Metal Detection

Systems

Model 1080
Metal Detection System
Product Manual

4630 Churchill, Suite 2

Shoreview, MN 55106
Phone: (612) 415-9690
Fax: (612) 415-9691

1994 SciTronics. All rights reserved. Printed in the U.S.A.

No part of this publication may be reproduced, translated into any language, stored in a retrieval system, or transmitted in any
form by any means without the prior written permission of SciTronics.

Table of Contents

Table of Contents
Warranty ................................................................................................................ iii
SciTronics Quality Control Standards ................................................................... iv

Section 1 Introduction
Using This Manual .............................................................................................. 1-1
System Overview ................................................................................................. 1-2
Standard Components .................................................................................... 1-3
Theory of Operation ...................................................................................... 1-4

Section 2 System Options

Overview ............................................................................................................. 2-1
Splice Detector .................................................................................................... 2-1
Metal Markers (Tramp Metal Locator) ................................................................ 2-1
Flag Drop Solenoid Operated ........................................................................ 2-1
Liquid Spray Pneumatic Operated ................................................................. 2-2
Coast Alarm ......................................................................................................... 2-2
Long Bar Detector ............................................................................................... 2-2
Shift Register ....................................................................................................... 2-2
Remote Reset ....................................................................................................... 2-2
Rotating Alarm Beacon ....................................................................................... 2-3
Controller/Sensor Connecting Cable ................................................................... 2-3
Single-Unit Coil System ...................................................................................... 2-3
Backlit LCD Trip Counter ................................................................................... 2-4

Section 3 Installation
Overview ............................................................................................................. 3-1
Unpacking the Metal Detection System .............................................................. 3-1
Detection Coils Station ........................................................................................ 3-1
Selecting an Installation Location ................................................................. 3-1
Assembling the Coils ..................................................................................... 3-2
Dual Coil System ..................................................................................... 3-2
Mounting the Structure .................................................................................. 3-3
Controller Enclosure ............................................................................................ 3-3
Mounting ....................................................................................................... 3-3
Wiring ............................................................................................................ 3-3
Options
Single Unit Coil System ................................................................................ 3-6
Splice Detector .............................................................................................. 3-6
Flag Drop Marker .......................................................................................... 3-7
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SciTronics Model 1080

Liquid Spray Marker ..................................................................................... 3-7

Rotating Alarm Beacon ................................................................................. 3-8
Remote Reset ................................................................................................. 3-8

Section 4 Operation
Overview ............................................................................................................. 4-1
Startup .................................................................................................................. 4-1
Operation of the Failsafe Circuitry Option .......................................................... 4-1
Shutdown ............................................................................................................. 4-2
System Calibration .............................................................................................. 4-2
Sensitivity Control ......................................................................................... 4-2
Splice Detector .............................................................................................. 4-3
Alarm Delay .................................................................................................. 4-4
Alarm Duration .............................................................................................. 4-4
Flag Drop Marker Option .............................................................................. 4-5
Liquid Spray Marker Option ......................................................................... 4-5
Long Bar Detector Option ............................................................................. 4-5
LED Indicator Lights ........................................................................................... 4-6

Section 5 Maintenance and Troubleshooting

Overview ............................................................................................................. 5-1
Maintenance......................................................................................................... 5-1
Spare Parts ........................................................................................................... 5-1
Troubleshooting ................................................................................................... 5-1
Gaining Access to the Electronics Modules .................................................. 5-1
Diagnostic LEDs............................................................................................ 5-2
Coil Drive Indicator Light ....................................................................... 5-2
Power A Indicator Light .......................................................................... 5-2
Power B Indicator Light .......................................................................... 5-2
Power C Indicator Light .......................................................................... 5-2
ASP Indicator Light ................................................................................. 5-2
Splice Indicator Light .............................................................................. 5-2

Section 6 System Specifications

Operational Specifications ................................................................................... 6-1
Electrical Specifications ...................................................................................... 6-1
Physical Specifications ........................................................................................ 6-2

Section 7 Drawings
List of Drawings .................................................................................................. 7-1
Drawings .............................................................................................................. 7-3

ii

Warranty

Warranty
SciTronics warrants all products of its manufacture to be free from defects in material and
workmanship. This warranty is effective for three years from the date of shipment to the
original Purchaser.
Upon notification by the Purchaser, SciTronics will correct any defects in equipment of its
manufacture either by repair in our plant or by supply of replacement parts to the Purchaser.
SciTronics must decide to its own satisfaction that the equipment is defective and has not
developed malfunctions as a result of misuse, modification, abnormal conditions of
operation, or attempted service not authorized by SciTronics.
SciTronics will not accept any product returned for refund or approve any backcharge for
labor, materials, or other costs incurred by the Purchaser or others in modification,
adjustment, service, or repair of SciTronics equipment unless such return or backcharge has
been authorized in writing to the Purchaser.
Any special test or requirement placed upon SciTronics products or products of other
manufacture used in SciTronics systems must be mutually agreed upon in writing by
SciTronics and the Purchaser prior to the date of shipment.
SciTronics reserves the right to make changes in design or construction of its products at any
time without incurring any obligation to make any changes whatsoever on units previously
purchased.
This warranty is expressly made by SciTronics and accepted by the Purchaser in lieu of all
other warranties, including warranties of merchantability and fitness for particular purpose,
whether written, oral, express, implied, or statutory. SciTronics shall not be liable for normal
wear and tear nor for any contingent, incidental, or consequential damage or expense due to
partial or complete inoperability of its products for any reason whatsoever. In no event shall
SciTronics liability exceed the original purchase price of the equipment.

