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TapTone 4000

Operations
Manual
M-412-102
Software Versions up to 7.0
Rev. C
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TapTone 4000
Operations Manual
Software Versions up to 7.0

M-412-102

Rev. C
(English)

TELEDYNE TAPTONE
49 Edgerton Drive
North Falmouth, Massachusetts
02556-2828 USA

Phone: 508-563-1000
Fax: 508-564-9945
www.taptone.com
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M-412-102 Table of Contents
Table of Contents

1.0 Introduction ................................................................................... 1


1.1 TapTone 4000 User Interface .......................................................... 1
1.2 Sensor Configurations ..................................................................... 2
2.0 Safety Precautions ........................................................................ 3
2.1 General Safety Precautions ............................................................. 3
2.2 Specific Cautions and Warnings ...................................................... 4
2.2.1 Conveyor Type Sensor Cautions and Warnings ........................ 4
2.2.2 X-ray Sensor Cautions and Warnings........................................ 4
2.3 Safety Label Descriptions ................................................................ 5
3.0 Programming Instructions ............................................................ 7
3.1 Main Menu ....................................................................................... 7
3.2 Home Screens ................................................................................. 8
3.2.1 System Configuration Home Screen ......................................... 8
3.2.2 Counters Home Screen ............................................................. 8
3.2.3 Change Home Screen ............................................................... 9
3.2.4 Change Machine Name ............................................................. 9
3.2.5 Change Button Prompts ............................................................ 9
3.3 Product Type Menu........................................................................ 10
3.3.1 Change Product Type ............................................................. 11
3.3.2 Copy Product Types ................................................................ 12
3.3.3 Enter Product Type Menu........................................................ 12
3.3.4 Change Product Type Name ................................................... 13
3.3.5 Change Product Height or Width Values ................................. 13
3.3.6 Change Container Icon............................................................ 14
3.4 Counters ........................................................................................ 15
3.4.1 Enter Detailed Counts Screen ................................................. 15
3.4.2 Clear Counters ........................................................................ 15
3.4.3 Last Reject List ........................................................................ 16
3.4.4 Last Reject Trend Graph ......................................................... 17
3.5 Rejector ON/OFF ........................................................................... 18
3.6 Inspection Conveyors Start/Stop .................................................... 18
3.7 Log In Menu ................................................................................... 19
3.7.1 Log-In Procedure..................................................................... 19
3.8 System Configuration Screen ........................................................ 20
3.8.1 Get to Configuration Screen .................................................... 20

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M-412-102 Table of Contents
3.9 Parameters Rejector ...................................................................... 21
3.9.1 Force Rejects .......................................................................... 23
3.9.2 Reject Acknowledge ................................................................ 24
3.9.3 Shaft Encoder ......................................................................... 25
3.10 Parameters (All Sensors) ............................................................. 29
3.10.1 Parameters - DSC ................................................................. 29
3.10.2 Parameters - Digital Inputs .................................................... 35
3.11.3 Parameters - X-ray ................................................................ 38
3.10.4 Parameters - Force/Compression .......................................... 40
3.10.5 Parameters - Proximity .......................................................... 42
3.10.6 Parameters - Acoustic ........................................................... 48
3.10.7 Parameters - Cocked Crown ................................................. 53
3.10.8 Parameters – High Frequency ............................................... 55
3.11 Histograms Menu ......................................................................... 59
3.11.1 Get to Histogram Screens ..................................................... 59
3.11.2 Select Histogram Type .......................................................... 60
3.11.3 Adjust Fixed Reject Limits ..................................................... 63
3.11.4 Adjust Autotracking Reject Limits .......................................... 64
3.12 Merit Values Menu ....................................................................... 65
3.12.1 Merit Value Boxes ................................................................. 65
3.12.2 X-Ray Merit Values ............................................................... 65
3.12.3 Force Merit Value ................................................................. 65
3.12.4 Optional Input Merit Values ................................................... 66
3.12.5 DSC Merit Values .................................................................. 66
3.12.6 Acoustic / Cocked Crown Merit Values .................................. 67
3.12.6 Proximity Merit Values ........................................................... 67
3.12.7 High Frequency Merit Value .................................................. 67
3.13 Trend Graphs ............................................................................... 68
3.13.1 Setup Logs ............................................................................ 69
3.14 Waveforms Menu ......................................................................... 70
3.15 Advanced Menu ........................................................................... 71
3.16 Add Inspection ............................................................................. 72
3.17 Trigger Setup ............................................................................... 76
3.17.1 Get to Trigger Setup Screen .................................................. 76
3.17.2 Trigger Screen Description .................................................... 77
3.17.3 Trigger Setup Procedure ....................................................... 78
3.18 Input Matrix .................................................................................. 79
3.19 Outputs ........................................................................................ 80
3.19.1 View Digital Outputs .............................................................. 80
3.19.2 Alarm Outputs (Ready-1, Fault-2, Good-3) ............................ 82
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3.19.3 Relay Outputs 1, 2 & 3 .......................................................... 84
3.20 Logs ............................................................................................. 87
3.20.1 Setup Logs ............................................................................ 88
3.20.2 View Log Files on Screen ...................................................... 88
3.20.3 Save Logs to Flash Card ....................................................... 90
3.20.4 Download Log Files through Ethernet.................................... 91
3.21 Interface Configuration ................................................................. 93
3.21.1 User Preferences .................................................................. 93
3.21.2 Languages ............................................................................ 94
3.21.3 Password Setup .................................................................... 95
3.22 Communications ........................................................................ 100
3.22.1 Ethernet Port ....................................................................... 101
3.22.3 Serial Port RS-232 .............................................................. 101
3.23 Touch Screen Calibration........................................................... 102
3.24 Date and Time ........................................................................... 103
3.25 Utilities ....................................................................................... 104
3.25.1 Machine Backup/Restore .................................................... 104
3.25.2 CF Card Utilities .................................................................. 105
3.25.3 DSP/COMM Board Upgrade ............................................... 106
3.25.4 Reset System Memory ........................................................ 106
3.26 Diagnostics Menu ...................................................................... 107
3.26.1 Rejector and Encoder Diagnostics ...................................... 107
3.26.2 Trigger Diagnostics ............................................................. 108
3.26.3 Inspection Diagnostics......................................................... 109
3.26.4 Input / Output Diagnostics ................................................... 110
3.26.5 Waveforms .......................................................................... 114
3.26.6 Software Versions ............................................................... 115
3.27 Alarm Menu ............................................................................... 116
3.27.1 Active Alarms Screen .......................................................... 117
3.27.2 Alarm Display ...................................................................... 118
3.27.3 Triggers ............................................................................... 119
3.27.4 Rejectors & Encoders .......................................................... 120
3.27.5 Inspections .......................................................................... 121
3.27.6 E-stops and Motors ............................................................. 122

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Table of Figures

Figure 1-1 TapTone T4000 Touch Screen Display ................................................................................................ 1


Figure 2-1 Safety Labels ........................................................................................................................................ 5
Figure 2-2 X-ray Safety Labels .............................................................................................................................. 6

Preface

All information within this manual is a copyright of Teledyne TapTone and may not be
duplicated without the written consent or approval from Teledyne TapTone.

Teledyne TapTone reserves the right to make changes to the manual without obligation to
notify any person(s) or entities of revisions. It is recommended that the installation of your
Teledyne TapTone equipment is performed or supervised by an authorized Teledyne
TapTone representative.

Reference Manuals

Machine Type Manual Type Manual Number Language


All T4000 Systems Operations Manual M-412-102 English
T4000 DSC Setup Manual M-412-064 English
T4000 DSC Maintenance Manual M-412-065 English
T4000 FS Setup Manual M-412-100 English
T4000 FS Maintenance Manual M-412-101 English
T4000 F/C Setup Manual M-412-104 English
T4000 F/C Maintenance Manual M-412-105 English
T4000 PBI-E Setup Manual M-412-070 English
T4000 PBI-E Maintenance Manual M-412-071 English
T4000 A, P, X, H Setup Manual M-412-073 English
T4000 A, P, X, H Maintenance Manual M-412-074 English
T4000 DSC, FS Trigger Air Purge Kit M-412-068 English
T4000 DSC, FS Belt Wash Kit M-412-069 English
T4000 DSC, FS, F, C Air Pressure Monitor Kit M-412-072 English
All T4000 Systems Ethernet Communications M-412-103 English

All T4000 Sensors Users Manual (Quick Guide) M-412-066 English


All T4000 Sensors Users Manual (Quick Guide) M-412-076 Spanish
All T4000 Sensors Users Manual (Quick Guide) M-412-077 German
All T4000 Sensors Users Manual (Quick Guide) M-412-078 French
All T4000 Sensors Users Manual (Quick Guide) M-412-079 Dutch
All T4000 Sensors Users Manual (Quick Guide) M-412-080 Portuguese
All T4000 Sensors Users Manual (Quick Guide) M-412-081 Italian
All T4000 Sensors Users Manual (Quick Guide) M-412-082 Swedish
All T4000 Sensors Users Manual (Quick Guide) M-412-083 Russian
All T4000 Sensors Users Manual (Quick Guide) M-412-084 Polish
All T4000 Sensors Users Manual (Quick Guide) M-412-085 Czechoslovakian
All T4000 Sensors Users Manual (Quick Guide) M-412-086 Chinese
All T4000 Sensors Users Manual (Quick Guide) M-412-087 Korean
All T4000 Sensors Users Manual (Quick Guide) M-412-088 Japanese
All T4000 Sensors Users Manual (Quick Guide) M-412-089 Thai

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M-412-102 Chapter 1: Introduction

1.0 Introduction
1.1 TapTone 4000 User Interface

Notice: This operations manual defined the user screens for every T4000 sensor.
Some sensors may not apply to your specific installation so just skip over those sections not
pertaining to your system.

The TapTone 4000 (T4000) control box is a high performance multi-function control platform
that performs all inspection processing and HMI (Human Machine Interface) functionality for a
wide variety of inspection sensors.
Some of the features include:
4 AC analog inputs
4 DC analog inputs
4 digital DC inputs (dedicated)
4 digital DC inputs (user selectable)
4 digital DC outputs (dedicated)
4 digital DC outputs (user selectable)
12 digital trigger sensor inputs
2 High speed encoder inputs
5 RS-232 serial ports
3 RS-485 serial ports
1 Ethernet port

Figure 1-1 TapTone T4000 Touch Screen Display

Notice: This manual covers software versions up to and including V7.0

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M-412-102 Chapter 1: Introduction
1.2 Sensor Configurations

1. T4000-DSC and T4000-PBI – Both systems measure for leakers using Patented dual
load cell technology.

2. Force – Measures for leaks using Patented single load cell technology. Systems may
be configured using the low pressure force (F) conveyor, low pressure compression
(C) conveyor or the high pressure force (FS) conveyor.

