DATA Count and Fill S 60

Transcription

1 DATA Detection Technologies Ltd. DATA Count and Fill Series DATA Count and Fill S 60 Operation and Maintenance Manual April 2012

2 PROPRIETARY AND CONFIDENTIAL Copyright 2010 by Data Technologies Ltd. All rights reserved. No part of this manual may be reproduced or copied in any form by any means- graphic, electronic, or mechanical, including photocopying, typing or information retrieval systems- without written permission of Data Detection Technologies Ltd. DATA Detection Technologies Ltd. 12 Hartom St., Har Hotzvim, Jerusalem 97775, Israel Telephone: (+972) Fax: (+972) DATA Technologies Ltd.

3 Safety Information SAFETY INFORMATION DATA Detection Technologies Ltd. believes that the safety of personnel working with and around our Systems is the most important consideration. Please read all safety information in this Operations and Maintenance manual before attempting to operate the System or perform any maintenance function. Identification and Warning labels are used to assist with identifying and classifying the System (see chapter 15). Hazards Electrical The DATA Count and Fill system is connected to high voltage (115 / 230 VAC). Laser Safety Precautions The DATA Count and Fill S-60 Detection unit is classified as Class 3B. However, the system is classified as Class 1; not requiring usage of protection means during standard system operations (see chapter 15). Moving Parts The DATA Count and Fill automatic systems are equipped with rotating parts. For your safety, always work with all covers closed. Be careful not to have any loose objects that may get caught by any of the moving parts. DATA Count & fill S 60 i

4 Safety Information Safety Features The DATA Count and Fill system can be equipped with an Emergency Stop button. This is a system configuration option, available upon request. Use the Emergency Stop button to immediately stop all system operation, preventing potential harm to you or the system. The Emergency Stop button is located on the system front panel. See chapter 3, section 3.1. To perform an emergency stop: Press the red Emergency Stop button. This will stop all system activity and cut off power to the system. To regain power after an emergency stop: Pull out the Emergency Stop button. ii DATA Technologies Ltd.

5 Safety Information Warnings 1. Obey and follow all warnings and cautions given in this manual. 2. Comply with all approved and established precautions for operating electrical and mechanical equipment. 3. All maintenance tasks should be performed only by trained, authorized personnel. 4. Verify that the power supply is turned off before beginning any maintenance procedure, replacement, or repair of parts (including insertion or removal of connectors). 5. When an Uninterruptible Power Supply (UPS) is connected, turn it off before beginning any system maintenance procedure. 6. When performing maintenance or service to the System, which may require working without the protective housing, protecting eyewear of at least OD 2.5 for 780 nm must be used. DATA Count & fill S 60 iii

6 Conventions CONVENTIONS The Conventions section explains basic symbols and navigation concepts used in this manual, including a glossary of abbreviations and acronyms. Symbols The following symbols have been inserted on the lefthand side of the text to assist in identifying notes, warnings, and procedures: Table 1. Symbols Symbol Description Note: Information describing the DATA Count and Fill S 60 functions. Caution: Information referring to the safe operation of the Data Count and Fill system. A Caution can also be a warning against the possibility of data loss or damage to the equipment. Danger: Information that warns of possible hazards to personnel and extreme hazards to the system. iv DATA Technologies Ltd.

7 Conventions Abbreviations and Acronyms A... Ampere bar... Bar (1 bar = 14.5 psi=0.1 Mpa) cc... Cubic centimeter cm... Centimeter CSV... Comma-Separated Value Format GUI... Graphical User Interface Hz... Hertz (frequency) IPA... Isopropyl alcohol l... Liter mm... Millimeter psi... Pounds per Square Inch UPS... Uninterruptible Power Supply V... Volts VAC... AC Voltage VDC... DC Voltage W... Watt µ... Microns DATA Count & fill S 60 v

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9 TABLE OF CONTENTS Table of Contents Safety Information... i Conventions... iv 1 Introduction System Description and Overview Standard Features and Options Counting Methods Carousels Touch Panel PC Getting Started Before You Begin System Description Main Hardware Subsystems Graphical User Interface and Controls Operation Workflow Setup Requirements Installation Notes Uninterruptible Power Supply (UPS) Operating the System Powering the System Up Powering the System Down Launching the Application Job Setup Selecting the User Selecting the Object Setting the Number of Objects per Bag Setting the Number of Bags DATA Count & fill S 60 vii

10 Table of Contents 6.2 Adjusting the System for the filling Bags Counting Loading Bags into the Carousel Counting Process Pausing the Count Aborting the Count Reports Viewing All Reports System Operation Messages Feeding Funnel Messages Bag Not in Place Counting Timeout Error Special Action and Operations Empty the Hopper Free Count Pausing the Free Count Advanced Settings Object Type Setup Enter new Object Duplicate an Object Edit and Object Object Parameters Calibration Parameters Calibration General Parameters User Name Setup Main System Parts Troubleshooting Application Error Messages Maintenance viii DATA Technologies Ltd.

11 List of Tables 12.1 Cleaning the System Cleaning the Feeding Path Pneumatic Unit Pressure Setting Inspection Periodic Filters Maintenance System Specifications Glossary Appendix A: Laser Safety LIST OF TABLES Table 1. Symbols... iv Table 2. System troubleshooting Table 3. System error messages Table 4. Periodical maintenance Table 5. Pneumatic unit filters DATA Count & fill S 60 ix

12 List of Figures LIST OF FIGURES Figure 1. System general view... 2 Figure 2. Main subsystems... 5 Figure 3. On/Off pushbutton... 8 Figure 4. Application screen... 9 Figure 5. Reconnect screen... 9 Figure 6. Home screen Figure 7. Exit screen Figure 8. Job Setup screen Figure 9. User name list screen Figure 10. Object type list screen Figure 11. Number of objects per bag screen Figure 12. Number of bags screen Figure 13. Filled batch count job setup screen Figure 14. Adjusting the carousel height Figure 15. Inserting bags screen Figure 16. Inserted bags confirmation screen Figure 17. Ready to count (Disengage) Figure 18. Counting screen Figure 19. Counting confirm screen Figure 20. Counting confirm screen only odd bags Figure 21. Remove bag message screen Figure 22. Confirm after removal screen Figure 23. Bags removed screen Figure 24. Bags removed screen Figure 25. Job Done summary screen Figure 26. Counting pause screen x DATA Technologies Ltd.

