OV-II Maintenance Manual

OV-II
Maintenance, Troubleshooting
and Service Manual
Document 42600-0905
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Industrial Dynamics Company, Ltd.
Document 426000905 Copyright. All rights reserved.
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electronic, or mechanical including photocopying, recording, taping, or information storage
and retrieval system) without written permission of Industrial Dynamics Company, Ltd.
Filtec and Industrial Dynamics are registered trademarks of Industrial Dynamics Company,
Ltd. All other trademarks are the property of their respective owners.
Contact Information
Corporate Headquarters: 3100 Fujita Street,
Torrance, California
90505-4007
U.S.A.
Telephone:(310) 325-5633
FAX: (310) 530-1000
Internet: www.filtec.com
Mailing Address: P.O. Box 2945,
90509-2945
U.S.A.
Shipping Address: 3100 Fujita Street,
90505-4007
U.S.A.
Customer Service: (800) 733-5173

Table Of Contents 1
Document 426000905
Table Of Contents
Chapter 1: Maintenance
Periodic maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Periodic maintenance procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Weekly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chapter 2: Troubleshooting
Troubleshooting Procedures Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mechanical/Routine Maintenance Problems . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Omnivision Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Inspection/rejection Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Rejecting Large Percentage of Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Rejecting No Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Rejected Bottles Not Stable On the Takeaway Conveyor. . . . . . . . . . . . . . . . 2-27
Faulty Bottles Detected But Not Rejected . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Rejecting Incorrect Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Complete System Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Chapter 3: Service
Repair and Replacement Procedures Overview . . . . . . . . . . . . . . . . . . . . . . . 3-1
Guidelines for repair or replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Broken Diffuser Glass Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Base Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Starwheel Seal Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Deadplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Base Inspection Strobe Lamp Power Supply Assembly. . . . . . . . . . . . . . . . . . . 3-8
Base Inspection Strobe Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Inspection Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Finish Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Neck Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Outer Sidewall enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

2 OV-II Maintenance, Troubleshooting and Service Manual
Document 426000905
Camera Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Lamp Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Chapter 1: Periodic Maintenance
Industrial Dynamics Company, Ltd. © Form 42600 (10/03) 1-1
PERIODIC MAINTENANCE OVERVIEW
This chapter provides guidelines for periodic maintenance on the
Omnivision All Surface Empty Bottle Inspector (ASEBI), including the
optional Outer Sidewall (OSW) Inspection System.
The Omnivision system is designed to operate without requiring intensive
amounts of maintenance. Industrial Dynamics Company (IDC) strongly
recommends that the maintenance procedures contained in this chapter be
followed as closely as possible. Consistent and timely maintenance of the
Omnivision system ensures long-term equipment reliability.
PERIODIC MAINTENANCE PROCEDURE
This section provides the daily, weekly and monthly routine maintenance
for the Omnivision system.
NOTE
The camera, mirrors, servos, and mirror heater(s) inside the optional
OSW system are enclosed and sealed off. They are designed to
operate on a long-term basis without regular maintenance being
required. None of the OSW system components require lubrication.
Do not open the OSW system enclosure unless absolutely necessary.
Opening the OSW enclosure allows dirt, product, water, and other
fluids/gases to contaminate the optical components.
Daily Maintenance
ITEM DAILY MAINTENANCE
Diffuser Glass Clean thoroughly top and bottom. Clean with a NONCAUSTIC,
NONABRASIVE commercially available glass cleaner (such as
Windex). Maintain cleanliness by adjusting the diffuser glass
wiper brush and water drip system. Dirty diffuser glass causes
“false rejects.”
Water Drip System Check and adjust for slow drip.
Inspection Head Lens and Optical
Window Glass
Clean inspection head lens and external cover glass surface with
lens tissue or soft cloth. Dirty window causes loss of light to
Inspection Head systems.
DO NOT CLEAN LENSES OR GLASS WITH ANY
CAUSTIC OR ABRASIVE MATERIALS.
Starwheel Suction Cups Check for splits, cuts, or other damage. Replace if worn or
detective. Defects cause loss of vacuum and rejection of good
bottles.

OV-II Maintenance, Troubleshooting and Service Manual
1-2 Industrial Dynamics Company, Ltd. © Form 42600 (10/03)
Purge Air (Suction Pipes) Check for air flow by holding hand in front of suction cups as
starwheel rotates past purge ports.
Upstream Bottle Washer Check and adjust for proper spray pattern and coverage. If not set
properly, causes "false rejects" due to conveyor soap on bottle
bottom.
Air Blow-off, Diffuser Glass Check for proper flow. Removes water, pulp and other objects
from glass surface prior to inspection.
Air Blow-off, Bottle Bottom Check for proper flow and pattern. If not set properly causes
"false rejects" due to conveyor soap on bottle bottom.
Microsonic Bottle Sensors Check line control operation by blocking and unblocking beams
with bottle. Receiver's red indicator should be ON when there is
no bottle and OFF when bottle is present.
Bottle Guide Belts Check for proper position and tightness. Change if too loose.
Check brackets for alignment.
Inspection Head Height Check the Inspection Head height (counts) listed on the
BOTTLE CHANGEOVER REQUIREMENTS screen. Check
Inspection Head height above starwheel using mechanical
counter. Also verify 13 mm (0.5 inch) clearance between bottom
of Finish Inspection lens and bottle crown. Be sure to “lock” the
raising mechanism after each adjustment. Verify inspection
height by running bottles.
Repeat this procedure for each bottle type.
Make sure the bottle neck guide belt is pulled away and clear
from the starwheel top plate when raising or lowering the
Inspection Head.
Infeed and Outfeed Bottle Guides Check for proper guides. Check all knobs and if necessary
tighten. Guide should blend smoothly with production conveyor
guide rails.
OSW Inspection Area Check the inspection area for any debris such as broken glass,
labels, or other foreign debris. Clear may debris out of the
inspection area.
OSW Guide Rails Check for proper cord tension; tighten if necessary. Check for
labels, glass, debris, etc., stuck to the guide rails and remove as
necessary. Inspect for any damage to the guide rails and wear-
strips.
OSW Diffuser Panels (on the light
source enclosure)
Check for scratches or other damage. Clean with a
NONCAUSTIC, NONABRASIVE commercially available
glass cleaner (such as Windex). Replace phenolic diffuser
panels at 6 month intervals to ensure consistent light levels for
inspection.

Weekly Maintenance
OSW Camera Window (on the
camera enclosure)
glass cleaner (such as Windex).
ITEM WEEKLY MAINTENANCE
Vacuum System Check efficiency of system by seating bottles firmly in all
pockets with pressure/vacuum converter running. Vacuum
Gauge on panel should read at least 22 inches Hg. If gauge reads
less, check suction cups and be sure bottles are seated firmly. If
reading still low, check piping for leaks and refer to Monthly
Maintenance Checklist for more details.
Reject Solenoid Valve Cycle manually by pressing small button on body of valve.
Diffuser Glass Check for proper slip when the glass disk is stopped. The glass
disk should run true and not bind against adjacent components.
Check for cracks, deep scratches, etc. Clean thoroughly.
Infeed and Outfeed Bottle Guides Check alignment and tighten all knobs securely. Bottles should
have approximately 3 mm (1/8 inch) clearance on each side as
they pass through guides. Guides should merge smoothly with
conveyor guide rails and give a smooth bottle transition into the
starwheel. Check and replace plastic wear inserts as necessary.
Takeaway System Lubricate the grease fittings located on the side of the Reject
Conveyor channel. Any good grade of bearing grease may be
used.
Starwheel Suction Cups Check for cracks, and replace if necessary. Check for bent
vacuum tubes (caused when pipes are not aligned to starwheel).
Replace and align vacuum tubes if necessary.
Light Source Lens Clean top surface thoroughly. DO NOT REMOVE THE
LENS.
OSW Light Source Check that the fluorescent lighting units are functioning
properly.

