Operating Instructions

Control Unit

PRIMUS

We reserve the right to change the contents due to product innovation or technical
improvement.
Please state type of equipment and serial
number when contacting us.
Please read these instructions and keep
the manual safe!
Please observe and follow the safety notes!
S+S Separation and Sorting Technology GmbH
Regener Strae 130
* D-94513 Schnberg
Telephone: +49 (0) 8554 308-0 * Fax: +49 (0) 8554 2606
E-mail: info@sesotec.com
Internet: http://www.sesotec.com
Service: Telephone: +49 (0) 8554 308-180

PRIMUS-BA-CU-EN-3123.docx

Manufacturer:
S+S Separation and Sorting Technology GmbH
D-94513 Schnberg, Germany
Contact:
S+S Separation and Sorting Technology GmbH
Regener Strae 130
D-94513 Schnberg, Germany
Tel.:
Fax.:
E-mail:
Internet:

+49 (0) 8554 3080

+49 (0) 8554 2606
info@sesotec.com
www.sesotec.com

Represented by:

PRIMUS-BA-CU-EN-3123.docx

Contents

Contents
1

General information

1.1

Introduction

1.2

Field of application

1.3

Application reasons

1.4

System identification

1.5

Symbols used

1.6

EC DECLARATION OF CONFORMITY

1.7

General view

Design and method of operation

2.1

Functional principle

2.2

Functional and control elements

2.2.1 Membrane keypad
2.2.2 Electronics board

7
7
8

Dimensions and technical data

3.1

Technical data sheet, see annex

3.1.1 Control unit optional version

9
9

3.2

Supply connections, see technical data sheet in the annex

3.3

Environmental conditions for operation, storage, and transport

3.4

Noise levels

Safety

10

4.1

Intended use

10

4.2

Safety signs

10

4.3

Dangers arising from non-compliance with safety notes

10

4.4

Safety information for operators

10

4.5

Safety information for operation, maintenance and cleaning

11

4.6

Safety information for commissioning

11

4.7

Safety information for storage and transport

11

4.8

Notes on residual risks

11

4.9

Notes on stable standing requirements

11

4.10 Consequences of unauthorised modification

12

4.11 Improper use

12

Commissioning

13

5.1

Mechanical Installation

13

5.2

Connecting the equipment

5.2.1 Pin configuration
5.2.2 Electrical connections
5.2.3 Performance data - connectors
5.2.4 Electrical connection of the equipment
5.2.5 Drawing of input / output connections
5.2.6 Behaviour of machine at start up
5.2.7 Relays operating status

13
13
13
14
14
16
17
17

Contents

10

11

12

Setting machine parameters

18

6.1

DIP switches

18

6.2

Amplification jumper

19

Operation

20

7.1

Using the membrane keypad

7.1.1 LED display: Operating status and product displays
7.1.2 LED display: Metal signal display
7.1.3 Preset product memories
7.1.4 Sensitivity setting, product teach-in process and product change

20
20
20
20
20

7.2

Operation board

22

Errors and fault rectification

23

8.1

Error messages
8.1.1 Faults on magnetic valves MV1 and MV2
8.1.2 Transmitter faulty
8.1.3 Flap position monitoring
8.1.4 External error input
8.1.5 Level monitoring
8.1.6 Receiver voltage too high
8.1.7 Receiver connection
8.1.8 Parameter memory
8.1.9 Transmitter connection

23
23
23
23
24
24
24
24
25
25

8.2

Undefined activation of switching outputs

25

8.3

Special notes on separators

26

8.4

Replacement of electronic boards

26

Maintenance and cleaning

28

9.1

Maintenance

28

9.2

Cleaning
9.2.1 Hints for cleaning
9.2.2 Cleaning instructions
9.2.3 Care advice for stainless steel

28
28
28
28

Spare parts

29

10.1 Spare parts drawing control unit standard version

29

10.2 Spare parts list control unit standard version

29

10.3 Spare parts drawing control unit optional version

30

10.4 Spare parts list control unit optional version

30

Shipping, preservation, waste disposal, transport, storage

31

11.1 Shipping, preservation, waste disposal

31

11.2 Transport

32

11.3 Storage

32

Annex

33

1. General information

General information

1.1 Introduction
The texts and illustrations in this instruction manual are for the exclusive purpose of explaining how to
operate and handle the control unit. The manufacturer accepts no responsibility for damage resulting
from the use or misuse of this equipment. All appropriate safety rules and regulations for the use of this
equipment must be adhered to. If you have any questions with regard to the installation and operation
of this equipment please do not hesitate to contact us.
This instruction manual may not be copied, saved on computer or otherwise reproduced without the
prior permission of the manufacturer. Nor may any extract of this instruction manual be similarly reproduced.

1.2 Field of application

The PRIMUS control unit is used in combination with S+S metal detectors and separators in the plastics,
wood, food, chemical, and in a special version also in the pharmaceutical industry. Depending on the respective version, these systems inspect packed, unpacked, or piece products, and bulk materials for
magnetic and non-magnetic metal contaminations.
Of course they also are suitable for similar applications in other branches of industry.

1.3 Application reasons

Product liability
ISO 9000
TQM (Total Quality Management)
Protection of machines and quality assurance

1.4 System identification

The information in this instruction manual only applies to the PRIMUS control unit. A label with the respective data is attached at every system.

1.5 Symbols used

Symbol

Signal
word

Meaning

Danger

Warning: Possibility of severe or even fatal personal injuries.

Danger

The lightning symbol is an explicit warning that there is danger from electric current.

