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FT-50c Fill Level Inspector

1. s003 E MI Mo c W piae Ro lo do lo 2555 5 c8 EIU EST dV R8 H H go jo age amp 75 6 DT S B ja a EEN E E agonia Bobo B OY 5 d c7 O aso yo NR K 22 M MIS ies ee we EE 8C CARD P T 617 m m o 5 Ee C m RVC i y E E mos S N WADE IN USR Lai E E J B IO te of pore El 5 818 E E 815 E 2 4 o4 fo 0 Locris o E 20 20 D 0 0 0 Hu P2 CN AS DH pa UH pOCR19 08 riga tana x Qigssgusso POS EJET peje Bap eos Beee A BC D 6 Figure8 1 Power Supply Circuit Board test points Test Output Range Xfmr Source Pare D t Reference point VDC VDC Winding Supply nnd ia 1 TP 6 5 5 0 5 2 28 VAC V Processor Logic Scintillation Detector 2 TP 2 12 11 5 12 5 28 VAC V Scintillation Tube Pulse Preamplifier Control Panel Serial Port Drivers 3 TP 4 22 18 0 22 0 28 VAC V Sensor Emitters Amplifiers Input Comparators 4 TP 5 12 11 5 12 5 28 VAC Unreg Control Panel Serial Port Drivers 5 J 1 1000 800 1200 28 VAC 22VDC Scintillation Detector 6 Q8 3 5 4 9 5 1 28 VAC 12VDC RS232 RS422 Drivers 7 P4 2 60 50 60 36 VAC Unreg Rejector Driver Rejector 8 TP 3 Ground Industrial Dynamics Company Ltd Document 40255 0600 8 15 FT 50 Fill Level Inspector Service Manual Warning 8 16 Testing the Power Transformer If the power supply is not functioning the failure may be caused by the loss of input power If the input power is missing test the
2. Figure 4 4 Align the Inspection Trigger Beam 1 Loosen the Centerline Bracket height Lock and using the Centerline Sensor Bracket Height Crank raise the bracket all the way 2 Center a properly filled and sealed production container in the inspection tunnel so that when the sensor mounting bracket is lowered it is aligned with the trigger beam 4 8 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation 3 Lower the bracket until the trigger beam contacts the container at the widest part of the lid or if the container is oriented upside down so the beam contacts the container as shown in Figure 4 4 4 Tighten the height locking handle to secure the trigger beam positioning 5 If you will not be performing further alignment procedures open the safety shutter by pulling the actuating rod out until it stops Industrial Dynamics Company Ltd Document 40255 0600 4 9 FT 50 Fill Level Inspector Service Manual Aligning the Missing Lid Sensor Height The Missing Lid Sensor is mounted on the Centerline Sensor Bracket Align the Missing Lid Sensor height after you align the Inspection Trigger Sensor height No Description Missing Lid Sensor Container Lid Container Travel Distance between Lid and Sensor Upper Locking Nut o 0 ON Lower Locking Nut Figure 4 5 Aligning the Missing
3. Fax Telephone Email techpubsefiltec com Email Industrial Dynamics Co Post Mail Ur e EE Department Address Torrance CA 90505 FB 2 FT 50 Fill Level Inspector Service Manual Document 40255 0600
4. MODE TIMER L B Stable Operation Indicator LED green D HL No Description 1 Sensitivity Adjustment 2 Operation Mode Selector D Timer Operation Selector NON 3 Operation Indicator red 4 Cover Figure 6 2 Calibrating the Upstream Inspection Trigger Amplifier 3 Set the Sensitivity Adjustment to minimum by turning it counterclockwise until it stops Notice the gauge needle moves to reflect setting level and the red Operation Indicator LED is on 4 Slowly turn the Sensitivity Adjustment clockwise until the red Operation Indicator LED is off You want the sensitivity adjustment to be on the edge of when the Operation Indicator LED turns off This establishes the minimum sensitivity point 5 Verify the setting by using a production container to block the beam and then remove it The Operation Indicator should be off when the container is blocking the beam and on when the beam is not blocked 6 Replace the amplifier cover Industrial Dynamics Company Ltd Document 40255 0600 6 31 FT 50 Fill Level Inspector Service Manual Calibrating the Bulged End Sensor Note Refer to Figure 6 2 when performing this procedure 1 Clear the inspection tunnel of any containers so the trigger beam is not blocked 2 Remove the amplifier cover and set the Operation Mode Selector to Dark D 3 Set the Sensitivity Adjustment to minimum by turning it counterclockwise until it stops Notice the gauge needle mov
5. 0 0 00 e eee eee ee 6 43 The Review Fill Level Tests uer eked ae tee E IMS 6 44 Chapter Seven Maintenance Procedures 7 1 Maintenance Schedules esa 7 3 Daily Schedule sii td e yu Spi ta I ees 7 3 Weekly Maintenance tro A O Sa eel 7 3 Monthly Martenance A da 7 3 120 Day Maintenance 2 RR eda ra Syne ceca pd 7 4 Maintenance Procedures praia ds Yu ed es 7 5 VIII Industrial Dynamics Company Ltd Document 40255 0600 Table of Contents Before You Perform Any Maintenance Procedure 7 5 Trigger Beam and Emitter Lenses 7 5 Bulged End and Missing Lid Sensors 0 0 0 0 00 00 ee eee 7 5 The FI 50 Housing bu uec ee oes e Sele HRS 7 6 Pressure Regulator and Air Filter oooooooooroommomo r 7 6 External Wiring 0020 pt ta bee Oho e a YS 7 6 Replacing the Rejector Pad visor ds a 7 6 Servicing the Regulator and Coalescing Air Filters 7 7 Chapter Eight Diagnostic and Repair Procedures 8 1 Diagnostic Error Messages 0 0 cece eee ee es 8 3 Error Number 2 sowe Lee an E oen E ae Pta e edes 8 3 Fror Number 2454 AD t as eet do o tT oe 8 3 Error Number 6 4 5985 S geriet e ete ek ue XO 8 3 Error Nu imbef 8 ii ood bo a NE dew 9 Ok Co deis 8 3 Brror N mber 925 inso ix bI IRA EN RU Se ES 8 4 Error N mberlO 2 uU IBS DD REM 8 4 Error Number 11 ooooooooorro ooo a 8 4 Error Number 12 44 iot ee nore e etra vae aloe ERN 8 4
6. 000 3 11 Secure the Floor Stand to the Floor 0 0 00008 3 13 Install the Slant Support Braces 0 0 0 0 eee eee eee 3 14 Install the Air Purge System eco sever ther Pp ES xw EIAS 3 19 Install the High Resolution Encoder 0 0 0 ce eee eee 3 21 Mounting the Encoder Inline 0 0 0 0 eee eee eee 3 21 Mounting the Encoder Onset e ark M efe de x 3 22 Install the Rejeetor 2 22129 24 s iex LR REI p viele 3 22 Connect the Main Power Source 0 0 0 cece cc cece eee ee 3 23 Standard Power Supply Wiring 0 0 0 eee eee eee 3 23 Wiring the Main Power Supply Cable to the I O Junction Box 3 25 Power Supply Wiring Examples 0 0 0 ee eee eee eee 3 27 Example A Standard 115 VAC or 230 VAC with Neutral line 3 27 Example B Using a Voltage Regulating Transformer 3 28 Example C Poly Phase Single Phase From the same System 3 29 Example D High voltage Poly Phase Systems Delta or Wye 3 30 Chapter Four Configuring the FT 50 for Operation 4 1 O A sO ha TTC PESE aaah eee es 4 3 Mechanical Configuration so rad da exte oa are eee ese e 4 4 Before You Been a a a Se hee ee ok ten els 4 5 Aligning the Fill Level Inspection Beam 0 00 00 000 4 6 Aligning the Inspection Trigger 2 0 0 0 0 cece eee ee eee 4 8 Aligning the Missing Lid Sensor Height 0 4 10 Aligning the Bulged
7. 2 Carefully remove each PROM with a PROM puller 3 Carefully align and then insert PROM U25 into socket U25 Do not force the PROM If you break the pins you must reorder the PROM 4 Carefully align and then insert PROM U26 into socket U26 If PROM U26 is shorter than the PROM socket align the left side of the PROM and socket so that the excess socket length is on the right Do not force the PROM If you break the pins you must reorder the PROM If LED 12 indicates CPU has locked up If LED 12 also called the Watchdog LED on the Processor Card is on this indicates the CPU has locked up This could indicate a software failure or processing error Reboot the machine and begin operations Serial Communications Card Serial communications cease Check to be certain Serial Communications has not been deacti vated If not the terminal board is malfunctioning and must be replaced The Control Panel If the display does not change when keys are pressed 1 Turn the FT 50 s power off and press the reset button and turn on the power to the machine Wait for the three beeps before releasing the Reset Button 2 Remove the FT 50 s cover and verify the ribbon cable from the touchpad is undamaged and properly connected to the terminal board 3 Inspect the control panel display touchpad for water damage If moisture is present replace the control panel Industrial Dynamics Company Ltd Document 40255 0600 Chapter
8. e If you will perform overfill detection align the bottom of the Gamma beam slot with the fill level of the contents in the container 6 Tighten the inspection head height locking handle to secure the head positioning 7 Ifyou are not in the Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to select CALIBRATE 8 Press Key 1 until you reach TARGET HEAD HEIGHT 9 Read the value displayed in the Head Height Counter The counter is located in the upper left corner on the front of the FT 50 see illustration 4 2 10 Use the Arrow Key to enter the value in the TARGET HEAD HEIGHT function 11 Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to select OPERATE 12 If you will not be performing further alignment procedures open the safety shutter by pulling the actuating rod out until it stops Industrial Dynamics Company Ltd Document 40255 0600 4 7 FT 50 Fill Level Inspector Service Manual Aligning the Inspection Trigger You must align the inspection trigger height so that the trigger beam contacts the container at the widest part of the lid 5 Description Trigger Height Lock Trigger Beam Emitter Trigger Beam Centerline Trigger Beam Receiver Container Travel 7 8 Trigger Horizontal Centerline ena p Trigger Vertical Centerline Width of Container at Trigger Point top up Oo AN DOA FWD Width of Container at Trigger Point botom up
9. No Description Weld both brackets 2 Weld three braces Weld both feet o Figure 3 16 Spot welding the mounting hardware 3 18 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Install the Air Purge System 1 Attach the air filter regulator to the vertical support pipe using the supplied UBolt You can mount the air filter in an alternate location providing the distance does not exceed the 40 inch length of the air hose No Description Pressure Adjustment Knob UBolt Output Air Hose to FT 50 Vertical Support Pipe 4 Air input attach input air hose l Figure 3 17 Installing the air purge system a A U N Industrial Dynamics Company Ltd Document 40255 0600 3 19 FT 50 Fill Level Inspector Service Manual 2 Connect the air line from the filter regulator to the air input of the FT 50 No Description 1 Air Regulator Disperser 2 Air Input 3 Air Hose from filter regulator Figure 3 18 Connecting the air line to the FT 50 3 Connect the input air source line to the input of the filter regulator The input air pressure should be approxi mately 80 120 psi at 1 5 cfm 3 20 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Install the High Resolution Encoder If you will be using the High Resolution Encoder op
10. 52 4 Parity Odd Even serte ratas ibi ad 10 6 52 5 CharacterSize x4 os ess O 10 6 S2 6 Multi Serial llle 10 6 S2 T Led Section Selector 2 0 00 00 00 ee eens 10 6 S2 8 Led Bank Selector visto iR RARE is 10 6 Slides Witches oos hor wkd andes ac esa m std S 10 6 VY o PUER os a A cee bees A GT SGA AES GI a eal SE 10 6 SW Ei A ah We ais Re ath ted gc a SAC c S 10 7 SMS esr cts NAM Rls Nhe A ae A he BE Ne 10 7 Controller Board LED Locations 0 0 0 000 ccc eens 10 8 LED Cohfigurallolisa 1 253 r st so eire adi RENS 10 9 LED Logic Iz 4443546 ea dew RMSE Se ORE Nien RES oii eg 10 9 LED Definitions oe 25 3 sce a OR REA RE OR AD Tek RED ROS 10 10 Section 1 Bank 1 S2 7 Closed S2 8 Closed 10 10 Section 1 Bank 2 S2 7 Closed S2 8 Open 10 10 Section 2 Bank 1 S2 7 Open S2 8 Closed 10 11 Section 2 Bank 2 S2 7 Open S2 8 Open 10 11 Industrial Dynamics Company Ltd Document 40255 0600 XI FT 50 Fill Level Inspector Service Manual XII Industrial Dynamics Company Ltd Document 40255 0600 Radiological Safety Radiological Safety Understanding Radiological Safety The Filtec FT 50 utilizes a small quantity of the radioisotope Americium 241 to produce low level gamma radiation The Americium 241 is in ceramic enamel form and its melting range is in the region of 900 degrees to 1050 degrees centigrade The Americium 241 is
11. Brror Number sre ara a ot Die e RU roc E 8 4 Error Number 14 5 2 cae eta oA ec See a ae ele A ae SOAR ae 8 4 Error Niimbet 15 sei or ica 8 5 Error N mber TO lets ici idea de beds 8 5 Error Number 22 o ooooooooooooorooronmomcoronooo 8 5 Error Number 23 2 0 0 00 eee eee a ES 8 6 Error N mber24 uu ake enh AO We aba te 8 6 Error N mber 2S uso ad a NEVER oR LS 8 6 Error Number 27 2 003 a dsd 8 7 Error N ibet 33 06500 a es 8 7 Error Number 34 5 LE dv Et wot stie erc 8 7 Error Number 46 0 cc ee ee nee hh 8 7 Error Number 47 2 0 0 00 cc eee eee o 8 7 Brror N mber48 i542 blak id dts ee hs 8 8 Error Number49 aii did 8 8 Error Number 50 0233 o oet LUXe a LII EN 8 8 Error Numbers asis ertet ree te Le aes 8 8 Error Number IZA 6 OO DA e t sr cce ene 8 9 Error Number 53 oooooooooooooorooronmonsoroooo 8 9 Error Number 54 0 0 cc ee eee hh 8 9 Error Numb t 5828 64 406 da BRE RIA nd dw ED MEAE beds 8 9 Error Number 61 5 0 os aa cea es DI eS T Wes 8 9 Error Number 66 0 0 0 0 eee teen nes 8 9 Error Number 67 i526 ie eS ORE BRA ad hes 8 9 Error Number Orea rotae nay ik aa a Modos ds EL 8 10 Error Number 72 ua da cda 8 10 Error N imber 86 veu V teh ood a hd ts EF VS bo dw alee as 8 10 Industrial Dynamics Company Ltd Document 40255 0600 IX FT 50 Fill Level Inspector Service Manual Error Number 117 3 never eka E Da ee outed 8 11 Error Number 013 02 ias erario E RN 8 11 Error Numbe
12. Installing the FT 50 Example C Poly Phase Single Phase From the same System 1 Neutral must be grounded at the main power panel 2 Connect the FT 50 ground stud to the plant Earth ground Do not connect the FT 50 neutral white to the ground stud 3 The FT 50 hot wire black can be connected to any of the three legs phases 4 In this system the leg to leg Y1 to O2 2 to O3 and G1 to 23 voltage is 208 VAC Any leg to neutral is 120 VAC Europe 380 220 eU 2 Q3 ZTN 3 115 230 Wn N VAC a PE 2 T 6 ae No Description 1 Plant Power Panel 2 FT 50 Power Junction Box 3 Set Voltage Select Switch to proper Voltage 4 Connect FT 50 pigtail leads to input power wires 5 FT 50 Ground Stud 6 External Breaker or Disconnect Figure 3 26 Main power wiring Example C Industrial Dynamics Company Ltd Document 40255 0600 3 29 FT 50 Fill Level Inspector Service Manual Example D High voltage Poly Phase Systems Delta or Wye 1 This example is identical to Example B except the input to the transformer is taken from a poly phase system All other condi tions of Example B apply 2 Some transformers have an internal electrostatic shield which should be grounded to Earth ground if possible however the FT 50 ground is suitable This shield may be attached to the transformer case in some units or it may have a separate wire
13. Ltd Document 40255 0600 XVII FT 50 Fill Level Inspector Service Manual XVIII Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview Chapter One FT 50 System Overview System OVOLVIBW IEA AA AAA 1 3 Fill Level Inspection Basics trea aa duae d ate e ace dea 1 4 How Underfill Inspection Works ooooooooommmmmm 1 5 How Overfill Inspection Works osos 1 5 Rejection Control Basics iii ead ies Sess sa ace d 1 6 System Specifications ire serer sben Teas ene ens Pocta obl eet DE 1 7 Power Requirements 52135 e340 ER E34 RI CEE Ree KR ERE ERIS 1 7 Operating Temperature 264 4 eee Kors ae eee eee eee ee BER 1 7 Pneumatics PR 1 7 Gamma SOUTCE taa a 1 7 Inspection Accuracy ie Ge AX Y ued RENE RERO E NR RN ee 1 8 Physical Size to os eee eaters Boos 1 8 Triggering O e atte aga idit cba eo 1 9 High Resolution Encoder citen cre eric 1 9 REE CUA EAN A A A Rak 1 9 Mounting sd ARS AA AAA LER RA Id ES 1 9 Height Adjustment setos Radin e dab erie 1 9 Contaimer PES iope deei Let ome ee Sete E EE ORO eee 1 10 Container Spangs sesei era pk Tor As id a 1 10 Control Panel mcs a Cees UI ed oie tems 1 10 Dyste meo Wale A AA ele Megat ay REI et a 1 11 Optional system Features tan nda er tuta 1 12 Bulged End Detection vc sce exerc SML qupd dient EA RS 1 12 Missing Lid DetePtloti 2S ve a IRE ERR ERE RE ER IRE A 1 12 Down Can Detection soos nats Boe eed uc uto es 1 12 D d Detection utei e d d Box eid e LAM baber
14. The mounting brackets themselves are not adjustable however the sensor height can be adjusted by positioning it in the proper mounting hole within the block 2 To determine the proper sensor height align fill level inpection beam first and perform Fill Level Optimization if needed and then refer to the Installation and Service Drawings Pack to locate the drawing of your bracket Use the information in the drawing to determine the proper position for the sensor Drawing Can Sizes 26796 8 12 16 oz 32293 8 10 12 16 24 oz 3 If you will not be performing further alignment procedures open the safety shutter by pulling the actuating rod out until it stops 4 14 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Wiring the External Reject Function You can connect any external switching device to the External Reject Function such as a manual contact switch or the switched output from another device A switching closure to ground signal is required When the signal is in the low state it will trigger the FT 50 to send the rejector activation signal Active Signal and Circuit Type Sensitivity Signal Wave Shape Inactive Signal NPN Low State Ground GND Open 20V p 1 Route the signal cable through one of the moisture resistant fittings in the bottom of the FT 50 If your FT 50 is equipped with an external I O Junction Box route the cable through one of t
15. default is odd S2 5 Character Size Allows selection of 7 or 8 bit characters The default is 8 bit S2 6 Multi Serial Enables the FT 50 for a multiple unit serial network and switches the serial port from active open to tri state RS 485 The default is RS 485 S2 7 Led Section Selector Defines current LED section The default is section 1 S2 8 Led Bank Selector Defines current logical LED bank The default is bank 1 SW3 Selects either RS 232 or RS 422 485 network communications The default is RS 232 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 10 Controller Board Dip Switches and LEDs SW11 Enables or disables the ability to write setup values to protected memory The default is enable SW13 Enables or disables the Auto Reset function The default is disable Industrial Dynamics Company Ltd Document 40255 0600 10 7 FT 50 Fill Level Inspector Service Manual Controller Board LED Locations The FT 50 s Controller Board contains 1 bank of 11 LEDs The LEDs are divided into logical sections and banks which are configured by dip switches S2 7 and 82 8 LEDs OO OMAN OA cCcnm Figure 10 2 Locating the LEDs on the Controller Board 10 8 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 10 Controller Board Dip Switches and LEDs LED Configurations The LED assignments below are listed by the Section and Bank Selecting a
16. j 2 5 in 1 No Description 1 Guide Rails 2 Area to be removed 3 FT 50 Centerline 2 4 Conveyor Side Wall 4 3 Figure 3 3 Creating a gap in the conveyor guide rails 3 Modify the guide rails upstream of the FT 50 to form ramp actions as described in your rejector manual The last ramp action should occur at least 12 inches 31 cm upstream of the FT 50 centerline mark Industrial Dynamics Company Ltd Document 40255 0600 3 7 FT 50 Fill Level Inspector Service Manual Mounting the FT 50 Assemble the Floor Stand The parts included for your installation are based on the instal lation height information you specified when you ordered your FT 50 If you cannot mount the FT 50 as originally planned or if parts are missing contact IDC Customer Service immediately There are three mounting configurations e Low Mount for installations below 33 inches 846 mm Standard Mount for installation heights between 33 and 60 inches 846 mm 1538 mm High Mount for installations above 60 inches 1538 mm 1 Use the following equation to determine the proper length for the vertical support pipe Los Hj Hg 11 Lo The length to which the pipe must be cut Ho The distance from the top of the conveyor chain to the floor 11 Subtract 11 inches 279 mm HL The fill level of the liquid in the container If you use this unit to inspect multiple containers with different fill levels use the followin
17. lates into the rejector area which can damage the equipment Reject Takeaway Conveyor The requirements for the reject takeaway conveyor are determined by the model of rejector you are installing Refer to the rejector manual that is included with your machine for specifications Industrial Dynamics Company Ltd Document 40255 0600 2 5 FT 50 Fill Level Inspector Service Manual 2 6 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Chapter Three Installing the FT 50 Before You Been rta AA AAA 3 3 Basie Terminology sos ppp ES PE X GaU dE satt da 3 3 Unpacking the FI 50 a PIER EXE Ep ipee tr eae ees Era 3 4 Installing the FT 50 Inspection System esses 3 5 Determining the Proper Location for the FT 50 3 6 Preparing the Conveyor Lise equ tea dti da T sox ER E eed ieee 3 7 Mounting the FT 50 ias IE ERR o E Re RR 3 8 Assemble the Floor Stand staba 3 8 Mount and Position the Inspection Head 3 11 Secure the Floor Stand to the Flo0r o oomooomomcronno 3 13 Install the Slant Support Braces ce cocco yx ray ek rasa d 3 14 Install the Air Purge System cesser ex er ones Hee ke xa 3 19 Install the High Resolution Encoder 00 00008 3 21 Mounting the Encoder Inline 0 0 6 0 6 6 bccn cee ence anes 3 21 Mounting the Encoder Offset 2 oL este xene tae kode 3 22 Install the Rejector Vado ex REO SERERE RARI ER 3 22 Connect the Main Powe
18. power transformer 1 Turn off all power to the FT 50 2 Remove the FT 50 s cover to access the power transformer inside Failure to turn off the power can result in severe electrical shock 3 Disconnect plug P1 from the transformer and turn the power to the FT 50 on 4 Refer to Figure 8 1 and test the following pins in the P1 connector on the processor card Reference Rated Voltage Voltage Range Connections A 36 VAC 38 43 VAC Pin 1 to Pin 2 red to red B 14 VAC 15 17 VAC Pin 3 to Pin 4 yellow to blue Pin 3 to Pin 5 yellow to blue C 28 VAC 30 34 VAC Pin 4 to Pin 5 blue to blue D 24 VAC 25 29 VAC Pin 7 to Pin 8 brown to brown Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Processing System Troubleshooting Main Processor Card If the Main Processor Card fails a total system shutdown will occur Check to be sure that all power sources are functioning correctly If they are functioning correctly replace the processor card U25 U26 JOP POOF PF OY OT TD Get Figure8 2 The Processor Card Industrial Dynamics Company Ltd Document 40255 0600 8 17 FT 50 Fill Level Inspector Service Manual 8 18 How to replace the software PROMs The software PROMs must be replaced as a set Each PROM is labelled as either U25 or U26 refer to figure 8 5 1 Locate PROMs U25 and U26 These are the PROMs that contain the machine software
19. set for High Priority Only Industrial Dynamics Company Ltd Document 40255 0600 5 43 FT 50 Fill Level Inspector Service Manual 5 44 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Chapter Six Calibration Procedures FT 50 Calibration Procedures mia Ae 6 3 Encoder Calibration Proced tess ia daa ken 6 4 Variable Speed Conve yorsis0 sow sab i uae ex e ung eres ep d 6 5 LED Definitions Quick Reference 0 00 ce cece eens 6 5 Conversion Factors ete ANO aep p 6 6 How to Determine if You Have Baseline Eight 6 6 Before YOu DES 2 ot239 ize AR 6 7 Standard Conveyor Calibration Procedure s 6 8 Unknown Sprocket Size Calibration Procedure 6 13 Executing the Encoder Calibration Routine 6 14 Fine Tuning the Rejector Timing seen 6 15 Non Standard Conveyor Calibration Procedure 6 18 Executing the Encoder Calibration Routine 6 20 Fine Tuning the Rejector Timing een 6 21 Fixed Speed Conveyors siae qeu ope A 6 24 Before You Beplti cs 02 oon Vue e Xx eR REN TRI REA 6 24 The Line Speed Calibration Procedure 06 00000000008 6 26 Fine Tuning the Rejector Timing cesse 6 27 Sensors Calibration Procedures micras dea rece ka dolo ee aed 6 29 Proximity SENSONS ceo 2 Rx Ud CERO ANA AD ER CER 6 29 Piber Opiie SenbsOPs d sioe et tec C Oe e ER PUO Ea E RE 6 29
20. the area from the inspection trigger to the rejector centerline must be clear You must be using a Proline rejector Before You Begin Your FT 50 must contain the Baseline Eight version of the system software to use the calibration procedures listed in this section If you do not have Baseline Eight contact IDC Customer Service for instructions pertaining to your baseline You must configure the FT 50 for a fixed speed production line by closing dip switch S1 3 before you begin the following procedure 1 Turn the FT 50 power on or press the reset button and the FT 50 will begin its start up sequence 2 Read the software version code in the displayed status message XX TDC BT 5 0 OMIS05T VERSION MGI STAT 0480 3 If the version code is MGI thru MZZ TYW thru TZZ or SAA thru SZZ Baseline Eight is installed If any other version code appears contact IDC Customer Service for instructions Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures 4 You must also remove the FT 50 s cover to access dip switch pack S1 When performing the calibration procedure you are required to change the settings for 51 5 Industrial Dynamics Company Ltd Document 40255 0600 6 25 FT 50 Fill Level Inspector Service Manual The Line Speed Calibration Procedure Note 6 26 1 Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode You m
21. 26 Alarm Missing Lid vos ea S s as 5 27 Alarm Bulged End 1422541523042 AEef cc IAE YS 5 27 Alarm DOW Gall aabt as WES ed ews 5 27 Alarm Dia Missing Lid i4 lt i2d lt a de o E nn 5 27 Alarm External Rejectcs xou dex Sex ties 5 27 Load Default Constants 2 oz ui e o CO SOR pa ee da 5 27 Can Width At TOS vatios Y 5 28 Maximum Can Diameter ic 5 28 Maximum Line Speed oa i52 o eeiee cipi d RS 5 28 Maximum Conveyor Speed visas RE LS es ad 5 28 Change Password mernirs kk en ote be kde eek aes 5 28 View TB1 amp TB4 Pin Assignments 00 5 29 View PLC Pin Assignments 2 osse As 5 30 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Clear System irc needs a ue bs 5 30 Current Language i boy Res ves er res had REA NONE 5 30 Contamer Text ts eta i eo Ls 5 30 of Container Types 44594 v 4e b Ee at 5 31 Current Container Type is sona Wes Ce eer v Du ERU dd 5 31 Eller add cad banana RII UAE T 5 31 Enderhll Text as corria Ek RIAM SES TIAQex Sexo Ra 5 31 Overfill Text o1 uvis a a EN AAG UES oe ag Ea 5 32 Missing Lid iere boda e entren edet Bad Ora e ave E 5 33 Missing Lid Textos crt orc eto ce da E ose 5 33 Bulged End eit eae ees eei OUR ere ee 5 34 Bulged End Text Sua rer UAE ERE dea 5 34 Down Cal 222 1k gib nee RE ERARRI RA EE ERE 5 35 Down Can Text osse eR paa 5 35 Diameter Missing Lid oye os Cv RE ec IRR AME IN has aes 5 36 Diameter Missing Lid Text ioo RE eee 5 36 External Reject i
22. 4 Measure and cut the slant brace to the determined length removing the excess from the open end 5 Attach a slant brace to each bracket check the brace angles as explained in step 2 and then tighten the pipe clamps securely Industrial Dynamics Company Ltd Document 40255 0600 3 15 FT 50 Fill Level Inspector Service Manual 6 Attach the slant brace floor mounting brackets to the slant brace stubs and then slide the stubs into the bottom ends of the slant braces approximately 1 5 inches The floor brackets should rest flat on the floor No Description 1 Slant Brace Stubs Figure 3 14 Attaching the slant braces and slant brace stubs 3 16 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 7 Mark the positions of the mounting holes and then anchor each bracket with two 1 2 inch x 4 inch lag bolts and lead floor inserts TT Figure 3 15 Anchoring the slant braces to the floor 8 Firmly tighten all bolts and pipe clamps and then tack weld the following points with an oxyacetylene welder Remember to remove the pipe clamps when you finish Industrial Dynamics Company Ltd Document 40255 0600 3 17 FT 50 Fill Level Inspector Service Manual Caution Do not use resistance type electrical ARC welding equipment The high electrical current will damage electronic components inside the FT 50
23. 5 The PLC Series Alarm functions are now activated in the system software The following options will now appear in the Function Menus Refer to Chapter 5 System Software for information on these functions PLC Pin Assignments PLC Output Pulse Width e Alarm Series Underfills e Alarm Series Overfills e Alarm Series Missing Lid e Alarm Series Bulged End e Alarm Series Down Can e Alarm Series Dia Missing Lid e Alarm Series Any Other Inspections 9 4 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 9 Using a PLC With Your FT 50 How to Determine the Signal Output Wiring The View PLC Pin Assignments Function lists the configuration of the PLC outputs for your FT 50 It also lists the normal voltage levels associate with the signals To view the PLC pin assignments 1 Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select CALIBRATE 2 Press Key 5 until VIEW PLC PIN ASSIGNMENTS appears 3 Press the Arrow Key to scroll through the list e The top line of the displays the output function and its assigned terminal pin The bottom line lists the voltage level and triggered action For example NORMAL gt gt 2V PULSE lt 2V means that the normal state signal voltage is greater than 2V and the pulsed state signal voltage is less than 2V 4 When you reach the end of the list the COMPLETED message appears Adjusting the PLC Output Signal Pulse Width To Adjust the PLC Output
24. A A AR Ae ee ee 8 9 Error Number 68 llle n 8 10 ErrorNu umber72 it Stone do Xe xu pia Re e ie 8 10 Error Number 8620 28 ia eek gee e d cU E eC Sees 8 10 Error Number 117 1 0 0 00 00 ccc ccc RR e 8 11 Error Number 118 0 0 0 e o A en 8 11 Error Number 119 cc cue See he he a pile Bens reb 8 12 Error Number TO iii 8 12 Error Number TDi ie aaa 8 12 Troubleshooting Procedures secure p RR cs 8 13 Major Component Subsystems 4 potet eesti Ede npe 8 13 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual Before Yo Begin o d beant Mte os pta eek tia 8 13 What You Should Do First star 8 14 Power Supply System Troubleshooting 0 005 8 15 Testing the Power Supply x e cues Veios td e tex ees 8 15 Testing the Power Transformer eee 8 16 Processing System Troubleshooting 0 00 eee eee 8 17 Main Processor Card ladera dape P C gels 8 17 Serial Communications Card 9 cese ERE RES 8 18 The Control Panek inte Soto Dee adas eo 8 18 Sensor System Troubleshooting o ooooicooomcoormosm s 8 20 Scintillation Tube Detector STD 0 0 00 ccc cece eee 8 20 Solid State Detector SSD esses 8 20 Optical SENSORS sat ovs wea soe uke wise ee eee en E S 8 21 Proximity SENSORS eni e Ate eet ads Ets TER e ERES ack RA 8 21 PO rte A ee eee ee ERR ie 8 21 Troubleshooting Problems with Rejectors 05 8 22 Proline Rejector Tr
25. Before You Begim chord e eet NL DL Reo s teda 6 29 Calibrating the Centerline Inspection Trigger issue 6 30 Calibrating the Upstream Inspection Trigger 6 31 Calibrating the Bulged End Sensor ocooocooommmcorocso 6 32 Calibrating the Down Can Sensor v4 see ore id 6 33 Radiation Detector Calibration Procedure sssuse 6 34 Solid State Detector cx oae x am ora rado Eque lol aE 6 34 Scintillation Tube Detector arial e naa ed En 6 34 Calibrating the Scintillation Tube Detector 04 6 35 Scintillation Detector Calibration Procedure 6 35 Fill Level Opti Zann 5o c ee pnt aia at 6 37 B tore You Begin seks A A CP du RR p ER 6 37 Leveling the Inspection Head c eese eee 6 38 Executing the Fill Level Optimization Routine 6 39 Establishing the Underfill Gamma Threshold 6 39 Establishing the Target Head Height ooo ooomomoomo 6 41 The Dynamic Reject Point Test 20 0 0 6 cece eects eee 6 42 The Dynamic Product Good Test 0 0 00 000 e eee 6 43 The Review Fill Level Testo he eins 6 44 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual 6 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures FT 50 Calibration Procedures The calibration procedures in this section should be performed only if your FT 50 is compl
26. Error Number 117 This error condition indicates there is a Host or MODBUS Serial Interface Framing Error or Reply Timeout timeout must be a minumum of 15 seconds Most communication errors are caused by excessive noise Check the termination of RX input Check the baud rate S2 1 e 52 1 CLOSED 9600 e 2 1 OPEN 1200 Check the character size S2 5 e 2 5 CLOSED 8 bit 1 stop e 52 5 OPEN 7 bit 2 stop Check the RX with a Voltmeter Perform the check when the line is in a steady state No transmission RS 485 e RX A GND e RX B 5VDC RS 232 e RX A 12VDC to 4VDC e RX B GND Error Number 118 This error indicates a host or Modbus serial RX overrun error The baud rate may be set incorrectly To correct this error check the baud rate setting which is controlled by dip switches S2 1 and S2 4 e 2 1 closed 9600 baud e 52 2 open 1200 baud Industrial Dynamics Company Ltd Document 40255 0600 8 11 FT 50 Fill Level Inspector Service Manual Note 8 12 Error Number 119 This error indicates a host or Modbus serial parity error occurred To correct this error check the parity setting which is controlled by dip switches S2 3 and S2 4 e 52 3 closed no parity e 2 4 closed odd e 52 4 open even Error Number 120 This error indicates there is a RX Receive Rate error Too many characters have been received in one second This error may be caused by line noise To correct this er
