LOCK Inspection Sytems LTD MET 30 Plus Operating Manual

N"t3'{{i?

MET

30+

MetalDetectors

Operating

Manual

INSPECTION

SYSTEMS

LTD

H3I$1

Lock

Inspection

Systems

MET

30+

Operatirg

Manual

Software

Version

1.xx

O

2001

LOCK

Inspection

Systems

Ltd

Lock

House

Neville

Street

Oldham Lancs OL9

6LF

Tel

0161

6240333

Fax

0161

524

5181

REF:Q875-0019-issue

3

MET 30+

Operating

Manual

Metal

Detectors

CONTENTS

1.

GENERAL

2. HEALTH

AND

SAFETY

2.1

Health

and

Safety

at

Work etc.

Act

3.

INTRODUCTION

4. SETTING

UP

THE

MACHINE

4.1 Deterctor

Display

and

Keypad

4.2 Initial

Test

4.3 Product

Setup

4,4 Timer

Setup

5.

USING

THE SOFTWARE

5.1

Power

up

5.2 Security

Codes

5.3 Operator

Menu

5.4 Supervisor

Menu

5.5

Engineers

Menu

6. OPERATION

CHART

7.

TROUBLESHOOTING

GUIDE

7.1

FalseTriggering/PoorSensitivity

7.2 Fails

to

detect

test

sample

7.3

Detects

sample

and does not

false trigger

7.4

Detects sample but false triggers

8.

SAMPLE

TEST

8.1

Operation

8.2

Recommended

action on failing

test

8.3

Engineering

setup

8.4

Sample

test

flowchart

9.

PRINTER

9.1

Print

Modes

9.2

Reports

9.3

Engineering

SetuP

9.4

Printer

Cable Diagrams

4 4

4

5 6

6 7 7

9

12

12 15 16 17

.,,

28 29

29 29 29 29

30

30 31 31 33

34

35 39

4l 43

10.

GLOSSARY

10.I

Aperture

10.2

Bargraph

f

0.3

Factory

Test

Setup

10.4

Fahe

Triggering

10.5

Metal-Free

Zone

70.6

Noise

10.7

Product

Effect

10.8

product

Guide

f

0.9

Sensitivity

10.10

Skid

ptate

10.I1

Systemchek

10.12

Test

Sample

10.t3

Trigger

44

44 44 44

44 44

44

45

45 45 45

45

3

1. GENERAL

The

instructions

given

in

this

manual

have

been

written

clearly

and

briefly

to

enable

an easy

understanding

of the

actions

necessary

to install

and

operate

this

equipment. ln

order

to ensure trouble-free

and reliable

service it

is

strongly

recommended

that

operators of the equipment are

provided

with

this

manual

in

order

to familiarise

themselves

with the

controls and

procedures.

2. HEALTH

AND

SAFETY

2.1 Health

and Safety at Work

etc. 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 operation

of the

plant

be competent

and experienced

in the work, and

that they

comply with

the statutory

requirements

and

regulations,

including

the

provisions

of

the Health and

Safety

at Work Act,

and

any

amendments

that may become legal

requirements.

Note: For

installation of the MET30 + refer

to

the

lnstallation

Manual

4

INTRODUCTION

This

is the manuar

for

the

MET

30+.

Berow

is

a

summary

of

the

information

contained

in

each

section

of

the

manual:

Setting

up

the

machine

A

description

of

the

user

interface

to

the

detector

(display

and

keypad)

is

in

this

section'

Following

this

is

a

test

to

make

sure

thai

the.

basic

,vri",r.r

is

working

correctly'

This

is

foflowed

by

details

of

how

to

set

up

the

,yste-m

ior

a

particular

product,

including

detection

parameters

and

timeriypu.

Using

the

software

A

complete

reference

to

the

software.

Every

option

in

the

software

is

described.

Operation

Ghart

Block

diagram

of

the

MET

30+

menu

system.

Troubleshooting

Guide

A list

of

common

problems

that

may

be

encountered

and

possible

solutions.

Sample

test

guide

Detail

sample

test

instructions.

Printer

Detail

printer

instructions.

Spares

List

A

list

of

spares

available

for

MET

30+.

Glossary

A list

of

terms specific

to

metal

detectors,

and

their

meanings.

3.

4.

SETTING

UP THE MACHINE

The detector

and

reject system

(if

fitted)

should now

be completely

installed.

The

aim

of this

section

is to describe

how

to set up

the detector

for

a

particular

product,

including

automatic

setting

of detection

parameters

and calibration

of timers for

accurate

rejection.

For more detailed

explanation

of the software,

please

consult

the next

section in the

manual.

lf

problems

are encountered

during setup, read

the troubleshooting

section

of the

manual.

4.1

Detector

Display

and Keypad

Switch

on

the

detector, but not the conveyor. The

display should

look similar

to that

shown

below.

Figure :

Detector

display and keypad

The display

has

two

lines of 20 characters,

and

after

power

on or reset,

the top line

shows

the

current

product

name

and the

bottom

line

shows a "bargraph".

The

bargraph

can

be used to see

how

good a product

setup is:

the circles

show the size

of signal

being

detected,

the more circles

the

larger

the signal. Solid

circles indicate

that

metal

has

been

detected. Hollow

circles

indicate

product

effect

or metal

contamination

that

is

not

large

enough to

trigger the

metal detector.

lf many hollow

circles

are

displayed

each time a

product passes

then the detector

may be at

risk

from

false

triggering.

When

no

signal is detected two circles will

be

displayed on the

bargraph

to

indicate that the

detector is

actively

looking

for metal.

6

The keypad

has three keys,

labelled

from

teft

to right

S:F_$B+]!,

!$, ,*,

tf

at

any

time it

is required

to

reset

the unit, all three buttons

on the

keypad

should

be

pressed

simultaneously.

This causes

the unit

to

reset

as though

it

has

just

been

switched

on.

4.2 Initial

Test

Every detector

is shipped

with a test sample

-

a small

piece

of

metal

to

test the

detector

with.

This test

sample will either

be embedded

in

the end

of a 30cm

grey

plastic

stick,

or

in

a credit-card-sized,

plastic-laminated

card.

Before

the

detector is

shipped,

it

is

set

up to see

this sample without

false

triggering

(false

triggering

is

when the

detector indicates

that

it has

seen metal

when

none

is

present,

and is

due

to

electrical

noise,

vibration,

large

product

effect, etc.).

This

setup is

stored

on the

detector

under

the name

"FACTORY

TEST

SETUP".

With

the detector

switched

on, and the

conveyor off check

the

bargraph

to make

sure

that

the

machine

is

not

false

triggering. Switch

the conveyor

on. The

bargraph

on

the

metal detector

should show no more activity with

the conveyor

running

than

when it

is off. lf the

detector starts to false

trigger, consult

the trouble-shooting guide.

lf a

reject

mechanism

is fitted,

use the reject override switch

in

the

power

supply

to

activate the

reject mechanism. lf this is

detected

by the

metal

detector

(i.e.

the

bargraph

shows

solid circles)

then consult the trouble-shooting

guide.

With the

conveyor

running,

pass

the

test

sample

through the

aperture.

The

detector

is least sensitive

in

the centre of the aperture,

so the best

test is

to

pass

the

sample

through the

centre of

the aperture. With a test stick

this is relatively

easy. With

a test

card,

it

may

be necessary to

put

the card

on

a box to lift

it

up

in

the

aperture,

but

make sure

that

the

box contains no metal itself,

by

passing

it

through

the aperture

on

its own and

making sure

the

head doesn't

trigger. When

passing

the test sample,

make sure

that hands,

rings,

watches

etc. are kept

away from

the aperture.

lf the

detector

does

not see the test sample, then check

that the

power

supply is

correctly

wired. lf

it is

then consult Lock.

4.3

Product

Setup

The

aim of this

subsection

is to

get

the

metal

detector to learn

the

characteristics of a

particular

product.

In

order to do this, some

product

samples will

be required. The

description

of how to use

the software

is kept deliberately brief in

this subsection, for

more detail

see the

next section in the

manual:

"Using

the software".

Press

on the keypad,

you

should be asked

to

enter

a security code. The

factoryGfault

setting

for

this

is

2000, so

press

FFJfiffi

to enter the

code.

