Loma IQ2 Service Manual Download

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Loma Systems

Loma IQ

Service Manual

Part No 814119, Issue Level K 19/02/03

LOMA IQ

Service Manual

Search Head and Controls

Contents

Open Flash Memory Programming Supplement

(only if present)

Amendment Record

on page 2

Summary of Contents for IQ2

Page 1: ...tems Loma IQ 2 Service Manual Part No 814119 Issue Level K 19 02 03 LOMA IQ2 Service Manual Search Head and Controls Contents Open Flash Memory Programming Supplement only if present Amendment Record on page 2 ...

Page 2: ...n added on 12v DC protection fuses Locations added to figure 2 F 9095 Reference to 12v Dc protection fuses added to DC rail checks F 11050 New control psu board and protection fuse part numbers added to spare parts list F Flash Step 9 re written to recommend a cold start after flash memory programming is completed F 7026 38mm Pharmaceutical aperture size corrected G 8023 Voltage free relay contact...

Page 3: ...ual frequency Auxiliary Aux relay menu positions added K 7026 Catalogue freefall ferrous in foil coil gaps added K 7026 Details of new trend type tracker added K 8023 Dual frequency information aded K 9095 Dual frequency balance phase integrity checks added K 11050 Dual frequency board part numbers added K ...

Page 4: ... Service Centres 2 Cautionary Advice 3 Product Description Environment 4 Fault and Error Diagnosis 5 Configuration Setup 6 Maintenance 7 Functional Testing 8 Wiring Connection Diagrams 9 Spare Parts Lists 10 Service Returns Form ...

Page 5: ...enweg 22 5708 HR Helmond Netherlands Telephone 31 0 492 573573 Fax 31 0 492 573570 E mail info lomasystems com FRANCE Loma Systems BV Panovenweg 22 5708 HR Helmond Netherlands Telephone 33 0 1 55695777 Fax 33 0 1 55174331 E mail info lomasystems com GERMANY Loma Systems BV Panovenweg 22 5708 HR Helmond Netherlands Telephone 49 0 69 50070357 Fax 49 0 69 50070405 E mail info lomasystems com USA SOUT...

Page 6: ...d Netherlands Tel Service 33 0 1 55695778 GERMANY Loma Systems BV Panovenweg 22 5708 HR Helmond Netherlands Tel Service 49 0 69 50070358 USA and SOUTH AMERICA Loma International Inc 283 East Lies Road Carol Stream Illinois 60188 USA Telephone 1 800 USA LOMA 1 630 588 0900 Fax 1 630 588 1396 CANADA Loma Canada Limited 333 Wyecroft Road Unit 2 Oakville Ontario Canada L6K 2H2 Telephone 1 800 387 7987...

Page 7: ...dule 4004 2 1 CAUTIONARY ADVICE CONTENTS Safety Warnings 2 Lethal Hazard Electrical Supplies 2 Working on Equipment 2 Lifting Equipment 2 Moving a Search Head 2 Using a Crane 3 Using a Fork Lift Truck 3 Dealing with Fire 3 ...

Page 8: ...e equipment with electrical 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 voltages 3 LIFTING EQUIPMENT Use only the correct slings and lifting tackle to move heavy items of equipment described in this manual Inspect all slings and lifting tackle prior ...

Page 9: ...it cannot tilt Raise the lift sufficiently to lift the head clear of the ground and any obstacles b Carefully move the head to the required location c Lower the forks and withdraw them from the head Dealing With Fire 4 In the unlikely event of fire occurring in an item of equipment manufactured by Loma Engineering it is important that a fire extinguisher containing the correct type of extinguishin...

Page 10: ...d Environment Module 5092 3 1 PRODUCT DESCRIPTION AND ENVIRONMENT CONTENTS Search Head and Control Unit Technical Specification 2 Electrical Supplies 3 Spurious Triggering 3 EMC Interference 4 Radio Frequency Interference 5 ...

Page 11: ...al detectors As standard the control unit is secured at the end of the search head This unit enables suitably trained personnel to set up change calibrate and obtain results from the system through a menu driven user interface The control board can be fitted with an optional board providing the following serial link options 1 x RS232 hardware hand shaking 1 x 20ma current loop and 1 x RS422 both s...

Page 12: ...ds Control unit connection details can be found in the Connecting to a Power Source on page 12 in the Maintenance section of this manual For specific wiring connection information including any conveyor wiring diagrams please refer to the Wiring Diagrams package in your Customised User Manual Spurious Triggering The Loma range of Metal Detectors is the product of many years experience and developm...

