30560599-MANUAL OV-1200-900 SERIE 3000-Ingles

Omnivision Series 3000
Maintenance and Parts Manual

for Models:
• 900
• 1200
• D1200
Document 30560599A
OMNIVISION 900/1200/D-1200
(Series 3000)
All Surface Empty Bottle Inspector
Maintenance and Parts

Manual
Software Version CFx
REVISION CONTROL:
The date appearing below is the date of the latest change to this
manual. The date shown at the bottom of each individual page
is the revision date of the manual when that page was last
revised.
Form 3056 (05/99A)

End User License Agreement
Industrial Dynamics Company's Omnivision All Surface Empty Bottle Inspector contains
software licensed from Microsoft Corporation.
1. The Omnivision contains intellectual property, i.e., software programs, that are licensed by
the end user customer (hereinafter “End User”).
2. This is not a sale of such intellectual property.
3. The End User shall not copy, disassemble or reverse compile the software program.
4. THE SOFTWARE PROGRAMS ARE PROVIDED TO THE END USER “AS IS” WITHOUT
WARRANTY OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING, BUT
NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. THE ENTIRE RISK OF THE QUALITY AND PERFORMANCE
OF THE SOFTWARE PROGRAM IS WITH YOU.
5. INDUSTRIAL DYNAMICS COMPANY AND ITS SUPPLIERS SHALL NOT BE HELD TO
ANY LIABILITY FOR ANY DAMAGES SUFFERED OR INCURRED BY THE END USER
(INCLUDING, BUT NOT LIMITED TO, GENERAL, SPECIAL, CONSEQUENTIAL OR
INCIDENTAL DAMAGES INCLUDING DAMAGES FOR LOSS OF BUSINESS PROFITS,
BUSINESS INTERRUPTION, LOSS OF BUSINESS INFORMATION AND THE LIKE),
ARISING FROM OR IN CONNECTION WITH THE DELIVERY, USE OR PERFOR-
MANCE OF THE SOFTWARE PROGRAM.
Form 3056 (05/99A) Copyright. All rights reserved.

No part of this publication may be reproduced or used in any form or by any means--graphic,
electronic, or mechanical including photocopying, recording, taping, or information storage and
retrieval system--without written permission of Industrial Dynamics Company, Limited.
INDUSTRIAL DYNAMICS COMPANY, LTD.
2927 Lomita Boulevard,

Headquarters Address Torrance, California 90505-5163
U.S.A.
P.O. Box 2945,
Mailing Address Torrance, California 90509-2945
U.S.A.
3100 Fujita Street,
Shipping Address Torrance, California 90505-4007
U.S.A.
Customer Service Center (800) 733-5173

Telephone Number
Headquarters (310) 325-5633

Telephone Number
Headquarters (310) 530-1000

Facsimile (FAX) Number
Contents
Contents
Chapters
Topic Page
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Product Safety Test Mark Information . . . . . . . . . . . . . . . . . . . . . . vii
Chapter Topic Page

1 Periodic Maintenance
Periodic Maintenance Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2 Troubleshooting Procedures
Troubleshooting Procedures Overview. . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mechanical/Routine Maintenance Problems . . . . . . . . . . . . . . . . . . . 2-1
Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Inspection/Rejection Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
3 Repair and Replacement Procedures

Repair and Replacement Procedures Overview. . . . . . . . . . . . . . . . . 3-1
Guidelines for Repair or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Emergency Repair and replacement Procedures . . . . . . . . . . . . . . . . 3-2
Base Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Inspection Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Touchpads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Video Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Outer Sidewall Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
4 Alignment and Calibration procedures

Alignment and Calibration Procedures Overview . . . . . . . . . . . . . . 4-1
Guide Assembly Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Microsonic Bottle Sensor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Inspection Head and Inspection Timing Trigger Alignment . . . . . . 4-3
Starwheel Vacuum System Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-5
Air System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starwheel Encoder Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) iii

Omnivision 900/1200/D-1200 Maintenance and Parts Manual
Contents
Appendix Topic Page
A Manufacturers Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
B Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
C Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
iv Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Preface
PREFACE
This Preface:
• provides an overview of the Omnivision 900, 1200 and D-1200
(Series 3000) Systems Maintenance and Parts Manual.
• explains how the software is identiÞed.
• provides a list of the Omnivision Series 3000 manuals.
Maintenance and Parts Manual Overview

This manual addresses the maintenance, troubleshooting, repair
and replacement, and parts ordering procedures for the
Omnivision Series 3000 All Surface Empty Bottle Inspectors
(ASEBI). The product line consists of Models OV 900, OV 1200 and
OV D-1200.
The Omnivision Systems may have the following conÞgurations:
HARDWARE
The Series 3000 hardware to support the following inspection
systems:
• Base Inspection
• Residual Liquid Detection (RLD)
• Inner Sidewall Inspection
• Finish Inspection
• Outer Sidewall Inspection
SOFTWARE
• Version Code Series CFx
NOTE
The Omnivision 900 and 1200 systems are supplied with single
chassis electronics and an inspection system which together
constitute System “A”. The Omnivision D-1200 is supplied with
dual chassis electronics and inspection system, namely System
“A” and System “B”, which operate independently of each other.
This allows for duplicate inspection systems which enables the
customer to continue operation of the production line if either
System “A” or System “B” is intermittent or fails.
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) v

This manual is organized as follows:
Chapter 1 Periodic Maintenance.

Chapter 2 Troubleshooting Procedures.
Chapter 3 Repair and Replacement Procedures.
Chapter 4 Alignment and Calibration Procedures.
Appendix A Manufacturers SpeciÞcations.
Appendix B Air Conditioner.
Appendix C Drawings and Parts Lists.
Software Identification
A software-based system allows the computer programs to be
updated by changing the programmable memory in the machine.
This ensures that the user can upgrade the capabilities of the
equipment as newer and higher performance programs are intro-
duced by Industrial Dynamics.
The software is identiÞed by a version code. The version code

refers to a group of features which represents the inspection
capabilities and the performance improvements. The version
code is identiÞed by three alpha characters, for example CFH.
The version code may be viewed on the Omnivision Sign-on

screen (also known as Customer Service screen). This screen
appears during the system power-up or when the system reset
switch is activated.
When calling Industrial Dynamics for assistance, always have the

Serial Number of the Omnivision and the software version code
available for reference purposes.
Omnivision Series 3000 Manuals

This manual is one of several documents that form the Omnivision
Series 3000 documentation set.
Other manuals include:
Installation Manual (Form 3053)

Operation Manual (Form 3054)
Start-up and Technical Reference Manual (Form 3055)
Outer Sidewall Inspection Start-up and Technical Reference Manual
(Form 3057)
Modbus Serial Communication Manual (Form 3129)
FT-45 RF RLD Radio Frequency Residual Liquid Detection Manual
(Form 3034)
vi Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Product Safety Test Mark Information
PRODUCT SAFETY TEST MARK INFORMATION

This Omnivision machine complies with all of the CE (Conformité
Européenne) Essential Health and Safety requirements of the
Electromagnetic Compatibility Directive (89/336/EEC) and
Machinery Directive (89/392/EEC).
The machine has a CE Mark afÞxed to it and is accompanied by an

EC Declaration of Conformity.
The Omnivision machine labels conform to the International

Electrotechnical Commission (Commission Electrotechnique
Internationale) International Standard for Graphical Symbols for
use on equipment as deÞned in CEI/IEC 417, amended in accor-
dance with Supplements:
• A (1974)
• B (1975)
• C (1977)
• D (1978)
• E (1980)
• F (1982)
• G (1985)
• H (1987)
• J (1990)
• K (1991)
• L (1993)
For your convenience, the following is a table of International

Symbols. These symbols appear both on the Omnivision as
machine labels and within Omnivision documentation.
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) vii

International Symbols
1 6 11
2 7 12
3 8 13
3
4 9 14
5 10
IntlSymbols
No. Description No. Description

1 Direct Current 8 Equipotentiality
2 Alternating Current 9 On (Supply)
3 Both Direct and Alternating Currents 10 Off (Supply)
4 Three-phase Alternating Current 11 Equipment protected throughout by Double
Insulation or Reinforced Insulation
(Equivalent to Class II of IEC 536)
5 Earth (Ground) Terminal 12 Reset
6 Protective Conductor Terminal 13 Caution, risk of electric shock
(Background Color - Yellow,
Symbol and Outline - Black)
7 Frame or Chassis Terminal 14 Caution (Refer to accompanying documents)
(Background Color - Yellow,
Symbol and Outline - Black)
viii Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Chapter 1: Periodic Maintenance
Chapter 1:
Periodic Maintenance
Contents
Topic Page
Periodic Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Industrial Dynamics Company, Ltd. © Form 3056 (06/98)


PERIODIC MAINTENANCE OVERVIEW

This chapter provides guidelines for periodic maintenance on the
Omnivision 900/1200, Series 3000 System, 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 PROCEDURES

This section provides the daily, weekly and monthly routine
maintenance for the Omnivision system.
NOTE
The cameras, mirrors, servos, and heaters inside the optional
Outer Sidewall (OSW) system enclosure are enclosed and sealed
off. These components are designed to operate on a long-term
basis without daily, weekly, or monthly maintenance being
required. None of the these components require lubrication. Do
not open the OSW system enclosure unless absolutely necessary.
Opening the enclosure allows dirt, product, water, and other
ßuids/gases to contaminate the cameras and mirrors.
Daily Maintenance
ITEM DAILY MAINTENANCE
Air Conditioner Check the Monitor Enclosure surface for excessive heat. If
the surface feels too warm, check the air conditioner for
malfunction (refer to Appendix B for details).
Diffuser Glass Clean thoroughly top and bottom. Maintain cleanliness by
adjusting the diffuser glass wiper brush and water drip
system. Dirty diffuser glass causes "false rejects."
Diffuser Glass Wiper Brush Wash in soap and water as required. Stock an extra wiper
brush for quick change.
Water Drip System Check and adjust for slow and consistent drip.
Industrial Dynamics Company, Ltd. © Form 3056 (06/98) 1-1

Inspection Head Lens and Clean inspection head lens and external cover glass
Optical Window 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.
Purge Air (Suction Pipes) Check for air ßow 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 Jet Blow-off, Diffuser Glass Check for proper ßow. Removes water, pulp and other
objects from glass surface prior to inspection.
Air Jet Blow-off, Bottle Bottom Check for proper ßow 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 Inspection Head height 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.
Vacuum Pump Filter and Clean Filter Bottle if dirty. Empty Exhaust Bottle as
Exhaust Bottle required.
1-2 Industrial Dynamics Company, Ltd. © Form 3056 (06/98)

Infeed and Outfeed Bottle Check for proper guides. Check all knobs and if necessary
Guides tighten. Guide should blend smoothly with production
conveyor guide rails.
OSW Inspection Tunnel Check the inspection tunnel area for any debris such as
broken glass, labels, or other foreign debris. Clear nay
debris out of the inspection tunnel.
OSW Guide Rails Check for looseness; 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. Make
sure the guide rails width and height are properly adjusted
for the current production bottle type.
OSW Diffuser Panels (located Check for scratches or other damage. Clean with a
inside the inspection tunnel on noncaustic, nonabrasive commercially available glass
the light source side) cleaner (such as Windex).
OSW Camera Windows (located Check for scratches or other damage. Clean with a
inside the inspection tunnel on noncaustic, nonabrasive commercially available glass
the camera side) cleaner (such as Windex).
OSW Blower Fans Check that the blower fans are causing air to ßow
forcefully out the bottom of the exhaust legs.

Weekly Maintenance
ITEM WEEKLY MAINTENANCE
Vacuum Pump Check oil level and Þll to 3/4 full.

Vacuum System Check efÞciency of system by seating bottles Þrmly in all
pockets with vacuum pump running. Vacuum Gauge on
panel should read at least 56 cm Hg (22 inches Hg). If
gauge reads less, check suction cups and be sure bottles are
seated Þrmly. 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.
(blue valve underneath
starwheel)
Rotating Diffuser Glass/Clear Adjust pressure washer for proper slip when glass disk is
Glass stopped. The glass disk should run true and not bind
against adjacent components. Check for cracks, deep
scratches, etc. Clean thoroughly.
Line Control System Cycle Line Control Sensors. If system does not function
properly, review Chapter 2 for troubleshooting guidelines
and review the Chapter 4 for calibration guidelines.
Infeed and Outfeed Bottle Check alignment and tighten all knobs securely. Bottles
Guides should have approximately 3 mm (1/8 inch) clearance as
they pass through guides. Guides should merge smoothly
with conveyor guide rails and give a smooth bottle
transition into the starwheel.
Takeaway System Lubricate the two drive shaft bearings' grease Þttings. The
grease Þttings are located on the side of the Reject
Conveyor channel below and downstream of the motor.
Any good grade of bearing grease may be used.
Trigger Assembly Clean plastic windows with soft cloth or cotton swabs.
Dirty windows result in lost triggering or trigger failures.
Starwheel Suction Cups Check for cracks, and replace if necessary. Check for bent
vacuum tube pipes (caused when pipes are not aligned to
starwheel). Replace and align vacuum tube pipes if
necessary.
Light Source Dome Lens Clean top surface thoroughly; DO NOT REMOVE LENS.
OSW Light Source Check that the ßuorescent or strobe lighting units are
functioning properly.

ITEM WEEKLY MAINTENANCE
OSW Diffuser Panels Check for scratches or other damage. Replace if necessary
by removing the panel through the bottom of the OSW
system enclosure. Clean with a noncaustic, nonabrasive
commercially available glass cleaner (such as Windex).
OSW Camera Windows Check for scratches or other damage. Replace if necessary
by removing the panel through the bottom of the OSW
system enclosure. Clean with a noncaustic, nonabrasive
commercially available glass cleaner (such as Windex).
OSW Filter Trap (located on top Check and, if necessary, clean the trap out.
of the OSW system enclosure)
Monthly Maintenance
ITEM MONTHLY MAINTENANCE
Air Conditioner Check the Þlter element. Clean or replace as necessary.

Refer to Appendix B for air conditioner problems.
All starwheels Check as follows:
a. Inspect the valve 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 difÞculties
are encountered, refer to the Chapter 3 for replacement
instructions.
b. Remove each suction cup and check for damage. Also
check the small Þlter 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 ßushes any debris out of the restrictors, pipes
and vacuum tubes.
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
in Base Cabinet and water ßow.
Air Filter Remove and clean the element in the air Þlter.
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 Þnd its source.
Guide Assemblies Plastic Wear Check the plastic Bottle Set Plates of the starwheel and the
Strips 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 identiÞes 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.
Bottle Guide Belts and Upper Check the bottle guide belts and upper and lower pulley
and Lower Pulley Assemblies assemblies. The pulleys should turn freely and not wobble
excessively. The belts should have strong tension and
should run smoothly in the pulleys.
Starwheel Drive System Check the starwheel drive system. The starwheel drive
motor shaft, the clutch/brake shafts and the starwheel
drive shaft should all be in alignment to prevent excessive
stress on the ßexible couplings. Check all screws and
tighten if necessary. The ßexible couplings should be
properly positioned on the shafts.
Starwheel Encoder System Check the Starwheel Encoder System. Tighten all bolts and
set screws. Proper belt tension should result in
6.4 to 9.5 mm (1/4 to 3/8 inch) deßection in center of belt
with moderate Þnger pressure.

