Maintenance

Training
This training is intended for
Maintenance personnel
 Parts of Machine

Computer Cabinet
Inspection Head
 Base Cabinet Front Door

Diffuser Starwheel
Glass Motor Power
Motor Supply

Vacuum
Venturi
Circuit Breaker with Tank
Panel

UPS Batteries
Base Strobe Gearbox
UPS
Assembly
PLC
Interface
 Base Cabinet Front Door
Vacuum
Surge Tank

Reject
Valve

Power Supply Drawer

Starwheel Motor Vacuum Venturi Pump
Reject Conveyor Motor Controller
Starwheel Motor Power Supply

Controller for
Reject Conveyor
Motor

UPS
 Base Cabinet Back Door

Machine
Pressure
Regulator
Base Strobe
Air Filter Bottom/
Diffuser
Blow-Off
Pressure
Starwheel Regulator
System
Air Filter

Starwheel Base Starwheel Main Power

Vacuum Cabinet Reject Pressure Transformer
Filter Drawer Regulator
Cabinet Drawer
Maintenance panel

Machine Input Pressure

min. 80PSI
Bottom blow off press.

Starwheel cleaning
pressure
Reject pressure

Main Regulator Air

Regulator Base blow off

Regulator Reject Pressure

Airfilter Panel

!!!
Cabinet Transformer 115VAC
UPS Card and Batteries
Motors for Diffuser and Brush Drive
 Rotating Glass Drive

Test Bottle
Neck Belt Sensor

Water Drip Valve

Body Belt

Airknife
Diffuser or Rotating
Glass
Base Strobe Lamp

Input voltages
LED 1000V
and 280V
Reject Valve
Vacuum Buffer Tank
Circuit Breakers and Voltage monitor
PLC interface
Computer compartment
 Finish Strobe
Inspection Head (LED) Power
+48V Supply
Cooling
Servo
System Controller

Computer
IR-RLD Board
Cage Power
IR-RLD Sensor

Base Camera

Hard Disk
Inner Sidewall
Camera

Servo Motor
for Zoom and
Brightness
CPU Card
Keyboard Finish and Thread
Reject Verifier Controller Card Camera
Alacron Board for (KCC)
Base, ISW, Finish & Thread Camera Breakout
Inspection Alacron Board for Board
OSW Inspection
Finish interface card
Camera Breakout board
Computer Card cage
 Reject verifier Sensor
located underneath computer card cage
 Hard Drive
located on side of computer card cage
Lenses under inspection head

IR-RLD
Base
ISW
Lens

Neck Belt

Finish lens Test Bottle Sensor

 Reject Verifier

Reject
Verifier
Touchpad LCD Display
Starwheel
 Starwheel Area

Valve plate
Sealring
 Valve Plate
Vacuum
Atmosphere

Reject Port
Vacuum/Pressure

Vacuum
Purge 5-7 psi
Guide rails (wearstrips)
Upper Starwheel Position

About 1-2mm
distance between
Bottle and Starwheel
plate. To be adjusted
with spacer
underneath
starwheel plate
 Position of Infeed Pulley
Pulley to push with belt slightly against bottle.
Deadplate
Base Blow off Air Knife
Air knife
Adjustment of Base Blow off Valve

Loosen bolts
and move valve

Adjust airflow
Conveyor encoder
Drive sprocket of encoder
 Infeed Sonics

Overheight
Bottle and
Down Bottle
Sensor
Sonic 1 to detect Sonic 2 to close
Missing Bottle gaps in front of
the Outersidewall
Infeed Sonics
Close up

Sonic Transmitter and Receiver

RF-RLD Sensor

RF-RLD Sensor
Position of RF sensors to bottle

2-3mm space
Adjustment of RF sensor blocks

Adjust the RF Guides, so

the bottles dont hit
against guide plates
Adjustment of RF sensor blocks
 Outer Sidewall Camera Box

Digital
OSW
Camera

Servo Motors
Elevator
Motor Freznel Lens
Mirror

Heater
Servo
Controller

Servo / Camera
Power Supplies Fuse for Elevator
Motor
Outer Sidewall Light Panel Box

Cooling Fan

Light Panel

Intake Air Filter

OSW camera elevation system

Drive motor for

elevation
system
OSW digital camera
OSW servo controller
OSW infeed guide rails
OSW rotator guides
 OSW rotator guides

Rotation OV2 OSW

Power
Power Switch
-When powering down the
UPS will keep the unit up for
about 1 minute.
E-Stops

E-stop
Press in Freewheel
Pull out Hard Break
Door Switch

Door Switch
Beacon Light Tower

Alarm

Warning

Ready

Test Bottle Request

System Power is On
This same color scheme is
used on all OMNI Screens in
lower bottom right corner.
 115VAC
Input

24VDC 24 VDC Power supply for Computer. On

output backside of UPS card bracket
DC-DC converter card
LEDS DC-DC converter card
 Base Cabinet Drawer
PS 5

HV Rectifier PS 3
XFMR 1

PS 4
PD 2

PS 1

Line Control
Module XFMR 2
(LCM)
Sensor connection blocks

Sensor blocks: SB1

and SB3 outside
base cabinet. SB2
inside base cabinet
 PLC Interface
38997
PLC Outputs Inputs

Fuse

Encoder
Reject
Inhibit
Brake Out (not recommended)
(System Ready)
Downstream Run Out
Downstream Gap Jam
Down Bottle

Upstream Spare
Throughput External Brake
Reject Down
(PIN) Bottle
UPS card and batteries
 Theory/Functionality:

The OV-II UPS is not a typical AC UPS.

