SESOTEC GENIUS ONE Operating Instructions Manual

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Translation of the Original

Operating Instructions

Control Unit

GENIUS ONE

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due to product innovation or technical

improvement!

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number when contacting us!

Please read this manual and keep it safe for

future reference!

Please observe and follow the safety notes!

Sesotec GmbH

Regener Straße 130

Telephone +49 (0) 8554 308-0 * Fax +49 (0) 8554 2606

E-mail: info@sesotec.com

Internet: http://www.sesotec.com

Service: Telephone +49 (0) 8554 308-173

GENIUS-ONE-BA-CU-EN-3211.docx

IMPORTANT

* D-94513 Schönberg

Page 1 of 163

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Page 1 Translation of the Original Operating Instructions Control Unit GENIUS ONE IMPORTANT We reserve the right to change the contents due to product innovation or technical improvement! Please state type of equipment and serial number when contacting us! Please read this manual and keep it safe for...
Page 2 Manufacturer: Sesotec GmbH D-94513 Schönberg, Germany Contact: Sesotec GmbH Regener Straße 130 D-94513 Schönberg, Germany Tel.: +49 (0) 8554 3080 Fax.: +49 (0) 8554 2606 E-mail: info@sesotec.com Internet: www.sesotec.com Contact Service: Sesotec GmbH Industriestraße 5 D-94513 Schönberg, Germany Service Hotline: +49 (0) 8554 308-173 E-mail: service.msg@sesotec.com...
Page 3: Table Of Contents
Design and method of operation Functional principle Performance features Application in production Function and control elements GENIUS ONE Control Unit – operating panel, home screen 2.4.1 GENIUS ONE Control Unit – built-in version 2.4.1.1 GENIUS ONE Control Unit – remote version 2.4.1.2...
Page 4 7.2.2 Power supply 7.2.3 Mains connection with mains plug 7.2.4 Mains connection via terminal box Connections to the GENIUS ONE Control Unit / IO unit 7.3.1 Electrical connections, supply voltage and relays 7.3.2 Electrical connections, switching functions, inputs/outputs 7.3.3 Electrical connections, CU interface 7.3.4...
Page 5 Contents 10.1.1 Main view 10.1.1.1 Home screen I with information about the operating situation 10.1.1.2 Home screen II with information about the operating situation 10.1.1.3 Home screen III Compliance Mode 10.1.1.4 Home screen IV with current counter values. 10.1.1.5 Home screen V for starting the auditcheck 10.1.1.6 Home screen VI for manual rejection, function test and unlocking 10.2 Select menu language...
Page 6 Contents 14.2.1.7 Create Login2Go 14.2.2 HW monitoring 14.2.2.1 IO unit 14.2.2.2 CU board 14.2.2.3 Versions 14.2.3 Statistics 14.2.3.1 Counter 14.2.3.2 Metal signal 14.2.3.3 Device 14.2.3.4 Settings 14.2.4 Interfaces 14.2.4.1 Network 14.2.4.2 LAN interface 14.2.4.3 WiFi 14.2.4.4 Connections 14.2.4.5 Serial I/O 14.2.4.6 SSTProt Server 14.2.5...
Page 7 IO unit - System errors 16.1.4 GENIUS ONE - Machine / application errors 16.2 Replacing GENIUS ONE Control Unit boards 16.2.1 Replacing main assemblies on the attached GENIUS ONE Control Unit 16.2.1.1 Replacing the CU board 16.2.1.2 Replacing the IO unit 16.2.1.3...
Page 8: General Notes
Possible residual risks are identified by safety notes and are described in the instruction manual. All the safety notes attached to the GENIUS ONE Control Unit and to the machine must be observed. Such safety notes always must be complete and clearly legible.
Page 9: Typographical Conventions
Feet/minute System parameter l/min Litres/minute Percent Volt GENIUS ONE Millivolt 1.2.7 Information categories There are two different types of information symbols: TIP / Important information: A tip or important information is identified by this symbol. Observe additional documentation: A reference to additional documentation outside this instruction manual is identified by this symbol.
Page 10: Additional Instruction Manuals
1. General notes 1.2.8 Additional instruction manuals The complete documentation of a system made by Sesotec GmbH comprises the instruction manual of the GENIUS ONE Control Unit and the additional instruction manuals depending on the system configuration and scope of delivery.
Page 11: Symbols Used
1.3.1 Identification The information in these operating instructions only apply to the GENIUS ONE Control Unit. A type plate with the respective data is attached to the side of the housing of the GENIUS ONE Control Unit and on every system.
Page 12: Field Of Application
Of course the GENIUS ONE Control Unit also is suitable for similar applications in other industry sectors. 1.3.3 Application reasons •...
Page 13: Design And Method Of Operation
(frequency converter) A Sesotec metal detector comprises a detection unit (metal detector coil) and a Control Unit. With the GENIUS ONE Control Unit the Sesotec metal detector operates according to the so-called "Balanced coil" principle: The transmitter winding in the detection coil creates a high-frequency electromagnetic field in the tunnel area.
Page 14: Application In Production
2. Design and method of operation 2.3 Application in production The GENIUS ONE Control Unit primarily is designed to be combined with Metal separators and conveyors. Examples: Conveyor applications, Liquiscan application, the GENIUS ONE Control Unit the GENIUS ONE Control...
Page 15: Genius One Control Unit - Operating Panel, Home Screen
2. Design and method of operation 2.4.1 GENIUS ONE Control Unit – operating panel, home screen Operating status: Time Operating, error, metal, auditcheck, (10) User compliance mode (11) Logbook Switch home screens (12) Batch number Metal tracer displays the signals from the last...
Page 16: Genius One Control Unit - Built-In Version
2.4.1.2 GENIUS ONE Control Unit – remote version In this version the CU board is integrated directly in the detection coil, the IO unit are mounted on the electronics housing cover and the power supply unit in the "GENIUS ONE" electronics housing. GENIUS ONE, remote Control Unit GENIUS ONE, CU adapter integrated in the detection coil 2.4.1.3 GENIUS ONE Control Unit integrated in the appliance housing...
Page 17: Genius One Control Unit / Io Unit
2. Design and method of operation 2.4.2 GENIUS ONE Control Unit / IO unit Jumper: "MO connection monitoring" 1-2, MO1 3-4, MO2 5-6, MO3 7-8, MO4 (16) "Service jumper" 5-6, plugged, enable, program update Test points: "Analog Out 1" 0-10 VDC "Analog Out 2"...
Page 18 2. Design and method of operation LEDs: (22) "Monitor LED, MO 1- 4" LD10 Metal output 1 (MO1) Metal output 2 (MO2) Metal output 3 (MO3) LD14 Metal output 4 (MO4) (22) "Monitor LED, relay 1- 3" LD11 Relay Fault (84, 81, 82) LD12 Relay Metal 1 (64, 61, 62) LD13...
Page 19: Genius One Control Unit / Cu Board
2. Design and method of operation 2.4.3 GENIUS ONE Control Unit / CU board Connections and terminals: "Receiver" J10, input signal from the detection coil "Transmitter" J7, output signal to the detection coil "Service interface" J11, diagnostics interface Test points: "Transmitter signal"...