Monthly Maintenance
ITEM MONTHLY MAINTENANCE
All starwheels Check as follows:
a. Inspect the valve seal ring, located in the bottom of the
starwheel hub, for scratches and any other imperfections that
would prevent a seal with the valve plate. If excessive wear,
scratching or other flaws are encountered, refer to the
Chapter 6 for replacement instructions.
b. Remove each suction cup and check for damage. Also check
the small filter screen (if installed), located inside the cup, to
be sure it is clean and not clogged. Replace any damaged
cups.
c. In the end of each vacuum pipe is a small restrictor
approximately 1.5 mm (0.060 inch) in diameter. Check these
restrictors to be sure they are not clogged. If they are, clean
them using a paper clip or other small diameter wire. A
compressed air nozzle is useful to blow through these
restrictors back down through the hub. This flushes any
debris out of the restrictors, and pipes. (Remove starwheel
first.)
d. Clean the entire starwheel using NONCAUSTIC,
NONABRASIVE SOAP, ORDINARY WATER AND A
SOFT BRUSH. RINSE WITH CLEAR, CLEAN WATER.
DO NOT RINSE WITH A HIGH PRESSURE NOZZLE.
DO NOT STEAM CLEAN. Reassemble after cleaning.
Air and Water Solenoid Valves Perform functional check of air and water solenoid valves and
water flow.
Air Filter Remove and clean the element in the air filter.
Starwheel System Pass a bottle through the entire starwheel system.
This checks the clearance of the guide assemblies, the dead plate,
the crossover points and entry back onto the conveyor. It should
be as smooth as possible.
Base Cabinet Check inside the base cabinet for signs of water leakage or other
corrosion. Corrosion should be removed immediately and any
water leakage should be investigated to find its source.

Guide Assemblies Plastic Wear
Strips
Check the plastic Bottle Set Plates of the starwheel and the
plastic guides on the infeed and outfeed guide assemblies for
damage. If the guide assembly plastic wear strips are worn or
damaged to the point they interfere with bottle handling, replace
them.
When ordering replacements for these parts, check for the dash
number stamped on each plate. This dash number positively
identifies the starwheel and guide assembly sections (with
accompanying plastic wear strips).
Dash numbers for the guide assemblies are always matched with
the same dash numbers for the starwheel. This is done so that the
starwheels and guide assemblies are always properly matched on
a production machine. When ordering starwheels and guide
assemblies, indicate whether top or bottom plates are needed and
give the dash number.
Bottle Guide Belts and Upper and
Lower Pulley Assemblies
Check the bottle guide belts and upper and lower pulley
assemblies. The pulleys should turn freely and not wobble
excessively. The belts should have strong tension and should run
smoothly in the pulleys.
Encoder System Check the Encoder System on both the main and reject
conveyors.Tighten all bolts and set screws as necessary.
OSW Diffuser Panels (on the light
source enclosure)
glass cleaner (such as Windex). Replace phenolic diffuser
panels at 6 month intervals to ensure consistent light levels for
inspection.
OSW Lamp Box Cooling Fan Check that the cooling fan is causing air to flow forcefully out of
the top of the enclosure.
OSW Light Source Check that the flourescent lighting units are functioning
properly. Replace regularly at 6 month intervals to ensure
consistent light level values for inspection.

~ BLANK PAGE INTENDED ~
Spindle Assembly Check the spindle assembly by removing the starwheel. The
Valve Plate should be smooth and free from defects. If it is
scratched or worn excessively, it must be replaced. The Valve
Plate Assembly must move freely in the vertical direction or it
will impart excessive drag to the starwheel. The Valve Plate
must slide easily up and down on the four Alignment Pins in the
Hub.
DO NOT USE AN OIL-BASED LUBRICANT IN THIS
AREA, IT MAY CLOG THE VALVE PLATE.
Check the flexible hoses connected to the vertical Port tubes to
ensure that they are not binding against starwheel drive
components, etc. If this assembly is binding and cannot be freed,
then it must be disassembled.
Starwheel Registration Plate Check that the "Tang" protrusion is not damaged. Replace if
worn or damaged with kit P/N 42928-1 or 42928-2.
Takeaway System Check the Takeaway System for loose parts and excessive wear.
Tighten all bolts securely.
Conveyor Wear Strips Check strips (located under the production chain) for excessive
wear or damage. Replace wear strips if excessively worn or
damaged.

Chapter 2: Troubleshooting Procedures
TROUBLESHOOTING PROCEDURES OVERVIEW
Many bottle handling and inspection problems can be solved during
routine maintenance. If you are experiencing inspection or bottle handling
problems, repeat your daily, weekly and monthly routine maintenance as
described.
Three key areas must work together to achieve optimum machine perfor-
mance: bottle handling, inspection, and rejection.
The best approach to troubleshoot the Omnivision is to check for the
source of problems in following order:
1. Mechanical or routine maintenance problems
2. Bottle handling problems
3. Inspection/rejection problems
MECHANICAL/ROUTINE MAINTENANCE PROBLEMS
The following table identifies the mechanical/routine maintenance
problems that may cause inspection and/or bottle handling problems, and
offers suggested solutions.
SYMPTOM PROBABLE CAUSE(S) SOLUTION
Soap is being detected as an
object
Air blow-off rate not adjusted
properly or not turned on, or not
receiving air or water, or the
excess soap air blow-off is not
aimed properly. Excessive soap is
being placed on upstream
conveyors.
Check air-blow off system and
adjust as necessary.
Water on the top surface of
the starwheel.
Water splashing in the inspection
area or starwheel became dirty
while being stored or from a
careless washdown and has
something on it that allows water
deposits.
Clean starwheel and dry it off.
Dirt or broken glass on the
diffuser glass.
Unclean production area or
broken glass not removed
promptly.
Clean diffuser glass. Remove any
broken glass.
Excessive false rejects. Contamination of the Inspection
lens (under-side) or OSW
windows from hard water residue.
Carefully clean Inspection
lenses/windows.

Finish False Reject count is
high.
Inspection Head not set to proper
height (13 mm or 0.5 inch above
the Finish Inspection station) for a
specific bottle type.
Check BOTTLE
CHANGEOVER
REQUIREMENT screen for
correct inspection head height
count and, if necessary, adjust
height with inspection head hand
wheel.
Starwheel does not hold
bottles.
-Main air pressure too low for
proper vacuum
- Guide belt may be old, stretched
or missing.
- Brittle or work sucker cups
- Increase air pressure to
minimum 80 psi.
- Check guide belt tension.
- Replace Sucker Cups
Bottles too tall or small for
starwheel.
Use of incorrect starwheel or a
starwheel with the wrong number
or type of spacers.
Check for correct starwheel dash
number/color and number of
spacers, if any. If necessary,
replace starwheel and/or add or
remove spacers.
One out of "x" number of
bottles is rejected every
starwheel revolution.
Starwheel sucker cup is missing or
damaged.
Replace sucker cup or replace
starwheel.
Bottles are bouncing off
bottle guide belts when
rejected.
- Bottle guide belts on either the
neck or the bottle body are
missing or misadjusted.
- Reject pressure to high.
- Check and, if necessary, replace
bottle guide belts.
All bottles are rejected. - Pressure/vacuum converter
failure (if so, Omnivision flashes:
Alarm: Vacuum Pressure
Failure). The vacuum gauge will
be out of tolerance and/or an error
message will be displayed on the
LCD monitor.
- Check for labels in OSW area.
Verify pressure/vacuum
converter is operational. Ensure
that main air valve is on, and
remove the rear Base Cabinet
door to verify that the vacuum
gauge reads at least 21 inches
Hg. Check for vacuum leaks in
plumbing. If you find any
vacuum problems, contact
Maintenance.
- Stop the line, remove label(s)
and insure the OSW window is
clean.

