Loma IQ2 User manual

IQ2Metal Detector
User Guide
IQ2Metal Detector User Guide
LomaIQ2 Cover 30/6/00 3:47 pm Page 1

IQ
2
Metal Detector User Guide
IQ2 English Page i Friday, November 17, 2006 12:46 PM

Preface
ii
Copyright and acknowledgements
Copyright © 2006 Spectrum Inspection Systems Ltd. All rights reserved.
Spectrum Inspection Systems Limited.
Summit Avenue
Southwood
Farnborough
Hampshire
GU14 ONY
England
Email: [email protected]
Web: http://www.loma.com
http://www.cintex.com
The IQ2 Metal Detector and this documentation are copyright material. No part of this
documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or
translated into any language, or computer language in any form or by any means without the
prior written permission of Spectrum Inspection Systems.
1Q2 Metal Detector is a trademark of Spectrum Inspection Systems. All other product
names are trademarks or registered trademarks of their respective owners
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 Spectrum
Inspection Systems.
This guide was designed and produced by Human Computer Interface Limited,
http://www.interface.co.uk
Part number: 814113 issue level N
IQ2 English Page ii Friday, November 17, 2006 12:46 PM

Preface
iii
Safety warnings
Listed below are all the safety warnings that are used in this manual. It is strongly
recommended that personnel who are, or will be, responsible for either installing, maintaining
or operating the equipment described in this manual should read and understand these
warnings.
1.
LETHAL HAZARD – ELECTRICAL SUPPLIES . A current of 100 milliamps passing
through the body for one second can kill. This can occur at voltages as low as 35V ac or
50V dc The equipment described in this manual uses electrical power which can be
lethal. Unless absolutely necessary, cleaning, inspection and maintenance must not be
carried out without first isolating the equipment from all electrical supplies.
2.
LETHAL HAZARD – COMPRESSED AIR SUPPLIES . The equipment described in this
manual may be supplied with a compressed air supply operating at a pressure which may
be lethal. Unless absolutely necessary, cleaning, inspection and maintenance must not
be carried out without first isolating the equipment from all compressed air supplies.
3.
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 voltages and/or compressed air
supplies. 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. Take care not to trap the earth wire or ribbon cable when closing the
enclosure lid.
4.
REJECT DEVICES . At no time, with compressed air and/or electrical power applied to an
automatic reject device, should any part of the body be placed within the operating area
of the reject device.
5.
EXCESSIVE NOISE . When an air blast reject device operates, the noise emitted may
constitute a noise hazard. While short exposure to this noise will not cause permanent
damage to hearing, prolonged exposure may cause some damage. It is recommended
that ear defenders are worn by personnel who are regularly exposed to the noise.
6.
HEAVY EQUIPMENT . The equipment described in this manual is extremely heavy and
considerable care must be taken when handling it. Sufficient personnel and a suitable
fork-lift truck or pallet truck must be used to ensure safe handling.
4028
IQ2 English Page iii Friday, November 17, 2006 12:46 PM

Preface
iv
7.
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 to lifting
the equipment to ensure that:
(a) The safe working load will not be exceeded.
(b) There are no frayed or broken strands.
(c) Hooks, rings, etc. are not damaged.
8.
MOVING METAL DETECTORS . The centre of gravity of some metal detectors is high.
Lower the height adjustment to its minimum before moving. Care must be taken when
moving such equipment on a slope to ensure that it does not topple over. This could
result in death or severe injury to an individual and/or severe damage to the metal
detector.
9.
CONTAMINANTS . Oils and greases must always be handled with care. Prolonged bare
skin exposure to certain oils and greases can cause skin problems. Always handle oils
and greases in accordance with the manufacturer's instructions.
10.
TRAPPED FINGERS . Do not place fingers on the underside of the conveyor when the
machine is operating. It is possible for fingers to be trapped and subsequently crushed
between a moving and fixed component of the machine.
11.
OSHA . In the USA, the Occupational Safety and Health Administration (OSHA) Acts quite
clearly place the burden of compliance on the user of equipment, and the acts are
generalised to the extent that determination of adequacy of compliance is a judgement
decision on the part of the local inspector. Hence Loma cannot be held responsible for
meeting full requirements of OSHA or OHSA with regards to any equipment supplied, nor
can Loma be held liable for penalty which may be assessed for failure to meet the
requirements of the acts as interpreted by an authorised inspector. Loma, however, does
act in a responsible manner with regard to safe design of equipment and will always work
with customers to assist where possible in the remedy of any violations at a reasonable
cost to the buyer.
4028
IQ2 English Page iv Friday, November 17, 2006 12:46 PM

