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Maintenance and Troubleshooting

4-26 Maintenance and Troubleshooting

Thermo Fisher Scientific

REC 4132 Rev

A96346

Figure 4–17.

Output Diagnostics

Path:

More Menus/Test/Diode Array

The diode array test turns

X-ray

s on using the currently selected product

settings and records the

X-ray

intensity as measured by each detector

diode. The number of diodes varies with aperture size.

Large differences between adjacent diodes is indicated in red, and may
indicate a diode failure if it is in the active area. The average count in the
center region is also displayed.

Select

IODE

RRAY

and the following screen displays:

Diode Array Test

Summary of Contents for EZx

Page 1: ...EZx Contaminant Detector User Guide REC 4132 Rev E Part Number 062477...

Page 2: ...ptember 2005 0588 Documents release of Software Version 1 0 0 2 Revision B August 2006 1143 Updated Radiation Survey Revision C April 2007 1412 Documents release of Software Version 2 0 Revision D Feb...

Page 3: ...no rights other than those granted you under this license The term Equipment means the equipment with which the Software Program is used The term Software Program means the original and all whole or p...

Page 4: ...any way to this license Thermo Fisher Scientific s liability will be for the actual value of the Software Program Thermo Fisher Scientific will not be liable for any lost profits lost savings any inc...

Page 5: ...d such warranty to buyer Seller s obligation under said warranty is conditioned upon the return of the defective equipment transportation charges prepaid to the seller s factory in Minneapolis Minneso...

Page 6: ...Purchaser agrees to underwrite the cost of any labor required for replacement including time travel and living expenses of a Thermo Fisher Scientific Field Service Engineer at the closest factory bas...

Page 7: ......

Page 8: ......

Page 9: ...Safety Label Canada Only vi X ray Hazard Safety Canada Only vii X ray Information vii UK Requirements for Installation Operation vii Canadian Requirements for Installation Operation viii US Requiremen...

Page 10: ...afety Precautions 2 3 Installation in the Production Line 2 4 Positioning in the Production Line 2 4 Adjusting the Height 2 5 Connecting Air to the System 2 5 Connecting Power to the System 2 6 Operat...

Page 11: ...lacing the Conveyor Belt 5 5 Removing the Old Belt 5 5 Installing the New Belt 5 11 Replacing Rollers 5 18 Replacing Electrical Component Parts 5 18 Safety Warnings 5 18 Replacing Fuses 5 19 Spare Par...

Page 12: ...cal Radiation Survey C 1 Critical Radiation Procedure C 1 Filter Selection D 1 Filter Definitions D 1 Filter Adjustments for Packages with Sharp Corners or Edges D 3 Adjustments for Cans D 3 Package E...

Page 13: ...Contents Thermo Fisher Scientific Contents v REC 4132 Rev E This Page Left Blank Intentionally...

Page 14: ......

Page 15: ...3 6 Figure 3 7 X ray Diagnostics 3 8 Figure 3 8 Safety Circuit Problem 3 10 Figure 3 9 Safety Circuit Errors 3 10 Figure 3 10 Statistics Menu 3 12 Figure 3 11 Shift Setup 3 13 Figure 3 12 Hour Setup...

Page 16: ...put Board with LED s 4 24 Figure 4 16 Input Diagnostics 4 25 Figure 4 17 Output Diagnostics 4 26 Figure 4 18 Diode Array Diagnostics 4 27 Figure 4 19 Diode Array Data 4 27 Figure 4 20 X ray Diagnostic...

Page 17: ...e A 11 Default Filter Configuration A 13 Figure A 12 Input Output Setup A 14 Figure A 13 Input Assignments A 15 Figure A 14 Input Assignments A 16 Figure A 15 Setup Input Devices A 16 Figure A 16 Inpu...

Page 18: ...gure A 46 Statistics Menu A 48 Figure A 47 Shift Setup A 48 Figure A 48 Hour Setup A 49 Figure A 49 Shift Setup A 50 Figure A 50 Second Shift Setup A 51 Figure A 51 View Statistics Screen A 52 Figure...

Page 19: ...ly Maintenance 4 13 Table 4 3 EZx Monthly Maintenance 4 16 Table 4 1 Alarm Definitions 4 18 Table A 1 Access Levels A 3 Table A 2 Aperture Sizes A 12 Table A 3 Demonstration of Contaminant Size as it...

Page 20: ...Contents vi Contents Thermo Fisher Scientific REC 4132 Rev E This Page Left Blank Intentionally...

Page 21: ...stallation provides the steps and instructions necessary to install the equipment Chapter 3 Operation provides information on equipment operation Chapter 4 Maintenance and Troubleshooting provides inf...

Page 22: ...alibration menu displays and variables BOLD CAPITALS are used for the names of keys Note Provides information of special importance to the reader c Hint This symbol indicates a hint that may be of val...

Page 23: ...ving parts must always remain in place during normal operation Remove only for maintenance with the machine s power OFF Replace all covers before resuming operation During maintenance a safety tag not...

Page 24: ...ctronics cabinet PC boards or modules There are voltages in excess of 115 V or 230 V in these areas WARNING Do not make changes to this equipment of any kind without prior consultation with Thermo Fis...

Page 25: ...produced when energized Do not insert any part of the body when energized X ray hazard Located on the roller mount places WARNING Moving parts can cause injury Keep hands and other objects clear duri...

Page 26: ...Hazardous voltage enclosed Voltage or current hazard sufficient to cause shock burn or death Disconnect and lockout power before servicing Located on cabinet near the Vortex rube CAUTION HOT Located...

Page 27: ...ive HSE office should have been informed at least 28 days before the machine is due to be used for the first time using from F2522 Your company needs to define a set of Local Rules with regards to ion...

