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1. DO NOT SCA IF IN DOUBT ASK RADIATION READINGS MAX READING uSv hr IN D EED SIDE BOTTOM TOP B INFEED SIDE Q 2 ris BOTTOM 9 hy BASE REAR CUSTOMER MODEL TYPE SERIAL No AXIS RAPID RADIATION CONVEYOR SURVEY MACHINE DRAWING Principles of Inspections PRINCIPLES OF INSPECTION CONTENTS X Ray Generation Detection of X Rays Product Absorption maging Software Contaminant Detection Module 4000 Principles of Inspections X Ray Generation X rays are one of many types of electromagnetic radiation that are produced for a particular use At some time or other most people will have received medical treatment or diagnosis which will have involved the use of x rays Indeed used in the correct manner x rays can be safely produced and have a number of uses one of which is for the inspection of food products Note X rays cannot make food products radioactive as soon as
2. Batch amp Shift Report Generation Manual Batch Reports may be generated manually by the user via the user interface Automatic Reports may be generated automatically the current product is changed before the completion of a batch or shift interval f the system is powered down then powered up while in run mode before the completion of a batch the current Batch will be terminated and a new Batch started Shift Report be generated by completion of a predetermined time interval set by the user between 5 minutes amp 24 hours A start time is also provided Batch Reports may be automatically generated by batch size set by the user from 10 to 10 000 where batch size equates to the number of accepted packs Batch Reports and Shift Reports may be disabled by the user All production data will be reset if the total pack count exceeds 999 999 Module 7011 Operators Guide and Setup Setpoint Status Report A setpoint Status Report will be generated each time the machine is taken into run mode and will include the following parameters Machine Type Report Title Time amp date ID Product number Product ID Source kV Source mA Algorithm e g convolution search dual AUTO amp so on Reject Status timing values Last normalise time date Other Reports It is possible to print the fault error log contents including the f
3. POSITION uSv hr 3 NFEED SIDE C BOTTOM D TOP QUTFEED SIDE OUTFEED G FRONI BASE FRONI J TOP REAR BASE REAR INFEED OUTFEED SIDE BOTTOM 13 Q REAR SE REAR CUSTOMER MODEL TYPE SERIAL HHEH Sys J lt CONVEYOR MACHINE TION A RAD SURVEY DRAWING DO NOT SCALE F INFEED SIDE A INFEED OUTFEED SIDE CF OUTFEED TOP FRONT ER FRONT REAR REAR RADIATION READINGS MAX READING POSITION uSv hr NFEED SIDE 1 1 BOTTOM D TOP OUTFEED SIDE F OUTFEED CUSTOMER TOP FRONT MODEI 20 BASE FRON TOP REAR BASE REAR SERIAL No toma
4. 220v 60Hz 110V 1 60Hz Load Current typical cc Rene dota Conveyor 110V 11 230V 6A Pipeline 110V 230V 2 Rapid 110V 230V 2 Environment Operating 2 to 40 C Relative 90 non condensing maximum Nomi al WMG 900mm 100mm one eae 5 to 80 to 100 psi at a volume of 25 cfm Weight Conveyor approximately 550 kilograms Pipeline approximately 350kilograms Rapid approximately 250kilograms Module 6000 Product Descriptions X Ray Subsystem The x ray components and control system are contained inside the central stainless steel cabinet X Ray Tank The x ray tube is mounted inside an oil cooled tank connected to a mains driven pump and a fan cooled radiator In order to stop the x ray tube from overheating the oil passing through the radiator is cooled and re circulated through the x ray tank The oil used is a mineral based transformer oil and should be treated as a such when considering handling and disposal requirements High voltage PSU The x ray power is supplied by a high voltage power supply whic
5. Module 7001 Operators Guide and Setup X RAY SCAN RUN POWER The RUN POWER parameter gives the user the opportunity to set the correct level of x ray energy required to penetrate through a product The greater the density of the product the higher the RUN POWER required and vice versa The correct level of power be examined by observing the histogram in the PRODUCT SETUP screen As rule of thumb the darker the image the better the sensitivity to all contaminants If the power is too low then the darkest part of the histogram will be close to the zero greyscale level A desirable greyscale level is around 40 to 50 but it may not always be possible The maximum kV available will depend on whether the AXIS unit is a low power up to 50kV or a high power to 75 NORMALISATION POWER During normalisation the signals from each of the detector array diodes is set to provide a uniform output Normally the NORMALISATION POWER would be set the same as the RUN POWER but the system has the capability of calibrating the detector at a different x ray setting from that for inspection If for example a product is very dense and the max kV has been reached but the product still requires more penetration In this case if we enter a value in the NORMALISATION POWER entry box lower than the entered figure in the RUN POWER box we can increase the level of penetration However care should be taken when using this method because it is possible
6. key It will contain useful information relevant to the present screen Module 7004 Operators Guide and Setup Normalisation As described in the Principles of Inspection section a fan shaped beam of x rays is produced It can be seen that the detector diodes in the middle of the beam receive more energy than those on the outside due to the increased distance travelled Therefore each diode signal is adjusted to ensure that for a given x ray power each diode output is the same This process is called Normalisation It is carried out on start up when there is a product change or if the kV power or belt speed parameters are changed This process is the same for both conveyors and pipelines but the methods are different For both there must be no product in the x ray path during normalisation See section on Normalise Screen Messages Conveyor Normalisation The procedure for normalisation is as follows Make sure the system is at the Main Menu Ensure that machine is clear of all products and further products are inhibited Start the conveyor Check that the selector switch is in the on position Select the system Run Screen ON If Normalisation does not automatically start then press the Normalisation key and Normalisation will start Once completed the machine will enter scanning mode ready to inspect Pipeline Normalisation During the Normalisation process nothing must block the path from the x ray sourc
7. Grease Manufacturer Type B P Energrease LS2 Mobil Mobilux EP2 Texaco Multifak All Purpose EP2 Greasing All AXIS conveyor units fitted with outboard bearings require greasing at regular intervals Bearings should be greased four 4 times per year unless the environment or cleaning regime dictates that they are greased more frequently 1 2 Isolate the electrical and compressed air power supplies to the machine Remove the covers from the motor drive housing to gain access to the grease nipples on the drive unit bearings Using a grease gun apply grease to each nipple in turn Take care not to apply too much grease Grease should not issue from the bearing Refit the covers to the motor drive housing Using a grease gun apply grease to each nipple on the remaining roller bearings throughout the system Take care not to apply too much grease Grease should not issue from the bearing Switch on the electrical and compressed air power supplies to the AXIS machine Module 8000 Maintenance Air Regulator Water Trap Maintenance All AXIS Systems are fitted with an air regulator filter unit Adjust the pressure setting as described below Air Regulator Pressure Gauge Air Supply Drain Plug Water Collector 1 Check that the regulator pressure setting is correct This should be between 60 4 2 bar and 80psi 5 5 bar To adjust the regulator pressure pull up the cap and turn it either c
8. 0492 573573 Fax 0492 573570 USA and SOUTH AMERICA Loma International Inc 283 East Lies Road Carol Stream Illinois 60188 USA Telephone 1 800 USA LOMA 1 630 588 0900 Fax 1 630 588 1396 CANADA Loma Canada Limited 333 Wyecroft Road Unit 11 Oakville Ontario Canada L6K 2H2 Telephone 1 800 387 7987 905 842 4581 Fax 905 842 3460 REST OF WORLD Loma Customer Services Dept Unit 43 Campus Road Bradford West Yorkshire BD7 1HR UK Telephone 44 01274 378200 Fax 44 01274 729716 Module 1000 Cautionary Advice CAUTIONARY ADVICE CONTENTS Safety Warnings Local Rules UK Example Emergency Shutdown Dealing with Fire Audible Warnings Visual Indications Radiation Levels 5 Warning Due Diligence Module 2000 Cautionary Advice Safety Warnings Listed below are all the safety warnings that are used throughout this manual It is strongly recommended that personnel who are or will be responsible for installing maintaining or operating the equipment described in this manual should read and understand these warnings 1 LETHAL HAZARD ELECTRICAL SUPPLIES A current of 100 milli amps passing through the body for one second can kill This can occur at voltages as low as 35V ac or 50V dc The equipment described in this manual uses electrical power which can be lethal Unless absolutely necessary cleaning inspection and maintenance must not be carried out without first isolating the equipment f
9. particularly in the centre section of the conveyor model 5 Check that all of the curtains conveyor model are in good condition and that there are no splits in the material 6 Inspect the conveyor belt for damage and contamination 7 Check that the conveyor belt is correctly tensioned and is neither too tight nor too slack If a belt is too loose adjust it as described in the section titled Routine Maintenance Daily weekly Note Over tensioning the belt may cause damage to bearings and motors 8 Check the internal radiator fins are clear of dust and debris Module 8000 Maintenance Routine Maintenance Daily Weekly 1 The AXIS system is fitted with an air regulator and an integrated automatic water trap Check that the bottle filter is clean and the outlet not blocked Switch on the electrical and compressed air supplies to the system Switch the keyswitch to the x ray on position enter RUN mode and check that the reject mechanism successfully rejects a contaminated product into the reject bin Check that the conveyor belt is tracking correctly If tracking is not correct adjust it as described in the section titled Routine Maintenance Weekly Monthly The Daily Weekly routine must be carried out on a daily basis when the system is in constant use but can be stretched to a week when the demands on it are low If you have any queries relating to the maintenance of your system your Loma Service Centre wil
10. the amber fault lamp on the front left hand side of the control panel to reset the fault In addition also Press gt fault reset on the touch panel The system faults shown on the next page will be logged Module 7010 Operators Guide and Setup System Fault Indications and Possible Actions Indicated Fault Condition Action to be taken Guard Switch Check all guards are closed Check all emergency stops are out Check all access panels are on Low Air Pressure 10 E Check air supply to machine and that it is switched on Red Lamp Failure Check the filament bulb is not broken Check that the lamp is secure Tank Over Temperature Check tank and cabinet cooling systems are functioning Check radiators for blocked fins Conveyor Fault Check motor overload if fitted X Ray System is Out of Specification 237 Check x ray switch is on Check power level parameters Check beam path is clear Check system is warmed up and that mA value is at maximum Software Crash watchdog failure Reboot machine PEC Blocked Check product path at PEC and clear blockage as required Reject Confirmation Sensor Check that bin is not full Reject Confirm Fail customer option Remove offending product and retest Check reject timings are correctly set Check air supply to machine is okay Check reflector is clean Check PEC
11. where applicable Other Standard Equipment Air Pressure Switch An air pressure failure switch is fitted to both the conveyor excluding the Rapid and pipeline models The switch is set by Loma to operate if the pressure of the compressed air supply to the machine falls below approximately 3 bar 42 psi The conveyor then stops x rays switch off and the fault alarm and lamp are activated In the case of the pipe line all above will take place and the reject will stay open for failsafe operation Product Registration Photo Electric Cell The Loma AXIS conveyor model is supplied fitted with a photoelectric Cell PEC as standard The PEC is mounted on the side of the conveyor just prior to the x ray beam It is used to register the position of the products on the conveyor As an option the PEC may be mounted directly above the belt This is particularly suitable for the registration of products that have very little depth flat Bulkflow machines are not fitted with a PEC Internal cabinet thermostat cooler A thermostat is normally fitted to guard against system overheat Pipelines and some low power conveyors may not require cooling If the internal temperature of the cabinet should reach the set limit the thermostat will switch on a solenoid valve which in turn activates the cooler type will vary depending on application to cool the internal temperature This is set at manufacture and should not be changed Module 6000 Produ
