Insight installation manual iss3 - SIGMA Equipment...(Q875- 0201-5.0-ENG) Models Covered . INSIGHT HD Software Version 6.xx & 7.xx 2014 Loma Systems, a division of ITW Ltd. Summit

INSIGHT

Metal Detector

Installation Manual

‘Original instructions’

INSIGHT

Installation Manual (Q875- 0201-5.0-ENG)

Models Covered

INSIGHT HD

Software Version 6.xx & 7.xx

2014 Loma Systems, a division of ITW Ltd. Summit Avenue

Southwood, Farnborough Hants, GU14 0NY

Tel 01252 893300 Fax 01252 893322 Email: [email protected] Web: http://www.loma.com

Supplied By:

mailto:[email protected]

http://www.loma.com/

Doc. Ref. No: Q875-0201-5.0-ENG INSIGHT Installation Manual 29/01/15

Copyright Loma Systems. 2014. This document may not be copied, reproduced, duplicated or translated in any form, electronic or otherwise without prior official written consent from Loma Systems. Loma Systems will not be liable for any incidental or consequential damage in connection with the use of this document. Loma Systems reserves the right to change the contents of this document at any time without prior notice having been given. Amendments Loma Systems seek to update manuals to include new features and improvements whenever possible. The revision history is intended to highlight advances from previous issues of this document. Revision History Issue Date Revision detail 1 2 3 4 5

30th September 2010 02nd July 2012 19th October 2012 09th June 2014 29th January 2015

Initial release. Section 5 wiring diagrams updated. Sections 3, 4 and 5 updated. Section 5 updated. Section 4.2 updated.

File Name: Q875-0201-5.0-ENG - INSIGHT Standard Metal Detector Installation Manual

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CONTENTS

1. GENERAL 4

2. HEALTH AND SAFETY 4 2.1 Warnings and Cautions 4

2.2 Health and Safety at Work Act 4

2.3 Electromagnetic Radiation 5

3. HANDLING INSTRUCTIONS 5 3.1 Transport and movement 5

3.2 Delivery 6

4. EQUIPMENT RATING 7 4.1 AC Power Supply 7

4.2 Temperature Range 7

4.3 Environmental Protection 7

4.4 Airborne Noise Emissions 7

4.5 Environmental Considerations 7

5. INTRODUCTION 8 5.1 Siting of System 8

5.2 Conveyor or Frame 9

5.3 Conveyor Belt 10

5.4 Electrical Interference 10

5.5 Electrical Installation 12

5.6 Electrical supply 13

5.7 Electrical wiring 13

5.8 Timer Inputs 16

5.9 Relay Outputs 17

6. COMMUNICATIONS 21 6.1 USB (CON19) 21

6.2 RS232 / RS485 (CON18) 21

7. REJECT SYSTEM 22 7.1 Alarm Reject System 22

7.2 Photo-gated Reject System 23

8. TROUBLESHOOTING 24 8.1 False Triggering 24


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8.2 I/O Board Diagnostics 25

8.3 MCU reset 25

9. RECOMMENDED SPARES LIST 26

10. GLOSSARY 27 10.1 Aperture 27

10.2 Bargraph 27

10.3 Test Setup 27

10.4 False Triggering 27

10.5 Metal-Free Zone 27

10.6 Noise 27

10.7 Noise Test 27

10.8 Product Effect 27

10.9 Sensitivity 28

10.10 Systemchek 28

10.11 Test Sample 28

10.12 Trigger 28

10.13 Product Guide 28

10.14 Skid Plate 28


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1. GENERAL

The instructions given in this manual have been written clearly and briefly to enable an easy understanding of the actions necessary to operate this equipment. In order to ensure trouble-free and reliable service it is strongly recommended that installation engineers are provided with this manual in order to familiarise themselves with installation requirements and procedures. 2. HEALTH AND SAFETY

2.1 Warnings and Cautions

When this symbol is shown on the equipment it is used to indicate the possibility of electric shock

