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Filtec FT-70c, Service And Technical Reference Manual

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FT-70 Fill Level Inspector Service Manual

10-8

Controller Board LED Locations

The FT-70’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.  ©

  40256-0600

Summary of Contents for FT-70c

Page 1: ...FT 70c Service and Technical 40256 0600 Reference Manual for Can Inspection...

Page 2: ...FT 70c Fill Level Inspector Service and Technical Reference Manual Document 40256 0600 for Can Inspection...

Page 3: ...trial 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 Informat...

Page 4: ...ill Inspection 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 X Ray Generator 1 7 In...

Page 5: ...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 2...

Page 6: ...trol Panel 5 4 The Function Group Keys 5 4 The Arrow Keys 5 4 The Safety Interlock Switch 5 5 Selecting the FT 70 s Operating Mode 5 6 Selecting an Operating Mode 5 6 Software Functions List 5 7 Funct...

Page 7: ...otal Down Can 5 20 Reset Total Diameter Missing Lid 5 20 Reset Total External Rejects 5 20 Rejector Functions Group 5 21 Rejector Status 5 21 Fire Rejector On Demand 5 21 Rejector Pulse Width 5 21 Rej...

Page 8: ...t 5 32 Overfill Text 5 32 Missing Lid 5 33 Missing Lid Text 5 33 Bulged End 5 34 Bulged End Text 5 34 Down Can 5 35 Down Can Text 5 35 Diameter Missing Lid 5 36 Diameter Missing Lid Text 5 36 External...

Page 9: ...6 24 The Line Speed Calibration Procedure 6 25 Fine Tuning the Rejector Timing 6 26 Sensors Calibration Procedures 6 28 Proximity Sensors 6 28 Fiber Optic Sensors 6 28 Before You Begin 6 28 Calibratin...

Page 10: ...Air Filters 7 8 Chapter Eight Diagnostic and Repair Procedures Diagnostic Error Messages 8 3 Error Number 2 8 3 Error Number 5 8 3 Error Number 6 8 3 Error Number 8 8 3 Error Number 9 8 4 Error Number...

Page 11: ...nerator Troubleshooting Flowchart 8 19 Verify the Enable Signal at PX 1 8 20 Verify the Enable Signal at TB4 13 8 20 How to Replace the X ray Generator 8 21 Main Processor Card Troubleshooting 8 26 Re...

Page 12: ...ic 8 34 Rejector sticking or binding 8 34 Chapter Nine Using a PLC With Your FT 70 Using a PLC With Your FT 70 9 3 PLC Series Alarms 9 4 How to Determine the Signal Output Wiring 9 5 Adjusting the PLC...

Page 13: ...nk Selector 10 6 Slide Switches 10 7 SW3 10 7 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 Clo...

Page 14: ...Table of Contents XIII Industrial Dynamics Company Ltd Form 40256 0600...

Page 15: ...e the body There are no by products that can be ingested into the body The FT 70 is unlikely to create hazardous radiation levels for the following reasons The FT 70 s X ray Generator produces a relat...

Page 16: ...ainst an air ionization chamber survey meter whose response was corrected against an Americium 241 test source 2 Interlock Electronic Shutter closed The radiation levels are not measurable 3 Interlock...

Page 17: ...y 6 IN DUSTR IA L DYNAM IC S To rran ce Califo rn ia USA M ODEL FT 7 0 FI LL LE VE L IN SP EC TO R 4 3 5 1 2 36906 X FACTORY ADJUSTMENT ONLY DO NOT REMOVE INDUSTRIAL DYNAMICS CO TORRANCE CA U S A ENAB...

Page 18: ...KV 50 A with 2 015 inch BeKu Filters 1 4 7 5 2 3 4 5 6 7 1 4 8 5 8 6 3 No Description No Description 1 Inspection Head 5 5 cm Isodistance Contour 2 Inspection Tunnel 6 Radiation Detector 3 Sealed X ra...

Page 19: ...FT 70 Fill Level Inspector Service Manual XVIII FT 70 Certificate of X ray Output Measurement Figure 3 FT 70 Certi cate of x ray output measurement Industrial Dynamics Company Ltd 40256 0600...