13 List of Figures Figure 27. Counting abort screen Figure 28. View report screen Figure 29. Batch report screen Figure 30. Move funnel left Figure 31. Move funnel right Figure 32. Place bag screen Figure 33. Counting timeout error Figure 34. Empty Hopper screen Figure 35. Free count screen Figure 36. Free count pause screen Figure 37. Free count bag done screen Figure 38. Advanced setting screen Figure 39. Object type setup screen Figure 40. New object name screen Figure 41. Calibration directions screen Figure 42. Duplicate confirmation screen Figure 43. Edit object screen Figure 44. Remove object confirmation screen Figure 45. Calibration screen Figure 46. Hopper and gate Figure 47. Calibration speed screen Figure 48. Objects layer through Vibration Chute Figure 49. Calibration Size screen Figure 50. Calibration stopping screen Figure 51. Calibration stopping test screen Figure 52. Calibration stopping test screen Figure 53. Advanced calibration screen Figure 54. Edit object screen DATA Count & fill S 60 xi

14 List of FiguresError! No text of specified style in document. Figure 55. General parameters screen Figure 56. General parameters modifying screen Figure 57. User Name Setup screen Figure 58. User Name Setup screen Figure 59. System feed path parts Figure 60. Feed funnel (Funnel) Figure 61. Feed pipe Figure 62. Pneumatic sub-system Figure 63. Releasing the Vibration Chute Figure 64. Class 1 label Figure 65. Class 3B label xii DATA Technologies Ltd.

15 Introduction 1 INTRODUCTION The DATA Count and Fill is a system that counts small particles such as vegetable seeds, automatically filling bags according to a defined number of bags and number of seeds per bag. The DATA Count automatic filling series is available in two models: DATA Count and Fill S 25 DATA Count and Fill S 60 This Manual describes the Operation and Maintenance procedures for the DATA Count and Fill S 60 model, configured with one carousel. Caution: When working with the DATA Count and Fill systems in countries where the power supply may not be stable, the PC should be connected to a UPS. See section 4.2 for details. DATA Count & fill S 60 1

16 Introduction 1.1 System Description and Overview Figure 1. System general view The DATA Count and Fill S 60 accurately and quickly counts a large number of small objects, automatically filling bags. The system can count objects from 1 mm to 25 mm, at a counting speed of up to six bags per minute, each containing one thousand tomato seeds, and at an accuracy of up to 99.9%. It has a user friendly application interface and is easy to understand and operate. Maintenance is simple and straight forward, requiring a very short downtime. 2 DATA Technologies Ltd.

17 Introduction 1.2 Standard Features and Options Counting Methods The DATA Count and Fill S 60 system is an automatic system, counting in Batch count mode: Bags are filled according to a defined number of objects per bag, and according to the required number of bags. Note: After the Batch count is complete, the remaining objects in the Hopper can be counted in a Free count mode. See section 8.2 for details Carousels The DATA Count and Fill S 60 is equipped with one carousel, holding up to 30 bags, providing continuous counting and filling of bags Touch Panel PC The system has a small touch panel PC, allowing saving and later analyzing the counting data. Note: The DATA Count software is protected by a software protection dongle connected to the touch panel PC USB port. If this security device is not connected, the DATA Count software will not launch. The dongle also provides the information related to the system type when launching the application. DATA Count & fill S 60 3

18 Getting Started 2 GETTING STARTED 2.1 Before You Begin Before you begin working with the DATA Count and Fill S 60 system, read the following: The safety instructions. This manual the DATA Count and Fill S 60 System Operational and Maintenance Manual explains how to work with system; where, when and when to perform operations. The Maintenance chapter this chapter provides basic installation requirements for system proper operation, and periodical maintenance procedures. The Conventions section - explains the standards used in this manual and simplifies identifying, understanding, and performing procedures. The Glossary section explains the technical terms used in describing the system, and system functions. Use the glossary as a reference while working with the manual. Before you begin a procedure: Read the procedure through to the end. Thorough understanding of the entire procedure prevents unnecessary errors and loss of time. 4 DATA Technologies Ltd.

19 System Description 3 SYSTEM DESCRIPTION When describing the DATA Count and Fill S 60 system, it is easy to divide the system into two sections. The Hardware The Graphic User Interface 3.1 Main Hardware Subsystems Touch-Panel PC Detection unit Carousel Funnel Figure 2. Main subsystems Note: Each of the carousel ducts has a number engraved next to it on the carousel top surface. These numbers reflect the bag number being filled. DATA Count & fill S 60 5

20 System Description 3.2 Graphical User Interface and Controls The DATA Count and Fill S 60 is controlled by the DATA Count application, running on a touch panel PC. All user operations are performed through the touch panel, as described throughout the manual. 3.3 Operation Workflow 1. Fill the hopper with the objects to be counted. 2. Insert filling bags into the carousel. 3. Go to the Job Setup screen. a. Select the USER NAME. b. Select the OBJECT TYPE. c. Select NUMBER OF OBJECTS PER BAG. d. Select NUMBER OF BAGS. 4. Press Engage. a. Counting begins. b. Carousel completes counting. 5. Press CONFIRM and remove full bags. If number of bags is more than 30, insert new empty bags, and press ENGAGE to continue counting. 6. After the defined number of bags are filled, choose one of the options: DONE, to complete the job. BATCH REPORT, to view the Batch report. EMPTY HOPPER, for Free Count. 6 DATA Technologies Ltd.

