Page 2 Pressco Technology Inc. The contents of this manual are furnished for informational use only, are subject to change without notice, and should not be construed as a commitment by Pressco Technology Inc. Written and designed at: Pressco Technology Inc.
Page 3: Table Of Contents
Table of Contents Chapter 1 Introduction About this guide Safety Considerations Static Discharge Protection Chapter 2 Declaration of Conformity - DecoSpector 360 Chapter 3 Safety Information Health Warning - Photosensitive Epilepsy Symbols Used With This System Arc Welding Warning Product Label...
Page 4 Instructions for Safe Assembly Operations Shipping and Handling DecoSpector 360 Components Assembly, Location, and Mounting Requirements Install the Inspection Module Stability of the Control Enclosure Utilities to be Supplied by Customer Protective Earthing Electrical Connections for cabinets 77769, 77770, 81507, and 81508...
Page 5 Hold an Image On Screen Freeze on Defect Controls Show Can View Only Chapter 9 Print Quality Screen Load Part Images Retro-Spec Graph View Defects on Images Defect Classification View Inspection Results Options on Print Quality Screen ©2024 PRESSCO TECHNOLOGY INC.
Page 6 Forced Reject Change Units of Measure System Utilities Global Utilities Chapter 13 Alarms Clearing Alarms Alarm Descriptions Alarm Monitor Alarm History Chapter 14 Troubleshooting Oil or Dirt on the Inspection Tunnel Windows Full Power Cycle for DecoSpector ©2024 PRESSCO TECHNOLOGY INC.
Page 7 Chapter 16 Inspection Module Chapter 17 Maintenance Maintenance Cautions Preventive Maintenance Frequency Clean the Control Cabinet Filters Service Frame Use the Service Frame to Lift the Module for Maintenance Clean the Tunnel Windows Replace the Filter-Regulator Filters ©2024 PRESSCO TECHNOLOGY INC.
Page 8: Chapter 1 Introduction
This guide provides information about system features and technical specifications. It is intended for Administrator-level users. This guide provides the necessary information to operate a DecoSpector 360 system that is prop- erly installed and programmed. Some machine functions require specialized training. This training is available from Pressco and may be conducted at your plant or at Pressco in Cleveland Ohio, USA.
Page 9: Safety Considerations
Chapter 1 WARNING: - Warning messages indicate information which must be observed to prevent injury, data loss, or equipment damage. CAUTION - Caution messages indicate important information which must be observed to pre- vent: loss of data, poor system performance, or equipment damage. Note: Notes contain special information that warrants being set off from the body text as shown here.
Page 10: Chapter 2 Declaration Of Conformity - Decospector
The Technical Documentation demonstrates the fulfillment of the essential requirements as set out in Annex I of the above Directive. Pressco Technology Inc. 29200 Aurora Road Cleveland, Ohio 44139-1847 Manufacturer This declaration of conformity is issued under the sole responsibility of the manufacturer.
Page 11 Chapter 2 Date: 21 April 2021 CHAPTER 2 DECLARATION OF CONFORMITY - DECOSPECTOR 360...
Page 12: Chapter 3 Safety Information
Chapter 3 Safety Information This section contains operator safety information that must be read before operating or servicing the system. WARNING - This product contains no operator serviceable parts. Refer servicing to qualified personnel. To prevent electrical shock do not open cabinet doors whilst power is connected. WARNING - Do not, under any circumstances, tamper with sealed machine parts or devices.
Page 13: Symbols Used With This System
Chapter 3 Flashing lights used for vision inspection systems or fire alarms Certain video games or TV broadcasts containing rapid flashes or alternating patterns of dif- ferent colors Bright, contrasting patterns such as white bars against a black background Flashing white light followed by darkness Stimulating images that take up your complete field of vision, such as being very close to a TV screen or computer monitor Certain colors, such as red and blue...
Page 14: Arc Welding Warning
Chapter 3 Warning: Arc flash and shock hazard Warning: UPS voltage present when power is off Warning: UPS Disconnect Warning: Electrical interlock Danger: shock and arc flash explosion hazards Arc Welding Warning WARNING - Potential equipment damage can occur if the vision equipment is not fully powered down prior to any arc welding performed on the line where the vision equipment is installed, specifically but not limited to our encoders.
Page 15: Warning Devices
Chapter 3 6) Electrical wiring diagram number (Pressco number) 7) Voltage range in Volts AC 8) Frequency range in Hertz (Hz) 9) Inspection module current rating 10) Air conditioner current rating 11) Place of construction Warning Devices The Pressco system has warning devices that indicate system failure or report excessive defects or warnings for your production line.
Page 16: Prohibited Use
Chapter 3 Intended Use - The Pressco system is designed and constructed for use in an indoor industrial environment, always sheltered from the weather. Space Required - The Pressco system and accompanying sensors must be installed in a place that will enable safe and easy installation, size changeover, user operation, and maintenance procedures. ...
Page 17 Chapter 3 During machine operation: Only one operator is needed to operate the machine. All others must keep at a safe dis- tance. Operators must be familiar with all machinery connected to the Pressco equipment and know how to use emergency stop devices. Note: the emergency stop devices may not be connected directly to the Pressco equip- ment, but it is important to know how to use them.
