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Installation

This chapter provides generic information covering the installation of the Loma IQ

3

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:

■

Installing a Metal Detector Head

Provides guidance for installing a metal detector head only.

■

Installing a Metal Detector System

Provides guidance for installing a metal detector system, consisting of a metal detector head
fitted to a Loma conveyor and including standard and optional equipment.

■

Site Considerations

All Loma machines are designed and tested against recognised international standards for
Electromagnetic Compatibility, to operate under factory conditions. This section provides
further information on the impact of RF interference.

Installing a Metal Detector Head

This section provides information covering the installation of a Loma IQ

3

Metal Detector Head in a

logical sequence.

The following sub-sections provide more information:

■

A list of applicable

safety warnings

to be observed when installing the metal detector head is

provided.

■

Receiving and Unpacking

Some basic checks should be carried out on receipt of the machine to ensure that it has not
been damaged in transit.

■

Moving the Detector Head

Depending on the size and weight of the detector head, either a crane or a fork-lift truck will
be required to lift and move it into the final location. This section provides some guidance for
moving the machine safely.

■

Detector Head Mounting Positions

Diagrams are included to provide details for mounting detector heads in different positions.

■

Mounting a Detector Head onto a Conveyor

There are a number of points to consider when fitting a new Loma Metal Detector head to an
existing conveyor of whatever manufacture, or when building a new conveyor to incorporate a
metal detector head. This section provides some guidance.

■

Connecting the Detector Head Electrical Supply

This section provides guidance on connecting an electrical supply to the detector head.

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Summary of Contents for IQ3

Page 1: ...IQ3 Metal Detector User Guide Document Number 814180 2 0 ENG ORIGINAL INSTRUCTIONS Copyright 2014 Loma Systems ...

Page 2: ......

Page 3: ...tector Works 8 General 8 Balance Stability 8 General and Foil Wrapped Products 8 Product Effect and Phasing 8 Product Effect 8 Phasing 9 Tracker Feature 10 Metal Free Zone 10 Detector Performance 10 Types of Metal 12 Shapes and Orientation of Metal 13 Testing Metal Detector Performance 13 Test Frequency 13 Product Test Samples 13 Test Wands 14 Testing Guidelines 14 Test Records 14 Learn Feature 15...

Page 4: ... ISO9000 25 End User Licence Agreement 26 Technical Specifications 27 IQ 3 Metal Detector Head 27 European Belt Conveyors 28 Installation 29 Installing a Metal Detector Head 29 Warnings 30 Receiving and Unpacking 30 Moving the Detector Head 30 Detector Head Mounting Positions 32 Mounting a Detector Head onto a Conveyor 34 Connecting the Detector Head Electrical Supplies 38 Installing a Metal Detec...

Page 5: ...1 Introduction 51 Metal Detector Search Heads 52 Standard Features 52 Optional Features 52 Conveyor Belts 53 Flat Belts 53 Plastic Modular Belts 54 Reject Devices 55 Reject Devices 55 Stop On Detect 55 Air Blast 56 Pusher 56 Plough 56 Retracting Band 56 Powered Decliner 56 Signal Only 56 Reject Bins 57 Electrical Services Box 57 Guards 57 Air Pressure Switch 57 Optional Equipment 58 Audible Alarm ...

Page 6: ... 69 Establishing a Good Product Learn 70 Establishing Detector Performance 70 Introduction 70 Relative Detectability of Non Ferrous Metals 70 Regular In Line Detector Performance Testing 71 Handling Rejected Products 71 Getting the Results 72 Frequency Selection 72 Operating Instructions 73 Setting Up the Metal Detector 73 Setting Up the Metal Detector 73 Setting the Time and Date 73 Setting the L...

Page 7: ...ts 100 Using Performance Validation 102 Setting Up PV Testing 102 Running a Performance Validation Test 105 Logs and Reports 107 Reports 107 Logs 108 Errors Report 108 Purpose 108 Running the Report 108 Report Contents 108 Example Problems 109 Faults Report 110 Purpose 110 Running the Report 110 Report Contents 110 Example Problems 110 Setup Report 113 Purpose 113 Running the Report 113 Report Con...

Page 8: ... Running the Report 118 Report Contents 118 Contaminants Log 118 Purpose 118 Viewing the Log 118 Printing the Contaminants Report 119 Clearing the Log 119 Errors Log 119 Purpose 119 Viewing the Log 119 Printing the Errors Report 120 Clearing the Log 120 Faults Log 120 Purpose 120 Viewing the Log 120 Printing the Faults Report 121 Clearing a Fault 121 Clearing the Log 121 Batch Log 122 Purpose 122 ...

Page 9: ...s 125 Cleaning 125 Cleaning regime 125 Cleaning solutions 126 Belt conveyor versions 126 Air Regulator Unit Maintenance 127 Conveyor Belt Maintenance 127 Plastic Modular Belt Section Replacement 127 Setting the Belt Tension and Tracking 127 Adjusting the Drive Chain Tension 128 Adjusting the Reject Devices 128 Pusher and Retracting Band Rejects 128 Air Blast Reject 128 Software Upgrades 128 Glossa...

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Page 11: ...chapter Document Change Control This guide is a controlled document which is subject to change in line with changes to our products As the principle aim of the guide is to provide you with the information that you need we would welcome any comments or feedback that will enable us to make improvements to the guide Document Key Special text is used throughout the document highlighted through the use...

Page 12: ...nsure that acceptable quality standards are achieved and maintained for all products inspected to meet customer and legislative requirements Engineer This guide benefits engineers and technicians who need to initially install commission and integrate the machine into the production line and then carry out routine servicing and maintenance tasks to assure the high availability and performance of th...