3. Acoustic – Measures pressure or vacuum loss on beer crowns and steel cans using
the acoustic technology developed by TapTone.

4. Cocked Crown – Measures curvature of steel beer crowns for physical defects using
an analog proximity sensor.

5. X-Ray – Measures under and over fill level in cans, glass and plastic containers using
x-ray tube technology.

6. High Frequency – Measures under and overfill levels in plastic or glass containers
using non-radiation high frequency technology.

7. Proximity – Measures curvature on metal and foil lids for loss of vacuum or pressure
using an analog proximity sensor. There are three different sensor sizes depending on
container closure diameters.

8. Optional Inputs (1-4) – Four digital inputs used for any digital inspection sensors such
as Missing Label, Missing Foil, Optical Fill Level, UV Tamper Band, High Cap, Camera
Reject Signal, Reject signal from other equipment.

9. Reject Acknowledge – Photo trigger sensor used to verify that a rejected container
has been removed from the transport container after the reject station.

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M-412-102 Chapter 2: Safety Precautions

2.0 Safety Precautions


2.1 General Safety Precautions
Please refer to the following safety instructions before and during operation of the system:
Only personnel trained in machine operations must operate the system.
Internal maintenance should only be performed by personnel specifically trained on the
system.

CAUTIONS! PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT IF


THE FOLLOWING SAFETY PRECAUTIONS AND WARNINGS ARE NOT OBSERVED AT
ALL TIMES.

Do not operate the system with the enclosure open. Always turn power and air
supply OFF before opening the enclosure.

Do not disconnect any electrical connections when the system power is on.
Damage to electrical components may occur.

Use lockout/tag-out equipment to prevent injury or damage when servicing the unit.

Before connecting an external device, power down both the TapTone system and the
external device. After power is off, connect device then turn power on.

The internal electronics of this equipment are sensitive to electrostatic discharge


(ESD) and proper precautions must be adhered to when handling any electrical
components of the system.

Do not place radial or axial load on the shaft encoder when mounting to the conveyor.
Internal damage to the encoder disk will occur.

Avoid high pressure spray with aggressive cleaning solvents on components like the
photo triggers, load cells, touch screen display, belts and motors.

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M-412-102 Chapter 2: Safety Precautions

2.2 Specific Cautions and Warnings

WARNINGS! PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT IF THE


FOLLOWING SAFETY PRECAUTIONS AND WARNINGS ARE NOT OBSERVED AT ALL
TIMES.

2.2.1 Conveyor Type Sensor Cautions and Warnings

Do not operate the system with the safety guards open. Failure to do so may cause
severe injury.

Keep hands clear of the rejector ram, conveyor belts and inspection bridges whenever
the system is in operation.

Do not operate this equipment with long hair or baggy loose clothing. Serious injury
may occur if it gets caught in any moving parts.

This equipment may stop, start and change speeds automatically based on line
controls used with this system.

2.2.2 X-ray Sensor Cautions and Warnings

WARNING! - Keep hands clear of X-ray tunnel when X-ray lamp is on. X-ray energy is
transmitting when the X-ray lamp is ON.

WARNING! - This X-ray system MUST NOT be operated without the tunnel safety
shields installed.

NOTICE! - Make sure no product is blocking the X-ray window during the power-up
sequence as the open channel reading is measured at this time. Failure to do this will result
in false merit values and rejected containers.

WARNING! - Do not over compress the container in the belts. Damage to the load cell
sensor will occur.

CAUTION! - Do not pass any solid objects like test slugs or rail shims through the
compression belts. Damage to the load cell sensors will occur.

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M-412-102 Chapter 2: Safety Precautions

2.3 Safety Label Descriptions

Denotes reject lamp.

Lock-out electrical power before servicing.

General danger. (see manual) Hazard electrical shock.

Hazard hand crush. Stay clear.

Protective Earth.
AC input ground wire
only. General Chassis Earth Ground.

Figure 2-1 Safety Labels

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M-412-102 Chapter 2: Safety Precautions

Denotes X-ray lamp.

Indicates X-Ray caution


and emission direction.

Standard CE
Figure 2-2 X-ray Safety Labels

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M-412-102 Chapter 3: Programming Instructions

3.0 Programming Instructions


3.1 Main Menu

Home – System main run screen displayed at power-up.

Log In – Keypad to enter password for access to secure menus.

System Configuration – Main screen for system setup and adjustments to system
inspection parameters.

Advanced – Advanced user menus for system configuration and display setup.

Diagnostics – System diagnostics for troubleshooting.

Alarms – Access to the system alarm log screen.

Help – Displays help screens based on current screen location.

Step 1. Press the Menu key at the bottom left of the HMI Screen to display the Main
Menu icon buttons shown above.
Step 2. Select the icon to enter the desired menu or press the function key next to the
icon button to enter the desired menu.

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3.2 Home Screens


There are two choices for the home screen in the T4000. The system configuration home
screen displays the current inspection sensors, product type and counters. The Counters
home screen displays large counters and last merit value for each inspection sensor and
product type.

3.2.1 System Configuration Home Screen

3.2.2 Counters Home Screen

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M-412-102 Chapter 3: Programming Instructions
3.2.3 Change Home Screen

Step 1. Press the Advanced Menu button.


Step 2. Select Interface Configuration button.
Step 3. Select User Preferences button.
Step 4. Select the desired home screen style by pressing on it.
Step 5. Press Exit to return home.

3.2.4 Change Machine Name


Step 1. Double press the Machine Name box to get the text pop-up box.
Step 2. Enter the desired machine name, line, or location then press ENTER to save.

3.2.5 Change Button Prompts


Step 1. Select the ON check box to enable the button prompts. This feature which pop-up
a confirmation box before activating the command on certain buttons like stop/start
conveyors or rejector on/off commands.
Step 2. Select the OFF check box to disable the button prompts feature.

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3.3 Product Type Menu

Features:
Sixteen different product type setups.
All product type setups are completely independent of each other.
Copy one product type to another type.
Reset existing product type to factory default settings
Change name of product types to your specific product inspections.
Select specific container icons that closely match your container type.
Set the height and width adjustments for each inspection sensor.

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3.3.1 Change Product Type

Step 1. Press the desired product type (1-16) then press Select Product button to initiate
new product type selected. This process will take a few seconds to load the new
parameters into memory.
Step 2. Set the stand height and width to the settings indicated in the set sensor position
screen then press Done.
Step 3. Press Exit to return to Home Screen.

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3.3.2 Copy Product Types
Step 1. Press the Copy button to start copy process from existing product type to selected
product type.
Step 2. Select destination product type to copy to. Product 2 selected as destination type.
Step 3. Press copy button on bottom of screen.
Step 4. Press copy button inside pop-up menu to save all parameters from product 1 to
product 2. You can select cancel to exit without saving copy.
Step 5. Press done to return to home screen.

3.3.3 Enter Product Type Menu

Step 1. Press Product (1-16) to enter the specific product menu.


Step 2. Press Done to exit.

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3.3.4 Change Product Type Name

Step 1. Double press the current product name to get the change name pop-up box.
Step 2. Type in the new name then press ENTER to save the new name.
Step 3. Press Done to exit.

3.3.5 Change Product Height or Width Values

Step 1. Double press the height or width box to get the pop-up box.
Step 2. Set the value then press ENTER to store new value.
Step 3. Press Done to exit.

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3.3.6 Change Container Icon

Step 1. Press the desired container icon that best matches your product type.
Step 2. Press Done to exit.

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M-412-102 Chapter 3: Programming Instructions
3.4 Counters
3.4.1 Enter Detailed Counts Screen

Step 1. Press anywhere in the home counts screen box to enter the detailed counts
screen.

3.4.2 Clear Counters

Step 1. Press the Clear Counts button to get the pop-up menu.
Step 2. Press each check box to select individual counters to be cleared. You may also
Select all or Unselect All buttons as desired.
Step 3. Then press the Clear button to set selected counters to zero. Note once cleared
that data is lost, and cannot be retrieved.
Step 4. Press Done to exit.

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3.4.3 Last Reject List


The last rejects list is the 100 sample reject log shown in a list format. I displays Date, Time
and Merit Values for every rejected sample. Note values in red are the rejected merit value.
This log can be cleared, paused or run from the Setup Log Menu.

Step 1. Press the Last Rejects box to enter the detailed Last Rejects List.
View Trend – Press this to go to the reject trend graph screen.
Next Sensor – Take you to the trend graph of the next installed sensor if there are more than
one inspection.

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M-412-102 Chapter 3: Programming Instructions

3.4.4 Last Reject Trend Graph

Step 1. Press the View Trend button to get the reject trend graph screen. Red dots mean
that sample was rejected based on reject limits.

Setup Logs – Reject Log file can be Run, Cleared or Paused from this screen.

Show Mean - Displays the mean merit value as a gray line under the data samples. Press
again to Hide Mean which turns the mean OFF on the graph.

Get Last Container – Takes you to the last container trend graph that displays all passing
containers. Press again to return to last reject trend graph.

Calculate Scale – adjust the graph maximum and minimum scale automatically. Note you can
press on any scale value twice to bring up the key pad to manually set a desired scale value.

Next Sensor – Take you to the trend graph of the next installed sensor if there are more than
one inspection.

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3.5 Rejector ON/OFF

Step 1. Press the Reject ON button to enable reject function to activate whenever a failed
container is inspected. Notice the status bar will be green when rejector is on. Also
the rejector symbol will show ready to reject state. The rejector may be turned ON
from any screen.
Step 2. Press the Reject OFF button to disable the reject function. Notice the status bar
will turn red and a message will appear stating Rejector #1 is OFF. Also the
rejector symbol will show an X stating rejector is OFF. The rejector may be turned
OFF from any screen.

3.6 Inspection Conveyors Start/Stop

Step 1. Press ON button to Start conveyors turning. This can be done from any screen.
Step 2. Press OFF button to Stop conveyors turning. This can be done from any screen.

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3.7 Log In Menu

Locked Buttons – Any button with a pad-lock denotes password protected menu and
requires a higher permission password group to enter.
Enter Password – Users will gain access to features based on user group permissions. All
passwords must be 4 digits in length.
Pop-up keypad will disappear after 15 seconds if no buttons are pushed.

3.7.1 Log-In Procedure


Step 1 - Press Login button to get to the Password Keypad.
Step 2 - Enter the 4 digit password to allow access to your user group menus.
Step 3 - Press OK to continue once password is entered. You are now logged in.

