Best GENIUS Compact Installation instructions

© BESTnv
PRE-INSTALLATION FAX BACK CONFIRMATION CHECKLIST
Please return this completed form back to BESTnv by fax, after the pre-installation of the GENIUS Compact
→fax number : + 32 16 396 390
FROM : …………………………..………………..………………….(your company)
GENIUS Camera Sorter with serial number ………………...was delivered at our premises on
……………………………..…(date).
ITEM STATUS
YES / NO
- packed equipment : visible damage from the outside? □□
- equipment unpacked? □□
- unpacked equipment: visible damage? □□
- all items from packing list present? □□
- GENIUS Compact sorter unit mechanically installed? □□
- optical laser box (option) mounted? □□
- infeed shaker positioned? □□
- accept/reject shaker(s)/belt(s) positioned? □□
- infeed shaker electrically wired to GENIUS Compact? □□
- accept/reject shaker(s)/belt(s) electrically wired to GENIUS Compact? □□
- electrical connection 3 x 400V (+neutral and earthing) available? □□
- separate electrical connection cooling unit available? (option) □□
- piping air pressure supply: 3/4” (inch) connection? □□
- piping water supply (for optional bull nose)? □□
- piping cooling water to/from optional cooling unit: 3/4” (inch)? □□
- infeed conveying equipment installed? □□
- accept conveying equipment installed? □□
- reject conveying equipment installed? □□
- mechanical test of production line? □□
- product available? □□
Responsible person in the factory during installation : ………………………………...
I, …………………………………… hereby declare that the above status description is correct and that the
GENIUS Compact is ready for commissioning by the BESTnv Service department on:
………...……………… (date).
date & signature :…………………………..…………..

© BESTnv
Pre-installation checklist/
Confirmation fax
We would be most grateful if you could please fax this
checklist to us when all relevant items have been taken care of.
The installation engineer can only leave for your company after
we have received this completed and signed checklist,
confirming that all is ready for the installation.
If you have any question or problem concerning this checklist,
or any other item having to do with the pre-installation for which the
answer cannot be found in the Pre-installation Guide (chapter 2),
do not hesitate to contact our service department.

OPERATORS & MAINTENANCE MANUAL
Version 0.1 UK
© BESTnv
Compact Version
Compact Version

This Machine is a Product of BESTnv.
Copyright
All information in this manual is confidential and remains the unalienable property of
BESTnv.
This manual is subject to local and international copyright laws. No part of this manual may
be reproduced, copied or adapted in any way without explicit prior written permission of
BESTnv.
© BESTnv

Dear User,
You are now the proud owner of a new, state of the art GENIUS Optical Sorter and
we at BESTnv would like to congratulate you on your latest purchase. We are
convinced the GENIUS will constitute a serious contribution to improving the final
quality of your products and increasing your competitive position on the international
market.
We, the people at BESTnv, feel that selling a sorter is not simply the happy end of a
story, we consider it as the beginning of a long relationship between our two
companies, based on trust and professionalism. Even after the contracts have been
signed, our sales team will remain fully at your disposal. Please do not hesitate to
contact us in case you have any further questions or remarks.
We strongly believe that the professional and trustworthy relationship between our
two companies, gradually built up by our sales people during the negotiations, will be
adopted by our after-sales team and our service engineers. Their customer-oriented
problem-solving attitude reflects the philosophy that can be found everywhere at
BESTnv and constitutes the central core of our strategy: “A real professional
treatment does not end when the customer has signed the contract, this is merely a
starting point.”
We hereby wish you and your company a very successful future and are proud that
we have been able to contribute our share.
Bert Van der Auwera
Director Sales & Marketing

