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CUSTOM END-OF-LINE INSPECTION SYSTEMS

S E N T R Y

M E T A L D E T E C T I O N S Y S T E M

USER MANUAL

SENTRY USER MANUAL V13


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CONTENTS PAGEOVERVIEW................................................................................... 6

1. CONTROL PANEL .................................................................. 7

2. INITIAL STARTUP................................................................... 92.1. DESCRIPTION OF TERMS (RUN MODE) ........................................10

2.1.1. PHASE AND DATA SCREENS ................................................112.2. PRODUCT MENUS ...........................................................................14

2.2.1. Recalling a Menu ......................................................................162.2.2. Deleting a Menu........................................................................162.2.3. Copying a Menu........................................................................162.2.4. Creating a New Menu ...............................................................16

2.3. MENU SETTINGS .............................................................................172.3.1. Product Settings........................................................................182.3.2. Advanced Settings ...................................................................212.3.3. Reject Settings..........................................................................252.3.4. System Settings ........................................................................262.3.5. Security (Passwords) ...............................................................272.3.6. Test Settings .............................................................................282.3.7. Time & Date ..............................................................................292.3.8. Language ..................................................................................292.3.9. Machine Id ................................................................................292.3.10. Service Settings ........................................................................302.3.11. Statistics....................................................................................302.3.12. Diagnostics ...............................................................................31

3. SETTING UP THE METAL DETECTOR................................ 353.1. LEARNING THE PRODUCT..............................................................353.2. SETTING THE GAIN..........................................................................363.3. SETTING THE THRESHOLD) ...........................................................373.4. SETTING THE REJECT TIMING......................................................373.5. REJECT TACHO ...............................................................................383.6. PERIPHERAL DEVICES....................................................................39

3.6.1. SERIAL PRINTER.....................................................................393.6.2. SERIAL BARCODE SCANNER ................................................403.6.3. MIACS (Management Information & Control System)...............41

4. BACKING UP MENUS........................................................... 42

4.1. SERVICE PROMPT .......................................................... 43

5. TROUBLESHOOTING........................................................... 44

6. C E COMPLIANCE ................................................................ 47



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SPECIFICATION......................................................................... 49

APPENDIX 1 – MOTHERBOARD CONNECTIONS .................. 50

APPENDIX 2 - ELECTRICAL PINOUTS (MAIN BOARD): ......... 50

APPENDIX 2 - ELECTRICAL PINOUTS ( MAIN BOARD): ........ 51

APPENDIX 3 – PARAMETER GLOSSARY................................ 53

APPENDIX 4 – MENU LAYOUT................................................. 57



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SENTRY

METAL DETECTO R

USER M ANU AL

REVI SION 1.3 JUNE 2002

COPYRIGHT © 2002 THE CI NTEX G ROUP

ALL RIG HTS RESERVED

N O P A R T O F T H I S P U B L I C A T I O N M A Y B E R E P R O D U C E D , S T O R E D O N A

R E T R I E V A L S Y S T E M , O R T R A N S M I T T E D I N A N Y F O R M W I T H O U T T H E P R I O R

P E R M I S S I O N O F T H E C I N T E X G R O U P



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ELECTRICAL S AFETY NOTICE

Only qualified personnel should remove the front panel .Opening of thispanel will expose high voltage terminals.

COMPLI ANCE NOTICE

The equipment has been designed to be part of an “INSTALLATION” asdefined by the current European Directives. The operation of any rejectmechanism controlled by this equipment may be hazardous; it may operatewithout warning. Its design & implementation must be carried out bycompetent personnel in accordance with local health & safety regulations andappropriate “installation” documentation maintained. It contains hazardousvoltages which must be treated in accordance with this handbook.

Note: “CINTEX Limited” is referred to several times in this handbook.

This should be taken to include this company’s associate companies &agents.

Cintex of America Inc.6919 – 51st Street

Kenosha,Wisconsin 53144

USA

Tel: 262 657 7848Fax: 262 657 3056

CINTEX LimitedFeatherstone Road

Wolverton MillMilton Keynes MK12 5TH

England

Tel No: +44 (0) 1908 629200Fax No: +44 (0) 1908 579824



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OVERVIEW

CINTEX Sentry metal detectors are designed to detect metal contaminants ina wide range of products. A high frequency magnetic field is set up inside thedetector. Ferrous or non-ferrous particles cause minute disturbances of thefield. These disturbances are picked up by search coils, amplified and used totrip alarm circuits or trigger the automatic rejection of the contaminatedproduct. The coils are cast into an epoxy resin block to ensure the utmoststability and freedom from the effects of water or vibration.

In most instances, the product being checked also causes disturbances in themagnetic field. Unfortunately these disturbances are usually very much largerthan those from small metal particles. However, field disturbances have twofundamental parameters - “magnitude” and “phase”. A microprocessorcontinuously examines these two parameters and learns the signals from“clean” products. It keeps a running average and uses the information todisregard signals arising from them whilst still being sensitive to signals frommetal particles as these are of different phases. The microprocessor usessophisticated filtering techniques to further enhance the metal detectioncapability.

The sensitivity that can be achieved depends on the size of signal from theproduct and any variability in its phase. Clearly, for a consistent product, atiny disturbance will stand out as being due to a metal contaminant, leading tohigh sensitivity. If the phase varies from one product item to the next, a muchlarger contribution from a metal contaminant is needed before the combinedsignal will stand out as being significantly different from the norm to berejected as contaminated. The sensitivity will therefore be reduced. A piewould be a good example of a variable product. Each ingredient - the crust,the jelly and the filling will contribute a different phase. The metal detectorcan only sense the combined phase. If the proportions of such ingredientsvary, the overall signal will vary, leading to lower sensitivity. It is thereforedifficult to predict usable sensitivity - even if several samples are tried out.Only when the detector is sampling products under actual productionconditions can sensitivity be determined reliably.

When a contaminant is detected, the microprocessor tracks the contaminateditem as it moves out of the detector head towards the rejection device andoperates the reject device at the right time. The microprocessor also carriesout “housekeeping” tasks such as monitoring all key areas of the detector andreject device, and warning of a malfunction, running the alpha-numeric displayand, if required, reporting detection activity to a central computer.



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1. CONTROL PANEL

The diagram below shows the control panel for the ‘Sentry’ metal detector.The design has eliminated the need for additional external switches andindicators, such as an ‘Override’ switch or a ‘Metal’ lamp indicator, as allsettings and features are now accessible from the menu driven graphical userinterface (GUI).

The display is touch sensitive, so to select any of the displayed options at anytime, simply press the screen in the correct area. The touch positions arearranged as four along the bottom and two up the right side of the screen.See below :

Fig 1.1 - Touchscreen Layout

Touch sensitivepositions

StatusBar

Touchsensitivepositions



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At the top of the screen is the Status Bar. This is visible at all times on allscreens. There are four items of interest displayed, the SIGNAL, PRODUCT,Screen Name and the current time. See below for descriptions:

SIGNAL (percentage)This is the current output signal of the metal detector, displayed as apercentage of the ‘Threshold’. For example, if the current signal output is 5points, (as viewed on the engineer’s ‘Data’ screen), with a ‘Threshold’ of 10points, then this will give a signal percentage of (5/10) *100 = 50%.Under normal running conditions, a clean product should give a signalpercentage of around 60% of the threshold.During a ‘learn’ procedure, the signal is shown as ‘----‘.

PRODUCTDisplays the Product name for the current menu. There are 50 menusavailable to use. The ‘Product name’ is limited to 25 characters in length. Thename can include numbers, letters (upper case only), and spaces.

SCREEN NAMEThe current screen name is displayed in the top right corner of the screen. Itenables the user to quickly assess which screen is currently active.

TIMEThe current time is also shown. This area is also used to display the currentaccess level (if password access is used). Please see the Security section formore details on password access. Also ,if a service is soon required, it will beflagged up in this area of the screen



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2. INITIAL STARTUP

Once power is applied to the system , the control screen will give a display asshown below. Note that the software version is displayed in the top rightcorner of the screen. See below :

Fig 2.1 - Initialising screen

The ‘ Initialising ‘ meter will advance during the first few seconds, whilst thesystem is performing a self check on the stability (head balance) of thedetector. The head balance is acceptable once the percentage display in thebottom right corner has reduced below 100%.

This initialising period may last up to 30 seconds, after which point the screenwill change to the normal ‘Run Mode’ screen. If there is a problem detectedthe fault message will be displayed in the status bar at the top of the screen. Ifthe screen shows a fault ,ensure all metal items are removed from or aroundthe detector head, which should not be there, and reset the detector at themain power isolator.

Check that there are no faults are indicated in the top status bar. In ‘RunMode’, the screen will look as shown below. To quickly test the detection, seta ‘Threshold’ of 50 and pass through a large metal object. The bar graph willactivate to the right side of the screen and the message ‘ METAL ‘ will displayon the top of the screen.



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Figure 2.2 - Run Mode screen

2.1. DESCRIPTION OF TERMS (RUN MODE)

On the ‘Run Mode’ screen the terms are explained as follows:

SIGNAL GRAPH – The signal graph is a graduated scale that shows thecurrent metal signal. If the signal goes over half way up the scale, metal isdetected. This point is the Detection Threshold.

