCIONES DE ALMACENAMIENTO. ............................................................................. 22

SECCIÓN B..........................................................................................................................................................................23
SECCIÓN C ..........................................................................................................................................................................25
SECCIÓN D .........................................................................................................................................................................27
2
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SECCIÓN A
1. INTRODUCCIÓN
TyV Chile LTDA solicita a POLIMIN Ltda. el suministro de un carro de traslación, como parte de un
sistema de separación magnética de contaminantes ferrosos. El sistema de separación magnética se
compone por un electroimán de limpieza manual, modelo SE 12067 MC-1 y su correspondiente carro
de traslación, modelo TROLLMAG C4-50, suministro de POLIMIN.
Figura: Disposición conjunto Carro de Traslación y Electroimán en Planta.
3
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2. DESCRIPCIÓN DEL SISTEMA Y EQUIPO

2.1 DESCRIPCIÓN GENERAL DEL SISTEMA
El carro de traslación corresponde al modelo TROLLMAG C4-50, que se compone de una estructura
metálica base (chasis), que mediante un sistema de suspensión suministrado por el Cliente (grilletes,
conectores para cadenas, cadenas y tensores Jaw-Jaw), unen el carro de traslación al electroimán
(modelo SE 12067 MC-1). El carro de traslación se desplaza sobre vigas riel, para ser posicionado
sobre la polea de cabeza (posición de trabajo o carga) y sobre un cajón de recepción de chatarra
(posición de descarga o mantenimiento), donde al desenergizar el electroimán (desde el Tablero
Rectificador), éste desprende el material ferroso capturado, para posteriormente, mediante la
operación de traslación del carro, volver a su posición de trabajo (o carga).
En la figura N° 1, se presenta el emplazamiento en vista elevación, del conjunto carro de traslación y

electroimán de limpieza manual (modelo SE 12067 MC-1).
Figura N° 1.- Disposición general electroimán y carro de traslación.
NOTA 1: Las vigas riel, son suministradas por el cliente.

4
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2.2 DESCRIPCIÓN DEL EQUIPO
El equipo (carro de traslación) está compuesto por:

- Una estructura metálica (chasis).
- Cuatro Boguies.
- Sistema de alimentación y distribución eléctrica.
La descripción y características del carro de traslación se presentan a continuación:
GENERAL
Capacidad : 50 ton – Nominales
Puntos de Izaje :4
Equipo a Izar – mover : Electroimán modelo SE 12067 MC-1
DIMENSIONES
Largo total : 3.640 mm
Ancho total : 3.160 mm
Alto total (Aprox) : 933 mm
Trocha : 2.720 mm
Largo entre Boguies : 2.780 mm
Peso del conjunto : 6.400 kg
CONSTRUCCIÓN
Estructura principal : Ac. Carbono ASTM A-36.
Protección superficial esquema Epóxico.
Ruedas motrices : 4 c/u de un diámetro de 370 mm.
Ruedas conducidas : 12 c/u de un diámetro de 370 mm.
Reductores : 4 reductores marca SUMITOMO modelo BBB4.

4 motores eléctricos (c/u) : 2,2 Kw / 480 V / 3F / 50 Hz.
Potencia motor efectiva
a 1750 msnm : 2 Kw
DISTRIBUCIÓN ELÉCTRICA
Caja conexión motores : TB2
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En figura N°2, se muestran los componentes principales del carro de traslación:
Figura N° 2.- Detalle de componentes de carro de traslación.
2.3 DESCRIPCIÓN DE COMPONENTES
De acuerdo con lo señalado en el punto anterior, el carro de traslación integra cuatro elementos
principales, que son:
- Estructura base (Chasis)

- Sistema mecánico – incluye sistema motriz
- Sistema eléctrico de distribución de energía
- Equipos y elementos periféricos
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2.3.1 ESTRUCTURA BASE (CHASIS)

La estructura base del carro (chasis), está constituida por un armazón de elementos estructurales y
planchas de acero, todo en calidad ASTM A-36, unidades con soldadura continua de alta resistencia.
A continuación, en la figura N°3 se muestra el detalle del chasis.
Figura N° 3.- Detalle de Chasis de carro de traslación.
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2.3.2 SISTEMA MECÁNICO
El sistema mecánico del carro de traslación corresponde a los siguientes componentes:
- Sistema Motriz: compuesto por 4 boguies motrices.

