Filtec ft-70 User manual

FT-70 and FT-75
Operation Guide
40274-0600

FT-70 and FT-75
Operation Guide
Document 40274-0600
Fill Level Inspectors

Industrial Dynamics Company, Ltd.
Document 40274-0600 Copyright. All rights reserved.
No part of this publication may be reproduced or used in any form or by any means (graphic,
electronic, or mechanical including photocopying, recording, taping, or information storage
and retrieval system) without written permission of 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.
Contact Information
Corporate Headquarters: 3100 Fujita Street,
Torrance, California
90505-4007
U.S.A.
Telephone:[phone]
FAX: [phone]
Internet: www.filtec.com
Mailing Address: P.O. Box 2945,
Torrance, California
90509-2945
U.S.A.
Shipping Address: 3100 Fujita Street,
Torrance, California
90505-4007
U.S.A.
Customer Service: [phone]

Table of Contents
Industrial Dynamics Company, Ltd. Document 40274-0600 III
Table of Contents
Radiological Safety Information
Understanding Radiological Safety VII
Radiological Safety Guidelines VIII
Radiation Measurement Testing Data VIII
Radiation Warning Labels IX
Filtec Model FT-70/75 Radiation Exposure Profiles X
Chapter 1: FT-70/75 System Overview
Inspection System Description 1-3
Fill Level Inspection Basics 1-4
Rejection Control Basics 1-5
Optional System Features 1-6
High Cap/Bulged Can Detection 1-6
Missing Cap/Missing Lid Detection 1-6
Dud Detection 1-6
Low Foam Detection 1-7
Foil Seal Detection 1-7
Smashed Container Detection 1-7
Down Container Detection 1-7
Label Inspection 1-7
Reject Sorting 1-7
Serial Interface 1-7
Programmable Logic Controller Interface (PLC) 1-7
Chapter 2: Operating Your FT-70/75
Starting-Up Your FT-70/75 2-3
The Safety Interlock Switch 2-4
Container Changeover 2-5
Selecting the Container Type to be Inspected 2-5
Adjusting the Inspection Head Height 2-5
Adjusting the Conveyor Guide Rails 2-7
Adjusting the Centerline Trigger Bracket Height 2-7
Adjusting Optional Sensors and Sensor Brackets 2-8
Aligning the Missing Cap Sensor 2-9
Aligning the High Cap Sensor 2-11
Aligning the Smashed Bottle Sensor 2-13
Aligning the Inspection Trigger (Bottles) 2-15
Aligning the Missing Lid Sensor 2-17
Aligning the Bulged Lid Sensor 2-19
Aligning the Down Container Sensor 2-21
Aligning the Inspection Trigger (Cans) 2-22

FT-70/75 Fill Level Inspectors Operator’s Guide
IV Industrial Dynamics Company, Ltd. Document 40274-0600
Chapter Three: Using the System Software
The Operator Control Panel 3-3
Software Function Groups 3-4
The Function Keys 3-4
The Arrow Keys 3-4
Software Functions List 3-5
Software Function Descriptions 3-8
Fill Level Functions Group 3-8
Container Finish Functions Group 3-10
Counters Functions Group 3-11
Rejector Functions Group 3-13
System Functions Group 3-14
Diagnostics Function Group 3-15
Chapter 4: Diagnostics and Troubleshooting
Diagnostic Errors 4-3
Diagnostic Error Codes Listing 4-3
Diagnostic Error Codes Descriptions 4-6
Error Number 2 4-6
Error Number 5 4-6
Error Number 6 4-6
Error Number 10 4-6
Error Number 11 4-6
Error Number 12 4-6
Error Number 13 4-6
Error Number 14 4-7
Error Number 15 4-7
Error Number 16 4-7
Error Numbers 19 and 20 4-7
Error Number 22 4-7
Error Number 23 4-7
Error Number 24 4-7
Error Number 25 4-7
Error Number 27 4-8
Error Numbers 28 4-8
Error Number 33 4-8
Error Number 34 4-8
Error Number 46 4-8
Error Number 47 4-8
Error Number 48 4-8
Error Number 49 4-9
Error Number 50 4-9
Error Number 51 4-9
Error Number 52 4-9
Error Number 53 4-9