PHASE REFERENCE ARROW – This is shown on the ‘Run Mode’ screenabove. This arrow indicates the actual value of the ‘Reference phase angle’on the phase angle line, between –90° and +90°. This is normallyautomatically set by the system after a ‘learn’ has been carried out. If thesystem is set to DUAL Product Tracking, then there will be s second arrow ontop of the phase bar to show the second reference angle.

Product phase barwith respect to thereference phase.

Signalgraph

Phasereference arrow

DetectionThreshold

Rejecttotal

Packtotal



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PRODUCT PHASE BARThis bar indicates the Product phase angle of the product which was lastpassed through the system. Once again, this value will be between –90° and+90°. The bar starts from the reference arrow. This means that the furtheraway from the reference angle the current item passing through the head is,the longer the bar. If the current product passes through, then there should bealmost no bar visible.

REJECTSThis value shows the number of rejects for the current product menu since themenu was selected.

PRODUCTSThis value shows the number of products for the current product menu sincethe menu was selected.

The ‘Run mode’ screen has two further alternative displays. Firstly, there isthe screen shown above with the bar graph display (default screen) and thenthere is a ‘Data’ screen and a ‘Phase’ screen.

2.1.1. PHASE AND DATA SCREENS These ‘Data’ and ‘Phase’ screens are accessed by pressing either the ‘UP’ or‘DOWN’ arrows, whilst in the ‘Run Mode’ screen, but they are intended for useby engineers, therefore it is recommended that operators leave the systemshowing the normal ‘Run Mode’ screen. So that these screens may berecognised they are shown below:

Figure 2.3 - Phase screen

Signal pointer Phase semicircle(denotes threshold).



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The ‘Phase’ screen shows information related to the phase and signalmagnitude of the product passing. It is useful for experienced engineers toassess the properties of the product.The ‘tick’ shown around the outer ring is the current reference angle. Note thatif the system is being used in dual mode, there will be two ticks shown, one foreach reference phase.This screen also shows the typical phase angles produced by certain types ofmetal. Generally WET products appear at or around 0°, DRY products arearound ±90°.Once a product is passed through the system, the phase and magnitude ofthe signal is displayed on the phase semicircle. The outer ring of the phasesemicircle represents the current ‘Threshold’ point, so if the signal pointercrosses the outer ring, then this signifies a reject. This screen is forinformation only. No editing of parameters can be carried out on this screen.

Figure 2.4 - Data screen

The engineer’s ‘Data’ screen exists in order to give more detailed informationon the performance of the metal detector. It is not intended for normaloperator use, however the engineers will find the following descriptions useful:

RAWThese are the raw ‘P’ and ‘Q’ (phase and quadrature) signals from the metaldetector head, before filtering is applied. These are normally much greater invalue than the signal value and they give an indication that the basicelectronics are set up correctly.

ZERO



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The values shown represent the DC offset levels of these two ‘P’ and ‘Q’signals. When followed by a small ‘z’, this means the ‘P’ and ‘Q’ values arebeing constantly zero corrected. Once a pack passes through, the ‘z’ willdisappear, indicating that the zero correction is turned off as inspection istaking place.

FILTERThese are the ‘P’ and ‘Q’ values after the noise filtering has been applied.These should be close to, if not at, zero.

EFFECTThis is the magnitude of the product signal (combined from ‘P’ and ‘Q’) usedto generate the final product signal. There is a small indicating arrow besidethis value that shows that the value is increasing or decreasing. Once thevalue has peaked, the arrow disappears.

PHASEThis is the ‘Product phase angle’ displayed in degrees. This will varydepending on the type of product. The value is updated after the passing ofeach product.

REFThis is the reference phase of the system. This will be set meaningfully once a‘Learn’ procedure has been carried out on the product. REF2 will also bedisplayed for a DUAL tracking set up.

SIGNALThis is the output signal, derived from the phase and effect, from the metaldetector after noise filtering is applied, i.e. the final output used for detectionpurposes.

REJECTThis stores the signal value of the last reject passed through the detector.

THRESHOLD This is the sensitivity adjustment for detection. This will set thevalue above which the SIGNAL will cause a reject. Normally set to a value40% higher than the highest signal obtained from just the product.

SPEEDIf a tacho device is fitted to the system, the current measured belt speed isdisplayed in the bottom right of the screen. This value is only displayed if‘Tacho’ is enabled in service settings.

BAL This means balance. It is an indication of how well balanced the head is.Should not exceed 100%, and should preferably be less than 30%.



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STATUSThis reports the current status of the detector. There are many different statesthat may be reported here. These are listed below with explanations:

DETECTINGThe detector is ready and awaiting product.

PRODUCT FOUNDThe detector has recognised the presence of product passing (i.e. thepack threshold value has been exceeded).

METALThe signal has exceeded the threshold.

OVERRIDEThe detector is in the overridden state and is running only as aconveyor (or pipeline), but detection is totally suspended. Beware thatno detection or rejection will occur in this state.

STOPPEDIf the detector is being used in ‘Alarm & Stop’ mode, then this will bedisplayed upon a reject stopping the system. The reset key will need tobe activated to reset this condition.

FAULTAny valid fault condition arising on the detector will cause this to bedisplayed.

GAIN CHANGINGIf the detector is being remotely controlled via MIACS, then this will bedisplayed if the ‘Gain’ is being adjusted remotely.

TESTINGIf the detector is being remotely controlled via MIACS, then this will bedisplayed if a ‘Metal test’ is being invoked remotely.

2.2. PRODUCT MENUS

The Sentry is capable of storing up to 50 different product menus. Each menucan be programmed for an individual product type, and may then be recalledat any time. In order to be valid, a menu must be given a product name; thesystem will then sort them in alphabetical order (numbers are givenprecedence). When changing or creating menus, from the main run screen,simply press the Menus button. The ‘Menu’ screen will then be shown asseen below:



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Figure 2.5 – Menus Screen (Copy, Delete, Recall)

From the ‘Menus’ screen there are several options. These are:

• Copy a menu. (Copies from an existing menu to an empty position).• Delete a menu.• Recall a menu.• Create a New menu.

Note that the option to create a new menu only appears on the screen whenscrolling to an empty position. See below:

Figure 2.6 – Menus Screen (New menu)



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2.2.1. Recalling a MenuFrom the main ‘Run Mode’ screen, in order to recall a specific product menu,do as follows:

(Menus →→→→ (Use Up / Down To Select Menu) →→→→ Recall →→→→ Yes)

The system will now be set to the desired menu. Note that a menu may onlybe recalled if it has a name.

2.2.2. Deleting a MenuFrom the main ’Run Mode’ screen, in order to delete a specific menu, do asfollows:

(Menus →→→→ (Use Up / Down To Select Menu) →→→→ Delete →→→→ Yes)

The current highlighted menu will now be deleted. The menu positions willautomatically arrange themselves back in alphabetical order.

2.2.3. Copying a MenuFrom the main ’Run Mode’ screen, in order to copy a specific menu, do asfollows:

(Menus →→→→ (Use Up / Down To Select Menu) →→→→ Copy →→→→ Yes)

The current highlighted menu will now be copied to an empty position,however the menu will still require a name. The menu positions willautomatically arrange themselves back in alphabetical order.

2.2.4. Creating a New MenuFrom the main ’Run Mode’ screen, in order to copy a specific menu, do asfollows:

(Menus →→→→ (Use Up / Down To Select empty position) →→→→ New →→→→ Yes)

A new menu will now be created with the same settings as the current runningmenu (the ‘Advanced settings’ are loaded from the ‘Service Settings’). Themenu positions will automatically arrange themselves back in alphabeticalorder.



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2.3. MENU SETTINGSEach menu contains a record of settings arranged within sub categories. Forexample, settings relevant to rejection are within ‘Reject Settings’ and so on.These settings are easily navigated from the main ‘Run Mode’ screen by useof the ‘Goto’ button. Pressing the Goto button will pop up a menu window.Use the up / down arrows to scroll through the options and press the ‘OK’button to enter. See below:

Figure 2.5 – Goto Menu

The ‘Goto’ Menu displays a list of options that are relevant to the currentscreen. For example, when in the Product Settings screen, Product Settingswill not appear in the ‘Goto’ Menu options.Each of these options will contain either settings, or further option windows. Afull chart showing the menu layout is given in Appendix 3 of this manual.Please see below for a description of each of these settings:

Use UP / DOWNarrows to scrollthrough choices.

Pop upselectionwindow.

Press OK onceselection ismade.



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2.3.1. Product Settings

Threshold (Goto Product settings → Threshold)(Value range 0.5 to 10000)This will set the value above which the SIGNAL will cause a reject. Normallyset to a value 40% higher than the highest signal obtained from just theproduct. The LEARN button will allow the detector to automatically set thethreshold according to the products currently passing through.

Phase (Goto Product settings → Phase)(Value range –90°to +90°).The reference phase angle may be manually set here. Press LEARN to allowthe detector to automatically set the reference angle from the productscurrently passing.

