· Never put the x-ray detector into operation without the safety devices provided by the manufacturer. Only specially trained maintenance staff are allowed to operate the equipment without the safety devices.

· Shut the machine down immediately if the safety devices are not operating properly.

· or if there are other apparent defects which pose a danger. Any defects must be remedied or reported without delay.

· Always observe any warning signs attached to the machine. They help prevent dangerous situations. Removal of these warning signs is strictly prohibited.

· Never put the x-ray detector into operation

· if you have not received complete initial training from the owner or

· if you have not fully read these Operating Instructions or

· if you have not fully understood these Operating Instructions.

· Operating errors may result in severe injury or damage.

· Entering the area of the equipment is strictly prohibited for unauthorized persons. An unauthorized person is a person who has not been instructed to work on the x-ray detector.

· Wear closely fitting working clothes which cannot get caught in rotating parts (e.g. conveyor belt).

· Keep the floor at your place of work clean. Remove any oil and obstructions without delay.

Naked flames and smoking are not allowed.

Danger!

· Never touch any live parts. Electric shocks may lead to severe injury or death.

· During servicing or maintenance work always wear insulated safety shoes with thick crepe soles.

· Report any damaged cables to the maintenance staff immediately.

· Keep all access doors to the electrical equipment locked.

3.3 Connecting instructions

· Check to make sure the mains voltage is the same as that required for the equipment.

· The x-ray detector must be fitted and connected up by trained staff only.

· Observe general installation regulations for setting up and operating electrical equipment (VDE 0100).

· Consequently, never perform any work on the x-ray detector when it is switched on.

· Take precautions to protect human life and the machine in accordance with the local conditions and regulations.

· XRAY SHARK® series is designed for permanent, steady-state installation.

· Never connect or disconnect control cables or coaxial cables whilst the x-ray detector is switched on.

· Never connect mains cables, control cables or coaxial cables incorrectly.

· Observe the current-carrying capacity of the output contacts.

· Use screened/twisted-wire mains and control cables. Only connect the screening to the earth lead at the x-ray detector end.

· Never lay the mains cable and control cable together in a single cable run.

· Make sure the x-ray detector is properly earthen (neutral earth; avoid earth loops; use the shortest connection to the main earth).

3.4 Instructions about operation

To prevent XRAY SHARK^® series from ageing prematurely or being damaged beyond repair, please observe the following instructions:

· The x-ray generator should only switched on when it is in use for inspection. This will maximise the service life of the electronic circuitry.

· Only operate the x-ray detector under suitable conditions (refer to Normal use).

3.5 Protection against interference

The mains input of the x-ray detector is protected against interference. A high level of operational reliability and additional protection against malfunctions is achieved by the following measures:

· Use of mains filters if the mains voltage is affected by the switching-on of heavy-load appliances (compensation systems, welding equipment, HF furnaces, solenoid valves, etc.).

· Providing suppresser circuits for inductance appliances (solenoid valves, contactors, electromagnets) using RC elements (Resistor/Capacitor elements) in order to absorb the energy being released by switching off.

4 General Information

Validity: XRAY SHARK^® G40

Manufacturer: Cassel Messtechnik GmbH

In der Dehne 10

37127 Dransfeld

Germany

Print Date of this Manual: May 2010

This manual contains all needed information for operating the XRAY SHARK^® and is directed to operators as well as technical staff.

Before operation of this metal detector it is important this manual is read in its entirety. It is important that function and operation is understood. Please pay special attention to the safety notes.

At no time is any page to be removed from this manual. If this manual or any pages become lost, you should request a new manual immediately.

Note:

Cassel Messtechnik GmbH gives no implicit guarantees regarding standard qualities or suitability for a certain application.

This documentation contains information which is subject to copyright. No part of it may be photocopied, duplicated, translated or recorded on data media without prior consent from Cassel Messtechnik GmbH

5 Scope of application and qualification

5.1 Normal use

XRAY SHARK^® series is solely designed for detecting foreign bodies. For measurement the products may be in

· solid,

· liquid or

· powder

form.