21 Setup Requirements 4 SETUP REQUIREMENTS 4.1 Installation Notes Before installing the DATA Count and Fill S 60, verify the installation requirements, as specified in the Installation guide, are fully met. Following are the requirements and important notes for best performance of the DATA Count and Fill S Verify the system is positioned on a stable and level table or surface. 2. Ensure airflow supply for protecting the detector unit is free of dust and debris. Caution: The air regulator should be set to provide a pressure of 0.1 bar. 3. Check there is enough space around the system for powering it on and off, for filling the Hopper and adjusting the Gate, and for inserting and removing bags from the carousels. 4.2 Uninterruptible Power Supply (UPS) In countries where the power supply may not be stable, the DATA Count PC should be connected to an Uninterruptible Power Supply (UPS). The PC UPS assures that in case of an abnormal system stopping (as a power failure) the computer still has an independent power input, allowing to shut down properly. Note: If the system will be shut down for a long period, manually turn off the UPS. DATA Count & fill S 60 7

22 Operating the System 5 OPERATING THE SYSTEM Following are the procedures for powering the DATA Count and Fill S 60 system up and down. Note: Verify the air supply is connected to the DATA Count S-60 Pneumatic unit, and that the supplied pressure is set to 0.1 bar. For setting, see section Powering the System Up Press the On/Off pushbutton on the electric box left side panel. On / Off pushbutton Figure 3. On/Off pushbutton The pushbutton will light in green, the touch panel PC will turn on, and after about 30 seconds the following screen will show for about 2 seconds. 8 DATA Technologies Ltd.

23 Operating the System Figure 4. Application screen If the application does not identify the detection unit, the following error message appears. To reconnect: Figure 5. Reconnect screen 1. Verify the USB cable is connected, and that the counting head power cable is connected. 2. Press RECONNECT. After the system is connected and the application starts, the Home screen appears. DATA Count & fill S 60 9

24 Operating the System Figure 6. Home screen The Home screen is the main screen for all system operations. Note: The application software version and the DSP version appear on the lower right corner of the screen. 10 DATA Technologies Ltd.

25 Operating the System 5.2 Powering the System Down 1. Press Exit (X) in the upper right corner of the application home screen. Figure 7. Exit screen 2. Press OK to confirm application exit. 3. Power off the touch panel PC (Start Turn Off Computer). Wait for the PC to completely power down. 4. Press the On/Off pushbutton on the left side panel of the electric box. DATA Count & fill S 60 11

26 Launching the Application 6 LAUNCHING THE APPLICATION After powering up, the opening screen changes to the Home screen and you are ready to work with the DATA Count and Fill S 60 to count your objects. Counting with the DATA Count and Fill S 60 is performed in a Batch mode count: Bags are filled according to a defined number of objects per bag and number of bags. Note: The ABORT tab appears in the upper right corner of many screens. Press Abort to exit the stage you do not want to proceed with. Changes will not be saved. Note: The EMPTY HOPPER tab appears in the lower left corner of many screens. See section 8.1, for Empty the Hopper operation. 12 DATA Technologies Ltd.

27 Launching the Application 6.1 Job Setup Press JOB SETUP on the Home screen (Figure 6). The Job Setup screen appears. Figure 8. Job Setup screen When setting up a new job, the following elements are defined: User name Object type Number of objects per bag Number of bags DATA Count & fill S 60 13

28 Launching the Application Selecting the User Note: The User Name is important for the reports and data collection. To select a user: 1. Press USER. A list of user names appears. Figure 9. User name list screen 2. Scroll with the Up/Down arrows to find your name. The Names are listed alphabetically. See section 9.4, on how to add or delete a user. 3. Select the desired user name. 14 DATA Technologies Ltd.

29 Launching the Application Selecting the Object To select an object: 1. Press OBJECT TYPE. A list of objects appears. Figure 10. Object type list screen 2. Scroll with the Up/Down arrows to find the object to be counted. The Objects are listed alphabetically. See section 9.1, on how to define a new object or delete an existing object. 3. Select the required object type. 4. Set the gate height according to the gate height value written on the object type tab (see Figure 10). DATA Count & fill S 60 15

30 Launching the Application Setting the Number of Objects per Bag To set the number of objects per bag: 1. Press NUMBER OF OBJECTS PER BAG, and enter the required number. Figure 11. Number of objects per bag screen Press back to correct the number. Press to cancel. 2. Press OK to complete. 16 DATA Technologies Ltd.

31 Launching the Application Setting the Number of Bags To set the number of bags: 1. Press NUMBER OF BAGS, and enter the required number. Note: Although the carousel can hold up to 30 bags, the number of bags for a job can be set to a larger number. Figure 12. Number of bags screen Press back to correct the number. Press to cancel. 2. Press OK to complete. Once all required fields are filled, the RUN tab on the lower right corner of the screen is enabled (Figure 13). Note: Filling bags with a large number of objects may cause interference between adjacent bags. If the entered value for NUMBER OF OBJECTS PER BAG is larger than 10,000, the user can select if to count and fill only the uneven bags in the carousel. DATA Count & fill S 60 17

32 Launching the Application Figure 13. Filled batch count job setup screen Press OK, for filling only the odd numbered bags. Press WITHOUT SKIPPING, for filling all bags in the carousel. 18 DATA Technologies Ltd.

33 Launching the Application 6.2 Adjusting the System for the filling Bags The DATA Count and Fill S 60 supports various sizes of bags that can be placed in the carousel. To adjust the carousel bag holder: See Figure 14 for reference. 1. Insert a bag into the carousel holder. 2. Carefully release the carousel locking lever. 3. Release the carousel orientation screw. 4. Raise or lower the carousel to a height where the carousel duct is about 20 mm in the bag (supporting the bag in-place). 5. Tighten the carousel orientation screw. 6. Firmly lock the carousel locking lever. Locking lever Orientation screw Carousel duct Bag position Figure 14. Adjusting the carousel height DATA Count & fill S 60 19

34 Launching the Application 6.3 Counting Note: Before beginning the counting process, slide the feeding funnel (Funnel) left, so it's above the carousel. The RESUME button will become enabled only after the feeding funnel is moved to the left Loading Bags into the Carousel To load filling bags: 1. Press RUN on the Job Setup screen (see Figure 8). The Counting screen appears. Figure 15. Inserting bags screen 2. Rotate the carousel with the rotation keys, inserting the required number of bags into the carousel, starting from bag #1. 3. Press ENGAGE when all bags were inserted. The Counting screen is replaced with a screen asking if the bags were inserted. 20 DATA Technologies Ltd.

