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Filtec FT-50c, Service And Technical Reference Manual

The Filtec FT-50c Service And Technical Reference Manual is a comprehensive resource for understanding and troubleshooting the FT-50c. This essential manual is available for free download from manualshive.com in PDF format, providing users with instant access to detailed instructions and valuable insights into maximizing the product's performance.

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Chapter 3: Installing the FT-50

3-3

Before You  Begin

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 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

Summary of Contents for FT-50c

Page 1: ...FT 50c Service and Technical Reference Manual 40255 0600 ...

Page 2: ...FT 50c Fill Level Inspector Service and Technical Reference Manual Document 40255 0600 ...

Page 3: ...strial 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 3100 Fujita Street Torrance California 90505 4007 U S A Telephone 310 325 5633 FAX 310 530 1000 Internet www filtec com Mailing Address P O Box 2945 Torrance California 905...

Page 4: ...nspection Works 1 5 How Overfill Inspection Works 1 5 Rejection Control Basics 1 6 System Specifications 1 7 Power Requirements 1 7 Operating Temperature 1 7 Pneumatics 1 7 Gamma Source 1 7 Inspection Accuracy 1 8 Physical Size 1 8 Triggering System 1 9 High Resolution Encoder 1 9 Rejection 1 9 Mounting 1 9 Height Adjustment 1 9 Container Types 1 10 Container Spacing 1 10 Control Panel 1 10 System...

Page 5: ... Purge System 3 19 Install the High Resolution Encoder 3 21 Mounting the Encoder Inline 3 21 Mounting the Encoder Offset 3 22 Install the Rejector 3 22 Connect the Main Power Source 3 23 Standard Power Supply Wiring 3 23 Wiring the Main Power Supply Cable to the I O Junction Box 3 25 Power Supply Wiring Examples 3 27 Example A Standard 115 VAC or 230 VAC with Neutral line 3 27 Example B Using a Vo...

Page 6: ...ting the FT 50 s Operating Mode 5 6 Selecting an Operating Mode 5 6 Software Functions List 5 7 Function Descriptions 5 12 Fill Level Functions Group 5 12 Underfill Status 5 12 Overfill Status 5 12 Gamma Counts 5 12 Target Head Height 5 13 Gamma Threshold 5 13 Looktime Gate 5 13 Fill Level Optimization 5 13 Learn Target Head Height 5 14 Dyn Reject Pt Test 5 14 Dyn Prod Good Test 5 14 Review Fill L...

Page 7: ...tus 5 21 Fire Rejector On Demand 5 21 Rejector Pulse Width 5 21 Reject Next Container 5 21 Inspect Trig To C L Rej 5 22 Rejector Reaction Delay 5 22 System Functions Group 5 23 Current Container Type 5 23 Last Reject Detected 5 23 Beacon Status 5 23 Line Speed cpm 5 23 Line Speed cph 5 24 System Display 5 24 Conveyor Drive Sprocket 5 24 Serial Data ID Number 5 24 Host Modbus Port Status 5 25 Modbu...

Page 8: ...meter Missing Lid Text 5 36 External Reject 5 37 External Reject Text 5 37 Rejector Type 5 38 PLC Series Alarms 5 38 Serial Interface 5 38 External Trigger Logic 5 38 Known Chain Pitch Teeth 5 39 Encoder Resolution 5 39 Save Default Constants 5 39 Conveyor Segment Pitch 5 39 Teeth Conveyor Segment 5 39 Calibrate Encoder 5 39 Calibrate Encoder Value 5 40 Encoder Prescaler Value 5 40 Gamma Sample Cu...

Page 9: ... 29 Calibrating the Centerline Inspection Trigger 6 30 Calibrating the Upstream Inspection Trigger 6 31 Calibrating the Bulged End Sensor 6 32 Calibrating the Down Can Sensor 6 33 Radiation Detector Calibration Procedure 6 34 Solid State Detector 6 34 Scintillation Tube Detector 6 34 Calibrating the Scintillation Tube Detector 6 35 Scintillation Detector Calibration Procedure 6 35 Fill Level Optim...

Page 10: ...ror Number 9 8 4 Error Number 10 8 4 Error Number 11 8 4 Error Number 12 8 4 Error Number 13 8 4 Error Number 14 8 4 Error Number 15 8 5 Error Number 16 8 5 Error Number 22 8 5 Error Number 23 8 6 Error Number 24 8 6 Error Number 25 8 6 Error Number 27 8 7 Error Number 33 8 7 Error Number 34 8 7 Error Number 46 8 7 Error Number 47 8 7 Error Number 48 8 8 Error Number 49 8 8 Error Number 50 8 8 Err...

Page 11: ...ximity Sensors 8 21 Encoder 8 21 Troubleshooting Problems with Rejectors 8 22 Proline Rejector Troubleshooting 8 22 Quick Reference Troubleshooting Guide 8 25 Chapter Nine Using a PLC With Your FT 50 9 1 Using a PLC With Your FT 50 9 3 PLC Series Alarms 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 9 6 Remote Alarm ...

Page 12: ... 6 Multi Serial 10 6 S2 7 Led Section Selector 10 6 S2 8 Led Bank Selector 10 6 Slide Switches 10 6 SW3 10 6 SW11 10 7 SW13 10 7 Controller Board LED Locations 10 8 LED Configurations 10 9 LED Logic 10 9 LED Definitions 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 ...

