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Veritas iC

Troubleshooting / Preventive Maintenance


(Technical Training Report)

Purpose & Objective


Purpose:
- This section identifies some possible remedies when faults arise on the Veritas iC. This section does not give resolutions to all problems but is here as an aid to troubleshooting.

Objective:
- At the completion of this training participants should be able to:
Explain what needs to be done for maintenance Demonstrate how to remove and replace a light board Explain different alarm conditions Follow the electrical drawings for the Veritas iC

Alarm Screen
To reset an alarm press the Acknowledge all button. Two types of alarms can occur in the system; Alarms and Latched Alarms
Alarms- Require user intervention to fix and restart the Machine. Alarms are typically more mechanically or electrically related. ie. Main Line Contactor, Safety Relay, Thermal Overloads. Latched Alarms- Some latched alarms stop the machines. These alarms represent data and tracking faults

Latched Alarms
BP1 to BP2 out of Tolerance
- Definition
Bottle slipped or advanced out of the settable tolerance.

- Reasons
Bad Auto Configure Changed quadrat ratio Ware handling Container Sticks to belts Bad belts Bad BP Sensor

- Fix

Redo Auto Configuration Verify quadrat ratio Change belts

Latched Alarms
Ware Down Fault
- Definition
One of the two Down ware sensors have been triggered.

- Reason

Fallen bottles Sensor alignment Bad sensor Dirty sensor Improper wiring Clear bottle from sensor and the acknowledge alarm in Supervisor. Make sure the sensor is aligned with the reflector on both sides Verify the wiring and operation of the sensor input PLC I:1/[10] Clean Sensor and reflectors.

- Fix

Latched Alarms
Down Bottle Infeed
- Definition
Down bottle sensor has been activated

- Reason
Fallen bottle prior to the separator Sensor adjustment Faulty sensor

- Fix
Remove fallen bottle Make sure that the sensitivity is adjusted for the bottle in operation. Verify the sensor is working by viewing the input on PLC.

Latched Alarms
Station 1 MX1 Data Fault
- Definition
Data was not received in the data received window point.

- Reasons
Setup for reject result offset not correct

- Fix
ReAuto Configure

Latched Alarms
Station 2 MX2 Data Fault
- Definition
Data was not received in the data received window point.

- Reasons
Setup for reject result offset not correct

- Fix
Re Auto Configure

Latched Alarms
Tracking Fault
- Definition
Bottle was not detectible at one of the BP

- Reasons
Sensor malfunction

- Fix
Verify the operation of both Bp1 and BP2 sensors. Perform Auto Configure

Latched Alarms
BP1 Missed
- Definition
BP2 triggered on a bottle that BP1 did not.

- Reason
Faulty Sensor

- Fix
Verify the operation of both Bp1 and BP2 sensors.

Latched Alarms
BP2 Missed
- Definition
BP1 triggered a bottle that BP2 did not.

- Reason
Faulty Sensor Fallen bottle

- Fix
Verify the operation of both Bp1 and BP2 sensors. Check for fallen obstruction of bottle flow

Latched Alarms
Machine Setup Error
- Definition
Bad Machine Auto Configure (Alarms only during Auto Config.)

- Reason
5 second timer between BP1 to BP2.

- Fix
Make sure the Belt are running at the same speed as the conveyor. Verify the operation of BP1 and BP2.

Latched Alarms
Conveyor Speed too low
- Definition
A Data fault has occurred and the conveyor speed is less than 6 per second.

- Reason
Bad encoder Conveyor has stopped Faulty PLC analog card Low external speed control

- Fix

Make sure conveyor is running Verify the operation of the encoder Verify analog card of the PLC

Latched Alarms
Conveyor Speed too High
- Definition
Conveyor speed exceeds 60 per second

- Reason
External speed reference set too high. .