When this symbol is shown on the equipment it is used to indicate that the installation manual must be consulted before proceeding. Warning: If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. 2.2 Health and Safety at Work Act

The Purchaser shall comply with the instructions and information of this manual, and it is strongly advised that all personnel associated with this equipment be made familiar with the information contained herein. It is essential that the personnel engaged on the installation of the plant be competent and experienced in the work. They should comply with the statutory requirements and regulations, including the provisions of the Health and Safety at Work Act (UK), other EU relevant legalisation, relevant OSHA regulations, and any amendments that may become legal requirements. Note: For operation of the INSIGHT range of metal detectors refer to the Operating Manual.


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2.3 Electromagnetic Radiation

This device complies with the protection requirements of the Electromagnetic Compatibility Directive 2004/108/EC. Operation is subject to the following two conditions: a) This device may not cause harmful interference. b) This device must accept any interference received, including interference that

may cause undesired operation. This equipment has been tested and found to comply with the relevant EMC limits, which are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. The equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause interference to radio communications. Note: Changes or modifications not expressly approved by Lock Inspection or Loma Systems could void the authority to operate the equipment and invalidate any remaining warranty. 3. HANDLING INSTRUCTIONS

3.1 Transport and movement

CAUTION Risk of injuries due to incorrect transport.

• Transport must be carried out by qualified and authorised personnel. • Suitable lifting equipment must be used when transporting or handling the

metal detector. • Refer to the machine name plate for the total weight of the machine. • Ensure people are not in danger, in and around the lifting zone. • Ensure pallets are lifted and moved safely. Metal detectors are often top

heavy and a specific risk assessment and safe working procedure should be carried out and adopted.

• Wear appropriate PPE (including minimum safety shoes and gloves) Slings should be carefully positioned, so as to avoid tilting during lifting. The unit should be lifted and lowered with great care as metal detector systems can be top heavy. Do not use the metal detector aperture as a lifting point.


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3.2 Delivery

• The metal detector will be delivered generally on a pallet, secured with strapping and protective polythene sheet, and with all relevant documentation.

• Prior to signing from the carrier, the pallet and contents must be inspected for

damage. If damage is discovered, notify the driver immediately, complete the relevant paperwork and contact your supplier. The carrier must be notified at time of delivery, to prevent any claims being refused.


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4. EQUIPMENT RATING

Refer to the machine name plate for the correct voltage requirements. 4.1 AC Power Supply

• AC mains power supply voltage range 88-264Vac. • AC mains supply voltage fluctuation, not to exceed 10% of nominal voltage

• AC mains supply frequency range 47-63Hz

• AC current 1.3A/110Vac 0.8A/230Vac.

• THIS EQUIPMENT MUST BE EARTHED.

4.2 Temperature Range

• Operating temperature –10 °C to 40 °C (14 °F to 104° F) • Storage temperature –10 °C to 60 °C (14 °F to 140 °F)

4.3 Environmental Protection

• This equipment is for indoor use only

• The stainless steel metal detector head is protected to IP69K/PW12

• The painted aluminium metal detector head is protected to IP54/NEMA 12

• The power supply enclosure is protected to IP66, NEMA 4X. • Maximum relative humidity 80% for temperatures up to 31°C decreasing

linearly to 50% relative humidity at 40°C.

• Altitude up to 2000M.

• Installation category III. • Pollution degree 2.

4.4 Airborne Noise Emissions

• Noise level does not exceed 70dB under normal operating conditions.

4.5 Environmental Considerations

• Turn off the power to the unit when not in use.


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5. INTRODUCTION

This manual provides detailed instructions on the installation of the INSIGHT range of metal detectors. The aim of this section is to describe how to mount the metal detector and connect it into the control panel. You will need a conveyor or suitable frame, the Lock inspection metal detector, the Lock control panel and various cables. If the conveyor or frame is not supplied by Lock Inspection, then make sure that it meets the requirements listed under the section titled "Conveyor or frame". Experience has shown that causes external to a metal detector are the main reasons for faulty operation and false triggering. By carefully reading the sections below, and the information contained in the troubleshooting guide, such risks can be minimised. 5.1 Siting of System

For reliable operation, no metal should be allowed closer to the aperture than as detailed in Figure 1 below.