12. at ninety degrees to the product flow direction as shown in the diagram below Module 4000 Principles of Inspections Located on the under side of the centre section of the AXIS machine is a device known as the detector array which is positioned directly in line with the x ray beam A line of photosensitive diodes receive the x ray energy of which the values are then processed in the form of grayscales 0 black to 255 white These scan lines take place at hundreds of scans per second which means a direct relationship between scan rate and belt speed flow rate exists X Ray Tank t Collimator _ _ Detector Array 4 4 X Ray Beam lt 5 Product When product is not passing through the x ray beam the detector array receives 100 of the x ray energy over the entire length of the array When product is introduced through the beam less than 100 of x ray energy is received of which the signal values will be processed and shown as a grayscale image Product Absorption When we refer to the product absorption level we mean the amount of x ray energy that the product will consume absorb when x rays are passed through it The higher the density of the product passing through the beam the greater the product absorption factor At this stage it is worth noting that just because a product may measure to be higher than another product it does not follow that the greater size is necessarily of a greater overall d
13. checked for correct tracking before running the conveyors for any length of time The tracking adjusters are found adjacent to the end rollers of the AXIS conveyor machine If belt tracking needs to be reset carry out the belt tracking procedure described in the section titled Routine Maintenance Weekly Monthly in the Maintenance section of this manual Setting Up Reject WARNING REJECT DEVICES At no time with air and or electrical power applied to an automatic reject device should any part of the body be placed within the operating area of the reject device General The system is normally supplied with the reject mechanism correctly set up for at least one product If the Reject Delay and Dwell times need to be adjusted for further products these are set up via the user interface Refer to the sections titled Reject Setup in the operators guide Module 5000 Installation Pusher and Plough Rejects The system is supplied with the reject cylinders already set and normally no further adjustment should be necessary In certain instances Loma may supply a Reject Device only and the end user supplies the Reject Catchment Device Bin Table etc The safety of the Reject Device is therefore a function of the design of the Users Reject Catchment Device It becomes the User s responsibility to ensure the safety of the complete Reject System In most instances the product is delivered onto the system by conveyors The Syst
14. correct operation of the Axis machine when either the reject or vortex operate The AXIS pipeline machine also requires an additional air supply for the operation of the shutter piston located by the side of the collimator The minimum air pressure must not fall below 65psi 4 5 bar when the reject operates on all models In the case of a pusher reject a dump valve is also fitted in order to protect an operator in case of an emergency As soon as an emergency stop is activated the mains air supply is shut off and all air is exhausted from the system In addition for failsafe reasons an air pressure switch is fitted in order to alert the operator that the air supply is low and shut down the system generating a fault condition The mains air supply is to be connected as shown below to the input side of the air regulator and should be set to 5 5 bar 80 psi Pneumatic assembly pipeline shutter valve not shown Module 5000 Installation Checking Guards 15 2 Check that all guards and interlocks are securely fastened in place Check that the infeed and outfeed of the system are clear of obstructions Powering Up the System WARNINGS 1 LETHAL HAZARD ELECTRICAL AND COMPRESSED AIR SUPPLIES This equipment uses electrical and compressed air supplies that can be lethal Unless absolutely necessary work must not be carried out without first isolating the equipment from all electrical and compressed air supplies LETH
15. entered value a reject will be registered PEC DELAY Photo electric cell Just prior to the x ray beam a photo electric cell is situated in such a way that when obstructed i e product passing it will signal to the computer that the start of the pack has been registered Inspection is started when the PEC is triggered by the product The system captures an image the length of which is determined by the PRODUCT LENGTH The PRODUCT LENGTH must be correctly entered otherwise not all the product may be analysed WINDOW TOP This parameter is used to mask off part of the inspection area and can be observed as a blue band at the top of the screen It is useful when a section of the conveyor belt is contaminated or when a guide rail runs through the x ray beam The entered value in the WINDOW TOP entry box is referenced from the top of the screen WINDOW BOTTOM This parameter is used in the same way as WINDOW TOP with the exception that the entered value will signify the start of the masked area at the bottom of the screen This can also be observed as a blue area only at the bottom of the screen However the figure is still referenced from the top WINDOW WIDTH This is available in bulkflow pipeline applications and is used to set the lines per inspection frame PRODUCT LOCATOR This parameter is used to isolate the product from the background Progressively reduce this figure to obtain a clear image of the product on a white background
16. on the monitor The version being run on a particular machine is shown in the blue start screen Parameter values are then setup to optimize the system performance and requirements suitable for each application Contaminate Detection The analysis is carried out by comparing each image pixel to a threshold value and rejecting anything below this value i e it is denser and hence darker than the product itself This relationship to density means that if a contaminate is close to water it floats then it cannot be detected e g insects wood hair or paper Module 4000 Installation INSTALLATION CONTENTS Installation Mechanical Installation Electrical Installation Pneumatics Checking and Powering Up Module 5000 Installation Installation Mechanical Pre Installation Note For Pipeline Machines Please note that the infeed and outfeed product pipes need to be fixed to ensure they remain stationary when machine is normalised These fixings are the responsibility of the user unless supplied with the machine under the agreed machine specification Preparing to Install the Machine The system is dispatched from Loma Systems in the following state 1 Feet are screwed fully in 2 The X Ray tank breather screw is in and locked 3 Delicate items are covered in protective wrapping material and attached or
17. operation Bin Full customer option Remove product blocking the sensor or photocell Check reflector is clean Check PEC operation Module 7010 Operators Guide and Setup System Fault Indications and Possible Actions continued Indicated Fault Condition Action to be taken Reject Verdict Too Late 1 PLC Has No Data 1 Reboot machine PSU Fault 1 Reboot machine Grabber Fault 1 Reboot machine Sensor Error 1 Reboot machine If no specific fault is indicated then an authorised person trained by LOMA may need to carry out basic fault finding to isolate the problem and find the cause If in any doubt then the LOMA Service Centre must be consulted Module 7010 Operators Guide and Setup REPORTS Shift and Batch Reports The Axis machine can be setup to produce reports which can reflect activities of a single batch or a complete shift They can be printed either directly to a serial printer set at 9600 baud or if a node is supplied and fitted they can be sent as part of a Lomanet system Both are carried out via the 9 way din plugs at the rear of the machine Example of report style BATCH REPORT Time 10 25 00 Date THU 29 MAR 2001 Machine Identification Line 6 Product Number 2 Prod ct Tdentilication 9 CHEESE Wales 9 1022103 030 Batch Finish Time 10 253 00 Total Packs 785 Accepted Packs 778 Rejected Packs 7
18. surveys received the necessary radiation awareness training qualification In some countries this may be mandatory and it is recommended that the user seeks advice from the local health and safety executive Module 3000 LOMA AXIS RADIATION SURVEY REPORT X RAY FOOD INSPECTION UNITS 1 Unit Details Model Type Customer Serial No Address Year of manufacture Location of unit Reason for survey Installation Post maintenance Relocation Other specify 2 X Ray Tube Settings 3 General Checks Adequate guarding fitted Customer information provided Power On warning lights labelled visible from both sides and operate correctly X ray On warning lights labelled visible from both sides and operate correctly Fault warning lights labelled visible from both sides and operate correctly Emergency stops fitted labelled and operate correctly Conveyor interlocks fitted and operate correctly X ray warning labels fitted to infeed and outfeed 4 Dose Rate Results Refer to relevant unit drawing For measurement point dose rates see attached Drawing No External dose rate less than 5 Radiation Monitor used Model Type Serial No Calibration Date Comments Test conducted by approved Engineer Name Signature DO NOT SCAL N N DOUB RADIATION R EADINGS MAX READING
19. the event of an overheat condition the first sensor will signal to the control unit which in turn will activate a fault condition and the second as a failsafe will automatically cut the power to the x ray power supply Optional Equipment Reject confirmation PEC This device is normally fitted across the aperture of a reject bin directly in the path of the rejected product If the rejected product does not break the photocell beam in a given time a fault condition is activated The conveyor will then stop and the operator will be alerted by means of an audible alarm and lamp The fault will be displayed on the front screen Bin full PEC This device is normally fitted near to the top of the reject bin If the bin should fill up with rejected product there is a danger that further rejected product could be deflected back on to the conveyor and into the good product path If a bin full photocell is fitted the rising product will break the photocell beam and will activate a fault condition The conveyor will then stop and the operator will be alerted by means of an audible alarm and lamp The fault will be displayed on the front screen Module 6000 Product Descriptions Overhead PEC The Loma AXIS x ray machine as standard has a product registration photocell fitted to the side of the conveyor However if the product to be inspected is extremely flat there is a possibility that the side mounted version could not register positively In this c
20. the power source ceases x ray generation stops and no residual radiation is present The principle of x ray generation is one that is simple to understand and is shown in the diagram below An evacuated glass tube is used to house a cathode ve terminal and an anode ve terminal which is itself then housed inside a led lined oil filled tank which electrically insulates the tube from the case In addition the oil is circulated and cooled to dissipate the unwanted heat that is generated when x rays are produced A filament emits electrons inside the tube and a high voltage is then applied which accelerates the electrons towards the target on the anode When the electrons hit the target x rays are given off in the form of a conical shaped beam In effect the voltage controls the brightness and the current the contrast X RAY TUBE Current mA ELECTRON X RAY BEAM Ground Potential Detection of X Rays Once x ray generation has taken place and we have the aforementioned conical shaped beam the next step in the process used on the AXIS machine is to include a device which will receive the x ray energy and process its signal values To do this we first position an assembly directly under the x ray tank known as the collimator The collimator in effect allows only the small centre section of the x ray beam to be emitted approximately one millimeter in thickness This section of the beam can be considered to be fan shaped and positioned
21. 001 Operators Guide and Setup MEMBRANE KEYPAD Refer to Front Panel Layout Diagram shown on previous page Password Key key graphic The password system is active at all times If the user presses the password button a password entry dialogue will be shown on the screen Normal passwords are entered as four digit numbers For further information see Password Section Enter Key graphic The enter button is used to confirm data entry whenever the user needs to make a choice It does not exit from the screen in use Cancel Key graphic The cancel button is used to discard all data entry from the screen in use Help Key The help button activates a simple help file which can be navigated using the up down keys and provides information about the current screen that the user is in Menu Key The Menu button returns the user to parent menu screen Zoom Zoom Out Keys The Zoom feature is used to highlight and Zoom in on Contaminated Pixels on existing images It will be initiated by pressing the Zoom In button This will select the First Contaminant pixel which will then be highlighted Pressing the button again will select the Next Contaminant pixel and so on and so forth until all Contaminated Pixels have been seen Once all contaminated pixels have been seen the image will return to the first one again Coming out of zoom will be initiated by pressing the Zoom Out button Module 7001 Operators Guide an
