AQUANTIS CALLIFREEZE User manual

CALLIFREEZE®
USER’S GUIDE
Document No: CALLIFREEZE2019-2
July 2019

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Callifreeze 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 : [e-mail]
Website : www.aquantis.org

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Callifreeze User’s Guide 3
Contents
1Contact information........................................................................................................................................ 2
2About the user guide....................................................................................................................................... 5
2.1 Introduction........................................................................................................................................... 5
2.2 Nomenclature........................................................................................................................................ 5
2.3 Publication............................................................................................................................................. 5
2.4 Additional Documents ........................................................................................................................... 5
3Disclaimer........................................................................................................................................................ 6
4Safety information .......................................................................................................................................... 7
4.1 General safety instructions.................................................................................................................... 7
4.2 Laser classification (Class II)................................................................................................................... 7
5Transport and storage..................................................................................................................................... 8
5.1 Transport ............................................................................................................................................... 8
5.2 Transport inspection.............................................................................................................................. 8
5.3 Storage................................................................................................................................................... 8
6Sensor installation and integration................................................................................................................. 9
6.1 Installation guidelines............................................................................................................................ 9
6.2Power supply cables ............................................................................................................................ 10
6.3 Data interconnection........................................................................................................................... 11
7Operation ...................................................................................................................................................... 13
7.1 Sensor power-on and shutdown ......................................................................................................... 13
7.1.1 Power on ......................................................................................................................................... 13
7.1.2 Shutdown ........................................................................................................................................ 13
7.2 Connectivity......................................................................................................................................... 13
7.2.1 Connecting to the sensor via a PC................................................................................................... 13
7.2.2 Connecting to the sensor via the network infrastructure............................................................... 14
7.3 User Interface ...................................................................................................................................... 15
7.3.1 Introduction .................................................................................................................................... 15
7.3.2 Description of operation ................................................................................................................. 15
7.3.3 Display............................................................................................................................................. 15
7.3.4 Webserver interface........................................................................................................................ 17
7.3.5 Modbus TCP/IP interface ................................................................................................................ 34
8Maintenance & Disposal ............................................................................................................................... 35
8.1 Daily maintenance ............................................................................................................................... 35
8.2 Yearly maintenance ............................................................................................................................. 35
8.3 Disposal................................................................................................................................................ 35
9Troubleshooting ............................................................................................................................................ 36

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9.1 Unexpected stop and restart............................................................................................................... 36
9.2 Returns ................................................................................................................................................ 36
9.3 Repairs................................................................................................................................................. 36
10 Technical data .......................................................................................................................................... 37
10.1 General specifications ......................................................................................................................... 37
10.2 Electrical specifications........................................................................................................................ 37
10.2.1 High frequency electronics –GHz Technology............................................................................ 37
10.2.2 Low frequency electronics .......................................................................................................... 37
10.3 Mechanical specifications.................................................................................................................... 38
10.3.1 Materials..................................................................................................................................... 38
10.3.2 Computer-box............................................................................................................................. 38
10.3.3 HF measurement units................................................................................................................ 39

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2About the user guide
2.1 Introduction
The Callifreeze, a registered trademark of GEA, is intended to determine the level-of-frozenness (LOF) of your
food products. This device is developed and manufactured by Aquantis. The product number is indicated on the
device and has the format: AQFS-TS1-V3-2019-X. The X represents the unit-specific number. 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 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
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.
2.2 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
LOF level-of-frozenness
Mm-waves millimetre waves
TMU top measurement unit: emitter of receiver unit placed above the conveyor belt
UINT16 unsigned integer of 16 bits
2.3 Publication
Manual version 3.0 with Document No: CALLIFREEZE2019-1 was published on January 30th 2019.
2.4 Additional Documents
Additional documents for the CALLIFREEZE include:
▪CALLIFREEZE Fabrication Instructions (Document No: CALLIFREEZE2019-FAB-1): 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: CALLIFREEZE2019-BOM-1): Overview of the components
used in the Callifreeze. This document is solely meant CALLIFREEZE manufacturers.
▪CALLIFREEZE Product Label (Document No: CALLIFREEZE2019-LABEL-1): The label can be found on the
product.

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3Disclaimer
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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4Safety 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.
4.1 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 Callifreeze to protective earth via a low
resistive path (< 1 Ohm).
WARNING: A minimum distance of 0.1 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.
4.2 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.
Permitted sensor uses:
The Callifreeze system is designed for use in industrial environments
▪Measure LOF of products (layers) on a conveyor belt or free-fall.
▪Measure product thickness of products (layers) on a conveyor belt or free-fall.
No other uses are permitted.
Prohibited sensor uses:
▪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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5Transport and storage
5.1 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 mounting
5.2 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.
5.3 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 +50 °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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6Sensor installation and integration
6.1 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 your own products.
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:
✓In case a conveyor belt is used, the conveyor belt material should be rather transparent for mm-waves.
The insertion loss caused by the belt may not exceed 3 dB. Most plastic conveyor belt materials comply
with this requirement, metal conveyor belts don’t.
✓The HF emitter is mounted above (or underneath) the conveyor belt or products at 10 cm from the
product. The HF receiver is placed underneath (or above) 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 emitter and receiver (from antenna cover –to –
antenna cover) should not exceed 40 - 50 cm. Foresee sufficient margin (> 2 cm) such that under all
conditions moving parts 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 the product-thickness sensor at the antenna side as indicated in Figure 2. The product
thickness sensor is attached to a stainless-steel base plate which is mounted to the two wall-mount
spacers of the HF receiver unit. All units need to be mounted on metal frame which needs to be
accessible from the back to fix the different units.
a
b