• The shaded area is the metal-free zone. • The metal-free zone (MFZ) is generally 1½ times the aperture height (AH) for

fixed metal and 2 times the aperture height for moving metal. Some levels of vibration are normal in industrial environments, and the INSIGHT detector is designed to function under such conditions. However, false triggering can occur through sudden and heavy loading on to the conveyor belt, particularly when the detector is operating at high sensitivity. Neither the head nor the conveyor or frame should be attached directly to a vibrating packaging or processing machine. The detector head should be located to give easy access to the control panel. If the detector is to be placed close to a wall, it should be installed with the removable end-plate or control panel away from the wall.


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Figure 1 : Metal-Free Zone Requirements

5.2 Conveyor or Frame

If the detector head is mounted on a metal frame, it should be insulated from the frame with rigid insulating stand offs. (Refer to figure 2: mounting requirements). The framework should be of all-welded construction, not screwed or bolted. It should not be subjected to bending or twisting motions. If the frame is resting on metal, e.g. a gantry, it should be insulated from it. Care should be taken to make sure that the frame makes good and even contact with the ground. This is more easily achieved when the conveyor feet are adjustable. During operation of the metal detector, an electrical field is set up inside the detector and around the aperture. This field can cause very small electrical currents to flow in nearby metal structures. If the electrical path is intermittent then false triggering is likely. Typical problems are: loose bolts, corrosion, broken welds, open hinged doors, conveyor rollers etc. Make sure that all items of metalwork are bonded to each other or properly insulated from each other. All rollers should be insulated at one end.

MFZ

MFZ

AH

MFZ MFZ

MFZ

MFZ


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The conveyor belt, skid plate, product guides (if fitted) and product should not touch the top, bottom or sides of the aperture. Care should be taken to ensure that the skid plate does not distort under load and so touch the bottom of the aperture Skid plates and product guide rails should be totally metal-free; suitable materials include Trespa, Benelex, Tufnol, Arborite, UHMW and Delrin (Refer to figure 2: mounting requirements). 5.3 Conveyor Belt

Any conveyor belt passing through the detector must be totally metal-free. Joints in the belt should be made by non-metallic fastener or vulcanized. The joint should be angled across the belt or finger jointed, to reduce the chance of picking up contamination. Anti-static conveyor belts are not recommended. Plastic, plastic-covered or rubber belts should be used wherever possible. Woven belts should not be used as these are prone to getting contamination embedded in them. It is recommended to use white belts as black belting often contains graphite and is conductive. 5.4 Electrical Interference

All electrical interference should be suppressed at source. For example, in the case of solenoids, a suppression capacitor of suitable value and operating voltage should be placed across the device to ground as close to it as possible. Reputable solenoid suppliers can usually provide coils with built-in suppression. No cables must be routed through the aperture, and any heavy current carrying cables including motor cables must be routed well away from the detector and any of its cables. Inverters should be installed following the manufacturers recommendations. A typical installation requires EMC filter, cables from inverter to motor to be screened and the screen must be connected to earth at both ends. All Lock Inspection metal detectors are designed for noise free operation and have been tested to comply with international standards for Electromagnetic Compatibility. Machines should be installed in a position free from excessive electrical noise, such as large inverter drives. The electrical supply must be free from noise, and should be connected using screened or armoured cable, or run in metal conduit or trunking, to a dedicated mains connection that has a solid, noise free connection to earth.


