Filtec FT-50c Service And Technical Reference Manual

Fill level inspector

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FT-50c

Service and Technical

Reference Manual

40255-0600

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Page 1 FT-50c Service and Technical Reference Manual 40255-0600...
Page 2 FT-50c Fill Level Inspector Service and Technical Reference Manual Document 40255-0600...
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 ........XVI Filtec Model FT-50 Radiation Exposure Profiles ..... . XVII Chapter One: FT-50 System Overview .
Page 5 FT-50 Fill Level Inspector Service Manual Chapter Two: Installation Requirements ..... . 2-1 Installation Requirements Overview ....... . . 2-3 Power Supply .
Page 6 Table of Contents Software Configuration ......... . 4-16 Calibrating the Encoder and Rejector Timing .
Page 7 FT-50 Fill Level Inspector Service Manual Total Underfills ......... . . 5-17 Total Overfills .
Page 8 Table of Contents Can Width At Trig ........5-28 Maximum Can Diameter .
Page 9 FT-50 Fill Level Inspector Service Manual Variable Speed Conveyors ........6-5 LED Definitions Quick Reference .
Page 10 Table of Contents Before You Perform Any Maintenance Procedure ....7-5 Trigger Beam and Emitter Lenses ......7-5 Bulged End and Missing Lid Sensors .
Page 11 FT-50 Fill Level Inspector Service Manual Error Number 117 ......... 8-11 Error Number 118 .
Page 12 Table of Contents S1-5: System Configuration ....... . . 10-5 S1-6: Not Used .
Page 13 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 14: Radiological Safety
Radiological Safety Radiological Safety Understanding Radiological Safety The Filtec FT-50 utilizes a small quantity of the radioisotope Americium-241 to produce low level gamma radiation. The Americium-241 is in ceramic enamel form and its melting range is in the region of 900 degrees to 1050 degrees centigrade.
Page 15: Radiological Safety Guidelines
FT-50 Fill Level Inspector Service Manual • The radioactive material is sealed by double fusion welds into a stainless steel capsule. At manufacture, and again at instal- lation, this capsule is subjected to rigorous tests capable of detecting the leakage of ﬁve millionths of one percent of the contents.
Page 16 Radiological Safety 2. Source Shutter closed - The radiation levels are less than 0.05 MR/HR at distances greater than 5 cm from any surface of the gauge (including inside the tunnel). 3. Source Shutter open - The extent of the main gamma beam is completely contained within the tunnel formed by the inspection head and shielding bar.
Page 17: Radiation Warning Labels
Industrial Dynamics Co., Ltd. 2927 Lomita Boulevard Torrance, California 90509 (310)325-5633 Figure 1. Warning labels attached to Filtec Model FT-50 Inspection System. The information on these labels is very important and should be followed explicitly. Document 40255-0600 Industrial Dynamics Company, Ltd.
Page 18: Filtec Model Ft-50 Radiation Exposure Profiles
Radiological Safety Filtec Model FT-50 Radiation Exposure Proﬁles 4" - 7.5" Description Description Inspection Head Radiation Detector Inspection Tunnel Limits of Main Beam 5 cm Isodistance Contour Detector Window Sealed Americium-241 Shielding Bar (1/4” Thick Steel) Figure 2. FT-50 Radiation Proﬁle Schematic: Gamma Guage: 100 or 300 mCi Source.
Page 19 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600 XVIII...
Page 20 Chapter 1: FT-50 System Overview Chapter One: FT-50 System Overview System Overview ..........1-3 Fill Level Inspection Basics .
Page 21 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 22: System Overview
Chapter 1: FT-50 System Overview System Overview This manual provides information about the FT-50 Machine Type 05 (MT05) Inspection System for cans. The MT05 version of the FT-50 is equipped with the following: • Solid State Detector or Scintillation Tube Detector •...
Page 23: Fill Level Inspection Basics
FT-50 Fill Level Inspector Service Manual Fill Level Inspection Basics The FT-50 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 gamma radiation is directed through the container.
Page 24: How Underfill Inspection Works
Chapter 1: FT-50 System Overview To allow for slight variances in the ﬁll level an upper gamma threshold and a lower gamma 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-50 Fill Level Inspector Service Manual Rejection Control Basics The FT-50 tracks any container that fails inspection. Tracking begins the moment the container crosses the inspection trigger beam in the FT-50 and ends when the container reaches the rejector centerline. Description FT-50 Inspection Trigger Location...