Page 18: Lifting Heavy Objects
Chapter 3 Use the machine for purposes other than those listed in this manual Modify parts of the machine Allow unqualified personnel to operate or perform maintenance procedures on the machine Lifting Heavy Objects CAUTION - Some components are heavy. Take proper precautions to prevent personal injury or damage to equipment.
Page 19: Spare Parts Usage
Before resuming production, make sure all safety devices are in working order. Pressco Technology Inc. shall not be liable in any way if any of the above-described directions are not complied with. To obtain a spare parts list, contact the Spare Parts department at Pressco: SpareParts@- pressco.com.
Page 20: Chapter 4 Specifications - Decospector 360
Chapter 4 Specifications - DecoSpector 360 This instrument has been designed and tested in accordance with Publication EN61010-1 (2010) Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use and has been supplied in a safe condition. The instruction documentation contains information and warnings which must be followed by the user to ensure safe operation and to maintain the instru- ment in a safe condition.
Page 21 Note: The dimensions listed below include the Service Frames on which the modules are moun- Note: measurements do not include connectors The illustration below shows the measurements of the standard (pin stripper) inspection module DS6 (model 76610). Other module measurements are listed in tables below. CHAPTER 4 SPECIFICATIONS - DECOSPECTOR 360...
Page 22 Width from conveyor center- 20 inches [514 mm] and 14 inches [347 mm] line XL (pin stripper) inspection module DS7 (model 76620) and DS9 (model 80134) Width 33 inches [847 mm] Length 44 inches [1108 mm] CHAPTER 4 SPECIFICATIONS - DECOSPECTOR 360...
Page 23: Environmental Conditions
25.79 inches [655.07 mm] (34.85 inches [885.19 mm] Height with stand) Environmental Conditions The DecoSpector 360™ system is designed to be safe in the following environmental conditions: Note: Please consult Pressco Technology Inc. if your environmental conditions are outside of those listed. Condition...
Page 24: Electrical Specifications
Electrical Specifications The following are electrical specifications* for the DecoSpector 360™ control enclosure: *Note: the specifications are current as of the date of this publication and the wiring diagrams included in this publication.
Page 25: Chapter 5 Installation
Pressco Technology Inc. with the means and equipment necessary for the unloading, lifting, and handling of machine parts. Pressco Technology Inc. deems it important to have one of their tech- nicians supervise the process of unloading, handling, and lifting the machine. The technician can give useful advice as to the logical sequence in which the components should be unpacked and positioned for ease of assembly.
Page 26 WARNING - Only qualified personnel must be involved in the operation of unloading, hand- ling, and lifting the machine. Pressco Technology Inc. shall not be liable for damage to com- ponents and/or personal injury resulting from the involvement of unauthorized personnel and/or failure to comply with the directions provided in this manual in relation to lifting and transport.
Page 27: Decospector 360 Components
Chapter 5 Storing The machine should be stored indoors, still packed. Maintain regular temperature and humidity. DecoSpector 360 Components The following diagram shows the major components of the system. Your plant may have a different configuration based on your inspection requirements.
Page 28 Chapter 5 1) 4-port I/O box - (correlation signals) located near the correlation sensors 2) Light tree - location is plant-specified 3) Encoder - located near the tunnel 4) 8-port I/O box - (part detection and rejection signals) located near the tunnel 5) Tunnel - also called Inspection Module, mounted on a Service Frame 6) Operator interface - in some plants, this interface may be located in a remote location from the control enclosure...
Page 29: Assembly, Location, And Mounting Requirements
This is of vital importance for correct machine operation. WARNING - Pressco Technology Inc. shall not be liable in case of failures or damage to prop- erty and/or personal injury resulting from or connected with assembly if this has been carried out by unauthorized personnel, or is not in compliance with the indications given in this manual.
Page 30 Chapter 5 Lift the Module Using a forklift or other mechanical lifting device, lift the module using the two straps that are installed by Pressco prior to shipping. Use a hook, another strap, or your plant's preferred method. Place the module on top of the service frame. Secure the module in place with screws, as specified in the installation drawings.
Page 31: Stability Of The Control Enclosure
Chapter 5 Stability of the Control Enclosure Ensure the stability of the control enclosure. Also refer to the directives in the Personnel Safety sec- tion. To make sure the control enclosure is stable: 1. Make sure that the control enclosure frame [item 1] is secured properly. 2.
Page 32: Utilities To Be Supplied By Customer
Chapter 5 Utilities to be Supplied by Customer The following utilities are required to operate the DecoSpector system. Before making connection, make sure the utility matches the technical specifications. More than one connection of the utilities may be required depending on the number of modules installed. Refer to specific wiring diagrams. WARNING - This is a Protection Class 1 Product (provided with a protective earthing ground ter- minal).
Page 33: Electrical Connections For Cabinets 77769, 77770, 81507, And 81508
Chapter 5 Electrical Connections for cabinets 77769, 77770, 81507, and 81508 Make sure that the power outlet voltage matches the voltage required by the machine. Refer to the specifications for equipment included with your system: "Electrical Specifications" on page 24 WARNING - Power Switch is the power disconnect device. Do not position the equipment such that access to the disconnect switch is impaired.
Page 34 Chapter 5 Wiring Diagram - sheet 1 of 10 (120VAC) - Power Distribution CHAPTER 5 INSTALLATION...
Page 35 Chapter 5 Wiring Diagram - sheet 3 of 10 (230VAC) - Power Distribution CHAPTER 5 INSTALLATION...