- Tren Motriz: compuesto por motor eléctrico + reductor + eje motriz + piñón de ataque.
Los componentes mecánicos corresponden principalmente al sistema motriz, el que está compuesto
por 4 boguies motrices. Cada boguie motriz está compuesto por una (01) rueda motriz, tres (03) rueda
conducida (sin tracción). El tren motriz está compuesto por un motor eléctrico + reductor + eje motriz
+ piñón de ataque.
A continuación, en la figura N° 4, se presenta el detalle de la composición del boguie
Figura N°4.- Detalle Boguie.
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Ruedas Conducidas
Fabricadas en acero al carbono. Cuentan con rodamientos de bola rígidos protegidos por sellos, para
separar el lubricante de agente externos como: humedad ambiental, polvo en suspensión, partículas
metálicas, partículas minerales, etc. Además, cuentan con tratamiento de superficies apto para trabajo
a la intemperie.
Sistema Motriz
Compuesto por un tren motriz, que incluye un motor eléctrico + reductor + eje motriz + piñón de ataque
+ ruedas motrices.
Las ruedas son fabricadas en acero al carbono, con tratamiento de superficies apto para trabajo a la
intemperie, el que conecta en un extremo el motorreductor (sistema motriz) y en el otro la rueda motriz.
El tren motriz está compuesto por dos (4) motorreductores que, en conjunto, dan al carro de traslación
la tracción motriz. Estos se encuentran apernados a la estructura principal.
Placas de soporte
Corresponden a dos elementos estructurales, de los cuales uno soporta una rueda motriz junto al tren
motriz, y una conducida. El segundo elemento estructuras, soporta dos ruedas conducidas. Ambos
elementos estructurales (Placa de Soporte Rueda Motriz y Placa Soporte ruedas Motrices) se fijan a
la estructura (chasis), por medio de pernos y se separan mediante la misma estructura del chasis, para
disponer de una abertura fija que es definida por la viga riel.
Boguie
El boguie corresponde al conjunto compuesto por una unidad motriz + tres ruedas conducidas + dos
placas de soporte. En Figura N°4, aparece el boguie tipo, con sus partes y piezas principales.
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2.4 SISTEMA ELÉCTRICO
El sistema eléctrico está compuesto por:
• Un Tablero para conexión de motores TB2.

• Un Tablero de Traspaso TB1.
• Un Tablero de Fuerza y Control (TFC).
• Dos cajas de conexión de sensores (TB3-1 / TB3-2).
El tablero para conexión de motores TB2, alimenta eléctricamente los cuatro motores eléctricos del
carro de traslación y se conecta por medio de un cable de alimentación eléctrica, tipo plano, montado
sobre el sistema de electrificación Festoon, al Tablero de Traspaso TB1.
El Tablero de Traspaso TB1 debe ser conectado al Tablero de Fuerza y Control (TFC), físicamente
instalado, preferentemente, a un costado del Tablero Rectificador del Electroimán. El cableado de
interconexión eléctrica entre el Tablero TB1 y el Tablero TFC es alcance del cliente.
El Tablero de Fuerza y Control (TFC) contiene los circuitos de fuerza y control para la operación del
carro de traslación. Dicho Tablero de Fuerza y Control debe ser alimentado eléctricamente desde la
red del cliente. El cableado de fuerza (y opcionalmente el cableado de control) desde el punto de
alimentación dispuesto por el cliente y el Tablero TFC es alcance del cliente.
Las cajas de conexión de sensores (TB3-1 y TB3-2), conectan los sensores inductivos de posición al
Tablero de Traspaso TB1. El cableado de interconexión de señales eléctricas entre las cajas de
conexión de sensores y el Tablero TB1 es alcance del cliente. Ver plano eléctrico N° P-4785-E-08.
2.5 SISTEMA DE CONTROL
El sistema de control, asociado al carro de traslación del electroimán modelo SE 12067 MC-1, le
permite desplazarse entre dos posiciones, las cuales son:
- Posición de trabajo (o carga).

- Posición de descarga / mantenimiento.
Eléctricamente, se definen procedimientos internos de control en el Tablero TFC (lógica cableada),

para posicionar el carro en forma exacta y segura, en cada una de las posiciones definidas y descritas
anteriormente.
A continuación, se describen los principios de funcionamiento eléctricos y de control del carro.
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a) OPERACIÓN SISTEMA DE CONTROL
Principio de funcionamiento eléctrico del carro:
Al realizar la acción de traslación, el carro se desplaza con un movimiento continuo y constante a una
velocidad de 3 m/min desde la posición de trabajo hasta la posición de descarga y viceversa.
Para lograr detenerse en las posiciones descritas, el carro debe encontrarse con los sensores
inductivos de posición, ubicados en la viga riel (Plano N° P4785-G-002), en las dos posiciones definidas
para el proyecto.
Al detectar la placa sensora, montada sobre los boguies del carro, los sensores inductivos de posición
cierran el control del circuito eléctrico, produciendo la detención del carro.
Los sensores inductivos de posición se denominan:
- ZSL (A y B) : para detener el carro del electroimán en la posición de TRABAJO.