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 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 four ßexible hoses connected to the vertical Port
tubes to ensure that they are not binding on the Clutch/
Brake Mounting Bracket, etc. If this assembly is binding
and cannot be freed, then it must be disassembled.
Takeaway System Check the Takeaway System for loose parts and excessive
wear. Tighten all bolts securely. Check the alignment of the
motor shaft and the conveyor drive shaft. Readjust if
necessary. The ßexible coupling must be properly
positioned and the set screws tightened securely.
Conveyor Wear Strips Check strips (located under the production chain) for
excessive wear or damage. Replace wear strips if
excessively worn or damaged.
Vacuum Pump Check the vacuum pump for proper lubrication.
THE PUMP MUST USE OIL OR THE BEARINGS WILL
FREEZE. Normal oil usage during the Þrst week of
operation is approximately 30 to 90 milliliters (1 to 3
ounces) per 10 to 40 hours of pump operation. After the
Þrst week of operation, the normal oil usage is 30
milliliters (1 ounce) per 10 to 40 hours of pump operation.
Oil should accumulate at a noticeable rate in the Exhaust

Jar. If the pump does not use oil or the usage decreases,
remove the Oiler by disconnecting the union. Empty the
oil and remove the elbow Þtting from the bottom of the
Oiler and check the wick located in the oil feed tube. A
single wick should protrude from the center hole
approximately 9.5 mm (3/8 inch).
Pull the wick out to the proper length if necessary. Pour a

small amount of oil into the oiler and check to be sure the
oil drips slowly. Reassemble when the system is
functioning properly.

Heaters (located inside the OSW Verify that the heaters are working properly. Heaters are
system enclosure on the camera important because they prevent the camera’s mirrors from
side) fogging.
OSW System Conduit and Check and, if necessary, replace any damaged conduit or
Cables cable.

Chapter 2: Troubleshooting Procedures
Chapter 2:
Troubleshooting Procedures
Contents
Topic Page
Troubleshooting Procedures Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mechanical/Routine Maintenance Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Omnivision Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bottle Jams at Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bottle Jams at Outfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bottle Jams in the Inspection Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Starwheel Drive and Line Control System Malfunction . . . . . . . . . . . . . . . . . . . . 2-7
Starwheel Drive is Sluggish and Cannot Keep up with Filler . . . . . . . . . . . . . . 2-10
Conveyor Chain Encoder Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Customer Bottle Handling Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Inspection/Rejection Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Base Inspection Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Inner Sidewall Inspection Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Infrared Residual Liquid Detection Excessive False Rejects . . . . . . . . . . . . . . . . 2-21
Radio Frequency Residual Liquid Detection Excessive False Rejects . . . . . . . . 2-22
Finish Inspection Excessive False Rejects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Outer Sidewall Inspection Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Rejecting Large Percentage of Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Rejecting No Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Rejected Bottles Not Stable on the Takeaway Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Passing Faulty Bottles (Missed Rejects or False Accepts) . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Faulty Bottles Detected But Not Rejected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Rejecting Incorrect Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
System Faults (Beacon On, No Message) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Complete System Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39


TROUBLESHOOTING PROCEDURES OVERVIEW

Three key areas must work together to achieve optimum machine
performance: bottle handling, inspection, and rejection.
Many of the Omnivision performance problems can be solved

during routine maintenance. If you are experiencing inspection,
rejection, or bottle handling problems, repeat your daily, weekly
and monthly maintenance as described in Chapter 1.
The best approach to troubleshoot the Omnivision is to check for

the source of problem in following order:
1. Mechanical or routine maintenance problems

2. Bottle handling problems
3. Inspection/rejection problems
MECHANICAL/ROUTINE MAINTENANCE PROBLEMS

The following table identiÞes typical mechanical or routine
maintenance problems that may cause excessive false rejects and
offers suggested solutions.
PROBLEM PROBABLE CAUSE SOLUTION
Soap is being Air blow-off rate is misadjusted or Check air blow-off system and adjust as
detected as an object. not turned on, or not receiving air necessary.
or water, or the excess soap air knife
is not aimed properly.
Water on the top Water splashing in the inspection Clean starwheel and dry it off.
surface of the area or starwheel became dirty
starwheel. while being stored or from a
careless washdown and has
something on it that allows water
deposits.
Dirt or broken glass Unclean production area or broken Clean diffuser glass. Remove any
is on the diffuser glass not removed promptly broken glass.
glass. enough.
Contamination of Hard water residue. Carefully clean Inspection lens.

the Inspection lens
(underside).
Incorrect Inspection Inspection Head not set to proper Check BOTTLE CHANGEOVER
Head height. height (13 mm or 0.5 inch above the REQUIREMENTS screen for correct
Finish Inspection station) for a inspection head height count and, if
speciÞc bottle type. necessary, adjust height with inspection
head hand wheel.

PROBLEM PROBABLE CAUSE SOLUTION
Starwheel does not Vacuum input--vacuum turned off Turn on external vacuum and/or
hold bottles. or too low. Guide belt may be increase vacuum pressure.
missing. Check guide belt.
For systems which use an optional Turn on optional Venturi Pressure-to-

Venturi Pressure-to- Vacuum Vacuum Converter and/or adjust
Converter--air pressure is turned vacuum pressure.
off, too high or too low.
Strobe misÞres Trigger sensor is misadjusted. Contact Maintenance.

periodically. Strobe system malfunctioning.
Bottles too tall or Use of the incorrect starwheel or a Check BOTTLE CHANGEOVER
small for starwheel. starwheel with the wrong number REQUIREMENTS screen for correct
or type of spacers. starwheel number and number of
spacers, if any.
If necessary, replace starwheel and/or
add or remove spacers.
One out of "x" Starwheel sucker cup is missing or Replace sucker cup or replace
number of bottles is damaged. starwheel.
rejected every
starwheel revolution.
All bottles are Vacuum pump failure (if so, Verify vacuum pump is operational.
rejected. Omnivision ßashes: Ensure that circuit breaker CB1 is on,
Alarm: Pressure Failure). the pump mufßer jar is in place, and
The vacuum gauge will be out of remove the rear Base Cabinet door to
tolerance and/or an error message verify that the vacuum gauge reads at
will be displayed on the color least 508 mm Hg (20 inches Hg). Check
monitor. for vacuum leaks in plumbing, cracks or
jar leaks. If you Þnd any vacuum
problems, contact Maintenance.
A trigger block For Finish Inspection, the light ring Contact Maintenance.
(trigger sensor) has will fall off in intensity on one side.
somehow been
misaligned, causing For Base and Inner Sidewall, the
an off-center bottle bottles will appear to be off-center
image, and all or as they pass over the deadplate
almost all bottles are opening.
rejected.
Debris or broken Unclean production area. Clean the tunnel and remove any debris
glass in the OSW or broken glass.
tunnel.

BOTTLE HANDLING PROBLEMS

Under normal production line operating conditions, bottle
handling problems are generally the main cause of unreliable
bottle inspection and rejection.
NOTE
Good bottle handling is the most important prerequisite for
efÞcient 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. The following sections address troubleshooting different
aspects of each of these bottle handling processes.
Omnivision Bottle Handling Problems

If the optional OSW system is supplied, check to see if the bottles
pass through the OSW tunnel smoothly.
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 to operate properly, bottles must remain in
a bottle to bottle contact condition from Omnivision unit
through the entire OSW enclosure at all times.
OSW bottle handling problems are generally related to the OSW

guide rails. If the guide rails are improperly adjusted, bottles may
become stuck in the inspection tunnel or gaps between bottles may
develop. Excessively worn or damaged guide rails may cause the
same kinds of bottle handling problems.
NOTE
Removing any bottles immediately in front of the OSW System
or anywhere between the OSW System and the main
Omnivision unit during production may cause bottle handling
problems.
To troubleshoot main Omnivision bottle handling problems,

proceed as follows:

1. Go to the SELECT BOTTLE TYPE screen.
SELECT BOTTLE TYPE

Number Description
1 BOTTLE A
2 BOTTLE B
3 BOTTLE C
4 BOTTLE D
16 BOTTLE X
Bottle Changeover Requirements
Menu
> (BOTTLE NAME or MESSAGE) A
Last Rej on A: on B:
2. Select the correct bottle type which accesses the BOTTLE

CHANGEOVER REQUIREMENTS screen.
BOTTLE CHANGEOVER REQUIREMENTS
Current Bottle:
BOTTLE NAME OR MESSAGE
Guide IF/OF Number X023
Deadplate Dash Number X023
Starwheel number X023
Spacer number (0 if none) 2
Inspection Head Height (counts) 74
Previous Master Menu

> (BOTTLE NAME OR MESSAGE) A
3. Verify that:
• the correct bottle type has been selected
• the correct bottle guide assemblies, deadplate, starwheel
and spacers (if any) have been installed

• 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 SLIP RATIO on the LINE STATUS AND

CONTROL screen. If it is too low (below 3%), the bottles will
jam at the infeed due to a lack of sufÞcient line pressure and
cause glass breakage. The SLIP RATIO should typically be
between 5 and 10%.
If the SLIP RATIO is too high (above 10%), the bottles will be
spaced out at the Omnivision discharge and the infeed line
pressure will be too high causing bottle jams and more glass
breakage.
LINE STATUS AND CONTROL
Set Point Actual

Operating Mode : [Manual] Manual
Slip Ratio : 8 %
Conveyor Rate : 0 encs 0 BPM
Starwheel Rate : 20 encs 225 BPM
Encoder Counts : Conv 0 Star 0
Manual Current
Freewheel Mode : No
Stop Starwheel : No
Starwheel Motor: 20.0 % 20.0 %
Takeaway Motor : 15.0 % 15 %
Brake Torque : 0 % 0 %
Clutch Torque : 35 % 35 %
Clutch Feedback: A=102 B=36
Clutch Saver : [Enabled] Activeted
Line Parameter Setup Menu

3. 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.

4. Check the suction cups and the entire vacuum 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.
5. 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 adjustable guide should be adjusted to approxi-
mately 3 mm (1/8 inch) from the bottle. Securely lock the
knobs after making the adjustment.
Misalignment of discharge guide rails, especially the discharge

divider guide rail, will cause bottle jams if sudden downstream
backup conditions occur.
2. Verify that the deadplate discharge is set slightly higher 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 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 air pressure is set correctly.
5. Verify that the takeaway conveyor speed is set correctly. Details

follow later in this section.
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 (approxi-
mately 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 and jam in the deadplate
inspection opening.
Starwheel Drive and Line Control System Malfunction

Refer to Drawings 32383-0 and 32556-0 as applicable.
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 component failures.
NOTE
Whenever any of the doors are opened, the starwheel will stop
due to the machine's built-in safety interlock system unless
overruled by the bypass switch.
2. Check the upstream microsonic bottle Sensors No. 1 and No. 2

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 de-activate the red LED indicator. If
the sensors are functioning properly, proceed to Step #3.
a. If the sensors are not functioning, ensure that the Line

Control circuit breakers CB3 and CB5 on the base cabinet
power panel (see Figure 2-1) are on.
b. Reset the circuit breakers if necessary. If there are no

breaker problems, proceed to Step #3. If either circuit
breaker continues to trip, the LCM circuit card or power
supply may be faulty, or a short exists in the Omnivision
wiring. If it appears that a short has occurred, then follow
the procedures starting with Step #3. Any other sequence
may result in damage to the replacement units.
3. Check the starwheel drive motor in the base cabinet to verify it

is turning (Omnivision's main power switch in ON position,
Emergency Stop Button pulled out and upstream sensors
blocked):

• If the motor is turning then observe the LINE CONTROL

MODULE INPUTS AND OUTPUTS screen's SONIC 1
function, and verify that it responds to the upstream
Microsonic sensor (stops when Sensor No. 1 is unblocked).
• If the motor is not running, check the STAR DRIVE circuit

breaker, CB5, to verify it is in the ON position. If CB5
continues to trip, then either the starwheel drive motor is
shorted, the starwheel control circuits are faulty (or both
are faulty), or a short may have occurred in the wiring.
CAUTION
If it appears that a short has occurred, then follow the procedures
starting with Step #4 in order. Any other sequence may result in
damage to replacement units.
4. Set the Omnivision's main power switch to OFF. Check the

starwheel drive motor by disconnecting plug P7, from the plug
panel, and checking Pins 3 and 4 to Omnivision ground for
shorts. Use the motor mounting bracket for ground. See
Drawing 32556-0.
If the motor armature shows a short or very low resistance to

ground, replace the motor. Refer to Chapter 3 for replacement
procedures. If the motor checks good, proceed to Step #6. If the
motor is shorted, then it is important to continue with Step #5,
since the motor drive circuits may have been damaged.
5. With plug P7 disconnected, verify that the LINE CONTROL

circuit breaker CB3 is ON and the STAR DRIVE circuit breaker
CB5 is ON then set the Omnivision's main power switch to
ON.
• If the circuit breaker CB5 continues to trip, then the

starwheel motor control circuits are probably damaged and
must be checked.
• If CB3 trips, but CB5 does not, the Line Control power
control circuits are probably damaged and must be
checked.
In either case, proceed with Step #6. If the breaker does not
trip, then turn the main power switch OFF and reconnect plug
P7. Test the starwheel control system.
NOTE
STAR DRIVE motor circuit breaker CB5 tripping relates to the
LCM motor controller. LINE CONTROL circuit breaker CB3
tripping relates to LCM circuit card issues.