Page 28: ...operated on the work premises in the United States the following actions must take place Contact your State Health Department Authority and give advance notice of the planned installation Follow the r...

Page 29: ...en that is hit by the electrons The entire tube is immersed in oil shielded in lead and contained in a tank This ensures the X rays are contained within the tank except for a controlled beam used for...

Page 30: ...microsieverts per hour The US safety level rating is 5 0 microsieverts per hour Thermo Fisher Scientific equipment is engineered to emit radiation levels below these figures Safety limits in countrie...

Page 31: ...e Any unauthorized changes may render the equipment unsafe Lead curtains are fitted to the system and form part of the mechanical shielding It is imperative these are kept in place on the machine and...

Page 32: ...are carefully designed to prevent leakage of X rays this is the main reason for prohibition of mechanical modifications All panels and lids that can be opened or removed are interlocked The EZx preven...

Page 33: ...machine s capabilities describes its basic functions and lists its technical specifications The EZx system provides the optimum solution for locating foreign objects commonly found in packaged food p...

Page 34: ...thin metal lids The EZx inspection machine comes equipped with the following key features User friendly controls Easy setup and operation Detection of dense contaminants in metal packaging Variable i...

Page 35: ...produces X rays via an electrical current If there is no electricity connected to the machine X rays cannot be produced As the X ray tube is inefficient at producing X rays and most of the energy is c...

Page 36: ...The software includes highly advanced image processing and a user friendly intuitive touch screen environment to set up and run the machine The following requirements are needed to accommodate the EZ...

Page 37: ...pment against the order or packing slip Be sure to look for any accessories such as reject devices or product tubes ordered and shipped with the detector Some of the component pieces are small and may...

Page 38: ...y logged in and allows a new user to login This section outlines the procedure for entering information into the machine There are three means of entering information an alphanumeric keypad a numeric...

Page 39: ...d for 2 5 seconds the courser advances to the next space c A90937 Figure 1 4 Alphanumeric Display When the name has been completely entered press Enter to save the changes Note The PREV key moves the...

Page 40: ...Introduction 1 8 Introduction Thermo Fisher Scientific REC 4132 Rev E A96255 Figure 1 5 Drop Down Selections...

Page 41: ...e protection to 2500 volts Output Relay Voltage Current 240 VAC 6A 24 VDC 5A Scan Rate 2000 lines per sec maximum scan rate Note Scan rate is set to match the belt speed so that there is one sample pe...

Page 42: ...ssive line pressure drop Environmental Storage Ambient Air Temperature 25 to 70 C 13 to 158 F For 24 hours Rate of Change of Temperature 5 C min 9 F min Relative Humidity 5 to 95 non condensing Absolu...

Page 43: ...aration It is essential the equipment be placed on the production line in accordance with the guidelines set out in this chapter The customer must ensure qualified personnel are available to make the...

Page 44: ...l The precautions and procedures presented in this chapter must be followed carefully to prevent equipment damage and protect the operator from possible injury during installation Consider the locatio...

Page 45: ...Make sure only personnel trained by a Thermo Fisher Scientific representative perform installation and maintenance procedures in accordance with the instruction in this manual Allow only qualified ele...

Page 46: ...to the system Seasoning the tank Adjusting belt tracking Tank Alignment Performing a Critical Radiation Survey Position the EZx into the space provided in the production line using a forklift truck or...

Page 47: ...e threaded portion of each leveling foot and adjust up or down as necessary 3 Retighten all jam nuts A96350 Figure 2 1 Adjustable Leg 4 Ensure the system is level and vibration free Connect an oil fre...

Page 48: ...sed at no more than 20A The line power connection terminals for the EZx are located on the wiring panel terminal block TB1 The hot and neutral conductors must be connected to terminals L1 and L2 respe...

Page 49: ...s chapter outlines the procedures and menus needed to setup the EZx the first time the machine is put into production For more detailed instructions of the each menu and additional menus refer to Appe...

Page 50: ...irst powered on Cold Start the following screen displays Cold Start Login Figure 3 1 Cold Start Login Screen 3 Select USERNAME and select the user SYSADMIN Note When the EZX is first powered up Cold S...

Page 51: ...sers At the user setup screen create edit or delete users Use the following steps to setup new users Note The person setting up a new user must have System Administrator rights to assign Maintenance a...

Page 52: ...Fisher Scientific REC 4132 Rev E 1 Select MORE MENUS ACCESS SETUP USERS The following screen displays Cold Start User List Figure 3 3 Setup New Users 2 Select New User The following screen displays A9...

Page 53: ...the User Type from the drop down list of choices Operator Supervisor Maintenance or System Administrator If the selection is Operator set the Operator Privileges from the drop down list of choices Mac...

Page 54: ...as been performed but has not completed Requires a total elapsed time of about 55 minutes Short Seasoning should be performed if the machine has been off for four to five consecutive days Requires a t...

Page 55: ...YS After the machine has performed a Long Tank Seasoning it should be subjected to a Critical Radiation Survey and other initial inspections to ensure there is no X ray leakage and the machine is safe...

Page 56: ...X RAYS 3 Using the proper radiation detector check all areas of the machine indicated in the Radiation Survey Sheet in Appendix C Pay special attention to the infeed and outfeed areas The results of t...

Page 57: ...ath More Menus Test X ray Diagnostics 1 As in the Critical Radiation Survey select START X RAYS 2 After the X rays have started push the EMERGENCY STOP located on the front of the machine and make sur...

Page 58: ...Open the hoods and doors individually When a hood or door is opened a Safety Circuit Problem fault message displays on the screen A96734 Figure 3 8 Safety Circuit Problem Select the error display por...