Preface
v
12.
USE OF EQUIPMENT IN WORK AREAS WHERE EXPLOSIVE ATMOSPHERES MAY
OCCUR . CE Directive 94/9/EC – ATEX Directive – July 2003
(a)
LOCATION OF EQUIPMENT . This equipment is certified as category 3D for use in
zones designated 22 only.
(b)
INSTALLATION AND MAINTENANCE . Electrical enclosures should be inspected and
maintained on a regular basis to prevent the build up of dust deposits and to ensure
the integrity of seals.
Before undertaking maintenance the equipment must be disconnected from the
source of electrical power.
During installation and maintenance care should betaken to prevent the ingress of
dust into any electrical enclosure. Should dust ingress occur then all deposits must be
removed before the equipment is put into service.
Following installation and maintenance and before putting into service all electrical
enclosures and cable glands are to be correctly secured to prevent dust ingress.
Care must be taken during installation and maintenance not to damage door seals
and cable entry glands.
(c)
USE . To ensure safe operation deposits of dust on any surface should be removed
immediately to prevent an increase in the surface temperature of equipment.
13.
HEIGHT ADJUSTMENT . Care should be taken when adjusting the height of the Pipeline
and Pharmaceutical 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.
14.
LIABILITY . This machinery contains high voltages of a hazardous and potentially fatal
nature. Spectrum Inspection Systems Limited cannot accept any liability for death or
bodily injury resulting from improper work undertaken by unqualified operatives, or due to
deviations from the maintenance instructions within this manual.
This Liability statement is in addition to the terms of sale.
4028
IQ2 English Page v Friday, November 17, 2006 12:46 PM

Preface
vi
The following safety warnings relate to specific metal detectors in the IQ
2
range.
Pipeline detectors including filler specific versions
15.
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 the machine to fall over. This could result in death
or severe injury to an individual and/or severe damage to the detector.
16.
START UP WITH AUTOMATIC REJECT VALVE . When a pipeline is switched on, the
automatic reject valve changes state from “Reject” mode to “Run” mode. Do not put any
part of the body within close proximity of the reject valve outlet when the machine is
switched on. This could result in severe injury to an individual.
17.
HEIGHT ADJUSTMENT STAND-MOUNTED VERSIONS . When adjusting the height of a
detector assembly, do not unscrew the locating screw in the height adjustment strut. If it
is unscrewed and removed, the body of the detector and the reject valve may spin round
on the height adjustment strut, causing the machine to fall over. This could result in death
or severe injury to an individual and/or severe damage to the detector.
18.
SECURITY . The detector is mounted on a gas-filled height-adjustment strut. After
adjusting the height of the detector, make sure the adjustment handle is fully tightened. If
the handle is not fully tightened, the detector could rise on the strut. This could result in
severe injury to an individual and/or severe damage to the detector.
19.
HANDLING A HINGE MOUNTED VERSION ON A PA30 FILLER . When a pipeline is
mounted on a PA30, the detector must be removed from the PA30 before disconnecting
the PA30 from the main filler. Failure to do this may result in the PA30 falling over resulting
in death or severe injury to an individual and/or severe damage to the PA30.
20.
HANDLING A HINGE MOUNTED VERSION WITHOUT A STAND . Care should be taken
when fitting or removing the detector off the filler hinge. The detector should be lifted by
two persons using the handles fitted to the detector. If lifting is attempted by a single
person or the handles are not utilised then this could result in death or severe injury to an
individual and/or severe damage to the detector.
21.
HANDLING A HINGE MOUNTED VERSION ON A STAND . Care should be taken when
moving a detector as applied force and/or obstructions of the wheels may cause the
machine to fall over. Remove all attachments before disconnecting from the filler. Lower
the height adjustment to its minimum before moving. Failure to do this may result in the
4028
IQ2 English Page vi Friday, November 17, 2006 12:46 PM

