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Thermo Scientific APEX Metal Detector User's Guide - Cole

1. ITEM NO QTY DESCRIPTION DWG NO SPEC 4 84 11 97 304 07 4X 8 260 6 5 123 00 5 88 149 40 4 a 6 66 169 18 z c ACCEPT i i O O 7 25 184 15 8 98 228 19 J 4 D 9 22 03 HE p 180 19 I D NW Y 2280 POWER SUPPLY INLET CONTROL amp POWER SUPPLY CROSS BLOCK d 2 75 69 85 RECTANGULAR PORT ACCEPT STREAM 4 38 111 34 WITH REJECT BIN 22 84 580 23 5 19 131 88 APEX 500 Rx PHARMACEUTICAL METAL DETECTOR ELECTRICAL SUPPLY 85 260 VOLT AC SINGLE PHASE 47 65Hz d i CONSTRUCTION STAINLESS STEEL 304 CS ABS PLASTIC CONTROL PANEL FDA APPROVED Y FINISH STRAIGHTLINE STANDARD HIGH POLISH OPTIONAL CABLE LENGTHS 2 3 4 5 6 8 10 12 15 20 25 30 METER 11 53
2. 156 Phase Angle Page 2 niai exea eo roc a ex Sex ed a ee o LA obras Ses 157 Selecting the Wet Product Noise Filter sss 157 Selecting the Phased Noise Reduction Filter 158 Selecting the Quadrature Noise Reduction 159 Frequency and Gain Page T aasie eere 160 Setting High or Low Frequengy me e messe ener eene 161 Setting High or Low Gain 00 cece cece mmm seen nemen etes 162 Inhibiting Detection uoo rie tir entend na Ert PUR xe iP nA RR REND XR 162 Frequency and Gain Page 2 163 Calibrating the Detect meme nnn 163 Changing the Detect eee menm 164 Setting Multi Zone Detection csse m ee esse nennen 165 Locking the Detect nemen sensns 166 Calibrating the X and R Noise 166 Changing the Noise Threshold for 167 Changing the Noise Threshold for R sess mme essen nenne 167 Thermo Scientific APEX User s Guide Page 5 System and Tools Page l 168 QUGIIEY TES
3. 236 Printer Ser Up Pade L ee Sad oko Es 238 Attaching a Printer to the mmm eme nen 238 Navigating to the Printer Set Up 239 Activating Che PRIN GER reise etes dedi tien 241 Manual lign 242 Naming Your Detector exer oboe 243 Naming Your Product 244 Printer Set Up Page 2 reddes Lope ode 245 Activating an End of Day Print Out mmm 245 Activating a Reject Print Out 0 ccc sense ee ee heme seen eene 246 Activating a Print Out on 247 Security EeVel ess presa DR eats aval bic E EN RE 249 Entering a Supervisor Password ssssssssssssssses emm eese nnn 250 Setting Engineer and Operator 253 Retrieving a Forgotten 253 Undoing the Need for 254 LOQOING ple ET 255 Logging c 256 Maintenance and Troubleshooting se e 259 Service Repair and Replacem
4. tate 332 Saving Your TEP IP Settings a eere ee 333 Changing DHCP to ON ag uk Ie SER eam cvi le inea 334 Configuring an meme nnm 335 Accessing the Communications eee teeta teeta teeta een ed 335 Changing the Slave 336 Changing the Baud 337 Changing the Parity rosne anan aen a teet ote ten adio et ena e avt an 338 Saving Your RTU Settings iesus ree reto Pe ERR Ure ER ae Rr 339 Configuring the Modbus Hardware 341 Configuring the TCP IP D RE POUR EE bb dE beds 342 Card Scliematle n iet Ere CUM EE ER ICD E RE AAEE 342 Installing the TCP IP 342 Setting the Configuration 5 mmm 343 Pin Assignments for the Ethernet RJ45 343 Understanding the Status LEDs 344 Configuring the RTU RS 485 345 Card SchemlatlC reet are e ian eddie o Qt edo et eA 345 installing the Card rodea e ed eet retta er euer
5. i ee 36 52 e To calibrate the speed filter for conveyor applications see page 50 e For gravity feed applications see page 72 e For pipeline applications see page 88 e For pharmaceutical applications see page 104 Speed Filter Frequency Shown below is a typical narrow band filter screen Your screen however may look different depending on the type of application you are running conveyor gravity feed pipeline or pharmaceutical Speed Filter Frequency Thermo Scientific APEX User s Guide Page 171 Product Speed Your screen may look different depending on the type of application you are running conveyor gravity feed pipeline or pharmaceutical To change product speed press the Go button and key in the new product speed Product Speed Speed Filter Factory Menu For more information about these filters please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Speed Filter Factory Settings 001 The speed filter factory menu gives qualified personnel access to the following application specific speed filter settings e One narrow band speed filter e Three preset wide band speed filters SF WB bands 1 2 and 3 which are typically used in pipeline and pharmaceutical applications e One customizable wide band speed filter SF
6. 7 Navigate to the frequency menu Low High Frequency 8 Make sure a checkmark is showing next to the high frequency icon which looks like this High frequency icon Note If the checkmark is next to the low frequency icon press the Go button to select the high frequency setting 9 Press the Back button repeatedly to save your settings exit the menu and return to the Main Menu Page 54 Thermo Scientific APEX User s Guide Doing Full Product Calibration Before doing a full product calibration it is best to set the frequency and gain settings to high as described in the section above To do a full product calibration follow the instructions below 1 Make sure that the conveyor is turned on and uncontaminated product is passing through the search head In the example below we are monitoring jars of spaghetti sauce 2 Highlight your product name in the Main Menu Your screen will look different if I XR is enabled Product Name 3 Press the Go button and page 1 of the product menu appears Product Calibrate and Name SPAGHETTI 981 continued Thermo Scientific APEX User s Guide Page 55 4 Press the right navigation button to highlight the Full Product Calibration menu Full Product Calibration SPAGHETTI agi The detector s auto calibration function as shown by the icons and check
7. 4 Navigate to the reject trigger function Suppression Reject Trigger PHH1 001 continued Thermo Scientific APEX User s Guide Page 131 5 Make sure the reject trigger function is highlighted and press the Go button The X changes to a check mark Suppression Reject Trigger Setting Suppression Time Reject 1 This function is normally used only in gravity feed and pipeline applications and allows you to prevent vibration from the gate that diverts contaminated product from interfering with the search head Suppression Time PHH1 81 Keying In a Value for the Suppression Time Function To enable the suppression time function do the following 1 From the Main Menu navigate to the rejects menu Reject Totals Poa 2 Press the Go button and page 1 of the rejects menu appears Reject 1 continued Page 132 Thermo Scientific APEX User s Guide 3 Press the down navigation button twice and page 3 of the rejects menu appears Reject Suppression 4 Navigate to the suppression time menu Suppression Time FAHI 001 5 Press the Go button and an input screen appears Key in the desired suppression time in seconds and hundredths of a second In our example we accepted the current suppression time of 3 00 seconds Suppression Time
8. Page 180 Thermo Scientific APEX User s Guide Setting Time or Distance Units To set time or distance units for your reject 1 and or reject 2 devices do the following 1 Make sure the reject settings menu is highlighted Reject Settings 2 Press the Go button and the following menu appears Reject Settings The top part of this menu is used to manage your reject 1 device and the bottom part to manage your reject 2 device The part on the right to is used when enabled to reject all packages when calibrating your reject 1 device as described in the following section In addition note that currently you and the detector are managing the durations of both reject devices reject 1 and reject 2 using time units as shown by the check mark beside the clock icons 3 Highlight the reject 1 menu or the reject 2 menu as appropriate to your situation In the screen below the reject 1 menu is highlighted Reject 1 Duration Time continued Thermo Scientific APEX User s Guide Page 181 4 Press the Go button and the check mark moves to the distance ruler icon Reject 1 Duration Distance 5 Press the Back button to exit the menu and save your distance preference for managing the reject 1 device The APEX will now use distance settings in all relevant reject 1 or if selected in step 3 above reject 2 menus Setting the Re
9. 186 5 6 e C m 187 System and Tools Page 4 eben Dae end E RACE 192 Selecting the Language for the Display Panel s Help Text 192 System and Tools Pate 5 crue xxr rerit b eh eh nx SER ER 193 Displaying Your Software 193 Displaying Your APEX Model 194 Displaying Your System Set Up Code 194 Displaying Your Product Set Up 195 Quality ern E v re EUR 196 Overview of How the Quality Test Function 197 Testing the Detector Using QA Test Samples 198 Setting the Time Interval Between QA 200 Setting the Time Window for Doing a QA 201 Setting the Reject Device Used for the QA 202 Doing a Manual QA 203 Setting Limits for Peak Signal and Phase
10. Page 66 Thermo Scientific APEX User s Guide 5 Press the Go button to save your setting 6 Press the Back button repeatedly to return to the Main Menu Setting the Reject Duration Time To set the reject duration time do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 01 001 2 Press the Go button page 1 of the rejects menu appears Reject 1 3 Navigate to the reject 1 duration menu shown below Reject 1 Duration PARI 001 continued Thermo Scientific APEX User s Guide Page 67 4 Press the Go button and the reject 1 duration input screen appears Reject 1 Duration Xx x Lo 5 Key in a value for the reject 1 duration parameter For a typical gravity feed application key in a value of 1 00 6 Press the Go button to save your setting 7 Press the Back button repeatedly to return to the Main Menu Page 68 Thermo Scientific APEX User s Guide Setting Contaminant Detection Parameters This section assumes you have followed all the instructions from the start of the Setting Up Gravity Feed Applications to this point The reason for this is that before you can calibrate your detector the parameters described above must already have been set This section tells you how to do the following e Set up a monitoring baseline for the detector
11. continued Thermo Scientific APEX User s Guide Page 183 4 Press the Go button and the X changed to a check mark Reset Counts on Product Change 5 Press the Back button repeatedly to return to the Main Menu The total reject count is now reset to zero In addition for conveyor applications the total product count is also reset to zero as shown below Reject Totals P881 661 A 30 00 LL 509 MAL Resetting Product Parameters to the Default Settings This function allows you to reset the product related parameters for a particular product In other words the product parameters for all other products remain unchanged Reset Product to Defaults Example Imagine you are a supervisor at a dairy where you test salted butter ice cream and milk for the presence of metallic contaminants You have been testing three products recently named SALTED BUTTER ICE CREAM and MILK and now want to reset the product parameters for MILK to the detector s defaults settings continued Page 184 Thermo Scientific APEX User s Guide 1 In the Main Menu make sure the product named MILK Product 003 is highlighted Notice in our example that the detect level is currently set to 25 and the phase angle to 2 Product Name 2 Navigate to the reset product parameters function and make sure it is highlighted 3 Press the Go button
12. ITEM JPART QTY DESCRIPTION DWG NO SPEC SEARCH HEAD 11 97 304 07 4X 8 260 6 5 6 66 169 18 5 5 D E 3 83 7 25 184 15 97 18 os Lees P 8 98 228 19 amp 92 05 epee 3 p 180 19 Jl POWER SUPPLY INLET mace Hier CONTROL amp POWER SUPPLY 2 75 69 85 4 38 111 34 22 84 580 23 5 19 131 88 Se i ES 2 11 53 292 97 ROUND PORT ACCEPT AND A c REJECT STREAM y 1 50 38 10 on t i or 0 Jo 2 37 60 12 ig O DIMENSIONS ARE IN INCHES WITH MILLIMETERS 8 00 203 20 r7 s E L 2 00 50 80 4 A PORT O D CADD DATABASE AUTOCAD DO NOT SCALE DWG scaLE f Nd fog eM TOLERANCE c DATE 2 25 10 02 00 50 80 NERAN Eeo 755 00 o DTI 0 erty of Thermo Fisher Scientific It may not be copied or reproduced Therme ed work information this work unless expressly authorized by Thermo Fisher Scientific r AIR INLET D 3 Thermo Fishe EM O SCIENTIFIC 3 OUTLINE amp MOUNTING CUSTOMER APEX 500 Rx EOCATION HEAD amp PNEUMATIC REJECT SHEET 2 OF 4 A 497 RELEASED 22510 RSRK _USER REV REV 569 DESCRIPTION DAT
13. The following WAFs are accessed from page 4 e Excessive number of consecutive rejects in a conveyor application Warnings Alarms amp Faults Using this menu you can key in values to warn you when a specified number of rejects occurs in a specified number of units of product passing through the search head Navigate to the relevant number in this menu press the Go button and an input screen appears Key in your new setting and press the Back button to save your setting and exit Thermo Scientific APEX User s Guide Page 219 Inputs and Outputs System and Tools Page 2 The inputs and outputs menu allows you to manage the detector s physical and logical inputs and outputs The detector s physical inputs and outputs are found on the detector s wiring board where there are six input connectors labeled Input 1 6 and six output connectors labeled Output 1 6 In contrast the detector s logical inputs and outputs are controlled using the detector s functions meaning you the user set what you want the detector s inputs and outputs to operate Let s look at an example In a conveyor application you have physically connected your main Reject 1 device to Output 1 on the detector s wiring board and the reject device operates whenever it receives a voltage signal You decide you want to move your Reject 1 device to Output 6 so you move the wires from Output 1 to Output 6 on the de
14. continued Page 176 Thermo Scientific APEX User s Guide 2 To set the correct time press the Go button and an input screen appears Time 24 hour format 3 Use the navigation buttons to key in the correct time using the 24 hour format keying in appropriate values for the hours minutes and seconds Currently the clock reads 13 hours 40 minutes and 24 seconds 4 Press the Go button to save your setting and exit the menu Setting the Correct Date 1 Follow the instructions above to navigate to the date function Date YYYY MM DD 13 52 52 continued Thermo Scientific APEX User s Guide Page 177 2 Press the Go button and an input screen appears Date YYYY MM DD 2888 82 28 3 Use the navigation buttons to key in the correct date Make sure you key in four digits for the year YYYY two digits for the number of the month MM and two digits for the day DD carefully following the convention of year month day In the example above we set the following date February 28 2008 If you are used to expressing dates using a different convention such as 28 February 2008 please be careful keying in these numbers 4 Press the Go button to save your setting and exit the menu Setting Metric or I mperial Units See page 22 Metric I mperial Units Page 178 Thermo Scientific APEX User s Guide System and Too
15. 2 Navigate to the pulse length function and make sure it is highlighted AuditCheck Pulse Length FAHI 01 3 Press the Go button an input screen appears AuditCheck Pulse Length 4 Key in your pulse length in milliseconds 5 Press the Go button to save your setting and exit the function Setting the AuditCheck Signal Time Out When the AuditCheck solenoid fires a time out commences during which the detector waits for the AuditCheck signal Thus the AuditCheck time out signal is the length of time it takes the shuttle to travel the length of the AuditCheck tube plus the speed filter delay However if the internally generated signal time out pulse for some reason does not give the exact result you want you can manually enter a value Page 212 Thermo Scientific APEX User s Guide How the Detector Calculates the AuditCheck Signal Time Out When the AuditCheck signal time out is set to zero the detector automatically calculates the value using the following formula 60 1 75 SHW 2 OD Product Speed Signal Time Out ms Filter Delay Where Search Head Width SHW is in mm Overhang Distance OD is in mm Filter Delay is in ms and Product Speed is in m min Keying In a Value for Signal Time Out To key in a value for the signal time out do the following 1 Navigate to page 4 of the AuditCheck menu AuditCheck Setup 1 get on
16. 07387 02 2 of 2 Derived From 2007 by Thermo Fisher Scientific NOTES Ps CABLES LONGER THAN 30M 98 4 FT AVAILABLE AS A SPECIAL ORDER UP TO 90M 295 FT A N STANDARD ISOLATOR FOOT LENGTH IS 25 4 1 00 AUDIT CHECK OPTIONAL DIMENSIONS SHEET 2 ISOLATOR FOOT N INSULATING BUSHING SUPPORT FRAME TYPICAL 512 7 50 THRU WASHER amp AVAILABLE CABLE LENGTHS METERS FEET 2 1 6 2 6 6 3 9 8 4 13 1 5 16 4 6 19 7 8 26 2 10 32 8 12 39 4 15 49 2 20 65 6 25 82 0 30 98 4 M10 SCREW TOLERANCE UNLESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 5 31 07 Th F h a ermoFisher DRAWN BY 5 31 07 S C E N T F ANGLES CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 5 31 07 SHARP EDGES 1423 RELEASED DG RLK 12 21 07 REV DESCRIPTION BY APP DATE This document is confidential and is the property of Thermo Fisher Scientific Thermo It may not be copied or reproduced in any manner without the expressed written consent of Thermo This document also is an unpublished work of Thermo Thermo intends to and is maintaining the work as confidential information Thermo also may seek to protect this work as an unpublished copyright In the event o
17. CONNECT THE WIRING AND AIR LINES AS 12VDC SHOWN AUDITCHECK NON INVERTED ONLY THE CORRECT WIRING AND AIR i CONNECTIONS WILL RESULT IN THE APEX RX OPERATING IN FAILSAFE MODE REJECT 1 INVERTED Oke N REJECT VERIFY 1 CONVERGENT MODE SENSOR NPN SINKING LIGHT OPERATE BANNER VS1ANSCV10 12VDC REJECT 1 INVERTED x Sem S9 Pel os 2 16AWG RS485 BIAS TERMINATION SWITCH S1 485RX TERMINATION 485RX TERMINATION 485RX BIAS 485RX BIAS TERMINAL NC1 IS THE NORMALLY CLOSED RELAY CONTACT OF RELAY ALL WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL TERMINALS NC2 NC3 NC4 NCS AND NC6 ARE ELECTRICAL CODE AND ALL LOCAL CODES COMMON CONNECTION POSITION 1 2 INVERT SELECTABLE JUMPERS POSITION 2 3 INVERT WIRE GAGE REQUIREMENTS MINIMUM WIRE SIZE A POWER AC 120 240V 16AWG JP2 RS232 OR RS485 POSITION 1 2 RS232 B SENSORS 22AWG SUPPLIED W SENSOR POSITION 2 3 RS4B5 C DIVERTER REJECT 18AWG RELAY PCBA J1 AND J2 CONTACT RATINGS BOND WIRE SHOWN FROM APEX CONTROL TO ISOLATED REJECT ASSEMBLY TOP COVER PLATE DO NOT SCALE DWG 10A 125VAC ANY SURES ANE RELAY J1 J2 OUTPUTS ARE FUSED 2 250V COOPER BUSSMANN PC TRON FUSE OR EQUIVALENT t c ANGLES 172 GJB 01 14 10 CUST ORDER NO SET OUTPUT 1 REJECT 1 AND OUTPUT 5 FAULT TO CUST ORDER FIELD WIRING DIAGRAM INV
18. 204 uadit p EPUM bI AS de sai qu Rae EE te Edad eiie yd 206 Performing an AuditCheck Te St 0 cece cece eee eee eter emen 207 Displaying the Average Phase 208 Displaying the Average Peak 208 Setting the Lock Values Function cc cece eect eee eee ee eee eee tennant ated 208 Setting Manual Start Timing Limits and Reject Device Parameters 209 Setting Limits for Peak Signal and Phase 210 Setting the AuditCheck Overhang 210 Setting the AuditCheck Pulse Length mn 211 Setting the AuditCheck Signal eee eee eet 212 Error Messages WAFS at ER Ae EX 214 Defining Warnings Alarms and Faults WAFS 214 WAFs Are Not Mutually Exclusive mmn 215 Setting a for a Particular mmm 215 Learning About Other WAFS nner ennemis nnne 217 Page 6 Thermo Scientific APEX User s Guide Inputs Outputs iacu Lass ens mere rien etaed 22
19. 485RX TERMINATION EE TERMINALS NC2 NC3 NC4 NCS AND NC6 ARE ee ae SWITCH 1 MUST BE OPEN AND SWITCH I I GND 12V NEUTRAL COMMON CONNECTION WHEN WHITE 485RX BIAS 2 MUST BE CLOSED WHEN THE REJECT TLl 6 JUMPER WIRE IS ADDED BETWEEN PSU J1 N CYLINDER IS IN THE ACCEPT STREAM b MN AND RELAY J2 NC6 POSITION NON REJECT B 45V L 4 SELECTABLE JUMPERS LX I DC JP1 CPU RX INVERT steer pe POSITION 1 2 INVERT REJECT VERIFY 1 SGL J GND POSITION 2 3 INVERT B NPN SKNG 7 HALL EFFECT NORMALLY OPEN COM __ 4 ly 4 2 RS232 OR RS485 SOLID STATE MUTUAE J POSITION 1 2 85232 SENSORS REJECT VERIFY 2 SGL Mj POSITION 2 3 5485 NPN SINKING SS 9 9 E e ee SS SS A NORMALLY OPEN ______ ________ 1 CADD DATABASE AUTOCAD DO NOT SCALE DWG SCALE NOTES Ev SURES ANE TOLERANCE 1 ALL WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL AN RELAY PCBA J1 AND J2 CONTACT RATINGS WHEN TOREB EINE Pat DE EU UNLESS SPECIFIED ELECTRICAL CODE AND ALL LOCAL CODES REQUIRED S 10A 125VAC i US ous 07 10 08 2 WIRE GAGE REQUIREMENTS MINIMUM WIRE SIZE AN RELAY PCBA J1 J2 OUTPUTS ARE FUSED AT 2AMP 250V A A POWER AC 120 240V 16AWG A COOPER BUSSMANN PC TRON FUSE OR EQUIVALENT B SENSORS 22AWG SUPPLIED W SENSOR USE SOLID STATE FET Q2 OU
20. OUTLINE AND MOUNTING SHARP EDGES SEE SHEET 1 FOR REVISION INFORMATION REV DESCRIPTION BY APP DATE This document is confidential and is the property of Thermo Fisher Scientific Thermo It may not be copied or reproduced in any manner without the expressed written consent of Thermo This document also is an unpublished work of Thermo Thermo intends to and is maintaining the work as confidential information Thermo also may seek to protect this work as an unpublished copyright In the PART NUMBER TBD PIPELINE SYSTEM CEILING MOUNT event of either inadvertent or deliberate publication Thermo intends to enforce it s rights to this work under the copyright laws as published work Those having access to this work may not copy use or disclose the information in this work unless expressly authorized by Thermo PROJECTION SCALE 1 8 SIZE DRAWING NUMBER REV 07387M B302 XX A SHEET 2 of 2 Derived From 2008 by Thermo Fi sher Scientific O FLOW FRL MOUNTING PLATE LINE HEIGHT CADD DATABASE AUTOCAD Aur d DO NOT SCALE RAUS SCALE in any way wi sd ia bread x written n sent o ot hen rere ace Scie ntific This t ed js is an un ubllahes REMOVE ALL BURRS Thermo Fisl cientific Thermo er Scientific intends to and is maintaining the work as c ial 30 00 762 UNNECESSARY SHARP ED
21. TTE SET 391 GlOSSAFTY S Contacting Thermo Fisher Scientific sss usada desk au nM WAKE 399 Supplemental I nformation cse esee nnne nnne 403 Thermo Scientific APEX User s Guide Page 9 10 Thermo Scientific APEX User s Guide Getting Started Congratulations on the purchase of your new Thermo Scientific APEX metal detector The first thing to do is unpack your detector and complete the electrical installation and application specific mechanical set up For instructions on how to do this go to page 283 Now that your APEX detector is properly installed you are ready and we hope eager to learn how to use it Here in outline is what you will learn in this section Setting Global and Application Specific Parameters Once the detector is installed and ready to check your products for the presence of metallic contaminants you will use the detector s control panel to set up various global and application specific parameters In this manual the term product refers to anything you are testing for the presence of metallic contaminants Whenever you encounter a technical term you do not understand in this manual please go to the Glossary on page 393 for a brief explanation Global parameters are ones that you pretty much set and forget because they define how you want the detector s display screen to appear what language and units feet or meters yo
22. 6 Press the Go button to save your setting and exit the menu Thermo Scientific APEX User s Guide Page 133 Setting Amplitude Suppression Reject 1 This function is normally used only in gravity feed and pipeline applications and is used in conjunction with the suppression time function described above The amplitude suppression function is used to tell the detector how much amplitude suppression to apply to the vibration signal affecting the search head This is important because vibrations generate a vibration signal in the search head and these may have the same characteristics as a contaminated product signal As a result the detector may interpret vibration as contamination Suppression Amplitude Keying In a Value for Amplitude Suppression To key in a value for amplitude suppression do the following 1 Follow steps 1 3 in the section above to get to page 3 of the rejects menu Reject Suppression 2 Navigate to the amplitude suppression function and make sure it is highlighted Suppression Amplitude FHH1 001 continued Page 134 Thermo Scientific APEX User s Guide 3 Press the Go button and an input screen appears Showing the default value of 100 Suppression Amplitude 4 Key in a value in percent for amplitude suppression Start at 95 and test the detector s response to the gate s vibration in your particular operati
23. 95 Setting Reject Paratrieters 22 Glands ves 97 Understanding Reject Delay and Reject Duration 97 Setting the Reject Delay TiMe 0 ccc cece cece eee eee nner nnne 98 Setting the Reject Duration mme 99 Setting Contaminant Detection 101 Establishing a Baseline with No Product 101 Choosing the Correct Speed Filter Settings for the 104 Establishing Basic Product 105 Set Up Check List for Pharmaceutical Applications 108 Parameters You Have Already Set Up 108 Additional Parameters You May Want to Set Up 109 APEX Menu LLL Main Menu Page X ERA PES RUE 111 PFOGUGEINAIMG ERR PAAR SEX In 111 0 5 china 111 Reject Totals eee nek dante Sle eee Ze IER EY 112 Detect 113 Phase Angle MeN ede cri det nade E
24. Page 106 Thermo Scientific APEX User s Guide 6 When the auto calibration function is finished the detector displays the Main Menu screen which should now look something like this Product Name Notice that in our example the auto calibration function has learned the following basic parameters for our uncontaminated product e Detect level 64 e Phase angle A 91 23 What the Main Menu Screen 15 Telling You The Main Menu screen is now telling you that once the detector is monitoring your product stream any contaminated product that exceeds the detect level of 64 will be rejected And because the phase angle is 91 23 degrees the detector is monitoring a dry product Thermo Scientific APEX User s Guide Page 107 Set Up Check List for Pharmaceutical Applications This section lists the parameters you have already set by following the instructions from the start of the Setting Up Pharmaceutical Applications section up to this point in the manual This section also lists additional parameters you may want to set up to get your particular pharmaceutical application running to your satisfaction Parameters You Have Already Set Up Listed below are the parameters you have already set up for a typical pharmaceutical application Product Parameters e Product name Reject Parameters e Reject delay time e Reject duration time Contaminant Detection Parameters Set by the Detector s Calibrate Fu
25. bit 10 AuditCheck failed bit 11 NVRAM battery low bit 12 Excess Rejects bit 13 Memory Corruption bits 14 31 reserved bit set if fault active 30035 n a n a RO bitmap Alarm Status Parameters are the same as Fault Status 30036 41047 16389 R W enum Product Speed Encoder 0 Disabled 1 Enabled Note A Speed Learn must be performed for encoder to provide valid speed This is done by enabling the encoder using the controls at the front panel 30037 41048 16390 R W float Product Speed 0 1 to 999 0 m min Note Speed Encoder must be disabled to change speed remotely 30039 41050 16391 R W float Speed Filter Speed 0 1 to 999 0 Hz Note If Speed Filter Ratio is Learned updating Product Speed will update Speed Filter 30041 41052 16392 R W float Phase Angle 45 00 to 135 00 degrees 30043 41054 16393 R W float Phase Tracking Limit 0 00 to 135 00 degrees 30045 41056 16394 10 R W float Phase Tracking Fault Limit 0 00 to 135 00 degrees 30047 41058 RINININ 16395 11 R W enum v o v Phase Tracking 0 Disabled 1 Enabled 30048 41059 16396 12 R W string ime Product Name 18 chars in length 30057 41068 m 16397 13 R W enum Detection Type 0 Amplitude
26. 1 Multi Zone Thermo Scientific APEX User s Guide Page 358 5 3 8 8 3 2 ya 9 2 n p E a g D g 9 9 97 gt 9 2 9 vy vy os o Jg u 2 2 t M 2 lt o od o 16 16 gt i Sa zc amp a 4 a ao 30058 41069 1 16398 14 R W enum P Detection Inhibited 0 Disabled 1 Enabled 30059 41070 1 16399 15 R W enum P Photo Registration Setting the Photo Registration will also reset the statistics 0 No Photo Eye 1 Leading Edge 2 Middle 3 Length 30060 41071 1 16400 16 R W unsigned short P Package Length 0 to 5 000 mm 30061 41072 1 16401 17 R W unsigned short P Package Gap 0 to 10096 30062 41073 1 16402 18 R W unsigned short P Detection No pack Distance 0 to 5 000 mm 30063 41074 1 16403 19 R W bitmap Rejecter Configuration Bit 0 Reject 1 0 Normal or 1 Latching Bit 1 Reject 1 0 Non inverted or 1 Inverted Bit 2 Reject 2 Contaminant Reject 30064 41075 1 16404 20 R W unsigned short P Rejecter 1 Delay 0 to 5 000 mm 30065 41076 1 16405 21 R W unsigned short P Rejecter 1 Duration Distance 0 to 20 000 mm 30066 41077 1 16406 22 R W unsigned short P Rejecter 1 Duration Time 0 to 9990 ms 30067 41078 1 16407 23 R W unsigned short P Reject Confirm 1 Time 0 to 9
27. 110 4 33 me 163 6 42 AUDIT CHECK OPTIONAL APEX 500 ONLY AX 32 1 26 C 50 1 97 4X M10X1 5 y 12 47 TOLERANCE UNLESS SPECIFIED ENGINEER DATE 2x25 98 ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 5 11 06 Th Fi h a ermorisner DRAWN BY DATE 2X 25 98 170 6 69 al X XX SD amp P KW 5 11 06 S C E N T F ANGLES CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 5 11 06 SHARP EDGES Te e e is EO SA arg is the property FERME Fisher PART NUMBER APEX 500 1 00 OUTLI N E amp MOU NTING Serie poime li may not be Copied eee Rd HE mes 810109 810107 APEX 500 GRAPHICS SHOWN may seek to protect this work as an unpublished copyright In the SEE SHEET 1 FOR REVISION INFORMATION tees ore wrk unde capi os SCALE sgg DRAWING NUMBER REV SHEET use or disclose the information in this work unless expressly REV ECO DESCRIPTION BY APP DATE MOON 1 5 B 07387M BOOI 2 of 3 Derived From 2006 by Thermo Fisher Scientific 63 2 49 191 7 53 SCIENTIFIC AX 28 1 11 4X 66 6 26 THRU Metal Detector i 284 11 18 7 24 1 97 Lo tt 284 11 18 Jl 2X 10 39 2X 304 11 97 TOLERANCE UNLESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 5 11
28. 2 Press the Go button and the following screen appears Pass QA Test packs in sequence 3 Pass your quality test samples through the search head 4 The detector will exit the menu when the test is complete Thermo Scientific APEX User s Guide Page 203 Setting Limits for Peak Signal and Phase Angle This function allows you to set limits for the peak signal and phase angle values during QA testing and when these test values exceed your prescribed limits have the detector provide a warning alarm or fault 1 Make sure page 2 of the quality test menu is highlighted QA Test Timers and Reject 2 Press the down navigation button and page 3 of the quality test menu appears QA Test Warning Alarm Fault FARI 81 The icons this screen as follows Icon Description Peak signal icon Phase angle icon Ei Warning icon i Alarm icon Fault icon For more information on warnings alarms and faults WAFs see page 214 Page 204 Thermo Scientific APEX User s Guide Keying In Limits for Peak Signal and Phase Angle Values This menu allows you to key in limits for the peak signal and phase angle values obtained when running the QA test Limits are set as percent change above or below the previous average test value The function allows you to have the detector give you a warning alarm or fault when these limits ar
29. Details of the release Revision A July 2006 Revision B January 2007 Revision C March 2007 Revision D July 2007 Revision E August 2008 Revision F February 2009 Revision G March 2009 October 2009 Revision H Revision J June 2010 1054 1322 1369 2077 2163 2205 2624 First release of documents and software version 1 0 0 Updated name to Thermo Fisher Scientific and APEX 500 New specifications and operating instructions added for APEX 500 Added specifications and operating instructions for APEX 100 Added information about using the APEX oscilloscope software Updated to include APEX 300 and gravity feed and pipeline applications Updated the entire manual to make it more user friendly Added Appendix A describing the optional Modbus Communications Card Made minor changes to APEX User s Guide Added Appendix B describing the IntelliTrack XR IXR option Added information about using the wide band speed filter in the Rx Page 318 Thermo Scientific APEX User s Guide Appendix A Modbus Communications Card Thermo Scientific APEX User s Guide Page 319 320 Thermo Scientific APEX User s Guide Overview The optional APEX Modbus Communications Card is a hardware add on that allows the APEX to communicate with your company s Ethernet intranet or other internal network The APEX Modbus Communications Card comes in two versions a
30. If the optional AuditCheck hardware is installed on your detector set up the AuditCheck function When the AuditCheck function is enabled the detector s performance is automatically tested at regular intervals without the need for operator intervention Thermo Scientific APEX User s Guide Page 261 Troubleshooting Guide When a fault is displayed in the detector s display panel this troubleshooting guide will help you identify what problem has occurred and how to correct it If the APEX detects a fault the red LED indicator on the control panel turns on and stays lighted In addition the display panel will show a fault message These are described in more detail below Search Head Faults Problem Solution The search head cable connection is broken Examine the cable connections at both ends to make sure all wires are connected correctly The search head balance is out of range This sometimes occurs when the APEX is moved Please have the APEX reinstalled by a Thermo Fisher Scientific technician Other search head problems Contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Battery Low Fault Problem Solution The battery powering the memory is becoming discharged when the main AC power to the detector is off Replace the battery and or control panel However if the main AC power i
31. Pack B 45 00 to 135 00 degrees 30116 n a 2 n a n a RO float P QAT Learned Phase Angle Pack C 45 00 to 135 00 degrees 30118 n a 1 n a n a RO unsigned short P QAT Learned Peak Pack A 0 to 65535 30119 n a 1 n a n a RO unsigned short P QAT Learned Peak Pack B 0 to 65535 30120 n a 1 n a n a RO unsigned short P QAT Learned Peak Pack C to 65535 30121 41103 1 16432 48 R W unsigned short P QAT Time Interval 0 to 999 minutes 30122 41104 1 16433 49 R W unsigned short P QAT Fault Timeout 0 to 99 minutes 30123 41105 1 16434 50 R W enum P QAT Reject Device 0 None 1 Rejecter 1 2 Rejecter 2 30124 41106 1 16435 51 R W unsigned short Peak Warning Tolerance 0 to 99 30125 41107 1 16436 52 R W unsigned short P QAT Peak Alarm Tolerance 0 to 99 30126 41108 1 16437 53 R W unsigned short P QAT Peak Fault Tolerance 0 to 99 30127 41109 1 16438 54 R W unsigned short P QAT Phase Warning Tolerance 0 to 99 degrees 30128 41110 1 16439 55 R W unsigned short P QAT Phase Alarm Tolerance 0 to 99 degrees 30129 41111 1 16440 56 R W unsigned short P QAT Phase Fault Tolerance 0 to 99 degrees 30130 41112 1 16441 57 R W unsigned short M Infeed Photo Eye Distance 0 to 5 000 mm 30131 41113 1 16442 58 R W unsigned short M AuditCheck Overhang Distance 0 to 5 000 mm 30132 41114 1 16443 59 R W bitmap M Reject Duration Default Type Bit 0 Reject 1 0 Time or 1 Distance Bit 1 Reject 2 0 Time or 1
32. SEE TABLE i 14 12 358 77 100 PEU ii PRODUCT CHhUTE OPTIONAL 61 25 0175 SEARC EAD PIVOT ARM CADD DATABASE AUTOCAD DO NOT SCALE DWG SCALE REMOVE ALL BURRS AND UNNECESSARY SHARP EDGES JOB Ne Gil sea seers inform ThermoFisher ioc ore SCENT LE EC E OUTLINE amp MOUNTING CUSTOMER APEX 500 Rx LOCATION HEAD amp PNEUMATIC REJECT USER SHEET 4 OF 4 DESCRIPTION D 07404m Bo06 5 Derived From 2010 Thermo Fisher Scientific 4 3 2 1 ITEM PART NO DESCRIPTION DWG NO SPEC APEX 10075007500 CONVEYOR PSU AND RELAY ASSEMBLY gt DU 24VDC OUTPUTS mois INPUT POWER INPUTS INPUTS RELAY OUTPUTS 4 c ci CA 85 TO 264 VAC 50 60 HZ 1 PHASE 100 VA DISCUNNECT AND WIRE OVERCURENT PROTECTION BY CUSTOMER WIRING SHOWN SUPPLIES LINE VOLTAGE TO THE OUTPUT RELAYS NOTE CONTACT THERMO ELECTRON WHEN WISHING TO USE THESE DUTPUTS NPN OPEN COLLECTOR SINKING TRANSISTOR CARE MUST BE O PHS Pii Bud PiN DiN TAKEN WHEN USING THEM BLK 18AWG EE 11 TO PSU J1 L WHT_18AWG PRODUCT PHOTOEYE 12V BRN PHOTO EYE SGL BLK H COM BLU 1
33. do the following to change the detector s display to a graphical format 1 Make sure the Main Menu is displayed Product Name continued Thermo Scientific APEX User s Guide Page 389 2 Navigate to the system and tools menu System and Tools 3 Press the Go button and navigate to the Bargraph and Help Setup menu Bargraph and Help Setup CE 4 Press the Go button and the Toggle Help Text screen appears Toggle Help Text ON OFF mmmn amp 1 m ui ENNEN NENNEN 2 mmm i 5 Press the Go button and the heading text changes to dual bar graph The top part of the graph displays detect level data for the X channel and the lower part of the graph for the R channel as shown below Please note that the scales of the X and R channels may not be identical ttt Rt X channel 390 Thermo Scientific APEX User s Guide 6 Press the Back button repeatedly to return to the Main Menu allowing you to view IXR data in a graphical as well as numeric format Troubleshooting If any pop up information boxes shown below appear while you are setting up the I XR function here are the causes and suggested solutions All information boxes are marked with the following symbol e Please note that when the heading text display is active as opposed to the
34. gt i Sa zc amp a 4 a a a 30162 41140 1 16460 76 R W signed short M Output Relay 1 Specifies function assigned to output If value is negative the output is inverted 0 Disabled 1 Reject 1 2 Reject 2 3 AuditCheck 4 QAT 5 Warning 6 Alarm 7 Fault 30163 41141 1 16461 77 R W signed short M Output Relay 2 Same as for Output Relay 1 30164 41142 1 16462 78 R W signed short M Output Relay 3 Same as for Output Relay 1 30165 41143 1 16463 79 R W signed short M Output Relay 4 Same as for Output Relay 1 30166 41144 1 16464 80 R W signed short M Output Relay 5 Same as for Output Relay 1 30167 41145 1 16465 81 R W signed short M Output Relay 6 Same as for Output Relay 1 30168 41146 1 n a n a RO bitmap IXR Active Type Bits 0 1 IXR Type 0 X Only 1 R Only 2 Bit 2 PSC Enabled 0 Disabled 1 Enabled 30169 41147 1 16467 83 R W unsigned short P R Detect Level 0 65535 30170 n a 1 n a n a RO unsigned short M R Current Peak 0 65535 30171 n a 1 n a n a RO unsigned short P R Capture Delay Time From Opto Break Until IXR Signal starts Value 4 time in ms 30172 n a 1 n a n a RO unsigned short P R Capture Length Time From Opto Break Until IXR Signal starts Value 4 time in ms 30173 41148 1 16468 84 R W unsigned short P X Detect Level 0 65535 30174 n a 1 n a n a RO unsigned short M X Current Peak 0 65535 30175 n a 1 n
35. 1 00s 1 9 2 005 2 Navigate to the signal time out function and make sure it is highlighted AuditCheck Signal Timeout FAHI 01 3 Press the Go button and an input screen appears AuditCheck Signal Timeout 4 Key in your signal time out in milliseconds 5 Press the Go button to save your setting and exit the function Thermo Scientific APEX User s Guide Page 213 Error Messages WAFs System and Tools Page 1 The detector has three types of error messages a warning an alarm and a fault WAF Warnings are the least serious alarms are more serious and faults are the most serious type of error message To be notified when a warning alarm or fault occurs you must hardwire one or more external error notification devices lamp buzzer siren and so on to the detector s wiring board Warnings Alarms amp Faults Erri Error notification devices are normally connected to detector s wiring board using the following default outputs For more information see page 290 e Warning device Output 4 e Alarm device Output 5 e Fault device Output 6 For more information about assigning the detector s outputs see page 232 Defining Warnings Alarms and Faults WAFs 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and page 1 of the systems and tools menu
36. 16 16 384 5 16 1 280 6 x 16 96 7 16 7 Total 19 088 743 This clearly is an unrealistically high total reject count but illustrates how register values are used to assign a numeric value for the total number of rejects Resetting Statistics To reset the following APEX statistics set parameter change coil 16386 to one 1 This resets the following APEX statistics and the appropriate Modbus registers listed below to zero 0 e Total reject count e Quality Assurance Test count e AuditCheck count e Total pack count Resetting Peak Values To reset the APEX peak values set parameter change coil 16388 to one 1 This resets the current peak value to zero 0 Backing Up Critical APEX Settings Backing up critical APEX data is important because it provides insurance against catastrophic system failures Backing up your data does not take up a lot of space The amount of disk space needed to back up a single product for example is only 808 bytes as shown in the table below NVRAM allocation Space used bytes DSP configuration 96 HMI configuration 388 Single product configuration 324 Total 808 See glossary for explanation of acronyms Thermo Scientific APEX User s Guide Page 355 In addition backing up subsequent products after the first product has been backed up only uses 324 additional bytes because all of the detector s global parameters such as model type lang
37. 5 19 131 88 Se i EQ 11 82 300 25 ROUND PORI ACCEPI STREAM 9 78 248 55 A A WITH REJECT BIN A H 2 d i 1 50 38 10 QJ i 0 0 0 S e me 2 37 60 12 i O DIMENSIONS ARE IN INCHES WITH MILLIMETERS i SZ 8 00 203 20 5 ee CADD DATABASE AUTOCAD 9 Ln DO NOT SCALE DWG TII CENTIES v uS M BEES SS oes N O information in this work unless expressly authorized by Thermo Fisher 9 AIR INLET ThermoFisher REJECT gt nee SCIENTIFIC COLLECTION BIN OUTLINE amp MOUNTING CUSTOMER APEX 500 Rx EOCATION HEAD amp PNEUMATIC REJECT SHEET 3 OF 4 2497 RELEASED 2 25 10 L USER REV REV E99 micro DESCRIPTION DATE ee D 07404m B006 A 8 7 6 5 4 3 Derived From 007404 003 2010 Thermo Fisher Scientific 1 ITEM JPART NO QTY DESCRIPTION DWG NO SPEC 6 29 159 74 5 04 128 00 1 0 Jd APERTURE SIZES CHUTE ID WIDTH HEIGHT 100mm WIDE X 25mm HIG 3 38 85 9 61 15 5 100mm WIDE X 35mm HIG 3 38 85 9 X a 25 4 Tm 3 88 98 55 100mm WIDE X 50mm HIG 3 38 85 9 X 59 40 4 250 00 pa 435 48 650 165 10 E LY LL 9 75 247 65 Aum UE
38. 5 crs Eo L peee QA TEST LAMP RS485 BIAS TERMINATION SWITCH S1 485RX TERMINATION 485RX TERMINATION 485RX BIAS 485RX BIAS SELECTABLE JUMPERS JP1 CPU RX INVERT POSITION 1 2 INVERT POSITION 2 3 INVERT JP2 RS232 OR RS485 POSITION 1 2 RS232 POSITION 2 3 5485 CADD DATABASE AUTOCAD DO NOT SCALE DWG UNNECESSARY SHARP EDGES ANGLES 1 NEXT ASS Y CUST ORDER NO FIELD WIRING DIAGRAM CUSTOMER APEX 100 300 500 METAL DETECTOR o7 02 os 5 6 LOCATION CONVEYOR 07 10 08 635 627 058 676 _USER wooo o e ____ D07387m w001 c 1 2006 by Thermo Fisher Scientific ITEM PART NO DESCRIPTION DWG NO SPEC F INPUT POWER 12VDC OUTPUTS INPUTS INPUTS RELAY OUTPUTS RELAY OUTPUTS RS232 RS485 E SERIAL PRINTER E RS 232 INTERFACE 85 TO 264 VAC 50 60 HZ 1 PHASE E 9 PIN D CONNECTOR 100 VA DISCONNECT AND WIRE OVERCURENT PROTECTION TO THE OUTPUT RELAYS E85 mw 12VDC p REJECT 2 TO PSU J1 L TO PSU J1 N 18AWG 2 o Y o QA TEST LAMP REJECT VERIFY 1 1 SGL NOTE DRY CONTACT LIMIT SWITCH NORMALLY OPEN i DRY CONTACT Ber 1 m TERMINAL NC1 IS THE NORMALLY CLOSED A SENSORS a ma E Weeds RELAY CONTACT OF RELAY RLI RS485 BIAS TERMINATION SWITCH S1 DRY CONTACT NORMALLY OPEN eS
39. Applications This section lists the parameters you have already set by following the instructions from the start of the Setting Up Conveyor Applications section up to this point in the manual This section also lists additional parameters you may want to set up to get your particular conveyor application running to your satisfaction Parameters You Have Already Set Up Listed below are the parameters you have already set up for a typical conveyor application Product Parameters e Product name e Pack length e No pack distance e Pack gap Conveyor and Photo Eye Parameters e Conveyor belt speed e Photo eye to detector distance e Polarity of the photo eye input e Photo registration for product rejects Reject Parameters e Distance to the reject device e Signal duration for the reject device Contaminant Detection Parameters Set by the Detector s Calibrate Functions e X and R noise thresholds e Speed filter setting e Detect level e Phase angle setting Thermo Scientific APEX User s Guide Page 61 Additional Parameters You May Want to Set Up Listed below are additional parameters you may want to set up to get your particular conveyor application running to your satisfaction Belt Speed Encoder Function If your conveyor has a speed encoder this function allows the conveyor speed parameter to be set automatically For more details see page 124 Bin Full Notification If your reject bin is monitored by a photo eye th
40. B 1338 ADDED APEX 100 1 31 07 810109 810107 500 GRAPHICS SHOWN A 1054 RELEASED DG DG 8 16 06 pu udi i SCALE size DRAWING NUMBER REV SHEET REV ECO DESCRIPTION BY app DAE mm M OUR 1 4 B 07387M B001 C Fs Derived From 2006 by Thermo Fisher Scientific 4 3 2 HEAD WIDTH TABLE r 220 8 66 75 2 95 a T C FROM TABLE l 75 295 MANET C APERTURE i DIMENSION HEAD WIDTH 110 4 33 oRD mm INCH mm INC APEX500 APEX 100 135 5 31 FOR Thame 5 900 50 1 97 295 11 61 295 11 61 PESO T SEN 75 2 95 295 11 61 295 11 61 i 100 3 94 295 11 61 295 11 61 125 4 92 295 11 61 295 11 61 150 5 91 330 12 99 295 11 61 APERTURE HEIGHT gee hag 175 6 89 330 12 99 295 11 61 200 7 87 380 14 96 295 11 61 250 9 84 380 14 96 330 12 99 300 11 81 380 14 96 330 12 99 350 13 78 480 18 90 380 14 96 400 15 75 480 18 90 380 14 96 110 4 33 a er 450 17 72 480 18 90 380 14 96 Le 500 19 69 680 26 77 480 18 90 550 21 65 680 26 77 480 18 90 600 23 62 680 26 77 480 18 90 4X 12 47 110 4 33 He APERTURE WIDTH
41. Detection no Pack distance P881 901 Thermo Scientific APEX User s Guide Page 117 Rejects Menu Page 1 1 From the Main Menu navigate the rejects menu Reject Totals 2 Press the Go button and page 1 of the rejects menu appears Reject 1 Distance and Duration 001 s A A m BIB EP B8 388m m s Resetting the Counts for Reject 1 The appearance of the reject counts menu depends on whether you are using a photo eye PE to control the reject process As a general rule conveyor applications use photo eyes to control the reject process PE enabled but gravity feed pipeline and pharmaceutical applications do not PE disabled Please refer to the appropriated section listed below Resetting the Counts with the PE Enabled See page 119 This function is used only in conveyor applications with a product photo eye Reject Counts Reset nv 001 8 8 gt 6 8 Eto 388m ms Page 118 Thermo Scientific APEX User s Guide Resetting the Counts with the PE Disabled This function allows you to reset the current reject count to zero Note When you reset the reject count in this menu the reject count in the Main Menu is also reset to zero Reject Counts Reset FAHI 001 1 Make sure the reset menu is highlighted 2 Press the Go button and the counts are reset Setting the Distance to the Reject 1 Device See page
42. The flashing asterisk tells you the slave address has been changed Slave Address mm SLRVE ADDR BAUD RATE 9688 PARITY 5 If you are finished go to the Saving Your RTU Settings section this is important Or continue the set up as described below Page 336 Thermo Scientific APEX User s Guide Changing the Baud Rate You can set the following baud rates 1200 2400 4800 9600 19200 38400 or 57600 bits second To change the baud rate do the following 1 Make sure the baud rate function is highlighted Baud Rate SLAVE ADDR p BAUD RATE 3688 PARITY 2 Press the Go button repeatedly to scroll through the options for baud rate and highlight the one you want We selected 57600 3 Press the Back button to return to the RTU configuration screen The flashing asterisk tells you the baud rate has been changed Modbus RTU Configuration SLAVE ADDR BAUD RATE 576868 PARITY 4 If you are finished go to the Saving Your RTU Settings section this is important Or continue the set up as described below Thermo Scientific APEX User s Guide Page 337 Changing the Parity To change the parity do the following 1 Make sure the parity function is highlighted Parity SAVE SLAVE ADDR BAUD RATE 57688 PARITY 2 Press
43. To set the reject duration time do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 2 Press the Go button and page 1 of the rejects menu appears Reject 1 3 Navigate to the reject 1 duration menu shown below Reject 1 Duration PHA 1 001 continued Thermo Scientific APEX User s Guide Page 99 4 Press the Go button and the reject 1 duration input screen appears Reject 1 Duration Bl ch 4 BB 15s is l LEL x 5 Key in a value for the reject 1 duration parameter For a typical pharmaceutical application key in a value of 0 50 6 Press the Go button to save your setting 7 Press the Back button repeatedly to return to the Main Menu Page 100 Thermo Scientific APEX User s Guide Setting Contaminant Detection Parameters This section assumes you have followed all the instructions from the start of the Setting Up Pharmaceutical Applications to this point The reason for this is that before you can calibrate your detector the parameters described above must already have been set This section tells you how to do the following e Set up a monitoring baseline for the detector by calibrating the X and R noise thresholds which must be done when no product is present in the chute e Select the appropriate value for the speed filter e Establish basic product parameters detect le
44. details Page 96 Thermo Scientific APEX User s Guide Setting Reject Parameters This section tells you how to set reject parameters for a typical pharmaceutical application Reject Totals 386 66 Understanding Reject Delay and Reject Duration Timing In a pharmaceutical application the detector s search head surrounds a chute where product is falling vertically under the influence of gravity When the search head detects metallic contaminants in the product the product continues down the chute and is diverted into a secondary bin by a reject gate The gate stays closed for a set period of time usually about 0 50 seconds to divert the contaminated product then opens again to allow uncontaminated product to again flow freely Thus for the reject process to work properly two critical time parameters must be set e Reject Delay Time In most pharmaceutical applications where the gate is located close to the search head the reject delay time is usually set to 0 00 seconds Thus when the search head detects contaminants the gate closes immediately However in applications where the gate is located some way from the search head a time delay is needed because the product takes a finite time to move from the search head to the vicinity of the gate Clearly the reject delay time should be set to make sure that the gate closes before the contaminated product actually reaches the gate Reject delay times when
45. however that the photo registration function cannot be used with a reject 2 device 1 From the Main Menu navigate to the rejects menu Reject Totals P8681 661 2 Press the Go button and page 1 of the rejects menu appears Reject P881 801 Gr 29 8 8 0 0 E ag EDT ES 1 6 fma 1 50s jap x 3 Navigate to page 5 Reject 2 Distance and Duration Lc 881 EM 8 388 mes om X Thermo Scientific APEX User s Guide Page 141 Keying In the Distance to the Reject 2 Device There are two parts to this menu as shown below Part 1 Keying In the Distance or Delay This is set up in exactly the same way as the reject 1 device See page 44 Reject 2 Distance Delay P881 001 B E cm xX Part 2 Setting the Units of Measure This is set up in exactly the same way as the reject 1 device See the small screen shot at the top of page 45 and the text at the bottom of page 44 Reject 2 Distance Delay Units PB81 661 Gites c 2E OSes 551890 2 S 2X mmx Keying In the Signal Duration for the Reject 2 Device This is set up in exactly the same way as the reject 1 device See page 46 Reject 2 Duration P881 t 9 505 142 Thermo Scientific APEX User s Guide Assigning Tasks to the Reject 2 Device This function makes your reject 2 device responsible for the fol
46. will be rejected In summary by keying in values for the detect level you can fine tune which products are rejected For example if the contaminant signal is strong and the background noise varies widely during the working day in your particular operating environment you may see a number of false rejects You could remedy this situation by keying in a larger value for the detect level for example 100 Setting the Detect Level The detect level can be set using the detector s auto calibration function or by keying in a value e f you want the auto calibration function to set the detect level see page 55 conveyor page 73 gravity feed page 90 pipeline or page 105 Rx e f you want to key in a value for the detect level make sure the detect level function is highlighted as shown above Press the Go button and an input screen appears Key in a value for detect level Press the Back button to save your setting and exit the menu Phase Angle Menu See page 150 Phase Angle Thermo Scientific APEX User s Guide Page 113 Peak Signal The peak signal function is a display function meaning there are no parameters you can set for it In other words the peak signal function acts purely as a gauge and displays the highest signal seen by the search head since this function was last reset In our example the peak signal reading is 3 and is the highest signal produced by a series of contaminated products th
47. 06 Th F h ermoFisher DRAWN BY SD amp P KW 5 11 06 S C E N T F ANGLES CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 5 11 06 SHARP EDGES SEE SHEET 1 FOR REVISION INFORMATION REV DESCRIPTION BY APP DATE This document is confidential and is the property of Thermo Fisher Scientific Thermo It may not be copied or reproduced in any manner without the expressed written consent of Thermo This document also is an unpublished work of Thermo Thermo intends to and is maintaining the work as confidential information Thermo also may seek to protect this work as an unpublished copyright In the event of either inadvertent or deliberate publication Ther intends to enforce it s rights to this work under the copyright laws as a published work Those having access to this work may not c use or disclose the information in this work unless expressly authorized by Thermo PART NUMBER 810109 810107 APEX 500 100 OUTLINE amp MOUNTINC APEX 500 GRAPHICS SHOWN PROJECTION SCALE 1 3 SIZE DRAWING NUMBER REV 07387 1 SHEET 3 of 3 Derived From 2006 by Thermo Fisher Scientific CONVERSION COVER REPLACES EXISTING CONTROL PANEL 1 2 NPT INPUT POWER DSP2 3 METAL ELIMINATOR CONTROL PANEL REMOVED m 145 F 2
48. 240 Thermo Scientific APEX User s Guide Activating the Printer Once the printer is attached to the detector before you can print you must first activate the printer Note that once you have activated the printer whenever you change products or change various functions a print will occur 1 Follow steps 1 6 in the section above to reach page 1 of the printer set up menu Printer Setup Page 1 s ES x 2 Navigate to the activate printer function Activate Printer gg Ob A e 1 2 Note The X shows that the printer is currently inactivated 3 Press the Go button and the X changes to a check mark The printer is now activated and ready to print 4 Press the Back button to exit the menu Thermo Scientific APEX User s Guide Page 241 Manual Printing Only supervisors can do a manual print To use this function you must first activate the printer as described above Manual Print Cp 1 1 Jf 1 Make sure the manual print function is highlighted as shown above 2 Press the Go button and the keyboard screen appears 3 Key in your supervisor password then highlight the exit and save key in the keyboard screen 4 Press the Go button and the printer will start Shown below is an example print out kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk APEX THERMO BATCH REPORT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk
49. 28 24 610 1 279 19 483 TOLERANCE UNLESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS DMG 2 14 08 Th F h r XX o6 2 ermoFishe X XX 03 8 X XXX 010 25 DMG 2 14 08 S C E N T F ANGLES 5 DATE REMOVE ALL BURRS amp UNNECESSARY DMG 2 14 08 APEX 300D OUTLINE AND MOUNTING SHARP EDGES Sene anno feo PART NUMBER DROP THROUGH GRAVITY SYSTEM TBD CEILING MOUNT ry soa role he wrt os copo Ne even ot er ent or ell erate pubiicaron iermo SEE SHEET 1 FOR REVISION INFORMATION Gbublihed wart Ted avi acces lo i wat MOY POI COP SCALE SIZE DRAWING NUMBER REV SHEET REV ECO DESCRIPTION BY APP DATE v 1 9 07387 301 C 3of3 4 3 Derived From 2008 by Thermo Fisher Scientific 4 3 2 PRODUCT TUBE p MERE S L ETEC CENTER VALVE WITH OVERALL SYSTEM A B C H NOMINAL TUBE LENG TH APERTURE SPOOL PIECE SUPPORT SIZE TYPE SIZE WITH GASKET CLAMP GASKET TUBE LENG TH inch inch mm mm inch mm inch mm inch mm inch mm inch mm inch mm inch mm NO 30 87 784 1
50. 3 Navigate to the bin full event menu Bin Full event 4 The bin full error message currently triggers a fault notification To change the bin full error message to an alarm press the Go button repeatedly to scroll through the error message options described above When you reach the single alarm icon no other icons are present in the menu press the Back button to save your setting and exit the menu 5 Now in our example when the reject bin is full the detector lights the small red lamp you connected to Output 5 This alarm notifies you the reject bin is full Page 216 Thermo Scientific APEX User s Guide Learning About Other WAFs Please explore the remaining functions in the WAF menu using the navigation buttons to familiarize yourself with the types of problem that can trigger a WAF These include the following types of problems which are listed under the relevant page of the WAF menu WAF Page 1 Page 1 of the WAFs menu looks like this Warnings Alarms amp Faults The following WAFs are accessed from page 1 The reject has not been confirmed The reject bin is full The in feed photo eye is blocked Excessive number of consecutive rejects Excess Rejects This function allows you to set up a WAF in this example an alarm when an excessive number of consecutive rejects occur To key in parameters for the excess rejects function see page 4 of the
51. 32 00 812 8 15 47 392 9 PIPE 24 610 75 12 06 306 3 YES 42 93 1090 4 44 00 1117 6 7 00 177 8 27 53 699 3 8 40 213 4 2 24 06 611 1 6 87 1745 54 93 1395 2 56 00 1422 4 39 53 1004 1 NO i i 42 87 1088 9 38 00 965 2 21 47 426 2 HOSE 36 914 100 12 06 306 3 YES 54 93 1395 2 50 00 1270 0 33 53 732 5 24 06 611 1 66 93 1700 0 62 00 1574 8 45 53 1037 3 NO 33 50 850 9 33 00 838 2 16 78 472 2 2 5 or 3 PIPE 24 610 100 12 06 306 3 YES 45 56 1157 2 45 00 1143 0 8 00 203 2 28 84 778 5 8 89 225 9 24 06 611 1 57 56 1462 0 57 00 1447 8 40 84 1083 3 NO 45 50 1155 7 39 00 990 6 22 78 545 3 2 5 HOSE 36 914 100 12 06 306 3 YES 9 50 241 3 57 56 1462 0 51 00 1295 4 34 84 851 7 24 06 611 1 69 56 1766 8 63 00 1600 2 46 84 1156 5 NO 45 50 1155 7 39 00 990 6 22 78 578 6 3 HOSE 36 914 125 12 06 306 3 YES 57 56 1462 0 51 00 1295 4 34 84 884 9 24 06 611 1 69 56 1766 8 63 00 1600 2 46 84 1189 7 9 228 9 39 238 4 NO 37 12 942 8 35 00 889 0 w ee 18 59 578 6 39 PIPE 24 610 125 12 06 306 3 YES 49 18 1249 2 47 00 1193 8 30 65 884 9 4 24 06 611 1 13 12 333 9 61 18 1554 0 59 00 1498 6 42 65 1189 7 NO i 49 12 1247 6 41 00 1041 4 24 59 624 6 HOSE 36 914 150 12 06 306 3 YES 61 18 1554 0 53 00 1346 2 10 00 254 0 36 65 930 9 9 88 250 9 24 06 611 1 73 18 1858 8 65 00 1651 0 48 65 1235 7 ADAPTER OPTIONAL NOTES N CABLES LONGER THAN 98 4 FT 30m AVAILABLE AS A SPECIAL ORDER UP TO 295 FT 90m 2 PIPES AVAILABLE IN NYLON OR FIBERGLASS WRAPPED PTFE TOLERANCE UNL
52. 345 Setting the Configuration 346 Pin Assignments for a DB 9 mne 347 Page 8 Thermo Scientific APEX User s Guide Pin Assignments for a Screw 347 Understanding the Status LEDS mmm emnes 348 Configuring the RTU RS 232 Cat uo tiem rhe tici e eo CX OX E en 349 Installing the Card eee 349 Setting the Configuration SWitCheS cece cece cece eee eee mm emen 349 Pin Assignments for a DB 9 350 Pin Assignments for a Screw Connector 350 Understanding the Status LEDS nme eene 350 Understanding Registers SOL D ta Handigas aor boni ia eee dude cena he 351 Supported Operation Codes hee nns 351 Read Data iii ccc 352 Write brem 352 Register Details for Commonly Used APEX 353 Changing Prod cts eic ie rura IT aaa NTE ened 353 Retrieving Statistical Information meme 354 Backing Up Critical APEX Settings csssssssssssss memes 3
53. 44 Reject 1 Distance Delay PBB1 861 8 8 gt 0 8 TE E SM nsan x Changing the Units of Measure See the small screen shot at the top of page 45 and the text at the bottom of page 44 Reject 1 Distance Delay 1 601 GA o 0 8 e 0 0 1 e 390 1 61 1 505 Setting the Signal Duration for the Reject 1 Device See page 46 Reject 1 Duration PBB1 661 8 8 gt 0 8 LIE 6 368m mos 1 6EzA 1 505 Thermo Scientific APEX User s Guide Page 119 Displaying the Number of Quality Test Rejects This display function shows the number of rejects made by the Quality Test function Note In a real application when the Quality Test function has been enabled the X shown below is replaced by a number To learn more about the Quality Test function see page 196 Quality Test Rejects FARI Bal BB mp Asa LE 8 388 Displaying the Number of AuditCheck Rejects This display function shows the number of rejects made the AuditCheck function Note In a real application when the AuditCheck function has been enabled the X shown below is replaced by a number To learn more about the AuditCheck function see page 206 AuditCheck Rejects FARI Hat BB mp Asa 8 288m m sz Em x 1 Page 120 Thermo Scientific APEX User s Guide Rejects Menu Page 2 1 Fro
54. 7 24 184 1 97 50 2x 39 10 p 11 18 284 1 AUDIT CHECK OPTIONAL 2X 11 97 304 1 7 53 191 2 AVAILABLE at CABLE LENG THS FEET METERS 1 6 5 6 6 2 9 8 3 NOTES n Zi CABLES LONGER THAN 98 4 FT 30m AVAILABLE AS A SPECIAL ORDER UP TO 295 FT 90m 19 7 6 2 PRODUCT TUBES AVAILABLE IN WHITE BLACK ANTI STATIC OR WHITE WRAPPED WITH ANTI STATIC REJECT DIVERTER 262 8 FIBERGLASS WITH BLACK ANTI STATIC FLANGES WITH PNEUMATI OPTIONAL REJECT FLANGE EC T 3 FLAP GATE REJECT DIVERTER AVAILABLE WITH OPTIONAL RUBBER FLAP SEAL OPTIONAL 405 S 20 TOLERANCE UNLESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE IN INCHES AND MILUMETERS DMG 2 14 08 Th erm Fi sh er 06 1 5 DRAWN BY DATE 03 8 X XXX 010 T95 DMG 2 14 08 S C T F ANGLES 5 CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 2 14 08 APEX 300D OUTLINE AND MOUNTING SHARP EDGES 21 33 ADDED SHEETS amp CHG D TABLE RLK RLK 1 29 09 This document is confidential and is the property of Thermo Fisher PART NUMBER DROP THROUGH GRAVITY SYSTEM Scientific Thermo It may not be copied or reproduced in any B 2020 CHG D G 5TO 2 5 FOR 6 amp 8 RLK RLK 9 26 08 memo enas to TBD CEILING MOUNT A 1787 _ SEE SHEET 1 FOR REVISION HISTORY DG RIK 61208 corel so SCALE size DRAWING NUMBER REV SHEET use or ini in this work unless expressly REV ECO DES