Page 13: ...FT 50 Fill Level Inspector Service Manual XII Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 14: ...osure 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 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 ...

Page 15: ...A copy of this is supplied with your FT 50 2 Do not open or tamper with the enclosure containing the radio isotope source 3 Do not place your hands or any other body part between the source and detector when the safety shutter is open 4 Have inspection and wipe tests performed by a properly licensed technician at the specified 36 month intervals Indus trial Dynamics Service Technicians can do this ...

Page 16: ...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 ...

Page 17: ...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...

Page 18: ...Guage 100 or 300 mCi Source 1 5 2 3 4 6 8 7 4 7 5 6 1 3 7 4 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 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 19: ...FT 50 Fill Level Inspector Service Manual XVIII Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 20: ...ma Source 1 7 Inspection Accuracy 1 8 Physical Size 1 8 Triggering System 1 9 High Resolution Encoder 1 9 Rejection 1 9 Mounting 1 9 Height Adjustment 1 9 Container Types 1 10 Container Spacing 1 10 Control Panel 1 10 System Software 1 11 Optional System Features 1 12 Bulged End Detection 1 12 Missing Lid Detection 1 12 Down Can Detection 1 12 Dud Detection 1 12 External Reject Control 1 13 Serial...

Page 21: ...FT 50 Fill Level Inspector Service Manual 1 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 22: ...tector or Scintillation Tube Detector 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 Compan...

Page 23: ...on detector 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 pr...

Page 24: ...amma 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...

Page 25: ...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...

Page 26: ...t can cause electrical transients The neutral line must be properly grounded Operating Temperature Minimum 32 F 0 C 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 14 liters min Gamma Source The gamma source is a low ener...

Page 27: ...spection tunnel The size of your FT 70 was specified when you placed your order Containers Minute Feet Minute m min 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 Standard Wide Extra Wide Tunnel Width 4 5 inches 115 mm 5 5 inches 141 mm 7 5 inches 192 mm Tunnel Height 9 inches 230 mm 9 inches 230 mm 9 inches 230 mm Overall Width 25 25 inches 641 mm 2...

Page 28: ...gh 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 i...

Page 29: ...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 ...

Page 30: ...erent containers 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 with your unit Choices can include English Dutch French German Italian Portuguese or Spanish Ad...

Page 31: ...e PLC Note 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 Missin...

Page 32: ... 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 co...

Page 33: ...FT 50 Fill Level Inspector Service Manual 1 14 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 34: ...er Two Installation Requirements Installation Requirements Overview 2 3 Power Supply 2 3 Pneumatics 2 3 Physical Space 2 4 Conveyor System 2 4 Production Conveyor 2 4 Reject Takeaway Conveyor 2 5 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 35: ...FT 50 Fill Level Inspector Service Manual 2 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 36: ...d for electric motors or other equipment which can cause electrical transients The neutral line must be properly grounded 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 Pneumatics The FT 50 requires 7 psi to maintain the air purging of the ins...

Page 37: ... manual included with your FT 50 Production Conveyor A minimum 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 chai...

Page 38: ...the rejector This sensor detects container backup and will shut down the line before the backup accumu 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 C...

Page 39: ...FT 50 Fill Level Inspector Service Manual 2 6 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 40: ...the Slant Support Braces 3 14 Install the Air Purge System 3 19 Install the High Resolution Encoder 3 21 Mounting the Encoder Inline 3 21 Mounting the Encoder Offset 3 22 Install the Rejector 3 22 Connect the Main Power Source 3 23 Standard Power Supply Wiring 3 23 Wiring the Main Power Cable to the I O Junction Box 3 25 Power Supply Wiring Examples 3 27 Standard 115 VAC or 230 VAC with Neutral li...

Page 41: ...FT 50 Fill Level Inspector Service Manual 3 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 42: ...on of the flow is downstream Upstream is the direction opposite or against the conveyor flow Anything 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...

Page 43: ...d poorly 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 not...

Page 44: ...ctor you can proceed to Chapter 4 for instructions on how to configure the FT 50 and rejector to function with your production line Instructions for installing the rejector are contained within the rejector manual You should install the rejector after you have installed the FT 50 Figure 3 2 FT 50 Inspection System installation flow chart Determine the mounting locaton for FT 50 and rejector Prepare ...

Page 45: ... 3 5 seconds from a minor disturbance such as 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 Yo...

Page 46: ...nch 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 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 3 4 2 5 in...

Page 47: ...ons above 60 inches 1538 mm 1 Use the following equation to determine the proper length for the vertical support pipe 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 Lp The length to which the pipe must be cut HC The distance from the top of the conveyor chain to the floor 11 Subtract 11...

Page 48: ...t flanged 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 1 2 No Description 1 Remove excess from this end 2 Flanged end Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 49: ... 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 later Figure 3 7 Attaching the support braces to the base tripod 2 1 No Description 1 Support Pipe 2 Stop Plate 1 2 No Description 1 Support Brace 2 Retaining Bolts...

Page 50: ...ve the 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 Figure 3 9 Mounting the inspection head on the vertical support pipe 1 No Description 1 Pipe Clamp 1 2 3 No Description 1 Mounting Bolt 2 Gasket 3 Flanges...

Page 51: ...tion head is perpendicular to the conveyor 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 bottm of the FT 50 Shift the vertical support pipe in its mounting as needed until the inspection head is level Figure 3 10 Aligning the FT 50 to the conveyor ...

