System description A EN Metal detector MDA 0103 - Erhardt-Leimer ...

System description A 

Metal detector 

MDA 0103 

1. Safety instructions 2 

2. Function 4 

3. Transport 7 

4. Assembly 8 

5. Installation 10 

6. Commissioning 13 

7. Operation 15 

8. Troubleshooting instructions 15 

9. Repair 20 

10. Maintenance 20 

11. Disassembly 20 

12. Spare parts 21 

13. Technical data 22 

BEA--065382-EN-06 

EN

Metal detector MDA 0103 

1. Safety instructions 

1.1 Documentation 

1.2 Intended use 

1.3 User groups 

A page 2 


Keep the documentation for the E+L system/device in a safe place and 

accessible for personnel at all times. 

The documentation is part of the scope of delivery and must be read 

carefully prior to starting assembly, operation or maintenance work. 

The documentation for an E+L system essentially comprises the higher 

level system description (A), the individual descriptions of the components 

(B, C, ... W), spare part lists (X) and the circuit diagrams (Z). 

Proceed in accordance with the instructions in the system description. 

All important processes are described in the system description. 

Where necessary, reference is made to the descriptions of the individual 

components. 

The metal detector is only allowed to be used for scanning textile materials. 

The metal detector is only allowed to be installed in the customer's machine 

as defined by E+L. 

The metal detector is not allowed to be modified. 

The metal detector is built to the state-of-the-art. 

Despite this, during use of the device 

– Hazards to the user's health or 

– Damage to property may occur. 

Only use the metal detector 

– In correct working order, 

– With due attention to safety and hazards while observing the locally 

applicable, statutory and customary safety regulations as well as 

the regulations for the prevention of accidents. 

NOTICE 

The sensor must not be placed under mechanical load. It must not be 

used either as a ladder, support or depositing surface during service 

work. 

All the activities in this description are only allowed to be undertaken 

by the user groups listed in the following with the stated qualifications. 

Activities User groups Qualification 

Transport/assembly, commissioning, 

troubleshooting/repair, maintenance, disassembly 

Specialist personnel Technicians, industrial mechanics, fitters 

etc. 

Installation, disassembly Specialist personnel Electrical connection only by electricians

Activities User groups Qualification 

Operation Specialist personnel, unskilled personnel, 

trainees 

1.4 Explanation of symbols 


DANGER! 

Signifies that death or serious injury will occur immediately if the related 

safety measure is not taken. 

WARNING! 

Signifies that death or serious injury may occur if the related safety 

measure is not taken. 

CAUTION! 

Signifies that minor injury may occur if the related safety measure is 

not taken. 

NOTICE 

Signifies that a malfunction or damage may occur if the related measure 

is not taken. 

Jobs to be performed. 

Instruction by the operating organization 

BEA--065382-EN-06 A page 3


2. Function 

2.1 Purpose 

A page 4 


The metal detector senses magnetic and non-magnetic metal particles 

in moving webs. 

Crucial for the detection of the metal particles are the type, the weight 

and the shape of the particles as well as the distance of the particles 

from the sensor. 

The web may be dry or damp and may be a film, woven or knitted fabric, 

tufting, felt, woven or tufted carpeting. 

The web can be moved at a speed between 0.5 and 400 meters per 

minute over the sensor. 

The detection of a particle triggers a signal that you can use in various 

ways: 

– As a continuous signal that may be manually reset. This continuous 

signal can be used to stop the machine 

– Or as a pulse signal that is reset after a specifically adjustable time. 

This signal can be used for example to operate a counter or a 

marking device. 

The table below indicates the weight and distance at which spherical 

metal particles can be detected by the system: 

Distance to the 

surface of the 

sensor: 

Steel ST 37 

1.0036 

≤1 mm ≥ 2 mg 

(approx. ø 0.8 

mm) 

Spherical metal particles 

Stainless steel 

A2 

1.4301 

≥ 25 mg 


mm) 

Aluminum 

3.1645 

≥ 8 mg 


mm) 

Copper, 

electrical grade 

copper 

2.0060 

≥ 10 mg 


mm) 

In the case of needle-shaped metal particles, sensitivity is not only dependent 

on the weight of the particles but also the position in which the 

metal needles pass the sensor (see fig. and table below).