55. APEX User s Guide 3 Press the right navigation button to highlight the log out menu Logout t 1 1 2 081 4 Press the Go button The detector returns you the Main Menu which indicates you are now logged out Security Level P881 661 Thermo Scientific APEX User s Guide Page 257 258 Thermo Scientific APEX User s Guide Maintenance and Troubleshooting This section describes how to maintain and test your APEX detector and provides a troubleshooting guide to help you resolve problems should a fault occur Maintenance You should regularly clean the APEX if you want it to provide long term trouble free operation Please note that certain cleaning agents could affect the integrity and appearance of the plastics used on the search head Read the labels on all cleaning agents to make sure they do not adversely affect polycarbonate and polyester plastic materials If you have any questions about cleaning procedures please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Cleaning Please make sure that your cleaning procedures do not leave residues on the detector s surfaces because these might attract dust particles addition please dry all surfaces after cleaning In addition please consult the suppliers of your cleaning agents to make sure they are suitable
56. B APERTURE HEIGHT EPOXY LINED APERTURE Y ry 75 2 95 B 100 3 94 DROP THROUGH PRODUCT FLOW CABLE PORT TOLERANCE UNLESS SPECIFIED ENGINEER DATE 2X 25 98 ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 5 31 07 Th rm Fi h r X DRAWN BY DATE 155 6 09 A APERTURE WIDTH 75 2 95 DMG 5 31 07 SCIENTIFIC ANGLES CHECKED BY DATE p A 9501906 _ REMOVE ALL BURRS amp UNNECESSARY DMG 5 31 07 9 06 SHARP EDGES Te err is EO eA arg is the property Fisher PART NUMBER AP EX 300 UTLI N E AN D MO U NTI NG pep moy perbe copied i 810108 may seek protect this work as an unpublished copyright In the event of either inadvertent or deliberate ublication Thermo SEE SHEET 1 FOR REVISION INFORMATION Du a s SCALE s ze DRAWING NUMBER REV SHEET use Orc IsClose Information in Is work Unless expressly REV ECO DESCRIPTION BY APP gia eon 1 3 B 07387M B300 A 4of5 Derived From 2007 by Thermo Fisher Scientific 191 7 53 AX 6 6 26 THRU AX 28 1 11 284 11 18 ry 284 11 18 7 24 1 97 Y 2X 304 11 97 REMOTE CONTROL PANEL TOLERANCE UNLESS SPECIFIED ALL DIMENSIONS ARE IN
57. C 168 AUGILQGNOCK EMIT 168 Error Messages WAFS 169 adiacet 169 Bar Graph Help Text Set Up for the Display Panel 169 IntelliTrack Reve ex eR Mewes vie DEP a EY 169 System and Tools Page 2 dee wale es wes esses 170 Viewing Your Speed Filter 5 mm mmn 170 Inputs and Outputs Menu 172 Copying and Pasting Product Parameters 173 Setting the Time and 176 Setting Metric or Imperial Units 0c eee Ime 178 System and Tools Page 3 Rx ura i n 179 Setting the Photo Eye to Detector Distance 179 Setting Reject Duration Time or Distance for Your Reject Devices 180 Setting the Reject Packs During Learn 182 Resetting the Counts When Products 183 Resetting Product Parameters to the Default 184 Resetting the Parameters to the Default Settings
58. Distance Thermo Scientific APEX User s Guide Page 361 5 3 8 8 3 2 ZE 2 L amp D Ev 2 g g og o u E E 2 2 t 2 lt o od o i9 16 A2 x x t zu zc amp a 4 a a a 30133 1 n a RO bitmap M Speed Filter Status Bits 0 1 Wideband Mode 00 Slow 01 Medium 10 Fast 11 Custom Bit 2 Speed Filter Type 0 Narrow Band 1 Wideband Bit 3 Speed Filter Learn Enabled 0 Disabled 1 Enabled Bit 4 Factory Speed Filter Ratio Locked 0 Disabled 1 Enabled 30134 n a 1 n a n a RO bitmap M Speed Filter Learned Flags Bit 4 0 Conveyor Not Learned or 1 Conveyor Learned Bit5 0 Pipe or Drop through Not Learned or 1 Pipe or Drop through Learned 30135 n a 2 n a n a RO float M Speed Filter Factory Speed Used to Update Speed Filter when Speed is changed Frequency Ratio Ratio Speed M Min Speed Filter Frequency Hz 30137 41116 1 16445 61 R W__ bitmap M Warning Configuration Each Bit refers to a particular type Bit 0 Reject Confirmation Error Bit 1 Reject Bin Full Bit 2 Infeed Photo eye Blocked Bit 3 Detection With Stopped Belt Bit 4 Detection with no infeed photo eye sig
59. Fisher SCIENTIFIC XXX 1 16 1 2 NEXT ET CUST ORDER APEX OUTLINE amp MOUNTING CUSTOMER PIPELINE SYSTEM LOCATION FLOOR an E MM 2202201 DESCRIPTION ITEM PART NO DESCRIPTION DWG NO SPEC 18 00 457 2 RECTANGULAR PORT ACCEPT STREAM HEIGHT ADJUSTMENT WITH REJECT BIN 3 83 97 3 q 6 50 165 1 1 64 41 7 di WIDTH 4 84 123 0 ALARM FAULT OUTPUT 55 14 1 OPTIONAL CLEARANCE BETWEEN CHUTE AND BASE 55 CONTROL UNIT APEX 500 Rx PHARMACEUTICAL METAL DETECTOR SYSTEM ELECTRICAL SUPPLY 85 260 VOLT AC SINGLE PHASE 47 65Hz TYPE OF REJECT AIR CYLINDER ACTIVATED CHUTE 15 16 384 9 CONSTRUCTION STAINLESS STEEL 304 pss 228 2 i PLASTIC CONTROL PANEL PRODUCT CHUTE 35 10 ALL PLASTIC PARTS FDA APPROVED MATERIAL FINISH STRAIGHTLINE STANDARD 22 84 580 2 HIGH POLISH OPTIONAL STANDARD FEATURES FULLY ADJUSTABLE MOBILE STAND WITH LOCKABLE CASTERS 4 38 111 3 REJECT VERIFICATION FAILSAFE TOUCH PANEL KEYPAD OPTIONS AUDITCHECK ALARM FAULT OUTPUT REJECT ooo VALIDATION 1Q 0Q 3500 495 9 5 ay T 48 65 1235 8 AIR SUPPLY 5 5 BAR 80PSI WITH AUDITCHECK APPROVALS CE CERTIFIED OR Pl cCSAus 35 00 9 5 11 5 REJECT COLLECTION BIN QUALITY ISO 9001 CERTIFIED WITHOUT AUDITCHECK POWER SUPPLY INLET AIR INLET 3 38 85 9 X 61 15 5 21 53 541 9 AT 35 INFEED DIME
60. I XR function to work properly e When using the I XR calibration functions a minimum gap between the packages equal to the width of the search head is required e During normal production runs a minimum gap of 25 mm between packages must be maintained Please note that if the APEX detects no gap between the packages the I XR function will use the package length you entered but false rejects may occur as a result Thermo Scientific APEX User s Guide Page 369 Discussion of Product Requirements The IXR function may overcome some of the common pitfalls of phasing but it requires that products are fairly consistent as far as the signal they produce while travelling through the search head aperture The products themselves also need to be consistent in content volume and presentation orientation For example a product that has varying fat or salt contents may not produce the consistent signal the XR function requires to detect very small amounts of metallic contamination The volume of the product is also important because a larger volume of product will produce a larger signal As a result the volume of the product should be consistent to get the best performance from the I XR function Product presentation is another factor that is crucial to IXR function Presentation includes the shape and orientation of the product as it passes through the aperture For example a product that is cube shaped should have guide rails to insure
61. If you wish to manually change the IP subnet mask and gateway addresses please note the following e The DHCP setting must be set to off e For your changes to take effect you must save your settings How to change the IP subnet mask and gateway addresses as well as save your TCP IP settings is described in the following sections Changing the I P Address In order to change the IP address DHCP must be set to off 1 Make sure the IP address function is highlighted IP Address continued Page 330 Thermo Scientific APEX User s Guide 2 Press the Go button and an input screen appears IP Address 4 2 FHL iVV_s _11_vs_as_eA 3 Use the navigation buttons to enter the IP address then press the Go button to close the input screen The flashing asterisk indicates the IP address has been changed IP Address DHCP X DER PoE ee Pe 1 1 Maci 0 30 11 03 42 2 4 If you are finished go to the Saving Your TCP IP Settings section this is important Or continue the set up as described below Changing the Subnet Mask Address In order to change the subnet mask address DHCP must be set to off 1 Make sure the subnet mask function is highlighted 2 Press the Go button and an input screen appears 3 Use the navigation buttons to enter the subnet mask address then press the Go button to close the input screen The flashing asteri
62. Key in the appropriate distance mm or inches If you want to set a delay time first highlight the mos or ft5s function and press the Go button to select delay a time parameter which you will set in minutes and seconds in step 5 above Signal Duration for the Reject Device This function allows you to set the duration of the signal needed expressed in seconds and hundredths of a second to activate your Reject 1 device 1 Make sure the screen shown in the Distance to the Reject Device section above is displayed 2 Highlight the Reject 1 Duration function Reject 1 Duration PBB1 861 B cium 6 6 e 0 0 LEH 8 368m m s rm 1 6 pa 6 60s ES 3 Press the Go button and an input screen appears 4 Key in the appropriate duration time minutes and seconds If you want to set the duration parameter as a distance highlight the sm or soft function press the Go button to select a distance parameter then go to step 3 above and key in a distance mm or inches Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 Calibrate Noise Thresholds This calibration establishes a noise baseline for the detector and must be done with the conveyor running and no product present in the search head 1 Make sure the Main Menu is displayed 2 Highlight the frequency and gain menu 3 Press the Go button 4 Navigate to page 2 of the menu 5 Navigate
63. MACHINE ID DG DAIRY BATCH CODE BIG PRINT FROM 2008 11 02 07 31 18 TOR 2008 11 02 11 56 34 PRODUCT ICECREAM PHASE 2 28 DETECT LEVEL 40 REJECT COUNT 0 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk QUALITY TEST RESULTS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME RESULT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk AUDITCHECK TEST RESULTS kkkkkkxkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME RESULT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk FAULTS ALARMS WARNINGS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME TYPE Page 242 Thermo Scientific APEX User s Guide Naming Your Detector This function allows you to name your detector and have that name added to your printed reports This is useful if you have more than one APEX working in your facility Before the detector s name is added to your printed reports you must first activate the printer as described above Machine Identification 1 Highlight the detector icon press the Go button and the keyboard screen appears 2 Enter a name for your detector Limit 9 alpha numeric characters 3 Highlight the exit and save key in the keyboard screen 4 Press the Go button and the name of your detector appears in the menu as shown in the example below Our APEX is working at the DG DAIRY Machine Identification Thermo Scientific APEX User s Guide P
64. MILK A M SHIFT PHASE Phe ALS DETECT LEVEL 40 REJECT COUNT 0 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk QUALITY TEST RESULTS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME RESULT kkkkkkxkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk AUDITCHECK TEST RESULTS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkxk DATE TIME RESULT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk FAULTS ALARMS WARNINGS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME TYPE 2008 05 21 3 INFO POWER OFF 2008 05 21 TE 302 p 52 INFO POWER ON Page 248 Thermo Scientific APEX User s Guide Security Level If you wish to restrict access to your APEX detector you as a supervisor must assign passwords to operators engineers and yourself The following table shows the access privileges of operators engineers and supervisors as well as their default passwords Use the default passwords when entering this menu for the first time to set up security levels for yourself and your coworkers Unlike a personal computer no names are used only passwords Thus all Supervisors engineers and operators are recognized only by their passwords E 35 oS o Su Available to this Not Available 4 3 aS Ac Access Level to this Access Level 0 Read Lock None View everything Clear peak N A Language 1 Operator 1 OPR1 AutoLearn Adjust Learn detect level Phase angle Change product
65. Menu which should now look like this Product Name Notice that the initial setting for detect level and phase angle for the MILK P M SHIFT shown in step 6 where the settings were 40 and 90 respectively have changed and now match those for the MILK A M SHIFT 25 and 2 respectively as shown in the screen in step 2 above Summary MILK A M SHIFT parameters have now been copied to the MILK P M SHIFT Clearly by using copy and paste you have made a substantial saving in time and effort in comparison to the alternative re entering the product parameters re running the calibrations and so on Thermo Scientific APEX User s Guide Page 175 Setting the Time and Date Setting the correct time and date is useful especially if you use the detector s print function When the time and date are current your printed reports are stamped with the correct date and time allowing you to keep proper records for future reference 1 Navigate to the time and date menu on page 2 of the system and tools menu Date amp Time 2 Press the Go button and page 1 of the time and date menu appears Date amp Time ET 12 31 18 2005 82 29 Setting the Correct Time 1 Press the right navigation button to highlight the time function The figures in your display panel will differ from the example shown below Time 24 hour format 2eBBa8 B2 28
66. Metal Size 300KHz 200KHz 150KHz 100KHz Ferrous 1 0mm 98 96 96 94 4 0mm 130 120 114 108 Non ferrous 1 0mm 42 30 25 20 4 0mm 82 78 72 64 316 stainless 2 0mm 10 8 6 5 4 0mm 48 34 26 16 Understanding Some Basic Detector Vocabulary Listed below are definitions to help you understand some of the terms that will be used while setting up and operating your detector In addition many of these terms are defined in the manual s Glossary on page 393 Phase The phase angle of the product effect Locked Locked parameters are not automatically updated during a product learn The detect level and phase angle can be individually locked during a product learn indicating their previous value is not re learned A padlock symbol on the screen indicates a parameter is locked Frequency The operating frequency of search head is as follows 50 kHz 100 kHz 150 Hz 200 kHz 300 kHz and 500 kHz The APEX is capable of switching between two frequencies typically 50 kHz and 300 kHz or 100 kHz and equal to or above 300 kHz Head Gain Head gain is the signal amplification of the search head hardware Gain is controlled via the detector s main menu and can be high or low Thresholds Thresholds are maintained for resistive and reactive effects and if exceeded usually indicate a product is present Detect level If the signal from metal or noise exceeds the detect level then the reject
67. Note A product select input that is not assigned input 0 will always be treated as false Page 226 Thermo Scientific APEX User s Guide Setting the Product Select I nputs Setting the following two input functions allow you to select any of the first three products as the current running product using an external device Product Select 1 Input 0 0054 In summary you set up a physical input as described in the Using an External Device to Switch Products section above then use this function set up the logical input for switching among the first three products Then when a signal is received from an external device such as a PLC the detector stops analyzing whichever product it is set to and switches to one of the first three products using the table on the previous page Select an input number and a polarity for these inputs The polarity will determine whether the input is true when the input voltage is positive Thermo Scientific APEX User s Guide Page 227 Locking the Detector s Key Pad This function inactivates locks out the Go Back and navigation buttons on the detector s control panel when a signal is received on the input you assign to this function Input 1 6 When used in conjunction with a key switch for example it prevents unauthorized use of the detector Key Lock Input 1 Press the Go button and an input screen appears 2 Make
68. Pipeline Applications Listed below are the most commonly used functions for setting up a typical pipeline application Reject Delay Time This function is usually set to 0 00 seconds and tells the diverter valve to close immediately when contaminants are detected If your diverter valve is a long way from the search head you may need to set a longer delay time 1 Make sure the Main Menu is displayed 2 Navigate to the rejects menu 3 Press the Go button continued Page 6 4 On page 1 of the rejects menu highlight the Reject 1 Distance Delay function Reject 1 Distance Delay P881 661 Mea 0 a i fees x 3 005 a0 5 Press the Go button and an input screen appears 6 Key in an appropriate value in seconds and hundredths of a second for the reject delay time Reject Duration Time This is the time that the diverter valve remains closed to divert contaminated product to the waste tank and is usually set to 3 00 seconds 1 Navigate to the screen shown in the Reject Delay Time section 2 Highlight the Reject 1 Duration function Reject 1 Duration 3 Press the Go button and an input screen appears 4 Key in the appropriate value in seconds and hundredths of a second for the reject duration time Calibrate X and R Noise Thresholds See the instructions on page 5 Full Product Calibration See the inst
69. Press the Back button to exit the function Page 334 Thermo Scientific APEX User s Guide Configuring RTU Network This section tells you how to use the APEX software to modify the communication parameters for an RTU network You can set the following parameters using the APEX communications menu e Slave address 1 through 247 e Baud rate 1200 2400 4800 9600 19200 38400 and 57600 bits per second e Parity none odd or even Accessing the RTU Communications Menu To access the RTU communications menu do the following 1 Follow steps 1 7 in the Accessing the TCP IP Communications Functions section above to reach the screen shown below Communications 1 1 2 Press the Go button and the Modbus RTU Configuration menu appears Modbus RTU Configuration SLAVE ADDR 1 Teme RATE 3688 PRRITY __ NONE Thermo Scientific APEX User s Guide Page 335 Changing the Slave Address To change the slave address do the following 1 In the Modbus RTU Configuration screen highlight the slave address function Slave Address SLRVE ADDR 1 BAUD RATE 688 PARIT 2 Press the Go button and the following input screen appears Slave Address SLAVE ADDR 17 3 Enter the slave address using the navigation buttons We entered 007 as the new slave address 4 Press the Go button
70. Reject printing is now activated 3 Press the Back button to exit the function Page 246 Thermo Scientific APEX User s Guide Example of a Reject Print Out A typical reject print out looks like this REJECT 2008 05 21 15 50 00 4 789 This print out tells you that when you printed on May 21 2008 at exactly 3 50 p m four products out of a total of 789 products examined were rejected since the reject totals were reset Thus when you activate a reject print out the printer simply prints the current total or totals displayed in the reject totals menu in the Main Menu as shown in the example below Product Name Activating a Print Out on Power Up This prints a standard report whenever the detector is powered up For this function to work you must first have activated the printer Activate Printout on Power up 1 Make sure the power up function is highlighted 2 Press the Go button and the X is replaced by a check mark Power up printing is now activated 3 Press the Back button to exit the function Thermo Scientific APEX User s Guide Page 247 Example of a Power Up Print Out A typical power up print out looks like this kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk APEX THERMO BATCH REPORT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk MACHINE ID DG DAIRY BATCH CODE 12 345678 FROM 21008 057 21 98255857 BOE 2008 05 21 11 32 19 PRODUCT
71. SN 111 222 111 222 GH 212 121 212 121 1 1 MaCio o 306 11 _03_48_ The flashing asterisks in the screen above indicate that in this example we have changed the IP subnet mask and gateway addresses 2 Press the Go button There is a one second software pause during which time the Modbus card is reset The following screen then appears Modbus TCP IP Configuration 5 IP 123 129 123 123 SN 111 222 111 202 GH 212 121 212 121 O 8_309_11_93_43_2A Notice that the flashing asterisks have disappeared indicating that all your TCP IP communication settings have been saved and are now active 3 Press the Back button repeatedly to return to the Main Menu screen Thermo Scientific APEX User s Guide Page 333 Changing DHCP to To change the DHCP setting to on do the following Please note that if changes have been made to the IP subnet mask or gateway address both screens shown below may display a flashing asterisk next to the DHCP function 1 Make sure the DHCP function is highlighted Dynamic Host Control Protocol 2 Press the Go button The X changes to a check mark indicating that DHCP is now on and the network will configure the IP subnet mask and gateway addresses Dynamic Host Control Protocol IP 6 0 B 8 SN 0 0 0 8 ul 5 NM M D 1 1 36 11 63 42 2 3
72. Scientific APEX User s Guide How to Use the Parameter I nput Screens Parameter input screens are used to set or verify a value for a particular function you are interested in The right hand number in all input screens is marked above and below with a small triangle indicating that all the numbers in the screen can be changed using the navigation buttons Sample Input Screen ses Use the up navigation button increase the number marked by triangles Use the down navigation button to decrease the number marked by triangles Use the left navigation button to move to the number to the left Use the right navigation button to move to the number to the right Understanding the Detector s Main Menu In this section you are going to learn to navigate around some of the detector s menus and input screens More specifically you are going to set up a number of global parameters for the detector Global parameters are ones you set at the start of a project because this type of parameter once set does not often need to be changed You are going to do the following e Choose the language shown in the display panel e Remove the bar graph display at the top of the Main Menu and replace it with the more informative Help Text display e Set the appropriate units of measure meters or feet so the detector s menus display the units you prefer to work with Choosing a Language The default language for the display p
73. WB band 4 e A finite impulse response FIR filter e Access to all other speed filter settings Inputs and Outputs Menu See page 220 Inputs and Outputs Page 172 Thermo Scientific APEX User s Guide Copying and Pasting Product Parameters The copy product function highlighted below allows you to copy the detector s current product settings such as phase angle detect level and so on to another similar product This is a very useful feature if you are testing a series of identical products but need to keep track of different production runs shifts days and so on for quality assurance purposes Copy Product Example Imagine you are a supervisor at a dairy where milk is pasteurized cooled and poured into half gallon plastic containers The milk is tested for metallic contaminants before leaving the diary because metal screens are used to filter the milk as it comes in from the local farms in order to remove insects and other particulate matter For quality assurance reasons you need to test the output of the morning a m shift separately from the output of the afternoon p m shift 1 You have already named two products as follows For more information about naming a product see page 24 e MILK A M SHIFT e MILK P M SHIFT 2 Currently you are testing the output from the morning a m shift so your Main Menu and detector settings look like this Produc
74. a gap between packages that is at least as wide as the width of the search head e Pass about 30 50 uncontaminated packages through the search head 1 Make sure the Main Menu is displayed and that Product Name or the product name you entered previously is highlighted 2 Press the Go button and page 1 of the Full Product Calibration menu appears 3 Highlight the auto calibration function and start passing packages through the search head Press the Go button and wait until the Main Menu reappears Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 4 3 2 AVAILABLE CABLE LENGTHS METERS FEET 2 6 6 3 9 8 4 13 1 5 16 4 6 19 7 8 26 2 10 32 8 12 39 4 15 49 2 20 65 6 25 82 0 30 98 4 4 ISOLATOR FOOT PS SUPPORT FRAME TYPICAL 12 7 50 THRU qao BUSHING ea WASHER SCREW WITH OPTIONAL REMOTE CONTROL PANEL HLDNBSON EN MLINEES ADD INO HE DMG 5 11 06 nm ISOLATOR FOOT LENGTH IS 25 4 1 00 X X pb M Ther o Fisher A N REMOTE CABLES LONGER THAN 30M 98 4 FT AVAILABLE AS A SPECIAL ORDER UP TO 90M 295 FT Am o 0 gt c N T F c REMOVE ALL BURRS amp UNNECESSARY DMG 5 11 06 C 1685 ADDED SHEET 1 CHANGED REMOTE OPTION TO INCLUDE 100 DG RIK 1 8 08 pam nee APEX 500 100 OUTLINE amp MOUNTING
75. and a confirmation screen appears Decline 4 Press the left navigation button to select the Accept check mark Accept continued Thermo Scientific APEX User s Guide Page 185 5 Press the Go button The detector resets the product parameters including deleting the name MILK and returns you to the Main Menu Product Name aja 90 80 Notice that all parameters for Product 003 have now been reset to their factory defaults The detect level for example has been reset to 40 and phase angle to 90 Resetting the NVRAM Parameters to the Default Settings This function resets virtually everything in the detector to its factory default settings Only supervisors can enter this function However do not enter this function unless you are firmly resolved to delete all your product and other settings and start afresh This function clears everything from the detector s memory except the model of APEX 500 300 or 100 and type of application conveyor application gravity feed pipeline or pharmaceutical you are using You have been warned Proceed with caution Reset NVRAM to Defaults Resetting the NVRAM 1 Make sure the NVRAM function is highlighted as shown above 2 Press the Go button and the keyboard screen appears 3 Type in your supervisor password If you have not assigned a unique password to yourself you should use the d
76. button an input screen appears Detection no Pack distance Py 3 Key in the same value you entered for the pack length parameter In our example where we are testing packets of salted butter we entered a value of 12 4 cm for the no pack distance 4 Press the Go button to save your setting and exit the input screen Thermo Scientific APEX User s Guide Page 37 Disabling the Detection No Pack Function When the detection no pack function is disabled as shown in the screen below no rejects are made when a contaminant is detected that is not associated with a package Detection no Pack To disable the detection no pack function do the following 1 Make sure the Main Menu is displayed Product Name 2 Navigate to the systems and tools menu and make sure it is highlighted System and Tools 3 Press the Go button and page 1 of the system and tools menu appears System and Tools Page 1 ELI continued Page 38 Thermo Scientific APEX User s Guide 4 Navigate to the Warnings Alarms and Faults WAFs menu Warnings Alarms amp Faults 5 Press the Go button and page 1 of the WAFs menu appears Warnings Alarms amp Faults 6 Press the down navigation button and page 2 of the menu appears Warnings Alarms amp Faults 7 Navigate to the
77. button and navigate to page 3 of the system and tools menu System and Tools Page 3 3 Navigate to the oscilloscope function Oscilloscope 4 Press the Go button and the start up oscilloscope screen appears Understanding the Signal Path When products or contaminants pass through the search head they generate a pair of signals known as the X input signal and the R input signal These two signals are then passed through a series of filters where the signals are clipped filtered and analyzed as shown in the signal path diagram at the end of this section You can use the oscilloscope function to view the X and R signals or the combined signal at any point along the signal path For example in the start up oscilloscope screen above notice that there are two analog signal channels Channel 1 and Channel 2 Note however that the oscilloscope function also has two digital channels available for use Currently neither analog signal channel has been assigned but in the example below you will learn how to assign the X input signal to Channel 1 and the R input signal to Channel 2 Page 188 Thermo Scientific APEX User s Guide Accessing the Scope Configuration Menu The scope configuration menu allows you to control how the oscilloscope functions and how it displays the signals you are interested in To access the scope configuration menu do the following 1 Make sure th
78. button and the X changes to a check mark 2 Press the Back button to save your setting and exit the menu Page 162 Thermo Scientific APEX User s Guide Frequency and Gain Page 2 1 From the Main Menu use the navigation buttons to select the frequency and gain menu Frequency and Gain 2 Press the Go button and page 1 of the frequency and gain menu appears Press the down navigation button to get to page 2 Detection level and Noise Threshold 1 001 Calibrating the Detect Level This function allows you to calibrate only the detect level rather than having the detect level set by the Main Menu s auto calibration function which simultaneously calibrates the phase angle detect level and AuditCheck settings Calibrate Detect Level PHH1 81 Calibrating Only the Detect Level To calibrate only the detect level typically used in a conveyor application do the following 1 Turn the conveyor on and have some samples of uncontaminated metal free product ready to pass through the search head continued Thermo Scientific APEX User s Guide Page 163 2 Make sure the calibrate detect level function is highlighted as shown above 3 Press the Go button and a monitor screen appears Pass Product to Calibrate 4 Place the uncontaminated product samples on the conveyor so they pass through the search head 5 Wa
79. by calibrating the X and R noise thresholds which must be done when no product is present in the duct e Select the appropriate value for the speed filter e Establish basic product parameters detect level and phase angle Once you have finished this section your detector will be set up and ready to go to work monitoring your product stream for the presence of metallic contaminants Establishing a Baseline with No Product Present Before you can establish a monitoring baseline that is establish a background noise level for the X and R thresholds the parameters that allow the detector to identify metal contaminants you must make sure no product is falling through the duct 1 Make sure the Main Menu is displayed Product Name 0 4 90 00 2 Navigate to the frequency gain menu Frequency and Gain 2 BA 38 88 Thermo Scientific APEX User s Guide Page 69 3 Press the Go button and page 1 of the Frequency Gain amp Inhibit menu appears Frequency Gain amp Inhibit PARI 001 4 Press the down navigation key to select page 2 of the frequency gain menu Detection level and Noise Paul 001 5 Navigate to the Calibrate Noise Thresholds menu Note The background of the calibrate function is now highlighted in black Calibrate Noise Thresholds FAHI 001 EE C A LEA 4a 222088415 158 1
80. default setting is to assign Reject 1 to the Quality Test function 1 Navigate to the reject device menu and make sure it is highlighted Reject Device 001 Note The X indicates that currently no reject device is assigned to the Quality Test function 2 Press the Go button repeatedly to scroll through the reject device options which are as follows Icon Meaning 4B x No reject device is assigned 1 Assign reject device number 1 Reject 1 Assign reject device number 2 Reject 2 Note For your reject device to work it must be connected to the detector s wiring board and be assigned to a specific output Output 1 6 For more details see pages 290 and 232 3 When the option you want is shown in the screen press the Back button to save your selection and exit the menu We have chosen to use our reject 1 device for our quality testing Reject Device PHA 81 202 Thermo Scientific APEX User s Guide Doing a Manual QA Test This function allows you to do a manual quality test However for this manual test function to work you must already have calibrated the detector following the instructions in the Testing the Detector Using QA Test Samples section above In addition you must have three quality test samples ready to pass through the search head Manual Test FARI 01 1 Highlight the manual test function
81. failure faults are not cleared Clear All WAF Inputs 1 Press the Go button and an input screen appears 2 Make the appropriate positive assignments for the input Input 1 6 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Thermo Scientific APEX User s Guide Page 231 Outputs The outputs menu allows you to manage the detector s physical and logical outputs The detector s physical outputs are found on the detector s wiring board where there are six output connectors labeled Output 1 6 For more details about the detector s output wiring board see page 290 In contrast the detector s logical outputs are controlled using the output menu meaning you the user assign what you want the detector s outputs to operate In addition the outputs menu allows you to assign a polarity or to the voltage signal sent by the detector to your output devices Let s look at an example In a conveyor application you have physically connected your main Reject 1 device to Output 1 on the detector s wiring board and the reject device operates whenever it receives a voltage signal You decide you want to move your Reject 1 device to Output 6 so you move the wires from Output 1 to Output 6 on the detector s wiring board which is a physical change Next you access the detector s output function described in this section and tell the detector your reject d
82. feed to speed sensor LED incorporating current limit J4 pin 5 LED Current limited feed to speed sensor LED only J4 pin 6 Input 1 Speed sensor input exclusively used on this input J4 pin 7 Ov Ground return connection for speed sensor Caution Do not use these inputs for connection to any system or unit having signal voltages outside the range ground to 12 V because damage may occur Inputs Given below are the default applications for Inputs 1 6 Input Default Application Input 1 Speed sensor Input 2 n feed photo eye Input 3 Reject Confirm Bin Full Input 4 Not assigned Input 5 Not assigned Input 6 Not assigned Note Inputs can also be assigned to Bin Full Product Select 1 Product Select 2 Key Lock and Reject Suppression Thermo Scientific APEX User s Guide Page 289 Ou This tput Wiring Board Relay Settings and Fuses PCB is mounted above on the PSU PCB When removing this PCB or refitting it service action ensure connectors J 4 and J5 line up correctly with their mating halves on the PSU PCB Note that Relay 1 has both NO Normally open CAUTI ON and NC Normally closed contacts available All other Relays have only normally open contact Dangerous AC voltages and a common return pointthat can connect to a present on this PCBA field voltage such as live or neutral AC CO coc 20 201 EE Replacing Fuses All fuse
83. for use on conveyors and ancillary equipment and use the appropriate dilution levels when cleaning Do not use high pressure hoses to clean the APEX as these may damage the APEX or cause breaches in the integrity of the unit In addition using high pressure cleaning equipment may compromise safety and lead to problems with contamination Checking for Corrosion Although the APEX is made from corrosion resistant materials corrosion may occur For example stainless steel prevents surface corrosion by rapidly producing a strong and inert oxide layer Damage to this protective oxide layer may result if you rest iron objects on the detector s surfaces Please check for signs of corrosion on a regular basis and take preventative measures to stop corrosion occurring Any sign of corrosion should be investigated Please report any incidents of corrosion to Thermo Fisher Scientific Thermo Scientific APEX User s Guide Page 259 Recommended Test Procedures You should thoroughly test the detector and all reject devices when these are first installed and whenever a major component of the system is changed or altered for example when any part is serviced or repaired In addition when setting up the test procedures for your particular working environment please take note of the following considerations and recommendations Pass Test Samples Through the Center of the Search Head The least sensitive part of the search head is along the centerline
84. free of all metal and must not touch any part of the aperture at any time Metal Free Area For optimum performance non moving metal should be allowed no closer to the aperture opening than 1 5 times the smallest aperture height measured outward from the center of the aperture Moving metal should be allowed no closer to the aperture opening than 2 0 times the smallest aperture height measured outward from the center Thermo Scientific APEX User s Guide Page 307 of the aperture When a complete system with frame and throughput tube has been supplied by Thermo Fisher Scientific these considerations have already been factored in to the design of the system Factors That Can Influence the Operation of the Detector It has been proven that causes external to the APEX are the main reasons for faulty operation or random false triggering When installing the APEX on an existing or custom built pipeline system the instructions below should be carefully studied Only when correctly installed will the equipment perform optimally The APEX may have been installed correctly initially but conditions change that may cause intermittent problems with the metal detector If the APEX develops fault symptoms such as intermittent triggering the factors in this section should be carefully studied before any electronic servicing is contemplated Throughput Tubes Any tube material passing through the APEX must be totally metal free Sometimes metal pa
85. has properly completed both the open and close phases of the reject cycle In addition if a gate failure occurs the detector can stop the flow of product or notify you that a gate failure has occurred for example because the air supply to the gate has failed or product has built up on the gate or surrounding duct work For more details see page 137 Warnings Alarms and Faults WAFs Many of the detector s functions provide a warning alarm or fault when a condition needing your attention occurs This menu in conjunction with the appropriate hardwired external device allows this to happen For more details see page 214 Copying and Pasting Product Parameters This function is particularly useful when you are testing multiple products You can save considerable amounts of time and effort using the copy and paste functions because you do not need to re enter the product parameters for each product re run the calibrations and so on For more details see page 173 Thermo Scientific APEX User s Guide Page 77 78 Thermo Scientific APEX User s Guide Setting Up Pipeline Applications This section assumes you have already completed the electrical and mechanical installations for your detector If not see pages 283 for electrical set up instructions and 307 for mechanical set up instructions The purpose of this section is to present you with a brief tutorial allowing you to get your pipeline application
86. is always good practice to suppress electrical interference at its source and if trouble is experienced the offending source should be located and suppressed If this is not possible it may be necessary to operate the APEX at a reduced sensitivity A relay in the metal detector is often used to control solenoid valves power contractors and similar electrical devices When these devices are switched off the collapsing field of the winding generates a wide band interference which may be picked up by the search coils in the head and cause false triggering A capacitor of suitable capacity and working voltage connected across the offending device and grounded as close to the device as possible will often provide satisfactory suppression Pneumatic Air Connect incoming air to the detector s air regulator fittings using a coiled copper tube or air hose Adjust the incoming air pressure to 30 40 PSI 2 1 2 5 kg cm for pneumatic devices 40 80 PSI 2 8 5 6 kg cm for air rejects Thermo Scientific APEX User s Guide Page 301 Components of a Gravity Feed Application The gravity feed system must only be lifted and installed using the support frame At no time must the metal detector be used for lifting The ideal way to maneuver the equipment is to use support straps from the frame and lift into position The frame must be bolted into position ensuring a good earth connection The chute pipe section may then be bolted in position Ca
87. level is properly set metals and only metals will be tagged as contamination Dynamic host control protocol Thermo Scientific APEX User s Guide Page 393 Glossary Term DIP switch Display function Display panel DSP EMI Enum Fault FIR Function Global parameter Go button GW Help Text HMI ID IEC Indicator lights Definition Dual in line package switch A display function does just that it displays the current setting of a specific function and is in effect just a gauge No changes can be made to the function using the display function screen but the displayed values can often be changed by accessing other menus and functions The LED screen that shows the detector s Main Menu and related sub menus Digital signal processor Electro magnetic interference enumerator See WAF Finite impulse response filter Functions are accessed using the detector s Main Menu and are the software routines that control everything the detector does Most have parameters that can be set by you the user Parameter you set infrequently and which affect how data is shown in the display panel Global parameters include the language shown in the Main Menu the preferred units of measure meters feet used by the detector and whether Help Text is shown in the Main Menu The green button on the detector s control panel Gateway address The top part of the Main Menu that shows a brief desc
88. make sure that it matches the type of network TCP IP or RTU are configuring Then go to the appropriate section for detailed instructions about configuring your particular type of network e Fora TCP IP network go to the next section below e For an RTU network see the instructions on page 335 Configuring a TCP IP Network This section tells you how to use the APEX software to modify the communication parameters for a TCP IP network You can set the following parameters using the APEX communications menu Dynamic host control protocol on or off address Subnet mask address Gateway address Thermo Scientific APEX User s Guide Page 325 Accessing the TCP IP Communications Menu To access the detector s TCP IP communications menu do the following 1 Make sure the detector s Main Menu is displayed Product Name Hi 4 38 800 2 Navigate to the system and tools menu System and Tools PHH1 081 3 Press the Go button and page 1 of the system tools menu appears System and Tools Page 1 CE 4 Navigate to page 2 of the system and tools menu System and Tools Page 2 Page 326 Thermo Scientific APEX User s Guide 5 Navigate to the inputs and outputs menu Inputs and Outputs 6 Press the Go button and the detailed inputs and outputs menu appears Inputs and Outputs T 7 Navigate t
89. marks in the screen above is now ready to do the following e Learn the phase angle e Learn the detect level e Conduct an AuditCheck if this optional hardware is installed on your APEX 5 Press the Go button and the Performing Full Learn monitor screen appears Performing Full Learn continued Page 56 Thermo Scientific APEX User s Guide 6 When the calibration is complete the detector displays the Main Menu which should now look something like this Your screen will look different if IXR is enabled Product Name SPAGHETTI 7 Sometimes however the high frequency and high gain settings are too sensitive which saturates the detector s circuit When this occurs the APEX halts the calibration and displays a screen see below showing the next best option the high frequency low gain option a High Frequency Low Gain Option High Frequency Low Gain b Press the Go button to restart the full product calibration If this setting is too sensitive the following screen appears the low frequency high gain option c Low Frequency High Gain Option Low Frequency High Gain PHBI g Bel CELL peo 1 2 Sor Please note that if the frequency is changed the APEX must relearn the X and R noise thresholds for optimal performance The APEX software will take you to page 2 of the frequency and gain menu Follow the directions on page
90. meeting the full requirements of OSHA in respect to the equipment supplied or for any penalty assessed for failure to meet the requirements in respect to the equipment supplied as interpreted by an authorized inspector Thermo Fisher Scientific will use their best efforts to remedy such violation at a reasonable cost to the buyer European Directives Thermo Fisher Scientific products sold in Europe are compliant with European Directives relating to CE marking and all heads or systems head product transport and rejecting mechanisms are labeled in accordance with the directives Product labeling is affixed securely visible to the user and contains the following information Warnings of any residual risk nip points reject mechanisms inside PSU areas Name and address of Thermo Fisher Scientific Year of manufacture Product type Serial number Supply voltage and frequency Maximum rated current Identification of the protective earth terminal CE mark on machines Other Certifications The APEX is designed to operate in all parts of the world and as such is marked with a label bearing CE and cCSAus marks In addition the APEX is designed to be used in atmospheres where combustible dust may sometimes be present An explanation is given on the marking label The APEX is designed to operate in a Zone 22 hazardous area and complies with the following standards e IEC 61242 Electrical Apparatus for Use in the Presence of Co
91. micro fuse BK ETF type o Bussmann 3 15 A Fast acting BK EFF type o Wickmann 3 15 A Anti surge TR5 type o Wickmann 3 15 A Fast acting TR5 type o Bussmann PC Tron 3A type e Flto F6 Relay 250v AC 2A Thermo Scientific APEX User s Guide Page 269 270 Thermo Scientific APEX User s Guide Installing Your APEX Detector The first thing to do is unpack and inspect your detector and then familiarize yourself with its basic operating environmental safety installation and wiring requirements Please read the Theory of Operation section because this will help you properly install the detector as well as operate it successfully You should also note that one of the keys to making a successful installation is minimizing two types of interference For example installing the detector near electric motors which are a major source of radio frequency interference or close to large metal objects will negatively affect its performance Once you ve covered the theory part you ll move on to the practical nuts and bolts details about how to hard wire your detector as described on page 283 Thereafter you may need to set up and wire in additional components such a product reject device and so on Please go to page 291 the Mechanical Set Up section for more details For now let s get on with unpacking the detector Your APEX is a sensitive instrument and should not be handled in rough manner Doing so may af
92. needed are set in seconds and hundredths of a second e Reject Duration Time This is the time in seconds and hundredths of a second that the gate remains closed to divert contaminated product into the reject bin A typical time for a normal pharmaceutical application is 0 50 seconds Once you have set the reject delay time and reject duration time parameters you must test the reject process Thermo Scientific APEX User s Guide Page 97 Setting the Reject Delay Time To set the reject delay time do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 2 Press the Go button and page 1 of the rejects menu appears Reject 1 Distance and Duration PHH1 001 3 Navigate to the reject 1 distance delay menu shown below Reject 1 Distance Delay FHH1 001 4 Press the Go button and the reject 1 distance delay input screen appears Key appropriate value for reject 1 distance delay For a typical pharmaceutical application key in a value of 0 00 seconds This allows the reject gate to close immediately when metallic contaminants are detected Reject 1 Distance Delay PR 519 80 x x 1 5 r att a Page 98 Thermo Scientific APEX User s Guide 5 Press the Go button to save your setting 6 Press the Back button repeatedly to return to the Main Menu Setting the Reject Duration Time
93. note usually shows up in the X threshold where it increases the value Calibrate Noise Thresholds PHH1 81 Calibrating the X R Thresholds for Background Noise To calibrate the X and R thresholds for background noise in a conveyor application do the following 1 Turn the conveyor on making sure no product test samples and so on are on the conveyor or near the search head 2 Make sure the Calibrate Noise Thresholds function is highlighted as shown above 3 Press the Go button and a monitor screen appears 4 Wait for the calibration function to finish The detector will close the menu and assign values for the X and R noise thresholds Page 166 Thermo Scientific APEX User s Guide Changing the Noise Threshold for X In conveyor applications the noise threshold for X is often increased to prevent the detector interpreting vibration as contamination X Threshold 1 81 To change the noise threshold for do the following 1 Make sure the X threshold menu is highlighted 2 Press the Go button and an input screen appears 3 Key in a new setting for the X noise threshold 4 Press the Go button to save your setting 5 Press the Back button to exit the menu Changing the Noise Threshold for R R Threshold 1 81 27218 1 100 To change the noise threshold for R do the following 1 Make sure the R threshold m
94. of a second for the reject duration time Calibrate X and R Noise Thresholds See the instructions on page 5 Full Product Calibration See the instructions on page 5 I ntelliTrack XR I XR The IXR function allows you to detect stainless steel in wet products and metallic contaminants in wet and dry products having phase angles that vary from pack to pack IXR is used typically in conveyor applications and is not available for pipeline applications Please note that you must have an in feed photo eye or other triggering device installed for the IXR function to work IXR is not available for gravity feed or Rx appli cations Before using the I XR function you must set the following parameters e Pack length e Detection no pack distance e In feed photo eye distance e Photo eye registration Pack Length See the instructions on page 2 No Pack Distance See the instructions on page 2 In Feed Photo Eye Distance See the instructions on page 3 Page 7 Photo Registration For optimum performance the photo registration should be set to detect the middle of your product 1 Follow steps 1 5 of the Photo Registra tion for Product Rejects section on page 4 2 Press the Go button to select middle for photo registration Middle Photo Registration 1 801 Oo nw 1145 2 4 G 55 8 Enabling I XR To enable the IXR fu
95. on page 196 so please refer to the appropriate sections in the Quality Test write up for detailed instructions as the Timing Limits and Reject Device Parameters are very similar for AuditCheck and the Quality Test function AuditCheck Timers and Reject 001 continued Thermo Scientific APEX User s Guide Page 209 To start a manual AuditCheck do the following 1 Make sure the manual AuditCheck menu is highlighted as shown below Manual Test FAHI 001 2 Press the Go button to start the AuditCheck Setting Limits for Peak Signal and Phase Angle These functions have already been described in detail for the Quality Test function in the Quality Test section starting on page 196 so please refer to the appropriate sections in the Quality Test write up for detailed instructions as the Peak Signal and Phase Angle Parameters are very similar for AuditCheck and the Quality Test function AuditCheck Warning Alarm Fault levels co 1 Setting the AuditCheck Overhang Distance This function allows the filter delay to be accurately tracked when an AuditCheck test is performed 1 Navigate to page 4 of the AuditCheck menu AuditCheck Setup Page 210 Thermo Scientific APEX User s Guide 2 Press the right navigate button to highlight the overhang function AuditCheck overhang distance FAHI 01 3 P
96. otherwise Copy the software program for backup or in order to modify it Modify the software program and or merge it into another software program Subject to the following limitations transfer the possession of the software program to another party but only in connection with a transfer of the equipment If you transfer the software program you must transfer a copy of these license terms all other documentation and at least one complete unaltered copy of the software program to the other party Unless you have other copies of the software program to be used in connection with other equipment purchased from Thermo Fisher Scientific or one of its divisions you must at the same time either transfer all your other copies of the software program to the transferee of the equipment or destroy them Your license is then terminated The other party agrees to these terms and conditions by its first use of the software program You must reproduce the copyright notices s on each copy of the software program You may not do the following Use copy modify merge or transfer copies of the software program except as provided in this license Reverse engineer decompile or disassemble the software program Sub license rent lease or assign the software program Limitation of Remedies Thermo Fisher Scientific s liability under this license is as follows Thermo Fisher Scientific will a replace defective media or b make a warrant
97. output activates Thermo Scientific APEX User s Guide Page 279 Safety Precautions Listed below are the safety precautions for your APEX detector Please read them carefully because this information is important for your own personal safety and the safety of others General Safety Precautions Do not install operate or perform any maintenance procedures until you have read the safety precautions listed below Warning Failure to follow safe installation and servicing procedures could result in death or serious injury e Make certain only qualified personnel perform installation and maintenance procedures in accordance with the instruction in this manual e Allow only qualified electricians to open and work in the electronics cabinets power supply cabinet control cabinet or switch boxes e Covers over the electronics and rotating parts must always remain in place during normal operation Remove only for maintenance with the machine s power OFF Replace all covers before resuming operation e During maintenance a safety tag not supplied by the factory to be displayed in the ON OFF switch areas instructing others not to operate the unit ANSI B157 1 Warning High voltage that may be present on leads could cause electrical shock e All switches must be OFF when checking input AC electrical connections removing or inserting printed circuit boards or attaching voltmeters to the system e Use extreme caution when
98. packets of product Managing the QA Test During long production runs it is a good idea to test the detector s performance every two hours or thereabouts and the Quality Test function allows you to manage this process Here in outline is what the Quality Test function does Alerts your shift supervisor for example by flashing a light that two hours or other time interval has elapsed and the detector needs to be tested Gives your shift supervisor a 10 minute time window or other time interval in which to start testing Shuts down the conveyor automatically sounds a siren or takes other action you specify if your shift supervisor does not start testing within 10 minutes of the start testing signal being activated Monitors peak signal and phase angle during the testing process and provides a warning alarm or fault if the peak signal or phase angle values are not within the limits you specify Assign the reject device Reject 1 or Reject 2 used to remove contaminated test products from the conveyor during the QA test The default setting is to use the Reject 1 device Thermo Scientific APEX User s Guide Page 197 Learning the QA Test In our example during the testing phase the shift supervisor uses three different test samples of a contaminated test product in our example rectangular packets that mimic the shape and size of salted butter as follows e Sample A ferrous contaminant test ball in
99. polarity if negative input port is inverted 30153 41131 1 16452 68 R W signed short M Reject Confirm 1 Input Same as For Infeed Photo Eye Sensor 30154 41132 1 16453 69 R W signed short M Reject Confirm 2 Input Same as For Infeed Photo Eye Sensor 30155 41133 1 16454 70 R W signed short M Bin Full Input Same as For nfeed Photo Eye Sensor 30156 41134 1 16455 71 R W signed short M Product Select 1 Input Same as For Infeed Photo Eye Sensor 30157 41135 1 16456 72 R W signed short M Product Select 2 Input Same as For Infeed Photo Eye Sensor 30158 41136 1 16457 73 R W signed short M Reject Suppression Input Same as For Infeed Photo Eye Sensor 30159 41137 1 16458 74 R W signed short M Keylock Input Same as For Infeed Photo Eye Sensor 30160 41138 1 16459 75 R W unsigned short M Excess Reject Count 1 200 Note in order to update Excess Reject Count Excess Span must also be updated 30161 41139 1 16459 75 R W unsigned short M Excess Reject Span 1 200 Span must be less than Count Note in order to update Excess Reject Span Excess Count must also be updated Thermo Scientific APEX User s Guide Page 363 5 3 8 42 gt s l IEEE g 9 9 97 gt 9 2 9 vy vy os o Jg u FEES 2 2 s SU o 16 16
100. presence of metallic contaminants immediately up stream that is just before the toy was added to the product Thermo Scientific APEX User s Guide Page 123 Setting the I nverting Reject Function To enable the inverting reject function do the following 1 Make sure the inverting reject function is highlighted as shown above 2 Press the Go button and a check mark appears The inverting reject function is now active Inverting Reject 3 Press the Back button to exit the function Calibrating the Speed Encoder Function This function is used only in conveyor applications A speed encoder must be attached to your conveyor and hardwired to the detector In addition the detector s speed encoder function must be calibrated Speed Encoder Advantages of Using the Speed Encoder Function There are many advantages of enabling the speed encoder function First whenever you change conveyor speed the detector automatically displays the correct updated product speed in the main menu Second any other detector parameters that rely on product speed such as reject delay reject duration and speed filtering are automatically recalibrated to account for the change in product speed This is particularly useful if you monitor multiple products at different product speeds or inspect other products by manually passing them through the search head Thus you can monitor Product 1 with the speed enco
101. provides experienced on site service technicians who can assist you installing setting up calibrating maintaining and repairing your APEX They can also help you train your operators and solve virtually any APEX related problem Parts List 15 Provided For a detailed list of the spare parts available for your APEX please refer to the Parts List in the Supplemental I nformation section at the end of the manual Forms Needed for Repairs or Returns Before returning any equipment to Thermo Fisher Scientific you must contact your nearest Thermo Fisher Scientific Office for an RMA number which will authorize you to make the return In addition you will need to complete the appropriate Return Material Authorization RMA form Product Information Sheet and Decontamination Declaration Form which are shown on the following pages before returning any equipment to Thermo Fisher Scientific Contacting Thermo Fisher Scientific Please refer to the Contacting Thermo Fisher Scientific section on page 399 of the manual Thermo Scientific APEX User s Guide Page 265 Dear Customer Thank you for using our in house repair service To expedite your repair control costs and ensure that safety requirements are met please follow these simple steps 1 Send copy of this completed form with copy of your purchase order to the fax number or email address in the Contacting Thermo Fisher Scientific section under Obtaini
102. ready When running the calibration procedure please make sure that the gap between your packages the pack gap is equal to or greater than the width of the search head For example if your search head is 30 cm wide the gap between your packages should be Page 382 Thermo Scientific APEX User s Guide at least 30 cm Maintaining the appropriate pack gap is critical to the success of the calibration procedure To auto calibrate the XR function do the following 1 Make sure the detector s Main Menu is displayed Product Name 2 Press the Go button and page 1 of the Product Calibrate and Name menu appears Product Calibrate and Name FARI 001 3 Navigate to the Full Product Calibration menu and make sure it is highlighted Full Product Calibration PHB1 001 4 sure the conveyor is running at the speed you will use during normal production runs and press the Go button to start the IXR calibration The following screen appears Performing Full Learn Thermo Scientific APEX User s Guide Page 383 5 Place your packages on the conveyor and let them to pass though the search head making sure the appropriate pack gap is maintained between all the packages The bar graph in the screen monitors progress Currently the screen shows that four packages have been passed and the noise threshold for both the X