Page 52: ...e 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 Figure 3 11 Anchoring the base tripod to the floor 3 Bolt the tripod to the floor 1 No Description 1 Lag Bolt Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 53: ...ce Drawing Pack 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 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 th...

Page 54: ...brace by subtracting 6 inches from the measurement you made in the previous step 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 35 35 1 2 No Description 1 Measure from the hole to the floor while maintaining an angle of app...

Page 55: ...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 Figure 3 14 Attaching the slant braces and slant brace stubs 1 No Description 1 Slant Brace Stubs Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 56: ...wo 1 2 inch x 4 inch lag bolts and lead floor inserts 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 ...

Page 57: ...trical ARC welding equipment The high electrical current will damage electronic components inside the FT 50 Figure 3 16 Spot welding the mounting hardware 3 1 2 3 No Description 1 Weld both brackets 2 Weld three braces 3 Weld both feet Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 58: ... mount the air filter in an alternate location providing the distance does not exceed the 40 inch length of the air hose Figure 3 17 Installing the air purge system 1 2 3 4 5 No Description 1 Pressure Adjustment Knob 2 UBolt 3 Output Air Hose to FT 50 4 Vertical Support Pipe 5 Air input attach input air hose Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 59: ...re 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 1 2 3 No Description 1 Air Regulator Disperser 2 Air Input 3 Air Hose from filter regulator Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 60: ...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 I 00484 There are two drilling templates choose the one that suits your installation 4 Attach the encoder assembly by sliding ...

Page 61: ...tact an IDC Service Representative who will assess the situation and help you devise a solution 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 Refer to the rejector installation manual that is included with your inspection system for instructions on installing the rejector When you complete the re...

Page 62: ... situation If your FT 50 is not equipped with the optional I O Junction Box use the Standard Power Supply Wiring procedure 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 Warning Disconnect all electrical power sources from the equipment before attempting any installation procedu...

Page 63: ...le into the FT 50 3 Remove the cover from the power filter and route the power cable into the filter through the rubber grommet in the side Figure 3 22 Route the Power Cable into the Power Filter 1 3 2 No Description 1 Power cable 2 Watertight Cable Ports 3 Entrance to Power Filter 1 2 3 No Description 1 Rubber Grommet 2 Power Wires 3 Filter Cover Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 64: ...nstallation 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 Figure 3 23 Route the Power Cable into the Junction Box Connect the Power Cable To the FT 50 Hot Brown Neutr...

Page 65: ...t 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 Attach to ground point in box Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 66: ...ed in the FT 50 in this application Figure 3 24 Main power wiring Example A 1 7 5 115 230 2 6 N 9 10 11 12 8 H N H 115 VAC 115 VAC 3 7 5 115 230 4 6 N 9 10 11 12 8 H N H 115 VAC 115 VAC PE PE 230 VAC 115 VAC No Description 1 Plant Power Panel 115 VAC 2 Voltage Select Switch 115 V 3 Plant Power Panel 230 VAC 4 Voltage Select Switch 230 V 5 FT 50 Power Junction Box 6 Connect FT 50 pigtail leads to i...

Page 67: ...lation properties 3 Connect the FT 50 ground stud to the facilities ground system The neutral wire should also be connected to this ground stud 4 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 trans...

Page 68: ...d to any of the three legs phases 4 In this system the leg to leg Ø1 to Ø2 Ø2 to Ø3 and Ø1 to Ø3 voltage is 208 VAC Any leg to neutral is 120 VAC Europe 380 220 Figure 3 26 Main power wiring Example C 115 230 VAC 6 1 5 2 3 4 PE N Ø1 Ø2 Ø3 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 ...

Page 69: ...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 Figure 3 27 Main power wiring Example D 115 230 VAC 6 1 5 2 11 230 3 4 N Ø1 Ø2 Ø3 7 8 9 10 No Description 1 Plant Power Panel 2 FT 50 Power Junction Box 3 Voltage Select Switch 4 Conn...

Page 70: ... Sensor 4 14 Wiring the External Reject Function 4 15 Software Configuration 4 16 Calibrating the Encoder and Rejector Timing 4 16 Configuring the Inspection Looktime Gate 4 17 Configuring the Gamma Threshold 4 19 Setting the Overfill Gamma Threshold 4 20 Setting the Underfill Gamma Threshold 4 21 Configure the Missing Lid Function 4 22 Configure the Bulged End Function 4 22 Configure the Diameter...

Page 71: ...FT 50 Fill Level Inspector Service Manual 4 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 72: ...ion order Figure 4 1 FT 50 Inspection System Configuration Flow Chart Adjust head height for fill level inspection Adjust inspection trigger height Calibrate encoder if applicable and rejector timing Determine the inspection looktime gate Determine the gamma threshold Perform fill level optimization if need Configure down can function Configure dud detection function Adjust missing lid sensor Adjus...

Page 73: ... height 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 Figure 4 2 FT 50 mechanical adjustment mechanisms 6 INDUSTRIAL DYNAMICS Torrance California USA MODEL FT 50 FILL LEVEL INSPECTOR 4 3 5 1 2 5 1 3 4 6 6 6 6 2 No Description 1 Head Height Adjustment Crank 2 Head Height Cou...

Page 74: ...veyor 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 ca...

