AQUANTIS Moisture-Sense User manual

Moisture-Sense
USER’S GUIDE
Document No: MOISTURE-SENSE-2021
October 2021

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Moisture-Sense User’s Guide 2
1Contact information
Aquantis S.A.
EPFL Innovation Park Bâtiment C
CH-1015 Lausanne
Switzerland
Tel: [phone]
Aquantis Belgium B.V.B.A.
Generaal De Wittelaan 17C
B-2800 Mechelen
Belgium
Tel: [phone]
E-mail : [email protected]
Website : www.aquantis.org

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Moisture-Sense 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 Transport.........................................................................................................................................9
6.2 Transport inspection ........................................................................................................................ 9
6.3 Storage ............................................................................................................................................ 9
7Sensor installation and calibration........................................................................................................... 10
7.1 Installation guidelines .................................................................................................................... 10
7.2 Power supply cables....................................................................................................................... 12
External power connection ........................................................................................................ 12
Internal power connection......................................................................................................... 12
7.3 Data interconnection ..................................................................................................................... 13
8Operation................................................................................................................................................ 13
8.1 Sensor power-on and shutdown..................................................................................................... 13
Power on................................................................................................................................... 13
Shutdown .................................................................................................................................. 13
8.2 Connectivity................................................................................................................................... 14
Connecting to the sensor via a PC............................................................................................... 14
Connecting to the sensor via the network infrastructure ............................................................ 15
8.3 User Interface ................................................................................................................................ 16
Webserver interface .................................................................................................................. 16
Modbus TCP/IP interface............................................................................................................ 20
9Maintenance & Disposal.......................................................................................................................... 22
9.1 Daily maintenance.......................................................................................................................... 22
9.2 Yearly maintenance........................................................................................................................ 22
9.3 Disposal ......................................................................................................................................... 22

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10 Troubleshooting................................................................................................................................. 23
10.1 Unexpected stop and restart.......................................................................................................... 23
10.2 Sensor warnings and errors............................................................................................................ 23
10.3 Returns.......................................................................................................................................... 24
10.4 Repairs........................................................................................................................................... 24
11 Technical data.................................................................................................................................... 25
11.1 General specifications .................................................................................................................... 25
11.2 Electrical specifications .................................................................................................................. 25
11.3 Data connectivity / acquisition ....................................................................................................... 25
11.4 Mechanical specifications............................................................................................................... 26
Materials............................................................................................................................... 26
Computer-box ....................................................................................................................... 26
HF measurement units........................................................................................................... 27
Supporting mechanical pieces................................................................................................ 29
Assembled sensor.................................................................................................................. 33

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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 initialized as following:
1. Open the Logging Center on the web interface using the assigned IP address.
2. Ensure the conveyor belt is emptied, 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 centre 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 Moisture-Sense is intended to continuously monitor the moisture or dry matter of French fries and potato-
related products. This device is developed and manufactured by Aquantis. The product number is indicated on
the device and has the format: AQMS-XX-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 and quality control of frozen products
and/or freezing or thawing processes. When using the Moisture-Sense 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 Moisture-Sense
sensor.
The pictures in the user guide are for illustrative purposes only. The illustrations can differ in minor details from
your sensor, 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 be made 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: emitter of 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 of receiver unit placed above the conveyor belt
3.3 Publication
Manual version 1.0 with Document No: MOISTURE-SENSE2021-1 was published on May 1st, 2021.

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3.4 Additional Documents
Additional documents for the MOISTURE-SENSE include:
▪MOISTURE-SENSE Fabrication Instructions (Document No: MOISTURE-SENSE-2021-FAB-1): Protocol for
fabrication, adjustments and testing the Moisture-Sense including its different components. This
document is solely meant MOISTURE-SENSE manufacturers.
▪MOISTURE-SENSE Bill of Materials (Document No: MOISTURE-SENSE-2021-BOM-1): Overview of the
components used in the Moisture-Sense. This document is solely meant MOISTURE-SENSE
manufacturers.
▪MOISTURE-SENSE Product Label (Document No: MOISTURE-SENSE-2021-LABEL-1): The label can be
found on the product.