103. s application connector to the detector s COMMS1 connector Use the APEX Communication Module Mounting Kit to secure the card to the APEX motherboard 3 Reinstall the HMI CPU on the motherboard Setting the Configuration Switches To configure your Modbus card as an RS 232 termination node do the following 1 Locate the termination node ID baud rate and parity switches diagrammed below on the Modbus card Set all the switches to the zero or off position Node ID Baud rate Parity 2 Set DIP switch number 5 in the parity block to the one 1 or on position as diagrammed below because this is the switch that actually sets the Modbus card to the RS 232 configuration If this switch is off the card will be configured as an RS 485 card Thermo Scientific APEX User s Guide Page 349 Pin Assignments for a DB 9 Connector See the RS 485 section because the pin assignments are identical Pin Assignments for a Screw Connector See the RS 485 section because the pin assignments are identical Understanding the Status LEDs See the RTU RS 485 because the way the LEDs operate is identical Page 350 Thermo Scientific APEX User s Guide Understanding Registers The first part of this section gives you a quick overview of way the Modbus Communications Card uses registers to control and or monitor APEX functions The second part gives you step by step instructions about how to use the Modbus registers to chang
104. s Guide Page 3 Set Up Check List for Gravity Feed Applications 76 Parameters You Have Already Set 76 Additional Parameters You May Want to Set Up 77 Setting Up Pipeline Applications P 79 Setting Reject Parameters coss exi e uto cun OUR IS UPS p ect nes 81 Understanding Reject Delay and Reject Duration 81 Setting the Reject Delay 82 Setting the Reject Duration mmm 83 Setting Contaminant Detection 85 Establishing a Baseline with No Product 85 Choosing the Appropriate Wide Band Speed 88 Establishing Basic Product 90 Set Up Check List for Pipeline 93 Parameters You Have Already Set 93 Additional Parameters You May Want to Set Up 94 Setting Up Pharmaceutical Rx Applications
105. set e Reject Delay Time In most pipeline applications where the diverter valve is located close to the search head the reject delay time is usually set to 0 00 seconds Thus when the search head detects contaminants the valve closes immediately However in applications where the diverter valve is located some way from the search head a time delay is needed because the product takes a finite time to move from the search head to the diverter valve Clearly the reject delay time should be set to make sure that the valve closes before the contaminated product actually reaches the valve Reject delay times when needed are set in seconds and hundredths of a second e Reject Duration Time This is the time in seconds and hundredths of a second that the valve remains closed to divert contaminated product into the waste tank A typical time for a normal pipeline application is three seconds Once you have set the reject delay time and reject duration time parameters you must test the reject process Then if needed you may want to fine tune the detector s response to vibration caused by the diverter valve opening and closing by enabling the reject suppression feature Thermo Scientific APEX User s Guide Page 81 Setting the Reject Delay Time To set the reject delay time do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 01 001 2 Press the Go button and page 1 of t
106. supervisor 1 Log in and navigate to the screen below Forgotten Password O 1 lemma On 2 Ow 2 22 ga out continued Thermo Scientific APEX User s Guide Page 253 2 Press the Go button and a screen similar to the one below appears Contact Thermo to retrieve passwords 3 Make a note of the information in the screen Contact Thermo Fisher Scientific s technical support personnel as described in the Contacting Thermo Fisher Scientific section at the end of the manual Undoing the Need for Passwords Once you have set passwords but decide not to use them for all personnel supervisors engineers and operators you can undo the need for passwords and thus the need for any log in procedures as follows 1 Log in as a supervisor and navigate to the screen shown below which you can reach by following steps 1 6 in the Entering a Supervisor Password section above Activate Passwords O t 2 2 2 Press the Go button and the check mark in the passwords menu changes to an X Passwords are now no longer required and all personnel have full access to all of the detector s functions 3 Press the Back button to exit the menu The X next to the key icon tells you passwords are no longer required Security Level Page 254 Thermo Scientific APEX User s Guide Logging In If passwords have been
107. that it passes through the aperture parallel to belt and through the same part of the aperture each time Similarly a rectangular box must pass through the aperture with the same orientation as used when calibrating the product The I XR function requires a photo eye and a constant speed for each product for the real time product signal to match the one that is stored in memory during calibration A variable speed conveyor be used but changing the speed means the XR function must be recalibrated Please note however that the APEX has XR tracking feature that allows small and gradual speed changes over time to be accommodated In addition the I XR tracking feature allows the APEX to accommodate gradual changes in the product signal over time that occur due to slight variations in temperature belt speed or other non contaminant factors This feature often eliminates false rejects due to this type of variation in the product signal The Next Step Before you can start using the I XR function you must do the following 1 Set the proper pack length detection no pack distance photo eye distance and photo eye registration These four parameter must be set for the XR function to work properly 2 Enable the IXR function 3 Calibrate the system If you encounter problems while setting up the XR function please see the Troubleshooting section in this appendix or contact Thermo Fisher Scientific as describ
108. the appropriate hardwired external device allows this to happen For more details see page 214 Copying and Pasting Product Parameters This function is particularly useful when you are testing multiple products You can save considerable amounts of time and effort using the copy and paste functions because you do not need to re enter the product parameters for each product re run the calibrations and so on For more details see page 173 Page 94 Thermo Scientific APEX User s Guide Setting Up Pharmaceutical Rx Applications This section assumes you have already completed the electrical and mechanical installations for your detector If not see pages 283 for electrical set up instructions and 299 for mechanical set up instructions The purpose of this section is to present you with a brief tutorial allowing you to get your pharmaceutical application up and running as quickly as possible Here is an outline of what you will be learning If you are already familiar with some of the information covered you can always skip ahead to the next section Understanding Your Detector In this section you will learn how to e Use the detector s display panel Navigate the detector s menus and sub menus Set up global parameters for the detector Key in a name for your product Setting Reject Parameters In this section you will learn how to e Key in the reject delay time e Key in the reject duration time Setting Cont
109. the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Starting the Reject Suppression Cycle This function is used only in gravity feed applications When an input is received on the input you assign the detector starts the reject suppression cycle External Suppression Input 1 Press the Go button and an input screen appears 2 Make the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Page 228 Thermo Scientific APEX User s Guide I nputs Page 3 To navigate to page 3 of the inputs menu do the following 1 Follow steps 1 4 in the Inputs and Outputs section above pages 220 21 2 Press the right navigation button to highlight the inputs menu Inputs 1 1 3 Press the Go button and page 1 of the inputs menu appears Input Setup 4 Press the down navigation button twice and page 3 appears Input Setup Thermo Scientific APEX User s Guide Page 229 Assigning the I nput for Verification of a Reject Using Photo Eye 2 This function is used most often in gravity feed and pipeline applications The function assigns the input Input 1 6 for photo eye number 2 and is used to verify that the reject process has ceased
110. the design of the system Factors That Can Influence the Operation of the Detector It has been proven that causes external to the APEX are the main reasons for faulty operation or random false triggering When installing the APEX on an existing or custom built conveyor system this information below should be carefully studied Only when correctly installed will the equipment perform optimally The APEX may have been installed correctly initially but conditions change and these may cause intermittent problems with the metal detector If the APEX develops fault symptoms such as intermittent triggering the factors below should be carefully studied before any electronic servicing is contemplated Conveyor Belt Any conveyor belt passing through the APEX must be totally metal free Sometimes metal particles or grease that has become loaded with metallic dust becomes embedded in the conveyor belt during use Spilled product may also become embedded in the belting This generally occurs with woven belts and the contamination will trigger the APEX each time it passes through the aperture Plastic plastic covered or rubber belts should be used whenever possible The joint in the belt must be made of a non metallic fastener or vulcanized Carbon loaded anti static belts can cause random alarm signals especially when the APEX is operating at a high sensitivity Aperture Clearances The conveyor belt product guides and the product must be comple
111. the leading edge of the packet e Sample B A ferrous contaminant test ball in the middle of the packet e Sample C A ferrous contaminant test ball in the trailing edge of the packet Each sample is passed through the search head three times for two reasons First this allows the detector to average the three peak signal and phase angle values increasing accuracy and precision and second if the APEX detects contaminants three times in a row you can be confident it is working properly Testing the Detector Using QA Test Samples 1 Make sure no real product is on the conveyor If it is not running already start the conveyor Make sure the Quality Test function is highlighted Quality Test 2 Press the Go button and page 1 of the quality assurance test QAT menu appears QA Test Calibrate test samples FARI 81 This screen shows icons representing the three test samples Sample A Sample and Sample C that you will use during the testing process continued Page 198 Thermo Scientific APEX User s Guide 3 Press the right navigation button to highlight Sample A function also called the Pack A function Peak amp Phase Angle Pack A 001 4 Press the Go button a monitor screen with flashing hand sample A icon appears Peak amp Phase Angle Pack A 5 Place sample A on the conveyor allow it to pa
112. to the Help Text setting Notice that descriptive Help Text is now displayed at the top of the screen and will continue to be displayed until you change this setting Bargraph and Help Setup 7 Press the Back button repeatedly to return to the Main Menu Thermo Scientific APEX User s Guide Page 21 Choosing Your Preferred Units of Measure The display panel presents information such as conveyor speed in either metric meters or imperial units feet and inches Follow these instructions to the set units you prefer to use and have the detector display 1 Make sure the detector s Main Menu is displayed Product Name 2 Use the navigation buttons to select the system and tools menu System and Tools P881 901 p oK 30 0 p TETE 3 Press the Go button and page 1 of the system and tools menu appears System and Tools Page 1 4 Press the down navigation key and page 2 of the system and tools menu appears System and Tools Page 2 METRIC continued Page 22 Thermo Scientific APEX User s Guide 5 Use the navigation buttons to select the metric imperial function Metric I mperial Units 6 Press the Go button to toggle between imperial and metric units Highlight the units of measure meters or feet and inches you prefer to use 7 To exit and select the un
113. up and running as quickly as possible Here is an outline of what you will be learning If you are already familiar with some of the information covered you can always skip ahead to the next section Understanding Your Detector In this section you will learn how to e Use the detector s display panel Navigate the detector s menus and sub menus Set up global parameters for the detector Key in a name for your product Setting Reject Parameters In this section you will learn how to e Key in the reject delay time e Key in the reject duration time Setting Contaminant Detection Parameters In this section you will learn how to e Establish a noise threshold with no product present in the pipe e Select the appropriate setting for the speed filter e Establish basic product parameters detect level and phase angle Understanding Technical Terms If you encounter a technical term you do not understand in these sections please refer to the Glossary on page 393 For example the word product means anything the detector is testing for the presence of metal contaminants and is a word you will encounter often in this manual Let s get started Thermo Scientific APEX User s Guide Page 79 Understanding Your Detector In order to minimize the length of this already lengthy manual we are not going to repeat information here that has already been covered elsewhere in the manual and we hope you agree this is a wise c
114. which the reject must occur Typically the calibration function will set the appropriate value and no manual adjustment is necessary 4 Press the Go button to save your setting and exit the menu Manually Setting the Timing for a Reject 1 Complete This function is normally used in gravity feed and pipeline applications and is used to confirm that the gate the reject device has properly completed both phases the open and closed phases of the reject cycle This capability is useful because it allows you to hardwire the detector to shut down the flow of product and alert you when a gate failure occurs for example because the air supply to the gate has failed or the gate has stuck half way open which may occur when product builds up on the gate or the surrounding duct work This function allows you to fine tune the reject confirmation time by keying in a time a time window in which the reject must occur and thus be confirmed If a reject does not occur within this time window the detector issues a warning alarm or fault that notifies you an error has occurred during the reject process Reject 1 Complete Time PHH1 001 Gate Open Gate Closed Detector Must Be I nstalled For this function to work you must have a gate open and gate closed detector installed on the gate or diverter valve and this must be hardwired to the detector The gate detector works by confirming that the gate is indee
115. you a quick overview of how the detector is functioning e Red Flashing once indicates an excess product effect steady indicates a fault e Green Indicates a product is present in the detector s search head e Yellow Indicates a contaminant has been detected in the product The Navigation Buttons These allow you to navigate around the detector s menus and sub menus When you press a navigation button the display highlights an adjacent function using a black background You access the highlighted function by pressing the Go button In addition the four navigation buttons are used increase or decrease numbers and select characters and settings in various menus and input screens The Go Button Press the Go button to select or start one of the detector s functions The Back Button Press the Back button to stop one of the detector s functions or to return to the previous menu screen Pressing the Back button repeatedly will always take you back to the detector s Main Menu Using the Detector s Buttons The detector s buttons unlike those on a cell phone for example are not activated by direct mechanical force Instead a sensor below the image of the button on the control panel detects the movement of your finger to and away from the button s location As a result the best way to activate the button is to lightly tap the button and the key point here immediately move your finger away from the button For most peo
116. 0 I niputs Page L cec B Oa ir ODE X OC DOS e n S ob ug E 222 Viewing the Speed Encoder 1 Immer 223 Assigning the Input for the In Feed Photo Eye 223 Assigning the Input for the Reject Confirm 1 Photo Eye Reject 1 224 Assigning the Input for the Bin Full Photo Eye Reject 1 224 Iiputs Page Zeit oportere teasing et dial CER Ra xd 225 Using an External Device to Switch Products 226 Setting the Product Select 1 eee eee eee mm eee 227 Locking the Detector s Key nemen 228 Starting the Reject Suppression 228 5 Me Pan isa MUS 229 Assigning the Input for Verification of a Reject Using Photo Eye 2 230 Assigning the Reject 2 Confirm 1 m meme 230 Clearing All WAF Inputs eer dne tex eek nne YEN E n REN ER 231 OUEDEES dpi ped ada Dao as dub dae US UP RA ORI I D neis 232 Changing the Assignment of an Output 235 Changing the Polarity of an Output Device
117. 0029 n a 2 n a RO unsigned long P Total Pack Count 0 4 Billion Only updates if there is photo registration n a n a n a 16386 2 n a n a P Reset Statistics Resets all Counts 30031 41046 1 16387 3 R W unsigned short P Detect Level 0 65535 30032 n a 1 n a RO unsigned short P Current Peak Value 0 65535 n a n a n a 16388 4 n a n a P Reset Current Peak Value Reset Current Peak Value 30033 n a 1 RO enum M Operational Status 0 Normal 1 Learning Phase Learning Detect Level Learning Noise Threshold Learning AuditCheck Performing AuditCheck Performing Quality Test Learning Reject Confirm Time 2 3 4 5 6 Learning Quality Test 7 8 9 Learning DSV Filter Frequency 1 0 Calibrating Speed Sensor Thermo Scientific APEX User s Guide Page 357 Register Registers PCC Notification PCC Acknowledge Data Type Parameters 2 Read Register 3 Write Number of 2 2 Access o itmap S Parameter Type 9 Description ult Status bit 0 Reject Confirmation Error bit 1 Reject Bin Full bit 2 Infeed Photo eye blocked bit 3 Detection with a stopped belt bit 4 Detection outside of a pack bit 5 Phase tracking limit exceeded bit 6 Search Head Problem bit 7 QAT timeout bit 8 QAT failed bit 9 AuditCheck timeout
118. 1 Identify the broken or faulty parts 2 Locate the parts in the Parts List in the supplemental information section at the end of the manual 3 Find the part numbers for the items you need 4 Before you contact Thermo Fisher Scientific for your parts make sure you have the following information e Your APEX model and serial number Your company s purchase order PO number The date the parts are needed Your preferred shipping method A list of all the part numbers together with descriptions and the quantities needed 5 Contact Thermo Fisher Scientific by telephone or fax as described in the Contacting Thermo Fisher Scientific section at the end of the manual Please Note Modifications and repairs should only be performed under the supervision of a Thermo Fisher Scientific Service Engineer and with written consent from Thermo Fisher Scientific List of Commonly Required APEX Spare Parts Listed below are the commonly required spare parts and fuses used by your APEX Please only use spare parts as directed by Thermo Fisher Scientific or one of the company s authorized agents In addition please note that PCB s must be sourced from Thermo Fisher Scientific Fuses however can be sourced from any reputable supplier providing their rating is identical to the following e F1 PSU PCB 250 v AC 3 15 A 35 A breaking capacity Typically the following types of fuses are recommended o Bussmann 3 15 A Radial lead
119. 1 ANGLES CHECKED BY DATE Ja 98 10013 94 24 98 REMOVE ALL BURRS amp UNNECESSARY DMG 5 31 07 y gt SHARP EDGES here mayne be PART NUMBER AEE OU TNE AND cin 810108 may fala ros heme cyano copie SEE SHEET 1 FOR REVISION INFORMATION wo ess avi acces Yongwon Pot CoD SCALE SIZE DRAWING NUMBER REV SHEET REV ECO DESCRIPTION BY APP DATE v 1 3 B 07387M B300 A 30f5 4 3 Derived From 2007 by Thermo Fisher Scientific 4 3 2 REC TANG ULAR APERTURE HEADS C HEAD WIDTH mm B APERTURE A APERTURE WIDTH mm HEIGHT mm 100 150 200 250 300 350 400 450 500 550 75 145 145 145 145 145 145 145 145 145 145 100 145 145 145 145 145 145 145 145 145 125 145 145 145 145 145 145 145 145 145 Therma APEX FOO 150 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 SCIENTIFIC Metal Detector recu AUDIT CHECK OR SQUARE APERTURE HEADS 250 9 84 amp B mm 75 145 OR 250 100 145 OR 250 125 145 OR 250 7 150 145 OR 250 AX 12 47 175 145 OR 250 200 145 OR 250 225 145 OR 250 250 145 OR 250 4X M10X1 5 Y 12 47 A 100 3 94 AX 32 1 26 501 97 2X 25 98 i i m 24 98 A B 150 5 91 75 2 95 at Pel
120. 158 Thermo Scientific APEX User s Guide I nactivating the PNR Filter This is not recommended However if you need to inactivate the PNR filter do the following 1 Make sure the PNR filter menu is highlighted 2 Press the Go button and the check mark changes to an X 3 Press the Back button to exit the menu The PNR filter is now inactivated Selecting the Quadrature Noise Reduction Filter The default setting for the quadrature noise reduction QNR filter is off as indicated by the X in the QNR menu below The QNR filter is often used when testing wet products where it reduces 1 the background noise and 2 the number of uncontaminated units of product that are erroneously rejected as contaminated due to vibration Occasionally the QNR filter is used when testing dry products where it lowers the detect level and increases the ability of the search head to detect metals The QNR filter can be used in conjunction with the CLX and filters if needed Quadrature Noise Reduction FARI _ 81 Activating the QNR Filter 1 Make sure the QNR filter menu is highlighted as shown above 2 Press the Go button and the X changes to a check mark Quadrature Noise Reduction FAHI 001 3 Press the Back button to exit the menu The QNR filter is now Thermo Scientific APEX User s Guide Page 159 Frequency and Gain Page 1 When testing products setting the appropriate frequency an
121. 166 to calibrate the X and R noise thresholds Then return to the full calibration and continue Thermo Scientific APEX User s Guide Page 57 d Press the Go button to restart the full product calibration If this setting is too sensitive the following screen appears the low frequency low gain option e Low Frequency Low Gain Option Low Frequency Low Gain PHH1 172 Please note that this change in gain will result in the R and X noise thresholds being reduced by a factor of 4 f Press the Go button to restart the full product calibration If this setting is still too sensitive the following warning screen appears When this happens please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Saturation g Press the Back button to exit the calibration menu continued Page 58 Thermo Scientific APEX User s Guide 8 When the auto calibration function is finished the detector displays the Main Menu screen which should now look something like this Your screen will look different if IXR is enabled Product Name SPAGHETTI Notice that in our example the auto calibration function has learned the following basic parameters for our uncontaminated product in our example jars of spaghetti sauce e Detect level NN 53 e Phase angle 2 24 What the Main Men
122. 292 97 OPTIONS AUDITCHECK ALARM FAULT OUTPUT 9 78 248 35 VALIDATION 1Q 0Q PQ e A PRODUCT CHUTE FDA APVD POLYPROPYLENE L APPROVALS CE CERTIFIED EX Aa B cCSAus C md TR QUALITY SO 9001 CERTIFIED N 1 50 38 10 QJ i i 0 0 0 0 e 2 57 60 12 Lid O DIMENSIONS ARE IN INCHES WITH MILLIMETERS i SZ 8 00 203 20 9 H CADD DATABASE AUTOCAD 9 U DO NOT SCALE DWG scabE Imm UNNECESSARY SHaRP EDGES JOB NO zs mm E AIR INLET ThermoFisher REJECT Biol SCIENTIFIC COLLECTION BIN OUTLINE amp MOUNTING CUSTOMER APEX 500 Rx EOCATION HEAD amp PNEUMATIC REJECT SHEET 1 OF 4 A 2497 RELEASED USER REV REV E99 micro DESCRIPTION DATE ee D 07404m B006 A Derived From 007404 003 2010 Thermo Fisher Scientific 8 7 6 5 4 1
123. 2V BRN eo IN a E E ERI E E me SGL BLK PHOTO EYE REJECT VERIFY eoe SA NN TERMINAL NC1 IS THE NORMALLY CLOSED RELAY CONTACT OF RELAY RL1 TERMINALS NC2 NC3 NC4 NCS AND NC6 ARE NEUTRAL COMMON CONNECTION WHEN WHITE JUMPER WIRE IS ADDED BETWEEN PSU J1 N AND RELAY Je NC6 Ee ORBKSIOREK NIZ NIZ NIZ N Q z N lt s peo ca RT c Al Z m 4 M O 2 Eg lt r 12V BRN m B CONVEYOR SPEED SENSOR SPEED SENSOR SPEED SENSOR COM BLU z NOTES 1 ALL WIRING MUST BE IN ACCORDANCE WITH THE NATIONAL Tx RELAY PCBA J1 AND J2 CONTACT RATINGS ELECTRICAL CODE AND ALL LOCAL CODES 10A 125VAC 2 WIRE GAGE REQUIREMENTS MINIMUM WIRE SIZE A POWER AC 120 240V 16AWG RELAY PCBA J1 J2 OUTPUTS ARE FUSED AT 2AMP 250V B INTERLOCKS 22AWG SUPPLIED W INTERLOCK COOPER BUSSMANN PC TRON FUSE OR EQUIVALENT C SPEED PICK UPS 22AWG D DIVERTER REJECT 18AWG 2225 ADDED RELAY OUTPUT CONTACT RATINGS B 1906 ADDED APEX 300 CONVEYOR 1054 RELEASED DESCRIP TION RELAY PCBA RELAY OUTPUTS RS232 RS485 e He SERIAL PRINTER RS 232 INTERFACE 9 PIN D CONNECTOR GND 5 GND 6 0sr TX 7 RIS E p 25 PIN D CONNECTOR FI sese NC6 2 4 5 C6
124. 45 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 i 75 2 95 SQUARE APERTURE HEADS A amp B mm mm 75 145 250 100 145 250 ry 125 145 OR 250 501 97 541 97 Ei 150 145 OR 250 175 145 OR 250 155 6 09 APERTURE WIDTH 75 2 95 200 TASSE A 230 9 06 225 145 OR 250 250 145 OR 250 4X 32 1 26 4X M10X1 5 V 12 47 75 2 95 FOOTDIMENSION TABLE C D E mm INCH mm INCH mm INCH 8 145 571 1003 94 22 5 89 i 250 9 84 200 7 87 25 98 AUDIT CHECK C OPTIONAL HEAD WIDTH s HORIZONTAL APERTURE 250 9 84 HORIZONTAL PRODUCT FLOW Y 2X E TOLERANCE UNLESS SPECIFIED ENGINEER DATE i ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 5 31 07 Th F h Coe ermorisner 75 2 95 DRAWN BY DATE XXX DMG 5 31 07 S CI ENTI F C ANGLES CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 5 31 07 SHARP EDGES 2 100 3 74 a 29 98 This document is confidential and is the property of Thermo Fisher APEX 300 OUTLINE AND MOUNTING Scientific Thermo It may not be copied or reproduced in any PART NUMBER pde 810108 SEE SHEET 1 FOR REVISION INFORMATION nu n SCALE size DRAWING NUMBER REV SHEET REV ECO DESCRIPTION BY APP DATE Jmm M 1 3 B 07387M B300 A 2015 4 3 Derived From 2007 by T
125. 55 Detailed List of Modbus Registers eee rere re rte ere 357 Appendix B I ntelliTrack XR esee nennen 367 QU M cr 369 System Requirements sss en eee heme hehe nemen sess 369 Product Requirerents 369 Discussion of Product lt senem 370 Setting Up Related Functions cesses nnnm 371 Keying In the Pack Length eene sensns 371 Keying In the Detection No Pack Distance 372 Keying In the In Feed Photo Eye 374 Enabling Photo Eye Registration 376 Enabling the IXR Function onec en the o aee eter e eap Aud 378 Calibrating the IXR Function iso ecu ener na ened sacs coven Pra Erc rowed nei a reads 380 Learn the X and R Noise Thresholds ssssssssssssss mmm 380 Using the Auto Calibration Function 382 Using the I XR Calibration Function ssssssssess mmm men 385 Using the I XR Detect Level Calibration 385 EMR Tracking tech decade attente etuer tex ctl MA spud E 387 Understanding the IXR Display b snc eee oen rene 388 MPOUDICSNOOMING
126. 6385 to one 1 When you enter the product number in this register all APEX settings for this product are automatically updated and the APEX is now ready to start analyzing the new product you specified Example Imagine you are a Supervisor at a food packaging company During the morning shift your equipment packages milk product 001 and during the afternoon shift it packages ice cream product 002 In this example the number 001 was automatically assigned by the APEX software to milk because this was the first product you set up Similarly the number 002 was automatically assigned to ice cream because it was the second product you set up To view the list of currently set up products and to access their product numbers do the following 1 Go to the APEX Main Menu to display the currently running product in our example this is product 001 milk Product Name 30 5 ee aS A 36 66 continued Thermo Scientific APEX User s Guide Page 353 2 Press the right navigation button to display the next product product n 1 which in our example is product 002 ice cream Product Name ICE CREAM 3 Continue pressing the right navigation button to review all other products Retrieving Statistical Information In any production environment good record keeping is important because it allows you to monitor the detector s performance keep careful qua
127. 66 continued Page 70 Thermo Scientific APEX User s Guide 6 Press the Go button The detector immediately starts measuring calibrating the background X and R noise thresholds and the monitor screen below presents a bar graph of the progress of the calibration process The calibration takes roughly 20 seconds to complete Calibrate Noise Thresholds Bl Lg 1 uu pp 1 When finished the monitor screen disappears and the Calibrate Noise Threshold menu shown in step 5 reappears The screen now displays the calibrated measured values for the X and R noise thresholds and because these are background values the numbers should be low If the numbers are high it may be difficult to detect small metal contaminants over the background noise e Reducing High X Noise Thresholds An X threshold in excess of 1 000 usually indicates there is a problem with excessive vibration in your application As a general rule as the severity of the vibration increases the X threshold also increases Possible remedies include making sure the detector is completely isolated mechanically from the surrounding duct and or installing shock mounts for the detector e Reducing High R Noise Thresholds An R threshold in excess of 200 usually indicates that one or more of the following conditions is present o Excessive noise from electro magnetic currents EMCs and variab
128. 83 5 7 11 1 Thermo SCIENTIFIC PERADE Dy letal Detector 0 INTEGRAL VERSION TOLERANCE UNLESS SPECIFIED ENGINEER DATE CONDUIT ADAPTER NOTES ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 2 15 07 Th erm Fi sh er N ELECTRICAL ACCESS HOLES ARE SIZED FOR M20 CONDUIT FITTINGS OR CORD GRIPS 5 CORD GRIPS SUPPLIED X i i ron DRAWN BY DATE 1 2 NPT FITTINGS WILL NOT FIT INTO HOLES AND THEREFORE REQUIRE THE USE OF THE SUPPLIED ADAPTER 49 T 2 15 0 S C E N T C X XX 13 005 A N REMOTE VERSIONS A NEW REMOTE CABLE IS OPTIONAL FOR DSP3 AND METAL ELIMINATOR MODELS ANGLES 5 STANDARD UPGRADE UTILIZES EXISTING REMOTE CABLE DSP2 MODELS REQUIRE THE PURCHASE OF A NEW T CHECKED BY REMOTE CABLE ATO 12 LENGTHS CABLES LONGER THAN 98 4 FT ARE AVAILABLE REMOVE ALL BURRS amp UNNECESSARY DMG 2 15 07 AS A SPECIAL ORDER UP TO 90M 295 SHARP EDGES PAETE ESEE TETEE PARTNUMGER Aare B 1393 ADDED DSP2 NOTATION CHANGED NOTES DG RLK 3 28 07 _ seynen Terme menas jo 810106 DSP2 3 METAL ELIMINATOR TO APEX ute cud CF eng ter DE RIK 3 12 07 SCALE ise DRAWING NUMBER REV SHEET REV ECO DESCRIPTION BY APP DATE 1 4 B 07387M B002 B 1of2 Der
129. 990 ms 30068 41079 1 16408 24 R W unsigned short P Reject Confirm 2 Time 0 to 9990 ms 30069 41080 1 16409 25 R W unsigned short P Rejecter 2 Delay 0 to 5 000 mm 30070 41081 1 16410 26 R W unsigned short P Rejecter 2 Duration Distance 0 to 20 000 mm 30071 41082 1 16411 27 R W unsigned short P Rejecter 2 Duration Time 0 to 9990 ms 30072 41083 1 16412 28 R W unsigned short P Reject Suppression Time 0 to 9990 ms 30073 41084 1 16413 29 R W unsigned short P Reject Suppression Attenuation 0 to 100 30074 41085 1 16414 30 R W__ bitmap P Reject Suppression Trigger Source Bit 0 External Trigger Bit 1 Reject Output 30075 41086 1 16415 31 R W enum P PNR Filter 0 Disabled 1 Enabled 30076 41087 1 16416 32 R W enum P QNR Filter 0 Disabled 1 Enabled 30077 41088 1 16417 33 R W enum P CLX Filter 0 Disabled 256 CLX Ratio of 1 512 CLX Ratio of 2 768 CLX Ratio of 3 Thermo Scientific APEX User s Guide Page 359 5 3 8 8 3 2 ya 9 s n p E a g D g 9 97 gt 9 2 vy os o _ v ga 22 2 Pj SU S od o 16 16 gt x c zu zc amp a 4 a ao a 30078 41089 1 16418 34 R W enum P Search Head Frequency 0 Low F
130. APEX to set the reject 2 confirm time When the calibration is complete the APEX closes this screen and displays the appropriate reject 2 confirm time continued Page 148 Thermo Scientific APEX User s Guide 7 Reactivate your reject 1 device by going to the Outputs menu and assigning Output 1 to your reject 1 device as shown below For detailed instructions on doing this see the Output section of the manual Output 1 Function Troubleshooting Procedure Should the Calibration Fail If you see the following warning screen during the reject 2 confirm time calibration procedure check the following e If this warning screen appears before you pass a contaminated package check the polarity of the reject 2 confirmation input The reject confirmation can only be learned if the input is not active until the reject 2 device fires For example if the reject 2 confirm input is set to 3 the voltage on the input cannot be zero volts until after the reject 2 device has fired e So change the polarity highlight the reject 2 confirm time calibrate icon then press the Go button to redo the calibration Thermo Scientific APEX User s Guide Page 149 Phase Angle Page 1 For a brief overview of what phase angle is and its importance to the art and science of metal detection see page 278 As a general rule the following phase angles are representative of the following types of contaminants and non cont
131. CRIPTION BY APP DATE MOON 1 6 B 07387 301 C 163 Derived From 2008 by Thermo Fisher Scientific 44 11 1 THRU N EQUALLY SPACED ON B C B C ZERO VELOCITY i FIELD COMPRESSION FLANGES 30 762 OUTLET FLANGE DETAIL SOME SYSTEMS SEE TABLE MAX AUDIT CHECK OPTIONAL i i i 41 10 3 A T 7 E y V PLASTIC INSULATING MOUNTING SPACER 1 4 SUPPLIED T as PLASTIC INSULATING T SHOULDER WASHER SUPPLIED P H DETAIL A 1 TOLERANCE UNLESS SPECIFIED ENGINEER DATE M ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS DMG 2 14 08 Th erm Fi sh er FoF EJECT 06 1 5 e YS X XX 03 8 010 25 DMG 2 14 08 S C E N T F C ANGLES 5 CHECKED BY DATE REDE amp UNNECESSARY DMG 2 14 08 APEX 300D OUTLINE AND MOUNTING HARP EDGE Y Y This document is confidential and is the property of Thermo Fisher PART NUMBER DROP THROUGH GRAVITY SYSTEM Scientific Thermo It may not be copied or reproduced in any See nected TBD CEILING MOUNT Oty rate eon eco S SEE SHEET 1 FOR REVISION INFORMATION wo ess avi acces lo i wat MOY POI COP SCALE SIZE DRAWING NUMBER REV SHEET REV ECO BY APP DATE authorized by Thermo 9 B 07387 M B301
132. Check Lock PHA 001 cma 520281 002 13 26 B 88 AUDIT 1 4 13 25 continued Page 208 Thermo Scientific APEX User s Guide Why Locking the AuditCheck Values Is Useful Locking the AuditCheck values for phase angle and peak signal is useful because it prevents the less accurate auto calibration values over writing the more accurate AuditCheck values Auto calibration values are inherently more variable because the response of the search head to the passage of a contaminant is dependent on position for the simple reason that the edge of the head is significantly more responsive than the center As a result the AuditCheck values are significantly more accurate than the auto calibration values for the following reasons First the AuditCheck sample always passes through the head in exactly the same position and second the AuditCheck sample passes through the edge of the search head where its response to metallic contaminants is greatest Locking the AuditCheck Values 1 To lock the AuditCheck values for phase angle and peak signal highlight the padlock function 2 Press the Go button and the X changes to a check mark 3 Press the Back button to lock these values and exit the function Setting Manual Start Timing Limits and Reject Device Parameters These functions have already been described in detail for the Quality Test function in the Quality Test section starting
133. Confirm Input Enter a reject confirm time for your reject 2 device Described below Calibrate the system Described below Entering a Reject Confirm Time for the Reject 2 Device To enter a reject confirm time for your reject 2 device do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 1 continued Thermo Scientific APEX User s Guide Page 145 2 Press the Go button and page 1 of the rejects menu appears Reject 3 Navigate to page 6 Reject Confirm 4 Navigate to the Reject 2 Confirm Time function and make sure it is highlighted Reject 2 Confirm Time eer 1 5 Press the Go button input screen appears Enter the appropriate time interval In the example below we entered 0 5 seconds Reject 2 Confirm Time 6 Press the Go button to save your setting and exit the menu Page 146 Thermo Scientific APEX User s Guide Calibrating the Reject 2 Confirm Time In order to calibrate the reject 2 confirm time that is have the APEX set the appropriate time for you you must do the following e Turn off your reject 1 device by going to the Outputs menu and setting the logically assigned value to X off as shown below For detailed instructions on doing this see the Output section of the manual So change the reject 1 ou
134. D LOCK THE ELECTRI CAL SUPPLY Safe Disposal of the Detector See Safety in Transportation Handling and Installation for procedures There are no hazardous materials used on the metal detector head or system Page 314 Thermo Scientific APEX User s Guide Training Needs of Users We offer all customers full training for operations and maintenance staff Electrical Safety of the Detector Please note the following Earth Ground For more information see page 286 Supply Voltage Requirements and Connections For more information see pages 285 and 288 Other Wiring During Installation For more information see page 284 Electro Magnetic Environment Loss of sensitivity and false rejecting can occur under the following conditions Your metal detector is located close to equipment using variable speed controllers or high frequency heating equipment Your metal detector is located close to another metal detector operating at similar frequencies Walkie talkie hand held or radio frequency devices are operated close to the metal detector Loss of sensitivity may go unnoticed due to radio frequency RF signal swamping the input circuits If there is any doubt check calibration of the search head under these circumstances For assistance in finding solutions to your EM problems contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Low Voltage Dir
135. DU ERE 113 Peak Sigal 114 Frequency and Gain me essen nn 114 System and Tools MQNU ccccece cece ence eee e nese eese me mene n 115 Security cione ad A each et e ee 115 Main Sub Menu Page 1 nnn 115 Starting a Complete Product 116 Editing the Product Name ssssssssssssssseee eme sense heme here en ten nenne 116 Main S b Menu PadgeZ oie eU IR D RENTE LEE MEE E LES 116 Setting the Pack Length eee enne seen messen 117 Setting the Pack Gap o ee 117 Setting the No Pack Distance nemen 117 Rejects Menu Pade 1 belt Up nep ues 118 Resetting the Counts for Reject 1 118 Setting the Distance to the Reject 1 119 Changing the Units of MeaSure cece eee mme esee e nennen 119 Page 4 Thermo Scientific APEX User s Guide Setting the Signal Duration for the Reject 1 Device 119 Displaying the Number of Quality Test 120 Displaying the Numbe
136. E 268264 1 CPU M B TO S H BOARD CABLE 268265 1 PCBA POWER SUPPLY UNIT APEX 268392 1 PCBA RELAY BOARD APEX 268393 1 PCBA SEARCH HEAD DSP3 079073 1 SP2 Spare Parts Kit Apex 500 CONTROL PANEL ASSY APEX 500 089275 1 PSU CPU M B CABLE 268264 1 CPU M B TO S H BOARD CABLE 268265 1 PCBA POWER SUPPLY UNIT APEX 268392 1 PCBA RELAY BOARD APEX 268393 1 PCBA SEARCH HEAD DSP3 079073 1 All changes to this document must be approved by the product engineer New revisions must be given to the ECO coordinator and distributed to all relevant global manufacturing affiliates REC F 90B Page l of 1 ThermoFisher This page intentionally left blank Thermo SCIENTIFIC APEX Metal Detector Quick Start Guide Control Panel The main components of the detector s control panel are as follows e The display panel e The three red green and yellow indicator lights e The green Go button e The red Back button e The four blue triangular shaped navigation buttons Display panel Indicator lights Back button Go button Navigation button The Indicator Lights These give you a quick overview of how the detector is functioning e Red Flashing once indicates excess product effect steady indicates a fault e Green Indicates a product is present in the detector s search head e Yellow lndicates a contaminant has been detected in the product The Navigation Buttons These allow you to navigate around
137. E D 07404m B006 A Derived From D07404M BO03 2010 Thermo Fisher Scientific 8 7 6 5 T 4 3 2 1 ITEM PART NO QTY DESCRIPTION DWG NO SPEC SEARCH HEAD ARM 1 11 97 304 07 4X 8 260 6 5 I 6 66 69 18 ACCEPT o e 7 2 00 50 80 O D 7 25 184 15 3 83 97 18 8 98 228 19 D jE E t D 9 22 03 HE 1 coll p 180 19 I D ANZ POWER SUPPLY INLET CONTROL amp POWER SUPPLY CROSS BLOCK d 2 75 69 85 4 38 111 34 23 13 587 51
138. EAS gt 2X Inverting the Reject Function for Reject 2 This is set up in exactly the same way as the reject 1 device See page 123 Inverting Reject P881 861 ene om x Em 0 605 an x 5 6 gt 2x EG om x Page 144 Thermo Scientific APEX User s Guide Rejects Menu Page 6 This menu allows you to set up a time a time interval in seconds during which a package rejected by your reject 2 device must pass the photo eye monitoring your reject 2 bin allowing the reject to be confirmed Thus in order for this function to work you must do the following Make sure that your reject 2 device is downstream of your reject 1 device Ina typical conveyor application this means the reject 1 device is used to reject contaminated packages and the reject 2 device is used for AuditCheck and or QAT rejects Set up a photo eye to monitor packages entering the reject 2 bin Physically attach the photo eye to one of the detector s input terminals Inputs 1 6 For detailed instructions on doing this see the Inputs section of the manual Tell the APEX which Input 1 6 is being used that is make the logical assignment and set up the appropriate polarity for the signal from the reject 2 photo eye For detailed instructions on doing this see the Inputs section of the manual The example below shows that we have assigned our reject 2 photo eye to Input 5 with a positive polarity Reject 2
139. ERT MODE OF OPERATI N CUSTOMER APEX 500 RX LOCATION PNUEMATIC REJECT DEVICE APEX METAL DETECTOR 297 RELEASED 65 user DESCRIPTION D07387M WO04 8 7 6 5 4 3 Derived i 2010 Thermo Fisher Scientific 1
140. ESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE IN INCHES AND MILUMETERS DMG 4 23 08 Th erm Fi sh er 06 1 DRAWN BY DATE X XX 03 8 j ADAPTER X XXX 010 25 DMG 4 23 08 S C E N T F OPTIONAL ANGLES 5 CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 4 23 08 APEX OUTLINE AND MOUNTING SHARP EDGES rag eaaa ee of PART NUMBER PIPELINE SYSTEM i TBD CEILING MOUNT adverte or ico Ur ce Felis i Aa ae Be MOE BENER RIK RIK 51408 seers mc Wy toc ty fete SCALE DRAWING NUMBER REV SHEET REV ECO DESCRIPTION BY APP 1 8 B 97887M B302 XX A 1of2 Derived From 2008 by Thermo Fi sher Scientific 75 19 1 J5 19 1 11 25 285 8 eu m J5 19 1 __ l Y in i 75 19 1 REJECT VERIFIY OPTIONAL 9 00 228 6 1 00 25 4 cm MOUNTING PLATE xi 11 00 279 4 TOLERANCE UNLESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE ININCHES AND MLUNETERS DMG 4 23 08 Th F h 06 1 5 ermo IS er d T 25 DMG 4 23 08 S C T F ANGLES 5 CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 4 23 08 APEX
141. For example in a pipeline application where a contaminated raw material such as canola oil is diverted to a waste tank this function is used to confirm that normal flow has resumed to your manufacturing process Reject Confirm 2 Input 1 Press the Go button and an input screen appears 2 Make the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Assigning the Reject 2 Confirm Input This function assigns the input for the reject 2 confirm photo eye In a conveyor application for example the reject 2 confirm photo eye monitors reject bin number 2 and verifies that the reject has actually occurred It is often used in conveyor applications fitted with two reject devices one that handles contaminated products and the other that handles AuditCheck and Quality Test rejects Reject 2 Confirm Input 1 Press the Go button and an input screen appears 2 Make the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Page 230 Thermo Scientific APEX User s Guide Clearing All WAF Inputs This input can only be set to positive values When this input is closed that is is positive the APEX clears all resettable warnings alarms and faults WAFs Please note however that system
142. GES JOB a e o ee aes ct A A th ht la ublished work Those havin to this work not r disclose th TOLERANCE B5 information 1n tha work unless expressly authorized by Thermo Fisher Selenting e the UNLESS SPECIFIED a DWN P ermorisner OL rx 5 08 Pee ae A aS SST CASTER OPTIONAL APEX OUTLINE amp MOUNTING CUSTOMER PIPELINE SYSTEM EIN FLOOR STAND SHEET 1 2 usd RELEASED 7 3 08 RIK KK USER LOCATION REV DESCRIPTION DATE D 07387M B303 xx Derived From 2008 by Thermo Fisher Scientific 8 7 6 5 3 2 1 PRODUCT TUBE E METAL i d V we TUBE LENGTH DETECTOR SPOOL PIECE CENTER VALVE WITH OVERALL SYSTEM NOMINAL IN APERTURE WITH GASKET SUPPORT GASKET TUBE LENGTH SIZE SZ CLAMP inch PIPE 24 610 18 T US HOSE 36 914 100 ma t 2 5 OR 3 PIPE 24 610 100 55 seco lisri el soe oes 25 HOSE 36 914 100 2458 MEE QN 1189 7 PIPE 24 610 125 13 12 333 2 stis aseo 56 00 1270 0 HOSE 36 914 150 1235 7 CADD DATABASE AUTOCAD without the written of Thermo Fisher Scientific This document also is unpubli work of Thermo ene Thermo Fisher Scientific intends 2 is amomong s confidential information Bi a P TOLERANCE UNLESS COPIED Thermo
143. I nformation choose one Credit 1 you wish to pay by credit card please contact Thermo Fisher Scientific see the Contacting Thermo Fisher Scientific section at the end of the manual Please note that in order to protect our customers from accidental data compromise Thermo Ramsey Inc does not accept credit card numbers via email or fax Purchase order f you wish to pay via PO please send an official hard copy with this form Warranty Page 266 Thermo Scientific APEX User s Guide Problem Part 1 APEX serial number Part number Description of part Description of problem Product I nformation Sheet Problem Part 2 APEX serial number Part number Description of part Description of problem Problem Part 3 APEX serial number Part number Description of part Description of problem Thermo Scientific APEX User s Guide Page 267 Decontamination Declaration Form Please complete all parts of the decontamination declaration form In addition please note the following e Orders without a completed decontamination declaration form will not be processed and the equipment will be returned to the sender via collect freight e Please send this decontamination declaration form with a hard copy of your purchase order PO to the fax number or email address in the Contacting Thermo Fisher Scientific section at the end of the man
144. IXR dual bar graph display a textual description of the problem is also displayed Photo Registration Not Set The following information box appears when the photo registration has not been set X 0 cx Sx Solution Go to the Enabling Leading Edge Photo Registration section above for instructions about setting the proper photo registration Photo Eye Distance Is Set to Zero If the photo eye distance is set to zero an invalid setting for the IXR function the following information box appears Solution Go to the Keying In the In Feed Photo Eye Distance section above for instructions about setting the appropriate photo eye distance Thermo Scientific APEX User s Guide Page 391 The Six Product Maximum Has Been Reached If you attempt to set up more than six products the maximum allowed by the IXR function the following information box appears Solution Delete one of the previously set up products Signal Saturation Has Occurred If signal saturation occurs while you are calibrating the IXR function the following warning box appears Solution Go to the Frequency and Gain menu and adjust these settings to a lower level If the problem persists please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Page 392 Thermo Scientific APEX User s Guide Glossary In this glossary any term in italics refers to a
145. MATIC REJECT LOCATION APEX 500 Rx SYSTEM SHEET 2 OF 3 ste SHEET 1 R DESCRIPTION 8 7 Do7404m B005 Derived From D07404M 8001 2010 Thermo Fisher Scientific 4 3 2 1 ITEM PART NO DESCRIPTION DWG NO SPEC 18 00 457 2 ROUND PORT ACCEPT STREAM HEIGHT ADJUSTMENT WITH REJECT BIN 3 83 97 2 6 50 165 1 CHUTE WIDTH ALARM FAULT OUTPUT 55 14 1 OPTIONAL CLEARANCE BETWEEN CHUTE AND BASE 35 CONTROL UNIT 15 16 384 9 SEARCH HEAD pus 228 2 23 13 587 5 4 38 111 3 POWER SUPPLY INLET LINE HEIGHT 2 00 50 8 35 00 9 5 9 5 PORT O D 48 65 1235 8 WITH AUDITCHECK 5 Xy OR 35 00 49 5 11 5 WITHOUT AUDITCHECK REJECT COLLECTION BIN GOOD PRODUCT PORT AIR INLET 22 30 566 3 AT 35 INFEED HGT DIMENSIONS ARE IN INCHES WITH MILLIMETERS CADD DATABASE AUTOCAD DO NOT SCALE DWG SCALE 93 00 976 2 MES m 3 E 7 00 177 8 3 88 98 6 UNNECESSARY SHARP EDGES 208 TOLERANCE 10 00 254 0 25 00 635 0 18 00 457 2 OUTLINE AND MOUNTING CUSTOMER PNEUMATIC REJECT LOCATION APEX 500 Rx SYSTEM SHEET 3 OF 3 SEE SHEET 1 PART_NO DRAWING NUMBER RI DESCRIPTION Do7404m B005 8 7 Derived From D07404M BO01 2010 Thermo Fisher Scientific 6 5 4 3 2 1 ITEM PART NO DESCRIPTION DWG NO SPEC 307 00 12 09 304 07 11 97 6 5 260 4 OFF AUDITCHECK OPTIO
146. MILLIMETERS AND INCHES X X X X XX ANGLES REMOVE ALL BURRS amp UNNECESSARY SHARP EDGES SEE SHEET 1 FOR REVISION INFORMATION REV DESCRIPTION BY APP DATE This document is confidential and is the property of Thermo Fisher Scientific Thermo It may not be copied or reproduced in any manner without the expressed written consent of Thermo This document also is an unpublished work of Thermo Thermo intends to and is maintaining the work as confidential information Thermo also may seek to protect this work as an unpublished copyright In the event of either inadvertent or deliberate publication Thermo intends to enforce it s rights to this work under the copyright laws as a published work Those having access to this work may not copy use or disclose the information in this work unless expressly authorized by Thermo PART NUMBER 810108 ENGINEER DATE DMG 5 31 07 Th F h DRAWN BY DATE ermo IS er DMG 53107 SCIENTIFIC CHECKED BY DATE DMG 5 31 07 APEX 300 OUTLINE AND MOUNTING PROJECTION SCALE 1 3 s ze DRAWING NUMBER REV B 07387M B300 A SHEET 5of5 Derived From 2007 by Thermo Fisher Scientific 4X 1 11 28 1 AX G 26 6 6 THRU 1 11 18 284 2X
147. Make sure the detector s Main Menu is displayed Product Name 2 Select the product speed menu Product Speed continued Thermo Scientific APEX User s Guide Page 27 3 Press the Go button and the product speed input screen appears The figures in your screen however may be different because the screen displays the last setting used Product Speed 4 Use the navigation buttons to input the speed of the conveyor in meters per minute or feet per minute Press the Go button to save the conveyor speed and exit the input screen 5 Note that the speed of the conveyor is now displayed in the product speed section of the Main Menu Keying In the Photo Eye to Detector Distance The photo eye to detector distance is a critical parameter that must be entered to ensure your conveyor application works correctly 1 Take a tape measure and note the distance from the photo eye on the upstream or in feed side of the detector to the in feed side of the detector s search head 2 Make sure the Main Menu is displayed Product Name 3 Navigate to the system and tools menu System and Tools Page 28 Thermo Scientific APEX User s Guide 4 Press the Go button and navigate to page 3 of the system and tools menu System and Tools Page 3 5 Navigate to the photo eye set up menu PE distance and
148. NAL 184 15 7 25 267 74 10 54 B C 135 00 5 31 1 180 19 d 250 00 RN L 98 94 FIXING CRS 128 00 5 04 136 50 inl CONTROL amp POWER SUPPLY CRS 25 00 98 SEARCH HEAD APERTURE SIZES 100mm WIDE X 25mm HIGH 100mm WIDE X 35mm HIGH 100mm WIDE X 50mm HIGH CONSTRUCTION STAINLESS STEEL 304 ABS PLASTIC CONTROL PANEL FDA APPROVED FINISH STRAIGHTLINE STANDARD APERTURE HIGH POLISH OPTIONAL 100 X 25 21 84 86 CABLE LENGTHS 2 3 4 5 6 8 10 12 15 20 25 30 METER 98 55 3 88 100 X 35 31 75 1 25 ORTIONS AARM FAUT umur 100 X 50 46 73 1 84 VALIDATION IQ OQ PQ PRODUCT CHUTE BOTTOM FDA APVD POLYPROPYLENE TOP POLYCARBONATE APPROVALS CE CERTIFIED reussi cCSAus QUALITY ISO 9001 CERTIFIED 9 75 MEET 69 85 2 75 feni DIMENSIONS ARE IN MILLIMETERS WITH INCHES s PONE CADD DATABASE AUTOCAD DO NOT SCALE DWG PRODUCT CHUTE un CENSOR ET amp oid OPTIONAL RLK 7 22 09 x CUSTOMER LOCATION HGD A VALUES 0 23 10 ELEASED 22 09 pe D0 404M B002 B 8 7 6 5 4 3 Derived Tum D07390M 8003 2009 Thermo Fisher Scientific i SEARCH HEAD P ibid ARM 1
149. ND EXCLUSIVE REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT AND THE CORRECTION OF ANY DEFECT IN WORKMANSHIP IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES Purchaser agrees to underwrite the cost of any labor required for replacement including time travel and living expenses of a Thermo Fisher Scientific Field Service Engineer at the closest factory base Thermo Fisher Scientific 501 90th Avenue NW Minneapolis MN 55433 Phone 800 227 8891 Fax 763 783 2525 Page 316 Thermo Scientific APEX User s Guide Disclaimer Though the information provided herein is believed to be accurate be advised that the information contained herein is not a guarantee for satisfactory results Specifically this information is neither a warranty nor guarantee expressed or implied regarding performance merchantability fitness or any other matter with respect to the products and recommendation for use of the product process information in conflict with any patent Please note that Thermo Fisher Scientific reserves the right to change and or improve the product design and specifications without notice Thermo Scientific APEX User s Guide Page 317 Revision History Listed below is the revision history of the APEX User s Guide Revision number Date released ECO
150. NSIONS ARE IN INCHES WITH MILLIMETERS CADD DATABASE AUTOCAD DO NOT SCALE DWG SCALE 3 00 276 2 UNNECESSARY SHARP EDGES JOB NO aus 7 00 177 843 3 88 98 6 TOLERANCE ENG UNLESS SPECIFIED _ 06 10 00 254 0 25 00 635 0 18 00 457 2 OUTLINE AND MOUNTING CUSTOMER PNEUMATIC REJECT LOCATION APEX 500 Rx SYSTEM B 2585 uPDTAED PIVOT ARM amp ELEC S PLATE SHEET 1 OF 3 A paz USER 5 DESCRIPTION Do7404u 8005 Derived From D07404M BOOi 2010 Ay Thermo Fisher Selenite 8 7 6 5 4 3 1 2 ITEM PART NO DESCRIPTION DWG NO SPEC 18 00 457 2 ROUND PORI ACCEPT AND REJECT STREAM HEIGHT ADJUSTMENT 3 83 97 2 6 50 165 1 CHUTE WIDTH ALARM FAULT OUTPUT 55 14 1 OPTIONAL CLEARANCE BETWEEN CHUTE AND BASE 35 CONTROL UNIT 15 16 384 9 SEARCH HEAD pus 228 2 23 13 587 5 POWER SUPPLY INLET LINE HEIGHT 2 00 50 8 35 00 49 5 9 5 A PORT O D WITH AUDITCHECK vA S OR 35 00 49 5 11 5 WITHOUT AUDITCHECK 48 65 1235 8 GOOD PRODUCT PORT 92 00 50 8 INLET PORT O D REJECTED PRODUCT 22 30 566 3 PORT AT 35 INFEED HGT me N DIMENSIONS ARE IN INCHES WITH MILLIMETERS CADD DATABASE AUTOCAD 3 00 976 2 DO NOT SCALE DWG UNNECESSARY SHARF EDGES 7 00 177 8 3 4 3 88 98 6 TOLERANCE 10 00 254 0 25 00 635 0 26 18 00 457 2 OUTLINE AND MOUNTING CUSTOMER PNEU
151. Peak Test 1 0 to 65535 30094 n a 1 n a n a RO unsigned short P AuditCheck Learned Peak Test 2 0 to 65535 30095 n a 1 n a n a RO unsigned short P AuditCheck Learned Peak Test 3 0 to 65535 30096 n a 2 n a n a RO float P AuditCheck Learned Phase 45 00 to 135 00 degrees Average 30098 n a 2 n a n a RO float P AuditCheck Learned Speed 0 1 to 999 0 m min Average 30100 n a 2 n a n a RO float P AuditCheck Learned Phase Angle 45 00 to 135 00 degrees Test 1 30102 n a 2 n a n a RO float P AuditCheck Learned Speed Test 1 0 1 to 999 0 m min 30104 n a 2 n a n a RO float P AuditCheck Learned Phase Angle 45 00 to 135 00 degrees Test 2 30106 n a 2 n a n a RO float P AuditCheck Learned Speed Test 2 0 1 to 999 0 m min Thermo Scientific APEX User s Guide Page 360 5 3 B 8 3 2 9 2 n e n E o g D g 9 9 97 gt 9 2 9 T T os elt v2 2 t CM q o 16 16 i Sa zc amp 4 a a a 30108 2 RO float P AuditCheck Learned Phase Angle 45 00 to 135 00 degrees Test 3 30110 n a 2 n a n a RO float P AuditCheck Learned Speed Test 3 0 1 to 999 0 m min 30112 n a 2 n a n a RO float P QAT Learned Phase Angle Pack A 45 00 to 135 00 degrees 30114 n a 2 n a n a RO float P QAT Learned Phase Angle
152. Search Head Let s look at an example Looking at the figure on page 304 will help you understand the explanation that follows A milling company is monitoring the inflow of grain from their suppliers The grain falls down a duct under the influence of gravity and passes through the search head which surrounds the duct Whenever contamination is detected a gate immediately downstream of the detector slams closed in 50 milliseconds diverting the contaminated product to the reject bin After one second the gate slams open in 50 milliseconds allowing the product to again flow normally Unfortunately the vibration in the duct caused by the gate slamming open and closed is communicated to the search head which interprets the vibration as the passage of contaminated product To prevent this occurring any reject signal from the detector is suppressed for a period of time in our example 3 0 seconds after contamination is first detected Page 130 Thermo Scientific APEX User s Guide Activating Reject Suppression Reject 1 This function is normally used only in gravity feed and pipeline applications To activate or trigger the reject suppression process do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 2 Press the Go button and page 1 of the rejects menu appears Reject 1 P881 991 3 Navigate to 3 of the rejects menu Reject Suppression
153. Speed Sensor uses 5v auxiliary supply provided Keylock Product Select 1 Product Select 2 nfeed photo eye Reject Confirmation 1 bin full Reject Confirmation 2 External Suppression Electrical Supply 85 to 260 VAC 47 to 65 Hz 100 watts maximum Product Speed 0 5 m min 1 7 ft min to 1000 m min 3 300 ft min Air Supply AuditCheck 5 5 bar 80 psi Environmental e Operating Temperature o 10 C to 40 C 4 14 F to 4 104 F e Relative Humidity o 0 to 8096 non condensing o 80 to temperatures to 31 C 87 F decreasing linearly to 5096 relative humidity at 40 C 104 F Maximum Surface Temperature 60 C 140 F Altitude Up to 2000 m 1 2 miles Location Indoor or outdoor use Direct sunlight on the aperture could cause problems Protect the equipment from direct sunlight Environmental Protection IEC60529 IP66 NEMA 4X Ventilation None required Thermo Scientific APEX User s Guide Page 273 Front Panel Manufacturers GE Plastics Chi Mei Material reference Cycolac Polylac 757 Surface treatments None Operating temperature Continuous at 80 C 176 F Battery Approved type according to Table 3 of IEC 60086 1 Type E Battery type Sonnenschein SL 350 PCRN Nominal voltage 3 6 V Electrochemical system Lithium thionyl chloride Rated capacity 1000 mA hours Standard Features and Options Listed below are the standard features and options available for your APEX 500 300 an
154. TED BUTTER by navigating to the appropriate letter in the keyboard and pressing the Go button on the detector s control panel Use the keyboard s Space key to create the gap between the two words When finished your keyboard screen should look like this du 7 Highlight the exit and save key using the navigation buttons on the detector s control panel and press the Go button on the detector s control panel to save the name of the product you are testing in our example SALTED BUTTER Page 26 Thermo Scientific APEX User s Guide Setting Up the Conveyor and Photo Eye This section assumes that the photo eye is already connected to the detector using Input 2 on the wiring board and the conveyor is already running For more information about hard wiring your detector see page 289 In addition the example below assumes you are testing packets of salted butter as described above in the Naming the Product section Keying In the Product Speed This section assumes the conveyor belt is running and that you have already calculated its speed in either feet per minute or meters per minute using a mechanical tachometer Before proceeding make sure you have already set your preferred units of measure metric or imperial and that these are currently being displayed in the detector s display panel For more information about your setting your preferred units of measure see page 22 1
155. TPUT PSU J2 1 WHEN C DIVERTER REJECT 18AWG HIGH SPEED 12VDC REJECT COIL IS REQUIRED FIELD WIRING DIAGRAM CUSTOMER APEX 300 METAL DETECTOR LOCATION m GRAVITY FEED AND PIPELINE B 2225 ADDED RELAY OUTPUT CONTACT RATINGS 8 8 55 USER uo 6 1906 RELEASED 07 10 08 8656 SEBS REV 589 micro DESCRIPTION DATE D07387M WO042 Derived From 2007 Thermo Fisher Scientific 1 8 7 6 5 4 3 2 A REJECT VERIFY 2 SENSOR IS OPTIONAL TEM PART NO DESCRIPTION DWG NO SPEC FAILSAFE OPERATION APEX 500 RX PSU AND RELAY ASSEMBLY THE WIRING DIAGRAM SHOWN WILL ALLOW THE APEX RX METAL DETECTOR TO OPERATE IN FAILSAFE MODE THE APEX RX REJECT GATE WILL ONLY BE SET TO THE ACCEPT STREAM IF THE APEX RX PSU PC BA RELAY PCBA HAS POWER APPLIED HAS AIR SUPPLIED TO THE REJECT AND THERE ARE NO ACTIVE INPUT POWER 12VDC OUTPUTS INPUTS INPUTS RELAY OUTPUTS RELAY OUTPUTS RS232 RS485 FAULTS WITH POWER OR AIR REMOVED OR AN ACTIVE FAULT IS PRESENT THE APEX RX REJECT SERIAL PRINTER GATE WILL BE HELD IN THE REJECT STREAM RS 232 INTERFACE BY THE SPRING UN THE PNEUMATIC VALVE 85 TO 264 VAC ASSEMBLY 50 60 HZ 1 PHASE 9 PIN D CONNECTOR URNA REFERENCE DRAWING Ro SET DUTPUT 1 REJECT AND DUTPUT 5 DISCDNNECT AND WIRE 007355 009 FOR FAULT FAULT TO INVERT MODE OF OPERATION OVERCURENT PROTECTION ALARM FAULT OUTPUT INVERTED BY CUSTOMER 7 FIELD WIRING DETAILS 5
156. Thermo Scientific APEX Metal Detector User s Guide REC 4248 Rev J Part number 085381 English 2009 Thermo Fisher Scientific Inc All rights reserved For future reference write your APEX serial number below APEX serial Page 2 Thermo Scientific APEX User s Guide Table of Contents Getting Started FERE AKMMREE s 11 Setting Global and Application Specific 11 Setting Product ehem esee nnn 11 Managing Product Rejection Parameters 12 Choosing Your Application 12 Setting Up Conveyor Applications HEN IE 13 Understanding Your Detector redu oder nteger deber xix 14 Understanding the Detector s Control 14 Using the Detector s 15 Understanding the Screen Shots Used in this 16 Understanding the Detector s Main Menu 17 Choosing a Language ates docete dived eq dude ee i ag 17 Clearing the Speed Filter Warning Screen 20 Displaying He