Page 59: ...display Lift the hood on the Right Side Does the Power Supply Alarm display Does the alarm message Left or Right Hood display Lift the Center hood Does the Power Supply Alarm display Does the alarm me...

Page 60: ...Reject Setup If these items are not setup you cannot run product Note The user accessing the PRODUCT SETUP menu must have Maintenance Supervisor or specially assigned Operator level access Path More M...

Page 61: ...nter a name for the shift Start Day select the start day from the drop down list Start time select the start time for the shift Use the INCREASE DECREASE buttons or the numeric keypad to enter the shi...

Page 62: ...f there are shifts 7 days a week then make the number of days 7 A96379 Figure 3 13 Shift Setup 4 Press ACCEPT to save the shift setup Note The information is not saved unless ACCEPT is selected after...

Page 63: ...bove the second shift begins at 17 00 when the First shift ends and the second shift ends at 01 00 1 00 am Path More Menus Product Setup New Product Use the following steps to setup new product parame...

Page 64: ...information on Pad Leading Edge and Pad Trailing Edge Note If a product is not completely setup the product icon next to the product name has a red X and that product cannot be run until setup is com...

Page 65: ...nd then select FILTER SETUP There are two types of Filter Setup Quick Learn and Manual Filter A96366 Path Main Menu Product Setup New Edit Product Filter Setup Quick Learn Quick Learn uses a default f...

Page 66: ...art Threshold The following screen displays Figure 3 18 Diode Calibration in a Quick Learn WARNING If product is run during Diode Calibration the EZx does not operate properly A message displays at th...

Page 67: ...contaminated and uncontaminated products Observe whether the current filter settings can detect contaminated product without false tripping on good product If contaminated product is detected go to th...

Page 68: ...h the EZx software Some of the inputs and outputs are devices such as photo eyes and reject devices that require additional setup depending on the device Inputs are external devices that can be config...

Page 69: ...4132 Rev E Use the following steps to setup the Input settings 1 Select MORE MENUS SETUP I O The following screen displays A96247 Figure 3 19 Input Output Setup 2 Select Input The following screen dis...

Page 70: ...Photo Eye verifies when the package is entering the hood comes standard on the EZx Reject Verify Photo Eye verifies the package was rejected properly Bin Full Photo Eye detects if when the reject bin...

Page 71: ...evice the device has to be setup Use the following steps to setup the input device s 1 After the Inputs have been assigned select SETUP INPUT DEVICES The following screen displays A96327 Figure 3 22 S...

Page 72: ...hoto eye you must designate if it is Accept Stream monitors the accepted packages or the Reject Stream monitors the rejected packages Reject Verify and Bin Full the photo eye does two jobs verifies th...

Page 73: ...ir pressure is setup and the air pressure changes state something goes wrong i e pressure drops the air pressure alarm is activated The external alarm label is reported in the log when the alarm is ac...

Page 74: ...5 Output 1 is assigned Reject Device that indicates this output is activated when a product is rejected 2 There are 10 output assignments Figure 3 26 Unassigned the output has no assignment Reject Dev...

Page 75: ...the stack indicating a bad package Note Lamp 1 and Lamp 2 are optional and can be added to the stack if needed Ready this output is activated when the machine is ready to inspect product belt running...

Page 76: ...s with a list of alarms and an output is activated The operator must acknowledge all alarms by selecting Clear Alarms from the display alarms screen Figure 3 27 Shutdown the machine shuts down when th...

Page 77: ...r presses the button the display alarms panel is displayed From this screen the operator can clear the warnings and alarms The panel shows a more detailed description of each alarm Note User Configura...

Page 78: ...any consecutive rejects Determined in the ALARM SETUP menu The default setting is 5 and the rejects have to be consecutive Air Pressure Low indicates the air pressure to the reject device is low requi...

Page 79: ...the colors of the alarms listed below indicates the condition of the alarm Grey indicates the alarm is disabled Yellow indicates warning Orange indicates alarm Red indicates shutdown Pink indicates s...

Page 80: ...Operation 3 32 Operation Thermo Fisher Scientific REC 4132 Rev E This Page Left Blank Intentionally...

Page 81: ...are not required when carrying out routine maintenance tasks such as cleaning and tracking the belt Minimal tools are required for other maintenance tasks such as replacing the conveyor belt and roll...

Page 82: ...ers need to be replaced regularly Interlocks and E stops need to be replaced if they are damaged or broken Preventative daily maintenance by of the operator ensures the EZx continues to run normally S...

Page 83: ...ht before starting washdown Damage to the electronics could result from water moisture or contamination in the electronics housing Never add harsh chemicals or caustics to the washdown solution Do not...

Page 84: ...ion Survey on page 4 4 for complete instructions Visually and manually examine the shielding curtains on the infeed and outfeed sides of the chamber If there is any damage replace the curtains immedia...

Page 85: ...Maintenance and Troubleshooting Thermo Fisher Scientific Maintenance and Troubleshooting 4 5 REC 4132 Rev E Check the photo eye changes state when blocked Photo Sensors...

Page 86: ...lator Assembly A96726 Figure 4 2 Filter Regulator Assembly with Air Filters At the bottom of the filter bowls are push drains Place a container under the filters press the drains to one side to drain...

Page 87: ...to prevent slippage of the conveyor belt on the drive roller when the machine is loaded with product Table 4 1 EZx Daily Maintenance Checklist Daily Maintenance Completed Clean as necessary See Cleani...

Page 88: ...form a Diode Calibration for each product Check that the interlocks and E stops are working correctly The interlocks are placed inside the conveyor hoods and prevent X rays from being emitted once the...

