Operating Instructions INSIGHT GENIUS DATA MANAGEMENT
Contents
1. generated Normal status signal amplitude below threshold Metal detection threshold exceeded 5 3 7 Quitting the program To quit the INSIGHT GENIUS program press the Quit button The application will be closed and the connection to the metal detection control units are interrupted Yertication Do pou really want to exit the program 7 A certainty inquiry whether the program wants to be exited appears 16 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 4 Setup window Setup Menu Coilnuniber STE version l AWE Version Boardrnurmbper Compergatiorn Operation frequency HE Negative limit Positive limit 7 VOOQ OVVOORE The Setup window provides information about software version balance condition of the detector head and operating frequency This information is not changeable OPoe oY 8 Version no of the software of the controller board Version no of the software of the evaluation board Board version of the controller Receiver voltage in Volts Operating frequency of the metal detector in kHz Alternative frequency of the coil in KHz TecTronix INSIGHT GENIUS doc 5 Instruction manual Frequency divergence in percentage Negative boundary in percentage Positive boundary in percentage Number of the used detection coil The indicated values are besides the alignment invariable values and can only be used for information Detailed2. 320 Male connector type Hirschmann ELST 4012 PG9 Article No 08021325 back view 4 3 Serial data format RS232 and RS485 19200 Baud 8 Data bits 1 Stop bit no parity The INSIGHT GENIUS requires a baud rate to be set on the electronics board to 19200 Baud 7 TecTronix INSIGHT GENIUS doc 4 Instructions 4 4 Instruction for the installation of the serial interface board Option The serial interface board Industio CP 132 supplied by MOXA is used for the inte gration of the metal detector into the data management system It provides two additional serial interfaces one RS 422 and one RS 485 The data management system requires the RS 485 mode To install the board follow the instruction 1 Disconnect the PC from the mains supply 2 Remove the PC cover 3 Set the switches and jumpers according to the picture below SW 1 SW 2 JP 1 set COM 3 1 2 1 2 all switches ON JP 2 set COM 4 JP 1 and 2 set the load resistors for both ports SW 1 sets the automatic data direction control for both ports SW 2 sets both ports to RS 485 mode 4 Insert the board to a free PCI slot and close the PC with the cover Use the installation instruction of the board supplier All relevant steps are described in a comprehensive form 8 TecTronix INSIGHT GENIUS doc 4 Instructions 4 5 Software installation Insert the disk or CD Rom and open the file install exe You will get an installation menu which indic
3. NIUS doc 5 Instruction manual 5 12 Online diagram A The online diagram displays and records the metal signal of the last 10 minutes in steps of 1 second This diagram eases a diagnosis in case of failure red bar gt metal detection represents the threshold Signal amplitudes exceeding the threshold trigger a metal alarm blue bar gt signal noise 29 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 13 Metal diagram 2000 0 1500 0 1000 0 500 0 11 00 12 00 13 00 14 00 20 Sep 2000 The metal diagram records the amplitudes of the metal signal of the last 4 hours in steps of 1 min Each recording represents the maximum amplitude within the 1 min period The diagram has a time capacity of 24 hours After this period the recording starts at the beginning by overwriting the old datas red bar gt metal detection threshold Exceeding signals causes a metal alarm blue bar gt signal noise 30 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 14 Diagram feature The window diagram features allows to change time axis as well as the metal signal axis The button Treshold zooms the metal signal axis in reference to the threshold which gives more detailed information about the noise conditions or product signal characteristic To get back press the button again The lower arrow buttons are able to shift the diagrams The time axis skips 4 hours to the left or the righ
4. SIGHT GENIUS software package 9 5 Instruction manual 10 5 1 General 10 5 2 General overview 11 5 3 Main display 11 5 3 1 Task strip 12 5 3 2 Change of product number and product name 13 5 3 3 Change of parameters 13 5 3 4 Data transfer interrupt and restorage 14 5 3 5 Alarm and error messages 15 5 3 6 Bar graph display 16 5 3 7 Quitting the program 16 5 4 Setup window 17 5 5 Service display 18 5 6 Product parameter window 20 5 7 Date Time window 22 5 8 Password window 22 5 9 Test interval window 23 5 10 Product teaching 24 5 11 Log book menu 27 5 12 Online diagram 29 5 13 Metal diagram 30 5 14 Diagram feature 31 6 Address 32 3 TecTronix INSIGHT GENIUS doc 1 Introduction 1 Introduction The HACCP standard is an important part of the quality management in the food processing industry Tectronix Metal Detectors of the series GENIUS provide thanks to the sophisticated State of the art electronics beside the extreme ease of operation all relevant HACCP informations The storage of all parameters metal error and alarm status signals provided with date and time log book allows a comfortable evaluation and interpretation of sources of metal impurities Furthermore all functions are integrated that are necessary to meet the HACCP standards which includes the examination and filling of device and process datas The Central Data Management INSIGHT GENIUS provides well arranged displayed and recorded datas Additionally remote assist
