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Chapter 2: Troubleshooting Procedures

Industrial Dynamics Company, Ltd. ©

Form 42600 (10/03)

2-3

BOTTLE HANDLING PROBLEMS

Under normal production line operating conditions, bottle handling
problems are generally the main causes for unreliable bottle inspection
and rejection.

NOTE

Good bottle handling is the most important prerequisite for efficient
and reliable operation of the Omnivision system. The importance of
good bottle handling cannot be overstated.

Bottle handling problems can be caused by either the Omnivision's bottle
handling system or the customer's production line bottle handling. These
are addressed in the following sections.

Omnivision Bottle Handling Problems

If the optional OSW system is supplied, check to see if bottles pass
(rotate) through the OSW tunnel smoothly and in a uniformly overlapped
condition.

Good bottle handling for the OSW system consists of maintaining proper
synchronization with the main Omnivision unit. The OSW system bottle
rejection and bottle tracking are all provided through close-coupling to
the main Omnivision unit.

NOTE

In order for the OSW unit to operate properly, bottles must remain in
a bottle to bottle contact condition from Omnivision unit through the
entire OSW enclosure at all times.

The OV inspections are not
centered. This problem will
appear most on Finish.

For Finish/Thread Inspection, the
image light ring will fall off in
intensity on one side.

Recalibrate starwheel home
position. The Procedure on how
to do this is in the Service
Section.

For Base and Inner Sidewall
Inspection the bottle image will
appear to be off-center as they
pass over the deadplate opening.

Recalibrate starwheel home
position. The Procedure on how
to do this is in the Service
Section.

OSW is causing a high
amount of false rejects.

- Unclean inspection area.
- Poor bottle-handling causing
tracking errors

- Clean the tunnel and remove
any broken glass or debris.
- Ensure smooth bottle handling.
- Check wear on change parts.
- See the chapter titled "Bottle
Handling Problems"

SYMPTOM

PROBABLE CAUSE(S)

SOLUTION

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Содержание OV-II

Страница 1: ...OV II Maintenance Troubleshooting and Service Manual Document 42600 0905...

Страница 2: ...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...

Страница 3: ...False Rejects 2 8 Rejecting Large Percentage of Bottles 2 24 Rejecting No Bottles 2 25 Rejected Bottles Not Stable On the Takeaway Conveyor 2 27 Faulty Bottles Detected But Not Rejected 2 29 Rejecting...

Страница 4: ...2 OV II Maintenance Troubleshooting and Service Manual Document 426000905 Camera Enclosure 3 11 Lamp Enclosure 3 12...

Страница 5: ...igned to operate on a long term basis without regular maintenance being required None of the OSW system components require lubrication Do not open the OSW system enclosure unless absolutely necessary...

Страница 6: ...k Inspection Head height above starwheel using mechanical counter Also verify 13 mm 0 5 inch clearance between bottom of Finish Inspection lens and bottle crown Be sure to lock the raising mechanism a...

Страница 7: ...isk is stopped The glass disk should run true and not bind against adjacent components Check for cracks deep scratches etc Clean thoroughly Infeed and Outfeed Bottle Guides Check alignment and tighten...

Страница 8: ...them using a paper clip or other small diameter wire A compressed air nozzle is useful to blow through these restrictors back down through the hub This flushes any debris out of the restrictors and pi...

Страница 9: ...te whether top or bottom plates are needed and give the dash number Bottle Guide Belts and Upper and Lower Pulley Assemblies Check the bottle guide belts and upper and lower pulley assemblies The pull...

Страница 10: ...e Hub DO NOT USE AN OIL BASED LUBRICANT IN THIS AREA IT MAY CLOG THE VALVE PLATE Check the flexible hoses connected to the vertical Port tubes to ensure that they are not binding against starwheel dri...

Страница 11: ...e maintenance problems that may cause inspection and or bottle handling problems and offers suggested solutions SYMPTOM PROBABLE CAUSE S SOLUTION Soap is being detected as an object Air blow off rate...

Страница 12: ...If necessary replace starwheel and or add or remove spacers One out of x number of bottles is rejected every starwheel revolution Starwheel sucker cup is missing or damaged Replace sucker cup or repla...

Страница 13: ...the main Omnivision unit The OSW system bottle rejection and bottle tracking are all provided through close coupling to the main Omnivision unit NOTE In order for the OSW unit to operate properly bott...

