Model HMD-ST Static Mode Hot Metal Detector Operator s Manual Rev 1.3
Contents 1. Introduction... 2 2. Description... 2 2.1 Model Nomenclature...2 2.2 Specifications...2 2.3 Operating Principle...3 2.4 Sensitivity Adjustment...4 2.5 Additional Features...4 3. Location and Mounting... 4 3.1 Detector Installation Location...4 3.2 HMD Mounting...5 4. Utility Connections... 6 4.1 Electrical Connections...6 4.2 Cooling Water Connection...7 4.3 Air Purge Connection...8 5. Operation... 8 5.1 Controls...8 5.2 Automatic Threshold Level Description...9 5.3 Visible aiming laser...9 5.4 Self Test...10 5.5 Troubleshooting...10 6. Maintenance... 11 6.1 Regular Maintenance...11 6.2 Returns of the HMD-ST...11 7. Enclosure Dimensions... 12 P a g e 1
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 HMD-ST Base Model - 024 Power Input Power Input* 024= 24 VDC 110 = 110 VAC 220 = 220 VAC * does not affect base price 2.2 Specifications Example Part Number - HMD-ST-024 specifies a static mode hot metal detector with a power input of 24 VDC. All HMD's have relay, PNP and NPN outputs. 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 NO/NC @ 1A, PNP(S) or NPN (/S) type output @100mA Power Input 24 VDC, 110VAC, 220VAC @ 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: 217 mm L x 73 mm W x 167 mm H (with mounting bracket) (8.5 L x 3 W x 6.6 H) 1.8kg (4.0 lbs) Aiming laser Controlled by button on the back of housing Self testing TEST button and TEST PIN P a g e 2
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. Field of View: Vertical 15, Horizontal 4 Figure 2.2 demonstrates the vertical sensing field size versus hot metal target distance from the HMD (Hot Metal Detector) in normal application. HMD-ST 132 264 396 528 1000 2000 3000 4000-132 -264-396 -528 mm Figure 2.2: HMD-ST Vertical 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 264mm. The HMD will output a control signal to the PLC regardless if hot metal completely fills the scanning area or just a portion. P a g e 3
2.4 Sensitivity Adjustment This feature makes the HMD more stable and reduces detection errors caused by background infrared radiation sources, varying surface temperature or interference from water vapor and scale. 2.5 Additional Features Sensor amplifier circuit is designed by Modulated Signal Amplification Mode to automatically reduce the HMD-ST temperature drift. 3. Location and Mounting 3.1 Detector Installation Location HMD-ST should not be installed above heat sources, also avoid directly exposure to water vapor, excessive dust or smoke. If harsh ambient environment is unavoidable, connect clean, dry air to the air purge fitting on the enclosure. Heat shielding or fan can also be applied to dissipate water vapor or smoke. If conditions allow, mount the detector as close to the target as possible. This will supply enough infrared energy to provide strong signal. At the same time, detector must be kept far enough to protect it from being over heated. 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 Product P a g e 4 HMD-ST Mounting Distance min (m) max (m) min (inch) max (inch) Wire Rod 0.2 3 7.87 118.11 Bar 0.2 4 7.87 157.48 Billet 0.5 6 19.68 236.22 Blooms >2 >78.74 Strip Steel 0.6 2 23.62 78.74 Thin Plate 1 6 39.37 236.22
Thick Plate 1 8 39.37 314.96 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. 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 trigger the output. 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 M10 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 refer Section 4.2 Plumbing Connection and Section 4.3 Air-Purge Connection for installation details. High temperature Option- If the ambient temperature is more than 250 o C (480 o F), HMD FOC (Fiber Optic Cable) can be selected for the extreme high temperature. P a g e 5
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 11 x 0.34 mm² Outer metallic braid for mechanical protection. Overall diameter of 9 mm. Minimum bending radius of 30 mm. Note: Static 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 Ground 6 Blue J PNP (S) 7 Purple L Self test 8 Gray D Relay NO 9 White E Relay COM P a g e 6
10 Pink F Relay NC 11 Black C NPN ( ) Figure 4.1 Cable Terminal Wiring Description 4.2 Cooling Water Connection Description- Water cooling is required when the ambient temperature at the HMD s location is higher than 70 o C (158 o F) to protect the electronics inside. 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 Φ10 ID (or 3/8 ID) hose 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 Temperature vs. Water Flow Rate Graph, to determine the cooling water flow rate for the ambient conditions surrounding the HMD. P a g e 7
Figure 4.2: Ambient Temperature vs. Water Flow Rate 4.3 Air Purge Connection Description- Compressed plant air can be used to protect the lens from dust and vapor. Purge air cleans the lens, reduces maintenance times, and prolongs HMD-ST s life in where dusty or corrosive vapor is present. Compressed Air Requirements Must be clean, dry instrument air no oil, dust and contaminants included. Poor air quality will result in dirty lens and decrease detector performance. If the quality of compressed air can t be guaranteed, it should not be connected to avoid lens contamination and affect the detector performance. Air filtration prior to the inlet fitting is recommended to improve the quality of purge air Air Pressure range from 50 to 200 g/cm 2 (0.7 psi to 2.8 psi) Air Flow rate from 4 to 16 L/min (0.14 to 0.56 ft 3 /min) Connection- Connect the plant air source to the purge air barbed fitting on the detector s lens shroud with Φ10mm ID (or 3/8 ID) hose. Purge air flows out of the sensor shroud and dissipates into the ambient environment. 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. POWER = Green LED: HMD is powered. DETECT= Red LED: Hot metal target detected Detector Test and aiming laser button Potentiometer = Sensitivity range adjustment P a g e 8
TEST DETECT POWER 1 7 SENSITIVITY 5.2 Automatic Threshold Level Description Figure 5.1 Control Panel 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 aiming laser Aiming laser only shows when the TEST button is pressed or TEST PIN (Purple) is connected to the GROUND (Yellow). Once TEST Button is released or the TEST PIN is disconnected from Ground, aiming laser will turn off. P a g e 9
5.4 Self Test To test whether the HMD is in working condition, follow steps below: Connect power to the HMD to make sure green LED is on. Use multi-meter to measure the voltages on PNP output pin(blue) and NPN output pin(black), referring to 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 Press TEST Button or connect Self test Pin (Purple) to 0VDC Pin (Yellow), Red LED will be ON. Use multi-meter to measure the voltages on PNP output Pin(Blue) and NPN output pin(black), referring to 0VDC pin(yellow): 1. For PNP output: 24VDC 2. For NPN output: 0VDC 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 and 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. P a g e 10
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 for water flow blockage 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) 6.2 Returns of the HMD-ST Contact LOGIKA at 1-888-856-4452 (1-888-8LOGIKA) with the Serial Number of your HMD before you return our product. If we are unable to solve the problem by phone or email, 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
7. Enclosure Dimensions HMD-ST Side View P a g e 12
HMD-ST Front View P a g e 13