- Fix
Lower conveyor speed

Latched Alarms
Measures bottle width Out of Range BP1
- Definition
Bottle width exceeded Machine Setup PLC specifications (Alarms only during Auto Config)

- Reason
Sensor malfunction. Bottle fell Bottle not taped properly

- Fix

Verify sensor operation Make sure the bottle is taped high enough for both BP sensors.

Latched Alarms
Measures bottle width Out of Range BP2
- Definition
Bottle width exceeded Machine Setup PLC specifications (Alarms only during Auto Config)

- Reason
Sensor malfunction. Bottle fell Bottle not taped properly

- Fix

Verify sensor operation Make sure the bottle is taped high enough for both BP sensors.

Latched Alarms
Station to Station distance out of ran
- Definition
Variable for Station to Station distance is out of range during an Auto Configuration.

- Reasons
Sensor moved Sensor malfunction Bad encoder

- Fix
Verify sensor BP sensor functionality. Verify encoder signal on I:0/[0] Re Auto Configuration

Alarms
PLC Awaiting Data
- Definition
PLC requesting data from the Supervisor computer.

- Reason - Fix

Only a problem if the alarm stay on Lose Ethernet connection between the PLC and Supervisor Verify the connection to the Ethernet Switch and the two devices. . Make sure power is on the Ethernet Switch. Replace Ethernet cables between the Ethernet switch and the devices.

Alarms
Station 1 MX1 Offline
- Definition
Signal from the MX computer telling the Supervisor that the computer is Offline.

- Reason
Manually turned Offline Signal not reaching the PLC

- Fix
Turn the MX computer online. Verify the connection from MX J13 to Breakout 4 from Breakout 4 pin 9 to PLC inputs I:3/15.

Alarms
Station 2 MX2 Offline
- Definition
Signal from the MX computer telling the Supervisor that the computer is Offline.

- Reason
Manually turned Offline Signal not reaching the PLC

- Fix
Turn the MX computer online. Verify the connection from MX to Breakout and from Breakout to PLC

Alarms
Station 3 MX3 Offline
- Definition
Signal from the MX computer telling the Supervisor that the computer is Offline.

- Reason
Manually turned Offline Signal not reaching the PLC

- Fix
Turn the MX computer online. Verify the connection from MX to Breakout and from Breakout to PLC

Alarms
Low air Pressure
- Definition
Input air pressure below 50PSI.

- Reason
Air supply to low Main cutoff valve turned off. Limit switch not adjusted correct.

- Fix
Verify air supply Make sure valve is turned on. Properly adjust the limit switch on the air pressure sensor.

Alarms
Arm Released Magnets
- Definition
Plc received a signal to release the arm magnets

- Reason
Manually Pressed

- Fix
Secure the swing arm in position and press the arm release button to inactivate it.

Alarms
Station 1 MX1 GIO1 Alarm
- Definition
Programmable alarms set in the Genius software.

- Reason
Consecutive Rejects Excessive rejects No rejects

- Fix
Clean Optics Adjust inspection setup

Alarms
Station 2 MX2 GIO1 Alarm
- Definition
Programmable alarms set in the Genius software.

- Reason
Consecutive Rejects Excessive rejects No rejects

- Fix
Clean Optics Adjust inspection setup

Alarms
Station 2 MX3 GIO1 Alarm
- Definition
Programmable alarms set in the Genius software.

- Reason
Consecutive Rejects Excessive rejects No rejects

- Fix
Clean Optics Adjust inspection setup

Troubleshooting
No Conveyor Encoder
- Should see encoder signal on PLC I/1:0 and MX IO Module 3 input 3.
Bad encoder Bad Splitter Defective Module 3 on MX
Splitter 6 Encoder Splitter 7 PLC I:0/0 CC1B MX1 Mod 3/2 MX2 Mod 3/2 MX3 Mod 3/2

