TapTone T4000

Users Manual
M-412-066
Rev. A
(English Version)

TELEDYNE TAPTONE
49 Edgerton Drive
North Falmouth, Massachusetts
02556-2826 USA
Phone: 1-508-563-1000
Fax: 1-508-564-9945
Copyright 2009 TELEDYNE TAPTONE

TapTone T4000 Users Manual M-412-066 Rev.A

[1]

About TapTone T4000

The TapTone T4000 is a powerful control platform that
monitors multiple on-line inspections at line speeds up
to 2000 containers per minute. User controls are done
on the large color touch screen display. The inspection
sensors are based on five technologies. [1]
Acoustic Sensor (T4000-A) measures the acoustic
response of the lid to an electro-magnetic pulse. The
sound signal is proportional to the vacuum or pressure
level in the container. Low sound signals indicate a
seal defect. [2]

[2]

[3]

Proximity Sensors (T4000-P) measures the curvature

of metal lids or pop button closures. Reduced lid
curvature relates to loss of pressure or vacuum indicating
a seal defect. [3]

[4]

Single Load Cell Sensor (T4000-FS, T4000-F or

T4000-C) measures the force side wall of plastic or metal
containers during compression using a singe force
sensor. Reduced force will indicate leaker. [4]
Dual Load Cell Sensors (T4000-DSC or T4000-PBI)
two load cell sensors measures the force on the sidewall
of plastic containers at the entry and exit of the
compression belts. Reduced force at exit sensor
indicated leaker. [5]

[5]
[6]

X-Ray Sensor (T4000-X) measures the fill level using

an x-ray beam that penetrates container walls to view the
product level inside the container. Both over-filled or
under-filled containers can be rejected from the line. [6]

TapTone T4000 Users Manual M-412-066 Rev.A

SAFETY
LABELS

Operators must obey all safety labels and warnings.

WARNING: Reference Operations Manual for Details!

X-RAY EMISSIONS
DIRECTION LABEL:
X-ray Emissions in
Direction of Arrow!

WARNING: Electrical Shock Hazard!

WARNING: Hand or Limb Crush Hazard!

WARNING: Keep Hands Clear!

X-RAY INDICATOR
LAMP LABEL:
X-ray Emissions Present
when Lamp is ON.

REJECT INDICATOR
LAMP LABEL:
Rejector is OFF when
Flashing! OR
A rejected container
has occurred!

WARNING: Keep Hands Clear of x-ray Tunnel!

NOTICE: Refer to Operations Manual M-412-102 for complete list of Cautions and Warnings!

TapTone T4000 Users Manual M-412-066 Rev.A

MECHANICAL
SETUP

[4]

[3]
[4]
[1]

Before turning ON the T4000, inspect the equipment for

proper mechanical adjustments.
Check Height and Width Alignment of Belts:

Is the belt width set up for container? [1]

Is the belt height setup for container? [2]

[5]
[2]

Are all safety guards closed.? [3]

Are all E-Stop buttons reset (out)? [4]

[6]

Check Alignment of X-Ray Tunnel:

Is the x-ray tunnel set the proper height? [5]

[4]

Are the photo beams looking in the proper location? [6]

Are the conveyor rails in the proper position? [7]
[8]

Check Alignment of Inspection Head Assembly:

Is the head approximately 4mm above the top of the
container, 150 counts above the top of container? [8]

Is the container aligned directly beneath the center
of the sensor head? [9]

[7]
[9]
[12]

Are the photo beams looking in the proper location? [10]

Are the conveyor rails in the proper position? [11]

Is the red protective cleaning cover removed from
acoustic head sensor? [12]

[10]
[8]
[11]

TapTone T4000 Users Manual M-412-066 Rev.A

REJECTOR
SETUP

[2]

[1]

Review the rejector assembly before running the T4000.

Is the air cutoff gate open (up position)? [1]

Is the air pressure set properly? Set to 40-60 psi. [2]

Is the lubricator filled with petroleum-based 10weight oil? [3]

Is the water filter bowl full? [4]

[2]

To drain water from bowl when full, turn lever 90

degrees. [5] (check this only with air cutoff gate closed
(down position)!