5. T CTRONIX SYSTEMS INC METAL SHARK i Operating Instructions INSIC TACs ietS DATA MANAGEMENT 9 18812 96 Ave Surrey BC Canada V4N 3R1 Tel 001 604 607 6028 Fax 001 604 607 6026 e mail service metal shark com Customer Name Location Date in Service d m y We would like to take this opportunity to thank you for purchasing your Metal Detector from Tectronix The confidence you have placed in our product is sincerely appreciated and we will endeavor to provide the best service and support possible Please take the time to read the User Manual completely as this provides you with the expertise necessary to install and adjust the system according to your requirements In addition to this you will learn about the sophisticated op tions provided by the Genius electronics If you have any problems in the set up and operation of your system the Tectronix team are available to assist you Tectronix Systems inc 9 18812 96 Ave Surrey British Columbia Canada V4N 3R1 Telephone 001 604 607 6028 Fax 001 604 607 6026 E mail service metal shark com 2 TecTronix INSIGHT GENIUS doc Contents Contents 1 Introduction 4 2 System requirements 5 3 Installation 6 4 Installation instructions 7 4 1 Interface card 7 4 2 Cabling 7 4 3 Serial data format RS232 and RS485 7 4 4 Instruction for the installation of the serial interface board Option 8 4 5 Software installation 9 4 6 Starting the IN
6. ance by the Tectronix customs service support can be provided by a modem or ISDN board Features at a glance e Central and ease of operation of Tectronix Metal Detectors and Separators by a single PC e Clearly arranged display of all installed Tectronix devices and processing equipment e Central changing of device parameters in case of product and batch change e Central recording logging and evaluation of events of all connected Tec tronix units parameter changings alarm metal and error messages e Easy integration of the stored datas into the management system INSIGHT GENIUS e Simple and fast analysis of metal impurity sources e Reduction of machine down time and maintenance costs by means of re mote service support capability 4 TecTronix INSIGHT GENIUS doc 2 System requirements 2 System requirements The Central Data Management System INSIGHT GENIUS allows to connect up to 10 optional 40 Tectronix Metal Detectors and Separators equipped with the GENIUS control unit systems requirements Pentium Processor 233 MHz min RAM 32 MB pref 64 MB screen resolution 1024 x 768 RS 485 Interface board with automatic TxD RxD control Recommended Interface board MOXA Industio CP 132 optional 15 monitor pref 17 The data communication is handled by Tectronix interface protocol Remote service support can be operated by a modem or ISDN board 5 TecTronix INSIGHT GENIUS doc 3 Example installation 3 I
7. ates the recommended installation path Unzip listing Winzip Self Extractor INSTALL exe To unzip all tiles in INSTALL exe to the specified folder press the Unzip button Unzip To Folder Aun Winip E MNSIGHT aie Il Overwite Files Without Prompting A Bout Help Activate the Unzip button with the mouse which installes the software with the path C CDM Close the installation routine by pressing the Close button 4 6 Starting the INSIGHT GENIUS software package Call the Explorer and change to above stated directory Start then the file MSG_Visu exe 9 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 Instruction manual 5 1 General The Central Data Management INSIGHT GENIUS allows to display log and print out e Product data product name and parameters e Service and setup data e Metal alarms e Log book data including device and product statistics The exact meaning of the datas are explained in the instruction manual of metal de tector GENIUS The program consists of several menus or program windows e General overview This window is opened at the program start and displays product number product name device name and device status e Main menu Device parameters metal signals and the buttons to call the remain ing menus e Device parameters are displayed in service setup and product data menu e Log book allows the polling printing and storage of all historic re
8. corded events e Online metal signal diagram displays the current analog metal signals e Signal diagram records the maximum value of metal signals within 24 hours At the program start the main menu and the signal diagram are opened automatically The remaining menu can be opened and closed by using the buttons at any time 10 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 2 General overview Fr Nr Prod Mame Devicelyoe State Sensitivity Threshold Fhase Angle metal alarme number of errara The main menu contains all important informations of the individual devices By dou ble clicking on the desired device the main menu is closed and the main display for the selected device is opened see 5 3 5 8 and 5 9 5 3 Main display DOO D INSIGHT fel ES Total View Logbook Aetup Close Product Number ji Product Name JPROPUCT1 if Phase Angle 35 9 Reset Type Automatic F ia Change sengs 4 Change product Connect again Sensitivity 100 Delay Time 0 20 Duration fo 50 Tracking No Halfwave No E Quicklearn fis Conveyance speed 0 520 i Metalsignal Amplitude 0 Threshold V253G Tabulator strip for the change between the individual devices Display of the device parameters Button for restoration of the data transfer between PC and Control unit O Display for data transfer interruption between PC and Control unit In this situa tion the button Connection restore
