veritas icq

7/29/2019 VERITAS ICQ

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Veritas iC

Troubleshooting / Preventive Maintenance(Technical Training Report)


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Purpose & Objective

Purpose:

- This section identifies some possible remedies when faultsarise on the Veritas iC. This section does not giveresolutions to all problems but is here as an aid to

troubleshooting.

Objective:

- At the completion of this training participants should beable 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


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Alarm Screen To reset an alarm press the Acknowledge all button.

Two types of alarms can occur in the system; Alarms andLatched Alarms

Alarms- Require user

intervention to fix and

restart the Machine. Alarms

are typically more

mechanically or electrically

related. ie. Main LineContactor, Safety Relay,

Thermal Overloads.

Latched Alarms- Somelatched alarms stop the

machines. These alarms

represent data and tracking

faults


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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


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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

- Fix 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.


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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 inoperation.

Verify the sensor is working by viewing the input on PLC.


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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


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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


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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


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Latched Alarms

BP1 Missed

- Definition

BP2 triggered on a bottle that BP1 did not.

-Reason

Faulty Sensor

- Fix



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Latched Alarms

BP2 Missed

- Definition

BP1 triggered a bottle that BP2 did not.

-Reason

Faulty Sensor

Fallen bottle

-Fix


Check for fallen obstruction of bottle flow


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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 asthe conveyor.

Verify the operation of BP1 and BP2.


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Latched Alarms

Conveyor Speed too low- Definition

A Data fault has occurred and the conveyor speed is less than 6 persecond.

- 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


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Latched Alarms

Conveyor Speed too High

- Definition

Conveyor speed exceeds 60 per second

-Reason

External speed reference set too high. .

- Fix

Lower conveyor speed


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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.


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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.


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Latched Alarms

Station to Station distance out of ran- Definition

Variable for Station to Station distance is out of range duringan 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


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Alarms

PLC Awaiting Data- Definition

PLC requesting data from the Supervisor computer.

- Reason Only a problem if the alarm stay on

Lose Ethernet connection between the PLC and Supervisor

- Fix Verify the connection to the Ethernet Switch and the twodevices. .

Make sure power is on the Ethernet Switch.

Replace Ethernet cables between the Ethernet switch andthe devices.


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Alarms

Station 1 MX1 Offline

- Definition

Signal from the MX computer telling the Supervisor that thecomputer 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 fromBreakout 4 pin 9 to PLC inputs I:3/15.


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Alarms


- Definition


-Reason




Verify the connection from MX to Breakout and fromBreakout to PLC


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Alarms


- Definition


-Reason




Verify the connection from MX to Breakout and fromBreakout to PLC


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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.


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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.


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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


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Alarms


- Definition


-Reason

Consecutive Rejects

Excessive rejects

No rejects

-Fix

Clean Optics



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Alarms


- Definition


-Reason

Consecutive Rejects

Excessive rejects

No rejects

-Fix

Clean Optics



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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

MX1 Mod 3/2

CC1BMX2 Mod 3/2

MX3 Mod 3/2


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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


Arm release active

Poor alignmentBP1 Splitter 1

Splitter 2

CC1B

PLC I:0/2

MX1 Mod 3/1


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Troubleshooting

Bottle Present Sensor 2 not triggering


Module 3 input 1.

Bad encoder

Bad Splitter


Arm release active

Poor alignment BP2 Splitter 3

Splitter 4

CC1B

PLC I:0/3

MX2 Mod 3/1


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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.


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Troubleshooting

Rejector not firing

- The marching screen is updating but the rejectoris not taking bottles off the line.

Bad Solenoid Insufficient air

Offset in the Machine setup - PLC screen not adjustedcorrect.

Poor alignment

Poor wiring

- 24VDC

- PLC O:0/5 output to solenoid


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Troubleshooting

Arm Release will not engage


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


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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


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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


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Troubleshooting Assigning Cameras.

-Turn the MX Offline

-Go to the Setup screenfrom the One World Main

home screen


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-Select the Camera icon

and press Edit.

-In the camera screen press

Setup.


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-Located on the left hand side

is a drop down box that hasall of the camera connectedwith that MX computer.

- Each camera as a uniqueSerial Number assigned to it.

This number is marked on thecamera. View the numberand highlight it on the list ofcameras.


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-The camera should beoperational.

- Press the camera button andan image should appear

-Exit out

- Accept Changes

- Assigning camera iscomplete.

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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] tothe 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 theeffected light board. Use a light andobserve that all of the pin connectorsare seated in the sockets. If thisdoesnt work you may have to take the

control board off and re-set the pinconnections between the light boardand strobe board.

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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 LightPanel in the ExcitingDevices window

-Press Edit

- Once in the Setup screen

select Advanced andenter the advanced setup

option.

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Troubleshooting Initializing the light board

-Select GET to Retrievethe 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


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Troubleshooting Initializing the light board

- The light will operate as

they were before the shutdown.

- Press the camera buttonand an image shouldappear

- Press X and exit out of thecamera setup.

- Make sure to Accept

changes and continue tothe next camera and repeatthe initializing process.

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Trouble shooting Data Valid Alarms


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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 hasdetermined 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.


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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.

T bl h ti B ttl t


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Trouble shooting Bottle space wont

run

The bottle spacer is tied to an output on the PLC O:0/1. This is thestop bit for the spacer. If this bit is on the spacer will not run.

Check the alarm screen on the supervisor PC. Many alarm willtoggle 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


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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 orhas the gain set to high. It can reflect off of the edge of the

container.


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Preventive Maintenance

Daily

- Clear off any broken glass

- Clean Bottle Present sensors

-Clean Down Ware sensors

- Clean Cameras

- Clean Mirrors


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Weekly

- Clean conveyor and guide rails

- Clean blower filter

-Clean Air-condition Filter (If Applicable)


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Monthly

- Inspect and clean inside console.

Routine Maintenance


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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 LightboxAssemblies.

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 andreplace. Cleaning should be preformed once per week minimum, If dustand debris buildup is heavy in that time period, more frequent cleaningwill be necessary.

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

surfaces.

Replacing a Mirror


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Replacing a Mirror

How to remove a mirror

- Disable the electromagnets andswing the optics arm out

- Slide the mirror to be replaced upout of its mount then tip the mirroraway from the mount and remove

How to replace a mirror

-Determine which side is the firstsurface side. This can be done bytouching the glass with a pointedobject. If the reflection of theobject touches the end of the

object, that is the front surface. Ifthere is one glass thicknessbetween them, that is the backsurface.

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