Warning

Warning: Possibility of minor personal injuries or property damage.

Caution

Warning: Possibility of defects or destruction of the equipment.

Important Indicates an important information for the function.

information
Important
hint

Indicates an important hint for the function.

1.6 EC DECLARATION OF CONFORMITY

(see annex EC DECLARATION OF CONFORMITY)

1. General information

1.7 General view

Control unit standard version

Control unit optional version

Control unit membrane keypad

2. Design and method of operation

Design and method of operation

2.1 Functional principle

Detec tion c oil
Re
c

e iv
er

Control Unit

Tra
nsm
itte
r
Re c

Com puter
Signal amplifier

e iv
er

Data

Analog / digital
c onverter

Data

Digital signal
proc essing

LCD display
Keyboard

Quartz osc illator

Relay
24V outputs
24V inputs

Output
c ontrol
Monitoring

Power
supply

Memory for
8 products

The metal detector operates according to the so-called "transmitter-receiver" principle:

Detection is performed by a search coil that comprises a transmitter winding and two receiver windings. The transmitter winding is supplied with a frequency between 16-300KHz. Identical voltages are
thus induced in the two receiver windings on the left and right side of the transmitter winding. When a
metal particle passes through the search coil, it unbalances first the inductive field of receiver 1 and
then of receiver 2. These small voltage changes are evaluated by the control unit and are indicated as
a metal signal, which is used to trigger a separation process.
Due to their intrinsic conductivity that is caused e.g. by moisture, metal oxides, grease, salts, etc. many
bulk materials have a so-called product effect. For being able to detect metal contaminations the control unit must suppress or reduce this product effect.
This "suppression" of product effects may lead to a reduction of the stated scanning sensitivity.

2.2 Functional and control elements

2.2.1 Membrane keypad
The control panel of the control unit has the following control and indication elements
1

1
F
Empfindlichkeit Produktwechsel
sensitivity
product change

Auto-Set

2
3

1
2
3
4

LED display
Operator keys
LED display
Function key

5
6
7

Function key
Red LED
Red LED

Strung
fault

Metall
metal

8-digits
+,-,F
Navigation / operation
Esc / Reset
Esc / Reset
Test
Strung (fault)
Metall (metal)

Esc
Reset

Test

For machine operation and metal signal display

For operation and machine setting
Displays the selected setting function
For machine operation, closes the setting function
Reset to restore the unit after metal or fault signal
Test function for metal detector
Flashes when fault detected
Illuminates when metal detected

2. Design and method of operation

2.2.2 Electronics board

The drawing below shows the position of the key components and the arrangement of the connectors.
28
13

25

rejec t
duration

rejec t
delay time

14

28

10

23

15

26

MV2 time

27

17

18

19

ON
1
2
3
4
5
6
7
8
9
10

20
16

22
8
21

30
9

11

12
24

Connectors and terminals:

(1) Mains/Option:
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Metal 1:
Fault:
+24V:
Input/Output
Receiver
Transmitter
Ribbon cable connector
Mains/Option
Mains fuses
Metal 1
Fault

29

(1)
(9)
(2)
(3)

Memory devices:
Light diodes:

(10) Machine and product data

(11) Magnetic valve 1 status (MV1)
(12) Magnetic valve 2 status (MV2)
(13) Active light supply voltage -15V
(14) Active light supply voltage +15V
(15) Active light supply voltage +5V
(16) 7-segment display for parameters, faults and time functions
(17) Reject duration MV1 potentiometer
(18) Reject delay potentiometer
(19) Reject duration MV2 potentiometer
(20) DIP switch machine parameters
(21) BCD switch system setup
(22) Lock system setup parameters
(23) Lock operation sensitivity, product change, learn product
(24) Amplification low/medium/high
(25) Supply voltage +5V
(26) Supply voltage +15V
(27) Supply voltage -15V
(28) Common ground for all signals (GND)
(29) Sine wave signal to detection coil (transmitter)
(30) Sine wave signal from detection coil (receiver)

Switches:
Jumper:

Test points:

L/N:
Control unit power supply
O1/O2: Optional 24V module power supply
Potential free change over contact
Potential free change over contact
+24V external supply (only for solenoid supply)
24V Inputs/Outputs
Receiver connector
Transmitter connector
Connector for control panel

Elements connected to
mains voltage:
Elements connected to external voltage:

Potentiometer:

28

3. Dimensions and technical data

Dimensions and technical data

3.1 Technical data sheet, see annex

3.1.1 Control unit optional version
280
260
240
1

145

2 3 4 5 6 7 8

F
Empfindlic hkeit Pr oduktwechselAutoS
- et
sensitiv ity
pro ductchange
Esc
Reset
Test

240

Meta l
meta l

315

Str ung
fa ult

All measurements in mm

3.2 Supply connections, see technical data sheet in the annex

3.3 Environmental conditions for operation, storage, and transport
The environment of the control unit should be free of any chemical vapours such as softeners, chlorine, or similar substances. The control unit must not be exposed to direct sunlight or to other environmental influences (rain, snow, storm). For ambient temperature conditions for operation, storage, and
transport please refer to the technical data sheet in the annex.

3.4 Noise levels

Sound pressure level measurements (in acc. with DIN 45 635)
Peak value of sound pressure level at a distance of 1m from the machine surface and 1.60m above
the floor, LpA, 1m, max.
Result:
Idling:
Activated:

< 70 dB(A)
< 90 dB(A)

Measurement results for accessories and options: see annex.