Page 13: ...eumatic supplies About the Metal Detector Range Guidelines provide a summary of the available features and functions of the machine and descriptions of its component parts Getting Started Guidelines describe the basic controls and how to switch on log in and prepare the machine for use Using the Metal Detector Guidelines provide information covering good practice establishing detector sensitivitie...

Page 14: ...y be used throughout the document The icons and colour coding have the following meanings Notes and Warnings NOTE Notes as used to provide supplementary information WARNING Warnings are used to identify possible hazards which may cause damage to or malfunction of the equipment loss of life bodily damage or ill health in any form either immediate or latent Loma Systems cannot be held responsible fo...

Page 15: ...y any means without the prior written permission of Loma Systems The information in this guide is believed to be correct at the date of publication However our policy is one of continuous improvement and so the information in this guide is subject to change without notice and does not represent a commitment on the part of Loma Systems No liability is accepted for errors and omissions in this docum...

Page 16: ...s Door 3 No 15 Lane 1985 Chunsen Road Shanghai 200237 PRC Loma Systems Daalderweg 17 4879 AX Etten Leur Netherlands Tel 86 0 21 64102396 Fax 86 0 21 64102395 E mail cn sales loma com cn service loma com Web http www loma com Tel 31 0 492 573550 Fax 31 0 492 573570 E mail bnl sales loma com bnl service loma com Web http www loma com France Germany Sales and Customer Service Sales and Customer Servi...

Page 17: ...s the product signal threshold automatically using the average signal values obtained from a defined number of products that pass through the aperture Metal Free Zone Although the electromagnetic field is generated inside of the detector housing some of the field emanates out of the aperture on both sides This leakage area is defined as the Metal Free Zone Detector Performance Provides details of ...

Page 18: ...ies The first category consists of systems with a general purpose search head These systems are capable of detecting ferrous and non ferrous metals as well as stainless steels in fresh and frozen products either unwrapped or wrapped and even in metallized films The second main category consists of systems which have a ferrous in foil search head that uses a series of magnets rather than a balanced...

Page 19: ... essentially provides a filter so that signals of a known phase and amplitude can be ignored This is called phasing out the product signal Product Signal Contaminated Product Signal The Contaminated Product Signal diagram above shows how a signal from a metal contaminant although much smaller than the product signal can be easily detected The metal detector sees the one resultant signal of the met...

Page 20: ...ntered parameters for each product It should be noted that this type of system may allow metal contamination that would otherwise be detected if changes in the product force the working threshold to rise sharply Tracker initialisation will occur whenever the detector is powered on the running product is changed or the tracking limit parameters are changed Upon completion of the product learn routi...

Page 21: ...uoted in the tables below are for indication purposes only and are based on previous experience with similar products and applications The estimation of detection level does not take into account excessive product effect or interference Full product tests are required to validate any detection performance estimation The figures are also based on heads up to 650mm wide Above this width there will b...

Page 22: ...ve non magnetic metals such as copper aluminium brass and phosphor bronze When inspecting non conductive products these metals produce almost the same size signal as ferrous metals because they are all good conductors When inspecting conductive products increasing the test sphere size by at least 50 is a good practice Non Magnetic Stainless Steel High quality 300 series stainless steels such as ty...

Page 23: ...ng the detector and are monitored and reviewed on a routine and regular basis to ensure compliance with customer and legislative requirements Test Frequency Intervals between tests need to be short enough that if a fault is found products potentially affected have not left your premises and can be identified recalled and retested Once again if your company is a private label manufacturer ensure th...

Page 24: ...When using a reject device ensure that test samples which have a test wand attached successfully enter the reject bin or that the conveyor stops when using Stop on Detect Wherever possible fit metal detection equipment on your production line AFTER products have been wrapped Where this is not possible and you are manufacturing private label goods it is advisable to agree to the testing routine in ...

Page 25: ...ctor in the time period dictated by the on screen instructions If possible you should Learn the product on a running line so that the detector learns a product as it would normally be run See the Full Learn section for further details Update Learn The Update Learn process consists of following displayed instructions to pass a number of product samples through the detector aperture This process can...

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Page 27: ... the metal detector where caution should be taken to avoid potential hazards The labels used are listed and described in this section Safety 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 areas of the metal detector that are potentially hazardous which the machine is operati...

Page 28: ...ration and maintenance personnel read this guide before working on the IQ 3 metal detector and comply with the instructions and information contained herein It is essential that all personnel engaged in activities associated with the installation operation servicing and maintenance of the IQ 3 metal detector have been adequately trained and are appropriately qualified and experienced to do so All ...

Page 29: ...ted Wearers of these devices should therefore consult their doctor for advice on avoiding this hazard 4 WORKING ON EQUIPMENT If it is essential to work on the equipment with electrical and or compressed air power connected the work must be undertaken only by qualiﬁed personnel who are fully aware of the danger involved and who have taken adequate safety precautions to avoid contact with dangerous ...

Page 30: ...ng the height of Pipeline detectors Lower the height adjustment to its minimum before moving If appropriate measures are not taken severe injury to an individual or damage to the detector could result 17 SECURITY WHEN STAND MOUNTED Due to the high centre of gravity care should be taken when moving a pipeline metal detector on a stand as the applied force and or obstructions of the wheels may cause...

Page 31: ...WER Before disconnecting the metal detector from power removing the power plug or loosening the power terminals ensure that signal cables to other machines are disconnected first Safety Labels Safety labels are attached or etched in appropriate places to highlight areas of the metal detector where caution should be taken to avoid potential hazards The labels used are listed and described below Lab...

