SENSOR GUARD 2000

TABLE OF CONTENTS
SECTION
1 INTRODUCTION ......................................................................................PG 3
2 SPECIFICATIONS ......................................................................................PG 5
3 GENERAL DESCRIPTION ........................................................................PG 7
4 INSTALLATION .......................................................................................PG 11
5 SET UP-START UP ..................................................................................PG 25
6 OPERATION ............................................................................................PG 45
7 MAINTENANCE ......................................................................................PG 53

LIST OF FIGURES
FIGURE
1 SYSTEM DIAGRAM ...................................................................................PG 4
2 SYSTEM DIAGRAM ...................................................................................PG 7
3 INPUT PULSES - TIME MODE ...............................................................PG 8
4 INPUT PULSES - DISTANCE MODE ......................................................PG 8
5 SAMPLE CALIBRATION REPORT ...........................................................PG 8
6 CONVEYOR DETECTOR HEAD SITES .................................................PG 11
7 MULTIPLE CONNECTIONS - PROXIMITY SENSOR ..........................PG 12
8 SYSTEM DIAGRAM .................................................................................PG 13
9 DETECTOR HEAD MOUNTING ...........................................................PG 14
10 DETECTOR HEAD MOUNTING BRACKETS .......................................PG 15
11 DETECTOR HEADS - VERSIONS .........................................................PG 16
12 WIRE SIZE TABLE ...................................................................................PG 18
13 SYSTEM DIAGRAM .................................................................................PG 19
14 TERMINATION CARD............................................................................ PG 21
15 INPUT CONNECTIONS .........................................................................PG 22
16 OUTPUT CONNECTIONS .....................................................................PG 23
17 FRONT PANEL CONTROLS AND INDICATORS................................. PG 24
18 MENU SCREENS .....................................................................................PG 24
19 INITIAL PARAMETER SETTINGS ......................................................... PG 26
20 SAMPLE CALIBRATION REPORT .........................................................PG 27
21 TERMINATION CARD - HARDWARE ADJUSTMENTS .......................PG 41
22 PROCESSOR CARD - HARDWARE ADJUSTMENTS ............................PG 43
23 INITIAL PARAMETER SETTINGS .........................................................PG 44
24 SAMPLE CALIBRATION REPORT - NA LOOP 74.................................PG 48
25 FRONT PANEL CONTROLS AND INDICATORS................................. PG 50
26 MENU SCREENS ..................................................................................... PG 50
27 PARAMETER RECORD FORM ...............................................................PG 56

PG 1
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PG 2
 SECTION 1 - INTRODUCTION

SENSOR GUARD 2000 is a microcontroller based belt rip detection system. It can
stand alone, or be linked with other devices for central reporting and annunciation. A
microprocessor has been designed into the conveyor industry’s most successful belt
protection system - SENSOR GUARD.

Sensor loops are placed in the belt and monitored by detectors at the high potential
damage points. If the belt begins to rip, a sensor is destroyed and no longer detected.The
distance between loops is used to protect the conveyor belt at any speed, or if using a
quadrature pulse device, in either direction, the instant it starts to move. Unique patterns
of sensor loop locations are stored and used to optimize damage detection. The processor
maintains and prints, upon command, the following; event logs, alarms, system parameters
and the sensor loop placement pattern. If a sensor loop is damaged by trapped material,
etc. it is easily identified and deleted until a scheduled downtime permits its replacement.
The system continues Sensor Guard’s tradition of ruggedness in the harshest of mining
environments. No routine service is required. All major active components of the control
unit are on a single card with plug in connections.

SENSOR GUARD 2000 combines the benefits and flexibility of a computer with the
unequalled tradition of reliability, value and proven field performance of Sensor Guard.

PG 3
 FEED
SENSOR LOOPS HOPPER

BELT

DETECTOR
HEADS
CONTROL UNIT

PULSE SOURCE

CABLE
TO CONVEYOR CONTROLS

Figure 1 Sensor Guard 2000 System Diagram

PG 4
 SECTION 2 - SPECIFICATIONS
CONTROL UNIT
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . .12˝ W x 18˝ H x 7.25˝
(305 x 457 x 184mm)
FRONT DOOR CLEARANCE . .12˝ (305mm) PATH FROM LEFT SIDE
WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 lb (15.4 kg)
INPUT POWER . . . . . . .110/220 VAC 50/60 HZ or 7.5 VDC +- 10 %
OUTPUT POWER . . . . . . . . . . . . . . . . . . . . . .7.5 / 15 VDC 0.5 AMPS
OUTPUT CONTACTS . . . . . .RIP STOP, FAIL STOP, & AUXILIARIES;
ACTIVE, BY PASS, CALIBRATE . . . . . . . . . . . . . . . . . . .10A 277VAC,
15A 120VAC/30VDC RES
TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . . .-20 TO 50 DEG C

DETECTOR PAIR
DIMENSIONS . . . . . . .2ea 5.5˝ DIA x 4˝ (140 x 101mm) CYLINDERS
PLUS (POST 1995 UNITS) . . . . . . . . . . . . . . . . . . .8.5˝ x 11.5˝ x 4.5˝
(216 x 292 x 114mm) ENCLOSURE
WEIGHT . . . . . . . . . . . . . . . .12.5 lb (5.7kg) (POST 1995) 20 lb (9kg)
INPUT POWER . . . . . . . . . . . . . . . . . . . . . . . . . .7.5 / 15VDC 50 ma
OUTPUT SIGNALS . . . . . . . . . . . .POSITIVE 6.5 / 14 VOLT PULSES
TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . .-40 TO 100 DEG C

DETECTOR MOUNTING BRACKETS

MATERIAL . . . . . . . . .STEEL TUBING AND ALUMINUM KNUCKLE
DIMENSIONS . . . . . . . . . . . . .4˝ X 16˝ TO 28˝, (101 X 404 X 711mm)
3˝ X 4˝ (76 X 101mm) BASE PLATE
WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 LB (3.6 KG)

PROXIMITY SENSOR (3 WIRE NPN NORM OPEN)

DIMENSIONS . . . . . . . . . . . . . . . . . .1.181˝ DIA X 2˝ W 6 FT CABLE
(30 X 50 W 2M)
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..10 - 30 VDC / 200 MA
TEMPERATURE RANGE . . . . . . . . . . . . . . . . . . . . .-40 TO 70 DEG C

ENCODER (OPTIONAL FOR REVERSING CONVEYORS - QUADRATURE)

DIMENSIONS . . . . . . . . . . . . . . . . . .3˝ X 3˝ X 7˝ (76 X 76 X 178MM)
WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 LB (1.8 KG)
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30 VDC 100MA
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . .NPN OPEN COLLECTOR
TEMP RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 TO 70 DEG C

SENSOR LOOPS
PATENTED STAINLESS STEEL FIGURE EIGHT CONFIGURATION

PG 5
THIS PAGE INTENTIONALLY LEFT BLANK.

