Loma IQ3 User manual

IQ3Metal Detector User Guide
Document Number: 814180-2.0-ENG ORIGINAL INSTRUCTIONS Copyright © 2014 Loma Systems

Table of Contents
Introduction.............................................................................................1
About this Guide..................................................................................................................................2
General ............................................................................................................................................2
Audience..........................................................................................................................................2
Purpose............................................................................................................................................2
Organisation ........................................................................................................................................3
Document Change Control..................................................................................................................4
Document Key.....................................................................................................................................4
Notes and Warnings ........................................................................................................................4
Hyperlinks ........................................................................................................................................4
Copyright and Acknowledgements......................................................................................................5
The Loma Group of Companies..........................................................................................................6
About Metal Detection.............................................................................7
How a Metal Detector Works...............................................................................................................8
General ............................................................................................................................................8
Balance Stability ..............................................................................................................................8
General and Foil Wrapped Products ...............................................................................................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
Purpose..........................................................................................................................................15
Full Learn.......................................................................................................................................15
Update Learn.................................................................................................................................15
Reverse Learn ...............................................................................................................................15
Learn Setup ...................................................................................................................................15
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Safety First ...........................................................................................17
Safety Awareness..............................................................................................................................18
EC Declaration of Conformity............................................................................................................18
Safety Warnings ................................................................................................................................19
Safety Labels.....................................................................................................................................21
Safety Guards....................................................................................................................................22
Guarding ........................................................................................................................................22
Interlock switches...........................................................................................................................22
Safety Relay and Circuits ..............................................................................................................22
Responsibilities and Disclaimer.........................................................................................................22
Safety Measures................................................................................................................................23
Intended Use of the Machine.............................................................................................................23
Permitted Use ................................................................................................................................23
Improper Use.................................................................................................................................23
Noise Levels......................................................................................................................................24
End of Life Treatment........................................................................................................................24
Emergency Procedures.....................................................................................................................24
Quality Assurance .............................................................................................................................25
ISO9000.........................................................................................................................................25
End User Licence Agreement ...........................................................................................................26
Technical Specifications .......................................................................27
IQ3 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 Detector System....................................................................................................41
Warnings........................................................................................................................................42
Receiving and Unpacking..............................................................................................................42
Moving the Machine.......................................................................................................................43
Adjusting / Levelling the Conveyor ................................................................................................43
Clearance Requirements...............................................................................................................44
Connecting the Air Supply.............................................................................................................44
Connecting the Electrical Supplies................................................................................................45
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Table of Contents
Checking Guards ...........................................................................................................................47
Checking Belt Tracking (PV belt system only)...............................................................................47
Setting Up Reject Mechanisms......................................................................................................47
Remote User Interface...................................................................................................................47
Installing a Serial Link....................................................................................................................48
Site Considerations ...........................................................................................................................48
Electromagnetic Compatibility (EMC)............................................................................................48
Selection of Frequency Band.........................................................................................................48
Other EMC considerations.............................................................................................................48
Radio Frequency Interference.......................................................................................................48
About the Metal Detector Range...........................................................51
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.................................................................................................................................58
‘Bin Full’ Photo-eye........................................................................................................................58
LED Lamp Stack............................................................................................................................58
Overhead Electrical Services.........................................................................................................59
Product Guides..............................................................................................................................59
Product Registration Photo-eye.....................................................................................................59
PVS Indicator Lamp.......................................................................................................................59
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Reject Actuation Confirmation .......................................................................................................59
Reject Confirmation with Photo-eye ..............................................................................................59
Lockable Reject Bin and Status Monitor........................................................................................59
Pack Check Photo-eye ..................................................................................................................59
Getting Started......................................................................................61
User Interface....................................................................................................................................61
IQ3 Dual Line Display Menu Map..................................................................................................64
User Access ......................................................................................................................................65
Logging In and Out............................................................................................................................66
Logging In ......................................................................................................................................66
Logging Out ...................................................................................................................................67
Starting and Stopping........................................................................................................................67
Starting the Machine......................................................................................................................67
Stopping the Machine....................................................................................................................68
Emergency Stop ............................................................................................................................68
Starting the Machine after an Emergency Stop.............................................................................68
Using the Metal Detector ......................................................................69
Good Practice....................................................................................................................................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 Language.....................................................................................................................74
Setting the Machine ID...................................................................................................................74
Setting User Access Levels and Passwords .................................................................................75
Turning Off the Access Level Feature ...........................................................................................75
Configuring the Metal Detector..........................................................................................................76
Setting Up the Search Head..........................................................................................................76
Setting Up the Conveyor................................................................................................................78
Setting Up the Service Options......................................................................................................81
Setting the VF Balance..................................................................................................................82
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Setting the VF Drive.......................................................................................................................84
Setting Up the User Options..........................................................................................................85
Setting Up Serial Links...................................................................................................................86
Performing a Ferrite Tune..............................................................................................................87
Setting Up Product Signal Tracking...............................................................................................88
Setting Up the Reject Options .......................................................................................................90
Adding a New Product.......................................................................................................................92
Learning Products .............................................................................................................................94
Full Learn.......................................................................................................................................95
Update Learn.................................................................................................................................96
Learn Messages ............................................................................................................................97
Learn Setup ...................................................................................................................................98
Learn Limits .................................................................................................................................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 Contents...........................................................................................................................113
Contaminants Report.......................................................................................................................114
Purpose........................................................................................................................................114
Running the Report......................................................................................................................114
Report Contents...........................................................................................................................114
Learn Report....................................................................................................................................115
Purpose........................................................................................................................................115
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Running the Report......................................................................................................................115
Report Contents...........................................................................................................................115
Status Report...................................................................................................................................116
Purpose........................................................................................................................................116
Running the Report......................................................................................................................116
Report Contents...........................................................................................................................116
PV Test Report................................................................................................................................116
Running the Report......................................................................................................................116
Report Contents...........................................................................................................................116
Batch Report....................................................................................................................................117
Purpose........................................................................................................................................117
Running the Report......................................................................................................................117
Report Contents...........................................................................................................................117
Shift Report......................................................................................................................................118
Purpose........................................................................................................................................118
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
Viewing the Log ...........................................................................................................................122
Printing the Batch Report.............................................................................................................122
Clearing the Log...........................................................................................................................122
PVS Log...........................................................................................................................................123
Purpose........................................................................................................................................123
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Viewing the Log ...........................................................................................................................123
Printing the PVS Report...............................................................................................................123
Clearing the Log...........................................................................................................................123
Shift Log...........................................................................................................................................124
Purpose........................................................................................................................................124
Viewing the Log ...........................................................................................................................124
Printing the Shift Report...............................................................................................................124
Clearing the Log...........................................................................................................................124
Maintenance.......................................................................................125
Maintenance Warnings....................................................................................................................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
Glossary .............................................................................................131
Index...................................................................................................133
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