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Filtec FT-50 Operation Manual

Fill level inspector
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FT-50 Fill Level
Inspector
Operation Guide
Document 40272-0700

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  • Page 1 FT-50 Fill Level Inspector Operation Guide Document 40272-0700...
  • Page 2 FT-50 Fill Level Inspector Operation Guide Document 40272-0700...

  • Page 3: Contact Information

    Industrial Dynamics Company, Ltd.   Filtec and Industrial Dynamics are registered trademarks of Industrial Dynamics Company, Ltd. All other trademarks are the property of their respective owners.

  • Page 4: Table Of Contents

    Starting-Up Your FT-50 ........
  • Page 5 Error Number 46 ........4-6 FT-50 Fill Level Inspector...
  • Page 6 Error Number 47 ........4-6 Error Number 48 .
  • Page 7 The FT-50 Housing........

  • Page 8: Radiological Safety Information

    The FT-50 is unlikely to create hazardous radiation levels for the following reasons: • The FT-50’s radiation source produces a relatively weak source of low energy (low penetrating power) gamma radiation.

  • Page 9: Radiological Safety Guidelines

    FT-50 and surroundings with a plastic sheet or tarpaulin and call Industrial Dynamics immediately. 6. Do not relocate or dispose of the FT-50 without proper approval. A licensed technician must perform this function.

  • Page 10: Radiation Measurement Testing Data

    Radiation Measurement Testing Data 1. All measurements were taken with Technical Associates Model Pug-1 survey meter. The meter was cross calibrated against an air ionization chamber survey meter whose response was corrected against an Americium-241 test source. 2. Source Shutter closed - The radiation levels are less than 0.05 MR/HR at distances greater than 5 cm from any surface of the gauge (including inside the tunnel).

  • Page 11: Radiation Warning Labels

    Model No. __________________________________ Industrial Dynamics Co., Ltd. 2927 Lomita Boulevard Torrance, California 90509 (310)325-5633 Figure 1. The Safety labels attached to the FT-50 provide very important safety information and should be followed explicitly. viii FT-50 Fill Level Inspector Document 40272-0700...

  • Page 12: Filtec Model Ft-50 Radiation Exposure Profiles

    Filtec Model FT-50 Radiation Exposure Profiles Gamma Gauge: 100 or 300 mCi Source 4" TO " 7&8 Description Description Inspection Head 5 cm Isodistance Contour Inspection Tunnel Radiation Detector Sealed Americium-241 Shielding Bar (1/4” Thick Steel) Limits of Main Beam Detector Window Figure 2.
  • Page 13 FT-50 Fill Level Inspector Document 40272-0700...

  • Page 14: Chapter 1: Ft-50 System Overview

    Chapter 1: FT-50 System Overview Chapter 1: FT-50 System Overview Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 15: Inspection System Description

    Additional inspection options, such as missing cap detection, missing label detection, and smashed bottle detection, may be added to the FT-50 to enhance its functionality. For more information see “Optional System Features” on page 2-5. Figure 1-1. The FT-50 Fill Level Inspector.

  • Page 16: Fill Level Inspection Basics

    Chapter 1: FT-50 System Overview Fill Level Inspection Basics The FT-50 Fill Level Inspection systems utilizes a Container Radiation Profile Comparison Principle to create a radiation fingerprint of the container. To create a radiation profile a gamma beam is directed through the container.

  • Page 17: Rejection Control Basics

    FT-50 Fill Level Inspector Operation Guide Rejection Control Basics The FT-50 identifies and then tracks any container that fails inspection. Tracking begins the moment the container crosses the inspection trigger beam in the and ends when the container reaches the rejector centerline.

  • Page 18: Optional System Features

    Chapter 1: FT-50 System Overview Optional System Features The FT-50’s expandability allows you to add additional inspection capabilities to match your production requirements. Depending upon the FT-50 configuration you ordered, your unit may contain some of the following features: • High Cap/Bulged Can Detection •...

  • Page 19: Low Foam Detection

    Reject Sorting This option allows the FT-50 to classify the various types of rejects and then reject them into different reject bins, or reject conveyor lanes, based upon the classifications. This option requires the Servotec rejector.