BOTTLE HANDLING PROBLEMS
Under normal production line operating conditions, bottle handling
problems are generally the main causes for unreliable bottle inspection
and rejection.
NOTE
Good bottle handling is the most important prerequisite for efficient
and reliable operation of the Omnivision system. The importance of
good bottle handling cannot be overstated.
Bottle handling problems can be caused by either the Omnivision's bottle
handling system or the customer's production line bottle handling. These
are addressed in the following sections.
Omnivision Bottle Handling Problems
If the optional OSW system is supplied, check to see if bottles pass
(rotate) through the OSW tunnel smoothly and in a uniformly overlapped
condition.
Good bottle handling for the OSW system consists of maintaining proper
synchronization with the main Omnivision unit. The OSW system bottle
rejection and bottle tracking are all provided through close-coupling to
the main Omnivision unit.
NOTE
In order for the OSW unit to operate properly, bottles must remain in
a bottle to bottle contact condition from Omnivision unit through the
entire OSW enclosure at all times.
The OV inspections are not
centered. This problem will
appear most on Finish.
For Finish/Thread Inspection, the
image light ring will fall off in
intensity on one side.
Recalibrate starwheel home
position. The Procedure on how
to do this is in the Service
Section.
For Base and Inner Sidewall
Inspection the bottle image will
appear to be off-center as they
pass over the deadplate opening.
Recalibrate starwheel home
position. The Procedure on how
to do this is in the Service
Section.
OSW is causing a high
amount of false rejects.
- Unclean inspection area.
- Poor bottle-handling causing
tracking errors
- Clean the tunnel and remove
any broken glass or debris.
- Ensure smooth bottle handling.
- Check wear on change parts.
- See the chapter titled "Bottle
Handling Problems"

Excessively worn or damaged guide rails may cause bottle handling
problems inside the OSW tunnel.
NOTE
Removing any bottles immediately in front of the OSW System or
anywhere between the OSW unit and the main Omnivision during
production may cause bottle handling problems and false or missed
rejects.
To troubleshoot the bottle handling problems on the main Omnivision
unit, proceed as follows:
1. Go to the CONTAINER SETUP > BOTTLE CHANGEOVER
screen.
2. Select the correct bottle type by pressing the button which displays
the present bottle. Verify the Dash Numbers on the middle of the
screen.
3. Verify that:
a. the correct bottle type has been selected
b. the correct bottle guide assemblies, deadplate, starwheel and
spacers (if any) have been installed
c. the Inspection Head height is adjusted to the correct position
4. Proceed with troubleshooting various bottle handling problems as
explained in the following sections.

Bottle Jams at Infeed
1. Check the alignment of the infeed guides as it is possible the guides
could have vibrated out of alignment. Realign if necessary. There
should be approximately 2.4 to 3 mm (3/32 to 1/8 inch) bottle
clearance. The conveyor guide rails should merge smoothly into the
infeed guides.
2. Check the neck bottle guide belt. Be sure it is not binding and bottles
are running freely. Improper neck bottle guide belt adjustment can
cause jamming at the infeed.
3. Check the suction cups and the entire pressure/vacuum converter
system to ensure proper operation. Low vacuum can result in bottles
not being picked up cleanly at the input thus causing rough bottle
handling at the infeed.
4. Verify that the deadplate is set slightly lower than the top of the
conveyor chain (approximately 1 mm or 3/64 inch). This reduces drag
as the bottles engage the starwheel and pass through the inspection
zone. If the deadplate is too high, it places excessive back pressure on
the bottles resulting in rough bottle feeding.
Bottle Jams at Outfeed
1. The outfeed guide set should allow for approximately 3 mm (1/8
inch) gap from the bottle on each side. Check the knob is securely
locked in position.
2. Verify that the deadplate discharge is set equal or slightly higher than
the top of the conveyor chain (no more than 1 mm or,
3/64 inch). This allows the bottles to be "carried" back to level of the
conv. chain. If the deadplate is too high or too low, it can cause the
bottles to bounce and jam at the outfeed.
3. Verify the reject takeaway conveyor height is properly adjusted, i.e.,
the reject chain is slightly (2 mm or 1/16 inch) below the bottle
bottom when the bottle is “locked on” the starwheel.
4. Verify the reject pressure is set correctly.
Bottle Jams in the Inspection Zones
1. Check the deadplate, as it may be set incorrectly or has been bent out
of shape causing bottles to jam as they pass over the inspection areas.
The deadplate at the infeed side should be set slightly lower than the
top of the conveyor chain (approximately 1 mm or 3/64 inch) so the
bottles do not drag across its surface.

2. Check the neck and the body guide belts for adjustment. The guide
belts must provide the proper pressure to hold the bottles in the
starwheel pockets.
3. Low vacuum pressure can cause the bottles to be dropped down onto
the diffuser glass disk and jam in the deadplate inspection opening.
Starwheel Drive and Line Control System Malfunction
1. Check the starwheel, bottle guides, and infeed guides for binding, etc.
The starwheel should turn freely. Bottles passing through the system
should not encounter any resistance. Many times interference
problems in the starwheel or guides are interpreted as Line Control
failures.
2. Check both of the upstream microsonic bottle sensors to ensure they
are working properly. The red LED indicator on the receiver head
should be activated when the heads are aligned with no bottles
present. Passing a hand or bottle between the heads should deactivate
the red LED indicator.
3. Go to the DIAGNOSTICS > DIGITAL I/O screen. The SONIC 1
and SONIC 2 IN signal should be OFF (low) when the upstream
bottle sensors are blocked and ON (high) when the sensors are
unblocked.
4. If the starwheel drive is responding to the upstream sensors but the
starwheel does not have sufficient drive power, then there may be a
problem with the drive/brake system. Refer to the next chapter to
make the necessary adjustments.
Starwheel Drive is Sluggish and Cannot Keep up with Filler
If the starwheel slows down, causing excessive bottle spacing on the
outfeed and gaps into the filler, check the following:
1. Verify the Emergency Stop Switch on the front of the base cabinet is
pulled out.
2. Check the bottom of starwheel for pieces of broken bottles jamming
the starwheel.

3. Check the MACHINE CONFIGURATION > MOTOR screen
screen for irregular parameter values. Verify the running torque is
between 45% to 80%. Heavy bottles will require a setting.
4. Verify that Line Sensors 1 and 2 are functioning properly
5. Check the height of the Inspection Head to be sure it is not too low
and dragging on the top plate of the starwheel. There must be 13 mm
(0.5 inch) clearance between the bottle crown and the Finish
Inspection window. For systems equipped with thread of T-Ring
inspections the clearance should be.25 inch
6. Check the infeed and outfeed bottle guides to be sure the bottles are
not binding. The bottles must pass through the starwheel smoothly.
7. Remove the starwheel and thoroughly clean the valve plate and seal
ring in the starwheel hub using a mild solvent. Lubrication should not
be applied to these two mating surfaces. If the surfaces appear to be
damaged they should be replaced.
Conveyor Chain Encoder Problems
The conveyor chain encoder assembly is mounted on the side of the
conveyor, close to the starwheel shaft assembly.
It consists of a high resolution encoder attached to a special drive sprocket
(wheel). The production chain link pins drive the sprocket which in turn
drives the encoder.