iii

SciTronics Model 1080

SciTronics Quality Control Standards

SciTronics visually inspects all incoming goods and then assembles them according to
the best electronics shop standards.
SciTronics powers and tests each circuit to exacting operating specifications, observing
the correct function of each component.
When the unit is complete, the entire operating system is assembled and tested to meet or
exceed factory and customer specifications.
After a substantial burn-in period of up to 100 hours, the system is rechecked to the
original specifications. Only then is the system ready for shipment.

iv

Section 1 Introduction

Section 1 Introduction
Using This Manual

This manual contains the installation, operation, and maintenance

instructions for your SciTronics Metal Detection System.
NOTE
The warranty for your SciTronics Metal Detection
System is on page iii in this manual. Be sure to read it
so you are aware of its provisions and exclusions.
This manual is arranged in the following sections so that you can
find the information you need quickly and easily:
Section 1 Introduction
describes the organization of this manual as well as the
features and general operation of the metal detection system.
Section 2 System Options
describes the options that are available from SciTronics for
the metal detection system.
Section 3 Installation
provides instructions for unpacking and installing the metal
detection system and options.
Section 4 Operation
contains startup, shutdown, and calibration procedures for the
metal detection system and describes the function of the LED
indicator lights during normal operation of the system.
Section 5 Maintenance and Troubleshooting
explains how to fix minor problems that may occur with the
metal detection system, such as detecting damaged coils,
cables, and connectors.
Section 6 System Specifications
provides the specification data for the metal detection system.
Section 7 Drawings
includes the drawings for your specific metal detection
system.

1-1

SciTronics Model 1080

System Overview

The SciTronics Metal Detection System is designed to detect tramp

while scanning products such as highly mineralized or magnetic
ores (including magnetite and pyrites, even when conveyed on steel
cable belts) as well as copper, nickel, aluminum, aggregates, coal,
rubber, wood chips, sinter, and tar sands. It can also be used in
recycling plants to detect tramp while scanning plastics, glass, or
paper.
The metal detection system has the following features:
The latest electronic design, utilizing all solid-state ICs to
ensure long operating life and trouble-free operation.
Pulsed field operation, which requires no balancing or tuning
and is not affected by temperature and humidity.
A resident diagnostic monitor using LEDs to indicate the
operational status of the circuit.
Programming at the front panel for Alarm Delay, Alarm
Duration, Sensitivity Scale Factor, and Splice Detector
Duration and Threshold.
Automatic spike (interference) protection (ASP) circuitry.
Dual primary (120/240 V) electrostatic-shielded power
transformer and additional RFI-EMI filter for maximum
electrical isolation.
Field-replaceable relays and circuit modules.
Swing-away coil protection.
Conveyor velocity from 6 ft/min to 1,200 ft/min (1.83 m/min
to 365.76 m/min).
The SciTronics Metal Detection System is carefully engineered and
constructed to your specifications. SciTronics uses only the highest
quality components and materials available. With proper installation
and maintenance, your system will provide years of satisfactory
service.

1-2

Section 1 Introduction

Standard Components

The following components are included on all metal detection

systems
Externally located (mounted on the door):
Indicator Lights
Green normal light.
Red alarm light.
Trip Counter
Reset Switch
Internally located within the enclosure:
Sensitivity Control
Adjusts the level of detection.
Fuse, Power Switch, and Operate/By-Pass Switch
Alarm Delay
Delays relay contact transfer and is also used for timing for
downstream removal of tramp by a flopgate or diverter belt.
Alarm Duration
For timing the active interval of the metal marker, flopgate, or
diverter mechanism.
ASP (automatic spike detector)
An internal monitor that detects electrical noise interference
and discards it from the signal flow path before it can cause a
false trip. Typical noise interference includes communication
radio transmission, lightning, and startup of SCR-controlled
equipment.
Status and Diagnostic LEDs
Five standard LEDs and one optional LED (for the splice
detector) on the front panel indicate the operational status of
the following functions:
Generator coil continuity and drive
P-1: Power Logic A
P-2: Power Logic B
P-3: Power Logic C
ASP operation
Splice

1-3

SciTronics Model 1080

Theory of Operation

The SciTronics Metal Detection System measures the electrical

conductivity of material conveyed through the sensor area by
detecting the variations in a pulsed electromagnetic field.
The magnetic properties of a material are completely independent of
conductivity. Even highly mineralized ore has a much lower
conductivity than refined metal. Therefore, both magnetic and
nonmagnetic metals are efficiently detected while so-called product
effects are virtually eliminated.
The pulsed induction technique intensifies the generated
electromagnetic field for very short time intervals. Measurements
taken many hundred times every second during the concentrated
energy pulse provide a very high signal-to-noise ratio without the
heating and stress of the conventional continuous wave method.
A multicoil sensor system, mounted above and below the conveyed
material, causes a more uniform field, providing better detection
sensitivity throughout the burden cross-section. By generating a
configured field pattern, the desired tramp metal signals are
reinforced and extraneous electrical field signals are cancelled.