We reserve the right to change the contents due to product innovation or technical improvement.

4. Safety

Safety

Our equipment conforms to all official technical safety regulations. However, as a manufacturer we believe it is our duty to make you aware of the following information.
The following safety and danger notes are intended for your protection, for the protection of
third parties, and for the protection of the equipment. The safety notes therefore should always be observed!

4.1 Intended use

The equipment is intended for use in the following fields of application and only in combination with a corresponding detection coil of series GLS, DLS and P-SCAN RP: Suction/pressure conveyor applications, free-fall applications, and applications at a conveyor
belt. The equipment can be used in the plastics, food, animal feed, recycling, and chemical
industry. Basically it is possible to also use the system in other applications than the intended use stated herein, but such applications always require the prior consultation and
approval of S+S Separation and Sorting Technology GmbH.

4.2 Safety signs

Symbol

Signal word Location

Meaning

Mains voltage

This symbol indicates that mains voltage is used in the electronics housing, and that any connected external circuits
(e.g. at the metal relay) also may be energised. There is
danger of electric shocks due to the presence of mains voltage.
Connection symbols:

Cover of
the electronics
housing

"Mains" (1)
"Metal " (3/4) and "Fault" (2)
If the covering have to be removed during maintenance and repair works take notice of the references
in 4.5.

4.3 Dangers arising from non-compliance with safety notes

Any non-observance of safety notes constitutes a danger for life and health.

4.4 Safety information for operators

The control unit PRIMUS may only be operated in the intended purpose and in a perfect
functioning condition, especially the cover of the electronic housing has to be closed during
operation. Entered moisture has to be removed! All fixed warning signs on the equipment
may not be removed and have to be in a well recognizable condition. The operating instructions always have to be in a legible condition and complete available. Prior to commissioning always make sure that the applicable accident prevention regulations are
observed. If the control unit is not mounted at the detection coil, it must be properly and
firmly fastened by means of the four screws. The operator must make sure that the equipment is mounted at an ergonomic height for operation. The operator may only appoint
qualified personnel for operation, maintenance and repair work.

10

4. Safety

Emitted interference
Test report according to the provisions of:
BGV B11:2001-06
Regulations of the professional association for safety and
health at work.
Accident prevention regulations for electromagnetic fields.
E DIN VDE 0848-3-1: 05-2002 Safety in electrical, magnetic, and electromagnetic fields,
part 3-1: Protection of persons with active implants in the
frequency range of 0Hz to 300 GHz.
In the area where the operating personnel is working the electromagnetic field of the metal
detector or separator does not exceed the limits stated in the provisions. Therefore there
are no health impairments due to electromagnetic fields in this area for persons and for
wearers of medical implants such as cardiac pacemakers. Inside the coil of round or
closed tunnel coils, or on the surface of flat coils, the limits may be exceeded depending
on design and system version. If work is to be performed inside or at the search coil, persons and wearers of medical implants such as cardiac pacemakers may only enter the
equipment when it is turned off, provided that size and design allow this.

4.5 Safety information for operation, maintenance and cleaning

Because of energised components in the electronics housing there is a risk of injuries due
to electric shock or burns. During operation the cover of the electronics housing must be
kept closed. Only qualified personnel may operate and clean the equipment.
If the electronics housing must be opened for maintenance or cleaning purposes, remove
any dirt and moisture from the electronics housing, so that no larger amounts may get into
the interior. Always disconnect the power supply and any connected external circuits before
opening the cover. Any moisture that has penetrated into the interior must be removed
from the electronics housing.
If system parameters have to be changed while the system is energised, such work may
only be performed by a qualified electrician under strict observation of the attached warning
labels and with due regard to standard approved rules of electrical engineering.

4.6 Safety information for commissioning

To avoid any injuries due to energised parts in the electronics housing, the information in
5.1 and 5.2 must always be observed.

4.7 Safety information for storage and transport

Always observe the information in paragraph 11 to avoid any transport damage and personal injuries.

4.8 Notes on residual risks

Electrical circuits may still be live even after having been isolated from the mains. Switch
off immediately if a fault occurs.

4.9 Notes on stable standing requirements

To avoid any loss of stable standing, the information for transport, commissioning and operation must always be observed. Always make sure that the fastening screws of the control unit are tight during operation. When storing or transporting the control unit, place it on
the closed rear panel of the housing.

11

4. Safety

4.10 Consequences of unauthorised modification

Unauthorised modification or repair will invalidate all manufacturer declarations and guarantees.

4.11 Improper use

For other applications as enumerated in 4.1 the control unit PRIMUS intended for that is
regarded as inadmissible operation. Improper use also includes operating the equipment
with excessive mechanical, static or dynamic loads (e.g. heavy machine parts or strong vibration). It is furthermore not permitted to inspect any aggressive materials on the conveyor, such as materials containing lyes, acids, and solvents, or materials that react to
electromagnetic fields, or living persons or animals. The standard version of the control
unit must not be operated in Ex-areas. Operation in Ex-areas only is permissible with the
special Atex-version of the control unit, which is described separately.

