AQUANTIS CALLIFREEZE User manual
CALLIFREEZE®
USER’S GUIDE
Document No: CALLIFREEZE-2021-1
September 2021
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CALLIFREEZE® User’s Guide 3
Contents
1Contact information.................................................................................................................................. 2
2Quick Start: Calibration and Start up..........................................................................................................5
3About the user guide................................................................................................................................. 5
3.1 Introduction..................................................................................................................................... 5
3.2 Nomenclature.................................................................................................................................. 5
3.3 Publication....................................................................................................................................... 5
3.4 Additional Documents...................................................................................................................... 6
4Disclaimer ................................................................................................................................................. 7
5Safety information .................................................................................................................................... 8
5.1 General safety instructions............................................................................................................... 8
5.2 Laser classification (Class II).............................................................................................................. 8
5.3 Safe sensor usage............................................................................................................................. 8
6Transport and storage............................................................................................................................... 9
6.1 Package............................................................................................................................................ 9
6.2 Transport......................................................................................................................................... 9
6.3 Transport inspection ........................................................................................................................9
6.4 Storage ............................................................................................................................................ 9
7Sensor installation and calibration........................................................................................................... 10
7.1 Installation guidelines .................................................................................................................... 10
7.2 Power supply cables....................................................................................................................... 12
7.2.1 External power connection ........................................................................................................ 12
7.2.2 Internal power connection......................................................................................................... 12
7.3 Data interconnection ..................................................................................................................... 13
8Operation................................................................................................................................................ 14
8.1 Sensor power-on and shutdown..................................................................................................... 14
8.1.1 Power on ................................................................................................................................... 14
8.1.2 Shutdown .................................................................................................................................. 14
8.2 Connectivity................................................................................................................................... 14
8.2.1 Connecting to the sensor via a PC............................................................................................... 14
8.2.2 Connecting to the sensor via the network infrastructure ............................................................ 17
8.3 User Interface ................................................................................................................................ 18
8.3.1 Webserver interface .................................................................................................................. 18
8.3.2 Modbus TCP/IP interface............................................................................................................ 23
9Maintenance & Disposal.......................................................................................................................... 25
9.1 Daily maintenance.......................................................................................................................... 25
9.2 Yearly maintenance........................................................................................................................ 25
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9.3 Disposal ......................................................................................................................................... 25
10 Troubleshooting................................................................................................................................. 26
10.1 Unexpected stop and restart.......................................................................................................... 26
10.2 Sensor warnings and errors............................................................................................................ 26
10.3 Returns.......................................................................................................................................... 27
10.4 Repairs........................................................................................................................................... 27
11 Technical data.................................................................................................................................... 28
11.1 General specifications .................................................................................................................... 28
11.2 Electrical specifications .................................................................................................................. 28
11.3 Data connectivity / acquisition ....................................................................................................... 28
11.4 Mechanical specifications............................................................................................................... 29
11.4.1 Materials............................................................................................................................... 29
11.4.2 Computer-box ....................................................................................................................... 29
11.4.3 HF measurement units........................................................................................................... 30
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CALLIFREEZE® User’s Guide 5
2Quick Start: Calibration and Start up
The quick start requires the sensor to be correctly installed according to the guidelines in section 7. The sensor
can be initialized as following:
1. Open the Logging Center on the web interface using the assigned IP address.
2. Ensure the conveyor belt is empty, clean, and dry. Select and follow the instructions of the thickness
sensor calibration wizard (see section 8.3.1.2).
3. Ensure the conveyor belt is emptied, clean and dry. Next, calibrate the sensor via the NO PRODUCT
button (see section 8.3.1.3).
4. Once the system is set up, go to logging center and switch on the data acquisition by clicking on the
logging button (see section 8.3.1.1Error! Reference source not found.). At this moment, the data is
recorded and saved in .txt files. The directory gives you access to the files and allows you to open them.
5. To stop the data acquisition function, re-click on the logging button .
3About the user guide
3.1 Introduction
The CALLIFREEZE® is intended to continuously monitor the Level of Frozenness (LOF) of individual products (e.g.,
hamburger). CALLIFREEZE® is developed and manufactured by Aquantis. The product number is indicated on the
device and has the format: AQFS-TS1-2021-X. Please provide the product number during every communication
with Aquantis.
This user’s guide is intended for the personnel in charge of the process control of products (e.g., hamburger)
during freezing processes. When using the CALLIFREEZE® according to the user’s guide, no specific qualifications
are required to operate the system. Read this user guide carefully since the installation and operation in
accordance with these instructions is a prerequisite for proper functioning of the CALLIFREEZE® sensor.