Preface
vii
detector falling over. This could result in death or severe injury to an individual and/or
severe damage to the detector.
22.
HANDLING WITH A WATER JACKET FITTED . When a pipeline is fitted with a water
jacketed product pipe, surface temperatures of the product pipe and the water jacket coil
may be up to 75°C. Contact with the product pipe or the water jacket coil may result in
minor burns or light scalding.
23.
OPERATING WHEN USED FOR HANDLINKING . When a pipeline is fitted to a filler and
used for handlinking, the location of the filler knee control lever is located closer to the
detector infeed than the detector outfeed.
24.
DISCONNECTION OF POWER . 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.
Pharmaceutical versions
25.
ADJUSTMENT . The detector is mounted on a gas-filled height-adjustment strut. If the
height of the detector requires adjusting, make sure the adjustment clamp is fully
tightened afterwards. If the clamp is not fully tightened, the detector could rise on the
strut. This could result in severe injury to an individual and/or severe damage to the
detector.
26.
SECURITY . The metal detector head and product chute are mounted on an arm such that
they can be rotated when the tilt angle adjustment clamp is loosened. When loosening
the clamp to adjust the tilt angle, always support the head and product chute. If they are
not supported, severe injury could result to an individual.
Freefall versions
27.
REMOVAL OF A DIVERTER . Care must be taken when removing a diverter reject device.
Dropping the unit could result in severe injury to an individual.
28.
START UP WITH A DIVERTER . When a freefall detector is switched on, the diverter
reject device changes state from the “Reject” mode to the “Run” mode. Do not put any
part of the body within close proximity of the reject outlets when the machine is switched
on. This could result in severe injury to an individual.
4028
IQ2 English Page vii Friday, November 17, 2006 12:46 PM

Preface
viii
Emergency procedures
1.
EMERGENCY SHUTDOWN OF CONVEYORS . This equipment is fitted with an
emergency ‘Stop’ button. This is mounted on the front panel and is coloured red. In the
event of an emergency, which requires the metal detector to be immediately stopped,
press the ‘Stop’ button.
2.
DEALING WITH FIRE . In the unlikely event of fire occurring in an item of equipment
manufactured by Loma Systems, it is important that a fire extinguisher containing the
correct type of extinguishing material is used. Fire on electrical equipment must be
extinguished using a dry powder extinguisher (Blue label).
3.
AUDIBLE WARNINGS . A conveyor may be fitted with an indicator lamp and an alarm
which operates when a metallic contaminant is detected in the product. The maximum
volume of the alarm is type dependent and lies in the range of 110dB(A) to 125dB(A) at 1
metre.
Quality assurance
By your selection of a Loma metal detector system you have demonstrated your intention to
assure the quality of your products, and thereby protect your customers.
The following points are recommended:
1. Once your Loma metal detector system is installed you should contact your local Loma
Service Department to have the system commissioned.
2. Regularly check the operation of the metal detector (once an hour is recommended).
Keep accurate records of those tests and the metal samples being used, along with the
product details.
3. If the detector fails the test, quarantine the product from the last test and re-introduce
through the metal detector once the equipment is fit for use.
4. Have the equipment supported by a Planned Preventative Maintenance Contract. Details
can be obtained from your local Loma Service Department.
5. If you have or intend to have BS EN 9000 accreditation, write a section into your
Operating Procedures Manual covering metal detection procedures and have each
detector regularly calibrated with a certificate issued.
4028
IQ2 English Page viii Friday, November 17, 2006 12:46 PM