12

5. Commissioning

Commissioning

5.1 Mechanical Installation

Ensure that the equipment is securely installed and vibration-free. Installation under cover. Do not
install in an environment where there is risk of explosion.
Do not install in the vicinity of interference fields (e.g. near large electric motors or frequency inverters). The safe distance depends on the power of the motor or frequency inverter (approx.. 5 m).
Fix the control unit cabinet to a wall or frame using the screw holes provided (check the drawing for
dimensions). Ensure that it is securely fixed to support the weight of the control unit (approx. 5 kg).
The control unit must be installed in its own cabinet. On no account install it in other switchgear cabinets as there is a high risk of interference.
Always discuss with manufacturer prior to altering cable lengths between the electronic unit and the
detection coil. Always use original cables supplied with the machine. These connector cables must
be laid separately from other cables (use fixing clips or lay them in separate cable ducting).
Where several metal detectors are to be installed next to one another the distance between detection coils must not be less than 2 m. Where metal detectors are installed opposite one another the
distance between them must not be less than 10 m. These figures are for large machines, reduce
the distance by up to 50 cm for smaller machines. Please contact manufacturer if space is limited
and the distance between machines is less than that recommended.
Do not install the equipment in such a way that operation of the mains cut-off switch is hindered in
any way!

5.2 Connecting the equipment

To conform to CE standards all cables external to the electronics and Cable
Shield
electrical control housings must be shielded. The shielding must be
earthed immediately after the cable gland.

Housing

5.2.1 Pin configuration

5.2.2 Electrical connections

Model number

Type of connection

Function

Mains/Option

Connector for mains supply

Metal 1

Voltage free
relay contact
Voltage free
relay contact
+24V external

L/N:
Electronics power supply
O1/O2: Optional 24V module power supply connector
Normal operation:
Contacts 31 and 32 closed
On metal detected
Contacts 31 and 34 closed
Normal operation:
Contacts 21 and 24 closed
In case of fault:
Contacts 21 and 22 closed
Connector external power supply (+24V) Solenoid supply
(MV1 / MV2). Required for solenoids valve with power
consumption >5W

Fault
+24V

13

5. Commissioning

Model number

Type of connection

Function

Input/Output

24V inputs and outputs

1,2
3,4
4,5
6,7
7,8
9,10
10,11,12
11,12
12,13,14
15,16

Receiver

Connection for detection

coil:
Receiver

Transmitter

Connection for detection

coil:
Transmitter

1
2
3
4
5
1
2
3

MV1 switching output

Remove bridge when load (valve) to be connected
Ext. Reset button
Ext. Metal count
Ext. Test button
Manual separation
Ext. error input
NPN sensor 2 (level monitoring)
Disable metal detection
NPN sensor 1 (flaps monitoring)
MV2 switching output
Remove bridge when load (valve) to be connected
Receiver signal
Reference size for receiver signal
-15V
+15V
Transmitter 1
Reference size for transmitter signal
Transmitter 2

5.2.3 Performance data - connectors

Dry relay contacts
Switching outputs (MV1 / MV2)
Switching inputs

250VAC / 3A
120VDC / 3A
Maximum current load: 200 mA
Connection of make contacts against or 24V, or
PNP-outputs (NPN on request)

Switching elements (contactors, relays etc) may only be connected to the potential-free
contacts if interference is suppressed.

Relay connection for machine protection:

For the conveyor system to stop, both when metal is detected
or when there is a fault, the relays Metal and Fault must be
connected in series (see drawing on the right).

Metal 1

Fault

34 31 32

24 21 22
Wire jumper

Connection contacts

5.2.4 Electrical connection of the equipment

Maximum cable length for external components, switches and sen- Cable
Shield
sors is 15 m.
Only shielded cables should be used.
The shields must be attached directly to the electronics housing.

14

Housing

5. Commissioning

5.2.4.1 Mains supply via control electronics board

1 Conductor PE (yellow/green) to earth connection

to terminal L
2 Conductor L (brown)
to terminal N
3 Conductor N (blue)

5.2.4.2 Mains supply via safety socket

1. Connect the cable with mains plug to an existing socket.
2. After approximately 5 seconds the machine is ready for operation.

5.2.4.3 Mains supply via connection box

The following procedures should only be undertaken by qualified personnel. Before removing cover plates etc. make sure the equipment is isolated from mains or external voltage.
If the mains plug is removed, a terminal box and a suitable mains disconnector switch with
corresponding labelling/marking must be installed!
This disconnector switch must be easily accessible and must disconnect all poles from the
mains.

1. Remove mains plug.

2. Strip 5 cm length of insulation from cable and 1 cm from leads and attach cable cores.
Mains cable
4
5

3
1

1
2/3/4
5

3. Feed cable into connection box according to diagram below.

15

PVC - sheath
PVC - insulation
Conductor

5. Commissioning

Prior to this, always make sure that the mains supply to the terminal box is switched off.

Use a suitable shutdown unit i.e. emergency switch.

L
N
PE

Terminal box
3 pole terminal strip
Control unit mains cable
Mains supply
Conductor L (brown)
to terminal L
Conductor N (blue)
to terminal N
Conductor PE (yellow/green) to terminal PE

1
2
3
4
5
6
7

2
4

4. Close the terminal box

5. The unit is ready for operation approximately 5 seconds after switching it on.
Note:
The mains cable has a wire cross-section of 0.75 mm. The main supply fuse protection should be set
accordingly.
The electronic board contains no alternating mains fuse.