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Figure 2: Metal-Detector Mounting Requirements

NON-METALLIC BEARI NG HOUSING

NON-METALLIC BEARI NG HOUSING

NON-METALLIC SKI D PLATE

SUPPORT FRAME MUST NOT MAKECONTACT WI TH DETECTOR HEAD

FULLY WELDED SUPPORT FRAME

DETECTOR

PLASTI C INSULATIONMOUNTI NG BLOCK

SUPPORT FRAME

SCREW TO BOLT MOUNTI NGBLOCK TO SUPPORT FRAME

SCREW TO BOLT DETECTORTO MOUNTI NG BLOCK

DRI VE ROLLER EARTHED VIA MOTORBOLTED TO SUPPORT FRAME

DETECTOR I NSULATI ON DETAI LS

TRACKI NG ROLLER EARTHED THI S SIDE

I DLE ROLLER EARTHEDTHI S SIDE

I DLE ROLLER I NSULATED THI S SI DEVIA PLASTI C SPACER SHIM

PLASTI C SPACER SHI M

BELT JOI NT MUST NOTBE SQUARE

METAL FREE ZONE


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5.5 Electrical Installation

Danger of death due to contact with live parts!

• Electrical installation should only be carried out by qualified / competent electrical personnel.

• A responsible person should hold the access key. • Disconnect from power supply before commencing any work. • Refer to the machine name plate for the correct voltage requirements. • It is recommended that armoured type cable is used for the mains supply. • Mains supply should be protected by fuses or circuit breaker, and have means

of local isolation. • Terminals are provided at the DIN rail in the electrical enclosure, for ease of

connection. • Always check mains cable for damage. • This equipment must be earthed. (Refer to figure 3)

Figure 3: AC Mains wiring


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5.6 Electrical supply

The PSU is universal; accepting AC mains input in the range 88-264V AC, 47-63Hz, without adjustment. Also on the PSU is a LED, which used to indicate the presence of mains on the PSU. The fuse on the din rail is UL approved and rated at 2Amps 250V UL approved. 5.7 Electrical wiring

The mains input to the power supply should be wired into the separate PSU via the terminal rail. The low voltage outputs of the power supply then wired to the I/O board. A separate DIN rail is provided to accommodate auxiliary devices.

The power supply and I/O board are housed in a stainless steel enclosure with a lockable-hinged door. All electrical wiring has been designed to meet the requirements of EN 60204-1 electrical safety of machinery. Generally, the metal detector range has a current consumption of less than 3 Amps. The following cable sizes have been chosen to provide sufficient current carrying capacity and mechanical strength. Power wiring shall be black 1.0mm2 tri rated cable with current capacity of 17Amps. DC control wiring shall be blue 0.5mm2 tri rated cable with current capacity of 11Amps. All cable entries to the enclosure are via metal cable glands with high ingress protection. Pin Label Function 1 -12 -12V from PSU 2 +24 +24V from Input 3 +12 +12V from PSU 4 COM Common from PSU 5 +5 +5V from PSU 6 EARTH Ground connection on PSU supply

PSU to I/O Board CON15 Connections

On the board opposite each of the supply inputs of CON15 are a set of GREEN LED lights to indicate the status of the supply rails. If illuminated the supply rail has a voltage present.


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I/O Board 173A4005 iss 7


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Figure 4: Local Display, metal detector head to I/O board cable wiring diagram

I/O Board 173A4005 iss 7

Figure 5: Remote Display, metal detector head to I/O board and Display cable wiring diagram.

1. Power on LED 2. DC in from quad output power supply unit. 3. Reject relay. (2PCO) 4. Fault relay (2PCO) 5. Warning relay (2PCO) 6. Sensor inputs. 7. USB port. 8. RS232/RS485 port. 9. Insight head connections.


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10. Reset enable. 11. Reset switch. 12. Auxiliary output. 13. Reject output for pharmaceutical and vertical fall systems. Switch selectable. 14. Bin Lock relay / Interlock switch

5.8 Timer Inputs

There are six timer inputs on the I/O Board labelled CON9 to CON14. All timer input connections should be wired as follows:

Pin Use 1 ( +V ) 12V DC supply for sensor 2 ( T ) Sensor output to I/O Board 3 ( 0V ) 0V supply (signal return) for sensor

5.8.1 Tacho Input (CON9)

This input is for use with variable speed conveyor systems. These systems use an inverter or an encoder to generate a pulse stream which is proportional to the distance travelled by the belt, regardless of speed. The software counts pulses from the inverter, as each pulse represents a fixed distance that the product has travelled, accurate rejection is possible even if the belt stops or changes speed. The frequency of the pulse stream must be approx 250PPS when using V6.xx and 500PPS when using V7.xx .