RCPT1 120V 5A
50/60 Hz
CIRCUIT BREAKERS
OFF ON
AIR COND
RCPT2 220V 4A CB 6
50/60 Hz 7.0 A
OFF ON
BASE CABINET
CB 1 CB 7
UTILITY
OV 1200
7.0 A 7.0 A OV D-1200
MONITOR/SERVO SYSTEM A
CB 2 CB 9
7.0 A 7.0 A
OFF ON
OSW POWER LINE CONTROL SYSTEM B
CB 13 CB 3 CB 10
Circuit Breaker Part No.
4.0 A 7.0 A 7.0 A
CB1 thru CB3 91353
OSW LAMP A REJECT CONVEYOR
(Reject Conveyor Motor)
BASE-ISW STROBE CB4 & CB5 91342
CB 14 CB 4 CB 11
7.0 A 3.0 A 7.0 A CB6 92500
OSW LAMP B
CB7 thru CB12 91353
STAR DRIVE FINISH STROBE
(Starwheel Drive Motor)
CB 15 CB 5 CB 12 CB13 91341
7.0 A 3.0 A 7.0 A
CB14 & CB15 91353
OFF ON
Notes: Circuit Breaker CB8
does not exist on OV 1200/
RCPT1 120V 5A OV D-1200 panels.
50/60 Hz Circuit Breakers CB8 and
CB10 do not exist on OV 900
CIRCUIT BREAKERS
panel.
RCPT2 220V 4A
50/60 Hz OFF ON OFF ON
BASE CABINET AIR COND
CB 1 CB 6
7.0 A 7.0 A
OV 900
MONITOR/SERVO UTILITY
CB 2 CB 7
7.0 A 7.0 A
OFF ON
OSW POWER LINE CONTROL SYSTEM A
CB 13 CB 3 CB 9
4.0 A 7.0 A 7.0 A
OSW LAMP A REJECT CONVEYOR BASE-ISW STROBE

(Reject Conveyor Motor)
CB 14 CB 4 CB 11
7.0 A 3.0 A 7.0 A
OSW LAMP B STAR DRIVE FINISH STROBE

(Starwheel Drive Motor)
CB 15 CB 5 CB 12
7.0 A 3.0 A 7.0 A
OFF ON
BCPwrPnlOV9/12
Figure 2-1. Power Panels (Inside Base Cabinet)

6. The STAR DRIVE circuit breaker CB5 tripping with the

starwheel motor disconnected indicates a problem in the LCM
motor controller. The LCM contains an LCM circuit card and
two motor controllers (Star Drive and Takeaway Drive). If a
spare LCM circuit card, or a spare starwheel motor controller is
available, then refer to Chapter 3 for replacement procedures
and Chapter 4 for alignment procedures.
NOTE
Turn the STAR DRIVE circuit breaker CB5 OFF before
proceeding with Step #7.
7. Reconnect the starwheel motor plug P7 and check the system

as follows:
a. Check that the starwheel motor is turning in the correct

direction and that the speed can be controlled by using the
LINE STATUS AND CONTROL screen and the LINE
PARAMETER SETUP screen. Set the main power switch to
ON and the Emergency Stop to RUN position (pulled out).
b. When the microsonic bottle sensors are blocked, the

SONIC1 and SONIC2 on the LINE CONTROL MODULE
INPUTS & OUTPUTS screen should be HI. When both
sensors are unblocked, SONIC1 and SONIC2 on the LINE
CONTROL MODULE INPUTS & OUTPUTS screen
should be LO.
c. If the starwheel drive motor is responding to the sensors

and the tests in #7a and #7b are satisfactory, but the
starwheel does not have sufÞcient drive power, then there
may be a problem with the Clutch/Brake system. Refer to
Chapter 3 for Clutch/Brake replacement procedures.
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 Þller, check the following:
1. Verify the Emergency Stop Switch on the front of the base

cabinet is pulled out. Check the LINE CONTROL INPUTS &
OUTPUTS screen for irregularities.
2. 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.

3. Check the infeed and outfeed bottle guides to be sure the

bottles are not binding. The bottles must pass through the
starwheel smoothly.
4. Check the starwheel drive motor in the base cabinet while the
line is running to be sure the shaft is turning. If not, refer to
Chapter 3 for replacement procedures.
5. Remove the starwheel and thoroughly clean the valve plate

and seal ring in the starwheel hub using a mild solvent. Lubri-
cation should not be applied to these two mating surfaces. If
the surfaces appear to be damaged, refer to Chapter 3 for
replacement procedures.
6. Check the clutch drive HOLDING CLUTCH setting (0-100%)

to be sure it is set properly. Refer to Chapter 4 for alignment
procedure and the Parameter Setup Sheets.
7. Check the STARWHEEL MOTOR GAIN setting on the LINE

PARAMETER SETUP screen and verify the desired SLIP
RATIO is displayed per the Parameter Setup Sheets.
Conveyor Chain Encoder Problems

Refer to Drawings 29280 or 32509 as applicable.
The conveyor chain encoder assembly is mounted on the side of

the main stub conveyor next to the starwheel drive column. It
consists of a single high resolution encoder for OV 900/1200, and
dual encoders for OV D-1200.
The production chain link pins drive a sprocket (wheel), which in

turn drives one or two pulleys. These pulleys drive the encoder(s)
using timing belts. The encoder assembly may be adjusted up or
down in a slot so the drive sprocket contacts the chain link pins
properly.
The chain link pin signal is used by the starwheel drive system to
synchronize the starwheel speed to the conveyor chain speed.
The encoder 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.
Customer Bottle Handling Problems

Refer to the Start-up and Technical Reference Manual (Form 3055) for
details on customer bottle handling issues.

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 (Beacon ON, No Message)
• Complete System Failure
Excessive False Rejects

1. Check for and correct any 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 rim
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 scufÞng
• Large molding ridges
• Prominent seams

On the Outer Sidewall:

• Heavy scufÞng
• Extreme color variations
• Large air bubbles
• Heavy embossed lettering or molding
• Prominent seams
3. Go to the SYSTEM STATUS & CONTROL screen.
SYSTEM STATUS & CONTROL

Date 26 Jun Time 10:03 BPH: 48000
Total Bottles: 410988 BPM: 800
Total Rejects: 1200 % Rej: 0.29
Good Bottles: 409788 Test RV Now
Detect Percent
Subsys Reject Status Count Detect
RLD-IR OFF 0 0.00
RLD-RF OFF 0 0.00
Fin A OFF 500 0.12
Fin B OFF 0 0.00
Bot Low Up Plg LgO
Bas ON ON ON ON 0 0.00
ISW OFF OFF OFF OFF OFF 40 0.01
Crk Imp SwG Sem
Pla OFF OFF OFF OFF 0 0.00
View 1 View 2
OSW A1 OFF OFF 80 0.02
OSW A2 OFF OFF 80 0.02
OSW B1 OFF OFF 0 0.00
OSW B2 OFF OFF 0 0.00
Beacon OFF Reject Master OFF
Previous Clear All Count Master Menu
4. Determine which inspection subsystem is causing the

excessive false rejects by observing the DETECT COUNT and
PERCENT DETECT count columns.
5. Go to the REJECT HISTORY screen to determine which

inspection zone (or region) is causing the majority of false
rejects.

REJECT HISTORY
TB FIN OSW A OSW B Consec

No. RLD BASE ISW 1 2 1 2 Occur
1 R F PULB U 00010064 26
2 R F P PULB 00030055 18
3 T LB LB 00024004 15
4 T F UL U 00023005 21
Page 1 of 1 Total Messages: 4

PgDn Clear History Previous
REJECT HISTORY screen abbreviations and their meanings

are as follows:
Column Headings
• TB for Test Bottles
• FIN for Finish Inspection
• BASE for Base Inspection
• ISW for Inner Sidewall Inspection
• OSW A for Outer Sidewall Inspection, System “A”
• OSW B for Outer Sidewall Inspection, System “B”
• CONSEC OCCUR for Consecutive Occurrence
Reject Abbreviations
• T for Test Bottle
• R for RLD
• F for Finish Inspection
• P for Plugged Neck Inspection Area
• U for Upper Zone Inspection Area (Base/ISW)
• L for Lower Zone Inspection Area (Base/ISW)
• B for Bottom Zone Inspection Area (Base/ISW)
6. Select the suspect inspection system for viewing using the

DISPLAY CONTROL screen.

DISPLAY CONTROL
Display Mode Video Source
Disp Camera on Monitor Display OSWA1
Display Off
Display Fin
Display Each Bottle Display Base
Freeze/Hld Next Bottle Display ISW
Freeze/Hld Each Reject Display OSWA1
Freeze/Hld Next Reject Display OSWA2
Freeze/Hld Each Detect Display OSWB1
Freeze/Hld Next Detect Display OSWB2
Freeze On Each Bottle Clear

Freeze Timeout is Off Timeout 15 sec
Master Menu
> (BOTTLE NAME OR MESSAGE A
7. Use the FREEZE/HOLD NEXT REJECT function (the circle-

shaped button on the touchpad) to hold the image of the reject
bottle on the inspection monitor, and compare the frozen image
with the rejected bottle to determine whether the bottle should
have been rejected.
8. Once the responsible inspection subsystems/zones have been

identiÞed, refer to the following sections for detailed trouble-
shooting procedures as applicable.
Base Inspection Excessive False Rejects

1. If production operation allows turning the Omnivision rejector
OFF, do so by going to the SYSTEM STATUS & CONTROL
screen and turning OFF the REJECT MASTER function.
2. If it is not possible to turn the main rejector OFF, then turn OFF
the REJECT STATUS of the individual regions which appear
to be a problem.
3. From the MAINTENANCE screen go to the BASE STATUS

AND SENSITIVITY screen and verify the REJECT STATUS is
OFF for any suspect zones (or regions). Selection of the BASE
STATUS AND SENSITIVITY screen automatically causes the
monitor to display the Base camera image.

BASE STATUS AND SENSITIVITY

Reject Reset Period
Status Totals Totals
Total Bottles NNNNNN 405050
Good Bottles 403850
Base Detects NNNNNN 512
Plastic Detects NNNNNN
Bottom Zone On NNNNNN 300
Lower Rim On NNNNNN 450
Upper Rim On NNNNNN 0
Plugged/CS Off NNNNNN 0
Stress Crk Off NNNNNN 0
Impact Scr Off NNNNNN 0
Swing Gate Off NNNNNN 0
Semi-Trans Off NNNNNN 0
Sens. Pt Cnt Last Det
Bottom 150 0 G 0 G
Lower Rim 150 0 G 18 G
Upper Rim 150 0 G 20 G
Plugged/CS Limit Current Last Det
Upper 255 Lt Level Lt Level
Lower 0 170 G 175 G
Reset Base Counters Previous
4. Press the diamond-shaped button on the touchpad--this makes

it possible to view images of the Base as new bottles pass
through the system.
5. Verity the inspection zones are concentric with the bottle

bottom image. If they are not, go to the BASE CAMERA
SETUP screen and adjust the X and Y settings as required, and
then return to the BASE STATUS AND SENSITIVITY screen.
6. Use the circle-shaped button on the touchpad 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 SENS (sensitivity) 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 255 and lowest is 1.
9. Observe the PT COUNT (Point Count) and the LAST DET

(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 SENS is too high, then the PT COUNT
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 SENS 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 PT COUNT 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 SYSTEM STATUS AND
CONTROL 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 UPDATE STORAGE screen.
PLUGGED NECK/COLOR SORT EXCESSIVE FALSE REJECTS
If the CURRENT LT LEVEL (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 25. The LIGHT
LEVEL values of the rejected bottles will be held under the
heading LAST DET LT LEVEL (Last Detect Light Level). Normal
bottles should have LIGHT LEVEL readings ranging from 75 to
200.
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 25, then the
problem should not be corrected with sensitivity adjustment.
Such a condition indicates that insufÞcient light is reaching the
camera's sensor. If this happens, go to the BASE CAMERA
SETUP screen and take corrective measures.
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 ßint bottles. When running ßint bottles, the system
detects any intermixed amber bottles. Color Sort uses the same
information and the same adjustment as is used in the Plugged
Neck detection.

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 BASE CAMERA SETUP screen) must be adjusted Þrst.
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 setting the UPPER LIMIT value to 256 (maximum).
Inner Sidewall Inspection Excessive False Rejects

OFF, do so using the SYSTEM STATUS & CONTROL screen
and turning OFF the REJECTOR MASTER function.
2. If it is not possible to turn the main rejector OFF, turn OFF the
REJECT STATUS of the individual regions which appear to be
a problem.
3. From the MAINTENANCE screen go to the INNER

SIDEWALL STATUS AND SENSITIVITY screen. Selection of
the INNER SIDEWALL STATUS AND SENSITIVITY screen
automatically displays the Inner Sidewall camera image on the
monitor.

INNER SIDEWALL STATUS AND SENSITIVITY

Reject Reset Period
Total Bottles 433650 410460
Good Bottles 432150 409260
ISW Detects 500 350
Bottom Zone On 420 260
Lower Sw On 560 320
Upper Sw On 70 10
Plugged/CS On 40 20
Large Object On 0 0
Current Last
Point Detect
Sens. Count Pt Cnt
Bottom 150 0 G 19 G
Lower Sw 150 0 G 0 G
Upper Sw 150 0 G 0 G
Plugged/CS Limit Current Last Det
Upper 250 Lt Level Lt Level
Lower 20 180 G 175 G
Reset ISW Counters Previous
4. Press the diamond-shaped button on the touchpad to view

images of the Inner Sidewall inspection as new bottles pass
through the system.
5. Verify the inspection zones are concentric with the bottle

bottom image. If they are not, go to the INNER SIDEWALL
CAMERA SETUP screen and adjust the X and Y settings as
required, and then return to the ISW STATUS AND SENSI-
TIVITY screen.
6. Use the circle-shaped button to "freeze" the rejected bottles and

examine their images.
7. 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.
8. Observe the SENS (sensitivity) 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 255 and lowest is 1.
9. Observe the CURRENT POINT COUNT and the LAST

DETECT PT CNT (PT CNT means Point Count) 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 SENS is
too high, then the CURRENT POINT COUNT will be greater
than zero even for bottles which have no real object.

10. If a bottle is falsely rejected and the LAST DETECT PT CNT is

between 1 and approximately 30, then the SENS should be
lowered by 25 points. Clear the counters using the RESET ISW
COUNTERS function, then allow about 1,000 bottles to pass
through the system. If the LAST DETECT PT CNT 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 detect rate. Repeat this process until the
false reject rate is acceptable.
REJECT STATUS functions on the SYSTEM STATUS AND
CONTROL screen are set to ON, and that the main rejector is
turned on.

PLUGGED NECK/COLOR SORT EXCESSIVE FALSE REJECTS
If the CURRENT LT LEVEL (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 50. The LIGHT
LEVEL values of the rejected bottles will be held under the
heading LAST DET LT LEVEL (Last Detect Light Level). Normal
bottles should have Light Level readings ranging from 75 to 255.
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 25, then the
problem should not be corrected with sensitivity adjustment.
Such a condition indicates that insufÞcient light is reaching the
camera's sensor. If this happens, go to the INNER SIDEWALL
CAMERA SETUP screen and take corrective measures.
The "backup" Color Sort detects bottles which are extremely

dark with respect to the bottle type being run. For example,
when running ßint bottles, the system detects dark amber
bottles. Color Sort uses the same information and the same
adjustment as is used in the Plugged Neck detection.
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 INNER SIDEWALL CAMERA SETUP screen) must be
adjusted Þrst.
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. For most bottle types the "backup" Color Sort is not speciÞed to
detect bottles which are much lighter in color than the selected
bottle type. Unless the bottle type being run is an exception to
this rule, disable "backup" Color Sort by setting the UPPER
LIMIT to 256 (maximum).
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 RLD STATUS AND SENSITIVITY screen to disable

IR RLD rejects by turning OFF the IR DETECTS REJECT
STATUS function.
RLD STATUS AND SENSITIVITY

Reject Reset Period
Good Bottles 425000 405050
IR Detects OFF 40 20
RF Detects OFF 30 10
Last
Current Average Detect
Level Level Level
IR RLD Sensor 600 500 0
IR Detect Threshold 30 Gain 20
IR Camera Brightness 20 Zoom 68
RF Trigger Delay XX enc Width 40 enc
RF Reject Delay XX bot
Reset RLD Counters Previous


2. Look at the values for the IR RLD SENSOR under the heading
CURRENT LEVEL--they should range from approximately
100 to approximately 900. The value under the heading
AVERAGE LEVEL will normally be in the range from 200 to
600.
3. If the CURRENT LEVEL or AVERAGE LEVEL values are out

of the range cited in Step #2, or if the CURRENT LEVEL 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 zoom and
aperture calibration procedures should be checked.
4. If the readings are within range, then the IR DETECT

THRESHOLD may need to be lowered. When the IR RLD
CURRENT LEVEL value is less than the IR DETECT
THRESHOLD value, the bottle is detected. Therefore, a higher
IR DETECT THRESHOLD setting makes the system more
sensitive, a lower setting makes it less sensitive (typical range
is 20 to 100).
5. If a bottle is falsely rejected by the IR RLD detector, write down

the IR RLD SENSOR LAST DETECT LEVEL value. If this
value is greater than 20, lower the IR DETECT THRESHOLD
so that it is Þve points less than the IR RLD SENSOR LAST
DETECT LEVEL value. If the IR RLD SENSOR LAST
DETECT LEVEL value is less than 20, then the problem is not
over-sensitivity. If this is the case, check the IR RLD zoom and
aperture calibration procedures (refer to Form 3055).
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. Record the sensitivity control potentiometer reading located on

the RF RLD electronics panel. Unlock and decrease the sensi-
tivity setting as required until an acceptable false reject rate is
obtained. This is veriÞed by the LED bank displaying "green"
continuously. Lock the sensitivity control pot to preserve the
setting.

