Z+VX Supervisor's Manual

Supervisor's
Manual.
SORTEX Z+Vx
SORTEX Z+Vx
Contents
Safety ------------------------------------------------------------------------------------------------------------------------- 1
Warning Labels .....................................................................................................................................................1
Power & Air Safety................................................................................................................................................3
Power.................................................................................................................................................................................................... 3
Air ......................................................................................................................................................................................................... 4
Good Habits .......................................................................................................................................................................................... 4
Serial Plate ..........................................................................................................................................................................4
Beyond Day-to-Day Operation ------------------------------------------------------------------------------------------ 5

Passwords ............................................................................................................................................................5
Gaining Access.....................................................................................................................................................6
Changing Passwords............................................................................................................................................6
Modules & Partitions.............................................................................................................................................7
Using Supervisor Level Commands .....................................................................................................................8
Supervisor Facilities Menu ----------------------------------------------------------------------------------------------- 8

Sorting Setup Menu ..............................................................................................................................................8
Defect Size ..........................................................................................................................................................................8
Camera ................................................................................................................................................................................................. 8
Colour Defect Window........................................................................................................................................................................... 8
Colour Defect Area................................................................................................................................................................................ 9
Spot Defect Area ................................................................................................................................................................................... 9
Defect Detection ..................................................................................................................................................................9
Pulse Extension..................................................................................................................................................................................... 9
Camera ................................................................................................................................................................................................. 9
Colour Defects ...................................................................................................................................................................................... 9
Spot Defects.......................................................................................................................................................................................... 9
Ejector Delay........................................................................................................................................................................9
Camera ................................................................................................................................................................................................. 9
Colour Defects ...................................................................................................................................................................................... 9
Spot Defects.......................................................................................................................................................................................... 9
Sort Type ...........................................................................................................................................................................10
Camera Scaling................................................................................................................................................................................... 10
Reset................................................................................................................................................................................................... 10
Sort Configuration ..............................................................................................................................................................10
Configuration....................................................................................................................................................................................... 10
Sort Type ............................................................................................................................................................................................ 10
View Combination ............................................................................................................................................................................... 10
Visible Defect Propagation/IR Defect Propagation............................................................................................................................... 11
Camera ............................................................................................................................................................................................... 11
Standard ............................................................................................................................................................................................. 11
Region................................................................................................................................................................................................. 11
Extended ............................................................................................................................................................................................. 11
Use Presence...................................................................................................................................................................................... 11
Reverse Sort ....................................................................................................................................................................................... 12
Mode Controls ....................................................................................................................................................13
Save Working Mode...........................................................................................................................................................13
Rename Working Mode .....................................................................................................................................................13
Copy Working Mode ..........................................................................................................................................................13
Delete Mode.......................................................................................................................................................................13
User Access Level ..............................................................................................................................................14
Calibration...........................................................................................................................................................14
Product Feed ......................................................................................................................................................14
Sort Sensitivity ....................................................................................................................................................14
Stats Menu..........................................................................................................................................................14
Stats Graph........................................................................................................................................................................14
Fixed Thresholds ...............................................................................................................................................................14
Stats Histogram .................................................................................................................................................................15
Relative Thresholds ...........................................................................................................................................................15
Stats Data ..........................................................................................................................................................................16
Over Time ........................................................................................................................................................................................... 16
Single Measurement............................................................................................................................................................................ 16
Stats Log............................................................................................................................................................................16
Log Brokens ........................................................................................................................................................................................ 16
Log Defects ......................................................................................................................................................................................... 16
Clear Stats Log ................................................................................................................................................................................... 17
Save Stats Log.................................................................................................................................................................................... 17
Product Alarm ....................................................................................................................................................................17
Enabled/Disabled ................................................................................................................................................................................ 17
Clear ................................................................................................................................................................................................... 17
Summary............................................................................................................................................................................................. 18
Sampling............................................................................................................................................................................18
Sample Module ................................................................................................................................................................................... 18
Sample Interval Time........................................................................................................................................................................... 18
Sample Feed Rate .............................................................................................................................................................................. 18
Sample Size ........................................................................................................................................................................................ 18
Enhanced Presence Detection ............................................................................................................................................................ 18
Object Width........................................................................................................................................................................................ 18
Object Length...................................................................................................................................................................................... 18
Mode Configuration ............................................................................................................................................19
Foreground Lighting...........................................................................................................................................................19
Wiper Interval.....................................................................................................................................................................19
Tracking Configuration.......................................................................................................................................................19
Calibration Configuration ...................................................................................................................................................20
Wipe during Calibration ....................................................................................................................................................................... 20
Calibration Interval .............................................................................................................................................................................. 20
Machine Configuration........................................................................................................................................20
External Interlock Configuration .........................................................................................................................................20
Input State........................................................................................................................................................................................... 20
Output State ........................................................................................................................................................................................ 20
Input.................................................................................................................................................................................................... 20
Modules .............................................................................................................................................................................................. 21
Hopper Interlock Configuration ..........................................................................................................................................21
State ................................................................................................................................................................................................... 21
Full ...................................................................................................................................................................................................... 21
Low ..................................................................................................................................................................................................... 21
White Reference Calibration ..............................................................................................................................................21
White Reference Calibration Interval .................................................................................................................................22
Disabled .............................................................................................................................................................................................. 22
Test Facilities ......................................................................................................................................................22
Background Test................................................................................................................................................................22
Self Test.............................................................................................................................................................................22
Create Diagnostic File ......................................................................................................................................................................... 22
Full Ejector Test .................................................................................................................................................................23
First ejector to test............................................................................................................................................................................... 23
Last ejector to test ............................................................................................................................................................................... 23
Start .................................................................................................................................................................................................... 23
Continuous Loop ................................................................................................................................................................................. 23
Individual Ejector Test........................................................................................................................................................23
Module ................................................................................................................................................................................................ 23
Block ................................................................................................................................................................................................... 23
Position ............................................................................................................................................................................................... 23
Channel............................................................................................................................................................................................... 23
Frequency ........................................................................................................................................................................................... 23
Start .................................................................................................................................................................................................... 23
Wiper Test .........................................................................................................................................................................23
Vibrator Test .......................................................................................................................................................24
Test Mode ........................................................................................................................................................................................... 24
Lamp Maintenance .............................................................................................................................................24
Used ................................................................................................................................................................................................... 24
Remaining........................................................................................................................................................................................... 24
Ejector Rates ......................................................................................................................................................24
Caused By........................................................................................................................................................................................... 25
Ejector Fire Count...............................................................................................................................................25
Engineer & Special Engineer menus ---------------------------------------------------------------------------------25
Maintenance ----------------------------------------------------------------------------------------------------------------27
Optical System Components -------------------------------------------------------------------------------------------27

Foreground Lamps–Replacement ......................................................................................................................27
Background Lamp–Replacement .......................................................................................................................28
Wipers.................................................................................................................................................................30
Changing a Wiper Blade ....................................................................................................................................................30
Ejector Cartridges Removal and Refitting ---------------------------------------------------------------------------31

Identification of Failed Ejectors ..........................................................................................................................................31
Replacing an Ejector Block ................................................................................................................................................31
Control Box Dust Filter Removal and Replacement...........................................................................................................33
Servicing an Air Filter..........................................................................................................................................34
SERVICING ........................................................................................................................................................................................ 34
DISASSEMBLY................................................................................................................................................................................... 34
REASSEMBLY.................................................................................................................................................................................... 34
Air Regulator .......................................................................................................................................................35
Note: You have acquired a device which includes software (Microsoft Windows CETM) licensed by
Buhler SORTEX from one or more software licensors. Such software products, as well as
associated media, printed materials, and “online” or electronic documentation, are protected by
international intellectual property laws and treaties. The software is licensed, not sold. All rights
reserved.
Warning: When working in the vicinity of the machine, whilst it is running, ear defenders
may need to be worn. Refer to on-site management.
Safety SORTEX Z+Vx
Safety
Throughout these manuals;
A WARNING is a command which, if disregarded, is likely to cause injury as well as damage.
A CAUTION is an advice which, if disregarded, could damage the equipment or process.
A NOTE is a helpful hint, to help the reader perform the desired task.
Warning: Disconnect the machine from its electrical and pneumatic supplies before
removing any component or servicing the machine in any way, unless instructed
otherwise in the manual.
High voltages are present within the machine.
Never remove any guards or covers while the machine is powered up.
The machine contains moving parts. Do not work in the viewing area with the air
or power supplies on.
Ear defenders should be worn whilst working close to the machine.
Only trained operatives should operate this machine. Only trained engineers
should maintain it. The relevant manual should be read and understood –
including advice on safety labels.
Warning Labels
Hazardous areas of the machine are clearly labelled. If there is a label, you should assume that there is a
hazard nearby.
Red labels, usually circular, prohibit certain actions.
Yellow Labels, usually triangular, are a warning against danger.
Blue Labels, usually circular, are commands to perform mandatory actions.
NO WELDING
This red prohibiting label appears on both sides of the machine to ensure that welding
does not take place in the vicinity of the machine.
NO DRILLING
This red prohibiting label appears on the main trunking, on the right hand side of the
machine, to ensure that the frame is not drilled.
DO NOT EXCEED…
This label is situated on the filter regulator assembly and signifies the air pressure limits
for the machine.
WATCH YOUR FINGERS