22. AL HAZARD RADIATION Whilst every precaution has been taken to make sure that all the necessary guards and safety devices have been fitted to the Loma x ray unit it is recommended that all operatives are trained in the use of x ray food inspection machines In addition users must adhere to the necessary requirements required by their country state or province Furthermore it is the responsibility of the employer to create a set of local rules See example in Cautionary Advice regarding the safe use of x ray food inspection systems In the U K this is in compliance with the lonising Radiation s Regulations 1999 users outside of the U K should consult the relevant health and safety executive see also Radiation Surveys WORKING ON EQUIPMENT If it is essential to work on the equipment with electrical and or compressed air power connected the work must be undertaken only by qualified and authorised personnel who are fully aware of the danger involved and who have taken adequate safety precautions to avoid contact with dangerous voltages compressed air supplies or radiation Each x ray system manufactured by Loma Systems is fitted with emergency Stop buttons These are mounted on the front and sides of the control panel and at the rear of the machine In the case of a pipeline machine due to the size and no conveyor present only one emergency stop is required and this is situated on the front control panel The buttons are red in colou
23. CONTAM SIZE and lower than the AUTO THRESHOLD value a reject will be registered In addition the contaminant will be highlighted in red on the image 6 The CONTAM THRESHOLD allows the user to set an absolute reject point regardless to whether it is product or contaminant This is useful to guard against the possibility of a very large lower density contaminant being factored into the histogram 7 Window Top and Window Bottom is set to limit the inspection width This may be set to exclude fixed objects such as product guides from the analysis area Module 7001 Operators Guide and Setup The diagram below is a representation of the histogram that will be seen when in PRODUCT SETUP screen Number of pixels Absolute Threshold Product Density levels texture calculated over entire Auto Threshold Level product area lt Rescate Level gt 25 Two further parameters are located and used in the AUTO analysis mode of which are described below ERODE TOP BOTTOM This parameter should be used when the leading and trailing edge of a box or container is thick enough to cause a dense area to be registered which may cause false rejects The setting of this will in effect mask out the offending edges in pixel count However care must be taken not to mask out the product in certain applications ERODE LEFT RIGHT This parameter similar to the last is used in the case of a product having a dense edge on the si
24. GE REJECT MENU XRAY SETUP ADD DELETE NOTES 1 THIS DIAGRAM SHOWS THE BASIC MENU MAP AND MORE ENTERIES MAY EXIST FOR YOUR MACHINE CONFIGURATION POWER CHECK SETUP ALIGNMENT SECURITY TIME DATE SYSTEM SETTINGS LANGUAGE MACHINE SETTINGS ALIGNMENT SETTINGS AXIS MENU MAP CONVEYOR Operators Guide and Setup Menu Screen Navigation The table shown below illustrates the access requirements for each screen Screen Password Level None Operator Supervisor Quality Engineer Main menu Yes Yes Yes Yes Yes Run menu Yes Yes Yes Yes Change Product Yes Yes Yes Product Settings Yes Yes Yes Product manager Yes Yes Yes Product Setup Yes Yes Yes Reports machine id Yes Yes Yes Logs Yes Yes Yes View Report Log Yes Yes Yes New Product Yes Yes Product code Yes Yes Delete Product Yes Yes Reject Setup Yes Yes Yes Reject Setup No Yes Yes Yes Reject Confirm Binfull Yes Yes Yes Report Setup Yes Yes Detection Menu Yes Yes Image Setup Yes Yes Analysis Menu Yes Yes Missing Items Yes Yes X Ray Scan Yes Yes Auto Mode Yes Yes Explorer Yes Yes Bonefilter Yes Yes Security Yes System manager Yes Setup Alignment Yes Power Check Yes Language Yes Time Date Yes Module 7009 Operators Guide and Setup
25. LANGUAGES The language to be used will be set via the User Interface Password Protected The following languages will be available English English US format Danish Dutch Spanish Portuguese German French Module 7009 Operators Guide and Setup Password Protection The LOMA AXIS inspection system has been designed with the intention of producing an inspection system which is protected against misuse from untrained personnel Refer to the AXIS MENU MAP for guidance With this in mind four levels of password protection are present on the AXIS machine The password system is active at all times If the user presses the password button a password entry dialogue will be shown on the screen Normal passwords are entered as four digit numbers If a function button is pressed which requires a higher level password than the one currently active the password dialogue will be called automatically Engineer level access allows entry to the password system The password level will be automatically reset to the lowest level when the user returns to the Run screen There are five levels as follows Level Zero Default level Main Menu only Level Line Operator Level Two Supervisor Level Three Quality Assurance Level Four Engineer Operation at any level will automatically allow access to any of the functions at lower levels The Line Operator interface the run screen will allow e Simple cont
26. Loma Systems Axis Series X Ray Inspection Systems Conveyor and Pipeline Models Software Version AXIS X3 Loma Axis X3 User Manual Part No 814130 Issue Level C CONTENTS 1 The Loma Group Companies amp Service Centres 2 Cautionary Advice 3 Radiation Surveys 4 Principles of Inspection 5 Installation 6 Product Descriptions 7 Operators Guide and setup 8 Maintenance 9 Wiring Schematics amp Certificate of Conformity 10 Parts Listing amp Software Licence Module 0000 The Loma Group Companies amp Service Centres THE LOMA GROUP OF COMPANIES UK Loma Systems Limited Southwood Farnborough Hampshire GU14 ONY England Telephone 01252 893300 Fax 01252 513322 CANADA Loma Canada Limited 333 Wyecroft Road Unit 11 Oakville Ontario Canada L6K 2H2 Telephone 1 800 387 7987 Fax 905 842 3460 905 842 4581 NETHERLANDS Loma Systems BV Panovenweg 22 5708 HR Helmond Netherlands Telephone 0492 573573 Fax 0492 573570 USA Loma International Inc 283 East Lies Road Carol Stream Illinois 60188 USA Telephone 1 630 588 0900 Fax 1 630 588 1395 1 800 USA LOMA Internet address WWW LOMA COM Module 1000 The Loma Group Companies amp Service Centres THE LOMA GROUP SERVICE CENTRES UK Loma Customer Services Dept Unit 43 Campus Road Bradford West Yorkshire BD7 1HR Telephone 01274 378200 Fax 01274 729716 MAINLAND EUROPE Loma Systems BV Panovenweg 22 5708 HR Helmond Netherlands Telephone
27. O ANALYSIS but reddish brown can also be caused by EXPLORER being too sensitive In this case the EXPLORER SENSITIVITY needs to be increased to de sensitize the system Module 7001 Operators Guide and Setup The diagram below is a representation of the histogram that will be seen when in PRODUCT SETUP screen Number of pixels Absolute Threshold Auto Threshold Level Product Density levels and texture calculated over entire roduct area Explorer Zone Explorer Threshold Offset lt cRevscate Level gt 255 NOTE Remember that the EXPLORER mode of analysis is overlaid on top of the normal AUTO analysis Therefore all the AUTO parameters should be considered when setting up the AXIS machine for EXPLORER refer to AUTO ANALYSIS described earlier Module 7001 Operators Guide and Setup Glossary of Parameters COMMON PARAMETERS AUTO SENSITIVITY The system will automatically set a Auto Threshold level reject point for each product that passes In some cases it may be necessary to make a further adjustment to increase or decrease the sensitivity This can be achieved by adjusting the AUTO SENSITIVITY LEVEL Adjustment up will decrease sensitivity and adjustment down will increase sensitivity CONTAM SIZE Once the system has calculated the number of contaminated pixels present it will compare the figure to the entered value in the CONTAM SIZE entry box If the calculated figure is greater than the
28. S CORRECTLY EARTHED PLEASE CHECK SUPPLY VOLTAGE BEFORE SWITCHING ON Errors will affect Loma warranty THIS MACHINE WILL EMIT X RAYS IF NOT CONNECTED USING OFFSET FEED PIPES OR IN A PIPELINE amp SHOULD NOT BE ENERGISED UNTIL CORRECTLY INSTALLED For Axis pipeline machine Module 5000 Product Descriptions PRODUCT DESCRIPTIONS CONTENTS Technical Specification X Ray Subsystem Conveyors Safety Guards Devices Reject types Electrical services Other standard equipment Optional equipment Module 6000 Product Descriptions Technical Specification Loma AXIS Case Material kc ee ee Stainless steel 304L fabricated Bead blasted Environmental Protection Dust and waterproof to IP66 level Nema 4x Gastar aad Loma AXIS COMPUte faucets 933 MHz minimum TOANE TAES TERE ie 15 LOD Screen 12 1 ese Ca Re eer ars ta oe tae ee hs aie tee On adjustable feet Power Requirements Supply 220v 1ph 50Hz 380v 3ph 50Hz 415v 3ph 50Hz n
29. a certificate issued Finally at least on a yearly basis have your operators QA and maintenance personnel trained in the use of the equipment Details of available training can be obtained from your local Loma Service Department Module 2000 Radiation Surveys RADIATION SURVEYS CONTENTS Introduction Radiation Exam Interlocks and Emergency Stop Switches Radiation Dose Rates Routine Operational Testing External Radiation Measuring Dose Rate Frequency of Monitoring Summary of Test Procedures Example Survey Report and Form Module 3000 Radiation Surveys Introduction As with all x ray machines the LOMA AXIS produces ionising radiation when x rays are being generated However legislation governs the allowable emission levels and safe working practices when using a x ray machine With this in mind the AXIS machine has been designed to provide adequate shielding throughout the system with safety interlocks preventing the guards or access panels from being lifted or removed without x ray generation being stopped However it is recommended and may be required by your country state or province to document a radiation survey of the AXIS machine on the following occasions 1 Daily 2 After any maintenance has been performed 3 After the machine has been moved for any reason new location etc 3 After any damage has occurred to the system 4 the regulations of your country state or province A doc
30. achieved by engineering and design The stainless steel construction creates most of the shielding required with the addition of four lead loaded curtains These are fitted at each side of the internal x ray cabinet and at both ends of the conveyor for the infeed and outfeed of the machine For high power units two curtains are fitted at each of the four locations the two curtains are staggered to ensure that the fingers of each curtain overlap For these applications it is important that if for any reason the curtains are removed that this overlap is maintained In certain bulkflow applications the curtains may not be fitted and protection is provided by the fact that access cannot be obtained via the infeed and outfeed apertures Interlock switches In addition to the shielding of the guards each machine is fitted with interlock switches on all access panels that would allow access to the radiation areas When opened x rays will switch off and a fault condition is generated There is no residual radiation present when x rays are off Safety Relay and Circuits As safety is paramount two one on a pipeline failsafe relays are fitted to ensure that if a contact of the interlocks were to fail the safety relay will automatically detect the fault and therefore shut down x rays and activate a fault condition The conveyor safety relays work as follows The infeed cover outfeed cover and the rear panel interlocks are connected in series and monitor
31. ally reset the system does not automatically start up The conveyor covers need to be opened to clear blockages etc on the conveyor belt and it is important that the safety interlocks immediately shut down the system Opening each lid in turn and noting that the system immediately shuts down tests the interlocks As noted above the system needs to be re started before x rays can be generated again Module 3000 Radiation Surveys External Radiation Changes in radiation dose rate either at the surface of the machine or at the infeed and outfeed ports is most likely to be noted following any material alterations to the system such as a change in the arrangement of the conveyor or lids etc In addition if the x ray tubes operating voltage is raised or lowered this will affect the reading measured It is therefore important that a full radiation survey should be carried out following servicing or repair work Otherwise changes in the dose rate at the surface of the machine in general are unlikely to be noticed If changes are observed it will be at either the infeed or the outfeed ports because it is here that product enters and leaves the inspection chamber allowing some x rays to scatter along the conveyor belt In view of this the ports are the most important places for routine operational monitoring but all surfaces should be checked as well Frequency of Monitoring As noted above the most sensitive area for changes in the dose ra