Page 36: External Connections
Chapter 5 External Connections The connectors are on the side of the DecoSpector cabinet. P1) Inspection Module power 12Vdc /24Vdc /48Vdc E1) block connector - inspection module connections USB1 and USB2 - for data transfer 1) Auxiliary input 2) 8-port I/O (part detection and rejection) 3) 4-port I/O (correlation sensors) 4) Light tree 5) Trigger (camera)
Page 37: Commissioning
Chapter 5 Commissioning Before placing the machine into operation, make sure the following checks are completed: Completed Positioning and leveling of the unit Connection of compressed air line to connection points Connection of power supply to con- trol enclosure Connection of power supply to inspec- tion module(s) if applicable Proper wiring from the control enclos- ure to the inspection module using...
Page 38: Chapter 6 Basic Operation
Chapter 6 Basic Operation Log In Tap to log in. Enter your password (using the onscreen keyboard), then select Login. If you forgot your password, ask your Administrator to set a new password for you. If you have a biometric account, press your finger on the biometric device to log in. You must use the same finger that you used when you created the account.
Page 39: Dashboard Feature
Chapter 6 Dashboard Feature To view the Dashboard, select the Dashboard icon from the Control Panel. (If you do not see this icon, then it needs to be configured. Ask your Administrator to set it up.) The Dashboard is an optional feature that provides a high level view of how the Deco system is operating.
Page 40 See the descriptions of the various areas of the dashboard: Dashboard header information: System Info - Contains “DecoSpector 360” followed by the serial number of the machine and the version number of the software. Job Start Time - This contains the date and time of when the job was first loaded.
Page 41 Chapter 6 Charts and Graphs: Alarm Information chart - This chart shows the status of the alarms listed. When one of these alarms is triggered, but not cleared, the status circle to the left of the alarm name will appear red. Also, the alarm count in the graph is incremented.
Page 42: Overview Panel
Chapter 6 of the bars is above the threshold value, the bar will be displayed in red. If a vertical red line does not appear on the graph, it is because the threshold value is larger than the highest percent value currently represented on the graph.
Page 43: Graphs
Chapter 6 Swipe the graphs or use the buttons to display the different graphs. Graphs The DecoSpector system has several graphs for you to monitor production. Tap the blue dots below the graph, or select the left and right arrows to see the different graphs. The following are examples: Reject Rate and Part Rate Graph CHAPTER 6 BASIC OPERATION...
Page 44 Chapter 6 Reject Rate (per 1000 parts) Graph Part Position Feedback This tool helps determine the position of the part flow, and quality of material handling, within the DecoSpector 360™ tunnel. CHAPTER 6 BASIC OPERATION...
Page 45 Chapter 6 Print Blanket Correlation Graphs for Mandrel and Pin correlation are also available. Statistics Grid CHAPTER 6 BASIC OPERATION...
Page 46 Chapter 6 "Color Trend Graphs" on page 104 CHAPTER 6 BASIC OPERATION...
Page 47: Color Borders Around Images
Chapter 6 Color Borders Around Images The DecoSpector system displays a different color border around each image depending on the inspection status. A green border is shown below. This key is displayed in the "Print Green = good part Quality Screen" on page 83.
Page 48: Control Panel
Chapter 6 Control Panel "Log In" on page 38 2) System status "Online and Offline" below "Job Management" on page 55 - to change the part you are inspecting 5) "Relearn a Job" on page 54 "Statistics on the Control Panel" on the next page "Views from the Control Panel"...
Page 49: Statistics On The Control Panel
Chapter 6 Dark face with no outline. No user logged in: When you select the button in this state, the system will prompt you to log in. No user logged in - System is offline. Light face with no outline. No user logged in - System is online, capturing images, and/or inspecting parts.
Page 50: Notepad
Chapter 6 Notepad - Add messages to other DecoSpector users. Common phrases (provided from the Phrases drop-down menu) are normally used by Pressco Technicians to leave messages to oper- ators, especially when a remote connection has been set up. - The icon turns green when you Add Note, then Close the dialog. This notifies other users that there is a message waiting.
Page 51: Screen Capture
Chapter 6 English Slovak Chinese (simplified) Vietnamese Dutch French German Spanish for Latin America Portuguese Polish Screen Capture - Capture a screen image for reference, troubleshooting, or to send to Pressco technical support. The system briefly displays the file path after the capture is taken. Help Access help (manuals) from Settings | System Utilities | Help.
Page 52 Chapter 6 1. Plug a USB device into one of the USB Ports. Select Print Quality. 3. Select the Load button to load the desired image(s). Then Load Dataset. See "Load Part Images" on page 83 for more information about loading images. Select the Options button | Save Part Images.* The Save Images dialog is displayed.
Page 53 Chapter 6 7. Click Select Folder when you have selected the desired location. 8. Make other desired selections in the Save Image dialog and select Save. The images are saved to the device. CHAPTER 6 BASIC OPERATION...
Page 54: Chapter 7 Part And Job Management
Chapter 7 Part and Job Management This section describes how to have the DecoSpector system 'learn' your parts, and describes vari- ous job settings. Learn Parts The system must learn parts each time you load a part program or inspect a new part type. This ensures that the most recent decoration data is used for inspection.