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✓Mount the computational unit in the vicinity of the TMU and BMU with the cable glands pointed towards
the floor. Please foresee a save and easy access to the TMU, BMU and the computational unit in order
to facilitate the maintenance on the CALLIFREEZE measurement system.
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 HF units and the computational unit should be mounted rigidly on a frame limiting any vibrations
as much as possible.
✓Make sure there is no electromagnetic coupling from other devices operating in the same HF frequency
range: 61 - 61.5 GHz. Respect a distance of 5 m from the CALLIFREEZE system.
✓The cable distance between the computer-box and the HF units may not be longer than 6 m. Cables
longer that 6 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:SECTION A,B AND C SHOW CORRECTLY MOUNTED DISTANCE SENSORS.
THE LASER POINT OF THE DISTANCE SENSOR IS POINTED AT THE CENTRE REGION OF THE PRODUCT .SECTION D SHOWS THE
INAPPROPRIATE POSITIONING OF THE DISTANCE WHICH RESULTS IN WRONG MEASUREMENTS.
6.2 Power supply cables
The Callifreeze is powered via the computer unit which further distributes the power to the distance sensor,
emitter and receiver units. Figure 4 shows the incoming power (red) and the distribution links (blue). Please

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connect the main power to a single 230 VAC –50 Hz power source with an external switch or remote relay
controlled via a PLC. The power distribution to the emitter and receiver units is already foreseen.
FIGURE 4: POWER SUPPLY INTERCONNECTIONS.
6.3 Data interconnection
The data streams between the computer unit, distance sensor, emitter and receiver units are shown in Figure 5.
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.

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FIGURE 5: DATA SIGNAL INTERCONNECTIONS.

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7Operation
7.1 Sensor power-on and shutdown
7.1.1 Power on
The Callifreeze 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 restart9.1 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.
7.1.2 Shutdown
The Callifreeze 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.
FIGURE 6: WEBSERVERS SHUT DOWN BUTTON
7.2 Connectivity
7.2.1 Connecting to the sensor via a PC
The Callifreeze can be directly connected to a PC by means of the Ethernet RJ45 connector. 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. To do so, one
need to change the Ethernet adaptor settings 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 7 and press OK.

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FIGURE 7: 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.
7.2.2 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 sensor is equipped with a DHCP client to negotiate an IP address within the network domain.
Depending on your IT infrastructure it can be useful to assign a fixed IP address to the sensor based on its MAC
address [xx:xx:xx:xx:xx:xx]. This can typically be set as a rule at the router side.
STEP 1: connect the sensor the LAN.
STEP 2: connect to the sensor with the IP address which was automatically assigned during the DHCP
procedure.

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7.3 User Interface
7.3.1 Introduction
The Aquantis Free-space freezing sensor can be interfaced in different ways:
✓Display (read only)
✓Webserver interface (read & write)
✓Modbus TCP/IP (read & write)
In what follows, the different user interfaces are further explained.
7.3.2 Description of operation
7.3.2.1 Setting up the system
1. Open the dashboard via the web interface using the set IP address and go to control centre (see sections
7.3.4.2 and 7.3.4.3). Select in the control centre the appropriate mode (typically dynamic mode).
2. Select and follow the instructions of the sensor calibration wizard (see section 7.3.4.4).
3. Select and follow the instructions of the thickness sensor calibration wizard (see section 7.3.4.5).
4. Go to product specifications / signal processing and set the product parameters (see section 7.3.4.6). A
link to the product signal processing wizard is available (see section 7.3.4.7).
7.3.2.2 Run the system
1. Once the system is set up, go to logging centre and switch on the data acquisition by clicking on the
logging button (see section 7.3.4.8). 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.
2. To stop the data acquisition function, re-click on the logging button.
7.3.3 Display
The display is integrated in the computer-box (see Figure 8 - Figure 9). On the display, one can find the following
information:
✓Level-of-frozenness gauge & digital indicator:
▪static mode of operation: real-time LOF value.
▪dynamic mode of operation: LOF value is the average of the selected number of products which are
accepted for the measurement.
✓Product thickness gauge & digital indicator:
▪static mode of operation: real-time product thickness value.
▪dynamic mode of operation: product thickness value is the average of the selected number of
products accepted for the measurement.
✓Text field with sensor information:
▪Systems Date & time
▪Product label
▪Mode-of-operation STATIC | DYNAMIC
▪IP address + indication of webserver activity
▪Sensor status:
Status responses in static mode
“OK” Normal operation
“No HF power” HF unit are not powered
solution: switch on the emitter and receiver via web-interface or Modbus

