39 Test

METAL DETECTOR WITH
CONVEYOR APPLICATION
OPERATOR SET-UP MANUAL
WWW.FORTRESSTEC HNOLOGY.COM
Metal Detector with Conveyor Application System—Operator Setup Manual
INTRODUCTION
Thank you for purchasing an Interceptor Metal Detector with Conveyor 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, Interceptor Metal Detectors are available in a range of aperture sizes and configura-
tions 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 Interceptor 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.
 Auto Phase—learns and calibrates to product with both wet and dry characteristics.
 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.
Service Support:
Fortress Technology provides the highest standards of customer service in the industry. You simply receive the best,
most efficient response whenever you require help! We have a global service team to ensure our customers get the
fasted and most reliable service.
We believe that through the implementation of regular and preventative maintenance, and by conducting effective
training support and guidance, you can reduce break downs, eliminate waste and achieve maximum potential from
your product. Call us to find out about our training programs and preventive maintenance packages.
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
Brazil: +55 11 3641 6153
Version: 160610 www.fortresstechnology.com

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 Removing & Installing Display Panel .................................................... 9
1.8 Electrical Installation .......................................................................... 10
CHAPTER 2: GETTING ORIENTED ........................................................ 16
2.1 Interceptor Introduction .................................................................... 16
2.2 Menu Maps ........................................................................................ 17
2.3 Interceptor Interface .......................................................................... 21
2.4 Hard vs. Soft Keys ............................................................................... 22
2.5 Menu Navigation ................................................................................ 22
2.6 Editing Menu Options ........................................................................ 23
2.7 Main Menu ......................................................................................... 23
2.8 Serial Number .................................................................................... 23
CHAPTER 3: QUICK SETUP TUTORIAL .................................................. 19
3.1 Start Up Tests—Overview .................................................................. 19
3.2 Power Up Sequence ........................................................................... 19
3.3 Initial Signal Check.............................................................................. 20
3.4 Reject Systems ................................................................................... 21
3.5 Product Calibration ............................................................................ 28
3.6 Establish Sample Detection ................................................................ 31
3.7 Set Sensitivity Level ............................................................................ 31
3.8 Password Security .............................................................................. 32
3.9 Product Setup ..................................................................................... 34
CHAPTER 4: AUXILIARY FUNCTIONS ................................................... 38
4.1 Auxiliary Functions—Overview .......................................................... 38
4.2 Auto Test/ Test Request/ Halo® ....................................................... 38
4.3 Special Reject Options ........................................................................ 40
4.4 Date & Time Change .......................................................................... 42
4.5 IP Address ........................................................................................... 42
4.6 Name the Detector............................................................................. 43
4.7 FM Mode ............................................................................................ 43
4.8 Interceptor Input Configuration ......................................................... 45
4.9 Interceptor Output Configuration ...................................................... 49
4.9 USB Data Collection & Contact Reporter .......................................... 51
CHAPTER 5: FAQ’S & APPENDICES ....................................................... 55
5.1 FAQ’s (Frequently Asked Questions).................................................. 55
5.2 Faults .................................................................................................. 57
5.3 Appendices ......................................................................................... 59
Copyright © 2016 Fortress Technology Inc. www.fortresstechnology.com

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. REMARQUE : Ce document est disponible en Français.
Por comuníquese con service@fortresstechnology.com para obtener una copia. S.V.P. contactez service@fortresstechnology.com
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 radio frequency transmitter and emits 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 proce-
dures 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.
www.fortresstechnology.com Page 3
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.
Page 4 www.fortresstechnology.com
CHAPTER 1: INSTALLATION
1.1 Installation Overview
The aim of this chapter is to outline the general fundamentals of Interceptor Conveyor Metal Detector system installa-
tion and present the key considerations that must be taken into account to ensure trouble-free operation.
1.2 Package ontents

Your Interceptor Metal Detector kit includes the following:
Interceptor Metal Detector

(actual unit received may
differ from image shown)
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.
NOTE: If purchasing an integrated conveyor system from Fortress, the

Mounting Kit is not applicable.
1.3 Installation Tools

The installation of your Interceptor Detector system will require only 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)
1.5 Handling
The Interceptor 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.
Correct Method of Lifting Detector Incorrect Method of Lifting Detector
1.6 Installation ssentials

NOTE: If you have received a complete system from Fortress then all the basic
installation issues have been addressed.
Below are the important installation guidelines for successful Conveyor Metal Detector system results.
DIRECTION OF PRODUCT
1 6
5
2
3 4 7
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. Non-Metallic Slider Bed/Decking
Use a non-metallic slider bed (decking) material to support the product through the metal free area;
recommended materials are phenolic or micarta due to their low static generating characteristics.
3. Clearance
The belt, slider bed (decking), and product must not come in contact with the aperture walls.
4. Foot Isolation
Only one foot mount at the control end should make electrical contact with the mounting frame. The
remaining mounting feet must be electrically isolated from the frame using the isolators supplied with the
equipment. The supplied washer should be used for one-point grounding. Mounting connections should be
firmly fastened or loose mounting points can cause false rejections.
5. Photo Eye
Photo Eye is an optional sensor that can be installed on the infeed side of the Metal Detector for the purpose
of ensuring the most precise accuracy of the reject device. Contact Fortress for information on recommended
Photo Eye sensors. For more information on Photo Eye Setup, refer to Section 3.4.2.
6. Metal Free Conveyor Belt
The belt should be suitable for Metal Detector use; avoid anti-static belts or colored belts which may contain
carbon or metallic pigments. Where possible use plastic chain belting (eg: Intralox) in a natural color; do not
use metal splices (a vulcanized finger splice is preferred for belts which require splicing). If in doubt contact
Fortress for help in determining proper belting prior to installation; be sure to protect the belt from weld
splatter etc. when working near the Detector system.
1.6 Installation ssentials– continued

7. Roller Isolation
Rollers should be isolated at one end to avoid possible interference caused by loop effect. See below for
details.
To properly isolate a roller, use one of the following concepts:
1. Insert a nylon bushing on reduced shaft.

2. Use a non-metallic bearing housing.
3. Install isolation material behind bearing
and nylon bushings on mounting bolts.
To avoid Loop Effect, ensure the following:
1. Do not allow cross-members in the conveyor frame to form “loop shapes”.