Page 20: ...y Generator 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...

Page 21: ...FT 70 Fill Level Inspector Service Manual 1 2 Industrial Dynamics Company Ltd 40256 0600...

Page 22: ...Detector or Scintillation Tube Detector Centerline Trigger High Resolution Encoder required for variable speed production lines The FT 70 provides high speed over ll or under ll ll level container ins...

Page 23: ...ation detector Figure 1 2 Scanning the container The amount of radiation measured is the containers radiation pro le which is then compared against a master pro le Any container that deviates from the...

Page 24: ...x ray count at the detector This count condition is the normal count also called the good state When an under lled container passes through the beam there is less mass in the beam path so the x ray co...

Page 25: ...nd 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 70 and the FT 70 uses the pulses to...

Page 26: ...ed from any equipment that can cause electrical transients The neutral line must be properly grounded Operating Temperature Standard 32 95 F 0 35 C Extended 95 104 F 35 40 C Extreme requires external...

Page 27: ...inspection tunnel The size of your FT 70 was speci ed 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 2...

Page 28: ...High Resolution encoder is required for variable speed lines Rejection The rejector removes all containers that fail inspection from the production line Timing for the rejector is provided by the enco...

Page 29: ...hat 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 T...

Page 30: ...ferent 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...

Page 31: ...face PLC Note If you are unsure which options your unit contains refer to the System Con guration Sheet located inside a clear plastic pouch attached to the inside of the FT 70 s cover The System Con...

Page 32: ...s 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 pr...

Page 33: ...FT 70 Fill Level Inspector Service Manual 1 14 Industrial Dynamics Company Ltd 40256 0600...

Page 34: ...ter 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 Ind...

Page 35: ...FT 70 Fill Level Inspector Service Manual 2 2 Industrial Dynamics Company Ltd 40256 0600...

Page 36: ...sed 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 2...

Page 37: ...able of soft start up This means the conveyor can gradually accelerate from a full stop to production speed This prevents containers from sliding and upsetting on the chain The conveyor chain must run...

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 require...

Page 39: ...FT 70 Fill Level Inspector Service Manual 2 6 Industrial Dynamics Company Ltd 40256 0600...

Page 40: ...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...

Page 41: ...FT 70 Fill Level Inspector Service Manual 3 2 Industrial Dynamics Company Ltd 40256 0600...

Page 42: ...tion of the ow is downstream Upstream is the direction opposite or against the conveyor ow Anything that is before the reference point in the direction opposite of the ow is upstream Reference Point i...

Page 43: ...ndled poorly during shipping 2 Unpack the unit slowly and carefully so that you do not damage the equipment inside When removing the FT 70 Inspection Head grasp it by the sides do not pick it up by an...

Page 44: ...ector you can proceed to Chapter 4 for instructions on how to con gure the FT 70 and rejector to function with your production line Instructions for installing the rejector are contained within the re...

Page 45: ...ally 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 t...

Page 46: ...inch 13 cm wide gap in the conveyor guide rails on both sides of the conveyor Center the gap on the centerline mark you made in step 1 Figure 3 3 Creating a gap in the conveyor guide rails 3 Modify th...

Page 47: ...lations 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 inco...

Page 48: ...not anged 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...

Page 49: ...the vertical support pipe into the base tripod 5 If you are using a standard or high mount attach the support braces to the tripod Do not completely tighten the retaining bolts leave them loose enoug...

Page 50: ...ove 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 anges with t...

Page 51: ...spection head is perpendicular to the conveyor Place a small carpenter s level along the bottom of the FT 70 so that it spans the inspection tunnel You may need to raise the inspection head to allow r...

Page 52: ...the base tripod on the oor 2 Drill a mounting hole at each of the three 3 marks you made on the oor You must supply three 3 1 2 inch x 4 inch lag bolts and lead inserts Figure 3 11 Anchoring the base...

Page 53: ...lamp is only temporary After nal positioning adjustments are made you will spot weld the supports into place and remove the clamp 1 2 No Description 1 Pipe Clamp 2 Upper Slant Brace Support Brackets I...

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...

Page 55: ...the slant brace stubs and then slide the stubs into the bottom ends of the slant braces approximately 1 5 inches The oor brackets should rest at on the oor Figure 3 14 Attaching the slant braces and s...

