Contents

INTRODUCTION .................................................................... 1

UTILITY REQUIREMENTS ........................................................... 1

ELECTRICAL ................................................................ 1
AIR ......................................................................... 1
MECHANICAL LOAD ........................................................ 1

SHIPPING WEIGHT AND CRATE SIZE (approximate) .................................. 1

MECHANICAL INSTALLATION ...................................................... 1

INSPECTION HEAD .......................................................... 1
CUSTOMER SUPPLIED BACKUP SENSOR ...................................... 2

ELECTRICAL CONNECTION ........................................................ 3

FT-50/70 SLAT REJECTOR CONTROLS REJECTORCONTROLS .................... 4

SYSTEM ADJUSTMENT ...................................................... 5

ENCODER CALIBRATION .................................................... 6
BACKUP PROTECTION ..................................................... 12

Industrial Dynamics Company. Ltd. 2334-0895

Industrial Dynamics Company, Ltd. 2334-0895
INTRODUCTION
The Industrial Dynamics' LS-3 Slat Rejection System may be used
with the FT-50/70 Inspection System.This manual details the initial
mechanical and electrical installation and setup with the FT-50/70.

UTILITY REQUIREMENTS

ELECTRICAL
115 VAC, 50/60 Hertz. Total power consumption depends on the
inspection system.

AIR
Negligible Volume, 75 - 125 psig (517 - 862 kPa)

MECHANICAL LOAD
1/4 hp. load to customer's conveyor.

SHIPPING WEIGHT AND CRATE SIZE

(APPROXIMATE)
Weight - 400 lbs.

Size - 64" x 24" x 2 6 High

MECHANlCAL INSTALLATlON

INSPECTION HEAD
The Inspection Head may be mounted up to 32 container
diameters upstream of the Slat Rejector housing edge. IDC recom-
mends mounting the Inspection Head and Slat Rejector as close
together as possible to minimizethe chance of container tracking
errors causing false rejects and line jams. Observe the minimum
distances as shown on drawing 1-00475.

Refer to the attached Installation Drawings for details on mounting

the Slat Rejector relative to the FT-50/70 Inspection Head.

Industrial Dynamics Company, Ltd. 2334-0895 1

 The following drawings are included

Plan for the following constraints when installing the Slat Rejector:

The containers must not back up into the rejection area.

The Upstream Guide Rail must position containers properly
for rejection.

The Slat Rejector is physically connected to the Production

Conveyor drive system through either a common shaft or chain.
Minimize container backup by allowing sufficient distance
downstream of the reject area before locating a turn or other
potential line constraint.

CUSTOMER SUPPLIED BACKUP SENSOR

CAUTION
Failure to provide this sensor may allow the Slat Rejector to
incur serious and expensive damage.

The Customer must supply and install a Backup Sensor

downstream on the Production Conveyor to Sense containers
which might jam the line and damage the Slat Rejector. The
Backup Sensor must be interlocked with the Customer’s Program-
mable Logic Control system to stop the Production Conveyor
when a line jam occurs.

2 Industrial Dynamics Company, Ltd. 2334-0895

ELECTRICAL CONNECTION
The FT-50/70 electrical connections to the Slat Rejection System
are made through Terminal Blocks TB1 and TB4 in the FT-50/70
Inspection Head. Route the cable through one of the connectors on
the bottom of the Inspection Head near the mounting pedestal.
The electrical connections to TB1 are given in Table 1. The electrical
connections to TB4 are given in Table 2. Also refer to Drawing
27207, FT-50/70 System Wiring Diagram.

Table 1. TB1 Electrical Connections

Industrial Dynamics Company, Ltd. 2334-0895 3

FT-50/70 SLAT REJECTOR CONTROLS
There are several FT-50/70 functions used with the Slat Rejection
System. These functions are:

NUMBER OF SLATS - Sets the number of slats that are actuated

for each container. (Range 1 to 5, Default: 1)

SLAT TEST -Actuates the next 200 slats (approximatelytwice the

number of slats on an LS-3 Slat Rejector) which pass the Reject
Solenoid. Shows **COMPLETED**on the bottom line of the
display after you have pressed the arrow key to initiate the
command. If you press the arrow key again while the test is in
progress, the test will be reset and will actuate 200 slats from the
point you sent the additional command. For example: you start the
test and then press the arrow key again after 120 slats have been
actuated. The machine would reset and actuate 200 slats for a total
of 320. The slat test is automatically disabled when the ET-50
trigger senses containers.

