Page 1 FT-70c Service and Technical Reference Manual for Can Inspection 40256-0600...
Page 2 FT-70c Fill Level Inspector Service and Technical Reference Manual for Can Inspection Document 40256-0600...
Page 3 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
Radiation Warning Labels ....... . XV Filtec Model FT-70 Radiation Exposure Profiles ....XVI FT-70 Certificate of X-ray Output Measurement.
Page 5 FT-70 Fill Level Inspector Service Manual Chapter Two: Installation Requirements Installation Requirements Overview ......2-3 Power Supply .
Page 6 Table of Contents Aligning the Down Can Sensor ......4-14 Wiring the External Reject Function ..... . . 4-15 Software Configuration .
Page 7 FT-70 Fill Level Inspector Service Manual Diameter Missing Lid Width ......5-16 Minimum Diameter Missing Lid ..... . . 5-16 Counter Functions Group .
Page 8 Table of Contents Alarm Bulged End ........5-27 Alarm Down Can .
Page 9 FT-70 Fill Level Inspector Service Manual How to Access Diagnostic Error Codes ....5-41 Diagnostic Error Codes Listing ......5-42 Chapter Six: Calibration Procedures FT-70 Calibration Procedures .
Page 10 Table of Contents Chapter Seven: Maintenance Procedures Maintenance Schedules ........7-3 Daily Schedule .
Page 11 FT-70 Fill Level Inspector Service Manual Error Number 54 ........8-9 Error Number 58 .
Page 12 Table of Contents timing malfunctions occur ......8-30 Proximity Sensors: No triggering occurs ....8-30 Encoder Troubleshooting .
Page 13 FT-70 Fill Level Inspector Service Manual S2-3: Parity On/Off ........10-6 S2-4: Parity Odd/Even .
Page 15: Radiological Safety
FT-70 Fill Level Inspector Service Manual Radiological Safety Understanding Radiological Safety The Filtec Model FT-70 utilizes an x-ray tube to produce the x-ray radiation required for performing inspection activities. The secured and insulated x-ray source housing completely contains and shields all high voltage components within the x-ray housing assembly.
Page 16: Radiological Safety Guidelines
Radiological Safety Radiological Safety Guidelines 1. Do not tamper with the x-ray housing. 2. Do not place the hands between the x-ray source and the detector when the x-ray is turned on. 3. If you have any questions regarding the x-ray safety or operation, contact Industrial Dynamics.
Page 17: Radiation Warning Labels
TORRANCE, CA U.S.A. X-RAYS PRODUCED WHEN ENERGIZED. ENABLED +24VDC X-RAY EMMITTING Figure 1. Warning labels attached to Filtec Model FT-70 Inspection System. The information on these labels are very important and should be followed explicitly. Industrial Dynamics Company, Ltd. © 40256-0600...
Page 18: Filtec Model Ft-70 Radiation Exposure Profiles
Radiological Safety Filtec Model FT-70 Radiation Exposure Proﬁles 4" - 7.5" Description Description Inspection Head 5 cm Isodistance Contour Inspection Tunnel Radiation Detector Sealed X-ray Source Shielding Bar (1/4” Thick Steel) Limits of Main Beam Detector Window Figure 2. FT-70 Radiation Proﬁle Schematic. X-Ray Gauge: 45 KV @ 50 µ A with 2 (.015 inch) BeKu Filters.
Page 19: Certificate Of X-Ray Output Measurement
FT-70 Fill Level Inspector Service Manual FT-70 Certiﬁcate of X-ray Output Measurement. Figure 3. FT-70 Certiﬁcate of x-ray output measurement. XVIII Industrial Dynamics Company, Ltd. © 40256-0600...
Page 20 Chapter 1: FT-70 System Overview Chapter One: FT-70 System Overview System Overview ......... . 1-3 Fill Level Inspection Basics .
Page 22: System Overview
Chapter 1: FT-70 System Overview System Overview This manual provides information about the FT-70 Machine Type 05 (MT05) Inspection System for cans. The MT05 version of the FT-70 is equipped with the following: • Solid State Detector or Scintillation Tube Detector •...
Page 23: Fill Level Inspection Basics
FT-70 Fill Level Inspector Service Manual Fill Level Inspection Basics The FT-70 Fill Level Inspection system utilizes a Container Radiation Proﬁle Comparison Principle to create a radiation ﬁngerprint of the container. To create a radiation proﬁle a beam of x-ray radiation is directed through the container.
Page 24: How Underfill Inspection Works
Chapter 1: FT-70 System Overview To allow for slight variances in the ﬁll level an upper x-ray threshold and a lower x-ray threshold are plotted. The upper and lower thresholds form the tolerance range of the master proﬁle. Any scanned container that falls outside of this tolerance range fails the inspection.
Page 25: Rejection Control Basics
FT-70 Fill Level Inspector Service Manual Rejection Control Basics The FT-70 tracks any container that fails inspection. Tracking begins the moment the container crosses the inspection trigger beam in the FT-70 and ends when the container reaches the rejector centerline. Description FT-70 Inspection Trigger Location...
Page 26: System Specifications
Chapter 1: FT-70 System Overview System Speciﬁcations Speciﬁcations herein are listed for the FT-70. For speciﬁcations on the rejector refer to the rejector manual that was included with your FT-70. Power Requirements • 105 to 125 VAC, 50 or 60 Hz, 2.0 Amps, 1 Phase, or •...
Page 27: Inspection Accuracy
FT-70 Fill Level Inspector Service Manual Inspection Accuracy The basic ﬁll level inspection accuracy is ±0.4 mm. The accuracy obtained during production will degrade based on glass or plastic quality, liquid motion, foam, and conveyor speed. Containers/Minute Feet/Minute (m/min) Accuracy ±0.06 inch (1.6 mm) 135 (41) ±0.12 inch (3.1 mm)
Page 28: Triggering System
Chapter 1: FT-70 System Overview Triggering System The Trigger System uses a ﬁber-optic light source to transmit a light beam across the inspection tunnel to a receiver mounted on the opposite side. When a container passes through the beam, continuity is broken and a container present state is created.
Page 29: Container Types
FT-70 Fill Level Inspector Service Manual Container Types The FT-70 is compatible with aluminum, steel, and cardboard cans and can accommodate most shapes and sizes providing they do not exceed the physical dimensions of the inspection tunnel. Types of containers that can be inspected include: Figure 1-4.
Page 30: System Software
Chapter 1: FT-70 System Overview System Software The system software is contained in a set of upgradable PROMs that are mounted on the processor board. Some of the software capabilities are: • Multiple Container Types: If you run different container types on your production line, this feature allows you to switch between types quickly, without having to reconﬁgure all container parameters.
Page 31: Optional System Features
FT-70 Fill Level Inspector Service Manual Optional System Features The FT-70’s expandability allows you to add additional inspection capabilities to match your production requirements. Depending upon the FT-70 conﬁguration you ordered, your FT-70 may contain some of the following features: •...
Page 32: External Reject Control
Chapter 1: FT-70 System Overview External Reject Control Allows the FT-70 to accept reject signals from other inspection units, track the container, and time the rejection signal. For example a label inspector can send a reject signal to the FT-70 and the FT-70 can track and reject that container for the label inspection unit.
Page 34 Chapter 2: Installation Requirements Chapter Two: Installation Requirements Installation Requirements Overview ......2-3 Power Supply ......... . 2-3 Pneumatics .
Page 36: Installation Requirements Overview
Chapter 2: Installation Requirements Installation Requirements Overview Power Supply Proper power supply and wiring are critical to the performance of the FT-70. An unconditioned power source or improper wiring can create noise transients that adversely effect the CPU. Noise transients can create false rejects or cause premature failure of electrical components.
Page 37: Physical Space
FT-70 Fill Level Inspector Service Manual Physical Space When determining the physical spacing requirements, you must also consider the spacing requirements for the rejector. Refer to the FT-50 and FT-70 Installation and Service Drawing Pack for an overview of the space requirements.
Page 38: Reject Takeaway Conveyor
Chapter 2: Installation Requirements • Use either plastic or stainless steel chain, however do not use ﬂex chain within the inspection and rejection area. • IDC recommends that you select and install a backup sensor downstream from 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.
Page 40: Chapter Three: Installing The
Chapter 3: Installing the FT-70 Chapter Three: Installing the FT-70 Before You Begin ......... 3-3 Basic Terminology .