Page 32: ...aramount at least one fail safe relay is fitted to ensure that if a contact of the interlocks were to fail the safety relay will automatically detect the fault and therefore switch off the metal detector and generate a fault condition Responsibilities and Disclaimer Unless agreed otherwise in writing by Loma Systems any warranty claims are subject to the following No unapproved changes or addition...

Page 33: ...aken when carrying out tasks in areas of the metal detector that are potentially hazardous as identified with an appropriate safety label Removal of any guards covers and other protective devices must only be carried out by authorized or qualified personnel after first switching off and removing any power from the metal detector Note that interlocking devices are fitted to all inspection covers to...

Page 34: ...Regulations 2012 19 EU and CE Directive 2002 96 EC electrical and electronic equipment must be recycled at the end of its useful life The metal detector is considered to be a Large scale Stationary Industrial Tool LSIT as defined in Article 2 of the WEEE Regulations Consequently it is the responsibility of the user of the equipment to ensure the safe disposal of the machine at the end of its usefu...

Page 35: ...of Calibration This type of calibration is confined to the checking of the electronics of the metal detector against the original specification carrying out any adjustments or repairs as necessary This is normally carried out by the manufacturer against a written specification and using equipment traceable to national and international standards A certificate of calibration would then be issued fo...

Page 36: ...plied for use with the equipment and of all copies thereof made by Buyer collectively software Loma Systems grants the Buyer a non exclusive and non transferable license to use such software solely for use with the equipment The Buyer shall take all reasonable steps to protect Loma Systems proprietary interest in the software and shall not transfer or otherwise provide or sub licence the software ...

Page 37: ...ble in a range of heights and widths to suit a specific customer requirements which are agreed prior to manufacture and confirmed on the Order Acknowledgement provided Please review this document for dimensional information Power Requirements Voltage Standard Options 220 230V 1 phase 50Hz neutral and earth 110 120V 1 phase 60Hz neutral and earth Environment Operating Temperature 10 C to 40 C Relat...

Page 38: ...Options 380 400 440V 3 phase 50Hz neutral and earth 380 400 440V 3 phase 50Hz earth but no neutral 220 230 240V 1 phase 50Hz neutral and earth 220 230 240V 3 phase 50Hz earth but no neutral US Voltage 120V 1 phase 60Hz 240V 1 phase 60Hz Control Voltage 24V ac 50Hz Power Consumption 350VA Air Supply Pusher and Retracting Reject Optimum Pressure 80 psi 5 5 bar Minimum Pressure 65 psi 4 5 bar Maximum...

Page 39: ...ector Head in a logical sequence The following sub sections provide more information Warnings A list of applicable safety warnings to be observed when installing the metal detector head is provided Receiving and Unpacking Some basic checks should be carried out on receipt of the machine to ensure that it has not been damaged in transit Moving the Detector Head Depending on the size and weight of t...

Page 40: ...ng the detector head please follow the guidance included in the Moving the Detector Head section Unpacking the Detector Head Remove all packing and retain in case the detector head has to be repacked for return 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 ...

Page 41: ...cation 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 Carefully move the pallet to the required location Lower the forks and withdraw them from the pallet 31 ...

Page 42: ...ns 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 water or condensation 32 ...

Page 43: ...Installation 33 ...

Page 44: ...joints are preferred where possible as are finger joints for thicker belts Where modular belts are used joining rods must be non metallic 7 Rollers should be of a substantial construction to prevent bowing and crowned where applicable to help belt tracking on non modular belting 8 Rollers can be PVC coated steel or aluminium or manufactured in a good quality stainless steel 9 Rollers must be insul...

Page 45: ...tector is a radio frequency RF transmitter and receiver device that sets up an electromagnetic field in the head aperture The stainless steel case acts as a screen to prevent external metal or electrical or magnetic fields affecting the search coil assembly and to retain the field within the case However because there is an opening aperture through which the product to be inspected must pass some ...

Page 46: ...f is at some distance away from the head aperture 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 of the head aperture Conductive Products and Mounting Heads Vertically When mounti...

Page 47: ...elt Belt tracking systems should be easily adjustable Crowned rollers can help tracking with non modular belt types Always ensure that modular belt jointing pins are non metallic Skid Plate It is important that the belt does not touch the bottom or sides of the detector aperture The belt must be supported through the aperture by a non metallic material Materials that can generate high levels of st...

Page 48: ...ndependent of any other equipment and have a good ground earth connection Power cabling must be rated at no less than 5A current carrying capability and be routed into the control box area through one of the four gland entry holes provided Power cabling for a UL approved detector is 20 16AWG fed from a locally positioned switch or power breaker that is within easy reach of the operator The breaker...

Page 49: ...s not used A suitable earth conductor is also to be fitted 5 Crimp connectors onto the wires and connect to the Mains Filter as specified in the table below 6 Check that all connections are secure then refit the metal cover plate and front cover Ensure that the front panel cover fixing bolts have been tightened to 4Nm torque to maintain the integrity of the IP69K rating for the head preventing ing...

Page 50: ... longer connecting cable 2 6 m which is available from Loma under part number 419343 To power external sensors and PECs jumper JP7 on the mini control board is used to set the output voltage provided by the mini control board to either 12V or 24V as required When the jumper is set to the VEXT position 24V is provided on TBA2 Pin 6 When the jumper is set to the 12V VP position 12V is provided on TB...

Page 51: ... fork lift truck will be required to lift and move it into the final location This section provides some guidance for moving the system safely Adjusting Levelling the Conveyor For systems supplied that incorporate a conveyor the operating height may need to be adjusted so that it can be integrated into your production line This section provides some guidance for levelling the system Clearance Requ...