0/1
Chapter 0: Table of Contents
Operators & Maintenance Manual GENIUS Compact Version UK 0.1
Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
0. Table of Contents
0. Table of Contents ................................................................................... 0/1
Safety............................................................................................................... I
Preface A: General Safety................................................................................................. I
Preface B: GENIUS Compact Electrical Safety ............................................................... II
Preface C: GENIUS Compact General & Mechanical Safety .........................................IV
Preface D: GENIUS Compact Safety Labels ..................................................................VI
Preface E: GENIUS Compact optical sorter Warranty & Responsibility...........................X
I. Introduction.............................................................................................. 1/1
1.1. The GENIUS Optical Sorter Platform..................................................................... 1/1
1.2. Reliable operation and performance ...................................................................... 1/2
1.3. Easy to set and operate ......................................................................................... 1/2
1.4. Flexibility in Optical and Mechanical Configurations .............................................. 1/3
1.5. Principles of operation............................................................................................ 1/3
1.6. Minimum maintenance ........................................................................................... 1/4
II. Unpacking and placing of GENIUS Compact sorter ........................... 2/2
2.1. Unloading and unpacking....................................................................................... 2/2
2.2. Machine parts......................................................................................................... 2/3
2.3. Technical data ....................................................................................................... 2/4
2.4. Installation ..............................................................................................................2/7
2.4.1. Lifting the GENIUS Compact sorter unit ....................................................................................2/7
2.4.2. Placing the different units...........................................................................................................2/8
2.5. Full Pre-installation list ......................................................................................... 2/12
2.5.1. Preparation of the area ............................................................................................................2/12
2.5.2. The GENIUS Compact optical sorter .......................................................................................2/13
2.5.3. The infeed shaker.....................................................................................................................2/16
2.5.4. Accept/Reject shakers or belts (optional).................................................................................2/17
2.5.5. The nitrogen bottle ................................................................................................................... 2/18
2.5.6. Cooling Unit (optional)..............................................................................................................2/20
2.5.7. Product streams to and away from the GENIUS Compact sorter ............................................ 2/23
2.6. Pre-installation checklist summary....................................................................... 2/25

Chapter 0: Table of Contents
0/2 Operators & Maintenance Manual GENIUS Compact Version UK 0.1
Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
III. Theory..................................................................................................... 3/1
3.0. Introduction ............................................................................................................ 3/1
3.1. The Different Optical Configurations ...................................................................... 3/1
3.1.1. The GENIUS Compact-B (Basic) configuration..........................................................................3/2
3.1.2. The GENIUS Compact-N option ................................................................................................3/3
3.1.3. The GENIUS Compact-S (Surround/bottom) option .................................................................. 3/4
3.1.4. The GENIUS Compact-L (Laser) configuration..........................................................................3/5
3.1.5. The GENIUS compact-D (Dual) option ......................................................................................3/6
3.2. Theoretical background.......................................................................................... 3/7
3.2.1. Cameras..................................................................................................................................... 3/7
3.2.2. Illumination ................................................................................................................................. 3/8
3.2.3. Detection system........................................................................................................................3/9
3.2.4. Sorting Parameters .................................................................................................................. 3/11
3.2.5. Removal of the defects ............................................................................................................3/16
IV. Operating the GENIUS Compact.......................................................... 4/1
4.1. Introduction ............................................................................................................ 4/1
4.2. Location of the different parts................................................................................. 4/2
4.3. Control panel.......................................................................................................... 4/9
4.4. Main Power Switch & Emergency stop ............................................................... 4/12
V. Routine Operational Procedures .......................................................... 5/1
5.1. The different Startup/Shutdown Procedures .......................................................... 5/1
1. Complete Shutdown/Startup ............................................................................................................5/2
2. Emergency Stop...............................................................................................................................5/3
3. Standard Shutdown/Startup .............................................................................................................5/4
5.2. Using the Pollux Touchscreen navigation bar ........................................................ 5/5
5.3. Log-in ..................................................................................................................... 5/6
The Log-in menu ..................................................................................................................................5/6
5.4. Normalization ......................................................................................................... 5/8
5.5. Sorting.................................................................................................................. 5/11
5.6. Saving and loading Product Files......................................................................... 5/13
5.6.1. Loading Product Files: .............................................................................................................5/14
5.5.2. Saving Product Files ................................................................................................................5/14
5.7. Setting a New Product File................................................................................... 5/15
5.8. Sorting.................................................................................................................. 5/33
VI. Cleaning the GENIUS Compact ........................................................... 6/1
6.1. Cleaning Procedure .............................................................................................. 6/1
6.2. Detergents.............................................................................................................. 6/5