5.8.2 Product Photo-gating Input (CON10)

It is suitable for use in applications where accurate rejection of individual packs is necessary. A photocell is placed to detect product travelling along the conveyor, before it reaches the reject mechanism. Software-configurable delays mean that the photocell's position should not need adjusting for different pack sizes. The sensor must be of PNP type, connected to CON10 and positioned on the in-feed side of the metal detector.

When Product Photo-gating is not used and an accurate count of individual packs is required a PNP type sensor can be connected to CON10 and positioned on the in-feed side of the metal detector. Product count option must also be enabled in User Information.

5.8.3 Reject Systemchek Input (CON11)

This input is to enable the software to check that the reject system has activated correctly. A sensor is fitted on or near to the reject device, which then feeds a signal to the systemchek circuit each time the reject device operates.

If this signal is not received within a specified time period, the fault relay is activated.


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The timer input can be driven by most types of sensor, including reed switches, proximity sensors, and photocells. The sensor must be of PNP type and connected to CON11.

5.8.4 Product Systemchek Input (CON12)

This input is to enable the software to check that the rejected product has gone into the reject bin. Typically a retroreflective type photocell is fitted at the entrance to the reject bin, so the photocell beam is broken as the pack falls into the bin. The sensor must be of PNP type and connected to CON12.

5.8.5 Auxiliary Input (CON13)

The auxiliary input can be used for a variety of purposes. The software can be configured to drive any of the relays on the I/O Board when this input becomes active. For example, the input can be used as a "bin full" sensor, by setting the software to drive the warning relay if the input is active for more than two seconds. As another example, the input could be used as an "air failure" sensor; if the input becomes active for more than one second then the fault relay could be activated. Other alternatives are possible.

The recommended sensor depends on the application, but for a bin full situation, a retroreflective PNP type photocell could be used. The sensor is connected to CON13.

5.8.6 Auxiliary Input (CON14)

The auxiliary input can be used for a variety of purposes. The software can be configured to drive any of the relays on the PSU when this input becomes active. For example, the input can be used as a "bin full" sensor, by setting the software to drive the warning relay if the input is active for more than two seconds. As another example, the input could be used as an "air failure" sensor; if the input becomes active for more than one second then the fault relay could be activated. Other alternatives are possible. The recommended sensor depends on the application, but for a bin full situation, a retroreflective PNP type photocell could be used. The sensor is connected to CON14. 5.8.7 Reset SW (CON4)

The reset switch input allows an external switch to be fitted, this switch enables the operator to remotely accept an error flagged on the display and continue detection.

5.9 Relay Outputs

The PSU has three sets of relay outputs (CON5-CON7) which all work in the same way. The outputs are voltage-free, isolated relay contacts rated at 250V, 2A (non-


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inductive). The symbols on the silk-screen, by the side of the connectors, indicate the position of the relay contacts when the system is in default running state.

Failsafe operation can be achieved via correct wiring, an example of which is described in the "Fault relay" section below. The fault and reject relays are double-pole, double-throw, meaning that two sets of identical contacts are available for each relay.

All three sets of relays contacts (CON5-CON7) work the same way as described in the table below.

Pin PSU switched off Normal running condition Warning Relay 1 Open Closed (connected to pin 2) 2 Common Common 3 Closed (connected to pin 2) Open 4 Open Closed (connected to pin 5) N/A 5 Common Common N/A 6 Closed (connected to pin 5) Open N/A

Warning: Mains and SELV voltages may be switched by the relay provided that they are not mixed on any one relay. 5.9.1 Reject Relay (CON7)

When the detector is powered up and not detecting metal, the NC is closed and the GREEN reject LED is ON. When metal is detected, the NO contacts are closed. A reject device would be connected across pins 2 and 3 (or 5 and 6) so that it is activated when metal is detected.