Preface
ix
6. Finally, at least on a yearly basis, have your operators, QA and maintenance personnel
trained in the use of the equipment. Details of available training can be obtained from
your local Loma Service Department.
About this guide
This guide provides complete instructions for setting up and operating the Loma IQ
2
Metal
Detector range. It consists of the following chapters:
About the IQ
2
Metal Detector range
Provides a general introduction to the IQ
2
Metal Detector range, describing how it operates
and its typical applications.
Using the IQ
2
Metal Detector
Provides general information about using the IQ
2
Metal Detectors, including a simple
discussion of the principles of operation.
Setting up a new product
Gives step-by-step instructions for setting up a new product code and calibrating the metal
detector for that product.
Displaying and printing reports
Provides information about displaying and printing batch results and contaminant, error and
fault reports.
Setting up the IQ
2
Metal Detector
Explains how to calibrate the metal detector and set up parameters including the tracking
limits, time and data, and machine ID.
Using Performance Validation
Describes the benefits of the performance validation procedure and explains how to set up
the IQ
2
Metal Detector for PV testing.
Installing the IQ
2
Metal Detector
Gives general instructions for installing any of the IQ
2
Metal Detector range, together with
general rules about positioning for correct operation.
4028
IQ2 English Page ix Friday, November 17, 2006 12:46 PM

Preface
x
Maintenance
Gives detailed maintenance instructions for the IQ
2
Metal Detectors.
Appendices
Give information about special purpose options included in the Loma IQ
2
Metal Detectors.
Conventions
For clarity this guide uses the following typographical conventions:
Style Used for
e
,
K
Keys that you press on the IQ
2
Metal Detector control panel.
BOLD Names of menus and parameters that appear on the metal detector
display.
reference A cross-reference to another part of this guide, or to another guide.
3007
IQ2 English Page x Friday, November 17, 2006 12:46 PM

Preface
xi
The Loma group of companies
UK
Sales Customer Service
Loma Systems Loma Systems Customer Service
Southwood Unit 43 Campus Road
Farnborough Bradford
Hampshire West Yorkshire
GU14 0NY BD7 1HR
United Kingdom United Kingdom
Tel.: [phone] Tel.: [phone]
Fax: [phone] Fax: [phone]
E-Mail: [email protected] E-Mail:
Web: http://www.loma.com [email protected]
http://www.cintex.com
Canada USA and South America
Sales and Customer Service Sales and Customer Service
Loma Systems Loma Systems
Unit 11, 333 Wyecroft Road 283 East Lies Road
Ontario Carol Stream
L6K 2H2 Illinois 60188
Canada USA
Tel.: [phone] Tel.: [phone] / 1-800-USA-Loma
Fax: [phone] Fax: [phone]
E-Mail: [email protected] E-Mail: [email protected]
Web: http://www.loma.com Web: http://www.loma.com
http://www.cintex.com http://www.cintex.com
3007
IQ2 English Page xi Friday, November 17, 2006 12:46 PM

Preface
xii
Benelux France
Customer Service Customer Service
Spectrum Inspection Services BV Spectrum Inspection Services BV
Panovenweg 22 Panovenweg 22
5708 HR Helmond 5708 HR Helmond
Netherlands Netherlands
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
E-Mail:[email protected] E-Mail: [email protected]
Germany
Customer Service
Spectrum Inspection Services BV
Panovenweg 22
5708 HR Helmond
Netherlands
Tel: [phone]
Fax: [phone]
E-Mail: [email protected]
For details of other Loma offices and the worldwide distributor network, please visit the
Loma web site at www.loma.com or telephone one of the sales offices.
IQ2 English Page xii Friday, November 17, 2006 12:46 PM