2.2 Design 

Sensor MD 1003 

Distance to the surface 

of the sensor: 

Needle-shaped metal particles 

Steel 1.2206 

lengthwise 

Steel 1.2206 

crosswise 


Steel 1.2206 

standing 

≤ 1 mm ≥ 2 mg ≥ 5 mg ≥ 2 mg 

≤ 5 mm ≥ 5 mg ≥ 20 mg ≥ 5 mg 

NOTICE 

Sensitivity deteriorates considerably as the distance increases between 

the metal particles and the sensor surface. 

Metal particle 

Web 

Lengthwise Crosswise Standing 

Sensor surface 

6-core cable 

Red indicator White indicator 

for multiple detection 

Control unit SG 1030 

Red illuminated 

pushbutton 

The metal detector comprises a sensor MD 1003 over which the web 

is passed in its full width. The sensor contains a series of scanning areas 

arranged one behind the other, generally every 30 cm. In the middle 

of each scanning area is an amplifier card VK 4811 with an 

indicator. 



2.2.1 Accessories 

2.3 Operating principle 

A page 6 


A shielded, 6-core cable connects the sensor to the control unit 

SG 1030, a red illuminated pushbutton (RESET) is built into the door 

of the control unit. The operating voltage of the sensor is 24 VDC. 

Logic card LK 3101, for the connection of external display or marking 

devices. 

An alternating electromagnetic field is established in the scanning area 

of the metal detector. If the web now carries a metallic foreign body 

over the sensor, this alternating field will be distorted and a pulse triggered. 

At the same time, the red indicator illuminates on the back of the sensor 

for the scanning area in which the metal particle was detected (see 

figure). The pulse signal is amplified and sent to the control device. 

There the red illuminated pushbutton (RESET) illuminates, either as a 

signal of limited duration that resets itself, or as a continuous signal. 

If you have connected the continuous signal to the machine contact, 

your production machine stops automatically and you can remove the 

metal particle. If you press the illuminated pushbutton on the control 

unit, the signal is reset and your production machine can be restarted. 

If three or more scanning areas trigger an alarm, a white indicator underneath 

the connector illuminates. This indicates that the alarm may 

not have not been caused by metal particles in the web. 

The signals from the metal detector are made available for external 

use at the logic card LK 3101. In this way display or marking devices 

can be connected that indicate the scanning area in which the metal 

particle was detected. 

2.4 Special version metal detector MDA 0103 master-slave 

A master-slave metal detector comprises: 

– two sensors MD 1003 with an additional socket for the connection 

of a coaxial cable and 

– two control units SG 1030. 

At least 1000 mm 

Sensor MD 1003 Master Sensor MD 1003 Slave

3. Transport 

3.1 Transporting and unpacking 


To scan thicker non-woven materials, the two sensors are connected 

together to form one metal detector. One of sensors scans the top and 

the other the underside of the material. 

The mounting distance between the sensors should be at least 1 m so 

that the angle between the web plane and sensor plane does not exceed 

5°. See chapter 4.1.1 "Mounting distances". 

WARNING! 

Falling parts! 

Falling parts can cause injuries. 

Never stand under suspended loads. 

NOTICE 

The sensor must lie flat during transport. It must not suffer point loads. 

Risk of fracture! 

Only transport metal detector in the original packaging. 

Observe the transport instructions on the original packaging. 

After unpacking, check sensor and control unit for damage. 

Dispose of packaging material correctly. 



4. Assembly 

4.1 Application notes 

4.1.1 Mounting distances 

A page 8 

Angle < 5° 


NOTICE 



work. 

At least 500 mm At least 500 mm 

Angle < 5° 

The sensor can be mounted in any position and subsequently aligned 

with the web. 

The distance from the last path roller to the sensor and from the sensor 

to the next path roller must be at least 500 mm. 

Heavily magnetized, rotating steel rollers in the immediate vicinity can 

also interfere with the metal detector. Minimum distance approx. 

500 mm. 