157. Thermo Scientific APEX User s Guide Page 169 System and Tools Page 2 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and page 1 of the system and tools menu appears Navigate to page 2 by pressing the down navigation button System and Tools Page 2 METRIC HOH Viewing Your Speed Filter Settings The type of speed filter narrow band or wide band used by the APEX is set at the factory and depends on the type of application you are running conveyor gravity feed pipeline or pharmaceutical The screen below shows the narrow band filter which is used by conveyor and gravity feed applications and is the default setting Please note that if you are running a pipeline or pharmaceutical application this screen will show the wide band filter the default setting Speed Filter Calibrating the Speed Filter The speed filter calibration process differs depending on which type of application you are running conveyor gravity feed pipeline or pharmaceutical 1 Make sure the speed filter menu is highlighted Speed Filter Page 170 Thermo Scientific APEX User s Guide 2 Press the Go button and page 1 of the speed filter menu appears Speed Filter Setup NNI 861 3 Press the right navigation button to highlight the calibrate function Calibrate Speed Filter P B1 901
158. This field can cause very small electrical currents to flow in nearby metal structures This causes no problem if the loops are completely closed but if the electrical path is intermittent then false triggering of the detector is likely Typical causes of intermittent electrical loops include loose bolts on the framework or on the detector s mounting corrosion of metal work broken welds open hinged doors and broken or rubbing contacts Page 308 Thermo Scientific APEX User s Guide Interference be overcome by opening the conductive path with an insulating pad or closing the path by welding or tightening the bolts so that it cannot become intermittent The source of such loop interference can be very elusive and difficult to locate The larger the aperture in the APEX the greater the high frequency leakage out of the aperture and the greater the possibility of trouble from loops Metal Objects Near the Search Head The metal detector is very efficiently screened and metal near the top bottom and ends will not significantly affect the detector performance However metal positioned close to the aperture can cause interference problems if it moves or vibrates The area close to the aperture which should be kept metal free is known as the metal free zone This metal free zone is dependent upon the aperture dimensions and the sensitivity setting of the detector The metal detector is sensitive to moving metal It is not always
159. UPE You must key in your new password twice as follows a Key in your new password navigate to the exit and save key and press the Go button The display panel still shows the keyboard screen but a second key icon has appeared in the entry field b Key in your new password again navigate to the exit and save key and press the Go button The screen shown in step 7 above reappears Page 252 Thermo Scientific APEX User s Guide Setting Engineer and Operator Passwords Engineer Operator 1 and Operator 2 passwords are set in the same way as described above for supervisors 1 Go to the screen shown in step 7 in the Entering a Supervisor Password section above 2 Highlight the level Level 1 Level 2 or Level 3 for which you want to enter a password 3 Press the Go button and the keyboard screen reappears 4 Key in a new password for the level You must key in the new password twice as follows a Key in the new password navigate to the exit and save key and press the Go button The display panel still shows the keyboard screen but a second key icon has appeared in the entry field b Key in the new password again navigate to the exit and save key and press the Go button 5 Now that you as supervisor have set up passwords for all personnel using the detector you need to log out 6 See page 256 for log out instructions Retrieving a Forgotten Password This can only be done by a
160. WAF menu below Thermo Scientific APEX User s Guide Page 217 WAF Page 2 Page 2 of the WAFs menu looks like this Warnings Alarms amp Faults The following WAFs are accessed from page 2 e In conveyor application the belt has stopped e n a conveyor application there are no products on the conveyor but a contaminant has been detected e The product phase angle used to reject product has drifted beyond the limits you prescribed e There is a problem in the search head or oscillator In most instances this fault occurs because the head balance is out of the auto balance range and needs to be readjusted For further assistance please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual WAF Page 3 Page 3 of the WAFs menu looks like this Warnings Alarms amp Faults The following WAFs are accessed from page 3 e There was a problem when you ran the Quality Test function e There was a problem when you ran the AuditCheck function e The battery attached to the detector s CPU is getting low and needs to be replaced e The detector s CPU memory has been corrupted and should be reset to its factory defaults See page 186 for details Page 218 Thermo Scientific APEX User s Guide WAF Page 4 Page 4 of the WAFs menu looks like this Warnings Alarms amp Faults Hooooo AAS l
161. XX C 2 of 3 Derived From 2008 by Thermo Fisher Scientific TAB CHART LD HELD COMPRESSION BC F R PRODUCTTUBE METAL DETECTOR FLANGES BOLTCIRCLE RANGE 2 perg GRANGE ECTER HEIGHT TUBE HEIGHT e PERTURE mm inch mm C 145mm C 250mm inch mm inch mm inch mm inch mm inch mm HOLES inch mm inch mm inch mm inch mm inch mm inch mm 800 762 100 x 100 NO NO 5 00 127 0 60 152 5 13 36 20 919 5 165 419 4 20 508 9 20 2837 326 828 27 6858 7 178 23 584 400 101 6 125 x 125 NO NO 6 50 165 1 75 191 1 5 88 39 21 9959 17 5 445 4 20 508 11 21 2847 426 1082 28 7112 8 203 22 559 4 75 120 6 150 x 150 YES NO 7 75 1969 90 229 2 5 64 42 24 10729 18 5 470 8 20 508 13 24 3363 530 1346 29 7366 9 229 21 533 5 75 146 0 175x175 C 145 YES 26 660 9 229 21 533 925 2350 10 5 267 25 13 5027 1276 9 19 5 495 8 5 27 387 9 636 161 5 35 889 5 75 146 0 175 x 175 250 YES 24 610 11 279 19 483 787 2000 225 225 145 es 26 660 9 229 21 533 12 00 3048 135 343 25 13 5431 1379 5 21 5 546 8 9 31 490 5 836 2123 35 889 787 2000 225 225 250
162. a check mark appears The latching reject function is now active Latching Reject 3 Press the Back button to exit the function Page 122 Thermo Scientific APEX User s Guide Resetting the Latching Reject Function 1 When the latching reject function is enabled and the APEX detects a contaminated unit of product that must be manually removed from the conveyor the following screen appears in the detector s display panel Reject Latched 2 Remove the contaminated product from the conveyor 3 Clear the warning screen by pressing the Go button The detector is now ready to start analyzing your products Inverting the Reject Function Reject 1 In most APEX set ups products are rejected whenever metal is detected The inverting reject function however allows you to reject a product whenever metal is not detected You must have a photo eye installed for this function to work Inverting Reject FHH1 Bg 26 G22 a Example Imagine you are a breakfast cereal manufacturer running a conveyor application and every packet of cereal must go out containing a small plastic children s toy The toy manufacturer has hidden a small strip of child safe non toxic metal inside each toy allowing you to set the inverting reject function so that packets of cereal not containing metal are rejected In this example as a precaution the packets of cereal were tested for the
163. a high performance measuring instrument The quality of the installation has a direct effect upon performance and reliability Please read the installation instructions completely prior to installing the unit Definition of Various Product Effects Metal detectors are capable of detecting metal by measuring two effects resistive and reactive effects Resistive Effect Electrically conductive materials and many food products by nature are electrically conductive Salt and moisture content combine to produce resistive effects that must be overcome in order to detect small metal contaminants Page 276 Thermo Scientific APEX User s Guide Reactive Effect Ferro magnetic and electrically conductive materials produce reactive effects Iron is both electrically conductive and ferro magnetic The effect for small iron particles is ferro magnetic which is largely opposite that of a metal such as copper Copper is a strong electrical conductor Dry Products Dry products produce very little or zero product effect Examples of dry products are some tablets cookies candy chocolate dry powders oil based products such as peanut butter and cereals Wet Products Wet products produce a larger product effect Examples of wet products are bread buns cakes meat and dairy products Metal Film Products Products packaged using metallic wrappers usually require a low search head frequency such as 50 kHz Thermo Scientific APEX User s G
164. a n a RO unsigned short P X Capture Delay Time From Opto Break Until I XR Signal starts Value 4 time in ms 30176 n a 1 n a n a RO unsigned short P X Capture Length Time From Opto Break Until IXR Signal starts Value 4 time in ms Thermo Scientific APEX User s Guide Page 364 5 3 B 8 3 2 ya 9 s t n Sn g a 8 g 9 g 9 5 x gt o 9 a 29 2 EJT pa E 9 Y coo o i9 16 x t Sa zc amp a 4 a ao a 30177 1 n a RO enum M APEX Model 0 Model type not set 1 APEX 100 2 APEX 300 3 APEX 500 4 APEX 500 Upgrade 30178 n a 1 n a n a RO enum M Machine Type 0 Conveyor 1 Pipeline 2 Drop Through 30179 1 RO unsigned short M Search Head Width 0 5000mm 30180 n a 1 n a n a RO unsigned short M Aperture Width 0 250mm Does not apply to conveyors 30181 n a 1 n a n a RO unsigned short M Aperture Height 0 250mm Does not apply to conveyors 30182 n a 1 n a n a RO packed bytes M Software Version 1st Byte Major 2nd Byte Minor 30183 n a 1 n a n a RO packed bytes M Software Revision Beta 1st Byte Revision 2nd Byte Beta 30184 41149 1 16469 85 R W unsigned short M Current Year 2000 2099 Note In order to change date Current Month Day of Month
165. acceptable change for phase angle and the running average updated that is before the next package enters the search head For example if the current running average is 89 78 degrees and the limit for an acceptable change is 0 30 degrees the phase angle of the next package passing through the search head must fall in the range 89 48 90 08 degrees to be accepted and the running average updated Phase Angle 001 a v 8 38 1 8 86 To set a limit for an acceptable change in phase angle do the following 1 Highlight the acceptable change menu shown above 2 Press the Go button and an input screen appears Phase Tracking Limits 3 Key in your new setting for an acceptable change in phase angle in degrees and hundredths of a degree 4 Press the Go button to save your setting and exit the menu Thermo Scientific APEX User s Guide Page 155 Setting Limits for a Phase Tracking Fault Notification Use this menu to have the detector give you a fault notification when the phase angle of the product exceeds the default or user defined unacceptable change notification limit Phase Tracking Fault Limit FAHI 1 af oe et z 8 30 1 2 f E RENS EBEN In the example above the current phase angle setting is 90 degrees and the unacceptable change notification limit is a change in phase angle plus or minus 10 degrees Thus if the most r
166. aceutical applications test samples should be placed so they fall from same point as the product Ferrous Metals Are Easier to Detect than Stainless Steel The detector is not equally sensitive to all types of metal Depending on the type of product and application there can be three typical metal groups which will produce three different levels of detection Ferrous metals are the easiest to detect and non magnetic stainless steels are the most difficult to detect e Ferrous metals any iron derivative e Non ferrous metals any good electricity conducting metals such as aluminum copper brass and so forth e Stainless steel any of the 300 series stainless steels which are non magnetic These are often the most difficult metals to detect Page 260 Thermo Scientific APEX User s Guide Always Use Spherical Test Samples Your test samples should contain spherical metal contaminants Any other shape produces a different size signal depending on its orientation as it passes through the search head As a result miscellaneously shaped test samples can lead to inconsistent results Test the Entire Reject Process In most applications when the reject process fails the reject device is to blame So always test the entire reject process to verify your reject device is working properly In addition make sure that if the reject device fails you can safely recover your test samples If you have safety concerns about your reject proc
167. age 243 Naming Your Product Batches This function allows you to add the name of the batch of products you are testing to your printed reports To use this function you must first activate the printer as described above Batch Code E oh ira 8 14 1 Highlight the batch code icon press the Go button and the keyboard screen appears 2 Enter a name for your batch of products Limit 2 9 alpha numeric characters 3 Highlight the exit and save key in the keyboard screen 4 Press the Go button and your batch code appears in the menu as shown in the example below We are testing batch 01 123456 Batch Code Page 244 Thermo Scientific APEX User s Guide Printer Set Up Page 2 This menu allows you to set up end of day reject and power up print outs 1 To reach page 1 of the printer set up menu shown below follow steps 1 6 in the Navigating to the Printer Set Up Menu section above pages 239 40 Printer Setup Page 1 4 AS 2 Press the down navigation button and page 2 of the printer set up menu appears Printer Setup Page 2 Activating an End of Day Print Out This function allows you to print an end of day report For this function to work you must first have done the following e Activated the printer described above on page 241 e Set the detector s time and date function see page 176 Activate End of D
168. age 42 Setting Reject Parameters This section assumes that the reject device you are using to remove contaminated products from the conveyor is already connected to the detector s wiring board and ready to go to work If a reject device is not already connected to your detector see the Mechanical Set Up for Conveyor Applications section on page 292 In this manual and in the detector s menus the main reject device is referred to as the Reject 1 device Any secondary reject device is called the Reject 2 device The following sections are written on the assumption that you currently have only one reject device attached to your detector a Reject 1 device For information about keying in parameters for a Reject 2 device see page 141 Reject Totals Measurements You Will Need Before Starting Imagine our packets of salted butter moving along the conveyor and the search head suddenly detects a packet containing a metallic contaminant For now the contaminated packet continues its journey out of the search head and along the conveyor Around one meter from the detector however the packet passes the main reject device and is suddenly ejected from the conveyor into the reject bin One down more to go However before you can begin keying in parameters to control your reject device you must have the following information ready e The distance from the downstream edge of the search head to the cente
169. alve it will require a minimal amount of installation and adjustment When a search head only is provided proper installation is critical Correctly installed the metal detector will operate reliably for long periods without attention The customer is responsible for initial inspection of the equipment and site preparation It is essential that the customer place the equipment in the production or process line in accordance with the guidelines below The customer must assure that qualified service personnel are available to make interconnections with other production equipment and perform work at the installation site A Thermo Fisher Scientific Products Customer Service Representative is available to supervise installation and verify operation as well as train personnel assigned to operate and maintain the equipment APEX Installation Considerations Customers who intend to install the APEX metal detector should study the following factors that can influence the detector s performance The importance of studying this section and taking note of the information given is very important It has been proven that faulty metal detector operation such as random false alarm signals and undue sensitivity to vibration are usually due to incorrect installation of the metal detector or some other factors external to the metal detector itself Location of the Detector The APEX controls should be located to give easy access to the front panel The insta
170. aminant Detection Parameters In this section you will learn how to e Establish a noise threshold with no product present in the chute e Select the appropriate setting for the speed filter e Establish basic product parameters detect level and phase angle Understanding Technical Terms If you encounter a technical term you do not understand in these sections please refer to the Glossary on page 393 For example the word product means anything the detector is testing for the presence of metal contaminants and is a word you will encounter often in this manual Let s get started Thermo Scientific APEX User s Guide Page 95 Understanding Your Detector In order to minimize the length of this already lengthy manual we are not going to repeat information here that has already been covered elsewhere in the manual and we hope you agree this is a wise choice Please start at page 1 of the Getting Started section and read all the way through to the end of the Naming the Product section on page 26 When you have finished reading these sections you will know how to do the following e Use the detector s display panel e Navigate the detector s menus and sub menus e Set up global parameters for the detector e Key in a name for your product The Next Step Now that detour is over welcome back You are now ready to set up the specific parameters you will need to run your pharmaceutical application Read on for more
171. aminated products Degrees Contaminant or non contaminated product 130 Metallic ferrous conductive contaminants such as iron 90 Dry non conductive products such as cereals and grains 65 Non ferrous metallic contaminants such as brass and aluminum 20 30 Metallic contaminants such as 300 series stainless steel 0 Wet conductive products such as fresh meats and breads Accessing the Phase Angle Menu To access the phase angle menu do the following 1 From the Main Menu use the navigation buttons to select the phase angle menu Phase Angle 2 Press the Go button and page 1 of the phase angle menu appears Phase Angle and Tracking agi EU 30 007 X Page 150 Thermo Scientific APEX User s Guide Calibrating the Phase Angle Setting The phase angle and detect level and AuditCheck settings of the product is learned by the detector during its auto calibration procedure For auto calibration procedures for your specific application consult the list below e Conveyor applications see page 55 e Gravity feed applications see page 73 e Pipeline applications see page 90 e Pharmaceutical applications see page 105 Recalibrating the Phase Angle This calibration menu allows you to recalibrate the phase angle setting by running product through the search head To recalibrate the phase angle do the following 1 Make sure the calibration function is highlight
172. and R signal is 500 The I XR icon flashes telling you the APEX is currently learning the I XR signal Pass Products to Learn XR 6 After at least nine packages have been passed the preliminary XR signal learn is complete as shown by the check mark below the I XR icon in the screen below Pass Products to Learn Detect Level 7 Continue passing packages so the detector can now start learning the detect level The detect level icon flashes telling you the APEX is currently learning the detect levels The values for the detect levels update every 10 seconds and the entire learning process takes approximately 60 seconds to complete You may however stop the detect level calibration at any time by pressing the Go button for example when you are satisfied with the current detect levels for the X and R signals When the auto calibration procedure is complete the Main Menu reappears Currently as shown in the screen below the detect level is 554 for the X signal and 488 for the R signal Product Name Page 384 Thermo Scientific APEX User s Guide Using the I XR Calibration Function This function calibrates only the IXR function To use this function make sure the same prerequisites and similar procedures are followed as described in the Using the Auto Calibration Function section on page 382 To start the IXR calibration process do the following 1 Navigate to th
173. and Tools Page 4 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and page 1 of the system and tools menu appears Press the down navigation button to get to page 4 System and Tools Page 4 English zi Selecting the Language for the Display Panel s Help Text See page 17 Language B 475 Page 192 Thermo Scientific APEX User s Guide System and Tools Page 5 1 From the Main Menu navigate to the system and tools menu System and Tools P881 801 2 Press the Go button and page 1 of the system and tools menu appears Press the down navigation button to get to page 5 System and Tools Page 4 Ga VAA ey APEX 508 zl ET Displaying Your Software Version This screen displays the current version of the software you are using Software Version Thermo Scientific APEX User s Guide Page 193 Displaying Your APEX Model This screen displays the model number of the detector you are currently using If the information in this screen is incorrect or needs to be changed please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual APEX Model 5 Ml Bi B MESS 5 5 Displaying Your System Set Up Code Use this function when contact
174. anel is English but it can also display help text in the following nine languages e French German Italian Spanish Dutch Chinese Czech Russian Polish If you want to use a language other than English follow the instructions below continued Thermo Scientific APEX User s Guide Page 17 1 Turn on the detector and the Main Menu screen appears 2 Press the navigation buttons to select the system and tools menu as shown below iin 1 981 3 Press the Go button and page 1 of the system and tools menu appears m Notice the notation 1 5 in the screen above This tells you that you are currently on page 1 in the system and tools menu which is five pages long Page 18 Thermo Scientific APEX User s Guide 4 Press the down navigation button several times to scroll through pages 1 5 of the system and tools menu to see what they look like Select page 4 which is shown below ammi 5 Press the right navigation button to select English mmi English ZLA 6 Press the Go button repeatedly to scroll through the available languages and select the language you want displayed 7 To exit and have the detector use the language you chose in Step 6 press the Back button repeatedly until you return to the Main Menu Thermo Scientific APEX User s Guide Page 19 Clearing the Speed Filter Warning Scre
175. appears System and Tools Page 1 Page 214 Thermo Scientific APEX User s Guide 3 Navigate to the WAF menu Warnings Alarms amp Faults The icons in this screen as follows Icon Description y Warning Alarm Fault WAFs Are Not Mutually Exclusive The WAF menu contains many functions that can trigger a warning alarm or fault but the categories are not mutually exclusive This means that for each function shown in the four pages of this menu the detector can provide any of the following A warning only An alarm only A fault only A warning and an alarm A warning and a fault A fault and an alarm A warning and an alarm and a fault None of the above No icon is shown next to the function in the menu screen Setting a WAF for a Particular Function In this example you are going to tell the detector to give you an alarm when the reject bin is full Currently the detector gives you a fault We are assuming you have already hardwired a small red lamp or other error notification device of your choice to the default alarm output Output 5 on the detector s output wiring board 1 Make sure the WAF menu is highlighted Warnings Alarms amp Faults Thermo Scientific APEX User s Guide Page 215 2 Press the Go button and page 1 of the WAF menu appears Warnings Alarms amp Faults
176. arch head 1 Make sure the Main Menu is displayed 2 Navigate to the system and tools menu 3 Press the Go button 4 Navigate to page 3 of the menu 5 Highlight the photo eye set up menu 6 Press the Go button and the photo eye distance and head width menu appears continued Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 7 Highlight the in feed photo eye distance function Infeed Photo Eye Distance 8 Press the Go button and an input screen appears 9 Key in the photo eye to detector distance mm or inches Polarity of the Photo Eye Input Because photo eyes are either dark or light activated this function tells the detector how to interpret the signals from your particular photo eye 1 Make sure the Main Menu is displayed 2 Navigate to the system and tools menu 3 Press the Go button 4 Navigate to page 2 of the menu 5 Highlight the inputs and outputs menu 6 Press the Go button 7 Highlight the inputs menu 8 Press the Go button and the inputs set up menu appears 9 On page 1 of the menu highlight the In feed Photo Eye Input menu The 2 notation tells you that the photo eye is connected to Input 2 on the wiring board and has a positive polarity Infeed Photo Eye Input 10 To change these settings press the Go button and an input screen appears 11 Use the navigation buttons to select the ap
177. at passed through the search head since it was last reset Peak Signal PARI 901 ra 38 8068 The peak signal value can be reset in the following ways e f photo registration is enabled the peak signal value will automatically reset before each pack enters the search head or when each pack crosses the photo eye e Pressing the Go button while the peak signal icon is highlighted will reset the peak signal value Uses of the Peak Signal Function The peak signal function can be used to do the following e Establish the level of background noise over an entire day week or other extended time period e Monitor the maximum signal produced by contaminants during a specified time period for example the morning shift a 24 hour day a week and so on e Monitor the long term trends in the detector s signal to noise ratio Frequency and Gain Menu See page 160 Frequency and Gain Page 114 Thermo Scientific APEX User s Guide System and Tools Menu See page 168 System and Tools Security Menu See page 249 Security Level 1 Main Sub Menu Page 1 Page 1 of the Main Menu allows you to do a full product calibration and give the product you are testing a name 1 Start at the Main Menu Product Name 2 Press the Go button and navigate to page 1 of the detector s main sub menu Product Calibrat
178. atch reports Printouts are available in one of ten languages Thermo Scientific APEX User s Guide Page 275 Theory of Operation Your APEX operates on the balanced coil full loop detection system Traditionally three equally spaced coils surround the aperture or opening through which inspected material passes The central coil connects to an oscillator circuit to produce a magnetic field The coils on either side of the central coil receive this signal These are the receiving or input coils Input coils Since the input coils are equally spaced from the oscillator they receive equal amounts of signal The coils are wound in such a way that their signals oppose each other so the net signal across them is zero When a piece of metal enters the magnetic field it alters the field strength around it As this metal passes through the aperture it changes the balance of the receiving coils so that the net signal is no longer zero The APEX uses more than three coils in its design Up to three pairs of oscillator coils provide higher levels of sensitivity over traditional methods Parallel and series arrangements of coils are used These new coil arrangements are patented The APEX still uses two receive coils to produce the metal signal A digital signal processor DSP processes this signal The DSP performs the product compensation phasing residual compensation filtering and produces a reject signal Your APEX detector is
179. ay Printout 1 Make sure the end of day function is highlighted 2 Press the Go button and the X is replaced by a check mark End of day printing is now activated 3 Press the Back button to exit the function Thermo Scientific APEX User s Guide Page 245 Example of End of Day Print Out A typical end of day print out looks like this kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk APEX THERMO BATCH REPORT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk MACHINE ID DG DAIRY BATCH CODE 01 123456 FROM 2008 05 21 13 30 45 MOR 2008 05 21 12 59 59 PRODUCT PHASE 2 18 DETECT LEVEL 40 REJECT COUNT 1 kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk QUALITY TEST RESULTS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME RESULT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk AUDITCHECK TEST RESULTS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME RESULT kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk FAULTS ALARMS WARNINGS kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk DATE TIME TYPE Activating a Reject Print Out This function prints a brief report every time the detector rejects a product For this function to work you must first have activated the printer Activate Reject Printing 1 Make sure the reject function is highlighted 2 Press the Go button and the X is replaced by a check mark
180. ble remedies include making sure the detector is completely isolated mechanically from your conveyor and or installing shock mounts for the detector Reducing High R Noise Thresholds An R threshold in excess of 200 usually indicates that one or more of the following conditions is present o Excessive noise from electro magnetic currents EMCs and variable frequency drives VFDs Rectify by installing an isolation transformer and or line reactors o Metal in the detector s metal free zone Rectify by removing the metal o ground loop is present in the conveyor Rectify by installing plastic rollers in the conveyor 7 If you want to manually key in a different value for either the X or R noise threshold make sure the Calibrate Noise Thresholds menu shown in step 5 is displayed Navigate to the appropriate menu X or R and press the Go button An input screen appears allowing you to manually enter a value Thermo Scientific APEX User s Guide Page 49 Calibrating the Speed Filter Using a Ferrous Test Stick In this section you will learn how to calibrate the speed filter using a ferrous test stick The speed filter is a narrow band pass filter that rejects most background noise but still allows a maximum metal signal from the search head to be processed by the detector 1 Follow steps 1 4 in the Choosing Your Preferred Units of Measure section on page 22 to get to the menu shown below page 2 of the system and tools
181. bumps or by dumping heavy loads onto the conveyor belt particularly when working at very high detection sensitivities The APEX or its conveyor should not be fixed directly to a vibrating packaging or processing machine Electrical Loops Intermittent electrical loops are the largest single cause of faulty metal detector operation The search field in the metal detector sets up a high frequency electrical field in the aperture The metal case of the search head acts as a screen to prevent metal outside the detector head affecting the search field Some of the high frequency electrical field from the search coils does escape from the aperture through which the product passes This field can cause very small electrical currents to flow in nearby metal structures This causes no problem if the loops are completely closed but if the electrical path is intermittent then false triggering of the detector is likely Typical causes of intermittent electrical loops include loose bolts on the conveyor or on the detector s mounting corrosion of metal work broken welds open hinged doors conveyor idler rollers and broken or rubbing contacts Interference can be overcome by opening the conductive path with an insulating pad or closing the path by welding or tightening the bolts so that it cannot become intermittent Loop problems in rollers can usually be overcome by mounting the idler rollers closest to the APEX on an insulating block The metal bolts j
182. ces of false detections due to conveyor vibration when inspecting a wet product The CLX filter can be used in conjunction with the PNR and QNR filters if needed Use this filter only for wet products Wet Application Noise Filter 1 901 Please note the notation in the screen above This tells you that currently the CLX filter is not active Thermo Scientific APEX User s Guide Page 157 Activating the CLX Filter 1 Make sure the CLX filter menu is highlighted Wet Application Noise PBB1 081 Ls 2 Press the Go button twice and the 2x notation appears in the CLX menu as shown below Wet Application Noise Filter PARI B81 3 Press the Back button to activate the CLX filter save the 2x setting and exit the menu Selecting the Phased Noise Reduction Filter The default setting for the phased noise reduction PNR filter is on as indicated by the check mark in the PNR menu below and is used in all applications conveyor applications and gravity feed and pipeline applications to reduce background noise and increase the ability of the search head to detect metals In addition the PNR filter reduces the number of uncontaminated units of product that are erroneously rejected as contaminated The PNR filter can be used in conjunction with the CLX and QNR filters if needed Phased Noise Reduction 1 Bg X Eu Page
183. check mark by the letters MZ indicates the APEX is currently using multi zone two peak detection MultiZone Detection PARI 81 Enabling One Peak Detection This function is typically used in applications running large cases of product that fill 80 90 percent of the search head To enable one peak detection do the following 1 To allow the detector to tag contamination using only one peak press the Go button and an X appears next to the letters MZ 2 Press the Back button to save this one peak to verify contamination setting and exit the menu Thermo Scientific APEX User s Guide Page 165 Locking the Detect Level This function locks the current detect level setting so that it cannot be changed for example by running the auto calibration function In the screen below the detect level setting 40 is not currently locked To lock the detect level setting press the Go button and the X changes to a check mark indicating the detect level setting is now locked in our example at 40 Detection Level Lock FAAI 901 FA mn 5 10015 1868 Calibrating the X R Noise Thresholds This function allows you to calibrate the X and R noise thresholds for background noise and is typically used in applications where vibration from the conveyor creates background noise that the detector may interpret as a contaminant passing through the search head Vibration it is important to
184. circuit board Printed circuit board assembly Parameter change coil Photo eye a photo electric cell The maximum signal produced when a metallic contaminant passes through the search head Programmable logic controller Phased noise reduction filter Purchase order Any finished product incoming raw material and so on that is being checked for metal contaminants by the detector Parameters you set to control how product is controlled and identified in your particular application and operating environment Parameters you set to control how contaminated products or test samples are rejected in your particular application and operating environment Product signal compensation Power supply unit Quality assurance Page 396 Thermo Scientific APEX User s Guide Glossary Term QAT QNR RAM Reject device RFI RO R threshold RTU R W Rx Search head SF NB SF WB Speed filter Definition The Quality Assurance test one of the detector s quality control functions Quadrature noise reduction filter Random access memory Any mechanical device downstream of the search head that allows contaminated products to be separated from uncontaminated products In a typical conveyor application Reject 1 is the main reject device and Reject 2 the secondary reject device Radiated frequency interference In the Modbus registers a read only register Electrically conductive materials and
185. completely before the contaminated product actually reaches the gate Reject delay times when needed are set in seconds and hundredths of a second e Reject Duration Time This is the time in seconds and hundredths of a second that the gate remains closed to divert contaminated product into the reject bin A typical time for a normal gravity feed application is one second Once you have set the reject delay time and reject duration time parameters you must test the reject process Then if needed you may want to fine tune the detector s response to vibration caused by the gate opening and closing by enabling the reject suppression feature Thermo Scientific APEX User s Guide Page 65 Setting the Reject Delay Time To set the reject delay time do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 01 001 2 Press the Go button and page 1 of the rejects menu appears Reject 1 Distance and Duration PHH1 001 3 Navigate to the reject 1 distance delay menu shown below Reject 1 Distance Delay PARI 001 4 Press the Go button and the reject 1 distance delay input screen appears Key appropriate value for reject 1 distance delay For a typical gravity feed application key in a value of 0 00 seconds This allows the reject gate to close immediately when metallic contaminants are detected Reject 1 Distance Delay
186. ct device Any test procedure designed for your application should take into account the following Pass the Product Through the Detector s Centerline The metal detector s least sensitive point in the aperture is along the centerline of the opening Any testing should be done so that the test sample passes approximately through the centerline of the opening If the test sample is run at the side of the product tube or between the product tube and the detector this will produce a larger signal than through the centerline Page 304 Thermo Scientific APEX User s Guide Factors Affecting the Sensitivity of the Detector Sensitivity capabilities of different detectors used in different applications will vary A smaller aperture is capable of detecting smaller pieces of metal Product effect may also interfere with the detection capability It is dangerous to rely on a corporate standard to determine and test the detector s operation Ideally each detector should have its own standards of operation and a corporate outline should be used only as a maximum allowable guide Sample sizes should be selected so that they are clearly detectable peak signal size of approximately double the detect level when compared to the signal produced by the product or other interfering signals If samples are established which are very close to the product signal frustration on the part of operators can lead to a lack of confidence in the detector s operation T
187. ction runs and no product is moving through the search head then press the Go button The detector immediately starts measuring the X and R noise thresholds The monitor screen shown below presents a bar graph of the progress of the calibration which takes approximately 20 seconds to complete Calibrate Noise Thresholds 6 When the calibration is finished the Calibrate Noise Threshold menu reappears Calibrate Noise Thresholds 81 fk ioga s0 G ER This screen tells you the following about the IXR function La CAH The noise threshold for the X signal is 500 Is CAF The noise threshold for the signal is 500 7 Press the Back button repeatedly to exit the menu and return to the Main Menu Using the Auto Calibration Function To have your products properly calibrated during the I XR auto calibration procedure you should already have installed the appropriate guides to make sure each package passes through exactly the same spot in the search head and in the exact same orientation In other words the necessary guides are in place to handle problem packages such as rectangular packages that could otherwise pass through the search head in a variety of locations and orientations In addition during the calibration process you must run the conveyor at exactly the same speed you will use during your normal production runs Before starting have about 30 50 uncontaminated packages
188. d 100 detector Standard Features Your APEX included the following standard features Patented multi coil design Ease of operation Reject confirmation Product capacity of 100 Variable speed operation Dual frequency dual gain Epoxy lined head rated to P66 Two independent reject outputs Quality test on consecutive units of product Icons with help text in ten languages Sensitivity performance enhancement Reject inhibit to prove reject verification system AuditCheck and quality assurance rejects to a separate reject bin A bright display with a wide viewing angle Statistics and Information Your APEX provides the following user information and statistics Current product name Total number of rejected units of product Number of units of product rejected by the quality test Number of units of product rejected by AuditCheck Number of units of product passed when in package mode Error messages using LEDs and warning screens Page 274 Thermo Scientific APEX User s Guide Options Optional features of your APEX are as follows e Remote control panel located up to 30 meters away Certified test spheres White polypropylene aperture liner AuditCheck performance validation system Conversion kits to change a DSP3 to an APEX Field compression flanges which reduce the metal free zone Printer Options A local rewind or remote printer option is available In addition the printer is able to print b
189. d and write registers for the same parameter Page 322 Thermo Scientific APEX User s Guide Expert Knowledge Is Required to Modify Settings As a general rule only engineers programmers and others who have extensive experience managing network communication parameters and registers should attempt to change any configurations described in this appendix If you are not sure what you are doing please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual In addition having a list of current Modbus register values is very helpful when contacting Thermo Fisher Scientific Overview of the Installation Process This appendix assumes that a Thermo Fisher Scientific technician has already done the following to get the communication functions of the Modbus up and running e Installed the appropriate TCP IP or RTU Modbus Communications Card and made the appropriate hardware configurations by setting the card s DIP switches to the correct positions e Installed version 3 0 or higher of the detector s operating software in your APEX metal detector e Set up configured the appropriate communication parameters using the APEX software so that the APEX is recognized by your network Modifying the Modbus Settings Clearly if you want to upgrade from an RTU to a TCP IP network or vice versa you will have to purchase a new Modbus Communications Card However if yo
190. d gain settings will maximize the detector s ability to detect metallic contaminants Choosing the Optimal Settings for Frequency and Gain When testing any product for the presence of metallic contaminants it is best to run the detector at high frequency 300 KHz and high gain because this combination gives the best sensitivity However if your product has a significant product effect as shown by the flashing of the red indicator light on the detector s control panel when product passes through the search head using the high frequency and low gain setting will likely remedy the situation because the low gain setting cuts the signal produced by the product by a factor of 4 5 If the high frequency low gain setting still causes saturation move to the low frequency high gain setting and so on Frequency Gain Ability to detect contaminants 300 KHz High High Excellent 300 KHz High Low Very good 100 KHz Low High Good 100 KHz Low Low Fairly good Accessing the Frequency and Gain Menu To access the frequency and gain menu do the following 1 From the Main Menu use the navigation buttons to select the frequency and gain menu Frequency and Gain P881 091 continued Page 160 Thermo Scientific APEX User s Guide 2 Press the Go button and page 1 of the frequency and gain menu appears Frequency Gain amp Inhibit The frequency and gain icons shown in this m
191. d in one of two positions the open or closed position not stuck halfway open or closed During a normal reject cycle the gate first opens then closes actions that the reject complete function verifies has occurred However if the gate gets stuck half way open or closed during the reject Thermo Scientific APEX User s Guide Page 139 cycle the reject will not be confirmed and the flow of product be stopped and alarm triggered notifying you of the problem Keying In a Value for the Reject 1 Complete To enable the reject 1 complete function for gravity feed pipeline and pharmaceutical applications do as follows 1 Make sure that your reject 1 confirm and reject 1 complete inputs have been enabled and the sensors hardwired to the appropriate input on the detector s wiring board 2 Make sure the reject 1 confirm function is highlighted as shown above 3 Press the Go button and an input screen appears Reject 1 Complete Time 4 Key in an appropriate time window in seconds and hundredths of a second in which the reject must occur Typically the calibration function will set the appropriate value and no manual adjustment is necessary 5 Press the Go button to save your setting and exit the menu Page 140 Thermo Scientific APEX User s Guide Rejects Menu Page 5 Page 5 of the rejects menu is used to set up parameters for your reject 2 device Please note
192. de DSP2 3 Metal Eliminator to APEX B07387M B002 APEX 300 Outline and Mounting B07387M B300 APEX 300D Outline and Mounting Gravity Feed B07387M B301 System Ceiling Mount APEX 300P Outline and Mounting Pipeline System Ceiling B07387M B302 Mount APEX 300P Outline and Mounting Pipeline System Floor D07387M B303 Stand APEX 500 Rx System Outline and Mounting D07404M B005 APEX 500 Rx Head and Electronics Outline and Mounting D07404M B002 APEX 500 Rx Head Electronics and Reject Outline and D07404M B006 Mounting APEX Conveyor Field Wiring Diagram D07387M W001 APEX Gravity Feed and Pipeline Field Wiring Diagram D07387M WO002 APEX 500 Rx Pneumatic Reject Field Wiring Diagram D07387M W004 Thermo Scientific APEX User s Guide Page 403 This page intentionally left blank Global Affiliate Document APEX spare parts list ThermoFisher SCIENTIFIC APEX Spare Parts List Customer Prepared Date Description Part no QTY X SPI Always provided Spares Fuse Main power supply 089973 1 Fuse Output relays 086214 1 Test Spheres TBD Ferrous Non ferrous and 316 SST 1 of each type SP2 Spare Parts Kit Apex 100 CONTROL PANEL ASSY APEX 100 090586 1 PSU CPU M B CABLE 268264 1 CPU M B TO S H BOARD CABLE 268265 1 PCBA POWER SUPPLY UNIT APEX 268392 1 PCBA RELAY BOARD APEX 268393 1 PCBA SEARCH HEAD DSP3 079073 1 SP2 Spare Parts Kit Apex 300 CONTROL PANEL ASSY APEX 300 095297 1 PSU TO CPU M B CABL
193. der parameter enabled and Product 2 with the parameter disabled The speed encoder function is a product specific parameter Page 124 Thermo Scientific APEX User s Guide Overview of Set Up Some conveyor systems especially those that can be set to run at variable speeds have a built in speed encoder A typical speed encoder is constructed using a disk shaped gear with teeth around the periphery and is attached to a roller on the conveyor The teeth of the gear pass in front of a photo eye giving a square signal as shown in the figure below whose frequency is proportional to the speed of the conveyor In a typical conveyor set up the signal from the speed encoder is hard wired to Input 1 on the detector s wiring board Input 1 on the APEX is the dedicated physical input for the speed encoder signal For wiring details see page 289 In order for the speed encoder function to work optimally the speed encoder gear should be large and have a large number of teeth so that the maximum conveyor speed produces a signal of at least 500 Hz but no greater than 2 000 Hz In addition any signal from the speed encoder should not fluctuate or have missing pulses A nice steady signal is required A fluctuating signal will cause large changes in the speed display and will adversely affect all speed related parameters Acceptable Values for Inputs from the Speed Encoder The following table shows the resolution at the calibrated frequency F
194. derstand why suppression is useful and how it works here is some theory and a real world example of the suppression function in action Theory Behind the Amplitude Suppression Function In a typical gravity feed or pipeline application that diverts contaminated product for only one second and where vibration resulting from gate opening and closing lasts for three seconds there is a two second window where product continues to flow but where product may be erroneously tagged by the detector as contaminated This clearly is undesirable for a number of reasons first the product now flowing is not in all likelihood contaminated and second allowing the vibration signal to affect the detector would produce a fatal feed back loop This problem is resolved by suppressing the vibration signal just enough to prevent the detector from interpreting the vibration signal as contamination For example if you apply an amplitude suppression value of 75 to the vibration plus product signal from the search head 7596 of the signal goes to the detector s circuits for evaluation meaning the signal is analyzed to see whether it looks like a contaminated product is currently passing through the search head In this example by a process of trial and error by starting at 10096 and working down in 596 increments we have discovered that 75 amplitude suppression prevents vibration being tagged as contamination Example of How Gate Vibration Can Affect the
195. detection no pack function and make sure it is highlighted Detection no Pack Note that currently when the APEX detects a contaminant that is not associated with a package a fault results as shown by the presence of the fault symbol in the menu Thermo Scientific APEX User s Guide Page 39 8 Press the Go button repeatedly until all the warning alarm and fault symbols are cleared from the menu as shown below Detection no Pack 9 Press the Back button to save your setting and exit the menu Now no rejects are made when contamination that is not associated with a package is detected by the APEX Keying In the Pack Gap The pack gap is expressed as a percentage and in most conveyor applications should be set to 100 the default value Changing the pack gap however allows you to fine tune whether the APEX rejects only one or both units of product also known as packs or packages when there is uncertainty explained below about which of two packs entering the search head one after another is contaminated Pack Gap 1 901 Let us assume the following e You are testing multiple units of product packs or packets in a conveyor application where the length of the gap between the packs is about the same as the pack length e The pack gap function is currently set to the detector s default value of 100 In this type o
196. dures A photo eye is necessary to use the following APEX features e Automatic product tracking e Reverse detection e Photo registered reject timing Thermo Scientific APEX User s Guide Page 295 Conveyor Separation If there is a separate conveyor for the metal detector system be certain this conveyor does not make contact with the in feed and discharge conveyors Fastening them with a non metallic material is the recommended method as shown below Loop Effects and Roller Isolation Besides observing rules for metal free areas precautions must be taken to prevent the occurrence of loop effects A loop effect is caused by an electrical loop in the conveyor making intermittent contact Loop effect is caused by an electrical loop in the conveyor making intermittent contact This loop when closed can produce large electromagnetic fields When the loop opens the field collapses very rapidly causing the detector s field to be disturbed This results in false detection The following can cause loops e Rollers whose bearings make an intermittent connection e Any metal that crosses the conveyor frame and is not securely fastened such as the transfer plate loose cross members electrical conduit and retracting reject or flap gate reject devices Iniermitient loop due to bearings Bearing Side Panel Cross Ivbr bers Page 296 Thermo Scientific APEX User s Guide Note lo
197. e Configuring the RTU RS 485 Card This section tells you how to install and configure your RTU RS 485 Modbus Communi cations Card and how to interpret the four status LEDs on the card Please note that your particular card will be equipped with either a DB 9 connector or a screw connector Card Schematic For most applications here are the relevant parts of the Modbus RS 485 card The figure shows an RS 485 card equipped with a DB 9 connector Application connector DB 9 Fieldbus Connector Termination switch Node ID Address Switches Parity switches Baudrate switches Installing the Card To mount your RS 485 card on the APEX motherboard do the following 1 On the APEX motherboard remove the HMI CPU human machine interface central processing unit card 2 Install the RS 485 card on the APEX motherboard by connecting the card s application connector to the detector s COMMS1 connector Use the APEX Communication Module Mounting Kit to secure the card to the APEX motherboard 3 Reinstall the HMI CPU on the motherboard Thermo Scientific APEX User s Guide Page 345 Setting the Configuration Switches To configure your Modbus card as an RS 485 termination node do the following 1 3 Locate the termination node ID baud rate and parity switches diagrammed below on the Modbus card Set all the switches to the zero or off position This allows the APEX software to set all of the communicatio
198. e section to get there 2 Navigate to the reject device signal duration function Reject 1 Duration PHH1 001 The screen above shows that currently the reject 1 device remains active for 1 50 seconds 3 Press the Go button and the signal duration input screen appears Use the navigation buttons to key in your signal duration in seconds and hundredths of a second In our salted butter example we have entered our signal duration time of 2 02 seconds Reject 1 Duration Pee i se 175 Fx CHEELELEEH 776007 AX x 4 Press the Go button to save your settings and exit the input screen 5 Press the Back button repeatedly to return to the Main Menu Page 46 Thermo Scientific APEX User s Guide Setting Contaminant Detection Parameters This section assumes you have followed all the instructions from the start of the Setting Up Conveyor Applications to this point The reason for this is that before you can calibrate your detector the parameters described above must already have been set This section tells you how to do the following e Set up a monitoring baseline for the detector by calibrating the X and R noise thresholds which must be done when no product is present in the search head e Calibrate the speed filter using a ferrous test stick for most applications use the 2 0 to 4 0 millimeter test stick If the red indicator light on the control panel li
199. e and allowing product to flow through Contact Thermo Fisher Scientific for assistance as described in the Contacting Thermo Fisher Scientific section at the end of the manual Note If insertion testing is difficult to achieve side of the pipe method may be used for frequent sensitivity testing Adjustment to the test sample size should be made to compensate for the increase in sensitivity of the metal detector as you near the side of the aperture Under most circumstances the metal detection will be approximately 0 5 to 1 0 mm more sensitive as you reach the edge of the aperture If this method is used it is highly recommended that you use reject confirmation to ensure the correct performance of the system Testing Schedule The user must decide how often the detector should be tested If the test procedure can be designed to be simple it will help ensure that the test will be performed more Thermo Scientific APEX User s Guide Page 305 frequently As a guide it must be decided how much product would have to be put on hold for re inspection if a detector fails the test Typically the minimum frequency is once per shift while other applications require hourly tests be performed Rejected Product Examination If possible product which has been rejected by the detector during production should be examined to establish the source and type of contamination This may lead to an improvement in the process equipment upstream fr
200. e Channel 1 and Channel 2 signals to display together along the oscilloscope screen s horizontal center line go to the offset function on page 1 of the scope configuration menu and enter a higher or lower value to display the signals to your satisfaction Using the Oscilloscope s Trigger Functions There are three settings for the oscilloscope s trigger function as follows These functions are accessed from the lower right corner of the start up oscilloscope screen No Trigger This function is abbreviated in the start up oscilloscope screen as TRIG FREE and tells the oscilloscope to continuously process signal at the rate specified in the time base menu Thus when using this function the screen scrolls continuously Wait for Detection Trigger This function is abbreviated in the start up oscilloscope screen as TRIG WAIT DETECTION and tells the oscilloscope to wait until a signal is detected and then display it at the rate specified in the time base menu Thus when using this function the screen scrolls continuously Hold After Detection Trigger This function is abbreviated in the start up oscilloscope screen as TRIG HOLD DETECTION and tells the oscilloscope to wait until a signal is detected and then freeze the display so the signal does not scroll off the screen Thus when using this function the screen is static making captured signals easy to see and study Thermo Scientific APEX User s Guide Page 191 System
201. e IXR menu Calibrate IXR and IXR Info 2 Navigate to the calibrate icon and make sure it is highlighted Calibrate I XR FAHI 001 HET CAL EE ERI ERE Re i 3 Press the Go button Using the I XR Detect Level Calibration Function This function calibrates only the I XR s detect levels To calibrate the I XR detect levels make sure the same prerequisites and similar procedures are followed as described in the Using the Auto Calibration Function section on page 382 To start the I XR detect level calibration do the following 1 Make sure the Main Menu is displayed Product Name 28 a 500 x Mdh conjux continued Thermo Scientific APEX User s Guide Page 385 2 Navigate to the detect level menu Detect Level 3 Press the Go button and page 2 of the Detection Level and Noise Threshold menu appears Detection level and Noise Threshold 81 an aiH UNE EE E uc 188 4 Navigate to the calibrate detect level icon and make sure it is highlighted Calibrate Detect Level 981 272118 15 190118 168 5 Press the Go button Page 386 Thermo Scientific APEX User s Guide IXR Tracking The default value for IXR tracking is On and is a useful feature during long production runs lasting many hours or several days When I XR tracking is on the det
202. e and Name agi Page 115 Thermo Scientific APEX User s Guide Starting a Complete Product Calibration For more information about doing a full product calibration see the relevant section for your particular application e Conveyor applications see page 55 e Gravity feed applications see page 73 e Pipeline applications see page 90 e Pharmaceutical applications see page 105 Full Product Calibration Peel 081 lt M 1 2 Editing the Product Name See page 24 Edit Product Name ZW Main Sub Menu Page 2 1 Start at the Main Menu Product Name 2 Press the Go button 3 Navigate to page 2 of the detector s main sub menu Product Shape and Flow Page 116 Thermo Scientific APEX User s Guide Setting the Pack Length See page 35 This is used only in conveyor applications with a product photo eye and in pharmaceutical applications Pack Length P881 601 2 2 A cmt 8 166m Setting the Pack Gap See page 40 This is used only in conveyor applications with a product photo eye and in pharmaceutical applications Pack Gap P8681 091 QE amp c 0 100 2 2 Act 0 100 Setting the No Pack Distance See page 37 This is used only in conveyor applications with a product photo eye and in pharmaceutical applications
203. e exceeded by the current test values Thus you should set a small limit for example a 20 change for a warning a medium sized limit for example a 40 change for an alarm and a large limit for example an 80 change for a fault to occur Example In the example below we are going to change the peak signal limit for a warning from the default of 20 to 10 1 Navigate to the peak signal warning tolerance function Peak Warning Tolerance 2 Press the Go button and an input screen appears showing the warning icon and the current setting of 20 Peak Warning Tolerance Fa l o 20 Ax ar inf Del See I 1 3 Key a new percent value 10 and press the Go button to save your setting exit the input screen 4 Follow the basic outline in steps 1 3 above to change all other values in this screen Note that for a warning alarm or fault WAF to occur the appropriate external devices must be connected to the detector s wiring board and the WAF devices assigned to the appropriate output Output 1 6 For more information see pages 232 and 290 Thermo Scientific APEX User s Guide Page 205 AuditCheck System and Tools Page 1 The detector s AuditCheck function allows you to test the detector s ability to detect contaminants at the same time that product is passing through the search head The AuditCheck function typically is used only in conveyo