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3.8 System Configuration Screen

Features:
Displays the active inspections configured for the current product type (1-16) as
machine icons.
Allows user access to Parameters, Histogram, Merit Values and Waveform screens.

3.8.1 Get to Configuration Screen

Step 1. Press the System Configuration button, press any machine icon or press the
detailed counter screen as shown above.

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3.9 Parameters Rejector

Step 1. Select the rejector icon then press parameters to get to the rejector menu.
Step 2. Choose one of the four tabs at the top of the rejector menu to view.

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Step 3. Reject Distance (pulses) – Set the reject distance value in shaft encoder pulses.
Default value is 2500.
Step 4. Speed Compensation (ms) – Set the speed compensation value in milliseconds.
This parameter advances the reject timing based on shaft encoder speed. When
the line is slow the timing is low and as the line speeds up the timing is advanced
based on speed. This parameter is only needed for high speed beverage can
lines. Default value is 15 for normal operations.
Step 5. Pulse Width (ms) – Set the reject pulse width in milliseconds. The default value is
25 ms. This parameter defines the pulse time for the reject signal.
Step 6. Container Width (mm) – Measure the container width at the point where the
photo beam is triggering on the container in millimeters. Set the container widthe
width in milliseconds. The default value is 50 mm. This parameter is used only
when no shaft encoder is used for single inspections. This parameter is only used
with rejector #1output.

Step 7. Consecutive Alarm – Enable this feature then set the number on containers for
consecutive rejects. Once that number is reached, the alarm will activate. Press
the clear button to reset the alarm output. The default value is 5.
Step 8. Percent Alarm – Enable this feature then set the percent value. When that
percent value is reached out of the last 100 containers the alarm output will
activate. Press the clear button to reset the alarm output. The default is 15%.

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M-412-102 Chapter 3: Programming Instructions
3.9.1 Force Rejects

Step 1. Force Rejects – Select the number of containers to reject in a row then press
start. The containers pending count will let you know how many are left to be
rejected. Press Stop to halt the rejections until you press start again. Press Exit
when finished.

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M-412-102 Chapter 3: Programming Instructions
3.9.2 Reject Acknowledge
Any reject container that was missed will be detected by the reject acknowledge sensor and
the alarm condition will be set. This sensor is located after the reject station looking across
the transportation conveyor for the open spot where the container was before it was rejected.
If the photo sensor sees a container in the spot where the bad container should be than the
reject alarm condition will occur.

Step 1. Add Reject Acknowledge Inspection – Enable this feature only if the optional reject
acknowledge photo sensor kit in installed with your system.
Step 2. Once this feature is enabled go to the trigger inspection trigger setup screen and
teach the reject sensor distance. .

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3.9.3 Shaft Encoder

The shaft encoder menu is where you can select to use the shaft encoder for external
container tracking or internal timer without a shaft encoder.

Rules for when to use or not use the shaft encoder:


1. You MUST use a external shaft encoder when more than one inspection sensor is
used including DSC which uses two inspection sensors. Examples: DSC, AC, APX,
FSX, FX, CX and any inspection sensor with optional inputs like missing foil, CapVu™,
CodeVu™, Fill_ir (under and overfill together) or multiple missing labels.

2. You CAN use the internal timer mode when only one inspection sensor is used and
the trigger sensor MUST be (Sensor at Ref-1) only. Examples: A, P, X, CapVu™ and
CodeVu™, Fill_ir (underfill or overfill only) and single missing label.

3. You CAN use the internal timer mode for single inspection sensors with conveyors but
the speed reference input will not be used. You must manually set the conveyor speed
to a single fixed speed that will not vary or stop when production conveyor stops. The
inspection sensor will MUST be (Sensor at Ref-1) only. This mode is good for show
setups or simple sample testing where conveyor speed is not changing. Examples: F,
FS and C.

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External Shaft Encoder Mode – The external shaft encoder mode uses a shaft encoder
signal to track containers through the inspection heads. This is the recommended method for
operating the T4000 system because it will allow accurate tracking of the containers on lines
that stop or change speed frequently.

Internal Shaft Encoder Mode – The internal shaft encoder mode is used when no shaft
encoder signal is available. The internal timer produces the shaft encoder pulses that provide
the tracking and reject timing based on photo trigger passing times in milliseconds. This
method can be used for single inspection sensors only where minimal line speed variations
occur. The reject timing is adjusted based on passing times of the containers.

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Line Speed Mode – The production conveyor will determine the line speed mode. If the
production conveyor is variable speed then use the variable speed mode. If the conveyor is
one fixed speed then use the fixed mode. Note that the variable line speed mode will not
work for lines that stop and start or change speed quickly. For these conditions it is
recommended to use the external shaft encoder mode. This mode is good for setting up
machines before the encoder can be installed.

Variable Line Speed – Reject timing is adjusted based on photo beam passing times. It
requires the passing of one container from power-up to load the initial passing time in the
memory. Adjust the reject delay time at one fixed speed to set the reject timing to start. Then
the timing will automatically adjust based on trigger passing time. The container width value
must be entered to calculate the reject timing.

Fixed Line Speed – Reject timing is fixed based on the reject delay setting.

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Inspection Trigger Mode – This mode is used to select internal or external trigger sensor
signals to initiate and inspection. This mode should only be used for diagnostics or setup of
the acoustic inspection when the conveyor is stopped. It should not be used during any
normal production operations.

External Inspection Trigger – The external inspection trigger mode is the standard way to run
any T4000 inspections. It used the external photo trigger sensors to initiate an inspection of
that container.

Internal Inspection Trigger – The internal trigger mode bypasses the external trigger sensors
and uses the internal timer to define a fixed trigger rate. This mode would be used for
acoustic inspections where you would like to have the bottle stationary under the head and
continue to tap and collect microphone signals. You can change the internal trigger rate by
double pressing on the rate button and setting the desired time in seconds.

Internal Trigger Rate – The internal trigger rate can be adjusted using this parameter. The
range is (0.1 to 100 seconds) for this parameter. Default is 1.0 seconds.

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3.10 Parameters (All Sensors)
3.10.1 Parameters - DSC

Step 1 - Select the DSC icon then press parameters to get to the DSC parameters menu.
There are two pages of parameters for the DSC sensor.
Step 2 - Algorithm – Select the maximum or minimum data point for the calculation of
merit value for entry and exit sensors. Default selection is maximum.

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Step 3 - Inspection Window – Set the start and stop window percent for selected sensor.
Default setting is start=25% and stop=75%. All data between these two settings
will be searched for the maximum or minimum data point. This data point will be
used as the merit value for that inspection.

Step 4 - Mean Sample Size – Set the mean sample size for calculation the mean value.
The mean will not come into effect until the sample size is reached. This value is
used to adjust mean calculation used by the autotracking reject limits.

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Step 5 - Autotracking – Select fixed button then press setup to configure the upper and
lower autotracking reject limits for entry sensor, exit sensor and leak inspection.
These autotracking limits are based on values from the calculated mean value for
each inspection. The dashed lines on the screen indicate the position of the
autotracking limit to the mean. These limits must be inside the fixed reject limits
shown as solid lines on the screen. All auto tracking limits outside the solid reject
limits will be rejected by the solid limit.

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Step 6 - Calculation Method Setup – Press the calculation method button to enter the
second page of the parameters menu for DSC. These parameters apply to both
entry and exit sensors where applicable.

Step 7 - Exit Merit minus Offset – Use this parameter to reduce the Exit merit values if
they are greater than the Entry values. This parameter will only subtract the
selected value from the Exit merit value to keep the Leak value subtracting from
900. Default value is 0.

Example:
Entry Merit = 525
Exit Merit = 535
Then set Exit Merit minus Offset value to -10 to make the Leak calculation be 900.

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Step 8 - Leak Calculation – The Leak Calculation is a formula based on entry and exit
merit values. The Leak merit value is used to find micro leakers in the DSC
inspection.

Absolute Value – Calculates the leak value where when the exit merit value is greater than
the entry value it takes the absolute difference between the two values then subtracts it from
900. This leak value will never be greater than 900 for this method. You only need to use the
low leak limit for this algorithm. This is the default method to used.

Entry minus Exit – Calculated the exact value where the leak value could be greater than
900. This method is used in special cases only where you may want to reject for high leak
values as well as low leak values.

Step 9 - Entry Mean Substitution – This parameter is used to compensate for bottle
slippage between the belts during speed changes in the belts.

Disable – Turns this feature OFF. You will see zero’s in the Entry merit values if tracking is
lost between Entry and Exit photo triggers. This will cause very low leak calculations which
will then be rejected as false rejects.

Enabled – Turns this feature ON. If a tracking error cause the Entry merit value to be zero
then the MEAN merit value for the Entry sensor will be substituted as the entry value for that
container. The Leak calculation will use the Entry Mean value which should give a very close
leak reading to the actual value.

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Step 10 - Fill Level Compensation – This feature compensates for overfill conditions that
cause false rejects. Default is disabled.

Disabled – Turns this feature OFF.

Enabled – This turns the compensation ON.

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3.10.2 Parameters - Digital Inputs

How it works
Each digital reject input requires a photo trigger signal as well. The following example shows
a 100% trigger signal on the threads where a cap would be. The digital input only sees the
edges of the top of the bottle looking down. The missing cap sensor sees 20% of the total
passing time of the trigger input so this container will be rejected because the measured merit
value of the cap sensor is 20% and the reject limit was set to 50%. Any cap measured less
than 50% will be rejected.
The trigger sensor signal in green is looking across the bottle at the neck.
The cap sensor is looking down at the bottle from above.
The reject if above value is set to 50% and can be set in 1% increments by the user.

Trigger on cap 100% passing time.

Missing cap sensor sees only 20% and will be


rejected because it is lower than 50% setting.

Step 1 - Select the Optional Inputs icon then press parameters to get to the Digital Input
parameters menu.
Step 2 - Select the digital input Setup button to enter the setup screen.
Step 3 - Input Name - Double press the input name then type in desired inspection name.

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Step 4 - Inspection Window – Press the Setup button to enter the inspection window
screen. Adjust the Stop and Start percentage to place the window around the data
you would like to scan and determine the percentage of high signal between the
window. The example below shows 20% of the windowed area has a high signal.
The merit value for this inspection would be 20%. Press Apply to save new values.

Step 5 - Reject Mode - Select the Reject Mode (Less Than) or (Greater Than) merit value
will be rejected. The red line denoted the reject limit. The green bar is the pass
inspection merit value range and the red bar is the reject inspection merit value
range. The merit values are in 1% increments. Reverse the logic by switching from
Less Than to Greater than. The red and green bars will switch positions.