2. Cross members need to be isolated or fixed by welding (not bolting).
3. Be sure to isolate only one end of the rollers. Excessive static may be generated if both ends are
isolated.
Why Rollers can cause Loop Effect

From the Detector’s view, the roller and conveyor frame
forms an antenna shape which is very similar to the Bearing Roller
shape of the aperture. This shape will produce a large
field which is reflected back into the Detector. If it
remains constant in position and intensity the Detector
will not be affected. However, as the roller turns, the
bearings will change their electrical characteristics and
the loop field will collapse, generating a large error
signal. Even moving a closed loop can cause
interference. Loops react the same way regardless of
whether they are grounded or not. Conveyor
Frame
Electrical equivalent of
roller and bearing isolation
1.7 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.
5. Tighten screws. Torque = 2.0NM or 17 inch pounds.
See diagram below for removing and installing the display panel.
4
1.8 Electrical Installation
1.8.1 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
1.8.2 Metal Detector Control Bay Layout
DSP Board Ver. 9.2+

LK830
PL15 LK831
PL6
DISPLAY
PL800
PL830
PL820 PL810
LK840
PL840 LK841
LK810
LK811
LK821
LK820
LK801
LK800
LK850
LK851
PL850
PL601
SW1
EXTERNAL
PL860
IC245
LED560
R166
PL10 R157
24V DC 1 PL20
Encoder 2
Infeed Eye 3
0V DC 4 Input devices rated
24V DC 5 24VDC / 0.5A MAX
Non-isolated inputs must
Reject Check 1 6 be NPN type
Reject Check 2 7
0V DC 8 ASSR-3211-001E (Solid State Relay)
Isolated Input + 9 250V output withstand voltage
0.2A current rating
FORTRESS TECHNOLOGY
Isolated Input - 10
PL4 COPYRIGHT 1605
LK450
Alt Reject + PL11 1 1
2
Alt Reject - 2
PL870
3
Test Request + 3 4
Test Request - 4 5
Fault + 5
PL880
Fault - 6
RLY5
PL3
Reject Relay NC 1
LK451
Reject Relay Common 2 Relay Contact Ratings
Switching voltage – 250VAC / 30VDC MAX DSP BOARD
Reject Relay NO 3 5A current rating SD003 VER 9.2
1.8.3 DSP Layout
DSP Board Ver. 9.2+ Ethernet Ports for

connection with
5V Power Connector FTI boards
LK830
PL15 LK831
PL6
24V Power
PL830
PL820 PL810 PL800
DISPLAY
Ethernet Port for connection Connector
to SD004 Display board LK840
LK841
PL840
LK810
LK811
LK821
LK820
LK801
LK800
Ethernet Ports for
LK850
connection with LK851
FTI boards PL850
DSP reset
PL601
switch
EXTERNAL
Ethernet Port for connection SW1 Internal USB

PL860
to a PC. Uses external IP IC245

LED560
address & has no power
PL10 R166
1 PL20
2 R157
3
4
RTC battery
5
6
7
8 FORTRESS TECHNOLOGY
9 COPYRIGHT 1605
10
IC920 PL4
PL11 1 LK450
1
IC921 2
2
PL870
3
3 4 Ethernet Port for connection with SD029
4 IC922 5 Search Head board (channel A)
5
PL880
6
Ethernet Port for connection with SD029
PL3
RLY5
1 Search Head board (channel B)
LK451
2
3 DSP BOARD
SD003 VER 9.2
To use external 24V for I/O Connectors R166 & R157 must be removed.
PL10 – Inputs PL11 – Output Relays

Input devices rated
1 Alt Reject +
1 24V DC 24VDC / 0.5A MAX
2 Alt Reject -
2 Encoder Non-isolated inputs
3 Test Request +
3 Infeed Eye must be NPN type
4 Test Request -
4 0V DC 5 Fault +
5 24V DC 6 Fault -
6 Reject Check 1
7 Reject Check 2 ASSR-3211-001E (Solid State
8 0V DC Relay)
9 Isolated Input + 250V output withstand voltage
10 Isolated Input - 0.2A current rating
PL3 – Main Reject Relay

1 Reject Relay NC
PL4 – EZ-Lite Light Stack Connector
2 Reject Relay Common
1 Red 3 Reject Relay NO
2 Green
3 Yellow Relay Contact Ratings
4 24V DC Supply Switching voltage – 250VAC /
5 Buzzer 30VDC MAX
5A current rating
1.8.4 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.
DSP Board Ver. 9.2+

LK830
PL15 LK831
PL6
DISPLAY
PL820 PL810 PL800
PL830
LK840
LK841
PL840
LK810
LK811
LK821
LK820
LK801
LK800
LK850
LK851
PL850
PL601
SW1
EXTERNAL
PL860
IC245
LED560
R166
PL10 R157
24V DC 1 PL20
Encoder 2
Infeed Eye 3
0V DC 4 Input devices rated
24V DC 5 24VDC / 0.5A MAX
Non-isolated inputs must
Reject Check 1 6 be NPN type
Reject Check 2 7
0V DC 8 ASSR-3211-001E (Solid State Relay)
Isolated Input + 9 250V output withstand voltage
0.2A current rating
FORTRESS TECHNOLOGY
Isolated Input - 10
PL4 COPYRIGHT 1605
LK450
Alt Reject + PL11 1 1
2
Alt Reject - 2
PL870
3
Test Request + 3 4
Test Request - 4 5
Fault + 5
PL880
Fault - 6
RLY5
PL3
Reject Relay NC 1
LK451
Reject Relay Common 2 Relay Contact Ratings
Switching voltage – 250VAC / 30VDC MAX DSP BOARD
Reject Relay NO 3 5A current rating SD003 VER 9.2
1.8.5 Basic Reject Connection
Outputs (Relay)
GS5B-14 (250V/1.0A)
250V Output Withstand Voltage
1A Current Rating
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 1AMP current supply; contact Fortress Technology for
assistance: 1-888-220-8737 or 416-754-2898.
1.8.6 Photo Eye Connection
1.8.7 Reject Confirm—Optional & Input Wiring Diagram
1.8.8 Indicator Light Connection—Optional

The Interceptor 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 with Buzzer
Indicators Connection for Light
1.8.9 Shaft Encoder
1.8.9 Alternate Reject
1.8.10 Fault Output Typical Connection
Fault polarity Normally Closed by default,

can be inverted in software settings,
see fault setup menu
Outputs (Solid State Relay)

ASSR-3221 (250V/0.2A/10oHm)
250V Output Withstand Voltage
CHAPTER 2: GETTING ORIENTED

2.1 Introduction
The Interceptor metal detector is designed to operate at multiple frequencies of transmission simultaneously. This al-
lows improved detection performance for all metal types over a wide range of product applications. This manual de-
scribes the setup and use of the dual transmitter system and the frequencies are described as channel A for the high
frequency system, and channel B for the low frequency system.
System menus versus Channel Specific Menus:

Most menus in the user software are common to both channels and are referred to as System Menus or parameters.
System menus are common to both channels will not have a channel indicator displayed.
System Menus are:
 Reject  Language
 Product Select  I/O Setup
 Password  Pack Count
 Fault  Date / Time
 IP, Network settings, Serial Number and Detector Name
Menus and parameters that are channel specific will have the channel indicator displayed on both sides of the LCD
(A or B). In any of these menus pressing the Select Unit key will jump to display the other channel.
Channel Specific Menus are:

 Sensitivity (some sub-menus are system parameters)
 Calibrate (some sub-menus are system parameters)
 Test (some sub-menus are system parameters)
 Digital Filter
Note: All parameters, both system and channel specific are stored as a complete product record and once stored can
be recalled through the Select Product menu.
2.2 Menu Maps
Sensitivity Detection
Menu Mode
S2
Sensitivity Sensitivity: 100 Detect Mode: FM
FM Signal: 0 Th: 40 Est: 1
Large Metal
Large Metal
Threshold: 0
Peak Signal
Peak Signal
Reset Mode: detect
Select Product Product Edit Copy Product

Menu Menu Menu
Select S3
S1
Product: 1 Edit Copy Defaults Copy Product To: 1
Product
Name: PRODUCT1 Delete Backups Name: PRODUCT1
Delete Product
Menu
S2
Delete Product: 1
Name: PRODUCT1
Defaults
S3
Use default
settings
Are you sure? Yes
Backup Settings
S4
Backup Settings
Save Restore
Calibrate Menu Detector Power Setting

Calibrate Setup Fixed
S1
Detector Power : high
Phase: 90 Dry
Phase Mode Hold Setup

Phase Mode Hold: off
Photo - Calibrate: off
Phase Trigger Setup

Phase Trigger
3 of: 6
Dry Phase Limit Setup

Dry Phase Limit
90.00 Spread : 45
Wet Phase Limit Setup

Wet Phase Limit Setup
0.00 Spread : 45
Auto Phase
Auto Phase
Packs: 5
Product High Reject

Reject on Prod High
:off
Product Threshold Setup

Product High : 28000
R:18000 X:18000
Test Menu Test Mode

Test Setup Test: off
S1
Test Mode: Manual
Rej: 0 Sig: 10 Interval(min): 60
Test Signals
Test Sig: 10
R: 0 X: 0
Test Req. Samples

Test Request FE: 0
NFE: 0 SS: 0
Select
Channel A
Unit
A A
PRODUCT1 Reg: 0
Sens:100 Sig: 0
Channel B
B B
PRODUCT1 Reg: 0
Sens:100 Sig: 32767
Belt Speed
Reject Menu Reject Mode Belt Speed Est.
Menu S3 Reject Mode: Normal Belt Speed Learn
S3 Belt Speed Est: 0.0
Reject Setup
Del: 0 60 ft/min Pkg Length(in): 10
Dur: 0
Password Reject Setup Photoeye

Menu Passwords Distance
S4 Photo Reject: Mid S4 Photoeye Distance:
Password: Off Change Password 1
eye: 0 Setup 9.5 in
Logout Setup 0000
Reject Package
Password -
Digital Filter Check Length
Sensitivity Reject S4
Off Package Length:
Digital Filter: Med Hard Key Access Check:
Time: 200 Setup 10.0 in
Sens: 100 Sig: 0 Sensitivity 3
Password - Sel Rej Latch /

Freq / Bal / Ref Man. Rej
DSA
Prod.
Hard Key Access Manual Reject: Low DSA
Frequency: 000 Reject
Select Product 3 off Size: 1.0
Ref: 1200 Bal: 200 Latch:
Password - Alt Reject Peye Block

Language Calabrate Limit
Setup
Hard Key Access Photoeye Block Limit
Language: English Alt. Reject Setup
Calabrate 3 10.0Times Pkg Length
Del: 0.00 Dur: 0.25
Password - Minimum
Pack Count Test Reject Clock Pack Gap
Pack Count Hard Key Access Minimum Package
Reject Clock: 0
Test 3 Gap: 0.2 in
00000000000 Source: int Setup
Password - Sel
Detector
Unit
S4
Hard Key Access Detector (in) Setup

Select Unit 3 Depth: 12.0 Win: 3.9
Password - Time Reject with no

Clear Faults Correction running Product
Password Access Reject with no
Time Correction
Clear Faults 3 Running product: Off
Del: 0 Dur: 0
Password - Clear
Rej Count
Password Access Reject Check
Clear Rej Count 3
Pol
Polarity Rej: main
Continued Password - Clear R:1 R:1
Reg Latch
Password Access Bin Door
Clear Rej Latch 3 Timeout
Reject Bin Door
Password - Timeout(se
60
Sync c)
Password Access Reject Exit

Data Synchronize 3
Window
Reject Exit(in)
Password -
Window 0.0
Date/Time
Password Access
Date and Time 3 Reject Exit
Reject Exit (in)
Est: 0.0 Dist: 0.0
Faults
Faults Setup S4
Log
S3
Rej on Fault
Reject on Fault
Main: Off Alt: Off
Fault Latch
Fault Latch: Off
Excess Rejects
Excess Rejects: 0
Interval(min): 5
Fault Mask
Fault: Enabled
Cause: 24V
Fault Log
Log0: No faults
Age: 0 Clear
Date Code Noise Estimate

Version: 2014/909 S3 Noise Estimate
Select Unit R: 0 X: 0
Thresholds
S4
Thresholds
R: 40 X: 200
I/O Setup Input Setup
Input Setup S3 Use:
Reject Power-Up / Disable
Output Setup In: Pol: +
Reject Disable: Off
Power-up Reject Off
Date / Time
Date and Time
DC Filter
2014/12/17 10:10:00
DC Filter Med
Output Setup
Coeff: 50
Freq / Bal / Ref S4 Out: Pol: +
Frequency: 000 Src:
Internal Scope
Ref: 1200 Bal: 200
ID: 0 Capture : off
Lightstack Setup Clear Metal: 0.0
Network Setings LED Light Stack
IP: XXX.XXX.XXX.XXX Rej: Main Buz: Main
Product Writes
M: F8-99-55-XX-XX-XX
Product Writes: 0
Serial
Serial Number:
XXXXXXXXXXXXX
Detector Name
Detector Name
“Detector 0001”
2.3 Interceptor Interface

Regardless of the Detector application, the same user-friendly Interceptor 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 2.4 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 2.2 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
2.4 for further details.
11. Arrow Keys – used to navigate within menu options, and increase/decrease values when editing.
2.4 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:
CALIBRATE (refer to section 3.5), SENSITIVITY (refer to section 3.7), SELECT PRODUCT (refer to section 3.9), TEST (refer
to section 4.2), and SELECT UNIT (refer to section 2.5.1).
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
2.5 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) press UP/DOWN (+/-) arrow keys.
2.5.1 Select Unit Key