Page 56: ...two 1 2 inch x 4 inch lag bolts and lead oor inserts Figure 3 15 Anchoring the slant braces to the oor 8 Firmly tighten all bolts and pipe clamps and then tack weld the following points with an oxyac...

Page 57: ...electrical ARC welding equipment The high electrical current will damage electronic components inside the FT 70 Figure 3 16 Spot welding the mounting hardware 3 1 2 3 No Description 1 Weld both bracke...

Page 58: ...n mount the air lter 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...

Page 59: ...Figure 3 18 Connecting the air line to the FT 70 3 Connect the input air source line to the input of the lter regulator The input air pressure should be approxi mately 80 120 psi at 1 5 cfm 1 2 3 No D...

Page 60: ...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 Dril...

Page 61: ...contact 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...

Page 62: ...situation If your FT 70 is not equipped with the optional I O Junction Box use the Standard Power Supply Wiring procedure If your FT 70 is equipped with the optional I O Junction Box use the procedure...

Page 63: ...e screws securing the power switches bracket and pull the bracket out to gain access to the power cable wiring Figure 3 22 Route the Power Cable into the Power Filter 1 3 2 4 5 No Description 1 Power...

Page 64: ...installation procedure Failure to do so can result in personal injury and equipment damage 1 Remove one of the plugs in the bottom of the junction box and install a liquid tight tting 2 Route the main...

Page 65: ...rounded in the FT 70 in this application Figure 3 24 Main power wiring Example A Wire Terminal and Pin Hot Attach to TB5 pin 7 Neutral Attach to TB5 pin 8 Ground Attach to ground point in box 1 7 5 11...

Page 66: ...on properties 3 Connect the FT 70 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 gr...

Page 67: ...black can be connected to any of the three legs phases 4 In this system the leg to leg 1 to 2 2 to 3 and 1 to 3 voltage is 208 VAC Any leg to neutral is 120 VAC Europe 380 220 Figure 3 26 Main power...

Page 68: ...FT 70 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...

Page 69: ...FT 70 Fill Level Inspector Service Manual 3 30 Industrial Dynamics Company Ltd 40256 0600...

Page 70: ...n 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 X ray...

Page 71: ...FT 70 Fill Level Inspector Service Manual 4 2 Industrial Dynamics Company Ltd 40256 0600...

Page 72: ...n order Figure 4 1 FT 70 Inspection System Con guration Flow Chart Adjust head height for fill level inspection Adjust inspection trigger height Calibrate encoder if applicable and rejector timing Det...

Page 73: ...sor height Adjust the Down Can Sensor height Wire the External Reject Function After you adjust all mechanical parameters proceed to the Software Con guration section in this chapter Figure 4 2 FT 70...

Page 74: ...nveyor is con gured 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...

Page 75: ...h as expalined in Chapter 5 The Safety Interlock Switch 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...

Page 76: ...x ray beam slot with the ll 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...

Page 77: ...ise the bracket all the way 2 Center a properly lled 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...

Page 78: ...iented 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 alignmen...

Page 79: ...t Figure 4 5 Aligning the Missing Lid Sensor height 1 Loosen the bottom jam nut on the missing lid sensor 2 Center a properly lled and sealed production container in the inspection tunnel so that it i...

Page 80: ...ing 5 If you will not be performing further alignment procedures turn on the Safety Interlock Switch to reactivte the X ray Generator See Chapter 5 The Safety Interlock Switch Sensor Description Lid T...

Page 81: ...ached 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 Recei...

Page 82: ...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...

Page 83: ...ther alignment procedures turn on the Safety Interlock Switch to reactivte the X ray Generator See Chapter 5 The Safety Interlock Switch Drawing Can Sizes 26796 8 12 16 oz 32293 8 10 12 16 24 oz 4 1 3...

Page 84: ...0 is equipped with an external I O Junction Box route the cable through one of the moisture resistant ttings in the bottom of the junction box 2 Determine which pins on terminal bracket TB1 the signal...