5.2 Misuse

XRAY SHARK^® series is not designed for uses other than those listed in 3.1. Normal use- otherwise it is regarded as misuse. In particular, we draw attention to the fact that it is not allowed

· to change or remove safety devices from the x-ray detector or the associated peripheral equipment in order to perform measurements other than those indicated in 3.1. Normal use.

· to use the machine for a purpose which is not approved.

· to convert the machine without consent from Cassel Messtechnik GmbH in order to use it for a different purpose. Please bear in mind that if you perform any conversion work you may be deemed the manufacturer of the metal detector – with all the consequences!

5.3 Requirements for operating staff

To operate the XRAY SHARK^® series no special knowledge of measuring technology, mechanical engineering or electrical engineering is necessary. However, the operating staff must be at least 18 years of age and, before commencing work for the first time, must have received training from the owner of the machine.

After receiving initial training the operating staff must be in a position to perform the following activities without supervision:

· Put the x-ray detector into operation and take it out of operation.

· Be acquainted with the functions of the x-ray detector and be able to carry them out.

· Perform regular performance checks and visual inspections on the x-ray detector.

· Inspect the safety devices prior to commencement of work and during operation.

· Elimination of minor faults for which no occupational training in the field of mechanical engineering or electrical engineering is required.

5.4 Owner's obligation to exercise due care

XRAY SHARK^Ò series has been designed and built taking due consideration of a hazard analysis and after careful selection of the harmonised standards to be observed, as well as other technical specifications. It is therefore state of the art and guarantees maximum safety.

However, in practical operation this safety can only be maintained if all the necessary measures are taken. As part of his obligation to exercise due care, the owner must plan these measures and monitor their implementation

The owner of the equipment must, in particular, ensure

· that the machine is only subjected to normal use (refer to 3.1. Normal use).

· that the machine is only operated if it is in good working order and particularly the safety devices are regularly checked to make sure they are operative.

· that the Operating Instructions are always in a legible state and are available in their entirety at the place where the machine is used.

· that only adequately qualified and authorised staff operate, service and repair the machine.

· that before commencing work for the first time, and also thereafter on a regular basis, these staff receive instruction on all the relevant issues regarding safety at work and environmental protection and that they are acquainted with the Operating Instructions and particularly the safety instructions therein.

· that all the safety signs and warnings attached to the machine are not removed and remain legible.

5.5 Requirements for service and maintenance staff

To be able to perform maintenance work properly, a period of occupational training in the area of mechanical engineering or electrical engineering must have been successfully completed. Repair work may only be performed by trained maintenance staff.

For service and maintenance work on the x-ray detector knowledge of the English language is absolutely essential.

After initial training the service and maintenance staff must be in a position to perform the following activities without supervision:

· Conduct regular performance checks and visual inspections on the metal detector.

· Locate faults and remedy faults.

· Regularly inspect the safety devices.

· Initial commissioning, maintenance, repair and shutdown of the x-ray detector.

6 Transport

6.1 Safety instructions for transport and installation

Danger !

To prevent damage to the machine and hazardous injuries when transporting and installing the machine it is absolutely essential that the following instructions are observed:

· Transport and installation work may only be performed by qualified personnel observing the safety instructions.

· The machine may only be lifted using the frame provided.

· To transport the machine only the hoisting and sling gear specified here may be used.

· When selecting suitable hoisting equipment always take the following weights into account:

· depending on size and type, the x-ray detector can weigh up to 1,000 kg

· The transport route must always be guarded by a third person.

· The transport routes must be cordoned off and guarded so that no unauthorised persons may enter the danger zone.

· Any projecting sharp edges may cause injuries due to cuts.

· Suspended loads may drop, in which case there is a risk of fatal injury – never remain under suspended loads.

· Live ends of electric cables and components may cause injury due to electric shock.

· Parts lying unsecured on top of one another may slip and drop.

· During welding there is a risk of fire.

· Cables which have not been laid properly (e.g. radius of curvature too small) may cause smouldering fires and cable fires

· Also read the section General Safety Instructions.

6.2 Transporting

Always chose suitable lifting equipment.

Danger !