9. g manual for the GENIUS Control unit vie Display lolx HEHHEHE HH HHHH HHH HHHH HHHH al 1 system settings GENIUS 15 1 2000 04 00 Pint Save 2 Software STE 1 10 AWE 1 00 frequency 794 kHz Os Close 3 device DETECTOR 1 8 SS SS SS line LIHE 1 code change prod deactivated 4 code teach prod deactivated code setup deactivated Hr of metal detection 23d G Humber of malfunctions 1 List of products Product Sens Threshold Phase 1 PRODUCT 1 149 100 PRODUCT 2 19 100 3 PRODUCT 43 149 100 4 PRODUCT 4 19 100 5 PRODUCT 149 100 ee 6 PRODUCT 6 149 100 7 PRODUCT 7 149 100 0 PRODUCT amp 19 100 E E AE 2 TecTronix INSIGHT GENIUS doc 5 Instruction manual Print The Print button opens the printing menu for the current record Save The Save button stores the current record as a text file on the hard disk The listing of the record files can be set and read by the inifile Setup ini with the key directory The data is stored with date time and device identification structure Year month day device id i e 990601M txt 99 gt year 06 gt month 01 gt day M gt device id The datas can be processed with any editor or even with Excel 3 Close The Close button closes the displayed windows Display Display field for the recorded datas Scroll bar for long records 28 TecTronix INSIGHT GE
10. has to be operated 11 TecTronix INSIGHT GENIUS doc 5 Instruction manual Display for alarm and error messages of the Control unit Task strip with different programs Button for parameter changing Clicking this button allows to change the pa rameters Clicking a second time causes a transfer and change of the parameters at the addressed metal detector Control unit 5 3 1 Task strip Total View Logbook setup Llose The task strip allows four different selections e General overview 2 display an overview of all connected devices see chapter 5 2 e Log book 2 see chapter 5 11 e Setup gt eight submenus can be selected Setup menu chapter 5 4 Service menu chapter 5 5 Product data chapter 5 6 Date and time chapter 5 7 Diagram adjustments chapter 5 14 Test interval chapter 5 9 Password chapter 5 8 Product teaching chapter 5 10 The menu topics date time test interval and product teaching are secured by a password Essential functions could be erased e Quit escape 12 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 3 2 Change of product number and product name Product Humber po Product Hame Change product B The button Change product allows to change product number and product name of a current product After pressing the button the input fields turn to yellow and the product number and name can be changed The new datas are set when escaping the input f
11. ield or pressing the ENTER button 5 3 3 Change of parameters Ph hase Angle 435 3 Reset ype Automatic Change settings Sensitivity 100 Delay Time 0 20 Duration fo 50 Tracking No H Halfwave No WuIckleam Nc Conveyance speed 0 520 The parameters displayed in the main menu can be changed by pressing the button change parameter which enables the input After a parameter change press the but ton Send parameter to transfer the new data to the corresponding device After pressing Change parameter the bottom line will display the limits within the corresponding parameter can be adjusted 13 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 3 4 Data transfer interrupt and restorage 2 all Change product Connect again In case of interruption between the PC and the metal detector control unit the mes sage Connection interrupted is displayed The button Restore connection allows to restore the connection to the device Be sides this the program tries every 30 sec to restore the connection automatically A successful restorage of the connection will change to the main menu 14 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 3 5 Alarm and error messages Alarmmessage at device Line 1 Alarmmessage at device Line 2 Alarmmessage at device Line 3 Alarmmessage at device Line 4 with current error Receiver broken on 16 09 07 at 11 10 21 with current error Receiver bro
12. information which includes the significance of each single value can be found in GENIUS operating manual volume 2 5 5 Service display Operationmeode Operationmeode Time Distance Lrt EE AAE Synchronization of light barrier Flap control Sts o oa Eject Level control Quicktan LIFE Aim pressure control TEENY Air pressure control The service menu provides information about the current operating modes and char acteristics In dependence on your appliance type either the right or the left window appears Product conveying modes Conv gt Conveyor mode product is conveyed by belt conveyor Consens gt Conveyor belt and belt control system left window FF gt Free fall or gravity fall e g Rapid xxxx right window SC PC gt Vacuum or pressure conveying lines right window Time delay or distance measurement Used to control an eject unit after metal detection 18 TecTronix INSIGHT GENIUS doc 5 Instruction manual Time delay gt used with conveyors running at a constant speed The convey ing speed Is indicated in m s Distance gt used with conveyors which can run of a varying conveying speed The signals of proximity switches are used to get the set distance Light barrier This field indicates if a light barrier is used in order to determine the exact position of a contaminated product for exact and reliable rejection non Metal signal not synchronized with photoelectric ba
