Related Manuals for Loma IQ3
Summary of Contents for Loma IQ3
- Page 1 Metal Detector User Guide Document Number: 814180-2.0-ENG ORIGINAL INSTRUCTIONS Copyright © 2014 Loma Systems...
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Page 3: Table Of Contents
Document Key ............................. 4 Notes and Warnings ........................4 Hyperlinks ............................4 Copyright and Acknowledgements ...................... 5 The Loma Group of Companies ......................6 About Metal Detection ................7 How a Metal Detector Works ....................... 8 General ............................8 Balance Stability ..........................8 General and Foil Wrapped Products .................... - Page 4 Table of Contents Safety First ................... 17 Safety Awareness ..........................18 EC Declaration of Conformity ......................18 Safety Warnings ..........................19 Safety Labels ............................. 21 Safety Guards ............................ 22 Guarding ............................22 Interlock switches ........................... 22 Safety Relay and Circuits ......................22 Responsibilities and Disclaimer ......................
- Page 5 Table of Contents Checking Guards ........................... 47 Checking Belt Tracking (PV belt system only) ................47 Setting Up Reject Mechanisms ...................... 47 Remote User Interface ........................47 Installing a Serial Link ........................48 Site Considerations ........................... 48 Electromagnetic Compatibility (EMC) .................... 48 Selection of Frequency Band ......................
- Page 6 Lockable Reject Bin and Status Monitor ..................59 Pack Check Photo-eye ........................59 Getting Started ..................61 User Interface ............................ 61 IQ3 Dual Line Display Menu Map ....................64 User Access ............................65 Logging In and Out ..........................66 Logging In ............................66 Logging Out ...........................
- Page 7 Table of Contents Setting the VF Drive ........................84 Setting Up the User Options ......................85 Setting Up Serial Links........................86 Performing a Ferrite Tune ......................87 Setting Up Product Signal Tracking ....................88 Setting Up the Reject Options ....................... 90 Adding a New Product ........................
- Page 8 Table of Contents Running the Report ........................115 Report Contents ........................... 115 Status Report ........................... 116 Purpose ............................116 Running the Report ........................116 Report Contents ........................... 116 PV Test Report ..........................116 Running the Report ........................116 Report Contents ........................... 116 Batch Report ............................
- Page 9 Table of Contents Viewing the Log ........................... 123 Printing the PVS Report ....................... 123 Clearing the Log ........................... 123 Shift Log............................124 Purpose ............................124 Viewing the Log ........................... 124 Printing the Shift Report ....................... 124 Clearing the Log ........................... 124 Maintenance ..................
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Page 11: Introduction
This guide is copyright to Loma Systems. No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language, or computer language in any form or by any means without the prior written permission of Loma Systems. -
Page 12: About This Guide
Introduction About this Guide General This guide explains in plain language and by example how to use the IQ Metal Detector Head and Conveyor. It begins with a conceptual overview of metal detection and then walks through the processes required to install, operate and maintain the machine. Each process is cross referenced to detailed information covering the concepts, controls, parts, assemblies, software and items associated with the process. -
Page 13: Organisation
This guide is organised into the following chapters: ■ Introduction Guidelines provide an introduction to this guide and some general information, including global contact details for Loma Systems. ■ About Metal Detection Guidelines provide an introduction to metal detection, including an explanation of the basic principles and good practice guidelines. -
Page 14: Document Change Control
Users are actively encouraged to suggest changes or additions to the contents of this guide directly to Loma Systems by sending an email to manuals@loma.com. All document changes are processed in accordance with the standard Loma Systems document management system change process. -
Page 15: Copyright And Acknowledgements
Introduction Copyright and Acknowledgements Copyright © 2014 Loma Systems, a division of ITW Ltd. All rights reserved. Loma Systems Summit Avenue Southwood Farnborough Hampshire GU14 ONY England Email: sales@loma.co.uk Web: http://www.loma.com This document is copyright material. No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language, or computer language in any form or by any means without the prior written permission of Loma Systems. -
Page 16: The Loma Group Of Companies
+48 22 575 70 25 Fax: +48 22 575 70 01 E-mail: pl.sales@loma.com Web: http://www.loma.com For details of other Loma offices and the worldwide distributor network, please visit the Loma web site www.loma.com or telephone one of the sales offices. -
Page 17: About Metal Detection
About Metal Detection Industrial metal detectors are used in the pharmaceutical, food, beverage, textile, garment, plastics, chemicals, lumber, and packaging industries. Contamination of food by metal shards introduced during the manufacturing process is a major safety issue in the food industry. Metal detectors are widely used and integrated into production lines and play a vital role in preventing contaminated products from reaching customers. -
Page 18: How A Metal Detector Works
‘false triggering’. The robust construction and excellence in electronics and software design of Loma metal detectors provides a stable and reliable product where the likelihood of false triggering is minimised. -
Page 19: Phasing
About Metal Detection Phasing The diagram below shows how the magnetic and conductive properties of a product affect the product phase angle. Utilising the ‘Learn’ feature provided in the IQ Metal Detector, an average for the net signal received from a product during inspection is digitally processed to provide a phase angle and amplitude. This is then memorised for later recall against the product as a product ‘window’, as shown in the Product Signal diagram below and essentially provides a ‘filter’... -
Page 20: Tracker Feature
This could result in false triggering and rejection of good products. Loma Systems generally employ the use of fixed plastic guards fitted around both ends of the aperture. This serves a dual purpose in effectively preventing access to those areas and the accidental introduction of any metal contaminants. - Page 21 Each value shown is the diameter in millimetres (mm) of a spherical metal contaminant, as contained in Loma test wands. The detection performance figures quoted in the tables below are for indication purposes only and are based on previous experience with similar products and applications.