Step 6 - Reject Limit – Adjust the reject percentage with the left and right arrows or double
press the % button then set the reject limit to desired value. The range is 0% to
100% in 1% increments.

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Step 1 - Double press the reject limit value to change the reject limit. Set it to be about half
way between the good and bad container merit values shown in the Last Value %
line. The blue line denotes the last merit value detected. The range is (0-100%)
and the default value is 50%.
Step 2 - Press Apply to store new values.
Step 3 - Press Exit to return to home screen.

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3.11.3 Parameters - X-ray


The X-ray Parameters menu is used to adjust all parameters involved in calculation of fill
level merit values.

Step 1 - Select the x-ray icon then press parameters to get to the x-ray parameters menu.

Step 2 - Press the X-Ray Sensor button to enter the Inspection Window screen. Adjust the
start and stop bars which define the area of the x-ray signal that should be used
to determine the fill level merit value. Typically 25% and 75% are used for most
applications. Default values are 10% and 90%. Press Apply to store the new
values.

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Step 3 - Set the Autotracking feature to the OFF position by placing the check mark in the
OFF box. Typically Autotracking is not used in fill level reject limits. The default
setting is OFF.
Step 4 - Set the Mean Sample Size according to line speed. The mean is used to calculate
the autotracking limits when it is turned on. The mean is calculated even when the
autotracking is turned off. It can be viewed in the x-ray merit values screen. The
default value is 25.

Step 5 - Pass a completely empty container through the x-ray sensor then double press
the Empty button and set the value to match the Last X-Ray Value for that
container. This sets the Empty Range for that container type. Press Set to store
new value. This range is used for visual height adjustment reference only during
setup. It does not control any function of the x-ray inspection. The default value is
200.
Step 6 - Pass a completely full container through the x-ray sensor then double press the
Full button and set the value to match the Last X-ray Value for that container. This
sets the Full Range for that container type. Press Set to store new value. The
green bar displays the last container merit value in this screen. This can be used
as a visual aid in fine tuning the x-ray sensor height. The default value is 800.
Press either arrow to exit the screen.

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3.10.4 Parameters - Force/Compression

Step 1 - Select the Force icon then press parameters to get to the Force parameters
menu.

Step 2 - Algorithm – Select the maximum or minimum data point for the calculation of
merit value for entry and exit sensors. Default selection is maximum.
Step 3 - Inspection Window – Set the start and stop window percent for selected sensor.
Default setting is start=25% and stop=75%. All data between these two settings
will be searched for the maximum or minimum data point. This data point will be
used as the merit value for that inspection.
Step 4 - Mean Sample Size – Set the mean sample size for calculation the mean value.
The mean will not come into effect until the sample size is reached. This value is
used to adjust the autotracking reject limit.

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Step 5 - Autotracking – Select fixed button then press setup to configure the upper and
lower autotracking reject limits for entry sensor, exit sensor and leak inspection.
These autotracking limits are based on values from the calculated mean value for
each inspection. The dashed lines on the screen indicate the position of the
autotracking limit to the mean. These limits must be inside the fixed reject limits
shown as solid lines on the screen. All auto tracking limits outside the solid reject
limits will be rejected by the solid limit.

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3.10.5 Parameters - Proximity

Step 1 - Select the Proximity icon then press parameters to get to the Proximity parameters
menu.

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Step 2 - Algorithm – Select the Algorithm button to then choose the appropriate inspection
method based on your container style.

Pressure Difference – This algorithm calculates the difference from the left and right window
value to the center value. The greatest difference is calculated as the merit value. Use this
algorithm for pressure applications where the center value is higher than the left and right
chine values. Use this algorithm for pull tab beverage cans.

Pressure Ratio – This algorithm calculates the ratio of both the left and right chine’s to the
center value. This algorithm is the same as T500 pressure algorithm. Use this algorithm for
pressurized food cans.

Vacuum Difference – This algorithm calculated the difference from the left and right window
value to the center value. The greatest difference is calculated as the merit value. Use this
algorithm for vacuum applications where the center value is lower than the left and right chine
values. Use this algorithm for pull tab food cans.

Vacuum Ratio - This algorithm calculates the ratio of both the left and right chine’s to the
center value. This algorithm is the same as T500 pressure algorithm. Use this algorithm for
vacuum food cans.

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Step 3 – Midpoint Method – Select the midpoint method for choosing the data point to be
used for calculation of pressure or vacuum based on the center window range.

Maximum – Selects the maximum data point in the center window to be used for calculation
of pressure or vacuum.

Middle – Selects the middle data point of the center window to be used for calculation of
pressure or vacuum.

Minimum – Selects the minimum data point in the center window to be used for calculation of
pressure or vacuum.

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Step 4 – Inspection Window Setup – Select the position of left and right window bars for
left, midpoint and right chine’s. The active window is highlighted in dark blue. Set
up each of the three windows to highlight the area where the data points will be
selected for calculation of the merit value.

Left Chine – Adjust the left and right window % bars for the Left Chine search window.
Pressure mode will select lowest point in this window. Vacuum mode will select highest point
inside this window. This window sets up the data point used in the algorithm for profile
calculation.

Right Chine – Adjust the left and right window % bars for the Right Chine search window.
Pressure mode will select lowest point in this window. Vacuum mode will select highest point
inside this window. This window sets up the data point used in the algorithm for profile
calculation.

Midpoint – Adjust the left and right window % bars for the midpoint search window. The data
point selected will be chosen by the midpoint method selected above. Choices are maximum,
middle or minimum data point within the window.

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Step 5 – Autotracking Setup – This menu is where you set up the autotracking limits for the
profile algorithm. There are two methods for tracking the profile population. Make
sure the autotracking limits are inside the hard reject high and low limits.
Autotracking will never go below or above the hard limits.
OFF – Turn autotracking feature off.

Fixed – Select for fixed autotracking offset based on Low Offset and High Offset limits
displayed as dashed lines. Any merit values outside the dashed lines will be rejected. The
dashed lines move according to the offset values and mean merit value shown in green.

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Standard Deviation – Select for autotracking limits using the standard deviation of the data.
This method is for low reject limit only calculated by the standard deviation value selected.
The range is 0.0 to 10.0 standard deviation values.

Step 6 – Mean Sample Size – Set mean sample size for autotracking calculations. Press
enter to save the new value.

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3.10.6 Parameters - Acoustic

Step 1 - Select the acoustic icon then press parameters to get to the acoustic parameters
menu page 1 of 2.
Step 2 - Frequency – Select the frequency range based on the pressure or vacuum range
of your containers. Press ENTER to save then EXIT to return to menu.
The choices are as follows:
(0 to 3.255 KHz) – Low frequency range for vacuum can applications.
(0 to 9.765 KHz) – Mid frequency range for typical beer bottle applications.
(0 to 14.648 KHz) – High frequency for very high pressure glass bottles.

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Step 3 - Filter – Select the digital filter for your specific application. Press ENTER to save.
OFF – Standard setting is with the digital filter Off.

Filter 1 – Digital filter provides multi-tone rejection for spectrums with multiple peaks.

Filter Peak Percentage – Detects peaks only over the Peak Percentage for consideration of
peak detection. All peaks below this value will be filtered out.

Filter Spectrum Window – Select the start and stop percentage of the spectrum to look at the
main peak of interest.

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Step 4 - Inspection Window – Select the Inspection Window button to enter the
signal/spectrum window screen. Adjust the start and stop limits for processing the
signal in the time domain. These adjustments affect the frequency spectrum
calculation.
Start - Set the start red line to be at the beginning of the signal. Typically 2% to 5% of the
signal is normal. See red line on left side of signal shown below.

Stop - Set the stop red line to be at the end of the useful signal. Typically 75% to 80% of the
signal is normal. See red line on left side of signal shown below.

Step 5 - Low dB Mode – Select the mode to accept or reject containers for having a low
dB reading when the frequency is in the proper range. This is used for short
bottles that may have a good frequency but fail the dB inspection because the
spectrum has a low dB reading.
Reject - Reject means you will reject any containers that fall below the low dB setting no
matter what the frequency is.

Accept - Accept means you will not reject containers for low dB level if the frequency is in the
good range.

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Step 6 - Frequency Mean Sample Size – Select the mean sample size used to calculate
the mean for the frequency autotracking limits. The mean will start calculating after
the sample size is reached.

Step 7 - Loudness (dB) Mean Sample Size – Select the mean sample size used to
calculate the mean for the dB autotracking limits. The mean will start calculating
after the sample size is reached.

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Step 8 - Autotracking Setup – Press the setup button to enter the autotracking setup
menu. Both frequency and dB autotracking can be setup from this menu.
Frequency Autotracking
Off - Set to Off when no frequency autotracking limits are used.

Fixed - Select fixed to setup the fixed autotracking limits. The Low Offset and High Offset
limits are adjusted from the screen shown below. The green line is the calculated mean value
and the low limit value is subtracted from mean to create the Low Offset reject limit shown in
the left hand dotted line. The High Offset value is added to the mean value to create the High
Offset reject limit. These limits move along with the mean calculation. These autotracking
limits will only track to the fixed reject limits (solid red lines). Any containers outside the fixed
reject limits will always be rejected.

Standard Deviation – Select this method to setup the autotracking limits based on the
standard deviation value selected.

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3.10.7 Parameters - Cocked Crown


The Cocked Crown inspection is used for 28mm beer crowns. It was developed to find gross
physical defects in crown applications. There are three algorithms that measure the curvature
of the crown. They are Dimple, Symmetry and Height. The reject limits for all three
inspections are found in the Histogram Menu for the Cocked Crown inspection.

Step 1 - Select the cocked crown icon then press parameters to get to the cocked crown
parameters menu.
Step 2 - Height Mode – Press the height mode button then choose accept or reject mode
then press Enter to save value. The Height calculation is always done in the
center of the data.
Accept – Allows bottles to pass the cocked crown inspection when the crown is out of range
of the proximity sensor. This will illuminate false rejects for short bottles. Accept bottles out of
range of the proximity sensor.

Reject – Allows inspection of all bottles regardless of bottle height. Any crowns out of
proximity sensor range will be rejected. Reject bottles out of range of the proximity sensor.

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Step 3 - Inspection Window – Press this button to enter the cocked crown inspection
window screen. The Dimple and Symmetry algorithm calculations are done using
signal data between these window values. Press Apply to save new settings.
Start – Adjust the start time for the cocked crown algorithm window. Range is 0-100%.

Stop – Adjust the stop time for cocked crown algorithm window. Range is 0-100%.

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3.10.8 Parameters – High Frequency


The High Frequency sensor is used to measure relative fill level in plastic and glass
containers. It does not work with any metal containers. The shape and structure of the
container as well as the fill height will affect the high frequency measurement accuracy. It is
important to set up this sensor with the containers going down the middle of the tunnel.

