Z+VX Supervisor's Manual

August 12, 2022 | Author: Anonymous | Category: N/A

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Download Z+VX Supervisor's Manual...

Description

Supervisor's Manual. SORTEX Z+ Vx

SORTEX Z + V Vx x

Contents Safety ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- 1 Warning Labels.....................................................................................................................................................1 Power & Air Safety........................................................................... Safety ................................................................................................................................................3 .....................................................................3

Power.......... ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... ................ 3 Air ................... ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ............ 4 Good Habits ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... ................ 4

Serial Plate ................................................................................................................... ....................................................... ...................................................................................................................4 .......................................................4

Beyond Day-to-Day Operation ------------------------------------------------------------------------------------- --------------------------------------------------------------------------------------------- 5 Passwords ........................................................................... ...................................................................................................................................................... .................................................................................5 ......5

Gaining Access................................................................... Access ............................................................................................................................................... ..................................................................................6 ......6 Changing Passwords............................................................................................................................................6

Modules & Partitions........................................................................ Partitions .............................................................................................................................................7 .....................................................................7 Using Supervisor Level Commands ......................................................................... .....................................................................................................................8 ............................................8

Supervisor Facilities Menu ------------------------------------------------------------------------------------- ------------------------------------------------------------------------------------------------------ 8 Sorting Setup Menu......................................................................... Menu ..............................................................................................................................................8 .....................................................................8 Defect Size ................................................................................................................... ....................................................... ...................................................................................................................8 .......................................................8

Camera ..................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ...................... . 8 Colour Defect Window.......... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ............ 8 Colour Defect Area........ ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................... 9 Spot Defect Area ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ......... 9

Defect Detection ..................................................................................................................... ......................................................... .........................................................................................................9 .............................................9

Pulse Extension.................................. ..................... ...................... ..................... ..................... ...................... ..................... .................... 9 Camera ..................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ...................... 9 Colour Defects ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ............ 9 Spot Defects............................. ..................... ..................... ..................... ...................... ..................... ..................... ..................... ......... 9

Ejector Delay........................................................................................................................................................................9

Camera ..................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ...................... . 9 Colour Defects ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ............ 9 Spot Defects............................. ..................... ..................... ..................... ...................... ..................... ..................... ..................... ......... 9

Sort Type ...................................................................................................................... .......................................................... .................................................................................................................10 .....................................................10

Camera Scaling.................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... .......... 10 Reset......................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 10

Sort Configuration..............................................................................................................................................................10

Configuration............. ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 10 Sort Type .................. ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 10 View Combination .................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 10 Visible Defect Propagation/IR Defect Propagation.............. ..................... ...................... ..................... ..................... ..................... ....... 11 Camera ..................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 11 Standard ................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 11 Region....................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 11 Extended......... ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... .......... 11 Use Presence........................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 11 Reverse Sort .................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... .............. 12

Mode Controls .................................................................... ................................................................................................................................................ ................................................................................13 ....13

Save Working Mode...........................................................................................................................................................13 Rename Working Mode ........................................................ ................................................................................................................... .............................................................................................13 ..................................13 Copy Working Mode ............................................................................................................... ................................................... .......................................................................................................13 ...........................................13 Delete Mode.......................................................................................................................................................................13

User Access Level........................................................................... Level ..............................................................................................................................................14 ...................................................................14

Calibration...........................................................................................................................................................14

Product Feed .................................................................................................................................................. ......................................................................................................................................................14 ....14

Sort Sensitivity.................................................................... Sensitivity ................................................................................................................................................ ................................................................................14 ....14

Stats Menu.......................................................................... Menu ...................................................................................................................................................... ................................................................................14 ....14

Stats Graph........................................................................................................................................................................14 Fixed Thresholds .................................................................................................................... ........................................................ .......................................................................................................14 ...........................................14 Stats Histogram .......................................................... ...................................................................................................................... .......................................................................................................15 ...........................................15 Relative Thresholds .................................................... ................................................................................................................ .......................................................................................................15 ...........................................15 Stats Data ......................................................... ..................................................................................................................... .................................................................................................................16 .....................................................16 Over Time ..................... ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................. 16 Single Measurement...................................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 16

Stats Log............................................................................................................................................................................16

Log Brokens ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... .............. 16 Log Defects. ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... .............. 16 Clear Stats Log .................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... .......... 17 Save Stats Log... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 17

Product Alarm ............................................................................................................... ................................................... .................................................................................................................17 .....................................................17

Enabled/Disabled ..................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 17 Clear .................. ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 17 Summary................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 18

Sampling............................................................................................................................................................................18

Sample Module .................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... .......... 18 Sample Interval Time.......................... ..................... ...................... ..................... ..................... ...................... ..................... ................. 18 Sample Feed Rate ................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 18 Sample Size ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... .............. 18 Enhanced Presence Detection .................. ...................... ..................... ..................... ..................... ...................... ..................... .......... 18 Object Width.................. ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................. 18 Object Length......... ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ... 18

Mode Configuration ............................................................................................................................................19 ............................................................................................................................................19

Foreground Lighting...........................................................................................................................................................19 Wiper Interval.....................................................................................................................................................................19 Tracking Configuration.......................................................................................................................................................19 Calibration Configuration ...................................................... ................................................................................................................. .............................................................................................20 ..................................20

Wipe during Calibration ................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 20 Calibration Interval ................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 20

Machine Configuration........................................................................................................................................20

External Interlock Configuration.........................................................................................................................................20

Input State.............. ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ... 20 Output State ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... .............. 20 Input.. ..................... ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ... 20 Modules .................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 21

Hopper Interlock Configuration ....................................................... .................................................................................................................. ...................................................................................21 ........................21

State .................. ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 21

White Reference Calibration ........................................................... ...................................................................................................................... ...................................................................................21 ........................21 White Reference Calibration Interval ........................................................ ................................................................................................................... .........................................................................22 ..............22 Disabled .................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 22 Test Facilities......................................................................................................................................................22 Background Test................................................................................................................................................................22 Self Test.............................................................................................................................................................................22 Create Diagnostic File ..................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 22 Full Ejector Test.................................................................................................................................................................23 First ejector to test..... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 23 Last ejector to test .................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 23 Start ................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 23 Continuous Loop ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 23 Individual Ejector Test........................................................................................................................................................23 Module ................... ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... ... 23 Block .................. ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 23 Position ..................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 23 Channel..................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... 23 Frequency ..................... ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................. Start ................... ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 23 23 Wiper Test ........................................................ .................................................................................................................... .................................................................................................................23 .....................................................23 Vibrator Test ....................................................................... ................................................................................................................................................... ................................................................................24 ....24 Test Mode ..................... ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................. 24 Lamp Maintenance .......................................................................... .............................................................................................................................................24 ...................................................................24 Used .................. ...................... ..................... ..................... ..................... ...................... ..................... ..................... ..................... ....... 24 Remaining....... ..................... ..................... ...................... ..................... ..................... ..................... ...................... ..................... .......... 24 Ejector Rates .................................................................................................................................................. ......................................................................................................................................................24 ....24 Caused By............................ ..................... ...................... ..................... ..................... ..................... ...................... ..................... .......... 25 Ejector Fire Count...............................................................................................................................................25 Full Low..................... .................... ...................... ...................... ..................... ..................... ..................... ..................... ..................... ..................... ...................... ...................... ..................... ..................... ..................... ..................... ..................... ..................... ....... ....... 21 21

Engineer & Special Engineer menus ----------------------------------------------------------------------------------------- ---------------------------------------------------25 ---------------------25 Maintenance----------------------------------------------------------------------------------------------------------------27 Optical System Components Components ----------------------------------------------------------------------------------------- -------------------------------------------------------------------------------------------27 27 Foreground Lamps–Replacement ......................................................................................................................27 ......................................................................................................................27

Background Lamp–Replacement .......................................................................................................................28 .......................................................................................................................28

Wipers.................................................................................................................................................................30

Changing a Wiper Blade ....................................................... .................................................................................................................. .............................................................................................30 ..................................30

Ejector Cartridges Removal and Refitting --------------------------------------------------------------------------------------- ----------------------------------------------31 ----------------31 Identification of Failed Ejectors .................................................................................................................. ....................................................... ...................................................................................31 ........................31 Replacing an Ejector Block ................................................... .............................................................................................................. .............................................................................................31 ..................................31 Control Box Dust Filter Removal and Replacement...........................................................................................................33

Servicing an Air Filter.................................................................................... Fi lter..........................................................................................................................................34 ......................................................34

SERVICING ..................... ...................... ..................... ..................... ...................... ..................... ..................... ..................... .............. 34 DISASSEMBLY............. ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................. 34 REASSEMBLY.............. ..................... ..................... ...................... ..................... ..................... ...................... ..................... ................. 34

Air Regulator.......................................................................................................................................................35

Note: You have acquired acquired a device device which includes includes software (Microsoft Windows Windows CE TM  ) licensed by Buhler SORTEX from one or more software licensors. Such software products, as well as associated media, printed materials, and “online” or electronic documentation, are protected by international intellectual intellectual property laws and treaties. The software is licensed, not sold. All rights reserved. Warning:

When working in the vicinity vicinity of the machine, whilst it is running, ear ear defenders may need to be worn. Refer to on-site management.