32. amp will switch off The operator will be able to switch the conveyor on and off using the front panel switch but switching the conveyor off will disable x rays The system will load the parameters of the last used product or the default product Insert the key into the keyswitch located on the control panel and turn to the left x ray on position This does not mean that x rays are on just that they are merely in stand by position awaiting the command to switch on from the system computer Note is good practice to leave the system at this point to warm up the electronics for approximately half to one hour so as not to incur any drift as the system warms up The machine will also not normalise until there is sufficient current flowing in the filament circuit Operators Guide and Setup KEYSWITCH POSITIONS X ray on off cleandown Cleandown Mode Conveyor Cleandown mode allows the conveyor to be run with the covers open for cleaning It also ignores non conveyor related faults Pipeline Cleandown mode allows the reject valve to be forced to the normal position to allow cleaning System Product Parameters All product relative parameters are stored in a database The system parameters e g grabber and lane information are also stored in the database These product and machine settings can be saved to a floppy disc This can be done using the following method Help Screen A help screen is available by pressing the
33. ase an overhead photocell would be required Communications Package The AXIS machine also has the facility to send reports back to a central computer LOMANET to collate and archive for later reference Another option that can be supplied is a connection to a printer remote hand held or desktop This is via a serial link port at the rear of the machine The printer needs to be set at rate 9600 Baud Encoder Reject This option synchronises the reject timing with the speed of the conveyor The standard system operates a timed reject which does not compensate for any changes in the conveyor belt speed An encoder is therefore fitted on variable speed applications Cooling Methods A heat exchanger can be selected to replace the vortex The unit is an air to air heat exchanger that uses ambient air to cool the cabinet air via two isolated cooling circuits For environments where high ambient temperatures are expected a heat exchanger is used but in addition is fitted with peltier semiconductor coolers to provide additional cooling An air conditioning unit may also be fitted instead of the vortex Multilane Reject For some conveyor applications a dual lane system is fitted or multilane reject for bulkflow systems The dual lane system divides the conveyor width into two and product is passed down in two rows Multilane reject systems consist of up to 8 reject flaps across the width of the belt so that in bulkflow mode only the minimum pro
34. ated unless all such indicators are fully operational Radiation Levels Each Loma x ray inspection machine has a critical examination to ensure that the radiation levels emitted from the system are within the specified allowable limits fact at Loma we strive to be well inside the allowable limit to maximise confidence in a safe system The legislative figure in the UK is 1 Sv hour but the AXIS machine we generally achieve 0 145 hour on average In addition when a system is commissioned on a customers premises another critical examination is carried out and the results stored on record at Loma A copy of which is also provided to the customer see Radiation Surveys Module 2000 Cautionary Advice Occupational Safety and Health Administration Warning In the United States of America the Occupational Safety and Health Administration O S H A Acts quite clearly place the burden of compliance the user of equipment and the acts are generalised to the extent that determination of adequacy of compliance is a judgement decision on the part of the local inspector Hence Loma cannot be held responsible for meeting full requirements of O S H A or O H S A with regards to any equipment supplied nor can Loma be held liable for penalty which may be assessed for failure to meet the requirements of the acts as interpreted by an authorised inspector Loma however does act in a responsible manner with regard to safe design
35. boxed i e lamp stack Space Required for Installation and Maintenance It is important that sufficient free space is left at the front and back of an AXIS x ray machine to enable commissioning and maintenance personnel to easily gain access to components It is recommended that a minimum of 1 metre free space is available at the front and rear of the machine Removal of Packing Materials 1 Remove and discard all packing and protective materials 2 All AXIS machines are delivered secured to a pallet by 12mm bolts which are screwed through the feet of the machine Remove these bolts where fitted Removing the AXIS off the Pallet Note Refer to LIFTING AND MOVING AN AXIS MACHINE in this section Using a Fork Lift Truck 1 Position the forks beneath the machine at the lifting points indicated so that it does not tilt Refer to LIFTING AND MOVING AN AXIS MACHINE Raise the lift sufficiently to lift the machine clear of the pallet and any obstacles 2 Carefully move the machine to the required location following the advice stated in LIFTING AND MOVING AN AXIS MACHINE 3 Lower the forks and withdraw them from the machine Module 5000 Installation Adjusting Levelling the Machine 1 Level the machine by adjusting the foot studs The stud flats are 17mm A F Make sure that all feet are firmly on the ground and are evenly supporting the machine so that it does not rock If necessary anchor the machine to the ground using bolts
36. ct Descriptions Vortex Cooler In order to keep the internal temperature of the x ray cabinet down to an acceptable level a method of cooling is installed It should be noted that in some applications no cooling is fitted For those with cooling a vortex cooling unit is the standard method used see optional equipment for other methods Air flows through the vortex cooler and is discharged into the main x ray cabinet at a much reduced temperature The vortex does not operate all the time but only if necessary and operators should be made aware that it may operate at anytime when the machine is running It should be noted that the operation of the vortex will be inhibited if there is a reject This is to ensure that there is a full supply of air available to the reject mechanism Indicator lamp Stack In addition to the indicator lamps on the control panel a lamp stack is also fitted on the top of the x ray cabinet to indicate power on white x rays on red and fault amber In some cases an additional lamp stack is fitted at the front of the cabinet This is done to ensure all round visibility of the indictors e g when an air conditioning unit is fitted Audible Alarm An audible alarm is fitted to the x ray cabinet to alert the operator that the fault condition is active and the conveyor has stopped X Ray tank sensors In addition to the internal temperature of the cabinet two extra thermostats are fitted to the x ray tank itself In
37. culate product will have in terms of absorption factor A 2 x Absorption B 5 x Absorption x Absorption Module 4000 Principles of Inspections When we talk about the absorption factor it is useful to know that the density value is dependant on the specific gravity of the product and that by multiplying the specific gravity value of the product by the height we can calculate the absorption factor Equating Absorption 8 8 75mm 75mm H20 P Water has an SG specific gravity of 1 relative absorption be derived from multiplying the product height by the SG In the example above the absorption factor is 75 x 1 75 By introducing a 1mm steel contaminate of SG 8 the absorption of the water has been reduced to 74 x 1 1mm displacement but the overall absorption factor has increased 74 x 1 1 x 8 82 a 9 increase The system detects the density change If the above example is changed to 5mm high an even larger increase is observed 5 1 5 now becomes 4 x 1 1 x 8 12 a 140 increase From the following diagram it can be seen that contaminate A is more easy to detect than B With B the x ray beam passes through more of the product and therefore has a higher absorbency factor Module 4000 Principles of Inspections Imaging Software On the PC mounted in each x ray machine is loaded software dedicated to the image acquisition analysis and viewing
38. d The following materials are required to clean the machine Mild detergent Clean water Module 8000 Maintenance Daily 1 2 10 Isolate the electrical and compressed air power supplies to the system Check that there is no build up of debris on the conveyor and in the case of a pipeline clear any remaining product left inside the product pipe Check that the belt and belt rollers are clean and are free from a build up of either product or foreign material e g wrapping film Material on the rollers may cause incorrect tracking of the belt and also transfer dirt to the conveyor belt Check that the reject container is not full This is particularly important if a Bin Full detection device is not fitted If necessary empty the container in accordance with company practice on removal of rejected product Either wipe or wash the system using a mild detergent solution Pay particular attention to the centre section of the main cabinet behind the curtains as this area is not seen when in production Clean wipe the photoelectric cell PEC and the reflector These are located behind the inside curtains in the centre main cabinet and are mounted either side of the conveyor Should the machine be fitted with an overhead PEC wipe clean the face only as this is distance setting where no reflector is necessary Clean wipe the curtains on the infeed inner left inner right and outfeed If a hose wash is to be used the
39. d Setup CONVEYOR OPERATOR CONTROL PANEL X ray on off cleandown X ray on Conveyor start stop Fault Reset Module 7002 Operators Guide and Setup PIPELINE OPERATOR CONTROL PANEL Module 7003 Operators Guide and Setup START UP PROCEDURE The Loma AXIS x ray inspection system has been designed in such a way that it is very easy to power up ready to inspect product However a few points should be considered before switching on 1 Check that the air supply to the machine is 2 Check that all the guards are in their closed position 3 Check that all four emergency stops are in their out position 4 Check that all the access panels are in their closed position 5 For conveyor systems check that there is no remaining product inside the machine When these checks have been carried out and the necessary actions taken it is now ok to switch the Loma AXIS machine on by following the steps below Step one Step two Step Three Step Four Module 7004 Switch the machine on by the isolator positioned at the bottom left side of the machine The alarm will sound and the amber fault light will be on On power up the PC will automatically boot and the system will eventually show the main menu screen Refer to section on System Display Screens Press the amber fault reset button located on the front user control panel and the alarm will be muted Press the reset button again and the fault l
40. des It can be used independently or in conjunction with ERODE TOP BOTTOM It is particularly used to stop the possibility of false rejects in a round product The setting of this will in effect reduce the area to be inspected by pixel count As mentioned earlier care must be taken not to reduce or mask the product area Module 7001 Operators Guide and Setup AUTO Mode with BONE FILTER Pipeline and Conveyor Bulkflow Models This mode of analysis is only used on pipeline and conveyor bulkflow systems The algorithm is still of an adaptive nature but it incorporates some additional functions that allow the user to optimise the system for pipeline and bulkflow applications The main difference that should be understood is that these systems do not require a photocell to trigger the start of inspection Instead the system is continuously scanning and the image shown on the screen is one of a section number of scan lines at a time of either pipe pipeline model or conveyor Conveyor bulkflow model The inspection is carried out in the following way 1 The system will capture the product image representative of a number of scan lines in a section at a time and display it on the screen 2 The whole of the greyscale area is then examined so as to calculate its greyscale distribution and texture level whereupon an Auto threshold reject point will be set In addition to the calculated Auto threshold we can manually to increase or decrease sensitiv
41. duct is rejected when necessary Mass Measurement Missing Product These are two special functions incorporated into the software if requested Also separate rejects in addition to the contaminate can also be incorporated if required Variable Speed Due to production constraints a variable speed conveyor be necessary This is done by controlling the motor via an inverter instead of direct on line Roller Track Reject This is fitted instead of the reject bin Reject conformation and bin full PECs may also be fitted if required Module 6000 Operators Guide and Setup OPERATORS GUIDE AND SETUP CONTENTS Conveyor Layout Drawing Pipeline Layout Drawing Description of Analysis Modes and Parameters User Interface Conveyor amp Pipeline Start Up Procedure Normalisation Menu Map Conveyor Password Protection Fault and Error messages Reports System Display Screens Supplements Module 7000 Operators Guide and Setup Description of Analysis Modes and Parameters The Loma AXIS range of machines has been designed to incorporate a number of inspection modes This enables the user to optimise the system and choose the best mode of