- ZSH (A y B) : para detener el carro del electroimán en la posición de
DESCARGA/MANTENCIÓN.
Cabe destacar el hecho de que en ambas posiciones definidas (Trabajo y Descarga) se tienen dos
sensores inductivos de posición para entregar redundancia al sistema y prever la situación en caso de
que uno de los dos sensores falle, operará la detención del carro de traslación.
El sistema de control del carro cuenta con un botón de “Parada de Emergencia”, el cual se encuentra
dispuesto en la puerta del Tablero de Fuerza y Control. La función del botón de parada de emergencia
es la interrupción del trabajo del carro de traslación del electroimán, además de seguro eléctrico.
Para activar la parada de emergencia, solo hay que pulsar el botón, consiguiendo con esto, la
detención del carro; para restablecer las funciones del carro, se debe girar el botón, en el sentido que
indica la cubierta de este y volver a poner en operación el sistema de traslación.
b) SISTEMA DE SEGURIDAD
En el carro de traslación, los sistemas de seguridad están diseñados para proteger, tanto al operador,
como a los equipos (carro de traslación y electroimán).
Por otra parte, en las vigas riel, por donde se desplaza el carro de traslación, existen topes mecánicos
de carrera, posicionados en ambos extremos de carrera (son placas de acero, con goma, ubicados en
ambos extremos del riel), que trabajan en caso de fallar los dos sensores inductivos (ZSL (A y B) y
ZSH (A y B)). Lo anterior, para evitar el descarrilamiento del carro.
Como se mencionó con anterioridad, los sensores inductivos, se encuentran dispuestos para detener
el carro en las dos posiciones definidas (trabajo y descarga). Una vez detenido el carro en una de las
dos posiciones definidas, es necesario presionar el botón de parada de emergencia, para evitar que
alguna pulsación de los botones de partida del carro ocurra, de manera accidental o involuntaria. Para
mover el carro nuevamente, es necesario desbloquear el botón de parada de emergencia y accionar
el carro hasta la posición deseada.
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2.6 EQUIPOS Y ELEMENTOS PERIFÉRICOS
Los equipos y componentes periféricos son los elementos y sistemas que se encuentran fuera del
equipo principal (carro de traslación), corresponden al sistema de alimentación eléctrica y de control
del carro, dispositivos de control y sistema de suspensión del electroimán.
Los componentes periféricos, se detallan a continuación:
a) EQUIPOS ELÉCTRICOS (Tableros eléctricos y de control)
Los equipos eléctricos corresponden al tablero de fuerza y control TFC y tablero de transferencia TB1.
El conexionado eléctrico de fuerza y control va desde el tablero de fuerza y control TFC, al tablero de
transferencia TB1, para luego alimentar el carro mediante un cable plano (El cable plano se soporta
sobre el sistema de riel “Festoon”).
- Tablero de Fuerza y Control TFC
Caja eléctrica montada en las cercanías del panel rectificador del electroimán, alimentado
eléctricamente por el cliente, así como señales de mando Remoto/Local y entrega energía a Tablero
de Traspaso TB1, recibiendo desde este último las señales correspondientes a estatus de motores
(funcionando y detenido) y sensores de posición.
En su puerta se ubican las Botoneras de acción manual Partir/Parar, posiciones de Trabajo y Descarga,
Parada de Emergencia.
- Tablero de Transferencia TB1
Caja eléctrica montada en una columna estructural (o soporte equivalente) cercano a Carro, recibe
energía desde Tablero de Fuerza y Control TFC y entrega energía a Tablero de Motores TB2, por
medio de Festoon (cable plano c/ enchufe) y suministra además energía eléctrica a: (4) Sensores de
Posición (2 por cada posición), recibiendo desde ellos las señales correspondientes, para entregarlas
al Tablero TFC.
b) SENSORES DE POSICIÓN
Sensores inductivos de Posición, dos para posición de Trabajo y dos para posición de Descarga. El
sistema de posicionamiento (Trabajo y Descarga) del carro de traslación, incluye cuatro sensores y
sus correspondientes cajas de conexión.
- Sensores de posición: Sensores de posición inductivos

- Cajas de conexiones: TB3-1 y TB3-2
- Cajas eléctricas se emplazan a un costado de cada sensor inductivo de posición y conectan
eléctricamente dichos Sensores.
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c) BALIZA / BOCINA
Se suministra baliza/bocina, para posicionar cerca del carro de traslación cerca del tablero de fuerza y
control y que permite visualizar y oír cuando el sistema se encuentra en movimiento de traslación hacia
la zona de trabajo o hacia la zona de descarga/mantenimiento.
d) SOPORTE DE CABLES Y CABLES DE FUERZA Y DE CONTROL
Los cables de interconexión entre el tablero de traspaso TB1 y el tablero de paso sobre el carro TB2,
corresponden a cables planos flexibles, y son soportados por un sistema móvil del tipo riel “FESTOON”.
Las características de este dispositivo y sus componentes principales se indican a continuación:
• Riel Festoon
• Soportes deslizante y fijo
• Ménsula de Suspensión
• Carro P/Cable WST 1F-85P, Metálico
• Carro Arrastre MTS 1F/85
• Brazo de Arrastre
• Cable plano 20 metros
e) SISTEMA DE IZAJE
El sistema de izaje, corresponde a un conjunto de elementos (maniobra) para levante. A continuación

y de acuerdo a lo detallado en plano N° P-4785-GA-D-001, se describen los componentes principales:
- Grillete G-2140 2”
- Tensor 2.1/2”X24” JAW JAW HG-228
- Conector para cadena GR 100 1” Modelo A-1337 LOK-A-LOY
- Cadena 28 eslabones GR 100 1”
- Cadena 9 eslabones GR 100 1”
Además de los puntos señalados anteriormente, se proveen 4 conjuntos de topes de carrera

mecánicos con topes de goma. Cada conjunto de topes de carrera posee dos unidades para ser
instalados en ambos extremos del alma de las vigas riel.
13
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3. OPERACIÓN DEL EQUIPO
A continuación, se describen los modos operacionales del equipo, los que incluyen una descripción de
secuencias de accionamientos en el Tablero de Fuerza y Control y las precauciones que deben
tomarse y mantenerse durante la operación del carro de traslación.
3.1 PRECAUCIONES EN LA OPERACIÓN
El hecho de estar familiarizado con el equipo hace que disminuya la posibilidad de lesionar a personar
o las instalaciones, o bien, se produzca una avería en el carro de traslación. Dicho equipo, está
diseñado solo para transportar un modelo de electroimán en particular y por ningún motivo debe ser
ocupado para transportar otro tipo de elementos o equipos y en ninguna circunstancia a personas.
Acciones que nunca se deben realizar
• Nunca se debe superar la carga nominal del equipo
• Nunca transportar personas, u otros elementos que no sea el electroimán
• Nunca utilizar el equipo si está en malas condiciones
• No modificar ninguna parte o sus componentes
• No pasar ni permanecer bajo el carro, en ninguna condición.
3.2 DESCRIPCIÓN POSICIONES DE OPERACIÓN
El carro de traslación ha sido diseñado para operar en dos posiciones normales definidas, estos
corresponden a la posición de trabajo (carga) y posición de descarga/mantenimiento.
La operación del carro de traslación se realiza manualmente desde el Tablero de Fuerza y Control
(TFC), el cual opera mediante las botoneras para accionamiento del carro y luces piloto que indican
los distintos estados del equipo.
A continuación, se detallan los elementos incorporados en la puerta del TFC y que permiten la
operación del carro de traslación:
- Luz piloto blanca que indica “Equipo Energizado”.