Page 13: ...trical noise via its supply or airborne radiated sources Guidance on EMC Considerations when installing your equipment is given in your User Manual However as a first step to eliminating EMC interference the following considerations should be checked Electrical supply considerations The unit should have its own dedicated supply unless the line supply was known to be clean The earth should be robus...

Page 14: ...ise in the general vicinity of the detector location While those frequencies not close to the operating frequency of the detector will usually be filtered out this includes most walkie talkie frequencies unless the transmitter is held very close to the detector aperture It is not uncommon for the control frequency or a multiple of it used in modern speed controllers to cause interference To reduce...

Page 15: ...been increasingly problematic because they can severely interfere with general purpose metal detectors of all types and operating frequencies The interference occurs whenever the talk button is pressed or released resulting in on occasion very high signal readings often in the thousands leading to false triggering of the detector This effect can be eliminated by the addition of extra screening wit...

Page 16: ...Fault and Error Diagnosis Module 6022 4 1 FAULT AND ERROR DIAGNOSIS CONTENTS Cold Start 2 Run Errors 3 System Faults 4 Diagnostic Errors 6 LomaLink Diagnostic Errors 6 ...

Page 17: ... would show the warning message Not detecting located at the top of the Configuration menu Message Cause Solution Not detecting Spurious cold start 1 Establish and repair the cause of the problem for example carry out checks on the power supply DC rails as described in DC Rails on page 7 section in the Functional Testing section of this manual 2 Re commission the control unit as described in the C...

Page 18: ...ject dwell time setting problem Variable speed systems only 1 Check reject delay and dwell time settings 24 Speed too fast Belt speed is greater than the upper limit for existing filter resistors coil gap and belt speed Variable speed systems only 1 Decrease belt speed 2 Change filter resistors to lower value Refer to Belt Speed on page 14 in the Configuration Setup section of this manual 25 Speed...

Page 19: ... described in DC Rails on page 7 the Functional Testing section of this manual 12v out of spec 12v rail is less than 11 40v 1 Check 12v rail as described in DC Rails on page 7 in the Functional Testing section of this manual Powered up Logged every time the system is powered up No action required Verdict too late A pack has arrived at the reject point before the detector has sent a reject decision...

Page 20: ...g and link connectors from remote device 2 Check LomaLink PC other controlling device for reported errors Link failure A break in communication between the detector and LomaLink PC other controlling device The operation of the detector is unaffected 1 Check cabling and link connectors from remote device 2 Check connections between the detector and LomaLink PC other controlling device for loose or ...

Page 21: ...tails associated with the error The log can be found under Loma Menu on page 21 details of which are later in this manual 2 Check 5V rail as described in DC Rails on page 7 section in the Functional Testing section of this manual 3 Perform a hardware cold start as described in Hardware Cold Starting on page 8 in the Configuration Setup section of this manual 4 Replace the control board 5 Contact y...

Page 22: ...ata set 1 Check the controlling device for reported errors Unkn dataset chg The detector has received a change message for an unknown data set 1 Check the controlling device for reported errors Unkn command no The detector has received a command message indicating an unknown command 1 Check the controlling device for reported errors ...

Page 23: ...ser Interface 3 Step by Step Configuration 4 Variable Speed Systems 11 Calculating CTB Constant 12 Head Power control lines 13 Belt Speed 14 PEC Length Calculation 20 Loma Menu 21 Machine Details Menu 24 Serial Links 25 Remote Sensor Board 31 Reports Logs Package Upgrade 32 Menu Definitions 34 Principles of Operation 41 ...

Page 24: ...Units Photo eye PEC length Belt speed DSP Speed mode Filter resist Autocal Tolerance System config report Dbug system LOMA USE ONLY View diagnostics LOMA USE ONLY Diagnostics report Clear diagnostics ADC setup menu Copy prod 1 Clear fault log Diagnostics ADC type R signal ADC X offset value ADC X offset sign ADC R offset X signal ADC R offset sign Update checksum Machine details for ______________...

Page 25: ...Down arrow Bar graph display mode only increase sensitivity Bar graph display mode only decrease sensitivity Lock keyboard Status LED s Symbol Function The Run Detect LED indicates the detector is searching for metal The Calibrate LED indicates the detector is performing a calibration cycle The Run Error LED indicates that a run error has been logged The System Fault LED indicates that a system fa...