PG 6
 FEED
SENSOR LOOPS HOPPER

BELT
SENSOR

DETECTOR
HEADS CONTROL
UNIT

PULSE SOURCE
CABLE

TO CONVEYOR CONTROLS

Figure 2 Sensor Guard 2000 System Diagram

SECTION 3 - GENERAL DESCRIPTION

The system consists of sensor loops, normally factory installed in the pulley (bottom)
cover, a pair of detector heads with mounting brackets, a proximity sensor, encoder or
other pulse source, and a control unit.

The detector heads are mounted just past the high risk area(s). As the belt moves,
sensor loops in the belt pass over the heads which produce a pulse that is transmitted to
the control unit. The control unit compares time or distance pulses with a target stored in
its’ memory. If the belt is being damaged, a sensor loop is broken and no detector head
pulse is produced. The maximum allowable target stored in the control unit is exceeded
and the conveyor is stopped.

PG 7
 8 7
SECONDS SECONDS
DETECTOR CONTROL
HEADS UNIT
SENSOR LOOP PRODUCED PULSES

Figure 3 Input Pulses — Time Mode

BELT TRAVEL PRODUCED PULSES

PULSE
SOURCE
8 ENCODER PLS 7 ENCODER PLS
CONTROL
UNIT
DETECTOR
HEADS
SENSOR LOOP PRODUCED PULSES

Figure 4 Input Pulses — Distance Mode

LOOP TIME COUNTS DISTANCE

1 3.0 sec 15 cts 50.0 ft

2 6.1 sec 32 cts 100.9 ft
3 8.2 sec 42 cts 135.0 ft
4 5.9 sec 27 cts 97.0 ft
5 6.1 sec 32 cts 100.8 ft

~ ~ ~ ~
~ ~ ~ ~
74 6.1 sec 32 cts 100.8 ft
75 6.1 sec 32 cts 100.9 ft
76 (1) 3.0 sec 15 cts 50.0 ft
77 (2) 6.1 sec 32 cts 100.9 ft
78 (3) 8.3 sec 42 cts 135.0 ft
79 (4) 5.9 sec 27 cts 97.0 ft
80 (5) 6.0 sec 32 cts 100.0 ft

Figure 5 *Sample Calibration Report

SHOWS PATTERN REPEAT ON A BELT WITH 75 SENSOR LOOPS

PG 8
 THERE ARE THREE MODES OF SYSTEM OPERATION

1. STANDARD TIME MODE - In this mode the SENSOR GUARD 2000 functions
much as the original SENSOR GUARD. A belt run input signal is required (see pg
22-23) It starts a timer that allows the belt to reach the designated speed before
starting protection. The target is the longest interval in time between loops, seen
during calibration, plus the tolerance entered. During calibration the conveyor is
stopped and an alarm indication is given if the base level maximum time is
exceeded.
See Figure 3, Pg. 8

2. STANDARD DISTANCE MODE - This is the simplest distance mode and the
best choice when all the loops are functional and at approximately equal intervals.
Whenever the belt moves, a proximity sensor or other device provides pulses
corresponding to the distance traveled. During calibration, SENSOR GUARD
2000 records the number of pulses between the sensor loops in the belt. It labels
each loop, beginning with number one at the shortest interval. It uses the longest
interval plus the tolerance selected to establish the maximum distance allowed
without seeing a loop. If this maximum amount is exceeded when in normal
operation, the conveyor is stopped and a rip is indicated. During calibration, the
conveyor is stopped and an alarm indication is given if the base level maximum
distance is exceeded.
See Figure 4, Pg. 8

If the exact number of sensor loops is calibrated, the ID number of each sensor
loop will stay the same each revolution of the belt. This facilitates locating sensor
loops, splices and other areas of the belt. Every time power is applied the system
searches for the shortest interval and resynchronizes, maintaining the same number
for each sensor loop in the belt.
See Figure 5, Pg. 8

3. PATTERN DISTANCE MODE - This is the most useful mode for belts with loops
at random distances or when damaged loops need deactivated. When in this mode,
each intervals calibration value plus tolerance is used as its maximum distance
before indicating a rip. Since each interval’s value is used, the pattern in memory
must stay in sync with the belt. The correct number of loops must be entered for
proper calibration. The operation is correct if the pattern repeats with each
revolution of the belt. Each sensor loop maintains the same number. Calibration
always exits into the standard distance mode so that the count can be checked
before switching to pattern mode. System disturbances (such as power outages)
may cause the count to loose sync with the belt. Each time power is applied the
system searches for the shortest interval and re-syncs. While it is searching it
protects to the longest interval in memory plus the tolerance.

PG 9
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PG 10
 SECTION 4 - INSTALLATION

2
1

45 4 3

Figure 6 Typical Conveyor Detector Head Sites

DETECTION SITES: Each place where damage can occur should be considered for
protection. Typical sites are after;

1. loading points - about 94% of the incidents of damage

2. discharge points - about 4%
3. take ups and
4. turnovers - about 2%

PG 11
 CONNECT POSITIVE VOLTAGE
TO FIRST UNIT ONLY
TB2
V+
8
COM COM
GND

2
CHAN A CHAN A
A+
4
CHAN B CHAN B
B+

PULSE SOURCE EXISTING DEVICE OR CONTROL UNIT

1ST CONTROL UNIT

TB2

V+
+15 7

COM COM
GND 8
2
CHAN A CHAN A A+

4
CHAN B CHAN B B+

PULSE SOURCE EXISTING DEVICE OR CONTROL UNIT

1ST CONTROL UNIT

NOTE: For single channel devices channel B is not used

Figure 7 Multiple Connections To A Pulse Source

Bolt heads, key stock or chain sprockets are examples

of good targets on side of pulley or end of shaft.

NOTE: Requires 1 to 10 targets per foot of belt travel

PG 12
 FEED
SENSOR LOOPS HOPPER

BELT
SENSOR

DETECTOR
HEADS

PULSE SOURCE

CABLE

CONTROL TO CONVEYOR CONTROLS

UNIT

Figure 8 System Diagram

CONTROL UNIT The control unit is mounted in a steel enclosure with gaskets.
While moderate exposure to the elements can be tolerated, eye level height in a typical
control room, or mounting inside a larger enclosure, is recommended. Placing the control
unit close to the protected site reduces cabling costs. It also reduces the risk of resetting
the unit from a remote location without checking the belt condition first.

