Technical Note TN00171_3

Part Number: 811280

Issue 3

Work Order Number: Date:

Customer Name: Old Serial Number:

DESCRIPTION

RETROFIT KIT TO FIT AN IQ SEARCH HEAD BOARD WITH RF INTERFERENCE

PROTECTION ENCLOSURE TO AN EXISTING SEARCH HEAD - SINGLE FREQUENCY.

General Notes

• Effective Immunity Range: 400 - 470MHz (typically FM type hand held walkie-talkie radios).

• Can be fitted in the following IQ & IQ2 Metal Detectors: Conveyor heads (all sizes), Slimline & Catalogue
FreeFalls.

• If needed for Pipelines and 20mm pharmaceuticals with the smaller case please raise a technical enquiry before
customer commitment.

Drawings Required Description

7300-C4-48235 Mounting plate drawing
7300-C3-48234 Enclosure drawing
5000-C3-48243 Layout diagram
5000-C4-48239 Wiring daigram

Structures Required Description

ESTDRET/067 Electrical retrofit components - Single frequency
ESTDRET/067/1 Head balance fixed resistors (order as required)
ESTDRET/067/2 Head balance variable resistors (order as required)
ESTDRET/067/3 Head tune capacitors (order as required)

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RETROFIT INSTRUCTIONS TO MANUFACTURING

1. Ensure that the service copies of the instructions are included in the kit.
2. Pre-assemble / wire as much as possible. Ensure all required parts other than tooling requirements are with the kit.
Note if the job is for multiple RF kits then simply increase to receiver tune capacitor minimum by 1 per box to be
fitted. Likewise increase the resistor range quantity by 1 per value per box to be fitted and increase the head cable
length by 100mm per box to be fitted. No other parts require increasing.
3. Ensure Engineering check the kit before shipping.

EQUIPMENT REQUIRED TO SERVICE (All retrofits)

1. 3.5mm drill bit & drill.
2. General tool kit including a torque wrench able to torque at 4nm.
3. Dual beam oscilloscope + probes (40MHz bandwidth minimum).
4. DMM
5. Ferrite balance slug.
6. 2 off as a minumum of the following Receiver fine tuning capaciors (supplied with kit):

Value pF Description Part Number

2.2 Ceramic Plate (black top) 409101
3.3 Ceramic Plate (black top) 409102
4.7 Ceramic Plate (black top) 409103
6.8 Ceramic Plate (black top) 409104
10 Ceramic Plate (black top) 409105
15 Ceramic Plate (black top) 409106
22 Ceramic Plate (orange top) 409107
33 Ceramic Plate (orange top) 409083
47 Ceramic Plate (orange top) 409109
68 Ceramic Plate (orange top) 409056
100 Ceramic Plate (orange top) 409111
220 Ceramic Plate (purple top) 409100

7. 1 off of each of the following multi turn carbon tracked potentiometers for resistive component balance correction
value selection (supplied with kit).
Description RS Part Number
2K ohm 20 turn carbon track 1.25 inch 186-031
5K ohm 20 turn carbon track 1.25 inch 186-047
10K ohm 20 turn carbon track 1.25 inch 186-053
20K ohm 20 turn carbon track 1.25 inch 186-069

8. A complete range of 0.25W metal film resistors starting at 4.7 Ω through to 15KΩ, a minimum of 2 of each is
suggested. (Required to replace in value the potentiometer measured resistance to achieve balance, supplied with
kit) .
9. 200mm length of 12 core screened head board cable from which the internal wires can be removed and used to
extend existing wires if required. Loma part number 507200 (supplied with kit).

CATALOGUE FREEFALLS (Only)

10. 4.2mm drill bit & M5 tap & holder.

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Technical Note TN00171_3

GENERAL NOTE (All models)

1. The screen box is always fitted with the control line, receiver & balance connections facing towards the right hand
inside face of the case when looking into the end plate area.

MECHANICAL RETROFIT INSTRUCTIONS (All units except Catalogue FreeFalls)

1. If the kit contains a pre-configured (frequency components and slow speed components as required fitted) head
board already mounted into the screen box then use that assembly. However provided the existing head board is not
faulty then the option to fit that board into a screen box can be utilised.
2. Ensure that the machine is isolated before carrying out any of the work detailed below.
3. Remove the back plate from the search head by unscrewing the M6 hex head screws using a 10mm spanner/socket.
Ensure that the washers an insulators are kept safe.
4. Remove wiring connections to the existing head board, leaving the wires as long as possible.
5. Remove the head board and mounting plate from the head completely.
6. Drill 4 x 3.5mm mounting holes in the tufnol mounting plate to suit the wings on the existing search head assembly.
When mounting the screen box and its plate make sure that the box does not touch the inside of the case at any
point.
7. Connect / wire the search head cabling to the search head board RF protection assembly as shown in the wiring
diagram 5000/C4/48239. The 3 control line and balance wires are run under the screen box.
8. Remove the lid from the screen box to allow access for retuning the receiver. See retuning/balancing instructions
later in this document.