Page 26: ...nfiguration guide the unit can easily be set up from scratch as required Alternatively if only small changes are required to the configuration of the machine then the menu entries within the Service menu can individually be adjusted Refer to your User Manual for detailed menu information At the start of this chapter is a menu map for the Service menu upon which configuration details for the machin...

Page 27: ...wo The correct parameters must now be entered into the configuration menu To gain access to the parameters use the and keys to move to the parameter then press the key to accept the command The and keys will alter the parameter notice how the moves to the right and becomes either or when the display is in parameter edit mode Once the correct parameter has been entered simply press the key again to...

Page 28: ...FIXED unless your system is variable speed or free running For variable speed systems select VBLE and for free running select FRUN If in doubt about the required selection refer to the Principles of Operation section Belt speed If fixed speed mode has been selected this entry will appear in which case enter the belt speed NOTE VBLE Will be used when the conveyor speed is variable or sometimes when...

Page 29: ... to flow and CF freefall 76mm 129mm catalogue freefall 93mm 173mm catalogue freefall 125mm 219mm catalogue freefall 174mm Handtmann style units 50mm 6000 7000 slimline combo 76mm 20mm pharmaceutical 25mm 38mm pharmaceutical 30mm Ferrous in Foil 76mm Table 1 Computation of coil gap by head type and minimum aperture dimension Step Three The detector must now be set up for the desired user options Un...

Page 30: ...out of run Set to YES or NO as required Normally left at NO Cal trigger Turn this ON or OFF as required Used with pipeline when pipeline option in configuration is selected Dual frequency Only used on rectangular square conveyor heads Set to YES when the detector is built as a dual frequency Setting to YES automatically fixes the function of the Auxiliary relay to DUAL Aux relay Normally left at t...

Page 31: ...le 7026 5 9 Step Four Move to the Reject options menu and set up the detector as required for your application Reject options on page 39 are listed in the Definitions section of this chapter Press the C key once to exit the Reject options menu ...

Page 32: ...de the control box Perform a ferrite tune as follows Change to product F the Access ferrite entry in the User Options menu must be set to YES To do this press the key then the key until Ferrite F is shown now press the key to accept the setting To calibrate Ferrite F a Full calibration cycle must be completed Before doing this check to see if the conveyor is fitted with a photoeye prior to the det...

Page 33: ...ariable speed conveyors special hardware is required to drive the CTB Conveyor Time Base input on the micro control card Conveyor systems supplied by LOMA will already have this hardware fitted and commissioned but on head only sales the following information should be observed when using variable speed Overview In order for the reject timing to work correctly it must be supplied with information ...

Page 34: ...B rate must not exceed 100 pulses per second The calculation to confirm this figure is as follows Maximum belt speed x CTB constant 100 60 The minimum allowable CTB rate to ensure accurate reject resolution must exceed 4 pulses per coil gap The coil gap distance for your detector Rx can be found on the serial number plate located inside the control unit or from the coil gap chart located earlier i...

Page 35: ...t therefore enabling the best calibration and subsequent metal contamination sensitivity to be set This is achieved by the use of electronic switches controlled by the software and hardware fitted on the control board The actual switches and the functions controlled are part of the search head electronics board located behind the removable end plate on every detector The setting of these switches ...

Page 36: ...resistor directly across the receiver search head amplifier Reduces both product signal and metal contaminant signal regardless of mode of operation Normally associated with metallised film packaging or products that have very large inconsistent product effects Control lines 1 2 4 Resistor values are standard factory set components that decrease in value therefore increasing their effect Control l...

Page 37: ...or is 150 mm 6 rounded and my conveyor speed is 50 m min 164 fpm rounded Therefore according to the table following I can use either 150 180 220 or 330 KΩ resistor packs A suggested rule of thumb is to select the value whose range sets the speed required roughly central The resistor pack is factory set according to the specified speed However if the speed of the conveyor is altered from the origin...

Page 38: ... 299 41 322 44 345 77 358 50 391 54 414 57 437 60 460 63 483 66 505 69 180 61 8 81 11 102 13 122 16 142 19 163 21 187 24 208 27 229 29 244 31 270 34 291 37 312 40 325 41 353 45 374 47 395 50 408 51 437 55 458 58 220 50 7 67 9 84 11 100 13 117 15 134 17 153 20 170 22 187 24 201 25 221 28 238 30 255 32 258 34 289 37 306 39 323 41 335 43 357 45 374 47 330 34 5 45 6 57 7 68 9 79 11 91 12 102 13 113 15...