27. Line Speed The maximum production speed of the conveyor defined as cpm containers per minute Maximum Conveyor Speed The maximum production speed of the conveyor defined as mpm meters per minute Change Password Allows you to enter a three 3 digit password When the Password Option is active you must enter the code to enter the Calibrate Mode The default password is 222 To change the password do the following 1 Remove the FT 50 s cover to gain access to dip switch S1 8 2 Close dip switch S1 8 S1 8 is located on the processor card The Change Password function will not appear in the display unless the dip switch S1 8 is closed To disable the password protect function close switch S1 8 3 Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode 4 Press Key 5 until CHANGE PASSWORD appears and then press the Arrow Key for the ENTER PASSWORD prompt to appear 5 Use the numbered keys keys 1 6 to enter a number for each of the 3 digits Record the password for future reference Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software 6 After the new password is entered the FT 50 takes a few seconds to store the new password When the change is finished the COMPLETED message appears 7 Open dip switch S1 8 The Password Option is now activated You will be required to enter the password whenever you attempt to enter the Calibrate
28. Mode 8 Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to return to the Operate Mode 9 Replace the FT 50 s cover View TB1 amp TB4 Pin Assignments Displays the signal wiring assignments for pins in Terminal Blocks TBland TB4 It also lists the normal voltage levels associate with the signals To check which FT 50 inputs have been assigned to pins on Terminal Block TB1 and TB4 1 Press Key 5 until VIEW TB1 amp 4 PIN ASSIGNMENTS appears 2 Continue pressing the Arrow Key to scroll through the list e The top line of the displays the sensor or function and its assigned terminal pin The bottom line lists the voltage level and triggered action For example BLKD lt 1V UNBLOCKED gt 17V means that if the signal voltage is less than 1V the trigger is blocked and if the signal is greater than 17V the trigger is unblocked 3 When you reach the end of the list the COMPLETED message appears Industrial Dynamics Company Ltd Document 40255 0600 5 29 FT 50 Fill Level Inspector Service Manual 5 30 View PLC Pin Assignments Displays the PLC signal wiring assignments It also lists the normal voltage levels associated with the signals For more infor mation see Chapter 9 Using a PLC With Your FT 50 for more information To check the PLC pin assignments 1 Press Key 5 until VIEW PLC PIN ASSIGNMENTS appears 2 Press the Arrow Key to display the first pin assignment 3 Continue pressing
29. Name Parameter Default t Current Language English English Portuguese Spanish German French Italian Container Text 10 Characters Maximum Can t f Of Container Types 1 32 5 j Current Container Type 5 1 t Container Type Text 17 Characters Maximum Fill Level Present Not Present Present t Underfill Text 17 Characters Maximum Underfill t OVerfil Text 17 Characters Maximum Overfill t Missing Lid Not Present Not Present Standard Nonferrous Cap Under Foil t Missing Lid Text 17 Characters Maximum Missing Lid t Bulged End Present Not Present Not Present t Bulged End Text 17 Characters Maximum Bulged End Down Can Present Not Present Not Present t Down Can Text 17 Characters Maximum Down Can t Diameter Missing Lid Present Not Present Not Present t Dia Missing Lid Text 17 Characters Maximum Dia Missing Lid t External Reject Present Not Present Not Present t External Reject Text 17 Characters Maximum External Reject t Rejector Type Std Proline Std Proline HS Proline Slat Std LS 3 Slat HS LS 3 Slat HL Slat PLC Series Alarms Present Not Present Not Present Serial Interface Not Present Not Present IDC Interface Modbus Interface External Trigger Logic Remote Clear Of Error Remote Clear 5 10 External Reject Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Function Group Function Name Parameter Default Known Chain Pitch amp Teeth Present Not Present Present Encoder Resolution 50
30. No Description FT 50 and to convert the line voltage to the proper voltage for FT 50 The secondary side of the transformer must be connected to the hot and neutral wires in the FT 50 It makes no difference which wires from the secondary attach to input wires in the FT 50 but if color coded wires are used connect white to neutral Do not connect the transformer secondary terminals to the neutral on the primary because it negates the isolation properties Connect the FT 50 ground stud to the facilities ground system The neutral wire should also be connected to this ground stud If the transformer has an internal electrostatic shield ground it to the Earth ground if possible however the FT 50 ground is suitable This shield may be attached to the transformer case in some units or it may have a separate wire lead Examine the transformer carefully to determine if it is shielded and if so ground the shield 1 FT 50 Power Junction Box 2 Voltage Switch Proper Voltage 3 Connect FT 50 pigtail leads to input power wires 4 FT 50 Ground Stud 1 5 External Breaker or Disconnect 115 230 2 6 Separate Transformer Q 2 7 White 8 Blue Bot ATUS 7 N 8 a J 9 Black IS 115 230 S 3 10 Brown 440 etc C 115 230 VAC be C ees 9 li 10 N M o os JIN 6 5 4 n Figure 3 25 Main power wiring Example B 3 28 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3
31. No Description FT 50 Inspection Trigger Location Extent of Tracking Area gray Rejector Centerline a A O N Rejector Figure 1 3 Tracking a reject container The FT 50 uses the conveyor speed the distance between the inspection trigger and the rejector and the time it takes a container to travel that distance at that speed to maintain container tracking and rejector timing If your unit is equipped with a high resolution encoder coupled directly to the conveyor drive sprocket the encoder sends timing pulses to the FT 50 and the FT 50 uses the pulses to determine the containers position as it moves along the conveyor When the container reaches the rejector centerline the FT 50 emits a reject signal which activates the rejector and removes the container from the production line Units equipped with the soft encoder operate similarly however the timing pulses are simulated by the software 1 6 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview System Specifications Specifications herein are listed for the FT 50 For specifications on the rejector refer to the rejector manual that was included with your FT 50 Power Requirements e 105 to 125 VAC 50 or 60 Hz 2 0 Amps 1 Phase or e 220 to 250 VAC 50 or 60 Hz 1 0 Amp 1 Phase Input power must be computer grade and derived from a separate branch circuit isolated from any equipment that can cause electrical transients The neut
32. Regi Nbre ten tewa eee eees 5 40 Encoder Prescaler Value i204 hsc 2 cena cajon tira rob 5 40 Gamma Sample Cutoff Limit its ester esa 5 40 Gamma Samples Per Encoders iia a pu e iu ia 5 40 Diagnostics Function Group 5i LI naaa bate a aa 5 41 How to Access Diagnostic Error Codes oooocoocoocococooooo 5 41 Diagnostic Error Codes Listing llle 5 42 Chapter Six Calibration Procedures oooooooooooooo 6 1 FT 50 Calibration Procedures 0 0 e eee eee eee 6 3 Encoder Calibration Procedures 0 cece eee eee 6 4 Industrial Dynamics Company Ltd Document 40255 0600 vil FT 50 Fill Level Inspector Service Manual Variable Speed Conveyors 0 0 eee eee eee eens 6 5 LED Definitions Quick Reference 0 0 cece eee 6 5 CONVERSION Factors nd o Ud es a LA O aN 6 6 How to Determine if You Have Baseline Eight 6 6 Belore You Besi DR ea AAA bs 6 7 Standard Conveyor Calibration Procedure 0000005 6 8 Unknown Sprocket Size Calibration Procedure 6 13 Executing the Encoder Calibration Routine 6 14 Fine Tuning the Rejector Timing 0 0 00 0 oo 6 15 Non Standard Conveyor Calibration Procedure 6 18 Executing the Encoder Calibration Routine 6 20 Fine Tuning the Rejector Timing 0 0 00 020s eee 6 21 Fixed Speed Conveyors 2 i 22i kl e anida da
33. Signal Pulse Width 1 Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select CALIBRATE 2 Press Key 5 until PLC Output Pulse Width appears 3 Press the Arrow Key until the desired value is reached Industrial Dynamics Company Ltd Document 40255 0600 9 5 FT 50 Fill Level Inspector Service Manual Relay Types for Output Signals The FT 50 does not supply power to the PLC unit The FT 50 signal output is a solid state relay that closes upon each event occurrence Description Relay Type Sensor Gamma Failure Alarm Reed Latched Consecutive Alarms Reed Rejector Fill Level Status Off Reed Total Rejects Solid State Total Throughput Solid State Fill Level Rejects Solid State Bulged End Rejects Solid State Missing Lid Rejects Solid State A resistor of the appropriate value may be needed across the load attached to the relay The resistor absorbs the 2 ma leakage and meets the Minimum Current Load requirement Refer to the following illustrations for the resistor required for your specific voltage 9 6 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 9 Using a PLC With Your FT 50 E No Description X VDC 2 1 Field T 2 Diode must be used on inductive l
34. To switch operating modes 1 Press Key 5 until SYSTEM DISPLAY appears 2 Press the Arrow Key to select either the Operate or Calibrate mode If the Password Protect function is enabled you are required to enter the password before you can access the Calibrate mode Conveyor Drive Sprocket The number of teeth on the sprocket that is physically contacting the conveyor chain This is the primary value that is used to determine the encoder calibration Serial Data ID Number The FT 50 s serial port identification number This function applies only to units equipped with either the IDC or Modbus serial communications options For further information refer to the Serial Communication Manual Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Host Modbus Port Status Displays the character information in a Modbus serial communi cation string The counters have a range of 0 255 and then reset e LC is the last character that was received by the FT 50 e RX isa count of the characters received by the FT 50 e TX is a count of the characters transmitted by the FT 50 Pressing the Arrow Key sends the test message IDC HOST MODBUS TEST MESSAGE and the TX counter will increment by 30 For further information refer to the Serial Communication Manual Modbus Message Counters Displays the number of Modbus messages the FT 50 receives and defines them as good bad or other e Good is the number of go
35. Type 24 sd Mor er E heen donee HIS 5 23 Last Reject Detected uoo e eee MM a nr De NO 5 23 Beacon Status 2255 Sq ux ote exa Ee x fous esti ex aere EDO 5 23 Lane speed cpm gie bes eoa dU ERU doe eu A R UR A 5 23 Eine Speed eph 444i 24 e ERI da ACE Nave m hub ence 5 24 System Display 4 15 x x Moe OR REX ENORMES Qe URP de Y NUM 5 24 Conveyor Drive Sprocket avis Rex ER RE a DA REI CE 5 24 senal Data ID Number carece BS wae kde tore esq 5 24 Host Modbus Port Status 042 eos ie esa ed ak v Rt RR S a 5 25 Modbus Message Counters 0 0 eee eee ee eee 5 25 PLC Output Pulse Wibal add ds 5 25 Time Width OF Can 15 5 30 iaa Sa base eA pas CHAT ERAS 5 26 Chain Velocity uta ie tone eae A eee 5 26 Alarm IJnderfils id Pale I IER AA Fe ees ROS Pe RA 5 26 Aldrm Overhlls dada amie kaw boo ead PESE E Ea 5 26 Alarm Mis sing A E ad Aa BE 5 27 Alarm Bulged End via Mee vig a eee ese tes 5 27 Alarm Down dir pediria oda pen there eee od peed ie 5 27 Alarm Dia Missing Lid 0 2 cece eee ee eens 5 27 Alarm External Reject 2 sss Stn ane Sea Sead aie Be See obese E 5 27 Load Default Constants y a a IUE eases Ine EA 5 27 Industrial Dynamics Company Ltd Document 40255 0600 Table of Contents Can Width At Trig ceci a Pela P ERES HE 5 28 Maximum Can Diameter 22423 ere tee hho uox rr 5 28 Maximum Line Speed butt dae sd Sg als ees 5 28 Maximum Conveyor Speed espinita 5 28 Change Pass wOrd 24e ose doe es ees M ER IH E ERR 5 2
36. be tested at installation and every three years thereafter for leakage of radioactive material Maintenance tests or other service involving the radioactive material its shielding and containment shall be performed by persons holding a specific radioactive material license to provide these services Installation relocation maintenance repair and initial radiation survey of this device and leak testing installation replacement and disposal of sealed sources containing radioactive material used in this device shall be performed only by persons holding a specific radioactive material license to provide these services REMOVAL OF THIS LABEL IS PROHIBITED Serial No Model No X D Industrial Dynamics Co Ltd 2927 Lomita Boulevard Torrance California 90509 310 325 5633 Figure 1 Warning labels attached to Filtec Model FT 50 Inspection System The information on these labels is very important and should be followed explicitly XVI Industrial Dynamics Company Ltd Document 40255 0600 Radiological Safety Filtec Model FT 50 Radiation Exposure Profiles No Description No Description 1 Inspection Head 5 Radiation Detector 2 Inspection Tunnel 6 Limits of Main Beam 3 5 cm Isodistance Contour 7 Detector Window 4 Sealed Americium 241 8 Shielding Bar 1 4 Thick Steel Figure 2 FT 50 Radiation Profile Schematic Gamma Guage 100 or 300 mCi Source Industrial Dynamics Company
37. detect a can that has tipped over down Dud Detection Dud Detection detects improper pressurization of vacuum or pressure sealed containers Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview External Reject Control Allows the FT 50 to accept reject signals from other inspection units track the container and time the rejection signal For example a label inspector can send a reject signal to the FT 50 and the FT 50 can track and reject that container for the label inspection unit Serial Interface Provides serial network communications over RS 232 RS 422 RS 423 and RS 485 networks at 1200 or 9600 baud It allows direct control of the FT 70 from a host computer or PLC Included with this option is the proprietary IDC communications protocol and the standard Modbus communications protocol Programmable Logic Controller Interface PLC Provides direct access to the signal wiring so that you can transmit control signals to the FT 70 and receive signals from the FT 70 This option requires the I O Junction Box Industrial Dynamics Company Ltd Document 40255 0600 1 13 FT 50 Fill Level Inspector Service Manual 1 14 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 2 Installation Requirements Chapter Two Installation Requirements Installation Requirements Overview ooooooooooooorrrrrrr 2 3 POWER Supply receret ieee A da 2 3 Pneumatics e Doe ene Pathe E o A
38. different Refer to the System Configuration Sheet located inside the cover of your FT 50 for you specific factory configuration Switch Function Open 1 Closed 0 Switch Pack S1 S1 1 Inspection Logic Overfill Underfill 1 2 Software Protect On Off 1 3 Speed Tracking Variable Fixed S1 4 Languages Second English S1 5 System Configuration On Off S1 6 Not Used NA NA S1 7 Not Used NA NA 1 8 Password Required Not Required Switch Pack S2 S2 1 Baud Rate 1200 9600 S2 2 Handshake Flags On Off S2 3 Parity On Off On Off S2 4 Parity Odd Even Even Odd S2 5 Character Size 7 Bit 8 Bit S2 6 Multi Serial RS 485 RS 232 422 S2 7 Led Section Selector Section 2 Section 1 S2 8 Led Bank Selector Bank 2 Bank 1 Slide Switches Position A Position C S3 RS 232 RS422 RS 232 RS 422 485 S11 Save Setup Enable Disable S13 Auto Reset Disabled Enabled Industrial Dynamics Company Ltd Document 40255 0600 Chapter 10 Controller Board Dip Switches and LEDs Switch Function Definitions Dip Switch Pack S1 S1 1 Inspection Logic Switches the fill level inspection logic between underfill and overfill All fill level text is changed to reflect the current logic The default is underfill S1 2 Software Write Protect Enables or disables the write protect function When disabled the Save Default Constants function is removed from the function menu The default is enable S1 3 Speed Tracking Switches between variable and fixed speed tracking Var
39. ere ed a AS 5 17 Industrial Dynamics Company Ltd Document 40255 0600 V FT 50 Fill Level Inspector Service Manual VI Total Undetfills 2 s y p Ce b s RR RD es 5 17 Total Overhlls a2 Su hend oss ER PA AteRPR A qentRPUESM AS 5 17 Total Missing 1 105 ooo Lond eset a re Lotes 5 17 Total Bulged Bnd 3 dadas ERR EG Pee eee URS EG 5 18 Total Down Gan iD A RDA ui od de Gees 5 18 Total Dia Missing Lid 2222s ioca 5 18 Total External ReIBCU sia Y ex EX EUER 5 18 Reset All Counters 2 1 2 keloia y el e a pa 5 18 Reset Total Throughput Vries REST seed nee oe eee 5 18 Reset Total Rejects aac set eo eL su Ie oM Le Rer 5 19 Reset Lota Under Le csc Gece Seite ERI EE RE E ERE dc E 5 19 Reset Total QverlilL cing dra 5 19 Reset Total Missing Lid 0 0 0 2 cece eee ee eee 5 19 Reset Total Bulecd End asis pad e eR RENS Mex ex MES 5 20 Reset Total Down Can o acy oy PUR ace A UN LAGER 5 20 Reset Total Diameter Missing Lid 000000008 5 20 Reset Total External Rejectsu a Udo 5 20 Rejector Functions Group iiis oa bee E EON 5 21 R j ctor Status you a4 bed eder er yew As 5 21 Fire Rejector On Demand 5 5 4 i356 24 Sec AA ORE ERS 5 21 Rejector Pulse Width 2D eee acai eee ayes ee eee ows 5 21 Reject Next Container oinei DN qs x tse a EDUARD aes IAE Be 5 21 Inspeet Tig To CAR og sede y A ee 5 22 Rejector Reaction Delay vise ssec x ewe Seca ls 5 22 System Functions Group suas zv IS E EAE A ERR E 5 23 Current Container
40. iua RE RR san UU AUG HERE EAE 1 12 Down Can Detection csi IRE RR ADR age tas 1 12 Dud Detection 23 46d ger RE duce REOR en ees ptis ees 1 12 External Reject Controls 4 eee eee ER Rede A 1 13 Serial Interface e ess cR IM EDT oat eee phe S XEM 1 13 Programmable Logic Controller Interface PLC 1 13 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual Chapter Two Installation Requirements 2 1 Installation Requirements Overview 0 ce eee eee ee eee 2 3 Power SUPPLY ys as di I pega Hee aer eee seeds 2 3 PHCUMALCS tii rta ne hea ee Reha wwe ihe aes 2 3 Physical Space coss ve loca s eee eM Qe Calas ae One MER M ea 2 4 Conveyor System 24 es au va EN hee RATA ERN ON E eR A RN et 2 4 Production Conveyor pati ers Abe yes one in 2 4 Reject Takeaway Conveyor ia ee sed s e dette ss 2 5 Chapter Three Installing the FT 50 ooooooomcmmmmmmmo 3 1 Before You Besin toreo c MD eo dos ig e O AU ian 3 3 Basic Termology ic scat seve ts it 3 3 Unpacking the RITO casi sine eo Gye tea A ee ala ine S es 3 4 Installing the FT 50 Inspection System 0 0 0 0 cece ee eee 3 5 Determining the Proper Location for the FT 50 3 6 Preparing the Conveyor ice viu b Gp eRERRM GRE Sead 3 7 Mounting the RT 3O usu se de tee ERR RYE IRE Reps 3 8 Assemble the Floor Stang ons sS oa 3 8 Mount and Position the Inspection Head
41. lights when there is a Fault Alarm or other error in the system Reject Pulse Flashes one time for each container rejected Low Resolution Encoder Pulse Flashes once for each pulse Not used in this configuration Not used in this configuration External Reject Flashes one time for each input received from an external source requesting the next container to be rejected Not used in this configuration Inspect Trigger Indicator lights when the Inspection Trigger sensor is activated or when sensor is blocked AC Power Low Indicator lights when the input AC power to the FT 50 is too low to operate satisfactorily below 70 VAC 5 VDC Power Low Indicator lights when the 5 VDC power supply is too low to operate satisfactorily below 4 85 VDC Indicator is also on when the RESET button is pressed Detector Used to get a coarse calibration setting for the Scintillation Detector Section 2 Bank 2 S2 7 Open S2 8 Open LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 LED 8 LED 9 LED 10 LED 11 Inlabeler Sensor Input 1 Inlabeler Sensor Input 2 Inlabeler Sensor Input 3 Inlabeler Sensor Input 4 Inlabeler Sensor Input 5 Container Present System Timing Inspect Trigger Indicator lights when the Inspection Trigger sensor is activated or when sensor is blocked AC Power Low Indicator lights when the input AC power to the FT 50 is too low to operate satisfactorily below 70 VAC 5 VDC Power Low Indicator ligh
42. of container you must repeat this procedure for each different container type i e containers with different diameters or line speeds Industrial Dynamics Company Ltd Document 40255 0600 6 17 FT 50 Fill Level Inspector Service Manual Non Standard Conveyor Calibration Procedure Note 6 18 Use this procedure for conveyors that do not have a 1 5 inch chain pitch You must determine the conveyor s chain pitch and number of teeth per chain segment link to use this procedure If you can not determine the chain pitch and number of teeth per chain segment link call IDC Customer Support for assistance at e 888 434 5832 North America only e 310 325 5633 This procedure estimates the number of encoder pulses per 10 meters of conveyor travel therefore you must test the accuracy and make adjustments until the proper calibration is achieved 1 Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode You may be required to enter a password if your system is password protected 2 Press Key 4 until REJECTOR STATUS appears and check to be sure the rejector is activated If it is turned off press the Arrow Key to turn it on 3 Open dip switch S1 5 4 Press Key 5 until REJECTOR TYPE appears and use the Arrow Key to select the type of rejector installed in your system 5 Press Key 5 until KNOWN CHAIN PITCH amp TEETH appears and set to NOT PRESENT 6 Press Key 5 until ENCODER R
43. pen 2 3 Physical Space a aa 2 4 C nveyor Syst m sispan r v oet e WC DE ame tes Ane Ro E pede 2 4 Production Conveyor a0 cedes ont exe Pha rov RATER E Sees DR 2 4 Reject Takeaway Conveyor e204 cree cee cen hea Ce XA 2 5 Industrial Dynamics Company Ltd Document 40255 0600 2 1 FT 50 Fill Level Inspector Service Manual 2 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 2 Installation Requirements Installation Requirements Overview Power Supply Pneumatics Proper power supply and wiring are critical to the performance of the FT 50 An unconditioned power source or improper wiring can create noise transients that adversely effect the CPU Noise transients can create false rejects or cause premature failure of electrical components e The power must be computer grade e The FT 50 requires 115 VAC 410 at 50 60 Hz single phase power at 2 amps or 230 VAC 10 at 1 amp There is a voltage select switch inside the FT 50 which must be set to the correct input voltage e The power should originate from a clean branch circuit that is not used for electric motors or other equipment which can cause electrical transients The neutral line must be properly grounded e If power regulation cannot be maintained between 105 and 125 VAC or 220 to 250 VAC a voltage regulator must be installed Industrial Dynamics recommends the SOLA Micro Minicom puter Regulated Power Supply The FT 50 requires 7 psi to maintain
44. sealed inside a special type 304 stainless steel capsule that is double fusion welded This capsule is mounted in a stainless steel enclosure inside the FT 50 Inspection Head A Radiation Safety Shutter when opened permits a narrow beam of radiation to pass through the plastic radiation window in the enclosure When the safety shutter is closed all radiation is contained within the source enclosure There are two possible ways to be exposed to hazardous levels of radioactive material using this equipment externally through excessive exposure to a radiation source outside the body and internally by ingesting radiactive material The FT 50 is unlikely to create hazardous radiation levels for the following reasons e The FT 50 s radiation source produces a relatively weak source of low energy low penetrating power gamma radiation To receive a hazardous dose of radiation from this low energy source would require extremely long exposure directly to the main radiation beam While we warn against placing hands or other body parts in front of the gamma beam when it is turned on it would require several hours of exposure for the hand to receive an excessive radiation dose e The gamma beam is tightly confined by shields and collimators and is completely contained within the inspection tunnel Because the radiation beam does not spread outside the inspection tunnel it is highly unlikely that under normal circumstances an appreciable
45. that is before the reference point in the direction opposite of the flow is upstream Reference Point is the place on the conveyor being referenced This is usually either the FT 50 or the rejector Container is the bottle can jug jar or package that holds the product The size and shape of the container depends upon your application and can be made of either glass metal or plastic Inspection System includes both the FT 50 and the rejector Inspection Head is the FT 50 unit only Rejector is the rejector mechanism only Servotec or Proline Conveyor is the main production conveyor the FT 50 is to be installed on Takeaway Conveyor is also called the reject conveyor This is the conveyor or bin that rejected containers are moved to by the rejector Industrial Dynamics Company Ltd Document 40255 0600 3 3 FT 50 Fill Level Inspector Service Manual Unpacking the FT 50 Note 3 The FT 50 and all accessories such as mounting hardware the encoder spare parts and special lubricants are packed in individual boxes inside the main shipping box The radioisotope is shipped separately from the FT 50 and comes with special handling instructions 1 Inspect the outside of the packaging for damage If there is any damage make a note and contact the shipper immediately Damage to the outside does not necessarily indicate internal damage however it increases the likelihood because it indicates the container was handled poorl
46. the Arrow Key to scroll through the list When you reach the end of the list the COMPLETED message appears Clear System Clears the system by resetting all function parameters to factory defaults All current settings will be erased therefore use the Save Defaults function or record all parameters before executing this function if you want to save them Current Language Selects the native language mode of the FT 50 Available choices include English Portuguese Spanish German French and Italian English is always included regardless of what language option package is installed on your system Container Text Allows you to create a name for each container type This name is then displayed in the list of Current Container Types To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software of Container Types The maximum number of different container types that will be inspected by this FT 50 The maximum number allowed is deter mined by available system memory The value entered for this function determines the number of Current Container Types available Current Container Type A set of stored system parameters for a particular container type This function allows you to c
47. the air purging of the inspection head Air purging the unit keeps the electronics free of contaminants and corrosion The air purge system consists of an air filter pressure regulator unit mounted externally and an internal muffler disperser Input Air Supply 80 to 120 psi and not less than 1 5 cfm Pressure Regulator Output 0 5 cfm preset at factory For information on the air requirements for you rejector refer to your rejector manual Industrial Dynamics Company Ltd Document 40255 0600 2 3 FT 50 Fill Level Inspector Service Manual Physical Space Conveyor System 2 4 When determining the physical spacing requirements you must also consider the spacing requirements for the rejector Refer to drawings I 00401 and I 00415 in the Installation and Service Drawing Pack for an overview of the space requirements In some cases the addition of inspection options that require an upstream or downstream trigger can change spacing requirements In these instances you should also review the requirements for each option The following conveyor requirements are designed to achieve maximum inspection performance The rejector s conveyor requirements especially the Servotec s are more critical than the FT 50 s requirements When determining the conveyor requirements it is imperative that you include the rejector s conveyor requirements For the rejector s conveyor requirements refer to the rejector manual included
48. to get the Average Good Container Samples Interval GS a b c d e GS gt Repeat the previous three steps using a production container that is missing a lid Averaging the unsealed containers will give you the Average Bad Container Samples Interval BS Industrial Dynamics Company Ltd Document 40255 0600 4 23 FT 50 Fill Level Inspector Service Manual 4 24 12 Use the following equation to determine the Minimum 13 14 15 Diameter Missing Lid value MD GS B5 BS s MD 2 Press Key 2 until MINIMUM DIA MISSING LID appears and then use the Arrow Key to enter the MD value you calculated Test the configuration by running several containers with and without lids through the FT 50 If the containers are not identified and rejected properly e Ifsealed containers are identified as rejects decrease the Minimum Diameter Missing Lid value slightly and repeat step 14 until false rejects no longer occur e If unsealed containers are identified as good increase the Minimum Diameter Missing Lid value slightly and repeat step 14 until rejects are no longer accepted If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Configure the Down Can Function 10 11 If your FT 50 is not in the Calibrate Mode Pr
49. two functions reject the same container only one total reject count is recorded The Reject Next Can function is included in Total Rejects Total Underfills The total number of underfilled containers that failed the fill level inspection The counter automatically resets at 99 999 999 Total Overfills Displays the total number of overfilled containers that failed the fill level inspection The counter automatically resets at 99 999 999 Total Missing Lid The total number of containers that were detected with missing lids The counter automatically resets at 99 999 999 Industrial Dynamics Company Ltd Document 40255 0600 5 17 FT 50 Fill Level Inspector Service Manual 5 18 Total Bulged End The total number of containers that were detected with bulged ends The counter automatically resets at 99 999 999 Total Down Can The total number of down containers that were detected The counter automatically resets at 99 999 999 Total Dia Missing Lid The total number of containers that were detected with missing lids This counter is separate from and not included in the Total Missing Lid counter The counter automatically resets at 99 999 999 Total External Reject The total number of external reject signals received The counter automatically resets at 99 999 999 Reset All Counters Clears and resets all counters to zero Record all valuable data before executing this function To reset the Reset All Coun
50. with your FI 50 Production Conveyor Aminimum chain velocity of zero chain may stop without losing synchronization to a maximum chain velocity of 350 feet per minute 107 meters per minute The conveyor must be capable of soft start up This means the conveyor can gradually accelerate from a full stop to production speed This prevents containers from sliding and upsetting on the chain e The conveyor chain must run smoothly during its passage through the inspection and rejection area Conveyor motion that produces excessive foam or contents motion or creates slipping on the conveyor can decrease the accuracy of the fill level inspection or interfere with rejection e IDC recommends that all conveyor chain wear strips in the inspection and rejection areas be attached only on the upstream end This insures that when the wear strips thermally expand they will not cause the chain to bow upward and effect the inspection and rejection areas e The conveyor side channel must be at least 5 inches 12 6 cm tall in order to mount the rejector Industrial Dynamics Company Ltd Document 40255 0600 Chapter 2 Installation Requirements e Use either plastic or stainless steel chain however do not use flex chain within the inspection and rejection area e IDC recommends that you select and install a backup sensor downstream from the rejector This sensor detects container backup and will shut down the line before the backup accumu