The signal from the conveyor encoder is used to modulate the drive/brake
system and the Down Bottle/Jam functions.
The drive/sprocket assembly may be damaged by a loose production
chain or by pieces of metal, glass, or other foreign objects caught in the
production chain. Replace if damaged.
Also, check the encoder assembly for proper mounting. Replace if
damaged.
INSPECTION/REJECTION PROBLEMS
The following sections detail troubleshooting inspection and rejection
related problems including:
• Excessive False Rejects
• Rejecting Large Percentage of Bottles
• Rejecting No Bottles
• Rejected Bottles not Stable on the Takeaway Conveyor
• Passing Faulty Bottles (Missed Rejects or False Accepts)
• Faulty Bottles Detected But Not Rejected
• Rejecting Incorrect Bottles
• System Faults (Annunciator Lamp ON, No Message)
• Complete System Failure
Excessive False Rejects
The false reject rate is a measure of detection reliability (repeatability) of
the Omnivision. The rate of acceptable false rejects varies depending
upon bottle type, glass characteristics, defect characteristics, production
speeds, and other factors.
Do not immediately assume that excessive false rejects are caused by the
inspection sensitivity being too high. Often it will be due to problems
with inspection components exposed to the production environment. For
example, false rejects caused by common items such as broken glass,
heavy soap, excess dirt, etc., are due to routine maintenance or
mechanical problems rather than the inspection problems.
To find the causes of excessive false rejects proceed as follows:
1. Check for and correct any mechanical/maintenance-related or bottle
handling problems as discussed earlier in this chapter.
2. Look at the bottles being rejected to see if there is an unusual bottle
characteristic which could be interpreted as a defect. Typical false
reject problems to look for include:
On the Base:

• Heavy embossed lettering or molding
• Extreme wedges
• Extreme color variations
• Prominent seams
• Large air bubbles
• Thin spots in the heel
On the Inner Sidewall:
• Protruding glass knobs
• Extreme variation in thickness
• Birdswings
On the Plugged Neck/Color Sort:
• Extreme bottle color variations
For Residual Liquid:
• High levels of rinse carryover
• Extreme bottle color variations
• Bottles made from contaminated glass (such as recycled glass
which have blended multiple glass colors in it)
On the Finish:
• Heavy scuffing
• Large molding ridges
• Prominent seams

On the Outer Sidewall:
• Heavy scuffing
• Extreme color variations
• Large air bubbles
• Heavy embossed lettering or molding
• Prominent seams
3. Access the STATUS > REJECT HISTORY screen and watch the
DETECT COUNTS on the left for each inspection system. Decide
which inspection system is detecting unusually high numbers of
bottles:
If more than one system is recording extraordinarily high numbers of
false rejects, temporarily turn OFF the Omnivision's rejector by moving
the cursor to the MACHINE CONFIGURATION > REJECT
HANDLING function and pressing the Master Reject Enable button.
When a single inspection system's rejection capability is turned OFF, all
other systems continue to inspect and reject. If the REJECT MASTER
function is turned OFF, ALL inspection systems continue to inspect, but
NO REJECTS WILL TAKE PLACE.
NOTE
Consult your supervisor before turning OFF any inspection system's
rejection capability or turning OFF the Omnivision's main rejector.

4. When the detect rate is greater than desired but too low for the
suspected zone to be easily determined, use the REJECT HISTORY
screen which is reached from the SYSTEM DIAGNOSTICS screen.
The REJECT HISTORY screen shows which inspection zones (or
regions) are the source of the most recent rejects.
The reject code abbreviations are show in the figure above.
Once the responsible inspection systems (zones) have been identified,
refer to the following sections for detailed troubleshooting procedures as
applicable.
Base Inspection Excessive False Rejects
1. If production operation allows turning all BASE REJECTION OFF,
do so using the CONTROL > BASE screen and disable the
REJECT ENABLE function. (Set to 0.)
2. If it is not possible to turn all BASE REJECTION OFF, disable the
REJECT STATUS of the individual regions which appear to be a
problem.
3. From the INSPECTION SETUP screen go to the CONTROL >
BASE screen and verify the REJECT STATUS is OFF for any
suspect zones (if allowed).

4. Verify the inspection zones are concentric with the bottle bottom
image. If they are not, go to the CONTROL > BASE screen and
adjust the horizontal and vertical settings as required.
5. Check the Current Detects column to see if any of the inspection
zone is detecting more often than other zones.
6. Use the button with the bottle (under the image) to "freeze" the
rejected bottles and examine their images.
7. Observe that the frozen reject bottle image has small red dots marking
the places where it located the objects. These dots are called detection
points.
8. Observe the DETECT function. This is normally adjusted to a value
between 100 and 200. The higher the number, the more sensitive the
inspection zone will become. The highest possible value is 999 and
lowest is 1.
9. Observe the Detect Sensitivity and the LAST DETECT functions.
They indicate the relative strength of the detected object in terms of
the number of detection points. It goes up as the size and/or the
darkness of the object increases. When the SENSITIVITY is too
high, then the CURRENT DETECTS will be greater than zero even
for bottles which have no real object.
10. If a bottle is falsely rejected and the LAST DET is between 1 and
approximately 30, then the SENSITIVITY should be lowered by 25
points. Clear the counters using the RESET BASE COUNTERS
function, then allow about 1,000 bottles to pass through the system.

If the DETECT for the zone is still too high, then lower the
sensitivity by another 25 points. Again, clear the counters, let another
1,000 bottles pass through, and check the reject rate. Repeat this
process until the false reject rate is acceptable.
11. When the adjustment is complete, make sure that all the desired
inspection subsystems on the CONTROL > BASE screen have their
REJECT STATUS functions set to ON, and that the main rejector is
turned ON.
12. After adjustment, always verify reject operation by passing test
bottles for all the inspection zones through the system.
13. Save the new settings using the CONTAINER > BOTTLE
CHANGEOVER screen.
PLUGGED NECK/COLOR SORT EXCESSIVE FALSE REJECTS
If the CURRENT light level value goes below the LOWER LIMIT or
goes above the UPPER LIMIT, then the bottle is a reject.
Typically, the LOWER LIMIT value will be set to 1800. The LIGHT
values of the rejected bottles will be held under the heading LIGHT
DEFECT. Normal bottles should have LIGHT LEVEL readings ranging
from 2200 to 3000.
1. If the system seems to be falsely rejecting bottles due to the Plugged
Neck detector and the CURRENT LIGHT LEVEL values of these
false rejects are going below 1800, then the problem should not be
corrected with sensitivity adjustment. Such a condition indicates that
insufficient light is reaching the camera's sensor. If this happens, go to
the INSPECTION SETUP > BASE > CAMERA screen and take
corrective measures.
The Color Sort feature uses the same information and the same
adjustment as is used in the Plugged Neck detection.
The Color Sort detects bottles which have a gross color difference
with respect to the bottle type being run. For example, when running
amber bottles, the system detects any intermixed flint bottles. When
running flint bottles, the system detects any intermixed amber bottles.
2. If it appears that the system is rejecting bottles which are very light in
appearance but which are still an acceptable color, then raise the
UPPER LIMIT until it is above the LIGHT LEVEL value for the
lightest acceptable bottle.