Page 39: ...5 are in MΩ Ω Ω Ω PIPELINE APERTURE DIMENSION fixed speed maximum minimum Filter Value 90 100 Handtman n 112 130 140 150 82 12 57 8 103 15 119 17 129 18 180 74 10 52 7 93 12 108 14 116 15 220 61 8 42 6 76 10 88 12 95 12 330 40 6 28 4 51 7 58 8 63 8 470 28 4 19 3 35 5 41 6 44 6 750 17 3 12 2 22 3 25 4 27 4 1 13 2 9 2 16 3 19 3 20 3 1 5 9 2 6 1 11 2 13 2 14 3 PIPELINE APERTURE DIMENSION freerun maxi...

Page 40: ...vide by 25 4 and round to the nearest whole inch The speed is shown in metres per minute To convert to feet per minute multiply by 3 2808 The resistor values 68 to 750 are in KΩ Ω Ω Ω The resistor values 1 and 1 5 are in MΩ Ω Ω Ω 6000 7000 fixed or variable speed maximum minimum Filter Value 75 100 125 150 175 150 87 12 87 12 87 12 87 12 87 12 180 79 10 79 10 79 10 79 10 79 10 220 64 9 64 9 64 9 6...

Page 41: ...EST APERTURE DIMENSION or DIAMETER FREEFALL freerun maximum speed Filter Value 75 Contained Field all aperture diameters 100 125 150 175 200 225 250 275 300 325 68 165 209 220 275 330 385 441 496 551 606 661 716 120 93 117 125 156 187 218 250 281 312 343 375 406 150 75 95 100 125 150 175 200 225 250 275 300 325 180 63 79 83 104 124 145 166 187 208 229 249 270 220 51 64 68 85 103 119 136 153 170 18...

Page 42: ... are timed from the PEC Therefore it is important that the detector knows exactly how far the PEC is positioned from the final point in the detection process i e when the product has passed the farthest receiver coil When a PEC is used the distance from the PEC to the second receiver coil must be entered into the PEC length menu position The value entered can be in metric millimetres or imperial i...

Page 43: ...urn to Diagnostics View diagnostics Pressing to access Diagnostic error messages Clear diagnostics Pressing will clear down the Diagnostic error log Diagnostics report Pressing will transmit the contents of the log down the serial link if the Reports package is used Clear fault log Pressing will clear down the System error log provided the reports log package is fitted Copy product 1 Pressing will...

Page 44: ... channel offset value entry ADC R offset value A dc offset can be applied by entering a number Press to view the X channel offset direction ADC X offset sign The offset direction can be selected here either POS or NEG Press to view the R channel offset value entry ADC X offset value A dc offset can be applied by entering a number HOW TO ADJUST THE ADC The ADC setup menu positions allow the ambient...

Page 45: ...numbers observed after averaging are symmetrical then no adjustment is required Repeat for the X channel If the direction is biased one way then step down to the ADC R offset sign menu and select the direction that is in the opposite to the signal bias Step down to the ADC R channel value menu and enter the estimated number required to return symmetry to about 0v Return to the R signal menu and ob...

Page 46: ...or found on the serial number label located inside the control cabinet Or a line identification name or number Information is entered in the same manner as for Product name Software fitted The software version fitted to your detector is displayed Note The Software version fitted to your detector control board will also be displayed for approximately 0 5 seconds each time the detector is switched o...

Page 47: ...bly on page 30 unless initially supplied with your detector Please contact your local Group Service Centre with your requirements If the link is used to drive LomaLink then reference to the Serial Communications Handbook Loma is required to enable the correct interface protocol to be written This can be emailed to you upon request Link selection 20mA configuration settings and JP2 header and detec...

Page 48: ...terface as standard which is not compatible the chosen printer must have an optional RS422 serial interface supporting software handshaking fitted 20mA current loop The link is a 4 wire system supporting software handshaking The board has user configurable links LK1 2 depending upon whether the detector is to be the active or passive device the recommended setting is to make the detector active an...

Page 49: ...K1 TX OUT IN OUT IN OUT LK2 RX OUT IN OUT IN OUT Figure 9 20mA Configuration setting details JP2 Header Connector Link Type 16 Way Chassis Connector PIN FUNCTION RS232 RS422 20mA PIN COLOUR 1 Rx loop RX 14 Orange 2 Tx loop TX 11 Grey 3 Rx loop RX 3 White 4 Tx loop TX 13 Brown 5 Rx _422 RX 5 Violet 6 Rx_422 RX 6 Black 7 Tx_422 TX 7 Pink 8 Tx_422 TX 8 Yellow 9 Gnd GND 9 Green 10 Gnd GND 10 Green 11 ...