Page 52: ...E NOISE 7 HEAVY EQUIPMENT 8 LIFTING THE MACHINE 9 MOVING THE MACHINE 10 CONTAMINANTS For details see the Safety Warnings section The following emergency procedures apply to these procedures 2 DEALING WITH FIRE For details see the Emergency Procedures section Receiving and Unpacking Receiving the machine On receipt of your Loma inspection machine we recommend that you check the external packing for...

Page 53: ...When a machine fitted with wheels is to be pushed on the wheels it is important that it is moved carefully Avoid hitting obstacles with the wheels as this can damage the plastic wheel inserts inside the legs Using a Crane Position the straps under the frame and around the machine so that it will not tilt when lifted Then attach the straps to the crane Lift the machine carefully and move it to the ...

Page 54: ... the following components o Isolator Switch The external air supply is connected to the switch which is used to turn the supply to the system on and off The air supply is then fed into the Air Regulator o Air Regulator The air regulator is used to set the air pressure being supplied to the system A drain trap is provided to remove any water that collects in the system See the Maintenance section f...

Page 55: ...g 10mm O D tubing and set the air pressure using the regulator The air pressure should be set to 80psi 5 5 bar except when being used to supply an air blast reject device when the pressure should be set to 100psi 6 9 bar The minimum air pressure must not fall below 65psi 4 5 bar when the reject operates Care should be taken when cutting the compressed air supply tube to length before fitting to en...

Page 56: ...n viewed from the rear Beneath it on the bottom of the cabinet is the cable gland access for the power cable 3 Push the supply cable up into the Electrical Services Box through the cable gland 4 Split the cable inside the box and cut the wires to suitable lengths An armoured braided cable is recommended when cable conduit is not used A suitable earth conductor is also to be fitted 5 Crimp connecto...

Page 57: ...t the infeed and outfeed areas of the conveyor are clear of obstructions Checking Belt Tracking PV belt system only The belt must be checked for correct tracking before running the conveyor for any length of time If belt tracking needs to be reset See Conveyor Belt Maintenance for further details Setting Up Reject Mechanisms The conveyor system is supplied with the reject mechanism correctly set u...

Page 58: ...he field wiring is suitably hard It is still necessary however to ensure that the machine is not subjected to excessive electrical noise via its supply or airborne sources Selection of Frequency Band If two or more metal detectors sited within the same area are operating at the same frequency then they will interfere with each other leading to false rejects and unstable operation To overcome this ...

Page 59: ...eel conduit or use other techniques to ensure 100 screening of the cable Always follow the speed controller manufacturer s instructions for installation wiring screening and grounding In addition to following these guidelines most speed controller manufacturers supply input and output filters which can be fitted to the field wiring to dramatically reduce RF emissions if necessary All Loma metal de...

Page 60: ...Installation THIS PAGE IS INTENTIONALLY LEFT BLANK 50 ...

Page 61: ...nd user traceability Its breakthrough innovations including a new touch screen display can be easily retrofitted to older product versions on request 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 The items numbered i...

Page 62: ...ctor features and allow the setup and calibration of the system through a menu driven user interface The user interface can be mounted remotely as an option USB Connector Socket A USB connector socket is fitted on the right hand side of the control panel A USB memory stick can be used to download reports and logs from the system It can also be used when upgrading the system software version The US...

Page 63: ...ork as the metal detector This allows personnel to analyse and archive data O LomaLink serial link board required A serial connection is used to communicate with the metal detector using a remote PC o Ethernet serial link ethernet boards required O LomaOPC serial link ethernet boards required The LomaOPC application is installed onto a remote PC and a serial connection established to pass data usi...

Page 64: ...d joined by plastic hinge rods The following table gives details of the three different plastic modular belt types supplied by Loma Belt Type Design Applications Flat top Smooth closed surface Wrapped or loose products Flush grid Open grid pattern with a smooth surface Boxed or wrapped products Lightweight flush grid Open grid pattern with a smooth surface Boxed or wrapped products 54 ...

Page 65: ...ce uses compressed air to activate a carriage declining mechanism which guides the contaminated product into a reject bin mounted on the underside of the conveyor The carriage then returns to its original position Signal Only Alternatively a conveyor can be supplied without a reject device but with Signal Only output On detection of metallic contaminant in the product the control unit provides an ...

Page 66: ...e Plough reject device sometimes referred to as the diverter is suitable for removing cylindrical products being presented at a low rate from your production line An acetyl blade driven by a blast of high pressure compressed air moves across the conveyor belt to divert the contaminated product off of the conveyor belt and into a reject bin Plough reject devices are suitable for use with systems wh...

Page 67: ...ails if a PLC version is supplied The door of the box is fitted with the Isolator Switch Conveyor Stop and Start buttons and the Emergency Stop button as described in the table below The Isolator Switch is located on the front of the Electrical Services Box and is shown here in the ON position Power is being supplied to the machine The Isolator Switch is shown here in the OFF position Power is NOT...

Page 68: ...Confirmation with Photo eye O O O Lockable Reject Bin Monitoring O O O Pack Check Photo eye O O O S Standard fitting O Optional fitting The options are described in the following sections Audible Alarm The alarm sounds when a contaminated product is detected The maximum volume of the alarm lies in the range of 110 to 125 decibels dB at 1 metre but the level can be adjusted Bin Full Photo eye Warns...

Page 69: ...he side of the conveyor It is used to register the position of the products on the conveyor As an option the photo eye may be mounted directly above the belt This is particularly suitable for the registration of products that have very little depth PVS Indicator Lamp Illuminates when a pre programmed Performance Validation System test is required The normal colour is blue but it can be white if th...

Page 70: ...About the Metal Detector Range THIS PAGE IS INTENTIONALLY LEFT BLANK 60 ...