Table of Contents
Industrial Dynamics Company, Ltd. Document 40274-0600 V
Error Number 54 4-9
Error Number 58 4-10
Error Number 61 4-10
Error Numbers 64 4-10
Error Number 66 4-10
Error Number 67 4-10
Error Number 68 4-10
Error Number 72 4-10
Error Number 86 4-11
Error Numbers 92-100, 99, 100, 111-114, 116 4-11
Error Number 117 4-11
Error Number 118 4-11
Error Number 119 4-11
Error Number 120 4-11
Error Number 121 4-11
Error Number 123 4-11
Error Number 124 4-12
Error Number 125 4-12
Error Number 126 4-12
Troubleshooting Procedures 4-13
Is the power turned on 4-13
Is the power filter circuit breaker tripped 4-13
Is the X-ray Source Function enabled 4-13
The display does not respond when keys are pressed 4-13
The display shows a blinking cursor and the beacon is on 4-13
There is no display and the beacon is off 4-14
The display is garbled or operates erratically 4-14
False triggers or reject timing malfunctions are occurring 4-14
No triggering occurs 4-14
The rejector does not function 4-15
All containers are rejected 4-15
The rejector is operating erratically 4-15
The rejector arm is sticking or binding 4-16
The rejector arm remains extended 4-16
Rejected container trajectory is sloppy or inconsistent 4-16
Chapter 5: Maintenance Procedures
Maintenance Schedules 5-3
Daily Maintenance 5-3
Weekly Maintenance 5-3
Monthly Maintenance 5-3
120 Day Maintenance 5-4
Maintenance Procedures 5-5
Trigger Beam and Emitter Lenses 5-5
High Cap/Bulged Lid, Missing Cap/Lid, Down Container, and Smashed

FT-70/75 Fill Level Inspectors Operator’s Guide
VI Industrial Dynamics Company, Ltd. Document 40274-0600
Bottle Sensors 5-5
The FT-70/75 Housing 5-6
Pressure Regulator and Air Filter 5-6
External Wiring 5-6
Replacing the Rejector Pad 5-6
Servicing the Regulator and Coalescing Air Filters 5-6

Radiological Safety Information
Industrial Dynamics Company, Ltd. Document 40274-0600 VII
Radiological Safety Information
This section provides information about radiation, radiation safety
procedures, radiation certifications, and the radiation character-
istics of the FT-70/75.
Understanding Radiological Safety
The Filtec Model FT-70/75 utili es an x-ray tube to produce the
x-ray radiation required for performing inspection activities. The
secured and insulated x-ray source housing completely contains
and shields all high voltage components within the x-ray housing
assembly.
The x-ray assembly contains a thermal safety sensor that monitors
the temperature of the x-ray housing assembly and immediately
shuts off (de-energi es) the x-ray generator when the temperature
exceeds 60 degree C. When the x-ray generator is de-energi ed, no
x-ray is produced and there is no residual x-ray exposure.
The only possible way to be exposed to ha ardous levels of radio-
active material using this equipment is externally, through
excessive exposure to a radiation source outside the body. There
are no by products that can be ingested into the body.
The FT-70/75 is unlikely to create ha ardous radiation levels for
the following reasons:
• The FT-70/75’s X-ray Generator produces a relatively weak
source of low energy (low penetrating power) x-ray radiation.
To receive a ha ardous dose of radiation from this low energy
source would require extremely long exposure directly to the
main radiation beam.
• While we warn against placing hands or other body parts in
front of the x-ray beam when it is turned on, it would require
several hours of exposure for the hand to receive an excessive
radiation dose.
• The x-ray beam is tightly confined by shields and collimators
and is completely contained within the inspection tunnel.
Because the radiation beam does not spread outside the
inspection tunnel, it is highly unlikely that under normal
circumstances an appreciable radiation dose could be incurred
at a location other than directly in front of the main x-ray beam
when the x-ray source is turned on.

FT-70/75 Fill Level Inspectors Operator’s Guide
VIII
Radiological Safety Guidelines
1. Do not tamper with the x-ray housing.
2. Do not place the hands between the x-ray source and the
detector when the x-ray is turned on.
3. If you have any questions regarding the x-ray safety or
operation, contact Industrial Dynamics.
Radiation Measurement Testing Data
1. All measurements were taken with Technical Associates Model
Pug-1 survey meter that was cross calibrated against an air
ioni ation chamber survey meter whose response was
corrected against an Americium-241 test source.
2. Interlock/Electronic Shutter closed - The radiation levels are
not measurable.
3. Interlock/Electronic Shutter open - The extent of the main
x-ray beam is completely contained within the tunnel formed
by the inspection head and shielding bar. All radiation levels
outside the main beam are less than 0.05 MR/HR.
4. Machine has optional safety input provided that will disable
the x-ray. The normal inputs used are safety door interlock, or
conveyor run or any other safety item.
Industrial Dynamics Company, Ltd. Document 40274-0600