Gain (Goto Product settings → Gain)(Value range 1 to 4).Normally set to 1, this may have to be raised if the product generates a veryweak signal. Note that 4 is maximum gain and 1 is least gain. A gain of 1minimises system noise and allows for a more accurate assessment of theproduct phase, therefore should be used in preference over the other gains.

Tracking (Goto Product settings → Name)(Value range: OFF,ON, DUAL, AUTO, DIFFICULT, DUAL FIXED).

As each product will have a particular phase response, the system has toknow what the ideal phase for a given product should be. This is set by theREFERENCE PHASE angle. The system can be configured to track theproduct phase angles to allow for slight changes within the product, and varythe Reference Phase accordingly. This is set by the TRACKING parameter.The Tracking Mode can be set to the following modes:

Normally the ON mode is used.If difficult products are being used (i.e variable phase angles) then anothermethod may need to be selected:

• OFF – If the Tracking Mode is set to OFF, then no tracking will beperformed, and the Reference Phase will stay as that same value. Thiscan be used when the products passing do not change withtemperature or have variable moisture content. (This is equivalent tothe FIXED mode on the Autosearch2.)

• ON – When the Tracking Mode is set to ON, the software will take arunning average of the Phase Angles from the last few GOODproducts. The actual number of products used is set by the TRACKINGRATE parameter and can be anywhere from 1 to 1000 products,default is 256. If the products passing change phase too quickly, ie, the



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reference phase angle does not keep up with the changes in GOODproducts passing, then the Tracking Rate should be reduced. However,the rate should be set so that changes due to small contaminants arenot “Tracked” and still produce reject signals. A Phase Angle is trackedif there was no metal found within the product and that the angle iswithin ±4º of the Reference Phase.( This mode is equivalent to theSTANDARD mode on the Autosearch2.)

• DUAL – The Dual mode allows the system to operate with twoindependent Reference Phase angles. This is used when there are twotypes of products to be inspected at the same time, eg, White andBrown bread. In this mode there are two Reference Angles, REF1 andREF2. Each angle is independently tracked. The software willautomatically select the best angle to use during Metal Detection. (Thismode is equivalent to the DUAL PHASE mode on the Autosearch2.)

• AUTO – This mode will not only track the Reference Phase but will alsoautomatically track the Threshold. The idea of this mode is that thesystem will automatically configure itself for a new product. This isachieved by tracking the Reference Phase as per the normal trackingmode and the Threshold. The Threshold will automatically be adjustedto compensate for the product signal. If the product changes, thesystem will start to get a string rejects, one for each product thatpasses. When a set number of products passes, the system will set thethreshold according to the signal found during the string of rejects. Afterenough consistent rejects have been found, the system will “jump” tothe new settings, and the rejects will now become the current product.The idea is that after a product changeover, the first 10 or so productswill be rejected, whilst the software learns the phase and threshold forthe new product. The number of rejects to watch is set by the PHASEPEAKS and THRESHOLD PEAKS parameters. (This is equivalent tothe AUTOLEARN mode on the Autosearch2.)

DIFFICULT – Difficult mode allows a wider window for the PhaseTracking to operate in. Instead if being ±4º, then window is opened to±12º. This mode will be of use with a product that has a wide range ofphase signals. (This is equivalent to DIFFICULT on the Autosearch2).

• DUAL FIXED – This is the same as the DUAL mode, but neither of thephases are tracked. If the two phases are set close enough in theDUAL mode, it is possible for them to track to the same value.

For the large majority of applications, the ‘ON’ method will be used. Where anapplication becomes difficult to learn due to the phase of the product changing



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more than usual, then the ‘DIFFICULT’ method should be used. For productwhich changes erratically in phase and still gives a lot of false rejects in‘DIFFICULT’ mode, it is suggested that ‘OFF’ be used, so the reference phaseis set manually and the threshold raised to avoid false rejects. For productionlines where there are two discreet product phase angles then ‘DUAL’ shouldbe used, and if tracking is not required in dual mode then ‘DUAL FIXED’should be used.

Name (Goto Product Settings → Name)(May be any alphanumeric name up to 25 characters, including spaces).The names are alphabetically sorted in the menu to aid in the selectionprocess. Numbers have precedence over letters in this sorting process.Editing of names is performed using a vertical alphanumeric bar that isscrolled up and down to select the character. After a character is selected, itwill be automatically entered after one second of inactivity.The left and right arrows may be used to go back over and edit anycharacters. Once complete, use the ‘OK’ button to enter the name:

• Step 1 – Use the UP / DOWN buttons to scroll through characters.

• Step 2 – The character will be entered after 1 second of inactivity.

• Step 3 – The alphanumeric bar will move along one place to the right automatically after a character is entered.

• Step 4 - Continue in same way to complete the name, then press ‘OK’.

Figure 2.6 – Product Name screen



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Barcode (Goto Product Settings → Barcode)(May be any alphanumeric code up to 25 characters, including spaces). Thisis a string of characters used to represent the barcode of the current product.If a barcode scanner is attached to the system, when a barcode is scannedthe system will check all product barcodes for a match. If a match is found,that product will be recalled. If no match is found, the status bar will flash‘INVALID BARCODE’. To scan in a bar code for storage either type itmanually in the edit screen or scan a real product whilst in the edit screen.(Note that the bar code connects into the serial port of the Sentry).

2.3.2. Advanced Settings (Goto Product Settings → Advanced Settings)

Firstly, the ‘Advanced Settings’ menu will only be visible if the ‘AdvancedSettings’ option is enabled in the ‘Service settings’ menu. Once enabled(using the Cintex password), the menu will be visible within ‘Product Settings’.Note that this section serves to describe each of the settings, as editing is onlypermitted with Cintex assistance.

Detection Mode (Goto Product settings → Detection Mode )(Value range : Amplitude, Zero-cross, Template)The default mode is ‘Amplitude’. If in doubt, set the Detection mode to this.

Metal Detection is performed by simply comparing the Metal Signal againstthe THRESHOLD. If the Metal Signal crosses over the Threshold, metal isseen and the reject will operate. As soon as metal is found, the system willqueue a reject operation to occur after the REJECT DELAY time has elapsed.The reject will last for the length of time the metal is detected in the head plusthe length of the REJECT DURATION. Since the timing of the reject starts assoon as the metal is detected, it becomes obvious that the timing will beaffected by the size of the metal contaminant. A large piece of metal will bedetected earlier than a small piece, so the reject will operate sooner, albeit forlonger. For this reason the Sentry has various DETECTION MODES. Thedetection mode can be set to one of the following:

• AMPLITUDE This is the default mode, as described above. Assoon as the amplitude (size) of the Metal Signal gets bigger than theThreshold, the reject will start timing. In most cases, an externalphotocell will be required across the reject device to guarantee hittingthe product. The reject signal should be gated with the photocell, so thedevice will only operate when the reject signal is present AND thephotocell is obstructed. In these cases, the Reject Duration should beset so that when a large contaminant is detected, the reject will stay onlong enough for the product to reach the photocell. The Reject Delaymust be set short enough, so that with the long Reject Duration, as fewas possible packs are removed with a small metal piece. If the systemis a “PipeLine” or similar, no photocell is required, the reject will simplyeject product where the metal contaminant is likely to be. This is the



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default detection mode; it is the same as the mode used byAutosearch2 and provides high levels of detection reliability.Alternatively if the AMPLITUDE mode is combined with the PRODUCTPEC, then perfect reject timing will be guaranteed – this is therecommended configuration.

• ZERO CROSS A first step in trying to obtain more accuratereject timing, without a photocell, is Zero Cross. Instead of starting thereject timing that instant the Threshold is breached, this mode will waitfor two peaks to occur. As soon as the second peak is detected, thereject timing will be started. This means timing will now start from thesame point within the head. It is called Zero Cross because by the timethe second peak has occurred, the Metal Signal will have passedthrough zero from the first to the second peak. The two peaks mustoccur within the Reject Duration of each other. This means that if onepeak occurs, because of vibration or external movement of the head,the reject will not operate on the next peak if there is a long timebetween them. Whilst Zero Cross does provide better accuracy thanAMPLITUDE it is still not perfect, because all the timing is still basedaround the Metal Signal. If the metal is at one extreme of a product,there will be a discrepancy between the reject timing and the actualproduct – the metal piece will be hit perfectly though!

• TEMPLATE With some larger products, say a 20kg block ofcheese, there is still a large amount of Metal Signal, even after PhaseNulling – this is called Residual Effect. TEMPLATE was designed to tryand remove the Residual Effect. During the learn process, the systemwill capture the Metal Signal response from the good product. Thiscaptured template is stored in memory. In normal running mode, whena pack is detected, the software will subtract the learnt template fromthe incoming Metal Signal. This can reduce the residual product effectto almost nothing, but relies upon each product being consistent toeach other. This mode will not give any advantages on a widelyvarying product, such as fresh meat, in fact, if the product varies, thenthis mode will make the differences even bigger and cause a largenumber of false rejects. Another important point is that there is onlyenough memory space for one template – this means that a newtemplate has to be learnt for each product as they are used. If thetemplate is not learnt, or the power is cycled, the software will resort toAMPLITUDE mode until a template is learnt.