Page 75: ... 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 Figure 4 3 Setting the proper fill level inspection point 1 2 4 3 7 6 5 8 7 6 9 8 No Description 1 Head Height Adjustment Crank 2 Gamma Beam Source 3 Inspection Beam Centerline 4 Radiation Detector 5 Gamma Beam Horizontal ...

Page 76: ... 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 If you 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 Coun...

Page 77: ...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 1 3 5 4 7 6 8 2 7 6 9 No Description 1 Trigger Height Lock 2 Trigger Beam Emitter 3 Trigger Beam Centerline 4 Trigger Beam Receiver 5 Container Travel 6 Trigger Horizontal Centerline 7 Trigger Vertical Cen...

Page 78: ...he 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 ...

Page 79: ...gure 4 5 Aligning the Missing 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 2 3 1 4 5 6 No Description 1 Missing Lid Sensor 2 Container Lid 3 Container Travel 4 Distance between Lid and Sensor 5 Upper Locking Nut 6 Lower Locking Nut Indust...

Page 80: ...he 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 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 Extended Range Steel 0 5 inch 13 mm 0 88 inch 22 mm 91098 Standard 0 25 0 38 ...

Page 81: ...d to Centerline Sensor Mount Bracket Figure 4 6 Aligning the Bulged End Sensor 6 1 2 3 4 5 8 7 No Description 1 Sensor Emitter 2 Height Adjustment Lock 3 Container Lid 4 Sensor Beam 5 Sensor Receiver 6 Container Travel 7 Distance between Container Lid and Sensor Beam 8 Secondary Sensor Height Adjustment Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 82: ...d 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 ...

Page 83: ...rmine 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 3 If you will not be performing further alignment procedures open the safety shutter by pulling the actua...

Page 84: ... is equipped with an external I O Junction Box route the cable through one of the 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 TB4 ...

Page 85: ... additional procedures Configure the Missing Lid Function Configure the Bulged End Function Configure the Diameter Missing Lid Function 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 ...

Page 86: ...he Calibrate Mode Press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the CALIBRATE MODE 4 Press Key 5 until TIME WIDTH OF CAN appears 5 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 6 Record the value that appears in the T...

Page 87: ...KTIME 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 where D Average Time Width of Can step 7 L Looktime gate in milliseconds D 0 6 L Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 88: ...e cover 3 Open the radiation source shutter by pulling the actuating rod out until it stops 4 Start the conveyor and run it at the maximum production speed 5 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 6 Press Key 1 until GAMMA THRESHOLD appears 7 Place a properly filled sample production container on...

Page 89: ...ain 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 4 Use the following equation to determine the Overfill Gamma Threshold 5 Press Key 1 until you reach GAMMA THRESHOLD and use the Arrow Key to e...

Page 90: ...steps four more times and then average the value to get the average bad count BC 4 Use the following equation to determine the Underfill 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 50 press Key 5 until you reach SYSTEM DISPLAY and then press the Arrow...

Page 91: ...Mode 7 Calibrate the Missing Lid Sensor according to the instructions in Chapter 6 Calibrating the Missing Lid Sensor Configure the Bulged End Function 1 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 2 Open dip switch S1 5 3 Press Key 5 until BULGED END appears and use the Arrow Key to select PRESENT 4...

Page 92: ...switch S1 5 5 Press Key 2 until DIA MISSING LID STATUS appears and then press the Arrow Key to activate the function 6 Press Key 2 until DIA MISSING LID WIDTH appears 7 Start the conveyor and run it normal production speed 8 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 th...

Page 93: ...re not identified and rejected properly If sealed containers are identified as rejects decrease the Minimum Diameter Missing Lid value slightly and repeat step 14 until false rejects no longer occur 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 15 If you are finished configuring the FT 50 pr...

Page 94: ...n in the upright position intersects the down can sensor beam This is the Width at Down Can 7 Press Key 2 until WIDTH AT DOWN CAN appears and then press the Arrow Key to enter the measurement value 8 Measure the height of the can in millimeters Be sure to measure from the bottom to the top of the lid highest part 9 Press Key 2 until HEIGHT OF CAN appears and then press the Arrow Key to enter the m...

Page 95: ...til 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 If you are finished configuring the FT 50 press Key 5 until you reach SYSTEM D...

Page 96: ... 13 Learn Target Head Height 5 14 Dyn Reject Pt Test 5 14 Dyn Prod Good Test 5 14 Review Fill Level Test 5 14 Container Finish Functions Group 5 15 Bulged End Status 5 15 Missing Lid Status 5 15 Down Can Status 5 15 Diameter Missing Lid Status 5 15 External Reject Status 5 15 Width at Down Can 5 15 Height of Can 5 15 Diameter Missing Lid Width 5 16 Minimum Diameter Missing Lid 5 16 Counter Functio...

Page 97: ...23 Current Container Type 5 23 Last Reject Detected 5 23 Beacon Status 5 23 Line Speed cpm 5 23 Line Speed cph 5 24 System Display 5 24 Conveyor Drive Sprocket 5 24 Serial Data ID Number 5 24 Host Modbus Port Status 5 25 Modbus Message Counters 5 25 PLC Output Pulse Width 5 25 Time Width Of Can 5 26 Chain Velocity 5 26 Alarm Underfills 5 26 Alarm Overfills 5 26 Alarm Missing Lid 5 27 Alarm Bulged ...