Page 26: System Specifications
Chapter 1: FT-50 System Overview System Speciﬁcations Speciﬁcations herein are listed for the FT-50. For speciﬁcations on the rejector refer to the rejector manual that was included with your FT-50. Power Requirements • 105 to 125 VAC, 50 or 60 Hz, 2.0 Amps, 1 Phase, or •...
Page 27: Inspection Accuracy
FT-50 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-50 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-50 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-50 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-50 Fill Level Inspector Service Manual Optional System Features The FT-50’s expandability allows you to add additional inspection capabilities to match your production requirements. Depending upon the FT-50 conﬁguration you ordered, your FT-70 may contain some of the following features: •...
Page 32: External Reject Control
Chapter 1: FT-50 System Overview External Reject Control Allows the FT-50 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-50 and the FT-50 can track and reject that container for the label inspection unit.
Page 33 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600 1-14...
Page 34 Chapter 2: Installation Requirements Chapter Two: Installation Requirements Installation Requirements Overview ......2-3 Power Supply .
Page 35 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
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-50. 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-50 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 drawings I-00401 and I-00415 in the Installation and Service Drawing Pack for an overview of the space requirements. In some cases the addition of inspection options that require an upstream or downstream trigger can change spacing 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 39 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 40 Chapter 3: Installing the FT-50 Chapter Three: Installing the FT-50 Before You Begin ..........3-3 Basic Terminology .
Page 41 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 42: Before You Begin
Chapter 3: Installing the FT-50 Before You Begin Before you begin installing your FT-50, 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-50
FT-50 Fill Level Inspector Service Manual Unpacking the FT-50 The FT-50 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-50 and comes with special handling instructions.
Page 44: Installing The Ft-50 Inspection System
Chapter 3: Installing the FT-50 Installing the FT-50 Inspection System To install your FT-50 Inspection System into your production environment you must do the following: • Determine the proper location for the FT-50 and the rejector. • Prepare the conveyor. •...
Page 45 FT-50 Fill Level Inspector Service Manual Determining the Proper Location for the FT-50 Before you begin installing your FT-50 Inspection System and rejector you should understand all the requirements detailed in Chapter 2: Installation Requirements. The location of the FT-50 within the production line is very important.
Page 46: Preparing The Conveyor
Chapter 3: Installing the FT-50 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-50 on the side channel by drawing a vertical line with a marker. This is the centerline on which the FT-50 will be aligned when installed.
Page 47: Mounting The Ft-50
FT-50 Fill Level Inspector Service Manual Mounting the FT-50 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-50. If you cannot mount the FT-50 as originally planned, or if parts are missing, contact IDC Customer Service immediately.
Page 48 Chapter 3: Installing the FT-50 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-50 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-50 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-50 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-50 with the centerline mark you made on the conveyor. •...
Page 52: Secure The Floor Stand To The Floor
Chapter 3: Installing the FT-50 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-50 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-50 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-50 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-50 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-50 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-50. Description Weld both brackets. Weld three braces. Weld both feet. Figure 3-16. Spot welding the mounting hardware. Industrial Dynamics Company, Ltd.
Page 58: Install The Air Purge System
Chapter 3: Installing the FT-50 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-50 Fill Level Inspector Service Manual 2. Connect the air line from the ﬁlter/regulator to the air input of the FT-50. Description Air Regulator/Disperser Air Input Air Hose (from ﬁlter/regulator) Figure 3-18. Connecting the air line to the FT-50. 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-50 Install the High-Resolution Encoder If you will be using the High-Resolution Encoder option with your FT-50, 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-50 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-50 Connect the Main Power Source Before you begin wiring the FT-50 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-50 Fill Level Inspector Service Manual 2. Route the AC power cable into the FT-50 through one of the watertight cable ports located in the bottom of the FT-50. Description Power cable Watertight Cable Ports Entrance to Power Filter Figure 3-21. Route the Power Cable into the FT-50. 3.
Page 64: Wiring The Main Power Supply Cable To The I/O Junction Box
Chapter 3: Installing the FT-50 4. Wire the main power cable to the FT-50 power ﬁlter wiring. Connect the Power Cable: To the FT-50: 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 FT-50 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: Power Supply Wiring Examples
Chapter 3: Installing the FT-50 Power Supply Wiring Examples Example A: Standard 115 VAC or 230 VAC with Neutral line. 1. Local electrical codes may require that neutral be grounded at the main power panel. We do not advise grounding the neutral wire to any other point.