Page 85: ...hese additional procedures Con gure the Missing Lid Function Con gure the Bulged End Function Con gure the Diameter Missing Lid Function Con gure the Down Can Function Calibrating the Encoder and Reje...

Page 86: ...it at the maximum production speed 3 If your FT 70 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 4 Press Key 5 until...

Page 87: ...ress Key 1 until you reach LOOKTIME GATE and use the Arrow Key to enter the Looktime Gate Value you calculated 10 If you are nished con guring the FT 70 press Key 5 until you reach SYSTEM DISPLAY and...

Page 88: ...he 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 70 is not in the Calibrate Mod...

Page 89: ...chain and is positioned correctly as it passes through the inspection tunnel 2 Record the X ray Counts value that appears in the X ray Threshold display 3 Repeat the previous two steps four more time...

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 Under ll X ray Threshold 5 Press Key 1 until you reach GAMMA THRESHOLD a...

Page 91: ...te 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 70 is not in the Calibrate Mode...

Page 92: ...NG 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...

Page 93: ...If sealed containers are identi ed as rejects decrease the Minimum Diameter Missing Lid value slightly and repeat step 14 until false rejects no longer occur If unsealed containers are identi ed as go...

Page 94: ...an 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...

Page 95: ...5 until you reach SYSTEM DISPLAY and then press the Arrow Key to enter the Calibrate Mode 2 Open dip switch S1 5 3 Press Key 5 until EXTERNAL REJECT appears and use the Arrow Key to select PRESENT 4 C...

Page 96: ...ight 5 13 X ray Threshold 5 14 Looktime Gate 5 14 Fill Level Optimization 5 14 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 Finis...

Page 97: ...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 S...

Page 98: ...sing Lid 5 36 Diameter Missing Lid Text 5 36 External Reject 5 37 External Reject Text 5 37 Rejector Type 5 37 PLC Series Alarms 5 38 Serial Interface 5 38 External Trigger Logic 5 38 Known Chain Pitc...

Page 99: ...e Function Group Keys are numbered one through six Pressing a function key displays the rst function in that group Repeatedly pressing the same function key scrolls through the list of functions The A...

Page 100: ...ray Generator immediately shuts off so that no x rays are generated and it also deactivates the X ray Status Function in the system software If you turn the Safety Interlock Switch off you must perfor...

Page 101: ...sword 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 O...

Page 102: ...Function Group Function Name Parameter Default Fill Level Key 1 X ray Status On Off On Autoshutter Status Auto On Auto Underfill Status On Off Off Overfill Status On Off Off X ray Counts 0 65 000 Puls...

Page 103: ...0 99 999 999 Total Dia Missing Lid 0 99 999 999 Total External Reject 0 99 999 999 Reset All Counters Execute Reset Total Throughput Execute Reset Total Rejects Execute Reset Underfill Execute Reset O...

Page 104: ...00 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...

Page 105: ...acters Maximum Missing Lid Bulged End Present Not Present Not Present Bulged End Text 17 Characters Maximum Bulged End Down Can Present Not Present Not Present Down Can Text 17 Characters Maximum Down...

Page 106: ...nveyor Segment Pitch 50 700 1 10th mm 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 Puls...

Page 107: ...automatically disabled when the Safety Interlock Switch is turned off To turn the X ray Status back on you must 1 Turn the Safety Interlock Switch on 2 Press Key 1 until X RAY STATUS appears 3 Press...

Page 108: ...itch S1 1 X ray Counts Displays the X ray Count for the most recent container to pass through the FT 70 The X ray Count is the amount of radiation that passes through the container and is captured by...

Page 109: ...accuracy for applications that require higher accuracy than is achieved through normal ll level inspection parameters It narrows the margin between acceptable and rejectable containers See Chapter 6 F...

Page 110: ...r 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 di...

Page 111: ...the amount of time converted into encoder pulses required for the lid to pass through the inspection beam Minimum Diameter Missing Lid The minimum number of encoder pulses that de nes the diameter of...

Page 112: ...ed 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...

Page 113: ...r automatically resets at 99 999 999 Total External Reject The total number of external reject signals received The counter automatically resets at 99 999 999 Reset All Counters Clears and resets all...