Step 1 - Select the high frequency icon then press parameters to get to the high frequency
parameters menu.
Step 2 - Inspection Window – Press this button to enter the high frequency window. The
high frequency algorithm searches for the tallest peak value within the window
values. Press Apply to save new settings. Typical the peak is towards the end of
the signal so 10% to 100% are normal settings.
Start – Adjust the start time for the high frequency algorithm window. Range is 0-100%.

Stop – Adjust the stop time for high frequency algorithm window. Range is 0-100%.

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Note: The high frequency wave form is a step type signal as shown in the screen shot above.
The algorithm selects the highest step as the merit value.

Step 5 – Autotracking Setup – This menu is where you set up the autotracking limits for the
high frequency algorithm. There are two methods for tracking the profile
population. Make sure the autotracking limits are inside the hard reject high and
low limits. Autotracking will never go below or above the hard limits.

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OFF – Turn autotracking feature off.

Fixed – Select for fixed autotracking offset based on Low Offset and High Offset limits
displayed as dashed lines. Any merit values outside the dashed lines will be
rejected. The dashed lines move according to the offset values and mean merit
value shown in green.

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Step 6 – Mean Sample Size – Set mean sample size for autotracking calculations. Press
enter to save the new value.

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3.11 Histograms Menu
3.11.1 Get to Histogram Screens
This menu displays the histograms for leak inspection, entry and exit sensors. It also provides
access to the reject limits screen for each inspection.

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3.11.2 Select Histogram Type


Select the histogram type for viewing. The reject limits are exactly the same no matter how
you view the histogram.

Step 1 - Select the Histogram Type you wish to display when you enter the Reject Limits
screen. The three types of histograms are Fast, Zoom or Sample.

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Fast Histogram

Fast – This histogram contains all data since the last clear command and refreshes fast
because there is no zoom feature. The two long reds bars indicate the upper and lower reject
limits which can be adjusted with the arrows below. Press apply to store the new value. The
shorter red bar is the merit value position of the last container inspected. Any container above
or below the reject limits will be rejected by the system.

Zoom Histogram

Zoom – This histogram contains all data since the last clear command with zoom capabilities.
Zoom in 1, 2, 4 or 8 times to look at data more closely. The two long reds bars indicate the
upper and lower reject limits which can be adjusted with the arrows below. Press apply to
store the new value. The shorter red bar is the merit value position of the last container
inspected. Any container above or below the reject limits will be rejected by the system.

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Sample Histogram

Sample – This histogram contains the sample log file data up to 1000 containers. This
histogram is good for doing sample testing or machine qualifications where you want the log
data to be saved to the flash card. The two long reds bars indicate the upper and lower reject
limits which can be adjusted with the arrows below. Press apply to store the new value. The
shorter red bar is the merit value position of the last container inspected. Any container above
or below the reject limits will be rejected by the system.

Setup Logs – Press this button to setup the log files. Each log file is 1000 containers long and
the file is circular. Clear the log file then press run to start collecting data. These log files can
be saved to the flash card for downloading later via the Ethernet connection.

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3.11.3 Adjust Fixed Reject Limits


The high and low reject limits are adjusted from any of the histogram screen for that sensor
algorithm.

Low – Use the Low arrows to adjust the Low Reject Limit shown as the left red bar. All merit
values less than the low limit will be rejected.

High – Use the High arrows to adjust the High Reject Limit shown as the right red bar picture.
All merit values greater than the high limit will be rejected.

Apply – Press Apply to save your limit changes to memory and stay in this screen. Changes
are active once the apply button is pressed.

Apply & Exit – This button applies the changes then exits the menu.

Use this button to exit the screen without making any changes to the reject limits.

Clear Counts and Histograms – You can clear the histogram and production counters with this
button. Select the counters to set to zero then press clear.

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3.11.4 Adjust Autotracking Reject Limits


The Autotracking high and low offset reject limits screen is located in the Parameters menu
then go to the Autotracking Setup screen. The Offset limits track according to the mean value
show as the green bar below.

Low Offset – Use the Low Offset arrows to adjust the Autotracking Low Offset Reject Limit
shown as the left red dashed bar. This offset value is subtracted from the mean value to
create the tracking low reject limit. All merit values less than the low offset limit will be
rejected. The low reject limit should always be lower than the low offset value. The low offset
value will never track below the low reject limit. All merit values below the reject limit will
always be rejected.

High Offset – Use the High Offset arrows to adjust the Autotracking High Reject Limit shown
as the right red bar picture. This offset value is added to the mean value to create the tracking
high reject limit. All merit values greater than the high limit will be rejected. The fixed high
reject limit should always be greater than the high offset value. The high offset value will never
track above the fixed high reject limit. All merit values above the fixed reject limit will always be
rejected.

Use this button to exit the screen and return to Parameters menu. You MUST press
Apply to save the new Offset values you adjusted.

Clear Counts and Histograms – You can clear the histogram and production counters with this
button. Select the counters to set to zero then press clear.

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3.12 Merit Values Menu

Step-1 Select the any inspection sensor icon then press Merit Values to get to the merit
values menu.

3.12.1 Merit Value Boxes


Value – The merit value measured or calculated for each inspection parameter.

Low Limit – The current low reject limit based on hard limits or autotracking limits when
activated.

High Limit – The current high reject limit based on hard limits or autotracking limits when
activated.

Reject Limit – The single reject limit for optional input inspections.

Speed – container speed in feet/minute between the entry and exit photo beams.
To calculate meters/minute multiply by 0.3048
To calculate meters/second multiply by 0.00508
3.12.2 X-Ray Merit Values
Underfill/Overfill – X-ray merit value based on fill level between window parameters.

Empty – Marker point defined for an empty container in the parameters setup.

Full – Marker point defined for a complete full container in the parameter setup.

Open – Open channel reading between containers. This value is used to auto calibrate the
merit value calculation.
3.12.3 Force Merit Value
Force – Load cell sensor peak data point based on inspection window parameters.

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3.12.4 Optional Input Merit Values


Input 1, 2, 3, 4 – Merit value for each optional input used.

Reject Limit – Displays the current reject limit for each optional input.
3.12.5 DSC Merit Values
Entry – Entry load cell sensor peak data point based on inspection window parameters.

Exit – Exit load cell sensor peak data point based on inspection window parameters.

Leak – Leak merit value is calculated based on entry and exit merit values. See the
explanation for the Leak Calculation below.

Each load cell output is 0-10.00Vdc directly


proportional to force on sidewall of the
container.

Equivalent merit values are 0-1000 for each


load cell reading at the desired measurement
point.

Calculated Leak Algorithm

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3.12.6 Acoustic / Cocked Crown Merit Values

Acoustic
Frequency – Sound frequency in Hz. Range 0-14,648 Hz.
Loudness (dBx10) – Loudness of spectrum peak in (dB x10), Example: 615 is 61.5dB
Tone Strength (%x10) – Strength of signal in time domain. Example: 388 is 38.8%.

Cocked Crown
Height – Signal Height at the center of the profile. Merit 913 is equal to 9.13Volts.
Symmetry – Comparison of symmetry for left and right side of profile. Merit 962 is 96.2%.
Dimple – Percentage of curvature change on each side of profile. Merit 809 is 80.9%.

3.12.6 Proximity Merit Values

Proximity
Profile – Curvature merit value based on Algorithm selection. Range 1-1000.
Lid Height – Signal height at center of the profile. 1000 is 10.00 Volts.
Cocked – Percentage of slant of lid off center. Greater the merit value the greater the slant.

3.12.7 High Frequency Merit Value


Underfill/Overfill – High Frequency merit value based on relative fill level position inside the
bridge. Range 1-1000.

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3.13 Trend Graphs

The trend graphs are based on the log files for each inspection sensor. There are two types of
log files each 1000 containers long.

Sample log collects the last 1000 containers both pass and rejects.

Reject log collects the last 1000 rejected containers only.

The calculated mean can be displayed for each log file. Each trend graph can be cleared, run or
paused at any time. This does not affect the production counters.

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3.13.1 Setup Logs

Step 1 - Press any of the merit value boxes to go to the Trend Graphs menu.
Step 2 - Press the next sensor button to scroll through each active sensor log file.
Step 3 - Press Setup Logs button to Clear, Run or Pause that log file. Press OK to exit the
setup menu and return to the trend graph screen. Clearing the log does not affect the
production counters.
Step 4 - Press Hide Mean to turn the mean line off. Press Show Mean to turn it back on. The
mean value is calculated based on sample size set up in the parameters menu for
each inspection sensor.
Step 5 - Press the Calculate Scale button to recalculate each scale to fit all data on the screen.
Each individual scale can be custom set by double pressing on the individual number
and typing in the new value then press ENTER. Keep in mind that some data may be
outside the scale you selected.
Step 6 - Use the scroll bar to view actual merit values along the graph. The box indicates the
location of the data points in the merit value columns.
Step 7 - Press the Left Arrow to exit back to the merit values menu.

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3.14 Waveforms Menu

The waveform screen displays the analog profile of the last container inspected. Note this
screen is not fast enough to view every container. It is used to view analog data files for
sensor troubleshooting or setup. The scale on the side of the graph denotes the voltage
range of (0-10VDC) for each sensor.

Next Sensor – press this button to change the last container profile to the next active sensor.

Get Last Reject – press this button to view the last rejected container. Then press Next
Sensor to see the last reject for each active sensor. If no rejects have occurred then the
profile will be blank.

Auto Refresh – select auto refresh or turn it off and use manual refresh to get the next
container data points.

Refresh – press to view another good container waveform. The same reject wave form will
appear if no new rejects had occurred.

Exit – return to home screen.

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3.15 Advanced Menu

The Advanced menu provides access to high level user parameters that define the operation
of the system.

Add Inspection – Configure system by adding new inspection sensors. Default inputs and
outputs are automatically defined when specific sensors are added.

Trigger Setup – Teach trigger timing for each inspection sensor based on shaft encoder
speed.

Input Matrix – Redefine input signals from default settings. This menu is for highly advanced
users and must not be changed without changing wiring hardware.
Do not change any parameters in the Input Matrix menu unless you understand what you are
doing.

Outputs – View all digital output functions. Configure alarm output functions and PLC output
relay functions.

Logs – Configure, name and save merit value log files to flash card.

Interface Configuration – Menu access to all parameters for the HMI user interface screen
such as languages, passwords, communications, date/time, touch screen calibration and
user preferences.

Utilities – Menu access to the system backup/restore functions, CF card utilities, and
software upgrade functions.