Page 67: Example B: Using A Voltage Regulating Transformer
FT-50 Fill Level Inspector Service Manual 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-50.
Page 68: Example C: Poly-Phase/Single-Phase From The Same System
Chapter 3: Installing the FT-50 Example C: Poly-Phase/Single-Phase From the same System 1. Neutral must be grounded at the main power panel. 2. Connect the FT-50 ground stud to the plant Earth ground. Do not connect the FT-50 neutral (white) to the ground stud. 3.
Page 69: Example D: High Voltage Poly-Phase Systems (Delta Or Wye)
FT-50 Fill Level Inspector Service Manual Example D: High voltage 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. 2.
Page 70 Chapter 4: Conﬁguring the FT-50 for Operation Chapter Four: Conﬁguring the FT-50 for Operation Chapter Overview ..........4-3 Mechanical Configuration .
Page 71 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 72: Chapter Overview
Chapter 4: Conﬁguring the FT-50 for Operation Chapter Overview Before you can use your FT-50 Inspection System you must conﬁgure the FT-50 and the rejector to operate on your production line. There are two parts to conﬁguring the inspection system: •...
Page 73: Mechanical Configuration
FT-50 Fill Level Inspector Service Manual Mechanical Conﬁguration To mechanically conﬁgure the FT-50 you must complete the following procedures: • Adjust the Head Height for Fill Level Inspection. • Adjust the Inspection Trigger height. If your FT-50 contains the following options, you must also complete these additional procedures: •...
Page 74: Before You Begin
Chapter 4: Conﬁguring the FT-50 for Operation Before You Begin Before you begin conﬁguring the FT-50, 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-50.
Page 75: Aligning The Fill Level Inspection Beam
FT-50 Fill Level Inspector Service Manual Aligning the Fill Level Inspection Beam You must adjust the FT-50’s head height so the ﬁll level inspection beam contacts the container at the proper height. The FT-50 can perform either underﬁll inspection or overﬁll inspection, it can not perform both simultaneously.
Page 76 Chapter 4: Conﬁguring the FT-50 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-50 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-50 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-50 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-50 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-50 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-50 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-50 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-50 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-50 to send the rejector activation signal.
Page 85: Software Configuration
FT-50 Fill Level Inspector Service Manual Software Conﬁguration Before you begin conﬁguring the FT-50 software, complete the mechanical conﬁguration as explained in the previous section. To conﬁgure the FT-50 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-50 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 Gamma Counts Container enters Gamma beam Container exits Gamma beam...
Page 87 FT-50 Fill Level Inspector Service Manual 8. Use the following equation to determine the Looktime Gate in milliseconds. × D 0.6 where: D = Average Time Width of Can (step 7). L = Looktime gate in milliseconds. 9. Press Key 1 until you reach LOOKTIME GATE and use the Arrow Key to enter the Looktime Gate Value you calculated.
Page 88: Configuring The Gamma Threshold
Chapter 4: Conﬁguring the FT-50 for Operation Conﬁguring the Gamma Threshold The Gamma Threshold deﬁnes the gamma radiation count that is the dividing line between accepting or rejecting a container during ﬁll level inspection. Before you conﬁgure the Gamma 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 Gamma Threshold
FT-50 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 Gamma Threshold. •...
Page 90: Setting The Underfill Gamma Threshold
Chapter 4: Conﬁguring the FT-50 for Operation Setting the Underﬁll Gamma Threshold 1. Place a sample production container that is empty on the conveyor far enough upstream of the FT-50 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-50 Fill Level Inspector Service Manual Conﬁgure the Missing Lid Function 1. If your FT-50 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-50 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-50 Fill Level Inspector Service Manual 12. Use the following equation to determine the Minimum Diameter Missing Lid value (MD): 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.
Page 94: Configure The Down Can Function
Chapter 4: Conﬁguring the FT-50 for Operation Conﬁgure the Down Can Function 1. If your FT-50 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-50 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-50 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 ......... 5-5 Using the Control Panel .
Page 97 FT-50 Fill Level Inspector Service Manual Reset All Counters ........5-18 Reset Total Throughput .
Page 98 Chapter 5: System Software Clear System ........5-30 Current Language .
Page 99 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 100: The Control Panel
Chapter 5: System Software The Control Panel You can access all the FT-50’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. A remote, hand-held control is also available. The Remote Control Panel detaches from the FT-50, providing even higher system security.
Page 101: Selecting The Ft-50'S Operating Mode
FT-50 Fill Level Inspector Service Manual Selecting the FT-50’s Operating Mode There are two modes of operation for the FT-50: • 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-50.
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-50 Fill Level Inspector Service Manual Function Group Function Name Parameter Default ° Dia. Missing Lid Width 1-65,000 Pulses: Updating Constantly Updating Constantly Updating Last Reject ° Minimum Dia. Missing Lid 1-65,000 Pulses 55 Pulses Counters Key 3 Total Throughput 0-99,999,999 Total Rejects 0-99,999,999...
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-50 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 ‡ Known Chain Pitch & Teeth Present/Not Present Present ‡ Encoder Resolution 500/5000 Pulse 500 Pulse ‡ Save Default Constants Execute ∞ Conveyor Segment Pitch 50-700 (1/10th) mm 381 mm ∞...
Page 107: Function Descriptions
FT-50 Fill Level Inspector Service Manual Function Descriptions The following section contains function descriptions for each function group. Depending upon your FT-50 machine type, machine conﬁguration, and options package, some of these options may not apply to your FT-50. Certain functions are available only while in the Calibrate Mode or when dip switch S1-5 is open.
Page 108: Target Head Height
Chapter 5: System Software Target Head Height Allows you to record the Inspection Head height setting for the current container conﬁguration. To record the Target Head Height: 1. Press Key 1 until you reach TARGET HEAD HEIGHT. 2. Read the value displayed in the Head Height Counter. The counter is located in the upper left corner on the front of the FT-50 (see illustration 4-2).
Page 109: Learn Target Head Height
FT-50 Fill Level Inspector Service Manual Learn Target Head Height Precisely determines the optimum inspection head height for the container’s ﬁll level by leading you through a series of mechanical adjustments. This function is part of the Fill Level Optimization routine.
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-50 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-50 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-50 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-50 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-50 to the rejector. This function also effects the External Reject Function in the same way. Although the actual rejection is disabled all counters and alarms continue to accumulate.
Page 117: Inspect Trig To C/L Rej
FT-50 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-50 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-50’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-50. •...
Page 121: Time Width Of Can
FT-50 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 Missing Lid
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-50 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-50 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-50 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-50 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-50. 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: Overfill Text
FT-50 Fill Level Inspector Service Manual 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 128: Missing Lid
Chapter 5: System Software Missing Lid Prepares the FT-50 software for Missing Lid inspection by inserting the necessary options into the software. When set to Not Present it removes the options necessary for Missing Lid inspection from the software. This function does not activate or deactivate Missing Lid inspection, it only readies the machine.
Page 129: Bulged End
FT-50 Fill Level Inspector Service Manual Bulged End Prepares the FT-50 software for Bulged End inspection by inserting the necessary options into the software. When set to Not Present it removes the options necessary for bulged end inspection from the software.
Page 130: Down Can
Chapter 5: System Software Down Can Prepares the FT-50 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. This function does not activate or deactivate down can inspection, it only readies the machine.
Page 131: Diameter Missing Lid
FT-50 Fill Level Inspector Service Manual Diameter Missing Lid Prepares the FT-50 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-50 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: Rejector Type
FT-50 Fill Level Inspector Service Manual Rejector Type Selects the rejector model that is controlled by the FT-50. PLC Series Alarms Activates or deactivates the PLC Series Alarms Function. If set to PRESENT, the following options are activated: • PLC Output Pulse Width •...
Page 134: Known Chain Pitch & Teeth
Chapter 5: System Software Known Chain Pitch & Teeth This option applies to the Encoder Calibration Routine. If you know the conveyor chain pitch and the number of teeth per chain link, set this function to present. If you do not know the conveyor chain pitch and the number of teeth per chain link, set this function to not present.
Page 135: Calibrate Encoder Value
FT-50 Fill Level Inspector Service Manual Calibrate Encoder Value The number of encoder pulses emitted for every 10 meters of conveyor travel. For more information on this function, see Chapter 6: Encoder Calibration Procedures. Encoder Prescaler Value The conversion factor used by the Encoder Prescaler Value. This allows the FT-50 to process data at a faster rate.
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-50 Fill Level Inspector Service Manual Diagnostic Error Codes Listing The following list contains the FT-50 error codes. Depending upon your machine type, some of these errors may not apply to your FT-50. For 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...
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Page 140: Calibration Procedures
Chapter 6: Calibration Procedures Chapter Six: Calibration Procedures FT-50 Calibration Procedures ........6-3 Encoder Calibration Procedures .
Page 141 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 142: Ft-50 Calibration Procedures
Chapter 6: Calibration Procedures FT-50 Calibration Procedures The calibration procedures in this section should be performed only if your FT-50 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-50 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-50 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-50. The FT-50 uses these timing pulses to synchronize all inspection and rejection activities with the production conveyor’s speed.
Page 145: Conversion Factors
FT-50 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-50’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-50 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-50 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-50 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). 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-50 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-50 inspection tunnel without slippage. When ﬁnished, the FT-50 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-50 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-50 so that it passes through the FT-50 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-50 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-50 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-50 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-50. 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. Document 40255-0600 6-23...
Page 163: Fixed Speed Conveyors
FT-50 Fill Level Inspector Service Manual Fixed Speed Conveyors If your FT-50 is installed on a ﬁxed speed conveyor, you will use the Line Speed Calibration Procedure to synchronize your FT-50 and rejector. The Line Speed Calibration Procedure allows an FT-50 that is not equipped with a High Resolution Encoder to perform down can inspection on ﬁxed speed conveyor lines.
Page 164 Chapter 6: Calibration Procedures 4. You must also remove the FT-50’s cover to access dip switch pack S1. When performing the calibration procedure you are required to change the settings for S1-5. Industrial Dynamics Company, Ltd. Document 40255-0600 6-25...
Page 165: The Line Speed Calibration Procedure
FT-50 Fill Level Inspector Service Manual The Line Speed Calibration Procedure 1. Press Key 5 until SYSTEM DISPLAY appears and then press the Arrow Key to enter the Calibrate Mode. You may be required to enter a password if your system is password protected.
Page 166: Fine Tuning The Rejector Timing
Chapter 6: Calibration Procedures 12. Start the conveyor and adjust it to the speed it will run at during production. It is important that the chain run smoothly to obtain accurate calibration. Fine Tuning the Rejector Timing To ﬁne-tune the calibration accuracy you may need to adjust the Millimeter Translation Value estimated during the Millimeter Calibration Routine.
Page 167 FT-50 Fill Level Inspector Service Manual 19. To store the settings in system memory, close dip switch S1-2 and then press Key 5 until SAVE DEFAULT CONSTANTS appears. 20. Press the Arrow Key to execute. When COMPLETED appears, open S1-2 to protect the saved settings. 21.
Page 168: Sensors Calibration Procedures
Chapter 6: Calibration Procedures Sensors Calibration Procedures The FT-50 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. The proximity sensor used in the FT-50 is the Missing Lid (metallic) sensor.
Page 169: Calibrating The Centerline Inspection Trigger
FT-50 Fill Level Inspector Service Manual 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 170: Calibrating The Upstream Inspection Trigger
Chapter 6: Calibration Procedures 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 MODE...
Page 171: Calibrating The Bulged End Sensor
FT-50 Fill Level Inspector Service Manual 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 172: Calibrating The Down Can Sensor
Chapter 6: Calibration Procedures 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 173: Radiation Detector Calibration Procedure
FT-50 Fill Level Inspector Service Manual Radiation Detector Calibration Procedure The radiation sensor contained in the FT-50 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 gamma beam as it contacts the sensor.
Page 174: Calibrating The Scintillation Tube Detector
Chapter 6: Calibration Procedures 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 gamma inspection beam.
Page 175 FT-50 Fill Level Inspector Service Manual 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 176: Fill Level Optimization
Chapter 6: Calibration Procedures 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 177: Leveling The Inspection Head
FT-50 Fill Level Inspector Service Manual 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-50 so that it spans the inspection tunnel.
Page 178: Executing The Fill Level Optimization Routine
Chapter 6: Calibration Procedures 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 179 FT-50 Fill Level Inspector Service Manual 10. Lower the gamma beam into the liquid very slowly. When the average gamma counts reach the midpoint of the Static Full and Static Empty values, the system beeps and displays: @MIDPOINT, CONTINUE SLOWLY, LOWER INSP.
Page 180: Establishing The Target Head Height
Chapter 6: Calibration Procedures 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 181: The Dynamic Reject Point Test
FT-50 Fill Level Inspector Service Manual The Dynamic Reject Point Test The Dynamic Reject Point Test is used to verify the inspection accuracy under production conditions. You need thirty 100 percent reject production containers to perform this test. 1. Start the conveyor and run it at production speed. 2.
Page 182: The Dynamic Product Good Test
Chapter 6: Calibration Procedures The Dynamic Product Good Test The Dynamic Good Product Test is used to verify the inspection accuracy under production conditions. You need 30 good (not marginal) production containers to perform this test. If you run this test with actual production ﬂow, the FT-50 will sense this and automatically change the sample batch size to 128.
Page 183: The Review Fill Level Test
FT-50 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 184 Chapter 7: Maintenance Procedures Chapter Seven: Maintenance Procedures Maintenance Schedules ........7-3 Daily Schedule .
Page 185 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600...
Page 186: 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 187: 120 Day Maintenance
FT-50 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 Gamma Window for damage blockage.
Page 188: Maintenance Procedures
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 189: The Ft-50 Housing
FT-50 Fill Level Inspector Service Manual The FT-50 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 190: Servicing The Regulator And Coalescing Air Filters
Chapter 7: Maintenance Procedures 4. Insert the new pad by sliding it onto the shoe. Be sure the notch in the pad backing is positioned at the bottom. 5. Replace the retaining screw and washer. 6. Power up the rejector. Servicing the Regulator and Coalescing Air Filters Servicing the air ﬁlter consists of cleaning and/or replacing the air ﬁlter, sediment bowl, and gasket.
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Page 192 Chapter 8: Diagnostic and Repair Procedures Chapter Eight: Diagnostic and Repair Procedures Diagnostic Error Messages ........8-3 Error Number 2 .
Page 193 FT-50 Fill Level Inspector Service Manual Before You Begin ......... . 8-13 What You Should Do First .
Page 194: 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 Question Mark Key to view the error number in the LCD.
Page 195: Error Number 15
FT-50 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 196: Error Number 27
Chapter 8: Diagnostic and Repair Procedures Error Number 15 The Missing Lid 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 lid sensor.
Page 197: Error Number 46
FT-50 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 198 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 199 FT-50 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 200 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 201 FT-50 Fill Level Inspector Service Manual Error Number 68 No Encoder Pulses were received for the Diameter Missing Lid 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 202 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 minumum of 15 seconds.) Most communication errors are caused by excessive noise. Check the termination of RX input.
Page 203 FT-50 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 204: Troubleshooting Procedures
Chapter 8: Diagnostic and Repair Procedures 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 205: What You Should Do First
FT-50 Fill Level Inspector Service Manual What You Should Do First 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 206: Power Supply System Troubleshooting
Chapter 8: Diagnostic and Repair Procedures Power Supply 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 207: Testing The Power Transformer
FT-50 Fill Level Inspector Service Manual 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-50. 2.
Page 208: Processing System Troubleshooting
Chapter 8: Diagnostic and Repair Procedures Processing System Troubleshooting Main Processor Card 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.
Page 209: Serial Communications Card
FT-50 Fill Level Inspector Service Manual How to replace the software PROMs. The software PROMs must be replaced as a set. Each PROM is labelled as either U25 or U26 (refer to ﬁgure 8-5). 1. Locate PROMs U25 and U26. These are the PROMs that contain the machine software.
Page 210 Chapter 8: Diagnostic and Repair Procedures There is no display except for blinking cursor and the beacon is solid. 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 211: Sensor System Troubleshooting
FT-50 Fill Level Inspector Service Manual 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-50 Calibration Procedures for more information.
Page 212: Optical Sensors
Chapter 8: Diagnostic and Repair Procedures • If the detector power supply led is green, the power supply is functioning properly. Check the detector because the crystal in the detector has failed. Replace the SSD. Optical Sensors False triggers suddenly increase, or reject timing malfunctions occur.
Page 213: Troubleshooting Problems With Rejectors
FT-50 Fill Level Inspector Service Manual Troubleshooting Problems with Rejectors Proline Rejector Troubleshooting The rejector is operating erratically. 1. The air supply may be erratic. Verify the air pressure is in the proper operational range for the rejector. 2. Check to see if the cylinder is binding by shutting of the air pressure to the rejector and moving the rejector in and out by hand.
Page 214 Chapter 8: Diagnostic and Repair Procedures 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 215 FT-50 Fill Level Inspector Service Manual Terminal and Conductor Damage Terminal and conductor damage can cause intermittent open circuits. If this occurs, try the following procedures. 1. Check all the cable connections for terminal and conductor damage. If damaged, replace the cable. 2.
Page 216: Quick Reference Troubleshooting Guide
Chapter 8: Diagnostic and Repair Procedures Quick Reference Troubleshooting Guide Possible Cause Corrective Action Containers are not rejected. Rejector is not being Is the inspector detecting any rejects? Pass a energized by inspection unit. reject test can through the Inspection System.
Page 217 FT-50 Fill Level Inspector Service Manual Possible Cause Corrective Action Containers are rejected erratically. Time Delay is incorrectly set. 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.
Page 218 Chapter 9: Using a PLC With Your FT-50 Chapter Nine: Using a PLC With Your FT-50 Using a PLC With Your FT-50 ........9-3 PLC Series Alarms .
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Page 220: Using A Plc With Your Ft-50
Chapter 9: Using a PLC With Your FT-50 Using a PLC With Your FT-50 Programmable Logic Control (PLC) signals are provided by AC or DC optically isolated solid-state Relays. The FT-50 has separate PLC signals with a programmable pulse width (1-120 milli- seconds) that transmits one pulse for each event.
Page 221: Plc Series Alarms
FT-50 Fill Level Inspector Service Manual PLC Series Alarms To conﬁgure your FT-50 for operation with a PLC you must activate the PLC Series Alarms functions in the FT-50’s software. To activate the PLC Series Alarms: 1. Open dip Switch S1-5 to enter the System Conﬁguration 2.
Page 222: How To Determine The Signal Output Wiring
Chapter 9: Using a PLC With Your FT-50 How to Determine the Signal Output Wiring The View PLC Pin Assignments Function lists the conﬁguration of the PLC outputs for your FT-50. It also lists the normal voltage levels associate with the signals. To view the PLC pin assignments: 1.
Page 223: Relay Types For Output Signals
FT-50 Fill Level Inspector Service Manual Relay Types for Output Signals The FT-50 does not supply power to the PLC unit. The FT-50 signal output is a solid-state relay that closes upon each event occurrence. Description Relay Type Sensor/Gamma Failure Alarm Reed Latched Consecutive Alarms Reed...
Page 224 Chapter 9: Using a PLC With Your FT-50 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 225: Remote Alarm
FT-50 Fill Level Inspector Service Manual Remote Alarm The FT-50 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 226 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 .
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Page 228: Controller Board Switch Locations
Chapter 10: Controller Board Dip Switches and LEDs Controller Board Switch Locations The FT-50’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 229: Switch Function Configurations
FT-50 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-50 conﬁguration. Depending upon the options installed in your FT-50 the default conﬁguration may be different. Refer to the System Conﬁguration Sheet located inside the cover of your FT-50 for you speciﬁc factory conﬁguration.
Page 230: 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 231: Dip Switch Pack S2
FT-50 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 232: Sw11
Chapter 10: Controller Board Dip Switches and LEDs 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. Document 40255-0600 10-7...
Page 233: Controller Board Led Locations
FT-50 Fill Level Inspector Service Manual Controller Board LED Locations The FT-50’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. Industrial Dynamics Company, Ltd.
Page 234: Led Configurations
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-50.
Page 235: Led Definitions
FT-50 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 236: 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.
Page 237 FT-50 Fill Level Inspector Service Manual Industrial Dynamics Company, Ltd. Document 40255-0600 10-12...
Page 238 Technical Publications Department at Industrial Dynamics. Use the form on the following page to record your comments and then send the form to us in one of the following ways: techpubs@filtec.com Email: 310-530-1000 Fax: Industrial Dynamics Co.
Page 239 Documentation Feedback Form Industrial Dynamics Please deliver To: Received From: Technical Publications Department 310-530-1000 Fax: Telephone: techpubs@filtec.com Email Email: Industrial Dynamics Co. Technical Publications Department Post Mail Address: 3100 Fujita St. Torrance, CA 90505 FB-2 FT-50 Fill Level Inspector Service Manual...