2. If excessive false rejects persists after adjusting the sensitivity

control pot, the problem is not over-sensitivity. If this is the
case, return the sensitivity setting to its original value, lock the
pot and check the RF RLD setup procedure in Start-up and
Technical Reference Manual (Form 3055).
Finish Inspection Excessive False Rejects

off, then do so by going to the SYSTEM STATUS &
CONTROL screen and turning the REJECT MASTER function
to OFF.
2. Go to the FINISH STATUS AND SENSITIVITY screen.

Selection of the FINISH STATUS screen automatically
displays the Finish camera image on the inspection display
monitor.
FINISH STATUS AND SENSITIVITY

Finish Reject Status OFF
Reset Period
Totals Totals
Good Bottles 404940
Finish Detects 0 110
Detect Last Insp Total

Alg Threshold Results Detects
A (A6) 45 Good 0
B (B3) 45 Good 0
C (C1) 10 Good 0
D (D1) 15 Good 0
G (G1) 120 Good 0
Reset Finish Counters Previous

3. Press the diamond-shaped button on the touchpad--this makes

it possible to view the Finish image as new bottles pass
through the system.
4. The Finish image should be centered within the two dotted

circles (or inspection ring). This can be veriÞed by accessing the
FINISH SETUP screen and observing the X POSITION and
Y POSITION values. The AUTO TRACKING function should
be set to ON.
The STATUS for Algorithm D should be set to off since this

Algorithm is not functional at the present time.

FINISH SETUP
X Position 112 Y Position 107
Zoom 58 Brightness 22
Video Black Level Offset -100
Graphics Mode Trk A, Reject Sector
Camera Alignment Display Off
Status 1 2 3 4 5 6 7
Alg A On 6 4 12 32 90 45 5
Alg B On 15 10 45 32 3 6 4
Alg C On 10 3 4 5 4
Alg D Off 10 3 6 48
Alg G On 120
Auto Tracking On Modified AlgC Off
Slow Centering On
Fast Centering Full Search Radius 4
Fit Threshold 20 Centering Fit 60
Lt Compensation On Avg Intensity 50
Blk Level Clip% 60
Test Trigger On Fire Period 12
Menu
5. The Finish image should be checked for the correct size - two to
three pixels inside the outside edge of the doughnut (there are
sixteen pixels across the radial dimension on the doughnut). If
the image size is not correct, adjust the ZOOM on the FINISH
SETUP screen as necessary.
6. Use the circle-shaped button on the touchpad to "freeze" the

rejected bottles and examine their images.
7. Go back to the FINISH STATUS AND SENSITIVITY screen.

Check the TOTAL DETECTS column for algorithms A, B, C,
and G Detects. Observe which algorithm causes the excessive
false rejects. Adjust the respective DETECT THRESHOLD
value as desired. Typical DETECT THRESHOLD settings for
these algorithms should be:
Normal
Nominal
Algorithm Production
Range
Setting
A6 (A) 40 - 60 45
B3 (B) 40 - 60 45
C1 (C) 5 - 25 10
G1 (G) 100 - 200 120

NOTE
Increasing the value of A6, B3, or G1 decreases the sensitivity for
that algorithm, while decreasing the value of C1 will decrease its
sensitivity, thus reducing false rejects.
8. 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 G
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.
10. 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.
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 that the OSW system is responsible for false rejects.
b. Identify which System (OSW A or OSW B) is responsible

for the false rejects.
c. Identify which Camera (“1” or “2”) is responsible for the

false rejects.
d. Identify which View ("1" or "2") is responsible for the false

rejects.
e. Identify which Window is responsible for the false rejects.
f. If necessary, correct the responsible Window's position. If

window position is not causing false rejects, proceed to
Step “g”.
g. If necessary, correct the responsible Window's size. If

window size is not causing false rejects, proceed to
Step “h”.

h. If necessary, make adjustments to the responsible

Window's sensitivity settings. If window sensitivity is not
causing false rejects, proceed to Step “i”.
i. If the above steps do not take care of the excessive false

rejects problem, contact IDC for further technical
assistance.
NOTE
Do not change the OSW inspection window parameters PAR1
through PAR6. Analyzing which parameters to use requires
factory training and only authorized personnel should change
parameters selections.
To perform the above-mentioned general troubleshooting method,

proceed as follows:

OFF, do so using the SYSTEM STATUS & CONTROL screen
and selecting the REJECTOR MASTER function.
2. If it is not possible to turn the main rejector OFF as described

above, turn OFF the REJECT STATUS of the individual OSW
Camera/View which appears to be a problem.
3. From the MAINTENANCE screen go to the responsible

camera’s OUTER SIDEWALL STATUS AND SENSITIVITY
screen. Selecting the OUTER SIDEWALL STATUS AND
SENSITIVITY screen automatically displays the OSW camera
image on the monitor.
OUTER SIDEWALL STATUS AND SENSITIVITY

Reject Reset Period
Camera A1 Status Totals Totals
Total Bottles 0 0
Good Bottles 0 0
OSW Detects 0 0
View 1 Det. On 0 0
View 2 Det. Off 0 0
View 1 Current Last Window
Reject Point Detect Detect
Win Stat Sens Count Pt Cnt Count
1 On 80 0 G 0 G 0
2 On 80 0 G 0 G 0
3 On 80 0 G 0 G 0
4 On 80 0 G 0 G 0
5 On 80 0 G 0 G 0
6 On 80 0 G 0 G 0
7 Off 80 0 G 0 G 0
8 Off 80 0 G 0 G 0
9 Off 80 0 G 0 G 0
10 Off 80 0 G 0 G 0
PgDn Diffuser Spots On Reset
Reset OSW Counters Previous

OUTER SIDEWALL STATUS AND SENSITIVITY

Reject Reset Period
Camera A1 Status Totals Totals
Total Bottles 0 0
Good Bottles 0
OSW Detects 0 0
View 1 Det. On 0 0
View 2 Det. Off 0 0
View 1 Current Last Window
Reject Point Detect Detect
Win Stat Sens Count Pt Cnt Count
11 Off 80 0 G 0 G 0
12 Off 80 0 G 0 G 0
13 Off 80 0 G 0 G 0
14 Off 80 0 G 0 G 0
15 Off 80 0 G 0 G 0
PgUp Diffuser Spots Off Reset

Reset OSW Counters Previous
4. Use the [A/B] button to verify which System ("A" or "B") the
excessive false rejects are occurring on. Stay with the respon-
sible system for the rest of this procedure.
5. Identify the responsible View for the excessive false rejects by

observing which View has a corresponding high number of
PERIOD TOTALS.
6. Determine which Window is responsible for false rejects:
a. Look at the WINDOW DETECT COUNT column to locate

the responsible Window (or Windows). You may need to
use the PGDN (Page Down) function to access screen #2
which covers Windows #11 through #15.
b. Turn OFF the REJECT STAT (Reject Status) of the

individual Windows which appear to be the source of the
problem.
7. Press the touchpad's circle-shaped button to "freeze" the

rejected bottles and examine their images. Observe that the
frozen OSW reject bottle image has small red dots marking the
places within a Window where it located the objects. These
dots are called detection points.
8. Go to the OUTER SIDEWALL WINDOW SETUP screen.

Change the WINDOW NUMBER to the suspected Window's
number you determined as the source of the problem in
Step #6.

OUTER SIDEWALL WINDOW SETUP

OSW Camera A1 Average Light 0
Current View 1 Detect Level 0
Window Number 1 Last Detect 0
--------------------------------------
Window Parameters Window Enables
X1= 0 PAR1= 107 Inspection On
Y1= 190 PAR2= 100 Reject Stat On
HI= 30 PAR3= 15 Outline Stat On
WT= 18 PAR4= 20 Spot Mask Off
WB= 30 PAR5= 5 Scuff Mode Off
PAR6= 100
Menu
9. Set the window OUTLINE STATUS function to ON. The

selected window will have its dotted outline displayed. Watch
the window display on the monitor while performing the
following steps.
10. Verify the window's dotted outline is still properly positioned.

If it is not, perform Step #11. If is correctly positioned, skip Step
#11 and proceed to Step #12. If the window is both sized and
positioned correctly, skip Steps #11 and #12 and proceed to
Step #13.
11. If the window is incorrectly positioned, use functions X1 and

Y1 as required.
12. If the window's dotted outline display is improperly sized, use

functions HI (Height), WT (Width Top) and WB (Width
Bottom) as required.
13. If correcting a window's size and/or its position does not Þx an

excessive false reject problem, then try making very minor
adjustments to the window's detection sensitivity level by
going back to the OUTER SIDEWALL STATUS AND SENSI-
TIVITY screen.
14. If false rejects are caused by the SENS (Sensitivity) being set
too high, decrease the SENS setting by a few points at a time
until the excessive false reject problem is taken care of.

15. If checking and changing any parameters for the window's

size, location, and sensitivity levels does not take care of a false
reject problem, contact IDC for further technical assistance.
NOTE
Do not adjust parameters PAR1 through PAR6. Adjustment of
these parameters requires factory authorized training.
16. 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.
desired inspection subsystems have their REJECT STATUS
functions set to ON.

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 the Emergency Stop Switch

located on the front 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 ßaws causing the
rejections.
4. On the SYSTEM STATUS AND CONTROL screen, turn off

the REJECT MASTER function. (If you have both "A" and "B"
systems, use the [A/B] touchpad button to switch between
systems and turn off the REJECT MASTER function for both
systems.)

5. 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
6. Based on the information from Step #5, look for possible causes
and solutions as follows:
CAUSE CHECK SOLUTION
The vacuum system has The vacuum warning gauge Ensure that circuit breaker CB1 is
failed or low vacuum will be out of tolerance and/ on, the vacuum pump is
(less than 127 mm [5 or a red error message will be operational, the pump mufßer
inches Hg]). displayed on the monitor. and Þll jar are in place, and that
the vacuum gauge reading is
within speciÞcation. (Check
external vacuum system if so
equipped.)
The reject solenoid Unplugging the connector to Replace the reject solenoid valve.
valve is stuck on. the solenoid valve has no
effect.
The LCM Card has LCM (+48 VDC) voltage Replace the LCM Card.
failed in an "always on" always present across the
condition. reject valve.
A trigger block (trigger For Finish Inspection, the Readjust the Finish trigger block
sensor) has somehow light image ring (as seen on per the Trigger Alignment
been misaligned, the inspection display procedure.
causing an off-center monitor) will have less light
bottle image. intensity on one quadrant of
the displayed image.
For Base, and Inner Sidewall, Readjust the Base trigger block
the bottle image will appear per the Trigger Alignment
(on the monitor) optically procedure.
restricted (or cut off) on one
side.

The camera lens The inspection display Verify the servo controller for that
aperture servo and monitor display for one or camera is operating properly.
zoom servo position more of the zones will show Recalibrate as required.
have lost calibration or up as all dark, all white, or
are not functioning, will have an unusually small
causing an image which or unusually large bottle
is too bright, too dark, image.
or has the wrong zoom
setting.
Foreign object on Check optical inspection Clean the windows.
inspection system windows at the bottom of the
optics. Inspection Head Base plate.
Check the OSW optical
windows inside the tunnel.
One or more inspection On the SYSTEM STATUS & 1. If possible, turn OFF the
zones are too sensitive. CONTROL screen, the REJECT STATUS for any
DETECT COUNT for one or inspection system which has
more inspection systems will produced excessive rejects (if
have a high count. applicable, do this for both
the "A" and the "B" systems).
2. Clear the counters using the

CLEAR ALL CNT function
(on the "A" system).
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 over-
sensitivity. If no bottles are
rejected (this is what should
happen), turn the REJECT
STATUS back ON and allow
bottles to pass through the
system.
4. Use the guidelines given in

the following sections for
adjusting the inspection
sensitivities.

Rejecting No Bottles
1. Check for and correct any maintenance-related or bottle
2. On SYSTEM STATUS & CONTROL screen, verify that each

inspection subsystem's REJECT STATUS function is ON.
3. Verify that the following functions on the applicable STATUS

AND SENSITIVITY screens are ON:
Omnivision Screen Title Function
RLD STATUS AND SENSITIVITY IR DETECTS REJECT STATUS

RF DETECTS REJECT STATUS
FINISH STATUS AND SENSITIVITY FINISH REJECT STATUS
BASE STATUS AND SENSITIVITY BOTTOM ZONE REJECT STATUS
LOWER RIM REJECT STATUS
UPPER RIM REJECT STATUS
PLUGGED/CS REJECT STATUS
INNER SIDEWALL STATUS AND SENSITIVITY BOTTOM ZONE REJECT STATUS
LOWER SW REJECT STATUS
UPPER SW REJECT STATUS
PLUGGED/CS REJECT STATUS
LARGE OBJECT REJECT STATUS
OUTER SIDEWALL STATUS AND SENSITIVITY VIEW 1 DET. REJECT STATUS
VIEW 2 DET. REJECT STATUS
WINDOW REJECT STATUS (for
applicable windows)
4. Verify that the system is being triggered for inspection by

noting whether the PERIOD TOTALS counter (on any of the
STATUS AND SENSITIVITY screens listed in Step #3)
operates--when the starwheel is rotated, the bottle count
should increment accordingly.
If the bottle counter is not counting, then the problem is not

speciÞcally due to the rejector or the sensitivity of the
inspection zones. It is possible that the pin trigger sensor
(located underneath the Inspection Head) has been
contaminated and cannot "see" the pins, or that the Inspection
Head has not been put into the correct position, so the pins are
not breaking the sensor's beam. Correct the above problems if
necessary.