Page 50: ...e printer Press to accept When LomaLink or Reports is selected further menu entries within the link allow the protocol to be set Press the key to step down the menu below Baud rate 150 300 600 1200 2400 4800 9600 Data bits 7 or 8 Stop bits 1 1 5 OR 2 Parity ODD EVEN or NO Flow Ctrl NONE CTS RTS or XON XOFF Pressing the key in any menu position changes the to a use the keys to select entry required...

Page 51: ... will only locate one way round Refer to Figure 12 below Figure 12 Serial Link Board Location See figure 10 for connection information LK2 see figure 9 for link information LK1 see figure 9 for link information JP4 1 5 see figure 8 for link JP4 1 2 3 4 5 6 JP1 1 2 3 4 5 6 JP5 1 2 3 4 5 6 LK1 A B C D E LK2 A B C D E Serial link header board locates here Main control board JP1 Fixing pillar points ...

Page 52: ...gested that the connector be used as a template for marking out the hole positions prior to drilling When assembling the connector cable is inserted through the gland hole ensure the gasket is located between the connector and the outside face of the control box Secure with the screws provided screw heads to the outside Serial Link Wiring Tips When connecting printers to your detector the followin...

Page 53: ...nd in the Wiring Connections section of this manual TBA1 connector identifiers can be found in Figure 14 below Connector TBA1 Function 1 EXT 2 EXT 3 Binfull 4 PEC Photo eye 5 Reject Confirm 6 Remote Calibrate 7 Shaft Encoder 8 Shaft Encoder 9 EXT 10 EXT Figure 14 Remote Sensor Board Loma Part Number 416244 Fitting the Board The board locates into connectors JP3 and JP4 the board will only locate o...

Page 54: ...positive location into its base Only proprietary tools should be used to minimise the risk of damage Failure to observe this simple preparation may result in a poor insertion into the base This could result in permanent damage to the device and or operational failure of the detector Once fitted the menu positions associated with this device are automatically enabled Reference can now be made to yo...

Page 55: ...e serial link board can be found in the Configuration and Set up section of this manual the serial link protocol set up can be found in the Serial link Configuration on page 28 Figure 16 Reports Logs Package Integrated Circuit Location Main control board Reports Logs package optional fit ...

Page 56: ...ations where the product signal drifts up and down Product Signal Tracking on page 37 set up V1 5 above information is listed in the Definitions section of this chapter Reject time Please refer to the Installation and Guide to Commissioning section of this manual for details on the use of this feature Manual setup Turning this on allows the user to make manual adjustments to the calibration of the...

Page 57: ...ce a wet electrically conductive product that requires a LOW frequency E G polyfilm and metal film packaging Dual frequency detectors have a single minimum ferrite memory that is only available when the frequency option is set to HIGH Auxilliary Aux relay V1 5 upwards The function of the attention relay can now be selected according to need If the detector is a dual frequency system then the relay...

Page 58: ...aw slightly or build up a layer of moisture on the packaging creating a significant product signal In this event the threshold will have to be raised to allow the product to be passed without false rejection However this means that the sensitivity will become degraded when the product again becomes hard frozen as there will be a large difference between the product signal and threshold Turning the...

Page 59: ...all 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 would result In this event the working threshold will have to be raised to allow the product...

Page 60: ...ing limit Commences at the calibrated working threshold The value cannot be set less than the calibrated working threshold but may be increased up to the value of the Max limit Max limit Highest tracking limit Commences at twice the calibrated working threshold The value cannot be set less than the calibrated working threshold but may be increased up to the value of your choice However it is stron...

Page 61: ...ject device state is toggled No Reject dwell entry will appear in the Product setup menu for this mode of operation as it is not required This reject mode is only available if a photo eye is fitted Dwell extension 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 product is detected be...

Page 62: ...ich a reject confirmation signal must be received when a contaminated pack is rejected For example if the confirmation signal should occur within 50 to 150ms of the reject device being activated set the confirm delay to 50ms the confirm window to 100ms Bin full Select this if a bin full facility has been fitted to your system and you wish a system fault to be generated if the reject bin becomes fu...

Page 63: ...etermine whether or not the product is contaminated Figure 1 Metal detector with rectangular aperture and belt conveyor A typical detector is shown in Figure 1 It consists of a metal box with an aperture through which the product passes and a control unit that processes the signals Inside the metal box referred to as the search head there are three coils surrounding the aperture arranged as in Fig...