Safety

SORTEX Z+Vx

Safety Throughout these manuals; WARNING is is a command which, if disregarded, is likely to cause injury as well as damage. A WARNING A CAUTION   is is an advice which, if disregarded, could damage the equipment or process. A NOTE is a helpful hint, to help the reader perform the desired task.

Warning:

Disconnect the machine from its electrical and pneumatic supplies before removing any component or servicing the machine in any way, w ay, unless instructed otherwise in the manual. High voltages are present within the machine. Never remove any guards or covers while the machine is powered up. The machine contains moving parts. Do not work in the viewing area with the t he air or power supplies on. Ear defenders should be worn whilst working w orking close to the machine. Only trained operatives should operate this machine. Only trained engineers should maintain it. The relevant manual should be read and understood – including advice on safety labels.

Warning Labels Hazardous areas of the machine are clearly labelled. If there is a label, you should assume that there is a hazard nearby. Red labels, labels, usually circular, prohibit certain actions. Yellow Labels, Labels, usually triangular, are a warning against danger. Blue Labels, Labels, usually circular, are commands to perform mandatory actions.

NO WELDING This red prohibiting label appears on both sides of the machine to ensure that welding does not take place in the vicinity of the machine.

NO DRILLING This red prohibiting label appears on the main trunking, on the right hand side of the machine, to ensure that the frame is not drilled.

DO NOT EXCEED… This label is situated on the filter regulator assembly and signifies the air pressure limits for the machine.

WATCH YOUR FINGERS This label is located wherever there is a possibility of trapping or pinching hands or fingers. Care should be taken to follow the instructions in the manuals.

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S ORTEX Z+Vx   SORTEX

Safety

WATCH OUT This yellow warning label appears at various points on the machine to indicate dangerous areas.

WATCH OUT - ELECTRICITY This yellow warning label appears on protective guards covering hazardous electrical equipment. Where themachine, hazard isthere AC with a maximum 250V between any two points or located outside of the is no subsidiary of label. Labels in the vicinity of other hazardous voltages will show the voltages present (e.g. 100V is 100V DC). WATCH OUT – LETHAL VOLTAGES This yellow warning label appears in areas where there are lethal voltages present, such as on the Lamp Driver PCB Guard and the Heated Chute PCB Guard. Extreme care should be taken when working in these areas.

WATCH OUT – MOVING PARTS This yellow warning label appears on the wiper cover and the receptacle doors as a warning against moving parts which could trap fingers, etc. The wiper cylinder action is powerful and could cause serious injury.

WATCH OUT – HOT! This yellow warning label is attached to the lamp packs and any other surface that may become hot.

READ THE MANUAL This blue command label indicates that instructions in the manual must be followed. The labels on the Wiper Guards and Receptacle Doors refer to the changing of Wipers and any other operations that may occur within the sorting area between the optical box windows.

EARTH STUD LOCATION On the machine frame, the Earth Stud is located next to the label shown on the left.

Safety

SORTEX Z+Vx

Power & Air Safety Many areas of this machine’s interiors carry live mains electricity – at lethal voltages. Other areas carry lower, non-lethal voltages – but the wrong treatment of components when live can damage them irreparably. Also, there are maintenance operations which would become dangerous if the machine were to become active, while someone was working on it. Similarly, many of the machine’s operations rely on air power. In some areas (the ejectors, particularly), this power can have explosive effect, if released incorrectly. In others, air pressure powers movement which can be dangerous if there is a human (or part of a human) in the way.

Power When undertaking any maintenance work, anywhere in or near the machine, switch off the electrical power at the mains isolator. And, to guard against someone switching it on again, unaware of the danger, lock the isolator in the off position.

Power on (and power available, even if switched off)

Power off (and avoiding accidental switch-on)

Locking Power off Swing the yellow flap up, and slide it to the right. In the process, the projection will depress the Stop Stop switch, switch, switching off power to the machine (if it is not already switched off). Since the flap is sprung, insert something in the slots – to keep the flap in place. A screwdriver or something similar would keep the flap closed – but to avoid any  possibility possibility that power could be switched on during maintenance work, insert a padlock in the slot. With that in place, you can proceed with maintenance work, certain that nothing surprising will interrupt you.

Caution: Allow a minute or so for capacitors to discharge, discharge, before working on any PCBs PCBs or power supplies. Allow even longer, if working inside either optical box: the lamps and associated components become very hot, and take some time to cool down. NOTE: There are some maintenance operations – mostly tests and diagnoses of problems – in which power is required. Take great care during such operations – keeping cabinets closed, and keeping unauthorised personnel away from the machine. Heated Chute Machines A machine with a heated chute has two  mains mains isolators fitted. A typical layout is shown on the right. In such machines, take care to switch off both  isolators isolators during maintenance work, and to take the same precautions against accidental switch-on (see above).

Safety

S ORTEX Z+Vx   SORTEX Air When undertaking any maintenance work in the optical area (where the wipers operate), or in the ejector enclosure, switch the air supply off.

On multiple-module machines, the air supply is controlled by a black, lever valve (see illustrations). The singlemodule machine has a slightly different valve, with a red, curved lever – but the principles are the same. When the handle points in the direction of the airflow – the air supply is on. When the handle points upwards (across the direction of the airflow) – the air supply is off. In this state, a metal sleeve drops into place, preventing the air from being easily  turned turned on. This would prevent, for instance, something catching on the lever,horizontally. and turning it on inadvertently. To turn on the air, lift the sleeve in the direction of the arrow, and turn the lever But, to ensure that no-one deliberately turns on the air whilst you, or anyone else, is working on the machine – perhaps out of sight - you should insert a padlock into the lever & sleeve, as shown in the right-hand illustration.

Air supply on.

Air supply off,

Air supply off,

but unlocked

and locked

Note: If the wipers are operating at the time, t ime, always allow them to come to rest before switching off the air supply. This ensures that they are out of the way during any work in that area, and ensures that they won’t start up (unexpectedly), if the air supply is switched on again.

Good Habits Throughout this manual, there will be regular reminders to switch off air and power, before undertaking particular maintenance tasks – using the graphic on the right. However, it should become a matter of habit to ensure that air and power are switched off, every time  maintenance maintenance work is contemplated, and that any exception to this rule should be very carefully thought through.

Serial Plate A new serial plate has been designed for SORTEX machines, giving key information about the unit it is attached to. This has been done to comply with new European regulations (CE accreditation). An example is shown on the left. The information on this plate will be useful during installation, and during any contact with SORTEX Customer Services; we will need to know the model and, possibly, the serial number.

General Information

SORTEX Z+Vx

Beyond Day-to-Day Operation The work of a Machine Operator, responsible for the day-to-day operation of the Z+Vx, is described in the Operator’s Manual. Manual. Supervisors should familiarise themselves with these procedures – and those laid out in the Routine Maintenance booklet/poster. Maintenance booklet/poster. This section deals with the commands available to Supervisors – who are focused more on the long-term management of the Z+Vx. Starting on page 27, the Maintenance section deals with the replacement of consumable items (lamps, ejectors, filters etc.).

Passwords The Machine Operator can perform his tasks immediately upon switch-on; there is no need for a password to manage the Feed or Sensitivities. However, some of the commands available on the Z+Vx can have important consequences, and are therefore protected from casual investigation by untrained hands. There are four levels of access:Machine Operator

Adjust Feed Rates and Sensitivities. Switch Product Modes. Start a Calibration.

For the main operator of the machine – taking responsibility for its day-to-day running and responding to changing circumstances. May also take responsibility for Routine Maintenance and cleaning.