51. 0 3 Remove the cover from the power filter and route the power cable into the filter through the rubber grommet in the side Description Rubber Grommet Power Wires Filter Cover Figure 3 22 Route the Power Cable into the Power Filter 3 24 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 4 Wire the main power cable to the FT 50 power filter wiring Connect the Power Cable To the FT 50 Hot Brown Neutral Blue Ground Ground Stud Wiring the Main Power Supply Cable to the I O Junction Box Refer to wiring diagram in Chapter 11 when performing this procedure Warning Disconnect all electrical power sources from the equipment before attempting any installation procedure Failure to do so can result in personal injury and equipment damage 1 Remove one of the plugs in the bottom of the junction box and install a liquid tight fitting 2 Route the main power cable from the main power supply through the cable opening and into the Junction Box No Description 1 Cable Opening Plug Figure 3 23 Route the Power Cable into the Junction Box Industrial Dynamics Company Ltd Document 40255 0600 3 25 FT 50 Fill Level Inspector Service Manual 3 Connect the wires from the main power cable to terminal block TB5 within the junction box as follows Wire Terminal and Pin Hot Attach to TB5 pin 7 Neutral Attach to TB5 pin 8 Ground Atta
52. 0 providing even higher system security filtec MODEL FT 50 FILL LEVEL INSPECTOR Gees Haw mS E UNE Torrance California USA Figure 5 1 The FT 50 Control Panel Using the Control Panel The Function Group Keys The Function Group Keys are numbered one through six Pressing a function key displays the first function in that group Repeatedly pressing the same function key scrolls through the list of functions The Arrow Keys To change a parameter value enable disable a function or clear an error select the proper function and then press the Up or Down Arrow Key until the desired value is displayed You can press either Arrow Key unless directed otherwise After you make a change press another function key or wait 5 seconds and the value is entered into memory Industrial Dynamics Company Ltd Document 40255 0600 5 5 FT 50 Fill Level Inspector Service Manual Selecting the FT 50 s Operating Mode Note There are two modes of operation for the FT 50 e The Operate Mode limits the operator s access to those functions where no parameter value changes can be made The Operate Mode is the normal operating mode for the FT 50 The Calibrate Mode gives the operator access to all system functions and the ability to make parameter value changes and perform calibration procedures The FT 50 is equipped with a password feature which prevent
53. 0 5000 Pulse 500 Pulse t Save Default Constants Execute co Conveyor Segment Pitch 50 700 1 10th mm 381 mm Teeth Conveyor Segment 1 3 Teeth 2 Teeth co Calibrate Encoder Execute Calibrate Encoder Value Pulses 10m Pulses 10m Encoder Prescaler Value 2 50 Pulses 5 Pulses co Gamma Sample Cutoff Limit 1 50 Samples 4 Samples co Gamma Samples Per Encoder 1 50 Samples Diagnostics Key 6 System Diagnostic Error 0 69 6 Industrial Dynamics Company Ltd Document 40255 0600 5 11 FT 50 Fill Level Inspector Service Manual Function Descriptions The following section contains function descriptions for each function group Depending upon your FT 50 machine type machine configuration and options package some of these options may not apply to your FT 50 Certain functions are available only while in the Calibrate Mode or when dip switch S1 5 is open To determine the availability of a function refer to the Software Functions List Fill Level Functions Group Underfill Status This function activates or deactivates the underfill inspection capability of the FT 50 Deactivating this function inhibits detection and rejection of containers with fill levels below the underfill Gamma Threshold Underfill and Overfill can not be active simultaneously To activate Underfill you must close dip switch S1 1 Overfill Status This function activates or deactivates the overfill inspection capability of the FT 50 Deactivating thi
54. 00 Chapter 5 System Software Container Finish Functions Group Bulged End Status Activates or deactivates Bulged End detection Bulged End detection is based on the difference between the height of the container with a properly sealed lid and the height of the container with an improperly sealed or bulged lid Missing Lid Status Activates or deactivates Missing Lid detection Missing Lid detection utilizes proximity or optical sensors to detect the presence or absence of the lid Down Can Status Activates or deactivates Down Can Detection Down Can detection uses a optical sensor to detect cans that have fallen over from their upright position Diameter Missing Lid Status Activates or deactivates Diameter Missing Lid detection Diameter Missing Lid detection is based on the difference between the diameter of the container without a lid and the diameter of the container with a lid External Reject Status Activates or deactivates the External Reject function When activated the FT 50 will accept the reject signal from an outside inspection source and activate the rejector Width at Down Can The container diameter at the point where it intersects the Down Can Sensor Beam This option applies only to Down Can detection Height of Can The height of the container This option applies only to Down Can detection Industrial Dynamics Company Ltd Document 40255 0600 5 15 FT 50 Fill Level Inspector Service Manual Di
55. 5 Use the following equation to determine the Overfill Gamma Threshold GC BC _ T 2 where GC Average Good Counts step 9 BC Average Bad Counts step 3 T Overfill Gamma Threshold Press Key 1 until you reach GAMMA THRESHOLD and use the Arrow Key to enter the Overfill Gamma Threshold Value T you calculated in step 4 If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Setting the Underfill Gamma Threshold 1 Place a sample production container that is empty on the conveyor far enough upstream of the FT 50 so that it does not slip on the chain and is positioned correctly as it passes through the inspection tunnel 2 Record the Gamma Counts value that appears in the Gamma Threshold display 3 Repeat the previous two steps four more times and then average the value to get the average bad count BC a b c d e E BC 5 4 Use the following equation to determine the Underfill Gamma Threshold GC BC _ T 2 where GC Average Good Counts step 9 BC Average Bad Counts step 3 T Overfill Gamma Threshold 5 Press Key 1 until you reach GAMMA THRESHOLD and use the Arrow Key to enter the Underfill Gamma Threshold Value T you calculated in step 4 6 If you are finished configuring the FT
56. 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the Calibrate Mode 2 Open dip switch S1 5 3 Press Key 5 until EXTERNAL REJECT appears and use the Arrow Key to select PRESENT 4 Close dip switch S1 5 5 Press Key 2 until EXTERNAL REJECT STATUS appears and then press the Arrow Key to activate the function 6 Ifyou are finished configuring the FI 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Chapter Five System Software TNE Ont Panel te wis ester esse SA 5 5 Using the Control Panel 0 0 0 0 eee eee eee 5 5 The Function Group Keys eet ad tote td DE 5 5 De Arrow KEYS tos cec oles fe oe fl ae hs Sar O ed oY 5 5 Selecting the FT 50 s Operating Mode 0000 5 6 Selecting an Operating Mode 0 000000 5 6 Software Functions List 0 2 00 ee eee eee eee 5 7 Function Descriptions sd pasted a 5 12 Fill Level Functions Group 0 0 cece eee ee eee 5 12 Under TESTS A 5 12 O verni Status bik zc rush re DA LLL Is 5 12 Gamma Counts 222234540 eae eens Cedar twa ke ns 5 12 Target Head Height cto a 50 dia 5 13 Gamma Threshold 3 2 2 4452442 p REP sees 5 13 Looktime Grate seh st TRE eee ee ete ese yee ed 5 13 Fill Level Optimization 2b ed A e 5 13 Learn Target Head Height coverage
57. 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode Industrial Dynamics Company Ltd Document 40255 0600 4 21 FT 50 Fill Level Inspector Service Manual Configure the Missing Lid Function If your FT 50 is not in the Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the Calibrate Mode Open dip switch S1 5 Press Key 5 until MISSING LID appears and use the Arrow Key to select the type of missing lid sensor installed Close dip switch S1 5 Press Key 2 until MISSING LID STATUS appears and then press the Arrow Key to activate the function If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode Calibrate the Missing Lid Sensor according to the instructions in Chapter 6 Calibrating the Missing Lid Sensor Configure the Bulged End Function 4 22 If your FT 50 is not in the Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the Calibrate Mode Open dip switch S1 5 Press Key 5 until BULGED END appears and use the Arrow Key to select PRESENT Close dip switch S1 5 Press Key 2 until BULGED END STATUS appears and then press the Arrow Key to activate the function If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to re
58. 8 Diagnostic and Repair Procedures There is no display except for blinking cursor and the beacon is solid 1 Check to be sure the reset switch is not stuck 2 Check to be sure all PROMs on the processor card are seated properly 3 Replace the processor card There is no Display and the beacon is off 1 If you are using a remote control panel check that it is plugged into the connector on the inspection head correctly 2 Reset the FT 50 by pressing the Reset Button for three seconds while turning the machine off and on e If the beacon does not flash replace the beacon bulb and test again e If the beacon is solid there is a problem with the processor card e Ifthe beacon flashes once and stops there is a problem with the terminal card The display is garbled or operates erratically 1 Replace the processor card 2 Replace the terminal card Industrial Dynamics Company Ltd Document 40255 0600 8 19 FT 50 Fill Level Inspector Service Manual Sensor System Troubleshooting 8 20 Scintillation Tube Detector STD Unable to calibrate the Scintillation Tube Detector If the calibration LED does not double peak during the calibration procedure the detector is faulty and must be replaced See Chapter 6 FT 50 Calibration Procedures for more information Gamma counts decrease significantly within a short period of time If the gamma counts suddenly decrease significantly and continues to decrease the STD is w
59. 8 View TBI amp TB4 Pin Assignments 0 0 0 0 0000 5 29 View PLC Pin Assignments leida toes eee aks 5 30 Clear System coria a ais 5 30 Current language 24 oes somete pen AME ER SEE E 5 30 Container Texts eas rd oec M eror cd A au E Doe tier 5 30 Ol Container Types ccs esa E eR dup Rs ye x me eee 5 31 Current Container Type wiii id dd 5 31 Fill Levels ii ek vichd neg db ta RUE AAA 5 31 Under Tetas oes eR pees ld ona te 5 31 Overhl Text ro cae be pin ae oe Hoy ey edn Rees 5 32 Missing Tid ANS OI E EE 5 33 Missine Lid Testo xot ie sued uS aede rte LI Leere 5 33 Bulged End i299 tetori sas I a ip REED EN 5 34 Bulsed End lex ads 5 34 Down Cal l4 ta dee Red Se bse an RES Ee SER ASS 5 35 Down Can Texts ye eee teehee hee Se eet ds 5 35 Diameter Missing Lid 4 used nov SA be ee PES 5 36 Diameter Missing Lid Texts tie bod eee S 5 36 External Rejeet aid oposite ES 5 37 External Reject Text pm al ad 5 37 R j ctor Type A ok ei Ra bea deni LS 5 38 PDC Sete Se AEA e g a es pn e ad LE 5 38 senal Interface pre A eee eee ER 5 38 External Trigger Losa res SA doe e AA QURE 5 38 Known Chain Pitch amp Teeth 0 0 ee eee eee 5 39 Encoder Resol tiop secesie oe plead ue pews Pe eae Mes aoe ae 5 39 Save Default Constants 22 22 ne eda ped eae ed ene eae 5 39 Conveyor Segment Pelo it peek owe aes eu RE eee RS 5 39 Testi Conveyor Segment e od o dl Le ees 5 39 Calibrate Encoder silla de iii a ta 5 39 Calibrate Encoder Value s cn iiu
60. A 6 24 Before YOu Besoin suut ux yeaa seu as 6 24 The Line Speed Calibration Procedure 0045 6 26 Fine Tuning the Rejector Timing 0 0 0 0 2 eee 6 27 Sensors Calibration Procedures ua ds 6 29 Proximity Sensors 2 1i n i bees rra bed Hada ee 6 29 Fiber Optic Sensors ev va oss x an eevee y bee eee UOS 6 29 Before You Begin iua nes rs eds 6 29 Calibrating the Centerline Inspection Trigger 6 30 Calibrating the Upstream Inspection Trigger 0 6 31 Calibrating the Bulged End Sensor 0 0 0 0 eee eee eee ee 6 32 Calibrating the Down Can Sensor 0 0 0 6 33 Radiation Detector Calibration Procedure 0 0 0 0 e ee eee 6 34 Solid State DOCTORES ERE ERES ROS 6 34 Scintillation Tube Detector cc eo 6 34 Calibrating the Scintillation Tube Detector ooo oo ooooooo 6 35 Scintillation Detector Calibration Procedure 6 35 Fill Level Optimization lt 4 1 05 cce0 Reik e lake tata dace 6 37 Before YOU BES ias ex DOR REOS QU Sk NR PRI Sos 6 37 Leveling the Inspection Head 0 0 0 0 cece eee eee 6 38 Executing the Fill Level Optimization Routine 6 39 Establishing the Underfill Gamma Threshold 6 39 Establishing the Target Head Height 0 6 41 The Dynamic Reject Point Test seins teed vee ends 6 42 The Dynamic Product Good Test
61. Arrow Key to select the type of rejector installed in your system Press Key 5 until KNOWN CHAIN PITCH amp TEETH appears and set to PRESENT Press Key 5 until ENCODER RESOLUTION appears and enter the encoder resolution The standard encoder is 500 pulse The following table lists the encoders and the supported resolution The encoder resolution is set at the factory during assembly however if you upgraded the software you should check the encoder type and set it properly Part Number Description Resolution 24997 Standard 500 18916 Dual Track 1000 32637 Ultra High Resolution 5000 Close Dip Switch S1 5 Measure the diameter of the production container in milli meters at the point where the container intersects the trigger beam This is the containers can width at the trigger point Industrial Dynamics Company Ltd Document 40255 0600 6 13 FT 50 Fill Level Inspector Service Manual Note 6 14 9 Press Key 5 until CAN WIDTH AT TRIG appears and enter in millimeters the production container s width at the trigger point 10 Measure the diameter of the container in millimeters at its widest point This is the containers maximum diameter 11 Press Key 5 until MAXIMUM CAN DIAMETER appears and enter in millimeters the production container s maximum diameter Executing the Encoder Calibration Routine Use the largest possible opaque container when executing the Calibrate Encoder Routine The larger and more op
62. Can Status e Total Down Can e Reset Down Can e Width at Down Can e Alarm Down Can e Down Can Text e Down Can This manual assumes the default name for this option If you change the default text remember to substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 5 35 FT 50 Fill Level Inspector Service Manual Note 5 36 Diameter Missing Lid Prepares the FI 50 software for Diameter Missing Lid inspection by inserting the necessary options into the software When set to Not Present it removes the options necessary for Diameter Missing Lid inspection from the software This function does not activate or deactivate diameter missing lid inspection it only readies the machine To turn diameter missing lid inspection on or off you must use the Diameter Missing Lid Status function Diameter Missing Lid Text Allows you to create a custom name for the Diameter Missing Lid Option Any instance in which Diameter Missing Lid would have appeared in the software is replaced by the custom label you created The following options are effected Dia Missing Lid Status Total Dia Missing Lid e Reset Dia
63. DG ETH OO CMIS05 VERSION MGI STAT 0480 3 Ifthe version code is MGI thru MZZ TYW thru TZZ or SAA thru SZZ Baseline Eight is installed If any other version code appears contact IDC Customer Service for instructions 6 6 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Before You Begin 1 Remove the FT 50 s cover to access dip switch pack S1 When performing the calibration procedures you are required to change the settings for S1 5 and S1 6 2 Determine which calibration procedure to follow do the following e Attempt to find out the number of conveyor sprocket teeth This simplifies the calibration process by allowing you to use the Standard Conveyor Calibration Procedure e If you do not know the number of the conveyor sprocket teeth but have a standard conveyor use the Unknown Sprocket Size Calibration Procedure e If your conveyor is nonstandard the chain pitch is not 1 5 inches you must determine the chain pitch and number of teeth per chain segment link and use the Non Standard Conveyor Calibration Procedure If you can not determine the chain pitch and number of teeth per chain segment link call IDC Customer Support e 888 434 5832 North America only e 310 325 5633 Industrial Dynamics Company Ltd Document 40255 0600 6 7 FT 50 Fill Level Inspector Service Manual Standard Conveyor Calibration Procedure Note Use this procedure if you have a s
64. ESOLUTION appears and enter the encoder resolution The standard encoder is 500 pulse The following table lists the encoders and the supported resolution The encoder resolution is set at the factory during assembly however if you upgraded the software you should check the encoder type and set it properly Part Number Description Resolution 24997 Standard 500 18916 Dual Track 1000 32637 Ultra High Resolution 5000 Industrial Dynamics Company Ltd Document 40255 0600 10 11 12 13 14 15 16 17 18 Chapter 6 Calibration Procedures Determine your Conveyor Segment Pitch This information is part of your conveyor manufacture s specifications If the specifications are not available measure in millimeters 10 conveyor segments plates and divide the measurement by 10 Press Key 5 until CONVEYOR SEGMENT PITCH appears and use the Arrow Key to enter the Conveyor Segment Pitch Determine the number of teeth that contact each conveyor chain segment This information is part of your conveyor manufacture s specifications If the specifications are not available you must visually count the number of teeth that contact the segment Press Key 5 until TEETH CONVEYOR SEGMENT appears and use the Arrow Key to enter the number of conveyor drive sprocket teeth per conveyor chain segment Close Dip Switch S1 5 Measure the distance in millimeters from the trigger sensor beam to the centerline of the reject
65. End Sensor Height 0 4 4 12 Aligning the Down Can Sensor 0 0 c ee eee eee eee 4 14 Wiring the External Reject Function 0 0 00 ce ee eee 4 15 IV Industrial Dynamics Company Ltd Document 40255 0600 Table of Contents Software Configuration 2 sisi sd bea ge be e tes 4 16 Calibrating the Encoder and Rejector Timing 4 16 Configuring the Inspection Looktime Gate 04 4 17 Configuring the Gamma Threshold 0 00000 ooo 4 19 Setting the Overfill Gamma Threshold 00 4 20 Setting the Underfill Gamma Threshold 04 4 21 Configure the Missing Lid Function o oocoococococooorooo 4 22 Configure the Bulged End Function oo oococcococoocoooooooo 4 22 Configure the Diameter Missing Lid Function 4 23 Configure the Down Can Function 0 0 0 eee eee eee eee 4 25 Configure the External Reject Function 0 000000 08 4 26 Chapter Five System Software ooooooooccmcmmmmmmmmmo 5 1 The Control Panel ci EA AA 5 5 Using the Control Patel aiii Ge bout anu ee do 5 5 The Function Group Keys 0 0 0 cee eee ee eens 5 5 The ATTOW Keys 28 x Se SACER ae ieee OS eee OR EC EROR I 5 5 Selecting the FT 50 s Operating Mode 0 0 2c eee eee eee 5 6 Selecting an Operating Mode 0 cece eee eee eee 5 6 Software Pul c
66. FT 50c Service and Technical Reference Manual 40255 0600 FT 50c Fill Level Inspector Service and Technical Reference Manual Document 40255 0600 Industrial Dynamics Company Ltd Document 40255 0600 Copyright All rights reserved No part of this publication may be reproduced or used in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval system without written permission of Industrial Dynamics Company Ltd Filtec and Industrial Dynamics are registered trademarks of Industrial Dynamics Company Ltd All other trademarks are the property of their respective owners Contact Information Corporate Headquarters Mailing Address Shipping Address Customer Service 3100 Fujita Street Torrance California 90505 4007 U S A Telephone 310 325 5633 FAX 310 530 1000 Internet www filtec com P O Box 2945 Torrance California 90509 2945 U S A 3100 Fujita Street Torrance California 90505 4007 U S A 800 733 5173 Table of Contents Table of Contents Table of Content iii ed rea de de eed x wax Ed RR ee ws n Il Radiological Safety llllllllllllere XIII Understanding Radiological Safety llle XIII Radiological Safety Guidelines llle XIV Radiation Measurement Testing Data 0 0 cee eee eee XIV Radiation Warning Labels 5 eio
67. HAIN VELOCITY appears Note this value because you need to enter it in the following step 29 Press Key 5 until MAXIMUM CONVEYOR SPEED appears and enter the CHAIN VELOCITY value from the previous step The optimum encoder value for the current line speed is now calculated including the Calibrate Encoder Value Encoder Prescaler Value and Gamma Sample Cutoff Limit 30 While the conveyor is running at production speed place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT 50 If the reject is late check to be sure the encoder coupling is not slipping Try a rejection with a thin layer of grease on the pad If the resulting mark in the grease starts in the upstream third of the pad face and is centered then performance is acceptable If there are still significant early late problems and you are certain that you have a standard conveyor chain contact the Industrial Dynamics Customer Service 31 To store the settings in system memory close dip switch S1 2 and then press Key 5 until SAVE DEFAULT CONSTANTS appears 32 Press the Arrow Key to execute When COMPLETED appears open S1 2 to protect the saved settings 33 Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select the Operate Mode This returns the FT 50 to a secured operating mode and completes the calibration procedure 34 If you are using this production line to produce more than one type
68. Lid Sensor height 1 Loosen the bottom jam nut on the missing lid sensor 2 Center a properly filled and sealed production container in the inspection tunnel so that it is directly under the missing lid sensor 4 10 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation 3 Find your type of missing lid sensor in the table below and adjust the upper jam nut to raise or lower the sensor to the proper height Sensor Description Lid Type Maximum Height Above Lid 21242 Nonferrous Aluminum 0 4 inch 10 mm 21856 Photo Optic Sensor All 0 7 inch 18 mm 24596 Extended Range Aluminum 0 5 inch 13 mm Extended Range Steel 0 88 inch 22 mm 91098 Standard 0 25 0 38 inch 6 9 mm 4 When you achieve the proper height tighten the lower jam nut to secure the sensor positioning 5 If you will not be performing further alignment procedures open the safety shutter by pulling the actuating rod out until it stops Industrial Dynamics Company Ltd Document 40255 0600 4 11 FT 50 Fill Level Inspector Service Manual Aligning the Bulged End Sensor Height The Bulged End Sensor is mounted on a separate bracket that is attached to Centerline Sensor Mount Bracket nganan No Description Sensor Emitter Height Adjustment Lock Container Lid Sensor Beam Sensor Recei
69. Ltd Document 40255 0600 Chapter 6 Calibration Procedures The Dynamic Product Good Test The Dynamic Good Product Test is used to verify the inspection accuracy under production conditions You need 30 good not marginal production containers to perform this test If you run this test with actual production flow the FT 50 will sense this and automatically change the sample batch size to 128 1 Start the conveyor and run it at production speed 2 Press the Arrow Key and you are instructed to run thirty good production containers through the FT 50 Start them far enough upstream so they do not slide on the conveyor as they pass through the inspection area If you are using production flow the FT 50 automatically samples 128 containers The FT 50 must accept all 30 or 128 containers in order to establish the Dynamic Good Margin The Dynamic Good Margin compensates for fill level variance due to conveyor motion 3 If during this test the message LOW MARGIN RAISE 2 TICKS appears then a container has failed the test You must raise the inspection head 2 ticks and then press the Arrow Key to repeat the test 4 When the test is successfully completed you are asked to set the Underfill Threshold During the Dynamic Reject Point Test and the Dynamic Product Good Test the threshold is fine tuned Press the Arrow Key to accept the new threshold 5 The Dynamic Product Good Test is complete Press Key 1 to proceed to Review Fill Lev
70. Ltd Document 40255 0600 3 21 FT 50 Fill Level Inspector Service Manual No Mounting the Encoder Offset If you are using the offset mounting procedure you will need Two sprockets or flywheels providing a 1 1 ratio e A timing chain or timing belt e An adapter bracket to mount the encoder over the sprocket or flywheel 1 Because offsetting the encoder mount is a unique situation we can only provide you with guidelines for the procedure If you are unsure contact an IDC Service Representative who will assess the situation and help you devise a solution Description Encoder Conveyor Drive Sprocket Transfer Pulley Shaft and Mount Figure 3 19 Possible offset encoder mount 2 To wire the encoder refer to the directions provided for the inline mounting method Install the Rejector 3 22 Refer to the rejector installation manual that is included with your inspection system for instructions on installing the rejector When you complete the rejector installation proceed to the next step to wire the main power source to the FT 50 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Connect the Main Power Source Warning No Description Before you begin wiring the FT 50 to the power source be sure the power source meets the requirements explained in Chapter 2 Installation Requirements Four wiring examples that cover most wiring situations are provided at the
71. MUM LINE SPEED appears and enter the line speed in cpm for the container in use The program assumes 12 mm container spacing in order to perform prelim inary calculations Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures 12 Start the conveyor and adjust it to the speed it will run at during production It is important that the chain run smoothly to obtain accurate calibration Fine Tuning the Rejector Timing To fine tune the calibration accuracy you may need to adjust the Millimeter Translation Value estimated during the Millimeter Calibration Routine Experiment with a production container and observe the rejector timing Based on where the rejector pad contacts the container you must increase or decrease the value until the can contacts the pad correctly 13 Press Key 4 until REJECT NEXT appears and then press the Arrow Key to enter the number of containers you want to reject consecutively Choose a number such as 6 or higher to provide enough attempts to make adjustments When the number reaches zero you must repeat this step to reactivate the rejector 14 Press Key 5 until MILLIMETER TRANSLATION VALUE appears 15 Spread a light film of grease across the face of the rejector pad The container will leave a mark in the grease at the point it contacts the pad thereby making it easier for you to see where the contact is occurring 16 With the conveyor running at production speed pl
72. Missing Lid Dia Missing Lid Width e Minimum Diameter Missing Lid e Alarm Dia Missing Lid Dia Missing Lid Text Dia Missing Lid This manual assumes the default name for this option If you change the default text remember to substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 Note Chapter 5 System Software External Reject Prepares the FI 50 software for external reject inspection by inserting the necessary options into the software When set to Not Present it removes the options necessary for external reject inspection from the software This function does not activate or deactivate external reject inspection it only readies the machine To turn external reject inspection on or off you must use the External Reject Status function External Reject Text Allows you to create a custom name for the External Reject Option Any instance in which External Reject would have appeared in the software is replaced by the custom label you created The following options are effected e External Reject Status e Total External Reject e Reset External Reject e Alarm External Reject e External R
73. Pada cae 2 5 14 Dyna Reject Pt Test visa Ade ES 5 14 Dyn Prod Good Test emecoirici pio al 5 14 Review Fill Level Test de ad reta 5 14 Container Finish Functions Group 02 00 00 5 15 Bulged End Status suse aa Mele x eiue eee ht 5 15 Missing Lad Status yes A Rene A 5 15 Down Can Status ides li kit x RIA RR oda id 5 15 Diameter Missing Lid Status 0 0 0 e eee 5 15 External Reject Status 2292 pp e a praxi d RES 5 15 Width at Down Can zi este ee a he ee ed 5 15 Height op Gab 22 ehe mr tod d seta Cote mr 5 15 Diameter Missing Lid Width oooooooooooooo o 5 16 Minimum Diameter Missing Lid 000 5 16 Counter Functions Group 5 17 Total Throughlpit usos REX S ies 5 17 Total Rejects duo i CER EI ERE uw to e a debes Died 5 17 Total Underfils adore env P RES Boek ae 5 17 Total OVENS ne erre dodo ME ea 5 17 Total Missing Lid 5i spoelo d eI eprREXU A ES 5 17 Total B lgs d End wx copii Sada rH bee ane dera 5 18 Total Down Cant 4 i24 2656 re ERI LETTRE 5 18 Total Dia Missing Lid ita sc vues y en 5 18 Total External Reject Lo ao sey eee eee a HN ded 5 18 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual Reset All Counters ia a E ER bs 5 18 Reset Total Throughput shine 5 18 Reset Total Rejects eid eid evade S a a 5 19 Reset Total Underfill 225 y gy b ERU EAR le ote 5 19 Reset Total Over 5645 oen up es ai vu ER
74. Section and Bank is controlled by Dip Switches S2 7 and S2 8 The multiple banks are necessary to handle the various options available for the FT 50 LED Section 1 S27 close Section 1 S27 close Section 2 S27 open Section 2 S27 open Bank 1 S28 close Bank 2 S28 open Bank 1 S28 close Bank 2 S28 open 1 Diag Error Label 1 Remote Clr Inlabeler 1 2 Reject Pulse Label 2 Broken Slat or Batch Rej Inlabeler 2 3 Hi Res Encoder Label 3 Low Res Encoder Inlabeler 3 4 Low Foam Label 4 Optical FL Inlabeler 4 5 Downcan Smash Label 5 X ray Failure Inlabeler 5 6 Bulged High Cap Label 6 Extrn or FSR 1 Cntr Present 7 Missing Cap Lid Label 7 Slat Backup or Reject Verify System Timing 8 Trigger Label 8 Trigger Trigger LED Logic The standard detection logic for the LEDs is on when the sensor is blocked and off when a sensor is clear Some options such as High Cap Detection use reverse detection logic When reverse detection logic is used the LED is off when the sensor is blocked and on when the sensor is clear Refer to the System Configuration Sheet located inside the cover of your FT 50 for you specific configuration Industrial Dynamics Company Ltd Document 40255 0600 10 9 FT 50 Fill Level Inspector Service Manual LED Definitions 10 10 Section 1 Bank 1 S2 7 Closed S2 8 Closed LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 LED 8 LED 9 LED 10 LED 11 Fault Error Present The LED is on when ther
75. U d 5 19 Reset Total Missing Lid osos eese 5 19 Reset Total Bulged End avd sia I E iR ERES 5 20 Reset Total Down Can inde yea ih RS URS RI xs 5 20 Reset Total Diameter Missing Lid 5 20 Reset Total External Rejects 22 Sys I NR S NES aca 5 20 Rejector Functions Group 1 6 cece cee cece ees 5 21 REIGGEOL Status veces wg NAMES UE ak wd PIU TEN 5 21 Fire Rejector On Demand 0 00 ee eee eee 5 21 Rejector Pulse Width a race QUE E MR ear 5 21 Reject NexPContainer ori oed e eoe HERRERA CR Sls 5 21 Inspeet Trig To Clb Re Sx oec Le Ee ea ELS 5 22 Rejector Reaction Delays Suus vss a SOLUS ES 5 22 System Functions Group 0 00 cece eee eee eee eee 5 23 Current Container Type i 4 9sed ewe very hie detente 5 23 Last Reject Detected cs aei a E SO 5 23 Beacon Status 2avh2ceeu es oy eee eee ad 5 23 INS Speed eM mg oed v be I Rer pilo AS ai 5 23 Pane Speed epis A Sete E TES YER Pe ERA d 5 24 System Display iex eres Mae ey Sw ERAN NOMEN ae 5 24 Conveyor Drive Sprocket o oo oooooocoomoomooo 5 24 serial Data ID Number rat 5 24 Host Modbus Port Status 0 0 cee eee eee ee 5 25 Modbus Message Counters 0 0 0 e ee eee eee ee 5 25 PLC Output Pulse Width 22 22e deed ieee ad 5 25 Time Width Of Can isse ink RR De BEES A 5 26 Chain Velocity taa wes dex QR E HN aN Se XE MES 5 26 Alarm Underfills i ig ciated xu ER aa 5 26 Alarm Overfills accent e Eee cene Eu Ae 5
76. a Threshold sees 4 19 Setting the Overfill Gamma Threshold ss 4 20 Setting the Underfill Gamma Threshold 4 21 Configure the Missing Lid Function 00008 4 22 Configure the Bulged End Function nic 4 22 Configure the Diameter Missing Lid Function 4 23 Configure the Down Can Function esee enne 4 25 Configure the External Reject Function 0008 4 26 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual 4 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Chapter Overview Before you can use your FT 50 Inspection System you must configure the FT 50 and the rejector to operate on your production line There are two parts to configuring the inspection system e Mechanical Configuration consists of physically adjusting and aligning the FT 50 sensors and the rejector e Software Configuration consists of activating and setting all operational parameters for the inspection functions The following flow chart explains the configuration order Adjust head height for fill level inspection y Adjust inspection trigger height i Calibrate encoder if applicable and rejector timing i Determine the inspection looktime gate i Perform fill level Determine the optim
