Genius+ Ba Cu en 1113

Operating Instructions
Control Unit
GENIUS+
Customer: AZO GmbH + Co. KG
Serial no.: 11223009316-H

11223009317-H
Order no.: VAB057219
We reserve the right to change the con-

tents due to product innovation or tech-
nical improvement.
Please state type of equipment and se-

rial number when contacting us.
Please read these instructions and keep

the manual safe!
Please observe and follow the safety

notes!
S+S Separation and Sorting Technology GmbH
Regener Straße 130 * D-94513 Schönberg
Telephone: +49 8554 308-0 * Fax: +49 8554 2606
E-mail: info@sesotec.com
Internet: http://www.sesotec.com
Service: Telephone: +49 8554 308-180
1 GENIUS+-BA-CU-EN-1113.docx
Manufacturer:
D-94513 Schönberg, Germany
Contact:
Regener Straße 130
D-94513 Schönberg, Germany
Tel.: +49 (0) 8554 3080

Fax.: +49 (0) 8554 2606
E-mail: info@sesotec.com
Internet: www.sesotec.com
Represented by:
2 GENIUS+-BA-CU-EN-1113.docx
Contents
Contents
1 General information 6
1.1 Introduction 6
1.2 Field of application 6
1.3 Application reasons 6
1.4 System identification 6
1.5 Symbols used 6
1.6 EC DECLARATION OF CONFORMITY 6
1.7 Overview 7
2 Design and method of operation 8
2.1 Functional principle 8
2.2 Functional and control elements 9
2.2.1 GENIUS+ – Complete 9
2.2.2 Operating module with LCD graphic display 9
2.2.3 Cable glands 10
2.2.4 GENIUS+ – Controller board STE 11
2.2.4.1 STE version, article number 44006482 (used as from August 2010) 11
2.2.5 GENIUS+ – Evaluation electronics board AWE 13
2.2.5.1 AWE version, article number 44006480 13
3 Dimensions and technical data 14
3.1 Technical data sheet, see annex 14
3.2 Supply connections, see technical data sheet in the annex 14
3.3 Environmental conditions for operation, storage, and transport 14
3.4 Noise levels 14
4 Safety 15
4.1 Intended use 15
4.2 Safety signs 15
4.3 Dangers arising from non-compliance with safety notes 15
4.4 Safety information for operators 15
4.5 Safety information for operation, maintenance and cleaning 16
4.6 Safety information for commissioning 16
4.7 Safety information for storage and transport 16
4.8 Notes on residual risks 16
4.9 Notes on stable standing requirements 16
4.10 Consequences of unauthorised modification 16
4.11 Improper use 16
5 Commissioning 17
5.1 Mechanical mounting 17
5.2 Connection of the equipment 17
5.2.1 Connector assignments on the controller board 17
5.2.2 Electrical connection 18
5.2.3 Electrical performance 19
5.2.4 Electrical connection of the equipment 19
5.2.4.1 Mains supply via safety socket 19
5.2.4.2 Mains supply via connection box 19
6 Menu / Operation Genius+ (as from SW version 1.09) 21
6.1 General Operation 21
6.2 Quick Start 22
6.2.1 Language Selection 22
6.2.2 Teach-in of a new product 23
6.3 Menu structure 24
6.3.1 Operating mask 25
6.3.2 Change product 26
6.3.3 Teach in product 27
6.3.3.1 Quick teach 27
6.3.3.2 Automatic teach in 28
3
Contents
6.3.3.3 Manual teach in 29

6.3.4 Rapid/GF/Liquiscan additional setup menu 30
6.3.5 Parameters 30
6.3.5.1 Parameters 30
6.3.5.2 Change product name 31
6.3.5.3 Product options 31
6.3.5.4 Output adjust 31
6.3.5.5 Output lock 33
6.3.5.6 Output Level 33
6.3.5.7 Output options 34
6.3.5.8 Audit check 34
6.3.5.9 Conveying speed 35
6.3.6 Setup 36
6.3.6.1 Logbook 36
6.3.6.2 Report 38
6.3.6.3 Clear logbook 43
6.3.6.4 Trigger audit check (only when audit check activated) 43
6.3.6.5 Audit check main setup 43
6.3.6.6 Show counter 44
6.3.6.7 Change password 44
6.3.6.8 Device/line 45
6.3.6.9 Frequency deviation 45
6.3.6.10 Language 45
6.3.6.11 Clock/Date 46
6.3.6.12 Interface 46
6.3.6.13 Setup options 48
6.3.6.14 Air pressure monitoring (option) 48
6.3.6.15 Flap monitoring (option) 48
6.3.6.16 Ejection monitoring (option) 49
6.3.6.17 Light barrier (option) 49
6.3.6.18 Units 49
6.3.6.19 Device-Info 50
6.3.6.20 Revision 50
6.3.6.21 Login 50
6.3.6.22 Logout 51
7 Interfaces (option) 52
7.1 Serial interfaces 52
7.1.1 RS232 52
7.1.2 RS485 53
7.2 Ethernet interface (LAN - TCP/IP) 54
7.3 WLAN interface (WLAN - TCP/IP) 55
8 The use of the GENIUS+ for quality assurance 56
8.1 General procedure 56
8.2 Carrying out a performance validation 57
8.3 Autotest device (option) 58
8.3.1 Connection 58
8.3.2 Configuration of the autotest device 58
8.3.3 Auditcheck configuration 58
8.3.4 Running an auditcheck 59
9 Errors and error remedying 60
9.1 Error messages 60
9.1.1 Communication AWE 60
9.1.2 Receiver voltage too high 60
9.1.3 Air pressure 60
9.1.4 Eject control 60
9.1.5 Reject box full 61
9.1.6 Diverter position 61
9.1.7 Transmitter over temperature 61
9.1.8 Watchdog AWE 61
9.1.9 Conveyor belt control 61
4
Contents
9.1.10 Light barrier 61

9.1.11 EEPROM 62
9.1.12 Test result 62
9.1.13 Test timeout 62
9.1.14 Hardware AWE 62
9.1.15 Metal burst 62
9.1.16 External error 62
9.2 Undefinable activation of the switching outputs 63
9.3 Replacing the backup battery 64
9.4 Replacement of electronic boards 65
9.4.1 Replacing the control electronics board 65
9.4.2 Replacing the evaluation electronics board 66
9.4.3 Replacing the display board 66
10 Maintenance and cleaning 67
10.1 Maintenance 67
10.2 Cleaning 67
10.2.1 Hints for cleaning 67
10.2.2 Cleaning instructions 67
10.2.3 Care advice for stainless steel 67
11 Spare parts 68
11.1 Spare parts view 68
11.2 Spare parts list 69
11.3 Accessories 69
12 Shipping, preservation, waste disposal, transport, storage 70
12.1 Shipping, preservation, waste disposal 70
12.2 Transport 71
12.3 Storage 71
13 Annex 72
5
1. General information
1 General information
1.1 Introduction
The texts and illustrations in this instruction manual are for the exclusive purpose of explaining how to
operate and handle the control unit. The manufacturer accepts no responsibility for damage resulting
from the use or misuse of this equipment. All appropriate safety rules and regulations for the use of this
equipment must be adhered to. If you have any questions with regard to the installation and operation
of this equipment please do not hesitate to contact us.
This instruction manual may not be copied, saved on computer or otherwise reproduced without the
prior permission of the manufacturer. Nor may any extract of this instruction manual be similarly repro-
duced.
1.2 Field of application

The GENIUS+ control unit is used in combination with S+S metal detectors and separators in the plas-
tics, wood, food, chemical, and in a special version also in the pharmaceutical industry. Depending on
the respective version, these systems inspect packed, unpacked, or piece products, and bulk materials
for magnetic and non-magnetic metal contaminations.
Of course they also are suitable for similar applications in other branches of industry.
1.3 Application reasons

 Product liability
 ISO 9000
 TQM (Total Quality Management)
 Protection of machines and quality assurance
1.4 System identification

The information in this instruction manual only applies to the GENIUS+ control unit. A label with the re-
spective data is attached at every system.
1.5 Symbols used

Symbol Signal Meaning
word
Danger Warning: Possibility of severe or even fatal personal injuries.
Danger The lightning symbol is an explicit warning that there is danger from elec-
tric current.
Warning Warning: Possibility of minor personal injuries or property damage.
Caution Warning: Possibility of defects or destruction of the equipment.
Important Indicates an important information for the function.

information
Important Indicates an important hint for the function.
hint
1.6 EC DECLARATION OF CONFORMITY

(see annex – EC DECLARATION OF CONFORMITY)
6
1. General information
1.7 Overview
GENIUS+ Control Unit
Graphic display
7
2. Design and method of operation
2 Design and method of operation
2.1 Functional principle
Transmitter- Control electronics Display

receiver - Power supply - Standard
Metal electronics - Touch-screen
detection
coil
- Inputs/outputs
- Interfaces
U/f- converter M
The metal detector works with the so-called "balanced coil" principle:
The transmitter winding in the search coil creates a high-frequency electromagnetic field, which is re-
ceived by symmetrical placed receiver windings. The windings are connected against each other; when
undisturbed, the system is in balance.
An electrically conductible object within the detection area disrupts this balance and the electronic cre-
ates a switch signal.
A "teach in process” allows to suppress the conductivity of the product itself. Deviations from the
taught-in product are usually caused by metal contaminants, which are detected by the device with
high precision.
The metal detector is equipped with comprehensive test and analysis software to ensure fault-free op-
eration and retracing of product errors.
Interfaces allow simple operation as well as connection to a data management system.
For reasons of the employed technology it is not possible to guarantee 100% metal
detection.
8
2.2 Functional and control elements
2.2.1 GENIUS+ – Complete
Basic elements:
(1) Housing
2 (2) Operating module (LCD graphic
display or touch-screen (option))
(3) Cable glands
1 (4) Control electronics board - STE-
M
(5) Evaluation electronics board -
5 AWE-M
Additional options (not shown):

(6) Multi-frequency technology for
sensitivity optimization
(a) Duo (for few different prod-
4 ucts)
(b) Quattro (for many different
products)
(7) Serial interface RS232 with plug
(IP65, 4-pole)
(8) Serial interface RS485 with plug
3 (IP65, 4-pole)
(9) Ethernet interface (TCP/IP 100
Mbit/s, IP 65, RJ45)
(10) WLAN interface (802.11 b/g) with
integrated aerial
(11) USB interface (only in combina-
tion with touch-screen)
(12) Profibus (in preparation)
2.2.2 Operating module with LCD graphic display

(For the colour-touch-screen option please refer to the separate operating instruction)
(1) LCD display

(2) Function keys F1 - F4
(3) LED "Operation" (green)
(4) LED "Fault" (red)
(5) LED "Metal" (yellow):
(6) Resetting of the metal and alarm
9
LED "Operation" (green)

Illuminated when device is ready.
Requires:
- Power supply
- Outlets activated in "Outlet (Options)” menu
- Bypass function not activated
- Running conveyor (only in operation mode "conveyor with controller”)
The operation indicator LED is turned off during the teach-in process!
The green LED flashes
- As a warning (e.g. when the battery is too low)
- When requesting an audit (audit check)
LED "Fault” (red)

In case of a fault / error, the red LED flashes
LED ""Metal" (yellow)

The LED is not activated straight after detection, but parallel to the activation of solenoid
valve MV1 after a delay for the rejection time.
The LED is illuminated during manual ejection on the devices Rapid, GF or LIQUISCAN.
2.2.3 Cable glands
(7) Cable gland for the mains cable