Is the reject pad square to containers? [6]

Is the reject pad 2mm away from the containers on
the conveyor? [7]

Does the reject pad extend smoothly with no
sticking? [6] (check this with air cutoff gate closed
down position and no product running on line [1])

[3]

[4]
[7]

[5]

[6]

TapTone T4000 Users Manual M-412-066 Rev.A

INDICATORS AND
CONTROLS

The T4000 control panel allows operators to check

current product inspection results and change the
T4000 to different product types during product
changeover. System control is managed by color touch
screen with function keys. The power ON/OFF switch is
located on the right side or the front of the enclosuresee Turning System ON / OFF, page 7.

Color Touch Screen Display Various screens
show system status, parameters, statistical data, and
function key descriptions. Touch the screen location to
enter desired functions. [1]

Warning: Do not open cabinet door, there are no

user controls inside.

[6]
[5]
[4]

Main Menu Key This key opens the function key

icon list for the sidebar menus. [2]

7 Function Keys These keys are used to quickly
enter into specific menu screens . [3]

Status Lamp (Green) This lamp indicated system
status is OK when lit. See Alarm status bar in lower
right corner of display for alarm conditions if lamp is
OFF. [4]

[1]
[3]
[7]
[2]

Reject Lamp (Amber) This lamp will flash ON for

1 second each time a container fails any inspection. If
the rejector is disabled the lamp will flash on and off. [5]

X-RAY Lamp (Red) This lamp will light whenever
the x-ray emissions are ON. Do not stick you hands in
the x-ray tunnel when this lamp is ON. Press the x-ray
OFF button to disable the x-ray emissions. [6]

Power Switch This switch turns the AC power
ON and OFF to the display. [7]

[4]
[6]

TapTone T4000 Users Manual M-412-066 Rev.A

TURNING SYSTEM
ON / OFF

[3]

Before operating T4000, become familiar with the setup

and controls.
Turning ON TapTone T4000 System:

Turn ON the main power switch located on the front
of the motor control enclosure. [1]

[2]
[1]

Turn ON the display power switch located on the left

side of the display enclosure. [2]

Make sure all E-Stop buttons reset (out) and all
safety guards are closed. [3]

[6]

[3]

Press the START conveyor belts button to start

inspection belts turning. Production conveyor must be
turning before belt will turn.[4]
Turning OFF TapTone T4000:

[6]

Press the STOP conveyor belts button. Make sure

no containers are in the belts before stopping belts. [5]

Turn OFF the display power switch located on the
left side of the display enclosure. [2]

Turn OFF the main power switch located on the front

of the motor control enclosure. [1]
Prepare the TapTone T4000 for Cleaning:

[5]

[4]

Check that the all enclosure doors are closed and

locked. [6]

Check that the plastic transducer wash down cover
in place on the acoustic sensor head if applicable. [7]

[7]

TapTone T4000 Users Manual M-412-066 Rev.A

TURNING THE
REJECTOR ON / OFF

The T4000 reject function is controlled by the ON/OFF

buttons on the display. The amber reject lamp indicates
the status of the reject function. The reject lamp will be
off when the rejector is ON (enabled) and the reject
lamp will flash every second when the rejector is OFF
(disabled).

Turning Reject OFF Press the reject OFF button
to turn the reject function OFF (disabled). [0]
The reject lamp will flash every second when the
rejector is OFF (disabled). [2]

Turning Reject ON Press the reject ON button to
turn the reject function ON (enabled). [1]
The reject lamp will be OFF except when a reject is
detected. [2]

[0]

[2]

[1]

TapTone T4000 Users Manual M-412-066 Rev.A

TURNING THE X-RAY

EMISSIONS ON / OFF

The T4000 x-ray emissions function is controlled by the

rejector ON/OFF buttons. The x-ray lamp on top of
control box indicates the status of the x-ray emissions.
The x-ray emissions are ON when the x-ray lamp is lit.
The x-ray emissions are OFF when the x-ray lamp is not
lit. Section valid when x-ray fill height sensor installed.