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3.16 Add Inspection
Sensor selections are defined in the following table:

T4000 DSC contains two load cell sensors that use DC analog inputs 1 &
2 for entry and exit measurements.

The default inputs are:

Exit Sensor = Analog input 1, trigger input 2, reference input 1


Entry sensor = Analog input 2, trigger input 3, reference input 1

T4000 PBI contains two load cell sensors that use DC analog inputs 1 & 2
for entry and exit measurements.

The default inputs are:

Exit Sensor = Analog input 1, trigger input 2, reference input 1


Entry sensor = Analog input 2 with trigger input 3 and reference 1

T4000 Force/Compression contains one load cell sensor that uses DC


analog input 1 to measure pressure.

The default inputs are:

Load Cell Sensor = Analog input 1, trigger input 2, reference input 1

X-Ray fill level inspection uses DC analog input 3 to measure fill level.

The default inputs are:

PMT Detector = Analog input 3, trigger input 6, reference input 1

SSV-X = Analog input 3, trigger input 1, sensor at ref 1

High Frequency fill level inspection uses DC analog input 4 to measure fill
level.

The default inputs are:

High Frequency = Analog input 4, trigger input 7, reference input 1

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Proximity inspection uses DC analog input 4 to measure curvature.

The default inputs are:

Single Proximity sensor = Analog input 4, trigger input 7, reference input 1


Dual Proximity sensors = Prox1 – DC analog 2, trigger input 1 at ref1
Prox2 – DC analog 4, trigger input 7, ref 1

Acoustic inspection uses AC analog input 1 to capture the microphone


input. It uses Tap output 1 to drive the acoustic tap signal.

The default inputs and outputs are:

Microphone = AC analog 1, trigger input 1 (sensor at ref-1)


Coil = Tap 1 output

Cocker Crown inspection uses DC analog input 4 to measure curvature.

The default inputs are:

Cocked crown proximity = DC analog 4, trigger input 7, reference 1 at


acoustic sensor.

The 4 upstream digital inputs are defaulted as follows:

Optional Input-1 uses digital input 13, trigger input 9


Optional Input-2 uses digital input 14, trigger input 10
Optional Input-3 uses digital input 15, trigger input 11
Optional Input-4 uses digital input 16, trigger input 12

Either reference 1 or 2 can be selected for each input selection. Any of the
sensors can be mounted at Ref-1 or Ref-2 which eliminates the need for
another trigger sensor.
Reject Acknowledge sensor detects the presence of bottles on the line that
were missed by the rejector.

Reject Acknowledge #1 uses trigger input 4 and ref-1 input 1


Reject Acknowledge #2 uses trigger input 8 and ref-2 input 5

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Step 1 - Press the Advanced menu button to enter the Advanced menu selection list.
Step 2 - Select the Add Sensor button to bring up the Add sensor icon list.
Step 3 - Select the icon of the inspection sensor you would like to add. Refer the icon table
for definition of each inspection and the default inputs.
Step 4 - Press OK to move to the reference trigger selection screen. Select the reference
trigger based on which rejector you want the defective containers to be rejected
too.
 Rejector #1 timing is calculated from reference #1 which used reference trigger input
1.
 Rejector #2 timing is calculated from reference #2 which used reference trigger input
5.
 Exit>Reference #1 timing is calculated from exit trigger without a reference trigger
needed. This is for rejector output #1.
 Exit>Reference #2 timing is calculated from exit trigger without a reference trigger
needed. This is for rejector output #2.
 Default selection is Reference #1 for all systems. All sensors up stream will be
referenced to #1 for reject timing to rejector #1.
 Sensor at Reference #1 means that sensor is physically at reference input #1.
 Sensor at Reference #2 means that sensor is physically at reference input #5.

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Step 6 - Press Select to save the reference choice and move to the System Configuration
Complete screen then press OK to finish.
Step 7 - Now you can Add another Inspection or press Done to move to the Trigger Timing
Teach screen. You can also get to this screen from the Trigger Setup button in
the Advanced menu.

When using an optional input (13-16) with either Reference Trigger as the trigger for
that optional input. Then you must set up the Digital Input on that reference input in
the matrix. See the following example of the matrix setup as a DSC with a missing foil
digital input (13) at reference #1 trigger sensor.

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3.17 Trigger Setup
3.17.1 Get to Trigger Setup Screen
Trigger Setup from the Home Screen:

Trigger Setup from the Advanced menu:

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3.17.2 Trigger Screen Description

NOTE: Refer to Input Matrix for definition of each trigger sensor as setup in you system.
Detected – Displays the last container passed through the system.

Stored – Displays the stored passing times in DSP board.

Store Value – Press to save the detected values to the stored area in the DSP.

Distance (pulses) – Trigger distance in shaft encoder pulsed from that trigger sensor to the
reference #1 trigger sensor.

Width (pulses) – Trigger passing width in shaft encoder pulses for that sensor.

Distance (msec) – Trigger distance in milliseconds from that trigger sensor to the reference
#1 trigger sensor.

Width (msec) – Trigger passing width in milliseconds for that sensor.

Speed – Belt speed in feet per minute between Entry and Exit photo triggers.

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3.17.3 Trigger Setup Procedure

Step 1 - Now pass (ONLY ONE) container through the entire system with the shaft
encoder running and all trigger sensors setup to see the container in the normal
production position. You can observe the active trigger sensors with green check
marks will show detected timing values. Repeat several times to observe that they
are repeatable.

Step 2 - Press Store Values button to copy them to the Stored section of the screen.
These values are now stored in the DSP board memory for this container type.
You can re-teach the values at any time if you change positions of any trigger
sensors in reference to the reference #1 trigger sensor. The timing for the entire
system is now programmed for the existing sensors in that product type.
Step 3 - Press exit to go back to the Home screen. There you can see the inspection
sensors that you have configured for this product type.

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3.18 Input Matrix

WARNING – This menu is for advanced users only and should not be modified
without understanding its effects. This is where you can change the default inputs
after you add inspections. The wiring must be changed if you change input positions.

Step 1 - To modify any input parameter just double press the value to highlight it and bring
up the pop-up menu. Make you change then press ENTER to leave pop-up
screen.
Step 2 - Press Apply button to store the new change to memory.

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3.19 Outputs

There are two types of programmable outputs available for use:

Alarm outputs 1 and 2 – These outputs are optically isolated 24VDC which can be
programmed as system ready and system fault. The isolated outputs are located in the HMI
display box chassis.

Relay outputs 1-3 – These three outputs are PLC isolated 24VDC outputs for belt wash, CIP
and trigger air purge signals.

3.19.1 View Digital Outputs

Step 1 - Press the View Digital Outputs button to see the description and status of each
output. Red LED means the output is on with the switch (closed). Some signals
may be too fast for this display to update in real time like the reject pulse.

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3.19.2 Alarm Outputs (Ready-1, Fault-2, Good-3)

System Ready (Alarm 1) – This optically isolated output provides active on switch when
system is ready based on checks parameters in the Triggers, Rejectors & Encoder,
Inspections and E-Stops & Motors. A red box will appear around each alarm condition that
would cause the ready output to open which indicated system not ready to run. This output is
also connected to the green lamp in to indicate when the system is ready to run.

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System Fault (Alarm 2) – This optically isolated output provides active on switch when no
fault is present in the system. Any fault based on checked parameters in the Triggers,
Rejectors & Encoder, Inspections and E-Stops & Motors will open this output. A red box will
appear around each alarm condition that would cause a the fault output to open which
indicates a system fault.

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3.19.3 Relay Outputs 1, 2 & 3

The relay outputs (1-3) are controlled by the internal PLC in the motor control box. They
provided output control for the following features:

Trigger Sensor Air Purge Kit – This feature provides valve control of compressed air to blow
across the face of every photo trigger lens to keep it clean. It can be programmed to activate
on a timed interval for a timed duration as well as activate automatically for every rejected
container at the timed duration. Manual valve activation is provided as well. This option
requires one relay output.

Belt Wash and Dry Kit – This feature provides valve control for water and compressed air to
wash the belts with high pressure water then dry the belts with high pressure air. It can be
programmed to activate on a timed interval for a timed duration as well as activate
automatically for every rejected container at the timed duration. Manual valve activation is
provided as well. This option requires two relay output.

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Conveyor Deck Wash Kit – This feature provides valve control of high pressure water wash
nozzles to clean behind the rollers and belts as well as the top of the conveyor decks. It can
be programmed to activate on a timed interval for a timed duration as well as activate
automatically for every rejected container at the timed duration. Manual valve activation is
provided as well. This option requires one relay output.

Step 1 - Press the Outputs button then select the Relay output to program.
Step 2 - Set up then functions for the output based on the parameter descriptions below.
Step 3 - Once setup is complete press Apply to store the values.
Step 4 - Press Exit to return to the home screen.

Relay Output Name – Change the name of each output to match valve function.

Timed mode Enable – Enable or disable the timed mode function. Set to enable to use the
timed functions for controlling relay output functions. Set to disable for manual control of the
relay output from the Manual Activate screen.

Relay Output Pulse Width – Set the pulse width for the ON time in milliseconds. (range is 0-
3,000 seconds)

Interval – Set the time interval between relay output ON pulse widths. This time is set based
on production speeds and reject occurrences. Typical interval time is 60.0 to 120.0 seconds.
(range is 0-3,000 seconds)

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Start Delay – Set the delay time after the relay output timer finishes the interval counting. This
feature is used to stagger the on times when several relay outputs are used. Typical start
delay is 0.0 seconds. (range is 0-3,000 seconds)

Require Motors – This feature activates the timer mode only when the motors are running
when set to YES. Set to NO for continuous timer functions even when the motors are
stopped. This feature can save water and air whenever the production conveyors are
stopped. Typically set to YES.

Manual Activate – For manual activation of the relay outputs. For continuous on or off
operation of the relay output set the Timed mode Enable to the (disable) setting then you can
manually control the relay output function.

Reject mode Enable – Set to enable if relay output activation of timed pulse is desired directly
after any rejected containers. Disable to turn off the reject mode function. Typically se to
enable. Timed mode will continue in the background even if the reject was detected.

Activate after # Rejects – Set the desired number of rejects before the relay output timers
activate the timed sequence. Typically set to 1 to keep belts clean after every reject situation.
(range is 0-100,000 counts)

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3.20 Logs

The Logs file menu is used to setup each log file for viewing on the screen and storage to the
flash card. There are two types of log files each is 1000 containers in length.

Save Sample Logs – These log files contain the last 1000 passed and failed containers
through the system. They include all pass and failed container merit values, mean values and
line speed (DSC and PBI only). There is one log file for each of the four analog inputs. Each
log file is circular and continues to display the last 1000 containers unless paused or cleared.