1˝ by 1.25˝ (25 by 31mm) mounting tabs are located at the top and bottom of the
enclosure with 3/8˝ (9.5mm) on a 9.5˝ by 19˝ (241 by 483mm) pattern.

PROXIMITY SENSOR (DISTANCE MODES) Whenever possible, use al least 1/4˝

(6 mm) steel targets mounted on a non-driven pully which has at least a 90 degree wrap.
Where slip is not a problem, a driven pulley or an exposed shaft on the gearbox can also
be used as alternate mounting locations.

ENCODER Use the same slip precautions with a fixed mount and flexible coupling.

The control unit’s high input impedance allows it to be connected in parallel with
many devices already having pulse sources attached to the conveyor. When possible, this
simplifies the installation and reduces the cost, the number of devices that can fail and the
requirement for spares. or devices
See Figure F, Pg. 12 for multiple connections
See Figure 12, Pg. 18 for wire sizes

PG 13
 TYPICAL AVERAGE DIMENSIONS
8.5”
216MM 8.5”
216MM
LED &
ADJ FACE
TOWARD
EDGE OF
BELT BELT

3”, 75MM UNLOADED

1”, 25MM LOADED

NOTE: FACES OF DETECTORS MUST BE PARALLEL TO BELT SURFACE

TERMINAL BOX

NOTE: DETECTOR HEADS MUST BE DIRECTLY IN LINE ACROSS FROM EACH OTHER

12”-15”
305-381MM

TRAVEL

Figure 9 Detector Head Mounting

PG 14
 HEX HD BOLT
3/8-15 X 1.0” (25)
SELF LOCKING NUT

APPROX.
18.0” (457)

6 SET SCREWS
2 REQUIRED
2 PER AXIS

APPROX.
12.0”
(305)

DIMENSIONS IN ( ) ARE IN MILLIMETERS

(12.6)
.5”
(31.5)
(9.59) 1.25”
(69) .38” DIA.
2.75”
(104)
4.0 (31.5)
1.25”
.62”
(37.9)
(15.6) 1.5” (9.59)
.38” DIA.
3.0”
2 HOLES
(75.75)

16.25”
(410) 15”
(379)

(385) (379)
15.75” 15”

(3.1)
.125 35 DEG

Figure 10 Detector Head Bracket

PG 15
 4 CONDUCTOR
SHIELDED CABLE
TO THE CONTROL
UNIT

LED
GAIN LINK

ADJUSTMENT PORT

PRE 1995 DETECTOR HEADS

TERMINATION
BOX - DOOR
SHOWN OPEN

3-4 CONDUCTOR
SHIELDED CABLE
TO THE CONTROL
UNIT

POST 1995 DETECTOR HEADS

Figure 11 Detector Heads

PG 16
DETECTOR HEADS See Figures 9, 10, & 11, Pgs. 14 - 16

The same general mounting instructions apply for both types of detector heads, the
Pre-1995 manually adjustable units and the newer auto-adjusting ones. The major
difference is the termination box for the newer detectors. It should be mounted to the
side of the conveyor structure in an accessible location.
Box Dimension 8˝ x 11.5˝ x 4.5˝(203 x 292 x 114mm).
Hole Pattern 6˝ x 10.75˝ (152 x 273mm).

The pre-1995 manually adjustable detector heads should have the primary head with
the adjustment plug mounted on the accessible side of the conveyor. The other head has
an exposed rubber spot with the gain link imbedded in it. If the belt is wider than 48"
(1200mm) this link should be cut. Carefully remove enough of the silicone rubber to
expose the short bare wire. Cut this link. Spread the two halves apart and fill the hole
with silicone rubber or a similar waterproof compound. Adjust the heads when the belt is
stopped and there is no loop within 3 feet of the heads. The sensor loops are easily
located by a number branded into the cover. Slowly turn the screwdriver slot, located
behind the plug, until the red LED just goes out. Reverse the direction and turn 10
degrees. The LED should now stay on until a sensor loop passes by. It should go off and
come right back on.

Inside the front cover of the auto adjusting detector termination box is an assembly
with terminal strips and two LEDs. The yellow LED indicates power is on and the circuits
are functioning, ready for a sensor loop to pass by. The green LED is marked loop. It
comes on and yellow goes off each time a good sensor loop passes the detector heads. On
power up, the green LED stays on for up to 20 seconds, while the circuits are charging,
before switching to the yellow LED.

The mounting brackets provide head position adjustment. They should be bolted to
the conveyor structure so proper head position can be achieved. Care should be taken to
avoid steel bracing or large masses of metal. The center of each head should be nominally
8.5˝ (216mm) from the edge of the belt. The detector face should be parallel to, and
about 3˝ (75mm) from, the unloaded belt surface, or 1˝ (25 mm) from the loaded
surface.

PG 17
 DISTANCE FROM WIRE SIZE
DETECTOR HEADS OR PULSE SHIELDED CABLE
DEVICE TO CONTROL UNIT

1,000 ft ( 305m ) #20 A.W.G. (.75 mm2)

3,000 ft ( 915 m ) #18 A.W.G. (.75 mm2)
6,000 ft ( 1839 m ) #16 A.W.G. (1.5 mm2)
15,000 ft ( 4575 m ) #14 A.W.G. (2.5 mm2)
30,000 ( 9150 m ) #12 A.W.G. (4 mm2)

Figure 12 Wire Size Table

Distances over 5,000 ft (1500 m) are possible but not recommended.

PG 18
 TERMINATION - WIRING

FEED
SENSOR LOOPS HOPPER

BELT
SENSOR

DETECTOR
HEADS

PULSE SOURCE

CABLE

CONTROL TO CONVEYOR CONTROLS

UNIT

Figure 13 System Diagram

Whenever possible, bring the conduits into the bottom of the control box, termination
box and pulse device to minimize the entry of contaminants.

110/220 VAC—50/60 HZ, or 7.5 VDC operation is possible. Wire according to the
appropriate local code. The 110/220 selector switch is under the bottom wiring cover
with the incoming AC power terminals.

A 20 gauge, or larger, 2 pair shielded twisted cable is required from the detector heads
and a 2 pair from the pulse device to the control box. Do not run them with high power
or high current (1 amp or above) control lines. It is permissible to run these cables in
conduits with low level signal conductors. The use of multi-colored cable is strongly
recommended to reduce the likelihood of misconnections.
See Figure 12, Pg. 18.