Page 42: Before You Begin
Chapter 3: Installing the FT-70 Before You Begin Before you begin installing your FT-70, read this manual thoroughly so that you understand the installation processes and all installation requirements (chapter 2). We strongly recommended that you arrange for an Industrial Dynamics Field Representative to be present to supervise plant personnel during the installations and to review the completed installation.
Page 43: Unpacking The Ft-70
FT-70 Fill Level Inspector Service Manual Unpacking the FT-70 The FT-70 and all accessories such as mounting hardware, the encoder, spare parts, and special lubricants are packed in individual boxes inside the main shipping box. The radioisotope is shipped separately from the FT-70 and comes with special handling instructions.
Page 44: Installing The Ft-70 Inspection System
Chapter 3: Installing the FT-70 Installing the FT-70 Inspection System To install your FT-70 Inspection System into your production environment you must do the following: • Determine the proper location for the FT-70 and the rejector. • Prepare the conveyor. •...
Page 45: Determining The Proper Location For The Ft-70
FT-70 Fill Level Inspector Service Manual Determining the Proper Location for the FT-70 Before you begin installing your FT-70 Inspection System and rejector you should understand all the requirements detailed in Chapter 2: Installation Requirements. The location of the FT-70 within the production line is very important.
Page 46: Preparing The Conveyor
Chapter 3: Installing the FT-70 Preparing the Conveyor After you determine the installation location you must prepare the conveyor for the installation. 1. Mark the installation location of the FT-70 on the side channel by drawing a vertical line with a marker. This is the centerline on which the FT-70 will be aligned when installed.
Page 47: Mounting The Ft-70
FT-70 Fill Level Inspector Service Manual Mounting the FT-70 Assemble the Floor Stand The parts included for your installation are based on the instal- lation height information you speciﬁed when you ordered your FT-70. If you cannot mount the FT-70 as originally planned, or if parts are missing, contact IDC Customer Service immediately.
Page 48 Chapter 3: Installing the FT-70 2. Cut the vertical support pipe to the calculated length (L removing the excess from the end that is not ﬂanged. Description Remove excess from this end. Flanged end Figure 3-4. Removing the excess from the vertical support pipe. 3.
Page 49 FT-70 Fill Level Inspector Service Manual 4. Insert the vertical support pipe into the tripod until it stops. Do not completely tighten the retaining bolts, leave them loose enough so you can make alignment adjustments later. Description Support Pipe Stop Plate Figure 3-6.
Page 50: Mount And Position The Inspection Head
Chapter 3: Installing the FT-70 6. Attach the upper ends of the support braces to the vertical pipe with the pipe clamp. The pipe clamp is only temporary. After ﬁnal positioning adjustments are made, you will spot weld the supports into place and remove the clamp. Description Pipe Clamp Figure 3-8.
Page 51 FT-70 Fill Level Inspector Service Manual 2. Move the assembled unit into position on the conveyor. To achieve proper positioning you must do the following: • Align the centerline of the FT-70 with the centerline mark you made on the conveyor. •...
Page 52: Secure The Floor Stand To The Floor
Chapter 3: Installing the FT-70 Secure the Floor Stand to the Floor 1. Mark the position of the three (3) mounting holes in the base tripod on the ﬂoor. 2. Drill a mounting hole at each of the three (3) marks you made on the ﬂoor.
Page 53: Install The Slant Support Braces
FT-70 Fill Level Inspector Service Manual Install the Slant Support Braces If you are performing a high mount or low mount, install the slant braces. You can install the braces on either side of the vertical support pipe, depending upon available clearance from the conveyor and other objects.
Page 54 Chapter 3: Installing the FT-70 2. Determine the angle and length of the slant brace by stringing a measuring tape from the support bracket to the ﬂoor. Move the slant brace support bracket up or down to achieve the proper angle. Description Measure from the hole to the ﬂoor while maintaining an angle of approximately 35°.
Page 55 FT-70 Fill Level Inspector Service Manual 6. Attach the slant brace ﬂoor mounting brackets to the slant brace stubs and then slide the stubs into the bottom ends of the slant braces approximately 1.5 inches. The ﬂoor brackets should rest ﬂat on the ﬂoor. Description Slant Brace Stubs Figure 3-14.
Page 56 Chapter 3: Installing the FT-70 7. Mark the positions of the mounting holes and then anchor each bracket with two 1/2 inch x 4 inch lag bolts and lead ﬂoor inserts. Figure 3-15. Anchoring the slant braces to the ﬂoor. 8.
Page 57 FT-70 Fill Level Inspector Service Manual Caution Do not use resistance type electrical (ARC) welding equipment. The high electrical current will damage electronic components inside the FT-70. Description Weld both brackets. Weld three braces. Weld both feet. Figure 3-16. Spot welding the mounting hardware. 3-18 Industrial Dynamics Company, Ltd.
Page 58: Install The Air Purge System
Chapter 3: Installing the FT-70 Install the Air Purge System 1. Attach the air ﬁlter/regulator to the vertical support pipe using the supplied UBolt. You can mount the air ﬁlter in an alternate location providing the distance does not exceed the 40-inch length of the air hose.
Page 59 FT-70 Fill Level Inspector Service Manual 2. Connect the air line from the ﬁlter/regulator to the air input of the FT-70. Description Air Regulator/Disperser Air Input Air Hose (from ﬁlter/regulator) Figure 3-18. Connecting the air line to the FT-70. 3. Connect the input air source line to the input of the ﬁlter/regulator.
Page 60: Install The High-Resolution Encoder
Chapter 3: Installing the FT-70 Install the High-Resolution Encoder If you will be using the High-Resolution Encoder option with your FT-70, install the encoder so that it is driven by the sprocket shaft that drives the conveyor chain section that passes through the inspection system.
Page 61: Mounting The Encoder Offset
FT-70 Fill Level Inspector Service Manual Mounting the Encoder Offset If you are using the offset mounting procedure, you will need: • Two sprockets or ﬂywheels providing a 1:1 ratio. • A timing chain or timing belt. • An adapter bracket to mount the encoder over the sprocket or ﬂywheel.
Page 62: Connect The Main Power Source
Chapter 3: Installing the FT-70 Connect the Main Power Source Before you begin wiring the FT-70 to the power source be sure the power source meets the requirements explained in Chapter 2: Installation Requirements. Four wiring examples that cover most wiring situations are provided at the end of this chapter in Power Supply Wiring Examples.
Page 63 FT-70 Fill Level Inspector Service Manual 2. Route the AC power cable into the FT-70 through one of the watertight cable ports located in the bottom of the FT-70. Description Power cable Watertight Cable Ports Power Cable Routing Power Filter Wiring Power Switches Bracket Figure 3-21.
Page 64: Wiring The Main Power Supply Cable To The I/O Junction Box
Chapter 3: Installing the FT-70 4. Wire the main power cable to the FT-70 power ﬁlter wiring. Connect the Power Cable: To the FT-70: Brown Neutral Blue Ground Ground Stud Wiring the Main Power Supply Cable to the I/O Junction Box Refer to wiring diagram in Chapter 11 when performing this procedure.
Page 65: Power Supply Wiring Examples
FT-70 Fill Level Inspector Service Manual 3. Connect the wires from the main power cable to terminal block TB5 within the junction box as follows: Wire Terminal and Pin Attach to TB5 pin 7. Neutral Attach to TB5 pin 8. Ground Attach to ground point in box.
Page 66: Example B: Using A Voltage Regulating Transformer
Chapter 3: Installing the FT-70 Example B: Using a Voltage Regulating Transformer If voltage stability is a problem, a voltage regulating type trans- former should be used. This example uses a transformer to isolate the FT-50 and to convert the line voltage to the proper voltage for the FT-70.
Page 67: Example C: Poly-Phase And Single-Phase From The Same Distribution
FT-70 Fill Level Inspector Service Manual Example C: Poly-Phase and Single-Phase From the same Distribution System 1. Neutral must be grounded at the main power panel. 2. Connect the FT-70 ground stud to the plant Earth ground. Do not connect the FT-70 neutral (white) to the ground stud. 3.
Page 68: System
Chapter 3: Installing the FT-70 Example D: High voltage (380v, 440v, etc.) Poly-Phase Systems (Delta or Wye) 1. This example is identical to Example B except the input to the transformer is taken from a poly-phase system. All other condi- tions of Example B apply.
Page 70 Chapter 4: Conﬁguring the FT-70 for Operation Chapter Four: Conﬁguring the FT-70 for Operation Chapter Overview ......... 4-3 Mechanical Configuration .
Page 72: Chapter Overview
Chapter 4: Conﬁguring the FT-70 for Operation Chapter Overview Before you can use your FT-70 Inspection System you must conﬁgure the FT-70 and the rejector to operate on your production line. There are two parts to conﬁguring the inspection system: •...
Page 73: Mechanical Configuration
FT-70 Fill Level Inspector Service Manual Mechanical Conﬁguration To mechanically conﬁgure the FT-70 you must complete the following procedures: • Adjust the Head Height for Fill Level Inspection. • Adjust the Inspection Trigger height. If your FT-70 contains the following options, you must also complete these additional procedures: •...
Page 74: Before You Begin
Chapter 4: Conﬁguring the FT-70 for Operation Before You Begin Before you begin conﬁguring the FT-70, verify the following is completed: • The inspection head is completely installed and is correctly centered and leveled over conveyor chain as explained in Chapter 3: Installing the FT-70.
Page 75: Aligning The Fill Level Inspection Beam
FT-70 Fill Level Inspector Service Manual Aligning the Fill Level Inspection Beam You must adjust the FT-70’s head height so the ﬁll level inspection beam contacts the container at the proper height. The FT-70 can perform either underﬁll inspection or overﬁll inspection, it can not perform both simultaneously.
Page 76 Chapter 4: Conﬁguring the FT-70 for Operation 3. Loosen the Height Locking Handle for the Centerline Sensor Mounting Bracket and using the Sensor Bracket Height Crank, raise the bracket all the way. 4. Center a properly ﬁlled production container in the inspection tunnel so that when the inspection head is lowered, it is aligned with inspection beam.
Page 77: Aligning The Inspection Trigger
FT-70 Fill Level Inspector Service Manual Aligning the Inspection Trigger You must align the inspection trigger height so that the trigger beam contacts the container at the widest part of the lid. Description Trigger Height Lock Trigger Beam Emitter Trigger Beam Centerline Trigger Beam Receiver Container Travel Trigger Horizontal Centerline...
Page 78 Chapter 4: Conﬁguring the FT-70 for Operation 3. 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 4-4.
Page 79: Aligning The Missing Lid Sensor Height
FT-70 Fill Level Inspector Service Manual Aligning the Missing Lid Sensor Height The Missing Lid Sensor is mounted on the Centerline Sensor Bracket. Align the Missing Lid Sensor height after you align the Inspection Trigger Sensor height. Description Missing Lid Sensor Container Lid Container Travel Distance between Lid and Sensor...
Page 80 Chapter 4: Conﬁguring the FT-70 for Operation 3. 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. Sensor Description (Lid Type) Maximum Height Above Lid 21242 Nonferrous (Aluminum) 0.4 inch (10 mm)
Page 81: Aligning The Bulged End Sensor Height
FT-70 Fill Level Inspector Service Manual Aligning the Bulged End Sensor Height The Bulged End Sensor is mounted on a separate bracket that is attached to Centerline Sensor Mount Bracket. Description Sensor Emitter Height Adjustment Lock Container Lid Sensor Beam Sensor Receiver Container Travel Distance between Container Lid and Sensor Beam...
Page 82 Chapter 4: Conﬁguring the FT-70 for Operation Note Bulged end detection is only available when the containers are oriented in top-up position. 1. Center a properly ﬁlled and sealed production container under the downstream sensor mounting bracket. 2. Loosen the downstream sensor mounting bracket adjustment knob and adjust the sensor so that it is 1mm above the container lid.
Page 83: Aligning The Down Can Sensor
FT-70 Fill Level Inspector Service Manual Aligning the Down Can Sensor The Down Can Sensor is mounted on separate brackets that are attached on the bottom of the inspection head and aligned to the head centerline. Description Sensor beam Sensor Emitter Sensor Receiver Container Travel Figure 4-7.
Page 84: Wiring The External Reject Function
Chapter 4: Conﬁguring the FT-70 for Operation Wiring the External Reject Function You can connect any external switching device to the External Reject Function, such as a manual contact switch or the switched output from another device. A switching closure to ground signal is required. When the signal is in the low state it will trigger the FT-70 to send the rejector activation signal.
Page 85: Software Configuration
FT-70 Fill Level Inspector Service Manual Software Conﬁguration Before you begin conﬁguring the FT-70 software, complete the mechanical conﬁguration as explained in the previous section. To conﬁgure the FT-70 software you must perform the following procedures: • Calibrate the Encoder and the Rejector Timing. •...
Page 86: Configuring The Inspection Looktime Gate
Chapter 4: Conﬁguring the FT-70 for Operation Conﬁguring the Inspection Looktime Gate The Inspection Looktime Gate deﬁnes the time interval when the radiation measurement is taken. This interval coincides with the moment the container passes through the inspection beam. Description X-ray Counts Container enters x-ray beam Container exits x-ray beam...
Page 87 FT-70 Fill Level Inspector Service Manual 7. Repeat steps 5 and 6 four more times and then average the values. + + + + ------------------------------------------- - 8. Use the following equation to determine the Looktime Gate in milliseconds. × D 0.6 where: D = Average Time Width of Can (step 7).
Page 88: Configuring The X-Ray Threshold
Chapter 4: Conﬁguring the FT-70 for Operation Conﬁguring the X-ray Threshold The X-ray Threshold deﬁnes the x-ray radiation count that is the dividing line between accepting or rejecting a container during ﬁll level inspection. Before you conﬁgure the X-ray Threshold, you must have aligned the Fill Level Inspection Beam properly as explained in Aligning the Fill Level Inspection Beam.
Page 89: Setting The Overfill X-Ray Threshold
FT-70 Fill Level Inspector Service Manual 10. To complete the conﬁguration you must follow the appropriate procedure based on the type of ﬁll level inspection you will be performing: • If you will be performing overﬁll inspection proceed to Setting the Overﬁll X-ray Threshold. •...
Page 90: Setting The Underfill X-Ray Threshold
Chapter 4: Conﬁguring the FT-70 for Operation Setting the Underﬁll X-ray Threshold 1. Place a sample production container that is empty on the conveyor far enough upstream of the FT-70 so that it does not slip on the chain and is positioned correctly as it passes through the inspection tunnel.
Page 91: Configure The Missing Lid Function
FT-70 Fill Level Inspector Service Manual Conﬁgure the Missing Lid Function 1. 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. 2.
Page 92: Configure The Diameter Missing Lid Function
Chapter 4: Conﬁguring the FT-70 for Operation Conﬁgure the Diameter Missing Lid Function The Diameter Missing Lid function utilizes the Inspection Trigger Beam to determine if a lid is present, therefore you must align the Inspection Trigger Beam before you conﬁgure the Diameter Missing Lid function.
Page 93 FT-70 Fill Level Inspector Service Manual GS BS – ------------------------- - 13. Press Key 2 until MINIMUM DIA MISSING LID appears and then use the Arrow Key to enter the MD value you calculated. 14. Test the conﬁguration by running several containers with and without lids through the FT-70.
Page 94: Configure The Down Can Function
Chapter 4: Conﬁguring the FT-70 for Operation Conﬁgure the Down Can Function 1. 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. 2.
Page 95: Configure The External Reject Function
FT-70 Fill Level Inspector Service Manual Conﬁgure the External Reject Function Before you activate the External Reject Function, be sure you have the signal cable wired correctly, see Wiring the External Reject Function for proper wiring conﬁguration. 1. 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.
Page 96 Chapter 5: System Software Chapter Five: System Software The Control Panel ......... 5-4 Using the Control Panel .
Page 97 FT-70 Fill Level Inspector Service Manual Total Down Can ........5-18 Total Dia.
Page 98 Chapter 5: System Software Change Password ........5-28 View TB1 &...
Page 99: The Control Panel
FT-70 Fill Level Inspector Service Manual The Control Panel You can access all the FT-70’s system functions through the Control Panel. The Control Panel contains eight keys and a two-line LCD (Liquid Crystal Display) capable of displaying 24 characters per line.
Page 100: The Safety Interlock Switch
Chapter 5: System Software The Safety Interlock Switch The Safety Interlock Switch is a physical on/off switch located on the top of the FT-70. This switch must be turned on to enable the X-ray Generator. Other than for an emergency there is no need to turn the Safety Interlock Switch off.
Page 101: Selecting The Ft-70'S Operating Mode
FT-70 Fill Level Inspector Service Manual Selecting the FT-70’s Operating Mode There are two modes of operation for the FT-70: • The Operate Mode limits the operator's access to those functions where no parameter value changes can be made. The Operate Mode is the normal operating mode for the FT-70.
Page 102: Software Functions List
Chapter 5: System Software Software Functions List There are six function groups, each corresponding to a key on the control panel. In the following table: • A function denoted with the (*) symbol indicates it is available in the Operate Mode. •...
Page 103 FT-70 Fill Level Inspector Service Manual Function Group Function Name Parameter Default ° Width At Down Can 1-250 mm 79 mm ° Height of Can 1-250 mm 125 mm ° Dia. Missing Lid Width 1-65,000 Pulses: Updating Constantly Updating Constantly Updating Last Reject °...
Page 104 Chapter 5: System Software 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 System Display Calibrate/Operate Operate ° Conveyor Drive Sprocket 18-29 Teeth 25 Teeth °...
Page 105 FT-70 Fill Level Inspector Service Manual Function Group Function Name Parameter Default ‡ Current Language English English Portuguese Spanish German French Italian ‡ Container Text 10 Characters Maximum ‡ # Of Container Types 1-32 ‡ Current Container Type ‡ Container Type Text 17 Characters Maximum ‡...
Page 106 Chapter 5: System Software Function Group Function Name Parameter Default ‡ External Trigger Logic Remote Clear Of Error/ Remote Clear External Reject ‡ Known Chain Pitch & Teeth Present/Not Present Present ‡ Encoder Resolution 500/5000 Pulse 500 Pulse ‡ Save Default Constants Execute ∞...
Page 107: Function Descriptions
FT-70 Fill Level Inspector Service Manual Function Descriptions The following section contains function descriptions for each function group. Depending upon your FT-70 machine type, machine conﬁguration, and options package, some of these options may not apply to your FT-70. Certain functions are available only while in the Calibrate Mode or when dip switch S1-5 is open.
Page 108: Underfill Status
Chapter 5: System Software Underﬁll Status This function activates or deactivates the underﬁll inspection capability of the FT-70. Deactivating this function inhibits detection and rejection of containers with ﬁll levels below the underﬁll X-ray Threshold. Underﬁll and Overﬁll can not be active simultaneously.
Page 109: X-Ray Threshold
FT-70 Fill Level Inspector Service Manual X-ray Threshold Establishes the threshold value that the X-ray Counts must: • exceed for underﬁll rejection • not exceed for overﬁll rejection Any x-ray count value that falls outside of the X-ray Threshold triggers a rejection. Looktime Gate The time in milliseconds during which X-ray Counts are recorded for each container.
Page 110: Container Finish Functions Group
Chapter 5: System Software Container Finish Functions Group Bulged End Status Activates or deactivates Bulged End detection. Bulged End detection is based on the difference between the height of the container with a properly sealed lid and the height of the container with an improperly sealed or bulged lid.
Page 111: Diameter Missing Lid Width
FT-70 Fill Level Inspector Service Manual Diameter Missing Lid Width The container’s lid diameter translated into encoder pulses. In simpliﬁed terms this is 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 deﬁnes the diameter of a container with a lid.
Page 112: Counter Functions Group
Chapter 5: System Software Counter Functions Group The Counters record operational and performance data about the FT-70 and the production line it is operating on. This data is useful for plant performance management and for machine maintenance. Here are some other issues you should be aware of: •...
Page 113: Total Bulged End
FT-70 Fill Level Inspector Service Manual Total Bulged End The total number of containers that were detected with bulged ends. The counter automatically resets at 99,999,999. Total Down Can The total number of down containers that were detected. The counter automatically resets at 99,999,999. Total Dia.
Page 114: Reset Total Rejects
Chapter 5: System Software Reset Total Rejects Clears and resets the Total Rejects counter to zero. Record all valuable data before executing this function. To reset the Total Rejects: 1. Press Key 3 until RESET TOTAL REJECTS appears. 2. Press the Arrow Key to execute. Reset Total Underﬁll Clears and resets the Total Underﬁll counter to zero.
Page 115: Reset Total Bulged End
FT-70 Fill Level Inspector Service Manual Reset Total Bulged End Clears and resets the Total Bulged End counter to zero. Record all valuable data before executing this function. To reset the Total Bulged End: 1. Press Key 3 until RESET BULGED END appears. 2.
Page 116: Rejector Functions Group
Chapter 5: System Software Rejector Functions Group Rejector Status Disables or enables the reject signal transmitted by the FT-70 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 117: Inspect Trig To C/L Rej
FT-70 Fill Level Inspector Service Manual Inspect Trig To C/L Rej The distance in millimeters from the centerline of the inspection trigger beam to the centerline of the rejector pad. This value is required to establish the proper time for the rejector to actuate so the centerline of the rejector pad impacts the centerline of the container.
Page 118: System Functions Group
Chapter 5: System Software System Functions Group Current Container Type The container type that is currently being inspected. This function is only available if machine is conﬁgured for multiple container types. To select the Current Container Type: 1. Press Key 5 until CURRENT CONTAINER TYPE appears. 2.
Page 119: Line Speed (Cph)
FT-70 Fill Level Inspector Service Manual Line Speed (cph) The speed of the production line measured by cph (containers per hour). The measurement is the number containers that intercept the FT-70’s trigger beam in 60 minutes. To calculate cph use the following formula: ×...
Page 120: Host/Modbus Port Status
Chapter 5: System Software Host/Modbus Port Status Displays the character information in a Modbus serial communi- cation string. The counters have a range of 0-255 and then reset. • LC is the last character that was received by the FT-70. •...
Page 121: Time Width Of Can
FT-70 Fill Level Inspector Service Manual Time Width Of Can The time in milliseconds it takes the container to pass through the trigger beam. See also Looktime Gate. To change the Time Width of Can value: 1. Press Key 5 until TIME WIDTH OF BOTTLE appears. 2.
Page 122: Alarm Bulged End
Chapter 5: System Software Alarm Missing Lid The minimum number of consecutive missing lid rejects that will trigger an alarm condition. The count is reset to zero when a good container is detected. This function can alert you to seamer or sealer malfunctions.
Page 123: Can Width At Trig
FT-70 Fill Level Inspector Service Manual Can Width At Trig The container’s width in millimeters at the point where it inter- cepts the trigger beam as it travels on the conveyor. This value is required to establish the proper time for the rejector to actuate so the centerline of the rejector pad impacts the centerline of the container.
Page 124: View Tb1 & Tb4 Pin Assignments
Chapter 5: System Software 6. After the new password is entered, the FT-70 takes a few seconds to store the new password. When the change is ﬁnished, the COMPLETED message appears. 7. Open dip switch S1-8. The Password Option is now activated. You will be required to enter the password whenever you attempt to enter the Calibrate Mode.
Page 125: View Plc Pin Assignments
FT-70 Fill Level Inspector Service Manual View PLC Pin Assignments Displays the PLC signal wiring assignments. It also lists the normal voltage levels associated with the signals. For more infor- mation, see Chapter 9: Using a PLC With Your FT-70 for more information.
Page 126: Of Container Types
Chapter 5: System Software # of Container Types The maximum number of different container types that will be inspected by this FT-70. The maximum number allowed is deter- mined by available system memory. The value entered for this function determines the number of Current Container Types available.
Page 127: Underfill Text
FT-70 Fill Level Inspector Service Manual Underﬁll Text Allows you to create a custom name for the Underﬁll Inspection Option. Any instance in which “Underﬁll” would have appeared in the software, is replaced by the custom label you created. The following options are effected: •...
Page 128: Missing Lid
Chapter 5: System Software Note This manual assumes the default name for this option. If you change the default text remember to substitute the new name when reading this manual. To avoid confusion record the change in the manual. To create a name: 1.
Page 129: Bulged End
FT-70 Fill Level Inspector Service Manual To create a name: 1. Press the Arrow Key until the desired character appears. 2. Press Key 6 to advance to the next space. 3. Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text.
Page 130: Down Can
Chapter 5: System Software 3. Repeat steps 1 and 2 until you complete the entry and then press Key 5 once to enter the text. Down Can Prepares the FT-70 software for down can inspection by inserting the necessary options into the software. When set to Not Present it removes the options necessary for down can inspection from the software.
Page 131: Diameter Missing Lid
FT-70 Fill Level Inspector Service Manual Diameter Missing Lid Prepares the FT-70 software for Diameter Missing Lid inspection by inserting the necessary options into the software. When set to Not Present it removes the options necessary for Diameter Missing Lid inspection from the software. This function does not activate or deactivate diameter missing lid inspection, it only readies the machine.
Page 132: External Reject
Chapter 5: System Software External Reject Prepares the FT-70 software for external reject inspection by inserting the necessary options into the software. When set to Not Present it removes the options necessary for external reject inspection from the software. This function does not activate or deactivate external reject inspection, it only readies the machine.
Page 133: Plc Series Alarms
FT-70 Fill Level Inspector Service Manual PLC Series Alarms Activates or deactivates the PLC Series Alarms Function. If set to PRESENT, the following options are activated: • PLC Output Pulse Width • Alarm Series Underﬁlls • Alarm Series Overﬁlls • Alarm Series Missing Lid •...
Page 134: Encoder Resolution
Chapter 5: System Software Encoder Resolution Selects the resolution of the encoder installed in your system. The Standard High Resolution Encoder is 500 pulse. The Ultra High Resolution Encoder is 5000 pulse, and is required when using the Diameter Missing Lid option. Save Default Constants Saves the current operating conﬁguration to nonvolatile memory.
Page 135: X-Ray Sample Cutoff Limit
FT-70 Fill Level Inspector Service Manual X-ray Sample Cutoff Limit This value is calculated automatically during the encoder calibration. The normal value range is 3 to 4 and should be equal to or 1 more than the number of X-ray Samples Per Encoder when using a high speed production line.
Page 136: Diagnostics Function Group
Chapter 5: System Software Diagnostics Function Group Displays the current diagnostic error. Clearing the error stops the warning beacon from ﬂashing and the Remote Alarm PLC output signal. How to Access Diagnostic Error Codes Note Do not use the Reset Switch to clear diagnostic errors. To view the error: 1.
Page 137: Diagnostic Error Codes Listing
FT-70 Fill Level Inspector Service Manual Diagnostic Error Codes Listing The following list contains the FT-70 error codes. Depending upon your machine type, some of these errors may not apply to your FT-70. For complete error descriptions, see Chapter 8. No Diagnostic Error Rejector Status Is Off Consecutive Reject Queue Error...
Page 138 Chapter 5: System Software Reject Queue Count Abnormally Large Container Detected Reject Delay Position Error Fill Level Reject Detection is Turned Off During Inspection Diameter Missing Lid Error-Exceeded Consecutive Reject Limit Diameter Missing Lid Error-No Encoder Pulse Production Line Speed Too High BBU RAM Batter is Low Broken Slat Or Pin Broken Slat Sensor Failure...
Page 140 Chapter 6: Calibration Procedures Chapter Six: Calibration Procedures FT-70 Calibration Procedures ....... . 6-3 Encoder Calibration Procedures .
Page 142: Ft-70 Calibration Procedures
Chapter 6: Calibration Procedures FT-70 Calibration Procedures The calibration procedures 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 Calibration • Radiation Detector Calibration Industrial Dynamics Company, Ltd.
Page 143: Encoder Calibration Procedures
FT-70 Fill Level Inspector Service Manual Encoder Calibration Procedures The encoder calibration method you will use is based upon whether your production conveyor is variable speed or ﬁxed speed. Variable Speed Conveyors Variable speed conveyors require a high resolution encoder that is coupled directly to the conveyor drive sprocket.
Page 144: Variable Speed Conveyors
Chapter 6: Calibration Procedures Variable Speed Conveyors If your FT-70 is installed on a variable speed conveyor line, you must also install the High Resolution Encoder. The encoder attaches to the conveyor and sends timing pulses to the FT-70. The FT-70 uses these timing pulses to synchronize all inspection and rejection activities with the production conveyor’s speed.
Page 145: Conversion Factors
FT-70 Fill Level Inspector Service Manual Conversion Factors The following formulas may be helpful when performing the calibration procedures: Converting inches to millimeters: × 25.4 inches millimeters Converting feet per minute to meters per minute: × 3.28 feet ˙ meters Calculating containers per minute (cpm): containers per hour -------------------------------------------------- -...
Page 146: Before You Begin
Chapter 6: Calibration Procedures Before You Begin 1. Remove the FT-70’s cover to access dip switch pack S1. When performing the calibration procedures you are required to change the settings for S1-5 and S1-6. 2. Determine which calibration procedure to follow, do the following: •...
Page 147: Standard Conveyor Calibration Procedure
FT-70 Fill Level Inspector Service Manual Standard Conveyor Calibration Procedure Use this procedure if you have a standard conveyor with a 1.5-inch chain pitch and you know the number of teeth on the sprocket directly contacting the underside of the main production transport chain.
Page 148 Chapter 6: Calibration Procedures 9. Press Key 4 until INSPECT TRIG TO C/L REJ appears and use the Arrow Key to enter the measurement in millimeters. 10. Measure the diameter of the production container (in milli- meters) at the point where the container intersects the trigger beam.
Page 149 FT-70 Fill Level Inspector Service Manual 19. To verify the calibration 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 a number such as 6 or higher to provide enough attempts to make adjust- ments.
Page 150 Chapter 6: Calibration Procedures If the reject is late, check to be sure the encoder coupling is not slipping. Try a rejection with a thin layer of grease on the pad. If the resulting mark in the grease starts in the upstream third of the pad face and is centered, then performance is acceptable.
Page 151 FT-70 Fill Level Inspector Service Manual 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 speeds). 6-12 Industrial Dynamics Company, Ltd.
Page 152: Unknown Sprocket Size Calibration Procedure
Chapter 6: Calibration Procedures Unknown Sprocket Size Calibration Procedure Use this procedure to calibrate standard conveyors with a 1.5-inch pitch, but you don’t know the number of teeth on the sprocket directly contacting the underside of the main production transport chain.
Page 153: Executing The Encoder Calibration Routine
FT-70 Fill Level Inspector Service Manual 9. Press Key 5 until CAN WIDTH AT TRIG appears and enter (in millimeters) the production container’s width at the trigger point. 10. Measure the diameter of the container (in millimeters) at its widest point. This is the containers maximum diameter. 11.
Page 154: Fine-Tuning The Rejector Timing
Chapter 6: Calibration Procedures 16. Run the container 16 times (it is not necessary for the containers to pass the rejector), through the FT-70 inspection tunnel without slippage. When ﬁnished, the FT-70 automati- cally completes the encoder calibration calculations, including the Calibrate Encoder Value, Encoder Prescaler Value, Gamma Sample Cutoff Limit, and Conveyor Drive Sprocket Teeth.
Page 155 FT-70 Fill Level Inspector Service Manual 24. With the conveyor running very slowly so the reaction delay does not effect the result, place a production container upstream of the FT-70 so that it passes through the FT-70 without slipping. If the container appears to make contact on the upstream third of the rejector pad, proceed to step 26.
Page 156 Chapter 6: Calibration Procedures 28. Press Key 5 until CHAIN VELOCITY appears. Note this value because you need to enter it in the following step. 29. Press Key 5 until MAXIMUM CONVEYOR SPEED appears and enter the CHAIN VELOCITY value from the previous step.
Page 157: Non-Standard Conveyor Calibration Procedure
FT-70 Fill Level Inspector Service Manual Non-Standard Conveyor Calibration Procedure Use this procedure for conveyors that do not have a 1.5-inch chain pitch. You must determine the conveyor’s chain pitch and number of teeth per chain segment/link to use this procedure. If you can not determine the chain pitch and number of teeth per chain segment/link call IDC Customer Support for assistance at: •...
Page 158 Chapter 6: Calibration Procedures 7. Determine your Conveyor Segment Pitch. This information is part of your conveyor manufacture’s speciﬁcations. If the speciﬁcations are not available, measure (in millimeters) 10 conveyor segments (plates) and divide the measurement by 10. 8. Press Key 5 until CONVEYOR SEGMENT PITCH appears and use the Arrow Key to enter the Conveyor Segment Pitch.
Page 159: Executing The Encoder Calibration Routine
FT-70 Fill Level Inspector Service Manual Executing the Encoder Calibration Routine Use the largest possible opaque container when executing the Calibrate Encoder Routine. The larger and more opaque the container, the greater the accuracy of the sensor readings. For example, if the test container diameter is 28 mm, the calculation error factor is ±...
Page 160: Fine-Tuning The Rejector Timing
Chapter 6: Calibration Procedures Fine-Tuning the Rejector Timing To ﬁne-tune the calibration accuracy you may need to adjust the number of sprocket teeth estimated during the Calibrate Encoder Routine. Experiment with a production container and observe the rejector timing. Based on where the rejector pad contacts the container, you must increase or decrease the number of teeth until the can contacts the pad correctly.
Page 161 FT-70 Fill Level Inspector Service Manual 29. Run the conveyor at the same speed as in step 20 and place a can on the conveyor far enough upstream so that it does not slip on the conveyor as it passes through the FT-70. If the reject is late, check to be sure the encoder coupling is not slipping.
Page 162 Chapter 6: Calibration Procedures 37. If you are using this production line to produce more than one type of container, you must repeat this procedure for each different container type (i.e. containers with different diameters, or line speeds). Industrial Dynamics Company, Ltd. © Form 40256-0600 6-23...
Page 163: Fixed Speed Conveyors
FT-70 Fill Level Inspector Service Manual Fixed Speed Conveyors If your FT-70 is installed on a ﬁxed speed conveyor, you will use the Line Speed Calibration Procedure to synchronize your FT-70 and rejector. The Line Speed Calibration Procedure allows an FT-70 that is not equipped with a High Resolution Encoder to perform down can inspection on ﬁxed speed conveyor lines.
Page 164: The Line Speed Calibration Procedure
Chapter 6: Calibration Procedures 4. You must also remove the FT-70’s cover to access dip switch pack S1. When performing the calibration procedure you are required to change the settings for S1-5. The Line Speed Calibration Procedure 1. Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode.
Page 165: Fine Tuning The Rejector Timing
FT-70 Fill Level Inspector Service Manual 11. Press Key 5 until MAXIMUM LINE SPEED appears and enter the line speed (in cpm) for the container in use. The program assumes 12 mm container spacing in order to perform prelim- inary calculations. 12.
Page 166 Chapter 6: Calibration Procedures 17. Examine the marking in the grease. If your calibration procedure was accurate, the mark will be close to the center of the pad. If the mark is off, adjust the Millimeter Translation Value as follows: •...
Page 167: Sensors Calibration Procedures
FT-70 Fill Level Inspector Service Manual Sensors Calibration Procedures The FT-70 contains two types of sensors: • Proximity • Fiber-Optic Proximity Sensors Proximity sensors use an electromagnet to detect the presence of metallic objects, such as aluminum, tin, and steel. Proximity sensors do not require calibration.
Page 168: Calibrating The Centerline Inspection Trigger
Chapter 6: Calibration Procedures Calibrating the Centerline Inspection Trigger 1. Be sure there is no object blocking the inspection trigger beam. 2. Turn the Offset Adjustment clockwise until the Output Contrast LED reaches 10 and then turn the adjustment counter- clockwise until the LED drops to 5.
Page 169: Calibrating The Upstream Inspection Trigger
FT-70 Fill Level Inspector Service Manual Calibrating the Upstream Inspection Trigger 1. Clear the Upstream Inspection Trigger beam of any containers so that it is not blocked. 2. Remove the ampliﬁer cover and set the Operation Mode Selector to Dark (D). SENS Description Sensitivity Adjustment...
Page 170: Calibrating The Bulged End Sensor
Chapter 6: Calibration Procedures Calibrating the Bulged End Sensor Note Refer to Figure 6-2 when performing this procedure. 1. Clear the inspection tunnel of any containers so the trigger beam is not blocked. 2. Remove the ampliﬁer cover and set the Operation Mode Selector to Dark (D).
Page 171: Calibrating The Down Can Sensor
FT-70 Fill Level Inspector Service Manual Calibrating the Down Can Sensor Note Refer to Figure 6-2 when performing this procedure. 1. Clear the inspection tunnel of any containers so the trigger beam is not blocked. 2. Remove the ampliﬁer cover and set the Operation Mode Selector to Dark (D).
Page 172: Radiation Detector Calibration Procedure
Chapter 6: Calibration Procedures Radiation Detector Calibration Procedure The radiation sensor contained in the FT-70 is one of two types: • Solid State Detector (SSD) • Scintillation Tube Detector (STD) Solid State Detector 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.
Page 173: Calibrating The Scintillation Tube Detector
FT-70 Fill Level Inspector Service Manual Calibrating the Scintillation Tube Detector The calibration procedure uses the Calibration LED on the Calibration Board as an adjustment reference. Scintillation Detector Calibration Procedure 1. Clear the inspection tunnel of all containers so that nothing is blocking the x-ray inspection beam.
Page 174 Chapter 6: Calibration Procedures 4. Slowly turn the High Voltage Output Adjustment. The STD Calibration LEDs will rise until they peak and then begin to fall. Stop precisely when the LEDs begin to fall. 5. The peak, the point immediately before the LEDs begin to fall, is the proper calibration point.
Page 175: Fill Level Optimization
FT-70 Fill Level Inspector Service Manual Fill Level Optimization Fill Level Optimization is used to increase ﬁll level inspection accuracy for applications that require higher accuracy than is achieved through normal ﬁll level inspection parameters. It narrows the margin between acceptable and rejectable containers. Fill Level Optimization should only be used when performing underﬁll inspection.
Page 176: Leveling The Inspection Head
Chapter 6: Calibration Procedures Leveling the Inspection Head It is critical that you level the Inspection Head over the production line. If the head is not level, you will not achieve ﬁll level optimization. 1. Place a small carpenter's level along the bottom of the FT-70 so that it spans the inspection tunnel.
Page 177: Executing The Fill Level Optimization Routine
FT-70 Fill Level Inspector Service Manual Executing the Fill Level Optimization Routine The optimization routine steps you through the following options. All options are contained under Key 1 while in the Calibrate Mode. • Fill Level Optimization • Learn Target Head Height •...
Page 178 Chapter 6: Calibration Procedures 10. Lower the x-ray beam into the liquid very slowly. When the average x-ray counts reach the midpoint of the Static Full and Static Empty values, the system beeps and displays: @MIDPOINT, CONTINUE SLOWLY, LOWER INSP. HEAD 11.
Page 179: Establishing The Target Head Height
FT-70 Fill Level Inspector Service Manual Establishing the Target Head Height 1. Press Key 1 to begin the Learn Target Head Height procedure. 2. Precisely center a 100 percent reject container in the inspection tunnel and then press any key to continue. 3.
Page 180: The Dynamic Product Good Test
Chapter 6: Calibration Procedures 4. When the test is completed the Dynamic Reject Margin is displayed. The margin is typically 2-3 sigma. If the sigma is out of this range, you may be instructed to repeat the test at a lower setting.
Page 181: The Review Fill Level Test
FT-70 Fill Level Inspector Service Manual The Review Fill Level Test The Review Fill Level Test records and displays all values calcu- lated during the Fill Level Optimization Routine. Press the Arrow Key to scroll through the list when you need to review the following settings: •...
Page 182 Chapter 7: Maintenance Procedures Chapter Seven: Maintenance Procedures Maintenance Schedules ........7-3 Daily Schedule .
Page 184: Maintenance Schedules
Chapter 7: Maintenance Procedures Maintenance Schedules Daily Schedule Action Description Inspect/Clean Trigger Beam Emitter and Receiver lenses Inspect/Clean Trigger Beam Emitter and Receiver lenses Inspect/Clean Down Can Beam Emitter and Receiver lenses Inspect/Clean Bulged End Beam Emitter and Receiver lenses Weekly Maintenance Action Description...
Page 185: Day Maintenance
FT-70 Fill Level Inspector Service Manual 120 Day Maintenance Action Description Inspect Nameplate, Stickers, and Instruction Plates Service Pneumatic components per Rejector Manual Inspect Inspection Head Housing for dirt and moisture Inspect Wiring, insulation, terminals, terminal blocks Inspect Source Autoshutter Assembly Inspect X-ray Window for damage blockage.
Page 186: Before You Perform Any Maintenance Procedure
Chapter 7: Maintenance Procedures Maintenance Procedures Before You Perform Any Maintenance Procedure For safety, power down the equipment to be serviced before you begin any maintenance procedure. To power down the rejector turn off the Main Power Switch on the Junction Box. Trigger Beam and Emitter Lenses 1.
Page 187: The Ft-70 Housing
FT-70 Fill Level Inspector Service Manual The FT-70 Housing 1. Inspect for damage to metal housing and for wear on the cover gaskets. 2. Check to be sure the cover is securely tightened 3. Clean using a non-caustic nonabrasive soap, water, and a soft brush.
Page 188: Replacing The Rejector Pad
Chapter 7: Maintenance Procedures Replacing the Rejector Pad The actual lifespan of the rejector pad depends upon the operating conditions of your production line. Inspect the pad weekly and replace if worn, cracked, or hardened. Warning Turn off all power to your system before attempting any repair procedure.
Page 189: Servicing The Regulator And Coalescing Air Filters
FT-70 Fill Level Inspector Service Manual Servicing the Regulator and Coalescing Air Filters Servicing the air ﬁlter consists of cleaning and/or replacing the air ﬁlter, sediment bowl, and gasket. You can obtain replacement parts for these items from the air controls manufacturer. Warning Turn off all power to your system before attempting any repair procedure.
Page 190 Chapter 8: Diagnostic and Repair Procedures Chapter Eight: Diagnostic and Repair Procedures Diagnostic Error Messages ........8-3 Error Number 2 .
Page 191 FT-70 Fill Level Inspector Service Manual Error Number 125 ........8-13 Error Number 126 .
Page 192: Diagnostic Error Messages
Chapter 8: Diagnostic and Repair Procedures Diagnostic Error Messages The amber Warning Beacon on top of the inspection head signals an alarm or error condition by blinking rapidly. 1. Press the Key 6 to view the error number in the LCD. 2.
Page 193: Error Number 9
FT-70 Fill Level Inspector Service Manual Error Number 9 The write to EEPROM was not successful. This error indicates that either switch S11 is not set to the Write Enabled position or that EEPROM chip U29 is faulty. To correct this error: •...
Page 194: Error Number 15
Chapter 8: Diagnostic and Repair Procedures Error Number 15 The missing cap sensor input state logic level remains high. This occurs when two or more consecutive signals are received from the trigger beam, which indicates containers are passing through the unit, and no signals are received from the missing cap sensor.
Page 195: Error Number 23
FT-70 Fill Level Inspector Service Manual Error Number 23 This error occurs when an extra encoder pulse is detected. This error can occur when the conveyor stops or starts suddenly. To correct this error: • Check LED 3 and the signal at TB1-23 while the conveyor is running.
Page 196: Error Number 27
Chapter 8: Diagnostic and Repair Procedures Error Number 27 Containers are passing the inspection station, but the encoder is not sending pulses: at least 5 consecutive inspection triggers occurred without sensor transition. To correct this error: • Check the voltage at P6-2. The signal voltage should be between 0-12 volts.
Page 197: Error Number 48
FT-70 Fill Level Inspector Service Manual Error Number 48 The AC input voltage dropped below 90 volts on a 110 VAC system or below 185 volts on a 220 VAC system. During the time the voltage was low, no containers were inspected for any defect. When the power returns to normal, the system resets with no data being lost.
Page 198: Error Number 52
Chapter 8: Diagnostic and Repair Procedures Error Number 52 A container passed the trigger in less than 10ms. This can be caused by trigger reﬂections or line jams. To correct this problem: Adjust the gain on the trigger ampliﬁer. Error Number 53 The Reject Watchdog detected a queue error.
Page 199: Error Number 68
FT-70 Fill Level Inspector Service Manual Error Number 68 No encoder pulses were received for the Diameter Missing Cap Width function. Make sure switch S05 is in the “A” position and jumper S12 is in the “AB” position. This error condition is low priority and will not cause the Warning Beacon to ﬂash during HIGH PRIORITY ONLY operation.
Page 200: Error Number 117
Chapter 8: Diagnostic and Repair Procedures Error Number 117 This error condition indicates there is a Host or MODBUS Serial Interface Framing Error or Reply Timeout (timeout must be a minimum of 15 seconds.) Most communication errors are caused by excessive noise. Check the termination of RX input.
Page 201: Error Number 119
FT-70 Fill Level Inspector Service Manual Error Number 119 This error indicates a host or Modbus serial parity error occurred. To correct this error, check the parity setting which is controlled by dip switches S2-3 and S2-4: • S2-3 closed = no parity •...
Page 202: Error Number 123
Chapter 8: Diagnostic and Repair Procedures Error Number 123 The X-ray Status Function is turned off. Turn the status back on to activate x-ray generator. Error Number 124 X-ray Source Disabled through external input connected to pin TB4-5. Error Number 125 X-ray Generator failure detected during warm-up cycle and the generator will not activate.
Page 203: Major Component Subsystems
FT-70 Fill Level Inspector Service Manual Troubleshooting Procedures The troubleshooting procedures in this section are designed to help you isolate machine malfunctions and determine the proper corrective action. Once you determine the problem source, you will be directed to the appropriate corrective procedures that are contained in other sections of this manual.
Page 204: What You Should Do Before In-Depth Troubleshooting
Chapter 8: Diagnostic and Repair Procedures What You Should Do Before In-Depth Troubleshooting Before you begin detailed and time consuming troubleshooting methods check the following items ﬁrst. These are simple things that are often overlooked, but can cause a wide range of system problems: 1.
Page 205: Main Power System Troubleshooting
FT-70 Fill Level Inspector Service Manual Main Power System Troubleshooting Power supply instability and failures account for many malfunc- tions. We recommended testing the power supply voltages as a starting point when troubleshooting. You need a digital voltmeter with an impedance of at least 20,000 ohms per volt to perform these procedures.
Page 206: Testing The Power Transformer
Chapter 8: Diagnostic and Repair Procedures Testing the Power Transformer If the power supply is not functioning, the failure may be caused by the loss of input power. If the input power is missing, test the power transformer. 1. Turn off all power to the FT-70. 2.
Page 207: X-Ray System Troubleshooting
FT-70 Fill Level Inspector Service Manual X-ray System Troubleshooting Testing the X-ray Generator If the X-ray Generator is not generating, begin troubleshooting by verifying the following: 1. Is the X-ray Source Function set to Present and the X-ray Status Function turned on? •...
Page 208: X-Ray Generator Troubleshooting Flowchart
Chapter 8: Diagnostic and Repair Procedures X-ray Generator Troubleshooting Flowchart Green = On Yellow = Off = Off Green = On Verify X-ray No change Yellow = Off Status is in LEDs. = On turned on. Check enable signal. See Verify Generator is the Enable Signal functioning...
Page 209: Verify The Enable Signal At Px-1
FT-70 Fill Level Inspector Service Manual Verify the Enable Signal at PX-1 1. Remove connector PX-1 and insert the tester point into pin 9. 2. Press Key 1 until X-RAY STATUS appears and press the Arrow Key to turn the function on. If the tester indicates the signal is received, the generator is malfunctioning and must be replaced.
Page 210: How To Replace The X-Ray Generator
Chapter 8: Diagnostic and Repair Procedures How to Replace the X-ray Generator 1. Shut down the main power to the FT-70 and remove the FT-70’s cover to gain access 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.
Page 211 FT-70 Fill Level Inspector Service Manual 3. Disconnect the power cable from the x-ray generator. Figure 8-4. Disconnect the power cable from the generator. 8-22 Industrial Dynamics Company, Ltd. © 40256-0600...
Page 212 Chapter 8: Diagnostic and Repair Procedures 4. Remove the x-ray generator and the generator insulator that is between the generator and the chassis. Description Generator Generator Insulator Power Cable Connector PX-1 Power Supply Board Insulator Power Supply Board Figure 8-5. Remove the x-ray generator.
Page 213 FT-70 Fill Level Inspector Service Manual Caution The board and generator are a matched set and must be replaced as a unit. If you do not replace both the components together, damage to the FT-70 could result. 7. Replace the power supply board insulator with the new insulator provided in the replacement kit and install the new power supply board.
Page 214 Chapter 8: Diagnostic and Repair Procedures 9. Secure the generator with the eight securing screw. 10. Connect the new generator power supply cable provided in the replacement kit to the power supply board and to the generator. 11. Reconnect connector PX-1 to the power supply board. 12.