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Page 22: Types Of Metal
About Metal Detection Detector performance is also affected by the position of the contaminant in the aperture. The least sensitive point is located in the geometric centre of the aperture, so this ideally is where to test the detector performance each time if practical, to ensure consistency. As metal gets closer to the sides (coils) of the aperture, the signal generated becomes larger, making it easier to detect. -
Page 23: Shapes And Orientation Of Metal
Once again, if your company is a private label manufacturer, ensure that you agree upon any variation you make to testing procedures, in writing, with your retailer customers. To facilitate effective testing, all of Loma's Metal Detectors have an integral Performance Validation System (PVS) feature. -
Page 24: Test Wands
About Metal Detection Test Wands Loma Systems metal detectors are supplied with a set of plastic test ‘wands’ which contain spherical pieces of various metals in different sizes. These are convenient and easy to place into your test samples and also make the testing process even more efficient. -
Page 25: Learn Feature
About Metal Detection Learn Feature Purpose The Learn feature incorporated into the metal detector completely automates the configuration of the detector settings for a product. Three Learn process options are available. Full Learn The Full Learn process consists of following displayed instructions to pass a number of product samples through the detector aperture. -
Page 27: Safety First
Generally in an industrial environment some background noise is present due to the operation of electrical equipment and mechanical movements of machinery such as conveyors and electrical noise. In general operation, Loma metal detectors do not emit a level of noise that is hazardous. -
Page 28: Safety Awareness
A signed and dated EC Declaration of Conformity is provided with each metal detector delivered. Any modifications made to any part of the metal detector without the prior written agreement of Loma Systems will invalidate the EC Declaration of Conformity and also the product warranty. -
Page 29: Safety Warnings
Safety First Safety Warnings Listed below are the safety warnings that are applicable when using a Loma metal detector. It is strongly recommended that personnel who are, or will be, responsible for installing, maintaining or operating the equipment described in this manual should read and understand these warnings. - Page 30 Hence Loma cannot be held responsible for meeting full requirements of OSHA or OHSA. with regards to any equipment supplied, nor can Loma be held liable for penalty which may be assessed for failure to meet the requirements of the acts as interpreted by an authorised inspector.
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Page 31: Safety Labels
Safety First 23. HANDLING A HINGE MOUNTED VERSION ON A STAND. Care should be taken when moving a detector as applied force and/or obstructions of the wheels may cause the machine to fall over. Remove all attachments before disconnecting from the filler. Lower the height adjustment to its minimum before moving. -
Page 32: Safety Guards
Safety Guards Guarding For Loma metal detectors the use of guarding, including covers, panels, curtains and other methods is extremely important in order to restrict operators from accessing areas of the machine that are potentially hazardous whilst the machine is operating or to prevent exposure to potentially hazardous ionising and non-ionising radiation. -
Page 33: Safety Measures
Loma metal detectors ensure product safety, equipment protection and regulatory compliance by automatically removing contaminated products from the production line, stopping the line, alerting the operator or a combination of these. Improper Use ■ Loma metal detectors are not domestic appliances and should only be used in an industrial environment. -
Page 34: Noise Levels
In general operation, Loma metal detectors do not emit a level of noise that is hazardous. However, if an air blast reject device is fitted, the noise emitted when it operates may constitute a noise hazard. -
Page 35: Quality Assurance
It is recommended that any suspect test wands are destroyed and replaced. Loma can supply a vast range of test wand types / sizes at-stock. Specials can also be made to order. Please email teststicks@loma.com... -
Page 36: End User Licence Agreement
Metal Detector is licensed not sold. 1. Grant of Licence: Loma Systems shall at all times have and retain title and full ownership of all software, firmware programming routines, documentation supplied for use with the equipment and of all copies thereof made by Buyer (collectively “software”). -
Page 37: Technical Specifications
Technical Specifications Metal Detector Head The technical specification for the IQ Metal Detector Head is provided in the table below. Please note that this specification lists the available options in some cases. The exact specification for your metal detector head will depend on the options you have selected. General Metal detector heads are available in a range of heights and widths to suit a specific customer requirements, which are agreed prior to manufacture and... -
Page 38: European Belt Conveyors
Technical Specification European Belt Conveyors The technical specification for all European Belt Conveyors is provided in the table below. Please note that this specification lists the available options in some cases. The exact specification for your machine will depend on the options you have selected. General Each machine is designed to suit a customer's requirements. -
Page 39: Installation
This chapter provides generic information covering the installation of the Loma IQ Metal Detector in a logical sequence, both as a head only and as a system with the head fitted to a Loma conveyor. The following sections provide more information: ■... -
Page 40: Warnings
If on unpacking the detector head it is subsequently found to be damaged, take further pictures of the damage and send them to Loma Systems. Loma Systems will then carry out an investigation, including a review of the applicable carriage terms / Incoterms, to decide what action is to be taken. - Page 41 Installation ■ Lift the detector head carefully and move it to the required location. ■ Lower the detector head and remove the straps. Using a Fork Lift ■ Position the forks under the pallet and raise it sufficiently to clear of the ground and any obstacles.