Page 55: Job Management
Chapter 7 Note: the learn process may take much longer than normal if part handling is not correct. If there are physically damaged cans, off center cans, or adjacent cans in the image, then the system will have difficulty learning the can label. *Pre-Calibration only occurs if the job can size is not already calibrated.
Page 56 Chapter 7 1) New "New Part (First Time Inspecting a Part)" on page 58 Load - in the left column, select the job or label you want to inspect, then select Load "Part Changeover (Part Type Inspected Previously)" on the next page Relearn - Relearn the label 4) Color Zones...
Page 57: Part Changeover (Part Type Inspected Previously)
Chapter 7 Part Changeover (Part Type Inspected Previously) This process is used when you are changing over production. If you have inspected a part type pre- viously, you will change the Job and relearn the parts. To change parts: Step Button or Menu Item 1.
Page 58: New Part (First Time Inspecting A Part)
Chapter 7 Note: the learn process may take much longer than normal if part handling is not correct. If there are physically damaged cans, off center cans, or adjacent cans in the image, then the system will have difficulty learning the can label. New Part (First Time Inspecting a Part) This process is used when you are changing production to a new type of part that the DecoSpector system has never inspected before.
Page 59: Learn Auto-Detect
Chapter 7 8. Align the print blanket and select Save Alignment. The system collects part images, adjusts lighting, and creates templates. The system saves the templates, which are used as the standard to which it compares inspected parts during online operation. The system will post a temporary message that says "Learn Deco Finished."...
Page 60 Chapter 7 *If your Control Panel reads "Relearn," then the system will not detect whether parts are from the same job. See "Relearn a Job" on page 54. When you create a new job, the system skips the phase to determine whether the parts are from the same job.
Page 61: Align The Print Blanket
Chapter 7 Align the Print Blanket Align the image on the screen so it looks as close to your print blanket as possible. This step is only necessary if the system prompts you (usually when learning a new part). Note: if your system is configured to "Go Online After Job Learn," then you will not see these screens.
Page 62: Show Templates
Chapter 7 2. Select "Save Alignment." Show Templates These screens are available after the system collects part images and aligns the print blanket. If an inspected part does not match the learned templates, that part is considered defective. Note: if your system is configured to "Go Online After Job Learn," then you will not see these screens.
Page 63 Chapter 7 Select Align Print Blanket. Align the Print Blanket as necessary. To see the template: 1. Select the Show Template button. This becomes active after the system learns parts. 2. Compare the image to the actual part. 3. Relearn the part if the template or deviation is bad. 4.
Page 64: Color Zones - Manual, Optional
Chapter 7 Select "Show Deviation" (below the images). This shows the range of pixels that each inspected part can have. A darker image = more sensitive inspection. (NOTE: if you have Inspection zones set up, pixels might be yellow, depending on sensitivity - this is OK) Images are bad if: the images do not resemble the actual part you see 'ghosting,' or a repeated area...
Page 65: Inspection Zones
Chapter 7 1. Select New Zone. An adjustable circle is displayed on the image. This is the template image, so the colors are an average of all the learned parts. 2. Move and/ or resize the inner circle to an area on your part you want to monitor. Try to use an area that contains only one color, not shading nor borders.
Page 66 Chapter 7 Go to the job menu. 2. Select Inspection Zones. 3. Select New Zone. A default zone and inspection settings appear on the screen. 4. Move the zone to where you would like to adjust the sensitivity. (You can set up more than one zone) 5.
Page 67 Chapter 7 a and b represent red as it starts drifting towards yellow or blue Hue 1 affects Red and Green. If you expect to see red, but the can color is printing orange or purple, OR you expect to see green, but the can color is printing greenish-yellow or aqua, then increase Hue 1.
Page 68 Chapter 7 See also: "Inspection Zones Example" below View Inspection Zones from Print Quality Screen To see the inspection zones in action, go to the Print Quality tab. To view any- thing on this screen, you must load images. See "Load Part Images"...
Page 69: Confirm A Job Learn
Chapter 7 You can see the defect more clearly by looking at the "error" image. Click the appropriate dot under the image. Confirm a Job Learn Make sure the job is performing as expected. Check these things: Reject rate ("Statistics on the Control Panel" on page 49) If there are too many defects in the Last 100 parts: see if they really are bad parts or false rejects.
Page 70: Learn Log After Relearn
Chapter 7 Look at Latest Defects (in "Print Quality Screen" on page 83). Make sure they are really defects. If the system is rejecting parts with small defects, then adjust sensitivity and defect size. If it looks like the parts are mis-aligned on the screen, then relearn the part If there are too many false rejects in Last 100 Parts OR Latest Defects, then re-learn the part.
Page 71: Part Position Feedback
Chapter 7 Part Position Feedback This tool helps determine the position of the part flow, and quality of material handling, within the DecoSpector 360™ tunnel. There are three views: Part Position Camera Tilt Part Spacing To access the tool: Go to Settings | System Calibration | Part Position Feedback. Part Position is the first view.
Page 72 Chapter 7 By clicking anywhere you will switch to the Part Position view. Camera Tilt: By clicking anywhere other than a camera you will switch to the Part Position view. By clicking on the displayed camera you will switch to the Part Position view. By clicking on any other camera the view will be changed to show the specific Camera’s Tilt data.