(8) Cable gland for free use
(10) "Receiver" cable gland for connecting the
detector coil (when coil is removed)
(11) "Transmitter" cable gland for connecting the
detector coil (when coil is removed)
(13) Cable gland for free use (or connection of
the serial interface (option)
7 8 9 10 11 12 13
10
2.2.4 GENIUS+ – Controller board STE
2.2.4.1 STE version, article number 44006482

(used as from August 2010)
1 2 3 4 5 6b 7b
F1
6a 7a
15
9
JP205
JP206
JP200
JP201
JP202
JP203
3 3 3 3
2 2 2
1 1 1 11 2
1
1 2 3
JP400
10
13
JP100 JP101
12
16
F2 14
17
18
F4 F3
16 16
Jumper Position Comment

JP101 Unpopulated HW-Reset
JP400 1-2 MV 24V intern (default)
2-3 MV 24V via ST15 (plug 9)
JP203 2-3 Default
JP200 / JP205 / JP206 1-2 UART2 = RS232 (default)
2-3 UART2 = RS485
JP201 / JP202 Plugged Exclusion RS485 (default)
Fuse Description Type

F1 Mains supply 1,6A slow-blowing 1500A @ 250VAC 5x20mm
F2 Mains supply IC1 1,6A slow-blowing 35A @ 250VAC TR5
11
Connectors: (1) "Mains": Mains supply

(2) "Fault": Potential-free change-over contact
(3) "Metal 2": Potential-free change-over contact
(4) "Metal 1": Potential-free change-over contact
(5) "24V Output 1-2": 24V switching output
(6) a) 24 Inputs and outputs.
b) Connection detection coil/sensor electronic
(7) a) 24 Inputs
b) Serial interface RS485/RS232
(8) "Mains Out": Mains connection for additional ACDC module
2 pole (L/N)
(9) "24V External": Input for external 24V supply
(10) "24Voutput 3-4": 24V Switch outputs
(11) Serial interface / Frequency converter / GAD
(12) "DC-Output": Output voltages 24V, 5V and Vx
(13) Ribbon cable connector for control panel
(14) Ribbon cable connector for programming plug
Elements connected to mains (1) "Mains" connector
voltage: (2) "Mains Out" connector
(15) Mains fuse total
(16) Mains fuse single
Elements connected to exter- (2) "Fault" connector
nal voltage: (3) "Metal 2" connector
(4) "Metal 1" connector
Memory devices: (17) Device and product data memory
(18) Data battery for Logbook
12
2.2.5 GENIUS+ – Evaluation electronics board AWE
2.2.5.1 AWE version, article number 44006480

(used as from August 2010)
3 8 4 5
GND
9
2
11 10
6 7
GND
Connectors: (1) STE RS485: Interface RS485 to the controller board

(2) Power Supply: Power supply from the controller board
(3) Transmitter: Output signal to the detector coil
(4) Relay output: Control signal to the detector coil (multi-/quattro)
(5) Receiver: Input signal from the receiver
(6) UART1: Connection flasher
(7) Ribbon cable connection for programming plug
Test points: GND Common ground for all signals

(8) Transmitter Sine wave signal (45..50Vss) feeding the
transmitter coil
(9) Receiver Signal from the receiver coils
(10) Metal signal branch S
(11) Metal signal branch A
13
3. Dimensions and technical data
3 Dimensions and technical data
3.1 Technical data sheet, see annex
3.2 Supply connections, see technical data sheet in the annex
3.3 Environmental conditions for operation, storage, and transport
The environment of the control unit should be free of any chemical vapours such as softeners, chlo-
rine, or similar substances. The control unit must not be exposed to direct sunlight or to other environ-
mental influences (rain, snow, storm). For ambient temperature conditions for operation, storage, and
transport please refer to the technical data sheet in the annex.
3.4 Noise levels
Sound pressure level measurements (in acc. with DIN 45 635)

Peak value of sound pressure level at a distance of 1m from the machine surface and 1.60m above
the floor, LpA, 1m, max.
Result:
Idling: < 70 dB(A)
Activated: < 90 dB(A)
We reserve the right to change the contents due to product innovation or technical improve-
ment.
14
4. Safety
4 Safety
Our equipment conforms to all official technical safety regulations. However, as a manufacturer we be-
lieve it is our duty to make you aware of the following information.
The following safety and danger notes are intended for your protection, for the protection of
third parties, and for the protection of the equipment. The safety notes therefore should al-
ways be observed!
4.1 Intended use

The equipment is intended for use in the following fields of application and only in combination
with a corresponding detection coil of series GLS, RZ, DLS, ELS, and LIGNUM HX: Suc-
tion/pressure conveyor applications, free-fall applications, and applications at a conveyor belt.
The equipment can be used in the plastics, food, animal feed, recycling, and chemical in-
dustry. Basically it is possible to also use the system in other applications than the intended
use stated herein, but such applications always require the prior consultation and approval
of S+S Separation and Sorting Technology GmbH.
4.2 Safety signs

Symbol Signal word Location Meaning
Mains volt- Cover of This symbol indicates that mains voltage is used in the elec-
age the electronics housing, and that any connected external circuits
tronics (e.g. at the metal relay) also may be energised. There is
housing danger of electric shocks due to the presence of mains volt-
age.
Connection symbols:
"Mains" (1)
"Metal ½" (3/4) and "Fault" (2)
4.3 Dangers arising from non-compliance with safety notes
Any non-observance of safety notes constitutes a danger for life and health.
4.4 Safety information for operators

The control unit GENIUS+ may only be operated in the intended purpose and in a perfect func-
tioning condition, especially the cover of the electronic housing has to be closed during opera-
tion. Entered moisture has to be removed! All fixed warning signs on the equipment may not be
removed and have to be in a well recognizable condition. The operating instructions always
have to be in a legible condition and complete available. Prior to commissioning always make
sure that the applicable accident prevention regulations are observed. If the control unit is
not mounted at the detection coil, it must be properly and firmly fastened by means of the
four screws. The operator must make sure that the equipment is mounted at an ergonomic
height for operation. The operator may only appoint qualified personnel for operation, mainte-
nance and repair work. If potentially explosive materials are examined, the pertinent regula-
tions must be observed.
Emitted interference
Test report according to the provisions of:
BGV B11:2001-06 Regulations of the professional association for safety and
health at work.
Accident prevention regulations for electromagnetic fields.
E DIN VDE 0848-3-1: 05-2002 Safety in electrical, magnetic, and electromagnetic fields,
part 3-1: Protection of persons with active implants in the
frequency range of 0Hz to 300 GHz.
15
4. Safety
In the area where the operating personnel is working the electromagnetic field of the metal
detector or separator does not exceed the limits stated in the provisions. Therefore there
are no health impairments due to electromagnetic fields in this area for persons and for
wearers of medical implants such as cardiac pacemakers. Inside the coil of round or
closed tunnel coils, or on the surface of flat coils, the limits may be exceeded depending
on design and system version. If work is to be performed inside or at the search coil, per-
sons and wearers of medical implants such as cardiac pacemakers may only enter the
equipment when it is turned off, provided that size and design allow this.
4.5 Safety information for operation, maintenance and cleaning

Because of energised components in the electronics housing there is a risk of injuries due to
electric shock or burns. During operation the cover of the electronics housing must be kept
closed. Only qualified personnel may operate and clean the equipment.
If the electronics housing must be opened for maintenance or cleaning purposes, remove any
dirt and moisture from the electronics housing, so that no larger amounts may get into the inte-
rior. Always disconnect the power supply and any connected external circuits before opening
the cover. Any moisture that has penetrated into the interior must be removed from the elec-
tronics housing. If any maintenance work must be performed in energised condition, e.g. bat-
tery replacement, such work may only be performed by a qualified electrician under strict
observation of the attached warning labels and with due regard to standard approved rules of
electrical engineering.
4.6 Safety information for commissioning
To avoid any injuries due to energised parts in the electronics housing, the information in
5.1 and 5.2 must always be observed.
4.7 Safety information for storage and transport

Always observe the information in paragraph 12 to avoid any transport damage and per-
sonal injuries.
4.8 Notes on residual risks

Electrical circuits may still be live even after having been isolated from the mains. Switch
off immediately if a fault occurs.
4.9 Notes on stable standing requirements

To avoid any loss of stable standing, the information for transport, commissioning and op-
eration must always be observed. Always make sure that the fastening screws of the con-
trol unit are tight during operation. When storing or transporting the control unit, place it on
the closed rear panel of the housing.
4.10 Consequences of unauthorised modification

Unauthorised modification or repair will invalidate all manufacturer declarations and guar-
antees.
4.11 Improper use

For other applications as enumerated in 4.1 the control unit GENIUS+ intended for – that is re-
garded as inadmissible operation. Improper use also includes operating the equipment with
excessive mechanical, static or dynamic loads (e.g. heavy machine parts or strong vibra-
tion). It is furthermore not permitted to inspect any aggressive materials on the conveyor,
such as materials containing lyes, acids, and solvents, or materials that react to electro-
magnetic fields, or living persons or animals, and to operate the system in an Ex protection
area.
16
5. Commissioning
5 Commissioning
5.1 Mechanical mounting

 Ensure stable and non-vibrating installation! In house mounting and operation. Do not install the
system in an explosion proof zone.
 Do not install the detection coil and the electronic unit in the vicinity of interference fields (large elec-
tric motors and frequency converters!) The distance depends on the power consumption of the mo-
tor or of the frequency converter (value for orientation: 5 m).
 Mount the control cabinet by using the provided bores. i.e. at a wall or frame (dimensions are shown in
the outline drawings). Pay attention to good stability, as the weight of the control unit is approx. 6 kg.
 Never install the electronic unit in other switchgear cabinets, because this may lead to interference
effects.(e.g. from contactor controls)!
 Cable lengths may only be modified after consultation with "S+S". Use only original cables. Lay the
connecting cable in fixed installation apart from other cables (e.g. fix it with nailing clips or lay it in a
cable duct).
 If several metal detector systems are used, the distance of the detection coils must not be less than
2m, if these coils stand side by side. If the coils are arranged opposite to each other, the distance
must not be less than 10 m. These values apply to large systems; for smaller systems the distances
may be reduced to 50 cm. If, for reasons of space, these distances cannot be observed, please
contact S+S service!
 Do not install the equipment in such a way that operation of the mains cut-off switch is hindered in
any way!
5.2 Connection of the equipment

Cable
In order to meet CE conformity all cable outside of the housing have
to be shielded. The shields must be grounded immediately after the Shield Housing
cable gland.
The terminals "Mains" and "Evaluation Unit" are already factory reconnected.
According to the delivered option several connectors may be used.
5.2.1 Connector assignments on the controller board
17
5. Commissioning
5.2.2 Electrical connection
Signal Connection Function

