GRAVITY METAL DETECTOR

OPERATOR SET-UP MANUAL

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 Gravity Metal Detector System—Operator Setup Manual

INTRODUCTION
Thank you for purchasing a Stealth Gravity Metal Detector System from Fortress Technology Inc.
At Fortress we are committed to offering the most practical, functional and user-friendly metal detection solutions.
Built to customer specifications, Stealth Metal Detectors are available in a range of aperture sizes and configurations
for a variety of industrial applications.
This Operator Setup Guide is intended to get you up-and-running within minutes covering the basic setup procedure in
addition to the most commonly used system features.

Advanced Stealth Features:

 Core DSP – high speed Digital Signal Processor technology provides the highest processing power.
 Ultra-Sense – detection of the smallest metal contaminants with the highest sensitivity levels.
 Auto-Test – automated system testing reduces the high costs associated with manual testing.
 Auto-Cal – single pass product learning and automatic calibration allow for quick setup.
 Flash RAM – Flash Memory technology prevents information loss.
 Modular Design – fewer product parts render improved power-efficiency within a compact housing.
 Password Protection – flexible multi level security protection for critical parameters preventing unauthorized use.
 Multiple Product Storage – quick changeover between production line runs with retained settings.
 Control Options – display terminal can be made portable or mounted remotely; one terminal can operate
numerous Detector units.
 USB – allows quick method to collect reject, fault and event data and able to view on a PC based computer,
can also be exported to excel and PDF documents.
 Automated Data Logging Option – CONTACT Software enables Detector communication with a PC; Wireless
Ethernet connection available.

For more information including product brochures and regional contact information, please visit our website:
www.fortresstechnology.com

For technical support, please contact numbers below or e-mail: service@fortresstechnology.com

North America: 1-888-220-8737 or 416-754-2898
Europe: +44 (0) 1295 256 266
South America: +55 11 3641 6153

Copyright © 2014 Fortress Technology Inc. www.fortresstechnology.com

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STEALTH MANUAL—TABLE OF CONTENTS

INTRODUCTION .................................................................................. 1
SAFETY, CAUTIONS & CLEANING .......................................................... 3
CHAPTER 1: INSTALLATION ................................................................. 5
1.1 Installation Overview ........................................................................... 5
1.2 Package Contents ................................................................................. 5
1.3 Installation Tools .................................................................................. 6
1.4 Installation Location ............................................................................. 6
1.5 Handling ............................................................................................... 6
1.6 Installation Essentials ........................................................................... 7
1.7 Mechanical Installation ........................................................................ 8
1.8 Air Service............................................................................................. 9
1.9 Removing & Installing Display Panel .................................................. 10
1.10 Electrical Installation .......................................................................... 11
CHAPTER 2: GETTING ORIENTED ....................................................... 17
2.1 Stealth Interface—Introduction ......................................................... 17
2.2 Hard vs. Soft Keys ............................................................................... 18
2.3 Menu Navigation ................................................................................ 18
2.4 Editing Menu Options ........................................................................ 18
2.5 Main Menu ......................................................................................... 19
2.6 Serial Number .................................................................................... 19
CHAPTER 3: QUICK SETUP TUTORIAL ................................................ 20
3.1 Start Up Tests—Overview .................................................................. 20
3.2 Power Up Sequence ........................................................................... 20
3.3 Initial Signal Check.............................................................................. 21
3.4 Reject Systems ................................................................................... 22
3.5 Product Calibration ............................................................................ 25
3.6 Sensitivity Level .................................................................................. 27
3.7 Password Security .............................................................................. 29
3.8 Product Setup..................................................................................... 31
CHAPTER 4: AUXILIARY FUNCTIONS .................................................. 34
4.1 Auxiliary Functions—Overview .......................................................... 34
4.2 Auto Test/ Test Request ..................................................................... 34
4.3 Alternate Reject Options .................................................................... 36
4.4 Date & Time Change .......................................................................... 37
4.5 IP Address ........................................................................................... 37
4.6 Name the Detector............................................................................. 38
4.7 FM Mode ............................................................................................ 38
4.8 USB Data Collection & Contact Reporter Lite .................................... 39
CHAPTER 5: FAQ’S & APPENDICES ..................................................... 44
5.1 FAQ’s (Frequently Asked Questions).................................................. 44
5.2 Faults .................................................................................................. 46
5.3 Appendices ......................................................................................... 48

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SAFETY, CAUTIONS & CLEANING

Compliance with Safety Standards
The product has been designed to operate safely in accordance with the current technical and safety regulations,
including the provisions of the Health and Safety at Work Act, relevant EU legislation and OSHA regulations in addition
to any amendments that may become legal requirements.
While every precaution has been taken to ensure the operational safety of the system, it is the responsibility of the
owner and/or end-user to ensure that the guarding, safety devices, installation, operation and maintenance of the
system complies with all the requirements of the local health and safety regulation legislations and codes of practice. It
is highly recommended that a formal risk analysis be performed on this equipment prior to its use.
NOTA: El presente Documento de Seguridad está disponible en español.
Por comuníquese con service@fortresstechnology.com para obtener una copia.

Installation, Commissioning and Operation

 The metal detector system must be installed, connected, operated and maintained according to all
local regulations and codes as well as the instructions stated in this manual and other specific
operating instructions accompanying this manual. The safety warnings and instructions must be
read, understood and all safety instructions followed by persons who are involved in the installation
and use of the equipment.
 Persons supervising, performing maintenance or installation must be suitably qualified and
competent. Operators, sanitation operators, maintenance personnel, engineers and supervisors
should be given opportunity to study and discuss this manual prior to working with the system.

Electromagnetic Radiation
This device is an intentional radiator, emitting a low power radio signal designed for use within an industrial
environment. The product complies with Part 15 of FCC Rules (USA), and relevant legislation under CE Marking.

General Safety Guidelines

1. Read and understand the Operation Manual and all safety labels before operating this machine.
2. Only a trained person is to be permitted to operate this machine. Training should include instruction
in operation under normal conditions and emergency situations.
3. This machine is to be serviced only by trained and authorized personnel. Follow lockout procedures
before servicing.
4. Never reach into the machine for any reason unless the machine is at a COMPLETE STOP and
LOCKOUT procedures have been followed.
5. Never leave the machine stopped in such a manner that another worker can start the machine while
you are working on or within the machine and follow lockout procedures.
6. Never change or defeat the function of electrical interlocks or other machine "shutdown" switches.
7. Before starting this machine, check that: - All persons are clear of the machine. - No maintenance
work is being performed on the machine. - All guards are in place. - Keep the floor around the
machine clean and free of any scrap, sawdust, oil, grease etc. to minimize the danger of slipping.
Maintain safe working distance and use personal protection equipment as authorized by your
supervisor.
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SAFETY, CAUTIONS & CLEANING continued

8. There is a potential hazard of entanglement in this machine caused by items such as long hair, loose
clothing and jewelry. Make sure your clothing and hair fit closely to your body and that all jewelry,
rings and watches are removed.
WARNING: Hazardous Voltages and Air power may be present! Hazardous voltages can cause severe
injury or death. Disconnect all sources of power (electrical and air) before servicing. Multiple and/or
remote sources of power may be present.

Cleaning and Maintenance

Always isolate the system from the electrical and air services before any cleaning and or maintenance.
LOCKOUT PROCEDURE:

1. Announce lockout to other personnel.

2. Turn power OFF at main panel and remove all power plugs
3. Lockout power in OFF position, lock out all power plugs. Put key in pocket.
4. Remove all sources of air supply and lock the shut off device in OFF position
5. Clear machine of all personnel
6. Test lockout by turning machine power switch to ON.
During normal operation:
WARNING AUTOMATED MACHINERY:
1. Machinery and devices may operate without warning at any time.
2. Keep away from the operating area of the reject device while power is applied.
3. Keep hands clear of moving parts.
4. Do not tamper with, modify or attempt to override guards or safety switches.
5. Equipment is heavy – use lifting devices according to the Handling instructions in the installation/
operation manual.

Cleaning Guidelines
The metal detector requires routine cleaning for optimal performance. Determine whether the system purchased
utilizes a Stainless Steel or Painted Aluminum construction. For IP69K rated Stainless Steel units, the system can be
cleaned using pressure wash-down. Aluminum units should be cleaned by wipe-down using a damp cloth. Make sure
that the General Safety Guidelines are followed during cleaning and verify that all conduit entries are plugged before
washing the metal detector.
Use of chemical cleaning agents: Contact Fortress prior to the use of aggressive, corrosive or petroleum based cleaning
solutions. Chlorine based cleaning agents are likely to cause corrosion on stainless steel components. Petroleum based
cleaners or thread locking agents are likely to damage food grade plastics.