BACKUP STATUS - Sets the Backup System On or Off.

BACKUP/REJDISABLE DIST - Disables rejection when the

Backup Sensor Beam is blocked while the conveyor travels the
specified distance. Normally set to 2 to 4 times the container
diameter at the point the sensor beam crosses the container
sidewall. (Range: 1 - 2000 mm, Default: 150 mm)

NOTE
Consecutive batch rejects may disable rejection if containers are
forced together BEFORE the backup sensor point. If that is the
case, relocate the sensor, if possible (consult IDC Customer
Support for optional locations); otherwise, increase the REJ
DISABLE DIST to accommodate the largest string of consecutive
touching containers that would occur normally

BACKUP/REJ ENABLE DIST - Enables rejection when the

Backup Sensor Beam remains unblocked while the conveyor
travels the specified distance in mm. (occurs only after a backup
has disabled rejection) Normally set to 1 to 2 times the container
diameter at the point the sensor beam crosses the container
sidewall. (Range: 1 - 2000 mm, Default: 150 mm)

4 Industrial Dynamics Company, Ltd. 2334-0895

NOTE
In some installations, the backup sensor must be placed so that it
is across both the Reject/Accumulation and Production
Conveyors. In this case set the BACKUP/REJ DISABLE DIST to
just greater than 2 container diameters and set the BACKUP/REJ
ENABLE DIST value small enough to detect the normal space
between production containers (minimum spacing is 7 to 8 mm).
This will allow proper automatic recovery from a "Backup
Disable" sequence.

DISTANCE BETWEEN OILS - Sets the distance the conveyor and

slat will travel, in increments of 100 meters, between automatic slat
oiling cycles. Each oiling cycle sprays at the rate of 80 milliseconds
maximum per slat until 100 slats are oiled. This function is always
active when the LS-3 Slat Rejector is selected as the active rejector
type. (Range: 1 - 65,000 x 100 m, Default: 500 x 100 m)

BROKEN SLAT SENSOR - Sets the sensor On or Off.

SLAT REJECTOR LED INDICATORS

LED No. 4 of Section 1/Bank 1 on the FT-50/70 Processor Card shows
the state of the Slat Backup Sensor. If the LED is ON, the Sensor is
blocked, if the LED is OFF, the beam is unblocked.

LED No. 7 of Section 1/Bank 1 on the FT-50/70 Processor Card shows

the state of the Broken Slat Sensor. If the LED is ON, the Sensor
detects metal, if the LED is OFF, the sensor detects no metal.

SYSTEM ADJUSTMENT
Set the system parameters on the FT-50/70 Control Panel per the
constraints listed below:

INITIAL SETTINGS
INSPECT TRIG TO UL REJ- Set this function to the distance in
millimetersbetween the Inspection Head Trigger Beam and the
Slat Rejector Housing upstream edge.

NOTE
Ensure that the "Inspect Trigger to Rejector Centerline" value is
correct before performing the calibration procedure.

Industrial Dynamics Company, Ltd. 2334-0895 5

 NUMBER OF SLATS -The number of slats to be extended to reject
each container is usually established by trial and error. Use the
smallest number of slats that give smooth and reliable rejection.
Start with one and increase the number as required. Use no more
slats than the number equal to one inch less than the container
diameter (one slat/one inch). Example: on a three inch diameter
container, use no more than two slats.

ENCODER CALIBRATION
The Encoder calibration process establishes, in the computer, a
translation factor between encoder pulses and millimeters. This
information is then used to determine the distance the conveyor
chain travels (in millimeters) for each Encoder Pulse.

LOW RESOLUTION ENCODER

The Slat Rejector's built-in Low Resolution Encoder outputs 22
pulses per Encoder shaft revolution, which translates to 1 pulse
per inch [393 pulses per 10 meters] of Slat Rejector Chain travel. If
your system is supplied with the Low Resolution Encoder, the FT-
50 "ENC PULSES/10 M variable is initially set to 393.

NOTE
When the Slat Rejector is installed as detailed in the installation
drawings, the Slat Chain moves at the same speed as the
Production Conveyor. The initial FT-50/70 "ENC PULSES/10 M"
value should provide proper operation.

To verify correct operation with your installation, run the system

and observe the Slat Chain speed with respect to the Production
Conveyor. If the Slat Chain runs slower, decrease the (number)
ENC PULSES/10 M until proper Rejector timing is achieved. If the
slat runs faster, increase the value until proper Rejector timing is
achieved.