This key allows the tag operator to toggle between Channel A and Channel B in any menu where there are individual
settings. This is indicated by A or B on both sides of the LCD Display.
2.6 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.
2.7 Main Menu

Upon powering up your Interceptor Metal Detector, you will see the following Main Menu:
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.
2.8 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.
CHAPTER 3: QUICK SETUP TUTORIAL

3.1 Start Up Tests—Overview
With the Detector assembled and installed, it is now ready for use. The aim of this chapter is to outline the initial tests
that must be carried out before introducing the Interceptor Detector into production. These preliminary tests ensure
system functionality and configure the Interceptor 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:
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 value 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.
3.4 Reject Systems
3.4.1 Reject System and Functional Testing

Belt Stop / Alarm: Automatic stop and manual removal of contaminated products. Typically used for large bags or
boxes, hand fed or bulk material. Use of a photo eye is recommended for larges packs so that the stop point is
consistent regardless of the contaminant position. Due to the manual removal requirement this system should be
avoided if possible. It is also not suitable for high production rates.
Air Blast
Air Blast: Simple and fast reject suitable for light weight
packages typically under 1kg (2.2lbs), and belt width not
exceeding 350mm (14”). Use of a photo eye will allow
more accurate rejection especially for longer products.
Reject
Diverter Arm: Suitable for packages up to 5 kg (11lbs) and Diverter

belt width not exceeding 350mm (14”). Use of a photo
eye will allow more accurate rejection especially for long-
er products. Not as accurate as a kicker style device.
Reject
Photo Eye
Kicker / Pusher: Suitable for packages up to 5 kg (11 lbs)
and belt widths not exceeding 350 mm (14”). Heavy duty
versions can be used with products up to 50 kg (110 lbs)
and belt widths up to 710 mm (28”). A photo eye is a
mandatory requirement of this style of device. Reject
Flap Gate: Suitable to bulk products that have excellent Flap Gate
flow characteristics (powders, granules, etc).
Reject
Retracting Belt: Can be used with a wide range of

products both bulk flow and individual products. A photo
eye can be used to improve accuracy if the application is Retracting Belt
for single file, individual products.
Reject
3.4.2 Photo Eye Option

The Interceptor metal detector has an input to add a photo eye sensor that can assist in improving accuracy of the re-
ject system when inspecting single file, individual products. A photo eye must be used when a kicker style reject device
is to be used or if the automatic phase (product tracking) feature will be used. The photo eye must be installed at the
in-feed side of the detector and a set up procedure must be followed so that the control system knows the position of
the eye relative to the center of the detector in direction of travel. The detector uses the data of the package length,
belt speed, and the relative location of the sensor, in order to calculate and keep track of the product’s exact position
on the conveyor.
The Photo eye informs the detector of product position and length, and it will vary the reject timing so that
contaminated product is accurately rejected regardless of the location of the containment in the product (ex. front or
back). In applications where product is fast moving or long, a photo eye is highly recommended.
The sensor is situated at the point where product is entering the detector. Ensure that the sensor is perfectly aligned
with the reflector on the opposite side; see below for a connection diagram and a photo of a typical installation. Refer
to Section 1.8.6 for a wiring diagram that shows a photo eye powered from the detectors’ +24 VDC supply. Only
approved photo eyes should be powered from the detectors’ supply, contact Fortress for assistance. If supplying the
eye signal from another source, a dry contact must be provided to the infeed photo-eye input. One side will be wired to
PL10-3 input and the other to 0v (PL10-4).
The system can be set to reject contaminated product at its midline (mid) for a kicker, leading edge (lead) for a diverter
or for the entire length of the package (retract).
3.4.2 Photo Eye Option—continued
Photo Reject Setup:

In order for the detector to accurately use the photo eye information, it must ‘know’ where the photo eye is installed
relative to the center of the detector in direction of travel and the belt speed. Therefore a few values must be entered
in the photo eye set up menu (under Reject – Setup). The measurements can be entered in imperial or metric
measurements.
1. Photo eye distance measured from the eye to the middle of the detector (see below).
2. Head Depth which is the measurement of the distance through the detector.
3. Belt Speed must be entered. If the belt speed is not known then the detector can calculate this using the
procedure detailed in section 3.4.2.
INFEED PHOTO
EXIT EYE DISTANCE EYE DISTANCE
CENTER OF
HEAD PACKAGE
LENGTH
FLOW DIRECTION
PHOTO EYE PATH
HEAD
DEPTH
NOTE: Flanges are not considered part of “Head Depth”.

To configure the Photo Reject System:
1. From the Main Menu press the MENU button to display the Reject System Menu.
2. Press S3 to display the Reject Mode Menu.
3. Press S3 to toggle the Reject Mode, press the ENTER key when the “photo” option is displayed. This puts the
Detector in Photo Reject Mode.
4. After setting the Reject Mode to “photo” press MENU once to display the Photo Reject Setup Menu.
The “mid” option of Photo Reject means that the reject device will hit the middle of the package regardless of the
package size (kicker rejects) – it can be changed to “lead” (leading edge for diverter rejects) or “width” (entire length of
package for retracting rejects) by pressing S3.
The “eye” field refers to the polarity setting of your Photo Eye, it should read “low” when the sensor is not blocked and
“hi” when being blocked. If the opposite occurs then the polarity needs to be inverted by pressing S2.
5. Next, press S4 ‘Setup’ to arrive at Photo Reject Learn Menu.
6. Learn first requires manual entry of the ‘Photo Eye Distance’, package length and ‘Head Depth’ which is
measured manually. Press MENU once to display ‘Photo Eye Distance’
7. Press the DOWN Arrow (-), then S2 to enter. The measured photo eye distance (photo eye distance = middle
of head depth to photo eye), press ENTER after editing the value.
NOTE: The S4 key can be used to toggle the measurements to/from metric and
imperial units
8. Press MENU until display shows ‘Head Depth’ (head depth= while facing the display, the head depth is the
width of the detector.) Press S2 to enter head depth, press ENTER after editing the value.
9. Press Menu until display shows ‘Belt Speed’. Press S2 to edit the belt speed value and press ENTER after
editing the value. This completes the photo eye setup. If the belt speed is not known then a learn
procedure can be used to have the detector measure the belt speed. See belt speed procedure.