The

display

should

then show:

Do

sample

test

7

P.ress

fl_r9ur

times,

th.en

ffi

to choose

setup

product.

press

-"gain

to

choose "New

product",

and then

type in

the

product

name.*.Use

tne"ffi6pt

feys

to

change the current letter,

and when

this

is correct

press

$*g_-ffi$

to move

to

the next

letter.

when the

product

name

is finished, press

ffff;ffiffiiffio

accept

it.

The display

should

now

show:

+

Automatic Manual

Press

S",fiffiff

to choose

standard, resulting

in the following:

Adjust

tolerance

NO

Make

sure

that

the

conveyor

is switched

on

and that

product

is ready

to be

passed.

Once

ffi

is

pressed

to

start

the automatic

setup,

product

will

need

to be

passed

continuously

until

the setup is finished,

otherwise

the

detector

will be

unable

to

learn

the

product's

signal correctly.

While

passing

the

product

make

sure

that no

metal

goes

near the

aperture,

particularly

watches,

rings

etc.

Press

S-Hlgm

,

the display should

show

lnitialising for

Keep

passing

product

until

the display shows

something

similar to:

H=60

G=15

P=

0.0'

T=120o/o

Press

S'Eiffi

to

return

to the display

showing

the

product

name

and

bargraph. The

detector should now

be setup to ignore

the signal

from

the

product,

but

stitl see

metal. Pass

the

product

through the aperture

and

make

sure

that

detector

does not

trigger. lf

it doesn't, move

on to the

"Timer

setup".

lf

the detector

does

trigger

on the

product

read

the notes

below.

Notes

on

automatic setup

The detector

will

usually

be able

to set itself

up

automatically,

however

the following

points

should

be

borne in

mind.

Products

can have

different

effects

depending on

their temperature -

this

a

particular problem

when

frozen

product

starts to thaw,

or

a

hot

product

is

allowed to cool down. Orientation

of

product

can

also affect

product

effect,

e.g.

if a setup

is done

with

packs

passed

lengthways,

a

pack

passed

widthways

may be rejected.

8

lf

the

product

varies a lot

e.g.

pieces

of

meat;

or the environment

is

electrically

noisy,

then

the

sensitivity

of

the

detector may

need to be reduced.

In

order

to do

this read

about

"product

detection envelope",

"Height

adjustment"

and "Width

adjustment"

in

the next

section

of the

manual.

4.4

Timer

Setup

There

are

two

parts

to this.

The

first is to tell the detector what

sort

of

system is

connected

to

it, i.e. whether it is variable speed

and

whether

there

is a

product

gating

photocell

or

not.

The

second is to

set the correct

timer

values

to reject

the

correct

pack.

Press

S.Em

As

before

you

should

be asked to enter

the

security

code.

The

factory'"fefauif-setting

for this is 3000.

Using the

fli

and

i$

keys

scroll to

the

(e)

Engineering

setup

and

cycle

through the

available

options, the

two required

for

timer

setup

are:

(c)

Configure

system

and

(R)

Adjust reject timer.

To tell the

detector

about

the

system

connected to it,

enable

the relevant

timer

inputs

and

adjust

their

polarities

according to the

instructions in

the

subsection

entitled

"Configure

system"

on

page

25. ll the

conveyor and reject

mechanism

has

been

supplied

by

Lock

this should

be already set

up.

Every

product

has a

timer

associated with it.

This

timer

is responsible

for deciding

when the

reject

mechanism should be activated after metal contamination

has

been

detected

by

the software.

When

a

new

product

is

created the timer

values

for

the

are copied

into the

new

product.

lf the new

product

comes in a different size

pack

to the

it

may be

necessary

to adjust some of

the timer values.

The values

can

be

changed

in

the

"Adjust

reject timer" option on

page

23. Please

read this

before

proceeding.

There

are

two

basic situations with regard

to

setting timer

values:

either

there

is

a

synchronising

photocell,

or

there

isn't.

Other

variations will be

discussed

later.

9

4.4.1

No

Synchronising

Photocell

Only

two

parameters

are used in

this

situation:

delay

time and

reject

time.

trtaacr

''

YY"'

,l

deloy

treject

When the

detector detects metal

it

generates

a trigger

pulse.

This

starts

a delay

timer.

When

the delay

timer expires

the reject

relay is

activated.

The

time

for which

the

reject

relay

remains

active for

can be

changed

by adjusting

the reject

time. lf

there are

many

triggers,

the reject

relay will

be activated

after the

correct

delay, for

each trigger.

For an

immediate

reject,

set

the delay

time to

0.01.

4.4.2

SynchronisingPhotocell

This system

uses

a

photocell

to make

sure that the

contaminated

product

is in

the

correct

position

with

respect to

the reject mechanism.

Four

parameters

are used in

this

situation:

delay and

reject

time

as before, as well

as a

photocell

delay

time and

an

enabling

alarm time.

rrr9ger

nhrnfoeoll

^.,t^^

PU

r>s

ohotocell

deloy

rejec

r

oeroy

10

When the

detector

generates

a

trigger a delay

timer is

started

as

for

the

"no

synchronising

photocell"

situation. When

the delay

timer expires

an enabling

alarm

timer is started.

The reject mechanism will only

activate while

this

alarm

timer is

active.

As

each

product

passes

along the belt it

breaks

the synchronising photocell

beam and

generates

a

photocell pulse.

A

photocell

delay

timer

is then

started.

lf this

expires

and

the

product

was uncontaminated then

the

alarm

timer will

not

be

active

so nothing

happens. However if the

product

was contaminated

then,

when

the

photocell

delay timer expires, the alarm

timer

should

be active. ln

this case

the

reject

relay is

activated.

ln order to

set

this

timer

up, set

the delay time to 0.01s

and the alarm

time

to

something

large, e.g.

10.0s.

Set

the reject time,

0.2s

is typical for

an air-blast or

pusher

reject.

Pass a contaminated

pack

and adjust the

photocell

delay

until the

reject

mechanism

operates at the correct time

to

reject

the

pack,

i.e.

if the reject

mechanism

activates too

late

then reduce the

photocelltime,

and vice

versa.

Once

the

reject

and

photocell

delay times have been

set

up, the delay

and

alarm

times

need

setting. lf

these

times are

not

correct then

good packs

preceding

or

following

the

contaminated

pack

may

be

rejected

as

well.

Attach a

metal

sample

to

the back of the

pack

and

pass

the

pack

through

the metal

detector.

The

pack

should

be

rejected. lncrease

the delay time

by

0.1s

and

pass

the

pack

again.

Keep

doing

this until the

pack

is not

rejected.

Decrease

the delay

time by

0.15s

to

allow a safety

margin.

(lf

the system

has a

variable

speed conveyor

decrease the

taco

pulses

by 2to allow a safety margin.)

To set the

alarm

time a similar

procedure

is

performed.

This

time the metal sample

should

be

placed

on the

front

of the

pack,

and the

alarm

time decreased

until the

pack

is not

rejected. To speed up the

process,

adjust

the

alarm time in

large

steps

initially,

e.g.

10s,

5s,2s, 1s. lncrease the

alarm

time

by 0.15s

(or

2 delay

pulses)

to

allow a safety

margin.

4.4.3 Variable

Speed

Gonveyors

For

variable

speed conveyors,

the timers work

in exactly

the same

way,

except that

the

delay

time,

and where applicable

the

photocell

delay

time, are measured

in tacho

pulses,

i.e. these

values

are

based on distance travelled rather

than time

elapsed.

11

5,

USING

THE

SOFTWARE

This

section

of the

manual describes

what

the software

does and how

to use it. ]t is

intended

mainly

for

reference and

is

not

meant to

describe

how

the software

would

typically

be

used,

or why certain

options are

required.

5.1

Power

uP

When

the

unit

is

switched

on

it will display the

product

name and bargraph. This is

called

the

normal

running display.

TEST SETUP

oo

Pressing

the

ffi

or

ffi

keys

will cycle

the display through

the

product

setup,

status and

back

to

the

bargraph.

None of the

information can be

modified at

this

level.

Pressing

the

ffi

key will

first show a screen

showing

the reject and

product

counts:

I count:

3147

count:

1

The

to

be displayed

shows detection

parameters:

G=15

P= 3.7"

T=120o/o

W

is

the

width,

H

the height

and

P the

phase

(0)

used

for

detection

as is

shown on

the

diagram

below.

