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Filtec OV-II Maintenance, Troubleshooting And Service Manual

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OV-II
Maintenance, Troubleshooting
and Service Manual
Document 42600-0905

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Summary of Contents for Filtec OV-II

  • Page 1 OV-II Maintenance, Troubleshooting and Service Manual Document 42600-0905...
  • Page 2 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 3: Table Of Contents

    Table Of Contents Chapter 1: Maintenance Periodic maintenance overview ....... . . 1-1 Periodic maintenance procedure .
  • Page 4 Lamp Enclosure ......... . 3-12 OV-II Maintenance, Troubleshooting and Service Manual...

  • Page 5: Chapter 1: Maintenance

    Chapter 1: Periodic Maintenance PERIODIC MAINTENANCE OVERVIEW This chapter provides guidelines for periodic maintenance on the Omnivision All Surface Empty Bottle Inspector (ASEBI), including the optional Outer Sidewall (OSW) Inspection System. The Omnivision system is designed to operate without requiring intensive amounts of maintenance.
  • Page 6 OV-II Maintenance, Troubleshooting and Service Manual ITEM DAILY MAINTENANCE Purge Air (Suction Pipes) Check for air flow by holding hand in front of suction cups as starwheel rotates past purge ports. Upstream Bottle Washer Check and adjust for proper spray pattern and coverage. If not set properly, causes "false rejects"...

  • Page 7: Weekly Maintenance

    Chapter 1: Periodic Maintenance ITEM DAILY MAINTENANCE OSW Camera Window (on the Check for scratches or other damage. Clean with a camera enclosure) NONCAUSTIC, NONABRASIVE commercially available glass cleaner (such as Windex). Weekly Maintenance ITEM WEEKLY MAINTENANCE Vacuum System Check efficiency of system by seating bottles firmly in all pockets with pressure/vacuum converter running.

  • Page 8: Monthly Maintenance

    OV-II Maintenance, Troubleshooting and Service Manual Monthly Maintenance ITEM MONTHLY MAINTENANCE All starwheels Check as follows: a. Inspect the valve seal ring, located in the bottom of the starwheel hub, for scratches and any other imperfections that would prevent a seal with the valve plate. If excessive wear, scratching or other flaws are encountered, refer to the Chapter 6 for replacement instructions.
  • Page 9 Chapter 1: Periodic Maintenance ITEM MONTHLY MAINTENANCE Guide Assemblies Plastic Wear Check the plastic Bottle Set Plates of the starwheel and the Strips plastic guides on the infeed and outfeed guide assemblies for damage. If the guide assembly plastic wear strips are worn or damaged to the point they interfere with bottle handling, replace them.
  • Page 10 OV-II Maintenance, Troubleshooting and Service Manual ITEM MONTHLY MAINTENANCE Spindle Assembly Check the spindle assembly by removing the starwheel. The Valve Plate should be smooth and free from defects. If it is scratched or worn excessively, it must be replaced. The Valve Plate Assembly must move freely in the vertical direction or it will impart excessive drag to the starwheel.

  • Page 11: Chapter 2: Troubleshooting

    Chapter 2: Troubleshooting Procedures TROUBLESHOOTING PROCEDURES OVERVIEW Many bottle handling and inspection problems can be solved during routine maintenance. If you are experiencing inspection or bottle handling problems, repeat your daily, weekly and monthly routine maintenance as described. Three key areas must work together to achieve optimum machine perfor- mance: bottle handling, inspection, and rejection.
  • Page 12 OV-II Maintenance, Troubleshooting and Service Manual SYMPTOM PROBABLE CAUSE(S) SOLUTION Finish False Reject count is Inspection Head not set to proper Check BOTTLE high. height (13 mm or 0.5 inch above CHANGEOVER the Finish Inspection station) for a REQUIREMENT screen for specific bottle type.