The pictures in the user guide are for illustrative purposes only. The illustrations can differ in minor details from
the installed sensor since they are only intended to provide general information. Aquantis pursues a policy of
ongoing product development with all sensors. Changes in terms of supply scope are possible at any time with
regards to design, features and technology. The information listed in this user guide corresponds to the
information available at the time of going to press. Therefore, legal claims cannot bemade based on the technical
data, illustrations and information contained in the user guide.
The following nomenclature will help when reading this user guide.
3.2 Nomenclature
BMU bottom measurement unit: receiver unit placed underneath the conveyor belt
CSV comma separated values
dB decibels
EM(W) electromagnetic (waves)
GHz-waves electromagnetic waves in the GHz frequency range
HF high frequency, typically referring to the GHz frequency range
LF low frequency
TMU top measurement unit: emitter unit placed above the conveyor belt
LOF level-of-frozenness
UINT16 unsigned integer of 16 bits
3.3 Publication
Manual version 4.0 with Document No: CALLIFREEZE-2021-1 is published in September, 2021.
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3.4 Additional Documents
Additional documents for the CALLIFREEZE include:
▪CALLIFREEZE Fabrication Instructions (Document No: CALLIFREEZE-2021-FAB-4): Protocol for
fabrication, adjustments and testing the CALLIFREEZE® including its different components. This
document is solely meant CALLIFREEZE manufacturers.
▪CALLIFREEZE Bill of Materials (Document No: CALLIFREEZE-2021-BOM-4): Overview of the components
used in the CALLIFREEZE®. This document is solely meant CALLIFREEZE manufacturers.
▪CALLIFREEZE Product Label (Document No: CALLIFREEZE-2021-LABEL-4): The label can be found on the
product.
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CALLIFREEZE® User’s Guide 7
4Disclaimer
In no respect shall Aquantis incur any liability for any damages, including, but limited to, direct, indirect, special,
or consequential damages arising out of, resulting from, or any way connected to the use of the sensor, whether
or not based upon warranty, contract, tort, or otherwise; whether or not injury was sustained by persons or
property or otherwise; and whether or not loss was sustained from, or arose out of, the results of, the item, or
any services that may be provided by Aquantis.
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5Safety information
This sensor has been designed for save use but must be operated with caution. If used properly according to this
user’s guide, the CALLIFREEZE® poses no health concerns for the personnel.
5.1 General safety instructions
•Check the voltage rating before you connect the equipment to an electrical power source to ensure that
the required voltage and frequency match the available power source.
•Do not connect the equipment power cables to the power outlet if the power cable is damaged.
•If you use an extension power cable, ensure that the total ampere rating of the products plugged in to
the extension power cable does not exceed the ampere rating of the extension cable.
WARNING: The customer is responsible to connect all metal parts of the CALLIFREEZE® to protective earth via a
low resistive path (< 1 Ohm).
WARNING: A minimum distance of 1 meter around the emitter should be respected to stay within the maximum
electromagnetic exposure limit.
CAUTION: If any smoke or unusual odors are detected, disconnect the device from the electrical outlet and
contact Aquantis immediately. See page 2 for the contact information.
5.2 Laser classification (Class II)
The CALLIFREEZE® sensor system includes a visible class 2 laser for measuring the product (layer) thickness. The
laser-beam is normally pointed downwards to the conveyor belt on which the products pass. Do not stare into
the beam or direct the beam to anyone’s eyes.
WARNING: Do not directly view or point the laser pointer at an eye. Low power visible lasers do not normally
present a hazard but may present potential for hazard if viewed directly for extended periods of time.
5.3 Safe sensor usage
The CALLIFREEZE® system is designed for use in industrial environments.
▪Measure the LOF of layers of French fries and other potato-related products on a conveyor belt.
▪Measure thickness of layers of French fries and other potato-related products on a conveyor belt.
No other uses are permitted.
Prohibited sensor uses include:
▪Compromising or deactivating safety systems built into the sensor.
▪Removal of hazard or explanatory labels affixed to the sensor.
▪Opening the sensors enclosure (during operation or cleaning)
▪Modifying or converting the instrument
▪Using third party accessories
Notices:
▪Avoid shocks and impacts to the sensor.
▪Protect the sensor cables against damage.
▪Avoid exposure of sensor to aggressive media.
▪Mount the sensor only by means of the foreseen mounting spaces according to the installation
guidelines.