- Luz piloto verte que indica “Equipo Detenido”.
- Luz piloto roja que indica “Equipo Funcionando”.
- Luz piloto ámbar que indica “Falla Relé Térmico”.
- Botonera sin retención que permite “Arranque Local Trabajo”.
- Botonera sin retención que permite “Arranque Local Descarga/Mantención”.
- Botonera sin retención que permite “Prueba Sirena-Baliza”.
- Selector de dos posiciones que permite seleccionar “Modo Local / Modo Remoto”.
- Botón de parada de emergencia que detiene el carro de traslación.
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La lógica de operación del electroimán SE 12067 MC-1, define las posiciones y desplazamientos del
carro de traslación, las que, para este caso, se establecen en dos posiciones de operación, que
eléctricamente se definen a través de los sensores de posición inductivos, instalados en una de las
vigas riel. Los sensores mencionados, permiten fijar los puntos de operación de trabajo y
descarga/mantenimiento.
A continuación, se describen en detalle las posiciones del equipo.
Posición TRABAJO
La posición de trabajo del carro de traslación se define posicionando el electroimán sobre la polea de
cabeza de la correa transportadora, el electroimán queda a una distancia predeterminada por el cliente.
La posición está definida y asegurada por los sensores inductivos (ZSL (A y B)). Para esto se debe ver
la disposición mecánica, plano N° P-4785-GA-D-001.
Posición DESCARGA
La frecuencia de descarga del electroimán es definida por el operario, de forma visual, dependiendo
de la carga de fierros que electroimán haya atrapado, determinando si su cara magnética (cara donde
son capturados los fierros) está saturada de material ferroso, o de acuerdo a un criterio definido por la
operación de la planta.
La secuencia para ambas posiciones es la siguiente:
a. El electroimán energizado es desplazado, desde su posición de trabajo, hasta llegar sobre el

cajón de recepción de chatarra (posición de descarga), por medio del movimiento del carro de
traslación.
b. Al llegar a la posición de descarga, se procede a desenergizar el electroimán, el tiempo suficiente
para que los materiales ferrosos capturados, se desprendan sobre el cajón de recepción de
chatarra.
c. El electroimán desenergizado es desplazado, desde su posición de descarga, hasta la posición
de trabajo, por medio del carro de traslación. Una vez que llega a la posición de trabajo, se
energiza para nuevamente entrar en operación de trabajo (captura de material ferroso) y repetir
el ciclo.
d. La posición de descarga del carro de traslación está determinada por la posición del electroimán
sobre el cajón de recepción de chatarra. La posición es definida y asegurada por los sensores
inductivos ZSH (A y B). Ver disposición mecánica, plano N° P-4785-GA-D-001.
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SECUENCIA DE OPERACIÓN
El control eléctrico del carro de traslación ha sido ideado para un fácil y eficiente trabajo. Se ha
dispuesto solo de dos botones de control de movimiento, condicionados por los sensores inductivos
de posición y el botón de parada de emergencia.
Primero, se deberá tener la precaución de mantener el sistema energizado, esto se puede comprobar
mediante la visualización de la luz piloto blanca que indica “Equipo Energizado”, dispuesta en el
Tablero de Fuerza y Control (TFC).
A continuación, se describe paso a paso, las secuencias del accionamiento en el TFC, para la
operación del carro de traslación.
3.3 OPERACIÓN TRABAJO
- Comprobar la indicación de “Equipo Energizado”, indicada por la luz piloto blanca encendida.
- Pulsar la botonera “Arranque Local Carga”. El carro de traslación se moverá en forma constante
y uniforme hasta la posición de trabajo.
- Una vez que el carro de traslación se detenga en la posición de trabajo, pulsar el botón de
parada de emergencia por seguridad.
- Presionar la botonera “partir” (energizar), dispuesta en tablero rectificador del electroimán, para
energizar dicho equipo y comenzar a atrapar materiales ferrosos.
3.4 OPERACIÓN DESCARGA / MANTENCIÓN
- Comprobar la indicación de “Equipo Energizado”, indicada por la luz piloto blanca encendida.
- Liberar el botón de parada de emergencia, girándolo como indica su cubierta.
- Pulsar la botonera “Arranque Local Descarga/Mantenimiento”. El carro de traslación se moverá
en forma constante y uniforme hasta la posición de descarga.
- Una vez que el carro de traslación se detenga en la posición de descarga, pulsar el botón de
parada de emergencia por seguridad.
- Presionar la botonera “parar” (desenergizar), dispuesta en el tablero rectificador del
electroimán, para desenergizar dicho equipo y liberar los materiales ferrosos capturados sobre
el cajón de recepción de chatarra.
- Liberar el botón de parada de emergencia, girándolo como indica en su cubierta.
- Pulsar el botón de “Arranque Local Carga”, y repetir el ciclo.
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4. MANTENIMIENTO E INSPECCIÓN
Para un óptimo, prolongado y eficiente trabajo del equipo, se hace necesario una periódica y rigurosa
mantención e inspección de carácter preventivo de los puntos que continuación se detallan:
4.1 COMPONENTES ELÉCTRICOS
Se recomienda cada 700 horas de trabajo de planta, efectuar una inspección y reapriete de todos los
puntos de conexión eléctrica:
• Contactos de las protecciones eléctricas.