Page 114: ...al Under ll 1 Press Key 3 until RESET UNDERFILL appears 2 Press the Arrow Key to execute Reset Total Overfill Clears and resets the Total Over ll counter to zero Record all valuable data before execut...

Page 115: ...until RESET DOWN CAN appears 2 Press the Arrow Key to execute Reset Total Diameter Missing Lid Clears and resets the Total Diameter Missing Lid counter to zero Record all valuable data before executi...

Page 116: ...2 Press the Arrow Key to re 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 exten...

Page 117: ...r the rejector to actuate so the centerline of the rejector pad impacts the centerline of the container Rejector Reaction Delay The response time in milliseconds between when the container fails inspe...

Page 118: ...status of the warning beacon There are three status choices On the beacon will ash once for each rejected container and continuously when a diagnostic error occurs The beacon will stop ashing when the...

Page 119: ...brate Mode When in Calibrate Mode if the FT 70 is idle no keys are pressed for 30 minutes the system automatically returns to the Operate Mode For more information see Selecting the FT 70 s Operating...

Page 120: ...dbus messages the FT 70 receives and de nes 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 w...

Page 121: ...s and 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 veloc...

Page 122: ...nces 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 functio...

Page 123: ...d Allows you to enter a three 3 digit password When the Password Option is active you must enter the code to enter the Calibrate Mode The default password is 222 To change the password do the followin...

Page 124: ...r pins in Terminal Blocks TB1and TB4 It also lists the normal voltage levels associate with the signals To check which FT 70 inputs have been assigned to pins on Terminal Block TB1 and TB4 1 Press Key...

Page 125: ...factory defaults All current settings will be erased therefore use the Save Defaults function or record all parameters before executing this function if you want to save them Current Language Selects...

Page 126: ...d by the Of Container Types function and the name for each container type is entered in the Container Text function X ray Source Tells the FT 70 software that the X ray Source Generator is present and...

Page 127: ...substitute the new name when reading this manual To avoid confusion record the change in the manual To create a name 1 Press the Arrow Key until the desired character appears 2 Press Key 6 to advance...

Page 128: ...cessary for Missing Lid inspection from the software This function does not activate or deactivate Missing Lid inspection it only readies the machine To turn Missing Lid inspection on or off you must...

Page 129: ...hine To turn Bulged End inspection on or off you must use the Bulged End Status function Bulged End Text Allows you to create a custom name for the Bulged End Option Any instance in which Bulged End w...

Page 130: ...a custom name for the Down Can Option Any instance in which Down Can would have appeared in the software is replaced by the custom label you created The following options are effected Down Can Status...

Page 131: ...tion 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 Miss...

Page 132: ...ect 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...

Page 133: ...Trigger Logic allows you to con gure an external trigger such a s a manual switch to perform either an External Reject or a Remote Clear of Error External Reject If the input TB1 20 is connected to gr...

Page 134: ...distance from one point on a conveyor chain segment to the same point on the next conveyor segment It de nes the conveyor segment pitch in tenths or millimeters Teeth Conveyor Segment De nes the numb...

Page 135: ...1 more than the number of X ray Samples Per Encoder when using a high speed production line X ray Samples Per Encoder This value veri es the correct X ray Sample Cutoff Limit It displays the number of...

Page 136: ...t 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 Arr...

Page 137: ...Consecutive Reject Limit 13 X ray Counts Below Reject Threshold Error 14 X ray Detector Error 15 Missing Lid Sensor Error 16 Trigger Beam Error 17 Encoder Sensor Error 18 Slat Rejector Backup Sensor...

Page 138: ...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 Mo...

Page 139: ...FT 70 Fill Level Inspector Service Manual 5 44 Industrial Dynamics Company Ltd 40256 0600...

Page 140: ...Fine Tuning the Rejector Timing 6 26 Sensors Calibration Procedures 6 28 Proximity Sensors 6 28 Fiber Optic Sensors 6 28 Before You Begin 6 28 Calibrating the Centerline Inspection Trigger 6 29 Calibr...

Page 141: ...FT 70 Fill Level Inspector Service Manual 6 2 Industrial Dynamics Company Ltd 40256 0600...

Page 142: ...cedures in this section should be performed only if your FT 70 is completely installed and fully operational This section contains the following calibration procedures Encoder Calibration Sensor Calib...