204. e only the correct type of cable entry Below is a table listing the suitable parts Supplier Parts long threads required Cable Sizes Hummel 1 291 2000 30 Grey 6 5mm to 12mm diameter 1 291 2001 30 Black 6 5mm to 12mm diameter 1 291 2002 30 Blue 6 5mm to 12mm diameter 1 291 200x 31 same as above 5 0mm to 9 0mm diameter 1 295 200x 30 same as above 10 mm to 14mm diameter 1 295 200x 31 Same as above 7 0mm to 12mm diameter Jacob 50 620PASWL EX Black 5 5mm to 13mm diameter 50 620PABL L EX Blue 5 5mm to 13mm diameter 50 620PASWL EXSI Black 5 5mm to 13mm diameter 50 620PABL L EXSI Blue 5 5mm to 13mm diameter Rolec 570 803 M20 Black 8 0mm to 13mm diameter 570 804 M20 Blue 8 0mm to 13mm diameter Mencom PCGEX M20L Grey 5 0mm to 13mm diameter PCGEX M20L B Black 5 0mm to 13mm diameter ATX 095605 Black suppliers provide blanking plugs that replace the part above or fit into the part above Suitable parts for use with conduit are also available from some of these suppliers When installing cables into the APEX there is a possibility of external cable twists being transmitted into the internal connections Avoid this by using 1 external grips 2 suitably designed cable entries or 3 conduit The APEX has been designed to accept plastic flexible conduit Metal conduit of any type should not be used The APEX accommodates the use of cable entries by providing six oversized M20 pla
205. e products get summary statistics such as the total reject count and back up all your important APEX settings And the final part which is presented in the form of table gives you a complete summary of all Modbus registers used by the APEX Data Handling This section gives you a quick overview of way the Modbus Communications Card uses registers to control and or monitor APEX functions and how to interpret register values Supported Operation Codes Here is a list of the operation codes supported by the Modbus Modbus function Function code Read coil 1 Read input discretes 2 Read multiple registers 3 Read input registers 4 Write coil 5 Write single register 6 Force multiple coils 15 Force multiple registers 16 Mask write register 22 Read write registers 23 Exception code Name 0x01 Illegal function 0x02 Illegal data address 0x03 Illegal data value Thermo Scientific APEX User s Guide Page 351 Read Data When the master wants to read a parameter it simply reads the appropriate register or registers Using the standard commands of the Modbus TCP it is possible to read all the data of the table Write Data Each parameter that can be modified by the master has two control bits to perform the handshaking operation which are implemented as coils These two control bits are named as follows Control bit Description Parameter change notification Used to notify the APEX that the mas
206. e scope configuration function is highlighted in the start up oscilloscope screen 2 Press the Go button and page 1 of the scope configuration menu appears Scope Configuration 1 2 ANALOG ANALOG CHE OFF TIMEEASE E AMPLITUDE 188 ee 4 TRIG SOURCE OFF TRIG REF CENTER 3 Press the down navigation button repeated until page 2 of the scope configuration menu appears as shown below Scope Configuration 2 2 DIGITAL CHi OFF DIGITAL CHz OFF Thermo Scientific APEX User s Guide Page 189 Assigning Signals to Channels In this example you are going to assign the X input signal to Channel 1 and the R input signal to Channel 2 However as you become more familiar with the oscilloscope you can assign a variety of signals to Channels 1 and 2 1 Make sure page 1 of the scope configuration menu is displayed and the analog channel 1 menu is highlighted Scope Configuration 1 2 ANALOG CH ANALOG CH Z zs AMPLITUDE 190 OFFSET 40 TRIG SOURCE OFF TRIG REF CENTER 2 Press the right navigation button to scroll through the analog channel 1 menu options then use the left navigation button to scroll back through the options Highlight the X INPUT option which assigns the X input signal to the oscilloscope s analog Channel 1 3 Press the down navigation button to exit the analog channel 1 menu and save your settin
207. e threshold with no product present in the duct e Select the appropriate setting for the speed filter e Establish basic product parameters detect level and phase angle Understanding Technical Terms If you encounter a technical term you do not understand in these sections please refer to the Glossary on page 393 For example the word product means anything the detector is testing for the presence of metal contaminants and is a word you will encounter often in this manual Let s get started Thermo Scientific APEX User s Guide Page 63 Understanding Your Detector In order to minimize the length of this already lengthy manual we are not going to repeat information here that has already been covered elsewhere in the manual and we hope you agree this is a wise choice Please start at page 1 of the Getting Started section and read all the way through to the end of the Naming the Product section on page 26 When you have finished reading these sections you will know how to do the following e Use the detector s display panel e Navigate the detector s menus and sub menus e Set up global parameters for the detector e Key in a name for your product The Next Step Now that detour is over welcome back You are now ready to set up the specific parameters you will need to run your gravity feed application Read on for more details Page 64 Thermo Scientific APEX User s Guide Setting Reject Paramete
208. e you need an RMA number e Fax 1 763 780 1537 Please complete the Return Material Authorization RMA form on page 266 of the manual Then fax it to us to get an RMA number e Email Please email the Service Department at Service W amp l Mpls thermofisher com and ask for an RMA number Page 400 Thermo Scientific APEX User s Guide List of Thermo Fisher Scientific Offices Worldwide Asia Pacific 86 21 6865 4588 86 21 6445 1101 fax China 86 800 810 5118 86 21 6445 1101 fax France 33 0 1 60 92 48 00 33 0 1 60 92 49 00 fax Germany 49 0 208 824930 49 0 208 852310 fax Italy 39 02 0521 78861 39 02 0521 272914 fax Mexico Latin America 52 01 55 5639 2360 52 01 55 5639 2227 fax Netherlands 31 0 31 76 579 5555 31 0 31 76 571 4958 fax South Africa 27 0 11 609 3101 27 0 11 609 3110 fax Spain 34 914 845 965 34 914 843 597 fax United Kingdom 44 0 1788 820300 44 0 1788 820301 fax United States Canada 1 800 227 8891 1 763 780 1537 fax Thermo Scientific APEX User s Guide Page 401 402 Thermo Scientific APEX User s Guide Supplemental Information The following supplemental information is included to help you install operate and maintain your APEX Description Document APEX Spare Parts List REC F 90 APEX Quick Reference Guide English REC F 58 APEX 500 100 Outline and Mounting B07387M B001 Electronics Upgra
209. ecent value for phase angle is larger than 100 degrees or smaller than 80 degrees the detector will notify you that a fault has occurred Modifying the Unacceptable Change Limits To modify the unacceptable change notification limits do the following 1 Make sure the phase tracking fault limit function is highlighted as shown above 2 Press the Go button and an input screen appears Phase Tracking Fault Limits 3 Key in a value in degrees and hundredths of a degree for an unacceptable change fault notification to occur 4 Press the Go button to save your setting 5 Press the Back button to exit the menu Page 156 Thermo Scientific APEX User s Guide Phase Angle Page 2 1 From the Main Menu use the navigation buttons to select phase angle menu Phase Angle 1 881 30 5 Ao a atx 2 Press the Go button and page 1 of the phase angle menu appears Press the down navigation button to get to page 2 Signal Enhancements Selecting the Wet Product Noise Filter The clip X filter CLX filter is used when testing wet products such as spaghetti sauce milk and so on and reduces the number of uncontaminated units of product that are erroneously rejected as contaminated The CLX filter caps the X signal at 1 2 or 3 times the detect level setting This is dependent on the current CLX setting This can help in reducing the occurren
210. ected product has indeed gone into the reject bin In gravity feed and pipeline applications the reject 1 confirm sensor and the reject 1 complete sensor functions confirm that the gate which diverts contaminated product into the reject bin has both opened and closed Calibrating the Two Confirm Complete Reject 1 Sensor Functions The calibrate menu allows you to calibrate the reject confirmation process by passing a contaminated test product through the search head and having it rejected For these functions to work you must 1 place a photo eye at the mouth of the reject bin for conveyor applications or 2 have a gate open and gate closed sensor installed on the reject gate for gravity feed pipeline and pharmaceutical applications In addition the photo eye or gate open and gate closed sensor must be hard wired to the detector s input wiring board The auto calibration however works whether you have one or two reject confirmation sensors active To calibrate the reject confirmation process do the following 1 Make sure the calibration menu is highlighted Calibrate Reject Confirm Time FAHI 881 Thermo Scientific APEX User s Guide Page 137 2 Press the Go button and the following screen appears Reject 1 Confirm Time 3 Pass a contaminated test product The reject confirmation process will be calibrated as soon as the package is rejected and act
211. ectives All of the recommendations for EMC apply to the prevention of electrical shock If access to the PSU area is required the incoming AC power supply should be isolated remotely and locked off Access to the PSU area by untrained personnel is not recommended Circuit Breaker The APEX should be permanently connected to its AC supply Please ensure that when installing the APEX a switch or circuit breaker is used and is positioned close to the metal detector in easy reach of the operator The switch or circuit breaker shall be marked as the disconnecting device for the metal detector DO NOT install the APEX in a position that makes it hard to use the AC mains isolator Thermo Scientific APEX User s Guide Page 315 Thermo Fisher Scientific Warranty The seller agrees represents and warrants that the equipment delivered hereunder shall be free from defects in material and workmanship Such warranty shall not apply to accessories parts or material purchased by the seller unless they are manufactured pursuant to seller s design but shall apply to the workmanship incorporated in the installation of such items in the complete equipment To the extent purchased parts or accessories are covered by the manufacturer s warranty seller shall extend such warranty to buyer Seller s obligation under said warranty is conditioned upon the return of the defective equipment transportation charges prepaid to the seller s factory in Minneapoli
212. ector tracks small changes in the X and R signals that may occur because of small hourly or daily temperature changes in your product or production environment In addition please note that for tracking to work there must be a gap between individual packages The minimum pack gap is 25 mm and the optimum pack gap is equal to or greater than half of the width of the aperture of the search head To verify I XR tracking is on do the following 1 Navigate to the IXR menu as described in steps 1 4 in the Enabling the IXR Function section on page 378 IntelliTrack X R Menu 2 Press the Go button and navigate to the Enable IXR Tracking menu Enable I XR Tracking PHH1 001 mg Jf Rt The default value for I XR tracking in On as shown by the checkmark next to the tracking icon in the above screen If tracking is set to Off as shown by an X next to the icon press the Go button and a checkmark appears 3 Press the Back button repeatedly to exit the menu and return to the Main Menu Thermo Scientific APEX User s Guide Page 387 Understanding the I XR Display Once the I XR function has been enabled the detector s Main Menu displays additional information that helps you monitor how the IXR function is operating specifically by displaying the following e Detect levels for both the X and R channels e Peak signal values for both the X and channels e A display show
213. ed Calibrate Phase Angle FARI 901 x ie 5 0 30 2 Press the Go button and a calibrate monitoring screen appears Pass Product to Calibrate Phase Angle 3 Pass the product through the search head When the green indicator light in the control panel flashes or stays on the phase angle setting in the screen above has been updated Thermo Scientific APEX User s Guide Page 151 Locking the Phase Angle Setting This function is used during the recalibration process described above and is used to lock the phase angle setting so it is not relearned during the auto calibration process This is useful when you have already established the appropriate phase angle setting for your application but are interested in recalibrating only the detect level or AuditCheck setting Phase Angle Lock FAHI 001 BINA 90 00 S Locking the Phase Angle Setting To lock the phase angle setting do the following 1 Make sure the padlock icon is highlighted 2 Press the Go button and the X changes to a check mark indicating the phase angle setting is now locked Phase Angle Lock FAHI 001 Am A 300 3 Press the Back button to exit the menu Page 152 Thermo Scientific APEX User s Guide Enabling the Detector s Phase Tracking Function The phase tracking function allows the detector to account for the small changes dri
214. ed software program operate or c replace the software program with a functionally equivalent software program as warranted For any claim including breach in any form related in any way to this license Thermo Fisher Scientific s liability will be for the actual value of the software program Thermo Fisher Scientific will not be liable for any lost profits lost savings any incidental damages or other economic consequential damages even if Thermo Fisher Scientific or its authorized supplier has been advised of the possibility of such damages Thermo Fisher Scientific will not be liable for any damages claimed by you based on any third party claim General Conditions of the License Thermo Fisher Scientific may terminate your license if you fail to comply with the terms and conditions of this license In such event you must destroy all your copies of the Page 312 Thermo Scientific APEX User s Guide software program You are responsible for payment of any taxes including personal property taxes resulting from this license Using the APEX in USA and Europe Please note the following Occupational Safety and Health Act OSHA The Occupational Safety and Health Act clearly places the burden of compliance on the user of the equipment and the act is generalized to the extent that determination of compliance is a judgment decision on the part of the local inspection Hence Thermo Fisher Scientific will not be responsible for
215. ed in the Contacting Thermo Fisher Scientific section at the end of the manual Page 370 Thermo Scientific APEX User s Guide Setting Up Related Functions For the IXR function to work properly you must set the following parameters e Pack length e Detection no pack distance e photo eye distance e Photo eye registration The following sections tell you how to set up these four parameters Keying In the Pack Length The pack length must be set for the IXR function to work properly To set the pack length do the following 1 Make sure the Main Menu is displayed Product Name 2 Press the Go button and page 1 of the product menu appears Product Calibrate and Name PBB1 81 3 Press the down navigation button to highlight page 2 of the product menu Product Shape and Flow Thermo Scientific APEX User s Guide Page 371 4 Press the right navigation button to highlight the pack length function Pack Length 001 t 0 1000 5 Press the Go button and the pack length input screen appears Pack Length Sf i Gif eB l a ak Yalin 6 Key in the length of the packages you are testing In the example below we keyed in 12 4 centimeters using the detector s navigation buttons Pack Length St jai 2322 ec 7 Press the Go button to save y
216. ees the detector is monitoring a dry product Thermo Scientific APEX User s Guide Page 75 Set Up Check List for Gravity Feed Applications This section lists the parameters you have already set by following the instructions from the start of the Setting Up Gravity Feed Applications section up to this point in the manual This section also lists additional parameters you may want to set up to get your particular gravity feed application running to your satisfaction Parameters You Have Already Set Up Listed below are the parameters you have already set up for a typical gravity feed application Product Parameters e Product name Reject Parameters e Reject delay time e Reject duration time Contaminant Detection Parameters Set by the Detector s Calibrate Functions e X and R noise thresholds e Speed filter setting e Detect level e Phase angle setting Page 76 Thermo Scientific APEX User s Guide Additional Parameters You May Want to Set Up Listed below are additional parameters you may want to set up to get your particular gravity feed application running to your satisfaction Suppression Time and Suppression Amplitude Functions These functions are used to prevent vibration from the gate interfering with the search head For more details see page 130 Reject Confirm Function If your gate is equipped with a position detector this function allows the detector to confirm that during a reject cycle the gate
217. efault password SUPE here that is enter only the four upper case letters SUPE 4 In the keyboard screen highlight the exit and save key continued Page 186 Thermo Scientific APEX User s Guide 5 Press the Go button and a confirmation screen appears To see what a confirmation screen looks like see step 3 on page 185 6 Press the left navigation button to highlight the Accept check mark Refer to step 4 on page 185 7 Think very carefully The next step cannot repeat cannot be undone 8 If you are absolutely sure you want to reset the detector press the Go button The detector resets virtually everything and returns you to the start up Main Menu screen which now looks like this Oscilloscope The oscilloscope function allows you to see every signal generated by the detector from the initial product contaminant signals seen by the search head to the final signal produced by the detector after the search head signals have been clipped filtered and analyzed for the presence of a metallic fingerprint In this section the path from the search head to the final signal in the detector is known as the signal path Oscilloscope Navigating to the Oscilloscope Function 1 From the Main Menu navigate to the system and tools menu System and Tools continued Thermo Scientific APEX User s Guide Page 187 2 Press the Go
218. en By now you will have noticed that a warning screen has appeared in the detector s display as shown below mmi This warning screen is telling you that the speed filter has not yet been calibrated something you will get to at a later stage of the set up process For the time being whenever this warning screen appears just press the Back or Go buttons to clear it Displaying Help Text In the Main Menu the default setting is to display a bar graph at the top of the screen You are now going to change this setting so that Help Text is displayed The Help Text provides a brief description of the screen you are looking at which makes navigating and using the detector s functions much easier 1 Make sure the detector s Main Menu is displayed 2 Use the navigation buttons to select the system and tools menu TTT PBB1 001 90 00 3 Press the Go button and page 1 of the system tools menu appears a oro Page 20 Thermo Scientific APEX User s Guide 4 Use the navigation buttons to select the bar graph Help Text menu ELIT RE BNMT CHECH 27 hy 5 Press the Go button and the following screen appears omi E 51 nunun 2 mmm mmm 7 mum mmum 6 Press the Go button once to toggle the screen from the bar graph setting
219. ent Parts 265 Ordering PANES er PUDE UE 269 Installing Your APEX Detector ener ius 271 Unpacking Your APEX oeste eter bee ta te eae 271 List of Included em ene 272 APEX Specificatii S decet uar ts x UE 272 Theory of e HC 276 Definition of Various Product 276 Understanding Some Basic Detector 279 Safety PrecauLblofis o nx exuere ne ex YR ES sade i blue EUREN RYE 280 Thermo Scientific APEX User s Guide Page 7 Electrical Set Up rin iius uia a a iR RR RT RR haai LOD Removing the Control memes eene mener 286 Installing Cable and Conduit to Your APEX 288 Input Wiring Board Pin mnn 289 Output Wiring Board Relay Settings and 290 Mechanical Set Up Instructions for Specific Applications 291 Mechanical Set Up for Conveyor Applications 292 Mechanical Set Up for Gravity Feed and Rx A
220. entific APEX User s Guide Page 321 Get Remote Access to APEX Parameters One of the main advantages of the Modbus Communications Card is that it allows you to set up many APEX parameters remotely using Modbus protocols To do this you will need a desk top computer linked via your network to the Modbus card running an application such as Modscan PC Master or other similar program Please note the following minor limitations e You cannot access the communications menu remotely All communication parameters such as IP address baud rate and so forth must be changed using the APEX display panel e Some parameters cannot be set remotely for safety or other reasons because a person must be present for example to pass a test package through the APEX Change Products Remotely The Modbus Communications Card allows you to change products remotely By changing a single Modbus register number 41045 and the parameter change notification coil register 16385 to one 1 all APEX settings for the designated product are immediately updated Get Real Time Statistics from the APEX The Modbus Communications Card also allows you to get real time operating and other statistics from the APEX In other words you can monitor the detector s performance remotely without going down on to the factory floor allowing you to monitor current reject totals detect level and so on Back Up Critical APEX Settings And finally the Modbus Communication
221. enu The icons shown in this menu are as follows Note The Xs show that both the AuditCheck and Quality Test functions are disabled In a real application where the AuditCheck and Quality Test functions have been enabled the Xs shown here are replaced by numbers representing the number of rejects Number of contaminated products P rejected by the detector Number of rejects A made by the AuditCheck function Top left side number Total number of rejects P A Q Top right side number Total number of products assessed Bottom number Number of rejects made by the Quality Test function Page 112 Thermo Scientific APEX User s Guide Detect Level The detect level function is part of the Main Menu as shown below Your screen will look different if IXR is enabled Detect Level PBB81 E Overview of the Detect Level Function The detect level can be set in two ways using the detector s auto calibration function or by keying in a value During the auto calibration procedure the detector first monitors the background noise level and assigns it a value say 15 Then after you have passed a test sample of contaminated product three times through the search head the detector sets the minimum detect level to 2 3 times the background level In our example the detector has assigned a value of 40 to the detect level As a result any product that gives a reading in excess of 40 the detect level
222. enu are as follows i High frequency d b i Low frequency ecl High gain C34 Low gain Currently the detector as shown in the figure above is set on high frequency and high gain the default setting Setting High or Low Frequency As indicated in the figure below the detector is currently set on high frequency Low High Frequency 1 To change to low frequency press the Go button and a check mark appears next to the low frequency icon and an X appears next to the high frequency icon Thermo Scientific APEX User s Guide Page 161 2 Press the Back button to save the low frequency setting and exit the menu Please that if you chance the frequency the APEX must relearn the X and R noise thresholds for optimal performance Setting High or Low Gain As indicated in the figure below the detector is currently set on high gain Low High Gain 1 To change to low gain press the Go button and a check mark appears next to the low gain icon and an X appears next to the high gain icon 2 Press the Back button to save the low gain setting and exit the menu Inhibiting Detection As indicated in the figure below when the APEX detects metallic contaminants passing through the search head it sends a signal to the reject device In other words the normal reject signal is not being inhibited Detection Inhibit 1 To inhibit the reject signal press the Go
223. enu is highlighted 2 Press the Go button and an input screen appears 3 Key in a new setting for the R noise threshold 4 Press the Go button to save your setting 5 Press the Back button to exit the menu Thermo Scientific APEX User s Guide Page 167 System and Tools Page 1 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and page 1 of the system and tools menu appears System and Tools Page 1 CE Quality Test See page 196 Quality Test AuditCheck See page 206 AuditCheck Page 168 Thermo Scientific APEX User s Guide Error Messages WAFs See page 214 Warnings Alarms amp Faults Manual Print Before you can use the manual print function you must first enable the printer To activate the printer see page 242 In addition if you need a password to access the detector you will need to enter your password to do a manual print 1 To start a manual print press the Go button If passwords are enabled the keyboard screen appears Enter your password Then highlight the exit and save key press the Go button and printing starts Manual Print Bar Graph Help Text Set Up for the Display Panel See page 20 Bargraph and Help Setup I ntelliTrack 1 XR See page 367 IntelliTrack XR Menu
224. er Scientific these considerations have already been factored in to the design of the system Factors That Can Influence the Operation of the Detector It has been proven that causes external to the APEX are the main reasons for faulty operation or random false triggering When installing the APEX on an existing or custom built gravity system follow the instructions below Only when correctly installed will the equipment perform optimally The APEX may have been installed correctly initially but conditions change and these may cause intermittent problems with the metal detector If the APEX develops fault symptoms such as intermittent triggering the factors in this section should be carefully studied before any electronic servicing is contemplated Throughput Tubes Any tube material passing through the APEX must be totally metal free Sometimes metal particles or grease that has become loaded with metallic dust becomes embedded in the tube due to static cling Plastic throughput materials supplied by Thermo Fisher Scientific use a unique anti static compound to help dissipate static These materials will not disrupt the metal detector and provide superior performance in static prone areas Aperture Clearances The plastic throughput must not touch the aperture in any way at any time Touching the inside of the aperture can cause nuisance rejects Mounting The support structure used for mounting the APEX should be constructed in a way
225. er s Guide Page 73 3 Press the Go button and page 1 of the product menu appears Product Calibrate and Name x 81 4 Press the right navigation button to highlight the Full Product Calibration menu Full Product Calibration FARI 801 The detector s auto calibration function as shown by the symbols check marks the screen above is now ready to do the following e Learn the phase angle e Learn the detect level e Conduct an AuditCheck if this optional hardware is installed on your APEX continued Page 74 Thermo Scientific APEX User s Guide 5 Press the Go button and the Performing Full Learn monitor screen appears Performing Full Learn a1 6 When the auto calibration function is finished the detector displays the Main Menu screen which should now look something like this Your screen will look different if IXR is enabled Product Name lr 100 A 99 31 Notice that in our example the auto calibration function has learned the following basic parameters for our uncontaminated product e Detect level NN 140 e Phase angle A 89 31 What the Main Menu Screen 15 Telling You The Main Menu screen is now telling you that once the detector is monitoring your product stream any contaminated product that exceeds the detect limit of 140 will be rejected And because the phase angle is 89 31 degr
226. ermo Fisher Scientific section at the end of the manual for further assistance The Next Step Now that you have completed the electrical and mechanical set up for your gravity feed application please go to the Getting Started section on page 11 to learn how to operate your newly installed APEX detector Page 306 Thermo Scientific APEX User s Guide Mechanical Set Up for Pipeline Applications The APEX detector is designed specifically for use in a pipeline application If this system was supplied complete with a framework non metallic throughput tube and automatic divert valve it will require a minimal amount of adjustment When a search head only is provided proper installation is critical Correctly installed the metal detector will operate reliably for long periods without attention The customer is responsible for initial inspection of the equipment and site preparation It is essential that the customer place the equipment in the production or process line in accordance with the guidelines below The customer must assure that qualified service personnel are available to make interconnections with other production equipment and perform work at the installation site A Thermo Fisher Scientific Products Customer Service Representative is available to supervise installation and verify operation as well as train personnel assigned to operate and maintain the equipment APEX Installation Considerations Customers who intend to in
227. ermo Scientific APEX User s Guide Caution Externally connected appliances shall comply with their relevant safety requirements Please ensure appliances such as solenoids and photo eyes are rated for the voltage they will be connected to and the field wiring into the search head is appropriately rated in terms of current and insulation Caution Ensure that AC power mains supply fluctuations do not exceed 10 of the nominal voltage Caution Do not install the APEX in a position that makes it hard to use the AC mains isolator Note The normal level of transient over voltages is impulse withstand over voltage category 11 of IEC 60364 4 443 Note Elsewhere in this manual are instructions for correct termination of cables The APEX does not use plugs and sockets for connection of external field wiring If such a method is required contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual for recommended methods Supply Voltage and Connections Given below are the requirements for the voltage supply and connections to your APEX detector e Input supply voltage range should not be outside the range 85VAC to 264VAC e Werecommend the APEX be fed from a clean AC supply and left powered e Connections are made inside the control panel on the PSU PCB Do not tee off with wiring for other external electrical equipment even other metal detectors e When ch
228. ess please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Keep Things Simple So Testing Is Done Frequently If the test procedures you implement are simple you and your operators are more likely to do them on a regular basis As a general rule the detector should be tested once per shift or at a minimum on a daily basis Keep Written Records of All Tests You should keep detailed written records as part of your overall quality assurance program of all tests done on the detector Good records allow you to build up a historical record of the performance of the detector and its associated components over time and will help you head off current problems and identify problems in the future Carefully Examine All Rejected Products All rejected products should be carefully examined to determine exactly what type of contamination they contain and most important of all to allow you to identify the exact source of the contamination Rejected products for example should be examined as soon as the shift ends or at a minimum on a daily basis to ensure that problems upstream of your detector are indentified and corrected in a timely manner Enable the Detector s QA Test Function Use the detector s QA Test function to ensure that its performance will be tested regular basis by you or your operators Enable the Detector s AuditCheck Function
229. ess the Go button to save your setting 7 Press the Back button repeatedly to return to the Main Menu Page 84 Thermo Scientific APEX User s Guide Setting Contaminant Detection Parameters This section assumes you have followed all the instructions from the start of the Setting Up Pipeline Applications to this point The reason for this is that before you can calibrate your detector the parameters described above must already have been set This section tells you how to do the following e Set up a monitoring baseline for the detector by calibrating the X and R noise thresholds which must be done when no product is present in the pipe e Select the appropriate value for the speed filter e Establish basic product parameters detect level and phase angle Once you have finished this section your detector will be set up and ready to go to work monitoring your product stream for the presence of metallic contaminants Establishing a Baseline with No Product Present Before you can establish a monitoring baseline that is establish a background noise level for the X and R thresholds the parameters that allow the detector to identify metal contaminants you must make sure no product is flowing through the pipe 1 Make sure the Main Menu is displayed Product Name 2 Navigate to the frequency and gain menu Frequency and Gain 81 gt 9 90 00 Thermo Scientif
230. estoring Your APEX Settings 1 Write all machine settings from a data file to the corresponding registers 2 Write product number 001 to register 41045 and set parameter change coil 16385 to one 1 3 Write all product settings for product 001 from a data file to the corresponding registers 4 Write product number 002 to register 41045 and set parameter change coil 16385 to one 1 5 Write all product settings for product 002 from a data file to the corresponding registers 6 Continue until all your products are restored Page 356 Thermo Scientific APEX User s Guide Detailed List of Modbus Registers Here is a detailed list of all registers used by the Modbus Communications Card Please see Key on page 366 and the Glossary on page 393 for a description of the acronyms and other terms used in this table 5 3 g 3 M 2 x n O y e c 2 7 9 599 gt 9 2 9 g g g o v u 2 v 2 o 2h 2 lt fo ED 5 5 30 9 c c z 20 amp 4 a a a 30020 41045 1 16385 1 R W unsigned short P Current Product Number 1 100 30021 n a 2 n a RO unsigned long P Total Reject Count 0 4 Billion 30023 n a 2 n a RO unsigned long P Contaminant Count 0 4 Billion 30025 n a 2 n a RO unsigned long P Quality Test Count 0 4 Billion 30027 n a 2 n a RO unsigned long P AuditCheck Count 0 4 Billion 3
231. evice is now connected to Output 6 which is a logical software based change Outputs Navigating to the Outputs Menu To navigate to the outputs menu do the following 1 Follow steps 1 4 in the Inputs and Outputs section above pages 220 21 2 Press the right navigation button to highlight the outputs menu Outputs continued Page 232 Thermo Scientific APEX User s Guide 3 Press the Go button the output set up menu appears Output Setup Description of the Icons The icons in the output set up menu are as follows Output Icon Logical software output device assignments g p 1 Main Reject 1 device Used in conveyor applications gt m m AuditCheck reject device ACHE Used in conveyor applications 3 ELI Quality Assurance Test reject device GAT Used mostly in conveyor applications S em s B Warning device This device is activated when one of the detector s functions issues a warning Usually connected to a light Alarm device This device is activated when one of the detector s functions issues an alarm Usually connected to a buzzer Fault device This device is activated when one of the detector s functions issues a fault Usually connected to a shut off switch What the Output Set Up Screen 15 Telling You In the output set up screen above Outputs 1 6 are listed at the top of the screen where all po
232. f conveyor application where you are testing multiple units of product such as packets of salted butter let us look at an individual packet of contaminated butter Clearly metallic contaminants could be present anywhere in the packet in the top middle sides or bottom of the package or in the leading or trailing edge of the packet Unfortunately when testing multiple packets if the metallic contaminant is in the trailing edge of Pack 1 the first packet entering the search head it may be hard for the detector to distinguish whether the contamination is in Pack 1 or the next pack that enters the search head Pack 2 Page 40 Thermo Scientific APEX User s Guide Explanation of the Theory Underlying the Pack Gap Function In the above example if you enter a value of 100 for the pack gap function both packs are rejected because as shown in the diagram below the overlap distance of the two packs falls within the 100 zone of the pack gap function which in turn falls within the no pack distances for Pack 1 and Pack 2 No pack distances are calculated by the detector using input from the photo eye on the conveyor or they can be set by you the user as described above Package Gap 100 gt me Package 2 Package 1 ke 5 Package Length Detection No Pack Distance from Product 1 Direction of Product Flow Thus by setting appropriate values for the pack gap f
233. f either inadvertent or deliberate publication Thermo intends to enforce it s rights to this work under the copyright laws as a published work Those having access to this work may not copy use or disclose the information in this work unless expressly authorized by Thermo PART NUMBER 810108 APEX 300 OUTLINE AND MOUNTING PROJECTION SCALE s ze DRAWING NUMBER 1 3 B 07387M B300 REV A SHEET lof 5 Derived From 2007 by Thermo Fisher Scientific 4 2 REC TANG ULAR APERTURE HEADS C HEAD WIDTH mm B APERTURE A APERTURE WIDTH mm HEIGHT mm 100 150 200 250 300 350 400 450 500 550 Themo Au ee ig ig ee paral 100 145 145 145 145 145 145 145 145 145 125 145 145 145 145 145 145 145 145 145 150 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 175 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 EPOXY LINED B 200 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 145 OR 250 APERIURE APERTURE HEIGHT 225 1
234. fect the integrity of the equipment and cause failure or compromise safety Unpacking Your APEX Your APEX metal detector has been properly packaged for shipment Inspect all packages before opening If there is any evidence of shipping damage notify the shipping carrier immediately because the carrier may be responsible for the damage Check the contents of the shipment against the order or packing slip Be sure to look for any accessories such as reject devices or product tubes ordered and shipped with the detector Some of the component pieces are small and may be inadvertently discarded with the packaging Check the equipment for any signs of damage in shipment If there is any evidence of shipping damage notify the shipping carrier immediately Included with each APEX metal detector are the following e APEX Metal Detector User s Guide the manual you are currently reading e Quick Start manual e Installation and mounting parts e Metal test samples Thermo Scientific APEX User s Guide Page 271 List of Included Components Your metal detector comprises the following components e Search Head Case and Coils Products are passed through the aperture of this case Note If remote mounting has been specified there is a separate control unit PSU 2 m 7 ft standard cable to 30 m 98 ft maximum e Search Head PCB The search head PCB is the interface to the coils in the search head It drives the oscillator coils with a
235. first time after installing the Modbus card e Scenario 2 Powering down the APEX for example by turning it off at night and powering it up again for example by restarting the APEX in the morning It is scenario 2 that sometimes causes a problem because the network may assign new addresses to the APEX leading to network problems Thus if you constantly power down and power up the APEX it is best to let the network assign the addresses when you first install the Modbus card scenario 1 and then change the DHCP setting to off to lock in these addresses Then during subsequent power ups and downs scenario 2 a network device cannot change these addresses eliminating potential network problems for the APEX Changing DHCP to Off To change the DHCP setting to off and lock in your current IP subnet mask and gateway addresses do the following 1 Make sure the DHCP function is highlighted The check mark indicates that DHCP is currently set to its default value on Dynamic Host Control Protocol Ait E 1 os continued Thermo Scientific APEX User s Guide Page 329 2 Press the Go button The check mark changes to an X indicating that DHCP is now off The flashing asterisk tells you the DHCP setting has been modified Dynamic Host Control Protocol 3 Press the Back button to exit the function Manually Changing Communication Parameters
236. ft that occur in phase angle during a daily or other long production run Phase Tracking 01 n x 1 2 Thermal Variations in the Product Can Affect Phase Angle For example when testing a hot wet product such as jars of spaghetti sauce moving along a conveyor the temperature of the product as it reaches the search head can affect the phase angle many production environments the ambient temperature of the building changes throughout the day for example by becoming hotter in the afternoon as the sun heats the sides and roof of the building This in turn causes the air temperature in the building to rise and the rate of cooling of the product to decrease during the afternoon Thus product entering the search head will be cooler in the morning and warmer in the afternoon and this gradual change in temperature throughout the day can cause the phase angle to gradually change or drift during the daily production runs How Phase Tracking Works By enabling phase tracking the detector allows the phase tracking setting to drift over time as long as the phase angle setting stays within certain predetermined limits and these limits can be either the default limits or the user defined limits you have keyed in The detector tracks the drift in phase angle over time by keeping a running average of the phase angles recorded since the last reset and comparing the most recent phase angle value against t
237. g The analog channel 2 menu should now be highlighted as shown below Scope Configuration 1 2 ANALOG CHi IHFUT ANALOG CHe TIMEEBASE AMPLITUDE 188 OFFSET 4e TRIG SOURCE OFF TRIG REF CENTER 4 Follow the instructions in step 2 to assign the R input signal R INPUT to the oscilloscope s analog Channel 2 5 Press the Back button to exit the scope configuration menu and return to the start up oscilloscope screen Further Exploring the Scope Configuration Menu Now that you know how to navigate the scope configuration menu we ll leave you to explore the remaining functions on your own However if you need additional help understanding or using any of the oscilloscope s functions please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Page 190 Thermo Scientific APEX User s Guide Here a few tips on using the scope configuration functions If you cannot see a signal trace on the oscilloscope screen go to the amplitude menu on page 1 of the scope configuration menu and enter a higher or lower value to bring the signal within range If the signal trace is either very compressed or very spread out along the horizontal time axis go to the time base menu on page 1 of the scope configuration menu and enter a higher or lower value to get the signal spread you want If you cannot get th
238. ghts when you pass the 4 0 millimeter test stick use a smaller size e Have the detector learn the appropriate detect level phase angle and peak signal settings by passing uncontaminated product through the search head e Have the detector do a Quality Test learn if applicable e Have the detector do an AuditCheck learn if applicable Once you have finished this section your detector will be set up and ready to go to work monitoring your product for the presence of metallic contaminants Establishing Noise Thresholds with No Product Present Before you can establish noise thresholds for the X and R signals you must do the following e Turn on the conveyor e Remove all product from the conveyor Now that the conveyor is running and no product is present in the search head follow the instructions below to calibrate the detector s settings for the X and R noise thresholds 1 Make sure the Main Menu is displayed Product Name continued Thermo Scientific APEX User s Guide Page 47 2 Navigate to the frequency and gain menu Frequency and Gain 3 Press the Go button and page 1 of the Frequency Gain amp Inhibit menu appears Frequency Gain amp Inhibit 881 4 Press the down navigation key to select page 2 of the frequency and gain menu Detection level and Noise 001 15 100 5 166 5 Nav
239. h Products This function allows an external device such as a programmable logic controller PLC to tell the detector to change the running product to one of the first three products Example You are a supervisor at a dairy In the morning you use your APEX and a conveyor application to analyze milk but at noon every day you need to start analyzing salted butter You have installed a PLC that changes the configuration of your conveyor every day at noon and need to alert the APEX when this change occurs This is done by having the PLC send signals to the detector s Inputs Inputs assigned to Product Select One and Product Select Two When input signal voltage changes due to the PLC the APEX can immediately stop analyzing milk Product 1 and load all the product parameters you have set for salted butter Product 2 The detector is now ready to start analyzing salted butter Product 2 1 Make sure appropriate menu is highlighted 2 Press the Go button and an input screen appears 3 Make the appropriate assignments for input Input 1 6 and polarity or 4 Press the Go button to save your settings 5 Press the Back button to exit the menu The APEX can automatically switch to any of the first three products as shown by the parameters in the table below New running Product select 1 Product select 2 product input input No change False False Product 1 True False Product 2 False True Product 3 True True
240. h in turn can attract deposits of dust Dust layers may be regarded as unhygienic and can be an explosion hazard Please ensure the APEX surfaces are regularly checked for build up of dust and any dust layers that form should be removed Warning The ambient temperature for the APEX operation is 10 C to 40 C 14 F to 104 F The APEX will not produce surface temperatures greater than 60 C 140 F at an ambient temperature of 40 C 104 F If APEX is used in a Zone 22 combustible dust environment ensure the ambient temperature does not exceed 40 C 104 F Warning The aperture is normally sealed with resin epoxy having a thermal stability adequate for the temperature of most products on conveyor belts under all operational conditions However some products may be hot when passing through the aperture and this may eventually degrade the resin epoxy Ensure hot products passing through the aperture do not raise the surface temperature of the resin above 60 C 140 F An aperture liner that protects the resin may be required if the product temperature is too high Thermo Scientific APEX User s Guide Page 281 282 Thermo Scientific APEX User s Guide Electrical Set Up All wiring except as noted is the responsibility of the customer Detailed below are the general electrical requirements and the types of supply voltage and connections needed when installing your APEX detector Please fo
241. he Back button repeatedly to return to the Main Menu Page 126 Thermo Scientific APEX User s Guide 7 Notice that now when you vary the speed of the conveyor the speed changes are automatically registered by product speed function Ours is set to 50 fpm Product Speed Understanding the Photo Queue Pack Count This display function is used only in conveyor applications The photo eye queue pack function displays the number of packs between the photo eye and the reject device This function is used when your reject device is located a long way downstream of your photo eye This menu is useful because it shows the number of individual units of product between the photo eye and your reject device This allows you to verify that the photo eye is working properly For example when product passes the photo eye the queue size increases and as product passes the reject device the queue size decreases Photo Queue Pack Count Thermo Scientific APEX User s Guide Page 127 Rejects Menu Page 3 1 From the Main Menu navigate to the rejects menu Reject Totals pagi ___ 2 Press the Go button and page 1 of the rejects menu appears Reject 1 3 Navigate to page 3 Reject Suppression Page 128 Thermo Scientific APEX User s Guide Suppressing Rejection Using an External Trigger Reject 1 When the suppress rejecti
242. he detector saves your previous setting Leading Photo Registration FAHI Aad BEEN a 5 Press the Go button repeatedly until a check mark appears beside the type of photo registration you want to use These options are mutually exclusive Press the Back button to save your setting and exit the menu Reject is triggered by the product s leading edge f Reject is triggered by the center of the product This is the recommended setting for conveyor applications Reject is triggered by the entire length of the product Page 34 Thermo Scientific APEX User s Guide Setting Product Parameters The three critical product parameters you need to set for a conveyor application are as follows e Pack length e No pack distance e Pack gap Read on to learn what these terms mean and how to set up these parameters for your conveyor application Keying In the Pack Length The length of the individual units of product moving along the conveyor for example packets of salted butter is referred to as the pack length of the product 1 Make sure the Main Menu is displayed Product Name 2 Press the Go button and page 1 of the product menu appears Product Calibrate and Name PBH1 81 3 Press the down navigation button to highlight page 2 the Product Shape and Flow menu Product Shape and Flow Thermo Scientific APEX User
243. he detector should be tested at its normal operating speed Test pieces should be inserted so that they travel through the detectors at the product s normal rate of flow This ensures that the detector and reject device responses are accurately tested The detector is not equally sensitive to all types of metal Depending on the type of product and application there can be three typical metal groups which will produce three different levels of detection as follows e Ferrous typically any magnetic metal is the easiest to detect e Non ferrous any good electrical conducting metal such as aluminum copper brass and so forth e Stainless steel the 300 series stainless steels which are non magnetic tend to be the most difficult metals to detect Test samples used should contain spherical metal contaminants Any other shape will produce a different size signal depending on its orientation as it passes through the detector This can lead to inconsistent results In addition any test procedure established must allow for the test product to be completely rejected by the reject device The reject device will tend to be the most likely point of failure in any detector system Care must be taken so that if the detector or reject device fails to operate correctly the test sample can still be recovered This can be achieved by the use of a second valve or a removable catch grid which can operate as a fail safe device catching the test sampl
244. he rejects menu appears Reject 1 Distance and Duration 3 Navigate to the reject 1 distance delay menu shown below Reject 1 Distance Delay FHH1 001 4 Press the Go button and the reject 1 distance delay input screen appears Key appropriate value for reject 1 distance delay For a typical pipeline application key in a value of 0 00 seconds This allows the reject gate to close immediately when metallic contaminants are detected Reject 1 Distance Delay PR BH 2nd x x 1 5 r att a Page 82 Thermo Scientific APEX User s Guide 5 Press the Go button to save your setting 6 Press the Back button repeatedly to return to the Main Menu Setting the Reject Duration Time To set the reject duration time do the following 1 From the Main Menu navigate to the rejects menu Reject Totals 2 Press the Go button and page 1 of the rejects menu appears Reject 1 3 Navigate to the reject 1 duration menu shown below Reject 1 Duration continued Thermo Scientific APEX User s Guide Page 83 4 Press the Go button and the reject 1 duration input screen appears Reject 1 Duration 8l ch 4 83 Abs l Fe x 5 Key in a value for the reject 1 duration parameter For a typical pipeline application key in a value of 3 00 seconds 6 Pr
245. he software program is licensed not sold Thermo Fisher Scientific Inc grants you a license for the software program only in the country where you acquired the equipment as defined below You obtain no rights other than those granted you under this license The term equipment means the equipment with which the software program is used The term software program means the original and all whole or partial copies of the software program used in connection with equipment sold by Thermo Fisher Scientific to the user including modified copies or portions of the software program Thermo Fisher Scientific retains title to the software program as well as all improvements modifications and enhancements to the software program whether made by Thermo Fisher Scientific or any other party Thermo Fisher Scientific owns or has licensed from the owner copyrights in the software program You are responsible for the selection of the equipment Following the commissioning of the equipment any change made by the user to the software program will terminate all warranties with respect to the equipment and software program All other trademarks are the property of Thermo Fisher Scientific Inc and its subsidiaries Thermo Scientific APEX User s Guide Page 311 Allowed Uses Under the License Under this license you may do the following Use the software program on only one piece of equipment at any one time unless the license information specifies
246. head width 6 Press the Go button and page 1 of the Photo Eye Distance and Head Width menu appears PE distance and head width 8 388 7 Press the right navigation button to select the In Feed Photo Eye Distance menu Infeed Photo Eye Distance Thermo Scientific APEX User s Guide Page 29 8 Press the Go button and an input screen appears The figures in your screen however may be different because the screen displays the last setting used Infeed Photo Eye Distance 17i im 9 Use the navigation buttons to input the distance from the photo eye to the center of the detector head In our example we would enter a distance in centimeters and millimeters Press the Go button to save your setting and exit the input screen Checking the Polarity of the Photo Eye Input This section assumes that your photo eye is already connected to Input 2 on the detector s wiring board Photo electric cells can send a signal to the detector either when it detects light or when it detects dark A light activated photo cell sends a signal when light is detected and a dark activated photo cell sends a signal when dark is detected You need to tell the detector which type of photo cell you are using If you do not know for sure key in a positive polarity in the input menu screen step 7 below and if that does not work try a negative polarity addi
247. hermo Fisher Scientific 4 3 2 REC TANG ULAR APERTURE HEADS C HEAD WIDTH mm i i B APERTURE A APERTURE WIDTH mm HEIGHT mm 75 100 125 150 175 200 100 145 Termo AlpEX SD ROD 150 145 145 145 SCIENTIFIC Detector 200 145 145 145 145 OR 250 145 OR 250 250 145 145 145 145 OR 250 145 OR 250 145 OR 250 155 6 09 300 145 145 145 145 OR 250 145 OR 250 145 OR 250 350 145 145 145 145 OR 250 145 OR 250 145 OR 250 400 145 145 145 145 OR 250 145 OR 250 145 OR 250 Y ry 242 9 53 FOOTDIMENSION TABLE LINED B APERTURE CABLE C D E APERTURE HEIGHT PORT mm INCH mm INCH mm INCH 145 5 71 100 3 94 22 5 89 250 9 84 200 7 87 25 98 Y 75 2 95 AUDIT CHECK OPTIONAL PORT Y ry 12 47 75 2 95 APERTURE 75 2 95 WIDTH A 150 5 91 gt VERTICAL APERTURE HORIZONTAL PRODUCT FLOW HEAD WIDTH 4X 32 1 26 145 5 71 2X D TOLERANCE UNLESS SPECIFIED ENGINEER DATE 2d ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 5 31 07 10 84 X r Y DRAWN BY DATE 2X E 5 31 07 S C E N T F
248. his running average If the new value falls within the prescribed limits the default or user defined acceptable change limit it accepts the value and updates the running average However if the running average exceeds the phase tracking fault limits the detector notifies you a fault has occurred Thermo Scientific APEX User s Guide Page 153 Enabling Phase Tracking To enable phase tracking do the following 1 Highlight the phase tracking function Phase Tracking 001 ts 2 Press the Go button and a check mark appears verifying phase tracking is now enabled Phase Tracking PHH1 001 38 0075 3 3 set acceptable change unacceptable change limits for the phase tracking function see the next two sections Page 154 Thermo Scientific APEX User s Guide Setting Acceptable Limits for Phase Tracking For this function to work you must already have enabled phase tracking When the acceptable limit for phase tracking function has been set as each package passes through the search head the package s phase angle is measured and then compared with the current running average for phase angle Then assuming that the phase angle measurement for the package does not exceed the current running average by 0 30 degrees the limit in the screen below for an acceptable change this package is passed as showing an
249. hoice Please start at page 1 of the Getting Started section and read all the way through to the end of the Naming the Product section on page 26 When you have finished reading these sections you will know how to do the following e Use the detector s display panel e Navigate the detector s menus and sub menus e Set up global parameters for the detector e Key in a name for your product The Next Step Now that detour is over welcome back You are now ready to set up the specific parameters you will need to run your pipeline application Read on for more details Page 80 Thermo Scientific APEX User s Guide Setting Reject Parameters This section tells you how to set reject parameters for a typical pipeline application Reject Totals PHH1 1 246 8 ij 380 88 BIxIx Understanding Reject Delay and Reject Duration Timing In a pipeline application the detector s search head surrounds a pipe where product is flowing under pressure When the search head detects metallic contaminants in the product the product continues along the pipe and is diverted into a waste tank by a valve that closes off the main pipe The diverter valve stays closed for a set period of time usually about three seconds to divert the contaminated product then opens again to allow uncontaminated product to again flow freely Thus for the reject process to work properly two critical time parameters must be
250. ic APEX User s Guide Page 85 3 Press the Go button and page 1 of the Frequency Gain amp Inhibit menu appears Frequency Gain amp Inhibit PARI 001 4 Press the down navigation key to select page 2 of the frequency gain menu Detection level and Noise Paul 001 5 Navigate to the Calibrate Noise Thresholds menu Note The background of the calibrate function is now highlighted in black Calibrate Noise Thresholds FAHI 001 EE C A LEA 4a 222088415 158 166 continued Page 86 Thermo Scientific APEX User s Guide 6 Press the Go button The detector immediately starts measuring calibrating the background X and R noise thresholds and the monitor screen below presents a bar graph of the progress of the calibration process The calibration takes roughly 20 seconds to complete Calibrate Noise Thresholds Bl Lg 1 uu pp 1 When finished the monitor screen disappears and the Calibrate Noise Threshold menu shown in step 5 reappears The screen now displays the calibrated measured values for the X and R noise thresholds and because these are background values the numbers should be low If the numbers are high it may be difficult to detect small metal contaminants over the background noise e Reducing High X Noise Thresholds An X threshold in excess of 1 000 us
251. ications e Gravity feed applications e Pipeline applications e Pharmaceutical Rx applications When you received your APEX it was configured at the factory to meet your particular working environment for example a conveyor application However if you now wish to use your APEX for a different application for example an Rx application please contact Thermo see Contact Information below for instructions on how to configure the APEX to handle your new application Contact Information You can telephone technical support at USA 1 800 227 8891 press option 3 or see page 399 of the APEX User s Guide for more contact options Conveyor Applications Listed below are the most commonly used functions for setting up a typical conveyor application Pack Length This is the length mm or inches of the product you are testing 1 Make sure the Main Menu is displayed 2 Press the Go button and the full product calibration screen appears 3 Navigate to page 2 of this menu continued Page 2 4 Highlight the pack length function Pack Length P881 601 5 Press the Go button and an input screen appears 6 Key in the pack length mm or inches No Pack Distance In most conveyor applications it is best to enter identical values for the pack length and no pack distance mm or inches 1 Make sure the screen shown in the Pack Length section above is displayed 2 High