42. e section cabinet to access the electrical services area The isolator switch is located at the bottom left hand side of the cabinet Beneath it on the bottom of the cabinet is the cable gland access for the power cable Module 5000 Installation 3 The system input power will depend on the country and system type that has been delivered For details refer to the rating plate mounted on the frame of the AXIS machine in conjunction with the wiring diagrams delivered with the user manual 4 Split the cable inside the box and cut the wires to suitable lengths An armoured braided cable is recommended when cable conduit is not used A suitable earth conductor is also to be fitted 5 Refer to Figure below for isolator switch wiring details Make the connections to the isolator switch as specified in Table 1 Table 1 Electrical Supply Connections 6 Check that all connections are secure then close and lock the door Module 5000 Installation Installation Pneumatics Connecting the Air Supply All AXIS x ray systems require a compressed air supply primarily to operate the automatic reject system In addition the standard AXIS conveyor model requires a further air supply to feed the vortex cabinet cooler situated on the top of the central cabinet In this situation when a reject occurs operation of the vortex is inhibited to allow maximum air to the reject mechanism It is therefore essential that the air supply is robust enough for
43. e then the Health and Safety Executive must be notified of this forthwith Module 2000 Cautionary Advice Emergency Shutdown of X Ray System Each x ray system manufactured by Loma Systems is fitted with emergency Stop buttons These are mounted on the front and sides of the control panel and at the rear of the machine In the case of a pipeline machine due to the size and no conveyor present only two emergency stops are required and are situated on the front control panel and the rear door The buttons are red in colour with a yellow background In the event of an emergency which requires the conveyor to be immediately stopped press the stop button and both x rays and the conveyor will be stopped Dealing With Fire In the unlikely event of fire occurring in an item of equipment manufactured by Loma Systems it is important that a fire extinguisher containing the correct type of extinguishing material is used Fire on electrical equipment must be extinguished using either a dry powder or carbon dioxide CO2 extinguisher Audible Warnings The AXIS x ray machine is fitted with an alarm which operates in the event of a fault condition The maximum volume of the alarm is 116 dB A and is adjustable via a potentiometer on the back of the alarm itself Visual Indications The AXIS x ray machine is fitted with indicator lamps which operate to show a particular status or in the event of a fault condition The machine must not be oper
44. e to the x ray detector The AXIS pipeline cabinet is on wheels which allows the system to be pulled forward so that the Product Pipe is no longer in the x ray beam When first switched on the shutter mechanism opens Normalisation must then be completed and pulses received within 10 minutes otherwise the shutter will close again The procedure for normalisation is as follows Warning Caution potential crushing hazard Make sure the system is at the Main Menu 2 Release the bottom locking bracket and pull the system fully forward into the Normalisation position Select the system Run Screen If Normalisation does not automatically start then press the Normalisation key and Normalisation will start Once completed the machine will enter scanning mode ready to inspect 5 Push the system back into the Run position locking the bracket in place Module 7005 SELECT PRODUCT PRODUCT SETUP AUTO SENSITIVITY EXPLORER OFFSET REPROCESS PRODUCT SETTINGS DETECTION MENU ANALYSIS MENU IMAGE MENU REJECT MENU XRAY SETUP RESET BATCH RESET XRAY REPORTS MACHINE ID VIEW _ SETUP NORMALISE MAIN MENU PRODUCT MANAGER REPORTS SYSTEM MANAGER MACHINE CODE SELECT SETTINGS VIEW REPORTS DETECTION MENU ANALYSIS MENU IMA
45. ed by the safety relay ES1 A contact of ES1 and the remaining emergency stops back door lower panel and lid interlocks are in series and monitored by safety relay 52 The Tank Over temperature switch ES1 and ES2 then control the Mains Voltage relay RL1 Both this circuit and safety relays status monitored by the PLC The PLC programme utilizes these signals to generate the X Ray Enable output which tells the PC to generate x rays or not A contact from ES2 also switches the main contactor which controls the inverter and the motor circuit Module 6000 Product Descriptions Reject Types Loma x ray machines are supplied with the following reject types e Blast reject e Pusher reject e valve pipeline only Alternatively a conveyor or pipeline can be supplied without a reject device with a Signal Only output On detection of a contaminant in the product the control unit provides an output signal only This can be used for wiring into other equipment such as a PLC Air Blast Reject An air blast reject is pneumatically operated On detection of a contaminant a high pressure blast of compressed air is directed from the air blast reject device to the product causing the contaminated product to be blown off the belt into the reject bin Pusher Reject A pusher reject is pneumatically operated On detection of a contaminant the compressed air supply activates the pusher causing it to push the contamina
46. ed with x rays on in such a manner PIPELINE NORMALISATION Care is to be taken when carrying this out to ensure correct posture and no over exertion is made Module 2000 Cautionary Advice Local Rules UK Example lonising Radiations Regulations 1999 Local rules 1 GENERAL These rules are provided in compliance with the lonising Radiations Regulations 1999 IRR99 Regulation 17 and the Associated Approved Code of Practice Work with lonising Radiation The rules are the general principles and description of the means of complying with the Regulations and should be seen as implementing part of the general safety policy required by Section 2 of the Health and Safety at Work etc Act 1974 Aims to ensure that work with ionising radiations is controlled so that 1 During normal working radiation doses to all persons are as low as reasonably practicable 2 Precautions have been taken to minimise the risk of equipment failure or other occurrence which may result in significant radiation doses to any person and 3 doses exceed those specified the Regulations 2 RADIATION PROTECTION SUPERVISOR RPS INSERT NAME OF RPS The RPS is responsible for ensuring the work is carried out in accordance with requirements of the regulations and for taking all reasonable steps to ensure that these rules are observed In addition the RPS should carry out a radiation dose rate survey of the unit at least once a month or after main
47. eject will operate for once activated REJECT DELAY This parameter is used to set the delay time required before the reject is activated This will be dependent on the belt speed or flow rate PRODUCT LENGTH This parameter defines the flow length of the product Depending upon the product presentation it may be necessary to add an allowance for product skew CONF WINDOW This is the reject confirmation window which is the time period allowed during which a reject confirmation signal is expected REPORTS START TIME This parameter is used to setup the START TIME of a new report INTERVAL This parameter is used to set the time period between shift reports BATCH SIZE This parameter is used to set the number of packs or items required in a batch OUTPUT This parameter is used to enable disable shift and batch report printing at the end of the elapsed time Module 7001 Operators Guide and Setup USER INTERFACE Conveyor amp Pipeline The user controls the system from an on screen menu system via a monitor screen and membrane switches To change the current system setup the user is presented with on screen decision boxes that correspond to the function selection keys F1 to F5 on the right hand side of the screen These are used to choose the action to be taken FRONT PANEL LAYOUT Display Area Selection Keys AXIS Password Key Alpha Numeric Keys Module 7
48. em has to have entry and exit points There is a possible hazardous area at the transfer between the conveyors Loma rely on the total line being made safe by the End User WARNING The internal cabinet areas of the machine contain electrical devices which are at 240V 220V or 110V potential depending on the supply voltage These voltages may cause injury or death on contact Work in this area should only be carried out by a qualified Technician with the Isolator switched off The Isolator is located at the bottom left hand side of the Electrical Services Box Diagnostic work should not be undertaken unless the Technician has been Loma trained WARNING For fixed speed conveyors and pipelines located in a wet environment a Ground Fault Interrupter or RCCB must be used This is not recommended for variable speed conveyors as the inverter may cause the device to trip Module 5000 ATTENTION IT 15 IMPERATIVE THAT THIS MACHINE IS CORRECTLY EARTHED PLEASE CHECK SUPPLY VOLTAGE BEFORE SWITCHING ON Errors will affect Loma warranty For Axis fixed speed conveyor machine Module 5000 ATTENTION IT 15 IMPERATIVE THAT THIS MACHINE IS CORRECTLY EARTHED THIS MACHINE SHOULD NOT BE SUPPLIED VIA AN EARTH LEAKAGE CIRCUIT BREAKER RCD PLEASE CHECK SUPPLY VOLTAGE BEFORE SWITCHING ON Errors will affect Loma warranty For Axis variable speed conveyor machine Module 5000 ATTENTION IT 15 IMPERATIVE THAT THIS MACHINE I
49. ensity A good example of this is to compare a quantity of water to a quantity of ice cream that measures the same in size This is shown in the diagram below Module 4000 Principles of Inspections 100mm of 100mm of Water Cream The density absorption factor of the water is approximately two times greater than the density of the ice cream This is mainly due to the fact that ice cream consists of a greater amount of air compared to water It can therefore be seen that the 100mm of water will absorb a much higher level of x ray energy than an equivalent quantity of ice cream In turn the detector array mentioned earlier would receive a lower quantity of x ray energy through the water compared to the ice cream The consequence of this is one that generates a lighter grayscale image on the screen in the case of the ice cream Further to our examination into product absorption it is important to remember that not all products will have an even absorption factor across its entire area The water ice cream example shows the density differences assuming both products are homogeneous In the case of a particulate product it must be understood that density values will vary across the entire area of the product Therefore it follows that the level of x rays reaching the array detector will also vary This will result in an image being shown on the screen of varying grayscale levels An example is shown below of the effect a parti
50. equire Module 7009 Operators Guide and Setup Fault and Error Messages The Loma AXIS x ray inspection system has been designed to incorporate a failsafe system There are two kinds of error conditions that can be generated by the Axis machine run errors and system faults Error data is logged continuously and when any of the following errors are detected the error type will be displayed as a text message on the screen and the machine response actioned whilst the condition is still active and for system faults until the reset is done from the operator panel Error conditions will be time and date stamped in the log Run Errors The following run error conditions will be logged Touching packs PV test required Conveyor only mode reject disabled Rejects too close applies to pulse reject only The run error relay will be closed until the condition is removed or clears itself The conveyor will continue to run System Faults When a system fault occurs the following actions take place The system fault relay will be closed The fault lamp is lit and the alarm sounds The generation of x rays will be terminated The conveyor will stop A system fault message is displayed on the screen The error condition will be logged The system fault will remain active until the condition is cleared and the system is reset To clear the fault condition the operator must first reset the offending condition such as an open guard and then Press gt
51. er to set an absolute reject point regardless to whether it is product or contaminant This is useful to guard against the possibility of a very large lower density contaminant being factored into the histogram WINDOW TOP and WINDOW BOTTOM is set to limit the inspection width This may be set to exclude fixed objects such as product guides from the analysis area EXPLORER Models This mode of analysis is used in conjunction with the AUTO algorithm and is in effect overlaid as an additional form of analysis This algorithm is useful when inspecting products which contain texture and irregularities whereby an additional analysis is applied to the densest areas in order to find a smaller dense contaminant The inspection is carried out as follows 1 2 3 4 5 After the AUTO SENSITIVITY level is set the system draws line back into the product corresponding with the figure set in the EXPLORER THRESHOLD OFFSET This is referenced from the AUTO THRESHOLD LEVEL line The system then looks for a large transition between pixels associated with a contaminant In order for a large transition between pixels to be considered a contaminant the calculated figure must be greater than the set figure in the EXPLORER SENSITIVITY entry box This in effect allows the user to set the sensitivity of the rescanned area Contaminants found by EXPLORER are highlighted in yellow on the image Red spots may occur which can be due to the AUT