5. If the problem is not resolved after trying Steps #1 through #4,

use the following table to look for possible causes and
solutions.
The pressure has failed. The pressure gauge will be Ensure that circuit breaker CB1 is
out of tolerance and/or an on, the external pressure line has
error message will be pressure and is connected, and
displayed on the color the pressure gauge reading is
monitor. Also, pressing the within speciÞcation.
actuation button on the
pressure gauge itself will
release no pressure (this test
must be done when the
starwheel's "Head 1" indicator
marks are aligned).
Encoder has failed. No encoder pulses as Bad encoder, power or wiring.
starwheel turns. Repair as required.
The rejector setup has On the REJECTOR SETUP 1. Go to the SELECT BOTTLE
been misadjusted. screen, the STARWHEEL TYPE screen to verify the
POCKETS, BASE/ISW/IR current bottle type
RLD REJECT DELAY, parameters.
SECONDARY RLD (RF
RLD) REJECT DELAY, 2. Go to the REJECTOR SETUP
FINISH REJECT DELAY, or screen.
the OUTER SIDEWALL
REJECT DELAY parameters 3. Verify all settings.
are incorrect.
Make sure the value entered
for STARWHEEL POCKETS
matches the actual number of
pockets on the starwheel
currently in use.
Inspection parameters Consult your authorized IDC
are incorrect. ALL the Representative for assistance.
inspection regions are
so insensitive that even
bottles with gross
bottom or Þnish defects,
or bottles with over
20 ml of water appear to
be good.

Rejected Bottles Not Stable On The Takeaway Conveyor

This problem is more critical on the OV D-1200 running at high
speeds (generally greater than 1000 bpm). 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. Look for possible causes and solutions as follows:
Reject Delay Check the Delay settings on the 1. Adjust the settings as
parameters not set REJECTOR SETUP screen. required.
properly. Verify the settings as follows:
2. For SECONDARY RLD (RF
MAIN REJECTOR = 0 ± 5 enc RLD) and OSW stations, the
BASE/ISW/IR RLD = 179 ± 5 enc number of bottles between
FINISH = 55 ± 5 enc each of these stations and the
BASE/ISW trigger
centerline should match the
respective numbers on the
screen. If not, adjust the
numbers accordingly.
Reject takeaway Check the TAKEAWAY MOTOR 1. If the rejected bottles tend to
chain speed not set GAIN on the LINE tip forward (on the takeaway
properly. PARAMETER SETUP screen. chain), then increase the
TAKEAWAY MOTOR
GAIN as necessary.
2. If the rejected bottles tend to

tip backward, then decrease
the TAKEAWAY MOTOR
GAIN as necessary.
The above adjustments

should result in the speed of
the takeaway chain being
equal to or slightly less than
the starwheel speed.

Too much upstream Check the SLIP RATIO and the 1. Verify the SLIP RATIO is
line pressure against starwheel HOLDING CLUTCH less than 10% (typically 5%
the starwheel - may (torque) on the LINE to 10%). If not, adjust the
cause sudden PARAMETER SETUP screen. STARWHEEL MOTOR
starwheel speed OFFSET and STARWHEEL
change when a MOTOR GAIN as required.
bottle is being
rejected. 2. Verify the HOLDING
CLUTCH is set between 35%
and 45%.
Reject blow-off Check the air pressure regulator Verify the pressure is set to
pressure too low. inside the base cabinet. between 276 and 414 kPa (40 and
60 psig).
Low starwheel Check vacuum gauge reading If the gauge reads less than 560
vacuum supply - inside the base cabinet. The mm (22 inches) of Hg, check
causing bottles to be vacuum system (internal or other items such as suction cups
released early or external), under normal and piping for leaks (explained
other bottles to be operation must maintain 560 to in the following sections) and
rejected when 660 mm (22 to 26 inches) of Hg refer to periodic maintenance
normal rejection while the starwheel is fully procedures as required.
occurs, i.e., ‘Drop off’ primed with bottles.
bottles.
Damaged starwheel Check suction cups for any Replace as necessary.
suction cups - damage, i.e., grossly worn out
causing reduced and split cup bellows or lips.
blow-off force as
well as less vacuum
holding force.
Starwheel suction Check the suction tube lengths. Replace the faulty suction
tube length is out of Correct length should allow tube(s) as necessary.
tolerance. about 5 mm (3/16 inch) of
bellows cup distance (or
compression of lips) with bottle
seated in the lower starwheel
pocket.
Starwheel top plate Check alignment of starwheel top Realign the starwheel height as
vertically plate against the bottle Þnish. The required.
misaligned with top plate should normally be just
respect to bottle below the Þnish (secondary)
Þnish. reinforcement ring for proper
bottle ‘pickup’ and ‘lockup’ in the
starwheel.

Reject conveyor Check the positioning of the Readjust the reject conveyor
chain height reject conveyor chain in relation chain as required.
misaligned. 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
(assuming a stainless steel reject
chain and standard conveyor
soap lubrication).
Downstream outside Check the reject bottle travel path Readjust the outside reject guide
reject guide rail against the outside reject guide rail so it is located
misaligned. rail. The rejected bottle should approximately 10 to 13 mm (3/8
not strike the outside rail during to 1/2 inch) behind the outside
bottle transfer. edge of the reject takeaway chain
(assuming a 3 1/4 inch chain
width).
Downstream divider The downstream divider guide Reposition the guide rail as
guide rail not rail should be positioned so it necessary.
positioned properly ‘locks up’ bottles with the
- causing interference starwheel to prevent the ‘free’
with the path of bottle in the starwheel pocket
rejected bottles. from being affected by the
downstream back pressure (line
jams).
Deadplate not Check bottle travel over the Realign the deadplate as
aligned properly. deadplate. Bottles must not required.
contact the deadplate until just
prior to bottles entering the
production chain.
Worn out starwheel Check and verify the valve plate Replace valve plate/seal ring if
valve plate/seal ring. is the special hard coated type necessary.
and is not badly worn out.
Restriction in Check the four hoses going from Replace hoses if necessary.
starwheel valve the valve plate to reject valve and
plate hoses. 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 Þttings which
may result in the hose wall
collapsing.

Contaminated reject Check the 3-way Mac type reject Replace the reject valve if
valve. valve. It should be positioned as contaminated.
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.
Passing Faulty Bottles (Missed Rejects Or False Accepts)

2. Check the SYSTEM DIAGNOSTICS and the DIAGNOSTIC

MESSAGE HISTORY screens. Look for possible causes and
solutions as follows:
Base Trigger Dirt or blockage. Clean lenses.

Trigger signal missing. Replace Trigger Block.
Finish Trigger Dirt or blockage. Clean lenses.
Trigger signal missing. Replace Trigger Block.
Base Strobe not ßashing Strobe light faulty. Replace strobe light.
Strobe power supply. Replace power supply.
Finish Strobe not Strobe light faulty. Replace strobe light.
ßashing
Strobe power supply. Replace power supply.
Sensitivity settings Go to affected inspection Readjust as necessary.
system's SENSITIVITY AND
STATUS screen.

Faulty Bottles Detected But Not Rejected

2. Check SYSTEM DIAGNOSTICS and DIAGNOSTIC

MESSAGE HISTORY screens. Look for possible causes and
solutions as follows:
Rejector Parameters Check settings on REJECTOR Turn ON the REJECT MASTER

SETUP screen. function. Adjust parameters if
necessary.
Check REJECT STATUS for Turn ON as necessary.
each inspection system
Rejector Air pressure. Set to 310 - 414 kPa (45 - 60 psig).
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.
The LCM Card has LCM (+48 VDC) voltage Replace the LCM Card.
failed in an "always off" present across the rejector
condition valve.
Reject Signal Check reject signal ßow. Replace faulty components/
parts.
Wiring. Repair loose or broken wiring.
Bottle Handling Check bottle handling at Replace/adjust parts as
reject point. necessary.
Encoder Turn starwheel and check Replace encoder or associated
operation on SYSTEM parts. Repair wiring if necessary.
DIAGNOSTICS screen.

Rejecting Incorrect Bottles

Check SYSTEM DIAGNOSTICS and DIAGNOSTIC MESSAGE
HISTORY screen. Look for possible causes and solutions as
follows:
Encoder Check by turning starwheel Replace encoder or associated

and watching SYSTEM parts.
DIAGNOSTICS screen.
Reject Timing or Consult your authorized IDC
Parameters Representative for assistance.
System Faults (Beacon On, No Message)

First, depress the system reset switch located at bottom left corner
of Upper Cabinet. If the fault does not clear, check the SYSTEM
DIAGNOSTICS and DIAGNOSTIC MESSAGE HISTORY
screens for indications of a fault condition. Look for suggested
causes and solutions as follows:
Incoming AC Power Check AC power distribution. Verify power on Terminal Block

TB1 in Base Cabinet.
Chassis "A" and "B" Check conÞguration and Replace faulty card with spare.
Cards operation.
Complete System Failure

If the whole system fails, look for possible causes and solutions as
follows:
Incoming AC Power Check Branch Circuit Repair/replace as necessary.

Breakers, fuses, etc.
Check Omnivision AC Repair/replace as necessary.
switches and circuit breakers.
Base Cabinet power Replace parts as necessary.
distribution.
System Wiring Check for loose connections, Repair as necessary.
etc.


Chapter 3: Repair & Replacement Procedures
Chapter 3:
Repair and Replacement Procedures
Contents
Topic Page
Repair and Replacement Procedures Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Guidelines for Repair or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Emergency Repair and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Microsonic Bottle Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wiring the Microswitch Sensor Into the System. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Starwheel Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Broken Diffuser Glass Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Base Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Clutch-Brake Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Starwheel Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Vacuum Oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Starwheel Seal Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Takeaway Conveyor Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Microsonic Bottle Sensor Receiver and Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Air jet blow-off nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Dead Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Rotating Diffuser/Clear Glass Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Reject Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Base Inspection Strobe Lamp Power Supply Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Base Inspection Dual Strobe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Inspection Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Finish Inspection Dual Strobe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Inspection Trigger Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Touchpads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Video Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Air Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Outer Sidewall Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Replacing OSW Fluorescent Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22


Chapter 3: Repair &Replacement Procedures
REPAIR AND REPLACEMENT PROCEDURES

OVERVIEW
These procedures outline the step-by-step instructions for
repairing or replacing Omnivision components. Read the complete
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 Þeld-
repairing any electronics cards and modules. Any attempt by
customers to Þeld-repair electronics cards and modules may void
the Omnivision's warranty provisions. Consult IDC Customer
Service for any questions about repairs and warranty.
WARNING
Turn off all electrical power before repairing or replacing any
Omnivision components. Failure to do so may result in electrical
shock causing SERIOUS BODILY INJURY or DEATH, and
damage to the machine.
GUIDELINES FOR REPAIR OR REPLACEMENT

Observe the following general guidelines before repairing or
replacing any Omnivision components:
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 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 cards and modules in a safe, dry

place.
7. Do not place the starwheel assembly upside down as damage

to the trigger pins can occur.

EMERGENCY REPAIR AND REPLACEMENT

PROCEDURES
Microsonic Bottle Sensor Assembly

If an upstream bottle sensor must be replaced, but there is no
immediately available replacement assembly, a temporary
replacement switch my be used. For example, a single pole
microswitch (see Figure 3-1) may be used temporarily in place of
the Microsonic bottle sensor to control the starwheel system.
Refer to Drawings 35750-0 as required.
NOTE
Any lever-actuated single pole switch which will respond to the
presence or absence of a bottle on the conveyor may be used.
NOTE
The following procedure will only perform satisfactorily on
slow production lines (up to 350 bottles per minute) with
sufÞcient back pressure to maintain bottle stability through the
Sensor switch. REPLACE THE DEFECTIVE MICROSONIC
BOTTLE SENSOR AS SOON AS POSSIBLE.
CAUTION
Microswitch sensor use is for emergencies only.
Wiring The Microswitch Sensor Into The System

1. Set main power switch to OFF.
2. Remove the cover from the conduit Tee, on the Microsonic

bottle sensor assembly, where the cable from the base cabinet is
connected (see Drawing 35750-0).
3. Disconnect the wire nuts from the white, black, red and the
shield. Loosen the squeeze connector and remove the cable that
runs to the base cabinet from the Tee Þtting. Cut the bare wires
from the red lead and apply tape or a wire nut. (This wire is
+15 volts DC.) Replace cover on Tee Þtting.
4. Connect the white and black wires to the microswitch sensor as

shown in Figure 3-1. Any lever actuated single pole switch
which responds to the presence or absence of a bottle on the
conveyor may be used.

NOTE
Connect white and black leads to microswitch as shown so
starwheel will run when sensor arm is actuated. Insulate RED
wire so it cannot short to ground.
1 5
2 No. Description
OMNIVISION 1 Production Conveyor

Microsw
2 Upstream Bottle Sensor
3 3 Upstream Bottle Sensor
4 6 4 Microswitch Sensor
7 5 Bottle Sensing Arm
6 Cable to OV Base Cabinet
5 7 Omnivision Base Cabinet
8 Shield
9 Red Lead - Insulate using
NC
4 tape or a wire nut
C 10 Black Lead
11 White Lead
NO
11 6 C Common
10 NC Normally Closed
NO Normally Open
9
8
Figure 3-1. Microswitch Sensor Installation
Starwheel Drive System

If any portion of the starwheel drive system fails, such as the
motor, couplings, clutch, etc., rendering the system inoperative,
the starwheel may be disconnected from the drive shaft and
function as a freewheeling unit. This allows the Omnivision to
operate in many production lines where there is sufÞcient bottle
pressure to drive a freewheeling starwheel.
To disconnect the starwheel refer to Figure 3-2 and Drawing 29034

or 33262 as applicable, and proceed as follows:
1. Loosen the set screw in the lower half of the ßex coupling
between brake/clutch and starwheel spindle shaft. Pull this
lower portion of coupling down towards the brake/clutch
assembly until it disengages from starwheel drive shaft
(starwheel shaft turns freely). Do not disturb the upper half of
coupling on starwheel shaft or encoder pulley.

1 2 3
10
9
No. Description
4 1 Encoder Pulley
2 Encoder Drive
Pulley
5 3 Timing Belt
4 Upper Flex
8 6 Coupling
5 Clutch/Brake
6 Lower Flex
OV D-1200 Coupling
7 Motor Mounting
Bracket
8 Drive Motor
(Gear Head)
7 9 Encoder
StarDrive
10 Clutch Bracket
1 2
3
10
9 4
8 6
OV 900/1200
Figure 3-2. Starwheel Drive System

2. Check bottle guide assemblies, guide belts, deadplate and

rejection system alignment to minimize bottle friction as much
as possible.
3. To re-engage the starwheel drive, push the lower half of

coupling back into position to properly engage top portion and
tighten set screw.
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 and is still intact, then refer to
Drawing 31068 (Detail “B”) and proceed as follows:
NOTE
This is a short-term procedure that usually allows you enough
time to obtain a spare diffuser glass disk without shutting the
production line down for an extended period of time. Replace
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 connector P17 from the drive motor to 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.
4. Realign the inspection trigger assembly (see Chapter 4 for

procedure).
BASE CABINET
Clutch-Brake Unit
To replace the clutch-brake unit refer to Drawing 29034 or 33262 as
applicable, and proceed as follows:
1. Before removing the clutch-brake unit, unplug connectors P7,

P8 and P9 from the starwheel drive motor, the clutch/brake
unit, and the encoder to the panel behind the starwheel drive
motor.
2. Remove the four bolts that hold the starwheel drive motor to
the mounting bracket. These bolts are located below the
bracket.

