Best GENIUS Compact Installation instructions

PRE-INSTALLATION FAX BACK CONFIRMATION CHECKLIST

Please return this completed form back to BESTnv by fax, after the pre-installation of the GENIUS Compact

→fax number : + 32 16 396 390

FROM : …………………………..………………..………………….(your company)

GENIUS Camera Sorter with serial number ………………...was delivered at our premises on

……………………………..…(date).

ITEM STATUS

YES / NO

- packed equipment : visible damage from the outside? □□

- equipment unpacked? □□

- unpacked equipment: visible damage? □□

- all items from packing list present? □□

- GENIUS Compact sorter unit mechanically installed? □□

- optical laser box (option) mounted? □□

- infeed shaker positioned? □□

- accept/reject shaker(s)/belt(s) positioned? □□

- infeed shaker electrically wired to GENIUS Compact? □□

- accept/reject shaker(s)/belt(s) electrically wired to GENIUS Compact? □□

- electrical connection 3 x 400V (+neutral and earthing) available? □□

- separate electrical connection cooling unit available? (option) □□

- piping air pressure supply: 3/4” (inch) connection? □□

- piping water supply (for optional bull nose)? □□

- piping cooling water to/from optional cooling unit: 3/4” (inch)? □□

- infeed conveying equipment installed? □□

- accept conveying equipment installed? □□

- reject conveying equipment installed? □□

- mechanical test of production line? □□

- product available? □□

Responsible person in the factory during installation : ………………………………...

I, …………………………………… hereby declare that the above status description is correct and that the

GENIUS Compact is ready for commissioning by the BESTnv Service department on:

………...……………… (date).

date & signature :…………………………..…………..

Pre-installation checklist/

Confirmation fax

We would be most grateful if you could please fax this

checklist to us when all relevant items have been taken care of.

The installation engineer can only leave for your company after

we have received this completed and signed checklist,

confirming that all is ready for the installation.

If you have any question or problem concerning this checklist,

or any other item having to do with the pre-installation for which the

answer cannot be found in the Pre-installation Guide (chapter 2),

do not hesitate to contact our service department.

OPERATORS & MAINTENANCE MANUAL

Version 0.1 UK

Compact Version

This Machine is a Product of BESTnv.

All information in this manual is conﬁdential and remains the unalienable property of

BESTnv.

This manual is subject to local and international copyright laws. No part of this manual may

be reproduced, copied or adapted in any way without explicit prior written permission of

BESTnv.

Dear User,

You are now the proud owner of a new, state of the art GENIUS Optical Sorter and

we at BESTnv would like to congratulate you on your latest purchase. We are

convinced the GENIUS will constitute a serious contribution to improving the final

quality of your products and increasing your competitive position on the international

market.

We, the people at BESTnv, feel that selling a sorter is not simply the happy end of a

story, we consider it as the beginning of a long relationship between our two

companies, based on trust and professionalism. Even after the contracts have been

signed, our sales team will remain fully at your disposal. Please do not hesitate to

We strongly believe that the professional and trustworthy relationship between our

two companies, gradually built up by our sales people during the negotiations, will be

adopted by our after-sales team and our service engineers. Their customer-oriented

problem-solving attitude reflects the philosophy that can be found everywhere at

BESTnv and constitutes the central core of our strategy: “A real professional

treatment does not end when the customer has signed the contract, this is merely a

starting point.”

We hereby wish you and your company a very successful future and are proud that

we have been able to contribute our share.

Bert Van der Auwera

Director Sales & Marketing

0/1

Chapter 0: Table of Contents

Operators & Maintenance Manual GENIUS Compact Version UK 0.1

Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS

General tel. +31 (40) 292 2622 - Service tel. +31 (40) 292 2620 - Fax. +31 (40) 292 2633 - Email: service.pulsarr@bestnv.com

0. Table of Contents

0. Table of Contents ................................................................................... 0/1

Safety............................................................................................................... I

Preface A: General Safety................................................................................................. I

Preface B: GENIUS Compact Electrical Safety ............................................................... II

Preface C: GENIUS Compact General & Mechanical Safety .........................................IV

Preface D: GENIUS Compact Safety Labels ..................................................................VI

Preface E: GENIUS Compact optical sorter Warranty & Responsibility...........................X

I. Introduction.............................................................................................. 1/1

1.1. The GENIUS Optical Sorter Platform..................................................................... 1/1

1.2. Reliable operation and performance ...................................................................... 1/2

1.3. Easy to set and operate ......................................................................................... 1/2