35 Launching the Application Figure 16. Inserted bags confirmation screen 4. Press OK. The carousel will rotate so that bag #1 is under the funnel, and counting will begin. Note: After filling the carousel with bags and pressing ENGAGE, the DISENGAGE button will be enabled. Pressing DISENGAGE enables the carousel rotating buttons for adding or removing bags (see Figure 17). Figure 17. Ready to count (Disengage) DATA Count & fill S 60 21

36 Launching the Application Counting Process The DATA Count and Fill S 60 counts in Batch count mode, during which bags are filled according to the number of objects per bag and number of bags values, preset during Job Setup. The Counting screen appears, showing the amount of objects being counted in each bag. Figure 18. Counting screen Note: Counts in red are out of the allowable counting tolerance, or had an operational error. See section 9.2, for object parameters calibration. See following for details on how to deal with red counts. Note: The counting can be paused during the counting process. See section for details. The counting process will continue until all bags in the carousel are filled. If more than 30 bags were defined for the NUMBER OF BAGS, load the carousel again until the set number of bags is filled 22 DATA Technologies Ltd.

37 The Counting confirm screen appears. Launching the Application Figure 19. Counting confirm screen Note: Before pressing CONFIRM, it is recommended to first remove bags with counts marked in red or rejected. If the NUMBER OF OBJECTS PER BAG was larger than 10,000, and the user selected to count and fill only the uneven bags in the carousel, the following screen will appear. Figure 20. Counting confirm screen only odd bags DATA Count & fill S 60 23

38 Launching the Application To remove counts marked in red from the carousel: 1. Select and press the count you want to remove. The REMOVE BAG message appears. Figure 21. Remove bag message screen 2. Press OK to remove. The carousel will rotate, bringing the bag to be removed in front of you for easy removal. 3. Repeat this action for all bags you want to remove. The remove rejected bags confirmation screen appears. 24 DATA Technologies Ltd.

39 Launching the Application Figure 22. Confirm after removal screen 4. Press CONFIRM to continue. The bags removed screen appears. Figure 23. Bags removed screen 5. Press REMOVED to continue. The Confirm after removal screen will appear. DATA Count & fill S 60 25

40 Launching the Application 6. Press OK. Figure 24. Bags removed screen If the count job is not complete, the Inserted bags confirmation screen (Figure 16) appears to continue counting. If the count job is complete, the Job Done summary screen appears. Note: After removing a bag from the carousel, the count of the removed bag will become empty and the BAGS DONE value (top of screen) will be updated accordingly. 26 DATA Technologies Ltd.

41 Launching the Application Figure 25. Job Done summary screen 7. Select one of the following actions: BATCH REPORT, to view the report. See section for Batch count reports. DONE, to start a new counting process. The Job Setup screen appears. FREE COUNT, to count the remaining objects in the hopper into the Empty Hopper container. See section 8.1 for details. HOME, to go to the Home screen. DATA Count & fill S 60 27

42 Launching the Application Pausing the Count The counting can be paused at any time during the counting process. This is done for inspection or for performing any other required action. To pause the count: 1. During the counting process, press PAUSE. The counting process will pause. The Batch Count pause screen appears. Figure 26. Counting pause screen 2. Do one of the following: Press RESUME to continue the counting. Press ABORT to stop the counting. The count will be rejected. 28 DATA Technologies Ltd.

43 Launching the Application Aborting the Count The ABORT button is active on many of the counting screens. Pressing ABORT will exit from the current stage, and the last count will be presented as REJECTED. To abort the count: 1. Press ABORT to stop the counting. The Abort confirmation message will appear. Figure 27. Counting abort screen 2. Do one of the following: Press OK to abort. Press CANCEL to continue. DATA Count & fill S 60 29

44 Launching the Application 6.4 Reports The reports allow viewing various counting parameters. Note: The Reports are saved in CSV format on the system touch panel PC, and can be opened by Microsoft Excel. C:\Programm Files\DATA Technologies\DATA Count&Fill \Statistics There are two paths for viewing Batch count reports: From the Job Done summary screen, see section From the Home screen, see section Viewing All Reports To view reports: 1. Press VIEW REPORTS on the Home screen. The View Reports screen appears. Figure 28. View report screen The reports are listed in a chronological order, with the last count on the top. 30 DATA Technologies Ltd.

45 Launching the Application Note: Counts in red are counts that were Aborted by the user. 2. Select the report you want to view from the list. 3. Press INSPECT BATCH. The Batch Report screen appears, showing the count details. Figure 29. Batch report screen 4. After reviewing, press DONE. The View Reports screen appears. DATA Count & fill S 60 31

46 System Operation Messages 7 SYSTEM OPERATION MESSAGES 7.1 Feeding Funnel Messages MOVE FUNNEL LEFT - appears when attempting to rotate the carousel when the feeding funnel is on the right side (above the feed pipe). Figure 30. Move funnel left MOVE FUNNEL RIGHT - appears if the feeding funnel is not on the right, before performing one of the following: Empty Hopper Free Count Calibration Figure 31. Move funnel right 32 DATA Technologies Ltd.

47 System Operation Messages 7.2 Bag Not in Place The carousel uses a sensor for detecting the presence of a bag in the filling location before starting to fill. If the sensor does not detect the presence of a bag, the following screen appears: To place a bag: Figure 32. Place bag screen 1. Insert a bag into the counting location of the carousel. Once the bag is inserted and detected, the RESUME button will become enabled. 2. Do one of the following: Press RESUME to continue the counting. Press ABORT to skip this bag. The count result for the missing bag will read REJECTED in red. DATA Count & fill S 60 33

48 System Operation Messages 7.3 Counting Timeout Error If during the counting process, the detection unit does not detect any object passing for over 1 minute, the following error message appears: Figure 33. Counting timeout error 1. Check and fix the cause. 2. Press OK. 34 DATA Technologies Ltd.

49 Special Action and Operations 8 SPECIAL ACTION AND OPERATIONS 8.1 Empty the Hopper This operation empties all objects from the hopper into a bag connected to the feed pipe or into a container placed under the feed pipe, without counting. To empty the Hopper: 1. Place the bag or container in its place. Raise the gate for faster flow (see Figure 46). 2. Press EMPTY HOPPER. An Empty Hopper confirmation screen appears. Figure 34. Empty Hopper screen 3. Press OK to empty all the Objects from the hopper into the container, without counting. 4. Press DONE when complete. DATA Count & fill S 60 35

50 Special Action and Operations 8.2 Free Count The free count operation counts all objects from the hopper into a bag or into a container. This operation is mainly performed after the job is done, counting the remaining objects from the hopper. To perform a Free Count: 1. Connect a bag or place a container at the feed pipe exit. 2. Press FREE COUNT from the Job Done summary screen (Figure 25). The counting screen appears, showing the amount of counted objects. Figure 35. Free count screen The counting process will continue until the counting is paused. Note: Pausing in the Free count mode is an action used for both pausing and stopping the count. 36 DATA Technologies Ltd.