Page 20: Cu Board On Adapter Board
2. Design and method of operation 2.4.4 CU board on adapter board Connections and terminals: "Connection to IO" J1, connection, IO unit (metal interrupt, VCC) "CU fan" J2-1, 24 V_L, connection for fan, adapter board J2-2, GND, connection for fan, adapter board Test points: "24 VDC"...
Page 21: Dimensions And Technical Data
3. Dimensions and technical data / 4. Modifications Dimensions and technical data If the GENIUS ONE Control Unit is integrated in the unit housing, see Operating Instructions of the „Metal detector/separator“. 3.1 Dimensions See technical data sheet "GENIUS ONE Control Unit".
Page 22: Safety
The safety notes therefore should always be observed! If the GENIUS ONE Control Unit is integrated in the appliance housing, the appliance (machine) safety data must be observed in addition: See operating manual for the "metal detector/metal separator".
Page 23: Personal Protective Measures
Its use nevertheless may still involve risks for the life and health of the user or of third persons, or damage to the machine or to other material assets, especially if the GENIUS ONE Control Unit it is used by untrained personnel, improperly, or outside its intended use, [see chapter 5.1 "Intended use"].
Page 24: Dangers For Persons With Physical Impairment
• If the GENIUS ONE Control Unit is not attached to a metal detector/separator, you must fasten it properly and stably with four screws. The user is responsible for ensuring that it is mounted at an ergonomic operating height.
Page 25: Safety Information For Operation
DANGER Energised components in the electronics housing of the GENIUS ONE Control Unit. ➢ If the electronics housing of the GENIUS ONE Control Unit is open, there is a risk of injuries due to electric shock or burns. ➢ During operation the cover of the electronics housing must be kept closed.
Page 26: Safety Information For Storage And Transport
Sesotec GmbH in case of resulting personal and/or property damage are excluded. 5.15 Improper use Other applications of the GENIUS ONE Control Unit than those listed in [section chapter 5.1 "Intended use"] are regarded as improper use. Improper use: •...
Page 27: Shipping, Transport And Storage
6. Shipping, transport and storage Shipping, transport and storage The GENIUS ONE Control Unit is a part of Sesotec metal detectors/separators. Observe the safety information in the operating manual for delivery, transport and storage of Sesotec metal detectors/separators. WARNING There is a risk of personal injury and transport damage in case of incorrect handling.
Page 28: Shipping
6. Shipping, transport and storage 6.1 Shipping Depending on their weight, Sesotec metal detectors/separators with GENIUS ONE Control Unit are differently packed for shipping. Weight <= 20kg Carton Weight > 20 kg Carton or shrink-wrapped on pallet or paltainer. Weight > 20 kg Transport crate on pallet or paltainer.
Page 29: Transport
Protect against moisture! Careful: Glass! Centre of gravity! 6.3 Storage Until final assembly, store the appliances and machines from Sesotec GmbH in closed, dry rooms and not outdoors. The following points are to be observed when storing the appliance (machine): •...
Page 30: System Installation
• Ensure stable and non-vibrating installation. • Do not install the detection coil and the GENIUS ONE Control Unit in the vicinity of interference fields (e.g. large electric motors and frequency converters!). As a value for orientation observe a distance of 5 m.
Page 31: Connection Of The Genius One Control Unit
Dimensions: See technical data sheet "GENIUS ONE Control Unit". • Lay the connection cables between the GENIUS ONE Control Unit and the detection coil separately and away from other cables (mains cables, motor cables, control cables). • Fix the connection cables or lay them in a separate cable duct.
Page 32: Mains Connection With Mains Plug
Conductor PE (yellow/green) to terminal PE Shield open to terminal PE (if present) 5. Close the terminal box. 6. The GENIUS ONE Control Unit is ready for operation when the supply voltage is turned on. Page 32 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...
Page 33: Connections To The Genius One Control Unit / Io Unit
DANGER Danger of electric shock when working at the GENIUS ONE Control Unit. ➢ Before you open the electronics housing of the GENIUS ONE Control Unit, always make sure that no mains or external voltage is connected. ➢ Carry out work on the cabling only in the switched-off condition.
Page 34: Electrical Connections, Supply Voltage And Relays
7. System installation 7.3.1 Electrical connections, supply voltage and relays Pos. Connection Type of connection Function "Low-active" +24 V Supply voltage connection Connection of 24 V supply voltage "Relay Metal 1" Potential-free relay contact Normal operation: Contact 61 and 64 closed Metal detected: Contact 61 and 62 closed "Relay Metal 2"...
Page 35 7. System installation Pos. Connection Type of connection Function (12) "Inputs" Switching inputs 24 V Switching functions 24 V, PNP switching 33 – 34 – 41 BIN: Monitoring container door 35 – 42 – 43 Reject check 36 – 37 – 44 Level monitoring AÜ...
Page 36: Electrical Connections, Cu Interface
Transmit data to the IO unit RX2: Receive data to the IO-unit Info: The CU adapter board only is used for the remote version of GENIUS ONE Control Unit. [see section 2.4.1.2, “GENIUS ONE Control Unit – remote version"]. Page 36 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...
Page 37: Drawings Of Input/Output Connections
The maximum cable length for external components, like switches and sensors is max. 15 m. Switching outputs Switching outputs The connection for the GENIUS ONE Control Unit signal device (signal combination) always is the identical. Switching outputs LT1 – LT5 = Signal device position 1 – position 5.
Page 38 7. System installation Switching inputs (PNP) Switching inputs (PNP) Switching inputs (PNP) Switching inputs (PNP/NPN, Analog,) CU interface Connection CU adapter board, Page 38 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...
Page 39: Electrical Performance Data Of Connections
➢ Always observe the load capacity of the relay contacts. In case of overload there is a risk of destroying the relay contacts. ➢ Provide fuses from to potential-free relay contacts outside the GENIUS ONE Control Unit, if the maximum ratings of the relay contacts could be exceeded.
Page 40: Genius One Control Unit / Cu Board (Evaluation Unit)
7. System installation 7.3.7 GENIUS ONE Control Unit / CU board (evaluation unit) Pos. Connection Type of connection Function "Receiver" Connection Functions detection coil, Receiver signal receiver Receiver signal Reference GND for receiver signal - 5 V + 5 V "Transmitter"...
Page 41: Starting Up Genius One Control Unit