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Page 42: Detector Head Mounting Positions
Installation Detector Head Mounting Positions This section contains standard mounting positions for Loma Metal Detector heads. When refitting the head control panel cover, the cover fixing screws must be tightened to 4Nm torque to maintain the integrity of the IP69K rating for the head; preventing ingress of... - Page 43 Installation...
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Page 44: Mounting A Detector Head Onto A Conveyor
Mounting a Detector Head onto a Conveyor Introduction Loma Systems have been manufacturing metal detector systems for many years and our current conveyor design incorporates this wealth of experience. There are a number of integration rules that have to be followed when fitting a new detector head to an existing or third party conveyor to attain optimal performance and avoid nuisance triggering. - Page 45 DRY mode. Loma metal detectors are designed to minimise any vibration or shock effects when operating with conductive products. To further enhance this resistance the conveyor must be designed with consideration to the above rules.
- Page 46 Mounting Horizontal Heads for Use with Conductive Products Loma heads up to 350mm in height are supplied with an adjustable height mounting kit. The purpose of the height adjustment is to enable the centre line of the conductive product to pass through the “centre line”...
- Page 47 Installation Other sources of moving metal can also include automatic reject devices, where the reject movement is detected or supply cables that are placed too close to the detectors aperture or not securely fixed down. ■ Vibration It is important that the detector is not subjected to excessive vibration. The conveyor must be substantial and well supported (all feet/wheels should be touching the ground and locked) to keep the detector stable.
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Page 48: Connecting The Detector Head Electrical Supplies
■ Spurious Triggering The Loma range of detectors is the product of many years experience and development. They are inherently reliable, provided that it is installed and set up correctly. Remember that the detector can detect can detect moving metal anywhere within its metal free zone. This is up to a distance of 3 times the smaller of the aperture dimensions away from the detector. - Page 49 Installation Remove the screw from the top of the metal cover plate and lower it down carefully The Mains Filter is mounted inside the panel housing mounted on the right hand side. Push the mains cable up through one of the available cable glands. Then Split the cable inside the box and cut the wires to suitable lengths.
- Page 50 Input / Output Signal Information To connect to external devices a Relay kit, Loma part number 6120PL500, consisting of a relay module, a cable that connects the relay module to the mini control board and some cable ties, can be supplied.
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Page 51: Installing A Metal Detector System
The dwell can be in units of time or distance depending upon the type of reject device. Installing a Metal Detector System This chapter provides generic information covering the installation of a Loma Metal Detector System in a logical sequence. The system includes a detector head fitted to a European conveyor belt. -
Page 52: Warnings
If on unpacking the machine it is subsequently found to be damaged, take further pictures of the damage and send them to Loma Systems. Loma Systems will then carry out an investigation, including a review of the applicable carriage terms / Incoterms, to decide what... -
Page 53: Moving The Machine
Installation ■ Wheels (if fitted) are screwed fully in and are locked (UK only), or supplied in a polythene bag which is placed inside the reject bin (Europe). Remove them from the reject bin and remove the packing material. Then fit the wheels to the out rigged legs of the machine frame. You may need to raise the machine to fit the wheels so please follow the guidance included in the Moving the Machine section. -
Page 54: Clearance Requirements
Do not start the machine and initiate the use of any compressed air before the Loma commissioning engineer has approved the installation. Except where a metal detector head only is being supplied, all Loma metal detector systems require a clean and dry compressed air supply, primarily to operate the optional automatic reject system. -
Page 55: Connecting The Electrical Supplies
Installation Air Supply Output Port 2 - The air supply is fed to the other side of a reject device. For example when fitted to the other side of a double acting air cylinder, the air drives a rod attached to a nylon blade back to its start position. Air Supply Dump Output Port 1 –... - Page 56 Installation ■ 50% of nominal voltage for more than 40mS. ■ 80% of nominal voltage for more than 100mS. Operation outside these limits may cause loss of function until the supply condition recovers to within limits. The standard metal detector conveyor is fitted with a starter isolator and a 24V ac control circuit. The supply voltage for the conveyor is indicated on the identification plate that is mounted on the frame.