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6Transport and storage
6.1 Package
A CALLIFREEZE® package contains the following items:
•1 x Emitter unit [H x W x D]: [187 x 177 x178] mm
•1 x Receiver unit [H x W x D]: [187 x 177x 178] mm
•1 x Computer unit [H x W x D]: [793.5 x 390x 267.4] mm
•1 x Laser based product thickness sensor
•1 x Set of thickness sensor mounting plates (3 pieces)
If above mentioned parts are missing, please contact Aquantis immediately.
6.2 Transport
For your own safety and to avoid damage to the sensor due to improper transport, respect the following
considerations:
•Transport should be performed by trained specialist staff only.
•The utmost care and attention are always required during unloading and transportation on company
premises.
Do not remove packaging until immediately before you start the installation.
6.3 Transport inspection
Upon receipt, please check the delivery for completeness and for any damage that may have occurred in transit.
In the case of transit damage that is visible externally, proceed as follows:
•Do not accept the delivery or only do so conditionally.
•Note the scope of damage on the transport documents or on the transport company's delivery note.
•Contact Aquantis.
Complaints regarding defects should be filed as soon as these are detected. Damage claims are only valid before
the applicable complaint deadlines.
6.4 Storage
Store the sensor under the following conditions:
•Do not store outdoors.
•Store in a dry area that is protected from water and dust.
•Do not expose to any aggressive substances.
•Protect from sunlight.
•Avoid mechanical shocks.
•Storage temperature: between –40 and +40 °C
•Relative humidity: max. 95%, non-condensing
•For storage periods of longer than 3 months, check the general condition of the individual units and
packaging on a regular basis.
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CALLIFREEZE® User’s Guide 10
7Sensor installation and calibration
7.1 Installation guidelines
The installation will be conducted by Aquantis engineers or Aquantis-certified engineers. Therefore, no specific
tools nor materials will be provided.
WARNING: The customer is responsible to connect all metal parts of the system to protective earth via a low
resistive path (< 1 Ohm). Aquantis is not responsible for any damage or dysregulation of the system and other
equipment due to no or a bad connection to earth.
The best sensor performance can be achieved by following these installation guidelines:
✓The conveyor belt material should be transparent for low-power microwaves. Most plastic conveyor
belt materials comply with this requirement, metal conveyor belts do not.
✓The emitter is mounted above the conveyor belt. To ensure accurate measurements, the Teflon cap of
the emitter should be installed close to the product (without touching the products). The receiver is
placed underneath the conveyor belt, well aligned with the emitter as shown in Figure 1. It is strongly
recommended to have as few as possible metal parts near the electromagnetic axis. The distance
between the bottom of the emitter and belt should be 12 cm. The distance between belt and top of the
receiver should be kept a minimum. Foresee sufficient margin near the receiver cover (> 2 cm) such that
under all conditions moving parts (e.g., conveyor belt) are not touching the instrument.
FIGURE 1: ORIENTATION OF THE SENSOR RELATIVE TO THE CONVEYOR BELT AND PRODUCT MOTION AXIS.
✓Please foresee free space (minimum 50 cm) around the top measurement unit (TMU) to facilitate the
installation of product-thickness sensor
✓Mount the computational unit in the vicinity of the emitter and receiver with the cable glands pointed
towards the floor. Please foresee a save and easy access to the emitter, receiver, and the computational
unit to facilitate the maintenance on the CALLIFREEZE® system.
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FIGURE 2: STAINLESS STEEL BASE PLATE FOR MOUNTING THE SENSOR MODULE AND THICKNESS SENSOR.
✓The conveyor belt thickness at the electromagnetic-axis should be constant (toothed sections of the
conveyor belt should not be placed in the EM field-of-view).
✓The emitter, receiver boxes and the computational unit should be mounted rigidly on a frame to
minimize any movement or vibrations.
✓Make sure there are no other devices operating in the same frequency range: 61-62 GHz. Respect a
distance of 1 m from the CALLIFREEZE® system.
✓The cable distance between the computer-box and the HF units may not be longer than 2.5 m.
✓For typical product thicknesses, the laser-spot of the thickness sensor should preferentially intersect
with the EM-axis at the top surface of the product. See
✓Figure 3 for details.
FIGURE 3: POSITIONING OF THE THICKNESS SENSOR:SECTION A,B AND C SHOW CORRECTLY MOUNTED DISTANCE SENSORS.
THE LASER POINT OF THE DISTANCE SENSOR IS POINTED AT THE CENTER REGION OF THE PRODUCT.SECTION D SHOWS THE
INAPPROPRIATE POSITIONING OF THE DISTANCE WHICH RESULTS IN WRONG MEASUREMENTS.