• Contactos de contactores de mando y auxiliares junto con relés térmicos.
• Contactos de borneras, presente en los todos los tableros eléctricos.
• Idealmente, soplar con aire seco, el interior de los tableros eléctricos.
Para efectuar el reapriete de los terminales de conexión eléctrica, se deberán destapar los tableros
eléctricos:
- Tablero de Fuerza y Control
- Tablero TB2
- Tablero TB1
- Cajas de conexión de sensores (TB3-1 y TB3-2).
El procedimiento para el reapriete de los terminales, consiste en desenergizar el Tablero de Fuerza y

Control, mediante un bloqueo en el alimentador de dicho tablero. El segundo paso es asegurar la
ausencia de tensión en los bornes de alimentación eléctrica, mediante un multímetro digital. Como
tercer paso y final, se pueden abrir los tableros eléctricos y proceder a la inspección y posterior
reapriete de los terminales de conexión eléctrica.
4.2 COMPONENTES MECÁNICOS
Debido a que el equipo se encuentra en zonas polvorientas, es importante la correcta lubricación en

los rodamientos de las ruedas de los boguies, la cual no debe exceder las 700 horas de trabajo o una
mantención anual si no se cumpliese la cantidad de horas primero. Como el equipo trabaja a baja
velocidad de rotación y la mayor parte del tiempo se encuentra en posición estática, se recomienda
utilizar grasas fabricadas con aceites minerales o sintéticos como base, en lo posible, con aditivos que
aumenten sus propiedades anticorrosivas, de esta manera, se contribuye a la impermeabilización
contra los contaminantes, la humedad y el agua.
Para efectuar cambios de rodamientos u otra pieza, se debe (previo desmontaje del electroimán y
posterior retiro del carro de traslación de las vigas riel) seguir los siguientes pasos:
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a. Para desarmar el sistema motriz (boguies), previo a la separación de las placas de las ruedas
motrices y ruedas conducidas, se debe retirar el motorreductor, luego la rueda motriz,
desmontar soporte enflanchado de motorreductor, retirar seguros Seeger que sostienen eje y
rodamientos en su lugar y finalmente rodamientos.
b. Para desmontar la rueda conducida, primero se debe retirar la tapa ciega y finalmente rueda
junto con rodamiento y tapa abierta posterior.
5. INSTRUCCIONES DE MONTAJE
5.1 TAREAS PREVIAS
Previo al montaje del equipo, se deberán realizar verificaciones geométricas de instalaciones en

terreno. En particular, se verificará nivelación y paralelismo de vigas riel, las cuales deberán estar
montadas cumpliendo las siguientes tolerancias:
- Paralelismo de vigas riel : 3 mm absolutos, como máxima desviación (trocha)

- Nivelación vigas riel : 3 mm absolutos, como máximo (Nivel)
- Verticalidad vigas riel : 0,4° absolutos, como giro máximo (Vertical)
En sección D, punto 1, aparecen las verificaciones previas al montaje que deberán cumplirse. En caso
de sobrepasar las tolerancias definidas, se deberá corregir el posicionamiento de vigas.
5.2 PROCEDIMIENTO DE MONTAJE

5.2.1 Montaje Mecánico.
Luego de realizar las verificaciones dimensionales según el punto anterior, se procederá a realizar el
montaje mecánico. A continuación, se presentan los pasos a seguir para el montaje del carro de
traslación en las vigas riel.
Montaje de carro de traslación sobre vigas riel:
- Izar el carro de traslación hasta posicionarlo en el extremo libre de las vigas riel.
- Ajustar, mediante las golillas de ajuste, la separación entre las placas de soporte de ruedas de
cada uno de los boguies.
- Deslizar el carro de traslación, a través de las vigas riel, hasta alcanzar la posición de trabajo
definida con anterioridad.
- Montar los topes de carrera mecánicos asociados a la posición de trabajo.
- Deslizar el carro de traslación hasta la posición de descarga/mantenimiento.
- Montar los topes de carrera mecánicos asociados a la posición de descarga/mantenimiento.
Nota: EL CARRO DE TRASLACIÓN SE DEBE MONTAR SIN LOS ELEMENTOS DE IZAJE DEL ELECTROIMÁN.
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Alternativamente y en caso de que no existan extremos libres en las vigas riel, es posible seguir el
siguiente procedimiento de montaje del carro de traslación:
- Separar los boguies (4) de la estructura chasis del carro de traslación.