52. erlocks After actuating any emergency stop it has to be manually reset before the x ray generator can be restarted Radiation Dose Rates In most if not all countries where ionising radiation is used there will be a maximum allowable emitted dose rate per hour In addition the dose measurement must be recorded at a set distance from the machine surface and around the machine at any aperture or discharge conveyor points In order to check that the emitted radiation level is within the guidelines a suitable radiation monitor must be used which is regularly calibrated at least once a year Please contact your Loma Customer Service office for details on obtaining the correct type of radiation monitor Routine Operational Testing After the x ray inspection system has been installed the service engineer will carry out a full radiation and safety survey of the x ray system For assurance that the system remains safe both the emergency shut down system and measurement of the surface dose rates need to be included in a regular test schedule The emergency stops provide the means for the operational staff to shut down the system rapidly Although the stops provided are of proven reliability it is important that they are tested on a frequent basis The test consists of actuating each stop individually while the x ray generator is operating and noting that the system immediately shuts down It is also a requirement that when the stop has been manu
53. essed air supplies REJECT DEVICES At no time with compressed air and or electrical power applied to an automatic reject device should any part of the body be placed within the operating area of the reject device In addition no attempt should be made to operate the AXIS x ray machine without the reject bin or guards in place EXCESSIVE NOISE When an air blast reject device operates the noise emitted may constitute a noise hazard While short exposure to this noise will not normally cause permanent damage to hearing prolonged exposure may cause some damage It is recommended that ear defenders are worn by personnel who are regularly exposed to the noise Module 2000 Cautionary Advice 10 11 12 13 14 HEAVY EQUIPMENT The equipment described in this manual is extremely heavy and considerable care must be taken when handling it Sufficient personnel and a suitable forklift truck or pallet truck must be used to ensure safe handling In addition attention should be paid to the Axis Lifting Points drawing in the Installation section of this manual LIFTING EQUIPMENT Use only the correct slings and lifting tackle to move heavy items of equipment described in this manual Inspect all slings and lifting tackle prior to lifting the equipment to ensure that a The safe working load will not be exceeded b There are no frayed or broken strands c Hooks rings etc are not damaged MOVING THE MACHINE The centre of gra
54. following information may be of use If necessary the Loma AXIS conveyor model has the facility to override the interlock switches for the purpose of running the conveyor to wash down To do this the power must be switched on and the key switch must be in the cleandown position refer to operators section Note When the keyswitch is in the cleandown position x rays cannot be generated therefore the user must insure that the AXIS is not in RUN in order that a fault condition is not generated Water jet nozzle is lt 12 5mm 1 2 diameter rounded Water delivery rate is lt 105 litres minute 23 1 gallons minute rounded Distance of nozzle from equipment 2 5 3 metres 8 2 9 8 ft rounded Note Do not inject water directly into bearings If not already actioned in the previous step switch on the electrical and compressed air power supplies to the system Switch the keyswitch to the x ray on position enter RUN mode and check that the reject mechanism successfully rejects a contaminated product into the reject bin Module 8000 Maintenance Weekly Inspection 1 Isolate the electrical and compressed air power supplies to the system 2 Check the security of fixtures and fittings and that all guards are securely fastened in place 3 Check that all interlocks and emergency stops function correctly 4 Check that the system and associated equipment has been cleaned correctly and there is no build up of product or debris
55. h controls the power level kV ranging from 20 to 75 kV depending on the model low or high power Filament PCB The current mA supplied to the filament in the tube is regulated via a separate PCB known as the filament board Detector Array The detector array comprises of a line of photosensitive diodes the number varies depending on width of conveyor 256 diodes for 200mm wide 384 diodes for 300mm wide 640 diodes for 500mm wide 768 diodes for 600mm wide which receive the x ray energy emitted from the x ray tube The detector scans at a rate of hundreds per second typically 620 depending on the belt product speed Both serial and parallel connections go directly to the PC the parallel connections providing the image data and the serial connection allowing full control of the sensor by the PC The PLC provides timing signals the form of the and acquire signals PLC The PLC has a number of functions Two of which controls and monitors both the power level and the current supply to the x ray tube In addition monitoring and control functions of the various systems is also undertaken This includes the reject signal and serial communication to the PC PC Computer The PC is also located in the centre section of the AXIS machine and is where the control software image processing software and hardware are located Data is received from the detector analysed and then displayed on the monitor The PC al
56. he cabinet on both the conveyor and pipeline models If the level is lower than stated telephone your local Loma service office for advice Note This oil level should not change unless a leak in the system is present In addition it should be noted that the oil is of a special insulating type and should not contain any moisture or air bubbles Refer to RECOMMENDED OIL AND GREASE On pipeline models check that the shutter mechanism inside the collimator assembly is operating correctly and that the DELAY BEFORE ON timer setting is correct This timer is located at the front of the cabinet behind the access panel Setting amp Adjusting the Conveyor Belt Tension amp Tracking NOTE Do not over tension the belt as this will cause premature wear of the bearings and damage the belt If the belt slips or moves during normal operation check the condition of the rollers and make sure that debris has not built up between the rollers and the conveyor belt This alone can cause tracking problems Follow the steps described below Note If any difficulty is found with tensioning or tracking consult your local Loma Customer Service Department Module 8000 Maintenance Adjusting the Belt Tension conveyor model only The belt tensioning screws are located adjacent to the second roller in from the end of the AXIS conveyor 1 Check that the belt and all rollers are clean and free from debris and greasy elements 2 Check that all roller
57. hen making adjustments 1 Remove the drive cover from the drive unit In some cases it may be necessary to remove the reject bin 2 Check the tension of the drive chain The chain should not be so tight that there is no movement whatsoever inversely it should not be so loose that the chain jumps the sprocket when running 3 the chain needs adjustment loosen the four bolts securing the motor and adjust accordingly 4 After adjustment tighten the four motor bolts and re check the tension 5 Check to ensure the sprocket alignment is correct and the grubscrews that lock the sprockets to the shafts are tight 6 If necessary lubricate the drive chain with a suitable lubricant 7 Replace the drive cover and any other covers removed Note If an encoder is fitted care must be taken to ensure that its position in relation to the sprocket is maintained Module 8000 Maintenance Adjusting the Reject Mechanisms WARNING REJECT DEVICES At no time with air and or electrical power applied to an automatic reject device should any part of the body be placed within the operating area of the reject device If the reject Delay and reject on times need to be adjusted these are set up via the user interface from the control panel Refer to the menu titled setup reject Pusher and Plough Rejects At the solenoid valve adjust the two throttle screws in conjunction with the reject delay and dwell times until the required reject t
58. iming and speed of operation are obtained The air pressure supplied to the conveyor affects both the reject timing and the speed of operation Air Blast Reject Since this type of reject has no throttles the only variables that can be adjusted are the reject delay and reject on times Signal Only Where signal only is required adjustment to the dwell and delay reject times is all that s necessary unless an auxiliary reject is fitted outside of the AXIS machine Module 8000 Wiring Schematics WIRING SCHEMATICS CERTIFICATE of CONFORMITY Module 9000 Parts Listing PARTS LISTING amp SOFTWARE LICENCE Module 10000
59. ity by adjusting the AUTO SENSITIVITY 3 The system will then check the contam size count whereby if it is higher than the manually set ABSOLUTE THRESHOLD and lower than the AUTO THRESHOLD value a reject will be registered 4 addition to the above three further parameters can be set to enhance or tolerate certain product characteristics such as small bones in pet food etc These are shown below and described on the next page Number of pixels Absolute Threshold Auto Threshold Level Product Density levels and texture calculated over entire product area Bone Filter Offset lt Level 7001 Operators Guide and Setup 5 7 8 The BONE FILTER OFFSET parameter as indicated sets area that the BONE FILTER SENSITIVITY parameter will operate in and is referenced to the AUTO SENSITIVITY value Any contaminants that fall into this zone will have a size factor applied to them In addition dense areas in this zone that are less than size are highlighted in brown and contaminants are highlighted in red yellow on the image The BONE FILTER SENSITIVITY parameter will set the number of adjacent contaminant pixels required before a reject is registered For example this can allow the user to regulate the size of a contaminant such as small pieces of bone that may not be required to be rejected such as pet foods in some cases The ABSOLUTE THRESHOLD allows the us
60. l be pleased to advise you WARNINGS 1 LETHAL HAZARD ELECTRICAL AND COMPRESSED AIR SUPPLIES This equipment uses electrical and compressed air supplies that can be lethal Unless absolutely necessary maintenance must not be carried out without first isolating the system from all electrical and compressed air supplies WORKING ON EQUIPMENT If it is essential to work on the equipment with electrical and or compressed air power connected the work must be undertaken only by qualified and authorised personnel who are fully aware of the danger involved and who have taken adequate safety precautions to avoid contact with dangerous voltages or compressed air supplies REJECT DEVICES At no time with air and or electrical power applied to an automatic reject device should any part of the body be placed within the operating area of the reject device Under no circumstances must the system be operated with any reject valve removed When working on pipelines the additional precaution of isolating the pump must also be taken before any work is carried out Module 8000 Maintenance Routine Maintenance Weekly Monthly Recommended Greases and Oils CONTAMINANTS Oils and greases must always be handled with care Prolonged bare skin exposure to certain oils and greases can cause skin problems Always handle oils and greases in accordance with the manufacturer s instructions Oil Manufacturer Oil Type SHELL Transformer 148 x ray tank
61. lockwise to increase the pressure or counter clockwise to decrease the pressure Push down the cap to lock it when finished 2 Check that the water trap is empty Empty it by pressing the drain pin The Weekly Monthly routine must be carried out on a weekly basis when the system is in constant use but can be stretched to a month when the demands on it are low If in doubt your Loma Service Centre will be pleased to advise you Module 8000 Maintenance Electrical Services X Ray Cabinet 1 Check that the internal cabinet fan is working this is located in the upper section of the cabinet This should be running all the time that mains power is on Note Do not attempt to check this with x rays on and interlocks overridden Check that the fan is working on the x ray tank cooling system located at the lower rear of the cabinet on the conveyor model and at the lower inside right on the pipeline model In addition the PC fan also needs be checked that it is operational to do this the radiator needs to be removed first Note Do not attempt to check this with x rays on and interlocks overridden Caution DO NOT operate the system if either of these two fans are not running In this unlikely event check the fuses or contact your local Loma Service Department Check the oil level in the x ray tank is approximately 15 mm below the filler plug The filler plug is located on the top of the x ray tank situated in the upper area of t