Troubleshooting
Bottle Present Sensor 1 not triggering
- Should see BP1 signal on PLC I/1:1 and MX IO Module 3 input 1.
Bad encoder Bad Splitter Defective Module 3 on MX Arm release active Poor alignment BP1

Splitter 1 Splitter 2

CC1B PLC I:0/2 MX1 Mod 3/1

Troubleshooting
Bottle Present Sensor 2 not triggering
- Should see BP2 signal on PLC I/1:1 and MX IO Module 3 input 1.
Bad encoder Bad Splitter Defective Module 3 on MX Arm release active BP2 Poor alignment

Splitter 3 Splitter 4

CC1B PLC I:0/3 MX2 Mod 3/1

Troubleshooting
Rejector not firing
- The marching screen is not updating.
PLC not communicating with the Supervisor computer
- For every bottle you should see com1 on the PLC flash

Emhart PLC serial IO program is not running

- Make sure that the Serial cable between both devices are connected - Reboot the Supervisor.

Troubleshooting
Rejector not firing
- The marching screen is updating but the rejector is not taking bottles off the line.
Bad Solenoid Insufficient air Offset in the Machine setup - PLC screen not adjusted correct. Poor alignment Poor wiring
- 24VDC - PLC O:0/5 output to solenoid

Troubleshooting
Arm Release will not engage
- Should see BP1 signal on PLC I/1:1 and MX IO Module 3 input 1.
Blown Fuse 9 Bad Control Relay 1 Poor wiring PLC O:5/15 to CR1 Arm release active Poor alignment of BP1

Troubleshooting
Camera not taking pictures
- Trigger Sensor

Bad BP Sensor Bad Splitter 2 BP1 Bad Splitter 4 BP2


- MX IO Module

Bad IO module 3 Not seated all the way Wired incorrect


- Conveyor Encoder

Signal not being sent to IO module

Troubleshooting
Camera not taking pictures
- GIO Trigger
Card Defective

- Camera trigger board


Cable connections Card defective

- Camera

Cable connections Defective Camera

- Ethernet cable - Ethernet Switch - Frame grabber - Camera not assigned correct in software

Troubleshooting
Assigning Cameras.
- Turn the MX Offline

- Go to the Setup screen from the One World Main home screen

Troubleshooting
Assigning Cameras.
- Select the Camera icon and press Edit.

- In the camera screen press Setup.

Troubleshooting
Assigning Cameras.
- Located on the left hand side is a drop down box that has all of the camera connected with that MX computer.

- Each camera as a unique Serial Number assigned to it. This number is marked on the camera. View the number and highlight it on the list of cameras.

Assigning Cameras.

Troubleshooting

- The camera should be operational. - Press the camera button and an image should appear - Exit out

- Accept Changes - Assigning camera is complete.


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Troubleshooting
Lights not acquiring
- Bad connection from MX computer to Light boards
The MX computer sends a signal from IO Mod. 2/[6] to the breakout boards. The trigger cable runs from the Breakout board to the Light driver board.

- Missing 24VDC from SPLY5 or 6 - Light board not initialized

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Trouble shooting a light board


Partial light board to dark:
- Bad cable
Try different connections Check all connections

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Trouble shooting a light board


Partial light board to dark
- Remove the cover from the back of the effected light board. Use a light and observe that all of the pin connectors are seated in the sockets. If this doesnt work you may have to take the control board off and re-set the pin connections between the light board and strobe board.

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Trouble shooting a light board


Entire Light board to dark or bright
- If after the Back Light Balancing procedure has been done. You observe one or two light boards that appear lighter or darker than normal, try the following steps to correct it.
Disconnect the power to the board. Reconnect power after 60 seconds and trigger the board. In the advanced light setup screen of the Gio bus Get and Set the light board power level.
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Troubleshooting
Initializing the light board
- Turn the MX Offline

- Enter the Setup from the


One World Main screen

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Troubleshooting
Initializing the light board
- Enter the camera setup by pressing the bottle image

- Enter the GIO Bus setup screen

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Troubleshooting
Initializing the light board
- Select Sidewall Light Panel in the Exciting Devices window - Press Edit

- Once in the Setup screen select Advanced and enter the advanced setup option.
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Troubleshooting
Initializing the light board
- Select GET to Retrieve the Power setting that is stored in the Light Panel LED Drive Board.