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CHAPTER 1: INSTALLATION
1.1 Installation Overview
The aim of this chapter is to outline the general fundamentals of Stealth Gravity Metal Detector system installation and
present the key considerations that must be taken into account to ensure trouble-free operation.

1.2 Package ontents

Your Stealth Metal Detector kit includes the following:

Stealth Gravity Metal

Detector
Test Samples
3 Rods (and/or)
3 Spheres (and/or)
3 Cards

Mounting Kit
4 Spacers
3 Large Isolators
3 Small Isolators
1 Washer

USB Drive

Hex Key (Allen)

CHECK YOUR PACKAGE TO CONFIRM THAT YOU HAVE RECEIVEDTHE COMPLETE SYSTEM,
INCLUDING ALL APPLICABLE COMPONENTS SHOWN ABOVE.

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1.3 Installation Tools

The installation of your Stealth Detector system will only require general tools – there are no special tools required.

1.4 Installation Location

The location of the Metal Detector is very important. The metal detector must be positioned on a solid surface/frame.
The Metal Detector must be set up in an area free from radiated electromagnetic interference and must be connected
to a power supply that is free from line (mains) borne interference.
Environmental Conditions: Temperature range -5 C to +50 C (23 F to 122 F)
Gravity detectors are built rugged to withstand the harshest production environments with IP69K certified Stainless
Steel construction.

1.5 Handling
The Stealth system’s weight depends on the application; the unit is designed to be robust and can be extremely heavy
in some cases.
Where the unit has to be lifted, it is strongly recommended that suitable lifting devices be used; keep the unit low to
the ground in order to avoid a dangerous topple-over effect.

WARNING!
Do not use the aperture as a means of lifting the Detector system via forklift. Use
appropriate weight capacity straps to support the unit if lifting by forklift and
hook the straps securely underneath both side of the mounting frame.

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1.6 Installation ssentials

NOTE: The Gravity detector package comes in a variety of versions to suit customer
application. The configuration depicted below represents a standard system set-
up.

Below are the important installation guidelines for successful Gravity Metal Detector system results.

Product Freefall Start Point (Test Piece Access)

Plastic Pipe Selection

Drop Height D1
Distance

Detector

Detector To D2 Overall Length

Valve Distance

Reject Output
Test Retrieval Drawer

Good Product Output

1. Metal Free Area

No metal can be located in or near the Detector’s aperture (the opening through which product travels). The
Metal Free Zone required is equal to 1.5x the smaller dimension of the aperture. For large moving metal (such
as rollers/covers) this zone should be at least 2x the smaller dimension.
2. Relationship of Freefall Distance and Valve Position
The maximum freefall distance is determined by the response time of the reject valve and the relative position
of the reject valve. Greater the freefall distance results in faster flowing product. In order to accommodate
higher freefall distance, the Detector to Valve Distance (D2) must increase as the valve needs more time to
reach full divert position.
Given factors such as drop height, flow rate and bulk density, Fortress Engineers can help ensure that the
system is designed and constructed to suit the application.
Contact Fortress Technology for assistance in calculating freefall height limitations of valve position.
3. Free Flowing Product
Product must be free-flowing in order for Gravity system to work properly. Product cannot be allowed to backup
or plug the valve or pipe area.
4. Pressure
There should not be any internal pressure to the pipe area. This will result in product leakage from valve. Sim-
ilarly, a vacuum presence in the pipe can affect valve operation. The pressure should not exceed the rated
maximum specification for the plastic pipe and divert valve.
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1.6 Installation ssentials– continued

5. Static
Static will be present in all application where non-conductive materials are falling through air. Care should be
taken to ground all metal components of the detector system (the valve, frame, pipe flanges, etc.). Although
the product pipe used already has an anti-static characteristic, use caution when touching the outside or inside
of the plastic pipe section. Charges can exceed 50,000 volts and can be dangerous. Contact Fortress Technology
for assistance in reducing or limiting static problems.
6. Piping
Do not load the reject valve by attaching pipe sections to either output port which may result in valve dis-
tortion and operation problems. All piping should be supported externally to avoid valve problems.
7. Maintenance
The valve and pipe section should be routinely inspected for wear or excessive product build-up which may
affect proper detection and rejection of contaminants.
8. Air Controls
The air controls must be located close to the divert valve in order to maintain maximum response speed.
9. Foot Isolation
Mounting connections should be isolated electrically or firmly fixed with a thread lock. Loose mounting points
can cause false rejections.
10. Reject Containment System
The outfeed of the Metal Detector passes to a diverter valve reject mechanism that diverts in two directions.
Good product proceeds to the next process while contaminated product is diverted by the reject valve to the
reject port. The reject port should be piped to a containment vessel to isolate all reject product.

1.7 Mechanical Installation

The Gravity metal detector’s framing typically has four 10mm diameter mounting holes. Each one must be securely
bolted and properly grounded to connecting frames, thus eliminating potential intermittent connections. Below is an
illustration of one of the mounting points:

Metal Detector

Metal Detector
Mounting

System Frame

System Frame Mounting

Hole 10.0 mm Diameter

Product Anti-Static Pipe

Chute

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1.8 Air Service

The Gravity system comes with a pre-installed Filter Regulator Lubricator – air service unit. All pneumatic components
such as the solenoid valve and cylinder actuator are connected and ready for use. A recommended air pressure of 60
PSI (4.0 bar) is required for proper operation of pneumatic components.

NOTE: Air Pressure determines the response time of the reject mechanism.

System Frame

Air Service Unit

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1.9 Removing & Installing Display Panel

NOTE: It is important to follow these instructions when
removing or installing the display panel.

1. Loosen cover bolts (using 5mm Hex Key as supplied) in a diagonal pattern, 1-2-3-4 until all tension is removed.
2. Be sure to follow this pattern until all bolts have completely loosened. This will ensure that the bolt retaining
O-Ring will stay in place and the cover bolts will remain will the cover.
3. To remove, unplug Ethernet connector cable attached to main board.
4. To re-install, plug display panel Ethernet connector cable to main board.
See diagram below for removing and installing the display panel.

4
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1.10 Electrical Installation

1.10.1 CSA Guideline

Pollution Degree, 2;
Installation Category, II;
Humidity, 0% to 75% RH, non-condensing
Electrical Supplies, rated 100-120/200-240V, 50-60Hz, 1A
Ambient Temperature Range, -5C to 50C

1.10.2 Metal Detector Control Bay Layout

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1.10.3 DSP Layout

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1.10.4 Basic Power Connection

The Metal Detector’s power supply is incorporated within the system’s electronic enclosure; the Detector’s internal
power is universal (working voltage 95-260V AC, 47-63Hz). The power cable should be wired to a suitable plug or device
with a circuit protection of 3 amps.

WARNING!
Only a suitably qualified Electrical Technician should wire the power supply
main cables.

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1.10.5 Basic Reject Connection

Reject Outputs (Fail Safe Operation)

Outputs are shown in power-on, not rejecting state.
State 1 & 2 will close
State 2 & 3 will open
** For connection of reject devices requiring greater than 0.2AMP current supply; contact Fortress Technology for
assistance: 1-888-220-8737 or 416-754-2898.

1.10.6 Reject Confirm—Optional & Input Wiring Diagram

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1.10.7 Indicator Light Connection—Optional

The Stealth has a set of outputs intended to be connected to low power (LED) indicator light stack systems (Banner EZ-
Lite for example). The light outputs are rated to 50 mA per output. Typical connection for a 3 color light system is
shown below:

Indicators Connection for Light Indicators Connection for Light with Buzzer

1.10.7 Alternate Reject

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1.10.8 Fault Output Typical Connection

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CHAPTER 2: GETTING ORIENTED

2.1 Stealth Interface—Introduction
Regardless of the Detector application, the same user-friendly Stealth control interface is utilized; the aim of this
chapter is to become familiarized with the terminology and basic operation of the control panel.