77. a counts are recorded for each container The Looktime Gate Value is determined by the containers width at the inspection point and the conveyor speed In simplified terms it is the amount of time the container requires to pass through the gamma inspection beam See also Time Width of Can Fill Level Optimization The Fill Level Optimization routine is used to increase fill level inspection accuracy for applications that require higher accuracy than is achieved through normal fill level inspection parameters It narrows the margin between acceptable and rejectable containers See Chapter 6 Fill Level Optimization for more information Industrial Dynamics Company Ltd Document 40255 0600 5 13 FT 50 Fill Level Inspector Service Manual 5 14 Learn Target Head Height Precisely determines the optimum inspection head height for the container s fill level by leading you through a series of mechanical adjustments This function is part of the Fill Level Optimization routine See Chapter 6 Fill Level Optimization for more information Dyn Reject Pt Test See Chapter 6 Fill Level Optimization for more information Dyn Prod Good Test See Chapter 6 Fill Level Optimization for more information Review Fill Level Test Allows you to review all settings that were determined during the Fill Level Optimization routine See Chapter 6 Fill Level Optimi zation for more information Industrial Dynamics Company Ltd Document 40255 06
78. a nest Latas a DA A is 5 37 External Reject Text i2 bw I a pa rns 5 37 R j ctor LV pee da RARE 5 38 PLC Series Alarms 2 22 24 4442 ke RR pu pA va Eua 5 38 Serial Interface 24 ketis e ip eae SEGUE a 5 38 External Trigger Logic iii pou DAR pea 5 38 Known Chain Pitch amp Teeth ooooooooomoom o 5 39 Encoder Resalutoli 22 kv A da peri ae 5 39 save Default Constants 2 2 54 0 044205 p s 5 39 Conveyor Segment Pitch coeli thug wee Ars 5 39 Testi Convey or Segment 5a Boa oh eee RA eee 5 39 Calibrate Encoder s td dee ee etwas tl E 5 39 Calibrate Encoder Value ceda ii ii A 5 40 Encoder Prescaler Value ooo ooooooooooooooo o 5 40 Gamma Sample Cutoff tt presse ese esas 5 40 Gamma Samples Per Encoder 0000 5 5 40 Diagnostics Function Group 0 cece eee eee 5 41 How to Access Diagnostic Error Codes 5 41 Diagnostic Error Codes Listing oooooooooooooo o 5 42 Industrial Dynamics Company Ltd Document 40255 0600 5 3 FT 50 Fill Level Inspector Service Manual 5 4 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software The Control Panel You can access all the FT 50 s system functions through the Control Panel The Control Panel contains eight keys and a two line LCD Liquid Crystal Display capable of displaying 24 characters per line A remote hand held control is also available The Remote Control Panel detaches from the FT 5
79. ace a production container preferably the container measured for the Can Width At Trig value upstream of the FT 50 so that it passes through the FT 50 without slipping and is rejected by the rejector 17 Examine the marking in the grease If your calibration procedure was accurate the mark will be close to the center of the pad If the mark is off adjust the Millimeter Translation Value as follows e If the rejector fired late the mark is in the downstream third of the rejector pad decrease the millimeter trans lation value by 2 e If the rejector fired early the mark is in the upstream third of the rejector pad increase the millimeter translation value by 2 18 Repeat steps 16 and 17 until the rejector is contacting the cans directly on the centerline of the pad Industrial Dynamics Company Ltd Document 40255 0600 6 27 FT 50 Fill Level Inspector Service Manual 19 To store the settings in system memory close dip switch S1 2 and then press Key 5 until SAVE DEFAULT CONSTANTS appears 20 Press the Arrow Key to execute When COMPLETED appears open S1 2 to protect the saved settings 21 Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select the Operate Mode This returns the FT 50 to a secured operating mode and completes the calibration procedure 22 If you are using this production line to produce more than one type of container you must repeat this procedure for each different containe
80. ack for more information 1 Attach the slant brace upper mounting brackets to the vertical support pipe using the supplied pipe clamps Leave the clamps loose enough so that you can slide the brackets to make adjust ments k re VA No Description 1 Pipe Clamp 2 Upper Slant Brace Support Brackets RS NR C Figure 3 12 Attaching the slant brace vertical mounting brackets Note The pipe clamp is only temporary After final positioning adjustments are made you will spot weld the supports into place and remove the clamp 3 14 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 2 Determine the angle and length of the slant brace by stringing a measuring tape from the support bracket to the floor Move the slant brace support bracket up or down to achieve the proper angle SS No Description 2 AAA 1 Measure from the hole to the floor while z maintaining an angle of approximately 35 Jt I 2 The mount brackets should be angled from 60 to 90 to each other 7 35 B 1 d d 4 o PES 0 Figure 3 13 Determining the length and position of the slant braces 3 Calculate the length of the brace by subtracting 6 inches from the measurement you made in the previous step
81. acy over several rejects using a single slat 28 If the container is not rejected properly make changes to the measured distance or number of sprocket teeth as follows e Verify the Inspect Trigger to C L Rejector distance is measured and entered correctly see steps 8 and 9 e Verify the number of conveyor drive sprocket teeth is entered correctly see step 10 The container position at reject can be in error by 0 5 inch for every 12 inches of distance from the inspection trigger to the rejector centerline or slat assembly For example e If the Inspection Trigger to Centerline Rejector distance is 24 inches and the container is 1 inch upstream of the rejector when it fires then the number of drive sprocket teeth should be reduced by one e If the container is 1 inch down stream when the rejector fires the number of teeth should be increased by one Industrial Dynamics Company Ltd Document 40255 0600 6 21 FT 50 Fill Level Inspector Service Manual 6 22 29 30 31 32 33 34 35 36 Run the conveyor at the same speed as in step 20 and place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT 50 If the reject is late check to be sure the encoder coupling is not slipping Try a rejection with a thin layer of grease on the pad If the resulting mark in the grease starts in the upstream third of the pad face and is centered then performa
82. ameter Missing Lid Width The container s lid diameter translated into encoder pulses In simplified terms this is the amount of time converted into encoder pulses required for the lid to pass through the inspection beam Minimum Diameter Missing Lid The minimum number of encoder pulses that defines the diameter of a container with a lid This function allows you to compensate for variances in the production and inspection processes 5 16 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Counter Functions Group The Counters record operational and performance data about the FT 50 and the production line it is operating on This data is useful for plant performance management and for machine maintenance Here are some other issues you should be aware of e The counters are active only for those functions that are active If you disable a function the associated counter or counters no longer include that function in the count When you reset a counter the current count is erased If you need the current count you should record it before you reset the counter Total Throughput Displays the total number of containers that passed through the trigger beam The counter automatically resets at 99 999 999 Total Rejects The total number of rejected containers The counter automatically resets at 99 999 999 Total Rejects is the sum of the rejections from all active inspection functions If
83. and base and possibly other parts of the stand in order to shift the position of the Inspection Head 4 n nm E A 2 Li U pales No Description 1 Vertical Centerline 2 Horizontal Centerline 3 Conveyor Figure 6 4 Leveling the Inspection Head 6 38 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Executing the Fill Level Optimization Routine The optimization routine steps you through the following options All options are contained under Key 1 while in the Calibrate Mode Note Fill Level Optimization Learn Target Head Height Dyn Reject Pt Test Dyn Prod Good Test Review Fill Level Test You can abort the optimization routine at any point in the process by pressing Key 6 Establishing the Underfill Gamma Threshold 1 Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode If your system is password protected you must enter the password before you are allowed to enter the Calibrate Mode Press Key 1 until FILL LEVEL OPTIMIZATION appears and then press the Arrow Key to begin determining the Gamma Threshold for the container Precisely center a 100 percent reject container in the inspection tunnel and then press any key to continue Lower the gamma beam into the liquid by slowly turning the Head Height Adjustment Crank T
84. andshake Flags 52 3 Parity On Off 52 4 Parity Odd Even S2 5 Character Size 52 6 Multi Serial S2 7 Led Section Selector S2 8 Led Bank Selector Slide Switches SWI i a ee al ees Controller Board LED Locations LED Configurations LED Logit fe ehh ater oe a LED Definitions Section 1 Bank 1 Section 1 Bank 2 Section 2 Bank 1 Section 2 Bank 2 Industrial Dynamics Company Ltd Document 40255 0600 10 1 FT 50 Fill Level Inspector Service Manual 10 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 10 Controller Board Dip Switches and LEDs Controller Board Switch Locations The FT 50 s Controller Board contains 2 Dip Switch Packs S1 and S2 which contain 8 switches each The Controller Board also contains 3 Slide Switches S3 S11 13 1 13 S2 A NW Nu X X X b J X I Nu MU N f Iu PODIDO E Ls LL E Figure 10 1 Switch locations on the Controller Board Industrial Dynamics Company Ltd Document 40255 0600 10 3 FT 50 Fill Level Inspector Service Manual Switch Function Configurations The default configuration for each option is indicated in bold The following table represents the standard FT 50 configuration Depending upon the options installed in your FT 50 the default configuration may be
85. aque the container the greater the accuracy of the sensor readings For example if the test container diameter is 28 mm the calculation error factor is 2 teeth If the test container diameter is 66 mm the calculation error factor is 1 tooth Slipping a short piece of pipe over the container neck is a useful way to increase the width of the can at the trigger point If you choose to do this you must repeat step 9 in order to enter the pipe diameter 12 Open dip switch S1 6 13 Start the conveyor and run it at the highest expected production speed You may not be able to achieve the highest possible speed unless the filler unit is running 14 Press Key 5 until CALIBRATE ENCODER appears and press the Arrow Key to execute the encoder calibration routine This procedure takes several seconds to complete When READY is displayed proceed to the following step 15 Place the container on the conveyor upstream of the FT 50 so the container passes through the inspection tunnel without slipping The FT 50 automatically calculates the prescaler value It takes several seconds for the FT 50 to make this calcu lation When RUN 16 CONTAINERS appears proceed to the following step Industrial Dynamics Company Ltd Document 40255 0600 16 17 18 19 20 21 22 Chapter 6 Calibration Procedures Run the container 16 times it is not necessary for the containers to pass the rejector through the FT 50 inspection tu
86. ay be required to enter a password if your system is password protected 2 Press Key 4 until REJECTOR STATUS appears and check to be sure the rejector is activated If it is turned off press the Arrow Key to turn it on 3 Open dip switch S1 5 4 Press Key 5 until REJECTOR TYPE appears and use the Arrow Key to select the type of Proline rejector installed in your system This procedure is only applicable to systems utilizing a Proline rejector If you are using a rejector other than a Proline you must use the variable speed production line calibration procedures 5 Measure the distance in millimeters from the trigger sensor beam to the centerline of the rejector Accurate measurement is extremely important for proper calibration 6 Press Key 4 until INSPECT TRIG TO C L REJ appears and use the Arrow Key to enter the measurement in millimeters 7 Measure the diameter of a production container in milli meters at the point where the container intersects the trigger beam This is the containers can width at the trigger point 8 Press Key 5 until CAN WIDTH AT TRIG appears and enter in millimeters the production container s width at the trigger point 9 Measure the diameter of the container in millimeters at its widest point This is the containers maximum diameter 10 Press Key 5 until MAXIMUM CAN DIAMETER appears and enter in millimeters the production container s maximum diameter 11 Press Key 5 until MAXI
87. brush off or curve and 5 7 seconds from a major distur bance such as a seamer or sealer Containers must be centered on the conveyor prior to passing through the inspection area Upstream ramp actions may be required to obtain proper positioning You will need at least 19 inches 49 cm of space along the conveyor in order to mount the FT 50 and rejector You may need more space for certain inspection options ramp actions if required and reject conveyor requirements The conveyor section that passes through the inspection area must be level and straight no turns or curves e The FT 50 can be installed on either the right side or left side of the conveyor however if you position it differently from the orientation you specified when you placed the order you may need to reconfigure some add on sensors and triggers Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Preparing the Conveyor After you determine the installation location you must prepare the conveyor for the installation 1 Mark the installation location of the FT 50 on the side channel by drawing a vertical line with a marker This is the centerline on which the FT 50 will be aligned when installed 2 Create a 5 inch 13 cm wide gap in the conveyor guide rails on both sides of the conveyor Center the gap on the centerline mark you made in step 1 5 in
88. calibration Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures 10 11 12 13 14 15 16 Note Press Key 4 until INSPECT TRIG TO C L REJ appears and use the Arrow Key to enter the measurement in millimeters Measure the diameter of the production container in milli meters at the point where the container intersects the trigger beam This is the containers can width at the trigger point Press Key 5 until CAN WIDTH AT TRIG appears and enter in millimeters the production container s width at the trigger point Measure the diameter of the container in millimeters at its widest point This is the containers maximum diameter Press Key 5 until MAXIMUM CAN DIAMETER appears and enter in millimeters the production container s maximum diameter Press Key 5 until MAXIMUM LINE SPEED appears and enter the line speed in cpm for the container in use The program assumes 12 mm container spacing in order to perform prelim inary calculations Press Key 5 until CONVEYOR DRIVE SPROCKET appears and enter the number of teeth on the conveyor chain sprocket or the number of teeth on the chain sprocket at the drive shaft where the encoder is directly coupled Start the conveyor and run it at the maximum required production speed If this is not possible because the filler is not running run it at the highest speed available If you cannot perform steps 17 and 18 while run
89. ch to ground point in box 3 26 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Power Supply Wiring Examples Example A Standard 115 VAC or 230 VAC with Neutral line 1 Local electrical codes may require that neutral be grounded at the main power panel We do not advise grounding the neutral wire to any other point 2 The FT 50 must be grounded as shown The neutral wire should not be grounded in the FT 50 in this application 5 115 VAC 115 230 2 1 2 2 115 VAC H N i N N iin 9 10 No Description E 1 Plant Power Panel 115 VAC i 2 Voltage Select Switch 115 V fi 3 Plant Power Panel 230 VAC TIVA a H 12 4 Voltage Select Switch 230 V PE 8 5 FT 50 Power Junction Box 1 a 7 6 Connect FT 50 pigtail leads to input power wires 7 FT 50 Ground Stud 5 8 External Break Di t reaker or Disconnec 230 VAC m a 9 White 3 2 2 19 Blue 115 VAC H 11 Black i QN f 9 M 10 6 115 VAC a aS 11 Ml 12 4 PE 8 7 7 H Figure 3 24 Main power wiring Example A Industrial Dynamics Company Ltd Document 40255 0600 3 27 FT 50 Fill Level Inspector Service Manual Example B Using a Voltage Regulating Transformer If voltage stability is a problem a voltage regulating type trans former should be used This example uses a transformer to isolate the the 1
90. container and continuously when a high priority diagnostic error occurs The beacon will stop flashing when the diagnostic error is cleared Line Speed cpm The speed of the production line measured by cpm containers per minute The measurement is the number containers that intercept the FT 50 s trigger beam in 60 seconds To calculate cpm from cph containers per hour use the following formula Industrial Dynamics Company Ltd Document 40255 0600 5 23 FT 50 Fill Level Inspector Service Manual 5 24 Line Speed cph The speed of the production line measured by cph containers per hour The measurement is the number containers that intercept the FT 50 s trigger beam in 60 minutes To calculate cph use the following formula cpm X 60 cph System Display Switches the system between the Operate Mode and the Calibrate Mode The Operate Mode is the normal operating mode for the machine and allows access only to those functions required for production operation The Calibrate Mode grants the operator complete access to all system functions including configuration and container programming functions When the password function is activated the password must be entered before the user is granted access to the Calibrate Mode When in Calibrate Mode if the FI 50 is idle no keys are pressed for 30 minutes the system automatically returns to the Operate Mode For more information see Selecting the FT 50 s Operating Mode
91. ction tunnel The size of your FT 70 was specified when you placed your order Tunnel Width Tunnel Height Overall Width Overall Height Overall Depth Max Can Width at Trigger Max Can Width at Fill Level Minimum Fill Level Standard 4 5 inches 115 mm 9 inches 230 mm 25 25 inches 641 mm 18 inches 457 mm 4 inches 102 mm 2 125 inches 54 mm 3 25 inches 83 mm 1 25 inches 32 mm Wide 5 5 inches 141 mm 9 inches 230 mm 26 25 inches 667 mm 18 inches 457 mm 4 inches 102 mm 3 125 inches 80 mm 6 25 inches 159 mm 1 25 inches 32 mm Extra Wide 7 5 inches 192 mm 9 inches 230 mm 28 25 inches 717 mm 18 inches 457 mm 4 inches 102 mm 5 125 inches 130 mm 6 25 inches 159 mm 1 25 inches 32 mm Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview Triggering System The Trigger System uses a fiber optic light source to transmit a light beam across the inspection tunnel to a receiver mounted on the opposite side When a container passes through the beam continuity is broken and a container present state is created The trigger initiates all inspection activities and in conjunction with the encoder provides system timing for the rejector High Resolution Encoder The High Resolution Encoder is calibrated to the conveyor speed and container type and provides timing
92. cument 40255 0600 6 29 FT 50 Fill Level Inspector Service Manual Calibrating the Centerline Inspection Trigger Be sure there is no object blocking the inspection trigger beam Turn the Offset Adjustment clockwise until the Output Contrast LED reaches 10 and then turn the adjustment counter clockwise until the LED drops to 5 RO O E No Description S 1 Output Contrast LED X D filtec 2 Output LED 3 Offset Adjustment P N 23969 E Ga CONTRAST 3 1 Soo a ae 3j 70987654321 OUTPUT OFFSET g ___ 3 O lt Ss 2 Figure 6 1 Calibrating the Inspection Trigger Amplifier 6 30 Place a production container in the inspection tunnel so the inspection trigger beam is completely blocked Turn the Offset Adjustment clockwise until the Output Contrast LED returns to 5 Note the number of turns required to return the level to 5 Turn the Offset Adjustment counterclockwise half the number of turns required in the previous step Remove the container from the inspection trigger beam path The Output Contrast LED should increase to 10 and the Output LED should light Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Calibrating the Upstream Inspection Trigger 1 Clear the Upstream Inspection Trigger beam of any containers so that it is not blocked 2 Remove the amplifier cover and set the Operation Mode Selector to Dark D S
93. ding this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Overfill Text Allows you to create a custom name for the Overfill Inspection Option Any instance in which Overfill would have appeared in the software is replaced by the custom label you created The following options are effected e Overfill Status e Total Overfill e Reset Overfill e Alarm Overfill e Overfill Text This manual assumes the default name for this option If you change the default text remember to substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 Note Chapter 5 System Software Missing Lid Prepares the FT 50 software for Missing Lid inspection by inserting the necessary options into the software When set to Not Present it removes the options necessary for Missing Lid inspection from the software This function does not activate or deactivate Missing Lid inspection it only readies
94. dip switches and jumpers on the processor circuit board are configured properly You can find the factory settings by looking at the Configuration Sheet that is included with each machine and is stored in the plastic sleeve attached to the inside of the FT 50 inspection head cover Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Power Supply System Troubleshooting Power supply instability and failures account for many malfunc tions We recommended testing the power supply voltages as a starting point when troubleshooting You need a digital voltmeter with an impedance of at least 20 000 ohms per volt to perform these procedures Testing the Power Supply 1 Remove the FT 50 s cover to access the power supply inside 2 Using test point TP3 as ground test all voltages at the appro priate test points
95. e The minimum allowable distance between the scaled encoder pulses must be greater than 1mm 0 040 inch To correct this error Increase the encoder prescaler until this error no longer occurs When decreasing the Prescaler value the Calibrate Encoder Value is automatically increased to compensate for the higher resolution Error Number 25 This error indicates the high resolution encoder is scaled lower than the minimum allowable time There must be a minimum of 1 0 ms between the encoder pulses at maximum speed To correct this error e Check the encoder cable and the connection at P6 This error can be caused by noise on the encoder cable which connects to P6 Increase the encoder prescaler value until this error no longer occurs at high speed 8 6 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Error Number 27 Containers are passing the inspection station but the encoder is not sending pulses at least 5 consecutive inspection triggers occurred without sensor transition To correct this error Check the voltage at P6 2 The signal voltage should be between 0 12 volts e Check TB42 and LED 3 with dip switch S2 7 open Error Number 33 This error occurs when the number of consecutively rejected smashed containers exceeds the limit set in the Consecutive Down Can Reject Alarm function Error Number 34 Two or more consecutive inspection triggers have occur
96. e is a Fault Alarm or other error in the system Reject Pulse Flashes one time for each container rejected High Res Encoder Pulse Flashes once for each pulse Not used in this configuration Slat Backup Sensor Indicator lights when the sensor is activated or when sensor is blocked Bulged End Trigger Indicator lights when the High Cap sensor is activated or when sensor is blocked Missing Lid Trigger Indicator lights when the Missing Cap sensor is activated or when lid is present Inspect Trigger Indicator lights when the Inspection Trigger sensor is activated or when the sensor is blocked AC Power Low Indicator lights when the input AC power to the FT 50 is too low to operate satisfactorily below 70 VAC 5 VDC Power Low Indicator lights when the 5 VDC power supply is too low to operate satisfactorily below 4 85 VDC Indicator is also on when the Reset button is pressed Detector Used to get a coarse calibration setting for the Solid State Detector Section 1 Bank 2 S2 7 Closed S2 8 Open This section is used when the Label Inspection Option is installed in your FT 50 For More information refer to your Label Inspection Manual Industrial Dynamics Company Ltd Document 40255 0600 Chapter 10 Controller Board Dip Switches and LEDs Section 2 Bank 1 S2 7 Open S2 8 Closed LED 1 LED 2 LED 3 LED 4 LED 5 LED 6 LED 7 LED 8 LED 9 LED 10 LED 11 Fault Error Present The Indicator
97. e same way Although the actual rejection is disabled all counters and alarms continue to accumulate Fire Rejector On Demand Fires the rejector manually This function is used to test the rejector mechanism or to manually actuate it during start up to provide initial lubrication under no load To execute Fire Rejector On Demand 1 Press Key 4 until FIRE REJECTOR ON DEMAND appears 2 Press the Arrow Key to fire the rejector Rejector Pulse Width The time in milliseconds that voltage is applied to the rejector solenoid This translates into the speed with which the rejector ram extends and return to the ready position Reject Next Container Defines the number of containers to consecutively reject also called Batch Reject You enter the number of containers to reject and the FT 50 continues to reject until the counter reaches zero All containers rejected with this function are included in the Total Rejects counter This function is useful during testing and calibration procedures To activate the Reject Next function 1 Press Key 4 until REJECT NEXT appears 2 Press the Arrow Key to enter the number of containers to reject Industrial Dynamics Company Ltd Document 40255 0600 5 21 FT 50 Fill Level Inspector Service Manual Inspect Trig To C L Rej The distance in millimeters from the centerline of the inspection trigger beam to the centerline of the rejector pad This value is required to establish the proper time fo
98. e specified 36 month intervals Indus trial Dynamics Service Technicians can do this Keep a record of each inspection and test In the case of an accident which crushes or punctures the source enclosure seal off the area cover the FT 50 and surroundings with a plastic sheet or tarpaulin and call Indus trial Dynamics immediately Do not relocate or dispose of the FT 50 without proper approval A licensed technician must perform this function If you have any questions call Industrial Dynamics Radiation Measurement Testing Data XIV All measurements were taken with Technical Associates Model Pug 1 survey meter The meter was cross calibrated against an air ionization chamber survey meter whose response was corrected against an Americium 241 test source Industrial Dynamics Company Ltd Document 40255 0600 Radiological Safety 2 Source Shutter closed The radiation levels are less than 0 05 MR HR at distances greater than 5 cm from any surface of the gauge including inside the tunnel 3 Source Shutter open The extent of the main gamma beam is completely contained within the tunnel formed by the inspection head and shielding bar All radiation levels outside the main beam are less than 0 05 MR HR 4 The exposure rate in the main beam is measured to be approxi mately 60 MR HR at 5 cm from source enclosure containing 300 millicuries Industrial Dynamics Company Ltd Document 40255 0600 XV FT 50 Fill Level Insp
99. e ta 1 12 External Reject Control eie meer re DR pete too 1 13 Serial Heth ACS oos rotate qua DOM ce XH dvo ond unir o toute anh g 1 13 Programmable Logic Controller Interface PLC 1 13 Industrial Dynamics Company Ltd Document 40255 0600 Pt FT 50 Fill Level Inspector Service Manual 1 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview System Overview This manual provides information about the FT 50 Machine Type 05 MT05 Inspection System for cans The MT05 version of the FT 50 is equipped with the following e Solid State Detector or Scintillation Tube Detector e Centerline Trigger High Resolution Encoder required for variable speed production lines The FT 50 provides high speed overfill or underfill fill level container inspection When a container fails inspection the FT 50 can signal a rejector to remove the defective container from the production line Figure 1 1 The FT 50 Fill Level Inspector Industrial Dynamics Company Ltd Document 40255 0600 1 3 FT 50 Fill Level Inspector Service Manual Fill Level Inspection Basics No Description Gamma Source 2 Gamma Beam Gamma Detector The FT 50 Fill Level Inspection system utilizes a Container Radiation Profile Comparison Principle to create a radiation fingerprint of the container To create a radiation profile a beam of gamma radiation is directed through the container Some of the radiation is bl
100. ears and use the Arrow Key to enter the calculated Looktime value Chain Velocity The calculated velocity of the conveyor chain in mpm meters per minute This value is automatically calculated by the FT 50 Alarm Underfills The minimum number of consecutive underfill rejects that will trigger an alarm condition The count is reset to zero when a good container is detected This function can alert you to filler malfunctions Alarm Overfills The minimum number of consecutive overfill rejects that will trigger an alarm condition The count is reset to zero when a good container is detected This function can alert you to filler malfunctions Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Alarm Missing Lid The minimum number of consecutive missing lid rejects that will trigger an alarm condition The count is reset to zero when a good container is detected This function can alert you to seamer or sealer malfunctions Alarm Bulged End The minimum number of consecutive bulged end rejects that will trigger an alarm condition The count is reset to zero when a good container is detected This function can alert you to seamer or sealer malfunctions Alarm Down Can The minimum number of consecutive down can rejects that will trigger an alarm condition The count is reset to zero when a good container is detected This function can alert you to seamer or sealer malfunctions and conveyor dist
101. ected to ground TB1 21 the next container to pass the trigger will be rejected Remote Clear of Error If the input TB1 20 is connected to ground TB1 21 the diagnostic error will be cleared 5 38 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Known Chain Pitch amp Teeth This option applies to the Encoder Calibration Routine If you know the conveyor chain pitch and the number of teeth per chain link set this function to present If you do not know the conveyor chain pitch and the number of teeth per chain link set this function to not present When set to present you must also adjust the Conveyor Segment Pitch and Teeth Conveyor Segment options Encoder Resolution Selects the resolution of the encoder installed in your system The Standard High Resolution Encoder is 500 pulse The Ultra High Resolution Encoder is 5000 pulse and is required when using the Diameter Missing Lid option Save Default Constants Saves the current operating configuration to nonvolatile memory The constants are stored until they are overwritten by a more recent save To recall the settings from memory you must use the Load Default Constants function To save the default constants 1 Press Key 5 until SAVE DEFAULT CONSTANTS appears 2 Press the Arrow Key to execute Conveyor Segment Pitch The distance from one point on a conveyor chain segment to the same point on the next conveyor segment It defines