Optional Belt Speed Learn Procedure:
If the belt speed is not known and cannot be measured manually, the following procedure can be used to have the
detector calculate the belt speed.
10. From the Photo Reject menu, press S4 ‘Setup’. Press MENU until display shows ‘Belt Speed Learn’. Press S3 –
‘Learn’ to display ‘Belt Speed Est’ menu. Using a pack (or simulated pack), measure the pack length in
direction of travel. Press S4 and enter the measured pack length.
NOTE: Package Length depends on the product orientation when passing through
the Detector.
Example: the loaf of bread shown could be either 4” (100mm) or 12” (300mm) in Length.
Package Length: 4” (100 mm) Package Length: 12” (300 mm)
11. Once the Package Length is entered, pass the measured test pack so that it passes through the photo beam
at normal belt speed to automatically learn the belt speed. Before running the test pack, make sure that the
conveyor is running at its regular speed. After the pass is complete, the value displayed as ‘Belt Speed Est’
should change to a new value. You may repeat the procedure to ensure a consistent value is learned. Note
the learned value.
12. Press ‘Exit’ to display the ‘Belt Speed Learn’ Menu , press S2 to enter the belt speed value learned in the
above procedure and press ‘ENTER’ to store this value.
NOTE: If you are using external (Encoder) timing, be sure the belt is still running
at the same speed that was learned when you enter the speed number.
3.4.3 Delay & Duration

If you are finding that the reject device is not successfully removing the test samples from the production line in the
testing scenarios described, an adjustment to the Reject Delay and/or Duration is required.
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.
Diagram of Reject Delay and Duration is shown below:
Delay & Duration Timing
Reject Delay Timer

(wait before the Reject Device is activated)
Metal
Detector
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
2. To adjust the Reject Delay press S2, a flashing cursor will appear; use the LEFT/RIGHT arrow keys to scroll
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 “Reject Packs” (a pack of product containing a test sample) to ensure
that you get the right reject timing.
3.4.4 Reject Confirm

The Interceptor Metal Detector has the ability to ensure that the reject device has operated correctly during every re-
ject actuation. The reject confirm option requires a signal from a sensor that will be activated by a reject event. This
can be a sensor on the actuator itself (a magnetic sensor on the reject air cylinder) for example. Or, it may be a photo
eye sensor that will be activated by a product passing through its beam during rejection.
The proper connection for a typical reject confirm sensor is shown in Section 1.8.7. The drawing shows the sensor
being powered by the 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
monitored 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.
Reject Confirm Sensor Positions: Reject Mechanism

Position
Actuator Position Monitoring: By connecting a Sensor
position sensor on the reject mechanism, the Photo Eye Sensor
full movement of the reject can be accurately
confirmed. Refer to the diagram beside for an
example of typical kicker reject system sensing
the movement of the reject cylinder.
Reject Path Monitoring:
Alternatives to actuator position sensing; the
photo eye sensor can be used to monitor the
path of rejected product. For example a sensor
located on entry to the reject bin.
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.
3.4.4 Reject Confirm—continued

4. Press S3 to select ‘1’ for reject confirmation.
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.
Reject Bin Full Sensor:
To turn on the optional Reject Bin Full Sensor, wired to R2 input (see Section 1.8.7), and configure as follows:
1. From Main Menu press UP (+) key.
2. Press S3 for fault set up.
3. Press UP(+) twice to get to Fault Menu.
4. Press S4 then UP/DOWN (+/-) to go through the options till you see REJ BIN FULL.
5. Press ENTER then S3 to enable the option.
3.5 Product alibration

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).
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
Interceptor Detector automatically sets its phase point to ignore the product effect signal; the following table shows
typical
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
3.5.1 Product Effect—continued

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).
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 appear Green upon passing the product
through; however, sometimes it may not illuminate at all due to
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.
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 In-
terceptor control panel.
2. Press CALIBRATE Hard Key again and the display will show a “fast” learn mode.
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:
3.5.2 Quick Product Calibration Procedure—continued
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
Power” 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.
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 3.7 for further details.
3.5.4 Auto Phase

The Auto Phase option can be used to have the detector automatically track slow product effect changes and product
type changes (new flavor for example). It is used to phase out product effect as the product changes through the
production line. For example, a facility that runs various types of bread and doesn’t want to re-calibrate to product
when production changes product, or to compensate for product temperature changes that affects the product
signature over time. This feature is designed for packaged or single file products that can be monitored by a photo eye.
Please contact Fortress for assistance or questions regarding the proper conditions for using this feature.
NOTE: Do not proceed with Auto Phase Configuration without setting up Photo
Eye section 3.4.2
Configuring Auto Phase:

1. Press the CALIBRATE Hard Key on the right side of the Interceptor control panel followed by S1 to enter Set-
up.
2. Press the Calibrate Hard Key again and toggle to “auto”.
3.6 Establish Sample Detection
Now that the Detector is set and calibrated for the product to be run, a manual test is highly recommended to see how
well the system is working.
The Detector’s response in the event of metal contamination can be simulated using the supplied Test Samples. The
testing procedure is intended to confirm the Detector’s performance as well as the operation of the Reject system thus
ensuring that contaminated product will be correctly handled.
3.6.1 Functional Testing

For the next steps you will need to utilize the Test Samples (spheres, cards, or rods) included with your Interceptor Met-
al Detector. Follow these steps to test the Detector and Reject device.
1. Affix a test sample (sphere/ card/ rod) to your product. Fortress recommends using several methods to
simulate a variety of situations:
a. Placing the test piece at the leading edge of the product;
b. Placing the test piece at the trailing edge of the product;
c. Passing successive test packs;
d. Passing alternate test packs.
NOTE: Test samples should be passed through the center of the aperture (the
least sensitive area of detection). For more information, please refer to
“Metal Detector Basics”.
2. Pass the product with the affixed test sample through the Detector.
3. Check to see if the Signal reading exceeds 100, indicating a correct detection.
4. Monitor the operation and accuracy of the Reject Device in removing the contaminated product from the
production flow. If more reject 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 is advisable to lower the Sensitivity.
2. In the unlikely event of the Detector not detecting the test sample, try increasing the Sensitivity to the point
where background Signal for good product is approximately 60.
3.7 Set 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”.
3.7.1 Sensitivity Adjustment

To adjust the Sensitivity follow these steps:
1. Press the SENSITIVITY Hard Key on the right side of

the Interceptor control panel.
2. Press S3 and a flashing cursor will appear.
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.
3.7.2 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.
3.8 Password Security

Password protection prevents an unauthorized user from tampering with the Metal Detector; the Interceptor 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.
3.8.1 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.
3. The system is set up with default passwords that can be changed:

Level 1 - 1000
Level 2 - 2000
Level 3 - 3000
3.8.2 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.
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.
3.8.3 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.
3.8.4 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.
3.8.5 Wrong/ Forgotten Password

If you enter an incorrect password the following menu screen will appear:
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.
3.9 Product Setup

The Interceptor 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.
3.9.1 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 Interceptor 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.
3.9.2 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 Interceptor panel.
2. Press S3 to enter the Product Edit submenu.
3. Press S4 to enter the Backup Submenu.
4. Press S2 to save the current product settings as the Master settings (also known as the Factory Settings).
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.
3.9.3 Create a New Product