This label is located wherever there is a possibility of trapping or pinching hands or
fingers. Care should be taken to follow the instructions in the manuals.
Page 1
SORTEX Z+Vx Safety
WATCH OUT
This yellow warning label appears at various points on the machine to indicate
dangerous areas.
WATCH OUT - ELECTRICITY

This yellow warning label appears on protective guards covering hazardous electrical
equipment. Where the hazard is AC with a maximum of 250V between any two points or
located outside of the machine, there is no subsidiary label. Labels in the vicinity of other
hazardous voltages will show the voltages present (e.g. 100V is 100V DC).
WATCH OUT – LETHAL VOLTAGES

This yellow warning label appears in areas where there are lethal voltages present, such
as on the Lamp Driver PCB Guard and the Heated Chute PCB Guard. Extreme care
should be taken when working in these areas.
WATCH OUT – MOVING PARTS

This yellow warning label appears on the wiper cover and the receptacle doors as a
warning against moving parts which could trap fingers, etc. The wiper cylinder action is
powerful and could cause serious injury.
WATCH OUT – HOT!

This yellow warning label is attached to the lamp packs and any other surface that may
become hot.
READ THE MANUAL

This blue command label indicates that instructions in the manual must be followed. The
labels on the Wiper Guards and Receptacle Doors refer to the changing of Wipers and
any other operations that may occur within the sorting area between the optical box
windows.
EARTH STUD LOCATION

On the machine frame, the Earth Stud is located next to the label shown on the left.
Safety SORTEX Z+Vx
Power & Air Safety

Many areas of this machine’s interiors carry live mains electricity – at lethal voltages.
Other areas carry lower, non-lethal voltages – but the wrong treatment of components when live can
damage them irreparably.
Also, there are maintenance operations which would become dangerous if the machine were to
become active, while someone was working on it.
Similarly, many of the machine’s operations rely on air power. In some areas (the ejectors, particularly),
this power can have explosive effect, if released incorrectly. In others, air pressure powers
movement which can be dangerous if there is a human (or part of a human) in the way.
Power
When undertaking any maintenance work, anywhere in or near the machine, switch off the electrical power at
the mains isolator. And, to guard against someone switching it on again, unaware of the danger, lock the
isolator in the off position.
Power on (and power Power off (and avoiding

available, even if switched off) accidental switch-on)
Locking Power off

Swing the yellow flap up, and slide it to the right. In the process, the projection will depress the Stop switch,
switching off power to the machine (if it is not already switched off).
Since the flap is sprung, insert something in the slots – to keep the flap in place. A screwdriver or something
similar would keep the flap closed – but to avoid any possibility that power could be switched on during
maintenance work, insert a padlock in the slot. With that in place, you can proceed with maintenance work,
certain that nothing surprising will interrupt you.
Caution: Allow a minute or so for capacitors to discharge, before working on any PCBs or
power supplies.
Allow even longer, if working inside either optical box: the lamps and associated
components become very hot, and take some time to cool down.
NOTE: There are some maintenance operations – mostly tests and diagnoses of problems – in which
power is required. Take great care during such operations – keeping cabinets closed, and
keeping unauthorised personnel away from the machine.
Heated Chute Machines
A machine with a heated chute has two mains isolators fitted. A typical layout is shown on the right.
In such machines, take care to switch off both isolators during maintenance work, and to take the
same precautions against accidental switch-on (see above).
SORTEX Z+Vx Safety
Air
When undertaking any maintenance work in the optical area (where the wipers operate), or in the ejector
enclosure, switch the air supply off.
On multiple-module machines, the air supply is controlled by a black, lever valve (see illustrations). The single-
module machine has a slightly different valve, with a red, curved lever – but the principles are the same.
When the handle points in the direction of the airflow – the air supply is on. When the handle points upwards
(across the direction of the airflow) – the air supply is off. In this state, a metal sleeve drops into place,
preventing the air from being easily turned on. This would prevent, for instance, something catching on the
lever, and turning it on inadvertently. To turn on the air, lift the sleeve in the direction of the arrow, and turn the
lever horizontally.
But, to ensure that no-one deliberately turns on the air whilst you, or anyone else, is working on the machine –
perhaps out of sight - you should insert a padlock into the lever & sleeve, as shown in the right-hand illustration.
Air supply on. Air supply off, Air supply off,

but unlocked and locked
Note: If the wipers are operating at the time, always allow them to come to rest before switching off
the air supply. This ensures that they are out of the way during any work in that area, and
ensures that they won’t start up (unexpectedly), if the air supply is switched on again.
Good Habits
Throughout this manual, there will be regular reminders to switch off air and power,
before undertaking particular maintenance tasks – using the graphic on the right.
However, it should become a matter of habit to ensure that air and power are
switched off, every time maintenance work is contemplated, and that any exception
to this rule should be very carefully thought through.
Serial Plate
A new serial plate has been designed for SORTEX machines,
giving key information about the unit it is attached to. This has
been done to comply with new European regulations (CE
accreditation). An example is shown on the left.
The information on this plate will be useful during installation,
and during any contact with SORTEX Customer Services; we
will need to know the model and, possibly, the serial number.
General Information SORTEX Z+Vx
Beyond Day-to-Day Operation

The work of a Machine Operator, responsible for the day-to-day operation of the Z+Vx, is described in the
Operator’s Manual. Supervisors should familiarise themselves with these procedures – and those laid out in
the Routine Maintenance booklet/poster.
This section deals with the commands available to Supervisors – who are focused more on the long-term
management of the Z+Vx.
Starting on page 27, the Maintenance section deals with the replacement of consumable items (lamps,
ejectors, filters etc.).
Passwords
The Machine Operator can perform his tasks immediately upon switch-on; there is no need for a password to
manage the Feed or Sensitivities. However, some of the commands available on the Z+Vx can have important
consequences, and are therefore protected from casual investigation by untrained hands.
There are four levels of access:-
Machine Operator Adjust Feed Rates and Sensitivities. For the main operator of the machine –
Switch Product Modes. Start a taking responsibility for its day-to-day
Calibration. running and responding to changing
circumstances.
May also take responsibility for Routine
Maintenance and cleaning.
Supervisor Create new Product Modes. Adjust For staff who focus on the long-term
machine configurations related to sorting success of the sorting process.
product. Run tests.
Engineer Manage the mechanical and electronic For staff who maintain plant equipment.
workings of the machine.
Special Engineer ‘Expert’ setup and re-tasking of machine. For specialists in SORTEX equipment -
usually SORTEX engineers or high-grade
plant engineers
These are only guidelines. If a Machine Operator is expected to act on his own initiative, and produce the best
possible results from the machine, it may be that he should have Supervisor access. On the other hand, if an
Operator is only expected to monitor the machine’s progress, with no authorisation to make any changes, it
may be that Monitor access is sufficient.
The two higher levels of menu access – Engineer and Special Engineer - contain functions which deal with the
technical status of the machine, and are designed to be used by personnel trained to understand the
consequences of changing any of settings.
If you, or any of your staff, wish to know more about the deeper functions, and gain better understanding of the
capabilities of the SORTEX Z+Vx, SORTEX runs training courses at our London headquarters. Contact
Helpdesk@buhlersortex.com for more information.
Caution: However passwords are allocated, all staff should take care of their passwords –
not allowing them to become ‘common knowledge’. They should also be wary of leaving the
machine ‘logged in’ to a high access level – allowing anyone who comes along to (mis)use
that access.
NOTE: There is a ‘time-out’ function, which will return the machine to Monitor-level access if the
screen is unused for 20 minutes – but a lot can happen in 20 minutes.
While deciding how to allocate passwords, ensure that all those involved with the machine are clear about their
responsibilities, and what tasks they are expected to carry out – and ensure that they are given the appropriate
documents (manuals) and training to enable them to do so.
Page 5
SORTEX Z+Vx General Information
Gaining Access
Press the Facilities button, and select User Access Level from the list.
A new screen will appear. Select the required level of access.