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Page 57: Checking Guards
Core Terminal 1-phase Neutral Earth Do not start the machine and initiate the use of any electrical circuitry before the Loma commissioning engineer has approved the installation. Checking Guards ■ Check that all guards are securely fastened in place. ■... -
Page 58: Installing A Serial Link
Site Considerations Electromagnetic Compatibility (EMC) All Loma machines are designed, and tested, to operate under factory conditions and have been tested to recognised international standards for Electromagnetic Compatibility (EMC), both in terms of not emitting excessively and not being subject to undesirable operation in the presence of other equipment whose emissions also meet the standards. - Page 59 RF emissions if necessary. All Loma metal detectors are designed, and tested, to meet the requirements of the FCC and the new stringent European regulations for RF emissions, both in terms of not emitting excessively and not being subject to undesirable operation in the presence of other equipment whose emissions also meet the standards.
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Page 61: About The Metal Detector Range
The search head is available separately for fitting to your own conveyor or this can be supplied as a system, already fitted to a Loma conveyor. A Pipeline Metal Detector is also included in the range for inspecting pumped products. -
Page 62: Metal Detector Search Heads
Standard Features ■ Variable Frequency Capability - Loma is the only company in the industry that offers true variable frequency, operating between 40 - 900 kHz. This means that you can configure the same machine for use with a variety of products. Through the systems product 'Learn' feature, the correct frequency for a product can be automatically set in seconds, eliminating past performance restrictions caused by limited frequency metal detectors. -
Page 63: Conveyor Belts
Conveyor Belts Loma conveyors are fitted with either flat belts which are suitable for use with lighter products or plastic modular belts which are suitable for use with heavier products in a harsher environment. The belts are positively driven from a central drive sprocket that is secured on a square-section drive shaft. -
Page 64: Plastic Modular Belts
The plastic modular belt conveyors use a belt constructed from injected-moulded plastic modules, assembled into an interlocked unit and joined by plastic hinge rods. The following table gives details of the three different plastic modular belt types supplied by Loma: Belt Type... -
Page 65: Reject Devices
Reject Devices Reject Devices Loma Systems offer a range of reject devices for removing contaminated products from your production line, based on a number of factors including the product type, its general dimensions, the general set up of your production line and of course how you wish to handle contaminated products. -
Page 66: Air Blast
About the Metal Detector Range Air Blast The Air Blast reject device is suitable for removing contaminated wrapped products from your production line using a high pressure blast of compressed air to push the contaminated product off of the conveyor belt and into a reject bin. Generally a single nozzle is specified but a second nozzle can be fitted when required to provide more control or to reject over or underweight packs into a separate reject bin where the metal detector is being used in combination with a checkweigher. -
Page 67: Reject Bins
EMERGENCIES ONLY to stop the machine. Guards For Loma metal detectors the use of guarding, including covers, panels, curtains and other methods is extremely important in order to restrict operators from accessing contaminated products and also areas of the detector that are potentially hazardous. -
Page 68: Optional Equipment
About the Metal Detector Range The switch is set by Loma to operate if the pressure of the compressed air supply to the reject falls below 40psi (2.8 bar). The conveyor then stops. Optional Equipment The following options are available, depending on the type of reject mechanism fitted:... -
Page 69: Overhead Electrical Services
About the Metal Detector Range Overhead Electrical Services The Electrical Services Box may be mounted overhead instead of at the front of the conveyor as is standard. Product Guides Product guides are useful for centring products through the detector aperture and controlling product presentation to prevent skewing. - Page 70 About the Metal Detector Range THIS PAGE IS INTENTIONALLY LEFT BLANK...
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Page 71: Getting Started
Getting Started This chapter provides some basic guidelines for initially using the IQ Metal Detector. The following sections provide more information: ■ User Interface This section provides a brief description of the machine’s user interface so that you may navigate around the system to make the right selections. ■... - Page 72 Getting Started Access Levels Key Navigates you to the Access Levels options so that you may change the level of access you currently are using. You will need to enter the correct password set for the level you wish to access. OK / Enter Key Used when you want to select a menu option to change its value and then to confirm and implement the change.
- Page 73 Electrical Services Box When the IQ Metal Detector head is supplied fitted to a Loma conveyor, the following switches and buttons are also provided, mounted on the Electrical Services Box: The Isolator Switch is located on the front of the Electrical Services Box and is shown here in the ON position.