"Mains Out" Output mains voltage Supply for external ACDC module
"Fault" Potential-free relay con- Normal operation: Contact 21 and 24 closed
tact In case of a fault: Contact 21 and 22 closed
"Metal 1" Potential-free relay con- Normal operation: Contact 31 and 32 closed
tact In case of metal detection: Contact 31 and 34 closed
"Metal 2" Potential-free relay con- Normal operation: Contact 11 and 12 closed
tact In case of metal detection: Contact 11 and 14 closed
"24V External" Connection input 24V 24V input for external solenoid valve supply
"24V Output” 24V DC switching out- Low-active = no:
put Normal operation: 0V DC to 
In case of metal detection: 24V DC to 
Low-active = yes:
Normal operation: 24V DC to 
In case of metal detection: 0V DC to 
"" Ground (GND) Power supply for proximity switches and light barriers
Ground reference for the inputs IN1, IN2, LS and RST
"Outputs" 24VDC switching out- LM: Metal lamp lights on metal detection
puts wired to +24VDC LB: Operation lamp Activated for operation and audit
request (flashing)
LF: Fault lamp lights in case of errors
"24V" 24VDC Power supply Power supply for light barriers and proximity switches
Signal reference for outputs LF, LB and LM
Signal reference for inputs IN0 .. IN9
"Inputs" 24VDC switching inputs IN1 1. Proximity switch input for distance measurement /
to  diverter flap (NPN)
IN2 2. Proximity switch input for distance measurement /
diverter flap (NPN)
LS Start Autotest
RST External Reset input
wired to +24VDC
Inputs to 24V IN0-IN9 Switch inputs for special functions and options
"FU" Connection frequency Left Direction select frequency converter left
converter Right Direction select frequency converter right
"GAD" Connection 0-10V Analogue signal for frequency converter

Speed specification
18
5. Commissioning
5.2.3 Electrical performance
Potential-free relay contacts 250VAC/ 3A

120VDC/ 3A
24VDC outputs Entire max. current load: 500mA
Inputs: INI1 / INI2 / LS / RST Connection of make contacts against , resp. NPN outputs
Inputs: IN0 .. IN9 Connection of make contacts against+24 V, resp. PNP outputs
5.2.4 Electrical connection of the equipment
Maximum cable length for external components, switches and sen- Cable
sors is 15 m. Shield Housing
Only shielded cables should be used.
The shields must be attached directly to the electronics housing.
5.2.4.1 Mains supply via safety socket
1. Connect the cable with mains plug to an existing socket.

2. After approximately 5 seconds the machine is ready for operation.
5.2.4.2 Mains supply via connection box
The following procedures should only be undertaken by qualified personnel. Before re-
moving cover plates etc make sure the equipment is isolated from mains or external volt-
age.
Do not remove either the mains cable or the protective gland as these are essential parts
of the EMC configuration.
The main cable is a special EMC protected cable and should not be replaced by any other
cable.
If the mains plug is removed, a terminal box and a suitable mains disconnector switch with
corresponding labelling/marking must be installed!
This disconnector switch must be easily accessible and must disconnect all poles from
the mains.
1. Remove mains plug.

2. Strip 5 cm length of insulation from cable and 1 cm from leads and attach cable cores.
Mains cable: 1 Shield
2 Conductor
1 2
3 PVC insulation
4 Isolation
5 4 3
5 PVC covering
19
5. Commissioning
3. Feed cable into connection box according to diagram below.
Make sure that the mains supply is switched off.
Use a suitable shutdown unit i.e. emergency switch.
2 1 Terminal box
5 2 3 pin terminal
3 6 L 4 3 Control unit mains cable
N 4 Main supply
5 Conductor L (brown) To terminal L
PE 6 Conductor N (blue) To terminal N
7 Conductor PE (yellow/green) To terminal PE
7 8
8 Shield To terminal PE
IMPORTANT! Connect the shield to PE
4. Close the terminal box

5. The unit is ready for operation approximately 5 seconds after switching it on.
Note:
The mains cable has a wire cross-section of 0.75 mm². The mains supply fuse protection should be set
accordingly.
On the controller board STE are alternating mains fuses welded.
20
6 Menu / Operation
6 Menu / Operation Genius+ (as from SW version 1.09)

This chapter starts with a short manual and cross references in order to familiarise the reader with the
most important settings. Following this, all setup menus are described. As an orientation guide, the
menu structure can be folded out.
6.1 General Operation

The electronic can be operated with 4 buttons, which have different functions depending on the chosen
menu. The most common symbols are described as follows:
Symbol Function Comment / Example
Change product
Teach in product
(Product-) parameters
Setup / Settings
Scroll down
Scroll up
Back
Enter / Select
Tabulator / Next
Change Selection
<-> or
<->
Cancel
Decrease value
Increase value
21
6 Menu / Operation
6.2 Quick Start
6.2.1 Language Selection

(if required)
1. Turn on device; operating mask is displayed (see 6.3.1).
2. Press F4 button .
3. Press F1 until you reach the item marked with "*)" ( (language*).
4. Press F4 to select the menu item.
5. Select language and confirm with F4 (see 6.3.6.10).
6. Exit with F3 .
Please note:
For the GENIUS+ control unit are two language versions with the following languages.
Language version 1 Language version 2

 German  German
 English  English
 French  Czech
 Spanish  Polish
 Italian  Russian
 Swedish  Greek
 Finnish  Turkish
 Dutch
 Danish
 Japanese
22
6 Menu / Operation
6.2.2 Teach-in of a new product
Please ensure that only products without metal contaminants (metal free products)
are conveyed.
- Starting from operating mask, press F2
- Menu ”Teach in product" is displayed

- Select ”Automatic tech in" with F2
- In the product list, "**NEW** xxx" is selected

- Confirm with F4 or exit menu with F3
- The suggested standard name "Productxxx" can now be changed

- Select letters and numbers with F1 and F2
- F3 jumps to the next letter
- Confirm name with F4
- Conveying speed can be selected with F1 and F2

- Confirm with F4 or exit menu with F3 without saving any
changes
The figures in brackets show the optimal speed range for the selected
settings.
- For multi-frequency systems, the search frequency can be selected.
Press F3 "Yes" to do so.
- Continue with F2 "No" without changes to the search frequency
- Press F2 to switch between available search frequencies

- Confirm changes with F4 or exit menu with F3 without saving
any changes
- Follow the on-screen instructions and convey the product several times,
repeat the process if asked to do so
- Close with F2/F3
- The display will illustrate if learning was successful

- Close automatic learning with F2/F3
- The automatically calculated values for "Sensitivity" and "Product angle"

can be manually optimised with F1 and F2
- The threshold "Th” (typ. 40) can be adjusted separately
- Press F3 to go to the next value.
The signal display illustrates how recent changes affect the system’s per-
formance.
Genius+ is now optimised for the product and the environment.
Test the device with a metallic object.
23
6 Menu / Operation
6.3 Menu structure
Change product Teach in Parameters Setup

product  Parameters  Logbook
 Product name  Report )
4
 Quick teach
 Product options  Clear logbook )
3
 Automatic teach in
 Manual teach in  Output adjust  Trigger audit check (when audit
 Output lock check is activated)
 Audit check main setup )
2
 Output Level
 Output options  Show counter
 Change password )
2
 Audit check
 Device/Line )
2
 Start manu. reject  Conveying speed
 Frequency deviation )
2
 Flap test
 Teach in product  Language
 Clock/Date )
2
*)
 Interface )
2
For Rapid, GF and
LIQUISCAN mode, *)  Setup options )
2
this menu will appear For Rapid, GF and

 Air pressure monitoring )
1
before the learn LIQUISCAN mode,
 Flap monitoring )
1
menu. this menu will appear
before the learn  Ejection monitoring )
1
menu.
 Light barrier )
1
 Units )
2
 Device-Info
 Revision
 Login
 Logout
1
) when function is activated and
announced in setup level 2
2
) when announced in setup level 1
3
) if logged in setup level 1 or 2
4
) if "Printer portable" function is
activated
24
6. Menu / Operation
6.3.1 Operating mask
Displayed in normal operation mode.

Displayed information:
- Current product name (top right)
- Se: Sensitivity (0 - 100%)
- PA: Product angle (0° - 180°)
- Signal: Current signal of the detector
- Th: Threshold for metal detection (standard: 40)
- T/Q: Displays, if tracking (T) and/or quicklearn (Q) are activated
The bottom line displays the function of the operation buttons F1 to F4 and
can vary depending on the menu.
In the operating mask, the buttons have the following functions:
Operating mask:
 F1: Change product
 F2: Teach in product
 F3: Parameters
 F4: Setup
Different displays
While booting the system, the display shows for 2 seconds

Booten…
In the main menu.
When metal is detected but not yet rejected (e.g. because of light barrier
synchronisation (see 6.3.6.17)), the display shows
DETECTED
On synchronisation of the light barrier but before rejection of the product, the
display shows
Sync
If the outputs are disabled via menu settings, the display will illustrate this by
showing
Output OFF
In addition, the green operating light is off and a log entry is created.
If metal detection is deactivated over the digital bypass, the display shows
ByPass
In addition, the green operating light is off as well and a log entry is created.
Should an error occur, the mask on the left is displayed, the red error light
flashes and a log entry is created.
The picture on the left shows a light barrier error as an example.
The error message can be reset by pressing the RESET button, once the
cause of the error is corrected.
On detection of metal, the mask on the left is displayed, the yellow metal light
comes on and a log entry is created.
25
6. Menu / Operation
6.3.2 Change product
GENIUS+ can save up to 240 different products and their corresponding parameters. This functionality
enables quick product changes.

- "Change product" menu is displayed
- Select product from the list with F1 and F2 and confirm with F4
- The display automatically changes back to operating mask

- Go back to operating mask without product change with F3
Product A and B (for multi-frequency systems A1 to A4 and B1 to B4) are pre-set and are
only used to test the device.
These pre-set products are of no value for operating with actual products.
If the current product is selected again and confirmed with F4 , a batch change is se-
lected; i.e. the corresponding counters for metal and error are reset to 0 for the new
product batch.
Is the option "batch number” (6.3.6.13) activated; it can be entered for a product or batch
change. A batch number different to "0” will be saved in the log file.
For consistent batch monitoring, please ensure that "net on” or the learning of a new
product is followed by a manual batch change for the entered product. Only then a batch
number can be logged.
- Enter numbers with F1 and F2

- Press F3 to move to the next digit
- Confirm batch number with F4 and exit menu
The following logbook entries are possible:
Product change with batch number
Batch change with batch number
Product change without batch number
Batch change without batch number
26
6. Menu / Operation
6.3.3 Teach in product
6.3.3.1 Quick teach
This function is used to set up the device quickly for a new product. All product parameters (selection
of reject unit, conveying speed, etc.) are copied from the current product and don’t have to be re-
entered.
Ensure that only metal-free products are being used.
- Menu "Teach in product" is displayed

- Select "Quick teach" with F1
- For multi-frequency devices, the search frequency can be select by press-

ing FE ""yes"
- Exit with F2 "no" without changing the current search frequency
- Select a search frequency with F2

any changes
- Follow instructions on the display and convey the product several times;
repeat the process if asked to do so
- Finish with

- Finish automatic learning with F2/F3
- The automatically calculated values for "Sensitivity" and "Product angle"

can be manually optimised with F1 and F2
- F3 switches between "Sensitivity" and "Product angle"
- The threshold "Th” can be adjusted separately
- Confirm with F4 and switch to operating mask
The signal display illustrates how recent changes affect the system’s perfor-
mance.
27
6. Menu / Operation
6.3.3.2 Automatic teach in

- Select ”Automatic tech in" with F2
- in the product list, "**NEW** xxx" is selected

- confirm with F4 or exit menu with F3

- Letters and numbers can be entered with F1 and F2

- Confirm with F4 or exit menu with F3 without saving any changes
The figures in brackets show the optimal speed range for the selected settings.
- For multi-frequency systems, the search frequency can be selected. Press F3

"Yes" to do so.