Never lift the entire set of equipment at the upper body (see fig. below). The heavy weight of the entire set of equipment may cause severe damage.

Legende mit Linie (3): Never lift here !!!

7 System overview G40

7.1 Outside overview

X-ray G40 system overview

Legende mit Linie (2) (ohne Rahmen): 12

USB port (for external keyboard and mouse) and RJ45 Ethernet plugs (for remote support)

1: Touch screen

2: Mains switch

3: Buttons: Belt Start / Emergency / Switch On/Off / Reset

4: Light tower, indicates x-ray state (green=x-ray off, orange=pre-warn, red=x-ray on)

5: USB port (for external keyboard and mouse) and RJ45 Ethernet plugs (for remote support)

6: Compressed air connector, for cooling in environment above +30C

7: Air ventilation

8: Contamination alarm devices (Horn, Lamp)

9: Emergency stop button

10: Safety interlock switches. The x-ray generator won’t start if any of the switches is not closed.

11: Hand leaver to open the lid, e.g. to remove blocked products. Open the lid automatically switches the x-ray generator off.

12: Shielding curtain, made from lead equivalent material.

ATTENTION: Replace the curtain when worn out.

7.2 Background –Beam geometry

X-ray generators create a conical or fan-shaped beam with which to image the products. The main problem with the inspection of objects that are thick, as well as wide, is that the X-ray beam will pass through different amounts of the product depending on the beam angle:

Thickness high

Thickness low

Single beam triangle

In addition to this point, with thick materials, there is a reliance on “over-penetration, where the X-ray generator is operated at a level that is higher than the calibration level. This means that the beam will “blast through” the thinner sections, rendering them uninspectable.

It can also be seen that beam projection will cause the system to be much larger. There will be two options:

Single beam - Low power generator Single beam - High power generator

Large detector Smaller detector

Neither of the preceding options are optimal or compact:

A generator with a short focal length will produce large projection and hence image distortion, and a lot of burn through at the corners. The machine will be very wide.

A generator with a long focal length will need a very high power, because of the 1/R² effect of the beam dispersion. The machine will also be very tall. In addition the high energy will reduce the contrast in the image, thereby adversely affecting detection sensitivity.

7.3 G40 Single Sidedown generator

The G40 Single Sidedown uses a generator in the following geometry:

G40 Single Sidedown Generator

Side-shoot aligned with Fill-level

The preferred method, which is used in the G40 Single Sidedown system, is to align the X-ray beam with the top of the container (see above figure). This has the following advantages:

The volume of material that is inspected is maximized (at about 98%)
The system achieves a good inspection of the base region
The system is much more compact than the alternative geometries, because a short focal length actually improves the inspection.
The system therefore requires lower energy and power. This improves detection performance, reduces heat generation, improves the reliability, and reduces radiation emissions.

7.4 Jar Inspection Algorithm

7.4.1 Background

One of the common requirements for Xray applications, is for jar inspection. There is a need to inspect for:

Metal contamination, where metal detectors cannot be used due to the lid.
Glass contamination, due to (for example) glass chips being knocked from the lip of jar during the capping process.
Stones, etc. from the contents of container.

The applications are required to run at typically 150 to 600 bottles per minute.

7.4.2 Technical Points

Glass is fairly opaque to X-rays and therefore can be detected quite easily. However, if you have a glass container, you will need higher energy to penetrate the glass of the container, and this will reduce the sensitivity of the inspection. Due to the sensitivity of our detector, Sapphire can operate a jar inspection at energies of down to 60Kv (compared to 90Kv or more for competitive systems). However, the following points limit the accuracy of the measurement:

Features on the glass jar, such as stippling from the code or identification around the base, will need to be masked, since it can cause false rejects.
The area at the top of the jar, and around the thread on the neck, is very difficult to inspect.
The region close to the edge of the jar (from the sides) is not normally inspectable, because of the thickness of the wall of the jar. This can be resolved, at a cost, by using two inspection systems and turning the container.
The base of the jar has very thick glass and is also “domed”. It is therefore very difficult to inspect even if the X-ray beam is projected onto the base.
If you use a “top-shoot” system, the area under the rim of the bottle cannot be inspected.