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Page 74: Iq3 Dual Line Display Menu Map
Getting Started IQ3 Dual Line Display Menu Map... -
Page 75: User Access
In addition, an Access Timeout feature is provided which will automatically lock the machine when it senses no activity for a period of 5 minutes. During installation and commissioning, the Loma Engineer will set and provide you with passwords for accessing all user levels which you can then provide to staff as required. -
Page 76: Logging In And Out
Getting Started Logging In and Out This section provides guidance for logging in and out of the IQ Metal Detector. Logging In The following procedures assume that the machine is switched on and working normally and that machine access has been 'Locked'. To log in to the machine proceed as follows: Select the Keylock button to display the current user level, which should be... -
Page 77: Logging Out
Getting Started Logging Out To log out of machine, proceed as follows: Select the Keylock button to display the current user level, which following on from the process above should be ENGINEER. Use the Scroll buttons to select the LOCKED user level. Press the Tick button to confirm the selection. -
Page 78: Stopping The Machine
Getting Started Stopping the Machine To stop the machine, proceed as follows: Push the red Stop button to stop the conveyor. If you have finished using the machine, turn the Isolator Switch in an anti-clockwise direction. This will switch off the electrical supply to the machine. Emergency Stop To stop the machine in an emergency, proceed as follows: Press the red Emergency Stop button located in the centre under the user display. -
Page 79: Using The Metal Detector
Using the Metal Detector This chapter provides general information about using the IQ + Metal Detector, including some guidance on setting up the detector to provide the best results. The following sections provide more information: ■ Good Practice This section provides some guidance for maintaining an effective metal detection regime. ■... -
Page 80: Establishing A Good Product Learn
Loma Systems can supply a selection of sizes and types of metal test wands for attaching to product samples for testing purposes. There are three types of wands: ferrous (chrome steel), non-ferrous (brass), and 304 stainless steel. -
Page 81: Regular In-Line Detector Performance Testing
Using the Metal Detector Regular In-Line Detector Performance Testing It is important to maintain regular and accurate in-line performance testing of the metal detector using the same techniques as the initial performance testing. This should include tests to ensure that the reject systems are effective. -
Page 82: Getting The Results
Using the Metal Detector Getting the Results Before using the metal detector with a new product it is important to learn the product, to allow the metal detector to adjust itself to the highest possible sensitivity. The metal detector will either learn on the signal from the product, or if there is insufficient signal, will use reference learn settings. -
Page 83: Operating Instructions
Operating Instructions This chapter provides general information about using the metal detector, including some guidance on setting up the detector to provide the best results. The following sections provide more information: ■ Setting Up the Metal Detector This section provides guidance for setting up some basic features of the metal detector. ■... -
Page 84: Setting The Language
Operating Instructions To change the time and date, proceed as follows: Select Menus > Setup > Calendar to display the Calendar menu options. Use the Navigation Keys to select the Year option and press the OK / Enter Key to enable the current value to be edited. Use the Navigation Keys to select the required Year and then press the OK / Enter Key... -
Page 85: Setting User Access Levels And Passwords
Operating Instructions Setting User Access Levels and Passwords User accounts are used to manage access to the features and functionality available in the metal detector. Four access levels are available, which are described in the User Access section, and you may set specific passwords for each level. -
Page 86: Configuring The Metal Detector
Operating Instructions Configuring the Metal Detector Wherever possible, configuration of the metal detector will be carried out by Loma Systems before the machine is dispatched, or by a Loma Service Engineer during a commissioning visit. Primarily, the commissioning visit is required as part of the installation process so that the engineer can optimise machine performance in its actual working environment and for the products that are to be inspected. - Page 87 Operating Instructions ■ Band Frequency bands are used to prevent crosstalk between adjacent metal detectors that are operating on the same frequency. The options are OFF, or 1 through 10. If OFF is selected then all seventy (70) frequencies, 31 through 882, will be available for use for all products, making frequency selection and subsequent Learns a manual process.
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Page 88: Setting Up The Conveyor
Operating Instructions Learning the wand is the same as learning a product and can only be done when the Photeye option in the Menus > Service > Configuration > System menu has been set to NO. Once Ferrrite has been learnt then further access should be denied to prevent accidental use. To do this, navigate to the Menus >... - Page 89 Operating Instructions The calculation for this entry, measured in mm or inches, depends on the Units option selected in the Menus > Service > Configuration > General menu. It is calculated as follows: Measure the distance from the Product Registration Photo-eye to the face of the detector (L).
- Page 90 Options are provided to Energise or De-Energise the audible alarm. ■ Lamp Type Options of Dome and Stack are provided. The IQ3 Metal Detector system is generally supplied with an LED Lamp Stack so the Stack option should be selected.