Learn Pack (Goto Product settings → Advanced Settings → Learn Pack)(Value range:Enabled, Disabled)When enabled, this will include the learning of the ‘Pack Threshold’ in thenormal learn sequence in addition to the phase learn. Note that when a learn



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of the ‘Pack threshold’ takes place, the initial value used is the ‘Packthreshold’ value which appears in the ‘Service settings’ menu.

Learn Threshold (Goto Product settings → Advanced Settings → LearnThreshold)(Value range:Enabled, Disabled)When enabled, this will include the learning of the ‘Metal Threshold’ in thenormal learn sequence in addition to the phase learn.

Large Metal (Goto Product settings → Advanced Settings → Large Metal)(Value range:1000 to 60000)If the metal signal exceeds this value at any time, a fault condition will beinitiated, with a ‘Large Metal Fault’ message on the screen. One possiblescenario is a metal tool accidentally passing through the detector.

Pack Threshold (Goto Product settings → Advanced Settings → PackThreshold)(Value range:0.5 to 10000)Not to be confused with metal threshold, the pack threshold is used by thedetector to determine the presence of a pack passing through the head. Thisinformation is used to generate statistics (e.g. pack counts) and is also usedfor reject tracking . Upon commissioning of the system, there is a facility in theservice settings for the pack threshold to be learnt. This should be done withno product passing, but with the conveyor belt running. This allows the systemto sense the background noise and then set the pack threshold comfortablyabove it. It should be performed upon installation for each gain level. It shouldthen need no further adjustment.

Effect Counter (Goto Product settings → Advanced Settings → EffectCounter)(Value range: Enabled, Disabled)When enabled, the system will log the number of products passing throughthe detector, with the help of the ‘Pack threshold’ setting. Please note that notall product will be appropriate for pack counting. Those packs with very littleeffect (dry products) or a production line with very close pitched product, willcause difficulty for the effect counter. In this case a photo cell can bepositioned on the infeed of the head to act as a pack counter. In this case, the‘Product PEC’ setting in the service menu must be enabled, which will causethe system to count packs from the PEC and will hide the effect countersetting.

Phase Peaks (Goto Product settings → Advanced Settings → Phase Peaks)(Value range:3 to 20)This dictates the number of passes required to learn the phase of a product.There are typically 2 peaks on each pass.



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Threshold Peaks (Goto Product settings → Advanced Settings → ThresholdPeaks) (Value range:3 to 20)This dictates the number of passes required to learn the Threshold of aproduct. There are typically 2 peaks on each pass.

Tracking Rate (Goto Product settings → Advanced Settings →Tracking rate(Value range:1 to 1000)This is the number of packs used in the rolling average for tracking the phaseof the product. The higher this value, the softer the tracking .

Threshold Factor (Goto Product settings → Advanced Settings → ThresholdFactor) (Value range:0.1 to 1.0)This value is used to calculate the metal threshold, based on the highestsignal from a learnt product. So, whilst learning a product, if the highestthreshold of the product was 10 and the threshold factor was 0.6, then theprogrammed metal threshold would automatically be set to (10 / 0.6 = 17).The higher the factor (nearer to 1.0), the more sensitive the threshold will beset to the product. Default is 0.6.

TEMPLATE (Goto Product settings → Advanced Settings → TEMPLATE)This item is only visible when TEMPLATE detection is enabled.The value of this will be either ENABLED or DISABLED. If DISABLED, thismeans that a current template has not been learnt – pressing EDIT will bringup the learn template mode.If ENABLED, pressing EDIT will display the current template. This is theresidual signal that is removed from each product.When products which have a large product effect are learnt, even after thephase is set, they can still exhibit a fairly significant residual signal. TheTemplate method will learn and memorize this residual product signal andthen subtract it from subsequent products passing through. This will serve toreduce the threshold hence allowing for better detection levels. This methodwill only work with stable consistent products, for example uniform blocks ofcheese presented in a uniform presentation.It is important to remember that a template is not retained after a power down,so it will need to be relearnt if the power is cycled.



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2.3.3. Reject Settings

Figure 2.7 – Reject Settings Screen

Once again, accessed through the ‘Goto’ button, the reject settings menucontains parameters which are related to the rejection of the system. Seebelow for parameter descriptions and the view of the Reject Settings screen:

Override (Goto → Reject settings → Override)(Value range: Enable, Disable)If this is set to ‘Enable’ , then the detector is in an overridden state. Thismeans all detection and rejection is non-functional, however the conveyor willcontinue to run. This is useful in situations where there is no time to cure afault, but there is still a need to run a production line. The status bar will flashOVERRIDE to warn that the detector is overridden and the warning outputfrom the system is asserted.However, to aid the setup process a ‘METAL’ indication will still be given onthe status bar to indicate a reject.

Reject Delay/Distance (Goto → Reject settings → Reject delay/distance)(Value range 1 to 20000 mS)This value sets the time delay before actuating the reject mechanism. If atacho is being used then you will have to enter the actual distance from thecentre of the metal detector to the centre of the reject. Make fine adjustmentsto this value so that metal contaminated product is rejected every time. Testwith the metal in both leading and trailing positions on the product. If a tachodevice is fitted, this becomes Reject Distance. The reject will be fired after theproduct has travelled this amount of distance at the current measured beltspeed.



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Reject Duration (Goto → Reject settings → Reject duration)(Value range 0 to 20000 mS, note that ‘0’ enables Alarm & Stop mode)This value sets the duration of the reject actuation. Normally set to valuesmall enough to ensure rejection of just the contaminated product. NOTE ifthis value is set too low, then there is a chance of multiple detections from asingle contaminant.Note that in RBS mode only, the METAL signal alsoactivates the FAULT outputs to give more than one circuit.

Confirm time (Goto → Reject settings → Confirm time)(Value range 0 to 20000 mS)This value sets a time limit for confirming the rejection. A proximity switch orphoto eye can be used to detect the contaminated product as it falls from theline. If the photoeye does not detect it within the confirm time then it isassumed that a known contaminated product was not rejected and the faultrelay contact will change state, allowing for an alarm etc. Setting this value to‘0’ will turn off reject confirmation.

Excess rejects (Goto → Reject settings → Excess Rejects) (Value range 0 to 20000 reject per minute)If this value is set above zero, when this number of rejects is exceeded in anysingle minute, the system will alarm with a fault.The display will show a ‘HIGHREJECT RATE’ fault message. Setting this value to ‘0’ turns this feature off.

Reset Counters (Goto → Reject settings → Reset counters)This gives the option to reset the reject count. It will only reset the reject countfor the active menu. The reject count is viewable from within the‘STATISTICS’ menu.

2.3.4. System Settings

Figure 2.8 – System Settings Screen



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2.3.5. Security (Passwords) (Goto → System settings → Security)This section contains the settings for password protection on the metaldetector. There are three levels of password protection. If there are nopasswords ‘Active’ then there is free access to all system settings (with theexception of the ‘Service Settings’ menu). The ‘Service settings’ menu isaccessible only to Cintex service engineers.The three customer passwordlevels are:

USER – When active, this password is required for access to allsettings within the menu.

SUPERVISOR – When active this password restricts access to supervisorstatus settings. (See Appendix 2 at the rear of this manual).

ENGINEER – When active this password restricts access to engineerstatus settings. (See Appendix 2 at the rear of this manual).

AUTO LOG OFF – This feature may be enabled or disabled. It is only ofuse when used in conjunction with one or more of theabove password levels. If any of the above passwords areactive, then by enabling ‘Auto log off’, when using the ‘Goto’button from the Run screen, the pop-up menu will be asimplified cut-down menu with no access to editableparameter settings. In other words it is useful to enable‘Auto log off’ in order to hide the majority of sub menus fromthe operator. Access of course, may still be gained, but onlyby using a valid password.

Note on lost passwords:In the event that passwords are forgotten, then an overriding password isaccessible from the Cintex service department. The way in which this is usedis a follows:If a password is forgotten, then each time a password is prompted for, therewill be a 6 digit code in brackets displayed on the screen . This code can bequoted to the Cintex service department , who will then issue the customerwith a day password. Note that this password will only work until midnight,after which it will be useless. This gives plenty of time for the customer toreprogram their own passwords.When any password has been entered successfully the currently set accesslevel will be active for 10 seconds after the last key press. If no key pressoccurs for 10 seconds, the system will revert back to the protected state.Whilst accessing a password level, the access level is displayed in the topright of the screen where the time is normally shown.



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2.3.6. Test Settings

The test settings are relevant to the periodic testing of the metal detectorusing test pieces. See below for the test screen and a description of eachparameter:

Figure 2.9 – Test Settings Screen

Test Interval (Goto →→→→ System settings →→→→ Test settings →→→→ Test Interval)(Value range 0 to 60 minutes)This is the time interval at which the metal detector will prompt the user for ametal test to be performed. The message ‘METAL TEST REQUIRED’ willappear on the top of the screen.

Test wait (Goto →→→→ System settings →→→→ Test settings →→→→ Test Wait)(Value range 0 to 60 minutes)This is the maximum time allowed between being informed of a required metaltest and actually pressing the test key to perform it. If this time is exceeded,then the system will alarm with a message ‘AUTO TEST EXPIRED’.