3. Rotate the starwheel drive motor case clockwise until the ßex
coupling on the clutch shaft can be disengaged. If necessary,
the coupling on the starwheel drive motor shaft may be
loosened and lowered to make this step easier.
4. Remove the two bolts that secure the clutch mounting bracket
to the cabinet top plate. Be careful when removing these two
bolts and do not allow the clutch to fall on the other
equipment. Carefully remove the clutch and bracket assembly
from the Omnivision, taking care not to damage the encoder.
5. Remove the two couplings and keys from the clutch shafts.
Note the position on the shafts. Remove the four bolts that
secure the bracket to the top clutch face. Reinstall the bracket
on the new clutch and tighten the bolts securely. Reinstall both
the couplings and keys on the clutch shafts at approximately
the same position as the original unit. Apply medium strength
Loctite blue on the set screw threads and then tighten the set
screws securely.
6. Reinstall the clutch and bracket assembly using the two bolts
that fasten it to the top plate. Carefully position the coupling
and mating collar on the clutch shaft so they mesh with the
coupling on the starwheel drive shaft. Visually align these
couplings as concentrically as possible and tighten the two
bolts that secure the clutch mounting bracket to the top plate.
NOTE
It is very important that these two shafts be accurately aligned to
reduce vibration and wear.
Rotate the starwheel drive shaft and note the motion of the
clutch assembly. If there is any wobbling of the clutch or
couplings, readjust the entire system to make it run as
smoothly as possible.
7. Reinstall the starwheel drive motor by rotating it into position

and adjusting the coupling and collar to engage the bottom
coupling on the clutch shaft. If necessary, vertically adjust the
couplings so they mate smoothly.
NOTE
It is very important to accurately align the starwheel drive motor
shaft with the bottom shaft of the clutch.
Reinstall the four bolts that secure the starwheel drive motor to
its mounting bracket but do not tighten Þrmly at this time.
8. Plug the starwheel drive motor, clutch/brake and encoder

connectors P7, P8 and P9 into the panel behind the starwheel
drive motor.

9. Apply power to the Omnivision so the starwheel drive motor

shaft starts to rotate. Observe the rotation of the motor shaft
and its coupling to make sure that it is concentric with the
clutch coupling. Move the motor and adjust as necessary so the
two couplings run concentrically and then tighten the motor
mounting bolts securely. Block the upstream Microsonic bottle
sensors so the starwheel drive is activated. Observe the total
system running. It should run true and smooth with no wobble
or vibration. If any misalignment is seen, readjust the necessary
components.
Starwheel Drive Motor

To replace the starwheel drive motor refer to Figure 3-2 and
Drawing 29034 or 33262 as applicable, and proceed as follows:
1. Disconnect the starwheel drive motor plug P7 and the green

ground wire from the harness connector.
2. Remove the four bolts that hold the starwheel drive motor to
the mounting bracket. These bolts are located below the
bracket.
3. Rotate the motor case clockwise until the ßex coupling on the
clutch shaft can be disengaged. The coupling on the starwheel
drive motor shaft may be loosened and lowered to make this
step easier. Remove the motor from the base cabinet.
4. Remove the ßex coupling from the motor shaft and install it on
the new unit but do not tighten the set screw.
5. Reinstall the starwheel drive motor by rotating it into position

and adjust the coupling and collar to engage the bottom
coupling on the clutch shaft. Vertically adjust the bottom
coupling to mate with the collar and top coupling and securely
tighten the set screw. It is very important to accurately align the
starwheel drive motor shaft with the clutch bottom shaft.
Reinstall the four bolts that hold the starwheel drive motor to
its mounting bracket and securely tighten them.
6. Reconnect plug P7 and the green ground wire.
7. Apply power to the Omnivision so the starwheel drive motor

shaft starts to rotate (main power switch ON and Emergency
Stop switch pushed in). Observe the rotation of the shafts and
the couplings to assure they are aligned. Readjust the motor, if
necessary, so the two couplings run concentrically.

8. Pull out the Emergency Stop switch and block the upstream
Microsonic sensors so the starwheel drive system is activated.
Observe the total system running. It should run true and
smooth with no wobble or vibration. If an alignment problem
is noticed, readjust the components.
Vacuum Pump
To replace a Gast Vacuum Pump refer to Appendix A, Manufacturers
SpeciÞcations, for the Operating and Maintenance Instructions and
Service Kits information.
Vacuum Oiler
To replace the vacuum oiler, refer to Drawing 27766-0 and proceed
as follows:
1. To remove, Þrst unplug the connector from the oiler wiring to

the base cabinet wiring harness.
2. Loosen hose clamp on oiler tank and remove hose. Be careful of

dripping oil.
3. Unscrew the oil reservoir assembly from the vacuum pump

and remove from the Omnivision. Carry out the necessary
repairs or replace the unit.
4. Reverse the above steps to reinstall the oiler.
Starwheel Seal Ring

The seal ring (10287-0) 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 Þeld
using the procedure in Step #3. To replace the seal ring refer to
Drawing 30224 and proceed as follows:
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 ßat surface such
as a surface plate, press the seal ring against the emery paper
and move in circular motions until all blemishes are 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 are removed with the 320 grit emery paper,
then use 500 grit emery paper to put the smoothest possible
Þnish on both sides of the seal ring. It is absolutely necessary
that the seal ring be kept as ßat 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.
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 refer to Drawing 29034 or 33262 as appli-
cable, and 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 Þrmly
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 ßoat
freely to ensure a proper seal between the starwheel seal ring
and the valve plate.

Takeaway Conveyor Motor

To replace the takeaway conveyor motor refer to Drawings 26712
and 28726, and proceed as follows:
1. Remove the takeaway motor cover.
2. Remove the cover plate from the entrance elbow on the

takeaway motor case.
3. Pull the wires out of the elbow and take off the wire nuts.
4. Disconnect the conduit Þtting from the lower end of the elbow
and pull the wires from the elbow.
5. Remove the four bolts that hold the spacer and the takeaway
motor on the conveyor channel.
6. Remove the elbow from the old motor and insert it in the
replacement motor using pipe compound or teßon tape to
form a waterproof joint. Also be sure to orient the elbow so it
can be reattached to the conduit.
7. Place the coupling on the motor shaft but do not tighten it at

this time.
8. Remount the motor and the spacer being careful to align the
two Þttings so the collar ring is in the proper position. Finger
tighten the bolts until the couplings are positioned concentri-
cally and then securely tighten the four motor bolts and the
coupling set screw.
9. Attach the conduit to the elbow. Reconnect the harness wires to

the motor wires using wire nuts. (The wires on the replacement
motor may have to be cut to length in order to be replaced in
the elbow.) Observe the wire color codes while making these
connections. Replace the cover plate on the elbow and securely
tighten it so that the unit is watertight.
10. Turn the main power switch to the ON position and observe
the operation of the takeaway motor. It should run smoothly
and the coupling on the starwheel shaft should be in alignment
with the coupling on the sprocket shaft. If there is excessive
wobble or misalignment, reposition the takeaway motor so the
couplings run as smoothly as possible.

Microsonic Bottle Sensor Receiver and Transmitter

To replace the Microsonic bottle sensor receiver and transmitter
refer to Drawing 35750-0 as applicable and proceed as follows:
1. Remove the cover plate from the conduit tee on the receiver
side. Pull the wires and wire nuts out of the tee.
2. Unscrew the retainer nut on the front of the faulty sensor

housing and remove the sensor from the mounting bracket.
3. Be sure the wires are disconnected in the tee, then unscrew the
sensor head from the elbow and pull out the wires.
4. Push the wires for the replacement sensor through the elbow
into the conduit tee. Then screw the sensor into the elbow until
it is securely tightened (this must be a watertight connection).
Replace the sensor in the bracket and securely tighten the nut.
If the replaced unit is a receiver, then be sure the LED indicator
is located on the top side for easy observation.
5. Replace the wire nuts on the wires, observing color code for
proper wiring.
6. Turn ON the Omnivision's power and align the sensor so the

LED indicator is ON with no bottles in the beam. Test the Line
Control System for proper operation.
Air Jet Blow-off Nozzle

To replace the air jet blow-off nozzle refer to Figure 3-3 and
proceed as follows:
1. Remove the air nozzle assembly from the conveyor stub.
2. Disconnect the air hose at the nozzle.
3. Remove the nozzle from the bracket.
4. Install the new nozzle in reverse order. Make sure the air jet is
positioned as shown in Figure 3-3.
5. Adjust the air ßow so all soap and debris are blown off the
bottom of the bottle.

1 No. Description
1 Bottle
2 Air Blow-off Assembly
2 3 Air Inlet
CL 4 Air Jet Out
4
AirBlowOff
3
Figure 3-3. Air Jet Blow-off System
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 three bolts on the top

of the deadplate.
4. Install the new deadplate in place in reverse order.
No alignment is necessary for the deadplate.

Rotating Diffuser/Clear Glass Disk

To replace or remove a rotating diffuser/clear glass disk for
cleaning purposes, proceed as follows:
1. Turn OFF circuit breaker CB1 on the base cabinet power panel.
2. Remove the front door on the support column adjacent to the

glass disk.
3. Remove the black plastic diffuser cover by lifting it at both

ends until it is released completely.
4. Carefully, remove and discard any broken glass pieces.
5. Loosen the thumbscrew on the rotating brush assembly

column and slide the brush assembly forward to clear the
diffuser glass.
6. Remove the nut and the pressure washer that keep the rotating
glass disk on the spring-loaded drive spindle.
7. Push down the drive spindle, release the glass disk and slide it
gently forward to clear the machine. 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. (No diffuser side on
the clear glass disk).
• Screw down the pressure washer and nut Þnger-tight. DO
NOT USE A WRENCH.
• Set the rotating brush assembly so the brush clears the
pressure washer.

Reject Solenoid Valve

To replace the reject solenoid valve refer to Figure 3-4 for details.
Parts which are identiÞed or numbered are the only ones that can
be replaced in the Þeld. Disassemble only those parts necessary to
make repairs. DO NOT DISASSEMBLE THE SOLENOID
ASSEMBLY. Make sure Spools (12173 and 12184) are lubricated
with the proper grease (a medium Aniline Oil may be used).
1
5
4
2 3
RejSolVlv
7
8
9 6
10
11
12

1 Seal (B5-5007) 7 Solenoid Assy - DO NOT DISASSEMBLE
2 Gasket (16237) 8 Gasket (16236)
3 Return Spring (21169) 9 Spool (12173)
4 Gasket (B5-6010) 10 Return Spring (21158 [DC], 21167 [AC])
5 Mounting Screw (B4-0312-050, 4 each) 11 “O” Ring (17905-01, 2 each)
6 Spool (12184) 12 Retainer Assembly (R-00005) -
Includes 17905-01, 2 each
Figure 3-4. Reject Solenoid Valve Servicing

Base Inspection Strobe Lamp Power Supply Assembly

To replace the Base Inspection power supply assembly refer to
Drawing 31572 and proceed as follows:
1. Turn OFF the main power switch and wait at least 15 minutes
before proceeding to Step #2.
WARNING
Lethal voltages exist around the strobe lamp and power supply
assemblies. Wait at least 15 minutes after turning OFF the main
power switch. This wait allows the stored electrical charge to
dissipate. Failure to wait at least 15 minutes may result in
electrical shock, serious personal injury and even death.
2. Disconnect all cables and the air hose from the power supply.
3. Remove the three 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 Dual Strobe Assembly

To replace the Base Inspection dual strobe (ßash tube) assembly,
refer to Drawing 31572, and proceed as follows:
WARNING
2. Remove the entire Base Inspection power supply assembly

(refer to the Base Inspection Strobe Lamp Power Supply Assembly
section above).
3. Remove the bafße (30477) by loosening the four screws holding

it in place.
4. Loosen the two screws holding the upper reßective plate

(27851) and slide the plate out.
5. Pull out both existing ßash tubes (30493) from the base.

6. Before inserting the replacement ßash tubes, Þll each banana

socket with DC4 compound (or equivalent) to keep out
moisture.
CAUTION
Do not touch the replacement ßash tubes with bare hands.
Plastic gloves are supplied. Do not let the ßash tubes become
contaminated with any foreign materials. Contamination on the
ßash tubes may cause damage to the tube and/or shorten its
effective life. If the lamp is touched with Þngers 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 plastic covers, gently insert the new

ßash tubes’ banana plugs into their matching sockets.
8. Remove the plastic covers.
9. Reassemble the remaining parts and install the assembly in

place.
INSPECTION HEAD
Due to the interrelationships between cameras, optical compo-
nents, servos and the inspection software, certain replacement
procedures must be performed by an authorized, factory-trained
IDC Representative. These include replacing the following
assemblies:
• Base Inspection camera/optics

• Infrared Residual Liquid Detection (IR RLD) camera/optics
• Finish Inspection camera/optics
• Inner Sidewall Inspection camera/optics
• Base camera zoom servo
• Base camera brightness servo
• IR RLD zoom servo
• IR RLD brightness servo
• Finish camera zoom servo
• Finish camera brightness servo
• Inner Sidewall camera zoom servo
• Inner Sidewall camera brightness servo
If you suspect any of these components require replacement,

contact your designated authorized IDC Representative for
assistance.

Finish Inspection Dual Strobe Assembly

To replace the Finish Inspection dual strobe (ßash tube) assembly,
refer to Figure 3-5, and proceed as follows:
WARNING
2. Remove the ßash tubes’ banana plugs (4 each) from the Finish
strobe power supply.
3. Remove the bolts (4 each) and carefully lift the Finish optics
(including the cameras) from the lower housing.
4. Remove all bolts on the top of the heat sink (Þnned assembly).
Separate and remove the parts.
5. Remove the bolts on the front side of the lower housing.
6. Remove the thumbscrews (4 each) and pull out the dual strobe
assembly.
7. Carefully install the replacement strobe assembly in place.