1.4. Flexibility in Optical and Mechanical Conﬁgurations .............................................. 1/3

1.5. Principles of operation............................................................................................ 1/3

1.6. Minimum maintenance ........................................................................................... 1/4

II. Unpacking and placing of GENIUS Compact sorter ........................... 2/2

2.1. Unloading and unpacking....................................................................................... 2/2

2.2. Machine parts......................................................................................................... 2/3

2.3. Technical data ....................................................................................................... 2/4

2.4. Installation ..............................................................................................................2/7

2.4.1. Lifting the GENIUS Compact sorter unit ....................................................................................2/7

2.4.2. Placing the different units...........................................................................................................2/8

2.5. Full Pre-installation list ......................................................................................... 2/12

2.5.1. Preparation of the area ............................................................................................................2/12

2.5.2. The GENIUS Compact optical sorter .......................................................................................2/13

2.5.3. The infeed shaker.....................................................................................................................2/16

2.5.4. Accept/Reject shakers or belts (optional).................................................................................2/17

2.5.5. The nitrogen bottle ................................................................................................................... 2/18

2.5.6. Cooling Unit (optional)..............................................................................................................2/20

2.5.7. Product streams to and away from the GENIUS Compact sorter ............................................ 2/23

2.6. Pre-installation checklist summary....................................................................... 2/25

Chapter 0: Table of Contents

0/2 Operators & Maintenance Manual GENIUS Compact Version UK 0.1

Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS

General tel. +31 (40) 292 2622 - Service tel. +31 (40) 292 2620 - Fax. +31 (40) 292 2633 - Email: service.pulsarr@bestnv.com

III. Theory..................................................................................................... 3/1

3.0. Introduction ............................................................................................................ 3/1

3.1. The Different Optical Conﬁgurations ...................................................................... 3/1

3.1.1. The GENIUS Compact-B (Basic) conﬁguration..........................................................................3/2

3.1.2. The GENIUS Compact-N option ................................................................................................3/3

3.1.3. The GENIUS Compact-S (Surround/bottom) option .................................................................. 3/4

3.1.4. The GENIUS Compact-L (Laser) conﬁguration..........................................................................3/5

3.1.5. The GENIUS compact-D (Dual) option ......................................................................................3/6

3.2. Theoretical background.......................................................................................... 3/7

3.2.1. Cameras..................................................................................................................................... 3/7

3.2.2. Illumination ................................................................................................................................. 3/8

3.2.3. Detection system........................................................................................................................3/9

3.2.4. Sorting Parameters .................................................................................................................. 3/11

3.2.5. Removal of the defects ............................................................................................................3/16

IV. Operating the GENIUS Compact.......................................................... 4/1

4.1. Introduction ............................................................................................................ 4/1

4.2. Location of the different parts................................................................................. 4/2

4.3. Control panel.......................................................................................................... 4/9

4.4. Main Power Switch & Emergency stop ............................................................... 4/12

V. Routine Operational Procedures .......................................................... 5/1

5.1. The different Startup/Shutdown Procedures .......................................................... 5/1

1. Complete Shutdown/Startup ............................................................................................................5/2

2. Emergency Stop...............................................................................................................................5/3

3. Standard Shutdown/Startup .............................................................................................................5/4

5.2. Using the Pollux Touchscreen navigation bar ........................................................ 5/5

5.3. Log-in ..................................................................................................................... 5/6

The Log-in menu ..................................................................................................................................5/6

5.4. Normalization ......................................................................................................... 5/8

5.5. Sorting.................................................................................................................. 5/11

5.6. Saving and loading Product Files......................................................................... 5/13

5.6.1. Loading Product Files: .............................................................................................................5/14

5.5.2. Saving Product Files ................................................................................................................5/14

5.7. Setting a New Product File................................................................................... 5/15

5.8. Sorting.................................................................................................................. 5/33

VI. Cleaning the GENIUS Compact ........................................................... 6/1

6.1. Cleaning Procedure .............................................................................................. 6/1

6.2. Detergents.............................................................................................................. 6/5

0/3

Chapter 0: Table of Contents

Operators & Maintenance Manual GENIUS Compact Version UK 0.1

Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS

General tel. +31 (40) 292 2622 - Service tel. +31 (40) 292 2620 - Fax. +31 (40) 292 2633 - Email: service.pulsarr@bestnv.com