Supervisor

Create new Product Modes. Adjust machine configurations related to sorting product. Run tests.

For staff who focus on the long-term success of the sorting process.

Engineer

Manage the mechanical and electronic workings of the machine.

For staff who maintain plant equipment.

Special Engineer

‘Expert’ setup and re-tasking of machine.

For specialists in SORTEX equipment usually SORTEX engineers or high-grade plant engineers

These are only guidelines. If a Machine Operator is expected to act on his own initiative, and produce the best possible results from the machine, it may be that he should have Supervisor access. On the other hand, if an Operator is only expected to monitor the machine’s progress, with no authorisation to make any changes, it may be that Monitor access is sufficient. The two higher levels of menu access – Engineer and Special Engineer - contain functions which deal with the technical status of the machine, and are designed to be used by personnel trained to understand the consequences of changing any of settings. If you, or any of your staff, wish to know more about the deeper functions, and gain better understanding of the capabilities of the SORTEX Z+Vx, SORTEX runs training courses at our London headquarters. Contact [email protected] for for more information. [email protected]

Caution: However passwords passwords are are allocated, allocated, all staff should should take care of their passwords – not allowing them to become ‘common knowledge’. They should also be wary of leaving the machine ‘logged in’ to a high access level – allowing anyone who comes along to (mis)use that access. NOTE: There is a ‘time-out’ function, which will return the machine to Monitor-level access if the t he screen is unused for 20 minutes – but a lot can happen in 20 minutes. While deciding how to allocate passwords, ensure that all those involved with the machine are clear about their responsibilities, and what tasks they are expected to carry out – and ensure that they are given the appropriate documents (manuals) and training to enable them to do so.

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General Information

S ORTEX Z+Vx   SORTEX

Gaining Access

Press the Facilities Facilities button, button, and select User Access Level from Level from the list.

A new screen will appear. Select the required level of access.

Note: You can also use this screen to return the machine to a lower level of access, before leaving the machine in someone else’s hands.

An on-screen keyboard will appear. ‘Type’ the password and press OK OK.. If the password contains upperCASE letters, use the CAPS CAPS button button before entering them. Press it again to return to LOWERcase. The DEL DEL button button deletes letters already entered (it acts like a computer’s Backspace key). ESC will ESC will close the keyboard without entering any text into the system (useful if you have lost track of the password, and wish to start again). The text you ‘type’ will not appear on screen, but will be replaced with asterisks (****) – so that no-one can learn your password by watching you enter it.

Presuming that the correct password has been entered and OK OK’d, ’d, the screen will return to the ‘Home’ screen – but with a new set of commands available on the Facilities menu. Facilities menu.

Changing Passwords

On the User Access Level screen, Level screen, press Change Password. Password.

Use the keyboard to enter the new password. Press OK OK to to return to the User Access Level screen. Level screen. Inform those who need to know – what the new password is.

General Information

SORTEX Z+Vx

Modules & Partitions The SORTEX Z+Vx has one to three chutes, feeding one to three sorting modules. In the simplest of setups, all modules will be working in unison. However, it is possible to split these chutes into two or three partitions (Primary, Secondary, Tertiary), each of which can be treated differently. This enables a Secondary partition to be used to re-sort the output from the Primary sort and a Tertiary partition to re-sort output from the Secondary.

Note: Partitions are sometimes known as ‘Divisions’. Many of the SORTEX Z+Vx ‘s settings deal in Partitions Partitions.. You will set the Defect Size for one Partition at a time. You will Configure the Sort, one Partition at a time. A Machine Operator will see the machine’s operation as happening in one or more Partitions. On the other hand, a Supervisor has responsibilities to supervise the machine at a deeper level – and that involves an awareness of Modules Modules and and of their components. Each module has its own chute, its own vibrator (although there are setups in which a dual vibrator may serve a split chute). Each module may be served by two or four cameras (Front ( Front & & Rear Rear). ). Each module contains a bank of ejectors. Each module has its own receptacle. On many of the screens you will be dealing with, the settings you make will only apply to one Partition at a time, or to one Module at a time. In some cases, you will be dealing with one camera at a time, or even one ejector at a time. You may be dealing with the Front View or the Rear View, or a Combined Combined View. View. In all such cases, a selector (a drop-down) will show the active Partition or Module (or Camera) – and the settings you give will apply only to that item. If you need to apply these settings to all modules/cameras/ejectors, you will need to select each of them, in turn, and re-apply the settings

Supervisor’s Menus

S ORTEX Z+Vx   SORTEX

Using Supervisor Level Commands These are available once the correct password has been entered via the User Access Screen.

Supervisor Facilities Menu Press the Facilities Facilities button, button, and a menu of further commands appears. Press one of these and a screen (or a further menu) will appear.

Sorting Setup Menu Press Sorting Setup on Setup on the main Facilities Facilities menu menu produces a new menu. This menu offers the ability to make various adjustments to the detail of the sorting process. Select further items to reveal individual screens:-

Defect Size Camera Select the Camera (Front (Front or Rear Rear)) on which you wish to operate.

Colour Defect Window This selects the size of the ‘window’ which the software will use to make its calculations – in pixels. The software will examine a square of (in this case) 6 pixels per side, and assess whether a defect exists or not. It will then shift this window one pixel to the right, and re-calculate. and + symbols to lower or raise this number. Use the – the – and ‘Rounding up’ even-numbered Windows In this example, a Defect Window Size of 6 has been selected. This would surround the central, target pixel pixels

- with a 6x6 block of

.

But this would be asymmetrical – with a smaller area of interest below and to the left, than above and to the right – which would make the calculation less useful. So, the software adds a block

- to balance the ‘window’.

The software will examine this block for defects, before moving the whole block one pixel to the right, to repeat the process.

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Supervisor’s Menus

SORTEX Z+Vx

Colour Defect Area This selects the size of the colour defect which will trigger an ejection. In this case, a colour defect 10 pixels square (or larger) will be recognised as a colour defect, and the item will be ejected. Use the – the – and and + symbols to lower or raise this number.

Spot Defect Area This selects the size of the spot defect which will trigger an ejection. In this case, a spot defect only 1 pixel square (or larger) will be recognised as a spot defect, and the item will be ejected. Use the – the – and and + symbols to lower or raise this number.

Defect Detection

This screen switches on or off the detection of Colour Defects Defects and/or Spot Defects. Defects.

Pulse Extension With some products, the ejector might miss faulty examples, due to its size. This screen allows an imaginary extension to be added to faulty product, so that the ejector will fire a little longer.

Camera Select the Camera (Front (Front or Rear Rear)) on which you wish to operate.

Colour Defects Spot Defects This extension can be applied to each or either type of defect. and + symbols to lower or raise this number (in millimeters). Use the – the – and

Note: If Reverse Sort is enabled (see p. 12), there is only one Pulse Extension. A typical value would be 5 (or more).

Ejector Delay This screen controls the delay between the detection of a defect, and the firing of an ejector to reject it. This may be necessary with some products which fall more slowly.

Camera Select the Camera (Front (Front or Rear Rear)) on which you wish to operate.

Colour Defects/Spot Defects This delay can be applied to each or either type of defect. Use and + symbols to lower or raise this number. the – and the –

Note: If Reverse Sort is enabled (see p. 12) There will only be one Ejector Delay. A typical value would be 50.

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SORTEX ORTEX Z+Vx   S

Supervisor’s Menus

Sort Type This screen sets the type of sort the machine will undertake:– A Dark sort – in which the machine rejects defects which are darker than the normal product, or a Light Light sort, sort, in which the machine rejects defects which are lighter than normal.

Camera Scaling Effectively, this sets a sensitivity level below which the ejector never fires at product. It does so by the machine’s understanding of ‘white’ – raising or re-defining lowering the camera’s output against the level fixed during a White Reference Calibration (see p.21). For a Light Light sort, sort, there are some products which are, naturally, lighter than white (lighter than the White Calibration plate). This is particularly true when working in Infra-red. To combat this, the Camera Scaling factor is reduced below zero (to a negative level). This lowers the Coarse Gain of the Camera signal, thereby making ‘White’ lighter than the product – and allowing good product to pass through the machine without ejection. Raising the Camera Scaling (positively) has the reverse effect - of raising the Coarse Gain of the Camera signal. This has the effect of bringing the product closer to ‘white’. This can be useful if the product in question is dark. In such cases, the difference between good product and bad product may be very small. By raising the Coarse Gain, both readings are boosted, and the differences between them are easier to differentiate. Camera Scaling has no relevance in a Dark sort. and + symbols to lower or raise this number. Use the – the – and

Reset Use Reset Reset to to return the Scaling to zero.