3. If the false rejects are bottles which are very dark, adjust the
LOWER LIMIT to a value below the value of the darkest acceptable
bottle. If it is necessary to adjust the LOWER LIMIT to a value
below 50, then the image brightness (as controlled by the SETUP
BASE CAMERA screen) must be adjusted first.
For Color Sort to function, the LOWER LIMIT adjustment will
generally require a higher setting (more sensitive) than it would if
only Plugged Neck detection were being used.
4. If the Color Sort feature is not desired, then disable the feature by
clicking on the button to the left of Plug/Color so that it is red (off).
5. Save the new settings using the CONTAINER SETUP > BOTTLE
CHANGEOVER screen.

Inner Sidewall Inspection Excessive False Rejects
1. If production operation allows turning all ISW rejection OFF, do so
using the CONTROL > ISW screen and disable the REJECT
ENABLE function. (Set to 0.)
2. If it is not possible to turn all ISW rejection OFF, disable the
REJECT STATUS of the individual regions which appear to be a
problem.
3. Verify the inspection zones are concentric with the bottle bottom
image. If they are not, go to the INSPECTION SETUP > ISW
screen and adjust the horizontal and vertical settings as required.
4. Check the Current Detects column to see if any of the inspection
zone is detecting more often than other zones.
6. Observe that the frozen reject bottle image will have small red dots
marking the places where it located the objects. These dots are called
detection points.
7. Observe the DETECT function. This is normally adjusted to a value
between 100 and 200. The higher the number, the more sensitive the
inspection zone will become. The highest possible value is 999 and
lowest is 1.

8. Observe the Detect Sensitivity and the LAST DETECT functions.
They indicate the relative strength of the detected object in terms of
the number of detection points. It goes up as the size and/or the
darkness of the object increases. When the SENSITIVITY is too
high, then the CURRENT DETECTS will be greater than zero even
for bottles which have no real object.
9. If the DETECT for the zone is still too high, then lower the sensi-
tivity by another 25 points. Again, clear the counters, let another
1,000 bottles pass through, and check the reject rate. Repeat this
process until the false reject rate is acceptable.
10. When the adjustment is complete, make sure that all the desired
inspection subsystems on the CONTROL > ISW screen have their
REJECT STATUS functions set to ON, and that the main rejector is
turned ON.
CHANGEOVER screen.
PLUGGED NECK/COLOR SORT EXCESSIVE FALSE REJECTS
If the CURRENT light level value goes below the LOWER LIMIT or
goes above the UPPER LIMIT, then the bottle is a reject.

Typically, the LOWER LIMIT value will be set to 1800. The LIGHT
LEVEL values of the rejected bottles will be held under the heading
LAST DETECT. Normal bottles should have Light Level readings
ranging from 2400 to 4200.
1. If the system seems to be falsely rejecting bottles due to the Plugged
Neck detector and the CURRENT LIGHT LEVEL values of these
false rejects are going below 1800, then the problem should not be
corrected with sensitivity adjustment. Such a condition indicates that
insufficient light is reaching the camera's sensor. If this happens, go to
the INSPECTION SETUP > ISW > CAMERA screen and take
corrective measures.
The ISW Color Sort feature uses the same information and the same
adjustment as is used in the Plugged Neck detection.
The Color Sort detects bottles which are extremely dark with respect
to the bottle type being run. For example, when running flint bottles,
the system detects dark amber bottles.
2. If it appears that the system is rejecting bottles which are very light in
appearance but which are still an acceptable color, then raise the
UPPER LIMIT until it is above the LIGHT LEVEL value for the
lightest acceptable bottle.
3. If the false rejects are bottles which are very dark, adjust the
LOWER LIMIT to a value below the value of the darkest acceptable
bottle. If it is necessary to adjust the LOWER LIMIT to a value
below 25, then the image brightness (controlled on the
INSPECTION SETUP > ISW > CAMERA screen) must be
adjusted first.
For Color Sort to function, the LOWER LIMIT adjustment will
generally require a higher setting (more sensitive) than it would if
only Plugged Neck detection were being used.
4. If the Color Sort feature is not desired, then disable the feature by
clicking on the button to the left of Plug/Color so that it is red (off).
CHANGEOVER screen.

Infrared Residual Liquid Detection (IR RLD) Excessive False Rejects
There is no visual display for IR RLD. If the IR RLD system is producing
excessive false rejects, proceed as follows:
1. Go to the INSPECTION SETUP > RLD screen to display the RLD
parameters.
2. Look at the values for the IR RLD SENSOR under the CURRENT
heading -- they should range from approximately 100 to approxi-
mately 900. The value under the AVERAGE heading will normally
be in the range from 200 to 600.
3. If the CURRENT or AVERAGE values are out of the range, or if the
CURRENT value tends to occasionally have a value of 1,023 or of 0,
then the problem is not one of over-sensitivity. (You can determine
this by watching the readings while at least 1,000 bottles pass through
the system.) If this is the case, the IR RLD Sensitivity should be
revised to adjust the average to the recommended range.
CHANGEOVER screen
Radio Frequency Residual Liquid Detection (RF RLD) Excessive False Rejects
There is no visual display for RF RLD. If the upstream RF RLD system is
producing excessive false rejects, proceed as follows:

1. Verify that the RF PULSE WIDTH value for good bottles is approx-
imately 1500. If not, adjust the RF GAIN setting to obtain same. The
RF PULSE WIDTH value for bottles with residual liquid should
typically be between 80 and 90 counts.
2. When the RF PULSE WIDTH value is less than the RF DETECT
THRESHOLD value, the bottle is detected. Therefore, a higher RF
DETECT THRESHOLD setting makes the system more sensitive.
3. If a bottle is falsely rejected, then lower the RF DETECT
THRESHOLD as required.
If the false reject rate is still too high, then the problem is not over-
sensitivity. If this is the case, refer to the RF RLD Setup Procedures in
the Installation and Technical Reference Manual (Form 42602)
details.
CHANGEOVER screen.

Finish Inspection Excessive False Rejects
1. If production operation allows turning the Omnivision Finish
Rejection off, then do so by going to the CONTROL > FINISH
screen and set the REJECT ENABLED function to OFF. (0)
2. Selection of the CONTROL > FINISH screen automatically
displays the Finish camera image on the inspection display monitor.
3. Observe the Finish image and verify that it is centered within the two
dotted circles (inspection ring or donut). If it is not, then other
parameter settings may need to be adjusted. If all of the bottle have
the same displacement then the starwheel "home" position should be
re-calibrated.
5. If the Finish image is centered within the two dotted circles, then use
the circle-shaped button on the touchpad to “freeze” the rejected
bottles and examine their images.
6. Check the TOTAL DETECTS column for algorithms A, B, C, and D
Detects. Observe which algorithm causes the excessive false rejects.
Adjust the respective SENSITIVITY value as desired.

7. Clear the counters by selecting the RESET FINISH COUNTERS
function and allow 1,000 bottles to pass through the system. Observe
the TOTAL DETECTS column. If the numbers in this column are
still too high, readjust A, B, C, or D algorithms as applicable. Again,
clear the counters, let 1,000 bottles pass through and check the
TOTAL DETECTS column. Repeat the process until the false reject
rate is acceptable.
bottles for all the inspection systems.
9. When the process is complete, ensure that the REJECT STATUS for
all the desired inspection subsystems is ON, and that the main
REJECT MASTER function is ON.
CHANGE OVER screen.