Page 143: ...ine rejectors This method produces the best performance for your FT 70 Fixed Speed Conveyors Fixed speed conveyors use the Line Speed Calibration Procedure to synchronize your FT 70 and rejector The L...

Page 144: ...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 convey...

Page 145: ...in this section If you do not have Baseline Eight contact IDC Customer Service for instructions pertaining to your baseline 1 Turn the FT 70 power on or press the reset button and the FT 70 will begin...

Page 146: ...use 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 co...

Page 147: ...lect 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 resolutio...

Page 148: ...in 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 spro...

Page 149: ...ing a 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 measu...

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 fa...

Page 151: ...30 If you are using this production line to produce more than one type of container you must repeat this procedure for each different container type i e containers with different diameters or line spe...

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 PR...

Page 153: ...is 1 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...

Page 154: ...TRIG 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...

Page 155: ...e Inspection Trigger to Centerline Rejector distance is 24 inches and the container is 1 inch upstream of the rejector when it res then the number of drive sprocket teeth should be reduced by one If t...

Page 156: ...sulting mark in the grease starts in the upstream third of the pad face and is centered then performance is acceptable If there are still signi cant early late problems and you are certain that you ha...

Page 157: ...e You may be required to enter a password if your system is password protected 2 Press Key 4 until REJECTOR STATUS appears and check to be sure the rejector is activated If it is turned off press the...

Page 158: ...m 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...

Page 159: ...er 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 70 so the contai...

Page 160: ...he FT 70 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 s...

Page 161: ...enter the CHAIN VELOCITY value from the previous step The optimum encoder value for the current line speed is now calculated including the Calibrate Encoder Value Encoder Prescaler Value and Gamma Sa...

Page 162: ...ou 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 Ind...

Page 163: ...the inspection trigger to the rejector centerline must be clear You must be using a Proline rejector Before You Begin Your FT 70 must contain the Baseline Eight version of the system software to use...

Page 164: ...If you are using a rejector other than a Proline you must use the variable speed production line calibration procedures 5 Measure the distance in millimeters from the trigger sensor beam to the center...

Page 165: ...ease the value until the can contacts the pad correctly 13 Press Key 4 until REJECT NEXT appears and then press the Arrow Key to enter the number of containers you want to reject consecutively Choose...

Page 166: ...rejector is contacting the cans directly on the centerline of the pad 19 To store the settings in system memory close dip switch S1 2 and then press Key 5 until SAVE DEFAULT CONSTANTS appears 20 Pres...

Page 167: ...uity is broken This triggers the sensor signal indicating that an object is present in the beam The ber optic sensors used in the FT 70 are Centerline Inspection Trigger Upstream Inspection Trigger Bu...

Page 168: ...pection 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 Offse...

Page 169: ...he 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 th...

Page 170: ...e moves to re ect 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 adjus...

Page 171: ...needle moves to re ect 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...

Page 172: ...tor The Solid State Detector SSD uses a sensor and circuit board to detect the strength of the x ray beam as it contacts the sensor The SSD does not require calibration Scintillation Tube Detector The...

Page 173: ...ay inspection 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 th...

Page 174: ...s 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...

Page 175: ...application before attempting the procedure Fill Level Optimization has two goals To precisely tune the Under ll Threshold to the container ll level To precisely align the Inspection Head Height to th...

Page 176: ...it spans the inspection tunnel You may need to raise the inspection head to allow room to t the level between the conveyor and bottom of the FT 70 2 If the head is not level you must loosen the FT 70...

Page 177: ...ode 2 Press 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...

Page 178: ...the Container Pro le 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...

Page 179: ...ight into the system 8 Press Key 1 to accept the height setting and to proceed to the Dynamic Reject Point Test The Dynamic Reject Point Test The Dynamic Reject Point Test is used to verify the inspec...

Page 180: ...you are instructed to run thirty good production containers through the FT 70 Start them far enough upstream so they do not slide on the conveyor as they pass through the inspection area If you are us...

Page 181: ...Level Optimization Routine Press the Arrow Key to scroll through the list when you need to review the following settings Static Full Static Empty Static Margin Aperture Range Inherent Accuracy Learned...