• The Sesotec metal detector/separator with GENIUS ONE Control Unit is not installed in an Ex- protection zone. • The Sesotec metal detector/separator with GENIUS ONE Control Unit is not installed in the vicinity of interference fields (e.g. large electric motors and frequency converters).
Page 42: Commissioning The Metal Detector/Separator With The Genius One Control Unit
4. The GENIUS ONE Control Unit boots up after switching on the power supply. The metal detector is ready to operate once the GENIUS ONE Control Unit has booted up and the following characteristics appear: •...
Page 43: Operation Of A Metal Detector With Genius One Control Unit
9. Operation of a metal detector with GENIUS ONE Control Unit Operation of a metal detector with GENIUS ONE Control Unit Metal detectors/separators with GENIUS ONE Control Unit are intended to be used for the inspection of bulk materials and piece goods in free-fall, in vacuum/pressure conveying and conveyor belt applications in the plastics, food, animal feed, recycling and chemical industry.
Page 44: System Symbols: Quick Access And Overviews
9. Operation of a metal detector with GENIUS ONE Control Unit 9.1.1 System symbols: Quick access and overviews The system symbols in the main page contain quick access symbols and overviews. These system symbols always are available during operation. Components that are deactivated or not available are displayed in grey colour.
Page 45: Status Bar
9. Operation of a metal detector with GENIUS ONE Control Unit 9.1.3 Status bar Page 45 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...
Page 46 9. Operation of a metal detector with GENIUS ONE Control Unit Operating or Ready (depending on the set operating mode) Status message (green) "Operating". Metal detection is active and the outputs at GENIUS ONE are activated. Status message (green) "Ready". Metal detection not active (in operating mode "Conveyor belt with FC).
Page 47: Navigation And Control Elements
9. Operation of a metal detector with GENIUS ONE Control Unit 9.2 Navigation and control elements 9.2.1 Basic navigation elements HOME symbol Tap on this symbol to return to the home screen. Position UP symbol Use this symbol to scroll upwards.
Page 48: Basic Display Elements
9. Operation of a metal detector with GENIUS ONE Control Unit 9.2.4 Basic display elements Parameter group: Parameters are assigned an S or P. System parameters (general parameters) Product-specific parameters 9.2.5 Input methods - numeric keypad Example: Sensitivity: Numeric keypad Use the numeric keypad to directly enter a value, the original value will be deleted.
Page 49: Input Methods - Alphanumeric Keypad
9. Operation of a metal detector with GENIUS ONE Control Unit 9.2.6 Input methods - alphanumeric keypad Example: Product name: Text field This field shows the original text / new text. The text can have a maximum length of 20 characters.
Page 50: Start Product Inspection
9.4 Product inspection - error displays and signal devices Die GENIUS ONE Control Unit displays all the operating states such as "Metal detected" and "Error" on the operating panel. External error and signal devices (24 VDC) also can be connected. Such external devices may be signal lamps and signal horns (parallel connection is possible).
Page 51: Product Inspection - No Metal Detection
7. Check the product sequence. 8. Check the conveying speed (must match the set range). If you have performed all these measures and the metal detector with GENIUS ONE Control Unit still does not detect relevant metal particles, please contact our Sesotec service.
Page 52: User Interface
10. User interface 10 User interface The GENIUS ONE Control Unit in the maximum configuration is described in this manual. Depending on the application, some menu items or info boxes may be hidden to you in the masks shown. 10.1 GENIUS ONE Control Unit home screens 10.1.1 Main view...
Page 53 10. User interface 10.1.1.2 Home screen II with information about the operating situation The currently selected product with product number, sensitivity, product angle and the conveying speed are displayed here. The settings such as sensitivity, product angle or conveying speed can be changed by tapping the respective display box.
Page 54 10. User interface 10.1.1.4 Home screen IV with current counter values. Counter (current values) This home screen shows the current counter values for error and metal with their respective assignments. Device: Error counter and metal counter (cannot be reset). User: Counter for Error, metals and products (can be reset manually).
Page 55 10. User interface 10.1.1.6 Home screen VI for manual rejection, function test and unlocking Home screen IV Manual reject Tap on this symbol to activate or deactivate the switching outputs manually (applies only to the outputs configured for manual ejection). Manual ejection is automatically deactivated if the menu is changed.
Page 56: Select Menu Language
10. User interface 10.2 Select menu language Tap on this symbol to open the language selection menu. Select menu language Tap on the arrows to scroll through the list of available languages. The button for the selection of English language is additionally marked with a star symbol to provide an orientation point.
Page 57: User Login / Logout
10. User interface 10.3 User login / logout Tap on this symbol to open the user login menu, or the request to confirm the logout. Only those logged in as an administrator have no restrictions with regard to operation and parameter setting.
Page 58 10. User interface Login Use this menu and the displayed list of user levels to log in to the GENIUS ONE Control Unit with the corresponding authorisation. Your selection is highlighted in colour. User selection You can select a user by directly tapping a user box.
Page 59: Logbook
11. Logbook 11 Logbook Tap on this symbol to open the "Logbook". A logbook entry contains information such as event, current user, date and time. Logbook List of all events with user, date and time. List of events Example Error with error event, user, date and time. Arrow symbols The arrow symbols can be used to move the display area up or down.
Page 60: Logbook Options
11. Logbook 11.1 Logbook options Logbook Logbook options Description – Logbook options Symbol Open the "Logbook settings" menu. Open the "Logbook filters" menu. "Delete logbook" Tap on this symbol to delete all the logbook entries. "Logbook export" Tap on this symbol to export all the logbook entries. Precondition: USB stick must be plugged in on the IO unit.
Page 61 11. Logbook 11.1.2 Logbook filters Logbook Logbook options Logbook filters In this menu you can apply display filters for the complete logbook memory: • Events • Date / time Events: Filtering by events is deactivated if no checkbox is activated. The following checkboxes are available for selection.
Page 62: Product Teaching