To create a new product you are actually “copying and pasting” an existing product already stored in your Interceptor’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:
3. Press S1 to enter the Copy Product submenu.
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.
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.
3.9.4 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 Interceptor panel.
2. From the Select Product Menu, press the SELECT PRODUCT Hard Key again to scroll through the list of prod-
ucts and press ENTER to confirm a selection.
3.9.5 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:

3. Press the DELETE option (S2) from the Edit submenu of Select Product.
4. Press one of the upper Soft Keys (S1 or S3) to edit the Delete entry field.
5. Select the number of the product you want to delete. (Not the current running product)
6. Press the ENTER key – the name of the product will revert to the current product to confirm the delete
process.
CHAPTER 4: AUXILIARY FUNCTIONS

4.1 Auxiliary Functions—Overview
Now that your Interceptor 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 Inter-
ceptor 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/ Halo®

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 Interceptor 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
involvement; thus reducing the high cost of frequent manual testing. Auto Test works by injecting a simulated metal
signal (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 and Halo® are optional setups. Test Request is recommended
for Conveyor application as test samples can be easily inserted into the
production flow. Contact Fortress Technology for information regarding
Auto-Test and Halo® options.
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 Interceptor control panel.
2. From the Test Menu, press S1.

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

Request.
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 Interceptor control panel.
2. From the Test Menu press S3.

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.
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 Interceptor 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:
5. Use the corresponding Soft Keys to edit the values of Ferrous (FE), Non-Ferrous (NFE) and Stainless Steel (SS)
test sample passes.
4.2.3 Test Request Setup—continued

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.
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:
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 Special Reject Option
4.3.1 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 1.8.10 for setup instructions.
The Alternate Reject can remain activated for a longer period of time than the main reject; for example, if the main
reject is a fast-operating reject device (such as kicker or retract), the Alternate Reject might be a beacon light that
should remain activated for a longer duration so that it is more noticeable.
4.3.1 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.
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
automatically enable the Alternate Reject as an independent reject output.
4.3.2 Shaft Encoder

For applications where the belt speed will vary and where the belt may randomly stop and start during production, a
shaft encoder will be required to allow the detectors reject system to track belt movement rather than time. A shaft
encoder should be mounted in such a way that the belt movement will be detected and a pulse train sent to the
correct input of the detector. See Section 1.8.9 for the connect diagram of a typical shaft encoder. Contact Fortress for
recommendations regarding shaft encoder model types.
Once the encoder is correctly installed and connected to the encoder input, the reject menu can be set to allow the
detector to use the encoder pulses as a time base:
Configuring the Shaft Encoder:
To enable to the shaft encoder option in the software follow these steps:
1. From the Main Menu press the MENU key to access the Reject Menu
2. Press S3 to enter Reject Setup
3. Press the MENU key till you reach ‘Reject Clock’ menu.
With the encoder running, the top right of this display should show a clock rate. The value should change if
the belt speed is changed and should be ‘0’ if the belt is stopped. This confirms that the encoder signal is
being received by the detector (if the number does not change, then the encoder signal is not present and
therefore the encoder installation should be examined).
4.3.2 Shaft Encoder—continued

4. Press S2 ‘Source then the UP Arrow Key to edit the field to ‘Ext’ for external clock source and press ‘Enter’
to accept.
5. The detector is now using the encoder signal as the reject timing clock source. Return back to the main
reject menu and adjust the delay and duration numbers (now clock pulses versus seconds) until the reject
timing is correct.
NOTE: Under the ‘Reject Source’ – ‘Setup’ menu a delay and duration number
can also be adjusted. This is not normally required but in cases where
the reject device response time is slow (perhaps a retracting belt), then
this menu allows for device response time compensation by adding a
fixed time to the variable reaction when using an encoder signal.
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
3. Press S3 to change the IP address.
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 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.
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.
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.
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.
NOTE: If you are using external (Encoder) timing, be sure the belt is still running
at the same speed that was learned when you enter the speed number.
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 De-
tector in FM Mode.
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
mode. Use the mode that provides the best result.
4.8 Interceptor Input Configuration
4.8.1 Selecting Inputs
The software allows the inputs to be configurable to the desired uses.

To select the input function and map it to a physical input, follow these steps:
1. Press the SELECT UNIT Hard Key, press the DOWN Arrow (-) until you reach the input screen.
2. Press S1 and the UP/DOWN Arrow (+/-) to cycle through the different input functions.
3. Press ENTER to select the function you wish to edit (eg – Air Pressure).
4. Press S2 to select the input that this device is wired to (eg – iso 1).
5. Press ENTER when correct input is displayed. Polarity can be flipped (default = 0). Check that a change in
sensor state results in an * being displayed or not just in front of the input (eg - * iso 1 when the sensor is
blocked). This ensures the correct sensor is attached and is functioning.
The available functions are as follows:
Input Function Description

Tachometer Input for the Tach (Encoder)
SS-test Used with fortress test puck system - SS holster sensor
Nfe-test Used with fortress test puck system- NFe holster sensor
Fe-test Used with fortress test puck system- Fe holster sensor
Prod-select Input to select between product 1 and 2 (Product toggle)
Bin door Bin door sensor. Will trigger a fault depending on time set for an open reject bin door
Bin full Sensor to monitor if the reject bin is full
Rej-latch Will clear a reject latch when actuated from an external switch
Air pressure Triggers a fault when air pressure sensor changes state
Rej-exit Reject exit sensor. Photo eye at conveyor exit after reject - refer to setup section.
Rej-conf-1 Reject confirm input 2 sensor used to confirm reject return
Rej-conf-2 Reject confirm input 1 sensor used to confirm reject action
Infeed-eye Input for the Infeed Photo Eye
4.8.1 Selecting Inputs—continued
The Physical Inputs and their suggested use are:

Physical Input Pins Type Suggested Use
Tachometer PL10-2 NPN Tachometer / encoder
Rej-conf-1 PL10-6 NPN Rej confirm 1
Rej-conf-2 PL10-7 NPN Rej confirm 2 or Bin full
Infeed-eye PL10-3 NPN Infeed Eye
ISO-1 PL10-9/10 Isolated Air Pressure Switch
ISO-2 PL10B-3/4 Isolated Exit Eye
ISO-3 PL10B-5/6 Isolated Door Switch
ISO-4 PL10B-7/8 Isolated Remote Latch Reset
ISO-5 PL10B-9/10 Isolated Other
4.8.2 Reject Exit Sensor
The Reject Exit Sensor option will confirm when a pack leaves the reject area, monitor product back up and act as a
secondary reject confirm sensor. To use this option, an in-feed photo eye will be needed (and set up properly). The
same type of eye should be for both the infeed eye and the exit eye. These should both be polarized retro-reflective
photo eyes mounted on a common side of the conveyor (both mounted on the controls side for example).
The Reject Exit Sensor (eye) can monitor following conditions:
 Fault if a package is removed from the conveyor prior to reaching the reject system (Fault: Exit No Pack).
 Fault if a package is introduced to the conveyor flow anywhere between the infeed eye and the reject Exit eye
(Fault: Exit New Pack).
 Fault if a pack fails to be rejected properly and passes the exit eye (Fault: Reject Exit).
 Fault if downstream issues causes product to back up and blocks the exit eye (Fault: Exit New Pack and Reject Exit).
 Ensure that the in-feed eye is working correctly.
 Ensure that the Tachometer (if used) is working correctly.
NOTE: Ensure the unit is in photo reject mode and the belt speed is already
learned and accurately set before proceeding. (See Section 3.4.2)
To set up a Reject Exit Sensor follow these steps:

1. Wire the photo sensor into an available input.
2. Press the SELECT UNIT Hard Key on the right side of the Interceptor control panel followed by DOWN (-) arrow
key to enter Input Configuration Menu.
3. Press S1 and the UP/DOWN Arrow (+/-) till you see the “rej-exit” Menu.
4.8.2 Reject Exit Sensor—continued

4. Press ENTER to select the function.
5. Press S2 to set the “rej-exit” input function to the input that the sensor is wired to is displayed.
6. Once the correct input is displayed, press ENTER to confirm and EXIT.
After the Reject Exit Sensor is set up, Exit Eye position parameters need to be entered.
3. Press the MENU key till you reach ‘Reject Check’ menu, then S4 to enter Reject Check Setup
4. Press the UP/DOWN arrow keys (+/-) till you reach Reject Exit menu.
NOTE: If an encoder is being used, ensure it has reasonable resolution

(approximate 200-300 displayed rate at 75-100fpm or 20-30 M/m).
5. Measure the distance from the center-line of the detector to the exit sensor. Press S4 and enter this
distance.
6. Pass a clean package through the detector the conveyor and retrieve after the pack passes the exit eye. The
“Est” value will update. This value is the distance that the detector calculated to the reject exit eye. If
running small (length) packs, it’s easier to perform the estimate test with a pack larger than 150mm (6”)
long. The fine tune this with a small pack (25-50mm long or 1-2”).
7. The estimated value and measured value should be quite close. If they are, then enter the estimated value
in the Dst field.
8. A tolerance window is available to compensate for cases where the pack may slip or turn in normal
production causing unnecessary faults. From the Reject Exit menu, press the DOWN arrow key to display
the Reject Exit Window menu. The default window is 0.4(in) or 10(mm). This can be increased where
required to eliminate excess faults due to pack movement errors.
4.8.3 Bin Door Sensor

The Bin door sensor is used to monitor the position of the reject bin door or access cover. It is intended to create a
fault if the bin door has been open longer than a predetermined time. This will require a sensor (typically a door
interlock switch) to be installed on the bin access and connected to an appropriate input of the Interceptor main
board. Then the input used for this function must be mapped in the input menu, the ‘normal’ polarity set and a time
entered that will represent the allowed after the bin is opened until a fault will occur.
To configure the Reject Bin Door Sensor:
1. Wire a sensor into an available input.
2. Press the SELECT UNIT Hard Key on the right side of the Interceptor control panel followed by DOWN (-) arrow
key to enter Input Configuration Menu.
3. Press S1 and the UP/DOWN Arrow (+/-) till you see the “bin door” Menu.
4. Press ENTER to select the function.

5. Press S2 to set the “bin door” input function to the input used for the bin door sensor.
6. Once the correct input is displayed, press ENTER to confirm and EXIT.
9. Press the MENU key till you reach ‘Reject Check’ menu, then S4 to enter Reject Check Setup
10. Press the UP/DOWN arrow keys (+/-) till you reach Reject Bin Door menu.
11. Press S4 to set desired Reject Bin Door timeout.
NOTE: NPN versus PNP Sensors—PL10b (isolated inputs 2,3,4,5) can be configured
for either NPN (sinking) or PNP (sourcing) devices.
Refer to section 5.3.2 & 5.3.3 for device wiring information
4.9 Interceptor Output Configuration
4.9.1 Selecting Outputs

The software allows the outputs to be configurable to perform desired functions.
To configure outputs, follow these steps:
1. Press the SELECT UNIT Hard Key, press the DOWN Arrow (-) until you reach the input/output screen. Press
S4 to enter output setup. Select the output function and map it to a physical input.
2. Press S1 and the UP/DOWN Arrow (+/-) to cycle through the different output functions. See Chart B for a
list of available functions.
3. Press ENTER to select the function you wish to select or edit.
4. Press S3 to change the polarity. The options are “+” for normal operations, “-” to invert the output, “0” to
turn off the output and “1” to make the output always on. These polarities are saved in the product
memory so under different product numbers you can enable or disable different outputs, and set individual
polarities if required.
5. An example of holding an output always on (1) or off (0) would be if using a belt stop reject for a large
product but also using an air blast reject for a small product. The two rejects would be connected to
separate outputs and both selected as ‘reject’ and held on or off as the device requires when not in use.
6. Press S2 to change the new output source to link to the physical output. This output source is able to be
linked to multiple outputs. For example, if you need 3 reject outputs, you can tie the reject-main function to
any 3 of the outputs through the menu.
Chart A: The Physical Outputs and their suggested use are:
Physical Output Pins Suggested Use

PL3-Main Reject Reject-main -
PL11-1/2 Reject-alt -
PL11-3/4 Test-request +
PL11-5/6 Fault -
PL4-1 Light-red +
PL4-2 Light-yellow +
PL4-3 Light-green +
PL4-5 Buzzer +
PL5-1/2 Halo-fe (optional) +
PL5-3/4 Halo-nfe (optional) +
PL5-5/6 Halo-ss (optional) +
4.9.1 Selecting Outputs—continued

NOTE: Halo Functions require Halo auto-test hardware option.
Chart B: The available functions are as follows:
Output Description
Reject-main Output will follow the main reject timing
Reject-alt Output will follow the alt reject timing
Fault Fault output
Test-request Will activate on a test request
Light-red Control for red banner light
Light-yellow Control for yellow banner light
Light-green Control for green banner light
buzzer Control for an external buzzer or banner light with buzzer
Halo-fe FE output for halo board
Halo-nfe NFE output for halo board
Halo-ss SS output for halo board
none Will do nothing
4.10 USB Data Collection & Contact Reporter