5.2.5 Drawing of input / output connections

Optional

In p u t/O u tp u t
1

In p u t/O u tp u t
6

10

11

12

13

In p u t/O u t
14

15

16

10

11

123

MV1

Reset Metal
button count

External error input:

Test
button

Manual
separation

External
error
input

Disable
metal
Sensor1
detection

Potential-free contact
In case of error contact open

16

MV2

Sensor2

12

5. Commissioning

5.2.6 Behaviour of machine at start up

Lamps and outputs during start up phase:
Lamp / output
Red light
Yellow light
Metal relay 1
Fault relay
MV1 / MV2 switching outputs

Contact status
illuminates
illuminates
Contacts 31 and 34 closed (consistent with metal alarm)
Contacts 21 and 22 closed (consistent with fault status)
As programmed
High active or Low active

Lamps and outputs after start up phase (approx 5 seconds)

Lamp / output
Red light
Yellow light
Metal relay 1
Fault relay
MV1 / MV2 switching outputs

Contact status
off
off
Contacts 31 and 32 closed
Contacts 21 and 24 closed
As programmed
High active or Low active

5.2.7 Relays operating status

Without power

Operating

Fault DIP switch 5 = OFF

Fault DIP switch 5- = ON (metal on error)

Metal

17

6. Setting machine parameters

Setting machine parameters

6.1 DIP switches

System parameters may only be changed by qualified and skilled persons!
Always make sure that the control unit is isolated from the mains voltage and from any external voltage before you open the housing!
Various machine parameters may be set by means of the 10 pin DIP switch (see page 8, item 20)

Switch 1:

Reset mode

Hand

Auto

Switch 2:

Half wave evaluation

OFF

ON

Switch 3:

MV1 active

Low Active

High Active

Switch 4:

MV2 active

Low Active

High Active

Switch 5:

Metal on error

OFF

ON

Switch 6:

Frequency deviation P

OFF

ON

Switch 7:

Frequency deviation M

OFF

ON

Switch 8:

Metal Signal locked

OFF

ON

Switch 9:

Spare

OFF

ON

Switch 10:

Monitoring

OFF

ON

Switch 1:

This position determines whether the metal outputs should be reset manually or automatically (after preset reject duration).

Switch 2:

One and two half wave evaluation can be set here.

Switch 3:

This sets the switch status of magnetic valve connector 1 when metal is detected.
Low Active:
High Active:

Switch 4:

This sets the switch status of magnetic valve connector 2 when metal is detected.
Low Active:
High Active:

Switch 5:

Normal output 24V on metal detected 0V

Normal output 0V on metal detected 24V

Normal output 24V on metal detected 0V

Normal output 0V on metal detected 24V

This sets the switch status of metal relay 1 if the machine is at fault status.

In case that several metal separators are operated close to each other different operating frequencies
have to be set to avoid interferences.
Switch 6:
OFF
ON
OFF (ON)
Switch 7:
OFF
OFF
ON (ON)
no deviation
positive deviation
negative deviation
Switch 8:

Metal signal relay, locked (indicates metal signal)

When ON, the metal relay output remains closed until the RESET button has been
pushed (only enabled in Freefall (RAPID) or slow motion (PROTECTOR) mode)

Switch 9:

Spare
(special function depending on the applications)
Application "Standard conveyor mode" or
Application "Conveyor belt controller" and ON Failure at metal
Application "PROTECTOR" and ON No ejection when Power ON

Switch 10:

This activates and deactivates the self-monitoring function of the control unit.
18

6. Setting machine parameters

6.2 Amplification jumper

System parameters may only be changed by qualified and skilled persons!
Always make sure that the control unit is isolated from the mains voltage and from any external voltage before you open the housing!
By using the amplification jumper (see page 8, item 24) 3 sensitivity windows can be preset (low medium high). By using the + and - buttons on the membrane keypad the sensitivity in each window can
be adjusted.

Low amplification

Medium amplification

High amplification

19

7. Operation

Operation

7.1 Using the membrane keypad

7.1.1 LED display: Operating status and product displays

1 2 3 4

7.1.2

6 7

Example: LED 3 illuminates

An LED illuminates "Control unit ready"
The position of the active LED indicates the selected product
memory (product 3 as standard setting)

LED display: Metal signal display

If metal is detected the LEDs begin to light up from left to right.
Only when all 8 LEDs are illuminated is a metal alarm triggered.
When metal triggers a signal and an LED is already flashing, it
will continue to flash.

7.1.3 Preset product memories

The control unit controller incorporates 8 product memories of which memories 1, 2 and 3 are preset
and cannot be changed.
a) Sensitivity
b) Phase angle
c) Product learn cannot be carried out on the preset products (product change only)
Presetting with following values.
Product 1: low sensitivity,
Step 3, Product angle corresponds to vibration angle
Product 2: medium sensitivity,
Step 6, Product angle corresponds to vibration angle
Product 3: maximum sensitivity,
Step 8, Product angle corresponds to vibration angle
Products 4 and 8 are preset on delivery, preset parameters will vary depending on the model however
they can be changed at any time by the customer once access to the individual operator functions has
been given.
Vibration angle (greatest machine stability) is dependent on the coil and is therefore preset.
7.1.4 Sensitivity setting, product teach-in process and product change
System parameters may only be changed by qualified and skilled persons!
Always make sure that the control unit is isolated from the mains voltage and from any external voltage before you open the housing!
Only the following modes can be set if these switches are in ON position (see page 8, item 23).
Position ON: Clear product teach-in
Position ON: Clear product change
Position ON: Clear sensitivity parameters
By removing the jumpers the settings can be locked against unauthorised changes.

20

7. Operation

Sensitivity setting

Empfindlichkeit
sensitivity

Shortly press the (F) button once to change to the sensitivity

setting mode.
The sensitivity LED illuminates.
Use the (+) and () buttons to set the sensitivity in 8 steps.
Example: Sensitivity increased by one step from 5 to 6.
Press the (F) button again to accept the sensitivity setting.
If the (F) button is not pressed, the setting procedure will be
cancelled after approx. 5 seconds, and the original setting remains active.
Press the (Esc/Reset) button to exit the setting mode. Changes that have been made will not be accepted.