Turning X-ray Emissions OFF Press the reject
OFF button. The x-ray lamp will be OFF once the button
is pressed. Both the x-ray transmitter and rejector will
be turned OFF. [0]

Turning X-ray Emissions ON Press the reject
ON button to turn the x-ray emissions ON and the
rejector will be enabled. The x-ray lamp will be ON
once the button is pressed. [1]

[0]

Warning: Do not place your hands in the x-ray

tunnel area when the x-ray lamp is ON! [2]

[2]

[1]

9

TapTone T4000 Users Manual M-412-066 Rev.A

RETURN TO
HOME SCREEN

Return to Home Screen:

After turning ON the T4000, the Home Screen will

appear after the boot-up sequence.
This screen
provides access to the change products and clear
production counters screen.

Press the menu button to display Icon buttons. [1]

Press the Home button to return to the home screen
from any menu. [2]

[2]

[1]

10

TapTone T4000 Users Manual M-412-066 Rev.A

LOG IN
PASSWORD

The T4000 can store ten (10) different user groups with
different levels of authorization to specific setup menus.
Log In Procedure:

Any button that displays a pad-lock requires an
authorized password to enter that menu. [1]

Press the menu button [2] then press Log In button. [3]

[1]

Always enter four (4) digits for valid password. [4]

Press OK to activate password and remove pad-lock
from menus. [5]
[3]

[2]

[4]

[5]

[5]

11

TapTone T4000 Users Manual M-412-066 Rev.A

CLEAR
COUNTERS
[1]

The T4000 will record the production counters for all

inspections until the counters are cleared by the user.
The Clear Counters button is password protected so
only authorized users can reset the counters to zero.
Clearing the Counters:

Log In the password to un-lock the Clear Counts
button. See section Log In Password on page 11.

Press the Clear Counts button to enter the clear
counters menu. [1]

Select the Counters to be cleared by pressing the
check box next to each inspection sensor. Use the
Select All button to choose all inspections at once. [2]

Press the Clear button to reset all selected counters
to zero. [3]

Press the Close button to exit the clear counters
menu and return to Home Screen. [4]

[2]

[3]

[4]

12

TapTone T4000 Users Manual M-412-066 Rev.A

CHANGING
PRODUCT TYPES

The T4000 can store sixteen (16) different product

setups for easy recall when changing container styles
during normal production changeovers. The Product
button is password protected so only authorized users
can change product types.

[1]

Change Product Type:

Log In the password to un-lock the Change Product
button. See section Log In Password on page 11.

Press the Change Product button to enter the
product selection menu. [1]

Press the
selection. [3]

Select

Product

button

to

[2]

activate

Press the desired product type to match container

type. [2]

Set the sensor positions based on stored digital

indicator values then press Done. [4]

Press Exit to return to Home Screen. [5]

[3]

[5]

[4]

13

TapTone T4000 Users Manual M-412-066 Rev.A

The T4000 detailed counters screen will display all

active inspection sensors for that product type. Within
each sensor box will be the detailed counters for each
inspection algorithm that has upper or lower reject limits
to determine pass/fail status.

LAST
REJECTS SCREEN
[1]

Last Reject Screen:

Press anywhere on the counters box to enter the
detailed counters screen. [1]

The Last Rejects box displays the last 10 rejected
containers with time stamp, type of sensor and which
input number. [2]

Each sensor has a detailed counters box with total
production (black), total pass (green) and total fail (red)
counts with percentage rejects for each inspection. [3]

[3]

[2]

14

TapTone T4000 Users Manual M-412-066 Rev.A

TROUBLESHOOTING
ALARM CONDITIONS

The T4000 has a dedicated alarm tool bar where all

alarm to display system conditions and faults.
Alarm Tool Bar:

[1]

The alarm tool bar provides the user with instant

feedback to the operations of the T4000 system. This
tool bar is visible from every screen. [1]
When Alarm Bar is Green:

If the alarm bar is green this indicated there are no
alarm or fault conditions. [2]
When Alarm Bar is Red:

If the alarm bar is red this indicated a fault condition
that could effect operation of the system. [3]

[2]

If alarm conditions cannot be solved by operator then

contact your supervisor or maintenance personnel. [3]
Typical Fault Conditions:

[3]

Rejector 1 is OFF !