1-4

Section 2 System Options

Section 2 System Options

Overview

This section describes the options that are available from SciTronics
for your metal detection system.

Splice Detector

Splice Detector (Model 2055) or (Model 2050)

lowers the detection sensitivity, allowing splice/repair areas to pass the
sensor without tripping the alarm. The splice detector is mounted
adjacent to the main sensors, minimizing the splice signal duration
time. The splice detector includes a splice threshold that provides an
adjustable threshold of sensitivity or override. Large tramp may be
detected even though the splice/repair area is traversing the detection
station coils. The splice detector senses the belt splice before it passes
through the detector coil. The coil is desensitized for an instant while
the splice passes through.
The Model 2055 splice detector is recommended as the standard
application splice detector because it provides outstanding performance
in the less demanding application areas and is very cost efficient.
The Model 2050 splice detector is the proprietary coil. It utilizes the
same generator field and signal processing characteristics as the
main coils. This model is recommended for heavy-duty applications
with conductive magnetic ores and steel cable conveyor belts.

Metal Markers
(Tramp Metal
Locator)
Flag Drop Solenoid
Operated

Single-Flag Drop (Model #2075) or Multi-Flag Drop for two flags

(Model #2075-2) or three flags (Model #2075-3)
accurately indicates the location of tramp metal on the conveyor.
Detector reset is locked out until the flag is retrieved. This flag drop
marker consists of a solenoid, armature/flag assembly, and a lockout
circuit. A normally open contact connected to the active power line
causes the solenoid to operate upon metal alarm. The armature flag
assembly is released and drops on the conveyer. A switch operated by
the armature locks out the metal detector reset until the flag assembly is
retrieved and replaced. A length of chain is used on the flag so that it
does not bounce as it falls onto the moving conveyor. The flag drop
metal markers are available at 120 V or 240 V ac.
2-1

SciTronics Model 1080

Liquid Spray Pneumatic

Operated

Pneumatic/Liquid Metal Marker (Model #3025)

accurately indicates the location of tramp metal on the conveyor and
is recommended for use with the Model 1080 Coast Alarm where
multiple marks are required. It has a NEMA 9 rated solenoid.

Coast Alarm

Coast Alarm (Model #1030)

internally resets the electronics to register an alarm after an initial
trip. This item provides output contact closure to activate the metal
marker and causes the red alarm indicator light to flash, indicating
that tramp has been detected during the belt coasting interval. In
addition to the standard counter that totalizes all alarms, the coast
alarm includes a coast tramp counter that totalizes trips that may
occur after initial tramp detection.

Long Bar Detector

Long Bar Detector (Model #1040)

provides a sensitivity control to alarm when calibrated length is
exceeded. This is useful for rebar, pry bars, drill rod, and angle
stock, 18 in. (457.2 mm) or longer, that can catch in a transfer chute,
etc., and damage the belt.

Shift Register

Shift Register (Model #1050)

Automatic separation of the tramp is possible by using a flopgate
and diverter chute. The timing controls and relay contacts required
to operate these devices are provided as a standard feature on the
control panel. For long delays, the shift register enables the detector
to separate closely spaced tramp regardless of the delay required by
the flopgate. Long delays may occur when the belt has a very slow
speed or when the coils are mounted some distance from the head
pulley.

Remote Reset

Remote Reset (Model #2200)

allows the detector to be reset from a location distant from the
control panel. The remote reset includes red alarm and green
ready indicator lights as well as the alarm totalizer counter, in
an 8-in. x 10-in. x 4-in. (203.2-mm x 254-mm x 101.6-mm)
NEMA 4 enclosure. Cable up to 25 ft (7.62 m) is supplied.

2-2

Section 2 System Options

Remote Reset (Model #2230)

is an economy model consisting of the reset switch only in an 8in. x 10-in. x 4-in. (203.2-mm x 254-mm x 101.6-mm) NEMA 4
enclosure. Cable up to 25 ft (7.62 m) is supplied.

Rotating Alarm
Beacon

Rotating Alarm Beacon (Model #3015)

an attention-getting rotating blue beacon light (police type) that
lights upon tramp alarm. This light may be mounted on a flat
surface or a 1/2-in. (12.7-mm) pipe (Federal Model 121S Vitalite).
This item is available at 120 V or 240 V ac. The beacon light is also
available in amber or red.

Controller/Sensor
Connecting Cable

Controller/Sensor Connecting Cable

additional cable to connect the controller at distances over 25 ft
(7.62 m) (cable is included for distances up to 25 ft). The controller
may be placed up to 300 ft (91.44 m) from the coils detection
station.