Outer Sidewall Inspection Excessive False Rejects
The general troubleshooting sequence for identifying and correcting the
source of OSW-related excessive false rejects is as follows:
a. Verify the OSW windows are clean and not causing false reject
due to debris.
b. Identify which OSW Phase (OSW 1, 2, or 3) is responsible for the
false rejects.
c. Identify which OSW Window is responsible for the false rejects.
d. If necessary, correct the responsible Window's position. If
window position is not causing false rejects, proceed to item “e”.
e. If necessary, correct the responsible Window's size. If window
size is not causing false rejects, proceed to item “f”.
f. If necessary, make adjustments to the responsible Window's
sensitivity settings. If window sensitivity is not causing false
rejects, proceed to item “g”.
g. If the above procedures do not take care of the excessive false
rejects problem, window parameters may need to be adjusted.
NOTE
Analyzing which of the parameters to adjust requires factory training
and only authorized personnel should change parameters settings.
To perform the above-mentioned general troubleshooting method,
proceed as follows:
1. If production operation allows disabling all OSW REJECTION, do
so using the CONTROL > OSW screen and disable the OSW
REJECTS function. (Set to 0.)

2. If it is not possible to turn all OSW REJECTION OFF as described
above, disable the REJECT STATUS of the individual OSW View
which appears to be a problem.
3. Select PHASE SELECT and identify the responsible OSW
subsystem for the excessive false rejects by observing which system
has a corresponding high number of DETECTS.
4. Toggle PHASE 1 through PHASE 3 function and identify the
responsible Phase and Window (s) for false rejects as follows:
a. Look at the WINDOW DETECT COUNT column to locate the
responsible Window (s). You may need to use the Scroll function
to access the second screen to observe Windows #10 through #15.
b. Turn OFF the REJ (Reject) status of the individual Windows
which appear to be the source of the problem.
5. Press the button with a bottle so it displays the bottle as "crossed out"
under the image to freeze a rejected bottle.
6. Change the SENSITVITY on the suspected Window's number you
determined as the source of the problem in Step #5
7. If false rejects are caused by the SENSITIVITY being set too high,
decrease the SENSITIVITY setting by a few points at a time until
the excessive false reject problem is taken care of.

8. If changing the window's position, size or sensitivity corrects the
excessive false rejects problem, clear the counters using the RESET
OSW COUNTERS function, then allow about 1,000 bottles to pass
through the OSW System. If the WINDOW DETECT COUNT is
still too high, repeat the above-stated adjustments and run another
1,000 bottles as necessary until the false reject rate is acceptable.
9. When the adjustment is complete, make sure that all OSW
subsystems and their active windows have their REJECT STATUS
functions set to ON.
CHANGEOVER screen.
Rejecting Large Percentage of Bottles
When the system starts rejecting a large percentage of bottles, or all the
bottles, proceed as follows:
1. Stop the machine by pushing in one of the Emergency Stop Switches
located on the front and the back of the base cabinet.
2. Check for and correct any maintenance related or bottle handling
problems as discussed early in this chapter.
3. Check the rejected bottles and see if there are flaws causing the
rejections.
4. Use the Omnivision's built-in diagnostic tools to help determine the
nature of problems. The built-in diagnostic tools consist of the most
commonly used software screens and message features including:
• System Status Line message on any screen
• SYSTEM STATUS & CONTROL screen
• REJECT HISTORY screen
• SYSTEM DIAGNOSTICS screen
• DIAGNOSTIC MESSAGE HISTORY screen
5. Based on the information from Step #5, look for possible causes and
solutions as follows:

Rejecting No Bottles
1. Check for and correct any maintenance-related or bottle handling
problems as discussed earlier in this chapter.
2. On CONTROL > SYSTEM screen, verify that each inspection
subsystem's REJECT STATUS function is ON.
SYMPTOM CHECK SOLUTION
The vacuum system has
failed or low vacuum (less
than 127 mm [5 inches
Hg]).
The vacuum warning gauge will
be out of tolerance and/or a red
error message will be displayed
on the monitor.
Ensure that circuit breaker CB1 is on,
the pressure/vacuum converter is
operational, and that the vacuum
gauge reading is within specification.
The camera lens aperture
and zoom servo positions
have lost calibration or
are not functioning,
causing an image which is
too bright, too dark, or
has the wrong zoom
setting.
The monitor display for one or
more of the zones will show up
as all dark, all white, or will have
an unusually small or unusually
large bottle image.
Verify the servo controller for that
camera is operating properly.
Recalibrate as required.
Excessive Rejects on one
inspection.
Check optical inspection
windows at the bottom of the
Inspection Head Base plate.
Clean the windows.
Check the OSW optical windows
inside the tunnel.
On the STATUS >
SYSTEM screen, the
DETECT COUNT for one
or more inspection systems
will have a high count.
Contaminants on diffuser disk or
OSW window.
OSW for fallen bottles.
1. Clean diffuser disk and window.
2. Clear the counters using the
CLEAR ALL CNT function.
3. Release the emergency stop
switch long enough to let 5 to 10
more bottles run through the
Omnivision. If all the bottles are
still rejected, then the problem is
not image related. Check RLD
inspection sensitivity. If no
bottles are rejected (this is what
should happen) allow bottles to
pass through the system.

3. Verify that the system is being triggered for inspection by noting
whether the PERIOD TOTALS counter (on any of the STATUS
screens listed in Step #3) increments when the starwheel is rotated.
If the bottle counter is not counting, then the problem is not
specifically due to the rejector or the sensitivity of the inspection
zones. It is possible that the starwheel encoder (located underneath
the starwheel motor) has been disconnected and cannot detect the
starwheel turning.
4. If the problem is not resolved after trying Steps #1 through #4, use the
following table to look for possible causes and solutions.
No image appears as
stawheel turns
Starwheel encoder. Bad encoder, power or wiring.
Repair as required.
The bottle is inspected
and detected but not
rejected.
One or more of the reject settings
are incorrect.
Go to the CONTAINER SETUP >
TRIGGER SETUP screen to verify
the current bottle type parameters.

Rejected Bottles Not Stable On the Takeaway Conveyor
The rejected bottles may not be stable when they are released from the
starwheel, resulting in fallen bottles on the reject takeaway conveyor.
1. Check and correct any maintenance related problems as
discussed earlier in this chapter.
2. Re-calibrate take away motor in machine configuration motor
screen.
3. Look for possible causes and solutions as follows:
Wrong Bottle
Rejected.
Check the settings on the Bottle
Delay and in the CONTAINER
SETUP > TRIGGER AND
REJECT SETTINGS screen.
1. Adjust the settings as required.
2. For RF RLD and OSW stations,
the number of bottles between
each of these stations and the
BASE/ISW inspection
centerline should match the
respective numbers on the
screen. If not, adjust the
numbers accordingly.
Reject blow-off
pressure too low.
Check the air pressure regulator
inside the base cabinet.
Verify the pressure is set to between
276 and 414 kPa (40 and 60 PSI).
Bottles released early
or other bottles are
rejected when normal
rejection occurs, i.e.,
‘Drop off’ bottles.
Check vacuum gauge reading inside
the base cabinet. The pressure/
vacuum converter system, under
normal operation, must maintain 560
to 660 mm (22 to 26 inches) of Hg
while the starwheel is fully primed
with bottles.
If the gauge reads less than 560 mm
(22 inches) of Hg, check other items
such as suction cups and piping for
leaks and refer to periodic
maintenance procedures as required.
Damaged starwheel
suction cups - causing
reduced blow-off force
as well as less vacuum
holding force.
Check suction cups for any damage,
i.e., grossly worn out and split cup
bellows or lips.
Replace as necessary.
Bottles "hitting" reject
chain and falling over.
Check the positioning of the reject
conveyor chain in relation to the
bottle at the release (or blow-off)
point. Verify there is a clearance of 1
to 2 mm between the chain top and
bottom of bottle.
Readjust the reject conveyor chain
as required.

