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FB-2 FT-50 Fill Level Inspector Service Manual

Document 40255-0600

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Table of Contents4
Radiological Safety14
Understanding Radiological Safety14
Radiological Safety Guidelines15
Radiation Measurement Testing Data15
Radiation Warning Labels17
Filtec Model FT-50 Radiation Exposure Profiles18
System Overview22
Fill Level Inspection Basics23
How Underfill Inspection Works24
How Overfill Inspection Works24
Rejection Control Basics25
System Specifications26
Power Requirements26
Operating Temperature26
Pneumatics26
Gamma Source26
Inspection Accuracy27
Physical Size27
Triggering System28
High Resolution Encoder28
Rejection28
Mounting28
Height Adjustment28
Container Types29
Container Spacing29
Control Panel29
System Software30
Optional System Features31
Bulged End Detection31
Missing Lid Detection31
Down Can Detection31
Dud Detection31
External Reject Control32
Serial Interface32
Programmable Logic Controller Interface (PLC)32
Installation Requirements Overview36
Power Supply36
Pneumatics36
Physical Space37
Conveyor System37
Production Conveyor37
Reject Takeaway Conveyor38
Before You Begin42
Basic Terminology42
Installing the42
Unpacking the FT-5043
Installing the FT-50 Inspection System44
Preparing the Conveyor46
Mounting the FT-5047
Assemble the Floor Stand47
Mount and Position the Inspection Head50
Secure the Floor Stand to the Floor52
Install the Slant Support Braces53
Install the Air Purge System58
Install the High-Resolution Encoder60
Mounting the Encoder Inline60
Mounting the Encoder Offset61
Install the Rejector61
Connect the Main Power Source62
Standard Power Supply Wiring62
Wiring the Main Power Supply Cable to the I/O Junction Box64
Power Supply Wiring Examples66
Example A: Standard 115 VAC or 230 VAC with Neutral Line66
Standard 115 VAC or 230 VAC with Neutral Line66
Example B: Using a Voltage Regulating Transformer67
Using a Voltage Regulating Transformer67
Example C: Poly-Phase/Single-Phase from the same System68
Poly-Phase/Single-Phase from the same System68
Example D: High Voltage Poly-Phase Systems (Delta or Wye)69
High Voltage Poly-Phase Systems (Delta or Wye)69
Chapter Overview72
Mechanical Configuration73
Before You Begin74
Aligning the Fill Level Inspection Beam75
Aligning the Inspection Trigger77
Aligning the Missing Lid Sensor Height79
Aligning the Bulged End Sensor Height81
Aligning the down Can Sensor83
Wiring the External Reject Function84
Software Configuration85
Calibrating the Encoder and Rejector Timing85
Configuring the Inspection Looktime Gate86
Configuring the Gamma Threshold88
Setting the Overfill Gamma Threshold89
Setting the Underfill Gamma Threshold90
Configure the Missing Lid Function91
Configure the Bulged End Function91
Configure the Diameter Missing Lid Function92
Configure the down Can Function94
Configure the External Reject Function95
The Control Panel100
Using the Control Panel100
The Function Group Keys100
The Arrow Keys100
Selecting the FT-50'S Operating Mode101
Selecting an Operating Mode101
Software Functions List102
Function Descriptions107
Fill Level Functions Group107
Underfill Status107
Overfill Status107
Gamma Counts107
Target Head Height108
Gamma Threshold108
Looktime Gate108
Fill Level Optimization108
Learn Target Head Height109
Dyn. Reject Pt. Test109
Dyn Prod. Good Test109
Review Fill Level Test109
Container Finish Functions Group110
Bulged End Status110
Missing Lid Status110
Down Can Status110
Diameter Missing Lid Status110
External Reject Status110
Width at down Can110
Height of Can110
Diameter Missing Lid Width111
Minimum Diameter Missing Lid111
Counter Functions Group112
Total Throughput112
Total Rejects112
Total Underfills112
Total Overfills112
Total Missing Lid112
Total Bulged End113
Total down Can113
Total Dia. Missing Lid113
Total External Reject113
Reset All Counters113
Reset Total Throughput113
Reset Total Rejects114
Reset Total Underfill114
Reset Total Overfill114
Reset Total Missing Lid114
Reset Total Bulged End115
Reset Total down Can115
Reset Total Diameter Missing Lid115
Reset Total External Rejects115
Rejector Functions Group116
Rejector Status116
Fire Rejector on Demand116
Rejector Pulse Width116
Reject Next Container116
Inspect Trig to C/L Rej117
Rejector Reaction Delay117
System Functions Group118
Current Container Type118
Last Reject Detected118
Beacon Status118
Line Speed (Cpm)118
Line Speed (Cph)119
System Display119
Conveyor Drive Sprocket119
Serial Data ID Number119
Host/Modbus Port Status120
Modbus Message Counters120
PLC Output Pulse Width120
Time Width of Can121
Chain Velocity121
Alarm Underfills121
Alarm Overfills121
Alarm Missing Lid122
Alarm Bulged End122
Alarm down Can122
Alarm Dia. Missing Lid122
Alarm External Reject122
Load Default Constants122
Can Width at Trig123
Maximum Can Diameter123