- Montar los cuatro (4) boguies por separado, dos en cada viga riel.
- Para realizar el montaje de los boguies en las vigas riel, se debe ajustar la separación entre
placas de soporte de ruedas.
- Una vez ajustada la separación entre placas de soportes de ruedas de los cuatro (4) boguies,
se deberá izar la estructura chasis del carro de traslación.
- Posicionar la maniobra de izaje del chasis del carro de traslación, para fijar los cuatro (4)
boguies al chasis, utilizando el pasador ajustable.
- Montar los topes de carrera mecánicos (8 en total por carro de traslación), al extremo de los
rieles y posterior al montaje de las placas soporte de los sensores inductivos.
5.2.2 Montaje eléctrico.
El montaje eléctrico, se realizará sin energizar el tablero de fuerza y control TFC, de esta
manera todo el montaje eléctrico se realiza en ausencia de energía eléctrica. El procedimiento de
montaje es el siguiente:
- Posicionar el tablero de fuerza y control TFC a un costado del tablero rectificador del
electroimán.
Se recomienda montar el TFC, sobre una estructura de apoyo inferior, con la finalidad de
posicionar la puerta, a una altura aproximada de 0.8 m, desde su base al nivel de plataforma.
La fijación del tablero deberá realizarse mediante el uso de “orejas” de montaje disponibles o
utilizando elementos auxiliares, previamente aprobados por POLIMIN.
La acometida de cables de fuerza y control se debe realizar por la sección inferior del tablero
TFC, para lo cual se deben realizar las perforaciones correspondientes al tablero, en terreno.
El cableado, canalización y acometida de los cables de fuerza y control, deben realizarse de

acuerdo con la normativa eléctrica vigente y se deberá considerar el sellado de cada pasada
(perforación) de cables utilizando un sellante ignífugo.
- Posicionar tablero de traspaso TB1, en una columna en una posición cercana al

comienzo de las vigas riel.
Se recomienda montar el tablero TB1, en la columna estructural más cercana al punto terminal
de las vigas riel. La fijación del tablero deberá ser mediante elementos estructurales de soportes
y elementos auxiliares, apoyando el tablero sobre soportes UNISTRUT.
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La acometida de cables de fuerza y control se debe realizar por la sección inferior del tablero
TB1, para lo cual se deben realizar las perforaciones correspondientes al tablero, en terreno.
El cableado, canalización y acometida de los cables de fuerza y control, deben realizarse de

acuerdo con la normativa eléctrica vigente y se deberá considerar el sellado de cada pasada
(perforación) de cables utilizando un sellante ignífugo.
- Montar sistema de energización móvil (Riel Festoon).
Se montará el dispositivo de energización móvil desde el comienzo de la viga riel, hasta la

posición más alejada de este punto, que corresponde a la posición de trabajo del carro de
traslación.
Las consideraciones de montaje aparecen en las instrucciones del fabricante del dispositivo,
adjuntas en sección D del presente manual.
Finalmente, se procederá a montar el cable plano (que incluye los carros riel), sobre el riel guía
dejando libre sus dos extremos. En los extremos del cable plano se tiene un conector de pines
para ser conectado en el tablero TB1 y el otro extremo libre para ser conectado al tablero TB2
(montado sobre el carro).
- Sensores de posición
Para finalizar el montaje de componentes, se instalan los sensores inductivos de posición, los
cuales regulan la carrera del Carro de Traslación, los que serán instalados en terreno, acorde
al recorrido del electroimán en sus dos posiciones de operación definidas.
Para la instalación de los sensores de posición se deberá disponer del carro de traslación
montado y ubicado en la posición de trabajo y luego de limpieza.
Una vez ubicados los sensores de posición, se montarán las cajas de conexión asociadas a
dichos sensores (TB3-1 y TB3-2).
- Conexionado del sistema
Luego de haber instalado los tableros, ejecutado las canalizaciones y los cableados eléctricos,
se procederá a interconectar todos los equipos.
Para la interconexión se comenzará desde el tablero de fuerza y control (TFC), con el tablero
de traspaso (TB1); luego según lo indicado en punto anterior TB1 con TB2 y TB1 con caja de
conexión de sensores inductivos.
Finalizado el proceso de conexionado de fuerza y control, se proceden a realizar pruebas de

continuidad de extremo a extremo, en todos los tramos donde exista cableado de fuerza y
control.
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- Energización del sistema
Una vez que se realicen todas las conexiones eléctricas y de control del sistema y se realicen
los chequeos y protocolos mencionados en el punto anterior, se procederá a energizar el tablero
de Fuerza y Control (para esto debe realizarse la conexión del TFC con la alimentación
dispuesta por el cliente).
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6. INSTRUCCIONES DE ALMACENAMIENTO.
Para estos equipos, las instrucciones de almacenamiento son:
• Los embalajes deben ser protegidos contra lluvia y nieve. Siempre deben estar bajo techo.
• Instalar los bultos sobre superficies planas cubriendo toda su área, éstas pueden ser sobre
piso, loza, etc., garantizando la estabilidad.
• Los bultos no pueden estar montados uno sobre otro, ni montar nada sobre ellos.
• No voltear los bultos, mantenerlos en posición horizontal como indica la flecha ( )

Ver Figura 5.
Figura 5.- Bulto
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SECCIÓN B
LISTADO DE REPUESTOS PARA