Страница 14: ...troubleshoot the bottle handling problems on the main Omnivision unit proceed as follows 1 Go to the CONTAINER SETUP BOTTLE CHANGEOVER screen 2 Select the correct bottle type by pressing the button w...

Страница 15: ...on zone If the deadplate is too high it places excessive back pressure on the bottles resulting in rough bottle feeding Bottle Jams at Outfeed 1 The outfeed guide set should allow for approximately 3...

Страница 16: ...they are working properly The red LED indicator on the receiver head should be activated when the heads are aligned with no bottles present Passing a hand or bottle between the heads should deactivate...

Страница 17: ...with thread of T Ring inspections the clearance should be 25 inch 6 Check the infeed and outfeed bottle guides to be sure the bottles are not binding The bottles must pass through the starwheel smooth...

Страница 18: ...p ON No Message Complete System Failure Excessive False Rejects The false reject rate is a measure of detection reliability repeatability of the Omnivision The rate of acceptable false rejects varies...

Страница 19: ...the heel On the Inner Sidewall Protruding glass knobs Extreme variation in thickness Birdswings On the Plugged Neck Color Sort Extreme bottle color variations For Residual Liquid High levels of rinse...

Страница 20: ...If more than one system is recording extraordinarily high numbers of false rejects temporarily turn OFF the Omnivision s rejector by moving the cursor to the MACHINE CONFIGURATION REJECT HANDLING fun...

Страница 21: ...the figure above Once the responsible inspection systems zones have been identified refer to the following sections for detailed troubleshooting procedures as applicable Base Inspection Excessive Fal...

Страница 22: ...detection points 8 Observe the DETECT function This is normally adjusted to a value between 100 and 200 The higher the number the more sensitive the inspection zone will become The highest possible va...

Страница 23: ...f the rejected bottles will be held under the heading LIGHT DEFECT Normal bottles should have LIGHT LEVEL readings ranging from 2200 to 3000 1 If the system seems to be falsely rejecting bottles due t...

Страница 24: ...alue below 50 then the image brightness as controlled by the SETUP BASE CAMERA screen must be adjusted first For Color Sort to function the LOWER LIMIT adjustment will generally require a higher setti...

Страница 25: ...they are not go to the INSPECTION SETUP ISW screen and adjust the horizontal and vertical settings as required 4 Check the Current Detects column to see if any of the inspection zone is detecting mor...

Страница 26: ...vity by another 25 points Again clear the counters let another 1 000 bottles pass through and check the reject rate Repeat this process until the false reject rate is acceptable 10 When the adjustment...

Страница 27: ...hich are extremely dark with respect to the bottle type being run For example when running flint bottles the system detects dark amber bottles 2 If it appears that the system is rejecting bottles whic...

Страница 28: ...E heading will normally be in the range from 200 to 600 3 If the CURRENT or AVERAGE values are out of the range or if the CURRENT value tends to occasionally have a value of 1 023 or of 0 then the pro...

Страница 29: ...he RF PULSE WIDTH value is less than the RF DETECT THRESHOLD value the bottle is detected Therefore a higher RF DETECT THRESHOLD setting makes the system more sensitive 3 If a bottle is falsely reject...

Страница 30: ...centered within the two dotted circles inspection ring or donut If it is not then other parameter settings may need to be adjusted If all of the bottle have the same displacement then the starwheel h...

Страница 31: ...D algorithms as applicable Again clear the counters let 1 000 bottles pass through and check the TOTAL DETECTS column Repeat the process until the false reject rate is acceptable 8 After adjustment al...

Страница 32: ...causing false rejects proceed to item e e If necessary correct the responsible Window s size If window size is not causing false rejects proceed to item f f If necessary make adjustments to the respo...

Страница 33: ...rejects as follows a Look at the WINDOW DETECT COUNT column to locate the responsible Window s You may need to use the Scroll function to access the second screen to observe Windows 10 through 15 b Tu...

Страница 34: ...ve the new settings using the CONTAINER BOTTLE CHANGEOVER screen Rejecting Large Percentage of Bottles When the system starts rejecting a large percentage of bottles or all the bottles proceed as foll...

Страница 35: ...has the wrong zoom setting The monitor display for one or more of the zones will show up as all dark all white or will have an unusually small or unusually large bottle image Verify the servo controll...