Note: You can also use this screen to return the machine to a lower level
of access, before leaving the machine in someone else’s hands.
An on-screen keyboard will appear. ‘Type’ the password and press OK.
If the password contains upperCASE letters, use the CAPS button before
entering them. Press it again to return to LOWERcase.
The DEL button deletes letters already entered (it acts like a computer’s
Backspace key).
ESC will close the keyboard without entering any text into the system (useful if
you have lost track of the password, and wish to start again).
The text you ‘type’ will not appear on screen, but will be replaced with asterisks
(****) – so that no-one can learn your password by watching you enter it.
Presuming that the correct password has been entered and OK’d, the screen will
return to the ‘Home’ screen – but with a new set of commands available on the
Facilities menu.
Changing Passwords
On the User Access Level screen, press Change Password.
Use the keyboard to enter the new password. Press OK to return to the User
Access Level screen.
Inform those who need to know – what the new password is.
General Information SORTEX Z+Vx
Modules & Partitions

The SORTEX Z+Vx has one to three chutes, feeding one to three sorting modules. In the simplest of setups, all
modules will be working in unison.
However, it is possible to split these chutes into two or three partitions (Primary, Secondary, Tertiary), each of
which can be treated differently. This enables a Secondary partition to be used to re-sort the output from the
Primary sort and a Tertiary partition to re-sort output from the Secondary.
Note: Partitions are sometimes known as ‘Divisions’.
Many of the SORTEX Z+Vx ‘s settings deal in Partitions. You will set the Defect Size for one Partition at a
time. You will Configure the Sort, one Partition at a time.
A Machine Operator will see the machine’s operation as happening in one or more Partitions.
On the other hand, a Supervisor has responsibilities to supervise the machine at a deeper level – and that
involves an awareness of Modules and of their components.
Each module has its own chute, its own vibrator (although there are setups in which a dual vibrator may serve a
split chute). Each module may be served by two or four cameras (Front & Rear). Each module contains a bank
of ejectors. Each module has its own receptacle.
On many of the screens you will be dealing with, the settings you make will only apply to one Partition at a time,
or to one Module at a time. In some cases, you will be dealing with one camera at a time, or even one ejector at
a time. You may be dealing with the Front View or the Rear View, or a Combined View.
In all such cases, a selector (a drop-down) will show the active
Partition or Module (or Camera) – and the settings you give will
apply only to that item. If you need to apply these settings to all
modules/cameras/ejectors, you will need to select each of
them, in turn, and re-apply the settings
SORTEX Z+Vx Supervisor’s Menus
Using Supervisor Level Commands

These are available once the correct password has been entered via the User Access Screen.
Supervisor Facilities Menu
Press the Facilities button, and a menu of further commands

appears. Press one of these and a screen (or a further menu)
will appear.
Sorting Setup Menu
Press Sorting Setup on the main Facilities menu produces a

new menu.
This menu offers the ability to make various adjustments to the
detail of the sorting process. Select further items to reveal
individual screens:-
Defect Size
Camera
Select the Camera (Front or Rear) on which you wish to
operate.
Colour Defect Window
This selects the size of the ‘window’ which the software will
use to make its calculations – in pixels.
The software will examine a square of (in this case) 6 pixels
per side, and assess whether a defect exists or not. It will then
shift this window one pixel to the right, and re-calculate.
Use the – and + symbols to lower or raise this number.
‘Rounding up’ even-numbered Windows

In this example, a Defect Window Size of 6 has been selected. This
would surround the central, target pixel - with a 6x6 block of
pixels .
But this would be asymmetrical – with a smaller area of interest
below and to the left, than above and to the right – which would
make the calculation less useful.
So, the software adds a block - to balance the ‘window’.

The software will examine this block for defects, before moving the
whole block one pixel to the right, to repeat the process.
Page 8
Supervisor’s Menus SORTEX Z+Vx
Colour Defect Area
This selects the size of the colour defect which will trigger an ejection. In this case, a colour defect 10 pixels
square (or larger) will be recognised as a colour defect, and the item will be ejected.
Spot Defect Area
This selects the size of the spot defect which will trigger an ejection. In this case, a spot defect only 1 pixel
square (or larger) will be recognised as a spot defect, and the item will be ejected.
Defect Detection
This screen switches on or off the detection of Colour Defects

and/or Spot Defects.
Pulse Extension
With some products, the ejector might miss faulty examples,
due to its size. This screen allows an imaginary extension to
be added to faulty product, so that the ejector will fire a little
longer.
Camera
operate.
Colour Defects
Spot Defects
This extension can be applied to each or either type of defect.
Use the – and + symbols to lower or raise this number (in millimeters).
Note: If Reverse Sort is enabled (see p. 12), there is only one Pulse Extension. A typical value would
be 5 (or more).
Ejector Delay
This screen controls the delay between the detection of a
defect, and the firing of an ejector to reject it. This may be
necessary with some products which fall more slowly.
Camera
operate.
Colour Defects/Spot Defects
This delay can be applied to each or either type of defect. Use
the – and + symbols to lower or raise this number.
Note: If Reverse Sort is enabled (see p. 12) There will
only be one Ejector Delay. A typical value would
be 50.
Page 9
Sort Type
This screen sets the type of sort the machine will undertake:–
A Dark sort – in which the machine rejects defects which are
darker than the normal product, or a Light sort, in which the
machine rejects defects which are lighter than normal.
Camera Scaling
Effectively, this sets a sensitivity level below which the ejector
never fires at product. It does so by re-defining the machine’s
understanding of ‘white’ – raising or lowering the camera’s
output against the level fixed during a White Reference
Calibration (see p.21).
For a Light sort, there are some products which are, naturally,
lighter than white (lighter than the White Calibration plate). This is particularly true when working in Infra-red.
To combat this, the Camera Scaling factor is reduced below zero (to a negative level). This lowers the Coarse
Gain of the Camera signal, thereby making ‘White’ lighter than the product – and allowing good product to pass
through the machine without ejection.
Raising the Camera Scaling (positively) has the reverse effect - of raising the Coarse Gain of the Camera
signal. This has the effect of bringing the product closer to ‘white’. This can be useful if the product in question
is dark. In such cases, the difference between good product and bad product may be very small. By raising the
Coarse Gain, both readings are boosted, and the differences between them are easier to differentiate.
Camera Scaling has no relevance in a Dark sort.
Reset
Use Reset to return the Scaling to zero.
Sort Configuration
This screen sets a number of configurations for the machine
and its arrangements for sorting.
Configuration
This drop-down list offers a number of options, relating to the
ways in which operation within a machine may be split:-
• Single (all primary) – machine is undivided; all product
sorted according to Primary settings.
• Single (all secondary) - machine is undivided; all
product sorted according to Secondary settings.
• Dual (secondary on left) – machine is divided, with
primary on the right, secondary on the left.
• Dual (secondary on right) - machine is divided, with primary on the left, secondary on the right.
• Triple (tertiary on left) – machine is divided into three – tertiary, secondary, primary (from the left).
• Triple (tertiary on right) – machine is divided into three – tertiary, secondary, primary (from the right).
Sort Type
This offers the options of Normal or Transparent sorting.
View Combination
This offers the options of Combined or Independent views. That is, combining the information from one view
with the other – or treating the information independently.
Page 10
Visible Defect Propagation/IR Defect

Propagation
In the simplest terms, Defect Propagation adds a little to the
perceived width of a defect.
If a rice grain, with a spot defect at one end, falls past the
camera in a horizontal orientation, the main body of the grain
may fall to the left or right of the defect.
If so, the ejector may fire at the defect, but miss the grain.
So, Defect Propagation allows the width of a defect to be
exaggerated, so that the next ejector will also fire, and eject the
defective grain.
Camera
Select the Camera (Front or Rear) on which you wish to operate.
The following options may be applied to either/or Colour or Spot defects:-
Standard
Standard width propagation. If defective product overlaps two channels – both ejectors will fire (though this is
inter-related with the other settings on this screen).
Region
There are 16 (camera) pixels per ejector and, therefore, to each channel. The machine looks at the pixels at
each end of the channel with particular interest (for the purposes of propagation), because this is where the
positioning of a grain of defective rice might be ambiguous.
When a defect is detected in this edge region, the processor looks to see if it also appears in the other edge
region of that channel. If so, both ejectors will fire.
This setting increases the number of those pixels assigned to these edge regions.
1mm is the normal setting. 2mm gives even more propagation but, potentially, more wastage.
Extended
Extended width propagation. Similar to the standard propagation, but more so. Roughly speaking, the ejectors
on either side of a defect will fire, to ensure that item is removed. It is less accurate, in the sense that more
good product will be ejected.
However, it is effective with large products with small spot defects.
Use Presence
This adds an extra dimension to the Standard or Extended width propagation methods.
In simple terms, the processor holds a picture of where product is, and where it isn’t. It uses this knowledge to
judge whether this particular item of product lies to the right or to the left of the detected defect.
This would obviously seem preferable, but the presence calculation is of no help when the throughput is high.
This is because the product tends to overlap when the flow through the machine is very high. The machine
cannot distinguish between items, so the presence calculation doesn’t improve defect ejection.
In normal usage, Use Presence is Disabled.
Note: If IR lighting/cameras are present and enabled, another similar screen will be available – to set
Defect Propagation for that environment.
Note2: If Reverse Sort is enabled (see below), there is only one Defect Propagation. Typically, this is
disabled.
Page 11
Reverse Sort
The reverse sort is a reject concentrator, designed to
concentrate inputs of 1 good:2 bad or greater.
It does so by ejecting good product, firing at the centres of
objects that do not contain defect.
• Only available for position 1 cameras.
• Applies to Front & Rear, simultaneously
• Only available in Small Product mode.
• Only available in Dark Sort mode.
Partition
Select which partition this feature will apply to.
Reverse Sort
Enable or Disable. Once enabled, only Dark Sort will be available on the Sort Type screen (see p. 10) and the
standard Improver (see p. Error! Bookmark not defined.) will not be available.
Object Separation
Enables the object separation algorithm.
Reverse Sort Improver
Similar to the standard Improver (see p. Error! Bookmark not defined.), in that it fires at the center of the
object – though, in this case, it fires at good product.
A value of 0 gives the highest reject concentration.
A value of 3 gives the lowest reject concentration. Similar to being disabled.
Note: Remember, again, that ‘reject’ is good product.
Min Object Size
This is set to prevent the ejectors firing at small particles (dust). Usually set to 9 or more.
Max Object Length
There are two possible settings: 10mm or less, and 10mm to 15.3mm.
If an object exceeds this length, it may be ejected, even if there is an area of defect on the object. Typically set
to 10mm or less for rice.
Force Product Tracking
Forces product tracking to ON. Tracking is forced to “Ignore all
Defects”.
Note: A partition which is set to run a Reverse Sort will appear
as white, in the Working screen.
In the example on the right, the Tertiary partition is running a
Reverse Sort.
A Reverse Sort also has implications for:-
• Calibration – use Bypass button to stop calibration on the
modules being used for Reverse Sort.
• Ejector Delay (see p. 9)
• Pulse Extension (see p. 9)
• Visible/IR Defect Propagation. (see p. 11)
Note: With Reverse Sort enabled, Sensistivity operates in reverse. That is, the lower the
Sensitivity, the higher the ejection. If you are enabling a Reverse Sort, ensure that all Operators
understand these implications.
Page 12
Mode Controls
A Mode is a collection of settings – for Feed Rate, Sort Sensitivity and other factors – designed as a program to
sort a particular product to a particular quality. When the machine is set up, a number of modes will have been
created, with the objective of delivering the best possible sorting for the products the machine is likely to
encounter.
A Machine Operator may Recall Mode, Preview Mode and Compare Mode. Essentially, he may switch from
one existing mode to another existing mode. He may also make adjustments within a mode’s parameters – by
raising or lowering the Feed Rate or by raising or lowering Sort Sensitivity. However, he may not make any
changes to the modes themselves. That requires Supervisor access.
There may be occasions when the existing modes are not enough, and another mode needs to be established.
Often this comes with experience – the operator finds that he gets better results if he boosts the Feed Rate or
raises Sort Sensitivity (or vice versa). Rather than remember to do so every morning, it would be better if a new
mode were created – including these adjustments.
Save Working Mode

At Supervisor level, set up the
desired conditions and, from
the Facilities menu, select
Save Working Mode. You
will be asked to give the new
Mode a name – using the on-
screen keyboard.
This done, the operator will
be able to Recall this new
mode at any time, running the
machine with the new
parameters.
Note: If you select a name which already exists, you will be warned, and asked if you really want to
over-write it.
Rename Working Mode

If the existing mode is using a name which you wish to re-use (without over-writing it), use Rename Working
Mode to assign another name to the existing mode. You will be asked to give a new name for the Mode – using
the on-screen keyboard.
Copy Working Mode

You may wish to take an existing mode, and develop some variations on it. Use Copy Working Mode to create
an exact copy of the mode currently in operation. This will create a new mode, identical to the previous one.
The machine will ask if you wish to use a new name (advisable). Otherwise, you may find two modes with the
same name.
You can then Recall that copy, make the required changes, and then use Save Working Mode to keep it for
later use.
Delete Mode
If you are sure that a particular mode is not wanted, use Delete Mode to get rid of it. This should only be used if
a mode is particularly ineffective or wasteful. Much better to rename a mode, labeling it with the problems you
believe it has.
There is room in the machine’s memory for up to 99 modes – so there should never be any need to delete a
mode, to make room for another.
Page 13
Note: You cannot delete a Protected Mode.
User Access Level

This command is explained on page 6.
Calibration
This command is available to Machine Operators. See the Operator’s Handbook.
Product Feed
Sort Sensitivity
Stats Menu
This menu gives access to the Brokens Monitor (if fitted).

Note: At this point, there is no specific button on the main
menu for returning to the Working Screen; instead
touch the “Date/Time/Status” bar at the top of the
screen, and the menu will ‘collapse’.
Stats Graph
Trends in a Stats measurement are sometimes easier to spot
when the data is plotted on a graph.
The Stats Graph screen is shown with an example of the
percentage of broken rice plotted against time. Zoom control
is provided by the – and + symbols.
The buttons with arrows scroll the graph, up/down or right/left.
Different stats measurements can be selected from the drop-
down menu.
Note: If a Product Alarm is enabled for the selected
measurement then the lower & upper warning
levels are also marked on the graph as horizontal
lines.
Fixed Thresholds
The Brokens Monitor classifies individual rice grains four
categories, referred to as Head rice and Fractions 1, 2 & 3.
The maximum lengths of these four categories are set on the
Fixed Thresholds screen.
For example, a grain that has a length less than or equal to
the Max Length Fraction 1 and greater than the Max Length
Fraction 2 is classified as Fraction 1.
All the length measurements are in millimeters. Use the – and
Page 14
+ symbols to lower or raise each number.
The buttons to the right of the measurements determine the final classification of these four categories - as
either Whole or Broken.
For example, in the case shown, both Head & Fraction 1 are classified as whole grains whereas Fractions 2 &
3 are classified as broken grains.
The Maximum Length of the head category is effectively another oversize filter.
Stats Histogram
This screen displays the histogram of the lengths of the rice.
The histogram is a graph of the frequency of occurrence for
the different lengths of rice, in steps of 0.1mm.
The thin white line represents the position of the length
threshold as calculated for the Relative Brokens (see
relative Thresholds, below). The bars to the right of this line
correspond to whole grains, whereas the bars to the left
correspond to broken grains. This double-peak plot is fairly
typical.
The case shown here is for a very low level of Brokens; if the
Brokens contamination was higher, then the bump on the left
would be larger.
The button in the top right hand corner of the screen saves the current histogram to a named file (“stats.log”),
on the flash disk.
Relative Thresholds
‘Relative Brokens’ is an alternative approach to measuring the
brokens contamination level. Unlike the Fixed Brokens
measurement described on page 14, Relative Brokens does
not use a fixed length threshold to distinguish between whole
and broken grains.
Instead, Relative Brokens is defined relative to the average
length of the whole rice.
Note: That is true of the example on the right. Press the
button, currently labeled By Length, and the
calculation will now be By Area.
In the example on the right, any grain less that 0.75 of the
average length of the whole rice is classified as broken. The Brokens Monitor automatically estimates the
average length of the whole rice and then calculates a length threshold equal to the average whole grain length
scaled by the relative broken fraction.
If a grain is less than this length threshold then the grain is classified as broken.
This length threshold is displayed on the Stats Histogram as a thin white line (see page 15).
If the “Log Brokens” button on the Stats Log screen (see page 16) is enabled, the Brokens Monitor calculates
both the Fixed and the Relative Brokens measurements. The Relative Brokens measurement is referred to as
Brokens Rel on the Stats Data & Stats Graph screens (pp 14&16).
Page 15
Stats Data
The Stats Data screen lists the data recorded by the Brokens Monitor.
It can list two different measurements on the same screen, these measurements being selected from the pull-
down menus at the top of the screen.
In the case shown on the right, the two options selected are
% Head – percentage of rice qualifying as ‘Head rice’ (as
defined in Fixed Thresholds, see p. 14) – and
% Broken (Rel.) – the percentage of Brokens (as defined in
Relative Thresholds, see p. 15).
The list shows that the time of the most recent measurement
was at 13:52 (24 hour clock notation), at which time the
percentage of head rice was 84.1% and the percentage of
broken rice was 0.7%. This data can be compared with the
data recorded a few minutes earlier, at 13:44, when the
percentage of head rice was 72.4% and the percentage of
broken rice was 0.7%.
Over Time
The above example shows measurements taken every minute. This can show results changing over time.
Press the scroll bars to view the whole list.
Single Measurement
Press the Over Time button, and the label will change to
Single Measurement, and the screen will look something like
the example on the right.
This shows all the measurements available at this particular
moment.
Press the scroll bars to view the whole list.
Stats Log
Log Brokens
The Brokens Monitor is enabled & disabled from this screen
by the Log Brokens button. Before enabling the Brokens
Monitor in this way it is necessary to set the fixed length
thresholds (Fixed Thresholds, see p. 14) and Sampling
parameters (Sampling, see below).
You may view the results of this log via the Stats Data screen
(see p. 16) or the Stats Graph screen (see p. 14)
The log will hold up to 1500 successive measurements
(equivalent to a weeks worth of data if measurements are recorded every 10 minutes). After this limit is
reached, the oldest data is overwritten by the new data.
The “stats.log” file preserves the data after a power cycle, even though the Stats Data & Stats Graph screens
no longer display this data.
Log Defects
This button controls the logging of defects – added to the ‘Brokens’ log.
Page 16
Clear Stats Log
Press this button to start logging afresh. But…
Save Stats Log
…press this first, to save the existing log to the Z+Vx’s flash disk. This will be saved to a file called ‘stats.log’,
and may be copied on to a laptop computer. When you press this button, you will be prompted for a file name.
You may choose another, although the extension (.log) remains the same.
A saved “stats.log” file can be downloaded to a remote PC and analysed with Microsoft™ Excel. The “stats.log”
file is located under “/flashdisk/Newton/stats.log” (or equivalent, if you have given the file another name). To
import a saved log file into Excel, choose “delimited” in the first screen of the Excel import wizard, and “comma”
in the next. The first field (column) should be interpreted as a date: select “YMD” in the drop-down list for the
last step.
Saved log files have column labels in Excel; the original “stats.log” file does not have these column labels.
Product Alarm
If the measured quality of the product is outside preset limits
then a Product Alarm is raised. If a Product Alarm is active, an
external amber light bolted to the frame of the machine is lit
and the alarm is also listed on the Product Alarm screen.
Note: A Product Alarm and a machine fault are different
events. A Product Alarm indicates the quality of the
product flowing through the sorting machine
whereas a machine fault indicates the state of the
machine itself.
The following stats measurements can have an associated
Product Alarm – each selected via the drop-down list:-
• Percentage Broken
• Average Length Head
• Percentage Broken (relative)
• Average Length Whole (relative)
• Percentage of Colour Defects
• Percentage of Spot Defects
• Percentage of Combined Defects.
These 7 Product Alarms are all independent. A Product Alarm is set-up by assigning minimum & maximum
thresholds to one of these stats measurements. The alarm is triggered if the value for that stats measurement
is less than the minimum threshold or greater than the maximum threshold.
Note: These threshold levels are also marked on the Stats Graph.
Enabled/Disabled
Each measurement can be enabled or disabled, using this button. The label shows the current state.
Clear
Product Alarms are cleared by using the “clear” button on the Product Alarm screen (only available if an Alarm
is current).
If the quality of the product reverts to being within the preset limits then the Product Alarm is automatically
cleared. (Historical information about the quality of the product can be determined via the Stats Graph or Stats
Data screens.)
The Product Alarm is not raised for a measurement if the total number of singletons (single, identifiable bits of
product) for the measurement is less than 80% of the Sample Size – set on the Sampling screen (see next
page).
The Product Alarm screen can be accessed at the Operator password level.
Page 17
Summary
This button opens a screen (see right) which lists a summary
of the minimum & maximum thresholds for all the Product
Alarms that are currently enabled.
Sampling
This screen controls the methods used to sample product (for
the purposes of the Brokens Monitor).
Sample Module
The Sample Module sets the module from which all the images
are captured. It is recommended to select a module with a flat
chute. In the case of a Z3+ or Z4+, Module 2 is preferable
because the illumination towards the centre of the machine is
more uniform, resulting in a better silhouette of the rice.
Sample Interval Time
The Sample Interval Time is the time between measurements, typically set to around 15 to 30 minutes.
Sample Feed Rate
The Sample Feedrate is the reduced feedrate automatically set during the image capture stage of the
measurement process. It is recommended to set the Sample Feedrate at 60%, corresponding to about 1500
Kg/hour. This is about half the normal sorting throughput of a module. (The feed rate on the “working screen” of
the GUI is greyed-out during sampling.)
Sample Size
The Sample Size is the number of grains that are counted for each measurement. It is recommended to set the
Sample Size to 10,000. Note that the entry for the Sample Size is per thousands of grains.
Enhanced Presence Detection
Enhanced Presence Detection should be disabled.
Object Width
Object Length
The Minimum Object Width & Length are set so as to ignore all objects less than a certain size. It is
recommended to set both the Minimum Object Width & Length to 1.5mm.
The Maximum Object Width & Length are set so as to ignore all clusters of touching grains. Hence, the
Maximum Object Width & Length should be set to the dimensions of the largest expected grain.
Please note that the machine interprets these maximum limits as a maximum area (= Maximum Object Width x
Maximum Object Length) and then ignores any region* in the image with an area greater than this calculated
maximum area. (Hence, adjusting just one of either the Maximum Object Width or Length is sufficient.)
*The Brokens Monitor can handle up to 65535 regions.
Page 18
Mode Configuration
This menu contains items about the physical configuration of

the machine.
Foreground Lighting
The lamps which illuminate the product – the Foreground lamps
– are arranged in two banks, in the front and rear of the
machine, surrounding the product.
Each bank consists of four lamps, arranged in an arc
(see inset). The Foreground Lighting screen gives the
option of switching off (Disabling) the inner pair, or
the outer pair – not both.
Note: If both buttons are set to Enable, all tubes will
switch off. This is normal operation.
In a Combined Sort, this disabling applies to both sets of lamps – front and rear. In an Independent Sort,
there are separate controls for Front & Rear.
Wiper Interval
To perform its task properly, the machine needs a clear view of
the product. This requires that the optical windows are kept
clear of dust or grease. The wipers perform this function.
This screen controls the frequency of wiping. For a particularly
dusty or greasy product, the frequency might need to be as
often as every five minutes (as in the example shown), but with
most products, 20 or 30 minutes should be often enough.
Use the – and + symbols to lower or raise the number.
Note: Bear in mind that the feed must be stopped while
the wipers pass across – so a frequent wipe will
affect throughput rates.
In some circumstances, it may be necessary to Disable the wipers entirely – perhaps for some diagnostic
purpose. This should not be allowed to continue for long, during sorting.
Tracking Configuration
In the course of a sorting session, many factors may change –
the ambient lighting, the brightness of lamps, the dustiness of
the product – even the product itself may vary slightly, from
supplier to supplier.
The SORTEX Z+Vx ‘tracks’ these changes, and compensates
for them, automatically.
This screen offers four alternative approaches (Tracking
Reference) to this:-
• None – used for test purposes. The tracking processes
still run, the machine still stops to wipe & calibrate from
Page 19
tracking incidents, but product brightness is not tracked.