Make sure that here only products without metal contaminations (metal-free products) are conveyed. The detection frequency with which the GENIUS ONE Control Unit operates is factory-set and depends on the device version and use. The detection frequency cannot be changed by the customer.
Page 63: Teach Process
13. Product change 12.1 Teach process 12.1.1 Display Product teach process begin Teach In this menu you can perform a teach process. (As Quickteach with single frequency or Fullteach with dual- or multi-frequency). Product teach process - Information about the product: Product name Product teach process - Information about the frequency: Currently set operating frequency.
Page 64 13. Product change 12.1.2 Display product teach process finished Teach results The automatically determined product parameters are displayed as teach results. Sensitivity: Maximum detection sensitivity with the taught product. In addition to the newly determined parameters the old parameters (5) on the left side are displayed for comparison.
Page 65 13. Product change 12.1.3 Determine sensitivities display Determine the sensitivities of the metal detector / separator (Performance test) With the help of this menu you can test the taught parameters or determine the sensitivities. The entire parameters of the taught product are displayed in this menu. Operating frequency The metal detector/separator is operated with this preset frequency.
Page 66: Quickteach
13. Product change 12.2 Quickteach The product-teaching procedure is started with Quickteach; the teaching procedure starts with the preset single frequency. The product teach process is started: Preparation for product teaching Prepare the product to be taught. Confirm preparation completion and start teaching After tapping the confirmation, the product can be taught with the preset single frequency.
Page 67 You can return to the screen mask with the teaching result by tapping the symbol. The GENIUS ONE Control Unit is now adjusted to the environment and the product. Check metal detection with a suitable test sample. Page 67 of 163...
Page 68: Fullteach
13. Product change 12.3 Fullteach The product teach process is started with Fullteach, the Fullteach process starts with the highest set frequency. Product conveying for every search frequency is the same as with a Quickteach. The teach process with the second or third frequency automatically starts when you manually close the teach process with the first or second frequency.
Page 69 The GENIUS ONE Control Unit now has adjusted itself to the environment and to the product. Metal detection should now be tested with suitable test samples. Page 69 of 163...
Page 70: Sensitivity Prediction After A Quickteach Or Fullteach
13. Product change 12.4 Sensitivity prediction after a Quickteach or Fullteach The sensitivity prediction is only available in the Conveyor belt operating mode in conjunction with a GLS MF tunnel metal detector. 12.4.1 Sensitivity prediction for Quickteach The product teaching process is the same as that described in [section 12.2, "Quickteach"]. The difference is that, once the product teaching process is finished, the sensitivity prediction appears in the "Teach results"...
Page 71 13. Product change 12.4.2 Sensitivity prediction with Fullteach The product teaching process is the same as that described in [section 12.3, "Fullteach"]. The difference is that the product teaching process is executed with a multi-frequency (3 frequencies). Once the product teaching process is finished, the sensitivity prediction appears in the "Teach results"...
Page 72: Teaching Results
13. Product change Confirmation symbol (Accept product parameters) On tapping the symbol, a query appears asking whether the results of the current teaching process should be accepted. If so, the teaching results are accepted by tapping the confirmation symbol and the frequency selected under Scanning sensitivity prediction is set. You can return to the screen mask with the teaching results by tapping the symbol.
Page 73 13. Product change Arrow symbols You can switch between the two screen masks for the teaching results with the symbol. Angle The product angles for the individual frequencies are displayed here. Accept teaching result On tapping the symbol, a screen mask opens in which the setting for the selected frequency is displayed.
Page 74: Product Change
Display of the product parameters (angle, sensitivity) of the selected product. Example: Product 4 Confirmation symbol (Change product) When you tap on the symbol the GENIUS ONE Control Unit changes to the selected product with its corresponding product parameters. With active batch management: •...
Page 75: Options
14. Options 14 Options Open the "Options" menu. Description – Options Symbol Open the "Product" menu. Open the "System" menu. Open the "Peripherals" menu. Open the "Inputs” menu. Open the "Coil" menu. Open the "Usb" (USB stick missing) menu. Open the "Usb" (USB stick plugged in) menu. Page 75 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...
Page 76: Product
14. Options 14.1 Product Open the "Product" menu. Complete overview of the menu items, which can differ in the on the application. Description – Product Symbol Open the "Product management" menu. Open the "Product data" menu. Open the "Teach" menu. Open the "Auditcheck"...
Page 77: Product Management
14. Options 14.1.1.1 Product change Product Product management Product change The product change is described in [see chapter 13, "Product change"]. 14.1.1.2 Create product Product Product management Create product Create product In this menu you can create a new product by entering a product name and a product number. The settings for the current product are adopted when creating a new product.
Page 78 14. Options 14.1.1.3 Delete product Product Product management Delete product Delete product In this menu you can delete an existing product. Product memory Use the position arrows to scroll through the list of already created products. Product selection By tapping on the product line in the product list you can mark one or more products; these are then given a coloured background.
Page 79: Product Data
14. Options 14.1.2 Product data Product Product data Product data This menu displays all the product parameters for the select product. Product parameter selection Use the arrows symbols to scroll through the list of product parameters. The currently set values are displayed.
Page 80: Teach
Conveying speed )* Default depends on operating mode. The product speed can be set at the GENIUS ONE Control Unit. Depending on the application the conveying speed range has defined setting limits. For reliable metal detection the product conveying speed must match the setting at the GENIUS ONE Control Unit.
Page 81: Auditcheck