51 Special Action and Operations Pausing the Free Count To pause the count: 1. Press PAUSE. The counting process will pause. The Free Counting pause screen appears. Figure 36. Free count pause screen 2. Do one of the following: Press RESUME to continue the counting. Press ABORT to stop the counting. The Free count Bag Done screen appears. DATA Count & fill S 60 37

52 Special Action and Operations Figure 37. Free count bag done screen 3. Press FINISH BATCH. The Summary screen appears (Figure 25). Note: If the Free count is stopped by the Abort button, it will be presented in red on the Report screen. 38 DATA Technologies Ltd.

53 Advanced Settings 9 ADVANCED SETTINGS Note: The DATA Count and Fill S 60 system is calibrated at the factory. The default parameters are the best parameters found for the specific system and for the tested objects. The Advanced Settings screen is reached from the Home screen (Figure 6), making it possible to perform the following: OBJECT TYPE SETUP. USER NAME SETUP. GENERAL PARAMETERS: viewing and modifying. Figure 38. Advanced setting screen Note: The calibration processes are performed with the objects counted into the Empty Hopper Container. Verify the Empty Hopper Container is in its place. DATA Count & fill S 60 39

54 Advanced Settings 9.1 Object Type Setup The Object Type Setup allows the user to: Enter a new object. Duplicate an existing object. Edit parameters of an object. Delete an object. Figure 39. Object type setup screen Note: The Objects are listed alphabetically. 40 DATA Technologies Ltd.

55 Advanced Settings Enter new Object When adding an object, its parameters need to be defined through the calibration process for use during counting. To enter a new object: 1. Press on ENTER NEW OBJECT. The Object Type Setup screen appears. Figure 40. New object name screen 2. Type the object name. Press back to correct the name. Press to cancel. 3. Press OK to confirm. The Calibration directions screen appears. DATA Count & fill S 60 41

56 Advanced Settings Figure 41. Calibration directions screen 4. Follow the directions in section 9.2, Object Parameters Calibration. 42 DATA Technologies Ltd.

57 Advanced Settings Duplicate an Object When duplicating an object, all object parameters and calibration values will be used for the duplicated object under a new object name. This reduces the need to calibrate a similar object type. To duplicate an object: 1. Press the object type. 2. Press DUPLICATE. A confirmation screen appears. Figure 42. Duplicate confirmation screen 3. Press OK to confirm, or CANCEL to abort. 4. Type a name for the duplicated object (see 9.1.1). DATA Count & fill S 60 43

58 Advanced Settings Edit and Object Editing an object allows changing object parameters without the need to create a new object. To edit an object: 1. Press the object type. 2. Press EDIT. The Edit Object screen appears. Figure 43. Edit object screen 3. Select the parameter to edit. The Calibration directions screen appears. See Figure Follow the directions in section 9.2, Object Parameters Calibration. Note: When editing an object parameter, pressing NEXT in the Calibration screen goes directly to the Calibration screen of the selected parameter. 44 DATA Technologies Ltd.

59 Advanced Settings To remove an object: Note: Objects can be removed only from the Edit Object screen. 1. Press REMOVE OBJECT. A confirmation screen appears. Figure 44. Remove object confirmation screen 2. Press OK to confirm. DATA Count & fill S 60 45

60 Advanced Settings 9.2 Object Parameters Calibration When creating a new object, or when editing an object from a list, the last action will open the Calibration screen. Figure 45. Calibration screen The Calibration process finds the best parameter values to ensure optimal counting speed and accuracy. Follow the preliminary actions: 1. Close the hopper gate (loosen the knob and lower it all the way down). 46 DATA Technologies Ltd.

61 Advanced Settings Gate Hopper Vibration chute Figure 46. Hopper and gate 2. Fill the Hopper with the required objects. Note: For best parameter calibration, make sure the objects are clean and undamaged. Fill the hopper with as many objects as possible. 3. Place the container in its place. 4. Press NEXT to enter the Calibration screen. The selected calibration parameter subtitle is highlighted. DATA Count & fill S 60 47

62 Advanced Settings Figure 47. Calibration speed screen Parameters Calibration To prepare the system for calibration: Raise the gate until the objects passing through the vibration chute are in one layer. See following Figure 48. Good (1 layer) Bad (more than 1 layer) Seeds Figure 48. Objects layer through Vibration Chute 48 DATA Technologies Ltd.

63 Advanced Settings Speed Calibration Speed calibration process sets the optimal count speed. To calibrate the speed: 1. Press TEST. 2. Watch the objects passing through the vibration chute, and look at the object count rate presented on the screen. 3. Manually raise or lower the gate to a height that ensures the objects passing through the object chute are in one layer (see Figure 48). 4. Check the objects flowing through the object chute and view the count rate on the Calibration screen. 5. Modify the frequency value (using the Up/Down arrows), finding the optimal values that will provide the smoothest passing of objects and the best count rate. Note: The Duty Cycle parameter also has an influence on the flow. However, do not modify this parameter. 6. After optimizing, press STOP TESTING. 7. Record the gate height value on the ruler, and enter it in the gate height value. 8. Press DONE to complete the speed calibration. The next Calibration screen appears, with the Size subtitle highlighted. DATA Count & fill S 60 49

64 Advanced Settings Size Calibration Figure 49. Calibration Size screen Size calibration provides the object size range the system will count. To calibrate the size: 1. Press TEST. The objects pass through the detector, measuring the minimum and maximum object size. Note: For accurate size calibration results, the number of samples counted by the detector should be at least 10,000 samples (this is internal count parameter. Not the number of objects). 2. Continue testing until the values in the minimum and maximum object size tab do not change significantly. Minimum Size- objects smaller than this size will not be counted. 50 DATA Technologies Ltd.