• Product – uses the product itself as a tracking reference.
• Ignore Spot Defects – self-explanatory.
• Ignore All Defects - self-explanatory.
Calibration Configuration
In order to track any changes in the environment, the machine
needs to Calibrate regularly. That is, it needs to check its stored
parameters against reality, and adjust the stored parameters to
actual readings.
This screen controls the frequency and behaviour of these
calibrations.
Wipe during Calibration
Normally, the machine will wipe the optical window, in order to
ensure that it gets the best possible view of the product flow.
There are some circumstances where this is undesirable (usually
while diagnosing problems) – so, this can be Disabled. This condition should not be allowed to persist, during
normal sorting.
Calibration Interval
This controls how often the machine calibrates. With a particularly tricky product, it might be necessary to
reduce this to five minutes (as in the example shown), but a longer gap between calibrations is more likely, in
normal circumstances.
Machine Configuration
This menu deals with a number of machine-related

configurations:-
External Interlock Configuration

This screen determines whether the machine can be stopped
by other machinery downstream of it, by means of the external
interlock input. It also controls when the external interlock
output will be activated.
Input State
Shows the state of the interlock input.
Output State
Shows the state of the interlock output.
Input
Enable/Disable the interlock input.
Page 20
The following table shows the effects of the combinations of inputs and input settings:-
Input State Input Machine Status
Off Disabled Sorting
Off Enabled Sorting
On Disabled Sorting
On Enabled Idle
Modules
These buttons select which module(s)control the interlock output. So, if Module 1 were Enabled, the interlocks
would be controlled by Module 1. If another Module were also enabled, the two would be combined (ANDed) to
control the interlock.
Hopper Interlock Configuration

This screen determines whether the machine will allow its feed
to be controlled by the level of product in the feed hopper.
State
This section shows the current state of the hopper sensors
Full
This section allows the enabling/disabling of interlocking – in
Secondary and Tertiary channels – responding to a full hopper.
Use the – and + symbols to set the Delay before the vibrators
respond to interlock signals.
Low
This section allows the enabling/disabling of interlocking – in Primary, Secondary and Tertiary channels –
responding to a nearly-empty hopper.
Use the – and + symbols to set the Delay before the vibrators respond to interlock signals.
White Reference Calibration

At intervals (see below) it is necessary to re-calibrate the
machine’s response to light. Lamps age and fade, and the
surrounding environment changes.
According to the interval set, by White Reference Calibration
Interval, the machine will prompt the Operator to perform a
calibration.
From this screen, select the module to calibrate (all must be
done at the same time) – and press Start.
The machine will wipe.
You will be prompted to insert the White Calibration Plate –
which has been supplied with the machine.
WARNING: Before proceeding with this check, switch off the air supply, to prevent the wiper
from operating.
Insert this, its lower lip resting on the ejectors, and press OK.
The machine will calibrate each module, and store the new reading – all future sorting will take this into
account.
At the end of each white calibration, you will be prompted to remove the plate – whilst the machine calibrates
for ‘black’.
The screen will report when the process is complete.
Caution: It is essential that the white plate is stored carefully between uses. If it is scratched
or stained, it cannot provide the white reference required. If it is warped or bent, it will not fit
properly into the chute (and will not provide the white reference required).
Page 21
White Reference Calibration Interval

This screen defines the period between White Reference
Calibrations (see above).
Use the – and + symbols to lower or raise the number (of
hours) between calibrations.
Disabled
It is possible to disable the warning which occurs when the
interval runs out. If this is done, you should ensure that a strict
maintenance schedule is set up and adhered to. The machine
cannot continue to do its job properly for long, without a White
Reference Calibration.
Test Facilities
This menu offers a number of diagnostic procedures.
Background Test
The Z+Vx’s cameras view the product against an illuminated
background – the better to identify defective product.
This background illumination is provided by a single lamp,
‘bounced’ on to the product by an adjustable reflector (one in
the front, one in the rear). In normal operation, the machine will
make its own adjustments to the angle of this reflector, in order
to raise or lower the background illumination.
This screen tests the operation of this adjustment.
Using the – and + symbols, decrease or increase the number
for Front and Rear reflectors. The numbers beside these
controls – the Camera Signals should decrease or increase as
you do so.
There is no correct figure for these Camera Signals – the only requirement is that they should change, along
with the changes you make to the angle of the reflector.
If the figures do not change, then the likelihood is that there is a fault with the motor which turns the reflector.
Self Test
Create Diagnostic File

This screen initiates a sequence of internal tests, the results of
which are written to a file. This file will help a SORTEX
engineer diagnose any problems with the machine.
The file is saved to
ftp:\\<ip.address>\cfdisk\Newton\diagnost.txt
Page 22
Full Ejector Test

This screen allows a range of the machine’s ejectors to be
tested.
First ejector to test
and
Last ejector to test
Define the range of ejectors to be tested.
Note: There are 64 ejectors in a module, arranged in 16
blocks of four.
Start
With the range selected, press Start to begin the test. Listen to the ‘note’ sounded by each ejector, whilst
watching the Status box. This will show the number of the each ejector, as it is tested.
A faulty ejector will sound significantly different from a good one. Note the number of a faulty ejector – to enable
its replacement.
Continuous Loop
With this On, the test will continue (cycling through the ejectors) until you press Stop.
Individual Ejector Test

This screen allows an individual ejector to be tested. Select:-
Module
Block
Position
Channel
…using the – and + symbols.
Frequency
Use this button to select a High frequency test, or a Low frequency test.
Start
Press this button to begin the test.
Wiper Test
This test will send the wiper across the optical windows, and
back again, to confirm that the wipers are operating correctly.
A failed wiper test may point to a faulty wiper cylinder. See
Repair & Replace, page 12, for the replacement procedure.
Alternatively, it may point to misaligned sensors - which tell the
machine when the wiper has reached the end of its sweep.
These may need to be re-aligned (a job for an experienced
engineer).
Page 23
Vibrator Test
Test Mode
Test Mode is selected by the button – showing To Open Loop
in the illustration. The title at the top of the screen shows that
Closed Loop is currently selected.
If the test were run now, it would continue until Aborted (the
Start button becomes an Abort button, during the test).
The Drive Level box reports how hard the vibrators are being
driven.
The Feedback Values box reports how strong those vibrations
actually are.
If this test is unsatisfactory, the vibrators may need to be
adjusted against those Feedback Values, to produce a satisfactory throughput. Press the To Open Loop
button.
In this configuration, the vibrator drive levels can be set, using the - and + controls, whilst monitoring the
feedback levels.
Lamp Maintenance
Here, a record is kept of how long each lamp has been lit,
since it was installed. This option reports that time, allowing
the Supervisor to estimate when a lamp should be replaced.
Used
Gives a reading of how many hours these lamps have been
burning
Remaining
Gives an estimate of how long these lamps have left, before
needing replacement.
When a lamp is replaced with a new one, press the ooo button, to ‘zero’ its value – otherwise it will be
impossible to know when it is ready for replacement.
NOTE: Lamps tend to fade during their lifetimes, so a lamp may appear to be burning adequately, but
fail to deliver the necessary illumination.
When a lamp is replaced before its time – for example, when the product being sorted needs a different type of
illumination - the usage of the ‘old’ lamp should be noted, and kept with the tube. In that way, it will be possible
to estimate its remaining life, when it is re-installed.
NOTE: Whenever a lamp is changed – for whatever reason, perform a White Reference Calibration (see
page 21) – as the light levels will have changed.
Ejector Rates
This screen shows how hard specific ejectors are working, by
showing Ejections per Minute (along the vertical axis of the
graph), against Ejector (along the horizontal axis).
The resultant graph should be relatively flat. A few bumps are
nothing to worry about – but attention should be paid to any
ejectors which are dramatically different from their neighbours.
If a single ejector, or a block of ejectors, consistently fires less
often than its neighbours (or not at all) – that may point to a
faulty ejector, or a faulty block, or a faulty daughterboard. Use
the Ejector Test (Full or Individual) to investigate ejectors
which may be faulty (see page 23).
Page 24
If, however, there is a wider anomaly – a big ‘hill’ or valley’, encompassing several ejector blocks, that may
mean that the machine is firing on false information. That may point to a damaged chute channel (the product is
arriving in the wrong place for the cameras to detect it), or to a dirty or scratched optical box window (the
cameras reading the dirt as if it were product).
Caused By
This button controls the scope of the graph. It shows ejections according to camera position. For example, you
could look at the ejections caused by the Front or Rear Cameras independently. Or, as in the example shown,
Anything.
Ejector Fire Count