13. ken on 16 09 01 at 11 10 21 with current error Receiver broken on 16 09 01 at 11 10 21 with current error Receiver broken on 16 09 01 at 11 10 21 o As soon as an alarm or error message is sent from a metal detector control unit it will be displayed on the screen in a red field It remains displayed until the problem is fixed or reset Eight different alarm and error messages exist and are displayed with an additional message box showing the faulty device date and time Alarm error message in Signification INSIGHT GENIUS Autobalance active balance Automatic balance of the detector head due to extrem changements in the surroundings is acti vated Receiver too high The automatic balance control is out of _ Receiver too low too low ee or receiver A unit or connection cable between detec faulty tor head and pc board AWE faulty Output overloaded Short circuit at the magnetic valve or cable Proximity switch faulty Proximity switches scanning the belt speed are faulty Battery low Battery on the control board is discharged 15 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 3 6 Bar graph display Metalsignal Amplitude 1 Threshold metal Metalsignal Amplitude 295 T old metal A bar graph display shows the analog signal amplitude of the metal detector As long as the bar is in blue colour no metal alarm is triggered When the bar turns to red a metal pulse is
14. nd resets to the starting position after the ejection period Two way setting A pusher is activated by metal detection and stays in its current position after the ejection period 20 TecTronix INSIGHT GENIUS doc 5 Instruction manual Tracking The tracking function can be activated On or not Off lt is used to compensate small changings of product characteristics or of the surrounding automatically to obtain optimum sensitivity Quicklearn Activated if input is On Used if a change of products should be detected and adjusted automatically This feature however requires sufficient soace between detector and eject unit i e at least three times of the product length If an ex treme change of the current product characteristic is detected a metal alarm is set If the following product has the same characteristic the parameters are ad justed automatically to the product and checked a third time The metal alarm is reset before the first product reaches the eject unit Half wave Activated when set to On Used mainly with intermittent operation stop and go to provide op timum detection capabilities This so called halfwave metal detection mode is more sensitive to interferences than the standard mode which is active when set to Off Conveying speed The field displays the current set conveying speed It should correspond to the actual speed of conveyor unit 21 TecTronix INSIGHT GENIUS doc 5 Instruction man
15. nstallation The picture below shows an example for an integrated metal detector and separator control system using the Central Data Management System INSIGHT GENIUS The communication is carried out by a simple shielded two wire cable using the RS 485 interface standard ewe s gs i Ae 3 d l z 7 a 4 4 Central Data Management INSIGHT GENIUS Metal Detector GLS Metal Separator RAPID 5000 Metal Detector GLS Metal Separator RAPID 6000 Combi Control System CCS 6 TecTronix INSIGHT GENIUS doc 4 Instructions 4 Installation instructions 4 1 Interface card The INSIGHT GENIUS software requires an RS 485 interface card Tectronix rec ommends the MOXA Industio CP 132 which can be delivered on request However any other interface card can be used which provides an automatic RxD TxD control 4 2 Cabling The connection cabling has to be carried out by a shielded two wire line which can also be supplied on request It has to be connected according to the diagram The wiring diagram relates to the recommended interface card Industio CP 132 If a differ ent card is used consider different pinning of the Sub D connector see operating manual Control Unit GENIUS Optional serial interface S S N T A A A A Female connector Sub D 9 pin o p o P m PAIN AIN for RS485 of Industio CP 132 back view GENIUS 1 GENIUS 2 GENIUS 3 GENIUS n Twisted pair shielded cable a ae Article No 08025