Sort Configuratio Configuration n This screen sets a number of configurations for the machine and its arrangements for sorting.

Configuration This drop-down list offers a number of options, relating to the ways in which operation within a machine may be split:

Single (all primary) – machine is undivided; all product sorted according to Primary settings.

Single (all secondary) - machine is undivided; all product sorted according to Secondary settings.

Dual (secondary on left) – machine is divided, with primary on the right, secondary on the left.

Dual (secondary on right) - machine is is divided, with primary on the left, secondary on the right.

Triple (tertiary on left) – machine is divided divided into three – tertiary, secondary, primary (from the left). left).

Triple (tertiary on right) – machine is divided into three – tertiary, secondary, primary (from the righ right). t).

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Sort Type This offers the options of Normal Normal or or Transparent sorting.

View Combination This offers the options of Combined or Independent Independent  views views.. That is, combining the information from one view with the other – or treating the information independently. independently.

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Visible Defect Propagation/IR Defect Propagation In the simplest terms, Defect Propagation adds a little to the perceived width of a defect. If a rice grain, with a spot defect at one end, falls past the camera in a horizontal orientation, the main body of the grain may fall to the left or right of the defect. If so, the ejector may fire at the defect, but miss the grain. So, Defect Propagation allows the width of a defect to be exaggerated, so that the next  ejector ejector will also fire, and eject the defective grain.

Camera Select the Camera (Front (Front or Rear Rear)) on which you wish to operate. The following options may be applied to either/or Colour Colour or or Spot Spot defects: defects:-

Standard Standard width propagation. If defective product overlaps two channels – both ejectors will fire (though this is inter-related with the other settings on this screen).

Region There are 16 (camera) pixels per ejector and, therefore, to each channel. The machine looks at the pixels at each end ofofthe channel with particular interest (for the purposes of propagation), because this is where the positioning a grain of defective rice might be ambiguous. When a defect is detected in this edge region, the processor looks to see if it also appears in the other edge region of that channel. If so, both ejectors will fire. This setting increases the number of those pixels assigned to these edge regions. 1mm is the normal setting. 2mm gives even more propagation but, potentially, more wastage.

Extended Extended width propagation. Similar to the standard propagation, but more so. Roughly speaking, the ejectors on either side of a defect will fire, to ensure that item is removed. It is less accurate, in the sense that more good product will be ejected. However, it is effective with large products with small spot defects.

Use Presence This adds an extra dimension to the Standard or Extended width propagation methods. In simple terms, the processor holds a picture of where product is, and where it isn’t. It uses this knowledge to judge whether this particular item of product lies to the right or to the left of the detected defect. This would obviously seem preferable, but the presence calculation is of no help when the throughput is high. This is because the product tends to overlap when the flow through the machine is very high. The machine cannot distinguish between items, so the presence calculation doesn’t improve defect ejection. In normal usage, Use Presence is Disabled Disabled..

Note: If IR lighting/cameras are present and enabled, another similar screen will be available – to set Defect Propagation for that environment. environment. Note2: If Reverse Sort is enabled (see below), there is only one Defect Propagation. Typically, Typically, this is disabled.

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Reverse Sort The reverse sort is a reject concentrator, designed to concentrate inputs of 1 good:2 bad or greater. It does so by ejecting good  product, product, firing at the centres of objects that do not contain defect. Only available available for position 1 cameras.

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Applies to Front & Rear, simultaneously

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Only available available in Small Product Product mode.

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Only available available in Dark Sort mode.

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Partition Select which partition this feature will apply to.

Reverse Sort Enable or Disable Enable or Disable.. Once enabled, only Dark Sort will be available on the Sort Type screen Type screen (see p. 10) and the standard Improver Improver (see (see p. Error! Bookmark not defined.) defined.) will not be available.

Object Separation Enables the object separation algorithm.

Reverse Sort Improver Similar to the standard Improver (see p. Error! Bookmark not defined.), defined.), in that it fires at the center of the object – though, in this case, it fires at good  product. product. A value of 0 gives the highest reject concentration. A value of 3 gives the lowest reject concentration. Similar to being disabled.

Note: Remember, Remember, again, that ‘reject’ is good product. Min Object Size This is set to prevent the ejectors firing at small particles (dust). Usually set to 9 or more.

Max Object Length There are two possible settings: 10mm or less, less, and 10mm to 15.3mm. 15.3mm. If an object exceeds this length, it may be ejected, even if there is an area of defect on the object. Typically set to 10mm or less for rice.

Force Product Tracking Forces product tracking to ON. Tracking is forced to “Ignore all Defects”.

Note: A partition which is set to run a Reverse Sort will appear as white, in the Working screen. In the example on the right, the Tertiary partition is running a Reverse Sort. A Reverse Sort also has implications for: Calibration – use Bypass button button to stop calibration on the modules being used for Reverse Sort.

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Ejector Delay (see p. 9) 9)

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Pulse Extension (see p. 9)

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Visible/IR Defect Propagation. (see p. 11)

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Note: With Reverse Sort enabled, Sensistivity operates in reverse . That is, the lower the Sensitivity, the higher the ejection. If you are enabling a Reverse Sort, ensure that all Operators understand these implications. implications.

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Mode Controls A Mode Mode is is a collection of settings – for Feed Rate, Sort Sensitivity and other factors – designed as a program to sort a particular product to a particular quality. When the machine is set up, a number of modes will have been created, with the objective of delivering the best possible sorting for the products the machine is likely to encounter. A Machine Operator may Recall Mode, Mode, Preview Mode and Mode and Compare Mode. Mode. Essentially, he may switch from one existing mode to another existing mode. He may also make adjustments within a mode’s parameters – by raising or lowering the Feed Rate or Rate or by raising or lowering Sort Sensitivity. Sensitivity. However, he may not make any changes to the modes themselves. That requires Supervisor access. There may be occasions when the existing modes are not enough, and another mode needs to be established. Often this comes with experience – the operator finds that he gets better results if he boosts the Feed Rate or raises Sort Sensitivity (or vice versa). Rather than remember to do so every morning, it would be better if a new mode were created – including these adjustments.

Save Working Mode At Supervisor level, set up the desired conditions and, from the Facilities Facilities menu, menu, select Save Working Mode. Mode. You will be asked to give the new Mode a name – using the onscreen keyboard. This done, the operator will be able to Recall Recall this this new mode at any time, running the machine with the new parameters.

Note: If you select a name which already exists, you will be warned, and asked if you really want to over-write it.

Rename Working Mode If the existing mode is using a name which you wish to re-use (without over-writing it), use Rename Working Mode to Mode to assign another name to the existing mode. You will be asked to give a new name for the Mode – using the on-screen keyboard.

Copy Working Mode You may wish to take an existing mode, and develop some variations on it. Use Copy Working Mode to Mode to create an exact copy of the mode currently in operation. This will create a new mode, identical to the previous one. The machine will ask if you wish to use a new name (advisable). Otherwise, you may find two modes with the same name. You can then Recall that copy, make the required changes, and then use Save Working Mode to Mode to keep it for later use.

Delete Mode If you are sure that a particular mode is not wanted, use Delete Mode to Mode to get rid of it. This should only be used if a mode is particularly ineffective or wasteful. Much better to rename a mode, labeling it with the problems you believe it has. There is room in the machine’s memory for up to 99 modes – so there should never be any need to delete a mode, to make room for another.

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User Access Level This command is explained on page 6.

Calibration This command is available to Machine Operators. See the Operator’s Handbook.

Product Feed This command is available to Machine Operators. See the Operator’s Handbook.

Sort Sensitivity This command is available to Machine Operators. See the Operator’s Handbook.

Stats Menu

This menu gives access to the Brokens Monitor (if fitted).

Note: At this point, there is no specific button on the main menu for returning to the Working Screen; instead touch the “Date/Time/Status” bar at the top of the screen, and the menu will ‘collapse’ .

