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Thermo Scientific
Metal Detector
APEX 100
Thermo Scientific APEX 100 User Manual
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2
Therm
o Sc
ienti
fic
APEX
User’s
Guid
e
©
2009
The
r
mo
Fis
he
r S
cie
nt
if
ic
,
Inc.
Al
l
rig
hts res
erved
For fu
ture
ref
eren
ce, w
ri
te you
r APEX
s
eria
l n
umber b
el
ow.
APEX serial # = __________________________________
1
3
Table of Contents
Default Chapter
1
Metal Detector
1
Table of Contents
3
Thermo Scientific APEX User's Guide Page
5
Thermo Scientific APEX User's Guide Page
7
Thermo Scientific APEX User's Guide Page
9
Getting Started
11
Setting Global and Application-Specific Parameters
11
Setting Product Parameters
11
Managing Product-Rejection Parameters
12
Choosing Your Application Type
12
Setting up Conveyor Applications
13
Understanding Your Detector
14
Understanding the Detector's Control Panel
14
Using the Detector's Buttons
15
Understanding the Screen Shots Used in this Manual
16
Understanding the Detector's Main Menu
17
Choosing a Language
17
Clearing the Speed-Filter Warning Screen
20
Displaying Help Text
20
Choosing Your Preferred Units of Measure
22
Naming the Product
24
Setting up the Conveyor and Photo-Eye
27
Keying in the Product Speed
27
Keying in the Photo-Eye-To-Detector Distance
28
Checking the Polarity of the Photo-Eye Input
30
Selecting the Correct Photo Registration for Rejects
32
Setting Product Parameters
35
Keying in the Pack Length
35
Keying in the No-Pack Distance
37
Disabling the Detection No-Pack Function
38
Keying in the Pack Gap
40
Setting Reject Parameters
43
Keying in the Distance to the Reject Device
44
Keying in the Signal Duration for the Reject Device
46
Setting Contaminant-Detection Parameters
47
Establishing Noise Thresholds with no Product Present
47
Calibrating the Speed Filter Using a Ferrous Test Stick
50
Establishing Basic Product Parameters
52
Changing the Current Product
60
Set-Up Check List for Conveyor Applications
61
Parameters You Have Already Set up
61
Additional Parameters You May Want to Set up
62
Setting up Gravity-Feed Applications
63
Setting Reject Parameters
65
Understanding Reject-Delay and Reject-Duration Timing
65
Setting the Reject-Delay Time
66
Setting the Reject-Duration Time
67
Setting Contaminant-Detection Parameters
69
Establishing a Baseline with no Product Present
69
Calibrating the Speed Filter Using a Ferrous Test Ball
72
Establishing Basic Product Parameters
73
Set-Up Check List for Gravity-Feed Applications
76
Parameters You Have Already Set up
76
Additional Parameters You May Want to Set up
77
Setting up Pipeline Applications
79
Setting Reject Parameters
81
Understanding Reject-Delay and Reject-Duration Timing
81
Setting the Reject-Delay Time
82
Setting the Reject-Duration Time
83
Setting Contaminant-Detection Parameters
85
Establishing a Baseline with no Product Present
85
Choosing the Appropriate Wide-Band Speed Filter
88
Establishing Basic Product Parameters
90
Set-Up Check List for Pipeline Applications
93
Parameters You Have Already Set up
93
Additional Parameters You May Want to Set up
94
Setting up Pharmaceutical (Rx) Applications
95
Setting Reject Parameters
97
Understanding Reject-Delay and Reject-Duration Timing
97
Setting the Reject-Delay Time
98
Setting the Reject-Duration Time
99
Setting Contaminant-Detection Parameters
101
Establishing a Baseline with no Product Present
101
Choosing the Correct Speed-Filter Settings for the Rx
104
Establishing Basic Product Parameters
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 Structure
111
Main Menu
111
Main Menu—Page
111
Product Name
111
Product Speed
111
Reject-Totals Menu
112
Detect Level
113
Phase-Angle Menu
113
Frequency and Gain Menu
114
Peak Signal
114
Security Menu
115
System and Tools Menu
115
Main Sub-Menu
115
Starting a Complete Product Calibration
116
Editing the Product Name
116
Main Sub-Menu
116
Setting the Pack Length
117
Setting the Pack Gap
117
Setting the No-Pack Distance
117
Rejects Menu
118
Resetting the Counts for Reject 1
118
Setting the Distance to the Reject-1 Device
119
Changing the Units of Measure
119
Setting the Signal Duration for the Reject-1 Device
119