Page 89: ...t the front screen Open the hoods and doors individually When a hood or door is opened a Safety Circuit Problem fault message displays on the screen A96734 Figure 4 3 Safety Circuit Problem Select the...

Page 90: ...h the list YES NO Lift the hood on the Left side Does the Power Supply Alarm display Does the alarm message Left Hood display Lift the hood on the Right side Does the Power Supply Alarm display Does t...

Page 91: ...nostics screen Path Run select running product Diode Calibration Diode Calibration normalizes or evens the response of the detector diodes making each diode read from 0 100 even though all diodes dete...

Page 92: ...Troubleshooting Thermo Fisher Scientific REC 4132 Rev E 3 Select DIODE CALIBRATION The following screen displays A96736 Figure 4 6 Start Diode Calibration 4 Select START TEST the following screen dis...

Page 93: ...kly Maintenance Completed Check interlocks and E stops See page 4 8 Check the oil temperature in the tank See page 4 8 Diode Calibration See page 4 11 CAUTION Do not use the interlocks or E stops as t...

Page 94: ...ectiveness of the door seals Check the condition of all the fans inside the machine Noisy or vibrating fans should be replaced Check that the air filters are clean and free from debris Clean or replac...

Page 95: ...d the compartment Contact Thermo Fisher Scientific immediately if any leaks are found Open the bottom cabinet and make sure fans are running If they are not contact Thermo Fisher Scientific immediatel...

Page 96: ...00031 1 Coalescing oil removal filter element right side ARO part number 100032 Table 4 3 EZx Monthly Maintenance Monthly Maintenance Perform a Radiation Survey if required See Appendix A Check roller...

Page 97: ...cond is in the lower right of the screen and the third is in the upper right of the screen If the touch screen is so out of alignment the user is unable to login the following procedure starts the tou...

Page 98: ...rter PE Fault Blocked or broken diverter photo Clear any blockage or inspect PE for damage Gap to small Packages following to close together or package too long Check package spacing Make sure package...

Page 99: ...cknowledges that the system has been cold started Type Cause Recovery Bad Data base Unable to read or write to database Cold start the machine Start up Failure Variable required for interface thread i...

Page 100: ...mminent lamp failure Power on reset Some of these conditions may be recoverable others may not Contact Thermo Fisher Scientific Service if the fault persists No USB Cable loose Check cable first Power...

Page 101: ...re are several quick checks the operator should make to avoid delays Check the screen display 1 If the display screen is blank check power to the system as described below 2 The EZx takes several minu...

Page 102: ...For safe operation replace only with 250 VAC SLO BLO T fuses or the correct size F1 2A F2 6 25A F3 10A F4 6 25A Figure 4 12 Fuse F1 F2 F3 A96733 A B Fuses F1 F2 and F3 are located just inside the mai...

Page 103: ...ection outlines the TEST functions of the system I O Diagnostics displays and exercises the digital inputs and outputs Diode Array displays the sensitivity of each X ray detector diode X ray Diagnosti...

Page 104: ...e Menus Test I O Diagnostics This section outlines the diagnostics performed by the EZx To further isolate an input or output fault LED s on the I O Board indicate the state of each input output A9672...

Page 105: ...agnostics screen shows the function assigned to each output and the current state of each output If the output is active the numbered button next to the assignment is blue The state of each output can...

Page 106: ...on using the currently selected product settings and records the X ray intensity as measured by each detector diode The number of diodes varies with aperture size Large differences between adjacent d...

Page 107: ...nance and Troubleshooting 4 27 REC 4132 Rev E A96347 Figure 4 18 Diode Array Diagnostics Select Start Test Getting the data may take a few seconds so be patient The following screen displays A96348 Fi...

Page 108: ...in the product list Balance KV displays the ratio between the KV and the KV values Stability mA displays the ratio between the mA and the mA Oil Temperature temperature of the oil in the tank surroun...

Page 109: ...match the speed setting there may be a fault in the motor control circuits or the motor has insufficient power to achieve the desired speed If the diagnostic shows correct operation but the belt does...

Page 110: ...nce and Troubleshooting 4 30 Maintenance and Troubleshooting Thermo Fisher Scientific REC 4132 Rev E A96349 Figure 4 21 Motor Speed Test The Belt Speed Setpoint value can be changed and used for testi...

Page 111: ...Maintenance and Troubleshooting Thermo Fisher Scientific Maintenance and Troubleshooting 4 31 REC 4132 Rev E This Page Left Blank Intentionally...

Page 112: ......

Page 113: ...on site service technicians to assist customers with installation setup initial calibration customer training maintenance and repair Contact the Thermo Fisher Scientific Field Service department at th...

Page 114: ...mine the broken or faulty part 1 Locate the part in the Parts List 2 Find the part number s for the item s you need 3 Before you contact Thermo Fisher Scientific for your parts make sure you have the...

Page 115: ...nneapolis MN 55433 Area Code Bill To Customer Ship To Returned From Return To Description Of Material Being Returned Describe Equipment Malfunction Or Defect If Any Symptoms Minimum Charge Informed Cu...

Page 116: ...08 852310 fax Italy 39 02 959514 1 39 02 953200 15 fax Malaysia 60 0 3 2300 1626 60 0 3 2300 1636 fax Mexico 52 01 55 5638 0237 52 01 55 5639 2227 fax Netherlands 31 0 33 454 9000 31 0 33 454 9009 fax...

Page 117: ...paired by a qualified Thermo Fisher Scientific Engineer This section outlines the procedures for replacing mechanical parts that can be done in the factory The EZx Conveyor is designed so a single per...