Page 215: Main Processor Card Troubleshooting
FT-70 Fill Level Inspector Service Manual Main Processor Card Troubleshooting 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. LED 12 Figure 8-7.
Page 216: Replacing The Software Proms
Chapter 8: Diagnostic and Repair Procedures Replacing the Software PROMs. The software PROMs must be replaced as a set. Each PROM is labelled as either U25 or U26. 1. Locate PROMs U25 and U26. These are the PROMs that contain the machine software. 2.
Page 217: The Display Shows A Blinking Cursor And The Beacon Is On
FT-70 Fill Level Inspector Service Manual The display shows a blinking cursor and the beacon is on 1. Check to be sure the reset switch is not stuck. 2. Check to be sure all PROMs on the processor card are seated properly.
Page 218: Sensor System Troubleshooting
Chapter 8: Diagnostic and Repair Procedures Sensor System Troubleshooting Scintillation Tube Detector (STD) Unable to calibrate the Scintillation Tube Detector If the calibration LED does not double peak during the calibration procedure, the detector is faulty and must be replaced. See Chapter 6: FT-70 Calibration Procedures for more information.
Page 219: Proximity Sensors: No Triggering Occurs
FT-70 Fill Level Inspector Service Manual • If the detector power supply is off, the detector is not getting power from the Main Power Supply Board. Test the Main Power Supply Board. • If the detector power supply led is green, the power supply is functioning properly.
Page 220: Rejector Troubleshooting
Chapter 8: Diagnostic and Repair Procedures Rejector Troubleshooting This section provides only basic rejector troubleshooting for the Proline and Servotec rejectors. For detailed information, or for information on other rejectors, refer to the appropriate rejector manual. Proline Rejector Troubleshooting The rejector is operating erratically 1.
Page 221: The Rejector Does Not Function
FT-70 Fill Level Inspector Service Manual The rejector does not function 1. Is the rejector activated? Turn the Rejector Status function on. 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 222: Containers Are Not Rejected
Chapter 8: Diagnostic and Repair Procedures 6. Verify the 4-Way Valve coil's resistance is within the range listed below, and replace if necessary: Low Limit Nominal High Limit 147.6 Ohms 164.0 Ohms 180.4 Ohms Note If intermittent or erratic rejector operation continues, contact Industrial Dynamics Customer Service for assistance.
Page 223: Containers Are Rejected Erratically
FT-70 Fill Level Inspector Service Manual Containers are rejected erratically Time Delay is incorrectly set 1. Pass reject test container through the inspector and observe the time delay synchronization. The rejector pad's centerline should contact the container’s centerline at the point of impact. 2.
Page 224: Chapter Nine: Using A Plc With Your
Chapter 9: Using a PLC With Your FT-70 Chapter Nine: Using a PLC With Your FT-70 Using a PLC With Your FT-70 ....... 9-3 PLC Series Alarms .
Page 226: Using A Plc With Your
Chapter 9: Using a PLC With Your FT-70 Using a PLC With Your FT-70 Programmable Logic Control (PLC) signals are provided by AC or DC optically isolated solid-state Relays. The FT-70 has separate PLC signals with a programmable pulse width (1-120 milli- seconds) that transmits one pulse for each event.
Page 227: Plc Series Alarms
FT-70 Fill Level Inspector Service Manual PLC Series Alarms To conﬁgure your FT-70 for operation with a PLC you must activate the PLC Series Alarms functions in the FT-70’s software. To activate the PLC Series Alarms: 1. Open dip Switch S1-5 to enter the System Conﬁguration 2.
Page 228: How To Determine The Signal Output Wiring
Chapter 9: Using a PLC With Your FT-70 How to Determine the Signal Output Wiring The View PLC Pin Assignments Function lists the conﬁguration of the PLC outputs for your FT-70. It also lists the normal voltage levels associate with the signals. To view the PLC pin assignments: 1.
Page 229: Relay Types For Output Signals
FT-70 Fill Level Inspector Service Manual Relay Types for Output Signals The FT-70 does not supply power to the PLC unit. The FT-70 signal output is a solid-state relay that closes upon each event occurrence. Description Relay Type Sensor/X-ray Failure Alarm Reed Latched Consecutive Alarms Reed...
Page 230 Chapter 9: Using a PLC With Your FT-70 No. Description Field Diode must be used on inductive loads Screw Terminals Plug-in Module Equivalent Circuit Only Ampliﬁer Pins Sockets in Mounting Rack Pull-up Resistor Edge Connector Logic L.E.D. Input 3.3K Ground (Common) Mounting Rack Fuse (Plug-in) Load (Connected to either the positive or...
Page 231: Remote Alarm
FT-70 Fill Level Inspector Service Manual Remote Alarm The FT-70 Remote Alarm option uses the Diagnostic Error signals to latch (hold LOW or SINK) the appropriate PLC output lines. Each Remote Alarm is initiated by a diagnostic error number (or group of error numbers) and remains latched until the diagnostic error number is cleared.
Page 232 Chapter 10: Controller Board Dip Switches and LEDs Chapter Ten: Controller Board Dip Switches and LEDs Controller Board Switch Locations ......10-3 Switch Function Configurations .
Page 234: Controller Board Switch Locations
Chapter 10: Controller Board Dip Switches and LEDs Controller Board Switch Locations 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.
Page 235: Switch Function Configurations
FT-70 Fill Level Inspector Service Manual Switch Function Conﬁgurations The default conﬁguration for each option is indicated in bold. The following table represents the standard FT-70 conﬁguration. Depending upon the options installed in your FT-70 the default conﬁguration may be different. Refer to the System Conﬁguration Sheet located inside the cover of your FT-70 for you speciﬁc factory conﬁguration.
Page 236: Switch Function Definitions
Chapter 10: Controller Board Dip Switches and LEDs Switch Function Deﬁnitions Dip Switch Pack S1 S1-1: Inspection Logic Switches the ﬁll level inspection logic between underﬁll and overﬁll. All ﬁll level text is changed to reﬂect the current logic. The default is underﬁll.
Page 237: Dip Switch Pack S2
FT-70 Fill Level Inspector Service Manual Dip Switch Pack S2 S2-1: Baud Rate Deﬁnes the baud rate (bits per second) for the user serial port (RS-422/423) as either 1200 or 9600. The default is 1200 baud. S2-2: Handshake Flags Enables the use of the Serial Hardware Handshake lines. The default is off.
Page 238: Slide Switches
Chapter 10: Controller Board Dip Switches and LEDs Slide Switches Selects either 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 Auto-Reset function. The default is disable Industrial Dynamics Company, Ltd.
Page 239: Controller Board Led Locations
FT-70 Fill Level Inspector Service Manual 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. LEDs: Figure 10-2. Locating the LEDs on the Controller Board. 10-8 Industrial Dynamics Company, Ltd.
Page 240: Led Logic
Chapter 10: Controller Board Dip Switches and LEDs LED Conﬁgurations The LED assignments below are listed by the Section and Bank. Selecting a Section and Bank is controlled by Dip Switches S2- 7 and S2-8. The multiple banks are necessary to handle the various options available for the FT-70.
Page 241: Section 1, Bank 1: S2-7 = Closed/S2-8 = Closed
FT-70 Fill Level Inspector Service Manual LED Deﬁnitions Section 1, Bank 1: S2-7 = Closed/S2-8 = Closed LED 1 Fault Error Present: The LED is on when there is a Fault Alarm or other error in the system. LED 2 Reject Pulse: Flashes one time for each container rejected.
Page 242: Section 2, Bank 1: S2-7 = Open/S2-8 = Closed
Chapter 10: Controller Board Dip Switches and LEDs Section 2, Bank 1: S2-7 = Open/S2-8 = Closed LED 1 Fault Error Present: The Indicator lights when there is a Fault Alarm or other error in the system. LED 2 Reject Pulse: Flashes one time for each container rejected. LED 3 Low Resolution Encoder Pulse: Flashes once for each pulse.

Filtec FT-70c Service And Technical Reference Manual

Table of Contents

Chapter One: Ft-70 System Overview

Chapter Two: Installation Requirements

Chapter Three: Installing the Ft-70

Chapter Four: Conﬁguring the Ft-70 for Operation

Chapter Five: System Software

Chapter Six: Calibration Procedures

Chapter Seven: Maintenance Procedures

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