NOTE
If adjusting the ET-50 ENC PULSES/10 M variable, under no
circumstances should the FT-50/70 ENC PULSES/10 M value be
decreased below 374 or increased above 412. If proper operation
cannot be achieved between these values, verify that the gearing
and location of the Slat Rejector are correct.

6 Industrial Dynamics Company, Ltd. 2334-0895

HIGH RESOLUTION ENCODER

CALIBRATION PROCEDURE #1 : (BY CALCULATION)

NOTE
This procedure is valid only for the High Resolution Encoder
IDC P/N 24997, which outputs 500 pulses per revolution.
Consult IDC Customer Service before using another Encoder.
This procedure may be used if you can identify all of the
variables for your particular system. All designations are with
respect to the shaft assembly to which the High Resolution
Encoder is connected.

Values required for calculation (accuracy is important):

=Number of teeth in conveyor drive sprocket

=Individual conveyor segment length in mm
=Number of sprocket teeth per conveyor segment
(calculated values),
=Conveyor distance (mm) traveled in one revolution of shaft
E, =#of encoder counts per 10 meters
E, =5,000,000 / * / or 5,000,000 /

This equation can be used for any type of conveyor system.

However, for a standard Production Conveyor with 1 . 5 (38.1 mm)
conveyor segments and two sprocket teeth per segment, the calcu-
lation simplifies considerablyy...,

= 1.5” (38.1 mm); = 2;

E, = 5,000,000 / * (19.05)] = 262,467 / N,

The following table was generated from this calculation and

includes the effect of the PRESCALER value. (See FT-50/70 manual
Encoder Calibration for further instructions). Shaded areas are
outside the recommended range.

Industrial Dynamics Company, Ltd. 2334-0895 7

 Table 3. Encoder Calibration Values for Standard 1.5 in. Conveyor
Chain

NOTE
Refer to Table 5 for "Maximum Encoder Resolution versus Line
Speed" restrictions.

CALIBRATION PROCEDURE # 2 (BY CALCULATION)

The second procedure for calibrating the High-Resolution Encoder
with nonstandard conveyors is to determine the distance
traveled per revolution of the drive shaft. This is obtained by
observing conveyor travel during one or more revolutions of the
high resolution encoder shaft (i.e. observing 2 revolutions would
require the distance to be halved) Once this distance is derived, the
number of encoder counts per 10 meters is found as follows:

8 Industrial Dynamics Company, Ltd. 2334-0895

 E, = 5,000,000 / = # encoder counts per 10 meters

Example:

when the distance per revolution equals 16.5 in.

(or 16.5 * 25.4 = 419.1 mm)

E, = 5,000,000 / 419.1 = 11,930 encoder counts/10m

Verify calculations using the Direct Measurement Method. If both

results are within± 5%, use the calculated values. If not, recalculate
and recalibrate.

CALIBRATION PROCEDURE #3: (BY DIRECT

MEASUREMENT)
The third procedure for calibrating the High Resolution encoder is
by direct measurement of a test standard. When doing this
procedure, to ensure the most accuracy, IDC recommends using an
opaque container or other cylindrical object (example: a plastic
pipe segment) as large as will fit through the trigger bracket. See
the Configuration Sheets (Form 2215,2387 or 2572) for the
supplied Inspection Head type, and also Table 4, to determine how
large an object will fit.

Table 4. Maximum Container Width. Dimensions in inches [mm]

1. Press the REJECTORkey until the top line of the Display

shows BOTTLE WIDTH AT TRIG.

2. Measure the width (diameter) of the Test Container where the

Trigger Beam intercepts the sidewall.

NOTE
Accurately measuring the Test Container's diameter where the
Trigger Beam intercepts its sidewall, and correctly entering this
value at the BOTTLE WIDTH AT TRIG prompt is very
important. The ET-50 bases its calculations on this value. For the
most accuracy, measure with measuring calipers or a micrometer.

Industrial Dynamics Company, Ltd. 2334-0895 9

 3. Use the UP/DOWN arrow keys to set the bottom line of the
Display to the measured value in millimeters. (To convert
inches to millimeters, multiply by 25.4).

4. Press the SYSTEM key until the top line of the Display shows
CALIBRATE ENCODER. The bottom line should show
EXECUTE (flashing).

5. Press either the UP or DOWN arrow key and the bottom line of
the Display will show READY (flashing).

6. Apply power to the conveyor drive system and adjust the

chain to the highest speed it will ever be run. Ensure that the
chain runs smoothly to obtain accurate calibration.