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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 Moisture-Sense 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 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 Moisture-Sense to protective earth via
a low resistive path (< 1 Ohm).
WARNING: A minimum distance of 1 meter from the emitter unit should be respected to stay within the
maximum electromagnetic exposure limit.
CAUTION: If any smoke or unusual odours are detected, disconnect the device from the electrical outlet and
contact Aquantis immediately. See page 2 for the appropriate contact information.
5.2 Laser classification (Class II)
The Moisture-Sense 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 Moisture-Sense system is designed for use in industrial environments
▪Measure themoisture or dry matter content 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.
▪Measure surface temperature 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 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 required at all times during unloading and transportation on
company premises.
Do not remove packaging until immediately before you start the installation.
6.2 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.
6.3 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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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. Calibration of the sensor can be conducted with included calibration kit.
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 microwaves. The insertion loss caused by the belt
cannot exceed 3 dB. Most plastic conveyor belt materials comply with this requirement, metal conveyor
belts don’t.
✓The Plow (HF emitter) is mounted 10 cm above the conveyor belt. The HF receiver is placed underneath
the conveyor belt, well aligned with the emitter as shown in Figure 1Error! Reference source not
found.). It is strongly recommended to have as few as possible metal parts near the electromagnetic-
axis. The distance between the emitter and receiver (from antenna cover –to –antenna cover) should
be kept to a minimum. Foresee sufficient margin (> 2 cm) such that under all conditions moving parts
are not touching the instrument.
FIGURE 1: STAINLESS STEEL BASE PLATE FOR MOUNTING THE SENSOR MODULE AND THICKNESS SENSOR .
✓Please foresee free space (minimum 50 cm) around the top measurement unit (TMU) to facilitate the
installation of the product-thickness sensor and infrared temperature sensor at the antenna side as
indicated in Figure 2.
✓Mount the computational unit in the vicinity of theTMU andBMU with the cable glands pointed towards
the floor. Please foresee a save and easy access to the TMU, BMU and the computational unit to
facilitate the maintenance on the Moisture-Sense system.

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Moisture-Sense User’s Guide 11
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 and the computational unit should be mounted rigidly on a frame limiting any
vibrations as much as possible.
✓Make sure there are no other devices operating in the same frequency range: 2.4-2.5 GHz and 5.725-
5.875 GHz such as Wi-Fi routers or extenders. Respect a distance of 1 m from the Moisture-Sense
system.
✓The cable distance between the computer-box and the HF units may not be longer than 3 m. Cables
longer that 3 will compromise the data acquisition speed.
✓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:CROSS SECTION (FRONT VIEW)A SHOWS CORRECTLY MOUNTED
DISTANCE SENSORS.THE LASER POINT OF THE DISTANCE SENSOR IS POINTED AT THE CENTRE REGION OF THE PRODUCT .
SECTION B,C AND D SHOW THE INAPPROPRIATE POSITIONING OF THE DISTANCE WHICH RESULTS IN WRONG
MEASUREMENTS.

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7.2 Power supply cables
External power connection
The Moisture-Sense is powered via the computer unit which further distributes the power to the distance sensor,
infrared temperature sensor, emitter and receiver units. Figure 4 shows the incoming power (red) and the
distribution links (blue). Please connect the main power to a single 230VAC –50 Hz power source with an external
switch or remote relay controlled via a PLC. The power distribution to the distance sensor is already foreseen.
FIGURE 4: POWER SUPPLY INTERCONNECTIONS.
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 streamsbetween thecomputer unit, distance sensor, infrared temperature 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.
8Operation
8.1 Sensor power-on and shutdown
Power on
The Moisture-Sense is switched on by plugging the power cord in a socket or by supplying the power via the PLC
system. The sensors 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 Unexpected stop and restart 10.1 Unexpected stop
and restart.
CAUTION: If any smoke or unusual odours are detected, disconnect the device from the electrical outlet and
contact Aquantis immediately. See page 2 for the appropriate contact information.
Shutdown
The Moisture-Sense sensors software needs to be shutdown properly prior to cut off its mains power. The system
is turned off via the webserver’s shutdown-button of by writing a “0” to the Modbus holding register 11. 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.