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7.2 Power supply cables
7.2.1 External power connection
The CALLIFREEZE® is powered via its computer unit which further distributes the power to the distance sensor,
emitter and receiver units. Please connect the main power to a single 230 VAC –50 Hz power source with an
external switch or remoterelay controlled via a PLC. Figure 4 shows the incoming power(red) and the distribution
links (blue). The power distribution to the distance sensor is already foreseen.
FIGURE 4: POWER SUPPLY INTERCONNECTIONS.
7.2.2 Internal power connection
In case own electrical cables are used to power the unit, the cable can be connected inside the computing unit.
The Line, Neutral and Earth connections should be made to the corresponding inputs of the EMI Filter located
in the right side of the computing box.
FIGURE 5: EMI FILTER CONNECTION.
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7.3 Data interconnection
The data streams between the computer unit, distance sensor, emitter and receiver units are shown in Figure 6.
From the computing unit, an ethernet cable which can be directly connected to a pc or a network. More
information can be found in the next section Connectivity.
FIGURE 6: DATA SIGNAL INTERCONNECTIONS.
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8Operation
8.1 Sensor power-on and shutdown
8.1.1 Power on
The CALLIFREEZE® is switched on by plugging in the power cord in a socket or by supplying power via an PLC
system. The sensor’s operating system boots up automatically upon switching on. This start-up phase takes a few
minutes. If the system doesn’t respond, proceed to section 10.1 Unexpected stop and restart.
CAUTION: If any smoke or unusual odors are detected, disconnect the device from the electrical outlet and
contact Aquantis immediately. See page 2 for the appropriate contact information.
8.1.2 Shutdown
The CALLIFREEZE® sensors software needs to be shutdown properly prior to cuting off its mains power. The
system is turned off via the webserver’s shutdown-button. Ensure that the sensor mains power is kept on for at
least 2 min after the shutdown process is initiated. Incorrect closing may affect the proper functioning of the
device. In case the power is switched off too early, check on the next start up if the software boots up and
functions normally.
FIGURE 7: WEBSERVERS MENU:SHUTDOWN BUTTON.
8.2 Connectivity
8.2.1 Connecting to the sensor via a PC
8.2.1.1 Via an Ethernet cable
The CALLIFREEZE® can be directly connected to a PC by means of the Ethernet RJ45 connector. The industrial PC
inside the computational box has two ethernet ports as shown in Figure 8. The IP address of port 1 is set to a
fixed IP address 192.168.3.100. Port 2 can be set to a fixed IP address required by the user from sensor’s
webpage. Port 2 can is set as a DHCP mode by default.
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CALLIFREEZE® User’s Guide 15
FIGURE 8: ETHERNET PORTS OF THE INDUSTRIAL PC.
PORT 1HAS THE FIXED IP ADDRESS,PORT 2CAN BE SPECIFIED BY THE USER.
The sensor can then be interfaced via a web browser or a dedicated PLC emulation software making use of the
MODBUS TCP protocol.
For direct interconnection to a windows PC, a fixed IP address need to be used: 192.168.3.100 or IP previously
specified by the user. To do so, one need to change the Ethernet adaptor settings of the Windows PC (that is
going to be connected with sensor) as follows:
STEP 1: Open the “Network and sharing center”.
STEP 2: Select “change adaptor settings”.
STEP 3: Select the Ethernet connection to which the sensor will be connected to the PC. Right-click on
the connection and select properties from the drop-down menu.
STEP 4: Under the tab “Networking”, select Internet protocol version 4 (TCP/IPv4), then select
properties.
STEP 5: Set the settings as indicated in Figure 9 and press OK.
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FIGURE 9: IP SETTINGS FOR DIRECT CONNECTION TO THE SENSOR.
STEP 6: Connect the sensor to your PC, open a web browser and navigate to http://192.168.3.100.
STEP7: Congratulations, you are now connected to the sensor.
The IP address of Port 2 in Figure 8: Ethernet ports of the industrial PC.
Port 1 has the fixed IP address, Port 2 can be specified by the User. can be changed via the web interface. By
clicking on the Aquantis logo, the maintenance screen can be opened. Under Network Configuration, a new IP
address can be entered and is saved by pressing APPLY (Figure 10).
8.2.1.2 Via the Wi-Fi hotspot
The CALLIFREEZE® can also be connected via the mobile Wi-Fi hotspot. The hotspot can be found as a Wi-Fi
network named according to its serial number AQFS-TS1-V4-XXXX-Y. The XXXX represents the year and Y the
sensor number. Once connected, the web interface can be opened via 192.168.4.200. Just as described in the
previous section, the IP address of Port 2 can be changed.