Page 98: ... Reject 5 37 External Reject Text 5 37 Rejector Type 5 38 PLC Series Alarms 5 38 Serial Interface 5 38 External Trigger Logic 5 38 Known Chain Pitch Teeth 5 39 Encoder Resolution 5 39 Save Default Constants 5 39 Conveyor Segment Pitch 5 39 Teeth Conveyor Segment 5 39 Calibrate Encoder 5 39 Calibrate Encoder Value 5 40 Encoder Prescaler Value 5 40 Gamma Sample Cutoff Limit 5 40 Gamma Samples Per En...

Page 99: ...FT 50 Fill Level Inspector Service Manual 5 4 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 100: ...roup 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 Arro...

Page 101: ...d feature which prevents 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 If the Password Protect Function is enabled you must enter the password before you can enter the Calibrate Mode If you enter the wrong pa...

Page 102: ...ion 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 Updating 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...

Page 103: ...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 Rejector Status On Off Off Fire Rejector On Demand Execute Off Rejecto...

Page 104: ...0 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 ...

Page 105: ... Present Bulged End Text 17 Characters Maximum Bulged End Down Can Present Not Present Not Present Down Can Text 17 Characters Maximum Down Can Diameter Missing Lid Present Not Present Not Present Dia Missing Lid Text 17 Characters Maximum Dia Missing Lid External Reject Present Not Present Not Present External Reject Text 17 Characters Maximum External Reject Rejector Type Std Proline HS Proline ...

Page 106: ...381 mm Teeth Conveyor Segment 1 3 Teeth 2 Teeth Calibrate Encoder Execute Calibrate Encoder Value Pulses 10m Pulses 10m Encoder Prescaler Value 2 50 Pulses 5 Pulses Gamma Sample Cutoff Limit 1 50 Samples 4 Samples Gamma Samples Per Encoder 1 50 Samples Diagnostics Key 6 System Diagnostic Error 0 69 Function Group Function Name Parameter Default 6 Industrial Dynamics Company Ltd Document 40255 0600...

Page 107: ...hreshold 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 this function inhibits detection and rejection of containers with fill levels above the overfill gamma threshold Overfill and Underfill can not be active simultaneously To ac...

Page 108: ...alue that falls outside of the Gamma Threshold triggers a rejection Looktime Gate The time in milliseconds during which gamma 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 Wid...

Page 109: ...ization 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 ...

Page 110: ... 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...

Page 111: ...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 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 112: ... 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 two functions reject the same container only one total reject count is recorded The Reject Next Can function is included in Total Rejects Total...

Page 113: ...tomatically 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 Counters 1 Press Key 3 until RESET ALL COUNTERS appears 2 Press the Arrow Key to execute Reset Total Through...

Page 114: ...l 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 ...

Page 115: ...til 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 E...

Page 116: ... 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 co...

Page 117: ...he 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 Indu...

Page 118: ...tus of the warning beacon There are three status choices 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 Off The beacon will flash once for each rejected container High Priority Only The beacon will flash once for each rejected container and continuously when a high priority dia...

Page 119: ...e Mode When in Calibrate Mode if the FT 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 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 ...

Page 120: ...us messages the FT 50 receives and defines them as good bad or other Good is the number of good messages received 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 adjuste...

Page 121: ...d then calculate the Looktime using the following equation 4 Press Key 1until LOOKTIME GATE appears 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 condit...

Page 122: ...ces 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 ...

Page 123: ...lows 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 Note The Change Password function will not appear in the display unless the dip...

Page 124: ... pins in Terminal Blocks TB1and 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 4 PIN ASSIGNMENTS appears 2 Continue pressing the Arrow Key to scroll through the list The top line of the displays the sensor or function and its assigned terminal pin The bottom lin...

Page 125: ...ctory 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...

Page 126: ...he 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 act...

Page 127: ...or 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 Overfill Status Total Overfill Reset Overfill Alarm Overfill Overfill Text Note 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...

Page 128: ...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 Total Missing Lid Reset Missing Lid Alarm Missing Lid Missing Lid Text Missing Lid Note 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...

Page 129: ...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 Bulged End Status Total Bulged End Reset Bulged End Alarm Bulged End Bulged End Text Bulged End Note 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...

Page 130: ...e in which Down Can would have appeared in the software is replaced by the custom label you created The following options are effected Down Can Status Total Down Can Reset Down Can Width at Down Can Alarm Down Can Down Can Text Down Can Note 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 conf...

Page 131: ...n 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 Reset Dia Missing Lid Dia Missing Lid Width Minimum Diameter Missing Lid Alarm Dia Missing Lid Dia Missing Lid Text Dia Missing Lid Note This manual assumes the default name for this option If yo...

Page 132: ...n 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 External Reject Status Total External Reject Reset External Reject Alarm External Reject External Reject Text External Reject Note This manual assumes the default name for this option If you change the default text remember to substitute the new...

Page 133: ...ments 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 ...

Page 134: ...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 ...

Page 135: ...e 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 occurre...

Page 136: ... 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 ...

Page 137: ...secutive 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 Encoder 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 Dow...