Product change

Produktwechsel
product change

Shortly press the (F) button twice to change to the product

change mode.
The product change LED illuminates.
Use the (+) and () buttons to select the new product memory.
Example: Change from product memory 3 to product memory
4.
Press the (F) button again to accept the selected product
memory.
If the (F) button is not pressed, the procedure will be cancelled after approx. 5 seconds, and the original setting remains
active.
Press the (Esc/Reset) button to exit the setting mode. Changes that have been made will not be accepted.

21

7. Operation

Product teach-in process

Ensure that only metal-free products are being used.

Automatic teach-in process is not possible if vacuum / pressure equipment conveying speeds are > 8 m/sec.

Auto-Set

Shortly press the (F) button three times to change to the AutoSet (product learn) mode.
The Auto-Set LED illuminates.
The product learn process will be automatically activated after
approx. 3 seconds. The display changes and a block of three
LEDs will flash alternately from the left to the right continuously.
(see diagram).
During this time (approx 1 minute) the products must be conveyed through the detector. Press the (F) button again to end
the teach-in process. If the electronics unit identifies a phase
angle, this is set.
If the product effect is too high no phase angle is identified and
the phase angle setting remains unchanged.
If the (F) button is not pressed, the learn process is automatically cancelled after approx. 1 minute, and all the
product data remain unchanged.
Pressing the (Esc/Reset) button also cancels the learn process, and all the product data remain unchanged.

Auto-Set

If the (F) button is shortly pressed four times (within 3 seconds), the Auto-Set mode is not activated, but the system returns to the normal detection mode.

7.2 Operation board

Because of energised components in the electronics housing there is a risk of injuries
due to electric shock or burns.
Therefore such work may only be performed by a qualified electrician under strict observation of the attached warning labels and with due regard to standard approved rules of
electrical engineering.
The following parameters can be selected via 3 potentiometers (see page 8 items 17, 18, 19) on the
control unit.
reject
duration

reject
delay time

MV2 time

Reject duration magnetic valve 1 / metal relay

Time function magnetic valve 2
Reject delay magnetic valve / metal relay

22

8. Errors and Fault Rectification

Errors and fault rectification

If you should have any questions, or if there should be any malfunctions, please
contact the manufacturer.

If you have any questions, please state the equipment type and serial number!

Service telephone: +49 (0) 85 54 - 30 8-180

8.1 Error messages
When an error message is detected the red Fault LED on the operator panel flashes and the fault relay trips out. In addition, on standard versions, a metal alarm signal is triggered. The appropriate fault
status is shown on the 7-segment display.
Example: The letter F and the fault number flash up alternately.

8.1.1 Faults on magnetic valves MV1 and MV2

This message is displayed if there is a short circuit or break in the magnetic valve switching outputs.
Error messages

F 01
F 02

Possible causes
Action
Short circuit or connection broken Check valve cable for breaks and renew if
to magnetic valve 1.
necessary.
Check valve cable plug and socket connections, remove and reinsert if necessary.
Short circuit or connection broken Check valve cable and connectors with Ohm
to magnetic valve 2.
meter for short circuit, replace if necessary.
Check magnetic valve resistance which should
be 320...340 (or 100...140 for pusher application).

8.1.2 Transmitter faulty

This message is displayed if the transmitter signal is not detected or the connection to the detector is
broken.
Error message

F 03

Possible causes
Transmitter cable between control unit and detector has a short
circuit or transmitter frequency is
incorrect.

Action
Disconnect transmitter cable at the detector
(triax cable) and measure with Ohm meter: replace if necessary or check transmitter frequency.

8.1.3 Flap position monitoring

Sensor 1 is an initiating signal sensor is connected to Input/Output, terminals 12-13-14
Sensor 1 controls the reject outlet.
Error messages

F 04

Possible causes
Is the reject mechanism faulty?
No air pressure?
Is the sensor faulty?
23

Action
Check reject mechanism
Check air pressure, pressure?
Change sensor

8. Errors and Fault Rectification

8.1.4 External error input

A potential-free contact for the monitoring of external error sources can be used at connector
"Input / Output", terminal 9-10.
In case of error: Contact open
Standard:
Option:
Option:

Compressed air monitor

Collective fault - frequency converter (FC monitor)

F 05
Option

Compressed air
monitor

FC monitor

Error message, external error input

The error source depends on the option that is used
Possible causes
No air pressure or air pipe broken

Action
Check air supply

Operating threshold of pressure moni- Adjust pressure monitor

tor is set too high.
After discharge of compressed air,
Increase time interval
pressure monitor should be disregarded for a certain time. This error
may appear if the time interval is too
short.
Frequency converter alarm message
Example:
Thermal contact of motor protection

Check the FC error code, take

measures as described in the operating
instructions of the frequency converter

8.1.5 Level monitoring

Sensor 2 is a level monitoring sensor connected to Input/Output, terminals 10-11-12
Error messages
Possible causes
Action
The container is full.
Empty container
Is the sensor faulty?
Change sensor
Sensor is not connected or connection Check sensor connection
cable is broken.