Note: width

and height

refer to characteristics

of the

electrical

signal

from

the

product,

and

have nothing to

do with

the

physical

dimensions of the

product.

12

The

height

value

is shown in

brackets if

height-checking is

disabled, i.e.

the

height is

not

being

used

for detection

and the

product

detection envelope

is

open-ended.

g

T

;-^

a

0

phate

h

height

w

widlh

f

Figure :

Product detection envelope

The

other

figures

displayed are

the

gain

(G)

and tolerance

(T).

The maximum

gain

of

the

system

is

15. lf the

product

effect

is large, the

gain

will

be

reduced.

The

tolerance

is the

amount

by

which auto-setup

values

were adjusted to

get

the

product

setup, for

example,

if

the

value of

width measured

during auto-setup were

50 and the

tolerance

120o/o,

then

the

value

of

width used

for detection and displayed in the screen

above

would

be 50

.

(1201100)

=

69.

By simultaneously

prgssing

t!'," and

$

key's the

following

the

engineering

displays

are

shown.

(i-0;

and

ff

key's can

be used

to cycle through the

displays.)

The first

screen

shows

version information:

30+Ev1.02 csum

=

DEC4

89235

286KHZ

The top

line

of

the display

shows the

version number stored

in the EPROM

and the

checksum

of

the

EPROM. The bottom line shows

the detector

id string. This is free

format

text

and

would typically be

used to

show the serial number

of the head, its

frequency

etc.

The

shows

A/D values ( For lock

service engineers

only

):

33

42 0;4

55

41

2,5

13

The next screen shows

the

digital

l/O

data

(

For

lock

service

engineers

only

):

Inputs:

00000000

Outputs

:

11111111

The

next screen shows

timer

parameters:

Ph,Dl

=

2.50,

2.00s

=

5.00,

0.35s

The abbreviations have

the

following

meanings:

Ph

Photocell delay

time

Dl Delay time

(from

trigger

to

start

of alarm

time)

Al Alarm time

(time

during

which

delayed

photocell

pulses

will

cause

rejects

to

occur)

Rj Reject time

The exact form of

the

display

varies

with

system

configuration.

lf

a variable

speed

conveyor

is being

used

all

timer values

apart

from reject

time

will be

displayed

as

a

number of tacho

pulses

(pul).

lf

the

system has

no

photocell

then

photocell

delay

time and alarm time

have

no

meaning,

so

they wilr

not

be

displayed.

The way

timers

work

and how

to

set them

up is

explained

in

the

subsection

entifled

"timer

setup".

The next

screen

shows

the

systemchek

time.

time

5.00s

The

next screen shows

system

configuration:

VPL

kITGRPA

tgrpa

1

10 10

01 101 101

10

The

letters have

the following

meanings

(1

means

on

or

yes):

rrvrr

-

Verticalfall

on?

rrP'l

-

Phase tracking

on

by

default?

',L"

-

Autolearn

on by

default?

t'kr'

-

Trackingenabled

for

current

product?

"1"

-

Autolearn enabled

for

current

product?

rrT"

-

Tacho enabled

(variable

speed)?

"t"

=

Tacho

input

polarity.

14

'rc'r

-

Photogated?

"Rt'

-

Reject

systemchek enabled?

"P" - Product

systemchek enabled?

"Ar' - Auxiliary

input

enabled?

Photogate

polarity.

Reject

systemchek

polarity.

Product

systemchek

polarity.

Auxiliary

input

polarity.

ttgtt=

ilfil

_

l-

ttptt=

il^||

_

a

The

shows

the NOISE TEST

option.

NOISE

TEST:-

Press'SEL'

Pressing

tn"

Fffi

key initiates

a Noise

Test. A message

is

displayed

asking

the

user to

wait.

After a short time the

data is

displayed

as detection

parameters.

Following

this

is

a screen showing

the serial

port

setup:

A:9600

N81

-

B:9600

E81 - RS2485

There

are

two serial

ports

on the Met

30+. The first

(called

A)

which is

set

to RS232.

The

second

port (called

B) which is

a dedicated RS422/485

(multi-drop)

The

first number

displayed

after the

':'

is the

baud rate. This is followed

by

the

parity

(N=None, E=Even, O=Odd,

M=Mark

[always

1],

S=Space

[always

0]). The

digits specify

the number

of data bits

and stop bits respectively.

After

this is

a

'-'

indicating

no

handshaking.

Following

this is either RS232

or

RS485

showing

the

mode

in

which

the

port

is being used,

and finally

there

is a letter

or

'-'

showing

the

type of

information

being

transmitted

on

the

port:

'-' means

no information, 'P'

means

printing,

'A'

means ADC data

(for

diagnostic

purposes).

5.2 Security

Codes

Four security

codes are used

by the software, in increasing

order

of

security

these

are: operator,

supervisor, engineer

and

Lock.

When

the

unit is

supplied

they are set

to a default

code but this can

be

altered

by the user. They

are:-

OPERATOR

1000,

SUPERVISOR

2000 and

ENGINEER

3000. The Lock

code is for

use

by Lock

lnspection

service

engineers

and contains machine

configuration

and

debug

options.

On

pressing

.$'ftKffi

from

the normal running

display

(where

the

product

name

and

bargraph

are

displayed),

the following

screen is

shown:

r

security code:

0

15

Entering the

operator code

allows access

only to the

operator

functions

(changing

product,

sample

test

and

print

report).

Entering

the

supervisor

code

allows

access

to

supervisor

functions

in

addition

to operator

functions

and

so

on. lf

any

of the

four

security

codes

have the

same value,

then the software

will allow

access

in

line

with

the

highest

level security

code.

For

example, if

the supervisor

and

engineer

codes

were the

same

then entering

this

code

would

allow

access to

the

engineering

options

(as

well as

the

supervisor

options).

The security

code will

remain

active for one minute after

the

last

key

press.

5.3

Operator

Menu

The lowest

level menu

looks

like:

Use_[[!*ff;

and

$

key's to select an

option shown by the

first

letter flashing

then the

-S*ffm

key

to select

it.

5.3.1

Test

This option

allows a test of the metal detection

sensitivity

to

be

done.

Firstly

the

software

asks

for a PIN

(personal

identification number):

Enter

number:

1234

After

the

is entered the user

has nine

seconds to

pass

the

metal

sample.

lf the

detector

fails

to detect

metal

in this time it displays the message

"TEST

FAILED",

and waits

for

the

ffiruffiffi

key

to be

pressed

and returns

to the

bargraph

display.

lf

metal

has

been

detected

then

"TEST

PASSED" is displayed

and waits

for the

(ffiffi

key to

be

pressed

before

returning

to the bargraph display.

5.3.2

Product

This

menu

item allows different

product

setups

to

be

chosen.

On

selecting this menu

item

a

product

name and

number

are displayed.

fhe,ff.;ffi keys

may be

used

to scroll

through

the

list of available

products.

When

the

desired

product

is

displayed

press

$Jffi

to

set up

the MET 30+

for

that

product.

Test

Print

Exit

16

5.3.3

Print

This menu

allows

you

to send a

report

to the serial

port

for

printing

if

the

'Print

on

demand'

option

has been

set in the engineering option. lf

'Print

on

event' has

been

selected

the

report is sent to the serial

port

as soon as

the

test has

been

done. lf

the

'Print'

option

is selected

when

'Print

on event'

is

used then

'Printing

on

event

is

displayed

and

it

ryfllgjgJ-'th" ffi

key before

returning

to the

menu.

To return

to

the

bargraph

the

ffi

and

#

keys must be

pressed.

When

the'Print

on demand'

option

ii

used

the-Piint

option 6 selected by

the

ffi

or

=*

keys.lhggflg

$ffi#t

f"V.

When

this

is

don*e_!!g display shows

'Printing

report'

and

'S*S!ffi$$

to end

print'.

Pressing

tn.

ffiffi

key

stops the

print

out.

The report

Cin be

re-printed by

selecting

the'Print'option

again.

No reports can be cleared

from

this

menu.

5.3.4

Exit

Select

this

to

return

to the

normal running display.