MECHANICAL RETROFIT INSTRUCTIONS (Catalogue FeeFalls)

1. If the kit contains a pre-configured (frequency components fitted) head board already mounted into the screen box
then use that assembly. However provided the existing head board is not faulty then the option to fit that board into
a screen box can be utilised.
2. Ensure that the machine is isolated before carrying out any of the work detailed below.
3. Remove the back plate from the search head by unscrewing the M6 hex head screws using a 10mm spanner/socket.
Ensure that the washers an insulators are kept safe.
4. Remove wiring connections to the existing head board, leaving the wires as long as possible.
5. Remove the head board from the head completely.
6. Place the screen box on to the divider plate, symetrically about the fixing holes for the removed board, make sure
the box does not touch the inside of the case at any point. Mark where the 4 new fixing holes are to be for the screen
box mounting legs. Drill & tap 4 x M5 fixing holes. Fix the box on to the divider plate using M5 X 10mm screws &
washers supplied with the kit. The intermediate tufnol mounting plate is not required.
7. Connect / wire the search head cabling to the search head board RF protection assembly as shown in the wiring
diagram 5000/C4/48239. The 3 control line and balance wires are run under the screen box.
8. Remove the lid from the screen box to allow access for retuning the receiver. See retuning/balancing instructions
later in this document.

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RE-SETTING RECEIVER & BALANCE INSTRUCTIONS (All units)

The receiver will require re-tuning due to the addition of 2 x 100pF capacitors in the receiver input circuit and the
balance redone due to the addition of a metal screen box.

BALANCE INSTRUCTIONS (All units)

1. Remove the fixed resistive balance resistors from the receiver board and measure their value.
2. Replace the resistors with a 20T carbon track potentiometer of a value that is at least 1KΩ greater than the resistor
value measured. For example if the measured value was 800Ω then use the 2KΩ potentiometer. The potentiometer
is prepared and fitted as shown below:

Reactive balance inductor.

Receiver tuning capacitors.

Centre leg connected to bottom Place the potentiometer in a position that allows
leg forming a variable resistor. adjustment to be made with the end plate refitted, i.e
Tinned copper wire extentions close to the reactive balance adjuster. The two joined
may be added to allow correct potentiometer wires connect to the centre receiver wire
placement when fitting on the the top wire will be made to which ever outer wire the
receiver board. removed resistor was connected to.

PROCEDURE (All units)

3. Connect the oscilloscope as follows: Key Tx = transmitter - Rx = receiver

• A x1 scope probe is connected to the Tx signal. (Do not use the probe ground, clip it back on the probe cable out of
the way).
• A x10 probe (compensated to the scope channel) is connected to the reciever input pin on the headboard. The probe
ground is connected to the Rx input ground pin on the headboard.
• The head power setting must be set to Max (no damping resistors must be connected when Rx tuning/balancing or
checking is done).
• Bring the sine wave at the reciever input to a null using adjustments made with the reactive balance slug and the
potentiometer. Note these controls are interactive.
• When a null is reached transfer the probe from the Rx input to TP2 further fine adjustment will be required.
• Once the null is reached then the receiver can be re-tuned. Note this will require removing at least 200pF from the
existing values fitted and adding new value to bring back to the correct tune point. It should only be necessary to
remove ceramic plate capacitors rather than the silva mica types.
• Receiver tune setting up conditions and instructions follow.

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Technical Note TN00171_3
Oscilloscope Set up

X axis

Set the transmitter

waveform (red wire) to
show a 180 degree
portion of the signal on
Rx signal as seen @
the Y axis. Adjust the
TP2 using a x10
amplitude to = the full
probe. The cross
height of the graticule.
over point is @ 90
You may use the
degrees, the signal is
calibrate controls on
created with a piece
the X & Y scope
of ferrite. The signal
channels to achieve
full pivots about 0v =
these settings
height centre line of the
of scope graticule.
graticule
90 degree cross
over point

full width of scope

graticule

• Using the x1 scope probe connected to the Tx signal. (Do not use the probe ground, clip it back on the probe cable
out of the way).
• Using the x10 probe (compensated to the scope channel) connected to TP2 on the headboard. The probe ground is
connected to the Rx input ground pin on the headboard.
• The head power setting must be set to Max (no damping resistors must be connected when Rx tuning or checking is
done).
• Using a piece of ferrite (part of a balance slug will do). Temporarily attach the ferrite to the end of the supplied
"Tune for Resistive" wand. Do not oversize the ferrite piece used to create the Rx signal, make it just big enough to
enable the signals to be clearly seen at TP2 when the wand is passed through the aperture.
• Rx capacitor value is made up using the bulk of the value is silva mica, at least 1 x 220 or 330 purple top ceramic
plate, the remainder is in ceramic plate.
• The signal at TP2 will lead the reference transmitter signal, (over tuned) remove capacitors (one at a time) until the
signal at TP2 lags the transmitter sugnal. Re-apply small values of supplied capacitors until the correct tune point is
re-established.
• When this is completed the probes are removed and the lid is fitted to the screen box.
• Replace the end plate ensuring that the hole in the middle at the top of the plate is fastened without the insulators,
before this screw is fitted ensure that the resistance between the endplate an the head case is greater that 250Ω. The
screws should be tightened to a torque setting of 4nm.
• Re-connect a x1 scope probe to the balance test point in the control box, set the scope to read 50mV per cm then
using the reactive balance slug and the potentiometer bring the signal back to a null. <50mV of signal should be
readily achievable.
• Remove the end plate. Remove the potentiometer and measure value. Make up that exact value from the range of
resistors supplied and fit in place of the potentiometer on the receiver board. Replace the end plate as described
earlier.
• The unit is now ready for re-use.

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