Page 64: ...s through the search head Subtracting the voltages from each of the coils will then no longer give zero such that the interaction of the object with the magnetic field can be measured as it moves through the head The differing signal picked up after subtracting the two receiver voltages will vary depending upon how conductive the object is For instance different types of metal will give different ...

Page 65: ... products such as cheese produce mainly resistive signals Metal contamination can produce an interaction that produces both considerable reactive and resistive signals Figure 3 shows the typical signals which would be traced out on an oscilloscope as a block of cheese moves through the search head A graph can be plotted of the reactive signal X against the resistive signal R known as a locus plot ...

Page 66: ...ow it must be set up for optimum performance in different applications Consider Figure 5 which shows the locus plot both for a tub of frozen ice cream and a 2mm Ferrous sample In this example if the control unit is set to look at the R signal only then when the R signal increases it must be due to contamination as the ice cream gives little R signal Figure 5 Locus plots for Ice cream tub and 2mm f...

Page 67: ...gnal as well but again if we look at only the X signal it will be difficult to see small pieces of metal as the cheese produces small X signals the same as a small ferrous contaminant will In order to see small pieces of metal it is necessary to combine the R and X signals to attempt to eliminate the product effect known as compensating out the product Applying the correct product compensation to ...

Page 68: ...onsiderable moisture content where the water can conduct thereby leading to considerable R signals large product effect Resistive working is limited to those products with a little moisture content such that they have sufficient product effect so as not to allow them to work dry but that the R signal is not large enough to let them work reactively As examples of working modes tea and coffee would ...

Page 69: ... a reference to compensate out those signals When the unit determines during a calibration cycle that Dry mode working is required the compensation value adopted is that from the ferrite wand reference this reference value is determined and saved in the unit during a ferrite tune see commissioning section Product Dispersion Some products which are uniform in size and composition will compensate ou...

Page 70: ...performance of metal detectors because they present a regular shape to the aperture irrespective of their orientation With irregular shapes the detectability will vary greatly with orientation since the sample will present a different cross section to the magnetic field in the search head according to its orientation Furthermore these effects differ in relation to non ferrous metals compared with ...

Page 71: ... Replacement 4 Control PSU Board Replacement 7 Filter Resistor Pack 8 Hardware Cold Starting 8 Control Board Links and Test Points 9 Power Supply 10 Connecting to a Power Source 12 End Plate Removal and Refitting 14 Search Head Board Single Frequency 16 Receiver Interface Board Single Frequency 20 Dual Frequency Detectors 21 ...

Page 72: ...ny anti static packaging to enable safe storage of removed boards or components 5 The use of a container in which to place individual items such as screws washers nuts that are removed during any of the operations is recommended This will help prevent loss and reduce the risk of metal contamination of any product 6 Metric threads are used throughout the detector 7 Clear Silicon rubber will be requ...

Page 73: ...ed An exploded assembly diagram is given in Figure 1 Display Board Removal Refitting 1 Using the 5mm allen key supplied with your equipment unscrew the 2 front hinged door screws on the control box and open the door 2 Unplug the display board drive connector from its mating plug on the control board and unclip the ribbon cable from behind its 2 retaining clips 3 Undo and remove the 6 metal M3 pill...

Page 74: ... in the bottom of the door 2 Undo the 10 hex M3 pillars that secure the overlay to the control box door 3 From the outside of the control box using a thin bladed palette knife gently insert into the seal around the overlay and the control box carefully break the seal by working the knife sideways around the full circumference of the seal 4 Remove the overlay 5 Clean off any old seal material remai...

Page 75: ...ar 124141 2 10 off M3 x 15 hex threaded pillar 124141 Apply approximately 5mm clear silicon rubber in a continuous bead around the centre line of the overlay fixing holes before fitting to the control box door Item 2 Item 1 Display board Overlay Control box These items form part of the overlay Ribbon cable tie wrapped in 2 places no requirement to remove ...

Page 76: ...cket for JP links 421092 F1 AC input fuse Display board connector J1 Programme plug F2 3 reject contact protection fuses Boot eprom required for flash memory programming and use of the engineers panel diagnosis h k Optional serial link board Optional sensor board Filter resistor pack Head board connector PL1 Relay LED s Watchdog LED TP8 9 JP9 JP10 Relay output connectors TP1 2 3 4 Assembly part nu...

Page 77: ... on page 6 in this section to help locate items referred to below Replacement Control Board must be the same assembly numbered part Remove the board for replacement purposes as follows 1 Using the 5mm allen key supplied with your equipment unscrew the 2 front hinged door screws on the control box and open the door 2 Undo and remove the 4 M3 pillars or nuts securing the PSU safety mesh screen cover...