5.4

Supervisor

Menu

The supervisor

menu

looks

like:

TPRCSEDcoselx Do sample test

The display

is

shown

with one oJ the letters

flashing, the text will

change

depending

on

which

letter

is selected. The # key cycles the

letter to

the left

and

the

tO

key to the

right.

The

letter

have

the

following meanings :

T

=

Do sample

test

C

=

Clear

counts

D = Delete

product

P

=

Select

product

S = Setup

product

R = Print report E

=

Edit

product

c = Set

system clock

o = Operator's

code

s

=

Supervisor's

code e = Engineering setup

| = Lock

engineering

x

=

Exit.

5.4.1

Do

Sample Test

(T)

:

Same

as

Test

option

in the operator

menu.

5.4.2

Select

Product

(P)

:

Same

as

Product

option in the operator

menu.

17

5.4.3

Print

Report

(R)

:

Same as

the

Print option

in the

operator menu

but

this time when

the reports

have

been

printed

Clear records ? No

is

displayed.

The

default is

No

but

this can be

changed

to

'Yes'

by

either

the

'ilE ' or'ffi' key. The

'S".ff"m

'

key

is

then

pressed

and returns

to the supervisor

menu.

5.4.4

Clear Counts

(C)

:

Use

this

option to clear the

reject

and

product

counts

to zero.

Note

that

product

counting

is only

reliable for

certain sorts of

product

with

well-defined

product

effects.

5.4.5 Setup

Product

(S)

:

The display

initially requests

selection between

set

up

for

a new

product

or

adjustment

of

an

old

product.

Use

ffiLlj

to move

the

position

of

the arrow

and

;ffiffi

to

confirm the selection.

'+ New

product

Adiust

old

product

5.4.5.1

New

Product

5.4.5.2

Adjust

Old Product

lf

"Adjust

old

product"

is

selected scroll

through

the

list of

products

and select one in

the

same

way as the

"Product" menu item above.

5.4.5.3

Automatic/Manual

Setup

After choosing

a

name for a new

product

setup or selecting an old

product

to adjust,

a choice

is displayed

between doing an automatic

or a manual

setup:

+

Automatic Manual

lf

"New

product"

is selected,

a

product

name must be

entered.

This is

done

by

scrolling

through the

alphab*gh*tne

fiff

keys. When

the

desired

character

appears

on the display

press

m, [_q,

mistake is made

press

the

ffffi

keys until

a

'<'

is displayed

and

then

press

Flffiffiffi#

to

move

back

to the

When

the full

name has been entered use the

ffi

keys

to display

the diamond,

then

press

Product names may be up to 20

cnaracters in length.

18

It

is not

recommended

to do a

manual setup,

this is

primarily

for testing

by

service

engineers,

Press

ffi

to

give

a choice to

proceed

with

a setup for

a

product

with

either

a

standard

or complex envelope.

It is recommended

that

the

standard

setup is used. In a few

cases

products

have

complex

product

signals

that will result

in false

triggering.

In such

circumstances

the

product

should

be re-setup using

the complex option

when

the number

of

passes,

and

consequently

length of time, required

to

obtain the

product

envelope

will

increase.

After

choosing

between

standard

and complex, an

option of adjust

tolerance

is

given:

st Tolerance

NO

Under

normal

circ_umstances,

it is recommended

that

the tolerance is

not

adjusted

by

pressing

S"Affi

Before

proceeding

to automatic

setup

make sure

that the

conveyor

is

running, a1d

pggduct is

passing

through

the aperture

or ready

to be

passed.

As

soon at

ffi

is

pressed

the detector will

initialise

the hardware

and

afterwards

will

expect a

product

to be

passed

through the aperture.

By use

of the

ift

and

l$

keys, Yes

can be selected to the Adjust tolerance

display,

in

which

case

the

following is seen before

proceeding

with

the automatic setup:

Tolerance = 120Vo

The tolerance

is the sensitivity

of

the

detector, the higher the number

the lower

the

sensitivity

of

the detector.

lt is not recommended

to reduce the

tolerance

below

the

defauft

value

of 120% but it can

be increased

to

reduce

the occurrences

of

false

triggering.

5.4,5.4

Automatic

Setup

Once

the hardware

has

been

activated,

the display will

change to:

Pass

product

1

Gain

=

15

19

The

product

should

then be

passed

through

the

aperture,

as

it

would

be

during

production,

until

the setup

parameters

are displayed.

Various

messages

are

displayed while the

automatic

setup

is taking

place,

as an

indication

of what

the

software

is

doing.

Once the

setup

parameters

are

displayed,

e.g.

W=45

p=1843)

5

P= 3.7'

T=120o/o

Press

$Fffi

to return

to the

normal running

display.

The

automatic

setup

is

now

complete.

5.4.6

Edit

Product

(E)

:

Displays the

edit

sub-menu.

EWHPGx Edit

product

name

This allows

the name

and

parameters

of the current

product

to be

altered.

The letters

have

the

following meanings

:

E = Edit

product

name

W = Product

width

H

=

Product

height

P=Productphase

G=Adjustgain

x=Exit

5.4.6.1

Width Adjustment

(W)

:

The display

will

show

something

similar

to

that

shown

below:

oo

The width can be changed

by

pressing

the

ffi

and

ffi

teys.

Use

the

bargraph

to see

how

close

to

false

triggering

the detector is.

5.4.6.2

Height

Adjustment

(H)

:

This option

allows adjustment

of

the

"height" of the

detection

envelope

(see

the

diagram of the

"Product

Detection

Envelope"

earlier).

ight checking=off

oo

20

keys

to

switch

between

using

the

height

or not

for metal

detection. Press

Now

adjust

the

height

as

necessary:

ioht = 0763

oo

5.4.6.3

Phase

Adiustment

(P)

:

Phase

=175.2"(176.1")

oo

The

phase

can

be

adjusted

by

using

tne

ff/#

keys.

The angle

in

brackets

represents

the

phase

of

the

current

product

(if

this can

be

reliably

measured).

5,4.6.4

Adiust

Gain

(Gi

:

The

maximum

Gain

of

the

system

is 15.

lf the

product

effect

is

large,

the

gain

will

be

reduced.

5.4.6.5

Exit

(x)

:

Selecting

the'x'

option

returns

to

the supervisor

menu.

5.4.7

Delete

Product

(D)

:

On

entering

this

option

you

will be

asked

which

product

setup

to

erase:

rase

product: 1

WHITE

BREAD

ffre

*qtffi

keys

scroll through

the

list

of

products

that

can be

deleted.

Note that the

FACTORY

TEST

SETUP

CANNOT

bE dEICtCd.

When

the

product

to

be

deleted

has been

chosen,

press

-SEB-€ffi

Confirmation

will

be

asked

for.

lf

''NO,

is selected

then

no action

is taken

and

the option

is exited.

lf

the

current

product

is

deleted

the

detector

will set

itself

up with the

FACTORY

TEST

SETUP.

21

5.4.8

Set real

time

clock

(c)

:

The

display shows

the

current

date

and

time

(DD/MM/yy):

date

and

time :

25101195

14:24:18

b{ru,

the

date

will

be

high-lighted.

Use

the

ffff

keys

to change

the

date.

press

lffiffitr

to.

move

onto

the

montn

and

adjust

ifris-as

necessary.

eressinl.S,'F..ffi#

again

will

allow

the

year

to be

changed,

then

the

hours

and

then

the

minutes.

5.4.9

Operator's Code (o)

:

This

allows the operator's

access

codg

to

be changed,

the

il}

and

igj

keys

select

each

number

and

the

ffi

key

sets

it.

The

new

cod6

will

oveiwrite'the

olo

on".

5.4.10

Supervisor's Code (s)

:

This

works in exactly

the

same

way

as the "operator's

code"

above.

5.4.11 Engineering

Setup

(e)

:

Can only

be

entered

by

using

the

Engineer

security

code.

5,4.12 Lock

Engineering

(l)

:

Can

only be

entered

by

Lock

engineers

using

a

code.

5.4.13

Exit

(x)

:

Exit the Supervisor

menu

and

returns

to the

Bargraph.

5.5

Engineers Menu

When

the engineer's

code

is entered

the

supervisor

menu

is

displayed.

All

options

are available

except

the

Lock

Engineer.

Selecting 'e'

enters

the

menu.