Page 71: ...pe describing how to start and stop the machine including stopping the machine in an emergency User Interface The IQ 3 Metal Detector provides a two line display user interface shown below in conjunction with a number of buttons that enable you to navigate to system options and make changes as required Operator Keys Cancel Key When this key is selected the display navigates back to the previous di...

Page 72: ... the currently selected product It also shows the top level Menus option Bargraph Display The bargraph display shows the signal in bargraph form with the threshold point represented by a fixed vertical bar approximately three quarters of the way along the display Using the Menus The options for setting up learning a product and checking the operation of the metal detector are accessed through the ...

Page 73: ...need to press the OK Enter Key for all available characters so if you haven t used them all you must keep pressing the OK Enter Key until the asterisk appears at the beginning of the option display to indicate that all characters have been selected Electrical Services Box When the IQ 3 Metal Detector head is supplied fitted to a Loma conveyor the following switches and buttons are also provided mo...

Page 74: ...Getting Started IQ3 Dual Line Display Menu Map 64 ...

Page 75: ...features to carry out routine product inspections and remove any contaminated products from the production line Supervisor This level of access is aimed at supervisors who need to use the machine functionality and features to manage the selection and inspection of a range of products It also includes access to features and functionality available to the Operator user Quality This level of access i...

Page 76: ...he first password number for editing 4 Use the Scroll buttons to select the required password number 5 Press the Tick button twice to confirm the selection and display the second password number for editing 6 Use the Scroll buttons to select the required password number 7 Press the Tick button twice to confirm the selection and display the third password number for editing 8 Use the Scroll buttons...

Page 77: ...is connected to a suitable power supply and if a pneumatic reject device is fitted a suitable air supply 2 Turn the Isolator Switch located on the Electrical Services Box in a clockwise direction This will switch on the electrical supply to the machine 3 The machine will then load its operating software and display the software version details in the 2 line display 4 Once the software has been loa...

Page 78: ...Stop button located in the centre under the user display The conveyor will then automatically stop Starting the Machine after an Emergency Stop To start the machine after an emergency stop proceed as follows 1 Ensure that any issue that caused you to stop the machine has been cleared 2 Turn the red Emergency Stop button clockwise to release the button which will then pop out to its original positi...

Page 79: ...s Effective removal of contaminated products from the production line to ensure that they are not delivered to customers is an essential part of the inspection process Getting the Results The IQ 3 Metal Detector has built in inspection settings to achieve the best detection results for a wide range of product types including those that create no product effect Frequency Selection Although the dete...

Page 80: ...ncluded because sensitivity is generally poorer than to other non ferrous contamination due to the relative conductivity of the material The wands are supplied in a range of sizes depending on the product type being inspected In dry running the sensitivity can be measured by placing the test wand at the trailing and leading edges of a representative sample of the product and then passing the produ...

Page 81: ...thin which enforcement authorities may instigate legal proceedings after notification of a complaint Handling Rejected Products A reject collection device such as a reject bin will typically be used to prevent contaminating products from being mixed with uncontaminated products Any rejected product should be kept segregated for later examination Never let your bin overfill It is advisable to exami...

Page 82: ...hat the optimum frequency can be chosen for any given product Generally dry products run at high frequencies but more conductive and non uniform products run at low frequencies The frequencies are split into 10 bands as shown in the table below This resolves any issues with cross talk between two metal detectors working in close proximity By setting one detector to use the available frequencies in...

Page 83: ... detector It is important that this is synchronised with other production equipment to assist with any investigations Setting the Language This section describes how to set the language to be used by the detector A wide range of languages are available for selection and the process is very simple Setting the Machine ID This section describes how to set a unique name number identifier for the metal...

Page 84: ...hen press the OK Enter Key to confirm the selection Setting the Machine ID The Machine ID is printed out on any Reports or Logs and can be edited to a convenient name to allow them to be easily associated to a machine Up to six characters either letters or numbers may be entered To set the Machine ID proceed as follows 1 Select Menus Machine details to display the Machine details menu options 2 Us...

Page 85: ...el password to be entered 3 Use the Navigation Keys to select the required first number and then press the OK Enter Key to confirm the selection This will then automatically select the second number for editing 4 Repeat step 3 until you have selected and confirmed each number required for the Operator user access level password Up to four numbers may be used 5 Once you have entered the required pa...

Page 86: ...h Head Setting Up the Conveyor Setting Up the Service Options Setting the VF Balance Setting the VF Drive Setting Up the User Options Setting Up Serial Links Performing a Ferrite Tune Setting Up Product Signal Tracking Setting Up the Reject Options Setting Up the Search Head To set up the search head proceed as follows 1 Select Menus Service Configuration Head to display the Head menu options whic...

Page 87: ...ble of 31KHz This of course can be changed to whichever frequency it is desired to start from When banding is set then it is recommended to set the default frequency as suggested by the following O Aperture dimension in the range of 75 125mm depending upon the band selected use the 405kHz upwards range o Aperture dimension in the range of 150 200mm depending upon the band selected use the 300kHz u...

Page 88: ...en press the OK Enter Key to confirm the selection 4 Repeat step 2 and 3 until you have selected and confirmed values for each option The System menu options available are as follows Photoeye This option refers to the optional Product Registration Photo eye that is located on the infeed of the conveyor When the option is enabled the photo eye acts as a timing start point for both correct detection...

Page 89: ...des timing pulses to the detector electronics whilst the conveyor is running A CTB constant entry field and an option to log speed problems will be visible When selected both reject delay in distance and dwell timing in time or distance must be set in the Rejects Setup screen O Freerun Select this option when there is no transport system in use other than the effects of gravity When selected the r...