Single Unit Coil

System

Single Unit Coil System (Model #2060)

(also known as the co-planer system)
designed for scanning products from underneath the conveyor or
slider bed, especially where it is not possible to mount an overhead
coil. This coil can be contoured for troughed conveyors. The coil is
made from monolithic, impact-resistant PVC. The standard Models
2050 and 2055 splice detector coils (when required) work in the
same way in the same position as the standard coils.
The coil cannot be damaged by frost chunks or by other types of
over-capacity load.
The overall dimensions vary with the size and speed of the
conveyor, but normally, the size will be approximately the width of
the belt x 14 in. (355.6 mm) x 3/4 in. (19.1 mm) thick.
The coil is highly sensitive, especially near the bottom of the belt.
The sensitivity decreases rapidly with the height above the bottom
of the belt. Therefore, this coil is not recommended for scanning
belts with an average burden height over 12 in. (304.8 mm) and
tramp size less than 1 cu. in.

2-3

SciTronics Model 1080

Backlit LCD Trip

Counter

2-4

Backlit LCD Trip Counter (Model #4095)

most useful in environments where the lighting is poor, such as
underground mining installations, tunnels, etc.

Section 3 Installation

Section 3 Installation
Overview

Unpacking the Metal

Detection System

This section provides instructions for unpacking and installing the

metal detection system and options.

1. Place the shipping containers on a stable surface and open

them, taking care not to damage the contents.
2. Carefully remove the metal detection system from the
shipping containers.
3. Inspect the contents and report any shipping damage or
missing parts to the carrier as soon as possible (most carriers
will not consider a claim unless notified within 15 days of
delivery).
NOTE
The bill of lading for this shipment is an acknowledgment by the carrier of the receipt of the equipment in
good condition. SciTronics is not responsible for any
loss or damage incurred during shipment. Note any
damaged or missing parts on the carriers delivery receipt. Sign the notation and have the carriers driver
also sign it. The consignee is responsible for initiating
claims against the carrier.

Detection Coils
Station
Selecting an Installation
Location

Consider the following factors when selecting a location for the

detection coils station on the conveyor:
Allow accessibility for tramp removal.
Do not place near large metal machinery that may move or
rotate within the range of the coils field.
Do not place near high voltage and current power cables for
SCR-controlled drive and crushing equipment.

3-1

SciTronics Model 1080

Be sure that the return idler is not within 4 ft (1.22 m) up or

downstream of the coils location.
There should be a minimum of crossbracing beneath the
coils.
The tramp should not coast over the head pulley.
Remove the metal conveyor deck plate and top cover between the
idlers. If a cover is needed, replace it with wood or plastic. The
spacing between idlers should be 36 in. (914.4 mm) or greater.
Remove the metal skirting approximately 3 ft (.91 m) from the coils.
Replace it with wood or plastic if desired.

Assembling the Coils

Dual Coil System

Assemble the coils by doing the following:

1. The field generator is the top coil, identified by the four-pin
connector. Position the connector facing up through the
fiberglass support member, away from the belt.
2. The receiver coil looks like the top coil but has a three-pin
connector. Position the connector facing down through the
fiberglass support members, away from the belt. The
connector should face the side of the conveyor closest to the
controller.
3. Referring to Drawing 1080-200-02, secure the two coils to the
support members using the nylon bolts and nuts that are
included.
Arrange the coils connectors on the same side of the support frame
(the side of the support frame that will provide the most direct route
to the controller enclosure).
Since the frame has a swing-away support for generator coil
protection, mount the frame on the conveyor so the hinge
arrangement for the top coil swings in the direction of belt travel.
The coils support members are drilled so the connector end of the
coils can be placed on either side of the conveyor; mount the coils
connectors on the same side of the conveyor as the controller.

3-2

Section 3 Installation

Mounting the Structure

The coils frame has a 2-in. x 2-in. x 18-in. (50.8-mm x 50.8-mm x

3.2-mm) angle iron footing that sits directly on the conveyor
stringers. Bolt or weld it into position. Refer to Drawing 1080-20002 for the completed assembly details.
NOTE
The frame may be shipped partially assembled.
Position the frame on the conveyor stringer so that the angle-iron
footing is centered between the idler sets (equal distance from the
upstream and downstream idler sets). Refer to Drawing 1080-200011. Be sure that the belt does not rub or touch the receiver (bottom)
coil. A 1- 12-in. (38.1 mm) clearance is recommended; a clearance of
more than 2 in. (50.8 mm) is not recommended. Adjustment holes
are provided, allowing the clearance of the generator coil above the
belt to be changed.

Controller Enclosure
Mounting

Mount the controller enclosure within 25 ft (7.62 m) of the coils

cables supplied. When using additional cable, you may mount the
enclosure up to 300 ft (91.44 m) from the coils cables.
Mount the junction box (if provided) on the coils connector side of
the conveyor.
Mount the controllers of synchronized pairs of detectors (for
operation on adjacent conveyors) within range of the required
interconnected 10-ft (3.05-m) synchronizing cable.

Wiring

Power and process control wiring is not supplied. Two customersupplied electric cables are required:
One 110 V, 60 Hz, electric cable to supply power to the
detector, which is approximately 40 W.
One cable to connect the process control relay to the
conveyor and feed system.