DA Enr

HVPx

22

The

letters

have the following meanings

.

D

=

Engineering

displays

R

=

Adjust

reject timer

C = Communication

setup

H = Height

checking

r

=

Print status

report

A

=

Autolearn

S

=

Sample

test

reminder

c = Configure system

V = Vibration

setup

x

=

Exit

T = Tracking B

=

Blocked

photocell

E

=

Engineers

code

P = Printer

setup

5.5.1

Engineering

Displays

(D)

:

This enters

the same disptay's as if

the

ffi

and S keys

were

pressed

from the

bargraph.

5.5.2

Autolearn

(A)

:

The

product

effect of some

products

can

vary with

time, temperature

and

batch. To

enable

metal

detection to

remain

accurate and

reliable

as

product

effect

changes,

two

types

of

adjustment

can be

made. The first is called Autolearn.

Sometimes,

for

example

first

thing

in

the

morning

or at the start of a new batch,

there can

be a large

change

in

the

product

effect of a

product.

With

autolearn enabled,

if the

detector

detects

a

consistent

phase

difference

from its current

setup, it

will automatically

learn

the

new

product

phase

angle.

5.5.3

Tracking

(T)

:

The

second

type of

product

effect

compensation

is

called

tracking.

The

detector

measures

the

phases

of

packs

as they

pass

and

tries to centre

the detection

envelope

on

this

phase.

This will cope

with slow drift over a

period

of time,

and

will

remain

sensitive

to metal contamination.

5.5.4

Adjust

Reject Timer

(R)

This

option

allows adjustment

of all basic timer

parameters:

delay

time, reject

time,

photocell

delay

time and alarm time.

Each

parameter

is adjusted

in

turn.

lf

the system does not

have

a

photocell

for

aligning

product

with the

reject

mechanism then the

photocell

delay

time

and alarm

time

are not

available

for adjustment.

lf the system

is variable

speed then the delay time and

photocell

delay

time are

measured

in

pulses

instead

of hundredths of a second.

While

in this

option, the letter

'R'

is displayed in the top right

corner

of

the screen

when

a

reject

occurs.

23

5.5.5

Sample

Test Reminder

(S)

:

This

allows

a

timer to be set which

will

set an alarm after a

duration

of time

set by the

user.

When

this

procedure

is

entered the

p'j

or

ff

fey is used

to

choose

if the timer is

to be used

or

not and th"

ffiffi

key to confirm.

lf

the

timer

is

to be used

the time

delay

before

the alarm

is

entered 1-1000 minutes. After the

time

has expired the

warning

relay

is

activated.

After a further 20 minutes the fault relay

is

activated

and

the display

changes to

indicate that

the sample test is overdue. The

display is reset

by

the

s,._ffi

r"y.

5.5.6

Blocked

Photocell

(B):

This

sets

the

time

in seconds

that the detector

waits for the

photocell,

if used, to

clear

before

an alarm

is

activated.

The

ffi

and

ffi

Xeys alter the values.

5.5.7

Communications

Setup

(C)

On

selecting

this,

a sub-menu

is

displayed:

A

Port B

Det

ld Exit

Options

1 allows

communication

parameters

to

be changed

for Port A. Firstly, the

baud

rate

needs

to

be

selected.

Press'ff@ untit the correct baud rate is displayed

and

then

press

$.ffi

Allowable rates are 300, 600,

1200, 2400, 4800,

9600 and

19200.

Then

select the

parity

(None,

Even, Odd); the

number

of data bits

(6,

7, 8);

the

number

of stop

bits

(1);

and whether

hand-shaking

is

enabled

('H')

or

not

('-').

Note: that

different

cables

and sockets will

be required for

RS4221485

as opposed to

RS232.

Adjustment

of communications

parameters

for

port

B

(option

2)

works in

exactly the

same

way

as

for

port

A. The exception is

that

port

A is dedicated

to RS232

and

port

B

is a dedicated

R54221485

(multi-drop).

Option

3

allows

the

detector

lD

to

be changed.

This is used

to

address

the

detector

in multi-drop

applications

(Datachek).

24

5.5.8

Configure

System

(c)

:

This option

also

has

a sub-menu:

Inputs

Syschek

Aux.

Exit

The first

option

(lnputs)

allows

all the

timer inputs

to be

enabled

or

disabled,

and

their

polarities

to be changed.

T=O_0

G=o->O

P=O_1

A=O-1

R=o_

X

The

letters represent the

different

timer inputs:

T Tacho

(for

variable

speed conveyors)

G

Gating

photocell

(used

to

detect

position

of

product

on

the

belt)

R

Reject systemchek

(to

check

that

reject

mechanism

operated)

P

Product systemchek

(to

check that

rejected

product

entered

the

bin)

A

Auxiliary input

(e.9.

bin full,

air failure

etc.)

X

Exit

(select

this to exit this

option)

The

hollow

circles indicate

that the input is

disabled, and

the solid

circles indicate

enabled

inputs.

An underscore

('_')

indicates

an

active-low

input,

while

a dash

('-')

indicates

an active-high input. Active

high

or

low

should

be

chosen

such

that the

usual

value

of the

input

(as

shown by

the 0 or 1) is low

(0),

and when

the

photocell

is

blocked

the

input should

go

high

(1).The

'Gating

photocell'

option

has

a ">" which

can be

changed

to

'('

,

this shows

leading

edge

trigger'>'

or

trailing

edge

trigger'<'.

On entry

to

the option the

letter'T'will

be flashing.

Use

tne it"y# keys

to scroll

the list

of

time

inputs.

When the desired

input.is

flashing,

press

ffi

The input

can now

be disabled/enabled

by

pressing

the S or

4[

key. Press

S_ffiffi

to

allow adjustment

of the

polarity (active

high/low).

C e the

polarity

so

that the

timer input

is

0 when

the

photocell

isn't

blocked. Press

To exit

this option

press

the .$.:/#

keys

until

'X'

is flashing

and

press

Syschek

allows

the systemchek

time to be changed. This is

only relevant

when

one

or

both

systemcheks

are enabled in Option

Inputs.

25

When the reject relay

is

activated

two timers

are

started,

one

for

the

product

systemchek

and

one

for

the

reject

systemchek.

lf

a signal

from

the

ielevant

systemchek

photocell

is not

received

within

the

"systemchek

time"

then

the

fault

relay

is activated,

and

will remain

activated

until

the

detector

is

reset.

Aux.

allows the fifth timer

input

(CN13

on

the

power

supply)

to

be used

in

a variety

of

applications,

for

example

as

an

air failure

detector

or bin

full

sensor.

To use this facility

proceed

as follows:

first

enable

the

auxiliary

input

in

option

Inputs,

Then

select

option

Aux.

Select the

message_that

most

nearly

describes

whai

the

np*!l__r_s__.being

used for,

by

using

the

i$

and

;s

keys

to change

the

message

and

SEffiE

to

accept it.

Now select the

"Aux.

active

time".

This

is

the length

of time

for

which

the

auxiliary

input

needs

to be high

(active)

continuously

before the

software

drives

the

output

l.9lgY_, .F_9,

a "bin

full"

sensor

the active

time

might

be

a couple

of

seconds.

press

S-E_EjHPr#

when the correct

time has

been

chosen-.

Finally,

ch._gg:-g$ich

output relay

to drive.

Use

the

fi and

#

t<eys

to

change

the

relay

and

StrHffi

to confirm

the

choice.

Although

there

is

a choice

of five

options

for which

relay

to drive

(including

none),

the

two most

useful

are: warning (e.g.

for

bin full ) and

fault (e.9.

for

air failure).

5.5.9 Engineer's Gode

(E)

:

This option

allows

you

to

change

the

engineer's

access

code.

This

is

done

in

exacly

the same

way as changing

the

operator

code described

earlier.

5.5.10 Height

Checking

This

option

can

select

the

'height

checking

enabled'

facility.

When

set,

all

subsequent

Automatic

setups will have

height

checking

enabled

until it

is

disabled,

5.5.11

Vibration

Setup

When

the

MET 30+ metal

detector

leaves

the factory,

the

Factory

Test

Setup

phase

angle is set

to same

angle

as vibration

and

calibrated

to

0 degrees.

This

option

enables

adjustment of

this

angle,

which

may

be if

some

of

the

metal

detector

components

have

to be repaired.