CARROS DE TRASLACIÓN
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LISTADO COMPLETO DE REPUESTOS

(Referencia: Listado General de Partes, Figura N°4)
REPUESTOS PARA PUESTA EN MARCHA (PEM) & COMISIONAMIENTO
Nº PARTE
POLIMIN
1 1 TRANSFORMADOR DE CONTROL POL-4785-0104
4 2 RELAY CONTROL POL-4785-0107
REPUESTOS PARA UN AÑO DE OPERACIÓN
REPUESTOS MECÁNICOS
Nº PARTE
POLIMIN
1 1 MOTORREDUCTOR POL-4785-0101
RUEDA MOTRIZ COMPLETA (INCLUYE EJE, RODAMIENTOS,
2 1 POL-4785-0102
RETENES, ETC)
RUEDA CONDUCIDA COMPLETA (INCLUYE, EJE,
3 1 POL-4785-0103
RODAMIENTO, RETEN, TAPA, ETC.)
REPUESTOS ELÉCTRICOS
Nº PARTE
POLIMIN
4 1 TRANSFORM. DE CONTROL POL-4785-0104
7 2 RELAY CONTROL POL-4785-0107
8 1 SELECTOR POL-4785-0108
9 2 PULSADOR POL-4785-0109
11 2 LUZ PILOTO, ROJA POL-4785-0111
12 2 LUZ PILOTO, VERDE POL-4785-0112
13 2 RELAY PROTECCIÓN TÉRMICA POL-4785-0113
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SECCIÓN C
PLANOS DISPOSICIÓN GENERAL Y CONTROL

PLANOS CARRO MOTORIZADO
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LISTADO DE PLANOS CERTIFICADOS
TIPO Nº DOC. DESCRIPCIÓN

Plano
P-4785-GA-D-001 Conjunto Carro y Electroimán – Disposición General
Mecánico
Plano
P-4785-GA-D-002 Outline
Mecánico
Plano
P-4785-E-01 Diagrama Elemental de Fuerza y Control
Eléctrico
Plano
P-4785-E-02 Tablero Eléctrico TFC
Eléctrico
Plano
P-4785-E-03 Borneras de Tablero Eléctrico TFC
Eléctrico
Plano
P-4785-E-04 Tablero Eléctrico TB1
Eléctrico
Plano
P-4785-E-05 Borneras Tablero Eléctrico TB1
Eléctrico
Plano
P-4785-E-06 Tablero Eléctrico TB2
Eléctrico
Plano
P-4785-E-07 Localización de sensores en zona de trabajo
Eléctrico
Plano
P-4785-E-08 Caja de conexión TB3-1 y TB3-2
Eléctrico
Plano
P-4785-E-08 Diagrama en bloques de fuerza y control.
Eléctrico
26
2 2
2 2 2 2
PIC PIC
CG CG
26-8 1 26-8 1
1 26-8 1 26-8
CG C CG
PI PIC
PIC PIC
CG CG
1 26-8 1 26-8
26-8 1 26-8 1
C CG C CG
PI PI
2 2
CG CG
CG CG
QT QT
1 1
2- 2-
2 2
I
P IC
P C
P IC
P IC
QT QT 2 2
CG CG 2-
1 2-
1
CG CG
2 2
CG CG
CG CG
QT QT
QT QT
CG CG
CG CG

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SECCIÓN D
PROTOCOLO DE RECEPCIÓN CARRO TRASLACIÓN
PRUEBAS Y VERIFICACIONES
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CONTENIDO
I) Condiciones de montaje estructural
Paralelismo de vigas riel

Nivel de Vigas Riel
Verticalidad de Vigas Riel
Cuadro resumen de tolerancia
II) Condiciones eléctricas preoperacionales
III) Condiciones eléctricas operacionales
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I) Condiciones de montaje estructural en vigas riel
Las siguientes actividades están destinadas a orientar el proceso de instalación de los rieles
por donde se desplaza el carro de traslación para electroimán. Estas deben contar con la
asistencia de un topógrafo para garantizar su correcto montaje y posterior puesta en marcha.
a) Paralelismo vigas riel
Para el montaje de las vigas riel se debe verificar las distancias entre los puntos A1-B1, A2-B2,
A3-B3. La distancia entre ellos corresponde a 1300 mm, (según plano P-4785-GA-D-01), y la
tolerancia no debe ser mayor a 3 milímetros absolutos.
Figura N°6.- Verificación de Montaje.
b) Nivel vigas riel
Para el correcto funcionamiento del carro de traslación, es fundamental que la base de montaje
posea un desnivel entre caras (nivel C1 y C2) no mayor a 3 milímetros.
Figura N°7.- Alineación de Nivel Base.
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c) Verticalidad
Es importante considerar también el paralelismo entre ejes perpendiculares de las vigas riel, o
verticalidad de la viga riel. Para tal efecto se considera un ángulo de rotación máximo de 0.4°,
en dirección al exterior nunca en el otro sentido.
α α
Figura N°8.- Paralelismo de vigas riel.
Cuadro resumen de tolerancias
ENTRE TOLERANCIAS SE CUMPLE
A1 B1 +3 -3 SI NO
A2 B2 +3 -3 SI NO
A3 B3 +3 -3 SI NO
C1 C2 3 SI NO
α +0,4º - 0º SI NO
NOTA: Todas la dimensiones en milímetros.
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II) Condiciones eléctricas preoperacionales. (Pruebas estáticas)
*Estas se realizan durante y después del montaje
SI NO
a) Posición y fijación de tableros en área requerida. ____ ____
b) Medición de continuidad bornes de llegada, tablero TFC motor 1 ____ ____
c) Medición de continuidad bornes de llegada, tablero TFC motor 2 ____ ____
d) Medición de continuidad bornes de llegada, tablero TFC motor 3 ____ ____
e) Medición de continuidad bornes de llegada, tablero TFC motor 4 ____ ____
f) Posición y fijación de sensores inductivos ZSL (A y B) / ZSH (A y B) ____ ____
g) Medición de continuidad del cableado. ____ ____
h) Medición de tensiones suministradas entre fases (voltaje) ____ ____
i) Medición de tensiones en Transformador de Control (480/120) ____ ____
__________________ _________________
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polimin@polimin.com
www.polimin.com
III) Condiciones eléctricas operacionales. (Pruebas dinámicas)