3-3

SciTronics Model 1080

NOTE
Only 110 V power should be controlled by the relay.
Do not run 480 V lines into the controller enclosure.
Wire the controller enclosure by doing the following:
1. Make openings in the enclosure for coils and process control
and power cables on site in the bottom of the controller box.
The holes may be placed elsewhere in the controller box if
necessary.
CAUTION
Do not allow metal chips or drill turnings from the
openings to enter the detector circuitry. Although the
circuit boards are vertically mounted to minimize the
collection of debris, it is still possible for a conductive
chip to lodge between component leads, which could
destroy the electronics when power is applied.
Cleanliness and caution in this area is strongly
recommended.
2. Route the power and process control wiring through or near
the bottom of the hinge side of the enclosure.
3. Referring to Drawings 1080-101-01 and 1080-101-02,
connect power and process control wires to TS-2.
4. The coils station cables may be run in 34-in. (19.1-mm)
conduit for permanent installation. Coils station cable
connections are shown on Drawing 1080-100-011 and
identified on the instrument front panel. Connect coils cables
to TS-1: G = top coil = generator
R = receiver coils = junction box
S = splice coil
CAUTION
Sharing coils cable conduit with any other lines or
cables may result in interference.

3-4

Section 3 Installation

5. Extra cable may be coiled within the enclosure. Since the coil
cables look similar, keep them identified for pulling through
the conduit.
NOTE
The metal detection system is designed for operation
from an ac power source with neutral at or near earth
potential. The system is not designed for operation from
two phases of a multi-phase system or across the legs
of a single-phase, three-wire system.
CAUTION
Check the polarity of the power mains. Many conduits
and outlets have incorrect identification or connections.
An incorrect ground may cause major electrical damage
within the instrument when power is applied.

3-5

SciTronics Model 1080

Options
Single Unit Coil System

Refer to Section 2 - System Options for more information on the

single unit coil system option.
The single unit coil system is shipped fully assembled and ready for
installation on the conveyor. Refer to Drawing 1080-200-011B for
dimensional information.

Splice Detector

Refer to Section 2 - System Options for more information on the

splice detector option.
Install the splice detector by doing the following:
1. Referring to Drawing 1080-200-03, place the rectangular
inductance splice coil at the edge of the belt between the coils
station and the upstream idler set.
2. Position the supporting angle iron so the top of the coil is as
high as the end of the troughing idler roller.
3. Weld or bolt the support angle to the stringer approximately 8
to 12 in. (203.2 to 304.8 mm) upstream from the edge of the
adjacent receiver coil for a dual coil. Mounting distance for a
single unit coil system is 6 to 8 in. (152.4 to 203.2 mm).
4. Secure the support pipe to the angle bracket with hose
clamps.
5. Mount the coil with the connector facing down, away from
the bottom of the belt in the direction of the belt edge.
6. Adjust the clearance between the face of the coil and belt by
sliding the support pipe either up or down on the angle
bracket.
7. Set the clearance to approximately 1 in. (25.4 mm) and
tighten the clamps.

3-6

Section 3 Installation

Flag Drop Marker

Refer to Section 2 - System Options for more information on the

flag drop marker option.
Install the flag drop marker by doing the following:
1. Fabricate a simple inverted L support from 2-in. x 2-in. x 18in. (50.8-mm x 50.8-mm x 3.2-mm) angle iron.
2. Tack weld or bolt the support to the conveyor frame between
the following downstream idler set from the detector coils
aperture on the same side of the conveyor from which the
tramp is to be retrieved. Mount it at a height so that the flag
does not contact the conveyed product and is one-quarter to
one-third of the belt width from the edge of the belt. Refer to
Drawings 1080-200-05 and 1080-200-07.
CAUTION
Do not weld the enclosure to the support plate. Welding
temperatures can damage internal components.
3. Supply the required voltage (120 V or 240 V as appropriate)
to the flag drop marker. The operating cable should not share
the same conduit or tray as the coils cables.

Liquid Spray Marker

Refer to Section 2 - System Options for more information on the

liquid spray marker option.
Placement of the spray marking system must be correlated to the
conveyor belt speed so that the dye mark coincides with the detected
metal. Install the liquid spray marker by doing the following:
1. To obtain greatest accuracy from the liquid spray marker,
place the spray gun after the first idler set following the
sensor coils station.
2. Position and secure the spray gun support rod onto the conveyor
frame so that the dye will spray directly onto the product being
conveyed. You can rotate the spray gun on the support rod for
either upstream or downstream spray, as desired.
3. The dye reservoir may be located up to 10 ft (3.05 m) away
from the solenoid valve and spray gun.
Refer to Drawing 1080-200-04 for assembly of the marking system
components.
3-7

SciTronics Model 1080

Rotating Alarm Beacon

Refer to Section 2 - System Options for more information on the

rotating alarm beacon option.
Install the rotating alarm beacon on a flat surface or a 12-in. (12.7mm) pipe. Any convenient distance from the controller is
acceptable. The mounting conduit and connecting wire for the alarm
beacon are not supplied by the factory.