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Page 91: Setting Up The Service Options
Dry products, access should be disabled to avoid incorrect use. Access is generally enabled by a Loma Service Engineer when the Ferrite product needs to be re-learnt following replacement of a circuit board or upgrading of the detector software. -
Page 92: Setting The Vf Balance
AutoBalance feature which automatically makes any P and Q channel balance adjustments necessary for each of the available frequencies. Manual adjustment is also possible and this is carried out by Loma Service Engineers when required. To set up the VF Balance, proceed as follows: Select Menus >... - Page 93 When the detector has been configured correctly, the measured balance will generally be lower than the balance setpoint. If in doubt contact your local Loma service centre for assistance. ■ Auto configure Enabling this option starts the AutoBalance process for all operating frequencies. The process commences by resetting the potentiometer positions for the P and Q channels for each frequency to 50.
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Page 94: Setting The Vf Drive
AutoBalance feature which automatically makes any P and Q channel balance adjustments necessary for each of the available frequencies. Manual adjustment is also possible and this is carried out by Loma Service Engineers when required. To set up the VF Drive, proceed as follows: Select Menus >... -
Page 95: Setting Up The User Options
If only the orange led is illuminated then the transmitter is still in safe mode. In this case, try lowering the on time value a little more and perform another restore drive. If the red LED stays on then contact your local Loma service centre for assistance. ■ Auto Configure Select this option to start the full setup process for all operating frequencies. -
Page 96: Setting Up Serial Links
Operating Instructions Setting Up Serial Links Serial links are set up through the Serial menu which provides options for selecting the type of data to be transmitted and/or received and how the data is communicated. To enable communications over a serial link to function, the detector must have as a minimum the additional serial link board with cabling. -
Page 97: Performing A Ferrite Tune
Operating Instructions ■ Data Bits Options for selecting the number of data bits to be used for the connection are provided. ■ Stop Bits Options for selecting the number of stop bits to be used for the connection are provided. ■... -
Page 98: Setting Up Product Signal Tracking
Operating Instructions To perform a ferrite tune, proceed as follows: Select Menus > Service > Options to display the Service Options menu options which are listed and described below. Use the Navigation Keys to select the Access Ferrite option and press the OK / Enter Key to select it Use the Navigation Keys... - Page 99 Operating Instructions Operating Conditions The Tracking limits parameters are only available if the Tracker option has been enabled in the Menus > Service > Options menu. For this option to be available, a Product Registration Photo-eye must be fitted and enabled in the Menus > Service > Configuration > System menu. Tracking is product relative and the function can be turned on or off individually for each of the available 100 product memories.
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Page 100: Setting Up The Reject Options
Operating Instructions The Tracker Limits menu options available are as follows: ■ Tracker Limits To display the options listed below you must first enable them by selecting the YES option. The following options are then displayed: o Min limit This option is used to set the lowest product signal level to be used by the Tracker feature when making automatic threshold adjustments. - Page 101 Operating Instructions The Reject Set Up menu options available are as follows: ■ Mode The following Mode options are provided for selection: o Pulse (only available if a photo-eye is fitted) If this option is selected, when a contaminated package is detected the reject delay time is counted down, in order for the package to travel from the photo-eye to the reject device, where-upon the reject is turned on for a time equal to the reject dwell time.
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Page 102: Adding A New Product
Reject > Control menu: ■ Disable rejects? Selecting this option temporarily disables the reject device. This feature is intended for Loma Service Engineer use only. Adding a New Product This section explains how to add a new product, following which a... - Page 103 Operating Instructions Use the Navigation Keys to select an unused product number and then press the OK / Enter Key to confirm the selection. Repeat steps 2 and 3 to scroll through all of the Product menu options until you have selected and confirmed values for each option.
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Page 104: Learning Products
Learning Products An essential part of inspecting products is to set up the metal detector parameters specifically for each product to optimise the detectors performance for each one. Loma metal detectors provide a Learn feature which automates this process. The Learn settings and the process to be followed is defined in the Menus > Learn >... -
Page 105: Full Learn
Operating Instructions ■ Update Learn This process is only available if you have previously carried out a Full Learn process for the product. It fine-tunes the phase value to minimize the signal, while still checking for metal in the product. Use an Update Learn to update the signal when the production line is running if false rejects are occurring because the signal has drifted. -
Page 106: Update Learn
Operating Instructions Update Learn Prior to carrying out an Update Learn, ensure that you have a number of representative sample products available to pass through the detector as part of the process. The Learn process utilises the currently selected product so ensure that you select the correct product through the Menus >... -
Page 107: Learn Messages
A product not specified for use with the machine is being used. ■ The product packaging is highly conductive. If in doubt, contact your local Loma Service Centre. +Working dry+ This message indicates that the product has so little moisture that it produces no product signal. -
Page 108: Learn Setup
The product Learn parameters for optimum detector performance are automatically selected during a Full Learn process so no manual adjustment of the parameters is normally required. If adjustments are required then you should contact your local Loma Service Centre in the first instance. - Page 109 Operating Instructions ■ P span threshold This field is only displayed if the PQ span option is enabled in the Menus > Service > Configuration > Learn Limits menu. It is used to set the P span signal threshold (Pmax – Pmin) to be used during inspection.