When

this

option

is

set the

following

symbols

are

seen

on

the display:

->[

]>-

26

While these

symbols

are

on the display

a ferrite

rod

must

be

passed

through

the

detector's

aperture.

When

the symbols

disappear

the vibration

angle

will

have

been

re-calibrated to

zero.

The Factory

setup

phase

angle

will

be zero

- i.e.

set

to ignore

vibration.

The displayed

phase

angles

of

all the

products

set

up

in

the

machine

will

have values

relative

to

the new

zero vibration

angle

and

will

NOT

need

adjustment.

5.5.12 Printer

Setup

(P)

:

This option allows

ygy

to set

up the

type

dgllgr

options.

The

three

options

are

cycled

with

the

i&

or # keys

and

set by

th"

ffi

key.

The

three

options

are:-

'Printing

disabled' i.e.

No

printer

output.

'Print

on demand'

i.e.

printer

output when

selected

from

the

menu.

'Print

on

event'

i.e.

prints

when

a reject

or setup

is

done.

Whgn

a

printout

is selectgqlgly&e

of

printer

is asked

for

this is

also

cycled

by the

$

or

i$

keys

and set by the

$ffi

t"y.

The types

are:-

'80

column

printer',

_,'4*0_

column

printer',

'40c

column

printer'

(compact)

and

'20

column

printer'.

The

F,ffiffiF

key

sets

the

type

and

returns

to

the

engineer's

menu.

5.5.13

Print

Status

Report

(r)

:

This option

will

print

out

all setup

parameters

for stored

products.

The

rS

or O. key

changes the

port

from

A

-

B. When

thu

ffiHffi

key is

pressed

the

detector

sends

the status

information to the

printer

or a PC in

receive

mode

then

returns

to

the

engineer's

menu.

5.5.14

Exit

(x)

:

Returns to

the supervisor's

menu.

27

6.

OPERATION

CHART

E.H

or[-T-l

tfl

It

t

E

r--------r-

I I

I

t

I

Bargraph

Disptay

I

tl

Operator

Sample

test

Product

select

Print

report

Exit

Edit

Product

[E]

Edit

name

lwl

Width

adjust

[H]

Height

adjust

[P]

Phase

adjust

[G]

Grain

adjust

[x]

Exit

E+tr

Information

Displays

Product

& reject

Counts

Product

setup

data

Supervisor

[T]

Sample test

[P]

Product

setup

[R]

Print reports

[C]

Clear

Counts

[S]

Setup

product

lEl

Edit

product

[D]

Delete

product

[c]

Clock set

[o]

Operator

code

[s]

Supervisor

code

[e]

Engineering

setup

tll

Lock

engineering

[x]

Exit

Engineering

displays

Version

etc.

Show

ADC

values

Show

port

setup

Timer

parameter

System

check

time

Noise

test

Show

comms ports

[D]

Engineering

disptays

[A]

Autolearn

on/off

[T]

Tracking

on/off

[R]

Adjust

reject

timer

[S]

Sample

test reminder

[B]

Blocked

cetttime

[C]

Comms

settings

[c]

Configure

inputs

[E]

Engineering

code

[HI

Height

checking

[V]

Vibration

setup

[P]

Printer

setup

[r]

Print

status

report

[x]

Exit

Port

A

Port

B

Detector

lD

Exit

28

7.

TROUBLESHOOTING

GUIDE

This

aim

of

this section

is to

list

common

problems

and

possible

solutions.

7.1 False

Triggering/Poor

Sensitivity

This

is the

most common

problem

with metal

detectors.

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

"FACTORY

TEST

SETUP"

product

and

pass

the test

sample

provided

with

the metal

detector.

Now

read the

relevant

paragraph

below:

7.2

Fails

to detect

test sample

The

detector

is now

less

sensitive

than when it left

Lock Inspection.

Check

that the

power

supply

cables

are wired

correctly. lf

everything

appears

to be

OK

call Lock.

7.3 Detects

sample

and

does not

false

trigger

The

detector

is

probably

working

correctly.

Redo

an automatic

setup for

the

product,

which is causing

problems.

lt may be

that the

product

effect

has

changed

since the

last

automatic

setup

was

done. Remember

that

product

mix,

size

and

temperature

can

all affect

the

signal from

the

product.

lf necessary,

reduce

sensitivity

to

reduce

false-triggering

or increase

it

to allow

smaller metal

samples

to be

seen.

Note

that

some

product

effects

make certain

metal samples impossible

to see.

7.4 Detects

sample

but

false triggers

There are many

possible

reasons for

this,

below is a list

of

possible

causes:

Conveyor

belt - belts should

be clean

and contain

no

metal.

Sometimes

metal

becomes

embedded

in

the

belt causing

it trigger the

head

at regular

intervals.

Under

no

circumstances

should

metal fasteners

be used

to

join

the ends

of

the

belt.

Moving metal

in the metal-free-zone

-

there must

be no

metal

in

the

metal-free

zone.

Consult

the

"Machine

Installation"

section

of the manual.

MovemenVvibration

-

make

sure that conveyor

feet

are level,

product

is transferred

smoothly

onto

the

conveyor,

and that

no

vibrating machinery

is

connected

directly to the conveyor.

Earth

loops

-

all metal items

must

be securely

bonded

to each

other

or insulated

from

each- lntermittent

metal-to-metal

contacts

can often

cause

problems.

Electrical

interference - all high-current

cables

should

be routed

well

away

from the

detector and

its

cabling.

29

8.

SAMPLE

TEST

As high

resolution

detectors are

sensitive

devices

that

may

drift

with

changes

in

environment,

it is

prudent

to have

an organised

procedure

for

physically

checking

the

system.

A

known

test sample,

shipped

with

each detector,

should

be inserted

into

an

identified fresh sample of

the

product

and

passed

through

the

detector.

lt

should

be

detected

and accurately rejected.

This

will

ensure

that

the

detector

timing

devices

and auto reject

mechanism

are functioning

correctly. lf

specifications

include

ferrous

and stainless,

both should

be used for

the

test. On a long

product,

the

metal

test

piece

should

be

positioned

at the leading

and then

the

trailing

edge

to ensure the

product

will be

rejected

under all

circumstances.

The Lock

metal detector's

provide

the

'Sample

test reminder'

facility

to ensure

regular testing

takes

place

while the

printer

facility

provides

a hard

record

of

the

frequency

and details of the

test.

This document

describes the operation

of the

'Sample

test

reminder';

details of the

printer

operation

are

given

in the

guide

to using

printers

with

Lock

lnspection

Systems

metal

detectors.

8.1

Operation

The operation

of

the

sample

test reminder

facility is

shown

in

Section

8.4.

This

shows

the

messages

given

on the detecto/s

display, the lights

on the

tower

(if

fitted),

the

state of

the

detector

and the

events/operator activities

to

change from

one state

to

another.

Figure

1 Section 8.4 shows the normal

state of the

detector, i.e.

the

product

under

test and

bargraph

are on the

display,

the

light

tower has

the

green

lamp

on

indicating

normal

operation.

When

the sample

time elapses

(reference

#2), normal

operation

continues

but

the disp|aychangesto''SAMPLETESTDUE.m>''andtheorange|ampturns on.

The detector

will

continuing functioning normally until

either

the

S"ffiF

key

is

pressed

or

2O

minutes elapses.

|neithercase(reference#3),theredlampisturnedonand''Dosampletest<

ffit

is displayed and the

belt will stop

provided

that the fault

relay

has been

configured

to stop the

conveyor

(see

the operating and installation

manual). The

detector

cannot

now

be used untilthe sample test

is

run successfully.

lf

the

qEffi

key

is

pressed (reference

#4) the belt is stopped

(if

configured to

do

so) and

the

operator

is

asked to enter a

P.l.N.

number by

the message

"Enter

P.l.N.:".

This

number

is recorded in the metal

detection sensitivity

test

report

(see

the printer guide)

which

also

provides

evidence

of

the

time when

the test

was run

and

the

phase

and

size of the test

sample

detected.

30

When

the

operator

is

ready,

the

belt is re-started

and

his

P.l.N.

number

entered.