Remote Reset

Refer to Section 2 - System Options for more information on the

remote reset option.
Wire the remote reset to the controller enclosure by doing the
following (refer to Drawing 1080-101-02):
1. Remove the jumper on TS-2 between terminals 10 and 11.
2. Connect wires WHITE on the remote reset to terminal 10 on
the controller enclosure and BLACK on the remote reset to
terminal 11 on the controller enclosure.
3. Connect the shield wire to earth ground at terminal 1 or to a
chassis ground.
The detector may now be reset after an alarm by either pressing the
pushbutton on the controller enclosure door or by pressing the
pushbutton on the remote enclosure.

3-8

Section 4 Operation

Section 4 Operation
Overview

Startup

This section contains the startup, shutdown, and calibration

procedures for the metal detection system and describes the function
of the LED indicator lights during normal operation of the system.

1. Be sure that power is connected to TS-2 terminals 1, 2, and 3.

2. Turn the contacts switch to BYPASSED to prevent
inadvertent shutdown of the conveyor.
3. Turn the power on at the control panel.
NOTE
If the red light is on at the control panel, press the
RESET switch to put the system into its normal
operating mode.

Operation of the
Failsafe Circuitry
Option

The failsafe circuitry operates on relay K4 (refer to Drawing 1080101-01). The contacts are held in the normal operating position by
the detector power supply. If the line power fails or the detector
power supply malfunctions, these process control contacts will
change to the alarm state.
A BYPASSED/OPERATE contacts switch enables you to restore
the contacts to normal regardless of the alarm condition of the
detector. This allows you to perform setup and calibration
procedures without stopping the conveyor or dropping the marker
flag.
NOTE
The failsafe circuitry is supplied as a no-charge option
by customer request only.

4-1

SciTronics Model 1080

Shutdown

1. Turn the contacts switch to BYPASSED so the conveyor will

continue operation.
2. Turn the power off at the control panel.
NOTE
If you do not turn the contacts switch to BYPASSED,
the conveyor is turned off also.

System Calibration
Sensitivity Control

NOTE
Calibration can be performed with the contacts in
bypassed mode. Refer to Operation of Failsafe
Circuitry in this section of the manual.
Adjust the metal detection system for the desired detection
sensitivity by doing the following:
NOTE
You can make this adjustment with the belt stopped if
desired. Move the test tramp by hand through the
detection coils at approximately the same rate as the
actual belt speed.
1. Select a round or cube shape piece of tramp approximately
the size of the smallest piece of metal to be detected.
NOTE
A round or cube shape piece of tramp produces the
most uniform calibration results.
2. Transfer the metal through the coils at approximately the
speed of the belt.

4-2

Section 4 Operation

3. Adjust the tramp sensitivity control to a value that causes an

alarm each time the metal travels through the coils. Moving
the control knob clockwise increases the sensitivity to detect
the smaller sizes of tramp. Moving the control knob
counterclockwise decreases the sensitivity, causing the
system to detect only larger tramp.
4. If the value needed to attain the desired sensitivity is greater
than 8 or less than 3, change the scale factor by doing the
following:
1) Locate the control recessed behind the panel.
2) Using a screwdriver, turn the screw counterclockwise to
shift the scale to lower the sensitivity and clockwise to
shift the scale to increase the sensitivity. By adjusting the
scale factor control, you can achieve the desired
sensitivity within the sensitivity control range of 8 and 3.
NOTE
If the test tramp is elevated above the bottom of the
belt during adjustment to simulate riding on top of the
burden, a smaller piece of tramp will cause alarm if it
passes through the coils on the bottom of the belt. This
is normal because even multicoil detection systems are
less sensitive near the center of the aperture.

Splice Detector

Calibrate the splice detector by doing the following:

NOTES
1. Follow steps 15 for the Model 2050 and steps 1,
4, and 5 for the Model 2055.
2. Before calibrating the splice detector, be sure that
you have already calibrated the sensitivity control
by following the procedure in Sensitivity Control
in this section of the manual and set the threshold
control to 10.
1. Turn the conveyor on so the belt is running and turn the
contacts switch to BYPASSED so the conveyor operation will
not be interrupted if the detector alarms on the splice.

4-3

SciTronics Model 1080

2. Set the splice sensitivity dial to 2.

3. Adjust the splice scale control (screwdriver slot) so that the
splice indicator light turns on each time the splice clamps
traverse the coil. Increase the splice sensitivity setting to 7.
4. Adjust the DURATION control so the splice just clears the
detection coils without alarm. Increase the setting slightly to
provide a margin for normal operational variations in speed
and loading.
NOTE
Repair patches must be marked with four or more pilot
clips, which should be mounted starting at the edge of
the belt that is scanned by the splice coil. Align them
with the leading edge of the clamp repaired area.
5. Decrease the threshold setting incrementally from 10 until the
splice just causes alarm after passing through the coils. Then
increase the setting by a value of 1 to allow for minor
variations caused by conveyor loading, etc.
NOTE
Because the variations in the above procedure depend
on the individual characteristics of each conveyor belt,
the margin required for reliable operation varies and
must be determined on site.