14. Options 14.1.4.1 Autotest settings Product Autotest Autotest settings If the system is equipped with an optional autotest unit, all the settings described below under <Auditcheck settings>, "Mode" menu, equally apply to the autotest. Like an auditcheck an autotest also can be started manually in homescreen by tapping on the "Test" symbol.
Page 82 14. Options Value range Standard value Unit Group 0…59 Hourly Defines the time for the auditcheck request. 0…23 h Daily 00:00 0…59 min Defines the time for the auditcheck request at the specified hour and minute. 15…540 Interval 0…23 h Interval start time 00:00 0…59 min...
Page 83 14. Options 14.1.4.3 Test samples Product Auditcheck Test samples Test samples In this menu displays you can define the number of test samples you want to use for the auditcheck. A maximum of 5 test samples are possible. Number of test samples Tap on the [+] or [-] symbols to add or remove test samples.
Page 84 14. Options 14.1.4.3.1 Settings for the Auditcheck test sample Test sample 1 The setting mask is the same for all the test samples used. Example: Test sample 1. By tapping on the right side of the corresponding product parameter in the screen mask, the associated setting menu opens.
Page 85 14. Options 14.1.4.4 Auditcheck start Product Auditcheck Auditcheck start If „Error on unsuccessful test“ is not activated, only a logbook entry is made and there is no error displayed in the status area. "Operating" or "Ready" is displayed in the status bar depending on the operating mode.
Page 86 14. Options Confirmation symbol Tapping on the symbol confirms that the current test sample will be skipped. If only 1 test sample was selected for the audit check, the error message "Auditcheck failed“ appears in the status area (see Figure 5). Cancel symbol By tapping on the symbol , the auditcheck is continued with...
Page 87 14. Options Confirmation symbol By tapping on the symbol , the auditcheck is aborted and the error message appears „Auditcheck failed“ (see Figure 5). Cancel symbol By tapping on the symbol , the auditcheck is continued from the point at which the auditcheck was interrupted. Figure 7 If the auditcheck is aborted, or if it was made with the wrong test samples, or if the set time for performing the auditcheck has...
Page 88: Eject
14. Options Error it the test was not successful (error not activated) If the time set for preparing the auditcheck has expired, you will automatically come back to the menu from where the auditcheck was started. An entry is made in this regard in the logbook.
Page 89 14. Options Manual reversing 0.25 … 50.00 Reversing start pos. 0.75 In the "Manual reversing" ejection mode, you can use the "Start Position" settings to set the distance from which the conveyor belt should automatically start to reverse after a metal signal. •...
Page 90 14. Options 14.1.6 Outputs Product Outputs Depending on the operating mode or options, switching outputs may execute explicitly defined functions and are thus not available for an individual setting. The following pages provide an explanation of the basic configuration and settings of the outputs. In Depending on the setting whether all outputs switch independently, more or fewer menu items are available.
Page 91: Outputs
14. Options 14.1.6.1 Output settings Product Outputs Settings The following switching outputs are available at the GENIUS ONE / IO unit. Metal Relay 1 MO 1 - 4, switching output 1, 24 VDC Metal Relay 2 Value range Standard value...
Page 92 “Pipe conveyor“ ON “Liquiscan” Activation of the switching outputs is possible via display function or via a switching signal at the input of the GENIUS ONE Control Unit /IO unit, connector J9, terminal 66 (AM). OFF: No "Manual reject". Latching ON / OFF Latching of the outputs MO/MR (requires manual reset of the metal alarm).
Page 93 14. Options 14.1.6.3 Outputs solenoid valves / Metal relay (independent) Product Outputs MO1 / MR1 // M02 - MO4 // MR2 Depending on the operating mode or options, switching outputs can execute explicitly defined functions and are therefore not available for an individual setting. With the preset "Outputs independent [ ]"...
Page 94: Compliance Mode
14. Options 14.1.7 Compliance mode Product Compliance Mode The compliance mode can only be activated via an associated licence. The compliance mode serves to reduce metal detections while at the same time meeting compliance requirements. This is achieved by setting the sensitivity of the metal detector so that the conveyed test samples are only just detected.
Page 95: Settings
“Pipe conveyor“ OFF “Liquiscan“ After errors, GENIUS ONE Control Unit also switches to the state as in the case of metal. In case of error, switching states additionally as with metal signal. Note: this setting can lead to problems in the conveying line, as material is constantly ejected.
Page 96 14. Options Value range Standard value Unit Group Half wave ON / OFF Half wave ON is necessary if products in conveyor operating mode can stop inside the coil when the belt is stopped, (Stop & Go) or in case of a slow conveying speed. Available only in "Conveyor belt"...
Page 97: System
14. Options 14.2 System Open the "System" menu. Description – System Symbol Open the "User management" menu. Open the "HW monitoring" menu (HW →Hardware monitoring). Open the "Statistics" menu. Open the "Interfaces" menu. Open the "Auditcheck" menu. Open the "Setup" menu. Open the "Factory settings"...
Page 98 14. Options 14.2.1 User management System User management In the user management you can store 75 users in three different user levels. You can freely assign rights to the individual users. The administrator is a special user, as he or she cannot be deleted and his or her rights cannot be changed;...
Page 99 14. Options Password (default) )* 5555 1111 0000 none ✓ ✓ ✓ ✓ User login ✓ ✓ ✓ ✓ Select menu language ✓ ✓ ✓ ✓ Read & filter logbook ✓ ✓ ✓ Manual rejection, test Product management, ✓ ✓ product parameters ✓...
Page 100 14. Options Fig. 2: The permanently assigned User ID is displayed here. User name On tapping the corresponding input box on the right-hand side, a screen mask with a keypad opens in which you can enter a user name. User level On tapping the corresponding input box on the right-hand side, a screen mask opens in which you can select the user level.
Page 101 14. Options Fig. 3: Rights Here you can select which rights the user is granted. Selectable rights: • Product change • Auditcheck settings • Teach • Conveying speed • Unlock reject bin • Delete logbook • Reset error • Rejection options •...
Page 102 14. Options 14.2.1.3 Create user System User management Create user In this screen mask you can add a new user. User name On tapping the corresponding input box on the right-hand side, a screen mask with a keypad opens in which you can enter a user name. User level On tapping the corresponding input box on the right-hand side, a screen mask opens in which you can change the user level.