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“Calibration needed” No product (thickness < the range specified in product database)
Low signal (signal too small for no product –< 80% of current calibration level)
solution: run sensor and thickness calibration wizards
“No Product or product to thin”Measured product thickness < minimum product thickness specified in the
product database
causes:
- Wrong product selection or database parameters
- Product is not placed correctly under the sensor
- Thickness sensor needs calibration –execute the thickness calibration
wizard
“Product to thick” Measured product thickness > maximum product thickness specified in the product
database
causes:
- Wrong product selection or database parameters
- Multiple products are stacked on top of each other
- Thickness sensor needs calibration –execute the thickness calibration wizard
FIGURE 8: LCD-DISPLAY:START UP SCREEN

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FIGURE 9: LCD-DISPLAY:DATA SCREEN
7.3.4 Webserver interface
Note: it is advised to make use of Google Chrome version 70.x or later for consulting the sensors webpages.

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7.3.4.1 The web page structure
FIGURE 10:EXAMPLE OF THE WEB INTERFACE.
▪DASHBOARD-page (home-page) [freely accessible - read only]
▪CONTROL CENTER-page [password protected –read/write]
oLINK TO: Sensor calibration wizard
oLINK TO: Thickness sensor calibration wizard
oLINK TO: Product specifications / signal processing
▪LINK TO: Product signal processing wizard
▪ABOUT-page [freely accessible - read only]

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7.3.4.2 Dashboard
Protection level: freely accessible.
FIGURE 11:DASHBOARD WEBPAGE
The home-page of the CALLIFREEZE sensor consist of a freely accessible dashboard (Figure 11) on which the
following parameters of the sensor are published:
1. PRODUCT SELECTION: shows the active product together with its product label as specified in the
product database. Pressing this button activates a drop-down menu in which a product from the product
database can be selected.
2. OPERATION MODE: shows the mode of operation of the sensor. In static mode of operation, the sensor
is continuously publishing new measurement values. This mode is intended to be used for at-line
measurements where the product under test is statically placed underneath the sensor’s aperture. In
dynamic mode of operation, the sensor is analysing each interaction of passing products. Only when
detected products are accepted for measurement (based on criteria specified in the product database),
the new measurement is published. In this mode, the product averaging is active, and you can select
the averaging number of the accepted products.
3. CURRENT DATE AND TIME: shows the real-time clock of the CALLIFREEZE sensor.

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4. SYNC SYSTEMS REAL TIME CLOCK: This feature is only available in the control center (see section
7.3.4.3). It allows to sync the clients real time clock with the sensors real time clock
5. LEVEL-OF-FROZENNESS GAUGE:
▪static mode: real-time LOF value (%).
▪dynamic mode: product-averaged LOF value (%) (only products accepted for measurement).
6. PRODUCT THICKNESS GAUGE:
▪static mode: real-time product thickness value (mm).
▪dynamic mode: product-averaged thickness value (mm) (only products accepted for
measurement).
7. SENSOR (POWER) STATUS: shows the power status of the emitter and receiver unit and the status of
the sensor.
8. SENSOR POWER STATUS: shows the power status of the emitter and receiver unit.
9. DYNAMIC MODE VARIABLE INDICATOR:
▪product averaging: shows the number of accepted products to average.
▪products detected: shows the number of products detected by the sensor since last reset or sensor
settings change.
▪acceptance efficiency: shows the relative portion of accepted products with respect to the number
of detected products.
10. RESET: reset the number of detected & accepted products to 0.
11. LOF CHART: shows the history of the LOF chart. Data on the outer right side of the chart is the most
recent data.
12. SENSOR CALIBRATION FOR STATIC MODE (Disabled feature on the DASHBOARD page, can be accessed
by the CONTROL-CENTER page): This static sensor reference calibration should be executed without the
presence of a product under the sensors aperture. This calibration needs to be executed in static mode
of operation.
13. FULLY FROZEN PRODUCT CALIBRATION (Disabled feature on the DASHBOARD page, can be accessed by
the CONTROL-CENTER page): a fully frozen reference calibration can be executed by placing a fully
frozen product (corresponding the selected product of the product database) under the sensors
aperture. This calibration needs to be executed in static mode of operation, but also has effect in the
dynamic mode of operation.
14. PRODUCT THICKNESS CALIBRATION WIZARD (Disabled feature on the DASHBOARD page, can be
accessed by the CONTROL-CENTER page): This wizard guides the user through the calibration process of
the product thickness sensor.
15. PRODUCT DATABASE (Disabled feature on the DASHBOARD page, can be accessed by the CONTROL-
CENTER page): This button gives access to the product database. In this database, products can be
specified. Also, products specific signal processing parameters can be calculated by means of an
integrated wizard.