Alarm Delay

The alarm delay control can be used to calibrate a metal marking

device or to stop the conveyor at a more accessible location for
removing tramp. Otherwise set it to zero.

Alarm Duration

The alarm duration control can be used to time the duration of a

spray-type metal marker or diverter gate for automatic tramp
removal. Otherwise set it to zero.

4-4

Section 4 Operation

Flag Drop Marker

Option

Use the alarm delay control to calibrate the flag marker. Adjust the
control to provide a sufficient delay for the flag to land on the tramp
location. This method allows the marker to be located any
convenient distance from the coils sensing station.
CAUTION
To minimize the possibility of losing the flag marker
or causing an inadvertent shutdown of the conveyor,
always turn the contacts switch to BYPASSED when
adjusting the metal detection system or turning the
power either on or off.

Liquid Spray Marker

Option

Calibrate the liquid spray marker by doing the following:

1. Be sure the conveyor is traveling at its rated speed and that
the metal detector is turned on.
2. Place a piece of tramp metal on the belt.
3. Observe the actuation of the marker as the tramp passes
through the sensor coils station.
4. Adjust the alarm delay control until consistent spotting of the
tramp is achieved.
5. Adjust the alarm duration control to increase or decrease the
duration of the spray, as desired.
6. The spray gun on the support rod can be rotated for finer
calibration control while using the minimum alarm delay
time.

Long Bar Detector

Option

Calibrate the long bar detector by doing the following:

1. Turn the conveyor on if it is not running.
2. Select a piece of tramp approximately the size to be detected.
3. Adjust the tramp sensitivity control to zero so there is no
interference with the bar calibration.

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SciTronics Model 1080

4. Start with a high sensitivity setting on the long bar detector to

establish that the selected bar tramp is within the detectable
range. Lower the setting, reducing the sensitivity on
subsequent passes of the tramp through the coils station until
the tramp is just reliably detected.
NOTE
The scale adjustment (screwdriver access) may be set
so the required detection is within midrange of the
sensitivity control.

LED Indicator Lights

The LED indicator lights monitor the following:

Coil Drive
This light turns on to indicate the correct connection and
operation of the generator (top) coil.
Power A, B, and C
This light turns on to indicate proper functioning of the three
main power blocks of the detector electronics.
ASP
This light indicates operation of the automatic spike
protection circuitry. The light is off or flickers momentarily
during normal operating conditions. When the light remains
on or flickers continuously, a problem in the receiver coils
(bottom) or cables is indicated.
Splice
This light indicates operation of the splice detector and turns
on when the splice goes through the coils station.
During normal operation, the coil drive and power A, B, and C
lights should turn on. The ASP light should be off and the splice
light should turn on only when the splice passes through the coils
station.

4-6

Section 5 Maintenance and Troubleshooting

Section 5 Maintenance and Troubleshooting

Overview

This section explains how to fix minor problems that occur with the
metal detection system, such as detecting damaged connectors,
coils, and cables.
NOTE
Any repair to the metal detection system should be done
by someone knowledgeable in electronics using a
quality oscilloscope.

Maintenance

No periodic maintenance is either required or recommended.

Spare Parts

No spare parts are recommended. Replacement indicator lights,

fuses, and socket-mounted relays and ICs are standard and usually
available locally. The factory maintains an inventory of all
components in case an item is not available in your area.

Troubleshooting

A problem is indicated when the metal detector does not detect

tramp or when it alarms at random or on a splice/repair area.
The electronics in the metal detector are technically complex.
Therefore, a quality oscilloscope and knowledge of electronics are
required to correctly diagnose an electronic problem. Since the
majority of field problems consists of damaged connectors, severed
or bruised cables, and an occasional IC component failure, a
knowledgeable electrician using a volt-ohmmeter and inexpensive
ICs can correct most of the problems encountered. The information
following addresses these types of problems.

Gaining Access to the

Electronics Modules

To gain access to the electronics modules, first remove the control

knobs on the cover panels using a 116-in. Allen wrench.

5-1

SciTronics Model 1080

Diagnostic LEDs
Coil Drive Indicator Light

The coil drive indicator light turns on when the generator coil,
cable, and connectors are operating properly. When the light is
not on, the metal detector will not detect tramp metal. Check the
coil and cable for damage. Using the ohmmeter, check the cable/
connector assembly for an open circuit or shorting between wires.

Power A Indicator Light

When the power A indicator light is not on, the detector may still
function but only at half or less of normal sensitivity. Replace IC
74C221 and IC 74C00.

Power B Indicator Light

When the power B indicator light is not on, the detector may still
function but only at half or less of normal sensitivity. Replace IC
74C221 and IC 74C00.

Power C Indicator Light

The power C indicator light should be continuously lit. If it is not,

the detector may indicate false alarms. Replace IC 74C20 (two).

ASP Indicator Light

The ASP indicator light flickers or turns on only when

intercepting potential alarm-causing interference. If the light
is on continuously, there may be a problem in the receiver
coil and cable system. Use the ohmmeter to check for continuity
of the coils and cable. The receiver coil resistance at the
connector with standard 25 foot cable lengths is
approximately 540 ohms 10%

Splice Indicator Light

The splice indicator light turns on only when the splice coil senses
metallic clips. When clips cannot be detected even at maximum
splice sensitivity, check the physical alignment of the coil. The
belt may have traversed out of the detection range of the coil.