252. ientific APEX User s Guide Example of Changing the Polarity for an Output Device To continue our example from the section above having moved your reject device to Output 4 you now want to change its polarity from positive to negative 1 Navigate to the 4 icon in the outputs menu Output 4 Polarity 2 Press the Go button and the icon changes to 4 indicating the polarity of Output 4 in now negative Output 4 Polarity 3 Press the Back button to save your changes and exit the menu Thermo Scientific APEX User s Guide Page 237 Printer Set Up Page 1 Before using the detector s print functions you must first do the following e Attach a printer to the detector s COM port e Activate the printer It is also useful to do the following e Set the detector s time and date function Attaching a Printer to the Detector Make sure the power to both your printer and the APEX is turned off Then connect your printer to the detector s serial printer COM port see the wiring diagram below APEX SERIAL PRINTER WIRING DETAIL i TT APEX METAL DETECTOR SERIAL PRINTER RELAY PCBA RS 232 INTERFACE RS232 RS485 9PIN D CONN k RS232 JUMPERS WIRES OPTIONAL WIRING 25PIN D CONN JUMPERS WIRES Page 238 Thermo Scientific APEX User s Guide COM Port Settings for Attaching a Printer Whe
253. igate to the Calibrate Noise Thresholds menu Note The background of the calibrate function is now highlighted in black Calibrate Noise Thresholds 1 001 le 22208841 158 166 Page 48 Thermo Scientific APEX User s Guide 6 Press the Go button The detector immediately starts measuring calibrating the background X and R noise thresholds and the monitor screen below presents a bar graph of the progress of the calibration process The calibration takes roughly 20 seconds to complete Calibrate Noise Thresholds ran Ceo r 1 uu pp 1 2 When finished the monitor screen disappears and the Calibrate Noise Threshold menu shown in step 5 reappears The screen now displays the calibrated measured values for the X and R noise thresholds and because these are background values the numbers should be low If the numbers are high that is larger than 1 000 for X and larger than 200 for R it may be difficult to detect small metal contaminants over the background noise Reducing High X Noise Thresholds An X threshold in excess of 1 000 usually indicates there is a problem with excessive vibration in your conveyor application As a general rule as the severity of the vibration increases the X threshold also increases Thus if higher conveyor speeds cause the X threshold to increase vibration is the likely cause Possi
254. ils see page 153 Copying and Pasting Product Parameters This function is particularly useful when you are testing multiple products You can save considerable amounts of time and effort using the copy and paste functions because you do not need to re enter the product parameters for each product re run the calibrations and so on For more details see page 173 Page 62 Thermo Scientific APEX User s Guide Setting Up Gravity Feed Applications This section assumes you have already completed the electrical and mechanical installations for your detector If not see pages 283 for electrical set up instructions and 299 for mechanical set up instructions The purpose of this section is to present you with a brief tutorial allowing you to get your gravity feed application up and running as quickly as possible Here is an outline of what you will be learning If you are already familiar with some of the information covered you can always skip ahead to the next section Understanding Your Detector In this section you will learn how to e Use the detector s display panel Navigate the detector s menus and sub menus Set up global parameters for the detector Key in a name for your product Setting Reject Parameters In this section you will learn how to e Key in the reject delay time e Key in the reject duration time Setting Contaminant Detection Parameters In this section you will learn how to e Establish a nois
255. in holes This feature requires a locking nut sufficiently tightened on the inside of the front panel Ensure that cable entry manufacturer s guidelines are followed when mounting these parts Pay particular attention to maintaining a high integrity seal Page 288 Thermo Scientific APEX User s Guide Input Wiring Board Pin Assignments This section describes the wiring inputs to the detector s PSU PCB A Typical inputs include a photo eye micro switch or key lock There are six inputs as shown in the table below Connector Name Application J3 pin 1 12v 12v feed to power a photo eye 3 pin 2 Input 2 Input internal pull up connect to Ov to activate 3 pin 3 Ov Ground return connection for photo eye J3 pin 4 12v 12v feed to power a photo eye J3 pin 5 Input 3 Input internal pull up connect to Ov to activate J3 pin 6 Ov Ground return connection for photo eye J3 pin 7 12v 12v feed to power a photo eye 3 pin 8 Input 4 Input internal pull up connect to Ov to activate J3 pin 9 Ov Ground return connection for photo eye J3 pin 10 12v 12v feed to power a photo eye 3 pin 11 Input 5 Input internal pull up connect to Ov to activate J3 pin 12 Ov Ground return connection for photo eye J4 pin 1 12v 12v feed to power a photo eye J4 pin 2 Input 6 Input internal pull up connect to Ov to activate J4 pin 3 Ov Ground return connection for photo eye 4 pin 4 5v 5v
256. in Name Function 1 RS232 TX Transmit signal 2 GND Signal ground 3 RS485 B Two wire TX RX lines 4 RS485 A Two wire TX RX lines 5 RS232 RX Receive signal 6 Shield Cable shield Thermo Scientific APEX User s Guide Page 347 Understanding the Status LEDs An RTU card is equipped with four status LEDs as shown below Here is what the LEDs on an RTU card are telling you LED Status What the lights are telling you 1 Processing Flashing green Processing Off Not currently processing 2 Bus error Off Normal or card not initialized Solid red Bus error 3 Bus ready Solid green Bus is ready Solid red Bus time out error Off Card not initialized correctly 4 DIP switches Off DIP switches are in use and the settings are good Solid green DIP switch settings have been modified by mailbox message Solid red DIP switches set to non active status that is all are off or set to illegal values Page 348 Thermo Scientific APEX User s Guide Configuring the RTU RS 232 Card This section tells you how to install and configure your RS 232 Modbus Communications Card and how to interpret the four status LEDs on the card Installing the Card To mount your RS 232 card on the APEX motherboard do the following 1 On the APEX motherboard remove the HMI CPU human machine interface central processing unit card 2 Install the RS 232 card on the APEX motherboard by connecting the card
257. indicate a product is present High threshold values may indicate external noise is present See X threshold and R threshold Variable frequency drive See WAF Warning alarm or fault Many of the detector s functions use WAFs in conjunction with a hardwired external device to notify you when some condition occurs that needs your attention a warning to alert you to something more urgent has happened an alarm and to automatically take action a fault if something more serious occurs Warnings often activate a light an alarm a buzzer and a fault a PLC that shuts something down such as the conveyor in a conveyor application or the flow of product a gravity feed or pipeline application Ferro magnetic and electrically conductive materials produce reactive effects Iron is both electrically conductive and is ferro magnetic As a result the properties of iron is different from a metal such as copper which is a strong electrical conductor The X threshold is a noise threshold for reactive signals Signals above the threshold usually indicate product or metal contaminant signals Excessive reactive signal could indicate external noise such as the presence of VFD EMI and vibration ground loops static and so on is present in the area around the metal detector Page 398 Thermo Scientific APEX User s Guide Contacting Thermo Fisher Scientific If you are located in North America United States or Canada please u
258. ing Thermo Fisher Scientific s technical support personnel as described in the Contacting Thermo Fisher Scientific section at the end of the manual The system set up code displays a string of characters that allows technical support personnel at Thermo Fisher Scientific with the aid of a decoder program to see the current settings of your system but not product parameters Product parameters are accessed as described in the following section System Setup Code Vi 8 B a Displaying Your System Set Up Code To display your system set up code do the following 5 5 1 Make sure the system set up code function is highlighted 2 Press the Go button and a display screen appears showing a code similar to the example below System Setup Code ZABFARSARAAAWHQA EA CIMARAUAARTECARE RRLHRD 765JCJEQM z iat Page 194 Thermo Scientific APEX User s Guide 3 Make a note of the character stream then press the Back button to exit the screen Displaying Your Product Set Up Code Use this function when contacting Thermo Fisher Scientific s technical support personnel as described in the Contacting Thermo Fisher Scientific section at the end of the manual The product set up code displays a string of characters that allows technical support personnel at Thermo Fisher Scientific with the aid of a decoder program to see the current settings of your product but n
259. ing for a Reject 1 Confirm 138 Manually Setting the Timing for a Reject 1 139 Rejects Menu Page 5 o v ht dou e tiep Suis 141 Keying In the Distance to the Reject 2 Device 142 Keying In the Signal Duration for the Reject 2 142 Assigning Tasks to the Reject 2 meme 143 Setting the Latching Reject Function for Reject 2 144 Inverting the Reject Function for Reject 2 144 Rejects Menu Pade O 4 EREX SERRE 145 Entering a Reject Confirm Time for the Reject 2 Device 145 Calibrating the Reject 2 Confirm Time cece eee eee mmm 147 Phase Angle Page L a2 ies ioca or dessen hotte diuo uud ie Meri s dudas 150 Calibrating the Phase Angle Setting ccc cece eee eee eee Hn 151 Locking the Phase Angle mnm 152 Enabling the Detector s Phase Tracking 153 Setting Acceptable Limits for Phase Tracking 155 Setting Limits for a Phase Tracking Fault
260. ing the above information in an easy to read graphical format Dual Display for Detect Levels The dual display for the X and R detect level looks like this The actual values in your screen almost certainly will be different Detect Level 901 Thus when the APEX detects a signal in either the X R channel that exceeds the displayed thresholds the package will be rejected Please note that when the display is highlighted as shown in the screen above pressing the Go button takes you directly to the Detection Level and Noise Threshold menu that is page 2 of the frequency and gain menu where these values can changed if needed Page 388 Thermo Scientific APEX User s Guide Dual Display for Peak Signals The dual display showing the peak signals detected on the X and R channels looks like this The actual values in your screen almost certainly will be different Peak Signal Please note when a package is rejected because of the presence of metallic contaminants the channel or channels X or R or both that was responsible is highlighted In the example below the X channel detected the contaminant causing the package to be rejected Peak Signal FAHI 081 Dual Bar Graph Display The dual bar graph display is only available if the heading text feature is disabled If the heading text feature is currently enabled as shown in the screen below
261. install the Modbus Communications Card Please go to the appropriate section for detailed instructions e Modbus TCP IP Communications Card Go to the following section page 342 e Modbus RTU Communications Card that you want to configure as an RS 485 device Go to page 345 e Modbus RTU Communications Card that you want to configure as an RS 232 device Go to page 349 Thermo Scientific APEX User s Guide Page 341 Configuring the TCP IP Card This section tells you how to install and configure your TCP IP Modbus Communications Card and how to interpret the four status LEDs on the card Card Schematic For most applications here are the relevant parts of the Modbus TCP IP Communications Card Application connector 9 RJ45 Ethernet connector 0 w v amp QUT RRD Installing the TCP IP Card To mount your TCP IP card on the APEX motherboard do the following 1 On the APEX motherboard remove the HMI CPU human machine interface central processing unit card 2 Install the TCP IP card on the APEX motherboard by connecting the card s application connector to the detector s COMMS1 connector Use the APEX Communication Module Mounting Kit to secure the card to the APEX motherboard 3 Reinstall the HMI CPU on the motherboard Page 342 Thermo Scientific APEX User s Guide Setting the Configuration Switches All switches should be set to the zero or off position which allow
262. ional hardware is installed on your APEX 5 Press the Go button and the Performing Full Learn monitor screen appears Performing Full Learn continued Thermo Scientific APEX User s Guide Page 91 6 When the auto calibration function is finished the detector displays the Main Menu screen which should now look something like this Your screen will look different if IXR is enabled Product Name lp 202 Ba 1 46 Notice that in our example the auto calibration function has learned the following basic parameters for our uncontaminated product e Detect level NN 202 e Phase angle A 1 46 What the Main Menu Screen 15 Telling You The Main Menu screen is now telling you that once the detector is monitoring your product stream any contaminated product that exceeds the detect level of 202 will be rejected And because the phase angle is 1 46 degrees the detector is monitoring a wet product Page 92 Thermo Scientific APEX User s Guide Set Up Check List for Pipeline Applications This section lists the parameters you have already set by following the instructions from the start of the Setting Up Pipeline Applications section up to this point in the manual This section also lists additional parameters you may want to set up to get your particular pipeline application running to your satisfaction Parameters You Have Already Set Up Listed below are the parameters
263. is displayed Product Name 3 Navigate to the system and tools menu System and Tools 5 4 Press the Go button and navigate to page 3 of the system and tools menu System and Tools Page 3 5 Navigate to the photo eye set up menu PE Distance and Head Width Page 374 Thermo Scientific APEX User s Guide 6 Press the Go button and page 1 of the Distance and Head Width menu appears PE Distance and Head Width Rm 8 388 all 8 388 7 Press the right navigation button to select the In Feed Photo Eye Distance menu Infeed Photo Eye Distance 8 Press the Go button and an input screen appears The figures in your screen however may be different because the screen displays the last setting used nfeed Photo Eye Distance Tra l i l 9 Use the navigation buttons to input the distance from the photo eye to the in feed side of the detector head In our example we would enter a distance in millimeters 10 Press the Go button to save your setting and exit the input screen Thermo Scientific APEX User s Guide Page 375 Enabling Photo Eye Registration We recommend that you set the photo eye registration function to detect the middle of your product but the I XR function will work when the photo eye registration is set to detect
264. is function allows you to be notified or the conveyor stopped when the reject bin is full For more details see page 217 Reject Confirm Function If you have an additional photo eye to confirm that a reject has indeed occurred this function notifies you if the reject does not occur For more details see page 137 Warnings Alarms and Faults WAFs Many of the detectors functions provide a warning alarm or fault when a condition needing your attention occurs This menu in conjunction with the appropriate hardwired external device allows this to happen For more details see page 214 Quality Test A Quality Test allows you to verify that the detector is working properly especially when testing products over long periods of time The Quality Test is a manual not an automatic test For more details see page 196 AuditCheck If the optional AuditCheck equipment is installed on your search head the AuditCheck function allows you to verify that the detector is working properly especially when testing products over long periods of time The AuditCheck tests occur automatically while product is running at time intervals you specify For more details see page 206 Phase Tracking The phase tracking function allows the APEX to automatically adjust the product phase for small variations in phase over long periods of time especially when testing wet products where the phase angle is sensitive to product temperature For more deta
265. it Product function and make sure it is highlighted Edit Product Name Page 24 Thermo Scientific APEX User s Guide 4 Press the Go button and the keyboard screen appears Exit amp Save cia BHII amp IBICID IE FGIH T 3IK L MIN ECCE iz XS 5 Please note there are four control keys in the keyboard screen as follows e The move cursor left control key e The move cursor right control key e The delete key e The exit and save key All other keys are simple character entry keys and function exactly as they do ona computer keyboard Exit amp Save Move cursor left key Move cursor right key Delete key Exit and save key The keyboard screen above shows the heading Exit amp Save because this is the key that is currently active in the screen as shown by its black highlight If you change the active key by using the navigation buttons in the detector s control panel the heading in the keyboard screen will change Thermo Scientific APEX User s Guide Page 25 6 Navigate to the keyboard s Delete key using the four navigation buttons on the detector s control panel and make sure the Delete key is highlighted Press the Go button on the detector s control panel four times to delete the P001 heading Use the navigation buttons on the detector s control panel to select the appropriate letters and type in the heading SAL
266. it for the calibration function to finish The detector will close the menu and assign a value for the detect level Changing the Detect Level The detect level is usually set by running the detect level calibration function or by running the Main Menu s auto calibration function This menu allows you to key in a new value for the detect level Detect Level PBH1 81 27218 15 19015 188 1 Make sure the detect level menu is highlighted as shown above continued Page 164 Thermo Scientific APEX User s Guide 2 Press the Go button and an input screen appears Detect Level Fa E gt eae D 2L eam EIS iue 1 lt 3 Key in a new setting for the detect level 4 Press the Go button to save your setting 5 Press the Back button to exit the menu Setting Multi Zone Detection Typically when a metallic contaminant passes through the search head it produces a signal having a positive peak followed by a negative peak because the metal passes through the two opposing search or input coils located in the search head When the detector analyzes this signal from the search head it looks for two peaks one positive the other negative Only when two peaks are detected will the APEX tag this as contamination by sending a signal to the reject device This two peaks to verify contamination set up is the default multi zone setting In the figure below the
267. its you chose in Step 6 press the Back button repeatedly until you get back to the Main Menu Thermo Scientific APEX User s Guide Page 23 Naming the Product In the examples that follow imagine you are a lead engineer in a dairy and are setting up the APEX detector to make sure no metallic contaminants have dropped into the dairy s products during the manufacturing process Your first assignment is to test packets of salted butter for the presence of metallic contaminants The packets of salted butter are rectangular in shape and are placed at regular intervals with a space between each packet on a conveyor that takes them through the detector s search head for analysis On the other side of the detector contaminated packets are pushed off the conveyor into a rejects bin by a mechanical arm your reject device A photo electric cell photo eye attached to the detector monitor the flow of packets on the conveyor This is photo eye number 1 which monitors the packets just before they enter the detector s search head This is a fairly typical set up for a conveyor application Follow the instructions below to give a name to the product in our example salted butter that you are testing 1 Make sure the detector s Main Menu is displayed Product Name 2 Press the Go button and page 1 of the product menu appears Product Calibrate and Name PBH1 81 3 Navigate to the Ed
268. ivates the reject confirmation sensor or sensors Reject Timing Is Application Specific Please refer to the two options that follow and chose the function that is appropriate to your particular conveyor gravity feed pipeline or pharmaceutical application Manually Setting the Timing for a Reject 1 Confirm This function the single reject confirmation function is used to confirm that a reject has indeed taken place For this function to work in conveyor applications you must place a photo eye at the mouth of the reject bin For this function to work in gravity feed pipeline and pharmaceutical applications you must 1 have a sensor installed on the reject gate and 2 hardwire the sensor to Input 3 on the detector s wiring board More specifically this function allows you to fine tune the reject confirmation time by keying in a time a time window in which the reject must occur and thus be confirmed If a reject does not occur within this time window the detector issues a warning alarm or fault that notifies you an error has occurred during the reject process Reject 1 Confirm Time FAHI 001 1 Make sure the reject confirm function is highlighted as shown above continued Page 138 Thermo Scientific APEX User s Guide 2 Press the Go button and an input screen appears Reject 1 Confirm Time 3 Key in an appropriate time window in seconds and hundredths of a second in
269. ived From 2007 by Thermo Fisher Scientific AVAILABLE CABLE LENGTHS METERS FEET 2 6 6 3 9 8 4 13 1 5 16 4 6 19 7 8 26 2 10 32 8 12 39 4 15 49 2 20 65 6 25 82 0 30 98 4 MINITEK CABLE ADAPTER M16 NEW CABLE 1 2 NPT INPUT POWER CONDUIT ADAPTER SUPPLIED WITH 19 7 53 284 11 18 REMOTE CABLE 2 304 11 97 4X 56 6 26 THRU REMOTE VERSION SEE SHEET 1 FOR REVISION INFORMATION REV ECO DESCRIPTION BY APP DATE TOLERANCE UNLESS SPECIFIED ENGINEER DATE ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES DMG 2 15 07 Th Fi sh er X 8 03 DRAWN BY DATE 3 01 XXX x13 LO05 DMG 2 15 07 S C E N T F ANGLES 5 CHECKED BY DATE REMOVE ALL BURRS amp UNNECESSARY DMG 2 15 07 SHARP EDGES Te seis the is EO RSS arg is the property oh Thee Fisher PART NUMBER ELECTRO N ICS U PG RAD E Clentitic ermo J t may copie or reproduced in any dehon conen oi meme TS 810106 DSP2 3 METAL ELIMINATOR TO APEX tn protectins wore aec U DENSA SOPO event of either madveneni or publication hamo a SCALE SUE DRAWING NUMBER REV SHEET authorized by Thermo e PROJECTION
270. ject Packs During Learn Function If you want all packages to be rejected during a calibration learn you need to enable the Reject Packs During Learn function To enable this function do the following 1 Highlight the Reject Packs During Learn menu Reject Packs During Learn 2 Press the Go button A checkmark appears showing this function is now enabled Reject Packs During Learn 3 Press the Back button to save your setting and exit the menu Page 182 Thermo Scientific APEX User s Guide Resetting the Counts When Products Change When analyzing a particular product for example Product 001 the reject totals menu displays the total number of rejects made for that particular product In addition in conveyor applications the reject totals menu displays the total number of units of product that have been analyzed The statistics settings menu allows you to reset both counts for a particular product for example Product 001 before you start analyzing another product for example Product 002 Statistics Settings 3 5 Resetting the Total Reject and Total Product Counts 1 Make sure the statistics settings menu is highlighted as shown above 2 Press the Go button and the following menu appears Statistics Settings EM 0 X 3 Press the right navigation button to highlight the reset counts menu Reset Counts on Product Change
271. l connection between the shaft and bearing assembly as shown below Plastic cap o Roller Bearing Isolation Method Isolating the bearing assembly requires isolation of the housing and mounting bolts An insulating sleeve is used to electrically isolate the bearing housing from the conveyor frame Plastic inserts are used to isolate the mounting bolts from the bearing assembly as shown below Insulating sleeve ieee Roller Plastic insert Conveyor frame j earing assembly Plastic Bearing Roller The plastic bearing assembly is one of the easiest designs to implement Most plastic bearings are available in standard mount designs However some plastic bearings contain a metal sleeve in the mounting holes which is internally connected to the bearing raceway With this bearing plastic inserts should be used to create the electrical isolation The Next Step Now that you have completed the electrical and mechanical set up for your conveyor application please go to the Getting Started section on page 11 to learn how to operate your newly installed APEX detector Page 298 Thermo Scientific APEX User s Guide Mechanical Set Up for Gravity Feed and Rx Applications The APEX detector is designed specifically for use in gravity feed and pharmaceutical Rx applications If this system was supplied complete with a framework non metallic throughput tube and automatic divert v
272. larities are currently set to plus and below are shown the default logical software based assignments for these output devices Because all of these assignments polarity device are logical they can be changed by you the user How you do this is described in the following section Thermo Scientific APEX User s Guide Page 233 Additional Output Screens Additional screens that may appear in the output set up menu are as follows e Output Unassigned This screen warns you that no output has been assigned Output Unassigned e Reject 2 Screen This screen allows you to assign a physical output Output 1 6 for the logical output reject 2 Reject 2 Output Page 234 Thermo Scientific APEX User s Guide Changing the Assignment of an Output Device In the following example you are running a conveyor application where the main reject device is currently assigned to Output 1 You want to change the reject device to Output 4 You would do this as follows 1 Navigate to the output set up menu as described in steps 1 3 on pages 232 33 Output Setup 2 Navigate to the reject device output icon which is highlighted below Output 1 Function 3 Press the Go button and a select option screen appears Reject 1 Output 4 Press the left navigation button to select the X to un assign the reject device from Output 1 and press the Go but
273. le frequency drives VFDs Rectify by installing an isolation transformer and or line reactors o Metal in the detector s metal free zone Rectify by removing the metal 7 f you want to manually key in a different value for either the X or R noise threshold make sure the Calibrate Noise Thresholds menu shown in step 5 is displayed Navigate to the appropriate menu X or R and press the Go button An input screen appears allowing you to manually enter a value X Threshold Thermo Scientific APEX User s Guide Page 71 Calibrating the Speed Filter Using a Ferrous Test Ball In this section you will learn how to calibrate the speed filter using a 2 0 to 4 0 milli meter ferrous test ball Please note that in a gravity feed application the default speed filter is a narrow band pass filter that rejects most background noise but still allows a maximum metal signal from the search head to be processed by the detector 1 Follow steps 1 4 in the Choosing Your Preferred Units of Measure section on page 22 to get to the menu shown below page 2 of the system and tools menu System and Tools Page 2 2 Press the right navigation button to select the speed filter menu Speed Filter 3 Press the Go button and the calibrate filter menu appears Calibrate Speed Filter 1 8 88H2 1 1 4 Press the Go button and the following moni
274. light the no pack distance function Detection no Pack distance P881 861 3 Press the Go button and an input screen appears 4 Key in the no pack distance mm or inches Pack Gap The pack gap is expressed as a percentage of the no pack distance and is best set to 100 Changing the pack gap allows you to fine tune whether the detector rejects only one or both units of product based on product spacing when there is uncertainty about which of the packs is contaminated 1 Make sure the screen shown in the Pack Length section is displayed 2 Highlight the pack gap function Pack Gap P881 091 QE amp c 0 100 2 2 A emt 0 160n Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 3 Press the Go button an input screen appears 4 Key in the pack gap as a percentage Product Speed This function is used to enter the speed of your conveyor for conveyor applications and the flow rate of your product in the duct or pipe for gravity feed and pipeline applications 1 Make sure the Main Menu is displayed 2 Highlight the product speed menu Product Speed 3 Press the Go button and an input screen appears 4 Key in the belt speed meters minute or feet minute Photo Eye to Detector Distance This is the distance from the photo eye on the upstream or in feed side of the detector to the in feed side of the se
275. lity control records and predict when future problems such as a wet product giving false rejects are likely to occur The following registers allow you to retrieve real time values for the following APEX statistics Read No of Description register registers Data type Current product number 30020 1 unsigned short Total reject count 30021 2 unsigned long Contaminant count 30023 2 unsigned long Quality Test count 30025 2 unsigned long AuditCheck count 30027 2 unsigned long Total pack count 30029 2 unsigned long Detect level 30031 1 unsigned short Current peak value 30032 1 unsigned short Understanding Register Formats All Modbus registers use the Big Endian format which means that the most significant byte MSB is received first when reading register addresses Thus when values are stored in multiple registers for example the values for total reject count the following rules apply e The MSB is received first when reading the starting address of the value e The least significant byte is received last when reading the highest address of the value Page 354 Thermo Scientific APEX User s Guide For example if register 30021 contains the value 0x0123 and register 30022 contains the value 0x4567 the total reject count is calculated as follows Register Mathematical Numeric value expression value 0x0123 0 16 0 0 4567 1 16 16 777 216 2 16 2 097 152 3 16 196 608 4
276. llation location of the display and or electronics box should be the first consideration Mounting the APEX For trouble free and reliable operation it is very important that the APEX be correctly mounted The support structure for mounting the APEX must transmit a minimum amount of vibration to the metal detector This structure must be flat and parallel thereby minimizing possible twisting torques to the metal detector case which can distort the electromagnetic field and cause false triggering While the APEX and the support structure may remain in contact nothing including the product must be allowed to touch any part of the aperture as this could cause wear of the aperture lining and give random false alarms Any pressure torque or electrical ground will cause the APEX to misfire Any support platform or throughput pipe that passes through the aperture must be completely free of all metal and must not touch any part of the aperture at any time Metal Free Area For optimum performance non moving metal should be allowed no closer to the aperture opening than 1 5 times the smallest aperture height measured outward from the center of the aperture Moving metal should be allowed no closer to the aperture opening than 2 0 times the smallest aperture height measured outward from the center Thermo Scientific APEX User s Guide Page 299 of the aperture When a complete system with frame and throughput tube has been supplied by Thermo Fish
277. llow these requirements carefully for your own personal safety and the safety of others In the following instructions the acronym PSU refers to the detector s power supply unit PCB refers to a printed circuit board and PCB A refers to a printed circuit board assembly Potential Causes of I nterference The detector is a balanced alternating current magnetic sensor and as a result is subject to interference from a variety of external mechanical electrical and magnetic sources These potential sources of interference are described in more detail below Mechanical Vibration Mechanical vibration induces alternating current eddy patterns in the detector s metal case which may interfere with the detector s X channel If the vibration is severe the R channel may also be affected Electro Magnetic I nduction When electro magnetic currents are induced in external hardware and cables this may cause three types of interference as follows e Dirty Power Lines This type of interference may occur when several pieces of equipment are connected to the same power line In most cases variable frequency drive motors are the culprits In general any equipment that utilizes switching technology is a potential source of contamination Both the X and R channel may be affected e Magnetic Fields Caused by High Currents in Wires and Cables Near Fields When high electrical currents pass through wires and cables they crea
278. lowing tasks e Rejecting contaminated products e AuditCheck rejects e Quality Test rejects Note You must previously have enabled the AuditCheck and Quality Test functions for these functions to be accessible in this menu Reject 2 Contaminant FAHI 001 X 2 fL 5 MEN Understanding the Reject 2 Icons Currently the reject 2 device is not responsible for product AuditCheck or Quality Test rejects as shown by the X against the appropriate icon Product rejects currently not enabled for the reject 2 device AuditCheck rejects currently not enabled for the reject 2 device Quality Test rejects currently not enabled for the reject 2 device Enabling Product Rejects Using the Reject 2 Device To enable product rejects using the reject 2 device do the following 1 Make sure the reject 2 function is highlighted as shown above 2 Press the Go button to change the X into a check mark 3 Press the Back button to activate your reject 2 device and exit the menu Enabling AuditCheck and Quality Test Rejects Using the Reject 2 Device For more details see the AuditCheck section page 206 and the Quality Test section page 196 Thermo Scientific APEX User s Guide Page 143 Setting the Latching Reject Function for Reject 2 This is set up in exactly the same way as the reject 1 device See page 122 Latching Reject P881 601 Ge 8 3684 cx a 60s x S S P
279. lp Texte te pete al 20 Choosing Your Preferred Units of 22 Naming the PEOCGEGE ere ra d as tran aded setters eames 24 Setting Up the Conveyor and 27 Keying In the Product sme 27 Keying In the Photo Eye to Detector Distance 28 Checking the Polarity of the Photo Eye Input sess 30 Selecting the Correct Photo Registration for 32 Setting Product Parameters 35 Keying In the Pack Length me menm 35 Keying In the No Pack lt mmm 37 Disabling the Detection No Pack Function ssssssssssm m 38 Keying In the Pack cece eee ene ene ene 40 Setting Reject 43 Keying In the Distance to the Reject Device 44 Keying In the Signal Duration for the Reject 46 Setting Contaminant Detection Parameters 47 Establishing Noise Thresholds with No Pr
280. ls Page 3 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and page 1 of the system and tools menu appears Press the down navigation button to get to page 3 System and Tools Page 3 Setting the Photo Eye to Detector Distance See page 28 This function is used only in conveyor applications PE distance Thermo Scientific APEX User s Guide Page 179 Setting Reject Duration Time or Distance for Your Reject Devices When a contaminant is detected the reject devices will fire after their respective delays have expired The outputs assigned to the reject devices will remain active for the reject duration assigned to each device This gives the reject device sufficient time to blast or push the contaminated product into the reject bin The reject durations can be based on time or distance units e Time based reject durations will keep the reject device active until a specified time interval has passed e Distance based reject durations will keep the reject device active while the product moves a specified distance The distance travelled is determined by the encoder pulses Please note that in a conveyor system that is setup to stop the conveyor if there is a reject this will never expire using a distance based reject duration because the belt is stopped and there are no encoder pulses Reject Settings
281. m automatic phase period It may be caused by contaminated product or metal elsewhere in the system QA Test Response Fault This type of fault only occurs in conveyor applications Problem Solution The QA test light has been Perform a QA test ignored and the interval timer has expired QA Test Result Fault Problem Solution During the QA test the Repeat the QA test so the required number of required number of detections detections are achieved of a specific peak size did not occur AuditCheck Fault This fault only occurs if the optional AuditCheck hardware is installed on your APEX and you are using the detector s AuditCheck capabilities to monitor performance Problem Solution This fault occurs during an Make sure that you have set up appropriate fault AuditCheck timed calibration limits for the AuditCheck function because the and indicates that there is signal produced by your product will vary Also problem with the signal verify that the Alarm Limit and Fault Limit have not produced by the AuditCheck been inadvertently misapplied metal ball as it passes through the search head with your product Page 264 Thermo Scientific APEX User s Guide Service Repair and Replacement Parts Listed below is information about how to get help servicing repairing and obtaining replacement parts for your APEX In addition Thermo Fisher Scientific
282. m the Main Menu navigate to the rejects menu Reject Totals Peal EN 2 Press the Go button and page 1 of the rejects menu appears Reject 1 3 Navigate to page 2 Reject Registration and Type Setting the Type of Photo Registration Used See page 32 This function is used only in conveyor applications with a product photo eye Photo Registration P881 601 ee med 2584 C0 Thermo Scientific APEX User s Guide Page 121 Setting the Latching Reject Function Reject 1 This function can only be used to latch your reject 1 device The default setting for the latching reject function is off as shown by the X next to the padlock icon in the screen below Latching Reject Example of Using the Latching Reject Function The latching reject function is normally used only in conveyor applications where shop floor personnel are responsible for manually removing contaminated product from the conveyor When contaminants are detected the detector sends a signal which remains on latched until manually reset The output signal to the conveyor or buzzer remains latched on until manually reset by the operator Enabling the Latching Reject Function To enable the latching reject function do the following 1 Make sure the latching reject function is highlighted as shown above 2 Press the Go button and
283. many food products by nature are electrically conductive Salt and moisture content combine to produce resistive effects that must be overcome in order to detect small metallic contaminants The R threshold is a noise threshold for resistive signals Signals above the threshold usually indicate product or metal contaminant signals Excessive resistive signals could indicate external noise such as VFD and EMI noise ground loops static and so on is present in the area around the metal detector Remote terminal unit In the Modbus registers a read write register Pharmaceutical application The large rectangular box with a hole in the middle through which products are passed to be tested for the presence of metallic contaminants Inside the magnetic field created by a pair of balanced coils is disturbed by the passage of metal allowing the detector s circuitry to tag the product as contaminated Speed filter narrow band Speed filter wide band The speed filter is a narrow band pass filter that rejects most background noise but still allows a maximum metal signal from the search head to be processed by the detector Thermo Scientific APEX User s Guide Page 397 Glossary Term Sub menu Thresholds VFD Warning WAF X threshold Definition Additional functions that are accessed from the detector s Main Menu Thresholds are maintained for resistive and reactive effects and if exceeded usually
284. mbustible Dust Part 0 General Requirements e IEC 61241 Electrical Apparatus for Use in the Presence of Combustible Dust Part 1 Protection by Enclosures tD Thermo Scientific APEX User s Guide Page 313 Important Safety Notices about Using the APEX Please note carefully the following safety warnings and notices Intended Uses for the Detector Your metal detector is intended to be used in food pharmaceutical and other applications where the presence of metal contaminants is undesirable It must not be used for any other purpose Your metal detector runs automatically and does not require constant operator presence During calibration the operator s presence will be required for up to five minutes typically He she will manually feed calibrated metal test sticks onto the product transport mechanism and verify that reject mechanisms associated with the installation operate successfully Product transport mechanisms are usually located at waist height as are reject mechanisms and user controls We recommend to customers that metal detector systems be sited within their premises conveniently for setting up and calibration Safety in Transportation and Handling Metal detector heads and systems form an integral part of your plant and when transporting handling and installing the unit your own plant safety instructions must be applied Because your metal detector and systems are tailored to application requirements it is i
285. menu System and Tools Page 2 2 Press the right navigation button to select the speed filter menu Speed Filter 3 Press the Go button and the calibrate filter menu appears Calibrate Speed Filter FAHI 001 1 1 4 Start up the conveyor and have the ferrous test stick ready If you are wearing a watch ring and so on and plan on catching the test stick as it exits the search head now would be a good time to take them off so they do not interfere with the search head Page 50 Thermo Scientific APEX User s Guide 5 Press the Go button and the following monitor screen appears Pass test stick to calibrate Speed Filter 6 Place the ferrous test stick on the conveyor upstream of the detector so that the test stick passes through the center not the edge of the search head 7 When the calibration is complete the following screen appears showing the new setting for the speed filter The value shown in your screen will probably be different because the setting depends on belt speed and aperture size of the search head Speed Filter Setup FAHI 001 6 94H2 1 1 Thermo Scientific APEX User s Guide Page 51 Establishing Basic Product Parameters Before putting your detector into service you must have it learn how to identify your uncontaminated product This is done using the detector
286. mo Scientific APEX User s Guide 3 Press the Go button and page 1 of the input set up menu appears Input Setup Viewing the Speed Encoder Input This function is used only in conveyor applications and is a display function meaning you cannot make changes to the input assigned to the speed encoder The speed encoder must be wired to Input 1 and is permanently assigned to Input 1 with a positive polarity Encoder Input FIXED Assigning the Input for the I n Feed Photo Eye This function is used only in conveyor applications and assigns the input for the in feed photo eye I nfeed Photo Eye Input 1 Press the Go button and an input screen appears 2 Make the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Thermo Scientific APEX User s Guide Page 223 Assigning the I nput for the Reject Confirm 1 Photo Eye Reject 1 This function assigns the input for the reject confirm 1 photo eye In a conveyor application for example the reject confirm 1 photo eye monitors reject bin number 1 and verifies that the reject has actually occurred Reject Confirm 1 Input 1 Press the Go button and an input screen appears 2 Make the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Pre
287. mpossible to be precise about product mass weight If precise values are required the shipping crate will be marked with the overall shipping mass of the product and this may be used as a reasonable guideline Ensuring User Safety Metal detector systems are usually incorporated into a customer product line If the metal detection system is fitted with product guards there may be mechanical hazards present The customer must ensure that upstream or downstream areas do not allow access to the mechanical hazards Typically some reject mechanisms are powerful and could cause non minor damage to personnel if guarding is not in place Because the reject mechanism is usually at the downstream end of the equipment the customer must ensure that sufficient guards are fitted downstream to prevent operator access into these areas Safe Practices During Use Maintenance and Repair This manual contains details as appropriate including the appropriate tools However because of its importance the warning contained in the maintenance section is repeated here TO GUARANTEE PERSONAL SAFETY CARE MUST BE TAKEN WHEN WORKI NG ON OR AROUND CONVEYORS REJECT MECHANI SMS OR PRODUCT TUBES AS WITH ALL SUCH DEVICES THE MAIN SUPPLIES ELECTRICAL AND AIR TO THE SYSTEM MUST BE LOCKED OFF WHEN PERFORMI NG REPAIR OR MAINTENANCE WORK AFTER DISCONNECTI NG THE AIR SUPPLY TO THE SYSTEM CYCLE ANY REJECT MECHANI SMS TO EVACUATE ANY AIR LEFT IN THE SYSTEM THEN SWITCH OFF AN
288. must also be updated 30185 41150 1 16469 85 R W packed bytes M Current Month Day of Month 1st Byte Month 2nd Byte Day of Month Note In order to change date Current Year must also be updated 30186 41151 1 16470 86 R W packed bytes M Current Time 1st Byte Hour 2nd Byte Minute Thermo Scientific APEX User s Guide Page 365 Machine parameter A global parameter that defines the underlying operation of the detector such as model type 100 300 500 application used conveyor gravity feed pipeline or Rx and the preferred units of measure feet or meters Product parameter Any product related parameter such as product name phase angle and so on RO Read only register R W Read write register For other abbreviations and acronyms see the Glossary at the end of the manual Thermo Scientific APEX User s Guide Page 366 Appendix B IntelliTrack XR Thermo Scientific APEX User s Guide Page 367 368 Thermo Scientific APEX User s Guide Overview The IntelliTrack XR IXR function is an intelligent software driven solution to two common problems that occur when trying to detect contaminants e Wet products where you are trying to detect non magnetic stainless steel e Products that produce inconsistent phase angles from package to package or within a single pack itself Before proceeding please make sure the APEX and it
289. n below presents a bar graph of the progress of the calibration process The calibration takes roughly 20 seconds to complete Calibrate Noise Thresholds Bl Lg 1 uu pp 1 When finished the monitor screen disappears and the Calibrate Noise Threshold menu shown in step 5 reappears The screen now displays the calibrated measured values for the X and R noise thresholds and because these are background values the numbers should be low If the numbers are high it may be difficult to detect small metal contaminants over the background noise e Reducing High X Noise Thresholds An X threshold in excess of 1 000 usually indicates there is a problem with excessive vibration in your application As a general rule as the severity of the vibration increases the X threshold also increases Possible remedies include making sure the detector is completely isolated mechanically from the surrounding chute and or installing shock mounts for the detector e Reducing High R Noise Thresholds An R threshold in excess of 200 usually indicates that one or more of the following conditions is present o Excessive noise from electro magnetic currents EMCs and variable frequency drives VFDs Rectify by installing an isolation transformer and or line reactors o Metal in the detector s metal free zone Rectify by removing the metal 7 f you want to manually key in a different value f
290. n Parameters to Your Reject Device It is important to match your photo registration parameters to the type of reject device you are using Rejects can be triggered in three different ways as follows e By the leading edge of the product e By the middle of the product e By the entire length of the product Use the following information to select the best photo registration setting for your particular application Leading Edge Rejects This setting is recommended for drop nose and retracting belt reject devices Middle of the Product Rejects This setting is recommended for air pusher and air jet reject devices Entire Length Rejects This setting is recommended for applications where the gaps between the units of product are variable When gaps vary the photo eye registers the reject using the leading edge of the product but automatically extends the reject duration to compensate for the length of the product Setting Photo Registration Parameters 1 Make sure the detector s Main Menu is displayed Product Name 2 Navigate to the reject totals menu Reject Totals A 938 88 continued Thermo Scientific APEX User s Guide Page 33 3 Press the Go button and navigate to page 2 of the rejects totals menu Reject Registration and Type 4 Press the right navigation button to select the photo registration menu Your screen may look slightly different because t
291. n attaching a printer to the detector s COM port please use the following communication parameters Parameter Setting Bits per second 9600 Data bits 8 Parity None Stop bits 1 Flow control None Navigating to the Printer Set Up Menu 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and page 1 of the systems and tools menu appears System and Tools Page 1 3 Press the down navigation button to get to page 2 and highlight the inputs and outputs menu Inputs and Outputs continued Thermo Scientific APEX User s Guide Page 239 4 Press the Go button and the inputs and outputs menu appears Inputs and Outputs 5 Navigate to the printer icon Printer Setup eg 6 Press the Go button and page 1 of the printer set up menu appears Printer Setup Page 1 gt Eh X Setting the Detector s Time and Date Functions Setting the detector s time and date functions is useful for two reasons First any reports you print will have a time and date stamp which helps you keep proper records as part of your quality assurance program And second the detector s end of day print out function will only work if the time function is set for the detector For instructions on how to set the detector s time and date function see page 176 Page
292. n parameters for your RS 485 card Node ID Baud rate Parity Please check that DIP switch number 5 in the parity block is set to the zero or off position as diagrammed below because this is the switch that actually sets the Modbus card to the RS 485 configuration If this switch is on the card will be configured as an RS 232 card yor 12345 Node 12 Parity To configure the Modbus card as an end node in your network set the termination switch to the one 1 or on position as diagrammed below Termination switch set to 1 or on position When the termination switch is on the Modbus internal termination resistor network is activated which eliminates reflections on the bus line Configuring a Non Terminated Node To configure the Modbus card as a non terminated node or when using an external terminator set the termination switch to the zero or off position Page 346 Thermo Scientific APEX User s Guide Pin Assignments for a DB 9 Connector Here are the pin assignments for an RTU card equipped with a DB 9 connector Pin Name Function 1 Not connected 2 RS232 TX Transmit signal 3 RS232 RX Receive signal 4 Not connected 5 GND Signal ground 6 5V Power supply 7 RS485 A Two wire TX RX lines 8 RS485 B Two wire TX RX lines 9 Not connected Pin Assignments for a Screw Connector Here are the pin assignments for an RTU card equipped with a screw connector P
293. n to change the polarity to minus as shown below nfeed Photo Eye Input 1 71 E Note if your photo eye were wired to Input 3 any other Input between 1 6 this menu would be used to make the change For a positive polarity on Input 3 for example you would enter 3 in this input screen 10 Press the Go button to save your setting and exit the input screen Selecting the Correct Photo Registration for Rejects If you are using a photo eye to control your reject device this function allows you to do the following e Make accurate and consistent rejects using a variety of reject devices such as drop nose retracting belt air pusher and air reject systems e Make accurate and consistent rejects even when the gaps between your individual units of product varies This function is particularly useful if you are inspecting packages that exceed six inches in length Here length means that as the front end of the package enters the search head the distance to its trailing edge is six inches or more When testing products longer than six inches using a photo eye and the appropriate parameters for the photo registration function allows you to accurately reject contaminated products Page 32 Thermo Scientific APEX User s Guide regardless of where the contamination is located in the package at the front in the middle or at the back Matching Your Photo Registratio
294. nal Bit 5 Phase Tracking Limit Exceeded Bit 6 Search Head Problem Bit 7 QAT Problem Bit 8 AuditCheck Problem Bit 9 NVRAM Battery Low Bit 10 Excess Rejects Bit 11 Memory Corruption Bits 12 15 unused 30138 41117 1 16446 62 R W bitmap M Alarm Configuration Same as for Warning Configuration 30139 41118 1 16447 63 R W bitmap M Fault Configuration Same as for Warning Configuration Thermo Scientific APEX User s Guide Page 362 5 3 8 8 3 2 ya 9 2 n x Q n E o g D g 9 9 97 x gt 9 9 9 vy os o u _ 2 2 t a x o dD o 16 16 x x Sa zc amp a 4 a a a 30140 41119 5 16448 64 R W string M Machine Identifier 9 chars in length 30145 41124 5 16449 65 R W string M Printer Batch Code 9 chars in length 30150 41129 1 16450 66 R W bitmap M Printer Setup Bit 0 Enable Printer Bit 1 Enable End of Day Printout Bit 2 Enable Print Rejects Bit 3 Enable Printout on Power On 30151 n a 1 n a n a RO unsigned short M Current Password Level 1 Passwords Disabled 0 Not logged in 1 Operator 2 Engineer 3 Supervisor 30152 41130 1 16451 67 R W signed short M nfeed Photo Eye Sensor Input Values range from 6 to 6 The number 0 6 specifies the output port 0 disabled the sign or indicates the input
295. nction do the following 1 Make sure the Main Menu is displayed 2 Highlight the system and tools menu 3 Press the Go button 4 Highlight the IXR menu 5 Press the Go button 6 Highlight the Enable I XR function 7 Press the Go button A checkmark appears as well as other I XR options indicating IXR in now enabled Enable I XR P881 601 E Grm 1 5 Wit Rex v Hi3 m 8 Press the Back button repeatedly to return to the Main Menu which now looks like this Product Name Page 8 Calibrating the I XR Function During the calibration you must run the conveyor at the same speed used in normal production runs There are two parts to the calibration process e Learn the X and R noise thresholds e Learn the detect levels for both the X and R signals 1 Make sure the Main Menu is displayed 2 Highlight the frequency and gain menu 3 Press the Go button and navigate to page 2 of the menu 4 Highlight the Calibrate Noise Thresholds function Calibrate Noise Thresholds P881 801 5 Make sure the conveyor is running at normal production speed Press the Go button and a monitor screen appears for about 20 seconds while the APEX measures the X and R noise thresholds Auto Calibrating the I XR Function To optimize the auto calibration procedure you should do the following e Run the conveyor at your normal production speed e Have
296. nctions e X and R noise thresholds e Speed filter setting e Detect level e Phase angle setting Page 108 Thermo Scientific APEX User s Guide Additional Parameters You May Want to Set Up Listed below are additional parameters you may want to set up to get your particular pharmaceutical application running to your satisfaction Reject Confirm Function If your gate is equipped with a position detector this function allows the detector to confirm that during a reject cycle the gate has properly completed both the open and close phases of the reject cycle In addition if a gate failure occurs the detector can stop the flow of product or notify you that a gate failure has occurred for example because the air supply to the gate has failed or product has built up on the gate or surrounding duct work For more details see page 137 Warnings Alarms and Faults WAFs Many of the detector s functions provide a warning alarm or fault when a condition needing your attention occurs This menu in conjunction with the appropriate hardwired external device allows this to happen For more details see page 214 Copying and Pasting Product Parameters This function is particularly useful when you are testing multiple products You can save considerable amounts of time and effort using the copy and paste functions because you do not need to re enter the product parameters for each product re run the calibrations and so on For mo
297. ng an RMA Number at the end of the manual A return material authorization RMA number will not be issued without a hard copy PO on file Once an RMA has been issued you will be sent a shipping label noting your RMA number and the address to which to ship the parts The assigned RMA number is valid for 30 days from the date of issuance If your part or parts are not received within 30 days 45 days for international shipments your PO will be cancelled and a new RMA will be required All parts for repair must reference a valid RMA number or the part will be returned at your cost Please do not ship partial shipments your return must be complete Any parts received separately will require a separate RMA Return only those products that are authorized by the RMA Additional products that are sent without approval may not be returned to you If no defects are found in a product you return an evaluation fee of 250 00 per part 500 00 per full system will be charged Return Material Authorization RMA Form Thermo Fisher Scientific s safety policy requires a decontamination form for any package received into our building Contact I nformation Contact Name Email Fax number Phone number Shipping Information Company name Address City State ZIP Billing Information if different from above Company name Address City State ZIP Tax exempt E Yes No Payment
298. ng environment If needed reduce in the value in increments of 5 until the appropriate value is determined In the example below we settled on a value of 75 after several tests under normal operating conditions at our facility Suppression Amplitude Bl E AM Jos m Q AS 5 Press the Go button to save your setting and exit the menu Thermo Scientific APEX User s Guide Page 135 Rejects Menu Page 4 1 From the Main Menu navigate to the rejects menu Reject Totals pagi ___ 2 Press the Go button and page 1 of the rejects menu appears Reject 1 3 Navigate to page 4 Reject Confirm Page 136 Thermo Scientific APEX User s Guide Calibrating Reject Confirm Times This calibration menu has two sub functions the Reject 1 Confirm Sensor function and the Reject 1 Complete Sensor function Both are currently disabled as shown by the X across the eye icons in the screens below In addition each sub function is used only by a particular type of application e Reject 1 Confirm Sensor The default values for reject 1 confirm sensor function looks like this Oe ese e Reject 1 Complete Sensor The default values for reject 1 complete sensor function looks like this MEd sse What the Confirm Functions Do In conveyor applications the reject 1 confirm sensor function confirms that rej
299. ng the APEX must transmit a minimum amount of vibration to the metal detector This structure must be flat and parallel thereby minimizing possible twisting torques to the metal detector case which can distort the electromagnetic field and cause false triggering While the APEX and the support structure may remain in contact nothing including the product must be allowed to touch any part of the aperture as this could cause wear of the aperture lining and give random false alarms Any pressure torque or electrical ground will cause the APEX to misfire Any support platform guide rails or conveyor belt including the joint in the belt which passes through the aperture must be completely free of all metal and must not touch any part of the aperture at any time The packaging on any product to be inspected must be completely free of any metal such as clips aluminum foil metallic labels staples and lids Metal Free Area For optimum performance non moving metal should be allowed no closer to the aperture opening than 1 5 times the smallest aperture height measured outward from the center of the aperture Moving metal should be allowed no closer to the aperture opening than 2 0 times the smallest aperture height measured outward from the center Page 292 Thermo Scientific APEX User s Guide of the aperture When a complete conveyor system has been supplied by Thermo Fisher Scientific these considerations have already been factored in to