Page 103 14. Options Rights Here you can select which rights the user is granted. Selectable rights: • Product change • Auditcheck settings • Teach • Conveying speed • Unlock reject bin • Delete logbook • Reset error • Rejection options • Reset metal •...
Page 104 14. Options 14.2.1.5 Copy user System User management Copy Copy user You can select a user who you wish to copy by tapping the row with the user name. The selected user will then be displayed with a coloured background. On tapping the symbol, a screen mask "Create user"...
Page 105: User Management
14. Options Value range Standard value Unit Group Autom. logout ON / OFF The automatic logout is activated. OFF: The automatic logout is deactivated. 0 … 65535 Autom. logout timeout Here you can set the time after which the automatic logout should take place. 14.2.1.7 Create Login2Go Using the Login2Go function, you can create a USB flash drive with corresponding user rights.
Page 106: Hw Monitoring
Info This info menu displays current measurement values such as system voltages and internal temperature in the housing of the GENIUS ONE Control Unit. It also shows information about the current consumption of the CU fan and the system operating hours.
Page 107: Versions
Time of manufacture CU-Hardware 05xxx CU Software V1.xx CU FPGA V0115 If necessary, all the above information may be useful for our Sesotec Service. 14.2.3 Statistics System Statistics Description – Statistics Symbol Open the "Counter" menu. Open the "Metal signal" menu.
Page 108: Metal Signal
14. Options 14.2.3.2 Metal signal System Statistics Metal signal Metal signal ("Metal tracer diagram") In this operating mask, the detector signal is shown over time (timeframe 60 s). Metal signals (signals ≥100) are displayed according to the signal magnitude. A new measured value is displayed every 300 ms and the display area is shifted by one position (scroll function).
Page 109: Settings
14. Options 14.2.3.4 Settings System Statistics Settings Settings Function Press the reset symbol in this menu to reset the current user counter values for fault messages and metal events. Fault Metal User 14.2.4 Interfaces System Interfaces Description – Interfaces Symbol Open the "Network"...
Page 110: Network
14. Options 14.2.4.1 Network System Interfaces Network Value range Standard value Unit Group COMGateway Function )* Default depends on operating mode. Here you can select the functions that are to be started on the COMGateway.Embedded. Disabled: The COMGateway.Embedded is not activated. MQTT: The MQTT client will be started on the COMGateway.Embedded.
Page 111: Wifi
14. Options Value range Standard value Unit Group IP address 255.255.255.255 IP address of the metal detector/separator. Only can be set when static LAN configuration is selected ("DHCP" is OFF). Subnet mask 255.255.255.255 sub netmask, network mask or netmask. Only can be set when static LAN configuration is selected ("DHCP" is OFF). Gateway 255.255.255.255 Standard gateway.
Page 112: Connections
14. Options Value range Standard value Unit Group DHCP ON / OFF DHCP enables connected clients to be integrated into an existing network without manual configuration of the LAN interface. The required data such as IP address, network mask, gateway, … are assigned automatically.
Page 113: Serial I/O
• Insight II • RTE The protocol that is used for the serial interface RS232. More detailed information about these protocols can be found in separate documents. Please contact our Sesotec Support. • 9600 • 19200 • 38400 Baud rate...
Page 114: Sstprot Server
Device address Specifies the identification address for the metal detector/separator. More detailed information about these protocols can be found in separate documents. Please contact our Sesotec Support. Local / Remote Mode ON / OFF If the Local/Remote Mode is activated, communication with the device from an external location is possible, but settings cannot be changed.
Page 115 Unit Group Error when test failed ON / OFF An error is generated if the auditcheck was not successful. The GENIUS ONE Control Unit switches to error state. Only logbook entry. Manual test sample ON / -OFF confirmation After the test sample has been conveyed, it must be checked whether the results are in the set range and whether the test sample complies with the specifications.
Page 116: Setup
14. Options 14.2.6 Setup System Setup Description – Setup Symbol Open the "Identification" menu. Open the "Operation" menu. Open the "Date / time" menu. Open the "Settings" menu. 14.2.6.1 Identification System Setup Identification Figure 2 Figure 1 Page 116 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...
Page 117: Operating
14. Options Identification In this menu you can enter a name for the metal detector/separator according to its application a device name and a name for the production line. Device name (name for the metal detector/separator) Tapping on the right side of the line opens a window in which you can enter the device name. After tapping on the confirmation symbol , the entered device name is saved, and you return to the previous setting menu.
Page 118: Set Date And Time
14. Options 14.2.6.3 Set date and Time System Setup Date / Time Setting of the day Tapping on the right display field (day) opens a menu in which you can enter the day as a number as described in section [section 9.2.5, “Input methods - numeric keypad“]. Tapping on the right display field (month) opens a menu in which you can enter the month as a number as described in section [section 9.2.5, “Input methods - numeric keypad“].
Page 119 14. Options Daylight saving time enabled or disabled If there is a tick in the checkbox, daylight saving time is activated. It can take up to 5 minutes to switch the time indication on the display. Arrow symbols By tapping on the symbols you can scroll the menu up or down.
Page 120: Settings
Setup Settings Figure 1 Figure 2 Settings In this menu you can set various system parameters of the GENIUS ONE Control Unit. Arrow symbols By tapping on the symbols you can scroll the menu up or down. Confirmation symbol Without changing any settings, you can return to the previous menu by tapping on the symbol. If the settings have been changed, tapping on this symbol opens a window with the question “Really...
Page 121 14. Options Value range Standard value Unit Group Brightness 35 - 100 Use this parameter to adjust the brightness of the control panel backlight to the conditions at your workplace environment. Higher Level Security ON / OFF The ejection control and ejection monitoring are activated with this parameter (exists only in conveyor belt operating mode).
Page 122: Factory Settings
14. Options 14.2.7 Factory settings System Factory settings Description – Factory settings Symbol Restore factory settings. When you tap on this symbol, a window opens with the question "Really restore factory settings?". After tapping on the symbol , the factory settings are restored. When you tap on the symbol , you come back to the previous menu.