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Chapter 0: Table of Contents
Operators & Maintenance Manual GENIUS Compact Version UK 0.1
Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
VII. Maintenance: ........................................................................................ 7/1
7.1. Warranty Limitations and General Conditions........................................................ 7/1
7.1.1. Warranty Limitations...................................................................................................................7/1
7.1.2. General conditions .....................................................................................................................7/1
7.2. Essential maintenance tasks:................................................................................. 7/2
7.2.1. Daily maintenance......................................................................................................................7/2
7.2.2. Weekly maintenance..................................................................................................................7/2
7.2.3. Monthly maintenance .................................................................................................................7/3
7.2.4. Yearly maintenance....................................................................................................................7/3
7.2.5. Preventive maintenance (recommended) .................................................................................. 7/4
7.3. Air Pressure Regulator ........................................................................................... 7/5
7.4. Hibernation of the machine .................................................................................... 7/7
7.4.1. Air Gun Draining and Test procedure .........................................................................................7/7
7.5. The Detection Belt.................................................................................................. 7/9
7.5.1. General ...................................................................................................................................... 7/9
7.5.2. Replacing the Detection Belt....................................................................................................7/10
7.5.3. Tensing and Tracking of Detection Belt ....................................................................................7/12
7.6. Greasing the bearings.......................................................................................... 7/15
7.7. Replacing the small return axle of the detection belt ........................................... 7/17
7.8. Cooling ................................................................................................................. 7/21
7.9. Electrical installations........................................................................................... 7/22
VIII. Troubleshooting.................................................................................. 8/1
8.1. Introduction ............................................................................................................ 8/1
8.2. General Troubleshooting and Alarm lights ............................................................. 8/1
General ................................................................................................................................................ 8/1
Alarm Lights ......................................................................................................................................... 8/1
8.3. Troubleshooting Procedures .................................................................................. 8/2
8.3.1. Procedure 1: Testing Main Air Pressure Regulator .................................................................... 8/2
8.3.2. Procedure 2: Testing Settings optional cooling unit ................................................................... 8/3
8.3.3. Procedure 3: Replacing compressed air valves (FESTO)..........................................................8/4

Chapter 0: Table of Contents
0/4 Operators & Maintenance Manual GENIUS Compact Version UK 0.1
Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
IX. Touchscreen Program .......................................................................... 9/1
9.0. Contents of Touchscreen Program......................................................................... 9/2
9.1. General info............................................................................................................ 9/3
9.1.1. Screen Layout ............................................................................................................................9/3
9.1.2. Help Menu.................................................................................................................................. 9/5
9.2. Log-in Menu ........................................................................................................... 9/6
9.2.1. Logging in................................................................................................................................... 9/6
9.2.2. User Levels ................................................................................................................................ 9/7
9.3. Main Menu ............................................................................................................. 9/8
9.4. Detection Menu ...................................................................................................... 9/9
9.4.1. Settings Menu ..........................................................................................................................9/12
9.4.2. Frame Grab Menu....................................................................................................................9/16
9.4.3. Scope Menu .............................................................................................................................9/21
9.4.4. Normalization Menu .................................................................................................................9/22
9.4.5. LED Lighting Menu...................................................................................................................9/24
9.5. Rejection Menu .................................................................................................... 9/25
9.5.1. Settings Menu ..........................................................................................................................9/26
9.5.2. Valve Test Menu .......................................................................................................................9/27
9.5.3. Belt Speed................................................................................................................................ 9/28
9.6. Product Setups Menu........................................................................................... 9/30
9.7. Expert Settings..................................................................................................... 9/31
9.7.1. User Management Menu.........................................................................................................9/31
9.8. Warnings and Errors Menu .................................................................................. 9/32
X. The Laser Box ...................................................................................... 10/1
10.1. Introduction ........................................................................................................ 10/1
10.2. Theory ................................................................................................................ 10/1
10.2.1. Laser Light Illumination ..........................................................................................................10/1
10.2.2. Basic principle laser sorting ...................................................................................................10/2
10.3. GENIUS Compact Laser Safety......................................................................... 10/3
10.3.1. Optical Laser Safety...............................................................................................................10/3
10.3.2. Laser Safety Labels (only with laser box) ................................................................... 10/5
10.4. Operation ........................................................................................................... 10/7
10.5. Cleaning & Maintenance .................................................................................... 10/8
10.5.1. Scan Shielding and Laser window ......................................................................................... 10/8