Page 138: ...Line Speed Too High 86 BBU RAM Batter is Low 87 Broken Slat Or Pin 88 Broken Slat Sensor Failure 89 Slat Sensor Is Off 90 Broken Slat Sensor Adjustment Error 91 Broken Slat Pushplate 117 Modbus Serial Interface Framing Error 118 Modbus Serial RX Overrun Error 119 Modbus Serial Parity Error 120 Modbus Serial RX Receive Rate Error 121 Modbus CTS Line Rate Error Error conditions that cause an alarm w...

Page 139: ...FT 50 Fill Level Inspector Service Manual 5 44 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 140: ...ine Tuning the Rejector Timing 6 27 Sensors Calibration Procedures 6 29 Proximity Sensors 6 29 Fiber Optic Sensors 6 29 Before You Begin 6 29 Calibrating the Centerline Inspection Trigger 6 30 Calibrating the Upstream Inspection Trigger 6 31 Calibrating the Bulged End Sensor 6 32 Calibrating the Down Can Sensor 6 33 Radiation Detector Calibration Procedure 6 34 Solid State Detector 6 34 Scintillat...

Page 141: ...FT 50 Fill Level Inspector Service Manual 6 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 142: ...edures in this section should be performed only if your FT 50 is completely installed and fully operational This section contains the following calibration procedures Encoder Calibration Sensor Calibration Radiation Detector Calibration Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 143: ...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 limi...

Page 144: ...d 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 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 c...

Page 145: ...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 IDC FT 50 MT 05 VERSION MGI STAT 0480 3 If the version code is MGI thru MZZ TYW thru TZZ or SAA thru SZZ Baseline E...

Page 146: ...se the Standard Conveyor Calibration Procedure If you do not know the number of the conveyor sprocket teeth but have a standard conveyor use the Unknown Sprocket Size Calibration Procedure 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 ...

Page 147: ... the type of rejector installed in your system 5 Press Key 5 until KNOWN CHAIN PITCH TEETH appears and set to PRESENT 6 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 Note The encoder resolution is set at the factory during assembly however if you upgraded the softwa...

Page 148: ...n order to perform prelim inary calculations 15 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 16 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 a...

Page 149: ... single slat 21 If the container is not rejected properly make changes to the measured distance or number of sprocket teeth as follows Verify the Inspect Trigger to C L Rejector distance is measured and entered correctly see steps 8 and 9 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 inc...

Page 150: ...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 o...

Page 151: ...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 ...

Page 152: ...ip 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 TEETH appears and set to PRESENT 6 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 Note The enc...

Page 153: ... tooth Note 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 i...

Page 154: ...RIG TO C L REJ appears and use the Arrow Key to enter the measurement in millimeters 21 Press Key 5 until CHAIN VELOCITY appears Note this value because you need to enter it in the following step 22 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 S...

Page 155: ...pection 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 If the container is 1 inch down stream when the rejector fires the number of teeth should be increased by one 26 Run the conveyor at the same speed as in step 16 and place a can on the conveyor far enough upst...

Page 156: ...ulting 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 3...

Page 157: ...u 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...

Page 158: ... 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 13 Press Key 4 until INSPECT TRIG TO C L REJ appears and use the Arrow Key to enter the measurement in millimeters 14 Measure the diameter of the production container in milli meters at the point where...

Page 159: ...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 ap...

Page 160: ...e FT 50 without slipping If the container appears to make contact on upstream third of the rejector proceed to step 29 Note 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 28 If the container is not rejected properly make changes to the measured distance or number of sprocket teeth as follows Veri...

Page 161: ...ter 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 33 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 rejec...

Page 162: ...u 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 ...

Page 163: ...e 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 Note You must configure the FT 50 for a fixed s...

Page 164: ...ocedures 6 25 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 S1 5 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 165: ...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...

Page 166: ...ER 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 place a production container preferably the container measured for the Can Width At Trig value upstream ...

Page 167: ...ved 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 container type i e containers with different diameters or line spee...

Page 168: ...roken This triggers the sensor signal indicating that an object is present in the beam The fiber optic sensors used in the FT 50 are Centerline Inspection Trigger Upstream Inspection Trigger Bulged End Down Can Before You Begin 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...

Page 169: ...inspection trigger beam is completely blocked 4 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 5 Turn the Offset Adjustment counterclockwise half the number of turns required in the previous step 6 Remove the container from the inspection trigger beam path The Output Contrast LED should increase to 10 and t...

Page 170: ...tivity 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 ...

Page 171: ...edle 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 ...

Page 172: ...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 remov...

Page 173: ...ctor 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 Industrial Dynamics Compa...

Page 174: ...ction beam 2 Turn the High Voltage Output Adjustment counterclockwise until it stops Figure 6 3 Calibrating the STD 3 Attenuate the inspection 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 1 2...

Page 175: ...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 ins...

Page 176: ...tion 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 Before you begin the Fill Level Optimization routine you must do the following Calibrate the encoder if needed Calibrate the Scintillation Tube Detector if needed Level...

Page 177: ...hat 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 stand base and possibly other parts of the stand in order to shift the position of the Inspection Head Figure 6 4 Leveling the Inspection Head 1 1 2 3 3 No Description 1 Vertical Centerl...

Page 178: ...ess Key 1 until FILL LEVEL OPTIMIZATION appears and then press the Arrow Key to begin determining the Gamma Threshold for the container 3 Precisely center a 100 percent reject container in the inspection tunnel and then press any key to continue 4 Lower the gamma beam into the liquid by slowly turning the Head Height Adjustment Crank The head height should be lowered well below the liquid level 5 ...