  • Page 20: Chapter 2: Operating Your

    Chapter 2: Operating Your FT-50 Chapter 2: Operating Your FT-50 Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 21: Starting-Up Your Ft-50

    “on” position (opened). For more information see “The Safety Shutter” on page 2-3. 2. Locate the main power switch for the unit. If your FT-50 has the external junction box option installed, the switch is located on this box.

  • Page 22: The Safety Shutter

    The safety shutter is a small metal door that, when closed, stops the emission of gamma waves that are required for fill level inspection. Your FT-50 can be equipped with either a manual safety shutter or an automatic safety shutter called the autoshutter. The autoshutter operates automatically by closing when the production line stops and opening when the production line is running.

  • Page 23: Container Changeover

    FT-50 Fill Level Inspector Operation Guide Container Changeover The FT-50 is equipped will certain features that allow you to change between different container types easily. If the production line the FT-50 is installed on is designed to produce more than one size or type of container, this procedure will explain how to reconfigure the unit for a different container type.

  • Page 24: Adjusting The Inspection Head Height

    Head Height Adjustment Crank Head Height Counter Centerline Trigger Bracket Height Adjustment Crank Centerline Trigger Height Adjustment Scale Centerline Trigger Bracket Centerline Trigger Bracket Height Lock Head Height Lock Figure 2-3. The FT-50 adjustment mechanisms. Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 25: Adjusting The Conveyor Guide Rails

    FT-50 Fill Level Inspector Operation Guide 2. Loosen the head height lock and, using the head height adjustment crank, adjust the head height as follows: • If the new setting is above the previous setting, crank the head up until the head height counter indicates you have reached the correct height.

  • Page 26: Adjusting The Centerline Trigger Bracket Height

    Chapter 2: Operating Your FT-50 Adjusting the Centerline Trigger Bracket Height When you adjusted the head height for the new container, the centerline trigger bracket also moved because it is attached directly to the inspection head. Therefore, you may need to adjust the trigger bracket to accom- modate the new container type.

  • Page 27: Adjusting Optional Sensors And Sensor Brackets

    After you have adjusted the head height and centerline trigger bracket height you may need to adjust any optional sensors or sensor brackets that are installed on the FT-50. Your Service Department should indicate whether or not you will need to make these adjustment and what the adjustment should be.

  • Page 28: Aligning The Missing Cap Sensor

    For more information see “Adjusting the Centerline Trigger Bracket Height” on page 2-7. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter”...
  • Page 29 FT-50 Fill Level Inspector Operation Guide 3. Center a properly filled and capped production container in the inspection tunnel so that it is directly under the missing cap sensor. 4. Find your type of missing cap sensor in the table below and adjust the upper jam nut to raise or lower the sensor to the proper height.

  • Page 30: Aligning The High Cap Sensor

    Chapter 2: Operating Your FT-50 Aligning the High Cap Sensor Description Sensor Emitter Height Adjustment Lock Container Cap Sensor beam Sensor Receiver Container Travel Distance between Container Cap and Sensor Beam Secondary Sensor Height Adjustment Figure 2-5. Aligning the high cap sensor Industrial Dynamics Company, Ltd.
  • Page 31 For more information see “Adjusting the Centerline Trigger Bracket Height” on page 2-7. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter” on page 2-3.

  • Page 32: Aligning The Smashed Bottle Sensor

    For more information see “Adjusting the Centerline Trigger Bracket Height” on page 2-7. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter” on page 2-3.
  • Page 33 FT-50 Fill Level Inspector Operation Guide Caution Do not use the smashed bottle function to detect the container base only. If the container is smashed down to the base it cannot be rejected properly and may damage the rejector. 3. Loosen the upstream sensor mounting bracket adjustment knob and adjust the sensor so that it contacts the bottle 1mm-2 mm below the point where the container is smashed.