Displaying the Number of Quality Test Rejects
120
Displaying the Number of Auditcheck Rejects
120
Rejects Menu
121
Setting the Type of Photo Registration Used
121
Setting the Latching-Reject Function (Reject 1)
122
Inverting the Reject Function (Reject 1)
123
Calibrating the Speed-Encoder Function
124
Understanding the Photo-Queue Pack Count
127
Rejects Menu
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)
132
Setting Amplitude Suppression (Reject 1)
134
Rejects Menu
136
Calibrating Reject-Confirm Times
137
Manually Setting the Timing for a Reject-1 Confirm
138
Manually Setting the Timing for a Reject-1 Complete
139
Rejects Menu
141
Keying in the Distance to the Reject-2 Device
142
Keying in the Signal Duration for the Reject-2 Device
142
Assigning Tasks to the Reject-2 Device
143
Setting the Latching-Reject Function for Reject 2
144
Inverting the Reject Function for Reject 2
144
Rejects Menu
145
Entering a Reject-Confirm Time for the Reject-2 Device
145
Calibrating the Reject-2 Confirm Time
147
Phase Angle
150
Calibrating the Phase-Angle Setting
151
Locking the Phase-Angle Setting
152
Enabling the Detector's Phase-Tracking Function
153
Setting Acceptable Limits for Phase Tracking
155
Setting Limits for a Phase-Tracking Fault Notification
156
Phase Angle
157
Selecting the Wet-Product Noise Filter
157
Selecting the Phased-Noise Reduction Filter
158
Selecting the Quadrature Noise-Reduction Filter
159
Frequency and Gain
160
Setting High or Low Frequency
161
Setting High or Low Gain
162
Inhibiting Detection
162
Frequency and Gain
163
Calibrating the Detect Level
163
Changing the Detect Level
164
Setting Multi-Zone Detection
165
Locking the Detect Level
166
Calibrating the X and R Noise Thresholds
166
Changing the Noise Threshold for X
167
Changing the Noise Threshold for R
167
System and Tools
168
Quality Test
168
Auditcheck
168
Error Messages (Wafs)
169
Manual Print
169
Bar-Graph/Help-Text Set-Up for the Display Panel
169
Intellitrack (IXR)
169
System and Tools
170
Viewing Your Speed-Filter Settings
170
Inputs and Outputs Menu
172
Copying and Pasting Product Parameters
173
Setting the Time and Date
176
Setting Metric or Imperial Units
178
System and Tools
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" Function
182
Resetting the Counts When Products Change
183
Resetting Product Parameters to the Default Settings
184
Resetting the NVRAM Parameters to the Default Settings
186
Oscilloscope
187
System and Tools
192
Selecting the Language for the Display Panel's Help Text
192
System and Tools
193
Displaying Your Software Version
193
Displaying Your APEX Model Type
194
Displaying Your System Set-Up Code
194
Displaying Your Product Set-Up Code
195
Quality Test
196
Overview of How the Quality Test Function Works
197
Testing the Detector Using QA Test Samples
198
Setting the Time Interval between QA Tests
200
Setting the Time Window for Doing a QA Test
201
Setting the Reject Device Used for the QA Test
202
Doing a Manual QA Test
203
Setting Limits for Peak Signal and Phase Angle
204
Auditcheck
206
Performing an Auditcheck Test
207
Displaying the Average Phase Angle
208
Displaying the Average Peak Signal
208
Setting the Lock-Values Function
208
Setting Manual-Start, Timing-Limits, and Reject-Device Parameters
209
Setting Limits for Peak Signal and Phase Angle
210
Setting the Auditcheck Overhang Distance
210
Setting the Auditcheck Pulse Length
211
Setting the Auditcheck Signal Time-Out
212
Error Messages (Wafs)
214
Defining Warnings, Alarms, and Faults (Wafs)
214
Wafs Are Not Mutually Exclusive
215
Setting a WAF for a Particular Function
215
Learning about Other Wafs
217
Inputs and Outputs
220
Inputs
222
Viewing the Speed-Encoder Input
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
Inputs
225
Using an External Device to Switch Products
226
Setting the Product-Select Inputs
227
Locking the Detector's Key Pad
228
Starting the Reject-Suppression Cycle
228
Inputs
229
Assigning the Input for Verification of a Reject Using Photo-Eye 2
230
Assigning the Reject-2 Confirm Input
230
Clearing All WAF Inputs
231
Outputs
232
Changing the Assignment of an Output Device
235
Changing the Polarity of an Output Device
236
Printer Set-Up