8 Installation instructions

Before installation, the system should be inspected for any physical damage. If there are any signs of physical damage to the system, then do not proceed. Contact Cassel immediately.

It is important to ensure the safe operation of the equipment that it is correctly installed and regularly serviced by a properly trained engineer.

Do not attempt to install or operate this equipment unless you have been trained to do so. Safe operation of the equipment will be ensured if you observe the following rules:

· Do not tamper with or modify any of the system electrical wiring or interlocks.

· Do not remove or attempt to operate the system with any parts or panels removed – Radiation hazards are present

· Do not use the equipment if it has been subject to physical damage.

· Do not place the system adjacent to a high source.

8.1 INITIAL INSTALLATION

It is important to ensure the safe operation of the system and that it is commissioned by a properly trained engineer.

To aid in the installation, it is advised that the customer site the system in its correct location with all necessary services connected, before Cassel engineers commission the system.

The X-ray system requires access to both the front and rear of the main cabinet; therefore it is important that the system has a minimum of 600mm clearance from any other equipment or walls.

Ensure that the system is located in the correct orientation for the product flow.

8.2 OTHER CONSIDERATIONS

The system should not be placed adjacent to a high EMC source.

The X-ray inspection system contains microprocessor-controlled equipment. Therefore, it is recommended that consideration be given to the conditioning of the AC supply to ensure reliable operation of the system.

8.3 CONNECTION OF SERVICES

Electrical Supply: 230 Volt 50Hz single phase

Air Supply: A clean, dry non-lubricated air supply is required. The Air supply should be connected to the supply port of the filter/regulator unit is located on the pneumatics panel. The air supply is used for cooling purposes and is regulated by a thermostat. Air supply is recommended for longterm operation, or in case of environment temperatures above +30C.

WARNING!

UNDER NO CIRCUMSTANCES SHOULD THE X-RAY INSPECTION SYSTEM BE OPERATED BEFORE IT HAS BEEN COMMISSIONED BY A CASSEL ENGINEER.

TO PREVENT UNAUTHORISED USE, LOCK OUT THE MAIN ISOLATOR SWITCH LOCATED IN THE SIDE OF THE MAIN CABINET.

9 Operation instructions

9.1 Starting the machine

1. Turn the machine on at ON/OFF switch on side of main cabinet.

Machine On/Off Switch

2. Ensure all access panels are closed and emergency stop (located on the front panel) is in the UP position

3. Ensure that the X-ray Inhibit key-switch (SYSTEM ON/OFF) is ON.

4. Press the Reset Button located under the screen. If the reset button light is on, check to ensure all panels are closed and the emergency stop is in the UP position.

System On/Off Switch and Reset Button

5. Ensure that the Conveyor is clear of product.

6. Start the conveyor by START BELT switch located under the main screen on the front panel.

7. The system will display the Operators Main Screen on the touch screen.

9.2 Operators Menu Screen

On start up the following Main Menu Display (Fig. 1) will appear on the screen.

Fig. 1 – Main Menu Display

This is the operators main working display and is indicated by ‘Password : 0’, shown in the bottom left screen. Refer to chapter “Access to Engineer Level 1” on how providing access to the various password protected system inspection parameters.

Image Panel

Displays X-Ray image.

Inspection Results Panel

Inspection Results

Displays Product – Pass, Contaminant, Mass, Extra Test.

Diagnostics

Displays inspected product status i.e. GOOD or CONT. Displays histogram chart.

Displays diagnostic and counter values.

X-ray Controls Panel

Calibration	To calibrate the x-ray generator
X-rays on	To start the x-ray generator
X-rays off	To stop the x-ray generator
X-rays status light indication	Shows ON/OFF status of x-rays Same light indications as light tower on top of main cabinet.

Main Displays Indications

Status

Appears bottom left of screen.

Indicates: X-rays on, X-rays off, emergency stop open.

Password

Appears bottom left of screen.

Indicates and provides access to Operators and Engineers program levels.

Engineers Level is protected by password.

To Reset Product Counters:

Press the Reset button and the counters - Pass, Contaminant and Mass on the Inspection Results panel will reset to zero.

Contaminant inspection colors:

The contaminant inspection therefore consists of the three algorithms running in parallel. Each part works independently and has its own tolerance, diagnostic and pixel colorization:

Algorithm	Color	Diagnostic	Tolerance	Setting
Density – high	Yellow	Contr.	Contam tol	Threshold Adj.
Density – low	Red	Contr.	Contam tol	Threshold Adj.
Contrast 1	Cyan	Cont1	Contrast limit	Contrast limit
Contrast 2	Pink	Cont2	Contrast limit 2	Contrast limit 2

9.3 Selecting a Pre-programmed Product

From the Main Menu (Fig 3) Select Setup.

Fig 3. Main Menu Display.

The system will display the Library menu (Fig 4).

Fig 4

Use the arrow buttons to highlight the product required. Or, press the Product Name to highlight the product required.
Press Exit button to select the product (the Form 2 menu will disappear), the Main Menu – Product Name and Image Panel will indicate the product selected.
The system will need to be calibrated before it can start inspecting product.

Parameter settings:

The previously stored parameters setting for the selected product can be displayed by Pressing the ‘Params’ button – the Parameter Entry panel will be displayed.

Press the Exit button on the Parameter Entry panel to return to the Library panel.

9.4 Calibrating the System

Select the product type to be inspected from the Library.
Ensure that the X-ray Inhibit key-switch (SYSTEM ON/OFF) in ON.
Ensure the Blue Reset Button light (located under the main screen). To switch the light Off – Press the Reset Button. If the light remains On, a panel is open or an emergency stop switch is not pulled up, or the X-ray Inhibit key (SYSTEM ON/OFF) is in Off position.
From the Main Menu Display press the Calibrate button in X-ray Control panel.

Main Menu Display

The Calibration Panel will appear on the Main Menu Display and system will perform the calibration routine.
The Calibration Panel will indicate the routine sequence of the calibration:

Calibration rountine: Xrays off

Zero detector Pre-warn

Xrays on

Gain detector Xrays off

Zero detector

The light tower above the main cabinet will indicate the routine sequence of the calibration, the light color sequence is also indicated in the X-ray Control panel (Main Menu Display).

The system will illuminate the pre-warn indicator light (orange light), at the end of calibration x-rays will be generated.

The system will indicate x-rays are being generated by illuminating the Red lamp, as well display X-RAY ON – bottom left of the Main Menu Display screen.

The light tower indicates the following:

X-RAY ON: Red

PRE-WARN: Orange

X-RAY OFF: Green

The X-ray Status Light indication in the X-ray Control panel display will illuminate red in color. Same light indications as the light tower on top of main cabinet, X-rays are ON.

Upon completion calibration the product image panel will be black in color.
The system is now ready for inspection.

9.5 Starting Inspection

Following calibration of the system:

1. Start the product transfer conveyor by turning the START BELT switch located under main screen – to ON position.

2. Transfer product through the conveyor.

Following opening of an access panel or activation of an Emergency stop (safety switch opened):

1. Ensure all access panels are closed and emergency stops are in the UP position. The emergency stops are Red in color and must be pulled up to be activated.

2. Ensure that the X-ray Inhibit key-switch (SYSTEM ON/OFF) is ON.

3. Press the Reset Button located under the screen. (light activated is to be off) If the light is on, a panel is open or an emergency stop switch is not pulled up, or the X-ray Inhibit key (SYSTEM ON/OFF) is in Off position.

4. X-ray production will not restart until the safety circuit is working and a manual reset is performed.

5. Press the Start Xrays button on the X-rays Control panel. The system will indicate x-rays are being generated by illuminating the Red lamp, as well display X-RAY ON – bottom left of the Main Menu Display screen.

6. Start the product transfer conveyor by turning the START BELT switch located under main screen – to ON position.

7. Transfer product through the conveyor.

Following stopping of X-rays by pressing ‘Stop Xrays’ button on the X-rays control panel:

1. Ensure all access panels are closed and emergency stops are in the UP position. The emergency stops are Red in color and must be pulled up to be activated.