Page 118: ...in Figure 5 2 The thumbscrews do not have to be removed completely A96301 Figure 5 2 Loosen Thumb Screws 5 Lift the tail roller and remove the roller 6 Move to the Drive roller end of the machine 7 L...

Page 119: ...belt 10 Do the following to loosen the motor mount Figure 5 4 A96304 Figure 5 4 Motor Mounting Screws Use a straight tip screwdriver to loosen the screws on the motor mount Loosen just enough to relea...

Page 120: ...isher Scientific REC 4132 Rev E A96307 Figure 5 6 Removing Driver Roller Assembly 13 Grasp the slider bed as close to the hood as possible and lift up A96308 Figure 5 7 Lift up on the slider bed 14 Pu...

Page 121: ...ement Parts Thermo Fisher Scientific Service Repair and Replacement Parts 5 9 REC 4132 Rev E A96309 Figure 5 8 Push slider bed forward 15 Move to the other end of the conveyor and slide out the top pi...

Page 122: ...eplacement Parts Thermo Fisher Scientific REC 4132 Rev E A96310 Figure 5 9 Remove the first half of the slider bed 16 Grasp the slider bed on this end as close to the hood as possible and lift up Figu...

Page 123: ...placing the belt is the reverse of removing the belt The length of the belt should be confirmed before attempting to fit it Install the tail end slider bed first 2 Place the belt around the tail end s...

Page 124: ...end reinstallation 3 Lift the front edge of the slider bed and slide back until it is engaged in the rear mounting anchors 4 Position hands on front of slider bed and push down until the slider bed is...

Page 125: ...eated 5 Place the other slider bed on top of the first slider bed under the belt make sure the slider bed is positioned correctly to be mounted on the other end A96318 Figure 5 14 Place slider bed on...

Page 126: ...E 8 Carefully pull the slider bed through the hood Lift the front edge of the slider bed and slide back until it is engaged in the rear mounting anchors 9 Position hands on front of slider bed and pus...

Page 127: ...acement Parts 5 15 REC 4132 Rev E 10 Slide the roller into the belt and sit in the mounting brackets A96321 Figure 5 16 Slide the roller into the belt A96322 Figure 5 17 Slide into mounting brackets 1...

Page 128: ...igure 5 18 Hook bearing retainer 12 Replace the drive belt Remember to tighten the motor mounting screws if they were loosened earlier to remove the old belt A96324 Figure 5 19 Replace the drive belt...

Page 129: ...132 Rev E A96325 Figure 5 20 Spacing 13 Replace the belt cover 14 Move to the tail end of the conveyor 15 Place the roller between the belt and the table slide the roller into the slots A96326 Figure...

Page 130: ...personnel trained by Thermo Fisher Scientific perform installation and maintenance procedures in accordance with the instructions in this manual Allow only qualified electricians trained by Thermo Fis...

Page 131: ...onically current limited The line power fuses F2 and F3 should never need to be replaced unless there is a catastrophic failure in power supply the motor drive or line voltage wiring Fuse F4 protects...

Page 132: ...Motor relay type 1 1 TERM BLK PLC OSC OPTO 24 48VDC 085263 Motor relay type 2 1 TERM BLK PLC RSC RELAY 24VDC 085338 Bearing 1 2 BRG RDL BALL 15MM X 35MM X11MM 085386 Ball Joint 8mm 1 BRKT STRUT BALL...

Page 133: ...ys and using the soft keys on the front panel to navigate through the menus Items included in this chapter are Access Logging In outlines the procedures for logging in to the machine the login require...

Page 134: ...32 Rev E The first step in using the EZx system is setting up users and assigning access levels There are three levels of access System Administrator Maintenance Supervisor Operator The following tabl...

Page 135: ...tistics 0 2 0 2 Ability to Create and Modify Users 0 0 0 2 Ability to Create other System Administrator Users 0 1 1 2 I O Diagnostic Display 0 1 2 2 Diode Array Diagnostics 0 1 1 2 X Ray Tube Diagnost...

Page 136: ...be accessed Note If this is the first time logging on when the machine is first started up or Cold Started refers to First Sign On page 3 2 At start up the following screen displays Normal Login Figur...

Page 137: ...nd select Login At the user setup screen create edit or delete users The USER SETUP SCREEN is accessed by selecting MORE MENUS ACCESS SETUP USERS Use the following steps to setup new users Note The pe...

Page 138: ...Scientific REC 4132 Rev E A96353 Figure A 3 Setup New Users 2 Select New User The following screen displays A96701 Figure A 4 New User Screen 3 Use the keypad entry system to enter the user name and p...

Page 139: ...Type from the drop down list of choices Operator Supervisor or Maintenance 5 If the selection is Operator set the Operator Privileges from the drop down list of choices Machine Setup Product Setup an...

Page 140: ...hen select Edit User The following screen displays A96702 Figure A 6 Edit User Screen 3 Make any necessary changes and select Close Use the following steps to delete existing users 1 Select MORE MENUS...

Page 141: ...S and SETUP Setup Sub Menu Figure A 7 Machine Setup The SETUP menus and their parameters are setup in this section The setup section consists of the following Global machine setup I O input and output...

Page 142: ...ry setting and should not be changed Number of Diodes the number of diodes used directly associated with the Aperture Size and is a factory setting that should not be changed Motor Pulses meter Puts o...

Page 143: ...o enter a machine name From the drop down menu select the units to use during operation Metric or English From the drop down menu select the language to be used The Aperture size of the specific machi...

Page 144: ...340mm 13 4in 85mm 3 3in 400mm 15 8in 100mm 4 0in 100 m per min 328 ft per min 420 340mm 13 4in 185mm 7 3in 400mm 15 8in 200mm 7 9in 50 m per min 328 ft per min 510 440mm 17 3in 85mm 3 3in 500mm 19 7i...