1 2 3

4 9

5
10
6

7
8
11
The buttons, LED indicators, and display can be categorized as follows:
1. Detect – illuminates with a red LED upon detection.
2. LED Bar Graph – center-reading meter contains a green and red zone to visually quantify the signal of product,
metal, or background noise. The larger the signal the more significant the effect/contamination being detected.
3. Fault – flashes upon system fault.
4. LCD Display – digital screen shows system status and enables programming via menus.
5. Soft Keys – used to edit menu options. Refer to Section 2.2 for further details.
6. Enter – used to confirm changes to menu options.
7. Exit – cancels any changes and returns to the previous menu.
8. Menu – navigates through submenus. Refer to Section 2.3 for further details.
9. Product – indicates with a green LED whether a product is running through the Detector; a red LED represents a
high product effect reading.
10. Hard Keys – dedicated shortcut keys provide quick access to the most commonly used features. Refer to Section
2.2 for further details.
11. Arrow Keys – used to navigate within menu options, and increase/decrease values when editing.
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2.2 Hard vs. Soft Keys

The keypad has a series of ‘Hard’ and ‘Soft’ Keys which can be defined as follows:
Hard Keys:
The Hard Keys perform the same function irrespective of where you are within the menu structure. These convenient
“shortcut” keys (arranged on the right of the keypad) represent the most commonly used functions including:
SENSITIVITY, SELECT PRODUCT, CALIBRATE, TEST, and SELECT UNIT.
Less common functions are accessed through the MENU key.
Soft Keys:
The Soft Keys change their function according to the menu display, these four keys arranged around the LCD display are
used to edit the function being displayed on the LCD next to that Soft Key.

Soft Key 1 Soft Key 3

Soft Key 2 Soft Key 4

2.3 Menu Navigation

To move from one menu screen to the next, simply press the MENU key; alternatively, while no entry field is being
edited (i.e. no flashing cursor is visible).

2.4 Editing Menu Options

After pressing the Soft Key associated with an option field, a flashing cursor will appear.
To cycle through or edit the value of the option press the same Soft Key again or use the UP and DOWN arrow keys
located in the circle keypad. The LEFT and RIGHT arrows are used to move the cursor across the entry field. To accept
the new selection press the ENTER key; to cancel the new selection and revert to the old one press the EXIT key.

NOTE: For a few submenu options (such as Polarity) pressing the associated Soft Key will actually
change the setting without the need to confirm via the ENTER button; however, this is not
the typical process.

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2.5 Main Menu

PRODUCT1 Rej: 0

Sens: 100 Sig: 23

The four menu items can be defined as follows:

S1 - PRODUCT1: The Current Product Name.
This field shows the name of the currently selected product (multiple products can be entered into the system).
Product information can be edited and products can be deleted via the Select Product Menu. Refer to Section 3.8 for
further details.
S2 - SENS: Sensitivity Numerical Setting.
The sensitivity number ranges from 0 to 999 and determines the size of metal that can be detected; smaller pieces of
metal can be detected with a higher sensitivity setting. Typically, the sensitivity is optimized between 30 and 200. Press
S2 to change the sensitivity or press the SENSITIVITY Hard Key to access the Sensitivity Menu. Refer to Section 3.6 for
further details.
S3 - REJ: The Reject Count.
The reject count increments with every reject occurrence (a signal reading of over 100) –press S3 to reset the Reject
Count.
S4 - SIG: Signal Reading.
The signal number displayed represents the relative size of the detection signal; to become detection, a signal must
exceed 100. The Signal Number can be reset by pressing S4. Refer to Section 3.3 for further details.

2.6 Serial Number

Each Metal Detector is assigned a serial number to represent the unit. To view the serial number of the Metal Detector:
1. Press the Hard Key, “SELECT UNIT” button.
2. Press UP/DOWN Arrow Keys until you see “Serial Number”. The number stated there is the serial number for
the metal detector.

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CHAPTER 3: QUICK SETUP TUTORIAL

3.1 Start Up Tests—Overview
With the Detector assembled and installed, it is now ready for action. The aim of this chapter is to outline the initial
tests that must be carried out before introducing the Stealth Detector into production. These preliminary tests ensure
system functionality and configure the Stealth Detector for usage with your unique product.
This simple setup procedure only takes minutes to complete!

NOTE: It is strongly recommended that you complete an entire setup of one product
before introducing additional products

3.2 Power Up Sequence

WARNING!
Keep away from the operating area of the reject device upon powering
up the unit.

Upon applying power to the detector, the unit will power up and go through the following start-up process:
1. The LED bar graph will go full scale left and right and then return to the normal operating mode of the centre
LED in the Green Zone.
2. The display will indicate the main menu window.
3. The reject device may operate and then return to the normal operating position depending on the settings of
your system.
The power up sequence will take approximately 5 seconds. Once complete, the Detector will be ready for the initial test
and you will see the Main Menu screen as shown below:

PRODUCT1 Rej: 0

Sens: 100 Sig: 23

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3.3 Initial Signal Check

Before moving forward it is important to ensure that the Detector has a quiet and stable starting point. After the Power
up sequence is complete, the LED bar graph should appear in the centre.
The detector will always pick up a small signal reading from its surrounding environment; however, in the absence of
product passing through the aperture, the signal should not show a value higher than 30.

NOTE: The Signal reading will display the highest value registered and maintain this val-
ue on screen until another detection occurs or until the signal is manually reset.

To test the initial signal follow these steps:

1. Make sure that the Detector’s aperture and the product tube are clean; verify that no metal is located within
the aperture.
2. Turn ON the surrounding machines for a simulation of the true operating environment.
3. Reset the signal by pressing S4.

4. Check to see if the detector is in a stable position with no detections falsely triggering and a steady signal
under 30 and display LED in the centre.

If the starting point signal is less than 30 you can proceed.

If the detector is showing signal of over 30 without any product running, it is advised that you stop and examine the
cause before proceeding further. Refer to the Troubleshooting Guide (FAQ’s) for possible causes and corrective
solutions.

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3.4 Reject System

3.4.1 Reject System and Functional Testing

Testing a Gravity system can be very difficult if testing access and recovery are not designed into the system. However,
testing is a simple process when using a convenient access port for introducing the sample plus a Test Sample Retrieval
Drawer for retrieving the sample.
Test Access Point
It is imperative that the test sample be inserted as close as possible to the point where the product begins its freefall.
An access point to introduce a test sample (plastic ball or cylinder with metal sample imbedded) must be provided
upstream of the detector system. The entry point can be a threaded pipe or miniature retractable gate situated above
the anti-static pipe of the detector with a diameter of over 1” to accommodate the size of the sample. The test port
location should allow the sample to travel at normal speed through the detector.
Test Sample Retrieval Drawer
A Test Sample Retrieval Drawer should be inserted into the normal product flow after the valve. It is typically used on
the “good product” output so that the test sample can be safely recovered if the detector fails to detect the sample, or
the valve fails to react properly. It is also recommended that a test sample retrieval drawer be used on the reject
output to ease the recovery of the test sample when it is rejected. Test Sample Retrieval Drawer can be quickly
inserted into the product flow during a test, and removed from the flow afterwards.

Test Sample Retrieval Drawer

3.4.2 Testing Procedure

For the next steps you will need to utilize the Test Sample included with your Stealth Metal Detector. Follow these steps
to test the Detector and Reject device.
1. Insert Test Sample Retrieval Drawer or similar test piece recovery device.
2. Drop the Test Sample through the detector via the Test Access Port;
3. Check to see if the Signal reading exceeds 100, indicating a detection.
4. Monitor the operation and accuracy of the Reject valve in removing the contaminated product from the
production flow. If reject timing adjustment is required refer to Section 3.4.3.
The Sensitivity will need to be adjusted given the following Signal reading scenarios:
1. If the signal shows a very high result (over 1000) it may advisable to lower the Sensitivity.
2. In the unlikely event of the Detector not detecting the test sample, try increase the Sensitivity to the point
where background Signal for good product is approximately 60.
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3.4.3 Delay & Duration

In Gravity applications the reject valve timing is very critical in ensuring contaminant rejection. Reject Delay is the
number of seconds from the moment of detection before the reject device activates. Reject Duration is the number of
seconds for which the reject device will be activated.
If the Gravity system has been supplied complete from Fortress, then the reject timing as well as reject confirmation
settings (if equipped) have already been set and tested. The reject operation should be tested after installation to
confirm that it is operating correctly and the settings adjusted if required.
Test routine: In order to test the reject system timing and operation you will need to drop test samples from the same
point that product will normally start its freefall. You will also need a method to recover these samples if they are not
successfully rejected. If the system is equipped with a test sample retrieval drawer, then the drawer should be manual-
ly put into the test position below the reject valve. The test retrieval drawer is designed to capture the test samples in
the event that they are not rejected. Prior to performing a drop test, the test samples should be tested on the rails of
the drawer to be sure that they are of the correct size that will not allow them to pass through the drawer but small
enough that the drawer can still be pulled out to retrieve the test samples.