Test Restart (Goto →→→→ System settings →→→→ Test settings →→→→ Test Restart)(value range 1 to 60 minutes)If an auto test is not completed within the Test Wait time, a fault is generated.Once the fault has been reset, the test must be started with the Test Restarttime.

Test Duration (Goto →→→→ System settings →→→→ Test settings →→→→ Test Duration)(Value range 0 to 60 seconds)



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After the ‘Test’ key is pressed, this sets the time allowed within which to passthe test piece through the metal detector. This time will be shown as acountdown on the ‘Test’ screen.

Pieces to find (Goto →→→→ System settings →→→→ Test settings →→→→ Pieces to find)(Value range 1 to 60 pieces).This dictates the number of test pieces to be passed through the system upona metal test request.

Note that during the time a test is being requested, the ‘warning’ and the ‘autotest required’ will be asserted on the system. If a test is not completed or if itfails then the ‘fault’ and ‘auto test expired’ outputs will then be asserted.

2.3.7. Time & Date (Goto → System settings → Time & Date)

Figure 2.10 – Time & Date Screen

The current time and date may be edited within this menu by using the ‘Select’key to highlight the appropriate value, then using the ‘Up / Down keys to alterthe value. Once finished, press the ‘OK’ key.

2.3.8. Language (Goto → System settings → Language)(Value range English/ American/ Spanish/Dutch/German/Italian/French )Select the appropriate language by pressing the ‘Edit’ key. Each successivepress will select a new language from the range. The American option simplyswitches the date format.

2.3.9. Machine Id (Goto → System settings → Machine ID)(Value range 0 to 999)A unique machine ID used when performing printouts . When using severalmetal detectors, it is sensible to set a unique machine ID for each one.



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2.3.10. Service Settings (Goto → System settings → Service settings)This area of the system is Cintex password protected , and is intended onlyfor use by Cintex service personnel. A list of the functions in this area can beviewed in the Menu Layout chart in Appendix 3 of this manual. Additionally,there is a description of each parameter in the Parameter description table inAppendix 2 of this manual.

2.3.11. Statistics (Goto → Statistics)The statistics page looks as shown below:

Figure 2.11 – Statistics Screen

Note that if the ‘Effect counter’ is turned on, there will be additional informationshowing the product count , product rate and reject ratio on this screen.The values on this screen are described as follows:

RejectsThis is the number of rejects which have occurred since the current producthas been running.

Reject RateThis is the number of rejects per minute updated every minute.

Tests PassedThis is the number of metal tests which have been passed successfully sincethe current product has been running.

Tests Failed



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This is the number of metal tests which have failed since the current producthas been running.

By pressing the Reset button, the values will be reset to a value of zero.

2.3.12. Diagnostics (Goto → Diagnostics)The ‘Diagnostics screen gives looks as shown below:

Fig 2.12 Diagnostics Screen

This screen gives useful information as to the health status of the main board.The software version is shown here, in addition to the status of the on boardpower supplies, including the battery. The temperature is also shown here,and should not ordinarily exceed 65 degrees c (149 f).Other useful information given is:

Time AliveHow long the board has been running since it was first produced. Stored inpermanent memory.

Motor Run TimeHow long the motor has been running since the system was first produced.Stored in permanent memory.

Serial NumberA unique serial number of the motherboard. Stored in permanent memory.

Born onThe date the board was first tested. Stored in permanent memory.



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Power upsThe number of times the system has been powered up at the mains.

Power failsThe number of times the mains voltage has dipped to below acceptablelevels.

ResetsThe number of times a board reset has occurred without a power fail havingoccurred.

Over temp faultsThe number of times the maximum working temperature has been exceeded.

Supply faultsThe number of times an onboard dc voltage rail has failed.

Digital inputsThis shows the 8 input states. They will toggle in real time as each input isactivated. The inputs are displayed as a row of 8 bits. Each bit is describedbelow, starting from left to right:

INPUT BIT NUMBER DESCRIPTION OF INPUTBIT 7 Reset keyBIT 6 Metal TestBIT 5 Conveyor runBIT 4 Product PECBIT 3 Low air pressureBIT 2 Bin fullBIT 1 Reject confirmBIT 0 TachoThis is a useful way of testing that the inputs are working.RS232 InputsThere are three RS232 control lines displayed here. These are DCD (datacarrier detect), DSR (Data set ready) and CTS (clear to send). They are onlyactive when displayed on the screen. These are used for debugging only.

RS232 InputsThere are 3 parameters displayed here:E = Number of errorsT = Transmitted bytesR = Received bytesThese are used for debugging only.

RS485 InputsThere are 3 parameters displayed here:E = Number of errorsT = Transmitted bytes



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R = Received bytes

These are used for debugging only.

LogThe Log holds the last 500 events that occurred on the system. The logs aresorted by date, so the user can select any available date and view the eventsthat occurred on that date. Most recent events are shown at the top of theevent screen. Events include all occurrences of metal, parameter changes,learns, metal tests, power ups, system faults i.e. all events are listed in timeorder.

TestsThere is an option to view the ‘Tests’ page. This is not the metal test page, itis a set of graphical test screens representing the live signals of the detector.They can be useful for engineers when fine tuning the detector and are usefulfor demonstration purposes. The test screens available are listed below:

Effect screenThis screen displays the live effect of the detector shown against the packthreshold. The ‘Pack Threshold’ is shown as a dotted line. Under normaloperating conditions, the effect should cross above the pack threshold when aproduct passes through.

Polar screenThis screen gives a polar plot of the detector output. It shows the constantchange in phase and magnitude of the output.

‘P’ screenThis screen gives a graphical plot of the ‘P’ channel against time. A sinusoidshould be seen when passing through a metal test piece.

‘Q’ screenThis screen gives a graphical plot of the ‘Q’ channel against time. A sinusoidshould be seen when passing through a metal test piece.

‘P & Q’ screenThis screen gives a graphical plot of the combined ‘P’ and ‘Q’ channelsagainst time.

Metal screen



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This screen gives a graphical plot of the signal shown against the metalthreshold. The signal will cross above the threshold if the metal is successfullydetected.

Note that the buttons on the right side of the screen will alter the scaling of thegraphs.



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3. SETTING UP THE METAL DETECTOR

This section describes the basic procedure for setting up a CINTEX Sentrymetal detector.

The first step in creating a product menu is to enter the product name. usingthe description in section 2.3.1 under ‘Product name’. Once a name isentered, the process of learning the product may commence. Once a productis learnt, the menu is relevant to that particular product only.

3.1. LEARNING THE PRODUCTIt is important that the product used during setup is taken directly from theproduction line, NOT PRODUCT THAT HAS BEEN STORED, as the learningresults could differ.Learning the product will automatically set the product phase signature, themetal threshold and the product pack threshold. Do not worry about all ofthese terms at present, other than to know that these values need to becorrect for the detector to properly function.

• From the screen , select: [Goto →→→→ Reject settings →→→→ Override]

and set the Override to enable. This will be confirmed by the message‘OVERRIDE’ flashing on the status bar . By doing this, unnecessary rejectsor belts stops will be avoided during the learn process.

• Select [Back] , then [Goto →→→→ Learn]. Start the conveyor, the screenshould look as shown below, then pass the product through as it wouldcome down the line.

Figure 3.1 – Learning Screen



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Pass the product through the metal detector as many times as are needed toprogress the top bar up to 100%. The lower bar indicates the progress ofeach learn cycle (pack threshold, phase,metal threshold). After completion ofthe learn sequence, the option box will pop up. Simply return to the ‘RunMode’. The product’s phase signature has now automatically been set in addition tothe metal threshold and the pack threshold. If the display shows a ‘SIGNALTOO HIGH’ message after learning, then the ‘GAIN’ must be turned down,and the product learnt once again.Also, if the message ‘BAD LEARN’ appears on the centre of the screen, referback to the section on ‘Tracking’ .Once the learn sequence is started, a timeris started. If no product is detected before this timer expires, a warning isdisplayed and the learn sequence aborts. (Test Duration sets the duration ofthis timer).

3.2. SETTING THE GAIN (Goto → Product Settings → Gain)

It is recommended that the Gain be set to a value of 1 to start with. If the Gainneeds to be adjusted , do as follows. Select ‘Gain’ as shown above. Press theEdit button and the display will look as shown below:

Figure 3.2 – Gain Edit screen

Now, use the + and – buttons to adjust the value. If the ‘SIGNAL TOO HIGH’’fault was displayed then decrease the gain by one point. Press the OK buttononce complete. Once the gain is changed, the screen will revert back to thelearn screen, as a change in ‘Gain’ will require the product to be re-learnt.



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3.3. SETTING THE THRESHOLD (Goto → Product Settings → Threshold)

The ‘Threshold’ has already been automatically set during the learn sequence, there should be no need to alter it. However, there is an option to manuallyset the Threshold. It is accessed as shown above and edited in the same wayas the ‘Gain’. If the detector is too sensitive (i.e. false rejects), then the‘Threshold must be increased, and vice versa.The Threshold value produced by the learn sequence is actually the highestproduct threshold divided by a factor of 0.6. For advanced users, this factormay be adjusted in the ‘Advanced Settings’ from within ‘Product Settings.‘Advanced settings’ will only be visible when enabled from within the ‘ServiceSettings’ menu.

3.4. SETTING THE REJECT TIMING

If NO reject device is present i.e. the system is Audible alarm & belt stop thensimply set the ‘Reject Mode’ as follows:

Select : Goto →→→→ Reject Settings →→→→ Reject Duration

and set the Reject Duration to ‘0’. A value of ‘0’ here denotes ‘Alarm andStop’.

• Switch the Override to ‘Disable’ and pass a good product through thedetector and check that there is no detection .

• Pass a product with the required test sample and check that it isdetected.

• The Threshold value can be adjusted to suit the test sample required.

TEST SAMPLES CAN BE SUPPLIED BY CINTEX .

• Once the machine has been set up for the product and is detectingyour metal samples, enter a suitable value of the ‘Reject Delay’. This isthe time to wait between detecting metal and operating the rejectmechanism and it allows the contaminated product to move out of theaperture and in front of the reject. This is accessed as follows:

[Goto →→→→ Reject Settings →→→→ Reject Delay]

• Enter also a suitable value for the ‘Reject duration’, this is the length oftime that the reject will operate. Accessed as follows:

[Goto →→→→ Reject Settings →→→→ Reject Duration]



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• If you are utilising reject confirmation then enter a suitable time herewhich is long enough to allow the confirmation to take place . This isaccessed as follows:

[Goto →→→→ Reject Settings →→→→ Confirm Time]

If confirm time is set to zero, then reject confirm is automatically turned off.

If using a Product PEC to improve reject timing accuracy on awkwardproducts, then the Product PEC in the Service settings parameter must beset to enable.

Generally, when using Amplitude detection, it is recommended that a ProductPEC is used before the head to aid with the reject timing consistency.If, however the line speed is low and pack spacing is generous, then the rejecttiming may be opened up to account for the variation in contaminant positionwithin the pack, and the use of a Product PEC may be avoided.

If using Zero-cross detection, it is less likely a Product PEC will be required,as the system uses the zero cross point to initiate reject timing.

3.5. REJECT TACHO

The only situation which would require the use of a tacho device, is where thecustomer is varying the speed of the belt on the metal detector. In such asituation, if the metal detector were set to use normal reject timing, this will ofcourse need to vary as the belt speed varies.By using a tacho, there will be no need to vary any settings on the machine, inother words as the belt speed varies the timing will remain correct.

If using a tacho, the following must be performed:

• Set Tacho to ‘Enable’ in the Service settings menu.

• Set a value into Pulse length, which appears below Tacho in theService settings menu.

• The pulse length may be calculated as follows:

Pulse length (mm) = Circumference of roller (mm)no. of tacho pulses per revolution

Note that the circumference of the roller is calculated as (Pi x d) where ‘Pi ‘ is3.142, and ‘d’ is the diameter of the roller in mm. Also note that RejectDuration and Reject Distance will now be in units of mm. Another alternativemethod of setting the pulse length correctly is to measure the belt speed witha measuring device , and then adjust the pulse length until the speed shownon the data screen matches the actual speed.



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3.6. PERIPHERAL DEVICES

There are a number of peripheral devices which may be connected to theSentry system. These are:

• Serial Printer.• Serial Barcode scanner.• MIACS network connection.

3.6.1. SERIAL PRINTER

Some users may wish to download information from the Sentry and print it outdirectly, hence keeping records.The information which may be printed is listed below:

• Statistics (information as viewed on the Statistics page).• Product settings (all parameters in the Product settings and Reject

settings menus).• System settings (all parameters in the System settings menu).• Reject settings (all parameters in the Reject settings menu).• Advanced settings (all parameters in the Advanced settings menu).• Test settings (all parameters in the Test settings menu).• Service settings (all parameters in the Service settings menu).• System information ((all information from the Diagnostics screen).• Log (all the events shown in the log from the Diagnostics screen).• Entire system (all of the parameters shown above, excluding the log).

In order to print out any of this information, simply select:

(Goto →→→→ Print →→→→ (Make selection) →→→→ Print)

The printer is driven directly from the serial port on the motherboard of theSentry. This is an RS 232 connection. The cable which connects to the printeronly requires 3 wires. This connection is shown below:

Signal name Printer connection(25way D)

Sentry connection J8(9way D skt)

Transmit Pin 3 Pin 3 (red)CTS (clear to send) Pin 20 Pin 8 (yellow)Ground Pin 7 Pin 5 (green)



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In order to ensure that the printer and Sentry will function together properly,the same BAUD rate must be selected on both devices. The serial BAUD rateon the Sentry is found in the Service settings menu and by default is set to9600 BAUD:

(Goto →→→→ System settings →→→→ Service settings →→→→ RS232 baud rate)

Ensure the printer is set to receive data at the same BAUDE rate.For debugging purposes there is an RS232 and an RS232 input statusviewable on the Diagnostics screen.The RS232 status shows when the CTS (clear to send) signal is beingasserted by the printer. This will alternate on and off the screen under normalprint conditions.The RS232 input status shows E (errors), T (transmitted bytes) and R(received bytes). This is used for debugging the serial connection only.

If at any time the print buffer needs to be cleared, then use the Printer bufferoption in the Service settings menu, choosing Yes to clear the buffer.

3.6.2. SERIAL BARCODE SCANNER

There is an option to connect a serial barcode scanner to the Sentry system. Ituses the same serial port as the printer, Both devices may be usedsimultaneously as the printer only uses the receive line and the scanner onltyuses the transmit line.For this situation a specific split serial cable will berequired.Firstly the barcode scanner needs to have a serial cable supplied with it, inaddition a wire link is required on the motherboard to supply 5 volts power tothe scanner. This link goes between pin 8 of U26 and pin 9 of the serial 9 way‘D’ connector J8 on the motherboard. Without this wire link there will be nopower to the scanner.Also ensure the scanner is configured to run in serial mode.

If fitted, a barcode may be scanned in for any product menu, by performingthe following:

(Goto →→→→ Product settings →→→→ Barcode →→→→ Edit)

Then press the button on the scanner to read in the code. The number willappear across the middle of the screen. Alternatively the number may bemanually entered. Once entered press the OK button to accept it.

If for any reason a barcode is scanned which already exists, then a warning“Barcode already exists” will appear on the screen and the barcode must bealtered to be unique.



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Now, when in production, if a barcode is scanned in and a match is found,then the matching menu will immediately become the active menu.

Once again if there are problems with using the scanner, ensure the BAUDrates are the same for the scanner and the serial port.

3.6.3. MIACS (MANAGEMENT INFORMATION AND CONTROL SYSTEM)

A separate manual is available explaining the use and connectivity of MIACSfor the range of Cintex systems. This section just describes the connection tothe Sentry metal detector.

Firstly there are two versions of MIACS, firstly MIACS 95 which uses a 4 wireRS485 network to communicate between machines, and secondly MIACS2002, which uses a more efficient 2 wire system. The Sentry supports both,however, if adding the Sentry to an existing MIACS 95 network, then thenetwork will need to be connected into J5 of the motherboard. Note that theconnections on the motherboard for MIACS are RJ45 connections. This is an8 pin high density lock-in style connector.

The wiring of this connector into the network is as follows:

From PC network RJ45 Cable colour (Sentry end)

Transmit + Blue/white (pin 5)

Transmit – Blue (pin 4)

Receive + Green/White (pin 3)

Receive- Green (pin 6)

This will allow connection into an existing MIACS 95 network.

Note that for a MIACS 2002 network using a 2 wire system, only the blue(pin4) and blue/white (pin5) wires are used. There is a jumper which needssetting if using MIACS 2002 2 wire mode (JP11 on main board must be set tothe end opposite the 0v end.Also, if the Sentry is at the end of the network , itmust have an additional jumper set (JP12 linked together), as this selects themachine as the end of the line (switches in a termination resistor).



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In addition, if using MIACS on a Sentry, the following parameters need settingfrom within the System settings menu:

1. MIACS – Enabled

2. MIACS address – Set to a unique address for each system.

3. Line number – Set to zero if using on MIACS 95 network, or a real linenumber if used on MIACS 2002.

4. BACKING UP MENUS

It is always important to have a back up copy of the menu settings in the eventof a loss of settings, or if someone has mistakenly changed the settings.There are two methods of keeping a backup.

Firstly as described in section 3.6.1 there is a facility to print out the Productsettings, Advanced setting, System and service settings and keep a hardcopy. It is recommended that once the detector is set up, that a hard copy ofthe settings be kept. Remember of course that it must be a serial printer.

The second method of backing up settings is found in the service settingsscreen. There are two options related to backing up. These are :

(Goto →→→→ System settings →→→→ Sercive settings →→→→ System Backup)

System backup – This can only be carried out by use of the Cintex passwordor a daily issued password.Cintex personnel will perform this backupuponinstallation once happy with the menu setup. This leaves an appropriateuseable set of menus in the onboard backup chip.

SOCKET PLUG



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This backup may be recalled at any time by selecting:

(Goto →→→→ System settings →→→→ Sercive settings →→→→ System recall)

The system recall feature can be performed by the customer, and is protectedto Engineer access level. So, if the passwords are active, an Engineerpassword will be required.