5.9.2 Fault Relay (CON6)

This relay is driven when a fault occurs in the system, for example the detector fails to "balance", or the product systemchek fails to detect product entering the bin. Typically the fault relay would be configured to stop the conveyor by connecting one end of the contactor coil to the NC contacts. This gives failsafe operation as the conveyor won't run when power is not applied to the detector.

5.9.3 Warning Relay (CON5)

The auxiliary timer input (CON13 AUX1 & CON14 AUX14) can be configured to drive this relay under certain circumstances. For example, a "bin full" system might be set up as follows. A photocell is set up across the top half of the reject bin and wired in to the auxiliary timer input (CON13). The software is configured to drive the warning relay when the auxiliary input is active for more than two seconds. Typically a warning beacon is connected across the NO contacts of the warning relay. As a result, if product builds up in the reject bin and blocks the entrance, the beacon will


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light.

5.9.4 Aux Out (CON3)

This output can be used to drive a relay only (approx. 100mA) and can be configure to react to the Auxiliary inputs. 5.9.5 Reset Enable (CON8)

CON8 is the reject enable link, for normal operation a wire link is fitted. If the link is absent then the system will stay in permanent reject mode after a reject. Sometimes it is required for the reject to be latched, the reject is reset by wiring a normally open key switch/reset button, across CON8 and the NC relay contacts on CON7 (Reject relay).

5.9.6 PH/VF (CON20)

CON20 is used to drive a coil based reject mechanism found on the Pharmaceutical and vertical fall detectors. JP1 switch is used to determine which reject system is connected. JP1 Switch Position JP1 VF Vertical Fall (0 - +12V) PH Pharmaceutical (-12V - +12V) The pharmaceutical coil can be driven both ways and the vertical fall coil can only be driven one way. 5.9.7 Miscellaneous configuration

There are two switches on the PSU (SW1 and SW2) between CN1 and the reject relay. These can be used to override the fault and reject relays and work as described below:

Position Reject (SW2) Fault (SW1) NORM Normal operation Normal operation OFF Always reject Always fault ON Never reject Never fault

The switches can be used, for example: to test that the reject mechanism is working; to prevent unnecessary interruptions to production in the event of a fault developing on the detector; to make sure that the relays are working etc.

5.9.8 Bin Lock Relay (CON2) and Interlock switch Input (CON21)

CON2 relay contacts are used to drive a solenoid Bin Lock release mechanism which is under software control. Interlock switch input CON21 monitors Bin lock


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status.

This feature only available on software version V7.xx


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6. COMMUNICATIONS

6.1 USB (CON19)

USB communications is the recommended method to configure and diagnose problems with the detector. It is the standard used on many PC systems and is simple to use for temporary connections due to its plug and play heritage. The connection is limited to 5 Meters and uses a A-Type to Mini-B USB cable. This connection requires a driver to be installed on the PC so the Optix package can communicate to the detector. 6.2 RS232 / RS485 (CON18)

Serial communication with the detector is achieved via this interface. Either RS232 or RS485 can be selected via the PCB links LK1 – LK5, these links MUST be fitted to ensure the I/O board functions correctly even if the interface is not being used!! The links are marked RS232 and RS485 so move the links to the required position to enable the require port type. RS232 is limited to 15 Meters with RS485 running to 1000 Meters. No driver is required on the PC to communicate with the Optix package. The communications are fixed with a configuration of:- Baud: 38400 Bits: 8 Parity: None Stop Bits: 1 Flow Control: Hardware CON18 Pin RS232 RS232

Direction RS485 RS485

Direction 1 RXD In TX+ Out 2 TXD Out TX- Out 3 CTS In RX+ In 4 RTS Out RX- In


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7. REJECT SYSTEM

A number of different systems can be created with the INSIGHT system to satisfy a wide range of user requirements. Information and advice is readily available from Lock / Loma engineering personnel. In this section of the manual, two common reject configurations are described. This is then followed by more general information, allowing the user to design a system to meet their needs exactly.