Page 145: ...s the first step in manually learning the product refer to Manual Filter on page A 33 This setup section allows you to setup the Input and Output parameters for the EZx Inputs and Outputs are connecti...

Page 146: ...te The user must be signed on with Maintenance or Supervisor rights to setup the I O parameters Path More Menus Setup I O Input Use the following steps to setup the Input settings 1 Select MORE MENUS...

Page 147: ...is entering the hood and comes installed on the EZx Reject Verify Photo Eye verifies the package was rejected properly Bin Full Photo Eye detects if when the reject bin is full External Alarm if there...

Page 148: ...nd range from photo eyes to reject devices If the input assignment is a device then the device has to be setup Use the following steps to setup the input device s 1 Select SETUP INPUT DEVICES The foll...

Page 149: ...o eye you must designate if it is Accept Stream monitors the accepted packages or the Reject Stream monitors the rejected packages Reject Verify Bin Full Photo eye does two jobs Verifies the reject an...

Page 150: ...s Use the following steps to configure outputs 1 Select MORE MENUS SETUP I O OUTPUT The following screen displays A96330 Figure A 18 Output Setup EXAMPLE 1 In Figure A 18 Output 1 is assigned Reject D...

Page 151: ...r combo units combination X ray and checkweighing machines Tells the checkweigher not to weigh the package and the package is rejected by the X ray system Lamp1 indicates a good package Lamp 2 indicat...

Page 152: ...shuts down when the event occurs the button turns red The machine does not run product and X rays are in stand by mode Shutdown and Stop Belt the machine shuts down when the event occurs The button on...

Page 153: ...arms to warn the operator or shut down the machine The alarm choices are listed below Alarm Setup Figure A 21 User Configurable Alarms Bin Full activated when the reject bin is full requires photo eye...

Page 154: ...ing properly Motor Speed Fault no speed pulses the EZx conveyor is off or an incorrect count that indicates the speed is incorrect Rejected Package a contaminated package was rejected during product i...

Page 155: ...Shutdown Shutdown and stop belt Disable Note Alarms that are at a level other than shutdown do not cause the X rays to go into standby mode and the machine still runs product 2 Select the Alarms to us...

Page 156: ...ollowing screen Utilities Sub Menu Figure A 22 Utilities Menu Path More Menus Utilities Print System The PRINT function prints the machine and product configuration to a connected serial printer The G...

Page 157: ...printer Figure A 23 COMM 4 Serial Port The SAVE AND RESTORE UTILITY offers the feature of saving or restoring the machine setup or product setup 1 Select MORE MENUS UTILITIES SAVE RESTORE The followin...

Page 158: ...ion do you want to take Add to Existing adds to the existing product or machine setup Create New creates a new file and writes over the old files Note If you create new and have products setup the cur...

Page 159: ...plays A96361 Figure A 26 Images View Button display the selected saved image Export Button images can be exported to a USB memory stick Reject Image Button displays the last 10 rejected images 2 Selec...

Page 160: ...select MORE MENUS UTILITIES UPGRADE SOFTWARE press START A96597 Figure A 27 Update Software The screen in Figure A 27 displays if there is not a software update available To check the current revision...

Page 161: ...screen displays a list of products The icon on each product button indicates the product setup status Indicates a product is setup and can be inspected Indicates the product is NOT setup To scroll th...

Page 162: ...ct Press the EDIT COPY or DELETE button to perform the desired action Use the following steps to setup a new product 1 Select New Product The following screen displays Product Edit Needs Learn Figure...

Page 163: ...ing Edge Note If a product is not completely setup an asterisk displays on the screen beside the product name and that product cannot be run until setup is complete There are two types of Filter Setup...

Page 164: ...e hood 10 minimum 5 Select STOP THRESHOLD 6 The machine is now in verifying mode Pass both contaminated and uncontaminated products 7 Select STOP CHECK 8 Select ACCEPT Hint The more products passed at...

Page 165: ...oduce images that have distinct dark bands around the package perimeter Used if there are dark edges present on the product container Should be applied before other filters Less than 100 of the produc...

Page 166: ...g an Edge Mask operation to the filter sequence First an overview of the manual filter setup Step I Set the filter sequence to Side Edge Mask Simple Threshold and Enhanced Gradient in that order Step...

Page 167: ...setup 1 To perform a manual filter calibration select Manual Filter from the SETUP NEW PRODUCT screen 2 Select Side Edge Mask for the first filter Set the thickness to 1 mm 3 Select Simple for the sec...

Page 168: ...hreshold Screen 8 Select Start Threshold A message displays at the bottom of the screen after the diodes are calibrated run product after it displays 9 Pass several products through the hood to obtain...

Page 169: ...imits button to see the threshold and thickness values for the Side Edge Mask filter Figure A 36 A96707 A96707b Figure A 35 Change Filter Limits A96708 Figure A 36 Side Edge Mask Filter Threshold and...

Page 170: ...isfied with the mask coverage select Accept saving the filter sequence Note At this point the edge mask has been successfully setup but the thresholds for the Simple and Enhanced Gradient still need t...

Page 171: ...ejects a good package during the verify mode of the threshold learning process see step 21 above in the Manual Filter Setup example select Change Filter Limits Refer to Table A 3 and verify you are no...

Page 172: ...s expected performance Actual performance may vary due to product effect Table A 3 Demonstration of Contaminant Size as it Relates to Belt Speed and Aperture Size Aperture Size Millimeters Belt Speed...

Page 173: ...he rejecter is from the X ray Duration how long the signal to the reject device should be on Reject Setup Screen Figure A 39 Product Reject Setup The TEST REJECTER button allows the user to pass packa...