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Chapter 0: Table of Contents
Operators & Maintenance Manual GENIUS Compact Version UK 0.1
Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
XI. FSV-System ..........................................................................................11/1
11.1. Introduction......................................................................................................... 11/1
11.2. Safety ................................................................................................................. 11/3
11.2.1. Interlock system FSV-system ................................................................................................. 11/3
11.3. Operation............................................................................................................ 11/4
11.3.1. Switching the FSV-module ON/OFF....................................................................................... 11/4
11.4. Cleaning ............................................................................................................. 11/5
11.4.1. CIP (Clean In Place)-system .................................................................................................. 11/5
11.5. Maintenance....................................................................................................... 11/6
11.5.1. Cooling ................................................................................................................................... 11/6
Attachments...........................................................................................INFO/I
Attachment A:Electrical Schematics...................................................................... INFO/III
Attachment B: Supplier Information ....................................................................... INFO/V
B 1: Infeed Shaker ......................................................................................................................INFO/VII
B 2: Power Supplies.....................................................................................................................INFO/IX
B 3: Electrical Components..........................................................................................................INFO/XI
B 4: Cooling................................................................................................................................ INFO/XIII
Attachment C:Spare Parts List.............................................................................INFO/XV

Chapter 0: Table of Contents
0/6 Operators & Maintenance Manual GENIUS Compact Version UK 0.1
Pulsarr Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]

I
Safety prefaces
Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
Preface A: General Safety
This manual contains all user information for the GENIUS Compact
Optical Sorter. Included herein is support for operating, maintaining
and servicing the GENIUS Compact Optical Sorter.
Read this manual carefully before operating
the GENIUS Compact Optical Sorter for the first time.
Special attention should be given to the material in:
Safety
- Preface B, Electrical safety:
describing all the safety features and the safety measures to be
taken with regards to a safe use of the electrical installation.
- Preface C: General & Mechanical Safety:
describing all the safety features and the safety measures to
be taken with regards to a safe use of the general & mechanical
installation, and especially the moving parts.
If this GENIUS Compact configuration is equipped with
a laser box (only for GENIUS Compact-L(aser) and GENIUS Compact-
D(ual) configurations):
- Please check the Laser Safety part of Chapter 10,
describing all the electrical safety features and the safety measures to
be taken with regards to a safe use of the laser box.
Adapting safety features, wrong use of controls, or performance of
procedures other than those specified in this manual,
can result in unsafe situations that can be harmful
for workers and/or sorter installation.
(a.o. hazardous radiation exposure if laser box is present)

Safety prefaces
II Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
Picture: Main power switch OFF
Preface B:
GENIUS Compact Electrical Safety
Electrical Safety
- The GENIUS Compact Sorter uses AC and DC voltages, all power requirements can be found in chapter
2 under 2.3. Technical Data.
- Service should be provided by qualified personnel, authorized by BESTnv.
- Always follow the electrical safety procedures when handling the electrical installation (see Basic
Electrical Safety Procedure and Main Power Safety Procedure later in this chapter).
Basic Electrical Safety Procedure
During maintenance and service of the electrical installation and when repairing or adapting the electrical
installation, all power to the installation should be cut, except to the main power switch installation.
In order to ensure the safety of the maintenance and service personnel the power should be cut by
pressing the Emergency button and locking the main power switch in the OFF position, using a padlock
with a shackle of 6 to 8mm thick in cross section, as indicated in the picture above (see also Main Power
Switch Safety label).

III
Safety prefaces
Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
Main Power Safety Procedure
When installing the GENIUS Compact sorter or when replacing the main power switch installation, all
power to the installation, including the main power switch, must be cut, in order to ensure the safety of
the maintenance and service personnel.
In order to accomplish this, all power connections to the sorter and related machinery should be cut,
either by use of circuit breakers or by removing the appropriate plugs from their sockets. In order to be
absolutely safe, it might be advisable to check, using a voltmeter, that the main power switch or any other
part of the installation is not charged.
Emergency Stop
In case of emergency press one of the Red/Yellow buttons (see picture) on the sorter. The electrical power
to all moving parts on the machine and to the lighting installation will be cut immediately.
Attention: - Do not use the Emergency Stop for routine shutdown!
-Frequent use of the Emergency Stop may result in damaged equipment or
premature failures of certain electrical or electronic components (see
Emergency Stop Label underneath).