Deadplate not aligned
properly.
Check bottle travel over the
deadplate. Bottles must not contact
the deadplate until just prior to
bottles entering the production chain.
Realign the deadplate as required.
Worn out starwheel
valve plate/seal ring.
Check and verify the valve plate is
the special hard coated type and is
not badly worn out.
Replace valve plate/seal ring if
necessary.
Restriction in
starwheel valve plate
hoses.
Check the hoses going from the
valve plate to reject valve and to the
vacuum and purge sources for proper
length and springs inside the hoses.
There should be no gap between the
springs and the copper tube fittings
which may result in the hose wall
collapsing.
Replace hoses if necessary.
Contaminated reject
valve.
Check the reject valve. It should be
positioned as close to the starwheel
valve plate as possible (by design).
The reject valve must not be
contaminated with oil or water in the
plant air line system.
Replace the reject valve if
contaminated.

Faulty Bottles Detected But Not Rejected
1. Check for and correct any maintenance related or bottle handling
problems as discussed earlier in this chapter.
Check DIAGNOSTICS > DSP BOARDS screen. Look for possible
causes and solutions as follows:
Rejector Air pressure. Set to 310 - 414 kPa (45 - 60 PSI).
Solenoid Valve not activating. Replace the Solenoid.
Plugged pressure lines/parts. Press button on Solenoid valve
several times while starwheel is
rotated to clear pipes and ports.
If not cleared, check the piping for
blockage.
Reject Signal Check reject signal flow. Replace faulty components/parts.
Wiring. Repair loose or broken wiring.
Bottle Handling Check bottle handling at reject
point.
Replace/adjust parts as necessary.
Encoder Check starwheel "Home"
position.
Replace encoder or associated parts.
Repair wiring if necessary.

Rejecting Incorrect Bottles
Check SYSTEM DIAGNOSTICS and DIAGNOSTIC MESSAGE
HISTORY screen. Look for possible causes and solutions as follows:
Incorrect Bottle Delay. Check the settings on the Bottle
Delay and in the CONTAINER
SETUP > TRIGGER AND
REJECT SETTINGS screen.
1. Adjust the settings as required.
2. For RF RLD and OSW stations,
the number of bottles between
each of these stations and the
BASE/ISW inspection
centerline should match the
respective numbers on the
screen. If not, adjust the numbers
accordingly.

Complete System Failure
If the whole system fails, look for possible causes and solutions as
follows:
Incoming AC Power Check Branch Circuit Breakers,
fuses, etc.
Repair/replace as necessary.
Check Omnivision AC switches
and circuit breakers.
Repair/replace as necessary.
Check AC power distribution. Replace parts as necessary.
System Wiring Check for loose connections, etc. Repair as necessary.

~ BLANK PAGE INTENDED ~

Chapter 3: Repair & Replacement Procedures
REPAIR AND REPLACEMENT PROCEDURES
OVERVIEW
The following procedures outline the step-by-step instructions for
repairing or replacing Omnivision components. Read the complete set of
instructions for each component to be repaired or replaced before
performing the procedure. Follow the instruction sequence as outlined.
NOTE
Industrial Dynamics Company (IDC) does not recommend field-
repairing any electronics cards and modules. Any attempt by
customers to field-repair electronics cards and modules may void the
Omnivision's warranty provisions. If you have any questions about
repairs and warranty, contact IDC.
WARNING
TURN OFF ALL ELECTRICAL POWER BEFORE REPAIRING
OR REPLACING ANY OMNIVISION COMPONENTS. FAILURE
TO DO SO MAY RESULT IN DAMAGE TO THE MACHINE AND
ELECTRICAL SHOCK, CAUSING SERIOUS BODILY INJURY.
GUIDELINES FOR REPAIR OR REPLACEMENT
Before repairing or replacing any Omnivision components, observe the
following general guidelines:
1. Handle all Electrostatic Sensitive Devices (ESD) such as electronic
parts, circuit cards and modules, in static-free work areas. Keep work
areas free from plastic wrappers, styrofoam materials and rubber
mats, etc. Wear anti-static wrist straps.
2. Do not make repairs on the electronic cards and modules.
3. Do not remove or insert any electronic cards, modules, plugs, jacks or
connectors with power applied to the unit.
4. Do not force electronic cards and modules into place.
5. Be sure the electronic cards and modules are installed in proper
locations.
6. Store all spare electronic components and assemblies in a safe, dry
area.

Broken Diffuser Glass Disk
If the diffuser glass disk is broken, but a piece of it is large enough to
cover the light dome lens, then proceed as follows:
NOTE
This is a short-term procedure that will usually allow you enough
time to obtain a spare diffuser glass disk without shutting the
production line down for an extended period of time. Replace the
diffuser disk with the IDC-approved diffuser glass. DO NOT USE
OTHER MATERIALS SUCH AS PLASTIC.
1. Remove the base cabinet front door (diffuser glass side).
2. Unplug the drive motor connector from the harness (squeeze the tabs
on the sides of the connector).
3. Rotate the good remaining piece of the diffuser glass over the lamp
source by hand.
BASE CABINET
Starwheel Seal Ring
The starwheel seal ring must be removed and repaired or replaced if it is
damaged or scratched as it will cause the system to lose vacuum pressure.
Minor scratches may be repaired in the field using the procedure in Step
#3.

1. Remove the 4-40 x 1/4-inch screw that secures the ring in the bottom
cavity of the starwheel
hub.
2. It may be possible to remove the seal ring by hand, but if it is wedged
too tightly, obtain three 4-40 x 1-inch screws and insert them in the
threaded holes in the seal ring. These three threaded holes are on 120
degree radii that are slightly larger than the valve port holes. Screw
the 4-40 screws into the seal ring symmetrically forcing it out of the
hub. If the seal ring appears to be repairable, proceed as follows,
otherwise go to Step #4.
3. Using 320 grit emery paper, placed on a very flat surface such as a
surface plate, press the seal ring against the emery paper and move in
circular motions until all blemishes have been removed. This process
should be carried out on both sides of the seal ring. Do not remove
more than 0.4 mm (0.015 inch) from each side of the seal ring.
After all blemishes have been removed with the 320 grit emery paper,
then use the 500 grit emery paper to put the smoothest possible finish
on both sides of the seal ring. It is absolutely necessary that the seal
ring be kept as flat and true as possible. Keep uniform pressure on the
seal ring, rotating it during the sanding motion. If the seal ring is
sanded to a wedge shape, it will not seal properly against the valve
plate.
Figure 5-1. Seal Ring

4. Clean the grit off the seal ring and blow out all holes with
compressed air. Note that the seal ring is keyed into the hub by a
small stainless steel pin, which is located on a slightly smaller radius
than the valve port holes. Line up the keying hole in the seal ring with
the pin in the hub and insert the seal ring in place. Lock it in position
by using the 4-40 x 1/4-inch screw. The seal ring requires no
lubrication.
Valve Plate
To replace the valve plate proceed as follows:
1. Remove the valve plate by removing the four 10-32 x 1/2-inch cap
screws that secure it to the valve plate support ring.
2. The support ring has four o-ring seals located in recessed grooves
to make a positive seal with the valve plate. Remove the o-rings and
clean the support ring thoroughly. If the o-rings are damaged, replace
them.
3. Fasten the new valve plate in position, using the four bolts removed
from the old unit. The valve plate should seat firmly against the
support ring forming an airtight seal by compressing the o-rings.