102. ector Service Manual Radiation Warning Labels CAUTION RADIOACTIVE MATERIAL SEE INSTRUCTION MANUAL BEFORE ATTEMPTING TO OPERATE REPAIR CLEAN OR MOVE THIS DEVICE SOURCE MATERIAL AMERICIUM 241 AMOUNT mCi mCi Bq DATE OF MFR 53 REMOVAL OF THIS LABEL IS PROHIBITED INDUSTRIAL DYNAMICS TORRANCE CALIFORNIA I N DO NOT PLACE HANDS OR ANY PORTION OF THE BODY BETWEEN THE RADIOISOTOPE SOURCE AND DETECTOR WHEN THE GAMMA BEAM IS ACTIVATED CLOSE SHUTTER WHEN REPAIRING OR MAINTAINING THE MACHINE NOTICE The receipt possession use and transfer of this device are subject to a general license or equivalent and the regulations of the U S NRC or of a state with which the NRC has entered into an agreement for the exercise of regulatory authority This device shall not be transferred abandoned or disposed of except by transfer to a person holding a specific radioactive material license to receive this device Operation of this device shall be immediately suspended until necessary repairs have been made if there is any indication of possible failure or damage to the shielding or containment of radioactive material or the ON OFF mechanism and indicator at intervals not to exceed three years This device shall be tested for proper operation of the ON OFF mechanism or indicator The sealed radioactive source contained in this cevice shall
103. edures Diagnostic Error Messages esa e hes Be Pawo 8 3 Error N umber25 od ae ies Gen EE REFER ES EN ee oe EE 8 3 Error Numberb iaa PI Us 8 3 Error Number 6 is hate ads ha OE 8 3 Error Number 8 epe RR oe See EUER dee ee 8 3 Error Number O cade ctas Git oxide taa 8 4 Error Number 10 0 0 0c ccc ccc eee eee nee 8 4 Error Numbers lll a oe e NOI 8 4 Error Number 12 a eee 8 4 Error Number 3 curs aa CEA E tete tr 8 4 Error Number 14 acu dss ee RETE RA Reg rei hoe 8 4 Error Number 5 3 wooded a Re ERE 8 5 Error Number l6 ut EMI X aae bes 8 5 Error Number22 us coder emot CR err De ette d edes 8 5 Error Number23 o dee cee Ret eS TENE Eee ER 8 6 Error N mber24 cse Ree E RR EE A E EE 8 6 Error Number 254 au ebbe MES 8 6 Error Number 27 5 4 ppc RR oz 8 7 Error Numbet 33 oecuaz quse enr ab P wie rb beet anie 8 7 Error Number 34 00 c ccc cece cee n 8 7 Error Numbet46 e 8 7 Error N umber47 2 056 c heres eon odo o eas 8 7 Error NumberdS 00d ck em t eH te Ee 8 8 Error Number 49 1 0 0 0 0 00 ccc cc cece cece en 8 8 Error Number 50 iia a Red Sea ROS ER 8 8 Error Nu umber bl usse ce Bie a atl Ea ela te vetet des 8 8 Error Number 52 coc ete ote e eto e AE re 8 9 Error Number 53 loe ri Peewee ete cua ee 8 9 Error N mbet54 ses a a p ow tie be Uae E EE 8 9 Error Numberb8 dt 8 9 Error N mber ol e eR Ep ERR REALE ER 8 9 Error Number 66 sedo eae o tet odor bee aria 8 9 Error Number 67 eerie
104. eject Text e External Reject This manual assumes the default name for this option If you change the default text remember to substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 5 37 FT 50 Fill Level Inspector Service Manual Rejector Type Selects the rejector model that is controlled by the FT 50 PLC Series Alarms Activates or deactivates the PLC Series Alarms Function If set to PRESENT the following options are activated PLC Output Pulse Width e Alarm Series Underfills e Alarm Series Overfills e Alarm Series Missing Lid e Alarm Series Bulged End e Alarm Series Down Can e Alarm Series Dia Missing Lid e Alarm Series Any Other Inspections PLC Assignments See Chapter 9 Using a PLC With Your FT 50 for more information Serial Interface Activates or deactivates the Serial Interface function For more information refer to the Serial Communication Manual External Trigger Logic External Trigger Logic allows you to configure an external trigger such a s a manual switch to perform either an External Reject or a Remote Clear of Error External Reject If the input TB1 20 is conn
105. el Test Industrial Dynamics Company Ltd Document 40255 0600 6 43 FT 50 Fill Level Inspector Service Manual 6 44 The Review Fill Level Test The Review Fill Level Test records and displays all values calcu lated during the Fill Level Optimization Routine Press the Arrow Key to scroll through the list when you need to review the following settings Static Full Static Empty Static Margin Aperture Range Inherent Accuracy Learned Gamma Threshold Dynamic Reject Average Reject Margin Dynamic Product Average Product Margin Dynamic Product Threshold Industrial Dynamics Company Ltd Document 40255 0600 Chapter 7 Maintenance Procedures Chapter Seven Maintenance Procedures Maintenance Schedules Lese tetti hr ion pb anenieds 7 3 Daily Scheduler ases da E CRX a NEU een 7 3 Weekly Maintenance 249 Quies ode iae e oU ence be nod 7 3 Monthly Maintenance oe sod eene epp idee xp eov 7 3 120 Day Maintenance id Eo ee OON Cep 2 7 4 Maintenance Procedures ese ced te tk aeo Lx n ha RO eoles da d 7 5 Before You Perform Any Maintenance Procedure 7 5 Trigger Beam and Emitter Lenses oie ey cone nee woke 7 5 Bulged End and Missing Lid Sensors 00005 7 5 The FIT 50 Housing cis iad tenant cons dina E EP ERE 7 6 Pressure Regulator and Air Piller a ape ee canara aes 7 6 External Wiring ad hatin eye ete Cat aded 7 6 Replacing the Rejector Pad vista ga ee ita s Rs 7 6 Servicing the Regula
106. en press the Arrow Key to enter the Calibrate Mode Press Key 1 until GAMMA THRESHOLD appears Place a properly filled sample production container on the conveyor far enough upstream of the FT 50 so that it does not slip on the chain and is positioned correctly as it passes through the inspection tunnel Record the value that appears in the Gamma Threshold display Repeat the previous two steps four more times and then average the value to get the average good count GC a b c d e GC 5 Industrial Dynamics Company Ltd Document 40255 0600 4 19 FT 50 Fill Level Inspector Service Manual 4 20 10 To complete the configuration you must follow the appropriate procedure based on the type of fill level inspection you will be performing e If you will be performing overfill inspection proceed to Setting the Overfill Gamma Threshold e If you will be performing underfill inspection proceed to Setting the Underfill Gamma Threshold Setting the Overfill Gamma Threshold 1 Place a sample production container that is overfilled by approximately 3mm to 5mm on the conveyor far enough upstream of the FT 50 so that it does not slip on the chain and is positioned correctly as it passes through the inspection tunnel Record the Gamma Counts value that appears in the Gamma Threshold display Repeat the previous two steps four more times and then average the value to get the average bad count BC a b c d e BC
107. end of this chapter in Power Supply Wiring Examples After you find an example that is similar to your situation choose one of the following procedures to complete the wiring There are two different wiring procedures depending on your FT 50 configuration Use the procedure appropriate for you situation e If your FT 50 is not equipped with the optional I O Junction Box use the Standard Power Supply Wiring procedure e If your FT 50 is equipped with the optional I O Junction Box use the procedure for Wiring the Power Supply Cable into the I O Junction Box Standard Power Supply Wiring Disconnect all electrical power sources from the equipment before attempting any installation procedure Failure to do so can result in personal injury and equipment damage 1 Check to be sure the voltage select switch is set to the appro priate input voltage 115 or 230 VAC and that the power switch is turned off 1 2 Voltage Selection Switch Circuit Breaker Power Switch Figure 3 20 Set the Voltage Select Switch Industrial Dynamics Company Ltd Document 40255 0600 3 23 FT 50 Fill Level Inspector Service Manual 2 Route the AC power cable into the FT 50 through one of the watertight cable ports located in the bottom of the FT 50 No Description 1 Power cable 2 Watertight Cable Ports 3 Entrance to Power Filter Figure 3 21 Route the Power Cable into the FT 5
108. erform either underfill inspection or overfill inspection it can not perform both simultaneously 1 Close the radiation source safety shutter by pushing the actuating rod in until no red paint is visible 2 Loosen the Head Height Locking Handle on the side of the inspection head and using the Inspection Head Height Crank raise the head all the way Description OMAN DOA A ON Head Height Adjustment Crank Gamma Beam Source Inspection Beam Centerline Radiation Detector Gamma Beam Horizontal Centerline Gamma Beam Vertical Centerline Time Width of Container top up Container Fill level Time Width of Container bottom up Figure 4 3 Setting the proper fill level inspection point Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation 3 Loosen the Height Locking Handle for the Centerline Sensor Mounting Bracket and using the Sensor Bracket Height Crank raise the bracket all the way 4 Center a properly filled production container in the inspection tunnel so that when the inspection head is lowered it is aligned with inspection beam 5 Lower the inspection head until the inspection beam height is in the proper position for either underfill or overfill detection e If you will perform underfill detection align the top of the Gamma beam slot with the fill level of the contents in the container
109. es to reflect setting level and the red Operation Indicator LED is on 4 Slowly turn the Sensitivity Adjustment clockwise until the red Operation Indicator LED is off You want the sensitivity adjustment to be on the edge of when the Operation Indicator LED turns off This establishes the minimum sensitivity point 5 Verify the setting by using a production container to block the beam and then remove it The Operation Indicator should be off when the container is blocking the beam and on when the beam is not blocked 6 Replace the amplifier cover 6 32 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Calibrating the Down Can Sensor Note Refer to Figure 6 2 when performing this procedure Clear the inspection tunnel of any containers so the trigger beam is not blocked Remove the amplifier cover and set the Operation Mode Selector to Dark D Set the Sensitivity Adjustment to minimum by turning it counterclockwise until it stops Notice the gauge needle moves to reflect setting level and the red Operation Indicator LED is on Slowly turn the Sensitivity Adjustment clockwise until the red Operation Indicator LED is off You want the sensitivity adjustment to be on the edge of when the Operation Indicator LED turns off This establishes the minimum sensitivity point Verify the setting by using a production container to block the beam and then remove it The Operation Indicator sh
110. ess Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the Calibrate Mode Open dip switch S1 5 Press Key 5 until DOWN CAN appears and use the Arrow Key to select PRESENT Close dip switch S1 5 Press Key 2 until DOWN CAN STATUS appears and then press the Arrow Key to activate the function Measure the width of the can in millimeters at the point where the can in the upright position intersects the down can sensor beam This is the Width at Down Can Press Key 2 until WIDTH AT DOWN CAN appears and then press the Arrow Key to enter the measurement value Measure the height of the can in millimeters Be sure to measure from the bottom to the top of the lid highest part Press Key 2 until HEIGHT OF CAN appears and then press the Arrow Key to enter the measurement value If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode Calibrate the Bulged End Sensor according to the instructions in Chapter 6 Calibrating the Down Can Sensor Industrial Dynamics Company Ltd Document 40255 0600 4 25 FT 50 Fill Level Inspector Service Manual Configure the External Reject Function 4 26 Before you activate the External Reject Function be sure you have the signal cable wired correctly see Wiring the External Reject Function for proper wiring configuration 1 If your FT 50 is not in the Calibrate Mode Press Key
111. ess the Arrow Key to execute When COMPLETED appears open S1 2 to protect the saved settings 29 Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select the Operate Mode This returns the FT 50 to a secured operating mode and completes the calibration procedure Industrial Dynamics Company Ltd Document 40255 0600 6 11 FT 50 Fill Level Inspector Service Manual 30 If you are using this production line to produce more than one type of container you must repeat this procedure for each different container type i e containers with different diameters or line speeds 6 12 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Unknown Sprocket Size Calibration Procedure Use this procedure to calibrate standard conveyors with a 1 5 inch pitch but you don t know the number of teeth on the sprocket directly contacting the underside of the main production transport chain This procedure initially estimates the number of sprocket teeth and then allows you to fine tune 1 Note Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode You may be required to enter a password if your system is password protected Press Key 4 until REJECTOR STATUS appears and check to be sure the rejector is activated If it is turned off press the Arrow Key to turn it on Open dip switch S1 5 Press Key 5 until REJECTOR TYPE appears and use the
112. etely installed and fully operational This section contains the following calibration procedures e Encoder Calibration e Sensor Calibration e Radiation Detector Calibration Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual Encoder Calibration Procedures The encoder calibration method you will use is based upon whether your production conveyor is variable speed or fixed speed Variable Speed Conveyors Variable speed conveyors require a high resolution encoder that is coupled directly to the conveyor drive sprocket This allows the FT 50 to track containers and synchronize the rejection of defective containers over a wide range of conveyor speeds and to use slat or Proline rejectors This method produces the best performance for your FT 50 Fixed Speed Conveyors Fixed speed conveyors use the Line Speed Calibration Procedure to synchronize your FT 50 and rejector The Line Speed Calibration Procedure allows an FT 50 that is not equipped with a High Resolution Encoder to perform down can inspection on fixed speed conveyor lines The Line Speed Calibration Procedure is limited to using only the Proline rejector and a fixed speed conveyor production line control system that does not allow the conveyor to stop while there are containers in the inspection area the area from the inspection trigger to the rejector centerline Industrial Dynamics Company Ltd Document 40255 0600 C
113. for damage to metal housing and for wear on the cover gaskets 2 Check to be sure the cover is securely tightened 3 Clean using a non caustic nonabrasive soap water and a soft brush Rinse with clean water e Do not wash with a high pressure nozzle e Do not steam clean Pressure Regulator and Air Filter 1 Inspect the polycarbonate sediment bowl for cracks and abrasion 2 Clean and drain the air filter sediment bowl 3 Inspect the air filter in the inspection head for clogging External Wiring 1 Check the external wiring between the sensors and the FT 50 for damage Check all connections carefully to be sure they are not loose 2 Check that insulating sleeves are in place Replacing the Rejector Pad The actual lifespan of the rejector pad depends upon the operating conditions of your production line Inspect the pad weekly and replace if worn cracked or hardened Turn off all power to your system before attempting any repair procedure See Before You Perform Any Maintenance Procedure at the beginning of this section 1 Power down the rejector 2 Remove the retaining screw and washer on the top of the rejector shoe 3 Slide the pad up to remove it from the shoe Industrial Dynamics Company Ltd Document 40255 0600 Warning Warning Chapter 7 Maintenance Procedures Insert the new pad by sliding it onto the shoe Be sure the notch in the pad backing is positioned at the bottom Replace
114. g Rejects Only Updating Constantly Target Head Height 0 999 Ticks 500 Ticks Gamma Threshold 0 5 000 Counts 750 Counts Looktime Gate 1 120 ms 17 ms Fill Level Optimization Execute Learn Target Head Height Execute Dyn Reject Pt Test Execute Dyn Prod Good Test Execute Review Fill Level Test Execute Finishing Key 2 Bulged End Status On Off Off Missing Lid Status On Off Off 2 Down Can Status On Off Off Dia Missing Lid Status On Off Off External Reject Status On Off Off Width At Down Can 1 250 mm 79 mm Height of Can 1 250 mm 125 mm Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual Function Group Function Name Parameter Default Dia Missing Lid Width 1 65 000 Pulses Updating Constantly Updating Constantly Updating Last Reject Minimum Dia Missing Lid 1 65 000 Pulses 55 Pulses Counters Key 3 Total Throughput 0 99 999 999 Total Rejects 0 99 999 999 3 Total Underfill 0 99 999 999 Total Overfill 0 99 999 999 Total Missing Lid 0 99 999 999 Total Bulged End 0 99 999 999 Total Down Can 0 99 999 999 Total Dia Missing Lid 0 99 999 999 Total External Reject 0 99 999 999 Reset All Counters Execute Reset Total Throughput Execute Reset Total Rejects Execute Reset Underfill Execute Reset Overfill Execute Reset Missing Lid Execute Reset Bulged End Execute Reset Down Can Execute Reset Dia Missing Lid Execute Reset External Reject Execute Rejector Key 4 Rejecto
115. g equation to determine this value H H 22 H Height of lowest fill level Ho Height of highest fill level Note Double check your calculations before cutting the pipe If you cut it incorrectly you can not complete the installation until you obtain a replacement pipe 3 8 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 2 Cut the vertical support pipe to the calculated length Lp removing the excess from the end that is not flanged No Description 1 Remove excess from this end 2 Flanged end Figure 3 4 Removing the excess from the vertical support pipe 3 Assemble the mounting base tripod Leave the bolts loose enough to slide the vertical support pipe inside Figure 3 5 Assembling the mounting base tripod Industrial Dynamics Company Ltd Document 40255 0600 3 9 FT 50 Fill Level Inspector Service Manual 4 Insert the vertical support pipe into the tripod until it stops Do not completely tighten the retaining bolts leave them loose enough so you can make alignment adjustments later ek da No Description 1 Support Pipe 2 Stop Plate e pgs Figure 3 6 Inserting the vertical support pipe into the base tripod 5 If you are using a standard or high mount attach the support braces to the tripod Do not completely tighten the retaining bolts leave them loose enough so you can make alignment adjustments late
116. h your unit Choices can include English Dutch French German Italian Portuguese or Spanish e Advanced Diagnostics The FT 70 uses advanced diagnostics software to identify system errors automatically Diagnostic routines are stored in the FT 70 CPU which allows you to troubleshoot problems quickly Industrial Dynamics Company Ltd Document 40255 0600 1 11 FT 50 Fill Level Inspector Service Manual Optional System Features Note The FT 50 s expandability allows you to add additional inspection capabilities to match your production requirements Depending upon the FT 50 configuration you ordered your FT 70 may contain some of the following features e Bulged End Detection Missing Lid Detection e Down Can Detection e External Reject Control e Dud Detection High and Low Container Pressure e Serial Controller Interface Modbus or IDC Protocols Programmable Logic Controller Interface PLC If you are unsure which options your unit contains refer to the System Configuration Sheet located inside a clear plastic pouch attached to the inside of the FT 50 s cover The System Configuration Sheet included with your unit lists all options that were installed at the factory Bulged End Detection Detects container lids that are bulged due to excessive pressure or contaner damage Missing Lid Detection This feature detects the presence or absence of the container lid Down Can Detection Uses an optical sensor to
117. hapter 6 Calibration Procedures Variable Speed Conveyors LED Number _ oO N O oa A OO PD If your FT 50 is installed on a variable speed conveyor line you must also install the High Resolution Encoder The encoder attaches to the conveyor and sends timing pulses to the FT 50 The FT 50 uses these timing pulses to synchronize all inspection and rejection activities with the production conveyor s speed The encoder must be calibrated for each different container type that is run on the production line The following calibration procedures apply only to FT 50 units that have Baseline Eight of the system software installed There are three different procedures depending upon your situation e Standard Conveyor Calibration Procedure for standard conveyors with a 1 5 inch pitch and you know the number of teeth on the sprocket directly contacting the underside of the main production transport chain e Unknown Sprocket Size Calibration Procedure for standard conveyors with a 1 5 inch pitch but you don t know the number of teeth on the sprocket directly contacting the underside of the main production transport chain e Non Standard Conveyor Calibration Procedure for conveyors that do not have a 1 5 inch pitch but you do know the number of teeth on the sprocket directly contacting the underside of the main production transport chain and the size of the conveyor segments chain links LED Definitions Quick Reference The followi
118. he head height should be lowered well below the liquid level Press the Arrow Key and the Static Full gamma count is displayed This is the average of 128 samples When ready to continue press the Arrow Key Use the Head Height Crank to raise the gamma beam above the liquid level as much as possible while keeping it below the container lid Press the Arrow Key and the Static Empty gamma count is displayed This is the average of 128 samples When ready to continue press the Arrow Key Industrial Dynamics Company Ltd Document 40255 0600 6 39 FT 50 Fill Level Inspector Service Manual 10 11 12 13 14 15 16 17 18 6 40 Lower the gamma beam into the liquid very slowly When the average gamma counts reach the midpoint of the Static Full and Static Empty values the system beeps and displays MIDPOINT CONTINUE SLOWLY LOWER INSP HEAD Continue to lower the head When the gamma counts reach the Static Full value the following message appears e BOTTOM GO DOWN 4 MORE TICKS IT ARROW KEY WHEN READY da Continue to lower the head 4 more ticks as indicated by the Head Height Meter and then press the Arrow Key Press the Arrow Key when you are ready to begin the Container Profile Test During this test you are required to repeat a series of actions Raise the head 1 tick and then press the Arrow Key Repeat this step until you
119. he moisture resistant fittings in the bottom of the junction box 2 Determine which pins on terminal bracket TB1 the signal wires must be attached to Normally this would be pins TB1 20 signal and TB1 21 ground however depending upon the options installed within your FT 50 these pins may be reassigned Use the View TB1 amp TB4 Pin Assignments Function to determine the proper wiring pin configuration see chapter 5 3 Connect the signal wires to the proper pins on TB1 Industrial Dynamics Company Ltd Document 40255 0600 4 15 FT 50 Fill Level Inspector Service Manual Software Configuration Before you begin configuring the FT 50 software complete the mechanical configuration as explained in the previous section To configure the FT 50 software you must perform the following procedures e Calibrate the Encoder and the Rejector Timing e Configure the Inspection Looktime Gate e Configure the Gamma Threshold If your FT 50 contains the following options you must also complete these additional procedures Configure the Missing Lid Function Configure the Bulged End Function Configure the Diameter Missing Lid Function e Configure the Down Can Function Calibrating the Encoder and Rejector Timing The encoder calibration and rejector timing are complex proce dures that require high accuracy Because of the nature of the these procedure we have included them in a separate chapter Chapter 6 Encoder Calibration a
120. he reject timing settings in the inspection unit Rejector Pad fatigue or failure Fatigued or worn pads cause the rejected container s trajectory to change Replace Rejector Pad Facility air pressure dropsoris The facility air supply pressure must be erratic maintained at 210 psi over the regulator pressure setting If facility air supply pressure drops when rejector operation is erratic install an accumulator upstream of the rejector air controls Rejector sticking or binding Check the rejector piston for smooth movement If it is binding you must replace the Servo unit See your Proline Manual for parts information Note If intermittent or erratic rejector operation continues contact Industrial Dynamics Customer Service for assistance 8 26 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 9 Using a PLC With Your FT 50 Chapter Nine Using a PLC With Your FT 50 Using a PLC With Your FT 50 sonrisas 9 3 PLE Senes Alanne a A ERE UE ERN ha ees LER 9 4 How to Determine the Signal Output Wiring 9 5 Adjusting the PLC Output Signal Pulse Width 9 5 Relay Types for Output Signals ee eR meer 9 6 Remote Alarm util avert tie Ble oh PEAS Gatien Gales hk Belted he 9 8 How to Clear a Remote Alarm 0 0 0000s cc ccc cee eens 9 8 Remote Alarm Error Number Designations 505 9 8 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Leve
121. iable speed tracking is used with the High Resolution Encoder on lines that run at more than one speed Fixed speed tracking is used on single speed lines and do not use the High Resolution Encoder For fixed lines the encoder pulse is simulated by the inspection unit s software The default is variable S1 4 Languages Switches between the main display language and the secondary display language When the secondary display language is selected a list of secondary languages appears in the Language Options Menu The default is English S1 5 System Configuration Switches the system between configuration mode and standard mode When active this mode activates various options throughout the software option menus The default is off S1 6 Not Used S1 7 Not Used S1 8 Password Enables or disables the password protect function The default is disabled Industrial Dynamics Company Ltd Document 40255 0600 10 5 FT 50 Fill Level Inspector Service Manual Dip Switch Pack S2 Slide Switches 10 6 S2 1 Baud Rate Defines the baud rate bits per second for the user serial port RS 422 423 as either 1200 or 9600 The default is 1200 baud S2 2 Handshake Flags Enables the use of the Serial Hardware Handshake lines The default is off S2 3 Parity On Off Enables the parity bit in the Serial Data transmission The default is off S2 4 Parity Odd Even Allows selection of odd or even parity when S2 3 is open The
122. ight Lock Figure 4 2 FT 50 mechanical adjustment mechanisms 4 4 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Before You Begin Before you begin configuring the FT 50 verify the following is completed The inspection head is completely installed and is correctly centered and leveled over conveyor chain as explained in Chapter 3 Installing the FT 50 The rejector is completely installed and is aligned correctly with the conveyor chain as explained in the rejector manual The takeaway conveyor is configured properly as explained in the rejector manual All ramp actions position the containers properly on the conveyor chain when they reach the inspection area Containers ride smoothly on the conveyor do not slide and are not agitated when they reach the inspection area The rejector air pressure is stable and set at the correct pressure All power cable wiring to the FT 50 and signal cable wiring to the rejector encoder and any remote sensors are complete The Safety Interlock Switch is turned on This switch must be on in order to activate the Gamma Generator Industrial Dynamics Company Ltd Document 40255 0600 4 5 FT 50 Fill Level Inspector Service Manual Aligning the Fill Level Inspection Beam 3 You must adjust the FT 50 s head height so the fill level inspection beam contacts the container at the proper height The FT 50 can p
123. indicates that either switch S11 is not set to the Write Enabled position or that EEPROM chip U29 is faulty To correct this error set switch S11 to the Write Enabled position position A or replace EEPROM chip U29 Industrial Dynamics Company Ltd Document 40255 0600 8 3 FT 50 Fill Level Inspector Service Manual 8 4 Error Number 9 The write to EEPROM was not successful This error indicates that either switch S11 is not set to the Write Enabled position or that EEPROM chip U29 is faulty To correct this error e Set switch S11 to the Write Enabled position position A execute the Save Default Constants Function and then set switch S11 to position C Check EEPROM U29 by executing the Load Default Constants function If an error occurs replace U29 and then execute the Save Defaults Function Error Number 10 This error occurs when the number of consecutively rejected containers exceeds the limit set in the Consecutive Fill Level Reject Alarm Function Error Number 11 This error occurs when the number of consecutively rejected containers exceeds the limit set in the Consecutive Missing Lid Reject Alarm Function Error Number 12 This error occurs when the number of consecutively rejected containers exceeds the limit set in the Consecutive Bulged End Reject Alarm Function Error Number 13 This error indicates the gamma counts detected by the scintillation tube are 12 below the of the reject threshold leve
124. iner and observe the rejector timing Based on where the rejector pad contacts the container you must increase or decrease the number of teeth until the can contacts the pad correctly 23 To verify the calibration press Key 4 until REJECT NEXT appears and then press the Arrow Key to enter the number of containers you want to reject consecutively Choose a number such as 6 or higher to provide enough attempts to make adjust ments When the number reaches zero you must repeat this step to reactivate the rejector Industrial Dynamics Company Ltd Document 40255 0600 6 15 FT 50 Fill Level Inspector Service Manual Note 6 16 24 With the conveyor running very slowly so the reaction delay does not effect the result place a production container upstream of the FT 50 so that it passes through the FT 50 without slipping If the container appears to make contact on the upstream third of the rejector pad proceed to step 26 The slat rejectors have a variation factor of 0 5 inch If you are using a slat rejector average the accuracy over several rejects using a single slat 25 26 27 If the container is not rejected properly make changes to the measured distance or number of sprocket teeth as follows e Verify the Inspect Trigger to C L Rejector distance is measured and entered correctly see steps 8 and 9 e Verify the number of conveyor drive sprocket teeth is entered correctly see step 15 The container p
125. iner diameter is 66 mm the calculation error factor is 1 tooth Slipping a short piece of pipe over the container neck is a useful way to increase the width of the can at the trigger point If you choose to do this you must repeat step 9 in order to enter the pipe diameter 19 Open dip switch S1 6 20 Start the conveyor and run it at the highest available speed You may not be able to achieve the highest expected production speed unless the filler unit is running 21 Press Key 5 until CALIBRATE ENCODER appears and press the Arrow Key to execute the encoder calibration routine This procedure takes several seconds to complete When READY is displayed proceed to the following step 22 Place the container on the conveyor upstream of the FT 50 so the container passes through the inspection tunnel without slipping The FT 50 automatically calculates the prescaler value It takes several seconds for the FT 50 to make this calcu lation When RUN 16 CONTAINERS appears proceed to the following step 23 Run the container 16 times it is not necessary for the containers to pass the rejector through the FT 50 inspection tunnel without slippage When finished the FT 50 automati cally completes the encoder calibration calculations including the Calibrate Encoder Value Encoder Prescaler Value Gamma Sample Cutoff Limit and Conveyor Drive Sprocket Teeth 24 Close dip switch S1 6 and then stop the conveyor 25 If you used a conta