PG 19
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PG 20
 Figure 14 Termination Card

All outside connections except for incoming ac power are made on this card. Relays,
power supplies and all other parts that may be at line voltage potential are mounted on it.
Located at the back of the control unit, it is convenient for wiring from any side.

PG 21
 FOR TIME MODE OPERATION, A
CONTACT CLOSURE OR ACTIVE COMMON
SIGNAL IS NEEDED TO INDICATE THE BELT
IS RUNNING, OR AT FULL SPEED.
BELT RUN

SP WHT
OUT-
OUT+ RED
DC-
DC+ BLK
SHIELD

DETECTOR
HEADS (no longer need blue wire)

F CH. GND SHIELD

A+
BLK
E
A-

D B+

B-
C
+7.5V

B +15V BRN
A GND BLU

OPTIONAL
PROXIMITY
QUADRATURE
SENSOR
DEVICE
(sngl chan)

OPTIONAL INPUT FROM

EXTERNAL 7.5 V DC
POWER SUPPLY

THE 110/220 VAC INPUT TERMINALS AND THE SELECTOR SWITCH ARE BEHIND
THE CIRCUIT BREAKER COVER BELOW THE TERMINATION CARD

INPUT CIRCUIT
BREAKER SWITCH
110V- OR 220V-
ON 110V
110V- -

- 200V-
OFF 220V
- EARTH GROUND-

Figure 15 Termination Card & AC Power Input Connections

(left hand side)
PG 22
 BELT RUN, LINE VOLTAGE

INPUT (TIME MODE)

OPTIONAL
AUX RIP STOP
CONTACTS FOR CONNECTION TO INDICATORS

FAIL FRONT TO
STOP PANEL CUSTOMER
JUMPER BYPASS BELT STOP
SWITCH CIRCUITS

AUX ELECTRONIC FAIL

CONTACTS

BYPASS

SYSTEM STATUS
INDICATING CONTACTS
CALIBRATE FOR OPTIONAL
CONNECTION TO
OPERATOR DISPLAYS

ACTIVE

Figure 16 Termination Card Output Connection (right side)

Rip stop, fail stop, auxiliary and status contacts are under the wiring cover on the
right. Rip and fail stop contacts are normally wired in series, with the bypass switch
around both. Electronic failures or belt damage will open contacts and stop the conveyor.
(normally open held closed)

The fail stop contacts can be separated and used for annunciation only. Remove the
jumper between the rip stop and the fail stop contacts. Move the bypass switch wires to
the rip contacts only. Connect the annunciation to fail stop or fail auxiliary contacts.
CAUTION!! THIS WOULD LEAVE THE BELT VULNERABLE TO DAMAGE AND IS NOT
RECOMMENDED.

PG 23
 RED YELLOW GREEN
L E D L E D L E D
RIP/FAULT BYPASS/CAL ACTIVE
SITE CONVEYOR DETECTION NEXT
ID STATUS MODE LOOP

C6HD BELT STOPPED STD DIST L=12

L C D DISPLAY

NORMAL SCREEN

ACTIVE
BYP CAL
KEYPAD

KEYSWITCH

Figure 17 Front Panel Controls and Indicators

Pressing <MENU> briefly displays “main menu” then shifts to the first of five active
menus. Switch from one to another by pressing its number, or <NEXT>, <PREV>.

1. Display event log

2. Display calibration log
3. System parameters
4. Diagnostics
5. Set date and time

Figure 18 Menu Screens

PG 24
 SECTION 5 - SET UP - START UP

See Figures 17 & 18, Pg. 24

MENU ITEM 5. DATE AND TIME…must be entered when the system is installed.

1. Put the key switch in <BYP> bypass.

2.. From the normal screen or menu screen press <5> then <ALTER>.
3. Press <ENTER> until the cursor is at the spot to be changed.
4. Press in the desired value then press <ENTER>.
5. When the changes are complete, press <OK> to load them into memory. Return
the key switch to original position.

MENU ITEM 3. PARAMETERS…are the items that need to be entered into the
control unit to customize it to your application. The control unit is delivered with initial
values that will let a typical conveyor run protected with few changes. They can be viewed
from the main or menu screen.
See Figure 19, Pg. 26

1. Press <3>. The first display will be site ID.

2. Press <NEXT> to step through the parameters.
3. Move key switch to bypass and press <ALTER> at the parameter you wish to
change.
4. After all of the changes have been entered press <OK> to store them in memory.
Return the key switch.
5. Pressing <ESCAPE> instead of <OK> erases the changes.

PARAMETER 1. SITE ID…allows reports and alarms to be customized for each

location. It can be any four digit alpha-numeric designation.

1. Put key switch in <BYP> bypass.

2. Press <ALTER> and the left most digit will blink.
3. Press <NEXT> or <PREV> until the character is correct.
4. Press <ENTER> and the next digit to the right will blink.
5. When the last digit is entered pressing <NEXT> will advance to the next parameter,
or if finished press <OK> to put the changes in memory. Return the key switch.

PG 25
PARAMETER INITIAL VALUE

1. Site ID xxxx
2. Number of loops 75
3. Mode STD Distance
4. Encoder Counts Reduction Ratio 1:1
5. Min Counts between Head Pulses 3

DISTANCE PARAMETERS

6. Base Protection Distance (ft) 1000

7. Distance Tolerance (%) 50
8. Max Head Pulses w/out Encoder Cts 4
9. Encoder Direction Forward
10. Encoder Counts/Rev 15
11. Measurement System English
12. Pulley Diameter (in) 60
13. Loop 1 Search Tolerance (cts) 2
14. Search for Loop 1 After Rip Stop? No

TIME PARAMETERS

6. Base Protection Time (sec) 35

7. Time Tolerance (%) 50
8. Min Time Between Head Pulses 1 sec
9. Max Head Pulses w/out Belt Input 4
10. Belt Start Delay (mm:ss) 50 sec

Figure 19 Initial Parameter Settings

PG 26
 PARAMETER 2. NUMBER OF LOOPS…for time or standard distance modes this
value must be equal to or greater than the actual number of sensor loops in the belt.
These modes protect to the largest interval recorded during calibration. Every loop in the
belt must be seen at least once. The initial value in the control unit is 75.

For operation in PATTERN DISTANCE MODE the loop count must be accurate to
stay in sync with the belt. Each revolution the longest interval, shortest interval…occur at
the same loop ID numbers. During calibration the number of pulse counts between each
sensor loop is recorded. The loop ID number begins with one (1) at the smallest number
of counts, or shortest interval between sensor loops.