Page 73: Camera Tilt
Chapter 7 Part Position Title - The title indicates if the information is shown in inches or millimeters. Green Part Flow Arrow - This shows the direction of the production flow under the tunnel. Color Coding - Dark blue indicates at least one part at that position. Lighter blue (cyan) indicates a higher concentration of parts at that position.
Page 74 Chapter 7 C1 through C4 - These are the cameras and act as a button to switch to the specified camera tilt plot. Part Spacing The part spacing plot collects information about how far apart consecutive cans are based on the part present signal for each part.
Page 75: Part Position Tool - Different Ways To View
- Pressing this will clear out the collected data for all plots (not just the current view). Part Position Tool - Different Ways to View This topic shows how you can view this tool within the DecoSpector 360™ system. For details about the tool, see "Part Position Feedback"...
Page 76 Chapter 7 System Overview - Large Graph View The large graph view allows you to see the online Part Position information. The information is identical to the view that is shown under System Settings – System Calibration. (click the part image to switch the large graph back to small graph view) CHAPTER 7 PART AND JOB MANAGEMENT...
Page 77: Chapter 8 View Defects And Part Images
Chapter 8 View Defects and Part Images You can view defects and part images in three screens: "Overview Panel" on page 42 "Print Quality Screen" on page 83 - Use Print Quality to view inspections on recent or saved images. This is where you can adjust inspection sensitivity. "Color Analysis"...
Page 78: Hold An Image On Screen
Chapter 8 Hold an Image On Screen Use the Freeze on Defect option to hold images on screen. Image is not held. Tap to manually hold. Image is held. Tap Release to release the image. For more options (such as holding defect images automatically), see "Freeze on Defect Controls"...
Page 79 Chapter 8 The Freeze on Defect Controls are displayed on the home screen. Select when to freeze a defect on screen. Latest Defect - Freeze the image of the last defective part. Each subsequent failing part freezes on the screen until another part fails. Latest Defect - Auto-Release - Freeze the last defective image for up to the specified number of seconds, which is selectable next to Release Time.
Page 80 Chapter 8 Select Defects controls Select the type of defects to freeze on screen (used with Freeze on Defect). = on. Any Defect - Display any defect. Print Quality Defects - Display only Print Quality defects, which include: wrong color, scuff, shadow, color void, and too much color.
Page 81: Show Can View Only
Chapter 8 empty pocket. Empty pockets are found when the system does not locate any feature edges during part location. This can happen if the part is too short, too dark, or there is another severe defect that causes the system not to find the part. Other Errors - Display other errors that do not fall into the other specified categories.
Page 82 Chapter 8 Show Detailed View - Shows the color zone information for each of the defined colors (shown in item 3). For more information about Delta E and other values, see "Color Meas- urements" on page 97. Hold - This is the manual hold button for Freeze on Defect. Release - This is the manual release button for Freeze on Defect.
Page 83: Chapter 9 Print Quality Screen
Chapter 9 Print Quality Screen This screen allows you to view recently inspected parts through the Retro-Spec interface. This allows you to see trends in inspection. It also allows you to change inspection settings and try them on images without interfering with current inspection. You must be an Administrator to save changes.
Page 84 Chapter 9 - Tap the load icon. 2. Select images to load for Data Set A (left side of the graph) and Data Set B (right side of the graph). Note: when you select Custom Set (from disk), up to 49 images from the selected folder are loaded.
Page 85: Retro-Spec Graph
Chapter 9 Any Defect switches all options on or off. 4. After the images are loaded, tap one of the bars at the top of the screen to see the cor- responding image below the graph. In the Color Analysis screen, the graph looks different than below.
Page 86: View Defects On Images
Chapter 9 The bars on the graph are color-coded, and the legend is displayed below the graph (if enabled). See also "Color Borders Around Images" on page 47. View Defects on Images There are two images available for each part: 1) part image, and 2) error image. Swipe, or use the navigation dots or arrows under the image to switch between images.
Page 87 Chapter 9 An error image example is shown below. The arrows (drawn for illustration purposes) indicate where the defects were found. Look at the classification legend to see what type of defect was found. The colors correspond to the colors in the error image. See also "Defect Classification"...
Page 88: Defect Classification
Chapter 9 Defect Classification When you view the Error image in the Retro-Spec interface, you can see what type of defect occurred on each part. The defects are color-coded in the Error image. You can select the type of defect to view. Note: one defect can fall into more than one classification.
Page 89: View Inspection Results
Chapter 9 Small Color Void - The system found no color where it was expecting to see color, in a relatively small area. View Inspection Results View the inspection results of each part. Use the Options button (from the Print Quality screen) to select which results to view. If the Results are not on your screen, enable it by selecting Options | Show Results Window | exit the menu.
Page 90: Options On Print Quality Screen
Chapter 9 Options on Print Quality Screen Tap Options to see Retro-Spec options on the Print Quality screen. CHAPTER 9 PRINT QUALITY SCREEN...
Page 91 Chapter 9 Sort Method Sort the parts in the Retro-Spec graphs in the upper part of the screen to view them the way you want to. Select Apply Sort to see the sorted graphs. Delete Parts Delete specific types of parts from the Retro-Spec graphs. Select Apply Delete to see the updated graphs.
Page 92 Chapter 9 Note: when you enable any "Show" option, select another part on the Retro-Spec graph to see the updates on the screen Show Inspection Zones Show the boxes where you set up "Inspection Zones" on page 65. Show Tooltips - not used Show Results Window Show the inspection results after loading images or applying updated inspection settings.