2. Ensure that the X-ray Inhibit key-switch (SYSTEM ON/OFF) is ON.

4. X-ray production will not restart until the safety circuit is working and a manual reset is performed.

5. Click the Start Xrays button on the X-rays Control panel. The system will indicate x-rays are being generated by illuminating the Red lamp, as well display X-RAY ON – bottom left of the Main Menu Display screen.

6. Start the product transfer conveyor by turning the BELT START switch located under main screen – to ON position.

7. Transfer product through the conveyor.

9.6 Images Screen

Click the Images button on main display

For access to resetting of product counters and storage of reject images – Press the Images button on main display:

The following Images Screen display will appear:

Images Screen Display

Storage of Reject Image

Press (right hand side of panel) the box Halt on Reject. A tick will appear in the box and the Halt button will change to Free.

The image will update when there is a reject. The system will place the reject images in a circular buffer. To access images stored in the buffer, press the left or right arrow buttons on the Display thumbnail images panel. With each press of the arrow button the stored thumbnail image will circulate through the buffer. Each thumbnail image has a number and time.

To store reject images to the main memory press the Store button.

To review the thumbnail image in detail:

Touch the thumbnail image and the image will transfer to the main product image screen. The reject image screen update will halt, to restart press the Free button.

Output Lut:

Refers to LOOK UP TABLE – press to display gamma range settings.

9.7 Reject Indication

Upon detection of a reject the system will illuminate red the Contaminant status light (in Inspection Results panel).

Inspection Results Panel

Optional equipment:

The contaminated product will be rejected via the reject device.

The system will illuminate the reject indicator light (blue light flashing), in light tower above the main cabinet and sound a siren.

The blue light flashing and alarm will stop after the rejected product is removed from the reject system.

9.8 System Shutdown

For system shutdown the following procedure is recommended.

FROM OPERATORS LEVEL – Password 0:

1. Click Password: 0 – (lower left hand side of the Main Menu Display). The following Password keypad will be displayed:

2. Enter 1111 via the keypad and press enter (Ent) on keypad

Password: 0 will change to Password: 1 and the Finish button will appear on the screen (lower right hand side of screen), as shown below,

3. Press the Finish button, and the following Exit Detection panel will appear (lower right hand side of screen):

4. Press the Shutdown button and the system will shutdown.

5. After the screen display has switched off, turn the machine power OFF via the main power isolator switch located at the side of the cabinet

Machine power ON/OFF Switch

9.9 Access to Engineer Level 1

The Engineers Level 1 provides access to the various parameter settings of the selected product to be inspected.

Access to the Engineers Level is via the Main Menu Display and is password protected.

To enter the Engineers Level 1, click Password - (lower left hand side of the Main Menu Display). The following display will appear:

Enter the password via the keypad (Password – 2222) and press (Ent) on keypad.

Press the Setup button and the following Parameters panel will be displayed.

Parameter Panel Display: Inspection Settings

Refer Parameter Setting Displays, for the various inspection parameters.

To return to Operators Level 1:

1. Press ‘Password‘ – lower right hand of the Main Menu Display.

2. Enter the password via the keypad (Password – 0000) and press enter (Ent) on keypad.

3. Main Menu will be displayed, Password: 0 in lower right hand of display indicates Operators Level.

9.10 Entering a New Product

1. From the Parameters Display Select Library.

2. The system will display the Library menu.

3. Press the ‘New‘ button in Library panel.

4. The keyboard ‘Enter Product Name’ will be displayed.

5. Type in new product name, press ‘Ent’ on keyboard to enter a new product name in the Product Library list.

The parameter settings will revert to the individual Default settings.

In order to achieve the optimum sensitivity on the new product, the inspection parameter settings need to be correctly set.

9.11 Parameter Setting Display

The Engineers Level provides access to Parameter Setting Display panels.

By pressing the top (up/down) red arrow buttons of the Parameters panel, the following inspection parameter panels are displayed.

Parameter Panel Display	Provides access to the following settings