If you are unsure of the exact number of loops enter an amount that is at least double
the estimated amount. Calibrate the unit and obtain a print out of the calibration log. See
figure below. Watch for the pattern to start repeating with the shortest loop interval. The
loop ID number immediately before this happens is the exact number of loops in the belt.
Enter this number and recalibrate,

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “2 NUMBER OF LOOPS” is displayed.
4. Press <ALTER> and the count will blink.
5. Press in the correct number and press <ENTER>.
6. Press <NEXT> to advance a parameter, if finished press <OK> to put the changes
in memory. Return the key switch.

Loop Time Counts Distance

1 3.0 sec 15 cts 50.0 ft
2 6.1 sec 32 cts 100.9 ft
3 8.2 sec 42 cts 135.0 ft
4 5.9 sec 27 cts 97.0 ft
5 6.1 sec 32 cts 100.8 ft
~ ~ ~ ~
~ ~ ~ ~
74 6.1 sec 32 cts 100.8 ft
75 6.1 sec 32 cts 100.9 ft
76 (1) 3.0 sec 15 cts 50.0 ft
77 (2) 6.1 sec 32 cts 100.9 ft
78 (3) 8.3 sec 42 cts 135.0 ft
79 (4) 5.9 sec 27 cts 97.0 ft
80 (5) 6.0 sec 32 cts 100.0 ft

Figure 20 Sample Calibration Report

SHOWS PATTERN REPEAT ON A BELT WITH 75 SENSOR LOOPS.

PG 27
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PG 28
 PARAMETER 3. MODE…The operating mode of the system. STANDARD TIME
protects to the longest interval between loops in time that was recorded during
calibration. STANDARD DISTANCE protects to the longest interval in pulse counts.
PATTERN DISTANCE protects each loop to its pulse value stored during calibration.
The mode initially in the unit is STANDARD DISTANCE.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “3 MODE” is displayed.
4. Press <ALTER> to cycle through the modes.
5. Press <ENTER> when the desired mode is displayed.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

DISTANCE PARAMETERS

PARAMETER 4. ENCODER COUNTS REDUCTION RATIO…This divides the

input pulses by the ratio selected, allowing the use of many devices that may already be on
the conveyor. A proximity sensor is supplied with the system for use on most conveyors.
For reversing conveyors, or ones that coast backwards, a quadrature encoder is required,
otherwise almost any source of pulses per belt movement will work, including ones with
differential outputs. Any device should be located to reduce slip, such as on a non-driven
pulley with significant wrap. Other locations will work as long as slip is not above 3 or 4%.
Choose the reduction ratio that will provide a resolution of 1 pulse to 10 pulses per foot
of belt travel. The initial reduction ratio is 1:1.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “4 ENCODER COUNTS REDUCTION RATIO” is
displayed.
4. Press <ALTER> to cycle through 1:1, 2:1, 4:1…128:1.
5. Press <ENTER> when the desired ratio is displayed.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

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PG 30
 PARAMETER 5. MINIMUM COUNTS BETWEEN HEAD PULSES…This feature
limits how close together head pulses will be recognized. It is normally set for 10 ft, but is
also useful if the two shortest loop intervals in the belt are identical. Enter a value
between them and the next shortest and they will be ignored and the next shortest will
become ID number one. The initial value is 3 counts.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “5 MIN COUNTS BETWEEN HEAD PULSES” is
displayed.
4. Press <ALTER> and the value will blink…
5. Press the value desired.
6. Press <ENTER>
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 6. BASE PROTECT DISTANCE…This is the value the unit uses to

protect the belt while calibrating in either of the two distance modes. 3-4 times the
normal loop to loop spacing is recommended. The initial distance is 1000 ft.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “6 BASE PROTECTION DISTANCE” is displayed.
4. Press <ALTER> then the distance desired.
5. Press <ENTER>
6. Press <NEXT> to advance a paramter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 7. DISTANCE TOLERANCE…This is the percentage that the control

unit will let the pulse count exceed the target, without a head pulse, before issuing a rip
stop of the conveyor. The initial value is 50%.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “7 DISTANCE TOLERANCE (%)” is displayed.
4. Press <ALTER> then the desired tolerance.
5. Press <ENTER> when the desired mode is displayed.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

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PG 32
 PARAMETER 8. MAXIMUM HEAD PULSES WITHOUT ENCODER
COUNTS…If this value is exceeded it indicates a loss of the distance pulses and issues a
fail stop of the conveyor. Consider the resolution of pulses to distance traveled when
choosing this value. The initial value is 4 pulses.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “8 MAX HEAD PULSES WITHOUT ENCODER
COUNTS” is displayed.
4. Press <ALTER> and the value will blink.
5. Press in the desired number of pulses.
6. Press <ENTER>
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 9. ENCODER DIRECTION…Only used on reversing conveyors with

quadrature devices, which can be mounted on either side of the conveyor. Choose
forward or reverse so that the loop count goes up when the conveyor is moving in the
forward direction. The initial direction is forward.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> “9 ENCODER DIRECTION” is displayed.
4. Press <ALTER> to cycle between forward and reverse.
5. Press <ENTER> when in the desired direction.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 10. ENCODER COUNTS/REVOLUTION…This value, combined

with the pulley diameter, is used to compute the distance between the loops. Speed
indication and the base protection distance used during calibration also depend on this
value. If the pulse device is not mounted on a pulley, use the gearbox or other ratio to
determine the pulses for each revolution. Each transition is registered so single channel
pulses count as two and quadrature ones as 4. The initial value is 15.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “10 ENCODER COUNTS/REVOLUTION” is displayed.
4. Press <ALTER> and the value blinks.
5. Press in the desired value.
6. Press <ENTER>
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

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PG 34
 PARAMETER 11. MEASUREMENT SYSTEM…Choose Metric (meters) or English
(feet). The initial system is English.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “11 MEASUREMENT SYSTEM” is displayed.
4. Press <ALTER> to cycle between ENGLISH and METRIC.
5. Press <ENTER> when the desired system is displayed.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 12. PULLEY DIAMETER…See ENCODER

COUNTS/REVOLUTION above. The initial value is 60.0 inches.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “12 PULLEY DIAMETER” is displayed.
4. Press <ALTER> and the value will blink.
5. Press in the desired diameter.
6. Press <ENTER>.
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 13. LOOP ONE SEARCH TOLERANCE…Provides flexibility when

searching for the shortest loop to loop spacing. The initial value of 2 counts should work
well unless two intervals are identical. “MINIMUM COUNTS BETWEEN HEAD
PULSES” (parameters) can be used to go to the next shortest interval. 1 could be
selected if the resolution permits but an occasional search failure could result. A higher
value can be used when play in the coupling or elsewhere in the system causes the interval
counts to vary slightly.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “13 LOOP ONE SEARCH TOLERANCE” is displayed.
4. Press <ALTER> and the value will blink.
5. Press in the desired number of counts..
6. Press <ENTER>.
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