Page 93 Chapter 9 Show Legends Show the color-coded Part Legend. Show Part Fit Graphics You must also enable Show Camera Images on the right side of the menu. This allows you to view the part registration graphics. CHAPTER 9 PRINT QUALITY SCREEN...
Page 94 Chapter 9 Enabling Part Fit Graphics also provides access to Part Locate Settings and "Inspection Zones" on page 65. Show Consistency Results This data is automatically displayed if the part failed for part registration consistency. To view it otherwise, Show Consistency Results in the Options. You must also enable Show Results Window.
Page 95 Chapter 9 Show Part Images Show the default inspected image. Show Camera Images Show the different views of the part. Show Camera Images must be enabled each time you enter the Options menu. It does not stay enabled. Show Template Mean Images Show the template images that were created when you learned this part.
Page 96 Chapter 9 Show the standard deviation images that were created when you learned this part. For more information, see"Show Templates" on page 62. CHAPTER 9 PRINT QUALITY SCREEN...
Page 97: Chapter 10 Color Analysis
The system sets up colors using either Automatic or Manual colors. This is set up during install- ation. Color Measurements The DecoSpector 360™ takes several color measurements. Use the measurement that best matches your plant's color measurement process. In the following examples, the "standard color" is Blue: RGB: 28, 82, 162. The color squares rep- resent different measured values.
Page 98 Chapter 10 Delta L Lightness. On the Delta L graph, a negative number represents a color that is darker than the standard. A positive number represents a lighter color than the standard. Delta H Hue. The attribute of color that enables an observer to classify it as red, green, blue, purple, etc., and excludes white, black, and shades of gray.
Page 99: Color Analysis Graphs
Chapter 10 On the Delta H graph, the higher the number, the further away that color is from the stand- ard. Delta C Colorfulness. The system may find an area to be more blue or less blue, for example. On the Delta C graph, a negative number means that the measured area is less colorful than the standard.
Page 100 Chapter 10 1) Data Set A - our example loaded Last 100 Images 2) Data Set B - our example loaded Latest Defects - Any Defects 3) Color key 4) Inspection results for the selected part 5) Can Color = the measured color on the selected part. Master Color = the learned color that the part should match.
Page 101 Chapter 10 CHAPTER 10 COLOR ANALYSIS...
Page 102: Color Analysis For One Color - Automatic Color Mode
Chapter 10 Color Analysis for One Color - Automatic Color Mode You can view the inspection results for one color. To see parts, select the Load icon and select a set or sets of part images. To see the information for one color: 1.
Page 103 Chapter 10 Select the Color Display Selection icon. Then, from the popup dialog, select the color(s) you want to view (the colors with a check mark will be displayed). Save changes and exit. Is Enabled - [Only when using Automatic colors] If a color is enabled, then the DecoSpector will analyze that color.
Page 104: Color Trend Graphs
Chapter 10 Color Trend Graphs On the home screen, you can view several color monitoring graphs. Swipe over the graph or select one of the dots under the graph to select different graphs. A dot is added to the chart every 1000 parts to indicate how the color is trending. You can set the Error and Warning limits for these graphs in the Color Analysis screen.
Page 105 Chapter 10 2. Select the rightmost dot to view the user-selectable graph. 3. Click on the graph to bring up the Zone setup screen. 4. Select one of the zones from the Zone setup screen (see below for information about select- ing zone using automatic colors, simplified Delta E, or manual color zones).
Page 106 Chapter 10 You might need to select one of the other dots underneath the graph to view the color zone graph that you selected. If you are using Automatic Colors: CHAPTER 10 COLOR ANALYSIS...
Page 107 Chapter 10 Select a color from the drop-down menu. Select a color measurement (Delta E, Delta L, Delta H, or Delta C). Select OK to save changes and exit. The selected graph is displayed on screen. When Simplified Delta E mode is enabled: Trend graphs will only display Delta E when Simplified Delta E mode is enabled: Instead of being able to scroll through five screens, you will only scroll through two screens: Delta E and a color/ measurement-specific graph.
Page 108 Chapter 10 If you are using Manual Color Zones: Select one of the color zones on the image (yellow circle turns blue when you select it). The Zone Name is displayed in the upper right of the screen. Select a color measurement (Delta E, Delta L, Delta H, or Delta C). CHAPTER 10 COLOR ANALYSIS...
Page 109: Chapter 11 Correlation
Chapter 11 Correlation The DecoSpector system provides correlation to the following machine parts: Mandrel, Print Blanket, and Pin Chain Note: Correlation is set up using Correlation Settings. This is usually performed during installation by Pressco. The correlation graphic on the Home (Overview) screen shows the status of machine parts. 1) The large dots with numbers show the alarm condition of the machine part.
Page 110 Chapter 11 To see a larger graph, click the graph in the upper screen. The graph will be displayed in the lower screen. The correlation graphs are color coded based on the reason the parts failed. The legend is dis- played when you view a larger graph in the lower screen.
Page 111: Mandrel Correlation
Chapter 11 Gray = Empty Pocket | Blue = Adjacent Can | Cyan = Out of Round | Orange = Register Issue | Red = Print Defect | Magenta = Color Defect | Green = Deco Trip Mandrel Correlation The mandrel numbers are located on the bottom of the graph. This is sorted in descending order, left to right, from the highest number of failed parts to the lowest number of failed parts.