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Page 110: Learn Limits
Operating Instructions ■ Head Gain Enabling this option locks the Head Gain settings, thus preventing the detector from changing them during a Full Learn process. Learn Limits The Learn Limits menu provides options to set up some parameters for the Learn process and to enable the display of other parameters in the Menus >... - Page 111 Operating Instructions ■ Threshold This option is used to set the maximum signal value to be used during a Full Learn process. If the signal exceeds this threshold then the frequency is automatically reduced. The default value is 5000. ■ Learn cycle The following options for setting the Learn cycle to be used are available for selection: O Short...
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Page 112: Using Performance Validation
Operating Instructions Using Performance Validation This section describes the benefits of the Performance Validation System and explains how to set up the metal detector for PV testing, with information about each of the parameters that need to be specified. Regular checking of the metal detector’s sensitivity should be a normal part of any quality assurance procedure. - Page 113 Operating Instructions If it cannot then a warning message will be displayed and a larger metal contaminant may need to be used. Once a successful inspection of the Fe test wand has been completed, the user is prompted to pass the same sample product pack with the test wand attached through the detector a number of times, set in the Number of passes option, until they have all passed inspection and the test is complete in the PVS screen as shown below.
- Page 114 Operating Instructions Guidance on determining the number of passes to be used For products that exhibit no product effect and where no Product Registration Photo-eye is fitted, place each test wand type onto the product sample at the leading edge for the first pass and then on the trailing edge for the second pass to ensure that the change of reject timing point still results in the correct rejection of the product.
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Page 115: Running A Performance Validation Test
Operating Instructions Running a Performance Validation Test To run a PV test, proceed as follows: To manually run a PV test, select Menus > Run PV Test to display the Run PV Test ? menu and press the OK / Enter Key to confirm that you want to run the test. - Page 116 Operating Instructions THIS PAGE IS INTENTIONALLY LEFT BLANK...
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Page 117: Logs And Reports
Logs and Reports This chapter provides information about the available logs and reports that are generated from information automatically collected by the IQ Metal Detector. To produce any report a Serial Link must have been previously set up to match the device receiving the report. -
Page 118: Logs
Logs and Reports Batch Report Shift Report Logs The IQ Metal Detector captures event data relating to Contaminants, Errors, Faults, Batches, PV tests and Shifts which are then made available for viewing. Each log can hold up to 20 records. If this number is exceeded and the log has not been sent as a report, then the oldest record is deleted to provide space for a new record. -
Page 119: Example Problems
Logs and Reports Example Problems Some example run error problems that may be displayed and suggested remedial actions are listed below. ■ Problem: PV test prompt - an automatic programmed PV test prompt has occurred. Action: Complete a PV Test. ■... -
Page 120: Faults Report
- 250mA. Note that detectors with large apertures will have drive currents below the normal 230 - 250mA range if operating at frequencies above 650kHz. If the message persists or the user is in doubt then contact your local Loma Service Centre for assistance. - Page 121 ■ Problem: +12V out of spec - the +12V rail is less than 11.40V. Action: – Contact your local Loma service centre for assistance. ■ Problem – Verdict too late - a pack has arrived at the reject point before the detector has sent a reject decision.
- Page 122 Logs and Reports ■ Problem: Bin full - the reject bin full sensor has been blocked for longer than 5 seconds and the transport system has stopped. The bin will need to be emptied before the transport can be restarted. Action: If the bin is full: 1.