16. pendently of the time and the weekday daily The time is additionally activated in this section With this settings the test for ward transfer signal is delivered to exactly this time which is set in the time field The Weekday field is still deactivated Test object Additional comments have to be made for the following three fields Up to three test objects can be set Therefore the numbers 0 to 99 are used Hereby the O means no test object A test object has to be set hence the first field can be set from 1 to 99 The other two test objects are optional If 0 no test object is selected for the second test object the third can only be 0 Hence the field is deactivated and set to 0 5 10 Product teaching The menu product teaching allows to start the product teaching procedure with a current running product Important Is the learning process started on base of the visualization it has also be completed by the visualization In case of remote teaching a direct ap pliance operation is not possible because of indefinite conditions The reason therefore is that the visualization always has to know the actual conditions of the appliance Thereby the conditions are extracted after each step If allina sudden work is continued directly at the appliance no information divulged to the visualization and it operates in its previous conditions 24 TecTronix INSIGHT GENIUS doc 5 Instruction manual Procedure The device has
17. rrier LS synchrony Metal signal synchronized with photoelectric barrier inverse detection A metal signal is created for products not containing any metal impurity Ejection monitoring Indicates whether the control waits for a revertive signal or not after the splitting Full indicator Indicates an alarm when the reject container is full Dimensional unit Indicates the dimension of the conveyor speed Meter per second Speed in m s Meter per minute Speed in meter per minutes Flap monitoring Indicates whether the ejection flap is in correct position or not i e operative Quickflap Pneumatic cylinder monitor In each case it needs a signal for release and a signal for reset 19 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 6 Product parameter window Productdata Magnetvalve Metall py Error Eject direction Tracking Quicklearn YVOOOWWO Lonvevaricitig spee ck O s04 This window shows information about metal detection modes and the most important parameter which is the processing speed of a product Output for magnetic valve High active or Low active The output is set to 24V at the High active mode when a metal alarm its set The Low active mode sets the output to OV in case of metal detection Metal in case of failure If YES is set the metal alarm output is also set in case of system failure Direction of ejection one way or two ways One way setting A pusher is activated by metal detection a
18. t side if the button is pushed once With this view the user is able to look at the daily progression precisely To go back to the actual curve close the win dow 31 TecTronix INSIGHT GENIUS doc 6 Address 6 Address Manufacturer s Tectronix Systems inc 9 18812 96 Ave Surrey British Columbia Canada V4N 3R1 Telephone 001 604 607 6028 Fax 001 604 607 6026 E mail service metal shark com Representative 32 TecTronix INSIGHT GENIUS doc
19. to run in the operating mask so that the teaching procedure can be started Otherwide the following window appears Learning product impossible because unit i not in operation mask Please switch to operation mask and try again First step of teach in procedure Please convey product several times then press Fl At first the F4 button appears in gray colour It can only be pushed when the lettering turns to black Second step The following message appears Please convey product again several times then press Fl Tum 2 F4 The actual teaching cycle appears in the lower left corner This step is repeated a several times max 15 times with products having an extremely high product effect Afterwards an error message appears and the process is broken off 25 TecTronix INSIGHT GENIUS doc 5 Instruction manual Learning product failed Product effect is too big The message can also appear earlier if the product effect in general is too high Third step In case of successful teach in procedure the following message appears Product successtully learned To get back to the main menu confirm this message 26 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 11 Log book menu fee Logbook Archrves Protecel The log book menu allows to poll all records Each button represents a corresponding listing shown on the picture below For more information see the operatin
20. ual 5 7 Date Time window time Bo 1 date e ho 2000 day y change By activation of this window date and time setting of the electronic unit are shown To change the value push the change button To send the changed value to the appli ance push the send button This window is secured by a password 5 8 Password window old password new password confirmation of password accept password The password locks the functions and can be changed in window The function change of product and parameter changes for example are secured by this password 22 TecTronix INSIGHT GENIUS doc 5 Instruction manual 5 9 Test interval window Testinterval The test interval which verifies the operability can be set by the visibility Only the appliance which is active on the main screen can be adjusted By activation the window actual shows the settings of the appliance The menu alarm interval provides the following settings no alarm hourly daily weekly Depending on the settings your choose a varying number of settings can be chosen in the following menu topics 23 TecTronix INSIGHT GENIUS doc 5 Instruction manual Described as following no alarm No further settings can be made The transmission of the settings to the appliance cuts the alarm function off hourly The setting of the weekday and time can be deactivated in this mode Every hour the alarm triggers inde
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