In order to be able to set a high sensitivity, it must be ensured there is 

no interference in the electromagnetic alternating fields above the sensor. 

Interference is caused, for instance, by motors and transformers, 

by chokes, by thyristor controllers or even by fluorescent lamps and 

heavily loaded cables. Avoid such sources of interference building up 

in the area of the sensor. Minimum distance 500 mm. 

The web must run parallel to the sensor. Height fluctuations will corrupt 

the measured result. See also chapter 2.1 "Purpose". 

The web should be in contact with the sensor. Here it is to be ensured 

the angle between the web plane and the sensor plane does not exceed 

5°.

4.1.2 Installation position 


In case of large web widths we recommend installing the metal detector 

horizontal, with the scanning face pointing upwards. 

4.1.3 Mechanical center support 

With high web tension or a long device (from 3 m) the sensor must be 

supported in the center by the customer. 

4.1.4 Electrostatic charging 

4.2 Sensor MD 1003 

Horizontal (scanning face upwards) 

NOTICE 

The center support must be made of magnetically non-conductive material, 

e. g. plastic. The support point must be padded, e. g. using foam 

rubber. 

WARNING! 

Electric shock! 

Electrostatically charged webs can cause electric shock. 

If the web is electrostatically charged by upstream production processes, 

an ionizing rod that discharges the web must be installed 

by the customer before the metal detector. 

Electrostatic charges caused by the web sliding over the sensor are 

discharged directly by the grounding straps on the metal detector. 

Mount sensor. For dimensions see dimension drawing. 

Particular attention is to be paid to the following mounting instructions! 

– Relative movements (vibration) in relation to other metal parts can 

trigger an incorrect signal. For this reason, the sensor must not be 

suffer vibration. 

Therefore use the anti-vibration bearings supplied to mount the 

sensor. 



4.3 Control unit SG 1030 

5. Installation 

A page 10 


– Excessive rotary movement of the sensor around its longitudinal 

axis can be avoided by fitting additional padded brackets to the end 

pieces. 

In this way you will avoid relative movement of the sensor in relation 

to metal parts nearby (frame structure, rollers). 

If the metal detector is longer than 3 meters, fit a center support. 

Mount control unit SG 1030 at least 1 m away from the sensor. 

The control unit can, like other electrical devices, interfere with the 

operation of the sensor. 

Fasten the control unit such that the illuminated pushbutton on the 

door can be clearly seen and is easy to operate. 

If necessary, install an additional external illuminated pushbutton 

(see also chapter Installation). 

WARNING! 


Live parts can cause an electric shock. 

Never touch live parts. 

Connect electrical cables as per the circuit diagram, during this 

task pay attention to the information on cross-section and screening. 

Lay signal cable separate from cables carrying interference or high 

currents (for example motor cables). 

Ensure the insulation is not damaged and the cables are properly 

fixed and protected.

5.1 Control unit SG 1030 

Transformer 

Line filter 

Line fuse 

4 AT for 110 to 125 V 

2 AT for 190 to 240 V 

Line connection 

Terminals 1 to 3 

Control card NK 2701 


The 6-core connection cable to the sensor is 4 m long. Connect the 

open end to the control unit SG 1030 according to the wiring diagram. 

With the aid of a shielded socket, you can extend the cable to a total 

length of a maximum of 15 m. Use a shielded cable with a crosssection 

of 0.75 mm 2 . 

Make sure that your line voltage matches the line voltage set on the 

control unit SG 1030. If necessary, change the connections on the 

transformer. 

Also check the line filter connection. 

Connect the devices with which you want to evaluate the signal 

from the sensor. That is either the machine contact to stop your 

production machine, a counting device or a marking device 



5.2 Sensor MD 1003 

Connector 

to the control unit 

5.2.1 Master-slave 

A page 12 

Ground strap 


Plug the connector on the connection cable into the socket on the 

sensor (see figure on left) and lock it by turning it to the right. 

Connect the metal grounding strap from the sensor to the earthed 

machine frame. Ensure the sensor is not additionally grounded. 

The sensor is electrically isolated from the machine frame by the 

anti-vibration bearings. 