X-Ray source is OFF !

E-Stop 1 Activated !

Inspection Motors Stopped !

Shaft Encoder Stopped !

Air Pressure Fault !

Trigger 1 Blocked !

Short Trigger 1 Break !

Long Trigger 1 Break !

15

TapTone T4000 Users Manual M-412-066 Rev.A

TOO MANY
FALSE REJECTS

If the T4000 has excessive false

following steps in order. For help
machine, see Mechanical Setup,
steps do not fix the problem, notify
maintenance department.

rejects, check the

with adjusting the
page 4. If these
your supervisor or

False Rejects?

Is the product type set the proper setting for the
container type? If not, set the product type to the proper
setting. See Changing Product Types, page 13.

Is the alarm bar red? If so, check the error message
on the screen. See Troubleshooting Alarm
Conditions , page 15.

Single Load Cell Sensor:

Is the conveyor belt height too high or too low? If so,
adjust the belt height to the proper setting.

Is the conveyor belt width too wide or too narrow? If
so, adjust the belt width to the proper setting.
Dual Load Cell Sensor:

Is the conveyor belt height too high or too low? If so,
adjust the belt height to the proper setting.

Is the conveyor belt width too wide or too narrow? If
so, adjust the belt width to the proper setting.

Acoustic or Proximity Sensors:

Is the transducer head too high or too low? If so, set
the transducer head to the proper height.

Is the photo beam shining over or through the
container? If so, reset the photo beam height and
alignment.
X-ray Sensors:

Is the x-ray bridge height too high or too low? If so,
set the x-ray bridge height to the proper setting.
Rejector System:

Is the rejector pad hitting the container properly? If
not, adjust the reject pad properly. See Rejector Setup,
page 5.

16

TapTone T4000 Users Manual M-412-066 Rev.A

DOES NOT
REJECT DEFECTS

If the T4000 is not rejecting known defective containers,

check the following steps in order. For help with
adjusting the machine, see Mechanical Setup, page 4.
If these steps do not fix the problem, notify your
supervisor or maintenance department.

Rejector Functions:

Is the rejector air supply turned on? If not, check the
air supply shut-off gate. See Rejector Setup, page 5.

No Rejection?

Is the air pressure properly set? If not, set the air

regulator to the correct pressure (40 to 60 psi). See
Rejector Setup, page 5.

Is the product type set the proper setting for the

container type? If not, set the product type to the proper
setting. See Changing Product Types, page 13.

Is the rejector cable properly plugged in? If not, plug

it in to the bottom of the junction box bottom left side
socket.

Is the reject lamp flashing? If so, press the reject ON

button to enable the rejector ON.
See Turning the Rejector ON/OFF, page 8.

Is the alarm bar red? If so, check the error message
on the screen. See Troubleshooting Alarm
Conditions , page 15.

Do counters automatically update? If not, clean the
photo beam lenses.

17

TapTone T4000 Users Manual M-412-066 Rev.A

CLEANING
PROCEDURES
[1]

[2]

The T4000 is NEMA-4X (IP65) rated for wash-down

which allow for low pressure hosing of the system with
water. Follow the cleaning procedures to ensure proper
operation.
Cleaning the System:

Turn the system OFF before cleaning. See section
Turning System ON/OFF on page 6.

DO NOT use high pressure water hose on face of
display. [1]

DO NOT use harsh cleaning chemicals on face of
display. Use only mild soap and water with a soft cloth
to clean the touch screen display. [2]
[3]

DO NOT use harsh cleaning chemicals on rubber

belts. Use only mild soap and water with a soft cloth to
clean the face of the belts. [3]

You can clean the rest of the machine with low
pressure water hose. [4]

[5]

Apply the plastic transducer wash down cover in

place on the acoustic sensor head if applicable. [5]

[4]

18