Page 174: ...rays and casts a shadow on the diode sensors The filter threshold is the minimum response received from an uncontaminated product Contaminants are typically denser than the product and produce a lower...

Page 175: ...Power Supply When a Quick Learn is performed the EZx sets default power settings based on the aperture size and the belt speed The higher the mA the brighter the image the KV increases the X ray penet...

Page 176: ...C 4132 Rev E Select either Contrast or Penetration the mA and KV respond accordingly Use the Increase Decrease button to set the parameters A96374 Figure A 41 Power Supply Setup Note A filter setup mu...

Page 177: ...t The PRODUCT screen displays Make changes to the product and select close Product Edit Setup Good Figure A 42 Edit Product Screen Note If the Belt Speed or Power Supply Setup is changed for a current...

Page 178: ...v E Product Edit Relearn Popup Figure A 43 Error message At the Product Setup screen select the product to be copied from the list of products Select COPY PRODUCT The Copy Product screen displays Figu...

Page 179: ...the setup At the Product Setup screen select the product to be deleted then select Delete A pop up asks Do you want to delete Product Name Select yes to delete the product no to return to the Product...

Page 180: ...nus Thermo Fisher Scientific REC 4132 Rev E Statistics sub menu Figure A 46 Statistics Menu 2 Select SETUP SHIFTS Shifts are run on a 24 hour clock Meaning the hours are set from 0 23 Setup Shift 1 Fi...

Page 181: ...e the alphanumeric keypad to enter a name for the shift Start Day select the start day from the drop down list Start time select the start time for the shift Use the INCREASE DECREASE buttons or the n...

Page 182: ...EASE button to change the days The days of the week increment based on the number of days If there are shifts 7 days a week then make the number of days 7 Setup Up Shift 2 Figure A 49 Shift Setup 4 Pr...

Page 183: ...le above the second shift begins at 17 00 when the First shift ends and the second shift ends at 01 00 1 00 am Highlight the shift to be deleted select DELETE SHIFT The VIEW STATISTICS screen allows y...

Page 184: ...S DAY buttons to scroll through the list of statistics If a USB memory stick is inserted into the machine the EXPORT STATISTICS button becomes active and the current statistics can be exported to the...

Page 185: ...active the user is asked if they want to enter a new Batch ID when the machine starts inspecting product Pressing CURRENT BATCH NUMBER brings up the numeric keypad to enter a new batch ID number There...

Page 186: ...ucts the numeric keypad pops up and the time in hours and or number of products has to be specified In the graphic example above the machine is configured to increment the batch number either after 4...

Page 187: ...your product 1 From the MAIN screen select RUN The following screen displays Figure A 54 Product Selection Note Only products that are completely configured display on this screen 2 Choose a product...

Page 188: ...the rejected package images Sample Package allows the operator to sample a package and store it as an image Clear Statistics Clears the data in the statistics screen Stop Inspection stops the inspect...

Page 189: ...in Figure A 56 The pass indicator turns green the total package count increments and the pass count increments Product Inspection Good Figure A 56 Passed Product Note During operation the green pass i...

Page 190: ...ure A 57 Failed Product The Fail indicator turns red the total packages increments and the failed count increments In Figure A 57 note the Total Packages count increments with each package the Pass in...

Page 191: ...eps to view rejected packages 1 Select REJECTED IMAGES from the RUN screen the following screen displays A96338 Figure A 58 Rejected Images 2 Select the reject you wish to view the button changes colo...

Page 192: ...ook at what caused the package to be rejected zoom in on the image by tapping on the location in the image to be examined View Image Zoom In Figure A 60 Example of Zoomed Image CANCEL ZOOM returns the...

Page 193: ...x Menus A 61 REC 4132 Rev E 3 To save the image press save and the image can be saved to a file on the EZx system or exported to a USB memory device the USB device must be plugged into the machine Sav...

Page 194: ...ssing the photoeye is displayed as an image after it is processed by the EZx View Image Sample Figure A 62 Sample Package The image can be saved from this screen and then it is added to the images tha...

Page 195: ...nd the lowest minimum value of the last 10 good packages scanned is displayed The average and minimum values are continuously updated as packages pass through the system The values of the filter thres...

Page 196: ...Scientific REC 4132 Rev E Note These filter changes are temporary until they have been saved to the product 4 Press SAVE TO PRODUCT to make any changes to the filter settings permanent for the product...

Page 197: ...mo Fisher Scientific Forms B 1 REC 4132 Rev E Appendix B Forms This appendix supplies tables for daily weekly monthly and yearly maintenance tasks Make copies of the tables for your convenience and fi...

Page 198: ...A Check the condition of the lead curtains at the entry and exit of the hood If they are worn or damaged replace them Check the belt tension See page 4 4 Check the air pressure See page 4 4 Check all...

Page 199: ...sher Scientific Forms B 3 REC 4132 Rev E Weekly Maintenance Completed Check interlocks and E stops See page 4 8 Check the oil temperature in the tank See page 4 28 Diode Calibration See page 4 11 Week...

Page 200: ...side machine for any oil leaks See page 4 15 Check inside the machine for water ingress and the effectiveness of the door seals See page 4 15 Check the condition of all fans inside the machine See pag...

Page 201: ...ing A radiation survey should be performed at the following times Always at the time of installation When a part has been replaced on the machine When the running product has been changed and In accor...

Page 202: ...Radiation Survey SheetTH and as displayed in Appendix C Pay special attention to the infeed and outfeed areas 4 After the radiation survey has been completed select STOP X RAYS 5 The results of the cr...