Stats Graph Trends in a Stats measurement are sometimes easier to spot when the data is plotted on a graph. The Stats Graph screen Graph screen is shown with an example of the percentage of broken rice plotted against time. Zoom control and + symbols. is provided by the – the – and The buttons with arrows scroll the graph, up/down or right/left. Different stats measurements can be selected from the dropdown menu.

Note: If a Product Alarm is enabled for the selected measurementt then the measuremen t he lower & upper warning levels are also marked on the graph as horizontal lines.

Fixed Thresholds The Brokens Monitor classifies individual rice grains four categories, referred to as Head rice and rice and Fractions 1, 2 & 3. 3. The maximum lengths of these four categories are set on the Fixed Thresholds screen. Thresholds screen. For example, a grain that has a length less than or equal to the Max Length Fraction 1 and greater than the Max Length Fraction 2 is classified as Fraction 1. and All the length measurements are in millimeters. Use the – the – and

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+ symbols to lower or raise each number. The buttons to the right of the measurements determine the final classification of these four categories - as either Whole or Broken Broken.. For example, in the case shown, both Head & Fraction 1 are classified as whole grains whereas Fractions 2 & 3 are classified as broken grains. The Maximum Length of the head category is effectively another oversize filter.

Stats Histogram This screen displays the histogram of the lengths of the rice. The histogram is a graph of the frequency of occurrence for the different lengths of rice, in steps of 0.1mm. The thin white line represents the position of the length threshold as calculated for the Relative Brokens (see relative Thresholds, Thresholds, below). The bars to the right of this line correspond to whole grains, whereas the bars to the left correspond to broken grains. This double-peak plot is fairly typical. The case shown here is for a very low level of Brokens; if the Brokens contamination was higher, then the bump on the left would be larger. The button in the top right hand corner of the screen saves the current histogram to a named file (“stats.log”), on the flash disk.

Relative Thresholds ‘Relative Brokens’ is an alternative approach to measuring the brokens contamination level. Unlike the Fixed Brokens measurement described on page 14, Relative Brokens does not use a fixed length threshold to distinguish between whole and broken grains. Instead, Relative Brokens is defined relative to the average length of the whole rice.

Note: That is true of the example on the right. Press the button, currently labeled By Length , and the calculation will now be By Area . In the example on the right, any grain less that 0.75 of the average length of the whole rice is classified as broken. The Brokens Monitor automatically estimates the average length of the whole rice and then calculates a length threshold equal to the average whole grain length scaled by the relative broken fraction. If a grain is less than this length threshold then the grain is classified as broken. This length threshold is displayed on the Stats Histogram as a thin white line (see page 15). If the “Log Brokens” button on the Stats Log screen (see page 16) is enabled, the Brokens Monitor calculates both the Fixed and the Relative Brokens measurements. The Relative Brokens measurement is referred to as Brokens Rel on the Stats Data & Stats Graph screens (pp 14&16).

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Stats Data The Stats Data screen Data screen lists the data recorded by the Brokens Monitor. It can list two different measurements on the same screen, these measurements being selected from the pulldown menus at the top of the screen. In the case shown on the right, the two options selected are % Head – Head – percentage of rice qualifying as ‘Head rice’ (as defined in Fixed Thresholds, see p. 14) – and % Broken (Rel.) – (Rel.) – the percentage of Brokens (as defined in Relative Thresholds, Thresholds, see p. 15). The list shows that the time of the most recent measurement was at 13:52 (24 hour clock notation), at which time the percentage of head rice was 84.1% and the percentage of broken rice was 0.7%. This data can be compared with the data recorded a few minutes earlier, at 13:44, when the percentage of head rice was 72.4% and the percentage of broken rice was 0.7%.

Over Time The above example shows measurements taken every minute. This can show results changing over time. Press the scroll bars to view the whole list.

Single Measurement

Press the Over Time button, Time button, and the label will change to Single Measurement, Measurement, and the screen will look something like the example on the right. This shows all the measurements available at this particular moment. Press the scroll bars to view the whole list.

Stats Log Log Brokens The Brokens Monitor is enabled & disabled from this screen by the Log Brokens button. Brokens button. Before enabling the Brokens Monitor in this way it is necessary to set the fixed length thresholds (Fixed (Fixed Thresholds, see p. 14) and Sampling parameters (Sampling (Sampling,, see below). You may view the results of this log via the Stats Data screen (see p. 16) or the Stats Graph screen (see screen (see p. 14) The log will hold up to 1500 successive measurements (equivalent to a weeks worth of data if measurements are recorded every 10 minutes). After this limit is reached, the oldest data is overwritten by the new data. The “stats.log” file preserves the data after a power cycle, even though the Stats Data & Stats Graph screens no longer display this data.

Log Defects This button controls the logging of defects – added to the ‘Brokens’ log.

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Clear Stats Log Press this button to start logging afresh. But…

Save Stats Log …press this first, to save the existing log to the Z+Vx’s flash disk. This will be saved to a file called ‘stats.log’, and may be copied on to a laptop computer. When you press this button, you will be prompted for a file name. You may choose another, although the extension (.log) remains the same. A saved “stats.log” file can be downloaded to a remote PC and analysed with Microsoft™ Excel. The “stats.log” file is located under “/flashdisk/Newton/stats.log” (or equivalent, if you have given the file another name). To import a saved log file into Excel, choose “delimited” in the first screen of the Excel import wizard, and “comma” in the next. The first field (column) should be interpreted as a date: select “YMD” in the drop-down list for the last step. Saved log files have column labels in Excel; the original “stats.log” file does not have these column labels.

Product Alarm If the measured quality of the product is outside preset limits then a Product Alarm is raised. If a Product Alarm is active, an external amber light bolted to the frame of the machine is lit and the alarm is also listed on the Product Alarm screen.

Note: A Product Alarm and and a machine fault are different events. A Product Alarm indicates the quality of the product flowing through the sorting machine whereas a machine fault indicates the state of the machine itself. The following stats measurements can have an associated Product Alarm – each selected via the drop-down list:

Percentage Broken

Average Length Head

Percentage Broken (relative)

Average Length Whole (relative)

Percentage of Colour Defects

Percentage of Spot Defects

Percentage of Combined Defects.

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These 7 Product Alarms are all independent. A Product Alarm is set-up by assigning minimum & maximum thresholds to one of these stats measurements. The alarm is triggered if the value for that stats measurement is less than the minimum threshold or greater than the maximum threshold.

Note: These threshold levels are also marked on the Stats Graph.

Enabled/Disabled Each measurement can be enabled or disabled, using this button. The label shows the current  state. state.

Clear Product Alarms are cleared by using the “clear” button on the Product Alarm screen (only available if an Alarm is current). If the quality of the product reverts to being within the preset limits then the Product Alarm is automatically cleared. (Historical information about the quality of the product can be determined via the Stats Graph or Stats Data screens.) The Product Alarm is not raised for a measurement if the total number of singletons (single, identifiable bits of product) for the measurement is less than 80% of the Sample Size – set on the Sampling screen (see next page). The Product Alarm screen can be accessed at the Operator password level.

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Summary This button opens a screen (see right) which lists a summary of the minimum & maximum thresholds for all the Product Alarms that are currently enabled.

Sampling This screen controls the methods used to sample product (for the purposes of the Brokens Monitor).

Sample Module The Sample Module sets the module from which all the images are captured. It is recommended to select a module with a flat chute. In the case of a Z3+ or Z4+, Module 2 is preferable because the illumination towards the centre of the machine is more uniform, resulting in a better silhouette of the rice.

Sample Interval Time The Sample Interval Time is the time between measurements, typically set to around 15 to 30 minutes.

Sample Feed Rate The Sample Feedrate is the reduced feedrate automatically set during the image capture stage of the measurement process. It is recommended to set the Sample Feedrate at 60%, corresponding to about 1500 Kg/hour. This is about half the normal sorting throughput of a module. (The feed rate on the “working screen” of the GUI is greyed-out during sampling.)

Sample Size The Sample Size is the number of grains that are counted for each measurement. It is recommended to set the Sample Size to 10,000. Note that the entry for the Sample Size is per thousands of grains.

Enhanced Presence Detection Enhanced Presence Detection should be disabled.

Object Width Object Length The Minimum Object Width & Length are set so as to ignore all objects less than a certain size. It is recommended to set both the Minimum Object Width & Length to 1.5mm. The Maximum Object Width & Length are set so as to ignore all clusters of touching grains. Hence, the Maximum Object Width & Length should be set to the dimensions of the largest expected grain. Please note that the machine interprets these maximum limits as a maximum area (= Maximum Object Width x Maximum Object Length) and then ignores any region* in the image with an area greater than this calculated maximum area. (Hence, adjusting just one of either the Maximum Object Width or Length is sufficient.) *The Brokens Monitor can handle up to 65535 regions.