7. Calibrate the Encoder:

a. Use the same test container measured for the BOTTLE

WIDTH AT TRIG. value. Place it on the Production
Conveyor, chain, well upstream of the FT-50/70, so it passes
through the Inspection Head smoothly and in the proper
position. The ENCODER PRESCALER VALUE is automati-
cally calculated on this container.

b. The bottom line of the Display now shows WIDTH = XXX

ENC PULSES for approximately two seconds. This value is
the number of Encoder Pulses (adjusted by the Prescaler
Value) for the container diameter just viewed. The top line
of the Display then changes to RUN 16 BOTTLE(S),
PLEASE and the bottom line shows READY (flashing).

c. Again, place the test container on the chain well upstream

of the FT-50/70 so it passes through the Inspection Head
smoothly and in the proper position. The top line of the
Display should now read RUN 15 BOTTLE(S), PLEASE
and the bottom line will still show READY.

d. Continue to pass the test container through the machine

until the bottom line shows WIDTH = XXX ENC PULSES
momentarily and then switches to CALIBRATEENCODER
on the top line and COMPLETED on the bottom line. The
system has now calculated the Encoder Pulses per 10
meters of chain distance as averaged over the last 16 passes
of the test container.

10 Industrial Dynamics Company, Ltd. 2334-0895

FINE TUNING ENCODER CALIBRATION
1. Select a bottle that will reject consistently (for any type defect)
and use it for the next tests.

2. Press the REJECTOR key until the top line of the Display
shows BOTTLE WIDTH AT TRIG.

3. Accurately measure the width (diameter) of the bottle where

the Trigger Beam intercepts the bottle.

4. Use the UP/DOWN arrow keys to set the bottom line of the
Display to the measured value in millimeters.

5. Apply power to the conveyor drive system. For variable speed

lines, set the conveyor to its lowest speed.

6. Place the test bottle on the chain well upstream of the FT-50/70 so
it passes through the Inspection Head smoothly, in proper
position and traveling at chain speed.

NOTE
The REJECTORSTATUS must be active before bottles can be
rejected.
The STATUS for the test bottle defect must be ON before the
defect will be detected. i.e. if the test bottle is underfilled, the
UNDERFILL STATUS must be ON.
The inherent accuracy of the Slat Rejector is ± 112 inch

7. Observe that, when the Slat Rejector rejects a group of bottles,

the Slat Rejector contact positions vary throughout the
tolerance range (“early” to “late”). If they are consistently
leading (“early”) or trailing the container (“late”), adjust the
ENC PULSES/10 M function:

a. Press the SYSTEM key until the top line of the Display
shows CALIBRATE ENCODER VALUE.

b. If the Rejector fired late (contact area was upstream),

slightly decrease this function’s value.

c. If the rejector fired early (contact area downstream),

slightly increase this function’s value.

d. Maintain the Calibrate Encoder Value (Encoder Pulses per

Ten Meters) below the value shown in Table 5 for the
conveyor line speed. Repeat this procedure until the Slat
Rejector is rejecting bottles consistently.

Industrial Dynamics Company. Ltd. 2334-0895 11

 Do not adjust the BOTTLE WIDTH AT TRIG or INSPECT TRIG
TO C/L REJ values.

Table 5. Maximum Encoder Resolution vs. Line Speed

BACKUP PROTECTION
The Slat Backup Sensor combined with the two functions,
BACKUP/REJ ENABLE DIST and BACKUP/REJ DISABLE DIST,
protects the Slat System when containers are backed-up in the
accumulation area. The sensor must be placed low enough to
detect fallen containers. If the Slat System continues to reject
containers, containers will jam into the extended slats and may
cause damage to the slats or slat chain. When the Slat Backup
Sensor is activated, the Reject Solenoid is disabled so containers
cannot be rejected.

Set the functions as follows:

BACKUP/REJ DISABLE DIST - Adjust this function so that the

Slat Backup Sensor does not activate when multiple containers are
rejected and pass in front of the sensor. The sensor must activate,
however, when containers back up on the takeaway and/or
accumulator chain (or Production Conveyor if so installed) and
stand in front of the beam for a specific travel distance.

BACKUP/REJ ENABLE DIST - Adjust this function to prevent

enabling of the Slat Reject Solenoid if there is any possibility of
containers backing up into the slats but not too much to prevent
rapid recovery from false disable sequences caused by multiple
touching containers.

12 Industrial Dynamics Company, Ltd. 2334-0895