NOTE: For most Gravity applications, the Delay should be set to zero to ensure a fast reject
response time. The Duration can be adjusted based on trial but is typically 0.5 seconds
or less.

Diagram of Reject Delay and Duration is shown below:

Delay & Duration Timing

Reject Delay Timer

(wait before the Reject Device is activated)

Metal Detected

Reject Duration Timer

(Reject Device enabled pulse) Time

0 Seconds

Reject Adjustment Procedure:

Follow these steps in order to correct the reject accuracy:
1. From the Main Menu press the MENU key once to get to the Reject Menu.

Reject Setup

Del: 0.00 Dur: 0.00

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3.4.3 Delay & Duration—continued

2. To adjust the Reject Duration press S4, a flashing cursor will appear; use the LEFT/RIGHT arrow keys to scroll
the cursor between the characters and UP/DOWN (+/-) arrow keys to adjust the values followed by ENTER to
confirm.
3. To adjust the Reject Duration press S4, a flashing cursor will appear; use the LEFT/RIGHT arrow keys to scroll
the cursor between the characters and UP/DOWN (+/-) arrow keys to adjust the values followed by ENTER to
confirm.
4. Press EXIT to return to the Main Menu.
5. Run the test procedure again using the test procedure described above to ensure that the reject timing is
correct.

3.4.4 Reject Confirm

The Stealth Metal Detector has the ability to ensure that the reject device has operated correctly during every reject
actuation. The reject confirm option requires a signal from a sensor that will be activated by a reject event. Examples of
sensors used include a reed sensor, inductive sensor or proximity switch.
The proper connection for typical reject confirm sensor is shown in Section 1.10.6 the drawing shows the sensor being
powered by detector which is only allowed for approved low power sensors – contact Fortress for assistance with
sensor selection. The detector requires only that Pin 6 of PL 10 changes state when a correct reject action occurs. The
default polarity requires this pin to be connected to common normally and opens when a reject action occurs, but the
polarity can be reversed in the Reject Confirm menu (see below). Once configured, every reject signal will be mon-
itored for the correct response from the reject confirm sensor. Failure of the confirmation signal to be received within
a time window will result in a Fault condition (Reject Confirm Fault) and the fault output will change state. In addition,
if at any time the reject device fails to return to its ‘home’ position after a reject, then a fault will also occur.
Configuring the Reject Confirmation System:
To enable the Reject Confirmation option in the software follow these steps:
1. From the Main Menu press the MENU key once to navigate to the Reject Menu.
2. Press S3 to enter Reject Setup.
3. Press the MENU key till you reach ‘Reject Check’ menu.
4. Press S3 to select ‘1’ for reject confirmation.

Reject Check Off

Time: 200 Polarity

5. Press S2 to select and edit the reject confirmation time. (Detector uses an internal clock which has 200 pulses
per second). Press ENTER to confirm. The number represents the amount of time it takes for the reject device
to extend and retract; exceeding this threshold will result in a fault.
6. Press S4 to enter the Reject Confirmation Device Polarity Menu where you can toggle the polarity of the reject
confirm sensors.

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3.5 Product Calibration

Every product has unique characteristics; the purpose of Product Calibration is to “teach” the Metal Detector these
product attributes known as “product effect”. The detector then “learns” the product in order to ignore or “phase out”
the inherent product effect at a particular phase point and mode (wet or dry).
NOTE: In Gravity applications most products will be ’dry’ and will not require individual product
settings. See below.

3.5.1 Product Effect

Metal Detectors detect metal based on measuring electrical conductivity and magnetic permeability. Many products
inspected inherently have one or both of these characteristics within their makeup. For example: any products that are
iron enriched, such as cereals, create a large magnetic signal for which the Detector must compensate in order to
detect small pieces of metal. Products with high moisture such as bread, meat, and cheese are electrically conductive
and produce large conductive signals – these are referred to as “wet” products. During a “fast” learn process, the
Stealth Detector automatically sets its phase point to ignore the product effect signal; the following table shows typical
product effect signals and categorizes them as wet or dry.

Typical “Wet” Products Typical “Dry” Products

Food: Meat, Cheese, Bread & Bakery Products, Fish, Food: Cereal, Crackers, Cookies, Frozen Food Products (<20°
Dairy Products, Salad F/- 7°C), Peanut Butter and Margarine (Vegetable oil is
not conductive)
Packaging: Metallic Films
Other: Wood Products, Plastics and Rubber (Products with
Other: Plastic and Rubber Products with high carbon black high carbon black content may be considered ‘wet’),
content. Textiles, Paper Products

The Detector will be set with factory settings which may not necessarily match those needed to run your product
(although Fortress strives to preset the Detector settings to meet the product application).

NOTE: In most Gravity applications the product is “dry” and/or will have little or no Product
Effect. It may not be necessary to perform a Calibration procedure.

To determine if factory settings correspond to your product application try the following:

1. Reset the Signal by pressing S4.

2. Pass a typical product through the Detector aperture while checking the Signal reading and a Product LED
illumination. If the Detector does not “see” the product (signal below 60) then the product effect may not affect
detection; or, the factory settings already match the product.
NOTE: Normally the Product LED will normally appear Green upon passing the product through;
however, sometimes it may not illuminate at all due to minimal product effect.

3. If the product generates a detection signal you are likely to have a product effect that needs to be calibrated
and, you should proceed with the Quick Product Calibration.

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3.5.2 Quick Product Calibration Procedure

To “learn” a new product or re-calibrate at any time simply press the Calibrate key twice and let the good product pass
through the Detector; the Detector will automatically learn the correct phase number of the product and determine
whether it is “wet” or “dry”. Below is a step-by-step breakdown:

1. Press the CALIBRATE hard key on the right side of the

Stealth control panel.

2. Press CALIBRATE Hard Key again and the display will show a “fast” learn mode.

Setup Fixed

Phase: 90.00 Dry

3. Run a typical product through the Detector at normal speed and orientation.
4. The menu display will change “Fast” to “Fixed” and the Phase number should change to a new value.
5. If the Product LED is green proceed to step 6, if the Product LED is red you may be prompted with the following
screen:

High Product Signal

Ignore Low-Power

A red Product LED indicates that product effect is excessive and may result in an erroneous phase number when
calibrating. The software will provide you with the option to switch to “Low Power” or “Ignore”. Switching to “Low Pow-
er” will lower signal strength to account for the high product effect. Press Soft Key (S4) to automatically switch to Low-
Power mode. After switching to Low-Power mode, the product needs to be recalibrated. Refer to the beginning of this
section for details. If your system was already present to “Low-Power” mode, lowering the power is not an option. You
will need to call Fortress Technology to troubleshoot: 1-888-220-8737 or 416-754-2898.

3.5.3 Confirm Proper Product Calibration

To ensure that Calibration was successful, try the following:
1. Return to the Main Menu by pressing the EXIT key.
2. Press S4 to reset the signal.
3. Pass the Product through the Detector.

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3.5.3 Confirm Proper Product Calibration—continued

4. If calibrated correctly, the signal should be under ‘60’ (20-30 typical).
NOTE: It is possible that Sensitivity may need to be adjusted in order to reduce the effect of
difficult product (get signal under 60). Please refer to Section 3.6 for further details.

3.6 Sensitivity Level

The Detector’s sensitivity level determines the size of metal that can be detected. Smaller fragments of metal are
detectable at higher sensitivity levels; however, higher sensitivity levels also make the Metal Detector more susceptible
to outside interference and product effect.
The goal is to optimize the Sensitivity so that it is maximized at a safe level without compromising overall system
performance.
 The factory default for Sensitivity is 100
 The Sensitivity number value can range from 0 to 999
 The typical Sensitivity setting used ranges between 30 to 200

General Rule: Sensitivity may be increased as long as Signal from product is under “60”.