  • Page 34: Aligning The Inspection Trigger (Bottles)

    To correctly align the beam, you must align the inspection trigger height so the trigger beam contacts the container at the widest part of the cap. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter”...
  • Page 35 FT-50 Fill Level Inspector Operation Guide 4. Lower the bracket until the trigger beam contacts the container at the widest part of the cap or lid. 5. Tighten the height locking handle to secure the trigger beam positioning. 6. If you closed the manual safety shutter, open it before resuming operation.

  • Page 36: Aligning The Missing Lid Sensor

    For more information see “Adjusting the Centerline Trigger Bracket Height” on page 2-7. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter”...
  • Page 37 FT-50 Fill Level Inspector Operation Guide 4. Find your type of missing lid sensor in the table below and adjust the upper jam nut to raise or lower the sensor to the proper height. Description (Lid Type) Maximum Height Above Lid Nonferrous (Aluminum) 0.4 inch (10 mm)

  • Page 38: Aligning The Bulged Can Sensor

    Chapter 2: Operating Your FT-50 Aligning the Bulged Can Sensor Description Sensor Emitter Height Adjustment Lock Container Lid Sensor Beam Sensor Receiver Container Travel Distance between Container Lid and Sensor Beam Secondary Sensor Height Adjustment Figure 2-9. Aligning the bulged can sensor Industrial Dynamics Company, Ltd.
  • Page 39 Bulged can detection is only available when the containers are oriented in top-up position. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter” on page 2-3.

  • Page 40: Aligning The Down Can Sensor

    For more information see “Adjusting the Inspection Head Height” on page 2-5. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter” on page 2-3.

  • Page 41: Aligning The Inspection Trigger (Cans)

    You must align the inspection trigger height so that the trigger beam contacts the container at the widest part of the lid. 1. If your FT-50 is not equipped with an automatic safety shutter, you must close the manual shutter before you proceed. For more infor- mation see “The Safety Shutter”...
  • Page 42 Chapter 2: Operating Your FT-50 3. Center a properly filled and sealed production container in the inspection tunnel so that when the sensor mounting bracket is lowered, it is aligned with the trigger beam. 4. Lower the bracket until the trigger beam contacts the container at the widest part of the lid, or if the container is oriented upside down so the beam contacts the container as shown in Figure 2-2-11.
  • Page 43 FT-50 Fill Level Inspector Operation Guide 2-24 Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 44: Chapter 3: Using The System Software

    Chapter 3: Using the System Software Chapter 3: Using the System Software Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 45: The Operator Control Panel

    FT-50 Fill Level Inspector Operation Guide The Operator Control Panel You can interact with the FT-50’s through the operator control panel. The control panel contains eight keys and a two-line LCD (Liquid Crystal Display) capable of displaying 24 characters per line.

  • Page 46: Software Function Groups

    System Function Group (Key 5) • Diagnostic Function Group (Key 6) Operator’s access to the FT-50’s system software grants you rights to specific functions required to operate the unit, therefore you will have limited access to each function group. The Function Keys Pressing a function key displays the first available function in that group.

  • Page 47: Software Functions List

    FT-50 Fill Level Inspector Operation Guide Software Functions List There are two types of software functions: Status and Operating. Status Functions display information about the status of a software function or system component. Pressing the arrow keys has no effect on a Status Function because it is not a changeable parameter, it only provides current operating information for a particular software function.
  • Page 48 Chapter 3: Using the System Software Function Group Function Name Parameter Default Fill Level Key 1 Underfill Status On/Off Overfill Status On/Off Gamma Counts 0-65,000 pulses: Updating Constantly Updating Constantly Updating Rejects Only Target Head Height 0-999 Ticks 500 Ticks Finishing Key 2 High Cap Status On /Off...
  • Page 49 FT-50 Fill Level Inspector Operation Guide Function Group Function Name Parameter Default System Key 5 Current Container Type 1-32 Last Reject Detected Beacon Status On/Off/High Priority Line Speed (cpm) 0-2500 cpm Line Speed (cph) 0-150,000 cph Diagnostics Key 6 System Diagnostic Error 0-121 Industrial Dynamics Company, Ltd.

  • Page 50: Software Function Descriptions

    Software Function Descriptions This section contains function descriptions for each function group. Depending upon your FT-50 machine type, machine configuration, and options package, some of these options may not apply to your FT-50. Fill Level Functions Group Underfill Status This function activates or deactivates the rejection of underfilled containers.
  • Page 51 External Reject Status Activates or deactivates the external reject function. When activated the FT-50 will accept the reject signal from an outside inspection source and activate the rejector. Counters Functions Group The counters record operational and performance data about the FT-50 and the production line it is operating on.
  • Page 52 Chapter 3: Using the System Software Total Rejects The total number of rejected containers. The counter automatically resets at 99,999,999. Total rejects is the sum of the rejections from all active inspection functions. If two functions reject the same container, only one total reject count is recorded.

  • Page 53: Rejector Functions Group

    Rejector Functions Group Rejector Status Disables or enables the reject signal transmitted by the FT-50 to the rejector. This function also effects the external reject function in the same way. Although the actual rejection is disabled all counters and alarms continue to accumulate.

  • Page 54: System Functions Group

    This function is only available if the unit is configured for multiple container types. For more information see “Chapter 2: Operating Your FT-50." To select the Current Container Type: 1. Press Key 5 until Current Container Type appears.

  • Page 55: Diagnostics Function Group

    The speed of the production line measured by cpm (containers per minute). The measurement is the number containers that intercept the FT-50’s trigger beam in 60 seconds. To calculate cpm from cph (containers per hour) use the following formula: -------- - Line Speed (cph) The speed of the production line measured by cph (containers per hour).

  • Page 56: Chapter 4: Diagnostics And Troubleshooting

    Chapter 4: Diagnostics and Troubleshooting Chapter 4: Diagnostics and Troubleshooting Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 57: Diagnostic Errors

    Diagnostic Error Codes Listing The following list contains the FT-50 error codes. Depending upon your machine type, some of these errors may not apply to your FT-50. For more information see “Diagnostic Error Descriptions” on page 4-4. No Diagnostic Error...
  • Page 58 Chapter 4: Diagnostics and Troubleshooting * 33 Smashed Bottle Detection Error-Exceeded Consecutive Reject Limit * 34 Smashed Bottle Detection Error-False Trigger * 46 Consecutive External Reject Alarm Encoder Resolution Too Low * 48 AC Input Voltage Low, Brownout Detected * 49 User Defaults Closed For One Or More Settings System Defaults Loaded For One Or More Settings Container Passed With No Encoder Pulses...

  • Page 59: Diagnostic Error Descriptions

    FT-50 Fill Level Inspector Operation Guide Diagnostic Error Descriptions Error Number 2 An attempt was made to activate the rejector while the rejector status function is turned off. For more information see “Chapter 3: Using the System Software.” Error Number 5 The maximum limit of 32 containers between the trigger beam and the rejector has been exceeded.

  • Page 60: Error Number 14

    Chapter 4: Diagnostics and Troubleshooting Error Number 14 The gamma counts reaching the detector decreased rapidly to a value that is 75 percent below the average count for the last eight containers. Report this error to your Service Department. Error Number 15 The missing cap sensor input state logic level remains high.

  • Page 61: Error Number 33

    FT-50 Fill Level Inspector Operation Guide Error Number 33 This error occurs when the number of consecutively rejected smashed containers exceeds the limit set in the Consecutive smashed bottle reject alarm function. Report this error to your Service Department. Error Number 34 Two or more consecutive inspection triggers have occurred with no smashed bottle sensor transition.
  • Page 62 Chapter 4: Diagnostics and Troubleshooting Error Number 51 A container passed without any encoder pulses. This can be caused by: • blocking the trigger with the line stopped • encoder failure • trigger reflections • line jams This error condition is low priority and will not cause the warning beacon to flash during high priority only operation.

  • Page 63: Error Number 47

    FT-50 Fill Level Inspector Operation Guide Error Number 67 The number of containers in the consecutive diameter missing cap reject alarm was exceeded. This is a high priority error condition and will cause the warning beacon to flash if beacon status is set to high priority only. If this error persists, report this error to your Service Department.