VII. Maintenance: ........................................................................................ 7/1

7.1. Warranty Limitations and General Conditions........................................................ 7/1

7.1.1. Warranty Limitations...................................................................................................................7/1

7.1.2. General conditions .....................................................................................................................7/1

7.2. Essential maintenance tasks:................................................................................. 7/2

7.2.1. Daily maintenance......................................................................................................................7/2

7.2.2. Weekly maintenance..................................................................................................................7/2

7.2.3. Monthly maintenance .................................................................................................................7/3

7.2.4. Yearly maintenance....................................................................................................................7/3

7.2.5. Preventive maintenance (recommended) .................................................................................. 7/4

7.3. Air Pressure Regulator ........................................................................................... 7/5

7.4. Hibernation of the machine .................................................................................... 7/7

7.4.1. Air Gun Draining and Test procedure .........................................................................................7/7

7.5. The Detection Belt.................................................................................................. 7/9

7.5.1. General ...................................................................................................................................... 7/9

7.5.2. Replacing the Detection Belt....................................................................................................7/10

7.5.3. Tensing and Tracking of Detection Belt ....................................................................................7/12

7.6. Greasing the bearings.......................................................................................... 7/15

7.7. Replacing the small return axle of the detection belt ........................................... 7/17

7.8. Cooling ................................................................................................................. 7/21

7.9. Electrical installations........................................................................................... 7/22

VIII. Troubleshooting.................................................................................. 8/1

8.1. Introduction ............................................................................................................ 8/1

8.2. General Troubleshooting and Alarm lights ............................................................. 8/1

General ................................................................................................................................................ 8/1

Alarm Lights ......................................................................................................................................... 8/1

8.3. Troubleshooting Procedures .................................................................................. 8/2

8.3.1. Procedure 1: Testing Main Air Pressure Regulator .................................................................... 8/2

8.3.2. Procedure 2: Testing Settings optional cooling unit ................................................................... 8/3

8.3.3. Procedure 3: Replacing compressed air valves (FESTO)..........................................................8/4

Chapter 0: Table of Contents

0/4 Operators & Maintenance Manual GENIUS Compact Version UK 0.1

Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS

General tel. +31 (40) 292 2622 - Service tel. +31 (40) 292 2620 - Fax. +31 (40) 292 2633 - Email: service.pulsarr@bestnv.com

IX. Touchscreen Program .......................................................................... 9/1

9.0. Contents of Touchscreen Program......................................................................... 9/2

9.1. General info............................................................................................................ 9/3

9.1.1. Screen Layout ............................................................................................................................9/3

9.1.2. Help Menu.................................................................................................................................. 9/5

9.2. Log-in Menu ........................................................................................................... 9/6

9.2.1. Logging in................................................................................................................................... 9/6

9.2.2. User Levels ................................................................................................................................ 9/7

9.3. Main Menu ............................................................................................................. 9/8

9.4. Detection Menu ...................................................................................................... 9/9

9.4.1. Settings Menu ..........................................................................................................................9/12

9.4.2. Frame Grab Menu....................................................................................................................9/16

9.4.3. Scope Menu .............................................................................................................................9/21

9.4.4. Normalization Menu .................................................................................................................9/22

9.4.5. LED Lighting Menu...................................................................................................................9/24

9.5. Rejection Menu .................................................................................................... 9/25

9.5.1. Settings Menu ..........................................................................................................................9/26

9.5.2. Valve Test Menu .......................................................................................................................9/27

9.5.3. Belt Speed................................................................................................................................ 9/28

9.6. Product Setups Menu........................................................................................... 9/30

9.7. Expert Settings..................................................................................................... 9/31

9.7.1. User Management Menu.........................................................................................................9/31

9.8. Warnings and Errors Menu .................................................................................. 9/32

X. The Laser Box ...................................................................................... 10/1

10.1. Introduction ........................................................................................................ 10/1

10.2. Theory ................................................................................................................ 10/1

10.2.1. Laser Light Illumination ..........................................................................................................10/1

10.2.2. Basic principle laser sorting ...................................................................................................10/2

10.3. GENIUS Compact Laser Safety......................................................................... 10/3

10.3.1. Optical Laser Safety...............................................................................................................10/3

10.3.2. Laser Safety Labels (only with laser box) ................................................................... 10/5

10.4. Operation ........................................................................................................... 10/7

10.5. Cleaning & Maintenance .................................................................................... 10/8

10.5.1. Scan Shielding and Laser window ......................................................................................... 10/8

Table of contents

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