Connect the two sensors using the co-axial cable supplied. 

NOTICE 

Make sure that the grounding straps on the sensors are connected to 

the same ground potential. 

5.3 External illuminated pushbutton "RESET" 

You can install an external illuminated pushbutton that, like the illuminated 

pushbutton on the control unit SG 1030, indicates that a metal 

particle has been detected and using which you can reset the continuous 

signal. 

Connect the lamp and the normally open contact according to the 

enclosed wiring diagram. The connection cable to the external illuminated 

pushbutton should be shielded and not longer than 

15 meters, a cable cross-section of 0.75 mm 2 is sufficient.

6. Commissioning 

6.1 Adjusting sensitivity 

WARNING! 

Cuts! 

Edges of moving webs can cause cuts. 

Never touch the edges of running webs. 


Commissioning sequence: 

– Adjust sensitivity of the metal detector, 

– Select signal, 

– And, if you have set a pulse signal, the duration of this signal. 

You can only adjust the sensitivity of the metal detector in the range defined 

by the size and type of the metal particles (see table in chapter 

2.1 Purpose). It is therefore not possible to detect particles smaller 

than those given in the table. You can however reduce an excessively 

high sensitivity that you do not want to use. 

The sensitivity setting can be heavily affected by the following circumstances: 

– Possible electromagnetic fields in the area of the sensor, 

– Vibration of the sensor during operation, 

– Metal residue in the web due to pretreatment in metal-laden baths 

(for example with iron or copper oxides, titanium dioxides or zinc nitrates). 

The sensitivity of the metal detector is adjusted using potentiometer R1 

on the sensor under the plastic cover that can be unscrewed (see figure). 

Potentiometer R1 

for the sensitivity 

Works setting: 8 

If you turn the potentiometer clockwise, the metal detector reacts 

more sensitively, turn it counter-clockwise to reduce the sensitivity. 

The upper limit is exceeded when the button on the control unit illuminates 

and can no longer be reset. In this case you must turn 

the potentiometer back until the signal can be reset again. 

We recommend you start by setting a value of between 8 and 9. 



6.2 Selecting signal 

6.3 Adjusting pulse signal 

A page 14 


During testing you can also use button S2 in the control unit on the 

control card NK 2701 to reset the signal (see figure below). 

Potentiometer R1 for adjusting 

the pulse signal 

Light emitting diode H1 (green) 

Operational 

S1 for the selection 

of the signal 

Button S2 for resetting 

the signal 

Use switch S 1 on the control card NK 2701 to select which signal is to 

be used to indicate a metal particle in the web. 

– In position "1" (on left), a metal particle in the web will trigger a continuous 

signal that must be manually reset. 

– In position "2" (on right), a metal particle in the web generates a 

pulse signal of limited duration. It then resets itself automatically. 

The duration of the pulse signal is set using potentiometer R1 on the 

control card NK 2701. The potentiometer R1 has no mechanical stop. 

Turn 20 turns counter-clockwise to set the minimum pulse duration 

of half a second. Each full turn that you now make clockwise will 

increase the length of the pulse duration by a little more than 

0.1 seconds. In this way you can set a maximum pulse duration of 

3 seconds.

7. Operation 

8. Troubleshooting instructions 

WARNING! 

Cuts! 




NOTICE 



work. 

The web should leave clear the outermost 20 millimeters of the scanning 

face, as in this area no metal particles are detected. 

The following applies in daily practice: 

The metal detector is ready for operation one minute after the operating 

voltage is applied. 

Test the function of the metal detector every day prior to starting the 

machine. Introduce a metal particle on a plastic rod into the scanning 

area and check whether a signal is triggered. 

WARNING! 

Cuts! 



WARNING! 


Live parts can cause an electric shock. 

Never touch live parts. 



8.1 The metal detector no longer detects a particle on part of the scanning face 

Amplifier card VK 4801 

(up to year of manufacture 09/2009) 

A page 16 


Terminal strips 

Fastening screw 

Indicator 

Amplifier card VK 4811 

(from year of manufacture 10/2009) 

If you find that part of the sensor no longer reacts to metal particles 

while the other neighboring areas signal metal particles, then the amplifier 

card VK 48.. is faulty in this area. 