Radiological Safety Information
IX
Radiation Warning Labels
Figure 1. Warning labels attached to Filtec Model FT-70/75 Inspection System. The information
on these labels are very important and should be followed explicitly.
?
6
INDUSTRIALDYNAMICS
Torrance,CaliforniaUSA
MODELFT-70
FILLLEVELINSPECTOR
4
3
5
1
2
36906-X
FACTORY
ADJUSTMENT
–ONLY–
DO NOT
REMOVE
INDUSTRIAL
DYNAMICS CO.
TORRANCE, CA
U.S.A.
ENABLED
+24VDC
X-RAY
EMMITTING
DO NOT REMOVE
CAUTION: X-RAY HAZARD
DO NOT INSERT HANDS OR ANY
PORTION OF BODY IN TUNNEL.
X-RAYS PRODUCED WHEN ENERGIZED.
X-RAY ON/OFF
CONTROL
X-RAY ON
INDICATOR
Industrial Dynamics Company, Ltd. Document 40274-0600

FT-70/75 Fill Level Inspectors Operator’s Guide
X Industrial Dynamics Company, Ltd. Document 40274-0600
Filtec Model FT-70/75 Radiation Exposure Profiles
X-RAY GAUGE: 45 KV @ 50 µ A with 2 (.015 inch) BeKu Filters
Figure 2. FT-70/75 Radiation Profile Schematic.
4" TO
7.5
"
1
1
2
3
3
4
4
5
5
6
6
7
7&8
8
No. Description No. Description
1 Inspection Head 5 5 cm Isodistance Contour
2 Inspection Tunnel 6 Radiation Detector
3 Sealed X-ray Source 7 Shielding Bar (1/4”Thick Steel)
4 Limits of Main Beam 8 Detector Window

Radiological Safety Information
Industrial Dynamics Company, Ltd. Document 40274-0600 XI
Figure 3. FT-70/75 Certificate of x-ray output measurement.

FT-70/75 Fill Level Inspectors Operator’s Guide
XII Industrial Dynamics Company, Ltd. Document 40274-0600

Chapter 1: FT-70/75 System Overview
1-1
Chapter 1:
FT-70/75 System Overview
Inspection System Description 1-3
Fill Level Inspection Basics 1-4
Rejection Control Basics 1-5
Optional System Features 1-6
High Cap/Bulged Can Detection 1-6
Missing Cap/Missing Lid Detection 1-6
Dud Detection 1-6
Low Foam Detection 1-7
Foil Seal Detection 1-7
Smashed Container Detection 1-7
Down Can Detection 1-7
Label Inspection 1-7
Reject Sorting 1-7
Serial Interface 1-7
Programmable Logic Controller Interface (PLC) 1-7
Industrial Dynamics Company, Ltd. Document 40274-0600

FT-70/75 Fill Level Inspectors Operator’s Guide
1-2 Industrial Dynamics Company, Ltd. Document 40274-0600

Chapter 1: FT-70/75 System Overview
Inspection System Description
This manual provides operator’s information about the bottle and
can versions of the FT-70 and FT-75 Inspection Systems. Unless
specifically indicted otherwise, this manual refers to both versions
of the FT-70 and FT-75 (FT-70/75).
• The FT-70 provides high speed overfill or underfill (not
concurrent) fill level container inspection.
• The FT-75 provides high speed concurrent overfill and
underfill fill level container inspection.
Additional inspection options, such as Missing Cap Detection,
Missing Label Detection, and Smashed Bottle Detection, may be
added to the FT-70/75 to enhance its functionality. For more infor-
mation see “Optional System Features” on page 1-6.
Figure 1-1. The FT-70/75 Fill Level Inspector.
Industrial Dynamics Company, Ltd. Document 40274-0600 1-3