Important backup note !

Please also note that all information including menus and password levels, isstored on the pluggable chip U43 of the motherboard. So in the event that amotherboard has been replaced, then swapping the chip onto the new board,and performing a system recall, will maintain all the customer settings exaxctlyas they were before.

4.1. Service Prompt

When a service is due, there will be a screen prompt as shown below:

In the top right corner of the screen where the time and date are shown, aservice indicator will be present showing a countdown series of four boxes.The service indicator will appear 4 weeks before the due date and as the fourweeks pass, another box will be highlighted, until the message eventuallyappears as ‘ Service Due’. The prompt will be cleared by the service engineeronce the service has been completed.



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5. TROUBLESHOOTING

If the equipment malfunctions, check the following items in the order shown.All these checks must be carried out by competent personnel takingappropriate precautions.

SYMPTOM ACTION

‘Reject ConfirmFault’ message.

The reject mechanism is operating too slowly or hasfailed. Taking appropriate precautions:-Check any high pressure air supply.Check that the reject mechanism can move freely.Check the actuator.Check continuity of any solenoids, solenoid valves etc.Check the operation of the reject mechanism sensor e.g.microswitch. If reject confirm is not needed then ensurethe Confirm Time is set to zero in the Reject settingsmenu.

‘Signal Too High’message.

The effect has exceeded 30,000. This can occur duringthe ‘Learn’ sequence. The signal from the product is toolarge. This can be because an abnormally large quantityof product is passed through the head at one time.Another possibility is the change in the product e.g. anormally frozen item is partially thawed. Try reducing the‘Gain’ and relearning the product.

‘System Fault’message.

A hardware error occurred on the main board, ContactCintex if fault persists.

‘24v powersupply fault’message

Check fuse F1 on the motherboard. The system 24vdchas failed.

‘Temperaturefault message’

An overtemperature has occurred, the motherboard hasexceeded 65 degrees c (149 F). Investigate as to whythe detector is running too hot.

‘Battery Back UpFailed’ message.

The settings are held in battery backed RAM. The RAMis powered from a rechargeable lithium battery. If theunit is left powered down for long periods or if the batteryis faulty, then this fault message will ocurr. Settings willbe loaded from the backup EEPROM in this case.

‘Head balance’fault.

The head balance has exceeded 100% for more than Iminute and must be investigated. Rebalance the head ifrequired. It is normal for a value of less than 30% to beshown.



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‘Low AirPressure’message.

The incoming air pressure has dropped below anacceptable level. This input is unused on upgrades asthe air pressure fail is transparent to the computer, itsimply trips the fault circuit.

‘Reject Bin full’message

The reject bin full sensor has been activated. Clear thebin of product and ensure the sensor is functioning.This input is unused on upgrades, as the bin full sensorsimply trips the fault circuit

‘Excess Rejects’message.

The number of metal rejects in any one minute hasexceeded the limit. Either investigate the product orreduce the ‘Excess rejects’ setting in the ‘RejectSettings’ menu.

‘Large metalfault’ message.

A metal signal in excess of the ‘Large metal ‘ setting hasoccurred. There may either be a very large piece ofmetal passed through, or the ‘Large metal’ setting is toolow. The ‘Large Metal’ setting is in the Advanced settingsmenu.

‘Auto testexpired’message.

The automatic metal test has not been performed in theallocated time. Reset the system and repeat the metaltest.

‘Bad Learn’message

During the learn sequence, if the phase varies outside of+ or – 4 degrees (or +/- 12 degrees for difficult), a badlearn will occur. Repeat the learn ensuring consistentpresentation of the product.

‘Reject ConfirmPEC Fault’message.

The reject confirm sensor has been obstructed for morethan 5 seconds. Check the sensor for correct alignmentand operation.

‘Power Spikedetected’

The mains voltage dropped to less than 15% of the ratedsupply and then recovered. This is an indication that theincoming mains voltage is fluctuating.

‘Metal – Beltstopped’message.

Metal has been detected whilst the detector is in Alarm &Stop Mode. Product must be removed and the systemreset.

‘Invalid barcode’message

A barcode has been scanned in which does not matchany of the menus. This will not trip the fault output.

‘ProductPEC’Fault

Product PEC permanently obstructed, or not fitted.



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Regular,Repetitive metalindication

Probably due to conveyor belt contamination.Mark the belt when the “metal” indication occurs. If“metal” is indicated each time the mark comes round,check the belt that is inside the detector when “metal” isindicated. Note that in some systems the belt passesthrough the head twice. Check both portions of the belt.Check for such things as flakes of rust or burnt product,metal debris, weld spatter, copper wire etc., uneven beltjoint.

Random,Occasional metalindication

Check display. If the bar shows a regular movement,which only occasionally goes past the threshold, checkthe belt as above. Also check for any loose metal platesor fixings which may be interfering with the detector.

Metal indication(without productpassing throughthe head)

Check for metal moving close to the detector. Ifrandom, switch off and check all connections. Observemachinery close by for any correspondence e.g. metalindication occurs when a motor stops, a thermostat cutsin or ram is actuated. Although immune to normaldisturbances, the head can be triggered by exceptionalsurges on the supply or data lines, excessive vibration orshock, or severe electric fields e.g. from RF heater. Alsocheck for any loose fixings (nuts or bolts) close to thehead.

Blank display Check incoming mains power.Check the push-in mains fuse near the transformer.Ensure the contrast pot on the motherboard is not turneddown. This is a large yellow pot at the bottom of the mainboard.Contact CINTEX if the fault persists.



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6. C E COMPLIANCE

When a complete metal detector system (e.g. metal detector plus conveyor)has been purchased the system is CE marked and compliant with all thestandards listed in the accompanying declaration of incorporation. Theequipment is supplied with a declaration of incorporation rather than adeclaration of conformity because the safety of the final installation isdependent upon adjoining machinery. For example, a conveyor system fittedwith a retracting band reject system can pose a serious hazard when placednext to an outfeed conveyor system. Consult EN294: Safety of Machinery formore details on how to construct a safe installation. Also to ensure electricalsafety to the standard EN60204, the mains connections must be made in theway illustrated in the accompanying system wiring diagram. Particularattention should be paid to the correct connection of the safety earth, whichshould be connected directly to the stud marked PE.

When a metal detector search head alone is supplied, the following guidelinesmust be followed if the system installation is to be CE compliant. It is beyondthe scope of this manual to set out all the actions which should be undertakento ensure a CE compliant installation, but some guidance can be given onelectrical safety, and electromagnetic compatibility. In particular, if the guidelines on EMC are followed the system should comply with the original EMCstandards to which the machine was tested.

Some general guidance can be given on electrical safety, but for more detailsrefer to EN60204 part 1 (Electrical Safety of Machines). In order to complywith EN60204-1, it is necessary to power control circuits via an isolatingtransformer. Extremely simple control circuits are exempted from thisrequirement, consult EN60204-1 for more details.

The Sentry incorporates the capability to run all conveyor peripherals such asreject solenoid, contactor etc from 24V A.C., thus providing transformerisolation and low voltage operation.

Over current protection is provided by a 2A anti surge fuse (F1) located on themother board and an additional 2A fuse on the incoming mains terminal insidethe head.

The Sentry detector does have a PE terminal for connection of the externalearth. The European standard EN60204-1 requires that the external earth beconnected to a terminal marked P.E. This terminal must be provided for in thesystem installation.

The earth connection to the search head itself must be made to the earth studmounted inside the electronics enclosure. Live and neutral must beconnected to the incoming mains terminal. The electronics itself is earthed bya connection from the earth stud to connector J12 on the main board.



PAGE 48 OF 57

To ensure system EMC compliance it is necessary to route the main cablebundle through the ferrite sleeve which is located within the electronicsenclosure, close to the cable gland entry point. The EMC regulations set outperformance criteria for electromagnetic emissions and immunity. The finalsystem installation will not have any effect on the emissions from the metaldetector, but it may well effect the immunity capabilities of the detector, andadditional system components, such as inverters, may pose an emissionsproblem in their own right. Therefore it is essential that the manufacturesrecommended installation for inverters, motors etc are followed to ensure anEMC compliant installation.



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SPECIFICATION

Mains supply 100,110,120,220,240V AC+ 10 - 15%50 - 60Hz single phase0.3kw nominal (up to 5A surge at power on)

Ambient temp. -10 to + 40 degrees C non condensingHose resistance Resistant to a jet from a hose of 12mm (0.5”)

bore under a pressure of 3.5Kg/cm(50psi) from a distance of 0.6M (24”)This exceeds IP65 and NEMA 4

Speed Range 1-300M/min according to application

Battery Back up Cell life 5 yearsDischarge time 3 months from power off

Electrical Switching:-Relay Outputs Maximum switched voltage 120Vac, 28vdc.

Maximum switched current 3A

Opto inputs Nominal 24vdc (Maximum Voltage: + 30V) Max. sink current 20 mA.

Sensitivity Dependent on aperture size and application .