The OV-II UPS is a DC UPS whose sole purpose is to switch
24VDC from the power supply in the Base Cabinet (which is
killed when the main power switch is thrown) to the 24VDC
battery for a period of one minute to allow Windows to have
time to properly shut down.
 UPS Battery
The Lead-Acid 24VDC UPS battery is charged with the
30VDC power supply that is mounted in the Base Cabinet.
CB-11, the breaker for this supply, is connected directly to
the in-coming 220VAC line to allow charging to take place
regardless of the state of the main power switch. The
power for this circuit is not subordinate to the main Power
Switch.
LCM on cabinet drawer

LCM
LCM download screen
 Vacuum Tubes
Starwheel

Encoder
Motor

Reference position
1
From Pin 1
Offset
Reject
conveyor
 Finish Thread Option
(Camra) (Camra)

IR RLD Base ISW

detection IR (Camra) (Camra)

Semitransparent
Mirrors

Protection LED Strobe Lamp

windows

Diffuser
glass (Brightfield
Option)

Rotating
glass

Light Source (Strobe Lamp)

IR Detection
Principle of function

IR
Infra Red photocell

Lens system to adjust brightness and zoom

Residual liquid inside bottle

BT#3
Rotating
glass

Light source
Principal of function for Base
Base
(Camra)

Semitransparent
mirrors

Protection
window and
lens

Diffuser lens
and
polarization
filters
Rotating
glass

Light source
 Base Outer Rim
Desciption of Inspection zones Middle Rim
Center
0
3
5

Camera
Image

Outer Rim

Middle Rim

Center
5 3 0
Principle of function
ISW
(Camra)

Semitransparent
mirrors
Protection
window and
lens Normal
mirror

Diffuser lens
and
polarization
filters
Rotating
glass
ISW Upper
Middle
Bottom
0
3
5

Upper

Bottom
Middle
5 3 0
Principle of function

Finish
(Camra)

Parabolic
mirrors
Light source
Caustic Detection (RF-RLD) OMNI
OSW II

Sensor position

BT#4
Transmitter Receiver
RF RF

Bottle with no caustic Bottle with caustic

OSW
Principle of OSW
OSW
(Camra)

Camra

Light Source

Mirror
Principel of rotation OSW

Lower
Neck Guides
Guides
Principel of OSW inspection

P1 P2 P3 P4 P5

A B C Neck
Guides

Defect on bottle
A Lower
Guides
P1 P2 P3 P4 P5

#4

A B C Neck guides
#3

#2

#1

Defect is detected in window 2

Lower
guides
P1 P2 P3 P4 P5

#4

A B C Neck
#3 Guides

#2

#1

Lower
Guides
Other defect in new bottle on zone 4

P1 P2 P3 P4 P5

#4

A B C Neck
#3 Guides

#2

#1

Lower
Guides
 Base
Camera/Display

3000 - 3500
Base Zone Setup
 Base
Algorithms
 Calibration Procedures
Base Inspection Setup
Zone Setup
Screen
Algorithm
Screen
Masks
 Inner Sidewall
ISW Calibration procedures
Base-Inner sidewall parameter description
s
Finish Inspection
 Finish

b C
a

A Sector
 Finish Locator Diagram
Width = 5 Width = 6
Light = 70 Light = 120
Width = 6
Light = 120 Tracking Window
Width
Locator Width = 6
Width = 5 Positions Light = 120
Light = 120

Width = 8 Width = 5
Light = 200 Light = 160

Width = 4 Finder Track Width = 5

Light = 120 Minimum Track Threshold = 80
Tracking
Centering
Screen
 Lane A
Will not allow Sector
Average Size light level to
drop below this value

Increasing this value makes it

easier to detect object.
DO NOT EXCEED 50!!
 Lane B
Will not allow Sector
Average Size light level to
drop below this value

Decreasing this value makes it

easier to detect object.
 Finish Setup procedures
Finish Setup
Camera/Display
 Horizontal
Registration
 Vertical
Registration
Masks
Window Setup
Algorithm
 OSW setup
OSW setup
Setup IR & RF
RLD
Base Zoom - 10
Line Control Screen
Test Bottle Program
 Test Bottles are
run from this
Screen

Start Test Here

Running Test Bottle Program
Time to start
after auto start

Next Auto Start

Test is running

Time to complete test and bottles to go

Results from test bottle
 Test bottle
Bottle Insertion
To change either selection below requires
maintenance level password access.
In order
Bottles must be run in order
This is the recommended method.
Random Order
Bottles can be run in any order. The machine
will automatically resort the order and show
results.
Bottle Changeover Screen
Changeover steps
 Changeover cautions
When seating starwheel verify valve plate
is clean.
Verify starwheel is seated correctly.
Tighten the starwheel locking handle is
extremely tight.
 Bottle Changeover
All parts associated with the changeover
are color coded to aid in this changeover
process.
Icon Identification
IR Residual Detection
RF Residual Detection
Aux Reject
Finish Detection
Thread Detection
Base Detection
Plugged Detection
ISW Detection
Large Object Detection
OSW Detection
Scuff Detect