238
Attaching a Printer to the Detector
238
Navigating to the Printer Set-Up Menu
239
Activating the Printer
241
Manual Printing
242
Naming Your Detector
243
Naming Your Product Batches
244
Printer Set-Up
245
Activating an End-Of-Day Print-Out
245
Activating a Reject Print-Out
246
Activating a Print-Out on Power-Up
247
Security Level
249
Entering a Supervisor Password
250
Setting Engineer and Operator Passwords
253
Retrieving a Forgotten Password
253
Undoing the Need for Passwords
254
Logging in
255
Logging out
256
Maintenance and Troubleshooting
259
Troubleshooting Guide
262
Service, Repair, and Replacement Parts
265
Contact Information
266
Ordering Parts
269
Installing Your APEX Detector
271
Unpacking Your APEX
271
List of Included Components
272
APEX Specifications
272
Theory of Operation
276
Definition of Various Product Effects
276
Understanding some Basic Detector Vocabulary
279
Safety Precautions
280
Electrical Set-Up
283
Removing the Control Panel
286
Installing Cable and Conduit to Your APEX
288
Input-Wiring Board-Pin Assignments
289
Output-Wiring Board-Relay Settings and Fuses
290
Mechanical Set-Up Instructions for Specific Applications
291
Mechanical Set-Up for Conveyor Applications
292
Mechanical Set-Up for Gravity-Feed and Rx Applications
299
Mechanical Set-Up for Pipeline Applications
307
Safety and Warranty Information
311
Appendix A-Modbus Communications Card
319
Overview
321
What the Modbus Communications Card Does
321
Engineering Details
322
Expert Knowledge Is Required to Modify Settings
323
Overview of the Installation Process
323
Modifying the Modbus Settings
323
Configuring Network Parameters with the APEX Software
325
Configuring a TCP/IP Network
325
Accessing the TCP/IP Communications Menu
326
Changing the DHCP Default Setting During Installation
329
Changing DHCP to "Off
329
Manually Changing Communication Parameters
330
Changing the IP Address
330
Changing the Subnet-Mask Address
331
Changing the Gateway Address
332
MAC Addresses
332
Saving Your TCP/IP Settings
333
Changing DHCP to "On
334
Configuring an RTU Network
335
Accessing the RTU Communications Menu
335
Changing the Slave Address
336
Changing the Baud Rate
337
Changing the Parity
338
Saving Your RTU Settings
339
Configuring the Modbus Hardware
341
Configuring the TCP/IP Card
342
Card Schematic
342
Installing the TCP/IP Card
342
Setting the Configuration Switches
343
Pin Assignments for the Ethernet (RJ45) Connector
343
Understanding the Status Leds
344
Configuring the RTU RS-485 Card
345
Card Schematic
345
Installing the Card
345
Setting the Configuration Switches
346
Pin Assignments for a DB-9 Connector
347
Pin Assignments for a Screw Connector
347
Understanding the Status Leds
348
Configuring the RTU RS-232 Card
349
Installing the Card
349
Setting the Configuration Switches
349
Pin Assignments for a DB-9 Connector
350
Pin Assignments for a Screw Connector
350
Understanding the Status Leds
350
Understanding Registers
351
Data Handling
351
Supported Operation Codes
351
Read Data
352
Write Data
352
Register Details for Commonly Used APEX Functions
353
Changing Products
353
Retrieving Statistical Information
354
Backing up Critical APEX Settings
355
Detailed List of Modbus Registers
357
Appendix B-Intellitrack™ XR
367
Overview
369
System Requirements
369
Product Requirements
369
Discussion of Product Requirements
370
Setting up Related Functions
371
Keying in the Pack Length
371
Keying in the "Detection No-Pack" Distance
372
Keying in the In-Feed Photo-Eye Distance
374
Enabling Photo-Eye Registration
376
Enabling the IXR Function
378
Calibrating the IXR Function
380
Learn the X and R Noise Thresholds
380
Using the Auto-Calibration Function
382
Using the IXR Calibration Function
385
Using the IXR Detect-Level Calibration Function
385
IXR Tracking
387
Understanding the IXR Display
388
Troubleshooting
391
Glossary
393
Contacting Thermo Fisher Scientific
399
Supplemental Information
403
Control Panel
406
4
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Thermo Scientific APEX 100 Specifications
General
Brand
Thermo Scientific
Model
APEX 100
Category
Metal Detector
Language
English
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