126. iner other than a production container for the calibration or used the pipe method press Key 5 until CAN WIDTH AT TRIG appears and enter in millimeters the production container s width at the trigger point see steps 14 and 15 Industrial Dynamics Company Ltd Document 40255 0600 Note Chapter 6 Calibration Procedures Fine Tuning the Rejector Timing To fine tune the calibration accuracy you may need to adjust the number of sprocket teeth estimated during the Calibrate Encoder Routine Experiment with a production container and observe the rejector timing Based on where the rejector pad contacts the container you must increase or decrease the number of teeth until the can contacts the pad correctly 26 To verify the calibration press Key 4 until REJECT NEXT appears and then press the Arrow Key to enter the number of containers you want to reject consecutively Choose a number such as 6 or higher to provide enough attempts to make adjust ments When the number reaches zero you must repeat this step to reactivate the rejector 27 With the conveyor running very slowly so the reaction delay does not effect the result place a production container upstream of the FT 50 so that it passes through the FT 50 without slipping If the container appears to make contact on upstream third of the rejector proceed to step 29 The slat rejectors have a variation factor of 0 5 inch If you are using a slat rejector average the accur
127. ing underfill inspection This is a highly complex procedure and you should contact IDC Customer Service to determine if Fill Level Optimization is suitable to your application before attempting the procedure Fill Level Optimization has two goals To precisely tune the Underfill Threshold to the container fill level To precisely align the Inspection Head Height to the Underfill Threshold Before you begin the Fill Level Optimization routine you must do the following e Calibrate the encoder if needed e Calibrate the Scintillation Tube Detector if needed Level the Inspection Head e Obtain an approved 100 percent reject production container from your Quality Assurance Department This is critical for performing the Fill Level Optimization properly e Obtain an approved 100 percent acceptable production container from your Quality Assurance Department Industrial Dynamics Company Ltd Document 40255 0600 6 37 FT 50 Fill Level Inspector Service Manual Leveling the Inspection Head It is critical that you level the Inspection Head over the production line If the head is not level you will not achieve fill level optimization 1 Place a small carpenter s level along the bottom of the FT 50 so that it spans the inspection tunnel You may need to raise the inspection head to allow room to fit the level between the conveyor and bottom of the FT 50 2 If the head is not level you must loosen the FT 50 mounting st
128. ization if need gamma threshold v Adjust bulged Configure bulged end sensor end function rufen Configure missing lid Your FT 50 may not Adjust missing lid sensor gt i function contain these options These procedures apply l only if your FT 50 is so equipped j i i Adjust dud detection Configure dud sensor detection function Adjust down can sensor 39 Configure down can function i Configure external reject function Figure 4 1 FT 50 Inspection System Configuration Flow Chart Industrial Dynamics Company Ltd Document 40255 0600 4 3 FT 50 Fill Level Inspector Service Manual Mechanical Configuration To mechanically configure the FT 50 you must complete the following procedures e Adjust the Head Height for Fill Level Inspection e Adjust the Inspection Trigger height If your FT 50 contains the following options you must also complete these additional procedures e Adjust the Missing Lid Sensor height e Adjust the Bulged End Sensor height e Adjust the Down Can Sensor height Wire the External Reject Function After you adjust all mechanical parameters proceed to the Software Configuration section in this chapter No Description 1 Head Height Adjustment Crank Head Height Counter Centerline Trigger Bracket Height Adjustment Crank Centerline Trigger Bracket Centerline Trigger Bracket Height Lock 6 Head He
129. k to see if the cylinder is binding by shutting of the air pressure to the rejector and moving the rejector in and out by hand If it is binding rebuild the rejector with a rebuild kit 3 The rejector Pulse Width function may need adjustment Contact IDC Customer Support for assistance The rejector remains extended 1 Turn the FT 50 s power off If the rejector remains extended repair or replace the Rejector Assembly 2 Close dip switch S2 8 on the FT 50 processor card and then turn cycle the power e If LED 2 remains on replace the processor card e Ifthe warning beacon is on and LED 2 is off replace the power supply 8 22 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures The rejector does not function 1 2 Is the rejector activated Turn the Rejector Status function on If you hear a clicking sound but the rejector does not activate the air pressure is not turned on Turn on air pressure to the rejector The rejector Pulse Width function may need adjustment Contact IDC Customer Support for assistance Disconnect the wire at TB1 26 and use a digital voltmeter to measure the resistance between the wire and TB1 25 The resis tance should be 165 ohms 10 Turn the FT 50 on and off and then use the Fire Rejector On Demand function to fire the rejector LED 2 on the processor card should flash for each reject pulse e Ifthe LED flashes but the reject
130. l To correct this problem calibrate the scintillation tube or SSD Error Number 14 The gamma counts detected by the scintillation tube decreased rapidly to a value that is 75 percent below the average count for the last eight containers To correct this problem calibrate the scintillation tube or SSD Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Error Number 15 The Missing Lid sensor input state logic level remains high This occurs when two or more consecutive signals are received from the trigger beam which indicates containers are passing through the unit and no signals are received from the missing lid sensor To correct this problem Check LED 7 dip switch S2 7 closed and S2 8 closed If the LED is on the input level is high Check the signal level on terminal block TB1 5 if you are using a nonferrous sensor check TB1 11 If no container is under the sensor the voltage range should be 3 to 5 volts If a container is under the sensor the voltage range should be 13 to 15 volts If the voltage is not within these ranges replace the sensor Error Number 16 The trigger beam is not sensing containers The gamma count pattern indicates containers are passing through the gamma beam however no trigger signal is received To correct this problem e Check to see that the trigger amplifier sensitivity is correctly adjusted The sensitivity may be set too
131. l Dynamics Company Ltd Document 40255 0600 5 19 FT 50 Fill Level Inspector Service Manual 5 20 Reset Total Bulged End Clears and resets the Total Bulged End counter to zero Record all valuable data before executing this function To reset the Total Bulged End 1 Press Key 3 until RESET BULGED END appears 2 Press the Arrow Key to execute Reset Total Down Can Clears and resets the Total Down Can counter to zero Record all valuable data before executing this function To reset the Total Down Can 1 Press Key 3 until RESET DOWN CAN appears 2 Press the Arrow Key to execute Reset Total Diameter Missing Lid Clears and resets the Total Diameter Missing Lid counter to zero Record all valuable data before executing this function To reset the Total Diameter Missing Lid 1 Press Key 3 until RESET DIAMETER MISSING LID appears 2 Press the Arrow Key to execute Reset Total External Rejects Clears and resets the Total External Rejects counter to zero Record all valuable data before executing this function To reset the Total External Rejects 1 Press Key 3 until RESET TOTAL EXTERNAL REJECTS appears 2 Press the Arrow Key to execute Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Rejector Functions Group Rejector Status Disables or enables the reject signal transmitted by the FT 50 to the rejector This function also effects the External Reject Function in th
132. l Inspector Service Manual 9 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 9 Using a PLC With Your FT 50 Using a PLC With Your FT 50 Programmable Logic Control PLC signals are provided by AC or DC optically isolated solid state Relays The FT 50 has separate PLC signals with a programmable pulse width 1 120 milli seconds that transmits one pulse for each event The signals are available in the FT 50 s I O Junction Box The FT 50 can report the following signals to a PLC e Sensor Gamma Failure Alarm e Latched Consecutive Alarms e Rejector Fill Level Status OFF e Total Rejects Total Throughput Fill Level Rejects e Bulged End Rejects Missing Lid Rejects and the following Remote Alarms e Rejector Fill Level Status OFF e Fill Level Series Alarm e Bulged End Series Alarm Missing Lid Series Alarm e Gamma Failure Alarm e Sensor Failure Alarm Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual PLC Series Alarms To configure your FT 50 for operation with a PLC you must activate the PLC Series Alarms functions in the FT 50 s software To activate the PLC Series Alarms 1 Open dip Switch S1 5 to enter the System Configuration 2 Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select CALIBRATE 3 Press Key 5 until PLC SERIES ALARMS appears and press the Arrow Key to select PRESENT 4 Close Dip switch S1
133. l the diagnostic error number is cleared The Remote Alarm Option and the PLC Interface Option may be used in the FT 50 simultaneously however they may not occupy the same signal output lines To determine the signal output wiring in your FT 50 see How to Determine the Signal Output Wiring in the previous section How to Clear a Remote Alarm A Remote Alarm is cleared when it is overwritten by another alarm or when the operator manually clears the alarm To clear the alarm manually 1 Press Key 6 and the error appears in the control panel display 2 Press the Arrow Key to clear the error Remote Alarm Error Number Designations Error Number Remote Alarm Designation 2 66 Rejector Fill Level Status Off 10 Fill Level Series Alarm 11 Missing Lid Series Alarm 12 Bulged End Series Alarm 13 14 Gamma Failure 15 16 17 32 Sensor Failure Industrial Dynamics Company Ltd Document 40255 0600 Chapter 10 Controller Board Dip Switches and LEDs Chapter Ten Controller Board Dip Switches and LEDs Controller Board Switch Locations Switch Function Configurations Switch Function Definitions Dip Switch Pack S1 S1 1 Inspection Logic S1 2 Software Write Protect S1 3 Speed Tracking 51 4 Languages S1 5 System Configuration S1 6 Not Used S1 7 Not Used S1 8 Password Dip Switch Pack 82 S2 1 Baud Rate 52 2 H
134. lead Examine the transformer carefully to determine if it is shielded and if so ground the shield 2 3 11 230 3 e Q oS uH 2 Pm 7 Ih 8 O e 0 O O a 4 115 230 VAC os C m o I 10 e e o o N o 6 No Description Plant Power Panel FT 50 Power Junction Box Voltage Select Switch A OO N Connect FT 50 pigtail leads to input power wires FT 50 Ground Stud External Breaker or Disconnect White Blue Black Brown gt O ON OW o Figure 3 27 Main power wiring Example D 3 30 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Chapter Four Configuring the FT 50 for Operation Chapter Overview tits as 4 3 Mechanical Configuration ii A ERO TOR ERAN a ds 4 4 before You B plti e pr ea ON 4 5 Aligning the Fill Level Inspection Beam 0 0000005 4 6 Aligning the Inspection Trigger isses nnne 4 8 Aligning the Missing Lid Sensor Height 05 4 10 Aligning the Bulged End Sensor Height issue 4 12 Aligning the Down Can Sensor lees enn 4 14 Wiring the External Reject Function ooommoommommm cm 4 15 Software Confipurdliono ci o coe ster REPE ci Rien 4 16 Calibrating the Encoder and Rejector Timing 4 16 Configuring the Inspection Looktime Gate issue 4 17 Configuring the Gamm
135. low e Check to see if LED 8 is on when no container is present If so it is blocked clean the trigger lens e Check the signal at TB1 2 It should be less than 1 volt when the beam is blocked by a container and 17 20 volts when the beam is clear e Check to see that the gamma threshold is set correctly It may be set slightly high False errors can occur when the line is stopped and the gamma threshold is too high Error Number 22 This error occurs when an encoder pulse is missed The encoder may be failing To correct this error Check LED 3 and the signal at TB1 23 while the conveyor is running LED 3 should pulse regularly and the signal at TB1 23 should be smooth and regular If LED 3 pulses irregularly or remains dark encoder pulses are missing Replace the encoder Industrial Dynamics Company Ltd Document 40255 0600 8 5 FT 50 Fill Level Inspector Service Manual Error Number 23 This error occurs when an extra encoder pulse is detected This error can occur when the conveyor stops or starts suddenly To correct this error Check LED 3 and the signal at TB1 23 while the conveyor is running LED 3 should pulse regularly and the signal at TB1 23 should be smooth and regular If LED 3 pulses irregularly extra encoder pulses are occurring Check the encoder wiring for water shorting problems Error Number 24 This error indicates the high resolution encoder is scaled lower than the minimum allowable distanc
136. m name for the Bulged End Option Any instance in which Bulged End would have appeared in the software is replaced by the custom label you created The following options are effected e Bulged End Status e Total Bulged End e Reset Bulged End e Alarm Bulged End e Bulged End Text e Bulged End This manual assumes the default name for this option If you change the default text remember to substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 Note Chapter 5 System Software Down Can Prepares the FT 50 software for down can inspection by inserting the necessary options into the software When set to Not Present it removes the options necessary for down can inspection from the software This function does not activate or deactivate down can inspection it only readies the machine To turn down can inspection on or off you must use the Down Can Status function Down Can Text Allows you to create a custom name for the Down Can Option Any instance in which Down Can would have appeared in the software is replaced by the custom label you created The following options are effected e Down
137. nce is acceptable If there are still significant early late problems and you are certain that you have a standard conveyor chain contact the Industrial Dynamics Customer Service If you performed the previous step step 29 at production speed then proceed to step 34 If you did not perform the previous step step 29 at production speed then you must repeat steps 19 thru 24 at production speed When you finish return to step 29 Press Key 5 until CHAIN VELOCITY appears Note this value because you need to enter it in the following step Press Key 5 until MAXIMUM CONVEYOR SPEED appears and enter the CHAIN VELOCITY value from the previous step The optimum encoder value for the current line speed is now calculated including the Calibrate Encoder Value Encoder Prescaler Value and Gamma Sample Cutoff Limit While the conveyor is running at production speed place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT 50 If the reject is late check to be sure the encoder coupling is not slipping Try a rejection with a thin layer of grease on the pad If the resulting mark in the grease starts in the upstream third of the pad face and is centered then performance is acceptable If there are still significant early late problems and you are certain that you have a standard conveyor chain contact the Industrial Dynamics Customer Service To store the settings in system memor
138. ncoder Pulse Missed 23 Extra Encoder Pulse Detected 24 High Resolution Encoder Minimum Distance Error 25 High Resolution Encoder Minimum Time Error 27 High Resolution Encoder Failure 33 Down Can Detection Error Exceeded Consecutive Reject Limit 34 Down Can Detection Error False Trigger 46 Consecutive External Reject Alarm 47 Encoder Resolution Too Low 48 AC Input Voltage Low Brownout Detected 49 User Defaults Closed For One Or More Settings 50 System Defaults Loaded For One Or More Settings 51 Container Passed With No Encoder Pulses 52 Container Less Than 10 Ms 53 Reject Watchdog Detected Queue Error Industrial Dynamics Company Ltd Document 40255 0600 54 58 61 66 67 68 72 86 87 88 89 90 91 117 118 119 120 121 Chapter 5 System Software Reject Queue Count Abnormally Large Container Detected Reject Delay Position Error Fill Level Reject Detection is Turned Off During Inspection Diameter Missing Lid Error Exceeded Consecutive Reject Limit Diameter Missing Lid Error No Encoder Pulse Production Line Speed Too High BBU RAM Batter is Low Broken Slat Or Pin Broken Slat Sensor Failure Slat Sensor Is Off Broken Slat Sensor Adjustment Error Broken Slat Pushplate Modbus Serial Interface Framing Error Modbus Serial RX Overrun Error Modbus Serial Parity Error Modbus Serial RX Receive Rate Error Modbus CTS Line Rate Error Error conditions that cause an alarm when the Beacon Status function is
139. nd Rejector Timing Procedures Proceed to Chapter 6 and complete the required procedure When finished return to this chapter and proceed to Configuring the Inspection Looktime Gate 4 16 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Configuring the Inspection Looktime Gate The Inspection Looktime Gate defines the time interval when the radiation measurement is taken This interval coincides with the moment the container passes through the inspection beam No Description Gamma Counts Time Width of Container Looktime Gate NR SON Container enters Gamma beam Container exits Gamma beam Figure 4 8 The Inspection Looktime Gate Open the radiation source safety shutter by pulling the actuating rod out until it stops Start the conveyor and run it at the maximum production speed If your FT 50 is not in the Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the CALIBRATE MODE Press Key 5 until TIME WIDTH OF CAN appears Place a sample production container on the conveyor far enough upstream of the FT 50 so that it does not slip on the chain and is positioned correctly as it passes through the inspection tunnel Record the value that appears in the TIME WIDTH OF CAN display Repeat steps 5 and 6 four more times and then average the values A D Industrial Dynamics Com
140. ng table defines the LEDs located on the controller board For more information on the LED banks refer to Chapter 10 Controller Board Dip Switch and LED Descriptions S1 B1 S1 B2 S2 B1 S2 B2 Diag Error Label 1 Remote Clr Inlabeler 1 Reject Pulse Label 2 Broken Slat or Batch Rej Inlabeler 2 Hi Res Encoder Label 3 Lw Res Encoder Inlabeler 3 Low Foam Label 4 Optical FL Inlabeler 4 Down Can Smash Label 5 FSR 2 INPUT Inlabeler 5 Bulged High Cap Label 6 Extrn or FSR 1 Cntr Present Missing Cap Lid Label 7 Slat Backup or Reject Verify System Timing Trigger Label 8 Trigger Trigger Industrial Dynamics Company Ltd Document 40255 0600 6 5 FT 50 Fill Level Inspector Service Manual Conversion Factors The following formulas may be helpful when performing the calibration procedures Converting inches to millimeters 25 4 x inches millimeters Converting feet per minute to meters per minute 3 28 x feet meters Calculating containers per minute cpm containers per hour O co PRODR How to Determine if You Have Baseline Eight Your FT 50 must contain Baseline Eight of the system software to use the calibration procedures listed in this section If you do not have Baseline Eight contact IDC Customer Service for instructions pertaining to your baseline 1 Turn the FT 50 power on or press the reset button and the FT 50 will begin its start up sequence 2 Read the software version code in the displayed status message xax I
141. ngle slat 21 22 If the container is not rejected properly make changes to the measured distance or number of sprocket teeth as follows e Verify the Inspect Trigger to C L Rejector distance is measured and entered correctly see steps 8 and 9 e Verify the number of conveyor drive sprocket teeth is entered correctly see step 15 The container position at reject can be in error by 0 5 inch for every 12 inches of distance from the inspection trigger to the rejector centerline or slat assembly For example e If the Inspection Trigger to Centerline Rejector distance is 24 inches and the container is 1 inch upstream of the rejector when it fires then the number of drive sprocket teeth should be reduced by one e If the container is 1 inch down stream when the rejector fires the number of teeth should be increased by one Run the conveyor at the same speed as in step 16 and place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT 50 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures If the reject is late check to be sure the encoder coupling is not slipping Try a rejection with a thin layer of grease on the pad If the resulting mark in the grease starts in the upstream third of the pad face and is centered then performance is acceptable If there are still significant early late problems and you are certain that yo
142. ning the conveyor at maximum speed you must repeat steps 17 and 18 later when maximum speed is available 17 18 Press Key 5 until CHAIN VELOCITY appears Note this value because you need to enter it in the Maximum Conveyor Speed function step 18 Press Key 5 until MAXIMUM CONVEYOR SPEED appears and enter the CHAIN VELOCITY value from the previous step The optimum encoder value for the current line speed is now calculated including the Calibrate Encoder Value Encoder Prescaler Value and Gamma Sample Cutoff Limit Industrial Dynamics Company Ltd Document 40255 0600 6 9 FT 50 Fill Level Inspector Service Manual Note 6 10 19 20 To verify the calibration press Key 4 until REJECT NEXT appears and then press the Arrow Key to enter the number of containers you want to reject consecutively Choose a number such as 6 or higher to provide enough attempts to make adjust ments When the number reaches zero you must repeat this step to reactivate the rejector With the conveyor running very slowly so the reaction delay does not effect the result place a production container upstream of the FT 50 so that it passes through the FT 50 without slipping If the container appears to be centered on the upstream third of the rejector pad at the point of contact proceed to step 22 The slat rejectors have a variation factor of 0 5 inch If you are using a slat rejector average the accuracy over several rejects using a si
143. nnel without slippage When finished the FT 50 automati cally completes the encoder calibration calculations including the Calibrate Encoder Value Encoder Prescaler Value Gamma Sample Cutoff Limit and Conveyor Drive Sprocket Teeth Close dip switch S1 6 and then stop the conveyor If you used a container other than a production container for the calibration or used the pipe method press Key 5 until CAN WIDTH AT TRIG appears and enter in millimeters the production container s width at the trigger point see steps 8 and 9 Measure the distance in millimeters from the trigger sensor beam to the centerline of the rejector If you are using a slat rejector measure from the beam to the upstream edge of the slat assembly Accurate measurement is extremely important for proper calibration Press Key 4 until INSPECT TRIG TO C L REJ appears and use the Arrow Key to enter the measurement in millimeters Press Key 5 until CHAIN VELOCITY appears Note this value because you need to enter it in the following step Press Key 5 until MAXIMUM CONVEYOR SPEED appears and enter the CHAIN VELOCITY value The optimum encoder value is now calculated including the Calibrate Encoder Value Encoder Prescaler Value and Gamma Sample Cutoff Limit Fine Tuning the Rejector Timing To fine tune the calibration accuracy you may need to adjust the number of sprocket teeth estimated during the Calibrate Encoder Routine Experiment with a production conta
144. nspection beam by placing a good production container in the inspection tunnel so that it blocks the inspection beam If your FT 50 is the extra wide inspection tunnel model you do not need to attenuate the inspection beam unless the LEDs are constantly at maximum Industrial Dynamics Company Ltd Document 40255 0600 6 35 FT 50 Fill Level Inspector Service Manual 4 Slowly turn the High Voltage Output Adjustment The STD Calibration LEDs will rise until they peak and then begin to fall Stop precisely when the LEDs begin to fall 5 The peak the point immediately before the LEDs begin to fall is the proper calibration point Turn the adjustor counter clockwise slowly until the LEDs return to the peak level again This is the proper setting Note Continuing to turn the adjustor past the calibration point will cause all LEDs to light This is the high noise region of the STD sensitivity range This is not the correct setting and will create malfunctions during fill level inspection 6 36 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Fill Level Optimization Before You Begin Fill Level Optimization is used to increase fill level inspection accuracy for applications that require higher accuracy than is achieved through normal fill level inspection parameters It narrows the margin between acceptable and rejectable containers Fill Level Optimization should only be used when perform
145. oads s y 3 3 Screw Terminals 4 Plug in Module Y S 4 5 Equivalent Circuit Only l 6 Amplifier 5A 2 Sa ieee ale O j 7 Pins 15 see o y E 8 Sockets in Mounting Rack 9 Pull up Resistor 14 6 5 10 Edge Connector NL 11 Logic Vec A L E D i Rc 12 Input TEB i ook D AS 13 Ground Common H 1d E 14 Mounting Rack P 15 Fuse Plug in 16 Load Connected to either the positive or 10 8 7 negative side of the source Figure 9 1 0 60 Volts DC 1 Amp max 2 ma leakage 10 ma min load 16 1 16 No Description VAC 1 1 Field j 2 2 Diode must be used on inductive loads i 3 3 3 Screw Terminals 4 4 Plug in Module Y Y 5 Equivalent Circuit Only i 6 Zero Voltage Check 5A Pd 1 7 Pins T T A S H 8 Sockets in Mounting Rack 15 i 9 Pull up Resistor 14 5 10 Edge Connector rA NA 11 Logic II 12 Input s Vcc ris m 3 l Hs 13 Ground Common 11 12 3 3K O 4 14 Mounting Rack 13 O 15 Fuse Plug in r4 16 Load Connected to either the positive or 9 8 negative side of the source 10 7 Figure 9 2 0 120 Volts AC 1 Amp max 2 ma leakage 50 ma min load Industrial Dynamics Company Ltd Document 40255 0600 9 7 FT 50 Fill Level Inspector Service Manual Remote Alarm The FT 50 Remote Alarm option uses the Diagnostic Error signals to latch hold LOW or SINK the appropriate PLC output lines Each Remote Alarm is initiated by a diagnostic error number or group of error numbers and remains latched unti
146. ocked by the container material and container s contents The remaining radiation emerges from the opposite side where the amount is measured by a radiation detector Es pus Figure 1 2 Scanning the container The amount of radiation measured is the containers radiation profile which is then compared against a master profile Any container that deviates from the master container profile fails inspection and is tagged for removal from the production line A master container profile is created by scanning several normal containers containers that are filled to the proper level The average is then calculated and the median container profile is determined Industrial Dynamics Company Ltd Document 40255 0600 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview To allow for slight variances in the fill level an upper gamma threshold and a lower gamma threshold are plotted The upper and lower thresholds form the tolerance range of the master profile Any scanned container that falls outside of this tolerance range fails the inspection If the containers profile exceeds the upper gamma threshold it is an underfill conversely if it exceeds the gamma threshold it is an overfill How Underfill Inspection Works The FT 50 is positioned so that containers pass through gamma beam at a point just below the desired fill level poin
147. od messages received e Bad is the number of bad messages received Other is the number of messages received with an incorrect Serial ID Number For further information refer to the Serial Communication Manual PLC Output Pulse Width Defines the output pulse width of all pulsed PLC outputs The range can be adjusted from 1 to 120 ms The output pulse from inspection functions is timed to pulse at the moment detection is made The Total Reject Output pulse occurs when the rejector is fired The Total Throughput pulse occurs when the container passes through the inspection trigger See Chapter 9 Using a PLC With Your FT 50 for more information Industrial Dynamics Company Ltd Document 40255 0600 5 25 FT 50 Fill Level Inspector Service Manual 5 26 Time Width Of Can The time in milliseconds it takes the container to pass through the trigger beam See also Looktime Gate To change the Time Width of Can value 1 Press Key 5 until TIME WIDTH OF BOTTLE appears 2 With the conveyor operating at maximum production speed place a sample production container on the conveyor far enough upstream of the FT 50 so the container is positioned correctly and does not slip on the conveyor chain as it passes through the inspection area 3 Record the Time Width value that appears Repeat steps 2 and 3 four more times and then calculate the Looktime using the following equation AA ve sobe 4 Press Key luntil LOOKTIME GATE app
148. of containers that can be inspected include am nca ese Figure 1 4 Some container types that can be inspected Container Spacing A minimum of 3 mm spacing between containers at the trigger point is required for proper triggering Containers must not be stacked or interleaved Control Panel The Control Panel Interface is mounted directly into the FT 70 and allows the operator access to all system controls The control panel consists of six function selection keys two arrow keys and a two line liquid crystal display LCD which displays system messages in the selected language 1 10 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 1 FT 50 System Overview System Software The system software is contained in a set of upgradable PROMs that are mounted on the processor board Some of the software capabilities are Multiple Container Types If you run different container types on your production line this feature allows you to switch between types quickly without having to reconfigure all container parameters Allows you to store container type parameters for up to 20 different containers e Password Protection Allows you to lock out access to system control parameters while allowing access to system status information Multiple Languages Allows you to select the language used to display all system information The language choices depend upon the language options you ordered wit
149. onfigure the FT 50 for a specific container and then save the configuration to memory for recall when switching between container types When you switch production between container types you need only select that container type from the Current Container Type list and all settings are loaded The number of container types is determined by the Of Container Types function and the name for each container type is entered in the Container Text function Fill Level Prepares the FT 50 software for fill level inspection by inserting the necessary options into the software When set to Not Present it removes the options necessary for fill level inspection from the software This function does not activate or deactivate fill level inspection it only readies the machine To turn fill level inspection on or off you must use the Fill Level Status function Underfill Text Allows you to create a custom name for the Underfill Inspection Option Any instance in which Underfill would have appeared in the software is replaced by the custom label you created The following options are effected e Underfill Status e Total Underfill e Reset Underfill e Alarm Underfill e Underfill Text Industrial Dynamics Company Ltd Document 40255 0600 5 31 FT 50 Fill Level Inspector Service Manual Note Note 5 32 This manual assumes the default name for this option If you change the default text remember to substitute the new name when rea
150. or If you are using a slat rejector measure from the beam to the upstream edge of the slat assembly Accurate measurement is extremely important for proper calibration Press Key 4 until INSPECT TRIG TO C L REJ appears and use the Arrow Key to enter the measurement in millimeters Measure the diameter of the production container in milli meters at the point where the container intersects the trigger beam This is the containers can width at the trigger point Press Key 5 until CAN WIDTH AT TRIG appears and enter in millimeters the production container s width at the trigger point Measure the diameter of the container in millimeters at its widest point This is the containers maximum diameter Press Key 5 until MAXIMUM CAN DIAMETER appears and enter in millimeters the production container s maximum diameter Press Key 5 until MAXIMUM LINE SPEED appears and enter the line speed in cpm for your conveyor This value assumes 12 mm container spacing for preliminary calculations Industrial Dynamics Company Ltd Document 40255 0600 6 19 FT 50 Fill Level Inspector Service Manual Note 6 20 Executing the Encoder Calibration Routine Use the largest possible opaque container when executing the Calibrate Encoder Routine The larger and more opaque the container the greater the accuracy of the sensor readings For example if the test container diameter is 28 mm the calculation error factor is 2 teeth If the test conta