Page 112: Correlation Diagnostics
Chapter 11 In this example, the part was correlated to Mandrel 24, Print Blanket 12, and Pin 72. Correlation Diagnostics Check to make sure the system is tracking the correlation of all machine parts. | Show Correlation Diagnostic Controls. The controls are displayed on the home screen.
Page 113 Chapter 11 1) Mandrel parts | 2) Print blanket parts | 3) Correlation values CHAPTER 11 CORRELATION...
Page 114: Chapter 12 Settings
Chapter 12 Settings - Adjust system settings. A grayed out item means that only higher user levels have permission to access that item. "Overview Display View" below System Calibration, Settings, and Utilities are for Admin- istrators only. Exit the Software from Global Utilities. Overview Display View Select what to display on the Overview screen.
Page 115: Forced Reject
Chapter 12 Show Normal Overview - Resets the home screen to default, hiding Freeze on Defect, Forced Reject, and Diagnostic Controls. Show Can View Only - This view allows you to view just the can image with details about the part. "Show Can View Only"...
Page 116 Chapter 12 1. Select Settings | Overview Display View. 2. Select Show Forced Reject Controls. These are displayed on the right side of the home screen. 3. To select a different option than what is displayed, select the drop-down menu and make another selection.
Page 117 Chapter 12 6. Tap Apply to save changes and exit. The correlation graphic at the top of the Home (Over- view) screen highlights the selected machine parts. To use Forced Reject: Put the system online to inspect parts. Tap the Start Forced Reject button. The system rejects those parts cor- related to the selected machine parts and conditions you selected.
Page 118: Change Units Of Measure
Chapter 12 The system uses an OR function to reject parts. That is, if you select mandrel 2 and print blanket 4, the system will reject the first part correlated to either machine part. When using Reject One or Reject Continuous, you must Select which correlated machine parts to reject.
Page 119: Remote Support
Pressco engineers to access your DecoSpector 360™ system remotely, and assist with troubleshooting and optimizing system performance. To use remote support, you must provide an Ethernet connection to the DecoSpector 360™ and outgoing Internet access to the specific support server, described in the "iTivity"...
Page 120 Teamviewer Each DecoSpector 360™ system is equipped with Team Viewer agent software. Team Viewer is installed at the Pressco factory on the DecoSpector 360™ system, in systems with version 6.2 software and higher. To use the Team Viewer connection method, the DecoSpector 360™ will need outgoing Internet access to TeamViewer.com via port 5938.
Page 121 DecoSpector’s IP address to support.pressco.com:23800. All other connections can remain blocked. Once the session is established, the DecoSpector 360™ shows up on our server and is identified by the serial number of the system. Our Engineers can then connect and offer assistance.
Page 122: Ups Information
Chapter 12 UPS Information UPS Information - View remaining battery life and other information about the UPS backup device. Log Viewer Settings | System Utilities | Log Viewer. View the system logs, including inspection changes, alarms, and errors. 1) Sort any column by selecting the column heading 2) Go to beginning of the log file 3) Page up 4) The current page of the log file.
Page 123 Chapter 12 8) Delete old log entries (Administrator only). Select the desired criteria, then select the Delete but- ton next to the drop-down box. The available log filters are shown below. Enable the desired filters. Create Support Package A support package is a set of files gathered by the system to help find system problems. You will send this package to Pressco service specialists so that they can troubleshoot your system.
Page 124: Global Utilities
Chapter 12 3. Browse to the desired folder, or make a new folder if desired. Tip: make a note of the Selected Folder. This is where the file is saved 4. Select Folder. The DecoSpector system will create a support package zipped file. [name example: SYSTEM-NAME_year_month_day_time.zip] The status window will be removed from the screen when the process is complete.
Page 125 Chapter 12 Job Management, accessed from Global Utilities, is the same menu accessed from the Control panel. See "Job Management" on page 55. Email Parameter Changes The “Email Parameter Changes” utility collects information about various parameter changes. This information will be periodically sent to pre-determined individuals via email. A queue is filled if someone makes changes to inspection parameters.
Page 126 Chapter 12 To get to this menu, from Settings | Global Utilities | Email Parameter Changes. Test Email - Operator-level users or higher may send a test email. CHAPTER 12 SETTINGS...
Page 127: Chapter 13 Alarms
Chapter 13 Alarms - Select the alarm icon to clear, configure, or view alarms. Each alarm is user-configurable to: enable the alarm, turn on the light tree, sound the horn, turn the rejector off, and many other options. Some alarms, including Inspection speed too slow, General failure, and System power loss cannot be disabled, because they are necessary for system operation.
Page 128 Chapter 13 Note: you must be an Administrator to access Alarm Setup. However, as an Operator, you can select an alarm name in the Active Alarms screen to see more information. Note: some alarms listed below are in available in later versions of software. Your system may not show all alarms listed.
Page 129 Chapter 13 Print Defects Per N Parts - The system detected too many print rejects in the last N parts. We typ- ically use this alarm to signal external I/O to allow the decorator to be stopped for adjustment. Adjacent Cans Per N Parts - The system detected too many adjacent cans in the last N parts.