3.6.1 Functional Testing

Testing a Gravity system can be very difficult if testing access and recovery are not designed into the system. However,
testing is a simple process when using a convenient access port for introducing the sample plus a Test Sample Retrieval
Drawer for retrieving the sample.
Test Access Point
It is imperative that the test sample be inserted as close as possible to the point where the product begins its freefall.
An access point to introduce a test sample (plastic ball or cylinder with metal sample imbedded) must be provided
upstream of the detector system. The entry point can be a threaded pipe or miniature retractable gate situated above
the anti-static pipe of the detector with a diameter of over 1” to accommodate the size of the sphere. The test port
location should allow the sample to travel at normal speed through the detector.
Test Sample Retrieval Drawer
A Test Sample Retrieval Drawer should be inserted into the normal product flow after the valve. It is typically used on
the “good product” output so that the test sample can be safely recovered if the detector fails to detect the sample, or
the valve fails to react properly. It is also recommended that a test sample retrieval drawer be used on the reject
output to ease the recovery of the test sample when it is rejected. Test sample retrieval drawer can be quickly inserted
into the product flow during a test, and removed from the flow afterwards.

Test Sample Retrieval Drawer

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3.6.2 Testing Procedure

For the next steps you will need to utilize the Test Samples included with your Stealth Metal Detector. Follow these
steps to test the Detector and Reject device.
1. Insert Test Sample Retrieval Drawer or similar test piece recovery device.
2. Drop the Test Sample through the detector via Test Access Port;
3. Check to see if the Signal reading exceeds 100, indicating a detection.
4. Monitor the operation and accuracy of the Reject valve in removing the contaminated product from the
production flow. If reject timing adjustment is required refer to Section 3.4.3.
The Sensitivity will need to be adjusted given the following Signal reading scenarios:
1. If the signal shows a very high result (over 1000) it may be advisable to lower the Sensitivity.
2. In the unlikely event of the Detector not detecting the test sample, increase the Sensitivity to the point where
the test samples are detected with a signal of 150 or higher. Then check that the background Signal for good
product is less than 60.

3.6.3 Sensitivity Adjustment

To adjust the Sensitivity follow these steps:

1. Press the SENSITIVITY Hard Key on the right side of the

Stealth control panel.
2. Press S3 and a flashing cursor will appear.

Sensitivity 100

Signal 50

3. Press the UP/DOWN arrow keys (+/-) to adjust the Sensitivity, the LEFT/RIGHT arrow keys can be used to scroll
the cursor between digits.
4. Press ENTER to confirm.

3.6.4 Confirm Sensitivity Level

To ensure that a proper Sensitivity level was successfully applied try the following:
1. Return to the Main Menu by pressing the EXIT key.
2. Press S4 to reset signal.
3. Pass a typical product through the Detector.
4. Check the signal reading – if it is below 60, you may increase the Sensitivity further (a signal between 40 to 60
is acceptable). If the Signal reading is above 60, you should try lowering the Sensitivity.
5. Any time the sensitivity has been changed a complete function test must be performed as described in Section
3.6.1.

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3.7 Password Security

Password protection prevents an unauthorized user from tampering with the Metal Detector; the Stealth allows you to
configure password protection. You are able to set passwords at three levels:
Level 0 = Factory Setting, no password protection
Level 1 = Very limited access; i.e.: operator
Level 2 = Some access including functions open to level 1; i.e.: QA
Level 3 = Access to all the functions, able to change passwords; and
assign functions to other levels; i.e.: supervisor/manager

NOTE: In order to turn on or configure the password protection the level

3 password holder must be present

3.7.1 Activate Password Protection

To enable or disable password security follow these steps:
1. From Main Menu press the Menu key and scroll to Password Menu.
2. To turn Password Protection ON press S3, you will be prompted to enter the password, and the display below
will appear.

Enter Password:

****

3. The system is set up with default passwords that can be changed:

Level 1 - 1000

Level 2 - 2000

Level 3 - 3000

3.7.2 Change Password

To change your passwords follow these steps:
1. From Main Menu press the Menu key twice to access the Password Menu.
2. From the password menu press S4 to enter the password Setup.

Password: ON

Logout Setup

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3.7.2 Change Password—continued

3. Press S3 to select the level for which the password needs to be changed.
4. Press one of the lower Soft Keys (S2 or S4) to modify the password – a password is made up of numeric
characters.
5. Press the UP/DOWN arrow keys (+/-) to change each character; LEFT/RIGHT arrow keys are used to scroll the
cursor between characters.
6. Press ENTER to confirm the new password and EXIT to return to the Password Menu.

Info: Record the new password in a safe place.

3.7.3 Password Hard Key Access and Function Setup

To set up Password access levels for functions follow these steps:
1. From the password menu press S4 to enter the password Setup.
2. Press the UP/DOWN arrow keys (+/-) to scroll through the functions. To change access level for a function press
S3 then press UP (+) to change to 1, 2 or 3.
3. Press ENTER to confirm the new setting.
4. Press UP/DOWN keys to continue or EXIT to return to the Password Menu.

3.7.4 Logout
The logout function found in the S2 position of the Password Menu reinstates password protection after you have
completed adjustments to the Metal Detector settings. Password protection will be reinstated automatically if no key is
pressed for 10 minutes.

3.7.5 Wrong/ Forgotten Password

If you enter an incorrect password the following menu screen will appear:

Password: Incorrect

Try Again Forgot It

Press S2 to “try again”. If you have forgotten your password, press S4 and the detector will display a Seed Number
which Fortress engineers can decode for you. Please be prepared to offer proof of your authority when calling in to
obtain the correct code.

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3.8 Product Setup

The Stealth allows you to store settings for up to 99 different products in its memory. Product settings (including
sensitivity and calibrated phase point) are instantly retrieved upon changing from one product to another.

3.8.1 Renaming Products

The Main Menu displays the name of the product currently being run; by default the Product Name is set to PRODUCT1
and no additional products are set up. To change the default product name to a more suitable or descriptive one, follow
these steps:
1. Press the SELECT PRODUCT key on the right side of the Stealth control panel.
2. Press one of the lower Soft Keys (S2 or S4) alongside the product name to edit the name.
3. A flashing cursor will appear on the first letter; press the UP/DOWN arrow keys (+/-) to change the
alphanumeric characters. The LEFT/ RIGHT arrow keys are used to scroll the cursor between characters.
4. Press ENTER to confirm.

3.8.2 Saving Master Product

After you have followed all the Quick Start procedures and renamed your product, it is strongly recommended that you
save the settings. With the Backup you can easily restore the saved product setup configuration at any time. This
capability proves to be valuable in cases where operator changes have a negative effect on the system’s performance
as it is easy to revert back to the stored settings.
To save a Master product record follow these steps:
1. Press the SELECT PRODUCT key on the right side of the Stealth panel.
2. Press S3 to enter the Product Edit submenu.

Product: 1 Edit

Name: PRODUCT1

3. Press S4 to enter the Backup Submenu.

Copy Defaults

Delete Backup

4. Press S2 to save the current product settings as the Master settings (also known as the Factory Settings).

Backup

Save Restore

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3.8.2 Saving Master Product—continued

To restore the back up at any time, simply press S4 in the menu shown above.

NOTE: Default and Restore should not be confused – the Default function changes the
current product settings back to the Fortress standard default settings; whereas
Restore returns the current product settings to your saved Master configuration.

3.8.3 Create a New Product

To create a new product you are actually “copying and pasting” an existing product already stored in your Stealth’s
memory into a new product slot. The first time that you create a new product you are copying the information from
Master product that is already set up. When creating subsequent new products you may copy from any product record;
adjustments to new products do not affect the settings of the product that was initially copied. Follow these steps to
setup a new product:
1. Press the SELECT PRODUCT key on the right side of the Stealth panel.
2. Press S3 to enter the Product Edit submenu.
3. Press S1 to enter the Copy Product submenu.

Copy Defaults

Delete Backup

4. To create a new product press either of the upper Soft Keys (S1 or S3) to select the “slot” number of the new
product – (remember to always choose a slot number that is not currently in use because the information in an
existing slot will be replaced by the copied contents). A flashing cursor will appear. Press the UP/DOWN arrow
keys (+/-) to adjust the slot number. Press ENTER to confirm.

Copy Product To: 1

Name: PRODUCT1

5. You can quickly edit the product name for your newly created product by pressing one of the lower Soft Keys
(S2 or S4) and then press ENTER to confirm.
After exiting, the newly created product will appear as the currently selected product in the Main Menu.

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3.8.4 Select a Product

To switch from one product to another, follow these steps:
1. Press the SELECT PRODUCT key on the right side on the Stealth panel.
2. From the Select Product Menu, press the SELECT PRODUCT Hard Key again to scroll through the list of products
and press ENTER to confirm a selection.

3.8.5 Delete a Product

NOTE: You CANNOT delete the current running Product and you can never delete
PRODUCT1.