151. or does not fire replace the power supply e If the LED does not flash replace the processor card Unstable Main Power Surges sags and transients in the AC mains can cause the inspection system to falsely reject good containers If this occurs try the following procedures 1 Check the AC power mains powering the inspection unit using line voltage measuring equipment to detect surges sags and transients Check the AC power mains neutral and ground lines for common mode voltages and currents Industrial Dynamics Company Ltd Document 40255 0600 8 23 FT 50 Fill Level Inspector Service Manual Terminal and Conductor Damage Terminal and conductor damage can cause intermittent open circuits If this occurs try the following procedures 1 Check all the cable connections for terminal and conductor damage If damaged replace the cable 2 Check all inspection unit and valve terminals for signs of moisture or water deposits If moisture is found use filtered dry compressed air to dry the unit Note If intermittent or erratic rejector operation continues contact Industrial Dynamics Customer Service for assistance 8 24 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Quick Reference Troubleshooting Guide Possible Cause Corrective Action Containers are not rejected Rejector is not being energized by inspection unit Is the inspector detecting any
152. orn out and must be replaced You can view the active gamma counts by using the Gamma Counts function High or erratic gamma counts If the gamma counts suddenly increase significantly or become erratic check to be certain the STD is grounded properly 1 Remove the STD and wipe it with a clean cloth 2 Wipe the mounting clamp and chassis also 3 Check to be sure the grounding wire is secure at both ends 4 Replace the STD making sure the mounting clamp contacts the STD firmly and cleanly Solid State Detector SSD High or erratic gamma counts If the gamma counts suddenly increase significantly or become erratic check to be sure the grounding wire is secure at both ends Gamma counts reduce to zero The detector power supply has failed e If the detector power supply led is red the power supply has failed and must be replaced e If the detector power supply is off the detector is not getting power from the Main Power Supply Board Test the Main Power Supply Board Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures e Ifthe detector power supply led is green the power supply is functioning properly Check the detector because the crystal in the detector has failed Replace the SSD Optical Sensors False triggers suddenly increase or reject timing malfunctions occur 1 Inspect and clean the lenses Use a cotton swab and isopropyl alcohol to clean the lense If
153. osition at reject can be in error by 0 5 inch for every 12 inches of distance from the inspection trigger to the rejector centerline or slat assembly For example e If the Inspection Trigger to Centerline Rejector distance is 24 inches and the container is 1 inch upstream of the rejector when it fires then the number of drive sprocket teeth should be reduced by one e If the container is 1 inch down stream when the rejector fires the number of teeth should be increased by one Run the conveyor at the same speed as in step 16 and place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT 50 If the reject is late check to be sure the encoder coupling is not slipping Try a rejection with a thin layer of grease on the pad If the resulting mark in the grease starts in the upstream third of the pad face and is centered then performance is acceptable If there are still significant early late problems and you are certain that you have a standard conveyor chain contact the Industrial Dynamics Customer Service If you performed the previous step step 26 at production speed then proceed to step 31 If you did not perform the previous step step 26 at production speed then you must repeat steps 12 thru 17 at production speed When you finish return to step 26 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures 28 Press Key 5 until C
154. oubleshooting ooocooccoccccncco 8 22 Quick Reference Troubleshooting Guide 00005 8 25 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Diagnostic Error Messages The amber Warning Beacon on top of the Inspection Head signals an alarm or error condition by blinking rapidly 1 Press the Question Mark Key to view the error number in the LCD 2 Press the Arrow Key to scroll through the error description and to clear the error condition When you clear the error the message resets to zero Error Number 2 An attempt was made to activate the rejector while the Rejector Status Function is turned off To correct this error turn the Rejector Status Function on Error Number 5 The maximum limit of 32 containers between the trigger beam and the rejector has been exceeded Measure the container s width at the point where the inspection trigger contacts the container and verify that this value is the value in the Can Width At Trig Function Error Number 6 A consecutive reject timing error that occurs when an encoder pulse is missed One pulse per container is required and starting and stopping the conveyor suddenly while a container is in the inspection trigger zone or improper encoder calibration caused a missed pulse To correct this error calibrate the encoder or replace the encoder Error Number 8 The EEPROM cannot be erased This error
155. ould be off when the container is blocking the beam and on when the beam is not blocked Replace the amplifier cover Industrial Dynamics Company Ltd Document 40255 0600 6 33 FT 50 Fill Level Inspector Service Manual Radiation Detector Calibration Procedure The radiation sensor contained in the FT 50 is one of two types e Solid State Detector SSD e Scintillation Tube Detector STD Solid State Detector The Solid State Detector SSD uses a sensor and circuit board to detect the strength of the gamma beam as it contacts the sensor The SSD does not require calibration Scintillation Tube Detector The Scintillation Tube Detector STD uses a Scintillation Tube to capture gamma rays and measure them The Scintillation Tube requires calibration approximately every three years 6 34 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Calibrating the Scintillation Tube Detector The calibration procedure uses the Calibration LED on the Calibration Board as an adjustment reference Scintillation Detector Calibration Procedure 1 Clear the inspection tunnel of all containers so that nothing is blocking the gamma inspection beam 2 Turn the High Voltage Output Adjustment counterclockwise until it stops No Description 1 STD Calibration LED 2 High Voltage Output Adjustment 00000000000 Figure 6 3 Calibrating the STD 3 Attenuate the i
156. pany Ltd Document 40255 0600 4 17 FT 50 Fill Level Inspector Service Manual 8 Use the following equation to determine the Looktime Gate in milliseconds Dx0 6 L where D Average Time Width of Can step 7 L Looktime gate in milliseconds 9 Press Key 1 until you reach LOOKTIME GATE and use the Arrow Key to enter the Looktime Gate Value you calculated 10 If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to return to the Operate Mode 4 18 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Configuring the Gamma Threshold The Gamma Threshold defines the gamma radiation count that is the dividing line between accepting or rejecting a container during fill level inspection Before you configure the Gamma Threshold you must have aligned the Fill Level Inspection Beam properly as explained in Aligning the Fill Level Inspection Beam 1 Remove the FT 50 cover and set dip switch S1 1 to the proper setting for the type of fill level inspection you want to perform e Overfill Inspection S1 1 open e Underfill Inspection S1 1 closed Replace the cover Open the radiation source shutter by pulling the actuating rod out until it stops Start the conveyor and run it at the maximum production speed If your FT 50 is not in the Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and th
157. pulses which the FT 70 uses to synchronize inspector and rejector activities This allows the microprocessor to track specific containers during inspection and rejection regardless of the conveyor speed The High Resolution encoder is required for variable speed lines Rejection The rejector removes all containers that fail inspection from the production line Timing for the rejector is provided by the encoder and inspection trigger This allows the conveyor to operate at variable speeds without loss of rejection index timing For more information on the rejectors see the rejector operation manual that is included with your system Mounting The FT 70 is mounted on a steel floor stand that is secured to the floor It will accommodate conveyor heights from 24 inches to 60 inches 61 5 cm to 153 8 cm The floor stand height is specified when you place your order Height Adjustment A mechanical height adjustment mechanism provides 6 5 inches 16 5 cm of vertical adjustment to accommodate various container heights The height is displayed in a small counter on the front of the FT 50 to provide adjustment measurement accuracy Industrial Dynamics Company Ltd Document 40255 0600 1 9 FT 50 Fill Level Inspector Service Manual Container Types The FT 70 is compatible with aluminum steel and cardboard cans and can accommodate most shapes and sizes providing they do not exceed the physical dimensions of the inspection tunnel Types
158. r No Description 1 Support Brace 2 Retaining Bolts a Figure 3 7 Attaching the support braces to the base tripod 3 10 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 6 Attach the upper ends of the support braces to the vertical pipe with the pipe clamp The pipe clamp is only temporary After final positioning adjustments are made you will spot weld the supports into place and remove the clamp No Description 1 Pipe Clamp Figure 3 8 Attaching the upper ends of the support braces Mount and Position the Inspection Head 1 Mount the inspection head to the top of the support pipe by connecting the flanges with the supplied hardware and tight ening securely No Description Mounting Bolt Gasket Flanges Figure 3 9 Mounting the inspection head on the vertical support pipe Industrial Dynamics Company Ltd Document 40255 0600 3 11 FT 50 Fill Level Inspector Service Manual 2 Move the assembled unit into position on the conveyor To achieve proper positioning you must do the following e Align the centerline of the FT 50 with the centerline mark you made on the conveyor Align the inspection tunnel so that it is centered over the conveyor chain and the inspection head is perpendicular to the conveyor Place a small carpenter s level along the bottom of the FT 50 so that it spans
159. r 50 The System defaults loaded for one or more settings are out of range A complete software setup must be performed This is a high priority error condition and will cause the Warning Beacon to flash if Beacon Status is set to HIGH PRIORITY ONLY Error Number 51 A container passed without any encoder pulses This can be caused by blocking the trigger with the line stopped encoder failure e trigger reflections linejams Check the gain on the trigger amplifier This error condition is low priority and will not cause the Warning Beacon to flash during HIGH PRIORITY ONLY operation 8 8 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Error Number 52 A container passed the trigger in less than 10ms This can be caused by trigger reflections or line jams To correct this problem Adjust the gain on the trigger amplifier Error Number 53 The Reject Watchdog detected a queue error If this error occurs repeatedly call IDC technical support Error Number 54 This error displays the Reject Queue Count If this error occurs repeatedly call IDC technical support Error Number 58 An abnormally large container was detected The reject delay encoder count exceeded the current encoder count This condition is generally caused by line jams If this error occurs continuously the rejector may be installed to near the trigger Error Number 61 The reject delay posi
160. r Source ues e erg da teh ede d 3 23 Standard Power Supply Wiring 00 eee eee 3 23 Wiring the Main Power Cable to the I O Junction Box 3 25 Power Supply Wiring Examples 605 2 eect va 3 3 27 Standard 115 VAC or 230 VAC with Neutral line 3 27 Using a Voltage Regulating Transformer 3 28 Poly Phase Single Phase From the same System 3 29 High voltage Poly Phase Systems Delta or Wye 3 30 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual 3 2 Industrial Dynamics Company Ltd Document 40255 0600 Before You Begin Chapter 3 Installing the FT 50 Before you begin installing your FT 50 read this manual thoroughly so that you understand the installation processes and all installation requirements chapter 2 We strongly recommended that you arrange for an Industrial Dynamics Field Representative to be present to supervise plant personnel during the installations and to review the completed installation Basic Terminology Throughout this manual you will encounter certain terminology that you may be unfamiliar with or may have a different meaning than it is normally associated with Downstream is the direction of the conveyor flow Anything that is past the reference point in the direction of the flow is downstream Upstream is the direction opposite or against the conveyor flow Anything
161. r Status On Off Off Fire Rejector On Demand Execute Off H Rejector Pulse Width 0 250 ms 22 ms Reject Next Container 1 299 0 Inspect Trig To C I Rej 1 300 mm 500 mm Rejector Reaction Delay 1 150 25 ms 5 8 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Function Group Function Name Parameter Default System Key 5 Current Container Type 1 32 1 m Last Reject Detected 5 Beacon Status On Off High Priority On Line Speed cpm 0 2500 cpm Line Speed cph 0 150 000 cph System Display Calibrate Operate Operate Conveyor Drive Sprocket 18 29 Teeth 25 Teeth Serial Data ID Number 1 62 Host Modbus Port Status LC RX TX Modbus Message Counters OK Bad Other PLC Output Pulse Width 0 120 ms 50 ms Time Width Of Can 0 65 000 ms Chain Velocity 0 300 mpm Alarm Underfill On Off Off Alarm Overfill On Off Off Alarm Missing Lid On Off Off Alarm Bulged End On Off Off Alarm Down Can On Off Off Alarm Dia Missing Lid On Off Off Alarm External Reject On Off Off Load Default Constants Execute Can Width At Trig 1 250 37 mm Maximum Can Diameter 1 400 62 mm Maximum Line Speed 1500 cpm 1000 cpm Maximum Conveyor Speed 21 120 mpm 74 mpm Change Password 3 digits numbers 1 6 222 View TB1 amp 4 Pin Assignments View PLC Pin Assignments Clear System Industrial Dynamics Company Ltd Document 40255 0600 Execute Execute Execute 5 9 FT 50 Fill Level Inspector Service Manual Function Group Function
162. r UO 9 ts ata rg als Lisa Eod 8 12 Error Number 120 5 ostro C id 8 12 Error Number 2L al oen oa ER SD ER dd t eda 8 12 Troubleshooting Procedures 0 0 eee eee eee eens 8 13 Major Component Subsystems 0 0 8 13 Before You Begin ivan a A PE AS ES 8 13 What You Should Do First 0 0 2 eee eee ee ee 8 14 Power Supply System Troubleshooting 000000008 8 15 Testing the Power Supply tte dba soe det ex e RR 8 15 Testing the Power Transformer 00 eee ee eee eee 8 16 Processing System Troubleshooting 0 0 0 e eee eee 8 17 Main Processor Card 22 455 UR MARS seen wre ee eae pets 8 17 Serial Communications Card 1 1 0 0 0 0 eee eee ee eee 8 18 The Control Panel sis a SG dean kee np Rod RAR ES ES 8 18 Sensor System Troubleshooting 5 uid tV STRIS 8 20 Scintillation Tube Detector STD o o ooooooooooooooo o 8 20 Solid State Detector SSD 2 0 00 000 es 8 20 Optical Sensors iseis caia hess EX p pee a eee eA 8 21 Proximity Sensors gieren oy ey eee Pe eh ee eee eased 8 21 En oder S d E Eon US p ue rU ee s a Rees Ae ae We ek 8 2 Troubleshooting Problems with Rejectors oooooooooooooo 8 22 Proline Rejector Troubleshooting 0 0 0 0 eee eee 8 22 Quick Reference Troubleshooting Guide 05 8 25 Chapter Nine Using a PLC With Your FT 50 9 1 Using a PLC With Your FT 50 2 0 ec eee 9 3 PIC Sere
163. r the rejector to actuate so the centerline of the rejector pad impacts the centerline of the container Rejector Reaction Delay The response time in milliseconds between when the container fails inspection and when the reject signal is sent to the rejector The FT 50 s processor uses this value to establish a lead time for the rejector pulse to compensate for the inertia of the rejector mechanism 5 22 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software System Functions Group Current Container Type The container type that is currently being inspected This function is only available if machine is configured for multiple container types To select the Current Container Type 1 Press Key 5 until CURRENT CONTAINER TYPE appears 2 Press the Arrow Key until the desired container type appears Last Reject Detected The type of failure that caused the most recent reject container The failure classification can be any of the inspection capabilities installed and active on your system Beacon Status Determines the operational status of the warning beacon There are three status choices e On the beacon will flash once for each rejected container and continuously when a diagnostic error occurs The beacon will stop flashing when the diagnostic error is cleared e Off The beacon will flash once for each rejected container e High Priority Only The beacon will flash once for each rejected
164. r type i e containers with different diameters or line speeds 6 28 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Sensors Calibration Procedures Before You Begin The FT 50 contains two types of sensors e Proximity e Fiber Optic Proximity Sensors Proximity sensors use an electromagnet to detect the presence of metallic objects such as aluminum tin and steel Proximity sensors do not require calibration The proximity sensor used in the FT 50 is the Missing Lid metallic sensor Fiber Optic Sensors Fiber Optic sensors project a highly focused light beam across a given space When a container passes through the beam the beam continuity is broken This triggers the sensor signal indicating that an object is present in the beam The fiber optic sensors used in the FT 50 are e Centerline Inspection Trigger e Upstream Inspection Trigger e Bulged End e Down Can 1 Before attempting to calibrate any sensor check the emitter and receiver to be sure the lenses are clean and unobstructed See Chapter 8 Maintenance and Repair for cleaning instructions 2 Before you begin any sensor calibration procedure close the Safety Shutter by pushing the actuating rod completely in so that no red is showing 3 Remember to open the Safety Shutter when you have finished the calibration procedure by pulling the actuating rod out until it stops Industrial Dynamics Company Ltd Do
165. radiation dose could be incurred at a location other than directly in front of the main gamma beam when the safety shutter is opened Industrial Dynamics Company Ltd Document 40255 0600 XIII FT 50 Fill Level Inspector Service Manual The radioactive material is sealed by double fusion welds into a stainless steel capsule At manufacture and again at instal lation this capsule is subjected to rigorous tests capable of detecting the leakage of five millionths of one percent of the contents Therefore as long as the source capsule s integrity is not compromised radioactive material cannot be released As an additional precaution the regulatory agencies require that a licensed individual inspect the radiation source and the shutter mechanism and conduct a leak test every 36 months Radiological Safety Guidelines You have been supplied with a copy of the Rules Regulations and Registration Requirements for your location however the following is a brief synopsis of the general requirements 1 Understand the rules regulations and registration require ments regarding the use of this equipment at your location A copy of this is supplied with your FT 50 Do not open or tamper with the enclosure containing the radio isotope source Do not place your hands or any other body part between the source and detector when the safety shutter is open Have inspection and wipe tests performed by a properly licensed technician at th
166. ral line must be properly grounded Operating Temperature e Minimum 32 F 0 C e Maximum 113 F 45 C Pneumatics The FT 70 is air purged to prevent contamination and corrosion to the electronics housed inside The air must be filtered dry compressed air at 80 to 120 psig with a volume of 0 5 CFM 138 to 827 kPa e 14 liters min Gamma Source The gamma source is a low energy 60 KEV Americium 241 radio isotope with a half life of 472 years The FT 50 uses a 100 mCi source for normal applications and a 300 mCi source for special applications Industrial Dynamics Company Ltd Document 40255 0600 1 7 FT 50 Fill Level Inspector Service Manual Inspection Accuracy The basic fill level inspection accuracy is 0 4 mm The accuracy obtained during production will degrade based on glass or plastic quality liquid motion foam and conveyor speed Containers Minute Feet Minute m min X Accuracy 600 135 41 0 06 inch 1 6 mm 1200 270 83 0 12 inch 3 1 mm 2200 500 152 0 21 inch 6 0 mm The FT 70 can maintain accuracy at conveyor speeds up to 350 feet minute 107 meters minute with a maximum velocity change of 15 1 encoder versions only The actual rate will vary depending upon the product density container density container size and shape and container spacing Physical Size The FT 70 is available in three sizes based on the dimensions of the inspection tunnel Larger containers require a larger inspe
167. reach the FULL BOTTOM POINT Press the Arrow Key when you are ready to proceed and then repeat step 14 until you reach the EMPTY TOP POINT When you reach Empty Top Point the following information is displayed Press the Arrow Key to scroll through each e Static Margin e Aperture Range e Inh Accuracy When THRESHOLD WILL BE SET appears press the Arrow Key and the FT 50 automatically programs the new Underfill Threshold If you do not want the threshold to be programmed press Key 6 to abort Press Key 1 to proceed to Establishing the Target Head Height Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures Establishing the Target Head Height 1 2 Press Key 1 to begin the Learn Target Head Height procedure Precisely center a 100 percent reject container in the inspection tunnel and then press any key to continue Lower the gamma beam into the liquid by slowly turning the Head Height Adjustment Crank Continue lowering the head until RAISE HEAD ONE TICK displays Stop lowering the head at this point Raise the head one tick as indicated by the Head Height Meter and then press the Arrow Key Repeat step 5 until TARGET HEAD HEIGHT appears You are now at the Target Head Height Note the head height indicated in the Head Height Meter you must enter the height in the next step Press Key 1 and then use the Arrow Keys to enter the Target Head Height into the system Pres
168. red with no Down Can sensor transition Check LED 5 on the Control Card ON indicates high level Also check the signal on TB1 14 Blocking the sensor should give 17 22 volts on TB1 14 When the sensor is not blocked the voltage should be less than 1 volt If the voltage is not in this range replace the sensor Error Number 46 The number of containers in the Consecutive External Reject Alarm was exceeded This is a high priority error condition and will cause the Warning Beacon to flash if Beacon Status is set to HIGH PRIORITY ONLY Error Number 47 The Encoder Resolution is to low Replace the encoder with an encoder that has higher resolution Industrial Dynamics Company Ltd Document 40255 0600 8 7 FT 50 Fill Level Inspector Service Manual Error Number 48 The AC input voltage dropped below 90 volts on a 110 VAC system or below 185 volts on a 220 VAC system During the time the voltage was low no containers were inspected for any defect When the power returns to normal the system resets with no data being lost This is a high priority error condition and will cause the Warning Beacon to flash if Beacon Status is set to HIGH PRIORITY ONLY Error Number 49 The User Defaults loaded for one or more settings are out of range Check all settings to be sure they are correct This is a high priority error condition and will cause the Warning Beacon to flash if Beacon Status is set to HIGH PRIORITY ONLY Error Numbe
169. rejects Pass a reject test can through the Inspection System With the reject switch set to ON the rejector should fire and the Reject LED on the processor card should flash Insufficient or no compressed air Open valve to air supply and adjust regulator air pressure to 65 psi Air lines contaminated or blocked Check all air lines to be sure they are free from contamination and that air passes through them freely Air pressure incorrect Adjust pressure to setting established during calibration procedure Rejector assembly has malfunctioned Inspect the rejector arm as described in the Routine Preventative Maintenance procedures Containers improperly positioned on the conveyor All containers are rejected The fill level calibration is incorrect and all containers are registering as rejects Industrial Dynamics Company Ltd Document 40255 0600 Review the Installation section for proper installation Repeat the Fill Level Calibration Procedure to establish the correct fill level inspection parameters continued on next page 8 25 FT 50 Fill Level Inspector Service Manual Possible Cause Corrective Action Containers are rejected erratically Time Delay is incorrectly set Pass reject test container through the inspector and observe the time delay synchronization The rejector pad s centerline should contact the container s centerline at the point of impact If not adjust t
170. ror Check the termination of the RX input e Check the RX input with a voltmeter while the line is in a steady state no transmission RS 485 RX A GND RX B 5VDC RS 232 RX A 12VDC to 4VDC RX B GND Error Number 121 This error indicates the CTS line Clear To Send is changing too rapidly for normal communication and therefore appears busy This error is usually caused by excessive noise e Check the termination of the CTS input Check the CTS input with a voltmeter while the line is in a steady state no transmission CTS A GND CTS B 5VDC For a quick solution you can connect TB1 5 and TB1 6 together Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Troubleshooting Procedures The troubleshooting procedures in this section are designed to help you isolate machine malfunctions and determine the proper corrective action Once you determine the problem source you will be directed to the appropriate corrective procedures that are contained in other sections of this manual Major Component Subsystems Before You Begin System failures fall into one or more of the following subsystem categories Power Supply System e Main Power Supply e Power Transformer Processing System e Main Processor Card e Serial Communications Card e Control Panel Sensor System e Scintillation Tube or Solid State Detector SSD e Optical Sen
171. s Alarms pito Sok ae a pee hey ht edhe Hee Y Wa Mei 9 4 How to Determine the Signal Output Wiring 00 9 5 Adjusting the PLC Output Signal Pulse Width 9 5 Relay Types for Output Signals 0 2 0 2 eee ee eee eee 9 6 Remote Alarm 22 21 21 1 4 p eta Reel ae ta dee Nee Geese be dae 9 8 How to Clear a Remote Alarm vesc bse as 9 8 Remote Alarm Error Number Designations 04 9 8 Chapter Ten Controller Board Dip Switches and LEDs 10 1 Controller Board Switch Locations 0 0 eee e eee ee eee 10 3 Switch Function Configurations 0 0 eee eee ee eee 10 4 Switch Function Definitions 224 a ek ea eee ol De Bach ea 10 5 Dip Switch Pack Sl star Reti Roe dir Reed es 10 5 SII Inspection Logic 204 5 01 use4e dise 10 5 S1 2 Software Write Protect 2 012604 ii pu I REX 10 5 S1 3 5peed Tracking seres RES X RE Nx Eod X RSEN 10 5 old Languages Lese a ux Dea yu bau s eie dt ura pau 10 5 Industrial Dynamics Company Ltd Document 40255 0600 Table of Contents S1 5 System Configuration 2 e ee eee eee eee 10 5 91 6 Not Used uscar a eee has 10 5 SIS NOE Used 045 ra bees Laos a t A 10 5 SI 8 Password sois M he ARES Eee ORES ODER TERES YU ES 10 5 Dip Switch Pack 82 oed bso a e d ua Eae a DERE aaa Re 10 6 S2 1 Baud Rate uu seo eed a 10 6 52 2 Handshake Plas vertida Y NIMES RA ERES 10 6 32 3 Patty On Off s sek a EG URS S A Was 10 6
172. s Key 1 to accept the height setting and to proceed to the Dynamic Reject Point Test Industrial Dynamics Company Ltd Document 40255 0600 6 41 FT 50 Fill Level Inspector Service Manual 6 42 The Dynamic Reject Point Test The Dynamic Reject Point Test is used to verify the inspection accuracy under production conditions You need thirty 100 percent reject production containers to perform this test 1 Start the conveyor and run it at production speed 2 Press the Arrow Key and you are instructed to run thirty 100 percent reject containers through the FT 50 Start them far enough upstream so they do not slide on the conveyor as they pass through the inspection area The FT 50 must reject all 30 containers in order to establish the Dynamic Reject Margin The Dynamic Reject Margin compensates for fill level variance due to conveyor motion 3 If during this test the message LOW MARGIN RAISE 1 TICK appears then a container has failed the test You must raise the inspection head 1 tick and then press the Arrow Key to repeat the test 4 When the test is completed the Dynamic Reject Margin is displayed The margin is typically 2 3 sigma If the sigma is out of this range you may be instructed to repeat the test at a lower setting Press the Arrow Key to repeat the test 5 If the margin is within the 2 3 sigma range COMPLETE is displayed Press Key 1 to proceed to the Dynamic Product Good Test Industrial Dynamics Company
173. s RE RR o YES XVI Filtec Model FT 50 Radiation Exposure Profiles o o ooo oo XVII Chapter One FT 50 System OvVervieW oooooooommmmmoo 1 1 SUSIGHEDVELVIEW vie eu exque de dero aah a cL M cae ee 1 3 Fill Level Inspection Bastes i usine ia DERE 1 4 How Underfill Inspection Works oo oooococcocoooooooo 1 5 How Overfill Inspection Works 0 0 cece eee ees 1 5 Rejection Control Basics 2 2 6 iioii i pr e pL RES 1 6 System Specificatlons o 4 2 vec d bad Ves ET ES Ne e c exce Ro d 1 7 Power R q irements otedi acp t rst odds SX S Reset ee do 1 7 Operating Temperature cte RR Re dd cette 1 7 o o aeos o ee Bone uet d a eda SI Du Cad a denti ds 1 7 Gamma SQUICO nec bse id dob Reese Re bbb tweed PERRA RR 1 7 INSDECHOMACCUIACY ox raw OA Saas SAS ewe eek 1 8 Physical Size creana nuke aea War eed E ee berg epe 1 8 Triggering Syste ic 4 5 xu REN OE RITE EI RE aH RAE 1 9 High Resolution Encoder Jus d od i gh ee Va su e 1 9 REO PA xe us oes fuk ebat lee Ls mE Ide 1 9 IMOUDLUHE s pree dc p EROR OUT UO ah quence ah wea deere d ws abe Geek a Cao 1 9 Height Adjustment 51 2 eso RERIIQ REED RE RRERID ddan 1 9 Container Types sues cv Ves DS XN Rede DM 1 10 Container Spang uo exeo quer qu ni ec Rebus LI d ced e eas 1 10 Control Panel 2c toed kid ciel a ede At e bep bue EAS 1 10 A ON 1 11 Optional System Features is pix ua A 1 12 Bulsed End Detection 5a ond ues one ev ees od ale ee ET SS 1 12 Missing Lid Detection
174. s function inhibits detection and rejection of containers with fill levels above the overfill gamma threshold Overfill and Underfill can not be active simultaneously To activate Overfill you must open dip switch 51 1 Gamma Counts Displays the gamma count for the most recent container to pass through the FT 50 The gamma count is the amount of radiation that passes through the container and is captured by the radiation sensor Scintillation Tube or SSD Each container s gamma count is compared to the gamma threshold for that container type If the gamma count falls outside of the gamma threshold the container is rejected 5 12 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Target Head Height Allows you to record the Inspection Head height setting for the current container configuration To record the Target Head Height 1 Press Key 1 until you reach TARGET HEAD HEIGHT 2 Read the value displayed in the Head Height Counter The counter is located in the upper left corner on the front of the FT 50 see illustration 4 2 3 Use the Arrow Key to enter the value in the TARGET HEAD HEIGHT function Gamma Threshold Establishes the threshold value that the Gamma Counts must e exceed for underfill rejection e not exceed for overfill rejection Any gamma count value that falls outside of the Gamma Threshold triggers a rejection Looktime Gate The time in milliseconds during which gamm