The

operator

has

10 seconds in which

to

pass

a test sample

(reference

#5). The

display

is

"Pass test

sample" and

a

figure,

which will

count down from

g

to 1.

lf the detector

fails

to

detect a metal

sample and the count

times

out

(reference

#7),

the

red light

is

turned on and the belt stopped with

the display

showing "Test

failed!

.t=SF-EFffi

>".

When

.$ffi

is

pressed

the operator

is asked

to

repeat

the test.

The detector

cannot be used again untilthere is

a successfultest.

On

completion

of a

successful test

(reference

#6)

the belt

is

stopped

to enable

the

test

sample

to be

removed,

the blue and orange lamps are

illuminated

and the

display

shows

"Test

passed

.i1"ffiffi t".

Re-starting

the

belt and

pressing

$$ffi

enables normal

operation

to be

completed.

8.2

Recommended

action on failing test

lf

the

standard

test

sample is

not

detected, the

product

setup

and reject

timers

should be

checked

and adjusted as required - refer

to the operating

and

instruction

manual.

lf

this should

occur, all

production

since the

should be

considered

as

suspect and

possibly

contaminated.

8.3

Engineering

setup

keys when

The

sample

test reminder

is

set

up from the engineer's menu which

is.accessed

by

inputting

the

engineer's

code and selecting

'e'

by

use

of CIj/#/F;S"HgHm

keys

when

the

following

will be seen

on the display:

Ineers

menu

The'S'option

should be selected

from

the engineer's

menu:

test reminder

Sample

test

reminder

on should be chosen by use

the

display

will show:

Sample test reminder

on

of the

31

After

pressing

ffiffi,

the

disptay

can

then

be

adjusted

to

give

the

time

in

minutes

of the sample

test

reminder

delay.

test

0120

is now

set

up

to

be

tested

al 120

minute

intervals

from

Therefore the machine powering

up:

tttt

0 60

120

180

240

SWITCH

ON

TEST

DUE

TEST

DUE

32

8.4

Sample

test

flowchart

Sonnole

test

flowchort

Key :

Disploy

ponel

llgrrt

tower

Mochine stote

[if

fit

Event

or ooerotor

octiorl

Product Borgroph

Normol

ooerotion

Somple

test

time elopses

SAMPLE

TEST

DUE

20 minutes

elopsed

Do

somple

test

SELECT

pressed

Enter

P.l.N.:

belt

stopped

Stort

belt

P.l.N.

number entered

Poss

test somole I

woitino

for

tcst somple

Poss test somole

Poss

test somple

Test Foiledl <SELECT>

Test

Possed

belt stopped

stort belt SELECT

pressed

33

9.

PRINTER

This

document

describes

how a

printer

can be

used to

provide

a record

of

the

operation

of a Lock

lnspections

Systems MET 30+ range

of

metal

detectors.

The

instructions

given

in this document assume

that

the

reader has

a copy

of

the Lock

lnspection

Systems.

Operating and

Installation

Manual

for

the relevant

metal

detector

and

is

familiar

with

the contents.

The

following

information is

available

from the

printer

output:

.

Product

and

reject counts.

.

The

metal

detector

product

settings.

.

Reject

reports.

o

Metal detection

sensitivity test reports.

o

FaulUincidentreports.

The

product

and reject counts enable

a record

to

be kept

of the number

of

products

tested and

the

number of

products

rejected.

The

product

settings

give

the name,

gain

height width,

phase

and

timer

values for

every

product

that

has

been

setup in the detector.

There

is a

reject report for every

product

in which

metal is

detected.

This report

gives

the time

of

the

detection, the

product

being

tested and the size

and

phase

angle of

the

signal

detected.

The metal

detection

sensitivity test

reports

give

a record

of

the time when a

test

sample

was

passed

though

the detector, the

PIN number

of the

operator who

performed

the

test, whether the

test was successful

and the

size

and

phase

angle

of

the

test

samPle.

The faulUincident

reports

give

the time and

details of any faults/incidents

that have

occurred

on

the detector.

Two modes

of operation are available,

"Printing

on Demand" and

"Printing

on Event".

Printing

on

demand saves

all

the

reports

in

the detector

and

they

can

be

printed

at

any

time

by

either the

operator or supervisor

with

only

the

supervisor having

the

authority

to

clear the

reports.

When

printing

on event

is selected, all reports are

printed

as

they

occur

provided

the

printer

is switched

on and connected.

lf

this

is

not

the

case,

the

reports

will

be

discarded.

34

The recommended

printers

are:

.

EPSON

LX-300:

Lock

part

no:

Cable:

Lock

part

no:

.

Martel

MCP9810:

Lock

part

no:

Cable:

Lock

part

no:

.

Paper rolls

MPS101/M58: Lock

part

no:

9.1 Print

Modes

9.1.1

Printing

on Event

Q638-0004

12843201

Q638-0002

128A320-2

Q638-0003

When

printing

on event

all

reports

are output

to the

printer

port

as they

occur. The

output

to

the

printer

would be similar to:

26/11/96 8:00:15 PRODUCT B

S 25

P 2.1

26/11/96 8:03:23 PRODUCT B

S 71

P 76.3

26/11/96 8:05:39

product

selected

[2]

PRODUCT A

26/11/96 8:07:48 PRODUCT A

S

227 P

102.3

26/11/96 8:07:55

PRODUCT

A

S 51 P

71.9

26/11/96 8:10:08 PRODUCT A

S 21

P 2.1

26/11/96

8:14:21

PRODUCT

A S

24 P 3.4

26/11/96 8:18:27 PRODUCTA

S

21 P2.1

26/11/96 8:26:50 PRODUCT A

S 75 P 78.5

26/11/96

8:28:17

PRODUCT

A

S 24 P

0.2

26/11/96

8:56:35 test started

26/1

1/96

8:56:35 operator

0000

26/11/96 8:56:38 fesf

passed

26/11/96

8:56:43

PRODUCT A S

3386 P

12.8

S = SLe of

signal

9.1.2

Printing

on Demand

P = Phase

of signal

When

printing

on

demand

all reports are entered

into a

buffer in

the detector

which

can

be

printed

at any time

from

either

of the operator's

or the

supervisor's

menus.

After

printing,

there

is an option

on the

supervisor's

menu to clear the buffer.

lf

the

buffer,

which

has the

capability

of holding

over 300

reports,

overflows

the oldest

reports

are

discarded

and an

incident

report of

"Messages

lost" is

entered.

35

The recommended

procedure

in this mode

is:

o

At fixed

time intervals,

print

reports

from

supervisor's

menu.

.

Clear

reports.

.

Clear

product

and reject

counts.

9.1.2.1

Operator's

Menu

The following

is displayed from

the

operator's menu:

est

Selecting "Print"

will

result in

a display as follows:

Set up

printer

or PC

on

port

A

Press

Sffi

if

the

printer

is connected

and switched

on.

9.1.2,2

Supervisor's

Menu

Moving the

cursor to

'R'

on the supervisor's

menu

will

result in

a display

as

follows:

TPRCSEDcoselx Print

Selecting

"Print

report"

will result in

a display as follows:

Set up

printer

or

PC

on

port

A

Press

$-ffi

if the

printer

is

connected and switched

on. When

printing

is

complete,

the supervisor will be

presented

with

the following

display:

report

records? No

The

Lfi

key should

be

pressed

to

give

the

message

"Clear

records?

Yes"

and the

ffi

key

pressed.

36

The

product

and

reject

counts

should

then

be

cteared

by

moving

the

cursor

to

the

,C,

option,

which

will result

in

the

following

display:

Pressing

results

in

the

following

display:

Clear

counts

Reset

reject

and

Product

counts?

No

The

iS,

key

should

be-Sressed

to

give

the

message

"Reset

reject

and

product

counts? Yes" and

the

ffiry

key

fressed.

37

9.1.3

Typical

Output

The output

from

the

printer

gives

a summary

of the

metal

detector's

status

and

product

setup,

followed by a list

of

reports.

A report

consists

of

a time

stamp

and

a

message.