To erase a stored product record, follow these steps:

1. Press the SELECT PRODUCT key on the right side of the Stealth panel.
2. Press S3 to enter the Product Edit submenu.
3. Press the DELETE option (S2) from the Edit submenu of Select Product.

Copy Defaults

Delete Backup

4. Press one of the upper Soft Keys (S1 or S3) to edit the Delete entry field.

Delete 2

Name: PRODUCT2

5. Select the number of product you want to delete.

6. Press the ENTER key – the name of the product will change to whatever product is selected at the time to con-
firm that product has been deleted.

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CHAPTER 4: AUXILIARY FUNCTIONS

4.1 Auxiliary Functions—Overview
Now that your Stealth Metal Detector has been calibrated and tested successfully, you are ready to integrate the
system into production. The aim of this chapter is to highlight and explain the optional features you have with the
Stealth Metal Detector – the functionality of these features elaborated upon in the Reference Manual along with other
features that are not covered in this Guide.

4.2 Auto Test/ Test Request

It is highly recommended that the sensitivity of the Detector is checked routinely as part of the quality control
procedure, using manual testing with test samples. However the Stealth offers two distinct methods of automated
testing to confirm the Detector’s performance as well as the response of the reject mechanism.
Auto Test: performs short interval testing of the Detector’s sensitivity and valve reaction without any operator in-
volvement; thus reducing the high cost of frequent manual testing. Auto Test works by injecting a simulated metal sig-
nal (identical to test metal sphere sample) that acts as a rejection. You can set the simulation to occur at either the
touch of a button (Manual option) or at regularly scheduled time periods of your choice (Auto option).
Test Request: you may set the Detector to automatically request a test procedure utilizing the test samples supplied at
regular intervals (Request option).

NOTE: AutoTest is an optional setup. Test Request is recommended for Gravity application as
test samples can be easily inserted into product flow.

4.2.1 Configuring AutoTest/ Test Request

To set up the AutoTest/ Test Request function follow
these steps:

1. Press the TEST Hard Key on the right side of the

Stealth control panel.

Setup Test: Off

Rej: 3 Sig: 71

2. From the Test Menu, press S1.

3. From the Test Setup submenu, press S3 repeatedly to select between AutoTest modes: Manual/ Auto/Request.

Test Mode: Manual

Interval (min): 60

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4.2.1 Configuring AutoTest/ Test Request—continued

4. Press the ENTER key to confirm the selection.
5. If you selected Manual mode, Test setup is complete and you may Exit.
If you selected Auto/Request press the S4 key to adjust the setting of the Interval (either increasing or decreasing the
test timing via the Arrow Keys), then press ENTER to confirm.

4.2.2 AutoTest Operations—Manual / Auto Mode

To execute AutoTest under Manual mode, follow these steps:
1. Press the TEST Hard Key on the right side of the Stealth control panel.
2. From the Test Menu press S3.

Setup Test: Off

Rej:0 Sig: 5

3. A simulated metal signal is instantly injected; check to confirm that a detection Signal and Reject increment
occurred and that the reject device was properly triggered.
To execute AutoTest under Auto mode, no action is required as the test will be run at the prescribed interval.

NOTE: If an AutoTest execution does not cause detection, a Fault is generated.

4.2.3 Test Request Setup

Test Request prompts the user to conduct testing using the supplied test samples at specified time intervals.
You can change the number of test passes that are required per test sample (Ferrous/Non-Ferrous/ Stainless Steel). To
setup the Test Request Passes follow these steps:
1. Press the TEST Hard Key on the right side of the Stealth control panel.
2. From the Test Menu press S1.
3. From the Test Setup Menu press the MENU key once.
4. The Required Passes submenu will appear as shown:

Test Request FE: 1

NFE: 0 SS: 0

5. Use the corresponding Soft Keys to edit the values of Ferrous (FE), Non-Ferrous (NFE) and Stainless Steel (SS)
test sample passes.

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Test Request Operation:

1. For the purposes of this tutorial set the Test Request time interval to a low value of 1 minute via the Test Setup
Menu – this modification will allow you to quickly access the Test Request features (you can later change the
interval to a more appropriate value).
2. When the Test Request time interval comes up the Test Required screen will automatically appear.
3. Press S4 to enter the Operator Code – a value between 0–99 that represents the identity of the Test Operator.

Test Required Enter

Operator Code: 0

4. Press ENTER after editing the Operator Code.

5. You will be presented with a series of three Test Pass screens starting with Run Ferrous. Run the Ferrous test
sample through the aperture per the number of passes selected in Required Passes.
6. After each test sample run, press S4 to move on to the next phase:

Run Ferrous Metal 1

Sig: 150 OK

7. At the end of the three test passes you will see a Test Complete screen showing the result.
A “Pass” indicates that all required passes generated a detection Signal above 100.
A “Fail” occurs when at least one of the test passes did not render a detection Signal above 100 and a Test
Signal Fault will subsequently appear.

4.3 Alternate Reject Option

The Alternate Reject option allows you to connect a second reject device with separate reject timing settings. When
configured, the secondary ALT Reject output of PL11 will function independently of the main PL3 reject replay. Refer to
the wiring diagram in Section 1.10.6 for setup instructions.
For typical Gravity systems, the optically isolated Alternate Reject Output is used to activate a 24VDC solenoid valve. It
is defaulted to have the same reject timing as the main PL3 reject relay, however, it can also be configured to function
independently.
The Alternate Reject can remain activate for a longer period of time than the main reject; for example, if the main reject
is a fast-operating reject device, the secondary reject might be a beacon light that should remain activated for a longer
duration so that it is more noticeable.

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4.3 Alternate Reject Option—continued

Configuring the Alternate Reject
To enable the Alternate Reject option in the software, follow these steps:
1. From the Main Menu, press the MENU key once to navigate to the Reject Menu.
2. Press S3 to enter Reject Setup.

Alt-Reject Setup

Del: 0.00 Dur:0.00

3. Press the UP Arrow key twice to find the Alternate Reject Menu.
4. Once you adjust either the Delay or Duration to a number above the default setting of zero, the system will au-
tomatically enable the Alternate Reject as an independent reject output.

4.4 Date and Time Change

To edit the date and time:
1. At the Main Menu press “Select Unit”; then the DOWN (-) arrow key to get to the Date and Time menu.
2. Press S2, a flashing cursor will appear; use the LEFT/RIGHT arrow keys to scroll the cursor between the
characters and UP/DOWN (+/-) keys to change the characters.
3. Once the date and time are updated, press ENTER to confirm and EXIT.

NOTE: Do Not Forget to change the time when Daylight Saving Time begins or ends

4.5 IP Address
Detector is shipped with Default address of 192.168.1.51, if connecting to a network consult CONTACT Software
manual.
To change the IP address:
1. At the Main Menu press the SELECT UNIT button.
2. Press the UP/DOWN Arrow Keys until you see IP address

IP: 192.168.1.51

M: f8-99-55-c7-71-5c

3. Press S3 to change the IP address.

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4.5 IP Address—continued
4. A flashing cursor will appear on the first letter; press the UP/DOWN arrow keys (+/-) to change the numeric
characters. The LEFT/RIGHT arrow keys are used to scroll the cursor between characters.
5. Press Enter to confirm.

4.6 Naming the Detector

This name will be visible in CONTACT Reporter Lite software to identify then Detector. The name of the Metal Detector
can be made more suitable or descriptive to production, line or plant.
Follow these steps:
1. At the Main Menu press the SELECT UNIT button.
2. Press the UP/DOWN Arrow Keys until you see Detector’s Name.

DETECTOR NAME:
DETECTOR001

3. Press one of the lower Soft Keys (S2 or S4) alongside the Detector’s name to edit the name.
4. A flashing cursor will appear on the first letter; press the UP/DOWN arrow keys (+/-) to change the
alphanumeric characters. The LEFT/RIGHT arrow keys are used to scroll the cursor between characters.
5. Press Enter to confirm.

4.7 FM Detect Mode

FM detection mode analyzes the detection signal and uses an algorithm to calculate the signal strength based on a
function of time and amplitude. This can significantly improve performance in certain applications. FM detect mode
adds a slight delay to the detection process which may be critical in a gravity / high speed application.
To use FM mode the detector needs to have information about the application (speed and detector size) to define the
signal spectrum. To set these two parameters follow these steps:
1. From the Main Menu, press the MENU key once to navigate to the Reject Men.
2. Press S3 to enter Reject Setup.
3. Press the DOWN Arrow (-), then S4 to enter Setup.
4. Press S2 to enter the calculated or measured belt speed (median if the application is variable), then UP/DOWN
(+/-) to go through the options till you see DETECTOR DEPTH & WIN.