62. o ignore the left and right edges for a set number of pixels However care must be taken not to erode the actual product ABSOLUTE THRESHOLD This defines the size of the contaminate to be detected and is measured in pixels EXPLORER SENSITIVITY This sets the difference between a suspect pixel and the surrounding pixel intensity For example with a setting of 20 the suspect pixel must have a greyscale value at least 20 less than the surround pixels in order to qualify as a contaminate THRESHOLD OFFSET This parameter is applied to the AUTO THRESHOLD creating an intensity range for inspection using the EXPLORER algorithm For example if the AUTO THRESHOLD value 80 and the EXPLORER THRESHOLD OFFSET value 20 areas of the product with pixel greyscale values between 80 and 100 will be inspected using the EXPLORER algorithm FILTER This parameter applies an algorithm comparing the target pixel with its neighbours OFF No filters applied LOW Filters 1 2 amp 3 applied MEDIUM Filters 2 3 amp 4 applied HIGH Filters 4 amp 5 applied_ FULL All filters applied Module 7001 Operators Guide and Setup AUTO with BONE FILTER BONE FILTER OFFSET This defines the area that the BONE FILTER SENSITIVITY operates in SENSITIVITY This sets the number of adjacent contaminate pixels that are required before a reject is registered REJECT REJECT DWELL This parameter is used to set the length of time that the r
63. of equipment and will always work with customers to assist where possible in the remedy of any violations at a reasonable cost to the buyer Module 2000 Cautionary Advice Advice On Due Diligence By your selection of a Loma x ray system you have demonstrated your intention to assure the quality of your products and thereby protect your customers The following six simple actions will help you maintain Due Diligence 1 Once your Loma x ray system is installed you should contact your local Loma Service Department to have the system commissioned Check a daily basis the radiation levels around the x ray system lt 1uSv hr using a suitable radiation meter Details available from Loma Systems Limited and record the results see Radiation Surveys Regularly check the operation of the x ray unit once an hour is recommended Keep accurate records of those tests and the contaminant samples being used along with the product details If the x ray test fails the test quarantine the product from the last test and re introduce through the x ray unit once the equipment is fit for use Have the equipment supported by a Planned Preventative Maintenance Contract Details can be obtained from your local Loma Service Department If you have or intend to have BS EN ISO 9000 accreditation write a section into your Operating Procedures Manual covering x ray test procedures and have each x ray radiation meter regularly calibrated with
64. ollowing parameters Machine Type Report Title Report Time 8 date Machine Identification Error fault description Time date problem occurred From the REPORTS screen the MACHINE ID must first be entered This is done using the alpha numeric buttons at the bottom of the front panel and then selecting the character required by pressing the appropriate button down the side The relevant report type must first be selected by choosing SELECT by pressing the REPORTS toggle switch until this is seen and then ACCEPT The chosen report is then selected using the ARROW buttons and then pressing ACCEPT This report can then be VIEWED or SETUP by once again using the REPORTS toggle switch and then ACCEPT Module 7011 Operators Guide and Setup Reject Images The standard conveyor can store up to 300 reject images These are continually overwritten as rejects occur Fault Log The standard conveyor will record a list of faults in sequential order which can be either viewed or sent to a printer Module 7011 Operators Guide and Setup Supplements If your machine is fitted with non standard software which has enhancements or added functions supplements are provided with this manual in this section for reference Module 7013 Maintenance MAINTENANCE CONTENTS Inspection and Cleaning Routine Maintenance Daily Weekly Routine Maintenance Weekly Monthly Module 8000 Maintenance Inspection and Cleaning Loma x
65. operation that suites the product and line conditions The following pages will describe the different analysis modes and parameters which will aid the user in setting up the AXIS machine for optimum performance The user should also refer to the relevant menu map for their machine and descriptions in the Glossary of Parameters The Analysis Modes are in the following order 1 Auto Conveyor model 2 Auto with Bone Filter Pipeline and conveyor bulkflow models 3 Explorer Conveyor Pipeline and bulkflow models AUTO Conveyor Model This mode of analysis is standard on all machines The inspection is carried out in the following way 1 Inspection is started when the PEC is triggered by the product 2 The system captures an image the length of which is determined by the PRODUCT LENGTH The PRODUCT LENGTH must be correctly entered otherwise not all the product will be analysed 3 The system examines the image and looks for the product by locating the first row of data that is darker than the set figure in the PRODUCT LOCATOR entry box 4 The whole of the greyscale area is then examined so as to calculate its greyscale distribution and texture level whereupon an Auto threshold reject point will be set In addition to the calculated Auto threshold we can manually increase or decrease sensitivity by adjusting the AUTO SENSITIVITY 5 The system will then check the contam size count whereby if it is higher than the manually set
66. r CONFIGURATION Pipeline model The pipeline is provided with only one power level as follows a 100 Watt System Tube voltage max 50 kV Tube current 1 0 to 2 0 The detector array is supplied in the 307mm wide unit only Conveyors A 370 watt 0 5hp 187W for the Rapid motor drives the conveyor which is as standard is fixed speed but if specified can be variable speed via an inverter In addition the conveyor is fitted with a suitable reject system that will best ensure that contaminated product is successfully placed in a suitable container e g reject bin The non crack surface makes it easier to clean and in addition is non absorbent The standard belt supplied is PU but Intralox belt may be supplied if required The conveyors are supplied in the following standard sizes Module 6000 Product Descriptions Nominal line height 900mm 100mm Belt widths 200mm Rapid 300mm 500mm and 600mm Typical Lengths 1900mm Rapid 2100mm Standard and 2800mm Bulk Flow Safety Guards Devices Guarding As with any x ray machine the use of guarding is extremely important in order to shield operators from the ionising radiation present when x rays are on Legislation sets very specific demands with regards to radiation limits surrounding a x ray machine Radiation levels must not be greater than 1 0 45 per hour The level emitted from the Loma AXIS machine is much less on average not greater than 0 1uSv per hour This is
67. r with a yellow background In the event of an emergency which requires the machine to be immediately stopped press the stop button and both x rays and the conveyor will be stopped In addition an alarm will sound and an amber lamp will be illuminated Module 5000 Installation 5 Before powering up any AXIS machine for the first time a suitably qualified person should be present to carry out a critical examination see Radiation Surveys For advice please contact your local Loma Service office 6 Switch on the compressed air supply to the system and open air isolator switch 7 At the bottom left hand side of the central electrical services cabinet switch on the mains isolator The system automatically boots up in a failsafe fault condition with the alarm sounding and the amber fault lamp on 8 Press the amber fault reset button the alarm should stop and then again to clear the amber fault lamp 9 On fixed speed conveyor models only operate the green Start switch located on the system control panel Check that the Conveyor belt runs the correct direction If incorrect swap two of the phase cables over in the incoming supply Variable speed conveyors will be correct and not need adjustment 10 At this stage contact an authorised key holder to insert the key into the x ray key switch and switch to the on position Refer to operators guide and setup section for further details Checking Belt Tracking The belt must be
68. ray inspection systems should provide trouble free operation particularly if a sensible routine maintenance procedure is carried out as described in this section The following topics are covered e Inspection and Cleaning e Routine maintenance If you have any queries relating to the maintenance of your x ray system your Loma Service Centre will be pleased to advise you WARNINGS 1 LETHAL HAZARD ELECTRICAL AND COMPRESSED AIR SUPPLIES This equipment uses electrical and compressed air supplies that can be lethal Unless absolutely necessary inspection and cleaning must not be carried out without first isolating the machine from all electrical and compressed air supplies 2 WORKING ON EQUIPMENT If it is essential to work on the equipment with electrical and or compressed air power connected the work must be undertaken only by qualified and authorised personnel who are fully aware of the danger involved and who have taken adequate safety precautions to avoid contact with dangerous voltages or compressed air supplies 3 REJECT DEVICES At no time with air and or electrical power applied to an automatic reject device should any part of the body be placed within the operating area of the reject device Under no circumstances must the system be operated with any reject valve removed When working on pipelines the additional precaution of isolating the pump must also be taken before any work is carried out Cleaning Materials Require
69. rols to start and stop the system e Controls to acknowledge and clear certain faults e Viewing basic statistical information e Normalisation of the x ray system It is protected by a 4 digit password access level 1 The Supervisor interface will allow e Setting of the product type to be run e Training of the system for a new product e g threshold e Adjusting the sensitivity parameter e Viewing the contaminate run error and system fault logs It is protected by a 4 digit password access level 2 Module 7009 Operators Guide and Setup The Quality Assurance interface will allow e Copying of product parameters in the product list e Creating a new product e Batch report setup e Clearing the contaminate run error and system fault logs e Saving or downloading batch reports logs or reject images Setting the kV level e Setting belt speed It is protected by a 4 digit password access level 3 The Engineer interface will allow e Setting detection parameters associated with the image processing e Access to service diagnostics e Normalisation of the detector for kV and mA levels e Saving of all product and machine setup parameters to disc It is protected by a 4 digit password access level 4 The factory settings for the four respective levels are 1111 2222 3333 and 4444 It is the users responsibility to decide what levels of access personnel shall have and also change the passwords from the ones provided if they r
70. rom all electrical supplies LETHAL HAZARD RADIATION Whilst every precaution has been taken to make sure that all the necessary guards and safety devices have been fitted to the Loma x ray unit it is recommended that all operatives are trained in the use of x ray food inspection machines Furthermore it is the responsibility of the employer to create a set of local rules See example at the end of this section regarding the safe use of x ray food inspection systems In the U K this is in compliance with the lonising Radiation s Regulations 1999 users outside of the UK should consult the relevant health and safety executive see also Radiation Surveys in this manual LETHAL HAZARD COMPRESSED AIR SUPPLIES The equipment described in this manual may be supplied with a compressed air supply operating at a pressure which may be lethal Unless absolutely necessary cleaning inspection and maintenance must not be carried out without first isolating the equipment from all compressed air supplies In addition it should be checked that all air pipes are properly connected WORKING ON EQUIPMENT If it is essential to work on the equipment with electrical and or compressed air power connected the work must be undertaken only by suitably qualified and authorised personnel who are fully aware of the danger involved and who have taken adequate safety precautions to avoid contact with dangerous voltages radiation see Radiation Surveys or compr
71. ry No attempt should be made to repair the x ray unit without advice from a qualified service engineer After maintenance the unit should be monitored using a suitably calibrated radiation instrument and a record kept of the monitoring results RISK HAZARD ASSESSMENT Potential hazards are Failure of an interlock resulting in generation of x rays while the cabinet door is open Radiation leakage from the cabinet as a result of misplaced shielding following repairs to the unit or non operation of an interlock Routine monitoring around the unit following repairs or maintenance should minimise this risk Fire or mechanical damage which may effect the integrity of the shielding Under normal operating conditions the equipment is adequately shielded and doses to operators will be low lt 50 uSv per year CONTINGENCY PLANS IMMEDIATE ACTION is necessary to prevent exposure of persons to radiation In the event of a fault SWITCH OFF the equipment and remove the key from the switch Do not use the equipment again until the fault has been rectified and the absence of any radiation leakage is verified Notify the RPS of the fault In the event that it is suspected that a person has received an over exposure then the RPS must be contacted immediately Under these circumstances the RPS must ascertain if a person has been exposed and the magnitude of the exposure If investigations determine that an over exposure has taken plac