This screen shows a record of the number of times individual
ejectors have fired. This can help plan servicing.
Ejector
Use the – and + symbols to select the number of the ejector
and…
Fire Count
…will show how many times that ejector has fired, since its
installation.
Below, the graph shows a reading for all the ejectors at once.
Although this is not as accurate as the above method, this can show up anomalies – a single ejector, or group
of ejectors, which is has been firing much more (or much less) than others. This can point to a fault in that part
of the ejection system.
Advanced
This opens a sub-screen which allows the fire count to be reset to zero –
by ejector, by module, by block (of four ejectors) or by position (one of the
four in a block).
Use the – and + symbols to select the number required, and press Reset
that item to zero.
Engineer & Special Engineer menus

There are two further levels of menu access – Engineer and Special Engineer. These contain functions which
deal with the technical status of the machine, and are designed to be used by personnel trained to understand
the consequences of changing any of settings.
If you, or any of your staff, wish to know more about the deeper functions, and gain better understanding of the
capabilities of the SORTEX Z+Vx, SORTEX runs training courses at our London headquarters. Contact
Helpdesk@buhlersortex.com for more information.
Page 25
Maintenance SORTEX Z+Vx
Maintenance
Read the Routine Maintenance booklet. This contains advice on day-to-day care of the machine. If
this advice is followed, the machine will work better, and major faults will be less likely to need
attention.
In all cases, observe the safety instructions given. Some of the components are heavy, and
can cause injury (to personnel or to the machine). Some are situated in potentially dangerous
areas of the machine (high voltages and/or moving parts). Others are very sensitive pieces of
electronics, which could be damaged by inappropriate handling.
Read the Safety Advice (p. 1). In particular, read the advice on power & air (p. 3) and try to develop Good
Habits (p.4) in all personnel who work with this machine.
This section deals with the replacement of items which are likely to need replacing, as a matter of routine –
consumable items. The Engineer’s Manual (in English only) deals with more complex repairs – which should
only be undertaken by experienced staff. It also contains a fuller Spares List.
SORTEX offers training courses for those wishing to know more about these procedures.
Optical System Components

Fluorescent lamps will fade with use, and will need to be replaced. Also, different lamps may be needed for
different sorting solutions.
Foreground Lamps–Replacement
Switch off the electrical supply.

Turn the air shut-off valve to the off position.
See safety advice, pages 3-4.
When the vibrator trays are clear of product, clean the area around the optical
box lid with a stiff brush before opening it.
WARNING: The contents of the optical box, particularly the lamp
packs and fluorescent tubes, will remain hot for some
time after switch off. Always ensure that the objects
you wish to handle have cooled, before proceeding.
Use the lid stay to keep the lid up.
In the Front Optical Box, undo the two catches (one on each side - right hand
catch arrowed – in red) and pull the lamp pack assembly towards you, locating
the catches in the posts to the rear (arrowed in blue).
Page 27
SORTEX Z+Vx Maintenance
NOTE: The method for replacing lamps in the rear optical box is
essentially the same as that for the front optical box, although the
mechanism for presenting the lamps for removal is slightly
different.
Warning: Always keep hands away from the ends of the lamp
pack when moving it, so as to avoid trapping or
damaging fingers.
Always make sure that the lamp pack is supported throughout the length of its
travel and until the catches are engaged. Do not allow it to fall freely, as this
could cause personal injury or damage to the machine.
The previous step rotates the lamp pack slightly and presents the lamps for
removal.
To remove the lamp, rotate it a quarter-turn and lift it out.
Fitting a new lamp is the reversal of the removal processes. Align the lamp pins with both end sockets and
push the lamp towards the lamp pack, simultaneously into both sockets, before rotating it a quarter-turn.
Always make certain that the lamp pack catches are correctly fixed in the securing posts. Failure to do so may
provide calibration problems.
Release the lid stay (ensuring that it is clipped into its retainer) and close the optical box lid.
Warning: When closing the lid, keep hands away from the door seal, to avoid trapping
fingers.
Turn on the air and electrical supply.
Note: When a lamp has been changed, perform a White Reference Calibration (see p. 21) – as the
light levels will have changed.
When a lamp has been replaced, use the Lamp Maintenance screen – to ‘zero’ this lamp’s
usage record. See p. 24.
Background Lamp–Replacement

When the vibrator trays are clear of product, clean the area around the optical
box lid with a stiff brush and open it, making sure that the door stay is in place,
to keep the door open.
WARNING: The contents of the optical box, particularly the lamp
packs and fluorescent tubes, will remain hot for some
time after switch off. Always ensure that the objects
you wish to handle have cooled, before proceeding.
Page 28
In the Front Optical Box, undo the two catches (one on each side - right hand
catch arrowed – in red) and pull the lamp pack assembly towards you, locating
the catches in the posts to the rear (arrowed in blue).
NOTE: The method for replacing lamps in the rear optical box is
essentially the same as that for the front optical box, although the
mechanism for presenting the lamps for removal is slightly
different.
WARNING: Always keep hands away from the ends of the lamp
pack when moving so as to avoid trapping or
damaging fingers.
Always make sure that the lamp pack is supported
throughout the length of its travel and until the
catches are engaged, do not allow it to fall freely as
this could cause personal injury or damage to the
machine.
Undo the two catches at the middle of each end of the lamp pack (arrowed in
red) - this allows the bottom pair of lamps to be moved out of the way,
presenting the background lamp for removal. To remove the lamp, rotate it a
1/4 turn and ease the lamp out by rotating it as you lift.
Fitting a new lamp is the reversal of the removal processes. Align the lamp pins with both end sockets and
push the lamp towards the lamp pack, simultaneously into both sockets, before rotating it a quarter-turn.
Always make certain that the lamp pack catches are correctly fixed in the securing posts. Failure to do so may
provide calibration problems.
Release the lid stay (ensuring that it is clipped into its retainer) and close the optical box lid.
Warning: When closing the lid, keep hands away from the door seal, to avoid trapping
fingers.
Turn on the air and electrical supply.
NOTE: When a lamp has been replaced, use the Lamp Maintenance screen – to ‘zero’ this lamp’s
usage record. See p. 24..
Page 29
Wipers
The wipers are also part of the Optical System – they ensure that the cameras have a clear view of the product.
Changing a Wiper Blade

Remove the rear wiper cover and then undo the 2 bolts at each end that
secure the front cover and remove.
Manually move the wiper assembly a little way towards the chute for
easier access. Reach down into the viewing area and push the sprung
wiper arm inwards (i.e. away from the window). At the same time pull the
wiper blade assembly upwards and away from the wiper arm. Remove
wiper blade from the assembly by sliding it upwards.
CAUTION: Release the spring-loaded arm carefully so that the
rubber buffer rests against the window.
Do Not Allow the Wiper Arm to Impact Against the Window!
Refitting a wiper blade is the reversal of the above procedure. Make sure
to push the wiper blade assembly down firmly until it clicks into place.
When the process is completed and all the wiper covers are back in place,
turn on the air supply and perform a wiper test (Facilities menu, Test).
Page 30
Ejector Cartridges Removal and Refitting

Ejector cartridges are exchangeable items. Faulty cartridges should be replaced in the machine with spares
and replacement cartridges ordered from SORTEX, part number A04-3417/3.
Identification of Failed Ejectors

In Test Facilities, perform a full ejector test and note the identification number of any ejectors that do not
operate. Ejectors are numbered in blocks of four from the left, as seen from the front of the machine.
Replacing an Ejector Block