Page 78: ...t up data and all applicable product data Guidance in configuring the search head is given in the Configuration and Set up Information on page 4 of this section It is essential that a hardware Cold Start be performed to ensure the detector settings are returned to their default values before commencing any data re entry Refer to Hardware Cold Starting below in this section for guidance FILTER RESI...

Page 79: ... with their uses are referred to in the relevant sections through out this manual Following are tables of the remaining control board links that are shown only for completeness of information Link Use Default setting JP7 Time base source selection Link 2 3 internal JP10 0V signal Ground IN Following is a table of the control board test points that are shown only for completeness of information Tes...

Page 80: ...tion against the risk of fire replace only with the same type and rating of fuse Incoming AC Protection Fuse The power supply forms part of the main control board it is fitted with a single protection fuse F1 located in the incoming ac supply circuit see Figure 2 on page 6 In the fuse blows on start up then it may be replaced however should the fuse blow a second time then further replacement is n...

Page 81: ...ly is the reverse of the above 12v DC Rail Protection Fuses Early issue control psu boards are fitted with a replaceable soldered fuse link located in positions R337 12 R338 12 Figure 2 on page 6 if the loss of either rail is due to an open circuit fuse then it is possible to replace these items If it is desired to attempt a replacement then the later re settable fuse type should be used Loma part...

Page 82: ...re 4 on page 12 in this section WARNINGS LETHAL HAZARD ELECTRICAL SUPPLIES A current of 100 mA passing through the body for one second can kill This can occur at voltages as low as 35V ac or 50V dc LETHAL HAZARD The control board and power supply are combined on a single board therefore this board contains high AC DC voltages A grounded mesh screen cover protects the power supply area of the main ...

Page 83: ...ds protected by a one piece safety mesh cover For boards with the two piece cover only the angled terminal cover access plate requires removal Figure 4 AC Power Ground input connection units built before November 2001 Figure 4 AC Power Ground input connection units built after November 2001 Live Neutral JP301 TP303 The earth connection is made to the control box ground stud located just below the ...

Page 84: ...he plate with the fixing holes ensuring the insulating water tight gasket edge is visible around the full circumference of the case Replace only the top centre bolt together with its O ring seal washer to secure and prevent the plate falling Do not fully tighten this bolt as it is removed later to allow an insulation continuity test to be carried out 2 Locate and partially tighten all the remainin...

Page 85: ... X 25 hex head bolts 108068 Quantity is end plate size dependent 2 Nylon shoulder washer 116036 Quantity is end plate size dependent 3 M6 X 20 hex head bolts 108064 Quantity is end plate size dependent 4 1 x O ring seal 106004 5 1 x Balance access hole bung 227014 Style may vary 6 1 x Sealing washer 114022 ...

Page 86: ... should be worn The process described seeks only to cover the minimum requirements needed to ensure a successful board replacement and does not cover the full set up process Once completed the detector will be functional however if any fine adjustment is required which may be indicated by a slight loss in performance then contact your local Group Service Centre to arrange a service call The compon...

Page 87: ...511001 3 2 off M3 x 16 pan head screws 108006 4 4 off M3 x 7 long metal spacers 124123 5 Metal screen plate 225472 6 Search head board 416180 Dedication required Connection Name 12 core cable Wire Colour Ctrl 2 control line 2 Orange Ctrl 1 control line 1 Pink R out resistive channel Black X out reactive channel White A gnd analogue ground Blue OSGO oscillator going Yellow Ctrl 3 control line 3 Gre...

Page 88: ... the 4 fixing screws spacers nuts 6 Take the board to a safe location and lay it on some anti static packaging refer to it now as a reference to ensure the replacement board is properly configured Configure as follows Reference Figure 6 on page 16 in this section for component locations Carefully unsolder the L1 inductor which may be either a fixed value small tubular or a variable copper cased ty...

Page 89: ...ay have been changed to 100 KΩ to optimise sensitivity at very slow belt speeds If they have been changed then copy the changes to the new board This modification is usually done in conjunction with R35 R44 Re fit the new board to the plate and the plate to the detector ensuring the metal spacer is fitted to the correct corner Reference Figure 7 on page 17 in this section Carefully solder the wire...

Page 90: ...be used to adjust the balance signal when the detector is in its quiescent state Removing the screwed metal bung located on the removable end plate on the search head case accesses the ferrite core Instructions as to its use are in the Testing section of this manual There are no user replaceable components located on this board Should the board develop a fault it will require replacing Contact you...