65 Advanced Settings Maximum Size- objects larger than this size will be counted as more than one object. 3. Press STOP TESTING. 4. Press DONE to complete the size calibration process. The next Calibration screen appears, with the Stopping subtitle highlighted. Figure 50. Calibration stopping screen DATA Count & fill S 60 51

66 Advanced Settings Stopping Speed Calibration The DATA Count and Fill S 60 continuously counts the number of objects passing through the detector at the highest optimal speed. Before the predicted count time is reached, the system will go into the stopping speed mode, allowing the system to convey the remaining objects at a slower feed rate. Stopping Speed calibration provides the optimal final count speed to receive an accurate object count. To calibrate the stopping speed: 1. Press CALIBRATE. The objects pass through the count detector, measuring the object feed rate. After one seconds of measuring, the system is ready for testing, and the CALIBRATE tab will be replaced with TEST. Figure 51. Calibration stopping test screen 2. Press TEST. 52 DATA Technologies Ltd.

67 Advanced Settings The objects will pass through the count detector, counting a certain number of objects. Figure 52. Calibration stopping test screen 3. Modify the stopping speed value to the highest value that provides an accurate object count. A higher value will provide a faster stopping speed, but the count accuracy may be affected. Note: In most cases, optimizing the stopping speed parameter will provide good results. If required, press the ADVANCED SETTING tab for enhanced optimization. 4. Press ADVANCED SETTINGS. The Advanced calibration screen appears. DATA Count & fill S 60 53

68 Advanced Settings Figure 53. Advanced calibration screen 5. Change other parameters that may influence the stopping speed and object count accuracy. Learn more about each of the parameters in General Parameters, section Repeat the stopping speed calibration. 7. Press DONE to complete the stopping speed calibration. The Edit Object screen appears. 54 DATA Technologies Ltd.

69 Advanced Settings Figure 54. Edit object screen 8. Press the DONE button. DATA Count & fill S 60 55

70 Advanced Settings 9.3 General Parameters The General Parameters screen is accessible from the Advanced Settings screen, and allows viewing and modifying various parameters of the objects and system. Caution: Modifying these parameters should be done only by an experienced person that passed formal training on the DATA Count and Fill S 60 system. Figure 55. General parameters screen The General Parameters are presented in four groups: Feeding Speed, Emptying Speed, Default Count, and Error. They are listed and defined below: Note: Some of the parameters are System related, and some are Object related. Object related parameters are the default parameters used when creating new objects. 1. Default Feeding Speed Parameters (Object related): Frequency- The frequency of the system vibrator. 56 DATA Technologies Ltd.

71 Advanced Settings Duty Cycle- percentage of the vibrator signal. 2. Emptying Speed Parameters (System related): Frequency- vibrator frequency for the Hopper Empty process. Duty Cycle- percentage of the vibrator signal for the Hopper Empty process. 3. Default Count until Parameters (Object related): Time to Stop Ahead- The time the counting system should stop before going into the count stop mode. Time between Pulses- The delay between the vibrator pulses. This parameter has a high influence on the count stop rate. 4. Error: Error Tolerance- The allowable error in the number of objects being counted. After reviewing, and if no changes are required, press the DONE button. DATA Count & fill S 60 57

72 Advanced Settings To modify a parameter: 1. Press the parameter to be modified. The General Parameters screen with a keypad appears. Figure 56. General parameters modifying screen 2. Modify the value shown in the parameter box. 3. Press OK to accept the change. 4. Press DONE after performing all the required modifications. 58 DATA Technologies Ltd.

73 Advanced Settings 9.4 User Name Setup The User Name Setup allows you to add a user name, or delete a user name from the list. Figure 57. User Name Setup screen Note: Names are listed alphabetically. To enter a new user: 1. Press ENTER NEW USER. The User Name Setup screen appears. DATA Count & fill S 60 59

74 Advanced Settings Figure 58. User Name Setup screen 2. Type the new user name. Press to correct the name. Press to cancel. 3. Press OK to confirm. To delete a user from the list: 1. Press the user name. 2. Press REMOVE. A confirmation screen appears. 3. Press OK to delete. 60 DATA Technologies Ltd.

75 Main System Parts 10 MAIN SYSTEM PARTS The DATA Count and Fill S 60 is built of the following main parts: 1. Hopper The hopper is located on the top of the system, and is where the user fills the objects to be counted. 2. Vibration Chute The vibrating path, conveying the objects from the Hopper through the upper tube to the detection unit. 3. Detection unit (internal) The detection unit includes detectors and other supporting elements, which comprise the detection capability to count fast and accurately. Vibration Chute Hopper Upper tube Detection unit Funnel Figure 59. System feed path parts 4. Feed funnel (Funnel) The funnel from which the objects pass through according to its position: DATA Count & fill S 60 61

76 Main System Parts When on the left, the counted objects pass through the funnel, pouring through the rotating carousel ducts into the bag. When on the right, the objects pass through the funnel and down through the feed pipe into a connected bag or container placed at its exit. Used during the Empty Hopper or Free Count procedures. Feed funnel (Funnel) 5. Feed pipe Figure 60. Feed funnel (Funnel) The pipe through which the objects exit from, pouring into a connected bag or into a container placed at its exit. 62 DATA Technologies Ltd.

77 Main System Parts Feed funnel (Funnel) Feed pipe Figure 61. Feed pipe Note: The feed pipe can be rotated manually for placing a larger bag, sack or container under it (see Figure 61). 6. Pneumatic sub-system The detection elements are protected by an air curtain, created by a constant airflow passing through the detection unit. The pneumatic unit is connected on a panel behind the PC, and includes the following parts: DATA Count & fill S 60 63

78 Main System Parts Air line in Detection unit air input Figure 62. Pneumatic sub-system The Pneumatic unit has a 3 stage filter assembly, connected to a main air valve with a pressure gauge. 7. Electric box On the rear of the system is the electric box, containing all the electrical components. Danger: Some parts and units in the electric box have high voltage. The electric box can be opened with a special key. 8. System chassis The DATA Count and Fill S 60 chassis is built of frame elements and has adjustable legs for leveling the system during installation. It includes: Frame Adjustable legs 64 DATA Technologies Ltd.