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Mode Configurat Configuration ion

This menu contains items about the physical configuration of the machine.

Foreground Lighting The lamps which illuminate the product – the Foreground lamps – are arranged in two banks, in the front and rear of the th e machine, surrounding the product. Each bank consists of four lamps, arranged in an arc (see inset). The Foreground Lighting screen gives the option of switching off (Disabling) the inner pair, or the outer pair – not both.

Note: If both buttons are set to Enable , all tubes will switch off. This is normal operation. Sort, this disabling applies to both  sets Sort, In a Combined Sort, sets of lamps – front and rear. In an Independent Sort, there are separate controls for Front & Rear.

Wiper Interval To perform its task properly, the machine needs a clear view of the product. This requires that the optical windows are kept clear of dust or grease. The wipers perform this function. This screen controls the frequency of wiping. For a particularly dusty or greasy product, the frequency might need to be as often as every five minutes (as in the example shown), but with most products, 20 or 30 minutes should be often enough. and + symbols to lower or raise the number. Use the – the – and

Note: Bear in mind that the feed must be stopped while the wipers pass across – so a frequent wipe will affect throughput rates. In some circumstances, it may be necessary to Disable Disable the the wipers entirely – perhaps for some diagnostic purpose. This should not be allowed to continue for long, during sorting.

Tracking Configuration In the course of a sorting session, many factors may change – the ambient lighting, the brightness of lamps, the dustiness of the product – even the product itself may vary slightly, from supplier to supplier. The SORTEX Z+Vx ‘tracks’ these changes, and compensates for them, automatically. This screen offers four alternative approaches (Tracking ( Tracking Reference) to this:

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None – used for test purposes. The tracking processes still run, the machine still stops to wipe & calibrate from

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tracking incidents, but product brightness is not  tracked. tracked.

Product – uses the product itself as a tracking reference.

Ignore Spot Defects – self-explanatory.

Ignore All Defects - self-explanatory.

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Calibration Configuration In order to track any changes in the environment, the machine needs to Calibrate regularly. That is, it needs to check its stored parameters against reality, and adjust the stored parameters to actual readings. This screen controls the frequency and behaviour of these calibrations.

Wipe during Calibration Normally, the machine will wipe the optical window, in order to ensure that it gets the best possible view of the product flow. There are some circumstances where this is undesirable (usually while diagnosing problems) – so, this can be Disabled Disabled.. This condition should not be allowed to persist, during normal sorting.

Calibration Interval This controls how often the machine calibrates. With a particularly tricky product, it might be necessary to reduce this to five minutes (as in the example shown), but a longer gap between calibrations is more likely, in normal circumstances. and + symbols to lower or raise this number. Use the – the – and

Machine Configuration

This menu deals with a number of machine-related configurations:-

External Interlock Configuration This screen determines whether the machine can be stopped by other machinery downstream of it, by means of the external interlock input. It also controls when the external interlock output will be activated.

Input State Shows the state of the interlock input.

Output State Shows the state of the interlock output.

Input Enable/Disable the interlock input.

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The following table shows the effects of the combinations of inputs and input settings:Input State Off Off On On

Input Disabled Enabled Disabled Enabled

Machine Status Sorting Sorting Sorting Idle

Modules These buttons select which module(s)control the interlock output. So, if Module 1 were Enabled, the interlocks would be controlled by Module 1. If another Module were also  enabled, enabled, the two would be combined (ANDed) to control the interlock.

Hopper Interlock Configuration This screen determines whether the machine will allow its feed to be controlled by the level of product in the feed hopper.

State This section shows the current state of the hopper sensors

Full This section allows the enabling/disabling of interlocking – in Secondary and Tertiary channels – responding to a full hopper. and + symbols to set the Delay Delay before before the vibrators Use the – the – and respond to interlock signals.

Low This section allows the enabling/disabling of interlocking – in Primary, Secondary and Tertiary channels – responding to a nearly-empty hopper. Use the – the – and and + symbols to set the Delay Delay before before the vibrators respond to interlock signals.

White Reference Calibration At intervals (see below) it is necessary to re-calibrate the machine’s response to light. Lamps age and fade, and the surrounding environment changes. According to the interval set, by White Reference Calibration Interval, the machine will prompt the Operator to perform a calibration. From this screen, select the module to calibrate (all must be done at the same time) – and press Start Start.. The machine will wipe. You will be prompted to insert the White Calibration Plate – which has been supplied with the machine.

WARNING: Before proceeding with this check, switch off the air supply, to prevent the wiper from operating. Insert this, its lower lip resting on the ejectors, and press OK OK.. The machine will calibrate each module, and store the new reading – all future sorting will take this into account. At the end of each white calibration, you will be prompted to remove the plate – whilst the machine calibrates for ‘black’. The screen will report when the process is complete.

Caution: It is essential essential that the white plate is stored carefully carefully between uses. If it is scratched scratched or stained, it cannot provide the white reference required. If it is warped or bent, it will not fit properly into the chute (and will w ill not provide the white w hite reference required).

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White Reference Calibration Interval This screen defines the period between White Reference Calibrations (see above). Use the – the – and and + symbols to lower or raise the number (of hours) between calibrations.

Disabled It is possible to disable the warning which occurs when the interval runs out. If this is done, you should ensure that a strict maintenance schedule is set up and adhered to. The machine cannot continue to do its job properly for long, without a White Reference Calibration.

Test Facilities

This menu offers a number of diagnostic procedures.

Background Test The Z+Vx’s cameras view the product against an illuminated background – the better to identify defective product. This background illumination is provided by a single lamp, ‘bounced’ on to the product by an adjustable reflector (one in the front, one in the rear). In normal operation, the machine will make its own adjustments to the angle of this reflector, in order to raise or lower the background illumination. This screen tests the operation of this adjustment. and + symbols, decrease or increase the number Using the – the – and for Front and Rear reflectors. The numbers beside these controls – the Camera Signals should Signals should decrease or increase as you do so. There is no correct figure for these Camera Signals – the only requirement is that they should change, along with the changes you make to the angle of the reflector. If the figures do not  change, change, then the likelihood is that there is a fault with the motor which turns the reflector.

Self Test Create Diagnostic File This screen initiates a sequence of internal tests, the results of which are written to a file. This file will help a SORTEX engineer diagnose any problems with the machine. The file is saved to ftp:\\\cfdisk\Newton\diagnost.txt

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Full Ejector Test This screen allows a range of the machine’s ejectors to be tested.

First ejector to test and

Last ejector to test Define the range of ejectors to be tested.

Note: There are 64 ejectors in a module, arranged in 16 blocks of four.

Start With the range selected, press Start to begin the test. Listen to the ‘note’ sounded by each ejector, whilst watching the Status Status box. box. This will show the number of the each ejector, as it is tested. A faulty ejector will sound significantly different from a good one. Note the number of a faulty ejector – to enable its replacement.

Continuous Loop With this On On,, the test will continue (cycling through the ejectors) until you press Stop Stop..

Individual Ejector Test This screen allows an individual ejector to be tested. Select:-

Module Block Position Channel and + symbols. …using the – the – and

Frequency Use this button to select a High frequency test, or a Low frequency test.

Start Press this button to begin the test.

Wiper Test This test will send the wiper across the optical windows, and back again, to confirm that the wipers are operating correctly. A failed wiper test may point to a faulty wiper cylinder. See Repair & Replace, Replace, page 12, for the replacement procedure. Alternatively, it may point to misaligned sensors - which tell the machine when the wiper has reached the end of its sweep. These may need to be re-aligned (a job for an experienced engineer).

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Vibrator Test Test Mode Test Mode is selected by the button – showing To Open Loop Loop in the illustration. The title at the top of the screen shows that Closed Loop is Loop is currently selected. If the test were run now, it would continue until Aborted (the Start button becomes an Abort Start button Abort button, button, during the test). The Drive Level box Level box reports how hard the vibrators are being driven. The Feedback Values box Values box reports how strong those vibrations actually are. If this test is unsatisfactory, the vibrators may need to be adjusted against those Feedback Values, to produce a satisfactory throughput. Press the To Open Loop button. In this configuration, the vibrator drive levels can be set, using the - and + controls, whilst monitoring the feedback levels.