The Interceptor 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.
4.10.1 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.
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.
4.10.2 Installing and using Contact 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 Reporter software:
The installer of the Contact Reporter software is provided on the USB key.
1. Connect the USB to your computer.
2. Click on “Open Folder to view and select “ContactReporter” and then “ContactReporterSetup”
3. Follow onscreen instructions to install Contact Reporter.
4.10.2 Installing and using Contact Reporter Software—continued

Navigating detectors:
1. Open Contact 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 Filters:

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
When turned off all of the data will be displayed current month.
in the window in chronological order (newest
first).
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).
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.
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.
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 1.8.
 Fasten any loose cable connections.
 Confirm that the Display Cable connector is plugged into the 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, see Section 1.6.
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 in the metal free area.
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
samples can still be detected.
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 reject 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.
Tel: 1-888-220-8737 or 416-754-2898 Email: service@fortresstechnology.com
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 reject
isolated input of the DSP board (PL10 pins 9 device set to factory default; typically about 60-80
& 10) is indicating a low pressure which may P.S.I.
impair the proper function of the reject
 Verify air pressure sensors are installed.
device.
 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 lim-  Check rejected product for metal contaminants.
Reject it set within the software Feature is ena-
bled via Fault Setup Menu.  Make sure the Detector is calibrated for the running
product
 Can be cleared via the Clear soft key (S3)
5.2 Faults—continued
Fault Possible Cause Corrective Action
Internal USB  There is an issue with the internal USB  Contact Fortress Service Dept.
storage. 1-888-220-8737 or 416-754-2898
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 masked
submenu.
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  Can be cleared via the Clear soft key (S3).
calibration 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 verify  Check that the reject device is functioning properly
that the contaminated product was properly and that the confirmation devices are positioned
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
5.3 Appendices
5.3.1 DSP Board
DSP Board Ver. 9.2+ Ethernet Ports for

connection with
5V Power Connector FTI boards
LK830
PL15 LK831
PL6
24V Power
PL830
PL820 PL810 PL800
DISPLAY
Ethernet Port for connection Connector
to SD004 Display board LK840
LK841
PL840
LK810
LK811
LK821
LK820
LK801
LK800
Ethernet Ports for
LK850
connection with LK851
FTI boards
PL850
DSP reset
PL601
switch
EXTERNAL
Ethernet Port for connection SW1 Internal USB

PL860
to a PC. Uses external IP IC245

LED560
address & has no power
PL10 R166
1 PL20
2 R157
3
4
RTC battery
5
6
7
8 FORTRESS TECHNOLOGY
9 COPYRIGHT 1605
10
IC920 PL4
PL11 1 LK450
1
IC921 2
2
PL870
3
3 4 Ethernet Port for connection with SD029
4 IC922 5 Search Head board (channel A)
5
PL880
6
Ethernet Port for connection with SD029
PL3
RLY5
1 Search Head board (channel B)
LK451
2
3 DSP BOARD
SD003 VER 9.2
To use external 24V for I/O Connectors R166 & R157 must be removed.
PL10 – Inputs PL11 – Output Relays

Input devices rated
1 Alt Reject +
1 24V DC 24VDC / 0.5A MAX
2 Alt Reject -
2 Encoder Non-isolated inputs
3 Test Request +
3 Infeed Eye must be NPN type
4 Test Request -
4 0V DC 5 Fault +
5 24V DC 6 Fault -
6 Reject Check 1
7 Reject Check 2 ASSR-3211-001E (Solid State
8 0V DC Relay)
9 Isolated Input + 250V output withstand voltage
10 Isolated Input - 0.2A current rating
PL3 – Main Reject Relay

1 Reject Relay NC
PL4 – EZ-Lite Light Stack Connector
2 Reject Relay Common
1 Red 3 Reject Relay NO
2 Green
3 Yellow Relay Contact Ratings
4 24V DC Supply Switching voltage – 250VAC /
5 Buzzer 30VDC MAX
5A current rating
5.3.2 Typical NPN Configured Connections
5.3.3 Typical PNP Configured Connections
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-UK@fortresstechnology.com
Fortress Technology Sistemas de Inspeção Ltda.

Rodovia: 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
Copyright © 2016 Fortress Technology Inc. All rights reserved. Patent Pending. The information, designs and artwork
contained in this document are confidential and may not be disseminated, distributed or copied without written consent
from Fortress Technology Inc. Specifications, designs, features and technology subject to change without notice.

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METAL DETECTOR WITH

Advanced Interceptor Features:

 Flash RAM – Flash Memory technology prevents information loss.

North America: 1-888-220-8737 or 416-754-2898

Version: 160610 www.fortresstechnology.com

Copyright © 2016 Fortress Technology Inc. www.fortresstechnology.com

SAFETY, CAUTIONS & CLEANING

Installation, Commissioning and Operation

General Safety Guidelines

SAFETY, CAUTIONS & CLEANING continued

Cleaning and Maintenance

1. Announce lockout to other personnel.

1.2 Package ontents

Interceptor Metal Detector

Hex Key (Allen)

NOTE: If purchasing an integrated conveyor system from Fortress, the

1.3 Installation Tools

1.4 Installation Location

Correct Method of Lifting Detector Incorrect Method of Lifting Detector

1.6 Installation ssentials

1.6 Installation ssentials– continued

To properly isolate a roller, use one of the following concepts:

1. Insert a nylon bushing on reduced shaft.

To avoid Loop Effect, ensure the following:

1. Do not allow cross-members in the conveyor frame to form “loop shapes”.

Why Rollers can cause Loop Effect

1.7 Removing & Installing Display Panel

1.8 Electrical Installation

1.8.1 CSA Guideline

1.8.2 Metal Detector Control Bay Layout

DSP Board Ver. 9.2+

1.8.3 DSP Layout

DSP Board Ver. 9.2+ Ethernet Ports for

Ethernet Port for connection SW1 Internal USB

to a PC. Uses external IP IC245

PL10 – Inputs PL11 – Output Relays

PL3 – Main Reject Relay

1.8.4 Basic Power Connection

DSP Board Ver. 9.2+

1.8.5 Basic Reject Connection

Reject Outputs (Fail Safe Operation)

1.8.6 Photo Eye Connection

1.8.7 Reject Confirm—Optional & Input Wiring Diagram

1.8.8 Indicator Light Connection—Optional

1.8.9 Shaft Encoder

1.8.9 Alternate Reject

1.8.10 Fault Output Typical Connection

Fault polarity Normally Closed by default,

Outputs (Solid State Relay)

CHAPTER 2: GETTING ORIENTED

System menus versus Channel Specific Menus:

Channel Specific Menus are:

2.2 Menu Maps

Select Product Product Edit Copy Product

Calibrate Menu Detector Power Setting

Phase Mode Hold Setup

Phase Trigger Setup

Dry Phase Limit Setup

Wet Phase Limit Setup