4. Move the spring-loaded assembly vertically by hand to be sure that
the bushings in the valve plate are not binding on the vertical pins. If
there appears to be any binding whatsoever, remove the valve plate
and ream the sleeve bushing slightly so that the entire assembly
moves freely in the vertical direction. This is a very important step
since the valve plate must float freely to ensure a proper seal between
the starwheel seal ring and the valve plate.
Deadplate
To replace the deadplate proceed as follows:
1. Raise the Inspection Head and remove the starwheel.
2. Remove the infeed guide at the operator side.
3. Remove the deadplate by loosening the Lock Knob on the top of the
deadplate.
4. Install the new deadplate in place.
5. Adjust the Upstream Bracket until the deadplate sits 1/8" lower than
the conveyor.
6. Adjust the Downstream Bracket until the downstream portion of the
Deadplate sits about 1/8" above the conveyor chain.
Valve Plate

7. Reinstall the starwheel and the infeed guide.
8. Lower the Inspection Head to its original position.

Rotating Diffuser Glass Disk
To replace or remove a rotating diffuser glass disk for cleaning purposes,
proceed as follows:
1. Turn OFF the OV-II.
2. Remove the two doors (if supplied) on the support column adjacent to
the glass disk.
3. Carefully, remove and discard any broken glass pieces.
4. Lift the Diffuser Disk Release Pin.
5. Swing the arm that supports the Diffuser Disk so that it is fully
exposed.
6. Remove the nut and the pressure washer that keep the rotating glass
disk on the drive spindle.
7. Release the glass disk and slide it out gently while angling it upward
towards the inside corner of the door support column. Do not let the
disk hit the adjacent objects.

NOTE
If the purpose is to clean the glass disk, clean it on both sides, with a
NONCAUSTIC, NONABRASIVE commercially available glass
cleaner (such as Windex).
8. Reinstall the parts in reverse order, paying attention to following
items:
• Make sure that the diffuser side is up (this does not apply to the
clear glass disk option).
• Screw down the pressure washer and nut finger-tight. DO NOT
USE A WRENCH.
• Make sure the rotating brush assembly bottoms out properly on
its support post. Set it so the brush clears the pressure washer.
Base Inspection Strobe Lamp Power Supply Assembly
To replace the optional Base Inspection Strobe Lamp power supply
assembly proceed as follows:
1. Turn the main power switch OFF and wait at least 15 minutes before
proceeding to Step #2.
WARNING
Wait at least 15 minutes after turning the main power switch OFF to
allow for the stored electrical charge to dissipate. Failure to do this
may result in electrical shock and serious personal injury.
2. Disconnect all cables and the air hose from the strobe housing.
3. Remove the two screws that secure the power supply to the base
cabinet structure.
4. Install the replacement power supply assembly.
5. Reconnect all cables and air hose.
Base Inspection Strobe Lamp Replacement
To replace the Base Inspection strobe lamp proceed as follows:
1. Turn the main power switch OFF and wait at least 15 minutes before
proceeding to Step #2.
WARNING
Wait at least 15 minutes after turning the main power switch OFF to
allow for the stored electrical charge to dissipate. Failure to do this
may result in electrical shock and serious personal injury.

2. Remove the entire Base inspection strobe assembly.
3. Remove the baffle by loosening the four screws holding it in place.
4. Loosen the two screws holding the upper reflective plate.
5. Pull out the existing flash tube (Item #14) from the base.
6. Before inserting the replacement flash tube, fill each banana socket
with DC4 compound (or equivalent) to keep out moisture.
CAUTION
Do not touch the replacement flash tube with bare hands. Plastic
gloves are supplied. Do not let the flash tube become contaminated
with any foreign materials. Contamination on the flash tube may
cause damage to the tube and/or shorten its effective life. If the lamp
is touched with fingers or is contaminated, make sure you wipe the
lamp clean using a glass cleaning solution and lens tissue or soft cloth
before installation.
7. Without removing the protective plastic bags, gently insert the new
flash tube’s banana plugs into their matching sockets.
8. Remove the plastic bag from each lamp.
9. Reassemble the remaining parts and re-install the assembly into the
machine.
INSPECTION HEAD
Due to the interrelationships between cameras, optical components,
servos and the inspection software, certain replacement procedures must
be performed by an authorized, factory-trained IDC Representative.
These include replacing:
• Base Inspection camera/optics
• Base camera zoom and brightness servos
• IR RLD camera/optics
• Finish Inspection camera/optics
• Inner Sidewall Inspection camera/optics
• Thread Inspection camera/optics
• Camera zoom and brightness servos
If you suspect any of these components require replacement, contact your
designated authorized IDC Representative for assistance.
Finish Lens
To replace the Finish Lens Protector proceed as follows:

1. Raise the Inspection Head an remove the starwheel.
2. Remove the three philip head screws. See figure below for screw
location.
3. Remove the lens retaining ring and replace the finish lens.
4. Place retaing ring back in postion with the three screws removed in
step 2.
NECK BELT
To replace the Neck Belt proceed as follows:
1. Raise the Inspection Head.
2. Remove the old neck belt and replace with a new belt.
3. Lower the Inspection Head and manually pass a bottle on the
starwheel through the inspection area.

4. Adjust the Neck Guide tension so the bottle is held firmly in place yet
can pass smoothly through the inspection area
OUTER SIDEWALL ENCLOSURES
CAMERA ENCLOSURE:
There are very few components inside the OSW camera enclosure that
may require replacement.

The camera, optics, servos, and mirror heater (s) which are enclosed and
sealed off inside the OSW camera enclosure are designed to operate on a
long-term basis without need for regular maintenance.
Do not open the OSW camera enclosure unless absolutely necessary.
Opening the enclosure allows dirt, product, water, and other fluids/gases
to contaminate the OSW system camera and mirrors.
Due to the interrelationships between the camera, optical components,
servos and the inspection software, the replacement procedures for these
components must be performed by an authorized, factory-trained IDC
Representative.
WARNING
Turning OFF the Omnivision’s main power may not terminate ALL
power supplied to the Outer Sidewall (OSW) system enclosure. If the
heater is employed, the power to the heater is supplied by an external
220 volt power feed. These heaters are normally live even when the
main Omnivision unit is turned off. The heaters are active to keep the
OSW mirrors from fogging. To disable ALL power to the OSW
system, turn OFF both the main power switch and the OSW heater
power.
LAMP ENCLOSURE:
1. Remove the OSW enclosure cover to access the lamp assy.
2. Disconnect the wiring connectors attached to the side of the
fluorescent lamp panel.
3. Unscrew the fluorescent lamp panel from its frame and remove the
panel.
4. Carefully press down on the red button at the base of the failed
fluorescent lamp and unsnap the lamp and remove it.
NOTE
In Step #4 be careful not to touch the replacement fluorescent lamp
with your bare fingers. Bare fingers leave oils on the lamp which may
cause lamp failure at a later time. If the lamp is touched with fingers,
make sure you wipe the lamp clean using lens tissue or soft cloth
before restoring power to the OSW system.
5. Install the replacement fluorescent lamp in its place, carefully guide
the lamp prongs into their proper locations and make sure the lamp
snaps into place and seats properly. It may be necessary to push hard
to get the replacement lamp to snap in fully.
6. Return the lamp panel to its frame and bolt it in place.
7. Connect the wiring connectors to the lamp panel.

8. Install the OSW enclosure cover back in place.
9. Turn on the circuit breaker and verify the replacement fluorescent
lamp is functioning properly.

OV-II Maintenance Manual

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OV-II Maintenance Manual