79 Troubleshooting 11 TROUBLESHOOTING The DATA Count and Fill S 60 is very reliable, and is easy to operate. The system will provide good and accurate counting results, as long as correct system and object calibrations are performed, and the system is periodically cleaned and maintained. The following table provides a list of possible issues that may occur while working with the DATA Count and Fill S 60 system. Table 2. System troubleshooting Trouble Possible Cause Solution The system does not power up. At power up a message appears "The detector is not connected" A message "Place Bag" appears. Bad electrical connection. Fuse failure. The application does not detect a connection with the detection system. The system does not detect a bag: The rear of the bag too far from the sensor. The sensor is dirty. Check the electrical connection. Check the fuse. Verify the USB cable is connected between the PC and the detection unit. Press RECONNECT on the screen message. Reset the PC. Reinstall the bag around the Feed pipe. Clean the sensor. DATA Count & fill S 60 65

80 Troubleshooting Trouble Possible Cause Solution The objects coming out of the hopper are pouring out very fast or very slow. The objects in the vibration chute are very "jumpy". During counting, a message appears "Detection line interruption or overloaded counting". During counting, a message reading: "Counting timeout error" appears The counting speed is too slow The counting results are inaccurate Check the height of the gate, to verify it suits the object size. The object setup parameters (mainly the feeding frequency) may not suit the objects. Possible mechanical interference in the detecting system. The gate is set to high, allowing a too fast object flow. The system and/or object parameters are not optimal. No objects passed through the detected system. The gate is set too low. The system and/or object parameters are not optimal. The system and/or object parameters are not optimal. Adjust the gate level. Check the system and object parameters. Recalibrate the object parameters. Check the detection path, verifying there is no mechanical interference. Check the system and object feeding parameters, and recalibrate if required. Check the feeding path, for missing objects or flow interference. Adjust the gate level. Check the system and objects feeding parameters, and recalibrate if required Check the system and objects feeding parameters, and re- 66 DATA Technologies Ltd.

81 Troubleshooting Trouble Possible Cause Solution A message Size might be wrong The objects being counted do not match the job object type. calibrate if required. Check and confirm the defined object type and objects in the hopper match. Note: On the PC desktop there is an extra shortcut that can be used for operating the system in single mode; enabling using the system without the carousel. For more details on how to use this option in case of malfunction of the carousel system, contact your local service provider. DATA Count & fill S 60 67

82 Troubleshooting 11.1 Application Error Messages The following table lists the DATA Count and Fill application errors. Note: When the To do action is "Call Service", first try powering down the system and powering back up. Note: If you cannot solve the error according to the recommendation, power down the system and call your local service. Table 3. System error messages Error # Description To do Error 1 & 2 "Wrong command" Call service Error 3 "Too many objects fell at once" Make sure the track is not overloaded Error 4 "Wrong ccd number" Call service Error 5 Error 6 Error 7 "Detection line interruption or overloaded counting" "Too many objects fell at once" "Too many objects fell at once" Clean detection area and avoid overload Check the track is not overloaded Check the track is not overloaded Error 8 "Disconnected ccd" Call service Error 9 Error 10 "Detection line interruption" Clean detection area "Malfunction in laser" Call service 68 DATA Technologies Ltd.

83 Maintenance 12 MAINTENANCE The DATA Count and Fill S 60 is almost a maintenance free system. However, to ensure optimal counting results, in both speed and accuracy, it is important to perform the following periodic maintenance procedures. Table 4. Periodical maintenance Daily Monthly Half-yearly Annually Clean the system with a lint free damp cloth. Remove remaining bags from the carousel. Inspect pneumatic unit filters, see section Check entire electrical system including main connection cable. Replace pneumatic unit filters, see section Inspection all machine threaded connections and tighten if required. Note: The frequency of cleaning depends on the environment and on the type of objects being used Cleaning the System Before cleaning the feeding path, clean the system area and covers using a lint free damp cloth Cleaning the Feeding Path Note: All parts of the feeding path: Hopper, Vibration Chute, Upper tube and Funnel, are made of Stainless steel. These parts can be disinfected when changing from one Object type to another. DATA Count & fill S 60 69

84 Maintenance Caution: Do not clean the Detection Unit with Air. If required, use vacuum for cleaning. Danger: Electrical Shock Hazard: High voltage is present at points in the Detector Unit. Contact with high voltage can result in injury or death. Do not open the Detector unit. Before attempting any maintenance task, ensure that there is no voltage present by powering down the System and disconnecting the AC power cord plug from the wall outlet. If the system PC is connected to a UPS unit, turn the UPS off and disconnect it from its power source Disconnecting facilities To disconnect system power supply: 1. Power down the system (see section 5.2). 2. Disconnect the electrical supply Removing parts and cleaning To remove the Hopper: The hopper is held in place with two locking latches. 1. Release the two holding latches. 2. Pull the hopper up and remove it from the system. To clean the feeding path: 1. Raise the gate to the highest point. 2. Clean the internal system feeding compartment from remaining counting objects and other debris. 70 DATA Technologies Ltd.

85 Maintenance To move the vibration chute backwards: 1. Turn the vibration chute locking lever to the rear. Locking latch Upper tube Figure 63. Releasing the Vibration Chute 2. Slide the Vibration Chute backwards, to enable the removal of the upper tube (see direction arrows). To remove the upper tube: 1. Remove the upper tube by pulling it up. The upper tube is held in place by magnets. 2. Clean the upper tube from its outside and inside. To remove the feed funnel: Vibration Chute 1. Remove the feed funnel by pushing it up a bit, and with a slight twist releasing it from its holding magnets. Then remove it from its holding frame. To assists with the removal, you may need to move the feed funnel to the left or to the right. 2. Clean the feed funnel from its outside and inside. DATA Count & fill S 60 71

86 Maintenance To remove the feed pipe: 1. Remove the feed pipe by pulling it down. The feed pipe is held in place by magnets. 2. Clean the feed pipe from its outside and inside Cleaning the sensors The DATA Count and Fill S 60 has four sensors: Homing position of carousel bag #1 Bag presence Funnel location, right and left To clean the sensors: If necessary, clean the sensor with a lint free cloth. Use IPA if required. 72 DATA Technologies Ltd.