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Page 123: Setup Report
■ Problem: Drive too low - (IQ3 only) the transmitter drive current is not set. Action: In the Menus > Service > Configuration > Drive Settings menu perform the Auto Configure operation. This will automatically reset all the drives for each of the detector operating frequencies. -
Page 124: Contaminants Report
Logs and Reports Working Mode Lock Minimum Threshold Maximum Threshold Detection Threshold Product Compensation Phase Angle Phase Lock Head Drive Head Drive Lock Head P Gain Head Q Gain Head RF gain Head Gain Lock Contaminants Report Purpose The Contaminants Report contains a complete record of reject activity which is useful for monitoring and analysing the occurrences and levels of contamination for specific products. -
Page 125: Learn Report
Logs and Reports Learn Report Purpose The Learn Report provides useful information covering when product Learn processes were carried out and the Learn settings used which can then be used for product investigations; providing confirmation that the Learn processes were carried out for specific products and that the detector was able to identify the types and sizes of contaminants used. -
Page 126: Status Report
Logs and Reports Status Report Purpose The Status Report contains accumulated product run data for the currently running product at the time it is sent to assist in investigating problems with specific products and batches. Running the Report To run the report, navigate to the Menus > Results menu, select the Status Report? option and press the OK / Enter Key. -
Page 127: Batch Report
Logs and Reports ■ Product name - Displays the product name. ■ Operator ID – Displays the entered identity of the test operator. ■ Test Samples Ferrous – Displays the number of passes and the size of the Ferrous test piece used. -
Page 128: Shift Report
Logs and Reports ■ Average Signal Good - Displays the average product signal for all products that passed inspection in the batch. Shift Report Purpose The Shift Report contains a record of completed shift information. Shifts are compiled on a time basis. This report is useful for monitoring and analysing shift reject rates so that improvements may be made to reduce production costs. -
Page 129: Printing The Contaminants Report
Logs and Reports Use the Navigation Keys to scroll through each of the available log entries. Each entry is displayed in turn and contains three lines of information for each one. The first line displays the Product Signal, the second line displays the Time and the third line displays the Date. -
Page 130: Printing The Errors Report
Logs and Reports Press the OK / Enter Key to select the option. If the log is empty a +Log empty+ message is displayed. If the log contains entries then the number of entries is briefly displayed. Use the Navigation Keys to scroll through each of the available log entries. -
Page 131: Printing The Faults Report
Logs and Reports Use the Navigation Keys to display the View Faults Log? menu option. Press the OK / Enter Key to select the option. If the log is empty a +Log empty+ message is displayed. If the log contains entries then the number of entries is briefly displayed. Use the Navigation Keys to scroll through each of the available log entries. -
Page 132: Batch Log
Logs and Reports Batch Log Purpose The Batch Log contains a record of completed batch information. Batches can be compiled on a time basis or a count basis where the Production Registration PEC is fitted. This log is useful for monitoring and analysing batch reject rates per product so that improvements may be made to reduce production costs. -
Page 133: Pvs Log
Logs and Reports PVS Log Purpose The PVS Log contains records of completed in-line detector performance testing activity which is useful for providing compliance evidence and when carrying out product investigations. The log can hold up to 20 records. If this number is exceeded and the log has not been sent as a report, then the oldest record is deleted to provide space for a new record. -
Page 134: Shift Log
Logs and Reports Shift Log Purpose The Shift Log contains a record of completed shift information. Shifts are compiled on a time basis. This log is useful for monitoring and analysing shift reject rates per product so that improvements may be made to reduce production costs. -
Page 135: Maintenance
Maintenance This chapter describes the maintenance procedures for the IQ Metal Detector. Your warranty may be invalidated if you do not follow the maintenance schedule set out within this user guide. This warranty statement is in addition to the terms of sale. The following sections provide more information: ■... -
Page 136: Cleaning Solutions
Maintenance Never immerse the Pneumatic Actuator as internal corrosion and permanent damage will result. Cleaning solutions Detergents are typically alkaline solutions. Disinfectants typically contain Chlorine or Ammonia. Every 3-4 weeks it is typical to revert to acid based cleaning solution to remove any build up of lime scale on stainless steel parts. -
Page 137: Air Regulator Unit Maintenance
Maintenance ■ For systems with reject confirm and bin full check their correct operation. Bin full will operate if the sensor is blocked for > 5 seconds. Air Regulator Unit Maintenance With the exception of systems fitted with Air Blast or Stop-On-Detect or electrically driven rejects the compressed air supply pressure to the fitted reject device is fed through an air regulator unit. -
Page 138: Adjusting The Drive Chain Tension
GUI software version is IQ3_Plus_v1.9.2.10._zip at the time of writing this document. 1. Obtain a copy of the applicable upgrade files for your system from Loma Systems. 2. Insert a USB memory stick into your PC and copy the following files onto it: IQ3_vX.X.X.Xs.hex... - Page 139 8. Exit the Loma software on the metal detector using one of the following methods: Method 1: CTRL-TAB and End Task in the Main Run Screen.
- Page 140 Maintenance THIS PAGE IS INTENTIONALLY LEFT BLANK...
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Page 141: Glossary
Glossary Aperture: The area through which product is passed. AutoBalance: A patented detector feature that automatically makes balance adjustments for each of the 70 available frequencies to provide optimum detector performance. Bin Full: Option which uses a PEC to indicate when a reject bin is full and needs to be emptied. - Page 142 Glossary Metal Free Zone: An area external to the metal detector aperture which must be free of any fixed or moving metal as it generates a signal that will be picked up by the metal detector Noise: Electrical signals generated by local sources such as un-suppressed solenoids and inverters, which can cause False Triggering or reduce detection performance.
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Page 143: Index
EC Declaration of Conformity 18 Moving the Machine 43 Electrical Services Box 57 Emergency Procedures 24 Noise Levels 24 Enabling the Tracker Feature - IQ3 89 End of Life Treatment 24 Optional Equipment 58 End User Licence Agreement 26 Organisation 3... - Page 144 Setting Up Serial Links - IQ3 86 Plough 56 Setting Up the Conveyor - IQ3 78 Powered Decliner 56 Setting Up the Metal Detector - IQ3 73 Product Effect and Phasing 8 Setting Up the Reject Options - IQ3 90 Pusher 56...
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