300. nge units function as shown below Reject 1 Distance Delay Units P881 001 H 8 8 gt 0 0 Page 44 Thermo Scientific APEX User s Guide b Press the Go button and the original units are changed from seconds to meters or feet if you have set these as your preferred distance unit Notice that the numbers in the adjacent menu have now changed Reject 1 Distance Delay P881 get B 9509 6 6 0 0 1167 6 360 8 1515 1 505 sure the screen shown step 3 is displayed the one where the reject distance is expressed in meters You are now ready to key in your reject distance in meters or feet and inches if these are your preferred units 4 Press the Go button and the reject distance input screen appears Use the navigation buttons to key in your reject distance In our salted butter example we have entered our reject distance of 1 17 meters Reject 1 Distance Delay fil mi X X 5 Press the Go button to save your settings and exit the input screen Thermo Scientific APEX User s Guide Page 45 Keying In the Signal Duration for the Reject Device Before starting make sure you know the signal duration time expressed in seconds and hundredths of a second needed to activate your main Reject 1 device 1 If you are not already on page 1 of the rejects menu follow steps 1 2 in the Keying In Distance to the Reject Devic
301. no product present in the search head e Calibrate the speed filter using a ferrous or other test stick e Establish basic product parameters detect level and phase angle e Have the detector do an AuditCheck learn if applicable Understanding Technical Terms If you encounter a technical term you do not understand in these sections please refer to the Glossary on page 393 For example the word product means anything the detector is testing for the presence of metal contaminants and is a word you will encounter often in this manual Let s get started Thermo Scientific APEX User s Guide Page 13 Understanding Your Detector This section helps you understand the detector s control panel and Main Menu and explains how to set up three global set it and forget it parameters language help text and units of measure Understanding the Detector s Control Panel The main components of the detector s control panel are as follows The display panel The three red green and yellow indicator lights The green Go button The red Back button The four blue triangular shaped navigation buttons The detector s control panel looks like this Display panel Indicator lights Back button Go button Navigation button Page 14 Thermo Scientific APEX User s Guide The Display Panel The display panel allows you to access all the detector s functions The Indicator Lights These give
302. nsible for initial inspection of the equipment and site preparation It is essential that the customer place the equipment in the production line in accordance with the guidelines below The customer must assure that qualified service personnel are available to make interconnections with other production equipment and perform work at the installation site A Thermo Fisher Scientific Products Customer Service Representative is available to supervise installation and verify operation as well as train personnel assigned to operate and maintain the equipment APEX Installation Considerations Customers who intend to install the APEX on an existing conveyor or a Thermo Fisher Scientific supplied conveyor should study the following factors that can influence the detector s performance The importance of studying this section and taking note of the information given is very important It has been proven that faulty metal detector operation such as random false alarm signals and undue sensitivity to vibration are usually due to incorrect installation of the metal detector or some other factors external to the metal detector itself Location of the Detector The APEX should be located to give easy access to the front panel The installation location of the display and or electronics box should be considered Mounting the APEX For trouble free and reliable operation it is very important that the APEX be correctly mounted The support structure for mounti
303. nu screen is displayed when the calibration is complete Gravity Feed Applications Listed below are the most commonly used functions for setting up a typical gravity feed application Reject Delay Time This function is usually set to 0 00 seconds and tells the gate to close immediately when contaminants are detected If your gate is a long way from the search head you may need to set a longer delay time 1 Make sure the Main Menu is displayed 2 Navigate to the rejects menu 3 Press the Go button 4 On page 1 of the rejects menu highlight the Reject 1 Distance Delay function Reject 1 Distance Delay 5 Press the Go button and an input screen appears 6 Key in an appropriate value in seconds and hundredths of a second for the reject delay time Page 5 Reject Duration Time This is the time that the gate remains closed to divert contaminated product and is usually set to one second 1 Navigate to the screen shown in the Reject Delay Time section 2 Highlight the Reject 1 Duration function Reject 1 Duration P881 661 Ca 0 02 Ee 0 005 Jm 1 64 x 3 Press the Go button an input screen appears 4 Key in the appropriate value in seconds and hundredths of a second for the reject duration time Calibrate X and R Noise Thresholds See the instructions on page 5 Full Product Calibration See the instructions on page 5
304. nute R inside radius of the pipe Thus the flow rate in gallons per minute divided by the pipe s radius squared times 6 13 equals the product flow rate in feet per minute Fpm Please note however that in the examples given below product flow rates are expressed in meters per minute You can set the wide band filter to the following speeds e Speed filter 1 Slow This is the default setting and is used typically for products flowing from 10 to 75 meters per minute Slow Product Speed e Speed filter 2 Medium This is used typically for products flowing from 75 to 300 meters per minute Medium Product Speed Page 88 Thermo Scientific APEX User s Guide e Speed filter 3 Fast This is used typically for products flowing from 300 800 meters per minute Fast Product Speed p i e Custom speed This setting is used when your product is flowing through the pipe either very fast or very slowly For help setting up a custom speed filter setting please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Setting Up the Speed Filter To set up the appropriate speed filter setting slow medium or fast do the following 1 Make sure the Main Menu is displayed Product Name 2 Navigate to the speed filter menu and make sure it is highlighted Slow P
305. o the communications menu Communications 1 1 continued Thermo Scientific APEX User s Guide Page 327 8 Press the Go button and the Modbus TCP IP Configuration screen appears In most instances the IP subnet mask gateway and MAC addresses are set automatically by the network and the appropriate addresses will be shown in the detector s display panel In the example below we have entered all zeros in this screen so we can show you how to change the communication parameters except the MAC address which cannot be edited Modbus TCP IP Configuration Here is a list of the communications parameters found in this menu Please note that all parameters are editable except the MAC address Parameters Description Editable DHCP Dynamic host control Yes you can set DHCP to either on protocol or off On is the default setting IP IP address Yes SN Subnet mask address Yes GW Gateway address Yes MAC MAC address No Page 328 Thermo Scientific APEX User s Guide Changing the DHCP Default Setting During Installation The default setting for DHCP is on as shown by the check mark next to the function Because the DHCP setting is set by default to on a network host device will set the subnet mask gateway and MAC addresses for you when you do either of the following e Scenario 1 Powering up the APEX for the
306. oduct 47 Calibrating the Speed Filter Using a Ferrous Test 50 Establishing Basic Product 52 Changing the Current Product heme nennen 60 Set Up Check List for Conveyor Applications 61 Parameters You Have Already Set Up 61 Additional Parameters You May Want to Set 62 Setting Up Gravity Feed Applications 63 Setting Reject Parameters boxe a Poets Elbe brin 65 Understanding Reject Delay and Reject Duration 65 Setting the Reject Delay e esee enn 66 Setting the Reject Duration meme 67 Setting Contaminant Detection Parameters 69 Establishing a Baseline with No Product 69 Calibrating the Speed Filter Using a Ferrous Test 72 Establishing Basic Product 73 Thermo Scientific APEX User
307. of the opening As a result it is best run test sample passes through the centerline of the opening If the test sample is run at the side of the aperture or product tube this will produce a larger signal than through the centerline The test procedure should consider this for consistent results Choose Appropriately Sized Test Samples Sensitivity capabilities of different detectors used in different applications will vary Smaller aperture is capable of detecting smaller pieces of metal Product effect may also alter the detection capability It is inadvisable to rely on a corporate standard to determine and test the detector s operation Ideally each detector should have its own standards of operation and a corporate outline should be used only as a maximum allowable guide Sample sizes should be selected so that they are clearly detectable when compared to the signal produced by the product or other interfering signals If samples are established which are very close to the product signal frustration on the part of operators can lead to a lack of confidence in the detector s operation Use the Normal Product Flow Rate During Testing The detector should be tested at its normal operating speed Test samples should be placed on conveyors so that they will pass through the detector at normal speed On pipelines test samples should be inserted so that they travel through the search head at the product s normal flow On gravity feed and tablet pharm
308. of the quality test menu appears QA Test Timers and Reject PHA 001 continued Page 200 Thermo Scientific APEX User s Guide 3 Navigate to the time interval menu Time Interval FARI 81 4 Press the Go button an input screen appears Key in the time interval want between tests in minutes maximum 999 minutes equivalent to 16 hours 39 minutes 5 Press the Go button to save your setting and exit the menu 6 When the time interval times out pass the three test samples in succession to perform the QA Test Setting the Time Window for Doing a QA Test This function allows you to set the time window the operator has to perform the QA test after the warning device such as a flashing light alerts him or her that a QA test needs to be done 1 Navigate to the fault time out function Fault Timeout FAHI 001 2 Press the Go button input screen appears Key in the time minutes maximum 99 that the operator has to start performing the QA test If he or she does not perform the test within this time window a fault will occur something that could for example stop the conveyor or sound a siren 3 Press the Go button to save your setting and exit the menu Thermo Scientific APEX User s Guide Page 201 Setting the Reject Device Used for the QA Test This function sets the reject device used during the QA test The
309. oining the roller to the insulating block should not make metal to metal contact with the conveyor or APEX An intermittent closed loop on a conveyor may also be due to lubricated bearings whose balls act as electrical contacts and whose resistance therefore varies as they move through the lubricant The source of such loop interference can be very elusive and difficult to locate The larger the aperture in the APEX the greater the high frequency leakage out of the aperture and the greater the possibility of trouble from loops Metal Objects Near the Search Head The metal detector is very efficiently screened and metal near the top bottom and ends will not significantly affect the detector performance However metal positioned close to the aperture can cause interference problems if it moves or vibrates The area close to the aperture which should be kept metal free is known as the metal free zone This metal free zone is dependent upon the aperture dimensions and the sensitivity setting of the detector The metal detector is sensitive to moving metal It is not always possible to discriminate if the metal is passing through the head or moving outside the head Metal in the metal free zone may cause the detector to be sensitive to vibration If the APEX vibrates or is accidentally bumped it will cause relative movement between the detector and the offending metal which could trigger the detector Page 294 Thermo Scientific APEX User
310. om speed filter setting please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Establishing Basic Product Parameters Before putting your detector into service you must have it learn how to identify your uncontaminated product This is done using the detector s full product calibration function which sets the following basic parameters for your product e Phase angle setting e Detect level Doing a Full Product Calibration To do a full product calibration follow the instructions below 1 Make sure product is falling through the chute 2 Highlight your product name in the Main Menu Product Name 3 Press the Go button and page 1 of the product menu appears Product Calibrate and Name PHH1 81 Thermo Scientific APEX User s Guide Page 105 4 Press the right navigation button to highlight the Full Product Calibration menu Full Product Calibration 1 01 The detector s auto calibration function as shown by the symbols check marks the screen above is now ready to do the following e Learn the phase angle e Learn the detect level e Conduct an AuditCheck if this optional hardware is installed on your APEX 5 Press the Go button and the Performing Full Learn monitor screen appears Performing Full Learn continued
311. om the detector It is also useful to display these contaminants so that all employees can see the benefit of the metal detector Tube Size Use the following formula to calculate the approximate duct chute dimensions for the system In Flow Rate Ibs hr x 0 024 Bulk Density Ibs ft Choose the duct chute size so the product fills no more than 8096 of the product tube Here is an example If the product to be inspected has a bulk density of 30 Ibs cubic ft and a flow rate of 15 000 Ibs hr the result would be 12 square inches With 80 fill the chute should be sized to 15 square inches The dimensions of the metal detector should be kept to the smallest size possible for the best sensitivity It is then a matter of choosing a product tube with the same square inches that is best suited for the application In the above example you could use a chute dimension as follows e 127 mm 5 x 76 mm 3 e 203 mm 8 x 51 mm 2 or 129 mm 4 75 diameter By choosing the 203 mm 8 x 51 mm 2 chute there will be a smaller stroke on the reject valve and a faster reaction time The metal detector will be approximately 25 mm 1 larger on both the length and width rounded up to the next available size giving an aperture of 250 mm 9 8 x 75 mm 3 If the product is prone to bridging the 127 mm 5 x 76 mm 3 or 120 mm 4 75 diameter units would be preferable Contact Thermo Fisher Scientific as described in the Contacting Th
312. on function is enabled you can manually suppress the reject device This is useful when you are conducting a Quality Test or other manual test of the detector s ability to detect contamination For this function to work you must do both of the following e Hardwire the button or other triggering device to one of the inputs Input 3 6 on the detector s wiring board the physical set up see page 289 e Tell the detector which input is being used the logical set up For more information about assigning inputs and logical set up procedures see page 222 1 Make sure the suppression external trigger menu is highlighted Suppression External Trigger 2 Press the Go button and a check mark appears The suppress rejection external trigger function is now enabled Suppression External Trigger Bal 3 Press the Back button to exit the menu Thermo Scientific APEX User s Guide Page 129 Activating Reject Suppression Reject 1 See page 131 This function is normally used only in gravity feed and pipeline applications Suppression Reject Trigger P881 081 G x A B Jun 6s 1 0 3 6 avv 100 Understanding Reject Suppression Reject 1 This function is normally used only in gravity feed and pipeline applications Before you can set parameters for the reject suppression function you must first activate the detector s suppression capabilities To help you un
313. oosing the AC power line for the detector note that starting heavy electrical machinery can create considerable though momentary volt drops in the line This can cause the detector to trigger Since detector power consumption is only 35 watts it is recommended that a lighting circuit be used rather than machinery power circuit Where this is not possible and line noise triggers the detector contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual for recommendations about a suitable isolation transformer or power line filter Note Do not use loads requiring power sources not generated or used by the APEX unless approved by Thermo Fisher Scientific Thermo Scientific APEX User s Guide Page 285 System Grounding On all metal detection systems it is important for safety and performance to implement good grounding techniques This should be made at the appropriate point at the PSU PCB Care must also be taken to ensure that the head or frame does not carry earth fault or operating currents from other systems Earth ground connections should be made at one point in the system and this point is the PSU PCB Use waterproof cable glands at all cable entries Recommended cable entries are listed in this manual on page 288 Caution All wiring must be done in accordance with field wiring diagrams the National Electrical Code and all local electrical codes Do not ro
314. op effect becomes greater in detectors having an aperture height greater than five inches 125 mm and a width greater than 12 inches 300 mm as shown in the figure below L5xB 1 5 APERTURE WIDTH APERTURE HEIGHT B Loops as far as 3 ft 1 m away may affect the operation of the detector depending on roller bearing frame materials and on the quality of the contact To avoid loop effects due to these causes the following steps are recommended e All cross members and transfer plates should be welded or securely fastened e Rollers cannot be secured but should be isolated from making electrical contact Note Only one side of each roller assembly needs to be isolated Do not isolate both ends Roller Isolation Methods The materials generally used to isolate rollers are plastic and phenolic Care should be taken to ensure raw products do not come into direct contact with phenolic materials Listed below are several methods for isolating rollers to prevent loop effects Stub Shaft Method With this design the roller shaft does not continue through the roller This separation removes the electrical loop within the roller as shown below Note The roller must be non metallic les Non metallic roller Shaft does not continue through the roller Thermo Scientific APEX User s Guide Page 297 End Cap Method Placing a closed ended plastic cap on one end of the roller shaft breaks the electrica
315. or both the X and R signals addition if you are going to use the IXR function for long production runs lasting several hours or days you should make sure the I XR tracking function is set to On the default value Learn the X and R Noise Thresholds Please note it is very important that while calibrating the X and R noise thresholds you run the conveyor at exactly the same speed you will use during your normal production runs Thus if you decide at a later date to change the speed of the conveyor during your normal production runs you must recalibrate the X and R noise thresholds To calibrate the X and R noise thresholds do the following 1 Make sure the Main Menu is displayed Product Name continued Page 380 Thermo Scientific APEX User s Guide 2 Navigate to the frequency and gain menu Frequency and Gain 3 Press the Go button and page 1 of the frequency and gain menu appears Navigate to page 2 as shown below Detection Level and Noise Threshold FAHI 1 80 4 Navigate to the Calibrate Noise Thresholds function and make sure it is highlighted as shown below Calibrate Noise Thresholds FARI 1 we 5 100 CALES Seale continued Thermo Scientific APEX User s Guide Page 381 5 Make sure that the conveyor is running at the speed you will use for normal produ
316. or either the X or R noise threshold make sure the Calibrate Noise Thresholds menu shown in step 5 is displayed Navigate to the appropriate menu X or R and press the Go button An input screen appears allowing you to manually enter a value X Threshold Thermo Scientific APEX User s Guide Page 103 Choosing the Correct Speed Filter Settings for the Rx For the Rx the default speed filter setting is the wide band speed filter 2 medium which works well for most Rx applications where products flow at a medium angle of 35 e Speed filter 2 Medium the default Rx setting This is used typically for products flowing at a medium angle 35 Medium Product Speed However if you have products flowing at other standard angles 25 or 45 you should use a different speed filter as shown below e Speed filter 1 Slow This is used typically for products flowing at a shallow angle 25 Slow Product Speed e Speed filter 3 Fast This is used typically for products flowing at a steep angle 45 Fast Product Speed Bal Page 104 Thermo Scientific APEX User s Guide e Custom speed This setting is used when your product is flowing through the chute either very fast or very slowly or because you are using a non standard angle that is an angle different from the standard angles of 25 35 and 45 For help setting up a cust
317. or of 2 3 times Thermo Scientific APEX User s Guide Page 11 Managing Product Rejection Parameters Once the detector is up and running and detecting metal contaminants the next task is to set up the all important product rejection parameters which fine tune the accept or reject process for your products Which parameters you use however depend on the type of application conveyor gravity feed pipeline or pharmaceutical you are using Conveyor Applications In this application a conveyor belt is used to pass the product through the detector s search head Gravity Feed also known as Drop Through Applications The search head surrounds a vertical duct where the product drops through the duct under the influence of gravity The detector s search head is installed around the outside of the duct Pipeline Applications The detector s search head is installed surrounding a pipe where product is flowing under pressure Pharmaceutical Applications The search head surrounds a chute where the product drops through the chute under the influence of gravity The detector s search head is installed around the outside of the chute Choosing Your Application Type Clearly the product parameters and product rejection parameters used by the APEX vary depending on the type of application you are using As a result you should now go to the specific section in this manual that explains the detailed set up procedures for your pa
318. ot system parameters System parameters are accessed as described in the previous section Product Setup Code Ce Vhp L b C S APEX 588 L Displaying Your Product Set Up Code To display your product set up code do the following 1 Make sure the system set up code function is highlighted 2 Press the Go button and a display screen appears showing a code similar to the example below Product Setup Code GECLRJMBSTRSYRSY El HQACQAAUT ZARIELA SAGEAGI ZRCRRRRRR 5 2 MECEL E 3 Make a note of the character stream then press the Back button to exit the screen Thermo Scientific APEX User s Guide Page 195 Quality Test System and Tools Page 1 The detector s Quality Test function allows you to conduct manual tests of the detector s ability to detect contaminants in contrast to the detector s AuditCheck function which does much the same thing only automatically and with a significantly greater degree of accuracy Either function however allows you to verify as part of your overall quality assurance program that the detector is working properly during long production runs lasting several hours several days a week and so on Quality Test nnn Navigating to the Quality Test Function 1 From the Main Menu navigate to the system and tools menu System and Tools 2 Press the Go button and
319. our pack length setting and exit the input screen Keying In the Detection No Pack Distance The detection no pack distance should also be set as described below 1 Follow steps 1 3 in the Keying In the Pack Length section above to reach this screen Product Shape and Flow 1 372 Thermo Scientific APEX User s Guide 2 Navigate to the Detection no Pack Distance function and make sure it is highlighted Detection no Pack Distance 1 3 Press the Go button and an input screen appears Detection no Pack Distance 4 Key in the length of the packages you are testing that is key in the same value you entered for pack length in the Keying In the Pack Length section above We keyed in 12 4 centimeters the same value we entered above for pack length Detection no Pack Distance Pe 5 Press the Go button to save your setting and exit the input screen Thermo Scientific APEX User s Guide Page 373 Keying In the I n Feed Photo Eye Distance The in feed photo eye to detector distance must be set for the I XR function to work properly To set the in feed photo eye distance do the following 1 Take a tape measure and note the distance from the photo eye on the upstream or in feed side of the detector to the in feed side of the detector s search head 2 Make sure the Main Menu
320. page 1 of the system and tools menu appears System and Tools Page 1 3 Navigate to the Quality Test function and make sure it is highlighted Quality Test Page 196 Thermo Scientific APEX User s Guide Overview of How the Quality Test Function Works The most commonly used types of test to verify the detector s response are as follows Three Metal Test This test uses three different types of metal placed in the center of three separate packets of product Clearly which metals you use depends on what contaminants you are interested in In a typical work environment this test is conducted using application specific conveyor gravity feed or pharmaceutical ferrous non ferrous or stainless steel balls This is the most frequently used of the three types of tests Positional Test This test uses a single contaminant of uniform size for example the application specific ferrous test ball placed in three different positions usually in the leading middle and trailing edge of three separate packets of product Size Test This test uses a single type of metal for example ferrous balls but uses three different sizes ranging through small medium and large Clearly how small medium and large are defined depends on your particular work environment and the size range of the contaminants you are interested in In a typical application the test balls are placed in the center of three separate
321. page 2 of the security menu appears Password Oii 1 Ow 2 HE 2 Press the right navigation button to highlight the passwords menu Activate Passwords 04 1 Ou 2 E Oi Page 250 Thermo Scientific APEX User s Guide 3 Press the Go button and a password needed mini screen appears Supervisor Login 4 Press the Go button and the keyboard screen appears complete with a key icon in the entry field as a reminder you are now entering a password Exit amp Save ee eres 5 Key in your default supervisor password SUPE and navigate to the exit and save key Your screen should now look like this If you are not sure how to use the keyboard screen see page 25 Exit amp Save Qui nen continued Thermo Scientific APEX User s Guide Page 251 6 Press the Go button and the following screen appears Notice that a check mark has appeared in the passwords menu which tells you that passwords have now been activated for the detector Activate Passwords 0 1 On 2 0 2 Ont 7 Navigate to the Level 4 supervisor password entry icon Edit Supervisor Password 8 Press the Go button and the keyboard screen reappears 9 Key in a new supervisor password for yourself anything but S
322. pipeline application please go to the Getting Started section on page 11 to learn how to operate your newly installed APEX detector Thermo Scientific APEX User s Guide Page 309 310 Thermo Scientific APEX User s Guide Safety and Warranty Information Please read this section carefully because it contains important safety and warranty information for which you are responsible Software License This document is confidential and is the property of Thermo Fisher Scientific Inc It may not be copied or reproduced in any way without the express written consent of Thermo Fisher Scientific This document also is an unpublished work of Thermo Fisher Scientific Thermo Fisher Scientific intends to and is maintaining the work as confidential information Thermo Fisher Scientific also may seek to protect this work as an unpublished copyright In the event of either inadvertent or deliberate publication Thermo Fisher Scientific intends to enforce its rights to this work under the copyright laws as a published work Those having access to this work may not copy use or disclose the information in this work unless expressly authorized by Thermo Fisher Scientific Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries All other trademarks are the property of Thermo Fisher Scientific Inc and its subsidiaries Terms of the Software License T
323. ple this to and away motion is not intuitive but with a little practice you will find this is the best way to activate the detector s buttons Thermo Scientific APEX User s Guide Page 15 Understanding the Screen Shots Used in this Manual In this manual a large screen shot means that is the only place or section in the manual where the function is explained contrast a small screen shot means the function is explained elsewhere in the manual Examples of both types of screen are shown below Large Screen Shot This is an example of a large screen shot Product Name Small Screen Shot This is an example of a small screen shot Product Name Tips on Using the Detector s Sub Menus Here are some tips to help you navigate the detector s menus and access all of its functions e Use the navigation buttons on the control panel to navigate to and highlight the function you want to use e Press the Go button to access the function If pressing the Go button does not work try the down navigation key because some functions menus and options are accessed using the navigation buttons not the Go button e Use the Back button to back out of any function or menu you are not interested in Note too that pressing the Back button allows you to exit a function without making any changes Pressing the Back button repeatedly will always take you back to the Main Menu Page 16 Thermo
324. possible to discriminate if the metal is passing through the head or moving outside the head Metal in the metal free zone may cause the detector to be sensitive to vibration If the APEX vibrates or is accidentally bumped it will cause relative movement between the detector and the offending metal which could trigger the detector Electrical I nterference It is always good practice to suppress electrical interference at its source and if trouble is experienced the offending source should be located and suppressed If this is not possible it may be necessary to operate the APEX at a reduced sensitivity A relay in the metal detector is often used to control solenoid valves power contractors and similar electrical devices When these devices are switched off the collapsing field of the winding generates a wide band interference which may be picked up by the search coils in the detector head and cause false triggering A capacitor of suitable capacity and working voltage connected across the offending device and grounded as close to the device as possible will often provide satisfactory suppression Pneumatic Air Connect incoming air to the detector s air regulator fittings using a coiled copper tube or air hose Adjust the incoming air pressure to 30 40 PSI 2 1 2 5 kg cm for pneumatic devices or 40 80 PSI 2 8 5 6 kg cm for air rejects The Next Step Now that you have completed the electrical and mechanical set up for your
325. pplications 299 Mechanical Set Up for Pipeline 307 Safety and Warranty Information eene 311 Appendix A Modbus Communications Card 319 e TP 321 What the Modbus Communications Card Does 321 Engineering Details bak Sends he vee OES EE Selves 322 Expert Knowledge Is Required to Modify 323 Overview of the Installation Process ssssssssssss mn 323 Modifying the Modbus mmm mese 323 Configuring Network Parameters with the APEX Software 325 Configuring a TCP IP ku Fur dene ree e XXe bn eR XE 325 Accessing the TCP IP Communications Menu ssssssss mm 326 Changing the DHCP Default Setting During Installation 329 Changing DHCP to ZOTf 22 eee ea ee ede 329 Manually Changing Communication Parameters 330 Changing the IP Address 330 Changing the Subnet Mask Address 331 Changing the Gateway Address sss ense e mene 332 MAC Addresses eiii
326. propriate input 1 6 and polarity Page 3 Photo Registration for Product Rejects This function allows you to select which part of the product triggers your reject device This function is usually used for products that exceed six inches in length Rejects are triggered in three different ways as follows the leading edge of the product E the center of the product i the entire length of the product 1 Make sure the Main Menu is displayed 2 Highlight the rejects menu 3 Press the Go button 4 Navigate to page 2 of the menu 5 Press the right navigation button to select the photo registration menu Leading Photo Registration P881 601 B m WA CI X 3 o nni 042 x xX gt 258 4 6 To change this setting press the Go button repeatedly until a check mark appears beside the part of the product that will trigger your reject device Distance to the Reject Device This function allows you to input the distance mm or inches from the downstream edge of the search head to the center of your main Reject 1 device 1 Make sure the Main Menu is displayed 2 Highlight the rejects menu 3 Press the Go button continued Page 4 4 On page 1 of the rejects menu highlight the Reject 1 Distance Delay function Reject 1 Distance Delay P881 661 0 8 0 02 36 ms 5 Press the Go button input screen appears 6
327. r applications and is used as part of your overall quality assurance program in particular during long production runs lasting several hours several days a week and so on The main advantage of using AuditCheck is that it is able to detect very small changes over time in the sensitivity of the search head and alert you well before contaminated products are likely to pass unnoticed In comparison to manual testing which is described in the Quality Test section above using the AuditCheck function is significantly more accurate and precise and is virtually foolproof meaning if AuditCheck is used regularly there is little chance of contaminated product passing unnoticed This section assumes you have already completed the mechanical installation of the AuditCheck components and have matched the speed of the test shuttle to the speed of the product moving on your conveyor AuditCheck Crt QUALITY TEST Navigating to the AuditCheck Function 1 From the Main Menu navigate to the system and tools menu System and Tools Pest zt 2 Press the Go button and page 1 of the system and tools menu appears System and Tools Page 1 Page 206 Thermo Scientific APEX User s Guide 3 Navigate to the AuditCheck function and make sure it is highlighted AuditCheck 4 Press the Go button and page 1 of the AuditCheck menu appears AuditCheck Calibrate te
328. r of AuditCheck 120 Rejects Ment Page 2 cie ot Ern imi acts Fe ac aed 121 Setting the Type of Photo Registration 121 Setting the Latching Reject Function Reject 1 122 Inverting the Reject Function Reject 1 mme 123 Calibrating the Speed Encoder 124 Understanding the Photo Queue Pack 127 Rejects Merit Pale Ese seen ceto ia 128 Suppressing Rejection Using an External Trigger Reject 1 129 Activating Reject Suppression Reject 1 130 Understanding Reject Suppression Reject 1 130 Activating Reject Suppression Reject 1 131 Setting Suppression Time Reject 1 cece eee e eect eee eee eee 132 Setting Amplitude Suppression Reject 1 134 Rejects Menu Page 4 nnns nnn 136 Calibrating Reject Confirm mme 137 Manually Setting the Tim
329. r of your reject device e The duration of the signal needed expressed in seconds and hundredths of a second to activate your reject device With this information in hand you are now ready to key in the needed values In our salted butter example we are going to use the following values e Reject distance 1 17 meters e Reject signal duration 2 02 seconds Thermo Scientific APEX User s Guide Page 43 Keying In the Distance to the Reject Device Before starting make sure you know the distance from the downstream edge of the search head to the center of your main Reject 1 device 1 From the Main Menu navigate to the reject totals menu Reject Totals 2 Press the Go button and page 1 of the rejects menu appears Reject 1 Distance and Duration 01 EiC 8 388 asm x 3 Navigate to the Reject 1 Distance Delay function Reject 1 Distance Delay Stop and look very carefully at the highlighted number in the screen above and note that the current setting is 0 300 meters as shown by the m after the number In other words the reject distance is not expressed in seconds which for some applications would be a valid setting a Ifthe number in the Reject 1 Distance Delay menu is shown as a time unit as indicated by an s after the number you should now change it to a distance unit To do so press the right navigation button and highlight the cha
330. radio frequency signal to produce an alternating magnetic field in the aperture e Control Panel The control panel houses the power supply the I O PCB and all processing and display functions Safe Storage Conditions for Your APEX Your APEX metal detector and associated equipment can be safely stored in ambient temperatures of 10 to 50 C 14 to 122 F with a non condensing humidity of 80 APEX Specifications There are three models of APEX the APEX 500 APEX 300 and APEX 100 The principal difference between the three models has to do with aperture size the size of the opening through which the product passes to be analyzed for metallic contaminants Specifications for the APEX 500 300 and 100 Listed below are the technical specifications for the APEX 500 Product Speed Depends on product dimension and belt speed Outputs Six NO relays All available as solid state open collector if required Contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual for details e Relays o 250 volt AC 1 amp max o 50 volt DC 1 amp max e FET o 30 VDC 1 amp max NO compatible o Output Allocation Menu selectable o Reject 1 Reject 2 AuditCheck Fault Alarm Warning and QA Lamp Page 272 Thermo Scientific APEX User s Guide Inputs Menu Selectable Six Inputs Active 12v DC 12 volt auxiliary supply for input sensors for the following e Belt
331. re details see page 173 Thermo Scientific APEX User s Guide Page 109 110 Thermo Scientific APEX User s Guide APEX Menu Structure The following pages provide a summary of the detector s complete menu structure using screen shots as a visual guide The screen shots are listed in the order in which they appear in the detector s menus and sub menus If you encounter any unfamiliar terms in this section please refer to the Glossary on page 393 for an explanation Main Menu Page 1 This is the starting point from which all the detector s menus and functions are accessed Product Name See page 24 Product Name P881 Product Speed See page 27 Product Speed Thermo Scientific APEX User s Guide Page 111 Reject Totals Menu The reject totals menu allows you to assess at a glance how many products have been screened and how many rejects of all kinds P A Q have been made In addition the reject total function tells you how many rejects have been made in the following three categories You may not be using the Quality Test and AuditCheck options especially if you are running a gravity feed or pipeline application e Number of contaminated products P rejected by the detector e Number of rejects A made by the AuditCheck function e Number of rejects Q made by the Quality Test function Reject Totals Understanding the Reject Totals M
332. re must be taken to avoid any weight or undo strains on the chute A gravity feed system consists of the following three major components Search Head The search head contains the search head board and the inspection coils the material passes through Control Unit and Integral Power Supply The control unit contains the user interface controls processing electronics and should always be mounted remotely The power supply unit which houses power supplies input output devices and the connection terminal strip should always be mounted remotely Reject Valve and Support Structure The reject valve and support structure are used on gravity applications The structure supports the metal detector reject valve and product inspection tube The control unit and power supply may be mounted directly to the structure Page 302 Thermo Scientific APEX User s Guide Mounting Methods The typical mounting method is to suspend the system with a threaded rod The threaded rod should support the complete load of the system When securing the threaded rod to the frame the isolation bushing should be used on all four mounting holes This electrically isolates the frame from any support structure The system is designed to support the metal detector reject assembly and associated parts Discharge and reject piping should have their own support structures Hanging piping from these ports may distort the reject body and render the reject inoperable I
333. requency 1 High Frequency 30079 41090 1 16419 35 R W enum P Search Head Gain 0 Low Gain 1 High Gain 30080 41091 1 16420 36 R W unsigned short P Resistive R Threshold 0 to 65535 30081 41092 1 16421 37 R W unsigned short P Reactive X Threshold 0 to 65535 30082 41093 1 16422 38 R W bitmap P Auto Learn Behavior Each Bit Locks out a particular stage of the Auto Learn Bit Enable Phase Lock Bit 1 Enable Detect Level Lock Bit 2 Enable AuditCheck Lock 30083 41094 I 16423 39 R W_ unsigned short P AuditCheck Time Interval 0 to 999 minutes 30084 41095 1 16424 40 R W unsigned short P AuditCheck Fault Timeout 0 to 99 minutes 30085 41096 1 16425 41 R W_ enum AuditCheck Reject Device 0 None 1 Rejecter 1 2 Rejecter 2 30086 41097 1 16426 42 R W unsigned short AuditCheck Peak Warning 0 to 99 Tolerance 30087 41098 1 16427 43 R W unsigned short P AuditCheck Peak Alarm Tolerance 0 to 99 30088 41099 1 16428 44 R W unsigned short P AuditCheck Peak Fault Tolerance 0 to 99 30089 41100 1 16429 45 R W unsigned short AuditCheck Phase Warning 0 to 99 degrees Tolerance 30090 41101 1 16430 46 R W unsigned short P AuditCheck Phase Alarm Tolerance 0 to 99 degrees 30091 41102 1 16431 47 R W unsigned short P AuditCheck Phase Fault Tolerance 0 to 99 degrees 30092 n a 1 n a n a RO unsigned short P AuditCheck Learned Peak Average 0 to 65535 30093 n a 1 n a n a RO unsigned short P AuditCheck Learned
334. requency Hz Resolution f m 50 55 98 4 108 3 100 105 98 4 103 3 200 205 99 7 102 2 500 505 99 9 100 9 750 755 99 9 100 6 1000 1005 99 9 100 4 1500 1505 99 8 100 2 2000 2005 99 8 100 1 f m feet per minute Calibrating the Speed Encoder Function You must calibrate the speed encoder function before you can use it 1 Turn on the conveyor and set the belt speed to maximum Use a tachometer to record the speed 2 Go to the product speed function in the Main Menu as described on page 27 and key in the reading for maximum belt speed We keyed in 100 feet per minute Product Speed P881 981 Thermo Scientific APEX User s Guide Page 125 3 Navigate as described in the above sections to the speed encoder function make sure the speed encoder function is highlighted as shown below Speed Encoder 4 Press the Go button and the monitor screen below shows a bar graph of the progress of the calibration process During the calibration the detector s speed encoder function automatically matches the pulses from the conveyor s speed encoder to the speed you entered in the product speed function Calibrating Encoder Frequency 5 When the calibration is completed the detector displays the following screen The value shown in your screen however may be different Speed Encoder LETT gp a 6 Press t
335. ress the Go button and an input screen appears AuditCheck overhang distance 4 Key in your overhang distance in meters or inches if you set inches as your preferred units of measure 5 Press the Go button to save your setting and exit the function Setting the AuditCheck Pulse Length The AuditCheck pulse length is the time it takes your product to travel the length of the AuditCheck tube The detector automatically calculates a value for pulse length using other parameters that have been set up such as the model of APEX you are using the type of application you are running conveyor gravity feed or pipeline and the values you have set for other functions However if the internally generated pulse for some reason does not give the exact result you want you can manually enter a value How the Detector Calculates Pulse Length When the value for AuditCheck pulse length is set to zero the detector automatically calculates the value using the following formula 60 Search Head Width 2 Overhang Distance Product Speed Pulse Length ms Where Search Head Width is in mm Overhang Distance is in mm and Product Speed is in m min Thermo Scientific APEX User s Guide Page 211 Keying In a Value for Pulse Length To key in a value for pulse length do the following 1 Navigate to page 4 of the AuditCheck menu AuditCheck Setup P881 661 f 1 00 1 6 ao 2 805
336. ription of the function you are currently using Human machine interface Identity International Electrotechnical Commission The indicator lights in the control panel show the current status of the search head There are three indicator lights red green and yellow Page 394 Thermo Scientific APEX User s Guide Glossary Term Input screen IP Keyboard screen LED LSB MAC Main Menu Monitor screen MSB MZ n a Navigate Navigation buttons NVRAM Definition An input screen is used for keying in values for a specific detector function The right hand number in the input screen is marked with a small triangle above and below indicating all the numbers in the screen can be changed using the navigation buttons Internet protocol A screen that appears in the display panel and looks like a computer keyboard The keyboard screen allows you to enter letters numbers and other characters for naming products setting passwords and so on Light emitting diode Least significant byte In the Modbus registers a machine setting one of the detector s global parameters Media access control address The initial menu shown in the detector s display panel The Main Menu is the starting point for accessing all of the detector s many functions A screen that incorporates a progress bar allowing you to monitor the progress of a function for example the detector s auto calibration func
337. roduct Speed 3 Press the Go button repeatedly to scroll through the speed filter options slow medium and fast and select the one you want 4 Press the Back button repeatedly to save your setting and return to the Main Menu Thermo Scientific APEX User s Guide Page 89 Establishing Basic Product Parameters Before putting your detector into service you must have it learn how to identify your uncontaminated product This is done using the detector s full product calibration function which sets the following basic parameters for your product e Phase angle setting e Detect level Doing a Full Product Calibration To do a full product calibration follow the instructions below 1 Make sure product is flowing through the pipe 2 Highlight your product name in the Main Menu Your screen will look different if I XR is enabled Product Name 3 Press the Go button and page 1 of the product menu appears Product Calibrate and Name continued Page 90 Thermo Scientific APEX User s Guide 4 Press the right navigation button to highlight the Full Product Calibration menu Full Product Calibration 1 001 The detector s auto calibration function as shown by the icons and check marks the screen above is now ready to do the following e Learn the phase angle e Learn the detect level e Conduct an AuditCheck if this opt
338. rs This section tells you how to set reject parameters for a typical gravity feed application Reject Totals PHH1 1 246 8 a4 38 88 BIxIx Understanding Reject Delay and Reject Duration Timing In a gravity feed application the detector s search head surrounds a duct where product is falling vertically under the influence of gravity When the search head detects metallic contaminants in the product the product continues down the duct and is diverted into a secondary duct by a gate that closes off the main duct Looking at the figure on page 304 will help you understand this explanation for a typical gravity feed application The gate stays closed for a set period of time usually about one second to divert the contaminated product then opens again to allow uncontaminated product to again flow freely Thus for the reject process to work properly two critical time parameters must be set e Reject Delay Time In most gravity feed applications where the gate is located close to the search head the reject delay time is usually set to 0 00 seconds Thus when the search head detects contaminants the gate closes immediately However in applications where the gate is located some way from the search head a time delay is needed because the product takes a finite time to move from the search head to the vicinity of the gate Clearly the reject delay time should be set to make sure that the gate closes
339. rs when the excess reject fault function has been activated and indicates that and excessive number of rejects have occurred within the specified time window Press Clear Fault Please note that this fault may be caused by excessive contamination in the product so please examine the rejected product to see whether it is heavily contaminated Photo Reject Fault This type of fault only occurs in conveyor applications using a photo eye Problem Solution This fault occurs when the photo reject function has been enabled contaminated product has been detected but the photo eye did not see the product Check the alignment of the photo eye Make sure the product is breaking the beam and check for reasons for false triggering such as metal in the belt Perform a complete test of the detector including the reject device Photo Eye Blocked Fault This type of fault only occurs in conveyor applications using a photo eye Problem Solution This fault indicates that the photo eye has been blocked for an excessive amount of time Check the photo eye for proper operation and alignment Thermo Scientific APEX User s Guide Page 263 Phase Limit Fault Problem Solution This fault occurs when a If necessary check and adjust the phase limits phase limit has been reached Check for contaminated product and metal during a learn phase or elsewhere in the syste
340. rticles or grease that has become loaded with metallic dust becomes embedded in the tube Aperture Clearances The plastic throughput must not touch the aperture in any way at any time Touching the inside of the aperture can cause nuisance rejects Mounting The support structure used for mounting the APEX should be constructed in a way that minimizes the amount of vibration transmitted to the APEX This structure must be flat and parallel This minimizes possible twisting torques to the case of the detector which will distort the electromagnetic field and cause false triggering Vibration and Mechanical Shocks Some level of vibration is present in most industrial environments and the APEX is designed to operate satisfactorily under these conditions However false triggering may be caused by sudden bumps or dumping of heavy loads nearby particularly when working at very high detection sensitivities The APEX should not be fixed directly to a vibrating packaging or processing machine Electrical Loops Intermittent electrical loops are the largest single cause of faulty metal detector operation The search field in the metal detector sets up a high frequency electrical field in the aperture The metal case of the detector head acts as a screen to prevent metal outside the detector head affecting the search field Some of the high frequency electrical field from the search coils does escape from the aperture through which the product passes
341. rticular type of application Find the relevant section as follows Conveyor applications Go to the page that follows this one page 13 Gravity feed applications Go to page 63 Pipeline applications Go to page 79 Pharmaceutical Rx applications Go to page 95 Page 12 Thermo Scientific APEX User s Guide Setting Up Conveyor Applications The purpose of this section is to present you with a brief tutorial allowing you to get your conveyor application up and running as quickly as possible Here is an outline of what you will be learning If you are already familiar with some of the information covered you can always skip ahead to the next section Understanding Your Detector In this section you will learn how to e Use the detector s display panel e Navigate the detector s menus and sub menus e Set up global parameters for the detector Setting Up the Conveyor and Photo Eye In this section you will learn how to e Set up the conveyor parameters e Set up the photo eye parameters Setting Product Parameters In this section you will learn how to e Key in pack length e Key in no pack distance e Key in pack gap Setting Product Reject Parameters In this section you will learn how to e Key in the distance to the product reject device e Key in the signal duration for the product reject device Calibrating Your Detector In this section you will learn how to e Establish a noise threshold with
342. ructions on page 5 Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 Rx Applications Listed below are the most commonly used functions for setting up a typical pharma ceutical application Reject Delay Time This function is usually set to 0 00 seconds and tells the chute to close immediately when contaminants are detected If your chute is a long way from the search head you may need to set a longer delay time 1 Make sure the Main Menu is displayed 2 Navigate to the rejects menu 3 Press the Go button 4 On page 1 of the rejects menu highlight the Reject 1 Distance Delay function Reject 1 Distance Delay PBB1 881 B cum 0 0 18352 5 161 9 155 jap 5 Press the Go button and an input screen appears 6 Key in an appropriate value in seconds and hundredths of a second for the reject delay time Reject Duration Time This is the time that the chute remains closed to divert contaminated product and is usually set to 0 15 seconds 1 Navigate to the screen shown in the Reject Delay Time section 2 Highlight the Reject 1 Duration function Reject 1 Duration P881 601 fies gt 6 0 005 am x 1 6 Rm x 3 Press the Go button an input screen appears continued Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 4 Key in the appropriate value in seconds and hundredths
343. s Minnesota and the submission of reasonable proof to seller prior to return of the equipment that the defect is due to a matter embraced within seller s warranty hereunder Any such defect in material and workmanship shall be presented to seller as soon as such alleged errors or defects are discovered by purchaser and seller is given opportunity to investigate and correct alleged errors or defects and in all cases buyer must have notified seller thereof within one 1 year after delivery or one 1 year after installation if the installation was accomplished by the seller Said warranty shall not apply if the equipment shall not have been operated and maintained in accordance with seller s written instructions applicable to such equipment or if such equipment shall have been repaired or altered or modified without seller s approval provided however that the foregoing limitation of warranty insofar as it relates to repairs alterations or modifications shall not be applicable to routine preventive and corrective maintenance which normally occur in the operation of the equipment EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT DELIVERED HEREUNDER INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE THE SOLE LIABILITY OF SELLER ARISING OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO BREACH OF THOSE WARRANTIES THE SOLE A
344. s F1 F6 are 2 Amp 250 volt fast acting fuses When replacing a fuse on Relays 1 6 use only this type of fuse Fuse Rating Relay Number Fl 2 amp 250 volt fast acting fuse Relay 1 F2 2 amp 250 volt fast acting fuse Relay 2 F3 2 amp 250 volt fast acting fuse Relay 3 F4 2 amp 250 volt fast acting fuse Relay 4 F5 2 amp 250 volt fast acting fuse Relay 5 F6 2 amp 250 volt fast acting fuse Relay 6 Page 290 Thermo Scientific APEX User s Guide Mechanical Set Up Instructions for Specific Applications Now that you have completed the electrical installation of your APEX detector the next step is to complete the mechanical installation The type of mechanical set up required depends on which type of application you are installing a conveyor a gravity feed a pipeline or pharmaceutical application Find the relevant mechanical set up instructions as follows e Conveyor applications Go to the page that follows this one page 292 e Gravity feed and pharmaceutical applications Go to page 299 e Pipeline applications Go to page 307 Thermo Scientific APEX User s Guide Page 291 Mechanical Set Up for Conveyor Applications The APEX with options is easily integrated into most conveyor line systems and requires a minimal amount of adjustment Correctly installed the metal detector will operate reliably for long periods without attention The customer is respo
345. s Card allows you to back up externally using your pre existing database software all of the detector s critical settings including performance statistics specific product settings detect levels reject counts and so on Thus in the event of a catastrophic failure you can quickly and easily restore all the APEX settings the ones you have spent so much time money and effort perfecting Regular back ups are also useful for checking that all APEX parameters are set correctly and are very helpful should you ever need to contact Thermo Fisher Scientific s technical support personnel as described in the Contacting Thermo Fisher Scientific section at the end of the manual for troubleshooting assistance Engineering Details The Modbus Communications Card is a microprocessor card that handles all field bus communications All data read and written from the field bus is held internally in the card s dual port random access memory RAM Various registers are defined and these map data held in the APEX onto the Modbus RAM Because the Modbus Communications Card does not support fully bi directional data transfer through the same memory position it implements a handshaking scheme so that higher layers can identify when something has changed This handshaking scheme is only implemented for registers that are written from the field bus and is not used when registers are read from the field bus As a result the Modbus uses different rea
346. s Detect level 2 Operator 2 OPR2 Manual AuditCheck Pack gap Manual QAT Detect no pack Manual print distance Learn and adjust Machine settings Phase angle Reject settings Detect level settings Learn I XR Phase and IXR Edit pack length tracking Learn reject AuditCheck settings confirmations QAT settings Reset reject counts 3 Engineer ENGI Everything except Passwords password changes NVRAM reset 4 Supervisor SUPE Everything Set APEX model or machine type SF factory menu 5 Factory Model machine Password required for SF factory menu every change Thermo Scientific APEX User s Guide Page 249 Accessing the Security Menu To access the security menu do the following 1 In the Main Menu screen navigate to the security menu Security Level 901 Notice there is X beside the key icon This tells you that no passwords have been set and that currently all personnel have full access to all of the detector s functions 2 To restrict access you must first set a password for yourself as supervisor and then set passwords for other users such as engineers and operators Each person can be given a unique password and assigned an appropriate security level Level 1 Level 2 or Level 3 Entering a Supervisor Password To set up a password for yourself as a supervisor do the following 1 Make sure the security level menu is highlighted as shown above Press the Go button and
347. s Guide Electrical nterference It is always good practice to suppress electrical interference at its source and if trouble is experienced the offending source should be located and suppressed If this is not possible it may be necessary to operate the APEX at a reduced sensitivity A relay in the metal detector is often used to control solenoid valves power contractors and similar electrical devices When these devices are switched off the collapsing field of the winding generates a wide band interference which may be picked up by the search coils in the detector head and cause false triggering A capacitor of suitable capacity and working voltage connected across the offending device and grounded as close to the device as possible will often provide satisfactory suppression Pneumatic Air Connect incoming air to the detector s air regulator fittings using a coiled copper tube or air hose Adjust the incoming air pressure to 30 40 PSI 2 1 2 5 kg cm for pneumatic devices or 40 80 PSI 2 8 5 6 kg cm for air rejects Head Balancing Metal detectors are sensitive instruments and after they have been shipped or moved we recommend the head be re commissioned by a suitable certified Thermo Fisher Scientific field service representative Photo Eye Installation and Connection A photo eye is used for conveyor systems inspecting discrete products or packages Refer to the specific photo eye installation manual for installation proce