7.1 Alarm Reject System

Figure 4 below shows an example of a simple alarm circuit, designed to stop the conveyor in the event of metal being detected and to activate an alarm. It is also recommended the optional reset latch is used to provide maximum system integrity.

Figure 6: Alarm Circuit Under normal operation, the relay contacts on CON7 keep the contactor enabled, allowing the conveyor to run. If metal is detected, the relay contacts switch over, disabling the conveyor and activating an audible and/or visual alarm.


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7.2 Photo-gated Reject System

In many cases the detector will be required to reject individual packs, without stopping the production line. A typical circuit to do this is shown below:

Figure 7: Photo-gated Reject Circuit In this circuit a solenoid valve is used to activate the reject mechanism (e.g. a pusher or air-blast). When metal is detected, the detector uses the input from the photocell connected to CON10 to decide when to activate the reject relay. On activation, the normally-open contacts close, switching on the solenoid, and rejecting the product. For systems using pneumatic reject mechanisms, the air supply should be clean and dry. With the exception of the air blast reject mechanism; the normal operating pressure should be 5.5 bar. (80psi)


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8. TROUBLESHOOTING

The aim of this section is to help solve problems, which may be encountered with the metal detector system. 8.1 False Triggering

There are many possible reasons for it, so the first thing to do is to narrow down the source of the problem. To do this, select the "TEST SETUP" preset and follow the procedure below.

False Triggering when no product is present?

Switch into Test Setup preset

Still triggering See below Switch back to product preset

and carry out a new auto setup

Re-Test with test samples Please check the following:- 1. All four supply voltage status indicator LED’s located on the I/O brd

are ON. 2. All wiring connections on the PSU are correct and secure. 3. All earth connections are correct and secure. 4. Mains supply is free from interference. 5. The support structure is free from vibration, and earth loops. 6. All metal objects are outside of the MFZ. 7. All fixing screws and nuts are tight. 8. Stop conveyor belt motor.

Still false triggering?

Switch back to product preset that was false

triggering? Re-Test with test samples.

Carry out a noise test without product and take note of setup figures.

Repeat without product but with Conveyor running and note setup

Contact Loma / Lock service dept. Have the setup and noise figures

Re-Test with test samples.

Carry out a new Auto setup and note the setup

figures.

Yes No

No

No

Yes Yes

Yes


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8.2 I/O Board Diagnostics

Two yellow LED’s are mounted on the I/O board to aid diagnostics, these can be monitored to assess the following issues with the board. MCU STATUS LED 1 indicates operating status of the MCU on the I/O board. On for normal run mode and Off indicates a problem. MCU STATUS LED 2 is used as a pulsed diagnostic light i.e. You count the pulses to determine the fault, the LED is timed to be off for 1 second and then flash the fault pulses during a fault condition. Example: The Tacho communication to the head has failed which is diagnostic code number 2, MCU STATUS LED 2 will flash twice quickly followed by turning off for 1 second.

MCU STATUS LED 1

MCU STATUS LED 2

Diagnostic Code

Fault

On Flashing faster than 1 per second

0 Running normally

On

1 Pulse 1 I/O communication failed

On 2 Pulses 2 Tacho communication Failed

On 3 Pulses 3 I/O communication message mismatch

On 4 Pulses 4 Tacho communication message mismatch

On 5 Pulses

5 Input refresh disabled

Off Off

N/A Processor not running

Off On

N/A Boot loader running

8.3 MCU reset

This button will restart the I/O board and can be used if the system locks up or requires restarting without turning off the main power. 8.4 Noise Test

In the unlikely event of the detector becoming faulty there is an option in the software called Noise Test, which can be used for fault diagnosis. The Noise Test is basically an auto setup, which measures the metal detector electronics noise level. The Noise Test should be carried out without product going through the detector and the unit must be free from any vibration. This information should be passed to the Lock / Loma technical department when contacting them for assistance.