Contents
xiii
2030
Contents
About the metal detector range 1
Introduction 2
Belt conveyor versions 3
Pipeline versions 9
Linker versions 14
Pharmaceutical versions 18
Freefall versions 20
Using the metal detector 27
Principles of operation 28
Getting the best results 29
Good practice 31
ISO9000 33
Entering a keycode 34
Selecting a product 34
The displays 35
Control panel 36
Adjusting the sensitivity/threshold 37
Using the menus 38
Setting up a new product 41
Setting up a product 42
Quick Setup Guide 46
Displaying and printing reports 49
Displaying batch results 50
Producing reports 51
Displaying the contaminants, run
errors, and system faults logs 55
IQ2 English Page xiii Friday, November 17, 2006 12:46 PM

Contents
xiv
2030
Setting up the metal detector 59
Calibrating the metal detector 60
Setting up the calibration parameters
manually 63
Setting the working mode 64
Setting the trigger thresholds 65
Adjusting the threshold and
compensation 66
Adjusting the head power 68
Setting the time and date 69
Setting the machine ID 70
Defining keycodes 70
Using Performance Validation 73
Introduction 74
Setting up PV testing 75
Running a performance validation
test 78
Installing the metal detector 81
General information 82
European belt conveyor versions 87
Pipeline versions 92
Handtmann versions 95
Pharmaceutical versions 98
Freefall versions (stand-alone) 99
Short and long frame versions with
diverter reject 103
IQ2 search head only installation 110
Mounting heads on conveyors 112
IQ2 English Page xiv Friday, November 17, 2006 12:46 PM

Contents
xv
2030
Maintenance 121
Inspection and cleaning procedures 122
Specific cleaning procedures 125
Routine maintenance 132
Appendices 137
Appendix A – Reverse Calibration 138
Appendix B – Commissioning Guide 140
Appendix C – Product signal tracking
menu 147
Appendix D – Service menu 149
Appendix E – Reject options 151
Appendix F – Wiring diagram for
external sensors 153
End-User License Agreement 155
Index 157
IQ2 English Page xv Friday, November 17, 2006 12:46 PM

Contents
xvi
2030
IQ2 English Page xvi Friday, November 17, 2006 12:46 PM

About the metal detector range
This chapter provides a general
overview of the product range,
explaining its operation and giving
examples of typical applications. It
also describes the key features of
each of the different models in the
range.
IQ2 English Page 1 Friday, November 17, 2006 12:46 PM

About the metal
detector range
2
5091
Introduction
To cater for the requirements of different types of product the IQ2Metal Detector is provided
in a range of different configurations. These share the same search head and control unit, but
differ in the conveyor used to pass the product through the search head.
The variants are as follows:
• Belt conveyor, with flat or plastic modular belts.
• Pipeline versions.
• Handtmann versions.
• Pharmaceutical versions.
• Freefall versions.
The differences between each of these versions are described in the subsequent sections of
this chapter.
Search head and control unit
The search head and control unit have been designed for use with continuous motion
conveyor systems, pipeline, pharmaceutical, and freefall metal detectors.
The standard search head and control unit are designed for use in an IP66 environment.
A second search head may be fitted when product is packaged in both non-foil and foil
packaging; this is called a Ferrous in Foil metal detector.
As standard, the control unit is secured at the end of the search head. This unit allows the
setup and calibration of the system through a menu-driven user interface.
The control unit is compatible with the following communication packages:
• LomaNet (optional reports/logs and serial link board required).
• LomaLink (optional reports/logs and serial link board required).
The control unit can be fitted with a number of external sensors; an optional sensor board is
required for this.
In addition, the control unit can be connected to a number of visual warning lamps.
IQ2 English Page 2 Friday, November 17, 2006 12:46 PM

About the metal
detector range
3
5091
Belt conveyor versions
This section describes Loma conveyors that are fitted with flat belts and plastic modular
belts. Flat belt conveyors are suitable for use with lighter products; plastic modular belt
conveyors are suitable for use with heavier products in a harsher environment.
Flat belts
The flat belt conveyors use a belt constructed from polyurethane belting.
IQ2 English Page 3 Friday, November 17, 2006 12:46 PM