Страница 36: ...the inspection zones It is possible that the starwheel encoder located underneath the starwheel motor has been disconnected and cannot detect the starwheel turning 4 If the problem is not resolved af...

Страница 37: ...e too low Check the air pressure regulator inside the base cabinet Verify the pressure is set to between 276 and 414 kPa 40 and 60 PSI Bottles released early or other bottles are rejected when normal...

Страница 38: ...alve plate seal ring if necessary Restriction in starwheel valve plate hoses Check the hoses going from the valve plate to reject valve and to the vacuum and purge sources for proper length and spring...

Страница 39: ...Air pressure Set to 310 414 kPa 45 60 PSI Solenoid Valve not activating Replace the Solenoid Plugged pressure lines parts Press button on Solenoid valve several times while starwheel is rotated to cl...

Страница 40: ...ses and solutions as follows SYMPTOM CHECK SOLUTION Incorrect Bottle Delay Check the settings on the Bottle Delay and in the CONTAINER SETUP TRIGGER AND REJECT SETTINGS screen 1 Adjust the settings as...

Страница 41: ...possible causes and solutions as follows SYMPTOM CHECK SOLUTION Incoming AC Power Check Branch Circuit Breakers fuses etc Repair replace as necessary Check Omnivision AC switches and circuit breakers...

Страница 42: ...OV II Maintenance Troubleshooting and Service Manual 2 32 Industrial Dynamics Company Ltd Form 42600 10 03 BLANK PAGE INTENDED...

Страница 43: ...TRICAL POWER BEFORE REPAIRING OR REPLACING ANY OMNIVISION COMPONENTS FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE MACHINE AND ELECTRICAL SHOCK CAUSING SERIOUS BODILY INJURY GUIDELINES FOR REPAIR OR RE...

Страница 44: ...ended period of time Replace the diffuser disk with the IDC approved diffuser glass DO NOT USE OTHER MATERIALS SUCH AS PLASTIC 1 Remove the base cabinet front door diffuser glass side 2 Unplug the dri...

Страница 45: ...ows otherwise go to Step 4 3 Using 320 grit emery paper placed on a very flat surface such as a surface plate press the seal ring against the emery paper and move in circular motions until all blemish...

Страница 46: ...ing the 4 40 x 1 4 inch screw The seal ring requires no lubrication Valve Plate To replace the valve plate proceed as follows 1 Remove the valve plate by removing the four 10 32 x 1 2 inch cap screws...

Страница 47: ...ry important step since the valve plate must float freely to ensure a proper seal between the starwheel seal ring and the valve plate Deadplate To replace the deadplate proceed as follows 1 Raise the...

Страница 48: ...II Maintenance Troubleshooting and Service Manual 3 6 Industrial Dynamics Company Ltd Form 42600 10 03 7 Reinstall the starwheel and the infeed guide 8 Lower the Inspection Head to its original positi...

Страница 49: ...support column adjacent to the glass disk 3 Carefully remove and discard any broken glass pieces 4 Lift the Diffuser Disk Release Pin 5 Swing the arm that supports the Diffuser Disk so that it is ful...

Страница 50: ...proceed as follows 1 Turn the main power switch OFF and wait at least 15 minutes before proceeding to Step 2 WARNING Wait at least 15 minutes after turning the main power switch OFF to allow for the s...

Страница 51: ...clean using a glass cleaning solution and lens tissue or soft cloth before installation 7 Without removing the protective plastic bags gently insert the new flash tube s banana plugs into their match...

Страница 52: ...ure below for screw location 3 Remove the lens retaining ring and replace the finish lens 4 Place retaing ring back in postion with the three screws removed in step 2 NECK BELT To replace the Neck Bel...

Страница 53: ...rm 42600 10 03 3 11 4 Adjust the Neck Guide tension so the bottle is held firmly in place yet can pass smoothly through the inspection area OUTER SIDEWALL ENCLOSURES CAMERA ENCLOSURE There are very fe...

Страница 54: ...turned off The heaters are active to keep the OSW mirrors from fogging To disable ALL power to the OSW system turn OFF both the main power switch and the OSW heater power LAMP ENCLOSURE 1 Remove the...

Страница 55: ...lacement Procedures Industrial Dynamics Company Ltd Form 42600 10 03 3 13 8 Install the OSW enclosure cover back in place 9 Turn on the circuit breaker and verify the replacement fluorescent lamp is f...

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