CAUTION
Do not touch the replacement ßash tubes with bare hands.
Plastic gloves are supplied. Do not let the ßash tubes become
contaminated with any foreign materials. Contamination on the
ßash tubes may cause damage to the tube and/or shorten its
effective life. If the lamp is touched with Þngers or is
contaminated, make sure you wipe the lamp clean using a
GLASS CLEANING SOLUTION AND LENS TISSUE OR SOFT
CLOTH before installation.
8. Reassemble and install the remaining parts in reverse order.

ce
pla
Re
S trb
Fin
No. Description
1 Inspection Head
(Reference)
2 Banana Plug,
4 each (Step #2)
4
3 Bolts for holding
optics (Step #3)
4 Bolts for holding
heatsink (Step #4)
5 Bolts on front side
of lower housing
(Step #5)
6 Thumbscrew,
4 each (Step #6)
7 Dual Strobe Lamp,
fully assembled
Figure 3-5. Finish Inspection Dual Strobe Lamp Replacement

Inspection Trigger Sensors

To replace either the Base Inspection or Finish Inspection trigger
sensors refer to Drawing 31124 and proceed as follows:
1. Turn OFF the main power switch and wait a few minutes
2. Remove the Inspection Head cover plate.
3. If the position of the inspection trigger pointer is not already

permanently marked on the surface of the Inspection Head
base plate, mark its exact position with a permanent marker.
4. Disconnect the inspection sensor wires from Terminal Block

BS2.
5. Hold the inspection sensor and remove both screws on the

pointer.
6. Pass the wires through the hole in the Inspection Head base
plate and remove the sensor.
7. Install the replacement inspection trigger sensor in reverse

order.
TOUCHPADS
To replace a touchpad (26818) refer to Drawing 29000 (sheet 2 of 8)
and proceed as follows:
1. Turn OFF the main power switch.
2. Use a thin smooth blade to peal the touchpad away from the
support column.
3. Gently pull out the touchpad wiring until the plug-in

connector is accessible. Check and note how the connectors are
attached (they are not polarized).
4. Disconnect the touchpad's plug-in connector.
5. Attach the replacement touchpad's plug-in connector and

make sure it is seated correctly.
6. Feed the touchpad plate wiring back into the support column.
7. Turn the main power switch ON and verify the touchpad is

operating properly.

8. Remove the adhesive backing liner from the touchpad and line
up the touchpad to the support column.
9. Press the touchpad into place on the support column.
VIDEO MONITORS
To replace either monitor refer to Drawings 28862, 37014-0 and
37222 and proceed as follows:
2. Remove the back cover from the monitor enclosure.

CAUTION
Be careful not to damage any of the wires or cables hanging
down from the center turret opening or the ground braid wires
attached to the base of the monitor enclosure. Snagging any of
these wires or cables may result in equipment damage.
3. Unplug the monitor's power cord from the AC power outlet.
4. Disconnect the monitor's signal cord from the connector.
5. Loosen the screws that attach the monitor to its support frame.
6. Carefully lift and remove the monitor.
7. Lift the replacement monitor up to the monitor enclosure and

with the CRT facing away from you, position it into its support
frame. Tighten down the screws until the monitor is secured.
8. Plug the monitor's AC power and signal cords.
9. Reinstall the monitor enclosure back cover.

AIR CONDITIONER
The air conditioner (35500) is heavy and before you remove it from
the machine, make arrangements to lift it using a hoist or an equiv-
alent equipment.
NOTE
The current model air conditioner (35500) replaces the earlier
model air conditioner (25728). Consult IDC for the replacement
kit if your machine is equipped with the earlier model air
conditioner.
To replace the air conditioner, refer to Drawing 35672-0 and

proceed as follows:
2. Disconnect the condensation drain tube from the air condi-

tioner's nipple.
3. Slide open the electronics enclosure's “A” side drawer and

disconnect the air conditioner’s AC power cord from the
harness.
4. Remove the bolts that secure the air conditioner to the top of
the electronics cabinet.
5. Attach a hoist or other lifting equipment to the support plate,

lift and remove the air conditioner.
6. Attach a hoist to the support plate of the replacement air condi-

tioner and raise it above the electronics cabinet opening.
7. Slowly lower the replacement air conditioner and align it with

the bolt holes. Once in place, install and tighten the bolts.
8. Reattach the condensation drain tube and AC power cord.

NOTE
After the replacement air conditioner is installed, there is no
need to adjust the air conditioner's thermostatic controls. The
thermostatic controls are preset at the factory.

OUTER SIDEWALL ENCLOSURE

There are very few components inside the OSW enclosure that
may require replacement.
The cameras, mirrors, servo controls and heaters which are

enclosed and sealed off inside the OSW enclosure are designed to
operate on a long-term basis without need for regular mainte-
nance. None of the OSW components require lubrication.
Do not open the OSW enclosure unless absolutely necessary.

Opening the enclosure allows dirt, product, water, and other
ßuids/gases to contaminate the OSW system cameras and mirrors.
The cameras and mirrors inside the OSW enclosure are positioned
and calibrated at the factory. If the mirrors are dislodged, moved,
or damaged, or if the solid-state cameras malfunction or fail
contact Industrial Dynamics for assistance.
WARNING
Turning OFF the Omnivision's main power does not terminate
all power supplied to the OSW system enclosure. The two
terminals, TB1-7 (L1) and TB1-8 (L2), supplying power to the
OSW system's heaters are controlled by the customer's main
circuit breaker panel. The 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 the main power at the customer’s circuit
breaker panel. Failure to do this may result in electrical shock
causing SEVERE PERSONAL INJURY or even DEATH. Refer to
the Input Power Wiring Diagrams in the Start-up and Technical
Reference Manuals (Forms 3055 and 3057) for details.
Replacing OSW Fluorescent Lamps

To replace any of the OSW ßuorescent lamps refer to Drawing
30043 and proceed as follows:
CAUTION
Before performing the following steps, make sure to protect the
interior of the OSW system's enclosure from any contaminants
such as dirt, product, water, and other ßuids/gases which might
affect the OSW system cameras and mirrors while performing
this procedure.
1. Look down the OSW inspection tunnel and identify which

System (“A” or “B”) has a failed ßuorescent unit. (System “A”
is always the system closer to the Omnivision infeed.)
2. Turn OFF the OSW system's main power switch.

WARNING
Wait at least 15 minutes after turning off the OSW system's main
power before opening the OSW enclosure to ensure that all
residual charge will dissipate away. Failure to do this may result
in electrical shock causing SERIOUS PHYSICAL INJURY.
3. Go to the OSW enclosure side where the failed ßuorescent

lamp is and remove the side panel.
4. Disconnect the wiring connectors attached to the side of the

ßuorescent lamp panel.
5. Unscrew the ßuorescent lamp panel from its frame and remove
the lamp panel.
6. Carefully press down on the red button at the base of the failed
ßuorescent lamp and unsnap the lamp and remove it.
NOTE
In Step #7, be careful not to touch the replacement ßuorescent
lamp with your bare Þngers. Bare Þngers leave oily spots on the
lamp which may cause lamp failure at a later time. If the lamp is
touched with Þngers, make sure you wipe the lamp clean using
lens tissue or soft cloth before restoring power to the OSW
system.
7. Put the replacement ßuorescent lamp (92878) in its place and

carefully guide the lamp prongs into their proper places 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.
8. Return the lamp panel to its frame and bolt it in place.
9. Connect the wiring connectors to the lamp panel.
10. Put the enclosure side panel back in its place and secure it.
11. Turn on the OSW system's main power switch and verify the
replacement ßuorescent lamp is functioning properly.


Chapter 4: Alignment & Calibration Procedures
Chapter 4:
Alignment and Calibration Procedures
Contents
Topic Page
Alignment and Calibration Procedures Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Guide Assembly Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Main Omnivision Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Outer Sidewall Inspection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Microsonic Bottle Sensor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Inspection Head and Inspection Timing Trigger Alignment . . . . . . . . . . . . . . . . . . . . . . . 4-3

Base Inspection Trigger Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Finish Inspection Trigger Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starwheel Vacuum System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Air System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starwheel Encoder Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6


Chapter 4: Alignment and Calibration Procedures
ALIGNMENT AND CALIBRATION PROCEDURES

OVERVIEW
Most of the procedures in this chapter are to be performed after the
completion of a repair or replacement procedure (see Chapter 3 for
details).
The majority of alignment and calibration procedures performed

by customers are associated with bottle handling.
In general, once an Omnivision is installed and started up, there

should be no need for adjustments to the electronics and
inspection cameras.
NOTE
Certain alignment and calibration procedures must be
performed by factory-trained authorized IDC Representatives
including:
• calibrating the inspection systems for new bottles types
• aligning and calibrating the solid-state cameras
• performing detailed printed circuit card adjustments
• performing inspection system software adjustments
If you suspect any of the above-mentioned procedures are required

to respond to a problem, contact your designated IDC Represen-
tative for assistance.
GUIDE ASSEMBLY POSITIONING
Main Omnivision Unit

There are two sets of guide assemblies on the main Omnivision
unit: the infeed guides and the outfeed guides.
Both the infeed and outfeed guide assemblies are Þxed in angle
and position. Also, no adjustments are needed during bottle
changeover procedure.
The guide assemblies are mounted on slotted plates on the

conveyor frame. The plates are adjusted and set in the factory to
allow for about 3 mm (0.125 inch) of clearance between the bottle
diameter and the guide sets.
A maximum gap of 5 mm (3/16 inch) is allowed between where

the production conveyor guide rails end and the Omnivision guide
assemblies start. No guide assembly adjustments are required in
the Þeld.

Outer Sidewall Inspection Unit

If the optional Outer Sidewall Inspection unit is supplied, ensure
that the bottle body guides and the bottle neck guides are parallel
through the entire OSW tunnel.
The guides should allow a smooth continuous bottle ßow through

the system with no bottle staggering or gapping. Adjust the guides
if necessary.
MICROSONIC BOTTLE SENSOR ALIGNMENT

Various production line conditions can cause the upstream or
downstream Microsonic bottle sensors to be knocked out of proper
alignment. If Sensor No. 1 (start-stop), Sensor No. 2 (modulator) or
Sensor No. 3 (Jam Detector) are out of proper alignment, restore
them to their correct alignment (see Figure 4-1). Also refer to Instal-
lation Drawings as applicable.
5 4
6
MicroSnsr
1 2 3
45 30 30

1 Sensor No 1 (Start/Stop), Upstream 4 Bottle Washer
2 Sensor No 2 (Modulate), Upstream 5 Production Conveyor
3 Sensor No 3 (Jam Detector), Downstream 6 Bottle Flow (Right-hand Machine)
Figure 4-1. Microsonic Bottle Sensors - Mounting Angles

INSPECTION HEAD AND INSPECTION TIMING

TRIGGER ALIGNMENT
There are two Inspection Timing Triggers (see Figure 4-2) to sense
bottle position (alignment) for the inspection process:
• The Base Inspection Trigger
• The Finish Inspection Trigger (optional)
The Base Inspection Trigger controls inspection timing for:

• Base Inspection
• Inner Sidewall Inspection
• IR Residual Liquid Detection
• Plugged Neck/Color Sort Detection
The Finish Inspection Trigger controls inspection timing for:

• Finish Inspection A (Primary System)
• Finish Inspection B (Secondary System)
The two trigger assemblies are mounted under the Inspection

Head Assembly Base Plate. The upstream assembly is the Base
Inspection Trigger and downstream one is the Finish Trigger
Assembly.
If either of the Inspection Triggers is damaged or suffers a

component failure, it must be aligned after replacement.
NOTE
The replacement and mechanical alignment of the Finish
Inspection and Base Inspection Trigger Assemblies should only
be performed by an authorized IDC Representative.
Base Inspection Trigger Alignment

If abnormal Base or Inner Sidewall Inspection video images occur,
they may be caused by the Base Inspection Trigger (see Figure 4-2)
being somehow moved from its correct position. If this is the case,
proceed as follows:
1. Remove the Inspection Head cover.
2. Move the pointer back to its original marked (etched) position

and tighten the pointer down.
3. Verify the Base and Inner Sidewall Inspection video images are
corrected to normal operation.

NOTE
In the event that abnormal Base Inspection, Inner Sidewall
Inspection, Plugged Neck/Color, Residual Liquid Detection
problems (such as misaligned video images) continue after
performing this procedure, contact an authorized IDC
Representative for assistance.
Finish Inspection Trigger Alignment

If abnormal Finish video images occur, they may be caused by the
Finish Inspection Trigger (see Figure 4-2) being somehow moved
from its correct position. If this is the case, proceed as follows:
1. Remove the Inspection Head cover.
2. Move the pointer back to its original marked (etched) position

and tighten the pointer down.
3. Verify the Finish Inspection video image is corrected to normal

operation.
NOTE
In the event that abnormal Finish Inspection problems (such as
misaligned video images) continue after aligning the Finish
Inspection Trigger, contact an authorized IDC Representative for
assistance.
No. Description
1 Alignment Pin (2 each)
2 Trigger Card
3 Base Trigger Pointer
4 Finish Trigger Pointer
5 Blower Fan
6 Finish Strobe Power
Supply
1
Ins
pT
rgP
ntr 2
6 5 4 3
Figure 4-2. Inspection Timing Trigger Pointers (OV D-1200)

STARWHEEL VACUUM SYSTEM ADJUSTMENT

The following procedure explains how to check and, if necessary,
correct the Omnivision's starwheel vacuum system.
1. Verify oil ßow has been established between vacuum pump

reservoir and exhaust jar. Do this by cleaning exhaust jar, and
check for buildup of approximately 29.6 milliliters (1 ounce)
per 10 hours of pump operation. If less, investigate and clean
reservoir/wick system.
2. Verify that valve plate ßexible hoses all have internal springs
and springs are in contact with copper tubing at each end
(no gaps).
3. With the starwheel rotating without bottles, verify a minimum

of 203 mm Hg (8 inches Hg) vacuum indicated on vacuum
gauge without ßuctuating over 51 mm Hg (2 inches Hg).
4. If central vacuum system is employed, this is the test that

veriÞes proper vacuum ßow rate and, thereby, an acceptable
central system. If less than 203 mm Hg (8 inches Hg) is
available from central system, investigate size of inlet lines and
request customer to comply if change is needed.
5. Stop the starwheel, load it with bottles and recheck the

vacuum. Indicator should read between 609 and 660 mm Hg
(24 to 26 inches Hg) while the starwheel is rotating.
NOTE
If your plant is located more than 1,220 meters (4,000 feet) above
sea level, nominal operating vacuum should be approximately
508 mm Hg (20 inches Hg). Every 305 meters (1,000 feet) increase
in altitude causes a vacuum loss of approximately 25.4 mm Hg
(1 inch Hg).
AIR SYSTEM ADJUSTMENT

The following procedure explains how to check and, if necessary,
correct the Omnivision's air system pressure.
1. Turn on the external air valve, and check the air Þlters for leaks.
2. Check the diffuser glass air blow-off (upper and lower bars) for
good air ßow across glass (adjust needle valve as required).
NOTE
The air system needle valve knob controls have set screws.
Before making any adjustments to the needle valve knob
controls, make sure you temporarily loosen the set screws. Once
the adjustments are made, tighten the set screws.

3. Check for proper alignment of air jet blow-off nozzle for

cleaning bottle bottom. Increase air ßow until sufÞcient
pressure is felt to blow-off chain soap carry over on bottle
bottom.
4. Set the reject air pressure to 345 to 414 kPa (50 to 60 psig). The
regulator and gauge are located on a panel inside the base
cabinet on the starwheel side. Adjust the regulator as follows:
a. Pull the red ring forward to unlock, and rotate the knob
slowly clockwise to increase pressure. After proper
adjustment is made, push in the red locking ring.
b. If 414 kPa (60 psig) cannot be reached or maintained with

all systems operating, check the input supply line for
proper size and 414 kPa (60 psig) minimum supply
pressure.
5. Check the starwheel purge air pressure. The purge air pressure
regulator, located directly behind the reject air gauge panel is
Þxed at 56 kPa (8 psig) and cannot be adjusted. Check air ßow
by using your Þngers to feel at the starwheel suction tubes
located in the purge quadrant (directly across from the Þnish
inspection zone).
6. With starwheel rotating at production speed, energize reject

solenoid valve and check for pulse of air through each suction
tube at the reject point over takeaway conveyor.
STARWHEEL ENCODER ALIGNMENT

1. Verify that each encoder drive pulley (see Figure 4-3) on the
spindle drive shaft, and the encoder pulley on the encoder
shaft, are aligned to allow the belt to run true without dragging
or binding. If the encoder pulley is out of alignment, bend the
encoder mounting bracket to bring the encoder pulley square
with the encoder drive pulley.
The encoder pulley and/or the encoder drive pulley may be

repositioned vertically on the shafts by loosening the set
screws. The encoder pulley must not be forced onto the
encoder shaft. It should slide easily into position.
NOTE
The encoder is a precision optical instrument (glass disk). If a
hammer is used to drive pulley onto shaft, the disk will be
broken.