- Once the Power level updates to display the stored settings, press SET to reinitialize the Light board.
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Troubleshooting
Initializing the light board
- The light will operate as they were before the shut down. - Press the camera button and an image should appear - Press X and exit out of the camera setup. - Make sure to Accept changes and continue to the next camera and repeat the initializing process.

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Trouble shooting Data Valid Alarms


Data valid station faults are typically caused by the Vision computer not being ready to take a picture when the next part arrives, or the container is at the reject handoff point before the vision system has determined if the part is good or bad. - Make all camera ROIs (Region of Interest) the same. All camera views should have the same size region of interest. - Try to increase the container spacing to give the vision system more time between camera acquisitions. - Increase the part delay between the first trigger (-) and the second (+). - Increase the reject offset in the vision system.

Trouble shooting 200 micro second error


A event viewer error for camera timed out 200 micro sec. Error. Is typically caused by the Vision computer not being ready to take the second picture before the first one has cleared the buffer. - Make all camera ROIs smaller. All camera views should have the same size region of interest.. - Increase the part delay between the first trigger (-) and the second (+) to allow time to clear the frame buffer.

Trouble shooting Bottle space wont run


The bottle spacer is tied to an output on the PLC O:0/1. This is the stop bit for the spacer. If this bit is on the spacer will not run. Check the alarm screen on the supervisor PC. Many alarm will toggle the bit to stop the spacer.
- All line control sensorsBack up, Back log. - The Down ware sensors along the conveyor. (front side and back side) The Reject verify across the cullet chute. - The arm magnets need to be engaged. - MX1 and MX2 need to be online. - Air pressure needs to be at least 50 PSI.

False rejects, hotspot on container


False rejects, hotspot on containers are typically caused by light entering the machine from the top or sides. If you see repeating rejects due to a light spot on the container, verify no stray light is entering the machine. Another cause can be from the Down ware sensors mounted along the conveyor. The sensors come equipped with a small plastic shield to try to prevent this from affecting production, but if the sensor is knocked out of adjustment or has the gain set to high. It can reflect off of the edge of the container.

Preventive Maintenance
Daily
- Clear off any broken glass - Clean Bottle Present sensors - Clean Down Ware sensors - Clean Cameras - Clean Mirrors

Preventive Maintenance
Weekly
- Clean conveyor and guide rails - Clean blower filter - Clean Air-condition Filter (If Applicable)

Preventive Maintenance
Monthly
- Inspect and clean inside console.

Routine Maintenance
Cleaning Mirrors and Lightbox Shields
- Use a soft, dry, lint-free cloth, carefully wipe dust and dirt from all mirror surfaces, as well as from the Lightbox Shields that cover the Lightbox Assemblies.

Cleaning Cooling fan intake filter


- Remove the re-usable filter by loosening the thumb screws and removing the filter cover. Tap dust from the filter away from the machine intake and replace. Cleaning should be preformed once per week minimum, If dust and debris buildup is heavy in that time period, more frequent cleaning will be necessary.

Cleaning Lenses
- Use a soft, dry, lint-free cloth, carefully wipe dust and dirt from all lens surfaces.

Replacing a Mirror
How to remove a mirror
- Disable the electromagnets and swing the optics arm out - Slide the mirror to be replaced up out of its mount then tip the mirror away from the mount and remove

How to replace a mirror


- Determine which side is the first surface side. This can be done by touching the glass with a pointed object. If the reflection of the object touches the end of the object, that is the front surface. If there is one glass thickness between them, that is the back surface.