Page 123: Licensing
14.2.9 Licensing System Licensing Some of the function of the GENIUS ONE Control Unit are not available as standard, but have to be enabled with a licence. You must contact Sesotec Service in order to purchase a licence. Description – Licensing Symbol Open the "Features"...
Page 124: Import
14. Options 14.2.9.3 Import System Licensing Import In order to be able to import a licence, the licence must be generated beforehand in the manufacturer's licence management. In order to import a licence, a USB flash drive containing the required licence file must be plugged into the USB port (J19) on the IO unit.
Page 125: Peripherals
14. Options 14.3 Peripherals Open the "Peripherals" menu. Description – Peripherals Symbol Open the "Reject options" menu. Open the "Monitoring" menu“. Open the "Signal device" menu“. ) Open the "Autotest" menu“. ) Open the "Sluice" menu. ) Open the "Direct outputs" menu. ) Open the "Light barriers"...
Page 126: Settings
14. Options Symbol Description - Ejection Options Call the "Settings" mask. Call the "Ejection Unit" mask. Call the "Ejection Control" mask. ) Call the "Ejection Monitoring" mask. ) Available only in operation mode “conveyor belt” when trigger light barrier is activated. Available only in operation mode “conveyor belt”...
Page 127: Ejection Unit
14. Options 14.3.1.2 Ejection unit Peripherals Reject options Ejection unit Value range Standard value Unit Group • Deactivated • Pusher • Blowing jet Ejection unit Disabled • Retraction belt (type of ejection unit) • Tilting belt • Swivel arm In this menu item, you can set the type of ejection unit. Disabled: No action.
Page 128: Ejection Check
14. Options Value range Standard value Unit Group 0.05…30.00 Duration 0.50 The metal detection serves as the reference point here. The time from the metal signal to the activation of the ejection unit is set here. This setting is used with conveyor belts without a trigger light barrier and requires a constant belt speed.
Page 129: Ejection Monitoring
14. Options 14.3.1.4 Ejection monitoring Peripherals Reject options Ejection monitoring Value range Standard value Unit Group Activate ON / OFF This setting mask is only available if the "Higher Level Security" option ([see section 14.2.6.4, "Settings"]) and the ejection unit ([see section 14.3.1.2,"Ejection unit"]) are activated. With this parameter you can activate the ejection monitoring, which checks whether all products with metal contamination enter the ejection container after a specified time.
Page 130: Flap
14. Options 14.3.2.1 Flap Peripherals Monitoring Flap Value range Standard value Unit Group • Deactivated • One sensor Monitoring mode • Two sensors “Rapid“ )* Default depends on operating mode. One sensor “Pipe Scan“ Disabled “Pipe conveyor“ Disabled “Liquiscan“ Disabled The function of flap reject units can be monitored.
Page 131: Level Monitoring
14. Options 14.3.2.3 Level monitoring Peripherals Monitoring Level monitoring Value range Standard value Unit Group • NPN • PNP Monitoring method • Disabled In this menu item you can set the active level at the switching input. The function requires the connection of a sensor, switching input at connection J7, terminal 37 (FS), see section [see section 7.3.2, „Electrical connections, switching functions, inputs/outputs“],and the activation of the sensor.
Page 132: Light Barriers
14. Options Value range Standard value Unit Group 0.10…5.00 Duration horn 0.50 This parameter defines the ON duration of the horn in case of a metal or fault event. The trigger event can last longer than the time set here (e.g. with a manual metal reset). Tapping on the right display field (Duration horn) opens a menu in which you can enter the duration as a number as described in [see section 9.2.5, „Input methods - numeric keypad.
Page 133: Settings
The light barriers monitoring is identical for all following light barriers. If a light barrier is energised for more than 10 seconds, the GENIUS ONE Control Unit interprets this as an error and displays a corresponding error message for the respective light barrier.
Page 134: Sync Light Barrier
14. Options 14.3.4.3 Sync light barrier Peripherals Light barriers Sync Value range Standard value Unit Group Activate ON / OFF With this setting you can enable the ejection synchronisation with the Sync light barrier. The function, light barrier synchronization is active. OFF: The function, light barrier synchronization is inactive.
Page 135: Autotest
1 … 3 Number of test samples Metal detectors/separators as an option can be equipped with an autotest unit. The GENIUS ONE Control Unit through the IO unit can activate this autotest unit and evaluate the result. The autotest is started depending on the respective settings [see section 14.1.4.1 "Autotest settings"].
Page 136: Sluice
14. Options 14.3.7 Sluice Peripherals Sluice The "Sluice" function is only available in the "Pipe conveyor" operating mode. Ejection time, valve time and delay can be set. Confirmation symbol If you have not changed any settings, you can return to the previous screen mask by tapping this symbol.
Page 137: Direct Outputs
14. Options 14.3.8 Direct outputs Peripherals Direct outputs MO1-MO4, MR1,MR2 Direct outputs • The "Direct outputs" function is activated via the inputs IN1-IN4. • If the "Direct outputs" function is activated, they can be configured for their use. • Outputs that are already assigned to another function are no longer available. 14.3.9 Speed control Peripherals Speed control...
Page 138: Inputs
14. Options 14.4 Inputs Open the "Inputs" menu. Description – Inputs Symbol Open the "External" menu. Open the "Digital" menu. Open the "Configurable" menu. 14.4.1 External inputs Inputs External Value range Standard value Unit Group External inputs ON / OFF To activate some functions external inputs are also available.
Page 139: Digital Inputs
Function Disabled • Product change Digital inputs (DI1- DI4) are available on the GENIUS ONE Control Unit, IO unit. In this menu item you can set the active level for the switching inputs. Product change: Possible through external signal combination at inputs DI1 - DI4. Allows a product to be selected from 16 stored products (see table).
Page 140: Configurable Inputs
Group Activate ON / OFF Four switching inputs are available on the GENIUS ONE Control Unit IO-unit (IN1 – IN4). These inputs are configurable for the sensors PNP / NPN in use. Connection J10, Terminal 94 (IN1) Connection J10, Terminal 86 (IN2)
Page 141 14. Options Belt stop A sensor can additionally be configured for the conveyor belt stop (only active in conveyor belt operating mode). Direct outputs With the "Direct outputs" function, the outputs MO1 – MO4 can be configured directly with the inputs IN1-IN4.
Page 142: Coil