A typical

printout is

as

follows:

Lock lnspection

Sysfems

Product and status

report at 26n 1/96

9:42:31

Id

string

of detector

-

DEV

Current

product

-

PRODUCT A

Product count

-

11245

Reject count

-

12

Product settings:

Name

gain

height width

phase

Photo

delay alarm reject

0 FACTORY

TEST

SETUP

15

(100)

40 103.4 1.00s

1.00s 1.00s

0.50s

1A

15

4 13.4

1.00s 1.00s 1.00s

0.50s

2

PRODUCT A

15

(110)

20

95.0 1.60s

0.32s

0.36s

0.50s

3 B

15 1 2

58.4 1.00s 1.00s 1.00s

0.50s

--

End of

producf

seffings

-

26/11/96

8:00:15

PRODUCT

A S 25 P

2.1

26/11/96

8:03:23 PRODUCT A

S

71 P 76.3

26/11/96

8:05:39

product

selected

[2]

PRODUCT

A

26/11/96

8:07:48 PRODUCT A S 227

P 102.3

26/11/96

8:07:55 PRODUCT

A

S 51 P

71.9

26/11/96

8:10:08 PRODUCT

A S 21 P 2.1

26/11/96

8:14:21 PRODUCT A

S

24 P

3.4

26/11/96 8:18:27

PRODUCT A

S 21 P 2.1

26/11/96

8:26:50

PRODUCT

A S 75 P 78.5

26/11/96

8:28:17

PRODUCT

A S 24 P

0.2

26/11/96

8:56:35 test stafted

26/1

1/96 8:56:35

operator

0000

26/11/96

8:56:38

fESf FAILED

26/1

1/96

8:56:44

test started

26/11/96

8:56:44 operator

1234

26/11/96

8:56:49 fesf

passed

26/11/96

8:56:43 PRODUCT A S 3386 P 12.8

38

9.2

Reports

9.2.1

Reject

Report

A reject report occurs whenever

metal

is

detected.

Format:

{time-stamp}

{Product

name}

{size}

{phase

angle)

9.2.2 System

Reports

9.2.2.1 Restart

A report

is

given

each

time

the

system

is re-started.

Format:

{time-stamp}

System

restarted -

{Product

name}

9.2.2.2 Product setup

A report is

given

each

time

a

product

is

setup.

Format:

{time-stamp}

Product

setup

[{Product

number}]

{Product

name}

9.2.2.3

Product Selected

A report

is

given

each

time

a

product

is

selected.

Format:

{time-stamp}

Product

selected

[{Product

number}]

{product

name}

9.2.2.4

Name

Change

A report is

given

each

time

a

product's

name is

changed.

Format:

{time-stamp}

Product

name

changed

from

{Product

name}

to

{product

name)

9.2.2.5 Message(s) Lost lf in

Print on

Demand

mode

and

the

buffer

fills,

the messages

lost

is

given.

Format:

{time-stamp} {number}

message(s)

lost

39

9.2.3

Sample

Test

Reports

9.2.3.1 Test

Started

A report

is

given

when

a

sample

test is

run.

Format:

{time-stamp}

test

started

9.2.3.2

Operator Pin

Number

When

a sample test is

run,

the

operator

is requested

to input

a

number.

Format:

{time-stamp}

operator

{PlN

number}

9.2.3.3

Test Passed

A

report is

given

to indicate

that

the detector

has

detected

the

test

sample.

This

is

followed

by a

reject report

for

the

test

sample.

Format:

{time-stamp}

test

passed

9.2.3.4

Test

Failed

lf the

test sample

is not

detected

within

g

seconds

of

the sample

test

start,

a failure

report is

given.

Format:

{time-stamp}

test failed

9.2.3.5 Test Timeout lf the

'Sample

test reminder'

facility

is

enabled,

a report

is

given

if

the

sample

test

has not been completed

successfully

in

the

prescribed

time.

Format:

{time-stamp}

test failed

9.2.4 Fault Reports

9.2.4.1 Balance Fault The detector has failed

to

balance

the head

-

call

Lock Inspection.

Format:

{time-stamp}

Fault

-

BALANCE

FAULT

40

9.2.4.2 Photocell

Error

One of the

photocells

has

been blocked for

a longer

time

than

specified

in

the

blocked

photocell

delay which

is

set

from

the engineer's

menu.

Remove

the

blockage or

increase

the

photocell

delay.

Format:

{time-stamp}

Fault

-

PHOTOCELL

ERROR

9.2.4.3

Reject

System Failed

The

reject

check

is

enabled and the

reject

system

has

failed

to

operate.

Check

the

reject system.

Format:

{time-stamp}

Fault

-

REJECT SYSTEM

FAIL

9.2.4,4

No Reject

into

Bin

The

system

reject

check is

enabled and

the

photocell

has

not

detected

a

product

entering the

reject bin within

the delay specified.

Format:

{time-stamp}

Fault - NO

REJECT

INTO

BIN

9.2.4.5 Auxiliary

Input Failed

The auxiliary

input

has

been activated. This

can have several

uses

and results

in

one

of

the

following messages:

Format:

{time-stamp}

Fault

-

AUXILIARY INPUT FAIL

Format:

{time-stamp}

Fault - AIR FAILURE

Format:

{time-stamp}

Fault

-

BLOCKAGE

Format:

{time-stamp}

Fault - FLAP FAULT

Format:

{time-stamp}

Fault -

BIN FULL

Format:

{time-stamp}

Fault - BELT

STOPPED

9.3 Engineering

Setup

Using

the engineer's

menu, the

engineer should

set up the following

41

9.3.1 Gommunication

Setup

Select Port

A 9600 baud N

parity

I I data bits

1

l

stop

bit

(Fixed)

H

Handshaking

(Some

records

may

be lost if

not

set)

RS232

9.3.2

Printer

Setup

Select'Printing

on Demand'

or'Printing

on

Event'

as required.

Select 80 col

for

the

Epson

printer.

Select 40C for

the

Martel

printer.

42

9.4

Printer

Cable Diagrams

P6i

SOTKET

L0(K

0610-0004

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txE

an

IONNECTOR

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25

W,AY'D'

PLUG

(D

LotK

PART No 0638-0|l01.

-

\J/

RTS

CT5

Nt

NI

TX

RX

OV

PRTNTER RS232

/-;\

srRtnL rruput

\7

FI6.

1 PRINTER CABLE

FOR EPSON LX]OO

O6]8.0015

\7

r:\

(4)

(6)

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ocrrorar

scnrel

rP67 s0(KET

6)

L0cK 0610-0004

-

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wAY D

PLU6

(D

L0tK PARI No 0618-0002

-

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PRINTER

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FOR

I'lARTEL

I'1TP9810

Q638-0016

(1)

(2/

(t)

\_-/

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ocrtounr

scRrrN

43

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

Factory

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

FACTORY

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.

lf 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,

earth loops,

high-current-carrying

cables,

welding

equipment

operating

nearby

etc.

44

10.7

Product

Effect

Some

products have

a signal,

which

can be seen

by the metal

detector

- this is

called the

product

effect.

lts 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;

salt content

e.g.

bacon,

butter

etc.;

and fat

content

e,g. meat. Many

other substances

have

some

product

effect.

10.8 Product

Guide

These are

pieces

of

plastic

designed

to

make

product pass

consistently

through

the

centre

of the aperture.

10.9 Sensitivity

The smallest

size

of metal contaminant

that can be

reliably detected

without

false

triggering.

lf the

detector

is

too

sensitive, unwanted rejection

of

good

product

will

take

place.

lf

the detector is not

sensitive

enough,

metal

contamination

may

be

missed. Sensitivity

can be

changed in

the

software

by changing

product

width

(and

sometimes

height).

For further

information

look up

"product, width"

and

"product,

height"

in the

index.

10.10 Skid

Plate

Lies between

the

bottom of

the

aperture

and

the upper

path

of the

conveyor

belt, to

support

product

as

it

travels through the

aperture. lt

should

not

distort

under

load

so

much that

it touches

the aperture.

10.11Systemchek

A means

of

veriffing

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).

lt is controlled

by one or two

photocells

connected

to the PSU

and settings

in the software.

10.12

Test

Sample

When a

metal

detector is shipped

by Lock, a test

sample

is

sent

with

it. This

is

a

small

piece

of

metal embedded in

a

plastic

stick

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.

10.13

Trigger

When the metal

detector detects metal.

lt is indicated

by the

bargraph

showing

solid

circles,

and

the

reject count

incrementing.

45

LOCK Inspection Sytems LTD MET 30 Plus Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual