Model HMD-ST Static Mode Hot Metal Detector Operator s Manual. Version

Transcription

1 Model HMD-ST Static Mode Hot Metal Detector Operator s Manual Version

2 Contents 1. Introduction Description Model Nomenclature Specifications Operating Principle Automatic Threshold Level Adjustment Additional Features Location and Mounting Detector Installation Location HMD Mounting Utility Connections Electrical Connections Plumbing Connection Air Purge Connection Operation Controls Automatic Threshold Level Description Visible laser aiming Self Test Troubleshooting Maintenance Regular Maintenance Returns of the HMD-ST Enclosure Dimensions P a g e 1

3 1. Introduction The Logika Technologies static mode hot metal detector, Model HMD-ST, is designed for automation of steel, aluminum and other industrial applications. It includes a rugged IP66 enclosure protecting state-of-the-art electronics and will withstand the harsh ambient conditions present in heavy industrial environments. The HMD-ST is used primarily for detection of hot metal above 300 C, including most shapes and dimensions of wire rod, bar, strip, thin plate, thick plate, billet and slab in production lines. 2. Description 2.1 Model Nomenclature Record your HMD-ST complete Model Number here: HMD - ST Specifications Base Model Power Input Low Temp Threshold Control Output ST 110: 110VAC 300: 300 C P: PNP24VDC 220: 220VAC 500: 500 C N: NPN24VDC 24: 24VDC Figure 2.1: Model Number Operating temp -25 C to +70 C (-13 F to +158 F). With water cooling: +120 (250 F) Detect Range 0.2-8m Response Relay < 20 ms, PNP/NPN < 2 ms LED Indicators Green = power on, Red = target detect Output Relay 5A, Choice of PNP or NPN S type Power Input 24 VDC, 110VAC, 5W Cable Insulation 20MΩ, 500VDC, 500 C (930 F) Housing Hermetically sealed cast aluminum enclosure rated IP66, includes cooling water connections and air purge. Size Enclosure: 235 mm L x 73 mm D x 180 mm H (with mounting bracket) (9.25 L x 3 D x 7 H) 3kg (6.6 lbs) Laser aiming Controlled by button on the back of housing. Self testing Self test activates when pin (purple) connected to 0VDC. P a g e 2

4 2.3 Operating Principle Detector - The HMD-ST receives infrared radiation from high temperature objects and transmits the image onto a photo sensor through specially designed optics, converting the light energy into an electrical signal. Range of view field: Figure 2.2 demonstrates the vertical sensing field size versus hot metal target distance from the HMD (Hot Metal Detector) for several scenarios. Figure 2.2: HMD-ST field of view Field Example: For a hot metal target located 1 meter from the front of the HMD (Hot Metal Detector), the field is Φ170mm. The HMD will output a control signal to the PLC regardless if hot metal completely fills the scanning area or just a portion. 2.4 Automatic Threshold Level Adjustment The HMD-ST includes an Automatic Threshold Level Adjustment to automatically decrease the detector signal when hot metal is detected to prevent detector signal saturation. The user adjusts the base gain level via a potentiometer mounted on the HMD s back. The detector will return to the base signal level upon exit of the hot metal from the scanning detection field. This feature makes the HMD more stable and significantly reduces detection errors caused by target black spots or varying surface temperature and interference from water vapor and oxide scale. 2.5 Additional Features Upon exit of the hot metal from the scanning detection field, the HMD s output signal changes within 3ms to decrease control lag time. The Modulated Signal Amplification Mode automatically reduces the temperature drift of the HMD-ST. P a g e 3

5 3. Location and Mounting 3.1 Detector Installation Location The installation distance between the HMD and the hot metal target should be selected to allow full coverage of the intended area while also protecting the detector from excessive process heat and maintaining a distance close enough to give the detector sufficient infrared energy to reliably detect the target. Mounting Distance- Select an approximate detector mounting distance from the hot metal target based on the following table. Consult Figure 3.1 to ensure that the distance that the HMD is mounted from the target will cover the entire process area. The field of the HMD should be oriented across the width of the process line for best coverage. Target HMD-ST Mounting Distance Product min (m) max (m) min (inch) max (inch) Wire Rod Bar Billet Blooms >2 >78.74 Strip Steel Thin Plate Thick Plate Slab >2 >78.74 Figure 3.1: HMD-ST Mounting Distance Interference- Background infrared radiation sources, such as other hot processes behind the target and reflected sunlight, should be reduced or eliminated: 1. Gradually reduce the sensitivity adjustment on the HMD-ST s control panel until the background interference is no longer detected in the absence of the target metal. See the Operation chapter of this manual for additional details. 2. If necessary, install a background radiation screen between the target and the interference source to block its infrared energy from reaching the HMD. P a g e 4

6 Other Installation Considerations 1. Position the HMD in order to reduce interfering infrared sources and choose a location that minimizes the presence of dirt, smoke and water vapor or other infrared absorbing substances. 2. Only a portion of the target is required to be in the HMD s field of view to create a hot metal output signal. 3.2 HMD Mounting Mounting Bracket - The HMD-ST has an adjustable mounting foot designed to allow easy rotation through horizontal and vertical axes. The HMD is fixed to the support with a single 12 mm bolt through the HMD-ST s base mounting stand. The support must be sufficiently rigid. Air, Cooling Water Fittings - The HMD-ST has a water-cooling jacket and an air-purged hood for protection of the window glass. These HMD s can therefore be used in harsh environments with high temperatures, steam, dust and smoke. Please see Section 4.2 Plumbing Connection and Section 4.3 Air-Purge Connection for further details on installing these protections for your HMD. High Heat Option- For installation where the ambient temperatures exceed 250 o C (480 o F), it is recommended that the HMD be ordered as HMD-FOC Fiber Optic Cable Hot Metal Detector. Remarks - For installation in environments that may include excessive water vapor or smoke, it is recommended that additional ventilation such as air curtains or fans be used to clear the area so the HMD can see the hot metal target. 4. Utility Connections 4.1 Electrical Connections Electrical Overview- All electrical connections (power and signal) to the HMD-ST are made via a 12-pin connector with ground. The HMD is supplied with a mating connector at the back of its enclosure and a standard 2-meter cable with the quick-connect assembly mating to the HMD and wired with ferrule terminals for the junction box connections. Custom cable lengths are available from Logika Technologies upon request. Cable Specification Multi-lead cables of 10 x 0.34 mm² Outer metallic braid for mechanical protection. Overall diameter of 9 mm. P a g e 5

7 Minimum bending radius of 30 mm. Each conductor is color-coded. Note: Static output and Relay output are isolated, allowing the two types of outputs to be used separately or at the same time. Number Color Pin No. Function 1 Brown K +24VDC/110VAC/220VAC 2 Red M 0V/Neut/Neut 3 Orange A +24VDC Out 4 Yellow B 0VDC Out 5 Green G Chassis Ground 6 Blue J PNP/NPN 7 Purple L Self test 8 Gray D Relay NO. 9 White E Relay Common 10 Pink F Relay NC. Figure 4.1 Cable Terminal Wiring Description 4.2 Plumbing Connection Description- Water cooling is required when the ambient temperature at the HMD s location is higher than 70 o C (158 o F). Temperatures above this level require protection for the electronics. A standard cooling water fitting is available at the HMD enclosure and copper heat exchanger tubing is embedded in the HMD housing to facilitate efficient heat removal from the HMD using circulating cooling water. Cooling Water Requirements Clean industrial water Maximum water inlet temperature of 25 o C (75 o F). Maximum water pressure of 4 bars (60 psi) Water flow rate of 1 to 2 L/min (0.35 to 0.56 cu ft/min) Connection- Use 3/8 flexible tube to connect the plant s cool water supply to the HMD cooling water fitting and secure with a hose clamp. Refer to Figure 4.2, Ambient P a g e 6

8 Temperature vs. Water Flow Rate Graph, to determine the cooling water flow rate for the ambient conditions surrounding the HMD. Figure 4.2: Ambient Temperature vs. Water Flow Rate 4.3 Air Purge Connection Description- Compressed instrument air can be used to prevent dust and vapor from entering the protective shroud around the lens of the HMD. Using air will reduce lens cleaning maintenance and prolong the HMD s life where dust or corrosive vapors are present. Compressed Air Requirements Must be clean, dry air free of contaminants. Air filtration prior to the purge inlet fitting is recommended for purge air of questionable quality. Air Pressure range of 50 to 200 g/cm 2 ( 0.7 to 2.8 psi) Air Flow rate of 4 to 16 L/min (0.14 to 0.56 cfm) Connection- Connect the plant purge air pipe to the air purge barb fitting on the lens shroud using 3/8 hose. The purge air flows out of the shroud and dissipates into the ambient environment. P a g e 7