Page 203: ...Critical Radiation Survey Thermo Fisher Scientific Critical Radiation Survey C 3 REC 4132 Rev E...

Page 204: ...Critical Radiation Survey C 4 Critical Radiation Survey Thermo Fisher Scientific REC 4132 Rev E...

Page 205: ...Critical Radiation Survey Thermo Fisher Scientific Critical Radiation Survey C 5 REC 4132 Rev E...

Page 206: ...Critical Radiation Survey C 6 Critical Radiation Survey Thermo Fisher Scientific REC 4132 Rev E This Page Left Blank Intentionally...

Page 207: ...Radiation Survey Sheet Machine Serial Number Week Ending Units of Measurement Point 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Date Time Initials Day 1 2 3 4 5 6 7...

Page 208: ...Radiation Survey Sheet Machine Serial Number Week Ending Units of Measurement Point 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Date Time Initials Day 1 2 3 4 5 6 7...

Page 209: ...hresholds When setting up a product always use the least number of filters needed to get the job done Less filters is always better from a processing load standpoint Note If the Power Supply settings...

Page 210: ...any sharp edges and is a two dimensional alternative to the gradient filter Table D 1 Suggest Filter Sequences Filter Sequence Usage Sensitivity Simple Finds large contaminants that are significantly...

Page 211: ...Gamma Gradient Side edge mask Simple Gamma Enhanced Gradient Cans and cardboard cylinders present some unique challenges because they produce X ray images having a dark edge inside the package perimet...

Page 212: ...a Simple Side edge mask Simple Gamma Gradient Simple Side edge mask Simple Gamma Enhanced Gradient The first simple filter provides contaminant checking at a reduced sensitivity in region A of the exa...

Page 213: ...Filter Selection Thermo Fisher Scientific Filter Selection D 5 REC 4132 Rev E This Page Left Blank Intentionally...

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Page 215: ...New Product A96253 Figure E 1 New Product Screen On this page there are 3 values to configure Minimum Package Gap the minimum amount of space between packages This is often determined by the type of r...

Page 216: ...he detector These 3 values are interrelated in that the Leading and Trailing Edge Pad values take up space inside the minimum gap To provide some time for the system to complete processing the package...

Page 217: ...needed or not Ideally the image of the package is surrounded by white space as demonstrated below If the image is clipped at the top of the image or the front of the package as demonstrated below incr...

Page 218: ...Package Edge Padding E 4 Package Edge Padding Thermo Fisher Scientific REC 4132 Rev E This Page Left Blank Intentionally...

Page 219: ...sing this button brings up the NETWORK SETUP screen This screen allows the user to configure the Ethernet network interface Pressing FTP SERVER enables or disables the File Transfer Protocol FTP serve...

Page 220: ...s an FTP server to allow remote access to the statistics files saved images saved setups and log files The FTP server requires a username and password to access it Any user who is a system administrat...

Page 221: ...e computers address and the username and password used to access the FTP server often at the top of the screen Near these is a button labeled Connect 1 Start the FTP client 2 Enter in the address the...

Page 222: ...Network Settings F F 4 Network Settings Thermo Fisher Scientific REC 4132 Rev E This Page Left Blank Intentionally...

Page 223: ...spread sheet software such as Excel There are 2 ways to extract the information Export the file to a USB memory device from the VIEW STATISTICS screen see View Statistics on page A 51 Download the fil...

Page 224: ...Package Timestamps Every time a package is rejected the time it was rejected and a reject reason code are appended to the statistics Each entry has the format of reason time Reason codes 1 Contaminant...

Page 225: ...g a product the last entry in the file the entry for the product currently being inspected the counts will have a filler value usually 0 but could be any value if inspection has been stopped and start...

Page 226: ...Statistics File G 2 Statistics File Thermo Fisher Scientific REC 4132 Rev E This Page Left Blank Intentionally...

Page 227: ...1 REC 4132 Rev E Appendix H Engineering Drawings Back Panel Wiring Diagram 07379X E045 Interconnect Drawing 07379X E082 Skid Wiring Diagram 07379X E046 Field Wiring Diagram 07379X E088 Wiring Diagram...

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Page 229: ...only difference is in the Conveyor Transport System The conveyor length has been shortened from 1 6m 5 25 ft to 1 0m 3 28 ft The conveyor shielding has also been shortened and is completely removable...

Page 230: ...type 1 1 TERM BLK PLC OSC OPTO 24 48VDC 085263 Motor relay type 2 1 TERM BLK PLC RSC RELAY 24VDC 085338 Bearing 1 2 BRG RDL BALL 15MM X 35MM X11MM 085414 Motor Drive 1 CONT MTR DC BRUSHLESS 90 240V 08...

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Page 233: ...s A 12 Set Date and Time A 11 Input Setup A 14 Setup Input Device3 23 A 16 Input output setup 3 20 Inspection and Unpacking 1 5 Installation 2 1 Adjusting the Height 2 5 Connecting Air 2 5 Connecting...

Page 234: ...ings See Running Product A 55 Reject Pack Image A 55 A 59 Sample Package A 62 Safety Messages ii General Precautions iii Radiation Specific Prec iv Seasoning the Tank 3 6 Long and short seasoning 3 6...

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Page 241: ...Administrator 2 Enter Thermo1 as the password The Main Screen displays LONG SEASONING Select More Menus Test Tube Diagnostics Start Long Season The EZx indicates when Long seasoning is complete RADIAT...

Page 242: ...tup Shift 2 Select Setup Shifts shifts are run on a 24 hour clock 3 Select a shift Name Start Day Start Time 4 Select Accept 5 Select a shift End Time Number of Days 6 Select Accept 7 To add another s...

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