  • Page 64: Error Number 120

    Chapter 4: Diagnostics and Troubleshooting Error Number 120 This error indicates there is a RX receive rate error. Too many characters have been received in one second. If this error persists, report this error to your Service Department. Error Number 121 This error indicates the CTS line (Clear To Send) is changing too rapidly for normal communication and therefore appears busy.

  • Page 65: Troubleshooting Procedures

    If your FT-50 is equipped with the autoshutter, the red signal beacon will be on indicating the shutter is open. • If you FT-50 is equipped with a manual safety shutter, check to be sure the shutter is opened. The display does not respond when keys are pressed 1.

  • Page 66: The Display Shows A Blinking Cursor And The Beacon Is On

    1. If you are using a remote control panel check that it is plugged into the connector on the inspection head correctly. 2. Reset the FT-50 by pressing the reset button for three seconds while turning the machine off and on.

  • Page 67: The Rejector Does Not Function

    FT-50 Fill Level Inspector Operation Guide The rejector does not function 1. Is the rejector activated? Verify the Rejector Status Function is enabled. 2. If you hear a clicking sound, but the rejector does not activate, the air pressure is not turned on. Turn on air pressure to the rejector.

  • Page 68: The Rejector Arm Remains Extended

    1. Is sufficient oil getting to the rejector? Check the oil level in the oiler (on some models only). 2. Turn the FT-50’s power off. If the rejector remains extended, contact your Service Department. Rejected container trajectory is sloppy or inconsistent 1.
  • Page 69 FT-50 Fill Level Inspector Operation Guide 4-14 Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 70: Chapter 5: Maintenance Procedures

    Chapter 5: Maintenance Procedures Chapter 5: Maintenance Procedures Industrial Dynamics Company, Ltd. Document 40272-0700...

  • Page 71: Maintenance Schedules

    FT-50 Fill Level Inspector Operation Guide Maintenance Schedules Daily Maintenance Action Description Inspect Trigger Beam Emitter and Receiver lenses Clean Trigger Beam Emitter and Receiver lenses Inspect High Cap Beam Emitter and Receiver lenses* Clean High Cap Beam Emitter and Receiver lenses*...

  • Page 72: 120 Day Maintenance

    Chapter 5: Maintenance Procedures 120 Day Maintenance Action Description Inspect Inspection Head Housing for dirt and moisture Inspect Wiring, insulation, terminals, and terminal blocks inside the Inspection Head and External Junction Box.* *Not all units are equipped with the optional External Junction Box. Industrial Dynamics Company, Ltd.

  • Page 73: Maintenance Procedures

    To power down the rejector turn off the main power switch on the junction box. If your FT-50 is not equipped with the autoshutter feature, you should close the manual safety shutter. For more information see “Chapter 2: Operating Your FT-50.”...

  • Page 74: The Ft-50 Housing

    Service Department. External Wiring 1. Check the external wiring between the sensors and the FT-50 for damage. Check all connections carefully to be sure they are not loose. 2. Check that insulating sleeves are in place. Report any problems to your Service Department.
  • Page 75 FT-50 Fill Level Inspector Operation Guide 1. Turn off the air flow control valve and depressurize all connected air lines. 2. Remove and clean the sediment bowl. If your unit contains a polycar- bonate bowl, inspect it for cracking or cloudiness; if present, replace it.

  • Page 76: Documentation Feedback

    Technical Publications Department at Industrial Dynamics. Use the form on the following page to record your comments and then send the form to us in one of the following ways: techpubs@filtec.com Email: 310-530-1000 Fax: Industrial Dynamics Co.

  • Page 77: Documentation Feedback Form

    Documentation Feedback Form Industrial Dynamics Please deliver To: Received From: Technical Publications Department 310-530-1000 Fax: Telephone: techpubs@filtec.com Email Email: Industrial Dynamics Co. Post Mail Address: Technical Publications Department 3100 Fujita St. Torrance, CA 90505 FT-50 Fill Level Inspector Operation Guide Document 40272-0700...

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