Page 179: ...gin the Container Profile Test During this test you are required to repeat a series of actions 14 Raise the head 1 tick and then press the Arrow Key Repeat this step until you reach the FULL BOTTOM POINT 15 Press the Arrow Key when you are ready to proceed and then repeat step 14 until you reach the EMPTY TOP POINT 16 When you reach Empty Top Point the following information is displayed Press the A...

Page 180: ...ISE HEAD ONE TICK displays Stop lowering the head at this point 5 Raise the head one tick as indicated by the Head Height Meter and then press the Arrow Key 6 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 7 Press Key 1 and then use the Arrow Keys to enter the Ta...

Page 181: ... 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 di...

Page 182: ...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 ...

Page 183: ...l 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 ...

Page 184: ...tenance 7 4 Maintenance Procedures 7 5 Before You Perform Any Maintenance Procedure 7 5 Trigger Beam and Emitter Lenses 7 5 Bulged End and Missing Lid Sensors 7 5 The FT 50 Housing 7 6 Pressure Regulator and Air Filter 7 6 External Wiring 7 6 Replacing the Rejector Pad 7 6 Servicing the Regulator and Coalescing Air Filters 7 7 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 185: ...FT 50 Fill Level Inspector Service Manual 7 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 186: ...on 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 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 ...

Page 187: ...ers and Instruction Plates Service Pneumatic components per Rejector Manual Inspect Inspection Head Housing for dirt and moisture Inspect Wiring insulation terminals terminal blocks Inspect Source Autoshutter Assembly Inspect Gamma Window for damage blockage Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 188: ...an scratch the lense 3 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 4 Inspect the beacons for cracks in the lenses and moisture inside the lenses Bulged End and Missing Lid Sensors 1 Inspect each sensor for debris and damage 2 Clean each sensor with a cotton swab lens tissue or a soft cloth Do...

Page 189: ...xternal 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 Warning Turn ...

Page 190: ... of this section 1 Turn off the air flow control valve and depressurize all connected air lines 2 Remove and clean the sediment bowl If your unit contains a polycarbonate bowl inspect it for cracking or cloudiness if present replace it Warning Cracked or cloudy polycarbonate bowls can explode when repressurized causing serious injury 3 Clean other parts using soap and water 4 Dry the bowl and other...

Page 191: ...FT 50 Fill Level Inspector Service Manual 7 8 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 192: ...r Number 25 8 6 Error Number 27 8 7 Error Number 33 8 7 Error Number 34 8 7 Error Number 46 8 7 Error Number 47 8 7 Error Number 48 8 8 Error Number 49 8 8 Error Number 50 8 8 Error Number 51 8 8 Error Number 52 8 9 Error Number 53 8 9 Error Number 54 8 9 Error Number 58 8 9 Error Number 61 8 9 Error Number 66 8 9 Error Number 67 8 9 Error Number 68 8 10 Error Number 72 8 10 Error Number 86 8 10 E...

Page 193: ...shooting 8 17 Main Processor Card 8 17 Serial Communications Card 8 18 The Control Panel 8 18 Sensor System Troubleshooting 8 20 Scintillation Tube Detector STD 8 20 Solid State Detector SSD 8 20 Optical Sensors 8 21 Proximity Sensors 8 21 Encoder 8 21 Troubleshooting Problems with Rejectors 8 22 Proline Rejector Troubleshooting 8 22 Quick Reference Troubleshooting Guide 8 25 Industrial Dynamics C...

Page 194: ...r 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 inspec...

Page 195: ...ive 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...

Page 196: ...ndicates containers are passing through the gamma beam however no trigger signal is received To correct this problem Check to see that the trigger amplifier sensitivity is correctly adjusted The sensitivity may be set too low Check to see if LED 8 is on when no container is present If so it is blocked clean the trigger lens Check the signal at TB1 2 It should be less than 1 volt when the beam is bl...

Page 197: ...he 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 t...

Page 198: ... 34 Two or more consecutive inspection triggers have occurred 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 contai...

Page 199: ...orrect 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 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 Nu...

Page 200: ...eded 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 position 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 St...

Page 201: ...on 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 U2...

Page 202: ... 1200 Check the character size S2 5 S2 5 CLOSED 8 bit 1 stop S2 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 RX A GND RX B 5VDC RS 232 RX A 12VDC to 4VDC 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 rat...

Page 203: ... this error Check the termination of the RX input Check the RX input with a voltmeter while the line is in a steady state no transmission 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 Check the termination of the CTS input Check the CTS input with a voltmet...

Page 204: ...he following subsystem categories Power Supply System Main Power Supply Power Transformer Processing System Main Processor Card Serial Communications Card Control Panel Sensor System Scintillation Tube or Solid State Detector SSD Optical Sensors Inspection Triggers Missing Lid Bulged End Down Can Proximity Sensor Missing Lid Encoder Rejector Systems Proline Rejector Before You Begin Before you att...

Page 205: ...breaker is tripped the power switch turns off Verify the power switch is turned on if not turn it on to reset the breaker 3 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 4 Are all dip switches and jumper...

Page 206: ...riate test points Figure8 1 Power Supply Circuit Board test points Reference Test Point Output VDC Range VDC Xfmr Winding Source Supply Description 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...

Page 207: ...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 ...

Page 208: ...r 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 Figure8 2 The Processor Card LED 12 U25 U26 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 209: ...tes 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...