SI NO
a) Verificación de estado de protecciones eléctricas en tablero TFC. ____ ____
b) Verificar condición de seguridad con botón de Parada de Emergencia activado. ____ ____
c) Verificar sentido de giro de los motores. ____ ____
d) Acercamiento y puesta a punto de sensores inductivos

ZSL (A y B) / ZSH (A y B) ____ ____
e) Accionar botón ARRANQUE LOCAL TRABAJO e interrumpir carrera para

verificación de parada de emergencia. ____ ____
f) Accionar botón ARRANQUE LOCAL DESCARGA / MANTENCIÓN y dejar

completar carrera para Verificación de trabajo sensor inductivo. ____ ____
g) Accionar botón ARRANQUE LOCAL TRABAJO y dejar completar carrera para

para verificación de trabajo de los sensores inductivos. ____ ____
h) Accionar botón ARRANQUE LOCAL DESCARGA / MANTENCIÓN y dejar

completar carrera para verificación de trabajo de los sensores inductivos. ____ ____
i) Repetir 2 veces operaciones de los puntos anteriores: e, f, g y h. ____ ____
j) Medir corrientes en las diferentes líneas de alimentación eléctrica para

verificación de un consumo simétrico entre fase 1, 2 y 3. ____ ____
__________________ _________________
Rut: 79.760.310-4
32

Certified For Construction OCT 16, 2018 Eriez Magnetics Erie Pennsylvania

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128 [3251]

VIEW THROUGH APERTURE

9.RECOMMEND IDLER SPACING 1200mm MINIMUM.

THE HEAD AND TAIL. 11.64 [296]

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

NOTES UNLESS OTHERWISE SPECIFIED BOLT OR WELD TO FRAME TITLE OUTLINE

DRAWING NUMBER REVISION

SPENCE GROWTH OPTIONS PROJECT INCHES [MILLIMETERS]

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

TITLE CONTROL CONNECTION DIAGRAM CCD

DRAWING NUMBER REVISION

SPENCE GROWTH OPTIONS PROJECT INCHES [MILLIMETERS]

1 1 ENCLOSURE - P/N 56055

2 1 GREEN LIGHT ASSEMBLY P/N 56066

3 1 ALARM LIGHT & HORN 115VAC - P/N 55008.11

4 1 ON/OFF SWITCH P/N 56069

5 1 RESET SWITCH P/N 56079

15 3/4 [400] 14 3/4 [375]

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

FOR CONSTRUCTION FOR

ERIEZ MAGNETICS SCALE NTS E.R. # PRIOR REF 3R-201310423

2110-ZM-005 DATE 4/21/2018

DRAWING NUMBER REVISION

VIEW THROUGH APERTURE

9.RECOMMEND IDLER SPACING 1200mm MINIMUM. 1 [25] T0 2 [51] 2110-ZM-005

TO ANTENNAS. REPLACE WITH NONMETALLIC STRUCTURE AS NEEDED. ERIEZ P/N:831970

ARC WELDING WITHIN 100 FT (30M). CLIP DETECTOR

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

SCALE NTS E.R. # PRIOR REF

DRAWING NUMBER REVISION

SPENCE GROWTH OPTIONS PROJECT INCHES [MILLIMETERS]

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

TITLE CONTROL CONNECTION DIAGRAM CCD

DRAWING NUMBER REVISION

SPENCE GROWTH OPTIONS PROJECT INCHES [MILLIMETERS]

3 16 Shoulder Washer - 0.806" ID (20.5mm) - Nylon

4 16 ISOLATION PAD, Fiberglass 4"X4"X1/4"

NYLON SHOULDER WASHER (BY ERIEZ)

4" X 4" FRP PAD

IDLER WASHER (EXISTING)

IDLER NUT (EXISTING)

electrically isolated from the conveyor frame.

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

FOR IDLER PULLEY ISOLATION W/ TAGGING

SCALE NTS E.R. # PRIOR REF 201507851

DRAWING NUMBER REVISION

1 2 SETS NON-METALLIC FLAG (SET OF 3) P/N 56036

2 30' CABLE, SO8, 18GA - NOT SHOWN - PN 10784

4 1 Gusset Plate, FDM Frame - PN 40050.4

5 4 Screw, Machine - Philips 1 4-20 X 12" - PN 11235

6 2 Bolt, 3/8-13 x 1.5" PN 10600

7 1 UPRIGHT - 2" FRP Souare tube - 46" Long - PN 40050.2

8 1 HORIZ. SUPPORT - 2" FRP Square tube X 33" - PN 40050.3

9 2 Bolt 3/8-13 x 3" - PN 10599

10 5 Bolt 3/8-13 x 1" - PN 10601

WORLD AUTHORITY IN ADVANCED TECHNOLOGY FOR MAGNETIC,

TITLE FLAG DROP MARKER

FOR 1235/1260 METAL DETECTORS W/ TAGGING

SCALE NA E.R. # PRIOR REF

DRAWING NUMBER REVISION

SPENCE GROWTH OPTIONS PROJECT INCHES [MILLIMETERS]

FOR BELT WIDTHS OF 90" OR LESS

1 1/16 [27] 1 1/16 [27]