72. s are square across the conveyor and are free to rotate 3 With the belt in a slack condition i e belt slipping when the motor is running and centralised along the length of the conveyor adjust the tensioning screws evenly until belt drive is achieved 4 Increase the tension until there is no slip condition with the belt under load full product load Setting the Belt Tracking The belt tracking screws are located adjacent to the rollers at the end of the AXIS machine With the belt tension set the belt should now be running down the centre of the conveyor If the belt moves to one side this indicates that the tracking needs to be adjusted 1 Turn the tracking screw on the same side of the conveyor to which the belt is moving by a quarter turn clockwise 2 Ifthe belt still moves in the same direction repeat Step 1 until the belt moves back to the centre of the roller NOTE Do not over tension the belt whilst adjusting the tracking 3 If necessary slacken the opposite tracking screw by turning a quarter turn counter clockwise NOTE When making adjustments to the tracking each adjustment should be in small increments at a time In addition time should be allowed for the belt to move before further adjustments are made Module 8000 Maintenance Adjusting the Drive Chain Tension conveyor model only WARNING When the cover is removed from the drive module the sprockets and chain are exposed Care must be taken w
73. screwed through the feet Due to the fact that each AXIS machine has an oil filled tank which the x ray tube is immersed in it is necessary to level the machine to ensure that 100 of the x ray tube is immersed To this end use a spirit level across the top of the cabinet in the direction of flow adjusting the feet until a level condition is achieved When the height and level is correct lock the foot stud half nuts The lock nut hexagon is 30mm A F Failure to do so can have an adverse effect on the components of the AXIS x ray system You are recommended to apply silicone sealant around the feet and floor Unlocking the X Ray Tank Breather Each AXIS machine is delivered with the x ray tank breather screw locked Therefore it follows that this screw needs to be unlocked before powering up the machine To do this open the rear access door at the back of the upper rear cabinet The breather screw is easily located on the top of the x ray tank filler plug Loosen the screw by two or three turns anti clockwise and close access doors It should be noted that conveyors fitted with other forms of cooling other than a vortex may require the complete top lid to be removed to gain access Installation Electrical Connecting Electrical Supplies The supply voltage for the system is indicated on the identification rating plate that is mounted on the frame The maximum line current is also shown 1 Open the door on the front of the centr
74. so communicates with the PLC When power is removed from the system e g due to a power failure the PC operating system will still shut down in an orderly manner due to a small internal UPS which maintains power for at least the duration of this process Module 6000 Product Descriptions User Interface The user interface is a display monitor which is fitted behind a clear polycarbonate panel Down the right hand side and below are a number of membrane switches which are used in conjunction with the screen information Down the left hand side are the control switches For more information see the Operators Guide User Interface Section X Ray PC Software This software is used to provide for the operator interface to the system gather and display image information of product passing through the machine and communicate with the PLC CONFIGURATION Conveyor model One of two power levels are provided on each unit and are as follows a 100 Watt System Tube voltage max 50 kV Tube current 1 0 to 2 0 b 400 Watt System Tube voltage max 75 kV Tube current 1 0 to 5 0 In addition to the two power levels available the detector array is selectable dependant on the width of the conveyor Two variations are available a 205mm for a 200mm wide Rapid conveyor b 307mm for a 300mm wide conveyor 512mm for a 500mm wide conveyor d 614mm for a 600mm wide conveyor 666mm for a 650mm wide conveyo
75. te are the ports and as a consequence these should be monitored most frequently To measure the dose rate at the two ports will take only a few minutes and should be carried out either once per day or once per shift as appropriate It is recommended that the dose rate at the ports be measured at the start of each shift or day so that each operating team can feel confident that all is well when they start work The results should be noted in some form of record so that any longer term trends can be observed Radiation shielding of the main beam and elsewhere in the console is intrinsic to the design and where additional shielding is fitted it is mechanically fixed by welding or bolting As consequence of this it is reasonable to assume that there will be no changes in dose rates at the surfaces of the machine etc and routine monitoring of these may therefore be less frequent In addition to this a full survey should be made following any maintenance that involves removing or changing any internal parts or following any damage which results in distorted or split housing or panels Where lead curtains are fitted over time these will wear and potentially tear Visual inspection of these on a daily basis is recommended so that signs of wear are picked up before the curtains become damaged and so prevent the potential of the external dose rate rising above an acceptable level Module 3000 Radiation Surveys Summary of Test Procedures for Radia
76. ted product off the belt into the reject bin Pneumatic Specification for reject type Pusher Optimum supply 5 5 Bar 80 psi Minimum supply 4 5 Bar 65 psi Maximum supply 6 0 Bar 90 psi Capacity Litres second at 100 10 Air Blast Optimum supply 6 8 Bar 100 psi Minimum supply 5 5 Bar 80 psi Maximum supply 8 0 Bar 120 psi Capacity Litres second at 100 20 Module 6000 Product Descriptions Electrical Services Electrical services to the x ray machine are inside the main x ray cabinet with mains cable entry points in the bottom The conveyor contactor and overload are also located inside the main x ray cabinet For conveyor motors controlled by an inverter no overload is fitted The isolator is used for isolating the electrical power to the machine and is located at the lower left hand side of the x ray cabinet Safety Devices Each x ray machine is fitted with emergency Stop buttons and cover panel interlocks These when operated switch x rays off and exhausts air out of the reject device
77. tenance Checks should also be made on the operation of any warning lights and door interlocks A record should be kept of the monitoring results dose rates should be noted in units of uSv h and safety system checks 3 AUTHORISED STAFF Only staff who have been trained in the use of the x ray unit may operate the equipment The staff authorised to use the equipment are listed below INSERT NAMES 4 DESIGNATION OF AREAS No controlled or supervised areas require to be designated in connection with this unit Module 2000 Cautionary Advice 5 2 5 3 5 4 7 1 7 2 7 3 8 1 8 2 8 3 8 4 GENERAL PRECAUTIONS Any failure of a warning light or interlocks must be reported to the RPS as soon as possible In the event of a fault resulting in the failure of the door interlock or shielding the equipment must not be used until it has been repaired A notice stating that the unit is out of use must be displayed on the unit Before generating any x rays check that the warning lights are functioning Before accessing the interior of the unit e g for cleaning check that the unit is disconnected from the power supply Do not tamper with or attempt to over ride the door interlock this could result in exposure to the primary x ray beam When the equipment is not in use remove the key to prevent unauthorised use MAINTENANCE Maintenance will be carried out by appropriately qualified service engineers when necessa
78. tion Leakage Daily or Shift Checks 1 Measure and record the radiation dose rate at the infeed and the outfeed port using the radiation monitor If it is greater than the maximum allowable shut down the system and report it immediately to the supervisor 2 Check the condition of the lead curtains ensuring no splits or broken segments Weekly Checks 1 Check the emergency stops If any of them fail report it immediately to the supervisor 2 Check the conveyor lid s If opening the lid does not immediately shut down the system then use the nearest emergency stop and report the failure to the supervisor Monthly Checks 1 Carry full radiation survey over the accessible surfaces of the machine using the radiation monitor After a Major Service 1 Carry out a radiation survey over all accessible surfaces and at the openings of the infeed and outfeed ports Check the emergency stops and the interlocks are operational After a machine has been moved 1 Carry out a radiation survey over all accessible surfaces and at the openings of the infeed and outfeed ports Check the emergency stops and the interlocks are operational Note When using the radiation monitor it must be moved slowly over the surface that you are measuring The suggested rate is less than 6 inches per second however users should refer to the monitor instruction manual and specification It is strongly recommended that persons appointed to carry out radiation
79. to over penetrate and lose the ability to detect small contaminants X RAY mA The x ray mA will in effect set the intensity of the x rays and is generally always set at its maximum allowable for the type of unit i e Low or High power The Low Power max 2mA and the High Power max 5mA ASPECT RATIO This is the aspect ratio of the image on the screen i e the scaling of height and width The value is normally to be set to 1 but for applications where the product flow length is greater than the scan length this may be adjusted to include a complete image of the product When changed from a value of 1 the image seen on the screen will be slightly distorted BELT SPEED The BELT SPEED value must be set to the actual speed of the system conveyor in metres per minute Module 7001 Operators Guide and Setup AUTO MODE SENSITIVITY This sets the level of sensitivity which is applied to the Auto algorithm ERODE TOP BOTTOM In some cases the product may be packaged inside a cardboard box or container that has a thick leading and trailing edge In such a case it is possible that these edges can be seen by the system as a dense area For these specific cases the ERODE TOP BOTTOM parameter can be used to ignore a set number of pixels in from the offending edges However care must be taken not to erode the actual product ERODE LEFT RIGHT This parameter works a similar way to ERODE TOP BOTTOM Where it is necessary for the system t
80. umented survey program assures the system is performing correctly has not been damaged and provides regular data that the system meets all radiation guidelines Note When your AXIS system is commissioned your Loma service engineer will carry out an initial survey report and provide you with a copy The UK regulations also require that radiological information is provided This information is given in the Cautionary advice section under Local Rules Radiation Exam To ensure that maintenance modification damage or distortion of the cabinet and cowlings etc do not result in any deterioration of the safety system it is important that regular checks are carried out Module 3000 Radiation Surveys Interlocks and Emergency Stop Switches Lids that may need to be opened by operating staff in order to clear obstructions etc are interlocked to prevent x rays being generated while the lid is open Service panels that only need to be opened by trained service personnel are similarly interlocked The interlocks used are either tongue or magnetic type safety switches which via safety relays trip the high voltage power supply and stop x ray generation The switch is fixed to the frame of the machine and a protective panel when properly seated closes the switch After the high voltage power supply has been tripped it is necessary to re start the inspection in order to generate x rays The emergency stop switches act in a similar manner to the int
81. vity of the conveyor is high Care must be taken when moving such equipment on a slope to ensure that it does not topple over This could result in death or severe injury to an individual and or severe damage to the machine refer to Axis Lifting Points in the Installation section of this manual CONTAMINANTS Oils and greases must always be handled with care Prolonged bare skin exposure to certain oils and greases can cause skin problems Always handle oils and greases in accordance with the manufacturer s instructions for types used see section on routine maintenance TRAPPED FINGERS Do not place fingers on the underside of the x ray conveyor belt when the machine is operating It is possible for fingers to be trapped and subsequently crushed between a moving and fixed component of the machine Trapped fingers is also to be avoided during pipeline normalisation WARNING LABELS The Loma AXIS x ray machine has a number of warning labels and engravings throughout the system Particular attention should be paid to the location of these warnings and their significance in operating the machine safely If necessary because of local requirements some labelling may also be provided in a second language GUARDS No machine is to be run without guards fitted unless for maintenance purposes and only if adequate precautions have been taken Under no circumstances is any interlock to be defeated This could lead to serious leakage of radiation if operat

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