Page 91: ...your detector search head case are a modified search headboard and a dual receiver interface board There are no user replaceable components located on either board Should the boards develop a fault they will require replacing Contact your local Group Service Centre for help As with a single frequency detector the receiver board contains a pair of user adjustable ferrite cores one for each operatin...

Page 92: ...Maintenance Module 8023 6 1 Frequency links Tx Inductors Balance inductors ...

Page 93: ...Functional Testing Module 9095 7 1 FUNCTIONAL TESTING CONTENTS Recommended Test Equipment 2 Balance 2 Reactive and Resistive Channels 4 Phase Integrity and Channel Noise 4 OSGO 5 DC Power Rails 7 ...

Page 94: ...ng if necessary for each operating frequency In the unlikely event of the balance value increasing beyond this point which a gradual loss of metal sensitivity or an increase of product effect may indicate The balance can be checked and adjusted as follows NOTE No metal or product should be present in the aperture whilst this check is in progress 1 Using the 5mm allen key supplied with your equipme...

Page 95: ...ector is a dual frequency type then remove both screwed bungs High frequency balance adjustment is through the left hand access hole 10 Using the non metallic trim tool inserted into the ferrite core immediately below the access hole a small penlight flashlight may be of assistance in locating the core Adjust the core until the reading is as small as it will go 11 If the balance cannot be adjusted...

Page 96: ...ct changes may be a symptom of phase integrity NOTE No metal or product should be present in the aperture whilst this check is in progress Checking Phase Integrity and Channel Noise single dual frequency detectors 1 Using the 5mm allen key supplied with your equipment unscrew the 2 front hinged door screws on the control box and open the door 2 Select an unused product memory position and set the ...

Page 97: ...ck wire connection pin on PL1 shown in Figure 3 Repeat the test for white noise and the test wand the peak to peak value observed for the test wand should not be than 1 5th of the recorded X channel voltage 6 To check the phase integrity for dual frequency types then change the frequency selection to LOW in the frequency menu position for the product memory chosen Repeat all the above tests for th...

Page 98: ...the Fault Relay to operate and in turn the Reject Device so that no product will pass undetected In the unlikely event of an OSGO generated System fault transmitter failure confirmation can be made by using the DMM set on the 20V DC range or equivalent to measure the voltage at PL1 with respect to the adjacent control board mounting hex pillar Figure 10 on page 20 in the Maintenance section of thi...

Page 99: ...d If this board is fitted it will need to be temporarily removed Primary Rail Nominal Voltage Upper Tolerance Lower Tolerance 5V Pin 1 ref Pin 2 5 00 5 25 4 75 5v ground Pin 2 12V grounds Pin 3 12V Pin 4 ref Pin 3 12 12 60 11 40 12V Pin 5 ref Pin 3 12 10 80 13 20 EXT Pin 6 ref Pin 7 12 10 80 13 20 Ext ground Pin 7 1 Adjustment can only be made to the 12V rails using RV1 located in the power supply...

Page 100: ...Wiring Diagrams Module 10088 8 1 WIRING CONNECTION DIAGRAMS CONTENTS Figure 1 Optional External Sensor Connection Ladder Diagram 2 ...

Page 101: ...Wiring Diagrams Module 10088 8 2 Figure 1 Optional External Sensor Connection Ladder Diagram ...

Page 102: ...Spare Parts Module 11050 9 1 SPARE PARTS CONTENTS Spare Parts Lists 2 ...

Page 103: ...Key 809125 1 per site Harsh Environment Keypad Cover 205297 1 per site Only if fitted to equipment Reject relay protection fuses 517026 5 per site Incoming AC supply protection fuse 517033 3 per site Replacement is limited 12v DC rail protection fuse 517104 2 per site Re settable type Silicone Rubber 804006 1 per site Used to seal the keyboard overlay only if required Hex pillar 12mm 124139 5 per ...

Page 104: ...Service Return Module 12005 8 1 SERVICE RETURNS FORMS CONTENTS Instructions 2 Form 3 ...

Page 105: ...e fault condition 5 Serial Number of the item if applicable Details can be found on the label that is located inside the Control Unit on one of the side sections an example of a typical label is shown below Please refer to The Loma Group Service Centres information at the front of this manual for the correct addresses of the respective service centres for the UK USA Canada etc An agreement of the ...

Page 106: ...Service Return Module 12005 10 3 RETURN FORM Customer Date Serial No Description of Item Description of Fault Authorisation Number North America only ...

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