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PG 36
 PARAMETER 14. SEARCH FOR LOOP AFTER RIP STOP…If a rip stop occurs
while in pattern distance mode the loop count may become out of sync with the belt
position. Upon restarting the belt a false rip stop would occur during the first revolution
of the belt. Searching for loop one and resyncing prevents this. CAUTION: While
searching for loop 1 the rip detection calculation uses the longest interval in the belt. The
initial decision is “no”.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “14 SEARCH FOR LOOP 1 AFTER RIP STOP” is
displayed.
4. Press <ALTER> to cycle between yes and no.
5. Press <ENTER>.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

TIME MODE PARAMETERS

(Appear when time mode is selected)

PARAMETER 6. BASE PROTECTION TIME…The maximum time allowed

between head pulses when calibrating in time mode. 3-4 times the normal loop to loop
time, at full speed, is recommended. The initial time is 35 seconds.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “6 BASE PROTECTION TIME” is displayed.
4. Press <ALTER> and the value blinks.
5. Press in the time desired.
6. Press <ENTER>.
6. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 7. TIME TOLERANCE…This is the percentage that the control unit

will let the time count exceed the target, without a head pulse, before issuing a rip stop of
the conveyor. The initial value is 50%.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “7 TIME TOLERANCE %” is displayed.
4. Press <ALTER> and the value blinks.
5. Press in the tolerance desired.
6. Press <ENTER>.
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

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PG 38
 PARAMETER 8. MINIMUM TIME BETWEEN HEAD PULSES…This feature
prevents a head pulse from being accepted until at least the entered amount of time since
the last head pulse. Any value can be entered that is smaller than the smallest interval you
wish to recognize. The initial value is 1 pulse.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “8 MINIMUM TIME BETWEEN HEAD PULSES” is
displayed.
4. Press <ALTER> and the value blinks.
5. Press in the time desired.
6. Press <ENTER>.
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 9. MAXIMUM HEAD PULSES WITHOUT A BELT INPUT…If

this value is exceeded it indicates that the conveyor is running without protection because
the belt run input has failed. This issues a fail stop to the conveyor and a message to the
display. If the belt run input is not activated until the conveyor is up to speed, allow for
the head pulses that occur during start up. The initial value is 4 pulses.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “9 MAX HEAD PULSES W/OUT BELT INPUT” is
displayed.
4. Press <ALTER> and the value blinks.
5. Press in the number of pulses desired.
6. Press <ENTER>.
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

PARAMETER 10. BELT START DELAY…This allows the conveyor to reach

operating speed before starting the protection. If the belt run input is activated by an “up to
speed” switch then set this timer for a few seconds. If it is activated when the conveyor first
starts to move then allow for the longest start up period. The initial value is 50 seconds.

1. Put the key switch in <BYP> bypass.

2. From the normal or menu screen press <3> for parameters.
3. Press <NEXT> until “10 BELT START DELAY” is displayed.
4. Press <ALTER> and the value blinks.
5. Press in the time desired.
6. Press <ENTER>.
7. Press <NEXT> to advance a parameter or <OK> to store changes in memory.
Return the key switch.

When all of the changes have been entered and checked, press <OK> to store them in
memory. Leaving the parameter section before pressing <OK> voids the changes made.

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PG 40
 HARDWARE ADJUSTMENTS - SELECTIONS

W1

W2

Figure 21 Termination Card Hardware Adjustments

TERMINATION CARD…Pull-up resistors to 7.5 and 15 volts are selectable by

jumpers for the head and distance pulse inputs.

Jumper W1…Head pull-up resistors are used when the newer style auto-adjusting
detector heads are connected for open collector output. Place the jumper left or right for
the appropriate voltage, 15 volts for most locations, 7.5 volts for areas requiring intrinsic
safety.

REMOVE THIS JUMPER WHEN USING THE PRE

1995 ADJUSTABLE HEADS, OR WHEN RESISTORS ARE
INSTALLED AT THE DETECTOR HEADS.

Jumper W2…Encoder pull-up resistors are for devices with open collector outputs.
Select voltage as for W1.

REMOVE THIS JUMPER WHEN USING A

DIFFERENTIAL OUTPUT DEVICE.

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PG 42
 W2

W3
BATT
OFF/ON
• • •

W5
W6

Figure 22 Processor Card Hardware Adjustments

PROCESSOR CARD…These jumpers select inputs for quadrature or single channel

encoders with differential or single-ended outputs.

JUMPER W2…Place a jumper from 1-2 for differential/line receiver inputs. Leave
open for single-ended ones. Place a jumper from 3-4 for single channel inputs (use A).
Leave open for quadrature ones. Jumper from 2-4 for storage.

JUMPER W3…Battery - OFF position for storage, ON position when unit is

installed.

JUMPER W5…Phase A: Put the jumper to the left for differential inputs, to the right
for single-ended ones.

JUMPER W6… Phase B: Put the jumper to the left for differential inputs, to the right
for single-ended ones. None required for single phase encoders.

The jumpers are initially set for single-ended quadrature operation.

PG 43
PARAMETER INITIAL VALUE

1. Site ID xxxx
2. Number of loops 75
3. Mode STD Distance
4. Encoder Counts Reduction Ratio 1:1
5. Min Counts between Head Pulses 3

DISTANCE PARAMETERS

6. Base Protection Distance (ft) 1000

7. Distance Tolerance (%) 50
8. Max Head Pulses w/out Encoder Cts 4
9. Encoder Direction Forward
10. Encoder Counts/Rev 15
11. Measurement System English
12. Pulley Diameter (in) 60
13. Loop 1 Search Tolerance (cts) 2
14. Search for Loop 1 After Rip Stop? No

TIME PARAMETERS

6. Base Protection Time (sec) 35

7. Time Tolerance (%) 50
8. Min Time Between Head Pulses 1 sec
9. Max Head Pulses w/out Belt Input 4
10. Belt Start Delay (mm:ss) 50 sec

Figure 23 Initial Parameter Settings

PG 44
 SECTION 6 - OPERATION

The initial values shipped in the control unit memory will allow many customers to
begin operation after only a calibration. Please review sections 3 and 5 before proceeding.
See Figure 23, Pg. 44.