Page 90: ...tly on how much the product signal deviates from the Learnt product reference Use this option where there is a high level of environmental noise O Standard The resultant signal is produced using a tuned detection filter This is the standard method of detection for conveyor and pipeline heads For reactive product the Rate option can give enhanced performance O Wide This detection filter is used whe...

Page 91: ...have selected and confirmed values for each option The Service Options menu contains the following options Tracker Enabling the Tracker functionality allows product threshold values to follow any changes in measured product effect This option is only available when a product registration photo eye is in use See Enabling the Tracker Feature for further details Reject time Selecting this option enab...

Page 92: ...t contain the toy are to be rejected Note that a Product Registration Photo eye must be fitted to use this option Access Filter If this option is selected then the Detection Filter option is included for selection in the Menus Learn Set Up menu Setting the VF Balance Setting the balance on the raw P and Q channels for all available operating frequencies to maximise sensitivity of the detector is c...

Page 93: ...o select the signal size that is injected into each channel to balance them out These values are automatically set for the selected frequency by the software when the AutoBalance feature is used The potentiometer positions can be manually adjusted within this menu but this is not recommended Balance setpoint The target value for the balance between the P and Q channels is displayed The default val...

Page 94: ...or each option The Drive Settings menu contains the following options Frequency The IQ 3 has seventy 70 different operating frequencies ranging from 31kHz up to 882kHz Each of the available frequencies can be selected from the drop down list Note that the frequency selected in this menu is independent of the frequency for the currently running product Drive On The drive on time for the selected op...

Page 95: ...configuration progress is displayed and will close automatically upon completion Configure current This entry sets the target transmitter drive current that the auto configure process will use subject to a maximum figure of 350mA For conveyor detectors using the standard board the default value is 230mA For conveyor detectors using the auto balance board the default value is 350mA Setting Up the U...

Page 96: ...e connection is going to be used Four options are available which are described below O Not used Select this option if you do not wish to use a serial connection O Lomalink Select this option if you wish to create a connection with the LomaLink application for two way communication and control LomaLink enables data to be requested from and sent to the metal detector and enables remote control of t...

Page 97: ... the detector head and is provided with the head to enable future Ferrite Tunes to be carried out To avoid it being lost the Ferrite Wand is stored inside of the detector head control panel fixed to the back wall of the panel You can remove it by twisting the wand which disengages the plastic retaining latch The wand can then be removed from the control panel and the panel refitted before carrying...

Page 98: ... the change in product effect For instance for a frozen product the product effect is very small when the product has just come out of the freezer allowing a low working threshold level to be used giving a high sensitivity to metal contaminants However if the line stops for any reason then the product could thaw slightly or if the product were not fully frozen a significant product signal increase...

Page 99: ...ons 2 Use the Navigation Keys to select the Tracker option and press the OK Enter Key to enable the current value to be edited 3 Use the Navigation Keys to select the YES option then press the OK Enter Key to confirm the selection 4 Repeat steps 2 and 3 above to select the required values for the Month Day Date Hours and Minutes options To set the parameters to be used by the tracker feature proce...

Page 100: ...It is strongly advised to set this value to just greater than the typical amount by which the product signal is expected to change All signals that exceed this value will be rejected o Max limit lock Once the Max limit value for the product signal has been entered the value can be locked to prevent an automatic change during a re Learn process o Adjustment This option is used to set a percentage b...

Page 101: ...l to the reject device where upon the reject device state is toggled The Reject dwell option will not be displayed for configuration in the Menus Service Options menu as it is not used o Dwell Extension If this option is selected when a contaminated product is detected the reject device is immediately activated and stays activated for a time equal to the reject dwell time If a second reject produc...

Page 102: ...lled Bin full Enable this option if a bin full sensor has been fitted to your system This sensor is fitted inside the bin towards the top As contaminated products stack up inside the bin once they break the sensor beam a system fault is generated to warn the operator that the bin must be emptied Double bag Select this option to reject products if the length is longer than expected For example bags...

Page 103: ...ct this option if you are sure that the product will exhibit no product effect The detector will then use the pre set ferrite phase angle rather than learn from the actual product If during the product Learn process a product effect is exhibited the detector will advise that the Learn process has failed You should then set the Product type to Unknown and repeat the learn process O Metal film Selec...

Page 104: ...ject collection device It must therefore be set to ensure clean removal of the contaminated product Please read through the information contained in the Reject delay section above for further guidance Reject timings may also be set in the Menus Service Reject Set Up menu Enter the reject dwell time in seconds or for variable speed systems enter the distance in metres PVS Test Select this option if...

Page 105: ...des an explanation for each one Full Learn Prior to carrying out a Full 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 Change menu before continuing To perform a Full Learn for a product procee...

Page 106: ...r Key to start the Update Learn process The name and number of the product being learnt are displayed 3 A WAIT message is then displayed 4 This is followed by a PASS PRODUCT message 5 When the PASS PRODUCT message is displayed start to pass products through the detector 6 A Learning message is then displayed along with a number which signifies either the time in seconds remaining to pass products ...

Page 107: ...his message indicates that the product signal being received exceeds the Max Threshold option value set in the Menus Learn Set Up menu This could be because the sample pack being used contains a contaminant or the Max Threshold option value has been set too low Check that the sample packs being used are representative of production packs For example if a frozen product is being learnt are the samp...

Page 108: ...Learnt is automatically selected If the option is not enabled then the Frequency to be used can be manually selected in the Frequency option Frequency The operating frequency for the detector assigned to a product memory is displayed or can be selected when operating manually Working mode The level of transmitter power is selected here by selecting options of P Mode Q Mode or Dry The mode is autom...

Page 109: ...r result Head Enabling this option locks the Head drive setting thus preventing the detector from changing it during a Full Learn process Head P gain The signal level of the P channel in phase signal is adjusted here The adjustment is made automatically during a Full Learn process based on the product effect on the electromagnetic field Manual adjustment is not recommended unless absolutely necess...

Page 110: ...ptions available are as follows PQ Gain This option is used to set the initial P and Q gain levels to be used when starting a Full Learn process Options of Min Low Med and Max are available for selection with Max being the default value RF Gain This option is used to set the initial RF gain level to be used when starting a Full Learn process Tap the arrow to the right of the field to display a dro...

Page 111: ... Registration Photo eye is NOT fitted selecting this option means that when a Learn process is started the system requests that you pass packs product samples through the detector for a period of 60 seconds The time remaining to pass packs is displayed on the screen Once the time available has reduced to zero the screen closes Tolerance This option is used to add a percentage safety margin to the ...

Page 112: ...ce Options menu The Menus Set Up PV Test Set Up menu will then become available A series of options the allow you to specify how the performance validation test operates and these are described below The PV Test Set Up menu is not available if the Reverse Mode option has been set to YES in the Menus Service Options menu To set up PV testing proceed as follows 1 Select Menus Set Up PV Test Set Up t...

Page 113: ... have all passed inspection and the test is complete Timing The following options are available for setting the test timing to be used O Off Selecting this option means that the user will initiate a PV test manually from the Menus Run PV Test menu O Interval Selecting this option means that the user will be automatically prompted to initiate a PV test after a specified time subject to a minimum in...

Page 114: ...ption value blank if this test piece should not be used as part of the PV test Non Fe Test In this option you can enter the non ferrous brass test piece size in mm to be used for PV testing Leave the option value blank if this test piece should not be used as part of the PV test St Steel Test In this option you can enter the stainless steel normally 304 annealed test piece size in mm to be used fo...

Page 115: ...nd size of the first test wand to be used previously specified in the PV Test Set Up menu Note that if no test sample sizes have been programmed then the display will show No Samples and a report will be produced immediately 4 You will then be prompted to pass test sample packs through the detector until the FE test is complete 5 Follow the prompts to repeat steps 3 and 4 for the NFE and SS tests ...

Page 116: ...Operating Instructions THIS PAGE IS INTENTIONALLY LEFT BLANK 106 ...

Page 117: ...alues for each option The Report Options menu provides the following options Form Feed When this option is enabled a page break is included between each report being printed Options of YES enabled and NO disabled are provided for selection Carriage Return When this option is enabled each report is started at the beginning of the next new line Options of YES enabled and NO disabled are provided for...

Page 118: ...reduce production down time Running the Report To run the report navigate to the Menus Logs Errors menu scroll down to the Errors Report menu option and then press the OK Enter Key The report will then be generated and sent over the serial link to the connected device Report Contents The report contains a list of the last run errors recorded up to a maximum of 20 under the following column heading...

Page 119: ...e the belt speed in the Menus Service Configuration System menu Problem Speed too slow belt speed is less than the lower limit for filter resistors coil gap and belt speed combination Variable speed systems only o Action Increase the belt speed in the Menus Service Configuration System menu Problem Rejects too close the reject system is still counting out the dwell for a reject when the next pack ...

Page 120: ...on This report is useful for monitoring the types of faults being generated that interrupt production and looking for potential trends so that improvements may be made to reduce production down time Running the Report To run the report navigate to the Menus Logs Faults menu scroll down to the Faults Report menu option and then press the OK Enter Key The report will then be generated and sent over ...

Page 121: ...u If the pack has not been correctly rejected the transport system will have stopped 1 Collect and remove from the line all product s both in the aperture and after the detector If there is any possibility that the contaminated product may have left the detector transport system then any possible contaminated product beyond the detector transport will need to be cleared as well It is advised that ...

Page 122: ...e detector and LomaLink PC or other controlling device for loose or broken wiring connectors Problem PV test timeout an automated prompt for the PV test has either not been actioned or completed within the window time set The transport system may have stopped o Action Clear system fault restart the transport if stopped and perform a PV test Problem PEC obstructed the product registration photo eye...

Page 123: ... the report navigate to the Menus Set Up Product menu scroll down to the Setup Report menu option and then press the OK Enter Key The report will then be generated and sent over the serial link to the connected device Report Contents The report contains information for the machine and currently selected product in several sections as described below Product Details Report This section contains som...

Page 124: ...Enter Key The report will then be generated and sent over the serial link to the connected device Report Contents The report contains a list of the last inspection records where contaminants were detected up to a maximum of 20 under the following column headings Date Displays the date that the report was generated Time Displays the time that the report was generated Machine Identification Displays...

Page 125: ... completed Report Contents The report contains some general information and a list of the options available in the Menus Learn Set Up menu with their associated values and selections Time Displays the time that the report was generated Date Displays the date that the report was generated Machine Identification Displays the machine ID Product Number Displays the product number Product type Displays...

Page 126: ...the detector for the batch Number of good packs Displays the number of packs accepted Number of bad packs Displays the number of packs rejected Maximum Signal Displays the maximum product signal detected for the batch Average Signal All Displays the average product signal detected for all packs passed through the detector for the batch Average Signal Good Displays the average product signal detect...

Page 127: ...ort The report is automatically created and sent over the serial link to the connected device each time a Batch is completed Batch completion may be automatically triggered by expiry of a time period or inspection of a specified number of packs This is set up in the Menus Set Up Batch Control menu Batch completion may also be manually triggered by resetting the batch data in the Menus Results menu...

Page 128: ...plays the time that the shift finished Shift duration Displays the time in hours and minutes that the shift lasted Number of good packs Displays the number of accepted packs inspected during the shift Number of bad packs Displays the number of rejected packs inspected during the shift Contaminants Log Purpose The Contaminants Log contains records of reject activity which is useful for monitoring a...