First disconnect the line voltage! 

Unscrew the cover on the back of the sensor. 

Fit an amplifier card that has been checked for correct function in 

place of the possibly faulty card. If the area now indicates detection 

of metal particles (after applying the line voltage), the other card is 

faulty. 

We recommend you keep a spare amplifier card. 

NOTICE 

The amplifier cards VK 4801 and VK 4811 are not compatible. 

Amplifier cards VK 4801 must be sent to E+L in case of a need for 

spare parts.

8.2 The metal detector no longer detects any particles in the entire scanning area 

Operational LED 

Fuses 

8.3 The signal can no longer be reset 

Check whether the line voltage is applied. 


Check the connections on the connection cable between sensor 

and control unit. 

Check whether, after pressing the illuminated pushbutton, the 

green indicator for "operational" illuminates again (see figure on 

left). 

– If it does not illuminate, check the fuses for the secondary voltage 

on the control card NK 2701. 

– If it illuminates, increase the sensitivity of the metal detector (see 

chapter "Commissioning"). 

If the fault has still not been rectified, the oscillator card OK 120. or 

the control card NK 0501 in the sensor is faulty. These cards must 

be matched exactly to your system. For this reason contact E+L 

service. 

Reduce the sensitivity of the sensor (see chapter "Commissioning"). 

Check whether the signal is triggered by external alternating electromagnetic 

fields, for instance from electric motors, transformers 

or fluorescent lamps. If this is the case, try to mount the sensor at 

least one meter from these sources. If necessary, select a different 

installation location. 

Check the ground strap on the sensor. It must be in contact with 

clean, rust-free metal on the grounded machine frame. 

If, in position "1", the signal output can no longer be reset using the 

button, or in the case of pulse operation in position "2" the output 

signal is a continuous signal, it is possible that one of the two control 

cards NK 2701/NK 0501 is faulty. 

Measure the operating voltage at the control board NK 2701, 

terminal 13 to terminal 8 and terminal 11 to terminal 12. Both voltages 

must be approx. +24 V. If one or both the voltages is missing, 

check the fuses F1 and F2 on the control card NK 2701. 



Measuring point: 8 9 7 

8.4 The sensitivity is inadequate 

A page 18 


Measure the operating voltage on the control card NK 0501, +12 V 

(measuring point 8 to measuring point 9) and -12 V (measuring 

point 7 to measuring point 9). 

If all voltages are present and the signal can still not be reset, you 

must contact E+L service. 

If you have to reduce the sensitivity due to electromagnetic interference, 

try to mount the sensor at least one meter from the sources 

of the interference. If necessary, select a different installation location. 

Check the material and the weight of the particles and compare 

with the table on pages 3 and 4 as to whether these particles can 

be detected. 

Check the distance from the metal particles to the sensor is not excessively 

large (see table in section 2.1 Purpose). 

8.5 The system detects metal particles even though there are none present 

Check whether powering up another machine triggers the signal. If 

yes, connect the metal detector to a different circuit and suppress 

the interference on the contacts of the related machine using capacitors 

and resistors. 

Measure the line voltage. If the voltage fluctuates by more than 

±10 %, you must connect the system to a different circuit. Also take 

into account the voltage drop when the drive motor starts up. 

Check the electrical supply leads for faults. 

Check whether the sensitivity of the system is set unnecessarily 

high. 

Check the coating. Small metal particles may have become 

jammed in the gaps. If these particles move, they will trigger the 

alarm. 

Check whether the coating has become detached at isolated 

points. 

In the case of polyester or polyester mix fabrics, the sensor is heavily 

charged electrostatically. Ensure the probe is effectively grounded. 

If necessary, install an ionizing rod in front of the sensor to 

discharge the web. 

Vibration causes contacts to open.

The sensitivity is set too high. 

8.6 The red indicator illuminates on switching on the system 


Check the metal detector for effects due to electromagnetic interference. 

The control unit SG 1030 may be mounted too close to the 

sensor. It must be mounted at least one meter away. 