FT-70/75 Fill Level Inspectors Operator’s Guide
1-4
Fill Level Inspection Basics
The FT-70/75 Fill Level Inspection systems utili es a Container
Radiation Profile Comparison Principle to create a radiation finger-
print of the container.
To create a radiation profile a x-ray beam is directed through the
container. Some of the radiation is blocked by the container
material and container’s contents while the remaining x-rays
emerge from the opposite side of the container where they are
measured by an x-ray detector.
The amount of radiation measured is the containers Radiation
Profile, or fingerprint, which is then compared against a Master
Container Profile .
Figure 1-2. Scanning the container.
To allow for slight variances in the fill level an Underfill Threshold
and Overfill Threshold are determined (both for the FT-75 and one
or the other for the FT-70). These thresholds form the tolerance
range for deviation from the Master Profile. This tolerance range
between the thresholds is called the Target Zone. Any container
with an x-ray count that falls below the Underfill Threshold is
rejected as an underfill and any container with a X-ray count that
rises above the Overfill Threshold is rejected as an overfill.
?6
INDUSTRIAL DYNAMICS
Torrance, California USA
MODEL FT-50
FILL LEVEL INSPECTOR
4
35
1
2
1
32
No. Description
1 X-ray Source
2 X-ray Beam
3 X-ray Detector
Industrial Dynamics Company, Ltd. Document 40274-0600

Chapter 1: FT-70/75 System Overview
1-5
Rejection Control Basics
The FT-70/75 identifies and then tracks any container that fails
inspection. Tracking begins the moment the container crosses the
Inspection Trigger Beam in the and ends when the container
reaches the rejector centerline.
Figure 1-3. Tracking containers that fail inspection.
To maintain container tracking and to synchroni e the rejector to
the conveyor, the FT-70/75 uses a high-resolution encoder coupled
directly to the conveyor drive sprocket. The encoder sends timing
pulses to the FT-70/75 which uses the pulses to determine the
container’s position as it moves along the conveyor between the
FT-70/75 and the rejector. When the container reaches the rejector
centerline the FT-70/75 emits a reject signal which activates the
rejector and removes the container from the production line.
1
23
54
X
No. Description
1 FT-70/75
2 Inspection Trigger Location
3 Extent of Tracking Area (gray)
4 Rejector Centerline
5 Rejector
Industrial Dynamics Company, Ltd. Document 40274-0600

FT-70/75 Fill Level Inspectors Operator’s Guide
1-6
Optional System Features
The FT-70/75’s expandability allows you to add additional
inspection capabilities to match your production requirements.
Depending upon the FT-70/75 configuration you ordered, your
unit may contain some of the following features:
• High Cap/Bulged Can Detection
• Missing Cap/ Missing Lid Detection
• Dud Detection (High and Low Container Pressure)
• Smashed Bottle Detection
• Down Container Detection
• Low Foam Detection
• Foil Seal Detection
• Label Inspection
• Reject Sorting (Servotec only)
• External Reject Control
• Serial Controller Interface (Modbus or IDC Protocols)
• Programmable Logic Controller Interface (PLC)
Note
If you are unsure which options your unit contains, contact your
Service Department for information.
High Cap/Bulged Can Detection
This feature utili es an optical sensor detect improperly seated
caps on bottles or bulged lids on cans.
Missing Cap/Missing Lid Detection
This feature detects the presence or absence of the container cap
(bottle) or lid (can). It is compatible with either plastic or metal
caps and lids.
Dud Detection
This feature detects improper pressuri ation of vacuum sealed or
pressure sealed containers.
Industrial Dynamics Company, Ltd. Document 40274-0600

Chapter 1: FT-70/75 System Overview
Low Foam Detection
This feature uses a optical sensor to detect a low foam condition
within the container. This option is only available for clear
containers.
Foil Seal Detection
This feature uses a proximity sensor to detect a foil seal under the
container cap. This option is available only for containers with
plastic caps.
Smashed Container Detection
This feature uses a optical sensor to detect a smashed (plastic) or
broken container (glass). This feature requires a slat rejector.
Down Container Detection
This feature uses a optical sensor to detect a container that has
been knocked over onto its side. Bottle versions require a slat
rejector.
Label Inspection
Depending upon the complexity of the container label configu-
ration, optical sensor arrays are used to detect the presence of a
label or labels, including barcode verification.
Reject Sorting
This option allows the FT-70/75 to classify the various types of
rejects and then reject them into different reject bins, or reject
conveyor lanes, based upon the classifications. This option
requires the Servotec rejector and is available for bottle versions
only.
Serial Interface
Provides serial network communications over RS-232, RS-422,
RS-423 and RS-485 networks at 1200 or 9600 baud. It allows direct
control of the FT-70/75 from a host computer or PLC.
Programmable Logic Controller Interface (PLC)
Provides direct access to the signal wiring so that you can transmit
control signals to the FT-70/75 and receive signals from the
FT-70/75. This option requires the I/O Junction Box.
Industrial Dynamics Company,Ltd. Document40274-0600 1-7Industrial Dynamics Company, Ltd. Document 40274-0600