Page 182: ...ntenance 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 70 Housing 7 6 Pressure Regul...

Page 183: ...FT 70 Fill Level Inspector Service Manual 7 2 Industrial Dynamics Company Ltd 40256 0600...

Page 184: ...ion 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 a...

Page 185: ...ickers 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...

Page 186: ...can 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 fo...

Page 187: ...with a high pressure nozzle Do not steam clean Pressure Regulator and Air Filter 1 Inspect the polycarbonate sediment bowl for cracks and abrasion 2 Clean and drain the air lter sediment bowl 3 Inspec...

Page 188: ...empting any repair procedure See Before You Perform Any Maintenance Procedure at the beginning of this section 1 Power down the rejector 2 Remove the retaining screw and washer on the top of the rejec...

Page 189: ...ted 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...

Page 190: ...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 Error Number...

Page 191: ...8 The display is garbled or operates erratically 8 28 Sensor System Troubleshooting 8 29 Scintillation Tube Detector STD 8 29 Unable to calibrate the Scintillation Tube Detector 8 29 X ray counts decr...

Page 192: ...een 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 Bottle Width At Trig Function Error Number 6...

Page 193: ...secutive 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 Cap Reject Alarm Funct...

Page 194: ...indicates containers are passing through the X ray beam however no trigger signal is received To correct this problem Check to see that the trigger ampli er sensitivity is correctly adjusted The sensi...

Page 195: ...e The minimum allowable distance between the scaled encoder pulses must be greater than 1mm 0 040 inch To correct this error Increase the encoder prescaler until this error no longer occurs When decre...

Page 196: ...r 34 Two or more consecutive inspection triggers have occurred with no Smashed Bottle sensor transition Check LED 5 on the control card ON indicates high level Also check the signal on TB1 14 Blocking...

Page 197: ...re correct This is a high priority error condition and will cause the Warning Beacon to ash if Beacon Status is set to HIGH PRIORITY ONLY Error Number 50 The System defaults loaded for one or more set...

Page 198: ...ceeded 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 po...

Page 199: ...Beacon to ash 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 X ray Sample cutoff limit may be...

Page 200: ...N 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...

Page 201: ...rect 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 T...

Page 202: ...s on the generator If green LED is off the generator is not receiving power from system Yellow Source Enabled LED should be on if unit is receiving the signal to enable generation If red LED is off an...

Page 203: ...bsystems System failures generally involve one or more of the following subsystem Main Power Supply Power Transformer X ray Generator Main Processor Card Serial Communications Card Control Panel Scint...

Page 204: ...aker When the breaker is tripped the power switch turns off Verify the power switch is turned on if not turn it on to reset the breaker 3 Is power reaching the FT 70 Verify the power from the factory...

Page 205: ...priate test points Figure 8 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 Scintill...

Page 206: ...turn off the power can result in severe electrical shock 3 Disconnect plug P1 from the transformer and turn the power to the FT 70 on 4 Refer to Figure 8 1 and test the following pins in the P1 conne...

Page 207: ...oftware If the X ray Status Function is turned off Error 123 appears and the beacon ashes to indicate that inspection can not commence until the X ray Generator is enabled 2 Check the diagnostic LEDs...

Page 208: ...received Check enable signal See Verify the Enable Signal at PX1 Generator is malfunctioning See How to Replace the Generator Check enable signal at TB4 13 See Verify the Enable Signal at TB4 13 Signa...

Page 209: ...ion on If the tester indicates the signal is received the generator is malfunctioning and must be replaced Verify the Enable Signal at TB4 13 1 Attach the tester point at TB4 13 2 Press Key 1 until X...

Page 210: ...to the inside of the unit 2 Remove the eight securing screws indicated with an x in the following drawing that pass through the heat sink and secure the x ray generator to the chassis Figure 8 3 Remo...

Page 211: ...FT 70 Fill Level Inspector Service Manual 8 22 3 Disconnect the power cable from the x ray generator Figure 8 4 Disconnect the power cable from the generator Industrial Dynamics Company Ltd 40256 0600...