F 08

8.1.6 Receiver voltage too high

This message is displayed if the RF voltage at the receiver is too high.
Error message

F 09

Possible causes
Large piece of metal (e.g. aluminium
ladder, screwdriver, hammer, bracelet) directly beside or in the detection
coil. Detection coil installed incorrectly
Detection coil installed incorrectly

Action
Check the coil and its immediate surrounding area. Sometimes pieces of
metal can be lodged inside or underneath the belt.
Check detection coil Operating Instructions Assembly). If the detector is a
DLS model check that the centre sleeve
or locking screws are not loose.

8.1.7 Receiver connection

This error message is displayed if there is a break in the receiver connection cable.
Error message

F 10

Possible causes
Break in receiver cable between electronics and coil

24

Action
Check receiver cable for breaks and renew if necessary.
Check connection cable plug and socket
connections, remove and reinsert if necessary.

8. Errors and Fault Rectification

8.1.8 Parameter memory

This message is displayed if the parameter memory (EEPROM) is unavailable or faulty
Error message

F 11

Possible causes
EEPROM unavailable or
faulty

Action
Check that EEPROM is properly sited (see page 8
item 10).
If necessary replace EEPROM.

8.1.9 Transmitter connection

This message is displayed if there is a break in the transmitter connection cable.
Error message

F 12

Possible causes
Break in transmitter cable to
detection coil.

Action
Check transmitter cable for breaks and renew if
necessary.
Check transmitter cable plug and socket connections, remove and reinsert if necessary.

8.2 Undefined activation of switching outputs

Possible causes
Machine incorrectly installed
Conveyor belt systems:
Intermittent contacts on the conveyor frame for
example due to:
Loose guide plates
Loose screw connections on the frame parts

Action
See Assembly

Changing contact resistance on the tension and

deflection roller bearings or on the drive roller

Insulate cross connections or tension and deflection rollers on one side.

Check and tighten all screw connections

If necessary weld frame parts.

Certain parts of the conveyor belt are conductive:

Contaminated with metal (welding spatter,
metal chips, abraded material.)
Belt junction causing metal alarm to signal
even when no product on moving conveyor

Clean conveyor belt of all residue.

If necessary replace conveyor belt.
Observe a minimum distance of 10mm between
pipe and coil. If necessary use a scanning pipe
with smaller diameter.
Repeat product teach-in procedure, if necessary
reduce sensitivity manually.
Check processed material carefully, if necessary
pass through detector again.
Check connections
Prevent static by additional earthing (please consult manufacturer) or by using ion spraying devices.

Circular coils:
Mechanical contact between scanning pipe and
detection coil.
Sensitivity setting too high
Metal particles hard to identify due to corrosion or
encapsulation
Loose contact at the detector cables
Material or conveyor statically charged (cracking
sound heard at the detection coil).

25

8. Errors and Fault Rectification

8.3 Special notes on separators

Metal is detected but is not rejected despite activation of the reject unit
Possible causes
Mechanism too slow

Action
Check air pressure (5 bar minimum)
Replace air hoses that are too thin and too long
with hoses that are as short as possible and
have a large diameter
Check the reject flap for jammed product

Attention! Risk of accident

Disconnect compressed air supply
beforehand
Reject duration too short

Increase reject duration

8.4 Replacement of electronic boards

2
3
1

1.
2.
3.
4.

Disconnect mains supply and external circuits and open cover of electronics housing
Remove connectors (1) and remove fastening screws (2)
Remove evaluation electronics board (3)
Install the new board in reverse order but do not connect to mains power supply!
The control unit electronic board is equipped with a memory module which contains all
the equipment settings and product data. If this memory board is transferred to the new
controller board no new settings need to be programmed.

26

8. Errors and Fault Rectification

Transferring all settings

(a)

New control unit

(b)

Old control unit

Procedure:

1. Remove data memory from the new (already installed) controller board (a) and put to one side.
2. Remove data memory from the old controller board (b) and
plug it carefully into the new controller board (a).
Ensure that the clipped corner on the memory device points to
the left.
3. All machine settings (DIP switches), as well as all potentiometer and jumper settings must be transferred to the new board.

4. Switch on power supply. The new board runs with the old parameters.

27

9. Maintenance and cleaning

Maintenance and cleaning

Prior to cleaning turn off the system with the master switch and disconnect the system
from the mains voltage.

9.1 Maintenance
The PRIMUS control unit is maintenance-free, yet it is still appropriate to inspect the equipment in
regular intervals:
Are all the fastening screws tight?
Is the housing seal in perfect condition, and does it provide proper sealing?
Also check all the cables for possible damage (e.g. at the cable sheath).

9.2 Cleaning
9.2.1 Hints for cleaning
-

Please ensure you follow the instructions below.

Specific machine components must be cleaned with specific substances. Please use the correct
materials and clean at regular intervals as suggested.
- If the building is being cleaned ensure the machines are covered up.
The following must not be used for cleaning:
- Sharp, hard or pointed objects
- Water or steam jet appliances
- Compressed air
- Hazardous and solvent-containing materials
- Cleaning agents that may attack the materials used
9.2.2 Cleaning instructions
For cleaning purposes we recommend that you use warm water with approved cleaning agents for the
respective application, and a soft, lint-free cloth. Once every week the coil shaft should be thoroughly
cleaned, removing any dirt accumulations and deposits. After cleaning wipe up any remaining drops of
water with a dry, non-fibrous cloth until the coil shaft is dry. From time to time apply oil to the stainless
steel framework (e.g. Nirostol 55 cleaning and maintenance oil which meets food industry standards).
9.2.3 Care advice for stainless steel
Only high-quality stainless steel is used in the systems. To prevent rust on the high-grade steel parts
do not use substances containing chloride (e.g. cleaning or disinfecting products) or operate the machine in an atmosphere containing chloride. If this is unavoidable the steel parts must be thoroughly
rubbed down immediately afterwards with cleaning oil e.g. Nirostol 55 cleaning and maintenance oil
(which meets food industry standards).
Important information for stainless steel models
Stainless steel models are extremely weatherproof and are therefore able to withstand most environmental conditions.
However, even stainless steel can be susceptible to a slight film of rust.
These deposits are caused by contact corrosion and can be removed by following the instructions below:
- Use a stainless steel cleaner: in principle any stainless steel cleaner may be used. Please ensure
you read the instructions prior to use.
- Use only cleaning agents that are halogen-free (i.e. without chlorides and fluorides), and salt and
hydrofluoric acid free.
- After each cleaning rinse the machine thoroughly with tap water
- Do not use the following: non-alloy materials or substances, abrasive cloths, cleaning agents containing salt or hydrofluoric acid, chrome, silver or brass cleaners.