Safety prefaces
IV Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
Preface C:
GENIUS Compact General & Mechanical Safety
General Safety:
To ensure the safety of all users: operators, cleaning and maintenance personnel, it is important that all
safety measures the GENIUS Compact Sorter has been equipped with (such as Emergency buttons,
fixed or removable guards, safety switches, warnings signs, etc...) are present and functioning. Never
tamper with any of these safety measures.
Emergency buttons should be pushed immediately whenever something may be going wrong, either
with the installation, or with one of the workers nearby. When the machine is stopped this way, it can not
accidentally be restarted, but must be started with a deliberate sequence of actions (see chapter 4).
It is generally advisable to give access to the machine only to those people who are aware of all safety
risks involved and are trained to operate such machinery.
It is recommended to always wear protective clothing when entering a production area and always take
all hygienic guidelines and rules into account.
Mechanical Safety:
A number of simple rules should be taken into account when working with the GENIUS Compact sorter
installation:
- Always check everyone is at a safe distance before switching on the detection belt, the infeed shaker
and/or the return system(s).
- Verify that no loose objects are lying on the detection belt, infeed shaker and/or return system.
- Before switching on any part of the sorter installation, make sure nobody is working on, in or under any
part of the machinery, including infeed shaker and return system.
- Never touch, or put objects on the detection belt, the infeed shaker or the return system when these
are functioning.
- When working with or near the sorter unit, never wear loose clothing or other loose attire that might
get caught between any belt and drive drums or return axles or could wind itself round rotating objects,
such as background drums, etc... .
All maintenance and cleaning activities (see chapters 6 & 7) should be performed with the machine
switched off, except if specifically indicated otherwise.
When in doubt, or when special and complicated procedures are required, please do not hesitate to
contact BESTnv for advice or to arrange a visit by an experienced service engineer.

V
Safety prefaces
Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
Attention! - Non-compliance with safety instructions on the machine or in this manual
may cause severe injury to personnel and major damages to the installation.
- Make sure all personnel that works with or in the vicinity of the GENIUS
Compact is properly instructed and up to date on all safety and operating
instructions.

Safety prefaces
VI Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
Preface D:
GENIUS Compact Safety Labels
Below you will find a list with pictures of all safety labels located on the GENIUS Compact installation.
For more info on the exact position of the labels, consult the pictures on the pages following the list.
Nr. Label name Picture Position
000 Identification plate 1- Left side of sorter
unit.
013 Electricity Label (large) 1- In the middle of all
doors and cabinets
containing electrical
installations.
014 Gear wheel Label
(large)
1- On all doors and/or
cabinets containing
moving parts (e.g.
gears, etc...).
015 Electricity Label (small) 1- Next to the electricity
racks inside the cabinet
of the sorter unit.
016 Gear wheel label
(small)
1- On the covers of
smaller gear boxes
(e.g. background drum
gears).
017 UK Lock Main Power
Switch
1- Underneath main
power switch on sorter
unit.

VII
Safety prefaces
Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
018 UK Hibernation 1- Upper corners of
sorter unit doors on
both sides.
019 UK Emergency Stop 1- Underneath every
Emergency stop on the
sorter unit.
021 UK Doors closed 1- In the centre of every
door of the sorter unit,
next to the lock.
022 UK No welding 1- Top or bottom of
sorter unit doors on
both sides.
2- Both sides of shaker
pan.
023 UK No high pressure 1- Above Touchscreen
display on door of sorter
unit.
025 UK Service Label 1- Inside door of sorter
unit.
026 UK Water in 1- Next to water
connections underneath
or on top of sorter unit.
027 UK Water out

Safety prefaces
VIII Operators & Maintenance Manual GENIUS Compact Version UK 0.1 © BESTnv
BESTnv Industrial Research BV, Marinus van Meelweg 20, 5657 EN, EINDHOVEN, THE NETHERLANDS
General tel. [phone] - Service tel. [phone] - Fax. [phone] - Email: [e-mail]
030 UK Main Power Switch 1- Above main power
switch on sorter unit.
031 UK No step 1- On top of rejection
unit.
2- On top of Laser box
(if present).
044 CE-label (only in EU) 1- On identification
plate on sorter unit.