  • Page 13: Bottle Handling Problems

    Chapter 2: Troubleshooting Procedures SYMPTOM PROBABLE CAUSE(S) SOLUTION The OV inspections are not For Finish/Thread Inspection, the Recalibrate starwheel home centered. This problem will image light ring will fall off in position. The Procedure on how appear most on Finish. intensity on one side.
  • Page 14 OV-II Maintenance, Troubleshooting and Service Manual Excessively worn or damaged guide rails may cause bottle handling problems inside the OSW tunnel. NOTE Removing any bottles immediately in front of the OSW System or anywhere between the OSW unit and the main Omnivision during production may cause bottle handling problems and false or missed rejects.
  • Page 15 Chapter 2: Troubleshooting Procedures Bottle Jams at Infeed 1. Check the alignment of the infeed guides as it is possible the guides could have vibrated out of alignment. Realign if necessary. There should be approximately 2.4 to 3 mm (3/32 to 1/8 inch) bottle clearance.
  • Page 16 OV-II Maintenance, Troubleshooting and Service Manual 2. Check the neck and the body guide belts for adjustment. The guide belts must provide the proper pressure to hold the bottles in the starwheel pockets. 3. Low vacuum pressure can cause the bottles to be dropped down onto the diffuser glass disk and jam in the deadplate inspection opening.
  • Page 17 Chapter 2: Troubleshooting Procedures 3. Check the MACHINE CONFIGURATION > MOTOR screen screen for irregular parameter values. Verify the running torque is between 45% to 80%. Heavy bottles will require a setting. 4. Verify that Line Sensors 1 and 2 are functioning properly 5.

  • Page 18: Inspection/Rejection Problems

    OV-II Maintenance, Troubleshooting and Service Manual The signal from the conveyor encoder is used to modulate the drive/brake system and the Down Bottle/Jam functions. The drive/sprocket assembly may be damaged by a loose production chain or by pieces of metal, glass, or other foreign objects caught in the production chain.
  • Page 19 Chapter 2: Troubleshooting Procedures • Heavy embossed lettering or molding • Extreme wedges • Extreme color variations • Prominent seams • Large air bubbles • Thin spots in the heel On the Inner Sidewall: • Protruding glass knobs • Extreme variation in thickness •...
  • Page 20 OV-II Maintenance, Troubleshooting and Service Manual On the Outer Sidewall: • Heavy scuffing • Extreme color variations • Large air bubbles • Heavy embossed lettering or molding • Prominent seams 3. Access the STATUS > REJECT HISTORY screen and watch the DETECT COUNTS on the left for each inspection system.
  • Page 21 Chapter 2: Troubleshooting Procedures 4. When the detect rate is greater than desired but too low for the suspected zone to be easily determined, use the REJECT HISTORY screen which is reached from the SYSTEM DIAGNOSTICS screen. The REJECT HISTORY screen shows which inspection zones (or regions) are the source of the most recent rejects.
  • Page 22 OV-II Maintenance, Troubleshooting and Service Manual 4. Verify the inspection zones are concentric with the bottle bottom image. If they are not, go to the CONTROL > BASE screen and adjust the horizontal and vertical settings as required. 5. Check the Current Detects column to see if any of the inspection zone is detecting more often than other zones.
  • Page 23 Chapter 2: Troubleshooting Procedures If the DETECT for the zone is still too high, then lower the sensitivity by another 25 points. Again, clear the counters, let another 1,000 bottles pass through, and check the reject rate. Repeat this process until the false reject rate is acceptable. 11.
  • Page 24 OV-II Maintenance, Troubleshooting and Service Manual 3. If the false rejects are bottles which are very dark, adjust the LOWER LIMIT to a value below the value of the darkest acceptable bottle. If it is necessary to adjust the LOWER LIMIT to a value below 50, then the image brightness (as controlled by the SETUP BASE CAMERA screen) must be adjusted first.
  • Page 25 Chapter 2: Troubleshooting Procedures Inner Sidewall Inspection Excessive False Rejects 1. If production operation allows turning all ISW rejection OFF, do so using the CONTROL > ISW screen and disable the REJECT ENABLE function. (Set to 0.) 2. If it is not possible to turn all ISW rejection OFF, disable the REJECT STATUS of the individual regions which appear to be a problem.
  • Page 26 OV-II Maintenance, Troubleshooting and Service Manual 8. Observe the Detect Sensitivity and the LAST DETECT functions. They indicate the relative strength of the detected object in terms of the number of detection points. It goes up as the size and/or the darkness of the object increases.
  • Page 27 Chapter 2: Troubleshooting Procedures Typically, the LOWER LIMIT value will be set to 1800. The LIGHT LEVEL values of the rejected bottles will be held under the heading LAST DETECT. Normal bottles should have Light Level readings ranging from 2400 to 4200. 1.
  • Page 28 OV-II Maintenance, Troubleshooting and Service Manual Infrared Residual Liquid Detection (IR RLD) Excessive False Rejects There is no visual display for IR RLD. If the IR RLD system is producing excessive false rejects, proceed as follows: 1. Go to the INSPECTION SETUP > RLD screen to display the RLD parameters.
  • Page 29 Chapter 2: Troubleshooting Procedures 1. Verify that the RF PULSE WIDTH value for good bottles is approx- imately 1500. If not, adjust the RF GAIN setting to obtain same. The RF PULSE WIDTH value for bottles with residual liquid should typically be between 80 and 90 counts.
  • Page 30 OV-II Maintenance, Troubleshooting and Service Manual Finish Inspection Excessive False Rejects 1. If production operation allows turning the Omnivision Finish Rejection off, then do so by going to the CONTROL > FINISH screen and set the REJECT ENABLED function to OFF. (0) 2.
  • Page 31 Chapter 2: Troubleshooting Procedures 7. Clear the counters by selecting the RESET FINISH COUNTERS function and allow 1,000 bottles to pass through the system. Observe the TOTAL DETECTS column. If the numbers in this column are still too high, readjust A, B, C, or D algorithms as applicable. Again, clear the counters, let 1,000 bottles pass through and check the TOTAL DETECTS column.
  • Page 32 OV-II Maintenance, Troubleshooting and Service Manual Outer Sidewall Inspection Excessive False Rejects The general troubleshooting sequence for identifying and correcting the source of OSW-related excessive false rejects is as follows: a. Verify the OSW windows are clean and not causing false reject due to debris.
  • Page 33 Chapter 2: Troubleshooting Procedures 2. If it is not possible to turn all OSW REJECTION OFF as described above, disable the REJECT STATUS of the individual OSW View which appears to be a problem. 3. Select PHASE SELECT and identify the responsible OSW subsystem for the excessive false rejects by observing which system has a corresponding high number of DETECTS.

  • Page 34: Rejecting Large Percentage Of Bottles

    OV-II Maintenance, Troubleshooting and Service Manual 8. If changing the window's position, size or sensitivity corrects the excessive false rejects problem, clear the counters using the RESET OSW COUNTERS function, then allow about 1,000 bottles to pass through the OSW System. If the WINDOW DETECT COUNT is still too high, repeat the above-stated adjustments and run another 1,000 bottles as necessary until the false reject rate is acceptable.

  • Page 35: Rejecting No Bottles

    Chapter 2: Troubleshooting Procedures SYMPTOM CHECK SOLUTION The vacuum system has The vacuum warning gauge will Ensure that circuit breaker CB1 is on, failed or low vacuum (less be out of tolerance and/or a red the pressure/vacuum converter is than 127 mm [5 inches error message will be displayed operational, and that the vacuum Hg]).
  • Page 36 OV-II Maintenance, Troubleshooting and Service Manual 3. Verify that the system is being triggered for inspection by noting whether the PERIOD TOTALS counter (on any of the STATUS screens listed in Step #3) increments when the starwheel is rotated. If the bottle counter is not counting, then the problem is not specifically due to the rejector or the sensitivity of the inspection zones.

  • Page 37: Rejected Bottles Not Stable On The Takeaway Conveyor

    Chapter 2: Troubleshooting Procedures Rejected Bottles Not Stable On the Takeaway Conveyor The rejected bottles may not be stable when they are released from the starwheel, resulting in fallen bottles on the reject takeaway conveyor. 1. Check and correct any maintenance related problems as discussed earlier in this chapter.
  • Page 38 OV-II Maintenance, Troubleshooting and Service Manual SYMPTOM CHECK SOLUTION Deadplate not aligned Check bottle travel over the Realign the deadplate as required. properly. deadplate. Bottles must not contact the deadplate until just prior to bottles entering the production chain. Worn out starwheel...

  • Page 39: Faulty Bottles Detected But Not Rejected

    Chapter 2: Troubleshooting Procedures Faulty Bottles Detected But Not Rejected 1. Check for and correct any maintenance related or bottle handling problems as discussed earlier in this chapter. Check DIAGNOSTICS > DSP BOARDS screen. Look for possible causes and solutions as follows: SYMPTOM CHECK SOLUTION...

  • Page 40: Rejecting Incorrect Bottles

    OV-II Maintenance, Troubleshooting and Service Manual Rejecting Incorrect Bottles Check SYSTEM DIAGNOSTICS and DIAGNOSTIC MESSAGE HISTORY screen. Look for possible causes and solutions as follows: SYMPTOM CHECK SOLUTION Incorrect Bottle Delay. Check the settings on the Bottle 1. Adjust the settings as required.

  • Page 41: Complete System Failure

    Chapter 2: Troubleshooting Procedures Complete System Failure If the whole system fails, look for possible causes and solutions as follows: SYMPTOM CHECK SOLUTION Incoming AC Power Check Branch Circuit Breakers, Repair/replace as necessary. fuses, etc. Check Omnivision AC switches Repair/replace as necessary. and circuit breakers.
  • Page 42 OV-II Maintenance, Troubleshooting and Service Manual ~ BLANK PAGE INTENDED ~ 2-32 Industrial Dynamics Company, Ltd. © Form 42600 (10/03)

  • Page 43: Repair And Replacement Procedures Overview

    Chapter 3: Repair & Replacement Procedures REPAIR AND REPLACEMENT PROCEDURES OVERVIEW The following procedures outline the step-by-step instructions for repairing or replacing Omnivision components. Read the complete set of instructions for each component to be repaired or replaced before performing the procedure. Follow the instruction sequence as outlined. NOTE Industrial Dynamics Company (IDC) does not recommend field- repairing any electronics cards and modules.

  • Page 44: Broken Diffuser Glass Disk

    OV-II Maintenance, Troubleshooting and Service Manual Broken Diffuser Glass Disk If the diffuser glass disk is broken, but a piece of it is large enough to cover the light dome lens, then proceed as follows: NOTE This is a short-term procedure that will usually allow you enough time to obtain a spare diffuser glass disk without shutting the production line down for an extended period of time.
  • Page 45 Chapter 3: Repair & Replacement Procedures 1. Remove the 4-40 x 1/4-inch screw that secures the ring in the bottom cavity of the starwheel hub. Figure 5-1. Seal Ring 2. It may be possible to remove the seal ring by hand, but if it is wedged too tightly, obtain three 4-40 x 1-inch screws and insert them in the threaded holes in the seal ring.

  • Page 46: Valve Plate

    OV-II Maintenance, Troubleshooting and Service Manual 4. Clean the grit off the seal ring and blow out all holes with compressed air. Note that the seal ring is keyed into the hub by a small stainless steel pin, which is located on a slightly smaller radius than the valve port holes.

  • Page 47: Deadplate

    Chapter 3: Repair & Replacement Procedures 4. Move the spring-loaded assembly vertically by hand to be sure that the bushings in the valve plate are not binding on the vertical pins. If there appears to be any binding whatsoever, remove the valve plate and ream the sleeve bushing slightly so that the entire assembly moves freely in the vertical direction.
  • Page 48 OV-II Maintenance, Troubleshooting and Service Manual 7. Reinstall the starwheel and the infeed guide. 8. Lower the Inspection Head to its original position. Industrial Dynamics Company, Ltd. © Form 42600 (10/03)
  • Page 49 Rotating Diffuser Glass Disk To replace or remove a rotating diffuser glass disk for cleaning purposes, proceed as follows: 1. Turn OFF the OV-II. 2. Remove the two doors (if supplied) on the support column adjacent to the glass disk.

  • Page 50: Base Inspection Strobe Lamp Power Supply Assembly

    OV-II Maintenance, Troubleshooting and Service Manual NOTE If the purpose is to clean the glass disk, clean it on both sides, with a NONCAUSTIC, NONABRASIVE commercially available glass cleaner (such as Windex). 8. Reinstall the parts in reverse order, paying attention to following items: •...

  • Page 51: Inspection Head

    Chapter 3: Repair & Replacement Procedures 2. Remove the entire Base inspection strobe assembly. 3. Remove the baffle by loosening the four screws holding it in place. 4. Loosen the two screws holding the upper reflective plate. 5. Pull out the existing flash tube (Item #14) from the base. 6.

  • Page 52: Neck Belt

    OV-II Maintenance, Troubleshooting and Service Manual 1. Raise the Inspection Head an remove the starwheel. 2. Remove the three philip head screws. See figure below for screw location. 3. Remove the lens retaining ring and replace the finish lens. 4. Place retaing ring back in postion with the three screws removed in step 2.

  • Page 53: Outer Sidewall Enclosure

    Chapter 3: Repair & Replacement Procedures 4. Adjust the Neck Guide tension so the bottle is held firmly in place yet can pass smoothly through the inspection area OUTER SIDEWALL ENCLOSURES CAMERA ENCLOSURE: There are very few components inside the OSW camera enclosure that may require replacement.
  • Page 54 OV-II Maintenance, Troubleshooting and Service Manual The camera, optics, servos, and mirror heater (s) which are enclosed and sealed off inside the OSW camera enclosure are designed to operate on a long-term basis without need for regular maintenance. Do not open the OSW camera enclosure unless absolutely necessary.
  • Page 55 Chapter 3: Repair & Replacement Procedures 8. Install the OSW enclosure cover back in place. 9. Turn on the circuit breaker and verify the replacement fluorescent lamp is functioning properly. 3-13 Industrial Dynamics Company, Ltd. © Form 42600 (10/03)

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