Measure the line voltage. If it fluctuates by more than ±10 %, you 

must connect the metal detector to a different circuit. Also take into 

account the voltage drop when the drive motor starts. 

Check the coating. Damage or soiling will cause a malfunction. 

The sensitivity is set too high. 

8.7 The white indicator on the sensor illuminates 

If three or more scanning areas trigger an alarm, the white indicator under 

the connector illuminates (see figure on left). It indicates that the 

alarm may not have been triggered by metal particles in the web. 

There are several causes for multiple triggering: 

– A larger metal object or a machine part has been moved over the 

scanning face (for example a dancer roller). 

– The sensor has moved around its longitudinal axis. This issue is a 

problem if there are other machine parts near the scanning area. 

Signal indication for 

multiple detection 

Check if the tension on the web at the sensor is so high that the 

sensor is moved during operation by the web, for example by 

seams. 

If necessary reduce the wrap angle and therefore the tension and 

provide a central mechanical support. 

– Of course, by chance several metal particles in different scanning 

areas may cause the illumination of the white indicator. 



9. Repair 

10.Maintenance 

11.Disassembly 

A page 20 


NOTICE 

For reasons of functional reliability, repair work on the coating and on 

electronic assemblies should only be undertaken at E+L. 

WARNING! 

Maintenance work is only allowed to be undertaken with the machine 

switched off. 

Switch off machine. 

Secure machine against switching back on. 

The metal detector is maintenance-free. However, the sensor should 

always be kept clean. Deposits increase the distance between the web 

and the sensor and therefore reduce the sensitivity of the system. 

Clean the scanning face regularly with a damp (not wet) cloth. Do 

not use solvents. 

WARNING! 

Disassembly is only allowed to be undertaken with the machine 

switched off. 

Switch off machine. 

Secure machine against switching back on. 

Disassemble in the reverse order of assembly as described in 

chapter "Assembly". 

During this process follow all instructions given in the chapters "Assembly" 

and "Installation".

12.Spare parts 

12.1 Oscillator card OK 

PC1 

Master 

Standard 

PC2 

Slave 

X2 X2 

1 2 3 1 2 3 

PC1 PC2 

OK 1202 

No. 325683 

Heat conductive paste 

See list of spare parts. 


The oscillator card OK 1202 replaces the oscillator cards OK 1201 

(Standard), OK 60011 (Master) and OK 60012 (Slave). 

In case of replacement, the following settings are to be made on the 

oscillator card OK 1202: 

Sensor MD 1003 Standard: 

Fit jumper X2 to position 1-2. 

Sensor MD 1003 Master: 


Connect wire from coaxial socket to contact PC1. 

Sensor MD 1003 Slave: 


Connect wire from coaxial socket to contact PC2. 

NOTICE 

Mount oscillator board with heat conductive paste! 


13.Technical data 

Erhardt + Leimer GmbH 

D-86136 Augsburg 

GERMANY 

Phone +49 (0)821 2435-0 

Internet http://www.erhardt-leimer.com 

E-Mail info@erhardt-leimer.com 

Nominal width NB 300 to 6000 mm 

(increments of 300 mm) 

Web type Woven and knitted, non-woven 

fabrics, felt, carpeting 

Web state Dry, moist (drained) 

Web speed 0.5 to 400 m/min 

Ambient temperature 0 to 40 °C 

Protection class 



IP 50 

IP 54 

Supply voltage 220/190/240 V switchable 

or 

110/125 V switchable, 50/60 Hz 

Control voltage 24 V DC 

Power consumption Approx. 160 VA 

Output changeover contact 

Switching capacity 

Switching voltage 

Switching current 

Subject to technical change without notice 

Max. 100 VA / 30 W 

Max. 250 v AC / 250 V DC 

Max. 5 A AC / 1 A DC, Ohmic 

load 

Output signal Continuous signal with reset button 

or pulse signal (adjustable 

0.5 to 3 s) 

Connection cable 6-core, shielded, 4 m long 

Dimensions W x H x D 



See dimension drawing 

234 x 334 x 160 mm

System description A EN Metal detector MDA 0103 - Erhardt-Leimer ...

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