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FIGURE 7: WEBSERVERS MENU:SHUTDOWN BUTTON.
8.2 Connectivity
Connecting to the sensor via a PC
8.2.1.1 Via an Ethernet cable
The Moisture-Sense 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 (near HDMI where ethernet cable is connected) can be set to a fixed IP
address specified by the user.
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 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 to the sensor) as follows:
STEP 1: Open the “Network and sharing centre”.
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.
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-IR1-DP-V2-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 (Password:
AquantisMoistureSense). Just as described in the previous section, the IP address of Port 2 can be changed.

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8.3 User Interface
The Aquantis Moisture-Sense can be interfaced in via:
✓Webserver interface (read & write)
✓Modbus TCP/IP (read & write)
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/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 10.
FIGURE 10: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. CALIBRATION: Calibrates the system without the product to correct for dirt or condensation on the
conveyor belt.
9. CALIBRATION: 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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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 11. 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 selecting the appropriate sensor configuration: products on conveyor or
products in free-fall.
FIGURE 11:THICKNESS SENSOR CALIBRATION WIZARD -SENSOR CONFIGURATION.
Next, one need to place a first 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 12.
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).

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FIGURE 13:THICKNESS SENSOR CALIBRATION WIZARD -THICKNESS INPUT OF REFERENCE 1.
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
The calibration of the main sensor is mandatory before using the sensor. Preventing doing this step will result
in incorrect sensor data.
•Empty the conveyor belt of all products or product parts. Important here is that the conveyor belt is
completely dry.
•Click on the NO PRODUCT calibration button in the logging centre (Figure 16). This automatically
calibrates the sensor during a few seconds.

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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 and MAC address. A static IP address will be active unless DHCP is
used to attribute the IP address automatically.
FIGURE 17:TCPIP SETTINGS PAGE.
8.3.1.5 About
Protection level: freely accessible.
The about-page contains basic information about the sensor as well as a download-link to the user-manual.
FIGURE 18:ABOUT PAGE.

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Modbus TCP/IP interface
8.3.2.1 Introduction
Interoperability between the Aquantis system and external systems is provided through Modbus over TCP/IP.
The Modbus server runs on standard port 502.
Through Modbus, data can be read, and some functions can be configured. Data reads are performed through
the Read Holding Registers (0x03) data function, while data writes are performed either through Write Single
Register (0x06), or through Write Multiple Registers (0x10).
All register addresses not mentioned here are either reserved or for internal use, do not depend on their value
unless instructed to do so. Writes to registers other than those mentioned in the section “Write Operations”
can cause the device to malfunction and cease working.
8.3.2.2 Operations
TABLE 1: MODBUS TCP/IP COMMANDS.
Function
Address
Unit
Data Type
Description
Error
state
0x00
None
unsigned 16-
bit integer
Bitmap of error flags. When a bit is set to 0, no error state is
present. A bit set to 1 means that submodule or system is in an
error state.
A total value of 0 therefore means no errors are set. Bits are named
in a manner where 0 is the least significant bit and 15 the most
significant bit.
Errors are non-latching and self-clear when applicable.
Bit 0
reserved
Bit 1
Temperature sensor status
Bit 2
Thickness sensor status
Bit 3
reserved
Bit 4
reserved
Bit 5
reserved
Bit 6
reserved
Bit 7
reserved
Bit 8
system starting
Bit 9
reserved
Bit 10
reserved
Bit 11
reserved
Bit 12
reserved
Bit 13
reserved
Bit 14
reserved
Bit 15
reserved