Page 129: ... select the Contaminants option 2 Use the Scroll buttons to display the Clear Contaminants Log menu option 3 Press the OK Enter Key to select the option The Contaminants log will be automatically cleared and the message Contaminants cleared is displayed Errors Log Purpose Run errors are classified as non serious but may require an operator s attention When generated the attention relay operates an...

Page 130: ...aring the Log To clear the Errors log proceed as follows 1 Select Menus Logs to display the Logs menu and select the Errors option 2 Use the Navigation Keys to display the Clear Errors Log menu option 3 Press the OK Enter Key to select the option The Errors log will be automatically cleared and the message Errors cleared is displayed Faults Log Purpose System faults are classified as serious and r...

Page 131: ...ct the Faults option 2 Use the Navigation Keys to display the Faults Log Report menu option 3 Press the OK Enter Key to select the option The report will then be generated and sent over the serial link to the connected device Clearing a Fault To clear a Fault proceed as follows 1 Select Menus Logs to display the Logs menu and select the Faults option 2 Use the Navigation Keys to display the Clear ...

Page 132: ...er of entries is briefly displayed 5 Use the Navigation Keys to scroll through each of the available log entries 7 Each entry is displayed in turn and contains four lines of information for each one 8 The first line displays the Product number the second line displays the Rejects number the third line displays the Time and the fourth line displays the Date Printing the Batch Report To print a copy...

Page 133: ...n Keys to scroll through each of the available log entries 7 Each entry is displayed in turn and contains four lines of information for each one 8 The first line displays the Product number the second line displays the PVS title the third line displays the Time and the fourth line displays the Date Printing the PVS Report To print a copy of the PVS Report proceed as follows 1 Select Menus Logs to ...

Page 134: ...l overwrite the oldest entry 5 Use the Navigation Keys to scroll through each of the available log entries 7 Each entry is displayed in turn and contains five lines of information for each one 8 The first line displays the Accepts number the second line displays the Rejects number the third line displays the Finish time the fourth line displays the Duration and the fifth line displays the Date Pri...

Page 135: ...ining the compressed air regulator Conveyor Belt Maintenance This section provides some guidance covering maintaining the conveyor belt Adjusting the Reject Devices This section provides some guidance covering adjustment of the reject devices Software Upgrades This section provides some guidance for upgrading the metal detector software Maintenance Warnings The following safety warnings apply when...

Page 136: ... less rigorous Prior to starting cleaning procedures ensure that the head control panel cover fixing screws have been tightened to 4Nm torque to maintain the integrity of the IP69K rating for the head preventing ingress of water or condensation Belt conveyor versions Isolate the electrical and pneumatic supplies to the conveyor If your conveyor system uses a harsh construction search head white pl...

Page 137: ...f the plastic hinge pins that are used to join the sections of the belt together that require changing If you do not clamp the belt it will roll off the loose sprockets when you remove the pin Carefully slide out the plastic hinge pins and remove the section of belt to be replaced Carefully interlock the new section of the belt Make sure the belt is located on the drive sprocket and correctly enga...

Page 138: ...tains the operating software for the metal detector The s in the file name signifies that it can be installed on systems that only have 2 x 2 MB 4 MB flash ROMs fitted in positions U1 and U2 on the Control Board IQ3_vX X X X hex This file contains the operating software for the metal detector It can be installed on systems that have an 8 MB flash ROM fitted in position U5 on the Control Board IQ3_...

Page 139: ...screen Method 3 Tap on the Software icon in the System Settings screen to display the Software screen Then scroll down to the bottom of the screen and tap on the Exit IQ software button 9 Load the Explore task on the IQ panel using one of the following methods Method 1 Plug in a USB keyboard and press Windows E Method 2 Double click My Device on the desktop 10 Navigate to the FFSDISK IQ3_GUI folde...

Page 140: ...Maintenance THIS PAGE IS INTENTIONALLY LEFT BLANK 130 ...

Page 141: ...to identify and reject contaminated products Electromagnetic Field An invisible electrical field emanating from a transmitter coil This field is generated by the flow of alternating oscillator frequency current around the transmitter coil s windings F False Triggering Product rejects caused by external effects and not by a contaminant in the product itself Ferrous A metal mainly composed of iron w...

Page 142: ...t can be seen by the metal detector R Reject A product containing a detected metal contaminant that has been removed from the production line by the metal detector S Serial Link A network connection which allows the metal detector to communicate with another device connected to the network Shaft Encoder A device fitted to variable speed conveyors to enhance accuracy of the reject timing Stainless ...

Page 143: ...tion of Conformity 18 Electrical Services Box 57 Emergency Procedures 24 Enabling the Tracker Feature IQ3 89 End of Life Treatment 24 End User Licence Agreement 26 Errors Log 119 Errors Report 108 Establishing a Good Product Learn 70 Establishing Detector Performance 70 F Faults Log 120 Faults Report 110 Frequency Selection 72 Full Learn 95 G Getting the Results 72 Good Practice 69 Guards 57 H Han...

Page 144: ...Q3 73 Setting the VF Balance IQ3 82 Setting the VF Drive IQ3 84 Setting Up PV Testing 102 Setting Up Reject Mechanisms 47 Setting Up Serial Links IQ3 86 Setting Up the Conveyor IQ3 78 Setting Up the Metal Detector IQ3 73 Setting Up the Reject Options IQ3 90 Setting Up the Search Head IQ3 76 Setting Up the Service Options IQ3 81 Setting Up the User Options IQ3 85 Setting User Access Levels and Pass...

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