Save Reject Logs – These log files contain the last 1000 failed containers through the
system. They include failed container merit values, mean values and line speed (DSC and
PBI only). There is one log file for each of the four analog inputs. Each log file is circular and
continues to display the last 1000 containers unless paused or cleared.

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3.20.1 Setup Logs

Step 1 - From the Advanced menu press the Logs button to get to the logs menu.
Step 2 - Press the Setup Logs button to enter the Logs setup screen.
Step 3 - All the active analog sensors will be displayed. Press the check box under the
Clear for each sensor to clear the log file. The log index value will go to zero.
Step 4 - Place a check mark in the Run column next to each analog signal you want to
start collecting the log. Note the reject log file will only increment for rejected
containers. Notice the LED will turn green when the log file is activated. Once the
log file reaches 1000 containers it will display a 1000 in the Log Index but the
green LED will show a circular pattern around it to indicate it is full and adding new
data as the old data is deleted.
Step 5 - Press the Pause check box for any log you would like to stop collecting data.
Press the Run box to continue collection the log file from where it stopped.

3.20.2 View Log Files on Screen

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Step 6 - The log files can be viewed from the Sample Histogram screens or the Trend
graphs from the Merit Value screen.

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3.20.3 Save Logs to Flash Card

Step 1 - From the Logs menu select one of the Log menus Sample or Reject logs.
Step 2 - Press the log file for the analog sensor you would like to save the log file.

Step 3 - Once in the Save Log screen double press the File Name then type in the new file
name with the (.csv) extension then press ENTER. These CSV files can be
opened into Microsoft Excel in your PC.
Step 4 - Once the file name is setup press the Create button save the log file to the flash
card where it will show up on the list. You can then scroll down the list and
overwrite existing files or delete unwanted files on the flash card. Press the return
arrow to go back the save log menu a to select another sensor log to save.
Step 5 - Press the Done button to return to the home screen.

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3.20.4 Download Log Files through Ethernet

Step 1 - From any web browser software type in the IP address of the TapTone system
you would like to collect the data from.
Step 2 - The T4000 Remote Interface browser page will appear.
Step 3 - Press the View Logs option to get to the download page.

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Step 4 - Press the LOGS Name to enter the Directory of LOGS. This directory displays all
the currently stored log files on the HMI flash card.

Step 5 - Select any log file to open with Microsoft Excel program.

Sample Log file created 12/19/2008 16:09:28 X-Ray DC3


Blocked Open
Channel Channel
Date Time Underfill Overfill Volts Volts UF Mean OF Mean - -
12/19/2008 16:09:29 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:29 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:29 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:30 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:30 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:30 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:30 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:31 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:31 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:31 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:32 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:32 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:32 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:32 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:33 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:33 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:33 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:34 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:34 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:34 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:34 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:35 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:35 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:35 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:36 158 158 1105 521 158 158 1000 0
12/19/2008 16:09:36 158 158 1105 521 158 158 1000 0

Sample log file

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3.21 Interface Configuration

3.21.1 User Preferences

Step 1 - Change the Machine Name by double pressing on the name box.
Step 2 - Select the desired Home screen type (system or large counters).
Step 3 - Select the Device Button Prompts feature to be On or Off. When ON is
selected some key prompts will ask you if you are sure before the command
is executed. An example is (Reject On/Off) or (Conveyors Start/Stop).
Step 4 - Press Exit to return to the Home screen.

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3.21.2 Languages

Step 1 - Select the desired language based on which flash card is installed in your
system.
Step 2 - Press Exit to return to the Home screen. The selected language will be
displayed in every screen.

Notice: Some screens may have English text as there was no suitable translation.
Please understand that some translations may have a slightly different meaning
than the English word that was intended.

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3.21.3 Password Setup

Step 1 - Select the Password number box by pressing it twice. (Supervisor 1-3) have
access to initial password setup. It is advised that you change the default
passwords once the system is setup.
Step 2 - Type in the new four digit password then press OK to save.

Step 3 - To change the Group Names double press on the group name to change then
type in the new name then press ENTER to save new name.
Step 4 - To change the Level double press the Level box to change then use the scroll
up/down and select the new level for the group selected. The default Level
authority is shown thin the password chart above.
Step 5 - To change any of the Advanced Password Features press the Advanced Setup
button. This page allows you to customize every password function and user level
authorized to enter that function.

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Caution: This section of the Password Feature is for advanced users and should not
be changed unless you understand what you are doing. If you get lost you can press
the Defaults button to return all password levels back to factory default values as
shipped.

Buttons & Alarms – You can change the defined access levels for rejector/x-ray On/Off
function, and clearing of alarm conditions.

Clear Data – You can change the defined access levels for clearing of counters, triggers, log
files, alarm history and select all prompts.

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Step 1 - Select the desired Level to change by double pressing the box then scroll through
to the new setting. Press ENTER to save the new level.
Step 2 - Press Exit to return to the Home screen or press the Left arrow to return to the
Define Access Levels menu page.

Products – You can change the defined access levels for changing all features of the
Product types menu.

Password Security – You can change the defined access levels for all password security
features.
Step 1 - Select the desired Level to change by double pressing the box then scroll through
to the new setting. Press ENTER to save the new level.
Step 2 - Press Exit to return to the Home screen or press the Left arrow to return to the
Define Access Levels menu page.

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Parameters – You can change the defined access levels for modifying of the parameters
menus.

Advanced – You can change defined access levels for advanced menus, configurations logs
and diagnostics.
Step 1 - Select the desired Level to change by double pressing the box then scroll through
to the new setting. Press ENTER to save the new level.
Step 2 - Press Exit to return to the Home screen or press the Left arrow to return to the
Define Access Levels menu page.

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Interface Configurations – You can change the defined access levels for modifying all
parameters involved with the HMI screen such as user preferences, languages,
communications, time and date.

Utilities & Diagnostics – You can change the defined access levels for flash card utilities
such as firmware upgrades, default settings and x-ray intensity settings.

Step 1 - Select the desired Level to change by double pressing the box then scroll through
to the new setting. Press ENTER to save the new level.
Step 2 - Press Exit to return to the Home screen or press the Left arrow to return to the
Define Access Levels menu page.

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3.22 Communications

Step 1 - You can change the default IP Address, Subnet Mask, Gateway and MAC address
for the HMI screen. This will allow access through the Ethernet Port for remote
screen display and flash card access to the system.
Step 2 - Press Set when done to store new values.
Step 3 - You can check the PLC status for any system with conveyors.
Step 4 - You can then Enable/Disable the RS-232 serial port and select the desired Merit
Value Streaming data to be. Scroll through the choices then press ENTER.
Step 5 - Press Apply to start the serial port streaming data function.

Notice that in very high speed lines the serial port data may not get every container
depending on line speed, number of inspections and the serial port speed of you
computer.

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3.22.1 Ethernet Port


The T4000 Ethernet connection is located on the bottom of the electronics control enclosure.
This port is used to connect via Ethernet to PC or plant network. Reference the T4000 Ethernet
Communications Users Manual M-412-103 for details on the features of the Ethernet port.

3.22.3 Serial Port RS-232


The T4000 serial port is used to retreive streaming merit value data from the T4000 DSP
board. This port required a 8-pin euro to DB-9 cable part number B-410-92.

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3.23 Touch Screen Calibration

Step 1 - Touch each square where the white dot is visible. This will calibrate the visual
screen display to the touch pad points. The screen will return to the Home screen
when calibration is complete.

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3.24 Date and Time

Step 1 - Press the Set New Time button to enter the new time and date for both the HMI
screen and the DSP boards. Press ENTER to save when done. This will
synchronize the HMI screen and DSP boards time to be exactly the same.
Step 2 - Press Done to exit back to the Home screen.
Step 3 - You would only use the Synchronize to Board Time button if you are replacing the
HMI and would like to set the time to the existing board time.

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3.25 Utilities

The Utilities menu provides access to the CF (compact flash) card and software upgrade
functions.

3.25.1 Machine Backup/Restore

Backup Current Product to CF Card – Save current product setup to compact flash card. This
will back-up all saved parameters to the card.

Restore Current Product From CF Card – Retrieve the current setup from the flash card and
load it into memory for this product setup.

Default Current Product – Set all parameters in the current product type to default factory
settings.

Backup User Settings to CF Card – Save all current user settings to compact flash card. User
setting are all systems settings not associated with a specific product setup.

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Restore User Settings From CF Card – Retrieve the current user settings from the CF card
and load it into memory.

Default User Settings – Set all user settings to default factory settings.

3.25.2 CF Card Utilities

Eject CF Card – Press this button then it will be safe to remove the CF card with the power
on.

Format CF Card – Erase and reformat the CF card. Using this function will cause loss of all
information saved on the CF card. Use this function to format a new CF card to the Redlion
HMI format.

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3.25.3 DSP/COMM Board Upgrade

Upgrade COMM code – This feature will upgrade the communications firmware from current
version on board to latest version on CF card. This process takes about 2 minutes to perform.
Any user set parameters will not be lost with this upgrade.

Upgrade DSP code – This feature will upgrade the DSP firmware from current version on
board to latest version on CF card. This process takes about 4 minutes to perform. Any user
set parameters will not be lost with this upgrade.

3.25.4 Reset System Memory

Initialize Memory – This function will reset all system memory to factory default settings.
Doing this will erase all user set parameters and product setups.

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3.26 Diagnostics Menu
The diagnostics menu allows the operator to view the status of each of the inspection
sensors and help to diagnose problems quickly within the system. Press the diagnostics
menu button to display the diagnostics menu list.

3.26.1 Rejector and Encoder Diagnostics

This screen displays the current settings of all rejector and shaft encoder parameters.

Step 1 - Press the Rejector and Encoder Diagnostics button to enter the screen.
Step 2 - Press Exit to return to the home screen.

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3.26.2 Trigger Diagnostics

This screen displays the status of each inspection trigger. Only trigger sensors with the green
check mark are active in this screen.

breaks – counts the number of times the trigger sensor has changes state for each sensor. A
properly operating system should have the same number of counts for each trigger sensor.

pulses – displays the number of shaft encoder pulses for the last container inspected. It also
stored the maximum and minimum pulse values since the last time the clear button was
pressed.

msec – displays the passing time in milliseconds for the last container inspected. It also
stores the maximum and minimum passing times since the last time the clear button was
pressed.

Clear – press to reset all values to zero.

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3.26.3 Inspection Diagnostics

Step 1 - Select the sensor and press the button to view all parameters associated with that
inspection sensor. Press the left arrow to return to the menu to select another
inspection sensor.
Step 2 - Press Done to return to the Home screen.