Page 130: Alarm Monitor
Chapter 13 System Power Loss - The system has lost power and is running on battery backup. Typically, the system will automatically shut down if the power is off for an extended period of time. System Temperature - The system temperature is too high. Perhaps the A/C is not working. This adversely impacts overall system performance and can cause the system to run slower and poten- tially miss inspecting parts.
Page 131: Alarm History
Chapter 13 Alarm History This operates like "Log Viewer" on page 122, except that the messages are only about alarms. CHAPTER 13 ALARMS...
Page 132: Chapter 14 Troubleshooting
Chapter 14 Troubleshooting This section contains some possible errors that might occur with the DecoSpector system, and actions you can take. Note: Some items are only available to advanced users, and may not be included in the Operator Guide. Symptom Possible Cause Action Restart the...
Page 133: Full Power Cycle For Decospector
Chapter 14 Full Power Cycle for DecoSpector This procedure should only be performed when a standard power cycle does not work (example: the software is not responding). CHAPTER 14 TROUBLESHOOTING...
Page 134 Chapter 14 WARNING - Keep clear of reject devices. Projectiles may cause injury. WARNING - When the system is powered down, there is still voltage present at the UPS. Only AUTHORIZED PERSONNEL should attempt to open the system. We recommend that only AUTHORIZED PERSONNEL have access to the keys.
Page 135: Chapter 15 Control Enclosure And Operator Interface Hardware
Chapter 15 Control Enclosure and Operator Inter- face Hardware 1) Touch screen monitor 2) Biometric login device 3) Keyboard tray 4) Power indicator LED 5) Power switch 6) Locks (Accessing the internal components with power OFF) 7) Vision processor (inside control enclosure) 8) Air conditioner CHAPTER 15 CONTROL ENCLOSURE AND OPERATOR INTERFACE HARDWARE...
Page 136: Usb Ports
Chapter 15 USB Ports There are USB ports available to back up or transfer data. Biometric Login Device The Biometric Identification login device is used to log in and out of the Pressco system. This device is optional and must be purchased with the system. To log in with this device, press your finger to the device.
Page 137: Power On And Off At The Control Enclosure
Chapter 15 Power On and Off at the Control Enclosure Power on: Turn on the switch [1] on the front of the cab- inet. The power indicator [2] will illuminate. The software will start automatically. (You must log in and put the sys- tem online to begin inspection) Note: it takes about a minute for the computer to start after the main power switch is turned ON...
Page 138: Chapter 16 Inspection Module
Chapter 16 Inspection Module WARNING - Keep hands away from the Vortex cooler [3] to avoid risk of burns. 1) DecoSpector 360™ inspection module 2) air connection for Vortex cooler 3) Vortex cooler 4) mechanical stop for the service frame...
Page 139 Chapter 16 This page left blank intentionally CHAPTER 16 INSPECTION MODULE...
Page 140: Chapter 17 Maintenance
Chapter 17 Maintenance Maintenance Cautions When carrying out maintenance or repair work: Disconnect master switch. For switch locations, refer to the Power Up and Power Down section. Before starting the machine, ensure that no person is close to the machine. If maintenance or repair requires the disconnection or removal of safety or protection systems, this operation must be supervised by authorized personnel who must ensure the prevention of personal injury or damage to the machine.
Page 141: Clean The Control Cabinet Filters
Chapter 17 Frequency - Number of times per: Action Shift Week Month Year Supplies Required Replace the two Filter/ Regulator Part number: 67622 - Filters: 30 minutes Kit Oil Removal "Replace the Fil- Replacement Filters ter-Regulator Fil- ters" on page 145 Clean the Control Cabinet Filters The filter should be cleaned once a month for best results.
Page 142: Service Frame
Chapter 17 Service Frame The service frame is used during inspection module maintenance and calibration. WARNING - This product contains no operator serviceable parts. Contact Pressco for ser- vice. How to Contact Pressco - Do not open the gearbox enclosure. Oil may spill from the gearbox if it is opened. - KEEP OFF the service frame.
Page 143: Clean The Tunnel Windows
Chapter 17 3. Crank the handle [A] to lower the module. Turn handle [A] counter-clockwise = module moves down. D) mechanical stop E) service frame does not move after reaching the mechanical stop F) locking device holds the module in place while you work Clean the Tunnel Windows The inspection tunnel windows need to be cleaned at least once per shift, depending on plant con- ditions.
Page 144 Chapter 17 Regular paper towels to clean the surfaces. These may scratch the surfaces or leave lint. Alcohol-based solvents. These may damage the plastic surfaces. Harsh chemicals. These may damage multiple surfaces. To clean the windows: 1. Ensure the production line is stopped, and the area surrounding the tunnel is clear (of people, parts, equipment).
Page 145: Replace The Filter-Regulator Filters
8. Flip the switch to change directions of the service frame. 9. Crank the handle to lower the module back into place. 10. Start production. 11. Select the Relearn button in the DecoSpector 360™ software, so that the system learns parts with the newly cleaned windows. Replace the Filter-Regulator Filters The filter/ regulator assembly shown below is installed with the inspection module.
Page 146 Chapter 17 Pressco part number Description Replace at least: Filter/ regulator. No filter change neces- sary. Kit (contains one each of 67620 and 67621) 67622 It is easier to replace both of these filters at the same time 67620 Filter oil removal Every 2000 hours 67621 Filter oil vapor removal...

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