Detector (in)

Dept: 12.0 Win: 3.9

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4.7 FM Detect Mode—continued

5. Press S4 to set the Window (Win). Fortress can supply the accurate number for this but calculating
approximately 75% of the smaller aperture dimension will suffice (for an aperture of 300mm x 150mm, use
75% of 150 = 112 as the Win value).
Before setting up FM detection it is assumed that the digital filter has been set and product effect has been calibrated.
In addition, test and record the signals from product and metal test samples in the ‘peak’ detection mode so a clear
comparison can be made later. A threshold number should also be assigned in order to scale the sensitivity number to
a reasonable value (near 100).
To set FM detection follow these steps:
1. Press the SENSITIVITY Hard Key on the right side on the control panel.
2. Press S2 to go to Detect Mode Menu.
3. Press S3 to toggle the Detect Mode, press ENTER key when the “FM” option is displayed. This puts the Detector
in FM Mode.

Detector Mode: FM

Th: 7 EST: 5

NOTE: The value in the “Det.” field, this is a representation of the background signal from
the product, belt and any noise sources.

4. With the system running, press S4 to clear the value and pass normal sample product through the detector (try
to pass product as it would be passed in production). The value in the “Det” field will change.
5. The “Th:” value (threshold) should be set 1 above the “Det” value. This value will be used to scale the
sensitivity adjustment range to a reasonable value.
6. Press EXIT to return to the Sensitivity Menu and run clean product through. Adjust the Sensitivity so the signal
is below 60.
7. Run product with test samples to ensure the metal detector is rejecting the desired samples and adjust the
sensitivity number as required.
8. Compare the result using FM Detection Mode versus the results previously obtained using the peak detection

4.8 USB Data Collection & Contact Reporter Lite

The Stealth metal detector series all have the ability to collect operational data that can be collected in two ways:
1. Network collection through the built in Ethernet port, which will require proprietary software from Fortress
(Contact) to manage the collection and display of data. Contact Fortress for further information regarding
network data collection system options.

NOTE: The detector must have the time set for the data collection to work properly. See
Section 4.4 for details.

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4.8.1 Collecting Data using the USB Port

1. Insert USB key into the USB port located on the display of the metal detector, accessed by lifting the clear dust
cover.
2. When the USB key is inserted the data will begin to sync automatically. The time of this sync will vary
depending on the amount of new data being transferred.
3. You can cancel the synching at any time by pressing S2.

Synchronizing Data
Cancel Progress 0%

4. When complete you will be prompted that the sync is finished. At this point you can remove your key and
continue on to sync another metal detector or bring your USB key to the computer to view the data.
NOTE: If the USB key is removed during the sync, damage to the USB key may occur.

4.8.2 Installing and using Contact Lite Reporter Software

NOTE: The computer must be running Windows 7 or newer operating system and have
version 4 of the .net framework installed (free download from Microsoft).

Installing Contact Lite Reporter software:

The installer of the Contact Lite Reporter software is provided on the USB key.
1. Connect the USB to your computer.
2. Click on “Open Folder to view and select “ContactReporterLite” and then “ContactReporterLiteSetup”
3. Follow onscreen instructions to install Contact Reporter Lite.

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4.8.2 Installing and using Contact Lite Reporter Software—continued

Navigating detectors:
1. Open Contact Lite software.
2. Insert the USB key into an available USB port. Contact will automatically check the USB key and load a list of
detectors that have been synced to the key.
3. Select detector to view specific data from the list on the left.

Filtering data—Quick Filers:

The quick filters are located in the ribbon across the top of the application. These allow you to filter the data in a click
for a selected detector.

Toggle Filter – Will turn the filter on and off. This Month – Will display all the data for the cur-
When turned off all of the data will be displayed rent month.
in the window in chronological order (newest

Today – Will display all the data for the current Previous Week – Will display all the data for the
day. previous calendar week.

This Week – Will display all the data from the Previous Month – Will display all the data for the
current week (Sunday to Saturday is considered a previous calendar month.
week).

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4.8.2 Installing and using Contact Lite Reporter Software—continued

Last 7 days - Will display all the data for the last 7 Last 30 days - Will display all the data for the last
days. 30 days.

Filtering data – Calendar Filter:

When using the quick filters you can visually see the days selected in the calendar. As well as viewing this calendar will
allow you to visually refine the filter.

Selecting Days - Clicking and dragging over days will select

multiple days. If you click and drag again your previous
selection will be lost. If you would like to add to the Selected by clicking
selection you can hold the shift key and select additional and dragging.
dates.
Selected by clicking
and dragging while
pressing “SHIFT”.

To select or deselect an individual day you can click on the Selected by clicking.
day while holding the “control” or “ctrl” key.
Selected by clicking
while pressing
“CTRL”.

Filtering and sorting by Type:

By clicking any of the columns you will sort the list by that column, and by clicking again will invert the list order. When
hovering over the column a small filter graphic will appear, clicking this will allow you to filter to one type of event.
Rejects, Faults, etc.

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4.8.2 Installing and using Contact Lite Reporter Software—continued

If you grab the “Type” column heading and drag it into the box above you will get the events sorted by type.

Exporting and printing data:

Pressing this will show a preview of the selected data.

From this screen you can print the report.

Prompts to name and save the data to an excel (.xls)

file.

Prompts to name and save the data to a PDF.

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CHAPTER 5: FAQ’S & APPENDICES

5.1 FAQ’s (Frequently Asked Questions)

5.1.1 Troubleshooting Guide

When a malfunction occurs it may not be serious and could be corrected easily. The following describes the most
common problems and solutions; please refer to the following before calling Technical Support.

WARNING!
Shock Hazard: Only qualified service personnel should remove the Detector cover.

 Machinery and devices may operate without warning at any time.

 Keep away from the operating area of the reject device while power is applied.
 Keep hands clear of moving parts.
 Do not tamper with, modify or attempt to override guards or safety switches.

Problem Check

Upon initial power-up the display does Remove the display cover and follow the respective check list below:
not light up.
 Make sure there is power going to the Detector per the Power Supply
connection instructions in Section 1.10.
 Fasten any loose cable connections.
 Confirm that the Display Cable connector is plugged into [PL-800
Display] Digital Board.
 The Green LED on the top center of Digital Board should be flashing; if
the green LED is not flashing, check if the Ethernet communication lights
are blinking. Try disconnecting and then reconnecting the power to the
detector.

The Detector is falsely triggering.  Inspect the rejected product with a off line metal detector to confirm
the presence of metal contamination.
 Investigate various symptoms of false triggers to determine the source.
Perform the Initial Signal Check described in Section 3.3 to determine
whether false triggering is coming from the conveyor, outside
environment, or product.
 Make sure all moving cross members or metal transfer plates are
Continued on next page electrically isolated

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5.1.1 Troubleshooting Guide—continued

Problem Check
The Detector is falsely triggering.  Look for any large pieces of metal around the aperture opening such
as metal guides, covers, wire cables, etc. that may move when the
system is on. Refer to the installation section for more information .
 The Detector may be detecting outside interference from the
surrounding area. Possible sources of such interference are:

1. Airborne electrical interference – static, radio (RF), earth loops,

variable frequency drives.
2. Vibration – moving metal.
3. Temperature fluctuation – ovens, freezer tunnels.
The Detector is capable of filtering any one of these types of interference
to a large extent through the digital filter settings; but, if at all possible, it is
recommended to identify and fix the source of interference to achieve
optimal performance from the Metal Detector.
If the product is the source of false triggering, try re-calibrating the system
as described in Section 3.5 and then adjust the Sensitivity if required
(Section 3.6).
Note: if you change the Sensitivity level, always ensure that your test

The reject device is malfunctioning. On the Display Panel confirm that the Signal level is exceeding 100 and the
red detection light is turning ON in the event of reject activation.

Warning: Keep away from operating area of the reject

device.

 Check if the solenoid and actuator/cylinder is changing state

upon a Signal of 100 or greater. If not, check whether the re-
ject cable is properly wired to the Digital Board reject output
(refer to Wiring Diagrams in 1.10)
 If actuator/cylinder valve is changing state, confirm there is
adequate air pressure to the device (typically 60 psi/4 bar).

If problems still persist contact Fortress Technology’s Technical Support for assistance.