CALIBRATION…This procedure monitors the conveyor for the number of head

pulses (sensor loops) entered and records in the memory the pattern of times or number
of pulses between them. It varies slightly depending on the mode of operation. In
distance mode, the conveyor should be in a minimal slip condition (no speed or load
changes). In time mode, the conveyor should also be running at operating speed.
Calibration is normally only required at start up or after a saddle is installed or any other
major change in the belt occurs.
Place the key switch in the <CAL> position. The screen will instruct you to press
<OK> to start calibration. The yellow indicator relays are energized. When the switch is
left in <CAL> position the screen will inform you when the calibration is complete. The
indicator will switch to green and the status relay to active. While in calibration mode the
system uses either the “BASE PROTECTION DISTANCE” or the “BASE
PROTECTION TIME” as the target for protecting the conveyor. If this target is
exceeded a message is displayed, the red indicator flashes and the rip stop contacts open.

NORMAL OPERATION
1. The key switch is in <ACTIVE>.
2. The green indicator is lit.
3. The normal screen is displayed.
4. The rip, fail and active relays are energized.

BYPASS OPERATION
1. The key switch is in <BYP> bypass.
2. The yellow indicator is flashing.
3. The bypass relay is energized.
4. The RIP STOP and FAIL STOP contacts are bypassed by key switch contacts.
5. The displays, alarms, fail and rip relays function as normal but the conveyor cannot
be stopped.

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PG 46
 RESETTING A RIP ALARM

Reminders are located on the inside surface of the outer door. Control over who may
reset, calibrate, or make changes is possible by limiting access to the key switch key.

1…VISUALLY CHECK THE BELT BE POSITIVE THAT IS IS NOT, OR IS

NO LONGER BEING DAMAGED.
2…In distance modes, note the loops reported damaged.
3…Put key switch in <BYP> bypass.
4…Press <CLEAR> then <ENTER> for each alarm.
5…Return the key switch <ACTIVE>.

If the conveyor shuts down again, quickly in distance modes or after the belt start
delay in time mode, then it is still being damaged or a major system fault has occurred. If
the conveyor travels to the same spot and shuts down again then a sensor loop has been
damaged and needs replaced/programmed out.

If the conveyor runs without further problems, there may have been temporary excess
side travel of the belt, or the sensor loop could be damaged and functioning
intermittently. If the same spot or loop number occasionally stops the conveyor, then it is
an intermittent loop and the loop needs replaced/programmed out.

RESETTING A FAIL ALARM

1…Check the inputs/devices reported to have failed.

2…Key switch to <BYP> bypass.
3…Press <CLEAR> then <ENTER> for each alarm.
4…Return the key switch to <ACTIVE>.

If no problem was found and the conveyor runs OK, the input/device may be
intermittent. Note the time, date, and type of alarm. If unable to reset or the alarm occurs
again see section #7 MAINTENANCE.

PG 47
Loop Time Counts Distance

1 3.0 sec 15 cts 50.0 ft

2 6.1 sec 32 cts 100.9 ft
3 8.2 sec 42 cts 135.0 ft
4 5.9 sec 27 cts 97.0 ft
5 6.1 sec 32 cts 100.8 ft

~ ~ ~ ~
~ ~ ~ ~
74 NA 6.1 sec 32 cts 100.8 ft
75 6.1 sec 32 cts 100.9 ft
76 (1) 3.0 sec 15 cts 50.0 ft
77 (2) 6.1 sec 32 cts 100.9 ft
78 (3) 8.3 sec 42 cts 135.0 ft
79 (4) 5.9 sec 27 cts 97.0 ft
80 (5) 6.0 sec 32 cts 100.0 ft

Figure 24 Sample Calibration Report

SHOWS PATTERN REPEAT ON A 75 LOOP BELT, 74 NOT ACTIVE

PG 48
 PROGRAMMING OUT A DAMAGED SENSOR LOOP

If a saddle has been put in, or any other major change has occurred, recalibration will
be required. If sensor loop damage occurs, doing the following until it is replaced is
strongly recommended.

STD TIME/STD DISTANCE MODE…If you wish to stay in this mode then enter
the calibration log and change the time value/counts value, for any loop number to the
desired new target. It is also possible to deactivate a sensor as described in pattern distance
mode below.
1. Press <2> to enter the calibration log.
2. Press <NEXT> or <PREV> until at the desired loop.
3. Key switch to <BYP> bypass.
4. Press <ALTER> then <ENTER> until cursor is at right spot.
5. Press in desired values then <ENTER>.
6. Press <OK> to load changes into memory.
7. Return the key switch to <ACTIVE>.

These modes protect all loop to loop intervals in the conveyor to the maximum value
in this log. If you wish to delete sensor loops without changing the protection over the
rest of the belt then switch to pattern distance mode. If the loop count calibrated was
accurate, use the standard procedure below. Otherwise, enter the correct number of
sensor loops. As long as the correct number is fewer, then calibration is not required or
recommended. See figure 24, pg. 48.

PATTERN DISTANCE MODE…This procedure keeps better track of the sensor

loops than recalibrating. It also prevents intermittent sensor loops from causing the
pattern in memory to shift out of synchronization with the conveyor. Printouts still show
the loop but show it with “NA” next to the number.
1. Press <2> to enter the calibration log.
2. Press <NEXT> or <PREV> until at the damaged loop number.
3. Key switch to <BYP> bypass.
4. Press <ALTER> then <ENTER>. The cursor will move next to the loop number.
5. Press <ALTER> then <ENTER>. “NA” (NOT ACTIVE) will appear and the
cursor move on.
6. Press <OK> to load changes into memory.
7. Return the key switch to <ACTIVE>.

Recalibration clears all NA’s. If the damaged loop was detected it will have to be
deactivated again. If a new sensor loop is retrofitted within a few feet (1 meter) of the
original, it can usually be reactivated without calibrating. Reactivate by pressing
<ALTER> when the cursor is under the “NA”. If both the original and the replacement
sensor loops are being detected destroy the original sensor loop be removing a small
section, or deactivate it.

PG 49
 RED YELLOW GREEN
L E D L E D L E D
RIP/FAULT BYPASS/CAL ACTIVE
SITE CONVEYOR DETECTION NEXT
ID STATUS MODE LOOP

C6HD BELT STOPPED STD DIST L=12

L C D DISPLAY

NORMAL SCREEN

ACTIVE
BYP CAL
KEYPAD

KEYSWITCH

Figure 25 Front Panel Controls and Indicators

Pressing <MENU> Briefly displays “MAIN MENU” then shifts to the first
of five active menus. Switch from one to another by pressing its number.