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9. RECOMMENDED SPARES LIST

DETECTOR HEAD ELECTRONICS

Board Description Part Number

Analogue Brd 173A4004

Digital Brd 173A4001

PSU I/O Brd 173A4005

Power Supply Q547-0092

VACUUM FLUORESCENT DISPLAY

Board Description Part Number

Keypad Membrane 173A2600

Display Brd Q901-0018


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10. GLOSSARY

10.1 Aperture The hole in the metal detector through which product passes. 10.2 Bargraph On the bottom line of the detector's display, after power on or reset, a line of circles is displayed. The more circles, the larger the signal from the product. Solid circles indicate that metal has been detected, while hollow circles indicate product effect or noise. 10.3 Test Setup This product setting is set up at the factory to detect the standard test sample provided with the detector, without false triggering. By selecting TEST SETUP and passing the standard test sample it is possible to see if the basic sensitivity of the detector has reduced since it left the factory. If it sees the sample but false triggers, then the environment is noisier (see noise below) than when the detector was initially set up. 10.4 False Triggering False triggering is when the detector indicates that it has seen metal when none is present. This can mean that good product is incorrectly rejected. 10.5 Metal-Free Zone Any metal that moves near to the aperture may be detected by the metal detector. This could result in false triggering. To prevent this, there should be a metal-free zone around the detector aperture i.e. an area where no metal is present. 10.6 Noise In connection with metal detectors, noise usually refers to electrical noise, sometimes called interference. Noise is unwanted signal picked up by the metal detector, sometimes resulting in false triggering or reduced sensitivity. Noise can be generated by unsuppressed solenoids, inverters, earth loops, high-current-carrying cables, welding equipment operating nearby etc. 10.7 Noise Test This is a fault diagnosis test, it is an automatic setup which can be carried out in the event of a fault occurring on the detector. The auto setup values should be noted and then passed to the Lock / Loma engineer when calling for assistance. 10.8 Product Effect Some products have a signal, which can be seen by the metal detector - this is called the product effect. Its effect, in some cases, is to partially mask the signal from metal contamination resulting in a lower sensitivity. Product effect can be caused: by small amounts of metal in the product's recipe e.g. iron-fortified cereals, vitamin


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tablets or packaging materials e.g. metallised film or recycled cardboard as well as salt content and fat content. 10.9 Sensitivity The smallest size of metal contaminant that can be reliably detected without false triggering. If the detector is too sensitive, unwanted rejection of good product will take place. If the detector is not sensitive enough, metal contamination may be missed. Sensitivity can be changed in the software by changing the product parameters. 10.10 Systemchek A means of verifying that the reject mechanism has operated when required to do so (reject systemchek) or that the contaminated product has entered the reject bin (product systemchek). It is controlled by one or two photocells connected to the PSU and settings in the software. 10.11 Test Sample When a metal detector is shipped by Loma / Lock, a test sample is sent with it. This is a small piece of metal embedded in plastic or a laminated card. This can be used to test the basic sensitivity of the metal detector, i.e. the sensitivity of the detector without compensating for product effect. 10.12 Trigger When the metal detector detects metal. It is indicated by the bar graph showing solid circles, and the reject count incrementing. 10.13 Product Guide These are pieces of non-metallic material designed to allow product to pass consistently through the centre of the aperture. 10.14 Skid Plate Non-Metallic component, which lies between the bottom of the aperture and the upper path of the conveyor belt. It is used to support product as it travels through the aperture. It should not distort under load so that it touches the aperture.


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Insight installation manual iss3 - SIGMA Equipment...(Q875- 0201-5.0-ENG) Models Covered . INSIGHT HD Software Version 6.xx & 7.xx 2014 Loma Systems, a division of ITW Ltd. Summit

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