28

10. Spare parts

10 Spare parts
Please state type of equipment and serial number when contacting us.
Spare parts and wearing parts must always be obtained from the manufacturer of from a
supplier that is certified by the manufacturer.

10.1 Spare parts drawing control unit standard version

10.2 Spare parts list control unit standard version

Item No.

Part

Part No.

Membrane keypad

33014230

Electronics housing with cover plate without

membrane keypad

33005970

Electronics housing

Evaluation electronics

44003888

Mains cable (not shown)

33014114

Remarks Drawing no.

Standard (RAL 9007)

Customized colour

29

10. Spare parts

10.3 Spare parts drawing control unit optional version

3
10.4 Spare parts list control unit optional version
Item No.

Part

Part No.

Membrane keypad control unit

33014230

Adapter plate for front panel

44003638

Electronics housing with cover plate

33002708

Evaluation electronics

44003094

Interface

44003888

Mains cable (not shown)

33014114

30

Remarks Drawing no.

11. Shipping, preservation, waste disposal, transport, storage

11 Shipping, preservation, waste disposal, transport, storage

11.1 Shipping, preservation, waste disposal
1.

Choose packing that is suitable for the type and size of unit, taking into account
whether the shipment is for export by sea or airfreight, or for national or international
road transport The packing material must protect the goods from all damage under
normal transport conditions.

2.

Depending on the size, weight and nature of the goods packing in cardboard boxes,
boxed pallets etc is only suitable for road transport.
Use reinforced card, corrugated cardboard, blister packing and shredded paper to fill
and protect the goods.
Electrostatic sensitive components (electronic boards, electronic modules, etc.) must
be packed in antistatic foil or foil bags prior to packing! ( t h i s i s e s s e n t i a l ! )
Stick additional warning labels on the outside of the packaging e.g. "Attention, electronic equipment, do not drop, etc. The packing should be sealed with adhesive tape
and, where the weight exceeds 50 kg, additionally with wrapping tape..

2a. When packing for international road transport use the instructions above (see point 2).
Larger and heavier shipments must also be protected as for export in wooden crates.
Care must be taken to ensure that the goods inside the packing are protected against
corrosion.
Any parts that will corrode easily must be wrapped in oil paper or corrosion-protective
foil. Care must be taken to prevent the components moving around within the packaging.
2b. International air freight shipments must be packed in wooden crates or on export paltainers.
Care must be taken that the goods are secure and well-protected inside the packing.
Any parts liable to corrode must be wrapped in oil paper, protective foil or sprayed
with anti-corrosion spray.
2c. Sea-freight must be packed in seaworthy export crates. These crates can be obtained
from specialist suppliers.
The crates must be lined with oil paper to make them resistant to sea water and prevent corrosion. In addition the goods must be protected against corrosion by use of a
spray or be wrapping in protective foil.
Care must be taken to ensure that the goods cannot move around inside the crate.
After packing the sea-freight crates must be properly closed.
The sea crates must also be fastened externally with securing tapes.
During loading care must be taken not to damage the external packaging.
The carrier must certify that the shipment has been accepted and loaded correctly by
detailing this on the bill of lading, loading list etc.

3.

Waste disposal: Observe the national waste disposal regulations.

31

11. Shipping, preservation, waste disposal, transport, storage

11.2 Transport
In order to avoid injury or damage to the unit it must be handled properly. In addition to
following the instructions below, general health and safety good practice and specific
accident prevention guidelines should be observed.
For correct handling and storage comply with the following symbols:

Protect against moisture

Careful: glass

Up

Centre of gravity

Do not compress the side walls of the unit or any attached parts by pulling obliquely on
ropes or chains.
Only remove handling safeguards once all installation work has been completed.
When handling in a loading area make sure the unit cannot topple over or slip.
Damage caused during transportation must always be reported to the manufacturer.

11.3 Storage
If possible the unit should be stored in a closed room until final installation.
If the unit is stored in the open it must be covered over with tarpaulins and open underneath to allow condensation to drain off.
Avoid any higher temperature fluctuations. It is possible that condensed water that has
formed in the packing cannot properly drain and may corrode equipment surfaces. If a
formation of condensed water cannot be avoided, suitable desiccants e.g. in the form of
bags must be placed in the packing.
If the unit has been packed for transportation by sea the packaging must not be damaged or opened during transit and storage.
For storage temperature and permissible air humidity please refer to the technical data
sheet.
For correct storage comply with all storage and handling symbols:

Protect against moisture

Careful: glass

32

Up

12. Annex

12 Annex

EC DECLARATION OF CONFORMITY

Technical data sheet

33