9 5. Operation 5.1 Controls The HMD-ST s Control Panel is located on the back of the housing. The following functions are available on the Control Panel. LED1 = Green: HMD is powered. LED2= Red: Hot metal target detected Detector Test and Laser aiming button Potentiometer = Sensitivity Range adjustment 5.2 Automatic Threshold Level Description Definition- The HMD-ST includes an Automatic Threshold Level Adjustment. The HMD s circuitry will automatically decrease the threshold level when hot metal enters the target area to prevent signal saturation. When a hot target leaves the detection area the threshold level returns to its base setting. Sensitivity- The user adjusts the Threshold Level Potentiometer upon installation to determine the base detector signal according to the application requirements. As the potentiometer setting increases from low to high (rotating clockwise), the HMD sensitivity (gain) increases. This enables the user to prevent interfering background radiation from resulting in false positives of the HMD s output. The lower the potentiometer setting, the hotter the target should be and the more interfering background radiation will be eliminated. 5.3 Visible laser aiming To use the aiming laser, follow the steps below: Connect power to the HMD. Press and hold the RED button on the back of HMD, the visible laser will be turned on to show the center of detection field to aid in proper alignment of detection field. Release the red button to turn off the laser. 5.4 Self Test To test whether the HMD is in working condition, follow steps below: P a g e 8

10 Connect power to the HMD to make sure green LED is on. Use multi-meter to measure the voltage between PNP/NPN output pin(blue) and 0VDC pin (Yellow): 1. For PNP output: 0VDC; 2. For NPN output: 24VDC Measure the connection of Relay: NO (Normally Open) pin (Gray) Common (White) disconnected NC (Normally Closed) pin (Pink) Common (White) connected Connect Self test Pin (Purple) to 0VDC Pin (Yellow), Red LED will be ON. Use multi-meter to measure the voltage between PNP/NPN output Pin(Blue) and 0VDC pin(yellow): 1. For PNP output: 24VDC 2. For NPN output: 0VDC P a g e 9

11 Measure the connection of Relay: NO (Normally Open) pin (Gray) (White) connected NC (Normally Closed) pin (Pink) Common (White) disconnected 5.5 Troubleshooting Missed Target- If the LED does not turn red when hot metal is in its detection field: 1. The threshold potentiometer is set too low. Go to Threshold Sensitivity Adjustment, Section 5.2, and recalibrate the sensitivity adjustment. 2. Check HMD s location, make sure the detection field covers hot metal. False Positive Target Detected- 1. The threshold potentiometer is set too high. Go to Threshold Sensitivity Adjustment, Section 5.2 and recalibrate the sensitivity adjustment. 2. If step 1 does not correct false positives, check for background sources of radiation such as reflected sunlight or hot processes behind the target line. Correct these conditions as necessary by adjusting the HMD s aim or by blocking the interfering radiation source. Additional notes 1. No Power- Check that the wiring connections are correct, that the connections are secure and tight and that the power supply is proper and normal. 2. If the housing temperature reaches over 70 o C (158 o F), then water cooling must be used (see section 4.2). If water cooling is already in use, then check the water s inlet temperature and for flow restrictions to the unit. 6. Maintenance 6.1 Regular Maintenance Diagnostics- the HMD-ST does not require maintenance at a fixed period other than periodic attention to the following to ensure consistent operation: Lens Cleaning- Routinely check the HMD-ST s glass for dust or oil residue. Clean as required with clean lint free soft cloth or lens cleaner. Adjustments- The threshold level sensitivity (see Section 5.2) P a g e 10

12 6.2 Returns of the HMD-ST Contact LOGIKA at ( LOGIKA ) with the Serial Number of your HMD before you return our product. If we are unable to solve the problem by phone or , LOGIKA will then provide you with a return authorization number. Do not return the HMD-ST without an authorization number. If the product is out of warranty, we will provide a repair estimate and then complete the repairs after your approval. P a g e 11

13 7. Enclosure Dimensions P a g e 12