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3.26.4 Input / Output Diagnostics

This screen displays the DC analog voltage for each of the 4 DC analog sensor inputs. If no
sensor is connected the voltage will read 0.000V. Each analog input has a range of 0.000-
10.000 VDC.

Inspection Triggers – Displays the status of each inspection trigger (1-12).

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Digital Input Diagnostics – This screen displays the status and setup of all four digital inputs.

DC Channel Voltmeter – This screen displays the live status of all four DC channel inputs.
You can test each sensor and see the voltage change live on this screen. Each channel may
change icon depending on inspection sensors selected.

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Optional Output Diagnostics – Displays the status of each digital output where the LED will
be red when the output is activated. Note this screen will not respond fast enough for very
short pulsed like the reject pulse.

Digital Output Test – This test will toggle all eight digital outputs on and off to test the
functionality of the hardware connected to each output.

WARNING! - Do not perform a Digital Output Test during live production run. This test
will actuate the reject output which may cause container jams at the reject station.

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3.26.5 Waveforms

This screen displays the analog profile of the last container inspected.

Next Sensor – press this button to change the last container profile to the next active sensor.

Get Last Reject – press this button to view the last rejected container. Then press Next
Sensor to see the last reject for each active sensor. If no rejects have occurred then the
profile will be blank.

Auto Refresh – select auto refresh or turn it off and use manual refresh to get the next
container data points.

Refresh – press to view another good container waveform. The same reject wave form will
appear if no new rejects had occurred.

Done – return to home screen.

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3.26.6 Software Versions

This screen displays the current versions of software for the following components:
HMI: Display software code
PLC: Programmable Logic Controller code
SP: Signal Processor Board DSP code
PLD1: Programmable Logic Device #1 code
PLD2: Programmable Logic Device #2 code
CM: Communications Board DSP code
PLD1: Programmable Logic Device #1 code
IO PLD: Interface Board Programmable Logic Device code

Upgrade – Press the upgrade button to see if you have the latest version of software on you
system.
Contact Teledyne TapTone to find out what the latest software version is to see if you would
like to upgrade your software.

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3.27 Alarm Menu

The Active Alarm bar will change color to display current system status.

Alarm Status Box – This home screen box displays the following information:
Date
Time
System Status
Alarm Log Messages
Current User Logged-In
Red Alarm Bar – Indicates one or more active alarm conditions are present which may affect
system functionality.

Green Alarm Bar – Indicates all active alarms are clear and system is functioning properly.

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3.27.1 Active Alarms Screen

You can access the Active Alarms Screen by pressing the alarm status box at the bottom
right side of the home screen to view the active alarms screen or press the alarm button from
the Menu buttons as shown below.

Active Alarms – Displays all active alarms currently effecting system status.

Alarm History – Stores all alarm conditions accumulated since the clear history button was
pressed. Most recent alarms are on top for list. Press the >> or << arrows to scroll through
the complete list of alarm history.

Clear Active Alarms – Press the CLEAR button to clear currently stored alarm history.

Exit – Return to Home Screen.

Configure Display Alarms – Press to enter the alarms configuration screens.

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3.27.2 Alarm Display


Step 1 - Press the Configure Display Alarms button to enter the alarm configuration
screens.
Step 2 - Select Alarm Display, Alarm Output 1, 2, or 3 tabs for configuration.

Alarm Display – This tab is used to configure the trigger, rejector & encoder, inspections, e-
stops & motors alarm conditions which are displayed in the alarm status box on the home
screen. Only alarm conditions checked will be displayed on the HMI screen on the Alarm
Box. There are some alarm conditions that are displayed across the entire screen such as E-
stop or safety guard openings.

System Ready (Alarm 1) – This tab is used to configure the trigger, rejector & encoder,
inspections, e-stops & motors alarm conditions which affect the digital output #3 on the I/O
board. This output is also connected to the green system status lamp on top of the control
cabinet. This alarm output 1 is typically used as the system status output which can be
connected to the customers PLC control system via the optically isolated output module 1 on
the chassis.

System Fault (Alarm 2) – This tab is used to configure the trigger, rejector & encoder,
inspections, e-stops & motors alarm conditions which affect the digital output #6 on the I/O
board. This output is connected to the optically isolated output module 2 on the chassis. This
output is typically used as the reject acknowledge alarm output for percent or consecutive
reject alarms. All other alarm conditions are turned off in to this output when used in this
configuration.

Good Signal (Alarm 3) – This tab is used to configure the trigger, rejector & encoder,
inspections, e-stops & motors alarm conditions which affect the digital output #8 on the I/O
board. This alarm group is used for the fail-safe output known as the good signal. This
output is also affected by the parameters for rejector-3 which is the good signal output.
The good signal provides a pulse for every good container which passes all inspections and
there are no alarm conditions defined by this alarm configuration. Typically this signal is only
used with a gate style rejector where the gate is closed unless the good signal commands it
to open and let the good container pass. The gate will stay open if the next container is good
or the user set pulse times out then the gate closes until the next good container signal.

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3.27.3 Triggers
The trigger alarm menu monitors any inspection trigger input. This menu is the same in all
for alarm output menus. Press the desired box to place a check mark which selects that
function to be reported in case of an alarm condition. Any box highlighted in RED indicated
that alarm condition is currently being reported.

Short – Short photo beam break is any break less than 50% of the stored value.
Long – Long photo beam break is any break greater than 50% of the stored value.
Blocked – Any photo beam break greater than 10 seconds.

Trigger # 1-12 correspond to the inspection trigger inputs as follows:


1 – Reject reference #1 trigger sensor.
2 – Exit load cell trigger sensor.
3 – Entry load cell trigger sensor.
4 – Reject #1 verification trigger sensor (optional).
5 – Reject reference #2 trigger sensor (optional).
6 – X-ray tunnel trigger sensor (optional).
7 – Proximity/Laser trigger sensor (optional).
8 – Reject #2 verification trigger sensor (optional).
9 – Digital input #1 trigger sensor (optional).
10 – Digital input #2 trigger sensor (optional).
11 – Digital input #3 trigger sensor (optional)
12 – Digital input #4 trigger sensor (optional).
Select All – Select all items and apply a check mark in each box to activate that alarm
function.

Clear All – Select and clear all check marks in each box to deactivate all alarms.

Apply – Saves any changes made since you entered this screen.

Apply & Exit – Saves any changes then exit to the home screen.

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3.27.4 Rejectors & Encoders


The rejector & encoder alarm menu monitors functionality of rejectors, reject verification and
shaft encoder. Press the desired box to place a check mark which selects that function to be
reported in case of an alarm condition. Any box highlighted in RED indicated that alarm
condition is currently being reported.

Rejector #1 & #2 – Set up reject alarms for each rejector.

Off – Alarm condition when rejector is turned off from the touch screen.

Consecutive – Alarm condition when the consecutive reject value is reached.

Percent – Alarm condition when the percent % reject value is reached.

Timing – Alarm condition when the reject timing from the reference trigger to the rejector has
exceeded the maximum amount of shaft encoder pulses allowed.

Reject Acknowledge #1 & #2 – Select alarm condition when a reject is missed and seen by
the reject verification trigger sensor.

Alarm – report a missed reject seen by the reject verification sensor.

Encoder – Set up alarm conditions for the shaft encoder.

Internal – Report is encoder function is in internal timing mode. This condition will only occur
for a software error in reading parameters from the DSP memory.

Turning – Report an alarm condition when shaft encoder is not turning. This alarm condition
can occur if the shaft encoder coupling is loose or the encoder has failed electrically.

Frequency – Reports when shaft encoder is in internal timing mode.

Trigger Diagnostics – Reports when the photo triggers are in internal timing mode.

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3.27.5 Inspections
This menu sets up the alarm conditions for the x-ray and load cell sensors. Do not select the
x-ray sensor alarms if your system does not have an x-ray sensor option installed. Press the
desired box to place a check mark which selects that function to be reported in case of an
alarm condition. Any box highlighted in RED indicated that alarm condition is currently being
reported.

X-ray #1 – Sets the alarm conditions for the x-ray inspection sensor.

OFF – Report an alarm condition when the x-ray sensor is turned off from the from the
touch screen.
Blocked Channel – Report an alarm condition if the x-ray beam calibration value for
blocked channel (no x-ray transmitting) rises above 0.5V. Normal blocked channel
value is between 0.3V to 0.4V.
Open Channel – Report an alarm condition if the x-ray calibration value for open channel
(normal transmission during open channel) drops below 1.0Volts. Normal open
channel should be between 8.5V and 9.5V (range is 0-10.0V).
Merit Range – Report an error if the x-ray measured merit value is above the open
channel value or below the blocked channel value.

Load Cells (Entry and Exit) – Set the alarm conditions for the entry and exit load cell
inspection sensors.

Low – Reports and alarm condition if the measured merit value voltage drops below 1.0V
during an inspection. This alarm clears after 5 seconds.
High – Reports and alarm condition if the measured merit value reaches 10V (saturation)
during an inspection. This alarm clears after 5 seconds.
Tracking – Reports tracking errors from Entry to Exit photo triggers.
High Frequency – Set the alarm conditions for the high frequency sensors.
Low – Alarm when the output voltage drops below 1.0V during inspection.
High – Alarm when the output voltage goes above 9.0V during inspection.

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3.27.6 E-stops and Motors


This menu sets up the alarm conditions for the emergency stops, door guards and motor
functions. Press the desired box to place a check mark which selects that function to be
reported in case of an alarm condition. Any box highlighted in RED indicated that alarm
condition is currently being reported.

E-Stop #1-4 – Report an alarm condition for any of the E-stop switches. Any E-stop condition
immediately stops the conveyors turning. Clearing an E-stop condition requires a manual
restart of the conveyors by an operator.

Active-1 – Not used for T4000 PBI-E system.

Active-2 – Reports an alarm when either of the two E-stop buttons located on the (left) side
of the PBI-E when standing at the touch screen.

Active-3 – Reports an alarm when either of the two E-stop buttons located on the (right) side
of the PBI-E when standing at the touch screen.

Active-4 – Reports an alarm when either of the two front sliding doors are open or the lift
guard on the back side of the PBI-E system is open.

Motors – Reports an alarm condition is the motor controller is not in the (motors running)
state.

Stopped – Reports an alarm condition when the motors are stopped from the touch screen
or fault in the motor controller VFD.

External Fault – Reports a user defined external fault. Press Setup to give this alarm fault a
meaningful name. An example would be a pressure switch to monitor rejector pressure and
warn you if above or below the limits. This signal is Input X5 of the PLC in the motor control
box. PLC is only installed in T4000 systems with conveyor motors.

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