Lamp Maintenance Here, a record is kept of how long each lamp has been lit, since it was installed. This option reports that time, allowing the Supervisor to estimate when a lamp should be replaced.

Used Gives a reading of how many hours these lamps have been burning

Remaining Gives an estimate of how long these lamps have left, before needing replacement. When a lamp is replaced with a new one, press the ooo button, ooo button, to ‘zero’ its value – otherwise it will be impossible to know when it is ready for replacement.

NOTE: Lamps tend to fade during their lifetimes, so a lamp may appear to be burning adequately, but fail to deliver the necessary illumina illumination. tion. When a lamp is replaced before its time – for example, when the product being sorted needs a different type of illumination - the usage of the ‘old’ lamp should be noted, and kept with the tube. In that way, it will be possible to estimate its remaining life, when it is re-installed. NOTE: Whenever a lamp is changed – for whatever whatever reason, perform a White Reference Calibration (see page 21) – as the light levels will have changed.

Ejector Rates This screen shows how how hard specific ejectors are working, by showing Ejections per Minute (along the vertical axis of the graph), against Ejector Ejector (along (along the horizontal axis). The resultant graph should be relatively flat. A few bumps are nothing to worry about – but attention should be paid to any ejectors which are dramatically different from their neighbours. If a single or a block of ejectors, fires often than ejector, its neighbours (or not at all) – consistently that may point to less a faulty ejector, or a faulty block, or a faulty daughterboard. Use the Ejector Test (Full or Individual Individual)) to investigate ejectors which may be faulty (see page 23).

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If, however, there is a wider anomaly – a big ‘hill’ or valley’, encompassing several ejector blocks, that may mean that the machine is firing on false information. That may point to a damaged chute channel (the product is arriving in the wrong place for the cameras to detect it), or to a dirty or scratched optical box window (the cameras reading the dirt as if it were product).

Caused By This button controls the scope of the graph. It shows ejections according to camera position. For example, you could look at the ejections caused by the Front or Rear Cameras independently. Or, as in the example shown, Anything.. Anything

Ejector Fire Count This screen shows a record of the number of times individual ejectors have fired. This can help plan servicing.

Ejector and + symbols to select the number of the ejector Use the – the – and and…

Fire Count …will show how many times that ejector has fired, since its installation. Below, the graph shows a reading for all the ejectors at once. Although this is not as accurate as the above method, this can show up anomalies – a single ejector, or group of ejectors, which is has been firing much more (or much less) than others. This can point to a fault in that part of the ejection system.

Advanced This opens a sub-screen which allows the fire count to be reset to zero – by ejector, by module, by block (of four ejectors) or by position (one of the four in a block). and + symbols to select the number required, and press Reset Reset   Use the – the – and that item to zero.

Engineer & Special Engineer menus There are two further levels of menu access – Engineer and Special Engineer. These contain functions which deal with the technical status of the machine, and are designed to be used by personnel trained to understand the consequences of changing any of settings. If you, or any of your staff, wish to know more about the deeper functions, and gain better understanding of the capabilities of the SORTEX Z+Vx, SORTEX runs training courses at our London headquarters. Contact [email protected] [email protected] for for more information.

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Maintenance

SORTEX Z+Vx

Maintenance Read the Routine Maintenance  booklet. booklet. This contains advice on day-to-day care of the machine. If this advice is followed, the machine will work better, and major faults will be less likely to need attention. In all cases, observe the safety instructions given. Some of the components are heavy, and can cause injury (to personnel or to the machine). Some are situated in potentially dangerous areas of the which machine (high and/or moving parts). Others are very sensitive pieces of electronics, could bevoltages damaged by inappropriate handling. Read the Safety Advice (p. 1). In particular, read the advice on power & air (p. 3) and try to develop Good Habits (p.4) in all personnel who work with this machine. This section deals with the replacement of items which are likely to need replacing, as a matter of routine – consumable items. The Engineer’s Manual (in English only) deals with more complex repairs – which should only be undertaken by experienced staff. It also contains a fuller Spares List. SORTEX offers training courses for those wishing to know more about these procedures.

Optical System Components Fluorescent lamps will fade with use, and will need to be replaced. Also, different lamps may be needed for different sorting solutions.

Foreground Lamps–Replacement Lamps–Replacement Switch off the electrical supply. Turn the air shut-off valve to the off position.

See safety advice, pages 3-4.

When the vibrator trays are clear of product, clean the area around the optical box lid with a stiff brush before opening it.

optical box, particularly the lamp WARNING: The contents of the optical packs and fluorescent tubes, will remain hot for some time after switch off. Always ensure that the objects you wish to handle have cooled, before proceeding. Use the lid stay to keep the lid up.

In the Front Optical Box, undo the two catches (one on each side - right hand catch arrowed – in red) and pull the lamp pack assembly towards you, locating the catches in the posts to the rear (arrowed in blue).

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Maintenance

ORTEX Z+Vx   SORTEX S

NOTE: The method for replacing lamps in the rear optical box is essentially the same as that for the front optical box, although the mechanism for presenting the lamps for removal is slightly different. Warning:

Always keep hands away from the ends of the lamp pack when moving it, so as to avoid trapping or damaging fingers.

Always make sure that the lamp pack is supported throughout the length of its travel and until the catches are engaged. Do not allow it to fall freely, as this could cause personal injury or damage to the machine. The previous step rotates the lamp pack slightly and presents the lamps for removal. To remove the lamp, rotate it a quarter-turn and lift it out.

Fitting a new lamp is the reversal of the removal processes. Align the lamp pins with both end sockets and push the lamp towards the lamp pack, simultaneously into both sockets, before rotating it a quarter-turn. Always make certain that the lamp pack catches are correctly fixed in the securing posts. Failure to do so may provide calibration problems. Release the lid stay (ensuring that it is clipped into its retainer) and close the optical box lid.

Warning:

When closing closing the lid, keep keep hands hands away away from the the door seal, to avoid avoid trapping trapping fingers.

Turn on the air and electrical supply.

Note: When a lamp has been changed, perform a White Reference Calibration (see p. 21) – as the light levels will have changed. When a lamp has been replaced, use the Lamp Maintenance  screen screen – to ‘zero’ this lamp’s usage record. See p. 24.

Background Lamp–Replacem Lamp–Replacement ent Switch off the electrical supply. Turn the air shut-off valve to the off position.

See safety advice, pages 3-4.

When the vibrator trays are clear of product, clean the area around the optical box lid with a stiff brush and open it, making sure that the door stay is in place, to keep the door open.

WARNING: The contents of the optical box, particularly particularly the lamp packs and fluorescent tubes, will remain hot for some time after switch off. Always ensure that the objects you wish to handle have cooled, before proceeding.

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Maintenance

SORTEX Z+Vx

In the Front Optical Box, undo the two catches (one on each side - right hand catch arrowed – in red) and pull the lamp pack assembly towards you, locating the catches in the posts to the rear (arrowed in blue).

NOTE: The method for replacing lamps in the rear optical box is essentially the same as that for the front optical box, although the mechanism for presenting the lamps for removal is slightly different. WARNING: Always keep hands away from the ends of the lamp pack when moving so as to avoid trapping or damaging fingers. Always make sure that the lamp pack is supported throughout the length of its travel and until the catches are engaged, do not allow it to fall freely as this could cause personal injury or damage to the machine.

Undo the two catches at the middle of each end of the lamp pack (arrowed in red) - this allows the bottom pair of lamps to be moved out of the way, presenting the background lamp for removal. To remove the lamp, rotate it a 1/4 turn and ease the lamp out by rotating it as you lift.

Fitting a new lamp is the reversal of the removal processes. Align the lamp pins with both end sockets and push the lamp towards the lamp pack, simultaneously into both sockets, before rotating it a quarter-turn. Always make certain that the lamp pack catches are correctly fixed in the securing posts. Failure to do so may provide calibration problems. Release the lid stay (ensuring that it is clipped into its retainer) and close the optical box lid.

Warning:

When closing closing the lid, keep keep hands hands away away from the the door seal, to avoid avoid trapping trapping fingers.

Turn on the air and electrical supply.

NOTE: When a lamp has been replaced, use the Lamp Maintenance  screen screen – to ‘zero’ this lamp’s usage record. See p. 24..