Page 212: ...ray generator 5 Disconnect connector PX 1 from the x ray generator power supply board 6 Remove the two securing nuts from the generator power supply board and then remove the board 1 2 3 4 5 6 No Des...

Page 213: ...the replacement kit and install the new power supply board 8 Install the new generator insulator that is provided in the replacement kit and carefully insert the new generator unit into the FT 70 Be...

Page 214: ...ver because the x ray generator takes approximately 5 hours to burn in after it is powered up you must perform the x ray calibration procedure twice Calibrate the x ray threshold now so that you can b...

Page 215: ...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 Figur...

Page 216: ...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 Ser...

Page 217: ...check that it is plugged into the connector on the inspection head correctly 2 Reset the FT 70 by pressing the Reset Button for three seconds while turning the machine off and on If the beacon does n...

Page 218: ...ay Counts function High or erratic x ray counts If the x ray counts suddenly increase signi cantly or become erratic check to be certain the STD is grounded properly 1 Remove the STD and wipe it with...

Page 219: ...able end you removed the light should be solid and round If there are any dark spots the cable contains ber optic strands Replace the cable Proximity Sensors No triggering occurs 1 Check LED 7 on the...

Page 220: ...to see if the cylinder is binding by shutting of the air pressure to the rejector and moving the rejector in and out by hand If it is binding rebuild the rejector with a rebuild kit 4 The rejector Pul...

Page 221: ...e replace the power supply If the LED does not ash replace the processor card Servotec Rejector Troubleshooting The rejector is operating erratically 1 Check all circuit breakers and fuses that power...

Page 222: ...lines contaminated or blocked Check all air lines to be sure they are free from contamination and that air passes through them freely 4 Air pressure is incorrect Adjust pressure to setting established...

Page 223: ...nction Rejector Pad fatigue or failure 1 Fatigued or worn pads cause the rejected container s trajectory to change 2 Replace rejector pad Facility air pressure drops or is erratic 1 The facility air s...

Page 224: ...r FT 70 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 Remot...

Page 225: ...FT 70 Fill Level Inspector Service Manual 9 2 Industrial Dynamics Company Ltd 40256 0600...

Page 226: ...ignals are available in the FT 70 s I O Junction Box The FT 70 can report the following signals to a PLC Sensor X ray Failure Alarm Latched Consecutive Alarms Rejector Fill Level Status OFF Total Reje...

Page 227: ...Key 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 wi...

Page 228: ...line of the displays the output function and its assigned terminal pin The bottom line lists the voltage level and triggered action For example NORMAL 2V PULSE 2V means that the normal state signal vo...

Page 229: ...relay The resistor absorbs the 2 ma leakage and meets the Minimum Current Load requirement Refer to the following illustrations for the resistor required for your speci c voltage Description Relay Typ...

Page 230: ...0 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...

Page 231: ...To determine the signal output wiring in your FT 70 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...

Page 232: ...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...

Page 233: ...FT 70 Fill Level Inspector Service Manual 10 2 Industrial Dynamics Company Ltd 40256 0600...

Page 234: ...tions The FT 70 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 th...

Page 235: ...gic 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 Passw...

Page 236: ...t more than one speed Fixed speed tracking is used on single speed lines and do not use the High Resolution Encoder For xed lines the encoder pulse is simulated by the inspection unit s software The d...

Page 237: ...mission The default is off S2 4 Parity Odd Even Allows 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...

Page 238: ...RS 232 or RS 422 485 network communications The default is RS 232 SW11 Enables or disables the ability to write setup values to protected memory The default is enable SW13 Enables or disables the Aut...

Page 239: ...FT 70 s Controller Board contains 1 bank of 11 LEDs The LEDs are divided into logical sections and banks which are con gured by dip switches S2 7 and S2 8 Figure 10 2 Locating the LEDs on the Control...

Page 240: ...and on when the sensor is clear Refer to the System Con guration Sheet located inside the cover of your FT 70 for you speci c con guration LED Section 1 S27 close Bank 1 S28 close Section 1 S27 close...

Page 241: ...is 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 Mi...

Page 242: ...rily 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 D...

Page 243: ...FT 70 Fill Level Inspector Service Manual 10 12 Industrial Dynamics Company Ltd 40256 0600...

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