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5.2 Faults

Fault Possible Cause Corrective Action

24V  Power supply not functioning properly  Power supply needs to be checked and/ or
replaced.

Air Pressure  The air pressure sensor connected to the  Verify air pressure going to the sensor with the
isolated input of the DSP board (PL10 pins reject device set to factory default; typically about
9 & 10) is indicating a low pressure which 60-80 P.S.I.
may impair the proper function of the re-
ject device.  Verify air pressure sensors are installed.

 Air pressure sensor not functioning  Verify air pressure proper functionality.
properly .  Faults can be cleared and masked in the software,
until a technician has verified and corrected the
causes of the fault

Balance  There is metal located within the Detector  Verify that no metal is located within the Detector
aperture. aperture.
 The Detector balance is excessive.  Check if LD3 (yellow LED) on DSP board is on.

Date Time  Indicates the time is not set.  Set the correct date and time.

Excess  The number of rejects has exceeded the  Check rejected product for metal contaminants.
Reject limit set within the software Feature is
 Make sure the Detector is calibrated for the
enabled via Fault Setup Menu.
running product
 Can be cleared via the Clear soft key (S3)

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5.2 Faults—continued

Fault Possible Cause Corrective Action

Internal USB  There is an issue with the internal USB  Contact Fortress Service Dept.
storage.

Large Metal  The large metal threshold limit has been  Verify that no metal is located within the Detector
exceeded. aperture.
 The large metal threshold has been set too  Increase the large metal threshold.
low Feature is enabled within Sensitivity
 Can be cleared via the Clear Soft key (S3) and
submenu.
masked in the software’s Fault Menu

Low Battery  This fault will be generated when battery  Replace with a CR2032 battery.
PL20 is low.

Peye Block  Photo Eye function is turned on.  Check reject settings, reject setup should
be normal.
 Turn photo reject off.

Phase Limit  A phase limit was exceeded during a cal-  Can be cleared via the Clear soft key (S3).
ibration or auto phase update.
 Check the phase point and perform a fast phase
calibration.

PROD  Product memory may be corrupted  Cycle power to clear memory or reset the product
Memory record via Reset in the Product, Edit Menu

Rej Bin Full  The reject bin is full (this may prevent  Check the bin and empty rejected product – handle
product from being successfully rejected according to operational procedures
into the bin)
 Check that the sensor in the bin is not misaligned
 Check the polarity of the input

Reject  Reject confirmation device(s) failed to  Check that the reject device is functioning properly
verify that the contaminated product was and that the confirmation devices are positioned
properly rejected correctly
 Check if the polarity setting and the time delay
within the software is set

Reference  DSP PL1 Wire not connected properly  Check if DSP PL1 board interconnection cable/plug
are fully located with no loose connections
 SH Board circuitry may be faulty
 Call Fortress for assistance to check if SH Board is
faulty

Test Signal  Test signal was not detected during a test  Check the sensitivity and perform a manual test
procedure
 Call Fortress for assistance to check if SH Board is
faulty

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5.3 Appendices

5.3.1 DSP Board

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5.3.2 Technical Specifications (Overview)

Technology

High frequency, low powered, electromagnetic coil system – monitored and controlled by Digital
Signal Processing.

Frequency of Operation of Coil

Crystal controlled in the range 1 kHz to 2 MHz. Single frequency units are the standard and are
adequate for most applications however dual frequency is available as an option.

Product Throughput Speed

1.0m/min to 2000m/min.

Temperature Range

 Storage: -10˚C to +50˚C (14˚F to 122˚F)

 Operating: -10˚C to +45˚C (14˚F to 113˚F)*

*Other equipment options available for operating temperatures outside this range

Power Input
 Voltage: 85 to 260 Volts AC
 Mains supply voltage fluctuations not to exceed +10 V/-15 V of the nominal voltage
 Power: 50 VA*
 Frequency: 50 to 60 Hz
 For connection to TN (EN60950-1.2001) power distribution system. For connections to oth-
er power distribution systems please contact your supplier.

*Assumes no loads on the switched power outputs.

Internal Battery
 Battery life: typical 7 years*
 Nominal voltage: 3.6 Volts D.C
 Battery Type: CR2032 Button

*Battery serves purely for real time clock. Data is stored on Flash and thus not affected by battery charge/
discharge.

Humidity Range
Maximum relative humidity: 95% for temperatures up to 55˚C.

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Environmental Protection
 Painted version medium duty: IP65, NEMA 4X
 Stainless Steel version heavy duty: IP69K

Warm Up Time
 Less than 5 seconds at an ambient temperature of 20˚C.

Indoor Environmental Operating Conditions

 Altitude up to 3500 m
 Pollution Degree 2 in accordance with IEC 664

Sound Output
 0 dBA at a distance of 1 m (not including Audible alarm system)

Switched Power Output

 Switched live and neutral, non-switched earth. Internally fused
 Maximum current: 1A

Reject Output Relay

 Volt-free changeover contacts that operate on the detection of metal
 Maximum current: 5A
 Maximum voltage: 250 Volts AC/DC

Alternative Reject Output Relay

 Solid State Volt-free changeover contacts that operate on the detection of metal
 Maximum current: 150mA
 Maximum voltage: 250 Volts AC/DC

Fault Output Relay

 Solid State Volt-free changeover contacts that operate if a fault occurs within the metal
detector
 Maximum current: 150mA
 Maximum voltage: 250 Volts AC/DC

Detect Signal
 Operates on the detection of metal

Product Library
 Capable of storing 99 products and associated parameters.

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Test Request Output

 Output that operates when a performance test becomes due or when a performance test becomes overdue
 Output type: Volt Free contact
 Maximum current: 150mA
 Maximum voltage: 250 Volts AC/DC

Pack Sensor Requirements

 Operating voltage: 24 Volts D.C.
 Operating current: 50 mA maximum
 Output type: NPN

Speed Sensor Requirements

 Operating voltage: 24 Volts D.C.
 Operating current: 50 mA maximum
 Output type: Push/ Pull
 Pulses per revolution: 200-1200
 Input frequency: 2 KHz (Typical)

Reject Confirmation Sensor Requirements

 Operating voltage: 24 Volts D.C.
 Operating current: 50 mA maximum
 Output type: NPN

Bin Full Sensor Requirements

 Operating voltage: 24 Volts D.C.
 Operating current: 50 mA maximum
 Output type: NPN

Pack Exit Sensor Requirements

 Operating voltage: 24 Volts D.C.
 Operating current: 50 mA maximum
 Output type: NPN

Communications
 Ethernet based IP (Industrial Protocol).
 Fortress Protocol (Internal Use).

Reject Counter
 Counts number of detections
 Counter range: 0 to 999
 This counter can be reset from the control panel

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Pack Counter
 This counter requires that an external pack sensor be fitted
 Counter range: 0 to 99,999,999
 Maximum count rate: 3500 packs/min. at a pack/space ration of 1:1
 This counter can be reset from the control panel

Spherical Sensitivity
 Sensitivity is expressed in diameters of spherical samples. This will vary on a number of vari-
ables including aperture size, frequency of operation and product effect.
 Non spherical objects such as wires will exhibit an orientation effect, ie they can be more easily detected
in certain axis. This will vary on a number of variables including metal type and position within the aper-
ture.

Sensitivity Ratios (typical)

 Dependent on frequency system and product effect eg at 300 kHz
 Non-Ferrous x 1.0 to 1.2 of the Fe diameter
 316 Stainless Steel x 1.2 to 1.5 of the Fe diameter
 Example (Dry product)
 1.0mm Fe
 1.0mm Non Fe
 1.2mm 316 SS
 Example (Wet product)
 1.2mm Fe
 1.5mm Non Fe
 2.0mm 316 SS

Timer Ranges
 Duration: Up to 3 minutes
 Delay: Up to 1 minute

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Gravity Metal Detector
Fortress Technology Inc.
51 Grand Marshall Drive
Toronto, Ontario
M1B 5N6, Canada
Tel: 1-888-220-8737
service@fortresstechnology.com

Fortress Technology (Europe) Ltd.

The Phantom Building
7 Beaumont Road, Banbury
OX16 1RH UK
Tel: +44 (0) 1295 256 266
info@fortresstechnology.co.uk

Fortress Technology Sistemas de Inspeção Ltda.

RRod. Presidente Tancredo de Almeida Neves,
3007 - Km 30,5 – Vila Rosina - Caieiras
CEP: 07748-400
Fone: +55 (11) 3641 6153
brasil@fortress-iis.com.br