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CALLIFREEZE® User’s Guide 17
FIGURE 10:NETWORK CONFIGURATION:CHANGING THE IP ADDRESS OF PORT 2VIA THE WEB INTERFACE.
8.2.2 Connecting to the sensor via the network infrastructure
The Aquantis sensor can be connected to the network infrastructure to access it from a distance, e.g., by means
of a PLC. The PC inside the computing unit has two ethernet ports. Port 1 is set for a fixed IP of 192.168.3.100.
The second port (near HDMI connection) is available for the DHCP client, or a fixed IP address can be set
according to the requirements.
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CALLIFREEZE® User’s Guide 18
8.3 User Interface
The Aquantis CALLIFREEZE® can be interfaced in via:
✓Webserver interface (read & write)
✓Modbus TCP/IP (read)
8.3.1 Webserver interface
Note: it is advised to make use of Google Chrome version 70.x or later for consulting the sensors webpages.
The web page structure
▪Logging Center [password protected –read/write]
▪Settings [password protected –read]
▪Product Parameters [password protected –read/write]
▪About [freely accessible - read only]
▪Shutdown
8.3.1.1 Logging Center
The logging center is used for data logging, visualization and calibration of the sensor. The details are explained
in Figure 11.
FIGURE 11:LOGGING CENTER
1. START / STOP: Start and stop of the data acquisition.
2. Pause the measurement.
3. Download the data in the form of .txt files.
4. X: Set the parameter of the horizontal axis.
5. Y1: Set the parameters of the vertical axes with Y1 on the left side on the graph.
6. Y2: Set the parameters of the vertical axes with Y2 on the right side on the graph.
7. CLEAR ALL: Clears the graph without removing the current acquisition data.
8. NO PRODUCT CALIBRATION: Calibrates the system without the product to correct for dirt or
condensation on the conveyor belt.
9. THICKNESS: Calibrates the thickness sensor via the wizard (see section 8.3.1.2).
10. FILE NAMING: Used for naming the files which already contain an initial date and time stamp.
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CALLIFREEZE® User’s Guide 19
11. FILE TREE: The file tree allows to display the data files. Note that new data files might only be visible
after refreshing the directory tree by closing and opening the “Measurements” directory.
12. CHART: Chart displaying the data points.
13. Pause update: The chart can be paused temporarily to allow zooming or other actions. The data
acquisition continues in the background. Once unticked, all data is displayed.
14. Single Y-axis: The single axis option allows to have a single axis.
8.3.1.2 Thickness sensor calibration wizard
Protection level: password protected.
The product thickness sensor calibration wizard starts with an introduction describing the prerequisites that
needs to be fulfilled prior to continue with the thickness calibration procedure as illustrated in Figure 12. The
product thickness sensor calibration procedure requires one or two non-transparent reference objects with
known thicknesses. The first and the second reference object should be, respectively, thicker and thinner that
the product thickness on the production line.
The calibration procedure is initiated by placing a non-transparent reference object (with known thickness) on
the conveyor belt in front of the sensor such that the red laser-spot is clearly visible on the top surface of the
object. This is illustrated in Figure 13.
FIGURE 12:THICKNESS SENSOR CALIBRATION WIZARD -REFERENCE 1.
Next, the exact thickness of the reference object needs to be provided in mm with a precision of 1 digit after the
comma. The same procedure is repeated for the second reference object (see Figure 13 - Figure 15).
FIGURE 13:THICKNESS SENSOR CALIBRATION WIZARD -THICKNESS INPUT OF REFERENCE 1.
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FIGURE 14:THICKNESS SENSOR CALIBRATION WIZARD -REFERENCE 2.
FIGURE 15:THICKNESS SENSOR CALIBRATION WIZARD -THICKNESS OF REFERENCE 2.
8.3.1.3 NO PRODUCT calibration
This calibration process is mandatory.
•Empty the conveyor belt. Important here is that the conveyor belt is completely dry.
•Click on the NO PRODUCT calibration button in the logging center (Figure 16). This automatically
calibrates the sensor during a few seconds.
FIGURE 16:CALIBRATION -NO PRODUCT BUTTON
8.3.1.4 TCP/IP Settings
Protection level: freely accessible.
The TCP/IP settings page shows the current IP aaddress. A static IP address will be active unless DHCP is used to
attribute the IP address automatically.
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