Page 210: ...nel 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 If the beacon does not flash replace the beacon bulb and test again If the beacon is solid there is a problem with the processor card If the beacon flashes once and stops there is a problem with the terminal card The di...

Page 211: ...denly 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 co...

Page 212: ... 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 The height of the sensor has been changed Check ...

Page 213: ...he 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 powe...

Page 214: ...0 5 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 If the LED flashes but the rejector does not fire replace the power supply 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 ...

Page 215: ...ble 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 Industrial Dynamics Company Ltd Document 402...

Page 216: ...d 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 Review the Install...

Page 217: ...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 drops or is erratic The facility air supply pressure must be maintained at 10 psi over the regulator pressure setting If facility air supply pressure drops when rejector operation is erratic install an accumulator upstream of the rejec...

Page 218: ... FT 50 9 3 PLC Series Alarms 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 9 6 Remote Alarm 9 8 How to Clear a Remote Alarm 9 8 Remote Alarm Error Number Designations 9 8 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 219: ...FT 50 Fill Level Inspector Service Manual 9 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 220: ...gnals are available in the FT 50 s I O Junction Box The FT 50 can report the following signals to a PLC Sensor Gamma Failure Alarm Latched Consecutive Alarms Rejector Fill Level Status OFF Total Rejects Total Throughput Fill Level Rejects Bulged End Rejects Missing Lid Rejects and the following Remote Alarms Rejector Fill Level Status OFF Fill Level Series Alarm Bulged End Series Alarm Missing Lid...

Page 221: ...5 until PLC SERIES ALARMS appears and press the Arrow Key to select PRESENT 4 Close Dip switch S1 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 Alarm Series Underfills Alarm Series Overfills Alarm Seri...

Page 222: ...ine of the displays the output function and its assigned terminal pin The bottom line lists the voltage level and triggered action For example NORMAL 2V PULSE 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...

Page 223: ...y 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 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 Rejec...

Page 224: ... Edge Connector 11 Logic 12 Input 13 Ground Common 14 Mounting Rack 15 Fuse Plug in 16 Load Connected to either the positive or negative side of the source 7 1 VAC 5A 14 L E D 3 3K 8 10 3 2 Rc 4 1 2 3 4 5 6 9 11 15 16 16 Vcc 12 13 No Description 1 Field 2 Diode must be used on inductive loads 3 Screw Terminals 4 Plug in Module 5 Equivalent Circuit Only 6 Zero Voltage Check 7 Pins 8 Sockets in Moun...

Page 225: ...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...

Page 226: ... S1 6 Not Used 10 5 S1 7 Not Used 10 5 S1 8 Password 10 5 Dip Switch Pack S2 10 6 S2 1 Baud Rate 10 6 S2 2 Handshake Flags 10 6 S2 3 Parity On Off 10 6 S2 4 Parity Odd Even 10 6 S2 5 Character Size 10 6 S2 6 Multi Serial 10 6 S2 7 Led Section Selector 10 6 S2 8 Led Bank Selector 10 6 Slide Switches 10 6 SW3 10 6 SW11 10 7 SW13 10 7 Controller Board LED Locations 10 8 LED Configurations 10 9 LED Lo...

Page 227: ...FT 50 Fill Level Inspector Service Manual 10 2 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 228: ...ions 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 S13 Figure 10 1 Switch locations on the Controller Board S2 S13 S1 S3 S11 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 229: ...Overfill Underfill S1 2 Software Protect On Off S1 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 S1 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 4...

Page 230: ...t 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 i...

Page 231: ... selection of odd or even parity when S2 3 is open The 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 B...

Page 232: ...s and LEDs 10 7 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 ...

Page 233: ...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 S2 8 Figure 10 2 Locating the LEDs on the Controller Board LEDs 1 2 3 4 5 6 7 8 9 10 11 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 234: ...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 LED Section 1 S27 close Bank 1 S28 close Section 1 S27 close Bank 2 S28 open Section 2 S27 open Bank 1 S28 close Section 2 S27 open 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...

Page 235: ... activated or when sensor is blocked LED 6 Bulged End Trigger Indicator lights when the High Cap sensor is activated or when sensor is blocked LED 7 Missing Lid Trigger Indicator lights when the Missing Cap sensor is activated or when lid is present LED 8 Inspect Trigger Indicator lights when the Inspection Trigger sensor is activated or when the sensor is blocked LED 9 AC Power Low Indicator ligh...

Page 236: ...ily below 70 VAC LED 10 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 LED 11 Detector Used to get a coarse calibration setting for the Scintillation Detector LED 1 Inlabeler Sensor Input 1 LED 2 Inlabeler Sensor Input 2 LED 3 Inlabeler Sensor Input 3 LED 4 Inlabeler Sensor Input...

Page 237: ...FT 50 Fill Level Inspector Service Manual 10 12 Industrial Dynamics Company Ltd Document 40255 0600 ...

Page 238: ...llowing page to record your comments and then send the form to us in one of the following ways 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 Email techpubs filtec com Fax 310 530 ...

Page 239: ...ntation Feedback Form Please deliver To Industrial Dynamics Technical Publications Department Received From Fax 310 530 1000 Telephone Email techpubs filtec com Email Post Mail Industrial Dynamics Co Technical Publications Department 3100 Fujita St Torrance CA 90505 Address ...

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