1. Display event log

2. Display calibration log
3. System parameters
4. Diagnostics
5. Set date and time

Figure 26 Menu Screens

PG 50
 VIEWING THE LOGS AND PARAMETERS

Scanning this information is a good way to learn the system. As long as the key switch
is in <ACTIVE> no changes can be made. You can return to the normal screen from any
screen by pressing <ESCAPE> a few times. If no activity occurs for three minutes, the
screen will automatically return from all screens except diagnostics.
See Figures 25 & 26, Pg. 50.

EVENT LOG…A record of the last 50 events ie; POWER UPS, CALIBRATIONS,
RIP/FAIL ALARMS,…NUMBERS 51, 52 & 53 record the last time the unit was in
bypass, active and calibrate modes
1. Press <1> from the normal or menu screen.
2. Press <NEXT> or <PREV> to scan the log.

CALIBRATION LOG…A record of the last successful calibration with the loop ID
number shifted so that the shortest interval is designated #1.
1. Press <2> from the normal or menu screen.
2. Press <NEXT> or <PREV> to scan the log.

SYSTEM PARAMETERS…All of the information which tailors the unit to this

particular conveyor. See parameters, section #5.
1. Press <3> from the normal or menu screen.
2. Press <NEXT> or <PREV> to scan through the parameters.

DIAGNOSTICS…Allows you to monitor, or displays the following; RIP ALARM

COUNTER, CALCULATED BELT SPEE T START-UP TIME COUNTER,
DATE/TIME OF LAST SUCCESSFUL CALIBRATION, SOFTWARE VERSION AND
CHECKSUM NUMBER.
1. Press <4> from the normal or menu screen.
2. Press <NEXT> or <PREV>.

PRINTING THE LOGS AND PARAMETERS

Any IBM compatible parallel printer, like HP Deskjets or Canon BJC-50, should
work. The printer port is located on the back side of the inner door. When the printer is
ready, enter the appropriate log and press <PRINT>. Protection continues while printing
is in progress,

PG 51
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PG 52
 SECTION 7 - MAINTENANCE

Troubleshooting - Alarms

RIP STOP - STD DISTANCE, STD TIME OR PAT DISTANCE. The values stored
in the control unit during calibration have been exceeded. VISUALLY CHECK THE
BELT FOR DAMAGE.

1. If the belt is undamaged and the rip stop repeats shortly after each time the belt
starts, check for head pulses. A lack of head pulses can be caused by: defective head,
defective power supplies, or bad cables, connections.

2. If clean, 5 volt or greater pulses, 25ms or longer, are on the input terminal but
aren’t being recognized, the processor card, termination card or connections could be
defective.

3. If the conveyor runs for a while then stops on the same loop number each time,
that loop is intermittent or totally defective. If the loop number is different each time that
the conveyor stops then side travel could be excessive, or the heads, connections etc.
intermittent.

RIP STOP - BASE PROTECT DISTANCE OR TIME. Normally only seen if the
parameter value is exceeded during calibration. VISUALLY CHECK THE BELT FOR
DAMAGE. This parameter is normally entered at start up. It shouldn’t need changed
unless a large interval occurs in the sensor loop pattern. If it continues to occur then
troubleshoot as above.

NO ENCODER COUNTS. The allowable number of head pulses without a distance

pulse has been exceeded. This indicates that the belt is moving but is not protected. A
problem exists with the pulse device, coupling, wiring, power supply, or control unit. If
you are not able to quickly resolve the problem, consider temporarily switching to the
time mode and using the belt run input.

NO BELT RUN INPUT. The allowable number of head pulses without a belt run
signal has been exceeded. This indicates that the belt is running but not protected. A
problem exists with the wiring, interface circuitry, or control unit.

CALIBRATION CHECKSUM ERROR. A problem exists in the data loaded in the

processor. Attempting a calibration table printout rewrites this data and should clear the
problem. If not, try cycling the power off and on, and finally change the processor card.

PG 53
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PG 54
 CALIBRATION INCOMPLETE. The procedure was aborted. The table still has the
values from the last successful calibration. This statement will normally be seen with a
“RIP STOP BASE PROTECT DISTANCE” or similar statement. Clear this condition
before attempting recalibration.

REPLACE BATTERY. The lithium battery on the processor card has discharged below
the level for operation, or the battery on/off shunt has become disconnected. Replace the
shunt or processor card and review system operation.
See W3, Pg. 43.

NO SENSOR POWER. Post 1998 units monitor sensor power through a wire
connected from 15 volts to the key switch. Monitor a termination card 15 volt terminal.
If 15 volts is present but the alarm won’t clear, check the connections from the
termination card terminal to the key switch then processor card, change the processor
card. If no 15 volts is present, cycle the A/C power off then on. If there is still no 15
volts disconnect all external wires from the 15 volt terminals. If the 15 volts will now reset
then there is a short circuit in the wiring, detector heads, or pulse device. If the 15 volts
still won’t come back then change the termination card.
If you are attempting to put a post 1998 card into a pre 1998 system contact your
normal Goodyear supply point for instructions.

UNEXPECTED HEAD PULSES. Detector head pulses have occurred between

expected pulses. This could be random noise or an old intermittent sensor loop. This will
only cause a problem in pattern distance mode. Increase parameter 5, minimum counts
between head pulses, to a value just smaller than loop number one, to minimize this
problem. This alarm uses the same trip number as parameter 8, max head pulses w/out
encoder counts.

PATTERN SEARCH FAIL. The unit could not find loop #1. See description of
Parameter 13 on page 35.

For additional information and assistance contact your normal source of Goodyear
Conveyor Belt.

PG 55
 PARAMETER
1. Site I D ________ ________
2. Number of loops ________ ________
3. Mode ________ ________
4. Encoder Counts Reduction Ratio ________ ________
5. Min Counts between head pulses ________ ________

DISTANCE PARAMETERS
6. Base Protection Distance (ft) ________ ________
7. Distance Tolerance (%) ________ ________
8. Max Head Pulses w/out Encoder Cts ________ ________
9. Encoder Direction ________ ________
10. Encoder Counts/Rev ________ ________
11. Measurement System ________ ________
12. Pulley Diameter (in) ________ ________
13. Loop 1 Search Tolerance (cts) ________ ________
14. Search for Loop 1 after Rip Stop? ________ ________

TIME PARAMETERS
6. Base Protection Time (sec) ________ ________
7. Time Tolerance (%) ________ ________
8. Min time between Head Pulses ________ ________
9. Max Head Pulses w/out Belt input ________ ________
10. Belt Start Delay (mm:ss) ________ ________

Figure 27 Parameter Settings Record

PG 56
SENSOR GUARD 2000
OPERATIONS MANUAL

revision level 1