Currently set deviation of the operating frequency from standard value "0". The frequency deviation can be set in steps within the factory-preset limits. The preset values only should be changed after having consulted our Sesotec Service. Page 142 of 163...
Page 143: Usb
"Import“ By tapping this menu symbol, all system settings or product data stored on a USB stick can be imported into the GENIUS ONE Control Unit. "Login2Go" By tapping on this menu symbol you can create a Login2Go USB stick.
Page 144 . Selected data are displayed with an activated checkbox . Tapping on the symbol again deletes the activation. All system data is transferred from the USB stick to the GENIUS ONE System data: Control Unit. All product data is transferred from the USB stick to the GENIUS Product data: ONE Control Unit.
Page 145: Create Login2Go
The user level is installed copy-protected on the USB flash drive. If a "Login2Go" flash drive has been created successfully, you can log into the GENIUS ONE by simply plugging the USB flash drive into the existing USB socket (J19) on the IO-board without having to enter your username and password beforehand.
Page 146: Metal Detector/Separator In Quality Assurance
16. Errors and fault rectification 15 Metal detector/separator in quality assurance It is essential that the proper function of the metal detector/separator is checked in regular intervals. For this purpose it must be checked whether one or several reference test samples are correctly detected and rejected.
Page 147 System errors are errors that are triggered by the self-monitoring function of electronic components used in the GENIUS ONE Control Unit (IO unit, CU board). These electric components are shown in the spare parts list with their respective designation and their Sesotec article number.
Page 148 16. Errors and fault rectification 16.1.4 GENIUS ONE - Machine / application errors WARNING Personal damage due to impact, pinching, or crushing. ➢ Make sure you disconnect the compressed-air supply before you perform any work on the reject unit. ➢ Vent the compressed-air line.
Page 149 16. Errors and fault rectification Error message Cause Action The door of the reject bin is Empty the ejection container. Reject bin open or damaged. Check sensor/cable.. Sensor/cable is defective Product jam in the area of the Eliminate product jam. Check light Trigger LB monitoring * light barrier at the inlet of the barrier and connection cable.
Page 150: Replacing Genius One Control Unit Boards
➢ Cleanse the housing of dirt and moisture before opening it so that nothing can get inside. ➢ Before you open the electronics housing of the GENIUS ONE Control Unit, always make sure that no mains or external voltage is connected.
Page 151 16.2.1 Replacing main assemblies on the attached GENIUS ONE Control Unit 16.2.1.1 Replacing the CU board Turn off the power supply and any external circuits on the GENIUS ONE Control Unit. Remove the fastening screws (6) and open the cover of the electronics housing.
Page 152 16.2.2 Replacing main assemblies on the remote GENIUS ONE Control Unit 16.2.2.1 Replacing the CU board 1. Turn off the power supply and any external circuits at the GENIUS ONE Control Unit. 2. Undo the fastening screws of the cover of the connection compartment of the detection coil and carefully remove the cover.
Page 153: Replacing Sub-Components
If this data memory is installed on the new IO unit, no further settings will be required at the machine, and GENIUS ONE Control Unit will continue to run as before. Buffer battery The buffer battery keeps date and time data when the GENIUS ONE Control Unit is without power supply. Page 153 of 163...
Page 154 Date and time settings will be lost when the buffer battery is replaced. In case of the installed version of the GENIUS ONE Control Unit the CU board must first be removed, because the buffer battery is placed directly under it on the IO unit and is thus not directly accessible.
Page 155 16. Errors and fault rectification 16.3.3 Internal fuse Fuse value: See technical data sheet "GENIUS ONE Control Unit". Remote and attached GENIUS ONE Control Unit: Procedure: 1. Turn off the power supply and any external circuits on the GENIUS ONE Control Unit.
Page 156: Maintenance, Cleaning And Repairs
➢ Maintenance work such as replacing the battery or replacing signal elements may only be performed when the system has been turned off. Maintenance work on the GENIUS ONE Control Unit only may be performed by a trained electrician with due observation of attached warning signs and in accordance with standard rules of electrical engineering.
Page 157 • Cleaning oil for metal surfaces. 17.2.2 Care advice for stainless steel Only high-quality stainless steel is used in Sesotec systems. To prevent rust on the high-grade steel parts do not use substances containing chloride (e.g. cleaning or disinfecting products) or operate the machine in an atmosphere containing chloride.
Page 158: Repair Work
• In case of repair work, or when replacing spare or wearing parts, only original parts from Sesotec may be used. • If any unauthorised modifications are made to the GENIUS ONE Control Unit, any guarantee, warranty and liability claims against Sesotec GmbH in case of resulting personal injury and/or property damage are excluded.
Page 159: Spare Parts
➢ In case of repair work, or when replacing spare or wearing parts, only original parts from Sesotec may be used. • If any unauthorised modifications are made to the GENIUS ONE Control Unit, any guarantee, warranty and liability claims against Sesotec GmbH in case of resulting personal injury and/or property damage are excluded.
Page 160: Decommissioning, Preservation, Shipping And Waste Disposal
Danger of electric shock in the electronics housing of the GENIUS ONE Control Unit. ➢ Make sure that the GENIUS ONE Control Unit is not energised by mains or external voltage before you start any decommissioning, preservation, shipping and waste disposal work.
Page 161: Shipping
19. Decommissioning, preservation, shipping and waste disposal 19.3 Shipping The GENIUS ONE Control Unit is a part of Sesotec metal detectors/separators. WARNUNG Personal or transport damage due to tipping, falling, or dropping parts of systems or machines. ➢ Make sure you use lifting/transport devices with sufficient lifting capacity.
Page 162: Waste Disposal
19. Decommissioning, preservation, shipping and waste disposal. Shipping methods: • National shipment National shipments, depending on the size, weight and nature of the goods, must be packed in cardboard boxes, paltainers, boxed pallets etc. in a manner suitable for road transport. Electrostatic sensitive components (electronic boards, electronic modules, etc.) must be packed in antistatic foil or foil bags.
Page 163: Annex
20. Annex 20 Annex • Technical data sheet • Spare parts drawing for GENIUS ONE Control Unit Accessories: • UL/CSA certificate • Option data sheets Page 163 of 163 GENIUS-ONE-BA-CU-EN-3211.docx...

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