- Confirm changes with F4 or exit menu with F3 without saving any
changes
- Follow the on-screen instructions and convey the product several times, re-
peat the process if asked to do so
- Finish with F2/F3

- Finish automatic learning with F2/F3
- The automatically calculated values for "Sensitivity" and "Product angle" can
be manually optimised with F1 and F2
The signal display illustrates how recent changes affect the system’s perfor-
mance.
28
6. Menu / Operation
6.3.3.3 Manual teach in
Ensure that only metal-free products are being used.

- Select ”Manual teach in" with F2
- In the product list, "**NEW** xxx" is selected

- Confirm with F4 or exit menu with F3


- Confirm with F4 or exit menu with F3 without saving any
changes
The figures in brackets show the optimal speed range for the selected set-
tings.
- For multi-frequency systems, the search frequency can be selected.

Press F3 "Yes" to do so.

any changes
- "Sensitivity" and "Product angle" can be manually optimised with F1

and F2
formance.
29
6. Menu / Operation
6.3.4 Rapid/GF/Liquiscan additional setup menu
In Rapid, GF and LIQUISCAN mode, an additional menu will appear before the learn menu. Specific
tasks can be carried out in this menu.
- F1 starts manual eject.

Solenoid valves MV1 and MV2 are activated. The yellow "metal" LED
lights up and the display shows "stop reject”.
- F2: Flap test (similar to "real" metal incident)

Valves and relays are activated (duration and delay are considered), yel-
low "metal” LED lights up.
- F3: Triggers "Teach in product" menu
6.3.5 Parameters
Starting from operating mask, select parameter menu with F3
Select parameter with F1 / F2 and confirm with F4
Leave the sub-menu with F3 to the next higher menu level
Changes in this menu are only applied for the current product.
6.3.5.1 Parameters
- Menu "Parameters" is displayed

- Select "Parameter" by pressing F4
- Select "Sensitivity", "Product angle" and "Threshold" with F1 and F2

manually.
- Change between Sensitivity", "Product angle” and "Threshold" with F3
- Confirm with F4
formance.
30
6. Menu / Operation
6.3.5.2 Change product name
- Select "Change product name" with F4

6.3.5.3 Product options
- Select "Product options" with F4
- Select options with F1

- Check or uncheck selected options with F2
- Exit menu with F3 without saving any changes
- Save changes with F4
Quicklearn:
This option automatically compensates sudden changes of product attrib-
utes (e.g. changes in recipe). The new product angle will be saved and log
file created.
Tracking: This option automatically compensates slow changes of product

attributes (such as changes in temperature). Changes of the product angle
are temporary and are not saved.
Stop & Go mode: This option is necessary when products might stop with-
in the detection coil (e.g. caused by conveyor stops).
6.3.5.4 Output adjust
- Select "Output adjust" with F4
A delay of 0 to 60 seconds can be selected in steps of 50ms.

In operation mode "conveyor with controller", the delay for solenoid valve 1
can be selected in steps of 0.01m
The duration of 0.05s to 60s can be selected in steps of 50ms. This is not
required in case outputs are set to "manual reset” or "self holding”
Values are selected with F1 / F2 .

F3 switches between delay and duration.
To confirm and jump to the next menu page, press F4
31
6. Menu / Operation
MV1 (24VDC output for solenoid valve 1) and MR1 (relay metal 1):
Delay (in s or m) and duration for output signal for MV1
In conveyor mode, "manual reset” also determines time and distance to

or conveyor stop.
MV2 (24VDC output for solenoid valve 2):

Delay and duration for output signal for MV2
Not applicable in "FlipFlop"-mode.
MV3 (output for solenoid valve 3):

Delay and duration for output signal for MV3
Not applicable in all configurations!
MR2 (relay metal 2):

Delay and holding period of metal relay MR2
If the outputs are not marked as independent (see 6.3.5.7 – Outputs (Options)), MV1/2 and MR1/2 are
setup together.
In operation mode "conveyor with controlling", delay is selected in steps of 0.01m.
Duration is not applicable for "manual reset”.
MV1/2, MR1/2
Delay (in s or m) and duration of output signals MV1/2 und MR1/2
In conveyor mode, "manual reset” also determines time and distance to

or conveyor stop.
32
6. Menu / Operation
6.3.5.5 Output lock
Output lock means that the outputs are activated after the selected delay upon metal detection but not
automatically reset. To reset them, press the "Reset” button.
The option is selectable for MV1/MR1, MV2 and MR2 as well as for output LM (lamp metal).
Output lock for the two solenoid valves MV1 and MV2 are set up in "Reset mode"(see 6.3.5.7).
Please note: In reset mode "manual", all outlets are set to "self holding"; the menu is not applicable.
- Select "Output lock" with F4
- Select output with F1

- Activate or deactivate option with F2
- Exit menu without any changes with F3
- Confirm changes and exit menu with F4
or
6.3.5.6 Output Level
- Select "Output Level" with F4

- Change between "Low", "High" and "Inactive" with F2
If the outputs are not marked as independent (see 6.3.5.7 – Outputs (Options)), MV1/2 and MR1/2 are
setup together

- Change between "Low", "High" and "Inactive" with F2
33
6. Menu / Operation
6.3.5.7 Output options
- Select "Output options" with F4
- Select option with F1

- Switch between options with F2
- Confirm changes and continue to the next option menu with F4
Outputs active: Inactive outputs are not activated upon metal detection; no
log entry is created. The operating mask displays "Output OFF”.
Outputs independent: Chose whether or not MV1/2 and MR1/2 are set up
independently or together.
Reset mode: Manual or automatic (time-controlled) resetting of solenoid

valve outputs
FlipFlop: Activation of a pusher unit with alternate rejects to left and right.
(requires MV1 and MV2)
Metal at fault: When an error occurs, metal detection is triggered and out-
puts are activated. Activation is triggered immediately, regardless of select-
ed delay.
Stop at fault: Conveyor will stop in case of an error.
6.3.5.8 Audit check
- Select "Audit check" with F4
- Switch between alarm modes with F2

- Exit menu with F3 without saving any changes
- Confirm changes and continue to next menu with F4
Alarm mode
- Off (no request for audit check)
- Every hour (starting on the hour)
- Every day (alarm time is selected in the next menu)
- Every week (alarm time and day is selected in the next menu)
- Extern (audit check is started via an external signal)
- Interval (start time and time interval are selected in the next menu)
- With every product change (from current product) after 1 minute at the
earliest an audit check is started; the check is repeated within a selectable
time interval.
The next menu also offers the option to select a delay time.
Please note:
For all modes (except "Off") an audit check and also be started manually by
selecting "Trigger audit check" in the setup menu
The audit check only starts when the device displays the operating mask or
the log file.
In all other cases, the device will try to start an audit check 5 minutes later.
34
6. Menu / Operation
- Select alarm time and/or time interval with F1 , F2 and F3

and confirm with F4
(Daily at …)
(Weekly at... on...)
(From .. every …)
(In case of product change delayed by … every …)
- Select test sample (Fe, V2A, NonFe or "User") and size/ID with F1 ,
F2 and F3 and confirm with F4 .
Up to 3 test samples can be entered.

All S+S test samples (Fe, V2A or NonFe (brass)) are pre-configured.
Customer specific test materials can be entered by selecting "User”.
- The maximal signal value for the selected test sample can be entered with
F1 , F2 and F3 . This helps to prevent, that large test sam-
ples (e.g. hammer, keys) trigger the audit check. By selecting 0 for a test
sample, the function is disabled.
- Confirm with F4 .
6.3.5.9 Conveying speed
- Select "Conveying speed" with F4
- Enter conveying speed with F1 and F2 , confirm with F4

or cancel without any changes with F3 .
The figures in brackets show the optimal speed range for the selected set-
tings.
Depending on selected velocity unit, values are displayed in m/s, m/min, ft/s
or ft/min.
For operation mode LIQUISCAN, conveyor speed can be replaced by fill
rating in tons per hour (t/h).
35
6. Menu / Operation
6.3.6 Setup
Starting from operating mask, select setup menu with F4 .
Select menu option with F1 / F2 and confirm with F4
Leave the sub-menu with F3 to the next higher menu level
Changes in this menu are only applied for the current product.
6.3.6.1 Logbook
- Select "Logbook" with F4
- Scroll through the saved incidents with F1 und F2 . All incidents

are in chronological order and displayed with date and time
- Leave "Logbook" with F4 "
The logbook contains 1,500 entries which are permanently saved (battery-
buffered).
The following information is available:

 Running number of the entry
 Date and time of the incident
 Message (error messages are marked with a )
 Optional: 2 lines of additional information (depending on entry)
36
6. Menu / Operation
Warning
Older entries are deleted without notification when the maximum number of entries is
reached.
The following messages and information are displayed in the logbook:
Type Incident Additional Infor- Comment

mation
Metal Metal - Global metal counter
- Metal signal
Info Mains on/off

Product change - Old Product number
- New Product number
Change of product data - Current Pd. number For learning, product angle and sensi-
- Product data group tivity are also displayed
Charge change - Charge number

Outputs on/off
Quick learn - Angle
Test requirements
Test start - User ID
Metal incident - Metal signal Active during test
Test result - Test number (1..3)
- Test sample
(e.g.V2A1.0)
- Test result
Test end - Overall result
Time /date settings
Change of system data - System data group
EEPROM Grundinit
Bypass active
RESET error
Warning Battery low

Logbook nearly full When a number of less than 50 free
entries is reached for the first time
Error Receiver too high - Error counter (global)

Transmitter over- - Error counter (global)
temperature
Watchdog AWE - Error counter (global)
Communication AWE - Error counter (global)
Flap position - Error counter (global)
Air pressure - Error counter (global)
Conveyor belt control - Error counter (global)
Reject container full - Error counter (global)
Reject control - Error counter (global)
Light barrier - Error counter (global)
EEPROM - Error counter (global)
Test result - Error counter (global)
Tester timeout - Error counter (global)
Hardware AWE - Error counter (global) Additional error information
3: Short-circuit relay output AWE
4: Initialisation error
Metal burst - Error counter (global)
External error - Error counter (global)
37
6. Menu / Operation
6.3.6.2 Report
This menu item only is available if "Printer portable" was selected as the interface protocol for COM2.
- Select "Report" with F4 .
Select the desired report type with F4
The following reports are available:

 Intermediate report
 Archive report
 Audit report
 Product statistics
 Batch statistics
 Device protocol
Please note:
The report is output through the serial COM2 interface in formatted form.
A maximum of 42 characters is output per line. Each line ends with LF (linefeed, ASCII 0Ah).
Every report can be directly printed with the EM report printer (option).
The following languages are supported:

 German
 English
 French
 Spanish
 Italian
 Swedish
 Finnish
 Dutch
 Danish
 Czech
 Polish
With Czech and Polish it may be that individual special characters are not correctly represented.
The system does not check whether an operational output device (e.g. printer) is
connected at the interface.
38
6. Menu / Operation
Examples:
Intermediate protocol
All entries are output to the printer in chronological order.

The number in brackets shows the current number of logbook entries.
Logbook entries will be kept.
++++++++++++++++++++++++++++++++++++++++++
Report: Intermediate (0024)
04.03.2010, 14:37:35
------------------------------------------
Device: Detector 1
Line: Line 1
------------------------------------------
04.03. 14:23:34 Power OFF
04.03. 14:23:41 Power ON
04.03. 14:24:25 Product changed
002 -> 001
04.03. 14:24:30 Metal
Signal=0615 Counter=00001
04.03. 14:24:37 Metal
001 -> 003
04.03. 14:24:55 Metal
04.03. 14:25:05 Metal
04.03. 14:25:12 !Level
Error counter=00001
04.03. 14:27:32 Product data changed
Product: 003 -> ParamGroup: 001
04.03. 14:28:25 Test requested
04.03. 14:28:35 Test started
UserID: 11000200
04.03. 14:29:00 Test metal
Signal=0312
04.03. 14:29:07 Test result
TP 1: Fe1,5 -> Test Ok
04.03. 14:29:13 Test metal
Signal=0161
04.03. 14:29:17 Test result
TP 2: V2A1,8 -> Test Ok
04.03. 14:29:17 Test end
-> Test Ok
04.03. 14:31:04 Metal
04.03. 14:31:07 ! Eject control
Error counter=00002
04.03. 14:31:08 Metal
04.03. 14:31:10 Metal
04.03. 14:31:17 Metal
04.03. 14:36:23 Batch changed
04.03. 14:36:35 Metal
04.03. 14:36:42 Metal
++++++++++++++++++++++++++++++++++++++++++
39
6. Menu / Operation
Archive protocol
As with the intermediate report, all entries are output in chronological order.
The number in brackets shows the number of the current printout for seamless reporting.
Attention:
After the output all the logbook entries will be permanently deleted.
For safety reasons a corresponding confirmation prompt will therefore be displayed before outputting is
started:
- Press F2 "No" to cancel the process, the logbook will be kept

- Press F3 "Yes" to confirm the process, the logbook will be cleared
- If a password has been specified for clearing the logbook, this password
must then be entered.
++++++++++++++++++++++++++++++++++++++++++
Report: Archive (0005)
04.03.2010, 14:42:21
------------------------------------------
Device: Detector 1
Line: Line 1
------------------------------------------
04.03. 14:23:34 Power OFF
04.03. 14:23:41 Power ON
002 -> 001
04.03. 14:24:30 Metal
04.03. 14:24:37 Metal
001 -> 003
04.03. 14:24:55 Metal
04.03. 14:25:05 Metal
04.03. 14:25:12 !Level
Error counter =00001
04.03. 14:28:35 Test started
UserID: 11000200
04.03. 14:29:00 Test metal
Signal=0312
04.03. 14:29:07 Test result
04.03. 14:29:13 Test metal
Signal=0161
04.03. 14:29:17 Test result
04.03. 14:29:17 Test end
-> Test Ok
04.03. 14:31:04 Metal
04.03. 14:31:07 !Eject control
Error counter=00002
04.03. 14:31:08 Metal
04.03. 14:31:10 Metal
04.03. 14:31:17 Metal
04.03. 14:36:35 Metal
04.03. 14:36:42 Metal
++++++++++++++++++++++++++++++++++++++++++
40
6. Menu / Operation
Audit report
The audit report in a clearly structured form shows all the events in connection with the last audit
check.
++++++++++++++++++++++++++++++++++++++++++
Report: audit
04.03.2010, 14:37:53
------------------------------------------
Device: Detector 1
Line: Line 1
------------------------------------------
003 Product 3: 100%, 125,1°
------------------------------------------
04.03. 14:28:35 Test started
UserID: 11000200
04.03. 14:29:00 Test metal
Signal=0312
04.03. 14:29:07 Test result
04.03. 14:29:13 Test metal
Signal=0161
04.03. 14:29:17 Test result
04.03. 14:29:17 Test end
-> Test Ok
++++++++++++++++++++++++++++++++++++++++++
Product statistics
The product statistics show the time of the last product change.
The number of errors and metal signals since this change are also displayed.
++++++++++++++++++++++++++++++++++++++++++
Report: Product
04.03.2010, 14:38:01
------------------------------------------
Device: Detector 1
Line: Line 1
------------------------------------------
003 Product 3: 100%, 125,1°
------------------------------------------
001 -> 003
Metal counter: 00008
Error counter: 00002
++++++++++++++++++++++++++++++++++++++++++
Batch statistics
The batch statistics show the time of the last batch change.
The number of errors and metal signals since this change are also displayed.
++++++++++++++++++++++++++++++++++++++++++
Report: Batch
04.03.2010, 14:38:22
------------------------------------------
Device: Detector 1
Line: Line 1
------------------------------------------
003 Product 3: 100%, 125,1°
------------------------------------------
++++++++++++++++++++++++++++++++++++++++++
41
6. Menu / Operation
Device report
The device report provides information about essential system settings.

It shows a list of all the teach product events and displays the total number of metal signals and errors
since start-up.
++++++++++++++++++++++++++++++++++++++++++
Report: Device
04.03.2010, 14:42:57
------------------------------------------
Device: Detector 1
Line: Line 1
------------------------------------------
STE SW: V1.09 HW: 03
AWE SW: V1.22 HW: 01
------------------------------------------
Coil number: 125
Frequency 1: 289 kHz
Frequency deviation: 1
------------------------------------------
------------------------------------------
Code 'Change product': 0000
Code 'Teach product': 0000
Code 'Paramters': 0000
Code 'Setup': 0000
Code 'Clear logbook': 0000
------------------------------------------
001 Product 1: 100%, 122,2°
002 Product 2: 100%, 125,1°
003 Product 3: 100%, 125,1°
004 Product 4: 100%, 122,2°
005 Product 5: 100%, 125,1°
006 Product 6: 99%, 14,5°
007 Product 7: 100%, 7,7°
008 Product 8: 100%, 14,5°
009 Product 9: 100%, 13,6°
010 Product 10: 100%, 14,0°
++++++++++++++++++++++++++++++++++++++++++
42
6. Menu / Operation
6.3.6.3 Clear logbook
- Select "Clear logbook" with F4
- Deleting the logbook requires confirmation

- Cancel with F2 "no" and retain logbook
- Delete logbook with F3 "yes”
- If a password was created for the logbook, it has to be entered to confirm
the process
6.3.6.4 Trigger audit check (only when audit check activated)
- Start audit check regardless of selected audit time with F4
The detailed procedure for audit checks can be found in chapter 8.2.
(Device test)
6.3.6.5 Audit check main setup
The "audit check basic setup" sets the general performance of the device for testing (in contrast to the
"audit check” settings in the parameter menu).
- Select "Audit check main setup" with F4
- Select option with F1

- Activate or deactivate with F2
- Cancel without changes with F3
- Confirm and continue to the next menu with F4
Error if test not OK: An error message is generated upon a faulty test.
Eject during test: Defines whether outputs are activated during the test.
Autotest device: For deactivating the automatic test device that is factor-
preset.
- Enter time for test start with F1 , F2 and confirm with F4

Sets the time until test must be started.
43
6. Menu / Operation
6.3.6.6 Show counter
- Select "Show counter" with F4
- Select "User counter" with F4
Available counters:
- User counter
- Sums up all metal incidents regardless of product of batch changes un-
til reset by user
- Metal counter
Sums up all metal incidents
- Error counter
Sums up all error incidents
- Product counter (only in combination with trigger light barrier)
Sums up all conveyed products
- Global
- All incidents since launch of device
- Product
- All incidents since selection of current product
- Batch
- All incidents since start of current charge
6.3.6.7 Change password
- Select "Change password" with F4
Available passwords:
- for change product
- for learn product
- for parameters
- for setup
- for clear logbook
- Enter password with F1 , F2 and F3 and confirm with F4
A password assigned previously has to be entered before a new one can

be assigned.
44
6. Menu / Operation
6.3.6.8 Device/line
The names entered appear on print outs of protocols and in the data management system (Insight-
Log.NET and Insight.NET).
- Select "Device/line" with F4
- Enter device name with F1 , F2 and F3 and confirm with

F4 .
- Enter line name with F1 , F2 and F3 and confirm with F4

.
6.3.6.9 Frequency deviation
When several S+S metal detectors or metal separators with the same search frequency are used near
each other, an interference in the signal can occur. To prevent this, a frequency deviation can be se-
lected. Changes of pre-installed values should only be made after consulting S+S.
- Select "Frequency deviation" with F4
- Enter with F1 , F2 and F3 and confirm with F4

- Confirm without changes with F3
The maximum approved range has been defined by S+S in final clearance.
6.3.6.10 Language
- Select "Language" with F4
- Select language and confirm with F4

- Exit "Setup" menu with F3
45
6. Menu / Operation
6.3.6.11 Clock/Date
- Select "Clock/Date" with F4
- Change digits with F1 / F2

- Press F4 to jump to the next value;
after setting the year, save changes and exit the menu with F4
6.3.6.12 Interface
Changes that are made in this menu will only become effective after the control unit
is restarted.
- Select "Interface" with F4
- Select interface COM2 (plug 7b) or COM1 (plug 11) with F1

- Select baud rate with F2
- Confirm with F4 or exit without changes with F3
Available baud rates:

- 115.2 kBaud
- 57.6 kBaud
- 38.4 kBaud
- 19.2 kBaud
- 9.6 kBaud
The other interface parameters cannot be changed. They are set to 8N1 (8
data bit, no parity, 1 stop bit).
In addition to that, no flow control is applied.
- Select device address with F1 / F2

- Exit without changes with F3
- Confirm with F4
The address in needed for addressing the device via interface.

This parameter has no impact when the serial interface RS232, Ethernet or
WLAN are used. It merely has to be different to 0.
For the bus-compatible interface RS485 distinct addresses have to be as-
signed in the network.
Value range: 0 (off), 1...254
- Select interface COM2 (plug 7b) or COM1 (plug 11) F1

- Select protocol with F2
- Confirm with F4 or cancel without changes with F3
46
6. Menu / Operation
The following selection can be made for COM1:

- Off
1 2
- SSTProt ) )
The following additional selections are available for COM2:

3
- Printer online )
3
- Printer portable )
2
- Insight2-Prot )
1
) S+S standard interface protocol
2
) Specifications on request
3
) In combination with EM report printer, baud rate 115.2kBaud
Please note:
If the "Printer online" option is selected, all the newly added logbook entries are output through the se-
rial COM2 interface.
Entries are output in formatted form with a maximum of 42 characters per line. Each line ends with LF
(linefeed, ASCII 0Ah).
The system does not check whether an operational output device (e.g. printer) is connect-
ed at the interface.
If events occur faster than they can be printed, some events will be skipped. Such skipped
entries can be recognised by way of the metal and error counters (see below). If neces-
sary, a full sequence of events without gaps can be printed subsequently by selecting the
"Printer portable" mode.
Possible output:
04.03. 14:23:34 Power OFF
04.03. 14:23:41 Power ON
002 -> 001
04.03. 14:24:30 Metal
04.03. 14:24:37 Metal
001 -> 003
04.03. 14:24:55 Metal
04.03. 14:25:05 Metal
04.03. 14:25:12 !Level
Error counter =00001
04.03. 14:28:35 Test started
UserID: 11000200
04.03. 14:29:00 Test metal
Signal=0312
04.03. 14:29:07 Test result
04.03. 14:29:13 Test metal
Signal=0161
04.03. 14:29:17 Test result
04.03. 14:29:17 Test end
-> Test Ok
04.03. 14:31:04 Metal
04.03. 14:31:07 ! Eject control
Error counter=00002
04.03. 14:31:08 Metal
04.03. 14:31:10 Metal
04.03. 14:31:17 Metal
04.03. 14:36:35 Metal
47
6. Menu / Operation
6.3.6.13 Setup options
- Select "Setup options" with F4
- Select setup option with F1 and activate with F2 .

- Exit menu without changes with F3 .
Error if too many metal: In case of 10 or more metal detections within 5

minutes an error message is created.
Batch number (currently not available): A batch number must be en-
tered for any product or batch change. A log file will be created.
Slider: A signal bar replaces the signal value display on the operating
mask.
6.3.6.14 Air pressure monitoring (option)
- Select "Air pressure monitoring" with F4
The air pressure can be monitored.

0.0s deactivates the monitoring.
A value different to 0 sets the maximum time, in which the air pressure can
drop below the limit set in the pressure controller without creating an error
message.
The value can be varied in steps of 0.5s up to a maximum of 5.0s.

Changing the factory pre-set value is usually not required.
6.3.6.15 Flap monitoring (option)
- Select "Flap monitoring" with F4
Flap monitoring can be configured in this menu.

0.0s deactivates the monitoring.
Values different to 0 set the time, which the flap may not extend when
switching from normal position to reject position and vice versa.
The value can be varied in steps of 0.2s up to a maximum of 20.0s.

Changing the factory pre-set value is usually not required.
48
6. Menu / Operation
6.3.6.16 Ejection monitoring (option)
- Select "Ejection monitoring" with F4
Available settings are:

- Inactive
- Ejection monitoring
Shows that the product has been ejected
- Filling level monitoring
Shows if the collecting tray still has enough capacity
- Ejection and filling level monitoring
Monitors ejection and filling level
6.3.6.17 Light barrier (option)
- Select "Light barrier" with F4
Configuration of light barrier settings.

Available settings are:
- None
- Sync
Products containing metal contaminants are ejected
- Inverse
Non-metallic products are ejected
6.3.6.18 Units
- Select "Units" with F4
Country specific conveyor speed display and time and date formats can be
configured here.
Formats for conveyor speed:
- m/s
- m/min
- ft/s
- ft/min
- t/h
Formats for date and time:

- dd.mm.yyyy, hh:mm:ss
- yyyy-mm-dd, hh:mm:ss
- mm/dd/yyyy, hh:mm am/pm
49
6. Menu / Operation
6.3.6.19 Device-Info
- Select "Device-Info" with F4
Current search frequency, frequency configuration (S: single, D: dual,

Q:quattro) and frequency deviation are displayed.
Two voltage values are displayed which may help with a quick diagnosis
during service.
Must values:
RECV = 1,500 mV
TX = 42,000 mV
Current operation mode is displayed

- Conveyor
- Conveyor with controlling
- Rapid (free fall systems)
- GF (vacuum and pressure pipeline systems)
- Liquiscan (pumped products)
6.3.6.20 Revision
- Select "Revision" with F4
Version number of the installed hardware and software components of STE

and AWE are displayed
- Exit menu with F4
6.3.6.21 Login
The menu options "sign in" and "sign out" lead to protected setup levels. These levels are usually not
used for normal operation, hence why they are not displayed.
There are currently three service / setup levels.
Level 0 -> "Standard"

The following options are available:
 Logbook
 Report )
1
 Clear logbook
 Trigger audit check )
1
 Show counter
 Language
 Device-Info
 Revision
 Login
 Logout
50
6. Menu / Operation
Level 1 -> "Setup level" via code "3080"

 Logbook
 Report )
1
 Clear logbook
1
 Audit check main setup

 Show counter
 Change password
 Device/Line
 Frequency deviation
 Language
 Clock/Date
 Interface
 Setup options
 Units
 Device-Info
 Revision
 Login
 Logout
Level 2 -> "IO-Level" via code ”2606"

 Logbook
 Report )
1
 Clear logbook
1
 Show counter
 Language
 Air pressure monitoring )
1
 Flap monitoring )
1
 Ejection monitoring )
1
 Light barrier )
1
 Device-Info
 Revision
 Login
 Logout
1
) if function is activated
- Select "Login" with F4
- Enter login code with F1 , F2 and F3 and confirm with F4
- To exit the menu, sign out (6.3.6.22) or restart the device
6.3.6.22 Logout
- Select "Logout" with F4

- Changes to operating mask and deactivates the entered code
51
7. Interfaces (option)
7 Interfaces (option)
The optional interfaces for the GENIUS+ control unit solely have the purpose of connecting the control
unit with the outside world. Various data protocols can be used to transfer a great variety of infor-
mation. Settings at the control unit also can be made through these interfaces.
Basically the GENIUS+ control unit can be connected to PC systems, suitable report printers, SPCs, or
other automation systems.
As an option S+S offers operating and data management software for PCs that is optimally matched to
S+S systems.
7.1 Serial interfaces

The RS232 and the RS484 interfaces at the ST7b connector cannot be used simultaneous-
ly.
7.1.1 RS232
The electrical specification complies with

the RS232-C standard (point-to-point con-
nection).
The following signals are led out:

Auswahlsteckbrücke R232  TxD Transmit data
Jumper RS232  RxD Receive data
 GND Signal ground
Signals for hardware flow control are not

provided.
The interface is led out at a 4-pole socket

at the bottom of the housing. The corre-
sponding mating plug is supplied with the
1 2 3 Gerätebuchse, Frontansicht
4 1 Device socket, front view system.
TxD TxD: braun / brown
RxD RxD: blau / blue The hardware of the RS232 interface is
GND: schwarz / black
3 2 activated if the jumper is set as shown in
GND: weiß / white
this drawing.
1 blue
2 brown
3 black / white
Information for connecting a PC

The 9-pole Sub-D socket of the PC (suitable RS232-USB converters also are possible) must be con-
nected with the system socket as follows:
PC GENIUS+
Pin 2 (Rx) Pin 1 (TxD)
Pin 3 (Tx) Pin 3 (RxD)
Pin 5 (GND) Pin 2 (GND)
Note on report printer connection

A suitable adaptor cable is required for connecting the EM report printer.
Cable lengths
Possible cable lengths depend on the baud rate that is used and on the cables. The values below are
general guide values:
Max. baud rate Max. cable length
115,2 kBaud app. 3 m
56,7 kBaud app. 5 m
19,2 kBaud app. 15 m
9,6 kBaud app. 50 m
52
7.1.2 RS485
The RS485 interface is designed as a two-

wire bus (differential transmission) and op-
erates in half-duplex mode (transmit or re-
ceive).
Auswahlsteckbrücke RS485 Busabschluss Up to 32 devices can be connected to the
Jumper RS485 Bus terminating bus, with a cable length of approx. 1000m.
resistor
The following signals are led out:
 a - data line
 b - data line
 Signal ground (GND)
The GND signals are not necessary for bus

1 2
operation, but they improve the communica-
3
Gerätebuchse, Frontansicht tion behaviour in case of long cables.

4 1
Device socket, front view
a b b: braun / brown The interface is led out at a 4-pole socket at
a: blau / blue
3 2
GND: schwarz / black the bottom of the housing. The correspond-
GND: weiß / white ing mating plug is supplied with the system
The hardware of the RS485 interface is ac-

tivated if the jumper is set as shown in this
drawing RS485.
1 blue
2 brown The line ends of the bus system must be
3 black / white
properly terminated.
As a rule this is done by the two devices at
the respective bus ends.
The bus terminating resistors are integrated
on the GENIUS+ STE board and can be ac-
tivated with the corresponding jumpers.
Attention
Devices that are connected in the middle of
the bus must not be terminated.
As a rule the connector assignment of the RS485 interface is not standardised.

Please observe the respective manufacturer's documentation when you connect different
devices.
Normally the 9-pole Sub-D socket of a PC is not compatible with the RS485 interface spec-
ification. Any direct connection may destroy or damage the PC and/or system hardware.
Corresponding expansion cards (e.g. Moxa) are available on request.
53
7.2 Ethernet interface (LAN - TCP/IP)
The Ethernet interface is implemented by way of an additional module that is wired as the RS232 inter-
face. The RS232 interface (COM2) must be configured to 115.2 kBaud.
Interface specifications
 Ethernet protocol acc. to IEEE 802.3
 RJ45 Ethernet 10BASE-T or 100BASE-TX (auto-sensing)
1 2 3 4 5
1 blue 4 red
2 brown 5 white
3 black
Front view of the additional Ethernet module

Connection LED Activity LED
Off No connection Off No activity
Yellow 10 Mbps Yellow Half-duplex
Green 100 Mbps Green Full-duplex
As a standard every device has the IP address 172.16.1.20 (netmask 255.255.0.0).

Information about configuring of the IP address can be found on the CD that is supplied with the inter-
face.
Network connector at the system:

The network connector is of IP65 compliant design.
If the network cable is removed, the supplied sealing cap must be attached to maintain
the protection rating.
Any conventional network cable can be used (see note). The protection rating, however,
can only be maintained if a suitable plug is used (plug available on request!)
Note on network cables:

For 100Base-TX (standard in PC technology) at least an unshielded CAT-5 cable (UTP - Unshielded
Twisted Pair) should be used. The maximum length is approx. 100 m.
54
7.3 WLAN interface (WLAN - TCP/IP)
The WLAN interface also is implemented by way of an additional module that is wired as the RS232 in-
terface. The RS232 interface (COM2) must be configured to 115.2 kBaud
Interface specifications
 Wireless 802.11b/g (54 MBps - 1 MBps with auto-fallback)
 Frequency range: 2.412 -2.484 GHz
 Output power 14dBm +1.5/-1.0 dBm
 Encryption 64/128-bit WEP / WPA
 WLAN short rod antenna 2.4GHz (26 mm)
 Range (depending on environmental conditions) approx. 20 m – 100 m
1 2 3 5 6 7
2 1 4
1 blue 5 yellow
2 brown 6 green
3 black 7 white
4 yellow / green
Information about configuring this module can be found on the CD that is supplied with the interface.
If the radio interface should not be available, the WLAN module can be configured through the serial
interface UART0 of the module. Further information can be found on the CD.
Standard settings:
IP address 172.16.1.21
Netmask 255.255.0.0
MAC address (fix) 00:20:4A:xx:xx:xx
Topology AdHoc network
Network name (SSID) SeSoTec
Channel 11
Authentication open/none
Encryption WEP64
Key (HEX) 07-E3-A1-E7-4A
WiPort web configuration:

User name admin
Password password
55
8. The use of the GENIUS+ for quality assurance
8 The use of the GENIUS+ for quality assurance

To meet the demands of Total Quality Management and the HACCP concept, the Genius+ device is
equipped with a permanent logbook of up to 1,500 entries and several counters for product, error and
metal incidents. It is also equipped with interfaces to connect to a subordinate quality management
system.
The interfaces (serial, Ethernet, WLAN and Profibus) enable a connection to the optional data man-
agement systems Insight.NET and InsightLog.NET. They also enable a simple connection of S+S met-
al detectors and separators to an existing quality and data management system used by the customer.
A critical element of the HACCP system is the regular monitoring of "critical control points"(CCPs).
Genius+ devices offer various configurable possibilities to carry out such tests securely and accurately.
To ensure that tests are reproducible, S+S offers a large number of different test samples. These
samples can be supplied in the form of cards, sticks, mini sticks, balls or bars (for LIQUISCAN) to
match different applications. Available materials include iron, V2A, V4A and brass. Available sizes
range from 0.2 mm to 10 mm, depending on the material.
8.1 General procedure

The procedure depends largely on the quality requirements of individual companies. The following out-
line should therefore be seen as a general guideline.
Please note:
Tests are usually carried out together with the product.
Most audit check settings are therefore product specific and are assigned to a particular prod-
uct.
1. Learn product (see chapter 6.3.3)

2. Convey product together with test samples. Select smallest test sample, which can be detected and
meets quality requirements. Up to 3 test samples can be appointed.
3. Set basic settings for the current product in the parameter menu "Audit check" (see 6.3.5.8)
 Alarm mode (time, Interval, external, …)
 Start time or interval (depending on mode)
 Test sample (defined under point 2, if applicable also user specific samples)
 Optional: maximum test signal for up to 3 test samples
4. If several GENIUS+ devices are used and connected to a subordinate system, a distinct allocation
with a significant identifier should be chosen in the setup menu "Device/line” (see 6.3.6.8).
5. Date and time should be set correctly (see setup menu "Time/date” under 6.3.6.11)
Depending on the quality requirements within the company, additional settings for the audit check can
be configured.
They can be found in the setup menu under "Audit check basic setup” (see 6.3.6.5)
 "Error when test unsuccessful"

In case of a faulty test (faulty result or execution) an error message is displayed. Certain configura-
tions (such as "stop when error") can mean that this stops the conveyor; applied to a Rapid metal
detector, the setting "metal when error” would mean the device switches to "Reject”.
 "Time to start test”
The time set here is the time to complete the test. If the test is not completed, this will lead in com-
bination with the previous option to an error.
56
8.2 Carrying out a performance validation
When reaching the testing time (triggered manually or externally) the user will
be required to enter the 8-digit user identification number and to perform the
test.
The green operation LED will flash on the front panel;
The digital "LB” output will also toggle with a frequency of approx. 1Hz.
In the illustrated example, the user has 5 minutes to start the test.
He is requested to convey the test sample. The procedure can be cancelled

should the test sample not be detected.
Upon successful detection of the test sample and when the defined test signal
is not exceeded, the user can accept the result or reject it, e.g. if the metal in-
cident was caused by fault.
or
If the signal exceeds the configured value, the user can only reject the result.
Steps 2 and 3 are now repeated for all defined test samples.
The error message on the left will appear, should one of the test be unsuc-
cessful or was not started on time and the device has been configured ac-
cordingly. The red fault LED will flash. The output "LF” will be deactivated.
The following logbook entries are created:
57
8.3 Autotest device (option)
8.3.1 Connection
The S+S autotest device is connected to the Genius+ control unit by way of the solenoid valve outputs
MV3 and MV4.
 MV4 triggers the test device
 MV3 functions as a feedback contact informing the control unit about metal detection.
8.3.2 Configuration of the autotest device
The autotest device can be configured in the Service menu -> Auditcheck main setup.
-> ->
 Error if test not OK

An error message is generated if a test is not OK.
 Eject during test
Defines whether outputs are activated during the test.
 Autotest device
As a factory-presetting the autotest device is activated; it can be deactivated with this menu
item.
 Time to do test
Defines the time up to which the test must be started.
(this setting has no meaning for the autotest!)
8.3.3 Auditcheck configuration
Auditcheck settings are product-specific and must be configured separately for every
product.
When new products are learned, the settings of the starting product are adopted.
For information on general settings please refer to chapter 6.3.5.8 in the operating instructions. All the
alarm modes are possible. Furthermore, the autotest also can be started manually from the menu.
->
Alarm modes
 Off (no request to perform auditcheck)
 Every hour (starting from the next full hour)
 Every day (the alarm time can be set in the next menu)
 Every week (the alarm day and time can be set in the next menu)
 External (the auditcheck is started by way of an external signal)
 Interval (the starting time and interval length can be set in the next menu)
 With every product change (from this product) an auditcheck will started after 15 seconds at
the earliest and will be repeated in a selectable interval.
58
It is not necessary to make any settings for the test pieces when using the autotest device. The Geni-
us+ control unit automatically selects test piece TT1 with the ID "User 31".
->
8.3.4 Running an auditcheck
The auditcheck is performed automatically. The result will be recorded in the logbook.
At the start of the test "99999999" will be displayed as user ID.
If the first test should not be successful within a time of 10 s, the control unit automatically tries to re-
peat the test.
If the above-mentioned time elapses without a successful test, the auditcheck, depending on the con-
figuration, will be terminated with an information entry in the logbook or with an error message.
59
9. Errors and error remedying
9 Errors and error remedying
If you should have any questions, or if there should be any malfunctions, please
contact the manufacturer.
If you have any questions, please state the equipment type and serial number !
Service telephone: +49 (0) 85 54 - 30 8-180
9.1 Error messages

Error messages are indicated by a flashing red "Fault" LED at the control panel, by a corresponding er-
ror message that appears on the display, and by a release of the fault relay (see 2.2.1).
If the system is configured correspondingly, it also indicates a metal alarm.
9.1.1 Communication AWE

This message appears if communication between control electronics board and evaluation electronics
board (see spare parts view 11.1 No.4) is interrupted and data can no longer be exchanged.
Possible causes Remedy
Data communication cable between evaluation elec- Check cable and connectors with ohmmeter;
tronics board and control electronics board is broken. Replace cable, if necessary
Interface module broken. Replace evaluation electronics board and control elec-
tronics board
9.1.2 Receiver voltage too high

This message appears if the RF voltage at the receiver is too high.
Big metal part (e.g. aluminium ladder, screwdriver, Check the detector head and the surrounding. Some-
hammer, bracelets) directly beside or in the detection times metal parts can be found inside or underneath
coil. the belt.
Improper installation of the search coil See Op. Man Detection coil: "Installation
If detector head DLS is used, check on loose centering
pins or fastening bolts.
9.1.3 Air pressure

Appears on display if the air pressure monitor responds Extend the air pressure recovery time
or the connection to the sensor is interrupted. Check the air pressure. Minimum value 2 bars. In-
crease, if necessary.
Check the cable to the air pressure monitor. Switch off
Power, open housing. Check with ducter at connector
6a (24V) and 7a terminal i2 (see 2.2.4).
With connected compressed air : < 20 Ω
Without compressed air connected: open
If not, replace sensor and/or cable
9.1.4 Eject control

Appears, after rejection, if no signal was sent by light Adjust delay time and reject duration time properly
barrier.
Causes: If the error repeats, check sensor and/or connection
Product was not rejected was not detected by the light cable
barrier
Sensor connecting cable broken
60
9.1.5 Reject box full

Appears, if the light barrier is blocked by products. Empty the reject box.
A short circuit in the connection cable causes the If reject box is empty and the error message is not
same error message resettable, check the connection cable
9.1.6 Diverter position

Appears during reject operation of the diverter, if
signal timing is not correct, Fix the diverter mechanics
diverter is broken Check diverter if tight or wedged pieces
diverter too slow Check air pressure (min. 5 bars)
Caution! Danger of accident!

Disconnect air supply!
Forward and return time set too short Prolong the time settings
Connection to the sensors defective Check cable and sensors
9.1.7 Transmitter over temperature

Evaluation electronics board defective Replace the evaluation electronics board
Coil or transmitter connection board defective Contact S+S service
Improper installation of the detection coil (see instruction manual of the detection coil: "In-
stallation"). With type DLS detection coil, check
whether the centering sleeves or fastening screws
are loose.
9.1.8 Watchdog AWE

Software error of the evaluation electronics board If this occurs several times, contact S+S service
9.1.9 Conveyor belt control

Motor overload (thermal contact) - Let the motor cool down
Error message E35 at the display of the frequency - Check the conveyor belt for possible mechanical
converter influences
- Reset the error message at the frequency con-
verter
Other frequency converter error As described in the frequency converter manual
Error messages E01 – E60 (see frequency con-
verter manual)
9.1.10 Light barrier

After a metal signal the synchronisation light barri- If this error is permanently repeated: Check the
er was not interrupted within the set time. connection cable
For example, this may be due to an unwanted

conveyor stop or to a defective connection cable.
61
9.1.11 EEPROM
System and product data memory defective. Replace the control electronics board
9.1.12 Test result

An error occurred while the system test (chapter Repeat the system test, check the test piece
6.3.6.5) was performed
If this occurs several times, check the system and
product settings.
9.1.13 Test timeout

The system test was not performed within the
specified time frame.
9.1.14 Hardware AWE

Error info 3 Check output 4 of the AWE (relay output) for cor-
Short-circuit relay output AWE rect polarity or short-circuit
Error info 4 Replace the evaluation electronics board
Initialisation error at the evaluation electronics
board
9.1.15 Metal burst

Accumulation of metal events
(if configured correspondingly)
More than 10 metal events within 5min
9.1.16 External error

Error signal at the external error input (IN8) of the Check and remedy the external cause of the error
control electronics board
62
9.2 Undefinable activation of the switching outputs

Improper installation of the search coil See operational manual detector coil: "Mounting"
With conveyor systems:
Open and close electric circuits at the frame of the con- Check and tighten all screw connections.
veyor system, e.g. due to: If necessary, weld frame parts.
 loose guide plates
 loose screw connections at frame parts
Changing contact resistance at the bearings of the ten- Insulate at one side cross struts, tension and deflection
sioning and deflection pulleys or the drive pulley rollers
Individual locations of the conveyor belt are conductive:

 Metallic impurities (welding spatter, metal chips, Remove residues from the conveyor belt
abraded matter...)
 Belt junction causes metal alarms If necessary, replace the conveyor belt
With round coils: A gap of at minimum 10 mm has to be kept between
Mechanical contact between scanning pipe and search scanning pipe and detector coil.
coil
Sensitivity too high Repeat product teach in procedure
Reduce sensitivity manually
Metal particles hard to identify due to corrosion or en- Check carefully the processed material if necessary
capsulation. inspect again.
Loose contact at the coil cables Check the connections
High electrostatic charging of the material (possibly au- Avoid static charging by additional grounding measures
dible clicking sound at the detection coil) (contact S+S service!)
Use of de-ionizing equipment
63
9.3 Replacing the backup battery
Because of energised components in the electronics housing there is a risk of injuries

due to electric shock or burns.
Therefore such work may only be performed by a qualified electrician under strict obser-
vation of the attached warning labels and with due regard to standard approved rules of
electrical engineering.
1. As a precaution, make a backup copy of the logbook entries

2. Do not turn off the power supply to avoid any loss of data
3. Open the cover of the electronics housing
Procedure - Replacing the backup battery:
Button cell CR2032 (for STE article number 44006482):
1. Carefully remove the old backup battery a) from its holder

2. Insert the new backup battery.
3. Always observe the correct polarity (positive pole on top)!
4. Close the cover of the electronics housing again.
5. Check whether the date and time settings are still correct, and
a whether the logbook entries are still there.
If the backup battery is not replaced in time, the following data will be lost:
Date, time, and all the entries in the logbook.
64
9.4 Replacement of electronic boards
The Control-Unit GENIUS consists of the following three boards: Control electronics board (3), eval-
uation electronics board (5) and display board (8).
8
1
4 6
9
3
9.4.1 Replacing the control electronics board

1. Disconnect voltage supply and external circuits and open the cover at the electronics housing
2. Remove connectors (1) and (6) and remove the fastening screws (2)
3. Remove the fan (9)
4. Take out the control electronics board (3)
5. Install the new board in reverse order, but do not connect mains power supply!
The data memory is located on the STE controller board. The memory contains all device
and product parameter settings.
If this memory device is transferred to a new board no new settings must be performed.
65
Replacement of the Data Memory:
STE article number 44006482
a: New controller board
a
b: Old controller board
c, d: Device and program memory
Instruction:
c 1. Remove data memory device c) from the board

2. Remove data memory d) from the old board b) and plug it
carefully into the new board a)
3. Check that the marking on. The memory device points to the
right
4. Switch on power supply. The new board runs with the "old"
b adjustments.
Date, time and recorded events in the logbook are not transferred, when changing the
Data memory device.
9.4.2 Replacing the evaluation electronics board

1 Disconnect voltage supply and external circuits and open the cover at the electronics housing
5. Remove the used connectors (1) and (6) and remove the fastening screws (4)
3. Take out the evaluation electronics board (5)
4. Install the new board in reverse order!
9.4.3 Replacing the display board

1. Disconnect voltage supply and external circuits and open the cover at the electronics housing
2. Remove the used connectors (6) and remove the fastening screws (7)
3. Take out the display board (8)
4. Install the new board in reverse order!
66
10. Maintenance and cleaning
10 Maintenance and cleaning
Prior to cleaning turn off the system with the master switch and disconnect the system from
the mains voltage.
10.1 Maintenance
The Genius+ control unit is maintenance-free, yet it is still appropriate to inspect the equipment in regu-
lar intervals:
 Are all the fastening screws tight?
 Is the housing seal in perfect condition, and does it provide proper sealing?
 Also check all the cables for possible damage (e.g. at the cable sheath).
10.2 Cleaning
10.2.1 Hints for cleaning
- Please ensure you follow the instructions below.

- Specific machine components must be cleaned with specific substances. Please use the correct
materials and clean at regular intervals as suggested.
- If the building is being cleaned ensure the machines are covered up.
The following must not be used for cleaning:
- Sharp, hard or pointed objects
- Water or steam jet appliances
- Compressed air
- Hazardous and solvent-containing materials
- Cleaning agents that may attack the materials used
10.2.2 Cleaning instructions

For cleaning purposes we recommend that you use warm water with approved cleaning agents for the
respective application, and a soft, lint-free cloth. Once every week the coil shaft should be thoroughly
cleaned, removing any dirt accumulations and deposits. After cleaning wipe up any remaining drops of
water with a dry, non-fibrous cloth until the coil shaft is dry. From time to time apply oil to the stainless
steel framework (e.g. Nirostol 55 cleaning and maintenance oil which meets food industry standards).
10.2.3 Care advice for stainless steel

Only high-quality stainless steel is used in the systems. To prevent rust on the high-grade steel parts
do not use substances containing chloride (e.g. cleaning or disinfecting products) or operate the ma-
chine in an atmosphere containing chloride. If this is unavoidable the steel parts must be thoroughly
rubbed down immediately afterwards with cleaning oil e.g. Nirostol 55 cleaning and maintenance oil
(which meets food industry standards).
Important information for stainless steel models

Stainless steel models are extremely weatherproof and are therefore able to withstand most environ-
mental conditions.
However, even stainless steel can be susceptible to a slight film of rust.
These deposits are caused by contact corrosion and can be removed by following the instructions be-
low:
- Use a stainless steel cleaner: in principle any stainless steel cleaner may be used. Please ensure
you read the instructions prior to use.
- Use only cleaning agents that are halogen-free (i.e. without chlorides and fluorides), and salt and
hydrofluoric acid free.
- After each cleaning rinse the machine thoroughly with tap water
- Do not use the following: non-alloy materials or substances, abrasive cloths, cleaning agents con-
taining salt or hydrofluoric acid, chrome, silver or brass cleaners.
67
11. Spare parts
11 Spare parts
If you should have any questions please state equipment type and serial number!
Spare parts and wearing parts must always be obtained from the manufacturer of from a
supplier that is certified by the manufacturer.
11.1 Spare parts view
1
14
2 7
3 4
10
11
15
9
5
12
6
3
13
68
11. Spare parts
11.2 Spare parts list
Item Sp/
Part Part No. Material Art. No. Goods No.
No. Con*
1 Display cover GENIUS+ 33010416 Sp 85381000
2 Display board GENIUS+ 44001078 Sp 85340090
3 Electronics housing GENIUS+ mounted 1.4301 44003910 Sp 73269098
to the detector head (incl. cover), bead
blasted
3 Electronics housing GENIUS+ remote 1.4301 33002708 Sp 73269098
(incl. cover), bead blasted
4 Evaluation electronics board GENIUS+ 44006480 Sp 85340090
AWE
5 Control electronics board GENIUS+ STE 44006482 Sp 85340090

6a Mains cable standard 04015479 Sp 85444290
6b Mains cable US version 33002438 Sp 85444290
7 Flat cable for display 44005994 Sp 85444290
8 Threaded joint M16x1.5 33001010 Sp 74199900
9 Receiver cable 44005410 Sp 85444290
10 Transmitter cable 04015444 Sp 85444290
11 Connection cable AWE-STE 44005966 Sp 85444290
12 Button cell (CR 2032, LITHIUM 3V) 33011070 Sp 85444290
13 Main fuse 47090930 Sp 85444290
14 Seal NBR 33009700 Sp 84799080
15 Fan (EBM Papst, type 414FH) 77010666 Sp 84145939
*Sp/Con = Spare part / Consumable
11.3 Accessories
Sp/
Part Part No. Material Art. No. Goods No.
Con
Portable printer EM "Custom Engineering" 77010665 85340090
Paper roll for printer EM 77010668
InsightLog.NET Central Data Management 44006118
Interface cable RS232 for printer / length 1 meter 44006236 85444290
Interface cable RS232 for PC 44001060** 85444290
Interface cable RS485 for PC / INSIGHT 44001038** 85444290
LAN XPORT
WIPORT
**Art. No. = Please state cable length!
69
12. Shipping, preservation, waste disposal, transport, storage
12 Shipping, preservation, waste disposal, transport, storage
12.1 Shipping, preservation, waste disposal
1. Choose packing that is suitable for the type and size of unit, taking into account
whether the shipment is for export by sea or airfreight, or for national or international
road transport The packing material must protect the goods from all damage under
normal transport conditions.
2. Depending on the size, weight and nature of the goods packing in cardboard boxes,
boxed pallets etc is only suitable for road transport.
Use reinforced card, corrugated cardboard, blister packing and shredded paper to fill
and protect the goods.
Electrostatic sensitive components (electronic boards, electronic modules, etc.) must
be packed in antistatic foil or foil bags prior to packing! ( t h i s i s e s s e n t i a l ! )
Stick additional warning labels on the outside of the packaging e.g. "Attention, elec-
tronic equipment, do not drop,” etc. The packing should be sealed with adhesive tape
and, where the weight exceeds 50 kg, additionally with wrapping tape..
2a. When packing for international road transport use the instructions above (see point 2).
Larger and heavier shipments must also be protected as for export in wooden crates.
Care must be taken to ensure that the goods inside the packing are protected against
corrosion.
Any parts that will corrode easily must be wrapped in oil paper or corrosion-protective
foil. Care must be taken to prevent the components moving around within the packag-
ing.
2b. International air freight shipments must be packed in wooden crates or on export pal-
tainers.
Care must be taken that the goods are secure and well-protected inside the packing.
Any parts liable to corrode must be wrapped in oil paper, protective foil or sprayed
with anti-corrosion spray.
2c. Sea-freight must be packed in seaworthy export crates. These crates can be obtained
from specialist suppliers.
The crates must be lined with oil paper to make them resistant to sea water and pre-
vent corrosion. In addition the goods must be protected against corrosion by use of a
spray or be wrapping in protective foil.
Care must be taken to ensure that the goods cannot move around inside the crate.
After packing the sea-freight crates must be properly closed.
The sea crates must also be fastened externally with securing tapes.
During loading care must be taken not to damage the external packaging.
The carrier must certify that the shipment has been accepted and loaded correctly by
detailing this on the bill of lading, loading list etc.
3. Waste disposal: Observe the national waste disposal regulations.
70
12. Shipping, preservation, waste disposal, transport, storage
12.2 Transport
 In order to avoid injury or damage to the unit it must be handled properly. In addition to
following the instructions below, general health and safety good practice and specific
accident prevention guidelines should be observed.
 For correct handling and storage comply with the following symbols:
Protect against moisture Careful: glass Up Centre of gravity
 Do not compress the side walls of the unit or any attached parts by pulling obliquely on
ropes or chains.
 Only remove handling safeguards once all installation work has been completed.
 When handling in a loading area make sure the unit cannot topple over or slip.
 Damage caused during transportation must always be reported to the manufacturer.
12.3 Storage
 If possible the unit should be stored in a closed room until final installation.
 If the unit is stored in the open it must be covered over with tarpaulins and open under-
neath to allow condensation to drain off.
 Avoid any higher temperature fluctuations. It is possible that condensed water that has
formed in the packing cannot properly drain and may corrode equipment surfaces. If a
formation of condensed water cannot be avoided, suitable desiccants e.g. in the form of
bags must be placed in the packing.
 If the unit has been packed for transportation by sea the packaging must not be dam-
aged or opened during transit and storage.
 For storage temperature and permissible air humidity please refer to the technical data
sheet.
 For correct storage comply with all storage and handling symbols:
Protect against moisture Careful: glass Up
71
13. Annex
13 Annex
 EC DECLARATION OF CONFORMITY
 Technical data sheet
Accessories:
 Data sheet interface
 UL/CSA certificate
72

Genius+ Ba Cu en 1113

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Operating Instructions

Customer: AZO GmbH + Co. KG

Serial no.: 11223009316-H

Order no.: VAB057219

We reserve the right to change the con-

Please state type of equipment and se-

Please read these instructions and keep

Please observe and follow the safety

Tel.: +49 (0) 8554 3080

6.3.3.3 Manual teach in 29

9.1.10 Light barrier 61

1.2 Field of application

1.3 Application reasons

1.4 System identification

1.5 Symbols used

Caution Warning: Possibility of defects or destruction of the equipment.

Important Indicates an important information for the function.

1.6 EC DECLARATION OF CONFORMITY

GENIUS+ Control Unit

2 Design and method of operation

2.1 Functional principle

Transmitter- Control electronics Display

Interfaces allow simple operation as well as connection to a data management system.

2.2 Functional and control elements

2.2.1 GENIUS+ – Complete

Additional options (not shown):

2.2.2 Operating module with LCD graphic display

(1) LCD display

LED "Operation" (green)

LED "Fault” (red)

LED ""Metal" (yellow)

2.2.3 Cable glands

(7) Cable gland for the mains cable

2.2.4 GENIUS+ – Controller board STE

2.2.4.1 STE version, article number 44006482

Jumper Position Comment

Fuse Description Type

Connectors: (1) "Mains": Mains supply

2.2.5 GENIUS+ – Evaluation electronics board AWE

2.2.5.1 AWE version, article number 44006480

Connectors: (1) STE RS485: Interface RS485 to the controller board

Test points: GND Common ground for all signals

3 Dimensions and technical data

3.1 Technical data sheet, see annex

3.2 Supply connections, see technical data sheet in the annex

3.3 Environmental conditions for operation, storage, and transport

3.4 Noise levels

Sound pressure level measurements (in acc. with DIN 45 635)

4.1 Intended use

4.2 Safety signs

"Metal ½" (3/4) and "Fault" (2)

4.3 Dangers arising from non-compliance with safety notes

4.4 Safety information for operators

4.5 Safety information for operation, maintenance and cleaning

4.6 Safety information for commissioning

4.7 Safety information for storage and transport

4.8 Notes on residual risks

4.9 Notes on stable standing requirements

- In the product list, "NEW xxx" is selected

- in the product list, "NEW xxx" is selected