348. s Guide Page 35 4 Press the right navigation button to select the pack length function Pack Length 5 Press the Go button and the pack length input screen appears Pack Length Sf i Gif sm eB it a ak alii 6 In the real world you would now measure the length of the product you are testing and key this value into the pack length input screen using the navigation buttons In our example we measured the length of our packets of salted butter noted that they are 12 4 centimeters in length and have keyed in this number into the input screen as shown below Pack Length lei ec gt 7 Press the Go button to save your pack length setting and exit the input screen Page 36 Thermo Scientific APEX User s Guide Keying In the No Pack Distance The no pack distance function in conjunction with the pack gap function allows you to fine tune whether the APEX rejects only one or both units of product also known as packs or packages when there is uncertainty explained in the Keying In the Pack Gap section below about which of the packs is contaminated In most conveyor applications it is best to enter identical values for the pack length and the no pack distance functions 1 Make sure the no pack distance function is highlighted Detection no Pack distance FARI 81 2 Press the Go
349. s associated operating environment and the product you are running meet the following requirements System Requirements The APEX and its associated operating environment must meet the following requirements e An in feed product photo eye is installed e The in feed product photo eye is positioned as follows o atleast 1x one times the smallest dimension of the search head s aperture and o no more than 5x this dimension from the in feed edge of the aperture e In feed guide rails are installed to prevent the packaged product from skewing e The conveyors are always run at a constant speed during your normal production runs and during the IXR calibration process Please note that if at a later date you change the speed of the conveyor on your normal production runs the function must be recalibrated e Version 4 0 0 or later of the detector s operating software is installed Product Requirements The product you are running must meet the following requirements e The product must be in package form Please note the IXR function should not be used for bulk products on conveyors for example apples grapes and so on or on liquids in pipelines e The leading edge of the packed product must consistently block the in feed photo eye This requirement is critical for the I XR function to work properly e The packaged product must not skew as it passes through the search head This requirement is also critical for the
350. s follows Which one you need depends on the communications protocol used by your existing network e Modbus TCP IP Communications Card This card allows your APEX to communicate with Ethernet and other networks using the transmission control protocol internet protocol TCP IP e Modbus RTU Communications Card This card which you can configure either as an RS 232 or RS 485 card allows your APEX to communicate with networks using the remote terminal unit RTU communications protocol Please note that version 3 0 or higher of the detector s operating software is needed for the Modbus Communications Card to work If you are not sure which version of the software is currently installed on your APEX please navigate to page 5 of the detector s system and tools menu which is shown below This screen shows that version 3 0 of the detector s operating software is currently installed Software Version 3 4 p APEX 388 L For more information about how to navigate to the Software Version screen please see page 193 SE SES What the Modbus Communications Card Does The Modbus Communications Card allows you to do the following Use your network to remotely access APEX parameters e e Change products remotely e Get real time statistics such as current reject count from the APEX e Back up critical APEX settings These are described in more detail in the following sections Thermo Sci
351. s full product calibration function which sets the following basic parameters for your product e Frequency and gain e Phase angle setting e Detect level e AuditCheck parameters if applicable Setting Frequency and Gain to High Before doing a full product calibration it is best to set the detector s frequency and gain settings to high To do this follow the instructions below 1 Make sure the Main Menu is displayed Product Name Or like this when IXR is enabled Product Name 1 continued Page 52 Thermo Scientific APEX User s Guide 2 Navigate to the frequency and gain menu and make sure it is highlighted Frequency and Gain Or like this when I XR is enabled Frequency and Gain 3 Press the Go button and page 1 of the frequency and gain menu appears Frequency Gain amp Inhibit 4 Press the right navigation button to highlight the gain menu Low High Gain PARI 001 X SO0kHz Thermo Scientific APEX User s Guide Page 53 5 Make sure a checkmark is showing next to the high gain icon which looks like this eol High gain icon Note If the checkmark is next to the low gain icon press the Go button to select the high gain setting 6 Press the Back button to save your setting and return to page 1 of the frequency and gain menu Frequency Gain amp Inhibit
352. s not turned off operation of the detector will not be affected Product Memory Fault This fault indicates the product memory has been lost or damaged Problem Solution Low battery could cause memory to be lost when the unit is not powered Check the battery Detector has been subjected to high static discharges or lightning Erase the memory Speed Encoder Fault This type of fault only occurs in conveyor applications using an external speed encoder Problem Solution The detector is not getting a signal or a properly pulsed signal from the external speed encoder Retest APEX using a test sample and with the belt running This may clear the fault If not check the functioning of the external speed encoder Page 262 Thermo Scientific APEX User s Guide Reject Confirm Fault The faults may occur when the reject confirm function has been enabled and the confirmation signal fails to return within the prescribed time limit Problem Solution The reject device has failed The reject device acted too slowly The switch has failed on your reject confirm device Check the action of your reject device and make sure it is working properly Check the reject confirm switch Increase the reject confirm time using the detector s reject confirm function Excessive Rejects Fault Problem Solution This fault only occu
353. s you to configure all of the card s communications parameters except the MAC address using the APEX software Pin Assignments for the Ethernet RJ 45 Connector Here are the pin assignments for the Ethernet RJ 45 connector Pin Signal Notes 1 TD 2 TD 3 RD 4 Normally left unused To insure signal integrity these pins are tied 5 together and terminated to the PE via a filter circuit in the module 6 RD 7 Normally left unused To insure signal integrity these pins are tied 8 together and terminated to the PE via a filter circuit in the module 1 8 Front view Thermo Scientific APEX User s Guide Page 343 Understanding the Status LEDs The Modbus TCP IP Communications Card is equipped with four status LEDs as shown below o9 is what the LEDs on a TCP IP are telling you LED Status What the lights are telling you 1 Link activity Off Link not sensed Green Link sensed 2 Module Off No power status Green 1Hz IP address not set using configuration switch Red 1Hz Invalid MAC address internal error Red 2Hz Failed to load Ethernet configuration Flash Red 4Hz Fatal internal error Red Duplicate IP address detected 3 Network The number of flashes equals status the number of connections made to the Modbus 4 Activity The LED flashes each time a packet is received or transmitted Page 344 Thermo Scientific APEX User s Guid
354. se the information below to contact Thermo Fisher Scientific If you are located elsewhere in the world please see the list of Thermo Fisher Scientific offices worldwide on the page that follows this one Getting Technical Support Here is the contact information for getting technical support for your APEX e Telephone 1 800 227 8891 Select option 3 in the voice menu Please follow the prompts for Technical Support and have your APEX serial number ready e Fax 1 763 780 1537 Use this number to get technical support e Email Please email us at Service W amp l Mpls thermofisher com Please include your APEX serial number in your message Ordering Parts Here is the contact information for ordering parts for your APEX e Telephone 1 800 227 8891 Select option 4 in the voice menu Please ask for the Parts Department and have your APEX serial number ready e Fax 1 763 780 2548 Use this number for ordering parts Please include the serial number of your APEX e Email Please email us at Parts W amp l Mpls thermofisher com e Street Address Please write to us for parts at the following address Thermo Fisher Scientific Attn Parts Department 501 90th Ave NW Minneapolis MN 55433 Thermo Scientific APEX User s Guide Page 399 Obtaining a Return Materials Authorization Number Here is the contact information for getting an RMA number e Telephone 1 800 227 8891 Please press Option 3 or stat
355. set for the detector you must first log in 1 In the Main Menu screen navigate to the security menu Security Level FHH1 TE Note The zero next to the key icon tells you that currently no one is logged in to the detector 2 Press the Go button and the log in screen appears Login FAHI 001 t Oti 1 2 3 Press the Go button and the keyboard screen appears complete with a key icon in the entry field as a reminder you are now entering a password Exit amp Save AIBICIPE FIGHT Se te continued Thermo Scientific APEX User s Guide Page 255 4 Key in your password navigate to the exit and save key and press the Go button If you are not sure how to use the keyboard screen see page 25 The Main Menu re appears showing your security level Level 1 Level 2 Level 3 or Level 4 next to the key icon The screen looks like this for Operator 1 who has just logged in as shown by the 1 next to the key icon Security Level Logging Out Always log out when you have finished using the detector because this prevents unauthorized personnel from accessing the APEX 1 In the Main Menu screen navigate to the security menu Security Level 2 Press the Go button and the log screen appears Login FAHI 001 t Ot 1 2 continued Page 256 Thermo Scientific
356. sk indicates the subnet mask address has been changed Subnet Mask DHCP X IP 123 123 123 123 3k SH 111 222 111 222 GH 6 D 1 1 MAcioo_320_11_03_48_2A Thermo Scientific APEX User s Guide Page 331 4 If you are finished go to the Saving Your TCP IP Settings section this is important Or continue the set up as described below Changing the Gateway Address In order to change the gateway address DHCP must be set to off 1 Make sure the gateway function is highlighted 2 Press the Go button and an input screen appears 3 Use the navigation buttons to enter the gateway address then press the Go button to close the input screen The flashing asterisk indicates the gateway address has been changed Default Gateway Address DHCP X IP 123 123 123 123 SN 111 222 111 222 212 121 212 121 1 1 3011 0542 2 4 to the Saving Your TCP IP Settings section this is important MAC Addresses Please note that the MAC address cannot be changed using the APEX software because it is set directly by the hardware Page 332 Thermo Scientific APEX User s Guide Saving Your TCP IP Settings Your settings will not be activated until you save your settings using the Save function 1 Navigate to the save function and make sure it is highlighted Save Configuration DHCP 123 123 123 123
357. ss the Back button to exit the menu Assigning the I nput for the Bin Full Photo Eye Reject 1 This function is used only in conveyor applications and assigns the input for the bin full photo eye This photo eye can be installed half way up or three quarters of the way up the bin giving you some warning before the bin is completely full In our example both the reject confirm and bin full photo eyes are assigned to Output 3 which is a common set up in conveyor applications Bin Full Input 1 Press the Go button and an input screen appears 2 Make the appropriate assignments for input Input 1 6 and polarity or 3 Press the Go button to save your settings 4 Press the Back button to exit the menu Page 224 Thermo Scientific APEX User s Guide 5 2 To navigate to page 2 of the inputs menu do the following 1 Follow steps 1 4 in the Inputs and Outputs section above pages 220 21 2 Press the right navigation button to highlight the inputs menu Inputs 1 1 3 Press the Go button and page 1 of the inputs menu appears Input Setup 4 Press the down navigation button and page 2 appears Input Setup Note The zeros in the screen above indicate that currently no inputs have been assigned for any of these functions Thermo Scientific APEX User s Guide Page 225 Using an External Device to Switc
358. ss through the search head and manually catch it on the other side or allow it to be rejected by your reject 1 device the default reject device for the Quality Test function Pass QA Test pack A to setup Lr Neun A 1154 GE A B5 889 g 1 1 Note As you pass the contaminated test sample through the search head the monitor screen will update and show you the number of passes made in this example 1 In addition the average peak signal value is also updated in this example 1150 as well as the average phase angle value in this example 65 00 continued Thermo Scientific APEX User s Guide Page 199 6 Repeat step 5 two more times Press the Go button and the Sample A screen reappears showing the average peak signal and phase angle values of the three passes you made QA Test Calibrate test samples FARI 1 GAT ETET 173 BAe 7 Press the Go button to exit the learn function 8 Repeat steps 3 6 for contaminated test samples B and C Setting the Time Interval Between QA Tests This function allows you to set the time interval between QA tests in minutes 1 Make sure page 1 of the quality test menu is highlighted QA Test calibrate 1 901 8 8 8 6 00 0 00 6 60 Note The detector s display panel will show actual values not zeros 2 Press the down navigation button and page 2
359. st samples EM 1 00 a Xr aum Performing an AuditCheck Test To perform an AuditCheck test do the following 1 Make sure the conveyor is running and that product is passing normally through the search head 2 Navigate to the test 1 function Peak amp Phase Angle test 1 3 Press the Go button and if the photo registration function is disabled the shuttle will fire immediately However if the photo registration function is enabled the shuttle will wait until the next package enters the search head then fire Thermo Scientific APEX User s Guide Page 207 Displaying the Average Phase Angle This function displays the average phase angle recorded during the AuditCheck test It is a display function meaning it cannot be changed by users Average Phase Angle FARI 1 DH 1 DNODZ O 13 26 0 00 AUDIT 1 4 CHECK lt 13 269 Displaying the Average Peak Signal This function displays the average peak signal recorded during the AuditCheck test It is a display function meaning it cannot be changed by users Average Peak PHA 001 cma 520291 002 soos aupiT 1158 B CHECK 13 26 B 88 1 4 a 13 2 Setting the Lock Values Function This function locks the AuditCheck phase angle and peak signal values so they cannot be changed when running the detector s auto calibration function Audit
360. stall the APEX metal detector should study the following factors that can influence the detector s performance The importance of studying this section and taking note of the information given is very important It has been proven that faulty metal detector operation such as random false alarm signals and undue sensitivity to vibration are usually due to incorrect installation of the metal detector or some other factors external to the metal detector itself Location of the Detector The APEX controls should be located to give easy access to the front panel The installation location of the display and or electronics box should be the first consideration Mounting the APEX For trouble free and reliable operation it is very important that the APEX be correctly mounted The support structure for mounting the APEX must transmit a minimum amount of vibration to the metal detector This structure must be flat and parallel thereby minimizing possible twisting torques to the metal detector case which can distort the electromagnetic field and cause false triggering While the APEX and the support structure may remain in contact nothing including the product must be allowed to touch any part of the aperture as this could cause wear of the aperture lining and give random false alarms Any pressure torque or electrical ground will cause the APEX to misfire Any support platform or throughput pipe that passes through the aperture must be completely
361. t is equally important that input piping should be independently supported and not supported by the metal detector s product tube It is necessary to electrically isolate the support from the hanging rods Use nylon bushings to do this Two bushings are needed on each mounting hole to isolate both the upper and lower mounting nuts as shown in the figure below Lock Nut Nylon Bushing Support Frame If you have any questions about installation requirements and restrictions please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Thermo Scientific APEX User s Guide Page 303 Testing a Gravity Feed System When testing a gravity feed system it is important to test both the sensitivity of the detector and the response of the reject valve To accomplish this a metal test sample must be inserted at or near the zero velocity point of the product Also a means for retrieving the test sample after it goes through the system should be incorporated in case the reject device fails to operate e Test ball insertion point Catch grate f Side view Test Procedures for Gravity Feed and Rx Systems A complete and thorough test of the metal detector system must be done upon initial installation and whenever a major component of the system has been changed or altered A complete check of the metal detector must include the reje
362. t Name 3 Navigate to the copy product function and make sure it is highlighted Copy Product Thermo Scientific APEX User s Guide Page 173 4 Press the Go button to copy the current product settings If passwords are enabled the keyboard screen appears Enter your password Then highlight the exit and save key and press the Go button 5 Press the Back button repeatedly to return to the Main Menu and make sure the product name MILK A M SHIFT is highlighted as show in step 2 above 6 Press the right navigation button to bring up the Product 2 screen you previously named MILK P M SHIFT as shown below The product name with be flashing on and off To select the MILK P M SHIFT press the Go button Product Name H 4 98 80 Notice that the detect level and phase angle settings are currently set to their default values of 40 and 90 7 Navigate to the paste product function Paste Product 8 Press the Go button and the following confirmation screen appears Decline continued Page 174 Thermo Scientific APEX User s Guide 9 Press the left navigation button to select the Accept check mark Accept 10 Press the Go button The detector pastes in the product parameters and closes the confirmation screen 11 Press the Back button repeatedly to return to the Main
363. te magnetic fields known as near fields These near fields may interfere with the detector s X and R channels especially when high current cables lie in close proximity to the detector e Electromagnetic Waves This source of interference is less common but is still a valid concern especially when the external wave interferes with a vital internal frequency in the detector s circuitry Both the X and R channel may be affected Alternating Conducting Loops Alternating conducting loops known as loop effects may create noise in the detector A loop effect may be created when a conductive path that varies in time lies in close proximity to the detector When a loop effect is created the X channel is the one most likely to be affected Thermo Scientific APEX User s Guide Page 283 Static Electricity Sometimes in conveyor applications static electricity is generated when the belt and slider bed rub against each other Because a moving or static charge is a form of electrical current moving or static charges may produce a magnetic field that randomly interferes with the magnetic field produced by the search head This type of interference creates noise in the detector and may affect both the X and R channel Moving Metal When metal moves through a magnetic field it creates a current Thus any metal that moves near the detector may cause interference in the detector interference that is easily confused with the effec
364. technical term that is defined elsewhere in the glossary Glossary Term Definition Alarm See WAF Application There are four types of applications conveyor Application specific parameter Auto calibration Back button CAL CLX Control keys Control Panel CPU Detect level DHCP gravity feed pipeline and pharmaceutical The term describes how product is passed through the detector s search head Parameters that must be set when using a particular application A function that allows the detector to set the phase angle detect level and AuditCheck settings using test contaminants The red button on the detector s control panel Calibrate An abbreviation used in the detector s function menus The clip X filter which reduces noise when wet products are being tested The four icons in the software driven keyboard screen that allow you to move the cursor left and right delete a character and exit from the keyboard screen This comprises the navigation Go and Back buttons the indicator lights and the display panel Central processing unit During the auto calibration procedure the detector measures the level of background noise the amount of background signal in the search head and multiplies this by a factor of 2 3 to set the detect level Any signal excessive noise contamination that exceeds the detect level is tagged as contamination However when the detect
365. tector s wiring board which is a physical change Next you access the detector s output function described in this section and tell the detector your reject device is now connected to Output 6 which is a logical software based change Inputs and Outputs T Navigating to the I nputs and Outputs Menu 1 From the Main Menu navigate to the system and tools menu System and Tools P881 _ 081 30 5 oD e x 2 Press the Go button and page 1 of the systems and tools menu appears System and Tools Page 1 Page 220 Thermo Scientific APEX User s Guide 3 Navigate to page 2 highlight the inputs and outputs menu Inputs and Outputs 4 Press the Go button and a more detailed inputs and outputs menu appears Inputs and Outputs T The icons shown in this menu are as follows Icon Description For more information 1 Inputs See the section following this one page 222 Outputs See page 232 Aes Print t S 238 rinter set up ee page Communications See page 319 Icon only appears if the set up communications option is installed Thermo Scientific APEX User s Guide Page 221 Inputs Page 1 The inputs menu allows you to manage the detector s physical and logical inputs The detector s physical inputs are found on the detector s wiring board where there are six inp
366. tely free of all metal and must not touch the aperture in any way whether on the top bottom or sides of the aperture The belt must not be allowed to wander from side to side and rub on the inside of the aperture because this could damage the aperture lining or cause false tripping Before fitting product guide rails check that they are completely metal free by passing them through the APEX if possible before installation Suitable guide rail materials include polyethylene polypropylene PBVC wood and wood laminates Metal in the Packaging Material Packaging material must be totally free from metal clips fasteners labels metallic ink and foil Certain types of low grade cardboard especially recycled cardboard may contain pieces of metal or metallic foil that may be detected when operating at high sensitivity Mounting The support structure used for mounting the APEX to the conveyor should be constructed in a way that minimizes the amount of vibration transmitted to the APEX This structure must be flat and parallel This minimizes possible twisting torques to the case of the detector which will distort the electromagnetic field and cause false triggering Thermo Scientific APEX User s Guide Page 293 Vibration and Mechanical Shocks Some level of vibration is present in most industrial environments and the APEX is designed to operate satisfactorily under these conditions However false triggering may be caused by sudden
367. tem and Tools Page 1 4 Navigate to the IXR menu and make sure it is highlighted IntelliTrack X Menu continued Page 378 Thermo Scientific APEX User s Guide 5 Press the Go button and the following screen appears Calibrate IXR and XR Info PHH1 001 6 Press the right navigation button to highlight the IXR menu Enable I XR FAKI 081 Aye 1 1 7 Make sure the IXR icon is highlighted and press the Go button The following screen appears showing the I XR function is now enabled because a checkmark is displayed next to the IXR icon In addition the screen shows additional XR options that are now available These additional functions are described in the sections that follow Enable I XR FAHI 01 EET AGT T v Bit continued Thermo Scientific APEX User s Guide Page 379 8 Press the Back button repeatedly to return to the Main Menu Please note that now the IXR function is active additional displays have been added to the Main Menu as shown below Please see the Understanding the I XR Display section on page 388 for more information about these additional displays Main Menu Calibrating the I XR Function There are two basic steps to calibrating the I XR function as follows e Learn the X and R noise thresholds e Learn the detect levels f
368. ter has modified a parameter Parameter change acknowledge Used to acknowledge that the APEX has processed the parameter change If the master wants to change a parameter it first updates the appropriate registers and then notifies the APEX by toggling the corresponding parameter change notification coil When the APEX has processed this change it toggles the corresponding parameter change acknowledge coil to signal that the parameter change has been processed If the parameter written by the master is outside the range of acceptable values then the APEX will not use it and will continue to use the previous value In this case the Read and Write registers will contain different values but the Read register will always contain the current value being used by the APEX Note that the parameter change acknowledge coil will still be toggled indicating that the APEX has processed it Page 352 Thermo Scientific APEX User s Guide Register Details for Commonly Used APEX Functions The section gives you step by step instructions about how to use the Modbus registers to change products get summary statistics Such as total reject count and back up all your important APEX settings Changing Products In order to change products remotely all you need to do is enter the product number using a program such as such as Modscan PC Master or other similar program into Modbus register number 41045 and set parameter change coil number 1
369. testing in on or around the electronics cabinet PC boards or modules There are voltages in excess of 115 V or 230 V in these areas Warning Use only the procedures and new parts specifically referenced in this manual to ensure specification performance and certification compliance Unauthorized procedures or parts can render the instrument dangerous to life limb or property Warning Keep hands and clothing away from all moving or rotating parts Page 280 Thermo Scientific APEX User s Guide Warning Do not place or store objects of any kind on the machine Warning This machine should not be operated at more than the production rate stated on your Equipment Specification sheet used in applications other than those stated in the original order or in a manner not specified by Thermo Fisher Scientific To do so may impair the protection provided by the machine Warning The APEX is cCSAus and CE approved and can be used in environments containing combustible dusts All modifications to the APEX must be approved in writing from Thermo Fisher Scientific This is to prevent any possibility of a modification causing a breach of the integrity of the equipment which might lead to the ignition of dust or other safety infringement Specific Safety Precautions The precautions listed below are specific to the APEX Read them carefully before using the machine Warning Humidity can cause surfaces of the detector to become damp whic
370. that minimizes the amount of vibration transmitted to the APEX This structure must be flat and parallel This minimizes possible twisting torques to the case of the detector which will distort the electromagnetic field and cause false triggering Vibration and Mechanical Shocks Some level of vibration is present in most industrial environments and the APEX is designed to operate satisfactorily under these conditions However false triggering may be caused by sudden bumps or dumping heavy loads particularly when working at very high detection sensitivities The APEX should not be fixed directly to a vibrating packaging or processing machine Electrical Loops Intermittent electrical loops are the largest single cause of faulty metal detector operation The search field in the metal detector sets up a high frequency electrical field in the aperture The metal case of the search head acts as a screen to prevent metal outside the detector head affecting the search field Some of the high frequency electrical field from the search coils does escape from the aperture through which the product passes This field can cause very small electrical currents to flow in nearby metal structures This causes no problem if the loops are completely closed but if the electrical path is intermittent then false triggering of the detector is likely Page 300 Thermo Scientific APEX User s Guide Typical causes of intermittent electrical loops include loose bol
371. the detector s menus and sub menus and are used to increase or decrease numbers and Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 select characters and settings in various menus and input screens The Go Button Press the Go button to select or start one of the detector s functions The Back Button Press the Back button to stop one of the detector s functions or to return to the previous menu screen Press repeatedly to return to the Main Menu Main Menu The APEX s Main Menu normally looks like this Product Name However if you have enabled the I XR function see page 8 the Main Menu looks like this Product Name Co X 50012 amp cool Naming the Product This allows you to name the product you are testing 1 Make sure the Main Menu is displayed 2 Press the Go button and the product calibration menu appears 3 Press the down navigation button to highlight the Edit Product Name function Edit Product Name P881 661 Page 1 4 Press the Go button and the keyboard screen appears 5 Key in a name for the product you are testing using the keyboard screen 6 Highlight the keyboard s exit and save key in the bottom right corner and press the Go button to exit the keyboard screen Changing Applications The APEX can be configured to handle four basic types of applications e Conveyor appl
372. the Go button repeatedly to scroll through the options for parity none odd or even and select the one you want We selected odd 3 Press the Back button to return to the RTU configuration screen The flashing asterisk tells you the parity has been changed Modbus RTU Configuration 4 Go to the Saving Your RTU Settings section this is important Page 338 Thermo Scientific APEX User s Guide Saving Your RTU Settings Your RTU settings will not be activated until you save your settings using the Save function 1 Navigate to the save function and make sure it is highlighted The flashing asterisks in the screen above indicate that in this example we changed all three communication parameters slave address baud rate and parity Save Configuration SAVE SLAVE ADDR 7 BAUD RATE 576868 LUN PARITY DD 2 Press the Go button to return to the RTU configuration screen The flashing asterisks have disappeared indicating that all your RTU communication settings have been saved Modbus RTU Configuration SLAVE RDDR 7 30 8 PRUD RATE 57688 17 PARITY 000 3 Press the Back button repeatedly to return to the Main Menu Thermo Scientific APEX User s Guide Page 339 340 Thermo Scientific APEX User s Guide Configuring the Modbus Hardware This section tells you how to configure and
373. the leading edge or entire length of your product The key point is the IXR function will not work if photo eye registration is set to Off To set photo eye registration do the following 1 Make sure the detector s Main Menu is displayed Product Name 2 Navigate to the reject totals menu Reject Totals 3 Press the Go button and navigate to page 2 of the rejects totals menu Reject Registration and Type continued Page 376 Thermo Scientific APEX User s Guide 4 Press the right navigation button to select the photo eye registration menu The screen below shows that currently the photo eye registration is set to detect the leading edge of the product Leading Photo Registration FAHI 001 5363 O05 5 Press the Go button repeatedly until the check mark is displayed next to the detect the middle of the package icon as shown below Middle Photo Registration FAHI p i BEEN G5 a 6 Press the Back button to save your setting and exit the menu Thermo Scientific APEX User s Guide Page 377 Enabling the I XR Function To enable the IXR function do the following 1 Make sure the Main Menu is displayed Product Name 2 Navigate to the system and tools menu System and Tools 3 Press the Go button and page 1 of the system and tools menu appears Sys
374. tion Most significant byte Multi zone detection meaning the search head must see two peaks not one to tag the signal as contamination Not applicable In this manual the term Navigate to means Use the four navigation buttons on the detector s control panel to move to and highlight the particular function you are interested in The four blue triangular buttons on the detector s control panel that allow you to move to a particular function or change the numbers in an input screen Non volatile random access memory In the Modbus registers a product setting for example product 001 Thermo Scientific APEX User s Guide Page 395 Glossary Term Pack gap Pack length Parameters Application specific Global Product Product rejection PCB PCB A PCC PE Peak signal PLC PNR PO Product Product parameter Product rejection parameter PSC PSU QA Definition This function allows you control whether one or both of two sequential units of product are rejected when there is uncertainty about which one is contaminated The pack gap function is expressed as a percentage and for a typical conveyor application should be set to 100 The length of the individual units of product for example packets of salted butter placed on a conveyor See Application specific parameter See Global parameter See Product parameter See Product rejection parameter Printed
375. tion make sure the photo eye is hard wired to Input 2 on the detector s wiring board For more information about input wiring see pages 222 and 289 1 Follow steps 1 4 in the Choosing Your Preferred Units of Measure section on page 22 to get to the menu shown below page 2 of the system and tools menu System and Tools Page 2 2 Navigate to the inputs and outputs menu Input and Outputs Page 30 Thermo Scientific APEX User s Guide 3 Press the Go button and the inputs and outputs menu appears Inputs and Outputs guest 4 Press the right navigation button to select the inputs menu Inputs 1 1 5 Press the Go button and page 1 of the input set up menu appears Input Setup 6 Navigate to the Infeed Photo Eye Input menu shown below nfeed Photo Eye Input Look carefully at the 2 notation in this menu which tells you two things e The in feed photo eye is connected to Input 2 on the detector s wiring board e The input voltage has a positive polarity Thermo Scientific APEX User s Guide Page 31 7 If you need to change the polarity on Input 2 to a negative polarity press the Go button and the in feed photo eye input screen appears nfeed Photo Eye Input 8 Press the left navigation button to underline the sign 9 Press the down navigation butto
376. tion transformer or power line filter Page 286 Thermo Scientific APEX User s Guide Wiring AC Power into the PSU We recommend using an AC power source that is not connected to heavy duty loads or loads that might cause interference or dropouts in the supply We do not recommend sharing an AC power source that feeds powerful motor invertors because they can cause interference problems Use a light circuit and supply the detector with an isolator switch J1 has a removable receptacle Remove it and connect AC power 85 VAC to 264 VAC Ensure a good earth ground to J1 See the figure below for the location of J 1 1 Inputs closed circuit dovm to Ov activates Opooooodg 7v 12v 24v 5v CAUTION Dangerous AC voltages present on this PCBA Caution Do not wire outputs directly from the PSU PCB A There are six open collector outputs provided on the PCB that may be connected to solenoids powered from DC voltages not exceeding 24 VDC nominal Do not use these outputs unless you have specialized knowledge If you need volt free relay outputs please use the PCB A mounted on the PSU Thermo Scientific APEX User s Guide Page 287 Installing Cable and Conduit to Your APEX There are six cable conduit entry points on the APEX These are located beneath the plastic front panel The APEX is supplied with a number of entries containing blanking plugs The remainder contain cable conduit entries Us
377. to the Calibrate Noise Thres holds menu Note The background of the calibrate function should now be highlighted in black as shown below Calibrate Noise Thresholds 6 Press the Go button and a monitor screen appears The calibration is complete when the screen above reappears showing the calibrated values for the X and R thresholds Typical values for these thresholds are as follows e X threshold lt 300 e R threshold lt 100 Full Product Calibration A full product calibration allows the detector to learn how to identify your uncontaminated product and sets the following basic para meters for your product e Phase angle setting e Detection level 1 Make sure the product name is highlighted in the Main Menu 2 Press the Go button and the Full Product Calibration function is automatically high lighted Full Product Calibration 091 mig USES Thermo Scientific APEX Quick Start Guide REC F 58E Part 085555 3 Make sure the conveyor is running and uncontaminated product is passing through the search head 4 Press the Go button and a monitor screen appears During the calibration process a series of frequency gain mini screens may appear which halts the calibration process as the detector searches for the optimum frequency gain settings for your product When this occurs press the Go button to restart the calibration process The Main Me
378. ton The detector returns you to the original output screen which now looks like this Output 1 Function Thermo Scientific APEX User s Guide Page 235 5 Navigate to the warning icon currently assigned to Output 4 and press the Go button The select options screen reappears Highlight the reject 1 icon and press the Go button The detector closes the menu and your reject device is now assigned to Output 4 as shown by the updated output screen below Output 4 Function 6 Finally and do not forget this key step disconnect your reject device from Output 1 on the detector s wiring board and reconnect it to Output 4 being careful not to switch the original polarity If you do you can always use this menu to change the polarity to minus For more details about the detector s output wiring board see page 290 Changing the Polarity of an Output Device You use this function to tell the detector to send a positive or negative voltage signal to a particular output Output 1 6 The screen below currently shows the following e Your reject device is currently assigned to Output 1 For your application to work your reject device must also be physically connected to Output 1 on the detector s wiring board e To trigger the reject device the detector sends a positive voltage signal to the reject device Output 1 Polarity continued Page 236 Thermo Sc
379. tor screen appears Pass test stick to calibrate Speed Filter Page 72 Thermo Scientific APEX User s Guide 5 Insert the test ball into the duct s insertion port which is always upstream of the detector Refer to the diagram on page 304 which shows a typical test set up for a gravity feed application If the red indicator light on the control panel lights when you pass the 4 0 millimeter test ball use a smaller size 6 Press the Back button to exit the calibration menu Look at the screen below the same screen as shown in step 3 above and notice that the calibration process has set the speed filter to 25 00 Hz and the product speed to 234 meters per minute Calibrate Speed Filter FARI Bei 25 88Hz 1 1 Establishing Basic Product Parameters Before putting your detector into service you must have it learn how to identify your uncontaminated product This is done using the detector s full product calibration function which sets the following basic parameters for your product e Phase angle setting e Detect level Doing a Full Product Calibration To do a full product calibration follow the instructions below 1 Make sure product is falling through the duct 2 Highlight your product name in the Main Menu Product Name Or like this when I XR is enabled Product Name 3 s see Thermo Scientific APEX Us
380. tput from this Output 1 Function To this Output 1 Function e Set your reject 2 device to reject contaminants during the calibration process Described below e Pass a contaminated package so the reject 2 device can reject it allowing the APEX to set the reject 2 confirm time Described below e Turn your reject 1 device back on which is a critical step Described below Calibration Procedure To calibrate the reject 2 confirm time do the following 1 Navigate to page 5 of the rejects menu and highlight the Reject 2 Contaminant menu Reject 2 Contaminant FAHI Bat tz X Penh 68 5 618 X F sk continued Thermo Scientific APEX User s Guide Page 147 2 Press the Go button a checkmark appears next to the contaminant icon which tells the reject 2 device to reject any contaminated packages Reject 2 Contaminant FAHI 001 s 5 61 X G 3 Press the Back button to save your setting and exit the menu 4 Navigate to page 6 of the rejects menu and make sure the calibration function is highlighted Calibrate Reject Confirm Time FHH1 001 9 eee 5 Press the Go button and the following screen appears Calibrate Reject Confirm Time 6 Pass a contaminated package so the reject 2 device can reject it allowing the
381. ts of vibration Permanent Magnets and Electro Magnets If permanent magnets and electro magnets are allowed near the detector they can cause interference especially those that move or are situated very close to the detector Interference from these sources may affect with the detector s X and R channels General Electrical Requirements When choosing the AC power line for the detector note that starting heavy electrical machinery creates momentary volt drops in the line Such spikes can cause the detector to trigger e When the control unit is mounted remotely from the search head the cable connecting it to the search head is of a specific type Do not substitute or splice on extra cable Cable can be cut to length and is not sensitive to movement If required contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual for extra cable or cable information e Be sure to observe the following critical wiring conditions to ensure proper connection of your detector e Ensure main power is OFF e Earth all enclosures and conduits An earth connection between all metal conduits is required e Connect the shields only where shown e Check that all wires are tight in their connections e Never use a megger to check the wiring e All conduits should enter the bottom of the enclosure Do not run conduit through the top or sides of the enclosure Page 284 Th
382. ts on the framework or on the detector s mounting corrosion of metal work broken welds open hinged doors and broken or rubbing contacts Interference can be overcome by opening the conductive path with an insulating pad or closing the path by welding or tightening the bolts so that it cannot become intermittent The source of such loop interference can be very elusive and difficult to locate The larger the aperture in the APEX the greater the high frequency leakage out of the aperture and the greater the possibility of trouble from loops Metal Objects Near the Search Head The metal detector is very efficiently screened and metal near the top bottom and ends will not significantly affect the detector performance However metal positioned close to the aperture can cause interference problems if it moves or vibrates The area close to the aperture which should be kept metal free is known as the metal free zone This metal free zone is dependent on the aperture dimensions and the sensitivity setting of the detector The search head is sensitive to moving metal It is not always possible to discriminate if the metal is passing through the head or moving outside the head Metal in the metal free zone may cause the detector to be sensitive to vibration If the APEX vibrates or is accidentally bumped it will cause relative movement between the detector and the offending metal which could trigger the detector Electrical Interference It
383. u Screen Is Telling You The Main Menu screen is now telling you that once the detector is monitoring your product stream any unit of contaminated product that exceeds the detect level of 53 will be rejected And because the phase angle is 2 24 degrees the detector is monitoring a wet product in our example jars of spaghetti sauce Thermo Scientific APEX User s Guide Page 59 Changing the Current Product To change the currently running product make sure the current product name is highlighted as shown below Your screen will look different if XR is enabled Product Name Navigate to the New Product With the product name highlighted press the right navigation button to change to a product with a higher product number or press the left navigation button to change to a product with a lower product number Note that the product name bar will flash while you are choosing which product to change to and some of the relevant product settings will be displayed In the example below product 002 has been selected Product Name Confirm the Product Change Once you have selected the product you want to change to press the Go button The product name bar stops flashing to show you the product has changed The APEX will now apply the new product s settings The product settings for the new product can now be modified Page 60 Thermo Scientific APEX User s Guide Set Up Check List for Conveyor
384. u are currently using an RTU Communications Card that has been configured as an RS 232 device and want to upgrade its capabilities to an RS485 device or vice versa all you have to do is change one of the DIP switches on your existing card as described in the appropriate RS 232 or RS 485 section of the Configuring the Modbus hardware section of this appendix Most other configuration changes for both a TCP IP and RTU Communications Card are made using the APEX operating software specifically by accessing the Modbus configuration menu These are described in detail in the Configuring Network Parameters with the APEX Software section of this appendix If you have questions or need additional help please contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual Thermo Scientific APEX User s Guide Page 323 324 Thermo Scientific APEX User s Guide Configuring Network Parameters with the APEX Software This section tells you how to use the detector s built in operating software to configure your network using the detector s communications menu and functions This section please note does not tell you how to reconfigure the hardware settings for your Modbus Communications Card This is covered in the Configuring the Modbus Hardware section on page 341 Please verify which type of Modbus Communications Card is installed in your APEX and
385. u prefer to use and so on In other words global parameters are ones that you will not change very often In contrast application specific parameters are ones you use to get your particular type of application conveyor gravity feed pipeline or pharmaceutical set up and running properly Application specific parameters sometimes need to be fine tuned to optimize the detector s performance for your particular operating environment Setting Product Parameters You use the detector s control panel to set up various product parameters The most critical product parameters you need to set are the following e Values for the X and R Noise Thresholds The X and R thresholds are background noise thresholds that are learned by the detector with no product present In conveyor applications the thresholds are learned with the conveyor running but with no product present on the conveyor or in the search head Similarly in gravity feed pipeline and pharmaceutical applications the thresholds are learned with no product present in the duct pipe or chute When the X and R noise thresholds are exceeded they indicate the presence of product as shown by the activation of the green product LED on the detector s control panel e The Detect Level Value Any signal from the detector s search head that exceeds the detect level will be tagged as a contaminant As a general rule the detect level should exceed the level of the background noise by a fact
386. uage setting preferred units of measure and so forth have already been backed up Overview of Backing Up Restoring Your APEX Settings The instructions given below are meant solely to provide you with an overview about how to set up an automated process for backing up and restoring your critical APEX settings As a result specific data storage details are not included In addition please note that the product parameters are only assessable for the currently selected APEX product This means that in order to do a complete product back up you must back up the settings for each product separately using the appropriate product number Backing Up Your APEX Settings 1 Read all machine settings and store them to a data file All machine settings are labeled with an M in the Data Type column in the detailed list of Modbus registers see pages 357 365 2 Write product number 001 to register 41045 and set parameter change coil 16385 to one 1 3 Read all product settings and store to a data file These product settings please note relate only to product 001 All product settings are labeled with a P in the Data Type column in the table of registers 4 Write product number 002 to register 41045 and set parameter change coil 16385 to one 1 5 Read all product settings and store to a data file These product settings please note relate only to product 002 6 Continue until all your products are backed up R
387. ual Please retain a copy of this decontamination declaration form for your records System Description Please provide a detailed description of your system equipment and the type of product analyzed Decontamination Procedures Already Performed Please describe all cleaning and other decontamination procedures already performed on the equipment you are returning Check All That Apply E Out of box failure L Non hazardous materials only L Hazardous material see below Hazardous Materials Q Carcinogen pathogen Ll Fungus virus bacteria Ll Toxic radioactive Ll Corrosive flammable reactive chemical hazard E Animal plant mineral Explain L Other Explain To the best of my knowledge this equipment is free of harmful or hazardous chemical biological or radioactive contamination understand that if the equipment is found to be contaminated regardless of the signature on this document the equipment will be returned at my company s expense or may be subject to an additional decontamination fee of 300 Signature Title Date Page 268 Thermo Scientific APEX User s Guide Ordering Parts For the fastest service when ordering parts please telephone or fax the nearest Thermo Fisher Scientific office For the office nearest you please see the Contacting Thermo Fisher Scientific section at the end of the manual The quickest way to get the parts you need is to do the following
388. ually indicates there is a problem with excessive vibration in your application As a general rule as the severity of the vibration increases the X threshold also increases Possible remedies include making sure the detector is completely isolated mechanically from the surrounding pipe work and or installing shock mounts for the detector e Reducing High R Noise Thresholds An R threshold in excess of 200 usually indicates that one or more of the following conditions is present o Excessive noise from electro magnetic currents EMCs and variable frequency drives VFDs Rectify by installing an isolation transformer and or line reactors o Metal in the detector s metal free zone Rectify by removing the metal 7 f you want to manually key in a different value for either the X or R noise threshold make sure the Calibrate Noise Thresholds menu shown in step 5 is displayed Navigate to the appropriate menu X or R and press the Go button An input screen appears allowing you to manually enter a value X Threshold Thermo Scientific APEX User s Guide Page 87 Choosing the Appropriate Wide Band Speed Filter In this section you will learn how to select the appropriate wide band speed filter setting based on the average product speed expressed for example in feet per minute Product speed is calculated from the product flow rate using the following formula Gpm R x 6 13 Fpm Where Gpm gallons per mi
389. uide Page 277 Product Phase Angle The APEX measures magnetic field changes and derives reactive and resistive components A clean product changes both components proportionately and this proportionality allows the APEX to discriminate between product characteristic and metal When metal is present the ratio of resistive to reactive components is not constant When the APEX learns the product it converts the ratio between reactive and resistive components to a phase angle Once this angle is known a clean product passing through the aperture can be largely ignored o 90 Reactive channel Non ferrous 65 degrees 9 Ferrous metal 135 130 degrees Non magnetic stainless steel 2020 30 degrees Resistive channel 180 APEX Operating Range 180 degrees 135 to 45 270 As a general rule the following phase angles are representative of the following types of contaminants and non contaminated products Degrees Contaminant or non contaminated product 130 Metallic ferrous contaminants such as iron 90 Dry non conductive products such as grains and cereals 65 Non ferrous metallic contaminants such as copper 20 30 Metallic contaminants such as stainless steel 0 Wet conductive products such as fresh meats and breads Page 278 Thermo Scientific APEX User s Guide Table Showing How Type of Metal Size of Metal and Frequency Affect Phase Angle
390. unction the detector will take one of the following actions e Reject Pack 1 only e Reject both packs e Reject Pack 2 only The following table illustrates what action the APEX will take when a contaminant is detected in one of the positions A F the diagram above and the pack gap function is set to 100 50 or 25 Pack gap Pack rejected when contaminant in the following position A F A B D E 100 1 1 1 and 2 1 and 2 1 and 2 2 50 1 1 1 and 2 1 and 2 1 and 2 2 25 1 1 1 1 and 2 2 2 Thermo Scientific APEX User s Guide Page 41 Entering a Value for the Pack Gap Function To enter a value for the pack gap function do the following 1 If you are not already looking at page 2 of the Product Shape and Flow menu follow steps 1 4 in the Keying In the Pack Length section above to reach this menu Product Shape and Flow 1 001 S c 0 100 Acs 9 100 2 Use the navigation buttons to select the pack gap menu Pack Gap 1 001 S c 0 100 A cU 6 168 3 Press the Go button and the pack gap input screen appears Pack Gap 4 Key in an appropriate value for pack gap In our example we have keyed in a value of 5096 Pack Gap ot 858 LA ac veuve 5 Press the Go button to save your pack gap setting and exit the input screen Thermo Scientific APEX User s Guide P
391. ut connectors labeled Input 1 6 In contrast the detector s logical inputs are controlled using the input menu which allows you the user to tell the detector which external input device is assigned to which input In addition the inputs menu is used to assign a polarity or to the voltage signal received from your external input device such as an in feed photo eye Assigning the correct polarity is important because an in feed photo eye sends a positive or negative voltage signal depending upon whether the photo eye is light or dark activated Inputs e j Example Let s look at an example In a conveyor application you have physically connected your in feed photo eye to Input 2 the default set up on the detector s wiring board You decide you want to move your in feed photo eye Input 6 so you move the wires from Input 2 to Input 6 on the detector s wiring board which is a physical change Next you access the detector s input function described in this section and tell the detector your in feed photo eye is now connected to Output 6 which is a logical software based change Navigating to Page 1 of the Inputs Menu To navigate to page 1 of the inputs menu do the following 1 Follow steps 1 4 in the Inputs and Outputs section above pages 220 21 2 Press the right navigation button to highlight the inputs menu Inputs 1 1 continued Page 222 Ther
392. ute coil cables through the same conduit with power cables or any large source of electrical noise Removing the Control Panel Before removing the control panel make sure the AC power supply is off The control panel is held in place with eight mounting bolts Remove these bolts to gain access to the search head power supply unit PSU and relay printed circuit boards PCBs Remote search heads have a separate control panel to access the PSU and relay PCBs Note The control panel also has internal PCBs for the operator display keypad and signal processing If any of these items need replacing disconnect the PSU and search head cables that connect to them Caution When removing or working with the control panel be careful when tightening the screws Do not tighten them too tight or breakage will occur Caution When removing the PSU PCB ensure that star crinkle washers are used on the two PCB mounting pillars adjacent to J1 mains AC power and J 2 Additionally ensure that pillars between relay PCB and PSU PCB are properly tightened and secured AC Power Wiring The detector power consumption is only 35 watts It is recommended a lighting circuit be used rather than a machinery power circuit If this is not possible and the line noise triggers the detector contact Thermo Fisher Scientific as described in the Contacting Thermo Fisher Scientific section at the end of the manual for recommendations of a suitable isola
393. vel and phase angle Once you have finished this section your detector will be set up and ready to go to work monitoring your product stream for the presence of metallic contaminants Establishing a Baseline with No Product Present Before you can establish a monitoring baseline that is establish a background noise level for the X and R thresholds the parameters that allow the detector to identify metal contaminants you must make sure no product is falling through the chute 1 Make sure the Main Menu is displayed Product Name 2 Navigate to the frequency and gain menu Frequency and Gain FAHI 001 Thermo Scientific APEX User s Guide Page 101 3 Press the Go button and page 1 of the Frequency Gain amp Inhibit menu appears Frequency Gain amp Inhibit PHA 1 Bei 4 Press the down navigation key to select page 2 of the frequency and gain menu Detection level and Noise Pag 001 5 Navigate to the Calibrate Noise Thresholds menu Note The background of the calibrate function is now highlighted in black Calibrate Noise Thresholds 1 001 LA 272 CALEA 158 166 continued Page 102 Thermo Scientific APEX User s Guide 6 Press the Go button The detector immediately starts measuring calibrating the background X and R noise thresholds and the monitor scree
394. you have already set up for a typical pipeline application Product Parameters e Product name Reject Parameters e Reject delay time e Reject duration time Contaminant Detection Parameters Set by the Detector s Calibrate Functions e X and R noise thresholds e Speed filter setting e Detect level e Phase angle setting Thermo Scientific APEX User s Guide Page 93 Additional Parameters You May Want to Set Up Listed below are additional parameters you may want to set up to get your particular pipeline application running to your satisfaction Suppression Time and Suppression Amplitude Functions These functions are used to prevent vibration from the diverter valve interfering with the search head For more details see page 130 Reject Confirm Function If your diverter valve is equipped with a position detector this function allows the detector to confirm that during a reject cycle the diverter valve has properly completed both the open and close phases of the reject cycle In addition if the diverter valve fails the detector can stop the flow of product or notify you that a failure has occurred for example because the air supply to the valve has failed or miscellaneous residue has clogged the valve For more details see page 137 Warnings Alarms and Faults WAFs Many of the detector s functions provide a warning alarm or fault when a condition needing your attention occurs This menu in conjunction with

Thermo Scientific APEX Metal Detector User's Guide - Cole

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