175. s unauthorized personnel from entering the Calibrate Mode Selecting an Operating Mode 1 Press Key 5 until SYSTEM DISPLAY appears 2 Press the Arrow Key to select either the OPERATE or CALIBRATE mode The current operating mode is displayed 3 Ifthe Password Protect Function is enabled you must enter the password before you can enter the Calibrate Mode If you enter the wrong password press the Arrow Key and try to reenter it The FT 50 automatically reverts to the Operate Mode if the machine is idle no keys are pressed for more than 30 minutes All outstanding parameter changes will be entered automatically Industrial Dynamics Company Ltd Document 40255 0600 Software Functions List Chapter 5 System Software There are six function groups each corresponding to a key on the control panel In the following table e A function denoted with the symbol indicates it is available in the Operate Mode e A function denoted with the symbol indicates it is available in the Calibrate Mode only e A function denoted with the symbol indicates it is available only when switch S1 5 is open in the Calibrate Mode e A function denoted with a cc symbol indicates it is available only when switch S1 6 is open in the Calibrate Mode Function Group Function Name Parameter Default Fill Level Key 1 Underfill Status On Off Off Overfill Status On Off Off Gamma Counts 0 65 000 Pulses Updating Constantly Updatin
176. sors Inspection Triggers Missing Lid Bulged End Down Can e Proximity Sensor Missing Lid e Encoder Rejector Systems Proline Rejector Before you attempt any diagnostic or troubleshooting procedure e Read and understand the procedure s thoroughly e Understand and comply with all safety precautions Have the proper diagnostic equipment on hand Industrial Dynamics Company Ltd Document 40255 0600 8 13 FT 50 Fill Level Inspector Service Manual What You Should Do First Before you begin detailed and time consuming troubleshooting methods check the following items first These are simple things that are often overlooked but can cause a wide range of system problems 1 8 14 Is the power turned on Verify that both the main power switch on the I O Junction Box and the internal power switch located on the power filter junction box are turned on Is the power filter circuit breaker tripped The internal power switch is an integrated switch circuit breaker When the breaker is tripped the power switch turns off Verify the power switch is turned on if not turn it on to reset the breaker Is power reaching the FT 50 Verify the power from the factory power system is reaching the FT 50 and that the power selector switch is set to the proper voltage 110v or 220v The power selector switch is located on the power filter junction box Are all dip switches and jumpers configured properly Verify the
177. t on the container As normally filled containers pass through the beam the contents block a portion of the radiation which reduces the gamma count at the detector This count condition is the normal count also called the good state When an underfilled container passes through the beam there is less mass in the beam path so the gamma count at the detector is higher than the good state and the underfilled container is detected as faulty How Overfill Inspection Works The FT 50 is positioned so that containers pass through the gamma beam at a point just above the desired fill level point on the container As normally filled containers pass through the beam the contents block a portion of the radiation which reduces the gamma count at the detector This count condition is the normal count also called the good state When an overfilled container passes through the beam there is more mass in the beam path so the gamma count at the detector is lower than the good state and the overfilled container is detected as faulty FT 50 Fill Level Inspector Service Manual Rejection Control Basics The FT 50 tracks any container that fails inspection Tracking begins the moment the container crosses the inspection trigger beam in the FT 50 and ends when the container reaches the rejector centerline co TH 2 3 O DOOU IOOOQOOOOODOQGO OO rool OOOd E xs Se
178. tandard conveyor with a 1 5 inch chain pitch and you know the number of teeth on the sprocket directly contacting the underside of the main production transport chain 1 Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode You may be required to enter a password if your system is password protected Press Key 4 until REJECTOR STATUS appears and check to be sure the rejector is activated If it is turned off press the Arrow Key to turn it on Open dip switch S1 5 Press Key 5 until REJECTOR TYPE appears and use the Arrow Key to select the type of rejector installed in your system Press Key 5 until KNOWN CHAIN PITCH amp TEETH appears and set to PRESENT Press Key 5 until ENCODER RESOLUTION appears and enter the encoder resolution The standard encoder is 500 pulse The following table lists the encoders and the supported resolution The encoder resolution is set at the factory during assembly however if you upgraded the software you should check the encoder type and set it properly 7 8 Part Number Description Resolution 24997 Standard 500 18916 Dual Track 1000 32637 Ultra High Resolution 5000 Close Dip Switch S1 5 Measure the distance in millimeters from the trigger sensor beam to the centerline of the rejector If you are using a slat rejector measure from the beam to the upstream edge of the slat assembly Accurate measurement is extremely important for proper
179. terminals terminal blocks Inspect Source Autoshutter Assembly Inspect Gamma Window for damage blockage 7 4 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 7 Maintenance Procedures Maintenance Procedures Before You Perform Any Maintenance Procedure For safety power down the equipment to be serviced before you begin any maintenance procedure To power down the rejector turn off the Main Power Switch on the Junction Box Trigger Beam and Emitter Lenses 1 2 Inspect each lense for debris and damage Clean each lense with a cotton swab lens tissue or a soft cloth Do not use paper towels because they are abrasive and can scratch the lense Apply several drops of medium viscosity oil to the lead screw on the trigger raising mechanism Be careful not to disturb the trigger raising mechanism Inspect the beacons for cracks in the lenses and moisture inside the lenses Bulged End and Missing Lid Sensors 1 2 Inspect each sensor for debris and damage Clean each sensor with a cotton swab lens tissue or a soft cloth Do not use paper towels because they are abrasive and can scratch the lense Insure that all parts are firmly attached to the mounting brackets and locking knobs are tight Do not disturb the position of the mounting brackets Industrial Dynamics Company Ltd Document 40255 0600 7 5 FT 50 Fill Level Inspector Service Manual Warning 7 6 The FT 50 Housing 1 Inspect
180. ters 1 Press Key 3 until RESET ALL COUNTERS appears 2 Press the Arrow Key to execute Reset Total Throughput Clears and resets the Total Throughput counter to zero Record all valuable data before executing this function To reset the Total Throughput 1 Press Key 3 until RESET TOTAL THROUGHPUT appears 2 Press the Arrow Key to execute Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Reset Total Rejects Clears and resets the Total Rejects counter to zero Record all valuable data before executing this function To reset the Total Rejects 1 Press Key 3 until RESET TOTAL REJECTS appears 2 Press the Arrow Key to execute Reset Total Underfill Clears and resets the Total Underfill counter to zero Record all valuable data before executing this function To reset the Total Underfill 1 Press Key 3 until RESET UNDERFILL appears 2 Press the Arrow Key to execute Reset Total Overfill Clears and resets the Total Overfill counter to zero Record all valuable data before executing this function To reset the Total Overfill 1 Press Key 3 until RESET OVERFILL appears 2 Press the Arrow Key to execute Reset Total Missing Lid Clears and resets the Total Missing Lid counter to zero Record all valuable data before executing this function To reset the Total Missing Lid 1 Press Key 3 until RESET MISSING LID appears 2 Press the Arrow Key to execute Industria
181. the conveyor segment pitch in tenths or millimeters Teeth Conveyor Segment Defines the number of sprocket teeth on the drive sprocket that contact the chain segment The typical value is 2 however some conveyors may have a value of 1 Calibrate Encoder Initiates the encoder calibration routines For more information on this function see Chapter 6 Encoder Calibration Procedures Industrial Dynamics Company Ltd Document 40255 0600 5 39 FT 50 Fill Level Inspector Service Manual 5 40 Calibrate Encoder Value The number of encoder pulses emitted for every 10 meters of conveyor travel For more information on this function see Chapter 6 Encoder Calibration Procedures Encoder Prescaler Value The conversion factor used by the Encoder Prescaler Value This allows the FT 50 to process data at a faster rate Gamma Sample Cutoff Limit This value is calculated automatically during the encoder calibration The normal value range is 3 to 4 and should be equal to or 1 more than the number of Gamma Samples Per Encoder when using a high speed production line Gamma Samples Per Encoder This value verifies the correct Gamma Sample Cutoff Limit It displays the number of 500 microsecond gamma samples that occurred between the last two encoder interrupts The encoder interrupt is determined by the line speed and prescaler value Industrial Dynamics Company Ltd Document 40255 0600 Chapter 5 System Software Diagnostics Func
182. the inspection tunnel You may need to raise the inspection head to allow room to fit the level between the conveyor and bottm of the FT 50 Shift the vertical support pipe in its mounting as needed until the inspection head is level No Description Vertical Centerline Horizontal Centerline Conveyor Figure 3 10 Aligning the FT 50 to the conveyor 3 12 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 3 Installing the FT 50 Secure the Floor Stand to the Floor 1 Mark the position of the three 3 mounting holes in the base tripod on the floor 2 Drill a mounting hole at each of the three 3 marks you made on the floor You must supply three 3 1 2 inch x 4 inch lag bolts and lead inserts No Description 1 Lag Bolt p s Figure 3 11 Anchoring the base tripod to the floor 3 Boltthe tripod to the floor Industrial Dynamics Company Ltd Document 40255 0600 3 13 FT 50 Fill Level Inspector Service Manual Install the Slant Support Braces If you are performing a high mount or low mount install the slant braces You can install the braces on either side of the vertical support pipe depending upon available clearance from the conveyor and other objects Refer to drawing I 00401 and I 00415 in the Installation and Service Drawing P
183. the lense is scratched chipped cracked or discolored replace it 2 Fiber optic strands in the cable may be broken Remove the cable from the sensor amplifier and shine a flashlight into the lense Looking at the cable end you removed the light should be solid and round If there are any dark spots the cable contains fiber optic strands Replace the cable Proximity Sensors No triggering occurs Check LED 7 on the processor board If the LED blinks when a container passes under the sensor the sensor is working Check to be sure the sensor height is set properly See Chapter 6 FT 50 Calibration Procedures for more information e The height of the sensor has been changed Check to see that the FT 50 head height has not been altered See Chapter 6 F1 50 Calibration Procedures for more information Encoder The encoder has a built in diagnostic that displays Error 22 when the encoder has failed and must be replaced e If the rejector timing is erratic and you are certain all settings are configured properly the encoder may not be installed properly or the encoder coupling may be slipping Industrial Dynamics Company Ltd Document 40255 0600 8 21 FT 50 Fill Level Inspector Service Manual Troubleshooting Problems with Rejectors Proline Rejector Troubleshooting The rejector is operating erratically 1 The air supply may be erratic Verify the air pressure is in the proper operational range for the rejector 2 Chec
184. the machine To turn Missing Lid inspection on or off you must use the Missing Lid Status function Missing Lid Text Allows you to create a custom name for the Missing Lid Option Any instance in which Missing Lid would have appeared in the software is replaced by the custom label you created The following options are effected Missing Lid Status e Total Missing Lid e Reset Missing Lid e Alarm Missing Lid e Missing Lid Text Missing Lid This manual assumes the default name for this option If you change the default text remember to substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance to the next space 3 Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text Industrial Dynamics Company Ltd Document 40255 0600 5 33 FT 50 Fill Level Inspector Service Manual Note 5 34 Bulged End Prepares the FT 50 software for Bulged End inspection by inserting the necessary options into the software When set to Not Present it removes the options necessary for bulged end inspection from the software This function does not activate or deactivate Bulged End inspection it only readies the machine To turn Bulged End inspection on or off you must use the Bulged End Status function Bulged End Text Allows you to create a custo
185. the retaining screw and washer Power up the rejector Servicing the Regulator and Coalescing Air Filters Servicing the air filter consists of cleaning and or replacing the air filter sediment bowl and gasket You can obtain replacement parts for these items from the air controls manufacturer Turn off all power to your system before attempting any repair procedure See Before You Perform Any Maintenance Procedure at the beginning of this section Turn off the air flow control valve and depressurize all connected air lines Remove and clean the sediment bowl If your unit contains a polycarbonate bowl inspect it for cracking or cloudiness if present replace it Cracked or cloudy polycarbonate bowls can explode when repressurized causing serious injury Clean other parts using soap and water Dry the bowl and other parts and blow out internal passages in the body using filtered dry compressed air Using filtered dry compressed air blow through the filter element from inside to outside to dislodge surface contami nants If the filter element is plugged replace it Apply a light coating of Dow Corning 44M grease or equiv alent to the bowl gasket and reassemble Industrial Dynamics Company Ltd Document 40255 0600 7 7 FT 50 Fill Level Inspector Service Manual 7 8 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures Chapter Eight Diagnostic and Repair Proc
186. tion Group Displays the current diagnostic error Clearing the error stops the warning beacon from flashing and the Remote Alarm PLC output signal How to Access Diagnostic Error Codes Note Do not use the Reset Switch to clear diagnostic errors To view the error 1 Press Key 6 to display the current diagnostic error number 2 Press the Arrow Key to scroll through the error definition 3 When you reach the end of the message press the Arrow Key once again to clear the error Industrial Dynamics Company Ltd Document 40255 0600 5 41 FT 50 Fill Level Inspector Service Manual 5 42 Diagnostic Error Codes Listing The following list contains the FT 50 error codes Depending upon your machine type some of these errors may not apply to your FT 50 For complete error descriptions see Chapter 8 No Diagnostic Error Rejector Status Is Off Consecutive Reject Queue Error Consecutive Reject Timing Error Missed Encoder Pulse EEPROM Cannot Be Erased Check S11 Or Replace U29 o o Oo oO N O Write To Eeprom Unsuccessful Check S11 Or Replace U29 10 Fill Level Detection Error Exceeded Consecutive Reject Limit 11 Missing Lid Detection Error Exceeded Consecutive Reject Limit 12 Bulged End Detection Error Exceeded Consecutive Reject Limit 13 Gamma Counts Below Reject Threshold Error 14 Gamma Detector Error 15 Missing Lid Sensor Error 16 Trigger Beam Error 17 Encoder Sensor Error 18 Slat Rejector Backup Sensor Is Blocked 22 E
187. tion at the rejection queue output exceeded the current encoder count If this error occurs repeatedly call IDC technical support Error Number 66 A fill level reject was detected while the Fill Level Status was turned off Turn the Fill Level Status on to correct this condition Error Number 67 The number of containers in the Consecutive Diameter Missing Lid Reject Alarm was exceeded This is a high priority error condition and will cause the Warning Beacon to flash if Beacon Status is set to HIGH PRIORITY ONLY Industrial Dynamics Company Ltd Document 40255 0600 8 9 FT 50 Fill Level Inspector Service Manual 8 10 Error Number 68 No Encoder Pulses were received for the Diameter Missing Lid Width function Make sure switch S05 is in the A position and jumper 12 is in the AB position This error condition is low priority and will not cause the Warning Beacon to flash during HIGH PRIORITY ONLY operation Error Number 72 This error condition indicates the Line Speed is to high The encoder may need to be calibrated or the Gamma Sample cutoff limit may be set too high This error can also be caused by noise on the encoder cable which connects to TB4 2 Error Number 86 This error condition indicates the BBU RAM Battery is Low Replace the Smart Socket for U27 or replace the Nonvolatile SRAM at U27 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 8 Diagnostic and Repair Procedures
188. tion with your FT 50 install the encoder so that it is driven by the sprocket shaft that drives the conveyor chain section that passes through the inspection system This ensures that the encoder is rotating at the same rate as the conveyor drive shaft The preferred method for mounting the encoder is inline directly attached to the shaft If you are unable to mount the encoder inline you can use an offset mount Refer to drawing I 00484 in the Service and Installation Drawing Pack for more information on installing the encoder Mounting the Encoder Inline 1 Drill and tap a 1 5 13 unc x 0 65 inch M12 6G x 1 65 cm hole into the sprocket shaft to mount the coupling stud 2 Insert the coupling stud into the sprocket shaft using Red Loctite 271 or an equivalent adhesive 3 Drill the encoder bracket mounting holes as shown on drawing 1 00484 There are two drilling templates choose the one that suits your installation 4 Attach the encoder assembly by sliding the flexible shaft over the coupling stud and securing the encoder with the included screws and the shaft with the included hose clamp 5 Attach the signal cable to the FT 50 by routing it through the watertight port in the bottom of the FT 50 and attaching the wires to the TB4 terminal bracket Wire Terminal Description Blue TB4 1 Ground Shield TB4 1 Cable shielding Black TB4 2 Signal Brown TB4 3 V voltage plus White Not used Spare Industrial Dynamics Company
189. tor and Coalescing Air Filters 7 7 Industrial Dynamics Company Ltd Document 40255 0600 FT 50 Fill Level Inspector Service Manual 7 2 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 7 Maintenance Procedures Maintenance Schedules Daily Schedule Action Inspect Clean Inspect Clean Inspect Clean Inspect Clean Description Trigger Beam Emitter and Receiver lenses Trigger Beam Emitter and Receiver lenses Down Can Beam Emitter and Receiver lenses Bulged End Beam Emitter and Receiver lenses Weekly Maintenance Action Description Inspect Inspection Head cover attachment Clean Inspection Head housing Inspect Air Supply Regulator pressure adjustment Inspect Rejector Pad Clean Purge air flow to Inspection Head Inspect Purge air filter Monthly Maintenance Action Description Check Inspection Head Cover Gaskets Lubricate Trigger Raising Mechanism lead screw and ways Check All external wiring Check All Beacon Lamps Inspect Nameplate Stickers and Instruction Plates Service Pneumatic components per Rejector Manual Inspect Inspection Head Housing for dirt and moisture Industrial Dynamics Company Ltd Document 40255 0600 7 3 FT 50 Fill Level Inspector Service Manual 120 Day Maintenance Action Description Inspect Nameplate Stickers and Instruction Plates Service Pneumatic components per Rejector Manual Inspect Inspection Head Housing for dirt and moisture Inspect Wiring insulation
190. tructions for installing the rejector are contained within the rejector manual You should install the rejector after you have installed the FT 50 Determine the mounting locaton for FT 50 and rejector Y Prepare the conveyor to install the FT 50 i Assemble the FT 50 floor stand i Mount the FT 50 inspection head i Install the encoder If applicable y Prepare the conveyor to install the rejector i Mount the rejector i Wire the main power source to the FT 50 Figure 3 2 FT 50 Inspection System installation flow chart Industrial Dynamics Company Ltd Document 40255 0600 3 5 FT 50 Fill Level Inspector Service Manual Determining the Proper Location for the FT 50 3 6 Before you begin installing your FT 50 Inspection System and rejector you should understand all the requirements detailed in Chapter 2 Installation Requirements The location of the FT 50 within the production line is very important To achieve maximum performance from your FT 50 the installation location must fulfill the following requirements These requirements are also detailed in installation drawing for the rejector Refer to the rejector manual for more information The FT 50 must be located far enough downstream from any production event that will excessively agitate the contents of the containers Typically 3 5 seconds from a minor disturbance such as
191. ts when the 5 VDC power supply is too low to operate satisfactorily below 4 85 VDC Indicator is also on when the Reset button is pressed Detector Used to get a coarse calibration setting for the Scintillation Detector Industrial Dynamics Company Ltd Document 40255 0600 10 11 FT 50 Fill Level Inspector Service Manual 10 12 Industrial Dynamics Company Ltd Document 40255 0600 Documentation Feedback Document 40255 0600 Documentation Feedback Help us provide you with better documentation Please forward any error s you find in this documentation and any other comments you have about this documentation directly to the Technical Publications Department at Industrial Dynamics Use the form on the following page to record your comments and then send the form to us in one of the following ways Email techpubs filtec com Fax 310 530 1000 Industrial Dynamics Co Technical Publications Department nen 3100 Fujita St Torrance CA 90505 Internet www filtec com If you send via E mail please be certain to include the document number and page number s of the subject material to facilitate correction of the problem This information can be found in the page footer Thank You Industrial Dynamics Technical Publications Department FB 1 Documentation Feedback Form Please deliver To Industrial Dynamics Technical Publications Department 310 530 1000 Received From
192. ttens it es ei cL AL iced a dd 5 7 Function Descriptions 0 2 ieee ieee eb igs ees calves LER EE 5 12 Fill Level Functions Group 140040 5 12 Undetfill Status 44er tio dora ia ia 5 12 Overfill StAtUs c eerte Gres ies Meet eR tene er e are Re Rs 5 12 Gamma COUNS esan nee ls mb d ee Reb D qaa dd e 5 12 Target Headset ua A ae Ce AER EE ATE 5 13 Gamma Threshold cis ror eec x oae x SE de quae 5 13 Looktime Gate oeoc esera a i b RI casas eee eS E Ee 5 13 Fill Level Optimization 24224 scere rper Abe eee Eee xS 5 13 Learn Target Head Height 5 2 sessi vidt ire Les 5 14 Dyn Reject Pt Testo ize tpe EE e tko ER eye eee qon 5 14 Dyn Prod G d Test A We RERO EVE 5 14 Review Fill Level Test 5 koci ERR ERp REESE REOREESAGO 5 14 Container Finish Functions Group 0 e cee eee eee eee ee 5 15 Bulged End Status 40 22 5 5svigeebed a a 5 15 Missing Did Status sece samanea nie dade tad Cau ina 5 15 Down an Stats s ener ar hg cud A ou e ode tal 5 15 Diameter Missing Lid Status 154v ete keke REC ER 5 15 External Reject Staus 4 0 o4 epp a be RES ou wee 5 15 Width at Down Can ss cides ke cido REERT AD n AW arde 5 15 Height Of Cans sce aco wees ae Dees a Ow ee a aa Pe eM 5 15 Diameter Missing Lid Width lees 5 16 Minimum Diameter Missing Lid 0 0 0 0 e eee eee 5 16 Counter Functions CrOBDGs es o DL sped vase Set S ts dd 5 17 Total Throughput 52 3 2 22x 7 p9 IP EBeR d ese EVEREST 5 17 Total RECS seiner Y oe eww
193. turn to the Operate Mode Calibrate the Bulged End Sensor according to the instructions in Chapter 6 Calibrating the Bulged End Sensor Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Configure the Diameter Missing Lid Function The Diameter Missing Lid function utilizes the Inspection Trigger Beam to determine if a lid is present therefore you must align the Inspection Trigger Beam before you configure the Diameter Missing Lid function Refer to Aligning the Inspection Trigger for instructions on aligning the Inspection Trigger Height 1 10 11 If your FT 50 is not in the Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the Calibrate Mode Open dip switch S1 5 Press Key 5 until DIA MISSING LID appears and use the Arrow Key to select PRESENT Close dip switch S1 5 Press Key 2 until DIA MISSING LID STATUS appears and then press the Arrow Key to activate the function Press Key 2 until DIA MISSING LID WIDTH appears Start the conveyor and run it normal production speed Place a properly filled and sealed production container on the conveyor far enough upstream from the FT 50 so that the can does not slip on the conveyor as it passes through the FT 50 Record the Samples Interval value that appears in the DIA MISSING LID WIDTH display Repeat the previous two steps four more times and then average the results
194. u have a standard conveyor chain contact the Industrial Dynamics Customer Service 23 If you performed the previous step step 22 at production speed then proceed to step 27 If you did not perform the previous step step 22 at production speed then you must proceed to step 24 24 With the conveyor running at production speed press Key 5 until CHAIN VELOCITY appears Note this value because you need to enter it in the following step 25 Press Key 5 until MAXIMUM CONVEYOR SPEED appears and enter the CHAIN VELOCITY value from the previous step The optimum encoder value for the current line speed is now calculated including the Calibrate Encoder Value Encoder Prescaler Value and Gamma Sample Cutoff Limit 26 While the conveyor is running at production speed place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT 50 If the reject is late check to be sure the encoder coupling is not slipping Try a rejection with a thin layer of grease on the pad If the resulting mark in the grease starts in the upstream third of the pad face and is centered then performance is acceptable If there are still significant early late problems and you are certain that you have a standard conveyor chain contact the Industrial Dynamics Customer Service 27 To store the settings in system memory close dip switch S1 2 and then press Key 5 until SAVE DEFAULT CONSTANTS appears 28 Pr
195. urbances Alarm Dia Missing Lid The minimum number of consecutive diameter missing lid rejects that will trigger an alarm condition The count is reset to zero when a good container is detected This function can alert you to seamer or sealer malfunctions Alarm External Reject The minimum number of consecutive external rejects that will trigger an alarm condition The count is reset to zero when the chain of consecutive external reject signals is broken This function can alert you to inspection problems occurring at the external inspection unit Load Default Constants Retrieves the user defaults that were saved to memory when the last Save User Defaults function was executed The defaults are loaded into active memory and become the new operating config uration of the machine To load the default constants 1 Press Key 5 until Load Default Constants appears 2 Press the Arrow Key to execute Industrial Dynamics Company Ltd Document 40255 0600 5 27 FT 50 Fill Level Inspector Service Manual Note 5 28 Can Width At Trig The container s width in millimeters at the point where it inter cepts the trigger beam as it travels on the conveyor This value is required to establish the proper time for the rejector to actuate so the centerline of the rejector pad impacts the centerline of the container Maximum Can Diameter The maximum diameter of the largest container that is run on this production line Maximum
196. ver Container Travel Distance between Container Lid and Sensor Beam AN Oat WN Secondary Sensor Height Adjustment Figure 4 6 Aligning the Bulged End Sensor 4 12 Industrial Dynamics Company Ltd Document 40255 0600 Chapter 4 Configuring the FT 50 for Operation Note Bulged end detection is only available when the containers are oriented in top up position 1 Center a properly filled and sealed production container under the downstream sensor mounting bracket 2 Loosen the downstream sensor mounting bracket adjustment knob and adjust the sensor so that it is 1mm above the container lid Note If you do not have enough adjustment range to position the sensor correctly reposition the sensor receiver and emitter in the bracket by moving it up or down enough hole positions to give you the range you need 3 Tighten the adjustment knob to secure the positioning 4 If you will not be performing further alignment procedures open the safety shutter by pulling the actuating rod out until it stops Industrial Dynamics Company Ltd Document 40255 0600 4 13 FT 50 Fill Level Inspector Service Manual Aligning the Down Can Sensor The Down Can Sensor is mounted on separate brackets that are attached on the bottom of the inspection head and aligned to the head centerline No Description Sensor beam Sensor Emitter Sensor Receiver A OU N Container Travel Figure 4 7 Aligning the Down Can Sensor 1
197. y close dip switch S1 2 and then press Key 5 until SAVE DEFAULT CONSTANTS appears Press the Arrow Key to execute When COMPLETED appears open S1 2 to protect the saved settings Press Key 5 until SYSTEM DISPLAY appears and press the Arrow Key to select the Operate Mode This returns the FT 50 to a secured operating mode and completes the calibration procedure Industrial Dynamics Company Ltd Document 40255 0600 Chapter 6 Calibration Procedures 37 If you are using this production line to produce more than one type of container you must repeat this procedure for each different container type i e containers with different diameters or line speeds Industrial Dynamics Company Ltd Document 40255 0600 6 23 FT 50 Fill Level Inspector Service Manual Fixed Speed Conveyors Note Note 6 24 If your FT 50 is installed on a fixed speed conveyor you will use the Line Speed Calibration Procedure to synchronize your FT 50 and rejector The Line Speed Calibration Procedure allows an FT 50 that is not equipped with a High Resolution Encoder to perform down can inspection on fixed speed conveyor lines Although you do not need to install the High Resolution Encoder we do recommend it to improve your system performance To use the Line Speed Calibration Procedure with a fixed speed conveyor production line e Your conveyor control system must not allow the conveyor to stop while there are containers in the inspection area
198. y during shipping 2 Unpack the unit slowly and carefully so that you do not damage the equipment inside When removing the FT 50 Inspection Head grasp it by the sides do not pick it up by any brackets or handles 3 Check all packing materials before discarding to make sure no parts are accidentally discarded 4 Inspect all parts for damage that may have occurred during shipping Immediately notify the responsible freight company and Industrial Dynamics Customer Service Department if any part s is damaged ON OORA WN FT 50 Inspection Head Encoder Assembly System Manuals I O Junction Box optional Air Purge Assembly FT 50 Floor Stand Assembly Rejector Assembly Rejector Assembly Figure 3 1 Unpacking the FT 50 Industrial Dynamics Company Ltd Document 40255 0600 Installing the FT 50 Inspection System Chapter 3 Installing the FT 50 To install your FT 50 Inspection System into your production environment you must do the following Determine the proper location for the FT 50 and the rejector Prepare the conveyor e Mount the FT 50 on your production line Install the High Resolution Encoder variable speed lines only Mount the rejector on your production line Wire the main power to the FT 50 After you physically install the FT 50 and the rejector you can proceed to Chapter 4 for instructions on how to configure the FT 50 and rejector to function with your production line Ins

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