WARNING: For these procedures, turn off the Mains power supplies, allow at least one minute
for high voltages to discharge.
For all operations concerning the ejectors or ejector boards TURN OFF THE AIR– the air
pressure is powerful in this region, and some operations can cause explosive
failures, if air pressure is present.
When opening the rear optical box lid, take care to use the handles provided – to avoid
trapping fingers between the lid and the Control Cabinet.
The contents of the optical box, particularly the lamp packs and fluorescent tubes, will remain
hot for some time after the machine is switched off. Always ensure that the
objects you wish to handle are cool enough to do so.
WARNING: Never dismantle the ejector manifold. Incorrect assembly can result in explosive
ejection of parts.
In addition, this unit is a fine-limit assembly, pressure-tested at SORTEX Ltd., and not
serviceable in the field – except by qualified SORTEX service engineers. Any leaks from the
ejector manifold will reduce performance and be difficult to locate and repair.
In the rear optical box, undo the two catches securing the lamp pack (one on
each side, right hand one displayed) and pull the lamp pack towards you,
locking it in place at the rear securing posts.
WARNING: Always move the lamp packs using the handle section
on the top cross member and keep hands away from
the ends of the lamp pack when moving so as to avoid
trapping or damaging fingers. Ensure that the lamp
pack is grasped firmly and controlled throughout the
length of its travel and until the catches are engaged,
do not allow it to fall freely as this could cause
personal injury or damage to the machine.
If working for any length of time in this area, it is advised that the lower
fluorescent lamp be removed. Otherwise extreme care should be exercised so
as to not place undue pressure on the fluorescent tube - possibly breaking it.
Undo the catches securing the ejector housing cover (one on each side, right
hand one displayed) and open.
Page 31
The ejectors are grouped in cartridges of four, so you will need to identify
which cartridges the failed ejector(s) belong to.
Identify the cartridge you wish to remove, then disconnect the ejector wiring
from the ejector daughter board (each ejector cartridge has its own daughter
board which, in turn, plugs into the ejector control board).
To remove an ejector cartridge, press the plastic clips together and pull it
upwards and out.
CAUTION: Double-check that the air pressure is turned off before
removing an ejector.
Replacement of an ejector is the reverse of the above procedure,
make sure to locate the notch on the ejector with the key on the ejector
manifold
Push downwards locating the air input connector into the tube below it,
pressing down firmly, but gently, until the cartridge-clips lock into place. It
should slot into place easily. If it does not, do not try to force it. Take it out and
try to relocate it again.
Page 32
Once replaced,
1. close up the ejector manifold cover,
2. replace the lamp pack
3. release the gas spring "locksafe" and close the optical box lid,
4. return the air pressure setting to normal.
5. Finally, perform an Ejector Test (see p. 23)
Note: It is likely that all the ejectors in a machine are of the same age,
so it is often the case that all of them should be replaced at once.
Ejector Fire Count (see p. 25) stores the ejector usage information.
When replacing ejectors, you should zero the reading on that
screen, so that you will know when to expect the next
replacements.
In normal use, ejectors should perform 5,000,000,000 cycles (or
2,500,000,000 for Large product), before needing replacement.
Control Box Dust Filter Removal and Replacement

Switch off the electrical supply, if necessary lock it off using the yellow
locking flap (push it upwards and slide to the right). Allow at least one
minute for high voltages to discharge before handling any PCBs or lamps.
Turn the Air Shut-off Valve to the off position.
Warning: Do not change the control box dust filters whilst
the fans are still running
The control box dust filters are located on either side of the control box and should be changed when they
become clogged with dust.
Undo the two retaining screws a quarter turn and remove the filter retainer.
Remove the old the dust filter and replace with clean one, replace the
retaining bracket, power up the machine and turn on the air.
The dust filters can be washed using water and a mild detergent. They must be dried thoroughly before
replacing. This should be done on a regular basis to ensure adequate airflow.
The part number for a replacement Dust Filter is 64334.
Caution: Never put a damp dust filter on the machine, never run the machine without dust
filters
Page 33
Servicing an Air Filter
Turn the air shut-off valve to the off position. See Safety advice, page 3
NOTE: Always allow the wiper assembly to return to its rest position before
turning off the air supply.
SERVICING
This unit has an automatic drain, which should remove any accumulating liquid in the
bowl. Check the drain pipe for blockage.
To operate automatic drain manually, lift operating pin in bottom outlet with a blunt
rod.
Clamp
ring
DISASSEMBLY
Unscrew the clamp ring on top of the unit. This will release the filter body, containing
the filter element.
Filter
bowl
Turn the filter bowl counter clockwise and remove from the filter body – along with the
bowl o-ring.
Do not remove the drains unless replacement is necessary.
Remove filter element. This element cannot be cleaned. If it is dirty, it must be
replaced.
Clean other parts of the unit with warm water and soap.
Rinse and dry parts. Blow out internal passages in body with clean dry compressed
air.
Inspect all parts before reassembly. Replace those found to be damaged.
REASSEMBLY
Lubricate o-rings with o-ring grease.
Assembling the unit is the reverse of the disassembly.
Arrows on indicator and body must point in same direction. Push the bowl into body
and turn it clockwise into body.
Caution: If the unit is difficult to re-attach, the parts are not correctly
located. Any attempt to force the bowl to screw in, against resistance,
may damage the unit.
Note: A nylon drain spacer sits at the bottom of the bowl. The retaining rod for
the filter passes through it. Ensure that this sits securely in its place, as
it can make re-assembly difficult.
Page 34
Caution: This air filter is not intended to be the sole filtering for the air supply – only to
remove minor contaminants. If this filter becomes clogged, quickly and often, check the
factory air supply.
The pre-installation requirements for this machine (see Preparation document)
are:-
1. Particle content (cleanliness of air) - supplied air to be filtered for a maximum particle size of 25
microns.
2. Water content (dryness of air) - dew point of 2°C (35°F).
3. Oil content - supplied air to have less than 1000 oil parts per million air parts by volume at 12°C (54°F).
These conditions must be achieved before the air reaches the machine.
Air Regulator
The air regulator, which controls the air pressure used by the
sorting machine, is located on the right-hand side, at the
bottom, in an angle of the frame (see right).
The T-bar at the top adjusts the air pressure.
Air pressure should never fall below 5bar (73 psi), nor above
7bar (102 psi).
Note: The Single-module machine (Z+1Vx) has a slightly different filter and regulator. However, the
principles of maintenance are similar.
Page 35
hler Sortex 2010
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Supervisor's Manual • SORTEX Z +Vx • English • Original Instructions • Part No. 027 - 0452 Issue 2 • © B��
B��
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hler Sortex
�� Ltd
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20 Atlantis Avenue
London, E16 2BF
United Kingdom
Tel +44 (0) 207 055 7777
Fax +44 (0) 207 055 7700
Email: sales@buhlersortex.com
www.buhlersortex.com
Registered in England no: 434274

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Supervisor's

Beyond Day-to-Day Operation ------------------------------------------------------------------------------------------ 5

Supervisor Facilities Menu ----------------------------------------------------------------------------------------------- 8

Engineer & Special Engineer menus ---------------------------------------------------------------------------------25

Optical System Components -------------------------------------------------------------------------------------------27

Ejector Cartridges Removal and Refitting ---------------------------------------------------------------------------31

WATCH YOUR FINGERS

WATCH OUT - ELECTRICITY

WATCH OUT – LETHAL VOLTAGES

WATCH OUT – MOVING PARTS

WATCH OUT – HOT!

READ THE MANUAL

EARTH STUD LOCATION

Power & Air Safety

Power on (and power Power off (and avoiding

Locking Power off

Air supply on. Air supply off, Air supply off,

Beyond Day-to-Day Operation

A new screen will appear. Select the required level of access.

On the User Access Level screen, press Change Password.

Modules & Partitions

Using Supervisor Level Commands

Supervisor Facilities Menu

Press the Facilities button, and a menu of further commands

Sorting Setup Menu

Press Sorting Setup on the main Facilities menu produces a

‘Rounding up’ even-numbered Windows

So, the software adds a block - to balance the ‘window’.

This screen switches on or off the detection of Colour Defects

Visible Defect Propagation/IR Defect

Save Working Mode

Rename Working Mode

Copy Working Mode

Note: You cannot delete a Protected Mode.

User Access Level

This menu gives access to the Brokens Monitor (if fitted).

This menu contains items about the physical configuration of

tracking incidents, but product brightness is not tracked.

This menu deals with a number of machine-related

External Interlock Configuration

Hopper Interlock Configuration

White Reference Calibration

White Reference Calibration Interval

This menu offers a number of diagnostic procedures.

Create Diagnostic File

Full Ejector Test

Individual Ejector Test

Ejector Fire Count

Engineer & Special Engineer menus

Optical System Components

Switch off the electrical supply.

Switch off the electrical supply.

Changing a Wiper Blade

Switch off the electrical supply.

Ejector Cartridges Removal and Refitting

Identification of Failed Ejectors

Replacing an Ejector Block

Replacement of an ejector is the reverse of the above procedure,

Control Box Dust Filter Removal and Replacement

Servicing an Air Filter

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