Maximum Line Speed123
Maximum Conveyor Speed123
Change Password123
View TB1 & TB4 Pin Assignments124
View PLC Pin Assignments125
Clear System125
Current Language125
Container Text125
Of Container Types126
Current Container Type126
Fill Level126
Underfill Text126
Overfill Text127
Missing Lid128
Missing Lid Text128
Bulged End129
Bulged End Text129
Down Can130
Down Can Text130
Diameter Missing Lid131
Diameter Missing Lid Text131
External Reject132
External Reject Text132
Rejector Type133
PLC Series Alarms133
Serial Interface133
External Trigger Logic133
Known Chain Pitch & Teeth134
Encoder Resolution134
Save Default Constants134
Conveyor Segment Pitch134
Teeth/Conveyor Segment134
Calibrate Encoder134
Calibrate Encoder Value135
Encoder Prescaler Value135
Gamma Sample Cutoff Limit135
Gamma Samples Per Encoder135
Diagnostics Function Group136
How to Access Diagnostic Error Codes136
Diagnostic Error Codes Listing137
Calibration Procedures140
FT-50 Calibration Procedures142
Encoder Calibration Procedures143
Variable Speed Conveyors144
LED Definitions Quick Reference144
Conversion Factors145
How to Determine if You Have Baseline Eight145
Before You Begin146
Standard Conveyor Calibration Procedure147
Unknown Sprocket Size Calibration Procedure152
Executing the Encoder Calibration Routine153
Fine-Tuning the Rejector Timing154
Non-Standard Conveyor Calibration Procedure157
Executing the Encoder Calibration Routine159
Fine-Tuning the Rejector Timing160
Fixed Speed Conveyors163
Before You Begin163
The Line Speed Calibration Procedure165
Fine Tuning the Rejector Timing166
Sensors Calibration Procedures168
Proximity Sensors168
Fiber-Optic Sensors168
Before You Begin168
Calibrating the Centerline Inspection Trigger169
Calibrating the Upstream Inspection Trigger170
Calibrating the Bulged End Sensor171
Calibrating the down Can Sensor172
Radiation Detector Calibration Procedure173
Solid State Detector173
Scintillation Tube Detector173
Calibrating the Scintillation Tube Detector174
Scintillation Detector Calibration Procedure174
Fill Level Optimization176
Before You Begin176
Leveling the Inspection Head177
Executing the Fill Level Optimization Routine178
Establishing the Underfill Gamma Threshold178
Establishing the Target Head Height180
The Dynamic Reject Point Test181
The Dynamic Product Good Test182
The Review Fill Level Test183
Maintenance Schedules186
Daily Schedule186
Weekly Maintenance186
Monthly Maintenance186
120 Day Maintenance187
Maintenance Procedures188
Before You Perform any Maintenance Procedure188
Trigger Beam and Emitter Lenses188
Bulged End and Missing Lid Sensors188
The FT-50 Housing189
Pressure Regulator and Air Filter189
External Wiring189
Replacing the Rejector Pad189
Servicing the Regulator and Coalescing Air Filters190
Diagnostic Error Messages194
Error Number 11194
Error Number 12194
Error Number 14194
Error Number 15195
Error Number 16195
Error Number 22195
Error Number 23195
Error Number 24195
Error Number 25195
Error Number 27196
Error Number 33196
Error Number 34196
Error Number 46197
Error Number 47197
Error Number 48197
Troubleshooting Procedures204
Major Component Subsystems204
Before You Begin204
What You Should Do First205
Power Supply System Troubleshooting206
Testing the Power Supply206
Testing the Power Transformer207
Processing System Troubleshooting208
Main Processor Card208
Serial Communications Card209
The Control Panel209
Sensor System Troubleshooting211
Scintillation Tube Detector (STD)211
Solid State Detector (SSD)211
Optical Sensors212
Proximity Sensors212
Encoder212
Troubleshooting Problems with Rejectors213
Proline Rejector Troubleshooting213
Quick Reference Troubleshooting Guide216
Using a PLC with Your FT-50220
PLC Series Alarms221
How to Determine the Signal Output Wiring222
Adjusting the PLC Output Signal Pulse Width222
Relay Types for Output Signals223
Remote Alarm225
How to Clear a Remote Alarm225
Remote Alarm Error Number Designations225
Controller Board Switch Locations228
Switch Function Configurations229
Switch Function Definitions230
Dip Switch Pack S1230
S1-1: Inspection Logic230
S1-2: Software Write Protect230
S1-3: Speed Tracking230
S1-4: Languages230
S1-5: System Configuration230
S1-6: Not Used230
S1-7: Not Used230
S1-8: Password230
Dip Switch Pack S2231
S2-1: Baud Rate231
S2-2: Handshake Flags231
S2-3: Parity On/Off231
S2-4: Parity Odd/Even231
S2-5: Character Size231
S2-6: Multi-Serial231
S2-7: Led Section Selector231
S2-8: Led Bank Selector231
Slide Switches231
Sw11232
Sw13232
Controller Board LED Locations233
LED Configurations234
LED Logic234
LED Definitions235
Section 1, Bank 1: S2-7 = Closed/S2-8 = Closed235
Section 1, Bank 2: S2-7 = Closed/S2-8 = Open235
Section 2, Bank 1: S2-7 = Open/S2-8 = Closed236
Section 2, Bank 2: S2-7 = Open/S2-8 = Open236

Filtec FT-50c - Documentation Feedback Form

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