5-2

Section 6 System Specifications

Section 6 System Specifications

Operational
Specifications

Tramp Metal

Detects both nonmagnetic and

magnetic metals.

Sensitivity

Maximum sensitivity is approximately

5% of aperture height; stable to 10%
within the same sector of the aperture
location.

Conveyor Velocity

Minimum: 6 ft/min (1.83 m/min).

Maximum: 1,200 ft/min (365.76
m/min).

Indicators

Red alarm light.

Green ready light.
Alarm totalizer: electronic LCD
counter, NEMA 4. May be wired to
provide zero set from front of case.
Backlit LCD (option).

Electrical
Specifications

Reset

Manual pushbutton switch located

between the indicator lights on the
enclosure door. Jumper-wire
selectable for automatic reset. Remote
stations available.

Line Power

Dual primary power transformer for

240/120 V 10%; 50/60 Hz; 40 VA; 1
phase.

Fuse Protection

Fuse: 1 A at 120 V: 0.5 A at 240 V.

Timed Output Contacts

One single-pole double-throw (SPDT)

passive contact set. 120 V at 10 A ac.

6-1

SciTronics Model 1080

Process Control Contacts

The alarm activates two sets of

passive isolated contacts: one set is
wired normally closed and one set is
wired normally open. Specify for
other contact arrangements. 120 V at
10 A ac.

Marker Contacts

Timed normally open passive contact

set. 120 V at 10 A ac.

Beacon/Horn Contacts

One passive normally open contact

set. 120 V at 10 A ac.

Spare SPDT Contacts

One SPDT passive contact set.

Jumper-wire selectable for timed
activation. 120 V at 10 A ac.

Operators

Relays, lights, and counter are

powered by a regulated 12 V supply
to ensure long operating life.
Socket plug-in electromechanical
relays with 2P2T and 3P2T contacts.
Relay coils rated for 12 V dc at 0.1 A.
#756 14 V dc bulb.

Physical
Specifications

Controller

NEMA 12 enclosure
Dimensions: 20 in. x 20 in. x 8 in.
(508 mm x 508 mm x 203.2 mm)
Includes lockable latch handle and
drip shield. NEMA 9, 7, and 4
available.
Control instrument and sensors rated
from 30o F to 140o F (34.4o C to
60o C). Specified for outdoor allweather use.

Coils

6-2

Sensor coils constructed from

monolithic, impact-resistant PVC.

Section 6 System Specifications

Coils Support Structure

Fabricated from Extran 500 fiberglass

reinforced pultrusions. Fire retardant
Extran 525 available.

Weight

Controller: 60 lb (27.21 kg).

Coils Set: 40 lb (18.14 kg), 42-in.
(1,067-mm) size.
Structure: 30 lb (13.61 kg).
Cables: 5 lb (4.54 kg).
Coils Junction Box (if provided): 5 lb
(4.54 kg).

6-3

SciTronics Model 1080

6-4

Section 7 Drawings

Section 7 Drawings
List of Drawings

This section includes the following drawings for your metal

detection system:

1080-100-01

Wiring Diagram, Coils Station

Connections (TS-1) with 3-coil flat
sensor coils

1080-100-01A

Wiring Diagram, Coils Station

Connections (TS-1) with 2-coil flat
sensor coils

1080-100-01B

Wiring Diagram, Coils Station

Connections (TS-1) with underbelt
mono coil flat

1080-100-011

Wiring Diagram, Coils Station

Connections (TS-1) with 3-coil sensor
coils contoured receiver coils

1080-100-011A Wiring Diagram, Coils Station

Connections (TS-1) with 2-coil sensor
coils contoured receiver coils
1080-100-011B Wiring Diagram, Coils Station
Connections (TS-1) with underbelt
mono coil contoured
1080-100-011C Wiring Diagram, Coils Station
Connections (TS-1) with underbelt
mono coil U-shaped
1080-100-011D Wiring Diagram, Coils Station
Connections (TS-1) with open-ended
search coil

1080-100-02

Wiring Diagram, Transducer Connections

(TS-1) with pipe coil

1080-101-01

Schematic, Power and Process Control

Connections (TS-2)

7-1

SciTronics Model 1080

1080-101-02

Wiring Diagram and Process Control

Connections (TS-2)

1080-200-00

NEMA 12 Enclosure

1080-200-000

NEMA 4 Enclosure

1080-200-01

Coil Support Structure 3-coil flat

sensor set

1080-200-011

Coil Support Structure 3-coil

contoured sensor set

1080-200-011A Coil Support Structure 3-coil

contoured sensor set

1080-200-02

Coil Support Structure Assembly

1080-200-03

Splice Detector Coil Mounting

1080-200-04

Liquid Spray Metal Marker

1080-200-05

Flag Drop Metal Marker Enclosure

and Dimensions

1080-200-07

Flag Drop Metal Marker Mounting

Location

___________

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7-2