87 Maintenance Reassembling the parts To reassemble the removed parts: Reconnect all parts back to their place, in a reverse order. Following are notes for reconnecting: Feed Funnel: The feed funnel is placed in its holding frame with orientation pins and magnets. Verify the funnel is assembled in the correct orientation and sits correctly in its holding frame. Upper tube: The upper tube is positioned with an orientation pin. Verify the tube is reassembled with the top opening facing the vibration chute (see Figure 63). Vibration chute: Move the vibration chute all the way forwards, inserting its front edge over the upper tube. See Figure 63 for locking the vibration chute in place. Hopper: The Hopper is held in place with two latches. Caution: Verify all parts are well connected, and that the vibration chute is firmly locked in place. DATA Count & fill S 60 73

88 Maintenance 12.2 Pneumatic Unit The Pneumatic unit includes a 3 stage filter assembly built of the following filters: Table 5. Pneumatic unit filters Description Size Color Air Filter (AF 20) 5 µ White Mist Separator (AFM 20) 0.3 µ White "sponge" Micro Mist Separator (AFD 20) 0.01 µ Black "sponge" Caution: The order of the filters is important for proper air filtering. The unit also includes an air regulator with a pressure gauge. The pneumatic unit requires periodical inspection and maintenance Pressure Setting Inspection Inspect the pressure gage daily, to verify the provided pressure is set to 0.1 bar. To adjust the regulator: 1. Pull the regulator knob down. 2. Rotate counterclockwise to increase the pressure, and clockwise to decrease. 3. Push the regulator back in place to lock its position. 74 DATA Technologies Ltd.

89 Maintenance Periodic Filters Maintenance Monthly: 1. Inspect the filters. 2. Drain the water. To drain the filter: a. Turn off the air supply to the system. b. Place a container under the filter. c. Rotate the bottom black plug clockwise. d. Pull it down to let the water drain. Annually: Replace the filters when they are dirty (change in color), or if there is a drop in pressure. Replace the filter elements each year. To replace the filter elements: a. Turn off the air supply to the system. b. Drain the filter (see above). c. Remove the filter bowl: carefully unscrew it clockwise and pull it down. d. Mark the orientation of the filter element, and remove the old filter element. e. Inspect the bowl O-ring for damage, and replace if required. f. Insert a new filter, noting its correct orientation. g. Reconnect the filter bowl, verifying that the O- ring is placed correctly, and the bowl is correctly screwed to the filter body. DATA Count & fill S 60 75

90 System Specifications 13 SYSTEM SPECIFICATIONS Counting speed: Six bags per minute, each containing one thousand tomato seeds Accuracy: 99.5% to 99.9% (depends on object size and shape) Object size range: 1 to 25 mm Maximum volume: 6 liter (6,000 cc) User selectable count to a preset number of Objects System dimensions (cm): H=205, W=83, D=75 (including the Hopper) Weight: 100 Kg Electrical supply: 115/230VAC, 1 phase Frequency: 50/60 Hz Power consumption: 150 W Circuit breaker rate: Minimum 10A, slow blow Air pressure: 0.1 bar Air consumption: 4.5 L/min Environmental conditions: Indoor use only 76 DATA Technologies Ltd.

91 Glossary 14 GLOSSARY The Glossary includes terminology used in the DATA Count and Fill S 60 Manual. Batch Count Object counting mode. Bags are filled according to a defined number of objects per bag, and number of bags. Carousel duct (Duct) The carousel pipes through where the objects pour from into the bags. The ducts also assist with holding the bags in place. DATA Count Unit The counting element which performs the object counting, constructed of detectors and various hardware components. Empty Hopper A feature of the system that enables the user to empty the hopper content into a container placed at the feed pipe exit. Empty Hopper Container The container placed under the feed pipe for Free Count and Empty Hopper processes. DATA Count & fill S 60 77

92 Glossary Feed funnel (Funnel) The part through where the counted objects flow through, navigating the objects to the carousel or to the feed pipe (bag/container). Feed Pipe The pipe through which the objects pass when going into a connected bag or a container. Free Count Object counting mode. All or some of the objects in the hopper are counted. Gate Height The distance between the gate lower edge and the vibration chute surface. This is a measured value that is used as a reference. Maximum Object Size The Data Count and Fill S60 counts objects larger than this size as a multiple of counts, according to the detected size. Minimum Object Size The Data Count and Fill S 60 ignores objects smaller than this size. Object The parts or elements that the DATA Count and Fill S 60 counts. 78 DATA Technologies Ltd.

93 Appendix A: Laser Safety 15 APPENDIX A: LASER SAFETY Read the following carefully before operating the system The DATA Count and Fill S-60 System uses three invisible laser sources for the counting of small objects process, classified as Class 3B (up to 100mW at 780nM). Although the space in which the laser beam is classified as Class 3B is covered, preventing laser radiation leaks from the counting unit, there is a chance of accidental radiation leak through the upper guide pipe. However, the laser beam at this region is classified as Class 1, and therefore harmless. Therefore, during standard system operations, the counting unit does not pose any risk to the operator. When performing maintenance or service to the System, which may require working without the protective housing, protecting eyewear of at least OD 2.5 for 780 nm must be used. DATA Count & fill S 60 79

94 Appendix A: Laser Safety The DATA Count and Fill S-60 System is designed and built to comply with the International Standard for Laser Products: IEC/EN : CDRH standard 21 CFR for class 1 laser product containing class 3B laser source. For this purpose, the following safety means are incorporated in the System: 1. Protective housing: The laser beams are enclosed in a well-built protective housing, with a labyrinth structure, preventing laser radiation leaks from the detection unit. All internal surfaces of the detection unit walls are covered with hard black anodic paint, avoiding beam radiation reflection. The laser beams are aimed straight at a CCD after reduced by a 0.8 mm wide aperture. 2. System Labeling: Identification and Warning labels are used to assist with identifying and classifying the System. a. Identification Label: A label identifying the product with the manufacturer and product data is attached to the system. b. Classification label (see Figure 64): The system is defined as a Class 1 Laser Product. 80 DATA Technologies Ltd.

95 Appendix A: Laser Safety Figure 64. Class 1 label c. Caution label (see Figure 65): A caution label of Class 3B Invisible Laser Radiation is attached to the detection unit. DATA Count & fill S 60 81

96 Appendix A: Laser Safety Figure 65. Class 3B label Note: The cover does not have an interlock. 82 DATA Technologies Ltd.