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Maintenance

ORTEX Z+Vx   SORTEX S

Wipers The wipers are also part of the Optical System – they ensure that the cameras have a clear view of the product.

Changing a Wiper Blade Switch off the electrical supply. Turn the air shut-off valve to the off position. See safety advice, pages 3-4.

Remove the rear wiper cover and then undo the 2 bolts at each end that secure the front cover and remove.

Manually move the wiper assembly a little way towards the chute for easier access. Reach down into the viewing area and push the sprung wiper arm inwards (i.e. away from the window). At the same time pull the wiper blade assembly upwards and away from the wiper arm. Remove wiper blade from the assembly by sliding it upwards.

CAUTION: Release the spring-loaded arm carefully so that t hat the rubber buffer rests against the window. Do Not Allow the Wiper Arm to Impact Against the Window!   Refitting a wiper blade is the reversal of the above procedure. Make sure to push the wiper blade assembly down firmly until it clicks into place.

When the process is completed and all the wiper covers are back in place, turn on the air supply and perform a wiper test (Facilities menu, Test).

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Maintenance

SORTEX Z+Vx

Ejector Cartridges Removal and Refitting Ejector cartridges are exchangeable items. Faulty cartridges should be replaced in the machine with spares A04-3417/3.. and replacement cartridges ordered from SORTEX, part number A04-3417/3

Identification of Failed Ejectors In Test Facilities, Facilities, perform a full ejector test and note the identification number of any ejectors that do not operate. Ejectors are numbered in blocks of four from the left, as seen from the front of the machine.

Replacing an Ejector Block WARNING: For these procedures, turn off the Mains power supplies, allow at least one minute for high voltages to discharge. For all operations concerning the ejectors or ejector boards TURN OFF THE AIR– the air pressure is powerful in this region, and some operations can cause explosive failures, if air pressure is present. When opening the rear optical box lid, take care to use the handles provided – to avoid trapping fingers between the lid and the Control Cabinet. The contents of the optical box, particularly the lamp packs and fluorescent tubes, will remain hot for some time after the machine is i s switched off. Always ensure that the objects you wish to handle are cool enough to do so. WARNING: Never dismantle the ejector manifold. manifold. Incorrect assembly can can result in explosive ejection of parts. In addition, this unit is a fine-limit assembly, pressurepressure-tested tested at SORTEX Ltd., and not serviceable in the field – except by qualified SORTEX service engineers. Any leaks from the ejector manifold will reduce performance and be difficult to locate and repair. In the rear optical box, undo the two catches securing the lamp pack (one on each side, right hand one displayed) and pull the lamp pack towards you, locking it in place at the rear securing posts.

WARNING: Always move the lamp packs using the handle section on the top cross member and keep hands away from the ends of the lamp pack when moving so as to avoid trapping or damaging fingers. Ensure that the lamp l amp pack is grasped firmly and controlled throughout the length of its travel and until the catches are engaged, do not allow it to fall freely as this could cause personal injury or damage to the machine. If working for any length of time in this area, it is advised that the lower fluorescent lamp be removed. Otherwise extreme care should be exercised so as to not place undue pressure on the fluorescent tube - possibly breaking it. Undo the catches securing the ejector housing cover (one on each side, right hand one displayed) and open.

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ORTEX Z+Vx   SORTEX S

Maintenance

The ejectors are grouped in cartridges of four, so you will need to identify which cartridges the failed ejector(s) belong to. Identify the cartridge you wish to remove, then disconnect the ejector wiring from the ejector daughter board (each ejector cartridge has its own daughter board which, in turn, plugs into the ejector control board).

To remove an ejector cartridge, press the plastic clips together and pull it upwards and out.

CAUTION: Double-check that the air pressure is turned off before removing an ejector.

Replacement of an ejector is the reverse of the above procedure,

make sure to locate the notch on the ejector with the key on the ejector manifold

Push downwards locating the air input connector into the tube below it, pressing down firmly, but gently , until the cartridge-clips lock into place. It should slot into place easily. If it does not, do not try to force it. Take it out and try to relocate it again.

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Maintenance

SORTEX Z+Vx

Once replaced, 1. 2. 3. 4. 5.

close up the ejector manifold cover, replace the lamp pack release the gas spring "locksafe" and close the optical box lid, return the air pressure setting to normal. Finally, perform an Ejector Test (see Test (see p. 23)

Note: It is likely that all the ejectors in a machine are of the same age, so it is often the case that all of them t hem should be replaced at once. Ejector Fire Count  (see (see p. 25) stores the ejector usage information. information. When replacing ejectors, you should zero the reading on that screen, so that you will know when to expect the next replacements. In normal use, ejectors should perform 5,000,000,000 cycles (or 2,500,000,000 for Large product), before needing replacement. replacement.

Control Box Dust Filter Removal and Replacement Switch off the electrical supply, if necessary lock it off using the yellow locking flap (push it upwards and slide to the right). Allow at least one minute for high voltages to discharge before handling any PCBs or lamps. Turn the Air Shut-off Valve to the off position.

Warning:

Do not change the control box dust filters whilst the fans are still running

The control box dust filters are located on either side of the control box and should be changed when they become clogged with dust.

Undo the two retaining screws a quarter turn and remove the filter retainer. Remove the old the dust filter and replace with clean one, replace the retaining bracket, power up the machine and turn on the air.

The dust filters can be washed using water and a mild detergent. They must be dried thoroughly before replacing. This should be done on a regular basis to ensure adequate airflow. The part number for a replacement Dust Filter is 64334 64334..

Caution: filters

Never put a damp dust filter on the machine, never never run the machine machine without dust

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Maintenance

S ORTEX Z+Vx   SORTEX

Servicing an Air Filter Turn the air shut-off valve to the off position. See Safety advice, page 3

NOTE: Always allow the wiper assembly to return to its rest position before turning off the air supply.

SERVICING This unit has an automatic drain, which should remove any accumulating liquid in the bowl. Check the drain pipe for blockage. To operate automatic drain manually, lift operating pin in bottom outlet with a blunt rod.

Clamp ring

DISASSEMBLY Filter bowl

Unscrew the clamp ring on top of the unit. This will release the filter body, containing the filter element.

Turn the filter bowl counter clockwise and remove from the filter body – along with the bowl o-ring. Do not remove the drains unless replacement is necessary. Remove filter element. This element cannot be cleaned. If it is dirty, it must be replaced. Clean other parts of the unit with warm water and soap. Rinse and dry parts. Blow out internal passages in body with clean dry compressed air. Inspect all parts before reassembly. Replace those found to be damaged.

REASSEMBLY Lubricate o-rings with o-ring grease. Assembling the unit is the reverse of the disassembly. Arrows on indicator and body must point in same direction. Push the bowl into body and turn it clockwise into body.

Caution: If the unit is difficult to re-attach, the parts parts are are not correctly located. Any attempt to force the bowl to screw in, against resistance, may damage the unit. Note: A nylon drain spacer sits at the bottom of the bowl. The retaining rod for the filter passes through it. Ensure that this sits securely in its place, as it can make re-assembly difficult. difficult.

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Maintenance

SORTEX Z+Vx

Caution: This air filter is not intended intended to be the sole filtering for the air supply – only to remove minor contaminants. If this filter becomes clogged, quickly and often, check the factory air supply. The pre-installation requirements for this machine (see Preparation document) are:1.

Particle content (cleanliness of air) - supplied ai airr to be filtered for a maximum particle size of 25 microns.

2.

Water content (dryness of air) - dew point of 2°C (35°F).

3.

Oil content - supplied air to have less than 1000 oil parts per million air parts by volume at 12°C (54°F).

These conditions must be achieved before the air reaches the machine.

Air Regulator The air regulator, which controls the air pressure used by the sorting machine, is located on the right-hand side, at the bottom, in an angle of the frame (see right). The T-bar at the top adjusts the air pressure. Air pressure should never fall below 5bar (73 psi), nor above 7bar (102 psi).

Note: The Single-module machine (Z+1Vx) has a slightly different filter f ilter and regulator. However, the principles of maintenance are similar.

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Bühl Bü ühle üh hler ler err Sor Sortex Sortex tex Ltd Ltd 20 Atlantis Avenue London, E16 2BF United Kingdom Tel +44 (0) 207 055 7777 Fax +44 (0) 207 055 7700

Z+VX Supervisor's Manual

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