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APPENDIX 1 – Motherboard connections / Adjustments

DISPLAYCONTRASTADJUSTMENT

J3

R44

J9

J2

J11

J4

J5

J8J7 J1

J1

UNUSED

PROGRAMMINGHEADER

SYSTEMINPUTS

SYSTEMOUTPUTS

SIGNAL INPUTFROM PREAMP& +12/-12v.

POWER ONTOBOARD

UNUSED

TOUCHSCREENINPUT

RS 232PRINTERPORT

2AFUSE

RS485PORTS

JP11

JP12



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APPENDIX 2 - ELECTRICAL PINOUTS (Cintex Main board):

CONNECTOR DESCRIPTION OF PIN SIGNAL

J1 (14way) OUTPUTS1 24vac supply2 24vac common.3 AC reject (solid state output)4 Reject output normally open5 Reject output normally closed6 Reject output common7 Fault output normally closed8 Fault output normally closed9 Fault output normally open

10 Fault output normally open11 Warning output normally open12 Warning output common13 +24vdc power14 Ground for 24vdc power

J2 (14 way) EXPANSION PORTFor future use only.

J3 (10 way) PROGRAMMING PORTProgramming header only for CPU

J4(8 way) RS485 INPUT PORTRJ45 connector

J5(8 way) RS485 OUTPUT PORTRJ45 connector

J6(7 way) TOUCHSCREEN INPUT1 Ground2 Key input 13 Key input 24 Key input 35 Key input 46 Key input 57 Key input 6

J7(12 way) SENSOR INPUTS1 Tacho input2 Reject confirm input3 Bin full input4 Low Air fail input5 Product PEC6 Conveyor running input (optional)7 Metal test8 Reset key input



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9 +24vdc power (connect to inputs to activate)10 +24vdc power (connect to inputs to activate)11 Ground for 24vdc power12 Ground for 24vdc power

J8(9 way) RS232 SERIAL INTERFACE1 DCD2 Receive data3 Transmit data4 DTR5 Ground6 DSR7 RTS8 CTS9 RI (OR 5 VOLTS FOR BARCODE SCANNER)

J9 (10 way) HEAD AMPLIFIER INPUT1 Ground2 Q signal input.3 Ground4 P signal input5 Ground6 Ground7 -12 volts dc8 -12 volts dc9 +12 volts dc

10 +12 volts dcJ12 (8 WAY) POWER INPUT

1 System ground.2 7VAC3 7VAC4 12VAC TAP25 12VAC CENTRE TAP6 12VAC TAP 17 24VAC8 24VAC

JUMPER SETTINGSJP2 LINK FITTEDJP3 LINK FITTEDJP4 LINK FITTEDJP5 LINK FITTEDJP6 LINK FITTEDJP8 LINK FITTEDJP11 Fit to 0v end for 4 wire or opposite end for 2 wire.JP12 Fit only if sentry is at the end of the network .

All other links NOT fitted.



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APPENDIX 3 – PARAMETER GLOSSARY

NAME DESCRIPTION DEFAULT MIN MAX ACCESSLEVEL

Threshold If the Metal Signal reaches this limit, metal isdetected

20.0 0.5 1000.0 USER

Phase Reference phase angle of product 90.0 -90.0 90.0 USERPhase2 Reference phase of secondary product - only

available when Product Tracking is DUALPHASES

90.0 -90.0 0.0 USER

Gain PreAmp Gain 2 1 4 USERTracking Selects how the detector tracks slight changes

in the productON - - USER

Detection Mode Controls when Metal is reported. AMPLITUDE - - ENGINEERName Product name Default Product - - USERBarcode Product Barcode. Used by attached barcode

scanner.- - USER

Override Overrides the reject output DISABLED DISABLED ENABLED SUPERVISORReject Delay Delay AFTER metal detector before reject

output operates2000ms 1 20000 SUPERVISOR

Reject Duration Length of time reject operates for. 800ms 0 20000 SUPERVISORConfirm Time Time limit allowed after reject operates during

which reject confirm input must be activated.0ms 0 20000 SUPERVISOR

Excess Rejects Maximum rejects per minute rate. 0rpm 0 20000 SUPERVISORReject Link Time in which to link two consecutive rejects

together.0ms 0 20000 SUPERVISOR



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Test Interval Time interval in which a metal test will beprompted for.

0mins 0 120 ENGINEER

Test Wait After initial prompt, auto test will wait for thislength of time for test to be carried out.

2mins 1 60 ENGINEER

Test Duration Max length of time a metal test will last. 10s 1 60 ENGINEERPieces To Find Number of test pieces to find during test

duration.1 1 60 ENGINEER

Language Language all text is displayed in. ENGLISH - - SUPERVISORMachine ID ID number given to machine. Shown on print

reports.1 0 999 ENGINEER

Large Metal Maximum allowable metal signal. 10000 1000 60000 ENGINEERPack Threshold Product effect threshold used to detect when a

product is passing through the head.200 1 10000 ENGINEER

Effect Counter Used to enable a product counter based onproduct effect.

DISABLED DISABLED ENABLED ENGINEER

Product PEC If connected, a PEC can be used to control packtiming.

DISABLED DISABLED ENABLED CINTEX

Noise Filter Frequency at which noise is filtered. 3Hz 2 33 CINTEXAdvanced Settings Controls whether or not Advanced Settings

menu allows 'per product' changes.DISABLED DISABLED ENABLED CINTEX

Back Light Time Timeout for screen back light. ALWAYS ON 0 10 CINTEXSystem Mode System configuration mode Autosearch CINTEXFrequency Reflects the current head frequency. HIGH LOW HIGH CINTEXTACHO Use tacho or not. DISABLED DISABLED ENABLED CINTEXPulse Length If TACHO enabled, this sets the length between

tacho pulses.20mm 10 100 CINTEX



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Fault Detection Controls whether faults are processed or not. ENABLED DISABLED ENABLED ENGINEERRS232 Baud Rate Transmission rate for serial comms. 9600 1200 115200 ENGINEERRS485 Baud Rate Transmission rate for comms. 9600 1200 115200 ENGINEERPrinter Buffer Number of bytes in print queue. 0 - - ENGINEERMIACS Use MIACS or not. DISABLED DISABLED ENABLED ENGINEERMIACS Address MIACS device address 1 1 63 ENGINEERLine Address MIACS 2001 Line Address (set to ‘0’ for ’95) 1 1 63 ENGINEERLearn Pack Learn pack threshold as part of Learn process. ENABLED DISABLED ENABLED ENGINEER

Learn Threshold Learn metal threshold as part of Learn process. ENABLED DISABLED ENABLED ENGINEER

Phase Peaks Number of peaks in which to learn the productphase.

10 3 20 ENGINEER

Threshold Peaks Number of product peaks in which to learnthresholds.

5 3 20 ENGINEER

Threshold Factor Divisor used to compute an acceptablethreshold, given the maximum achieved productsignal.

0.6 0.1 1.0 ENGINEER

Barcode String of characters used to select product froma remote source, such as a barcode scanner.

- - USER

Auto Log Off When a password is active, the system can beconfigured to log off and hide all editable menus.

ENABLED DISABLED ENABLED SUPERVISOR



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Test Restart If an auto test is not completed within the TestWait time, a fault is generated. Once the faulthas been reset, the test must be started with theTest Restart time.

2mins 1 60 ENGINEER

Frequency Tells system what head frequency is being used.Only used for display purposes.

HIGH LOW HIGH CINTEX

Tacho Defines whether or not the system should countpulses from an external tacho device.

DISABLED DISABLED ENABLED CINTEX

Pulse Length Describes the length of belt travel for each tachopulse. Used to calculate belt speed.

20mm 10 100 CINTEX

Next Service Defines month next service will be due. DISABLED DISABLED DECEMBER CINTEX

Service Code Used to prevent repeated use of ServicePassword. For Cintex personnel only.

ENABLED DISABLED ENABLED CINTEX

Maintenance mode Disables the all outputs but leaves the systemfunctional in every other way. Used for testing

DISABLED DISABLED ENABLED ENGINEER

Tracking rate Sets the number of packs over which the phaseaveraging is used. A higher number means moreaveraging and a softer tracking rate.

256 1 1000 ENGINEER



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APPENDIX 4 – MENU LAYOUT

OverrideReject DelayReject DurationConfirm TimeExcess RejectsReset Counters

UserSupervisorEngineerAuto log off

Test IntervalTest WaitTest restartTest DurationPieces to find

TestAbort

Abort

CopyDeleteRecallNew

Goto

Test

Learn

Menus

TestsLog

Maintenance modeSystem BackupSystem RecallLearn ThresholdLearn PackLarge MetalProduct PECEffect CounterNoise ThresholdNoise filterAdvanced SettingsBack light timeSystem ModeFrequencyFault DetectionTachoPulse lengthRS232 Baud rateRS485 Baud ratePrinter bufferNext serviceService code

Product SettingsSystem SettingsReject SettingsStatisticsDiagnosticsPrint

Detection modeLearn PackLearn ThresholdLarge MetalPack ThresholdEffect CounterPhase PeaksThreshold PeaksTracking rateThreshold FactorTemplate

Security Test Settings Time & DateLanguageMachine IDMIACSMIACS AddressLine numberService Settings

ThresholdPhaseGainTrackingNameBarcodeAdvanced Settings

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