2. The encoder mounting bracket is slotted to allow horizontal

movement for proper belt tension. Proper belt tension is
achieved when the belt can be deßected approximately 6.4 to
9.5 mm (1/4 to 3/8 inch) at the midpoint between the two
pulleys with moderate Þnger pressure. The belt does not have
to be “tight” to prevent slippage since it is a toothed belt.
CAUTION
Do not overtighten the belt. Excess belt pressure will cause
bearing failure in the encoder.
1 2 3
10
9
5
8 6 No. Description
1 Encoder
OV D-1200 2 Encoder Bracket
3 Encoder Pulley
4 Drive Pulley
7 5 Drive Belt
StarDrive 6 Upper Flex
Coupling
2 7 Clutch/Brake
1 3
10
9 4
8 6
OV 900/1200
Figure 4-3. Starwheel Encoders


Appendix A: Manufacturers Specificatins
Appendix A:
Manufacturers Specifications
Contents
Topic Page
Manufacturers Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Gast Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Norgren Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Motor, 3/4 HP, AC, 50/60 Hz (P/N 11215) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
Motor, DC, Gearhead (P/N 91516) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Motor, DC, Gearhead With Tachometer (P/N 93110) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Monitor, Color, 14", Multisync (P/N 94502). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12


Appendix A: Manufacturer Specifications
MANUFACTURER SPECIFICATIONS
Gast Vacuum Pump
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) A-1

A-2 Industrial Dynamics Company, Ltd. © Form 3056 (05/99)



Norgren Air Filters




Motor, 3/4 HP, AC, 50/60 Hz (P/N 11215)
.094
11215
A A
SPECIFICATIONS
Rated For: 230/460, 30 - 60 Hz, or
190/ 380, 30 - 50 Hz
Horse Power: 3/4
Frame: 56C
6.50
Type: UT
.81 4.88
RPM: 1750
Phase: 3
.56
Insulation Class: F
3.000 4.13
MANUFACTURER MFR’S P/N
US Electrical Motors Model F012X
125 Old Gate Lane (X = Blank or any
Milford, CONN. 06460 character O.K.)
A-A
4 X .344 X 1.25

Motor, DC, Gearhead (P/N 91516)
1.00
A
4 11 11/16
B
2 3/8 2 7 5/16
1 1/4
1.750
91516
1 7/8
1 1/2 D
1 1/2
C
4 5/8
1 5/8 1 5/8
E
SPECIFICATIONS No. Description

Type: DCPM A 1/8 NPT Drain Hole
Voltage: 90 VDC B 1/2 NPT
HP: 1/4 C Solid Washer Under Retaining Ring
Gear Ratio: 22:1 D Rubber Cap
Torque: 75 In.Lb E 1/4 Dia. Mounting Hole (4 Each)
Output Speed: 156 RPM
Current 2.5 Amps.
Duty: Continuous
MANUFACTURER MFR’S P/N
Temp. Rise: 40° C
Baldor Electric Co. 17465H
Wire Size: 18 AWG - Red, Black,
5711 S. 7th Street (JK-0 Gearmotor)
Green & Yellow Tracer
Fort Smith Conduit Fitting & Drain
Wire Length: 6 Inches Arkansas 72902 Hole
Motor Speed: 3450 RPM Tel: (501) 646-4711
Telex: 53-7425
Second Source: None

Motor, DC, Gearhead, With Tachometer (P/N 93110)
.624 12.718+/-.031
A 2.000
+/-.005
8.437+/-.031
B
1.690+/-.031
93110
4.000
+/-.031
3.463
+/-.031 A A .25
E
C
D
No. Description 3.875
1.375 .50
A Keyway (.187" x .093" x 1.125")
B Flat (1.125" Long) .75
C 2 Leads, 12" Long
3.312 2.160
D 3 Leads, 12" Long (Black-A2,
White-A1, Green/Yellow)
E Mounting Plate
F Hole, 10-32 UNF-2B (4 Each) A-A
F
SPECIFICATIONS MANUFACTURER MFR’S P/N

Torque: 100 In.Lb. Baldor Electric Co. 31778
Horse Power: 1/8 5711 S. 7th Street
Fort Smith
Type: DCPW
Arkansas 72902
RPM: 36 Tel: (501) 646-4711
Volts: 90 VDC Telex: 53-7425
Distributor:
Henberger Co.
(714) 454-2028

Monitor, Color, 14", Multisync (P/N 94502)
15 No. Description
.19
.69
13 1 Brightness Control
2 Contrast Control
3 AC Power In
4 Alignment Controls
3 5 Video in
6 Video Switch - Set to
ANALOG.
11.54
DO NOT SWITCH
WITH POWER ON
8 7 Screen Control
5 7
8 Focus Control
4
6
945 L
02 TT
H
OG ITC
AL SW
AN
VID
EO
2
1
SPECIFICATIONS SPECIFICATIONS Continued ...

Visual Performance: Input Signal Characteristics:
Resolution: 800 x 600 Non-interlaced Video: TTL Level, Positive Analog,
CRT: 13 in., 0.28 mm Pitch, 0.7 Vpp, 75 Ohms, Positive
Direct Etched Screen Sync: Separate Horizontal & Vertical
Linearity & Sync, TTL Level, Positive or
Geometry: 5% Negative
Brightness: 30 FL Environment:
Display Area: 8 H x 10.7 W, in. Temperature: Operating 40°F to 104°F
(191 H x 255 W, mm) Humidity: 10% to 85% relative,
Non-condensing
Convergence Center 0.3 mm,
Storage: 40°F to 140°F
Error: Corner 0.4 mm
Altitude: Up to 10,000 Ft (3,000 m)
Circuit Performance:
EMI/RFI UL, CSA, DHHS & VDE Class
Pulse Response: 16 nsec B Approved
Blanking Time: Horizontal: 5 µsec Nominal
Vertical: 700 µsec Nominal
Input Power Requirements:
Voltage: 85 - 264 VAC
Scan Rate: Horizontal: 15 - 40 kHz
(Multisync) Frequency: 47 - 405 Hz
Vertical: 40 - 120 Hz Power: 80 Watts
(Multisync)
Sync Selection:
Manufacturer: Mfr’s Part No:
Sync Selection: Automatic, Internal/External
Dynamic Displays QES 2014-162
Input Connectors: BNC or 9-pin “D” (715) 835-9440
Subminiature Connectors (800) 793-6862
Second Source: None

Appendix B: Air Conditioner
Appendix B:
Air Conditioner
Contents
Topic Page
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3


AIR CONDITIONER
Refer to the appropriate Installation Drawings and Assembly
Drawing 35672-0 as applicable.
The current Omnivision Series 3000 machines use the Rittal Air
Conditioner, Model SK 3290100 (IDC P/N 35500).
NOTE
The current air conditioner (IDC P/N 35500), replaces the earlier
Rittal unit, Model SK 3296 (IDC P/N 25728). Consult IDC for the
replacement kit, if required.
Maintenance Information
The following is a list of items to check when it appears that the air
conditioner is not working correctly. Note that these items may be
carried out as applicable and not necessarily in the same order as
presented here.
1. Check the air Þlter pad and replace or clean, when necessary.
The frequency will depend on the ambient conditions such as a
high concentration of sugar fumes in the air.
2. The water drain hose, which has a spring inside to keep it from
collapsing, should not loop up and cause restriction to the
drain of water.
The hose must come straight out from the spigot, then properly
guided and held down by clamps on top of the machine, and
down through the hole located at the top corner of the
Electronics Cabinet. If this is not done correctly, then water can
spill over and run down through any small holes in the ßoor of
the air conditioner into the Electronics Cabinet, causing
damage to computers and monitors.
If the hose is blocked, then a replacement hose of the same size

and type (P/N 35995), can be connected to the spigot of the air
conditioner and routed on the outside of the Omnivision
cabinet to the ßoor.
3. Check that there are no empty screw holes around the ßange
mount of the air conditioner, where water can drain into the
Electronics Cabinet. If so, screws should be placed in holes
and/or the holes sealed with RTV sealant (or equivalent).
4. Do not use a high pressure water hose to clean or wash off the
top of the Electronics Cabinet near the air conditioner or the
ßange mount of the air conditioner.
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) B-1

There is the chance of small leaks around the air conditioner,

allowing water into the machine. In any case, water is not good
for the life of the air conditioner.
5. Be sure ALL twist lock fasteners for the electronics drawers

(“A” and “B” sides) are locked as well as those on the back of
the Monitor Cabinet. If not, a break in the seal(s) will allow
moist air and water to access these areas. Do not use a high
pressure water hose on these areas during cleaning.
6. There is a large grey ßex hose, connected to a blower fan

mounted at the base of the Electronics Cabinet, which is routed
down from the Electronics Cabinet to the inside of the Monitor
Cabinet.
The cool air from the air conditioner Þrst goes to the Electronics
Cabinet. Then the air blower fan forces the air into the Monitor
Cabinet to assure the monitors run cool. The air then overßows
into the Electronics Cabinet, further assuring cool air for the
computers. The air is recirculated partially due to the air
blower fan and heat convection.
The end of the air hose in the Monitor Cabinet must not direct
air directly onto the monitors, otherwise condensation will
start where the air is directed at. On later model machines, the
end of the air hose is held securely in place by a bracket, where
a portion of the bracket protrudes inside the hose. If your
machine does not have this arrangement, then the hose should
be strapped to one of the two long vertical center connecting
pipes mounted between the two monitors.
The mouth of the air hose is aimed at the bottom ßoor of the
Monitor Cabinet, between two monitors. The hose should be
cut, if necessary, to give approximately four inches of clearance
between the mouth of the hose and the metal ßoor of the
cabinet.
7. The air conditioner leaves the factory with its temperature

setting at its coldest setting which is 20° C (68° F). Do not
adjust the temperature setting. Some air conditioners blow
extremely cold air. In high humidity environments this might
be apparent by the appearance of water beads of sweat all over
the outside of the Monitor Cabinet.
While it is normal for a little area of sweat to appear where the

air conditioner grey hose blows onto the bottom of the Monitor
Cabinet, the whole cabinet should not be enshrouded by it.
Otherwise this may result in heavy moisture condensation on
circuit cards that may damage the computers and monitors.
B-2 Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Feel the outside of the Monitor Cabinet with your hand. The
temperature should feel to be cooler than ambient but not icy
cold.
Consult IDC if the above-mentioned corrective actions do not

solve the problem.
Specifications
Dimensions in inch/mm: H=15.75/400, W=23.62/600,
(Without Vent Grille) D=13.39/340
Useful Cooling Capacity: L35 L35 4950 BTU/1450 W

(DIN 3168) L35 L50 3600 BTU/1060 W
Rated Voltage, Volts/Hz: 230/50/60

Rated Current, Max: 5.3 A
Starting Current: 16.6 A
Backup Fuse T: 6A
Power Consumption: L35 L35 710 W
L35 L50 840 W
Refrigerant: R 134a, 30 oz/840 gm
Max. Pressure: 335 psi/23bar
Temperature Range: 68°F to 131°F/20°C to 55°C
Noise Level: 62 dB (A)
Rating per EN 60529/10.91: External Circuit IP 44
Internal Circuit NEMA 12/13 (IP 54)
Duty Cycle: 100%
Type of Connection: Plug
Weight: 98 lb/44 kg
Color: Pebbly Grey - RAL 7032
Air Displacement of Fans: Unimpeded Air Flow
External Circuit: 540 cfm (910 m3/h)
Internal Circuit: 130 cfm (220 m3/h)
Temperature Control: Built-in Thermostat -
Range 68°F to 140°F/20°C to 60°C
Preset at 95°F/35°C
Model: SK 3290100
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) B-3

Specifications Continued ...

Manufacturer: Rittal - Werk
Rudolf Loh GmbH & Co. KG
Postfach 1662
D-35726 Herborn
Germany
Tel: (02772) 505-0
FAX: (02772) 505-319
Telex: 873913
U.S. & Mexico Headquarters: Rittal Corporation

One Rittal Place
SpringÞeld, OH 45504
U.S.A.
Tel: (513) 399-0500
(800) 477-4000
FAX: (800) 477-4003
B-4 Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Appendix C: Drawings and Parts Lists
Appendix C:
Drawings and Parts Lists
Contents
Topic Page
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Omnivision 900 Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Omnivision 1200/D-1200 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Outer Sidewall Inspection (Dual Station) Recommended Spare Parts. . . . . . . . . . . . . . . C-7
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8

Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Cameras/Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Cards/Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Diffusers/Lenses/Mirrors/Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Electrical, Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Encoders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Guiderails/Wear Plates/Wearstrips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Lamps/Light Sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Mechanical, Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
Motors/Motor Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-19
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20
Rejectors and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-21
Relays/Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22
Sensors and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22
Solenoid Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23
Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24
Drawing Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25
Main Assembly Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-36
Drawings Included In This Manual (Form 3056). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-37
Drawings Included In Start-up and Technical Reference Manual (Form 3055) . . . . . . C-40


RECOMMENDED SPARE PARTS

Industrial Dynamics recommends that a quantity of Omnivision
spare parts be kept on hand to reduce the time to return the system
to full operation. The components and assemblies recommended
as spares are listed below.
The critical spares are highlighted with an asterisk (*) next to the
part numbers. Critical spares are those parts that may cause
immediate machine failure and down time, if they fail.
Omnivision 900 Recommended Spare Parts

Part No. Description Quantity
BASE CABINET
*01795 O-Ring, Valve Plate 4
02709 Regulator, Pressure, 0-100 PSI 1
*10238 Lens, Convex, Base Strobe (If Bright Field Option Is Not Ordered) 1
*11104 Belt, Timing, Starwheel Encoder 1
*13241 Reject Solenoid Valve, 4 Way, MAC 1
*13243 Solenoid Valve, Water, 110 VAC 1
*13269 Clutch/Brake, Starwheel Drive 1
*14178-1 Glass, Diffuser (If Bright Field Option Is Not Ordered) 2
15544 Takeaway DC Drive Motor, 1/4 HP 1
16269 Diffuser Glass Gear Motor, LH 1
16270 Diffuser Glass Gear Motor, RH 1
*16514 Kit, Repair, Starwheel Drive DC Motor Brush 1
*25500 Belt, Diffuser Brush Drive, Upper (65T) 1
*25501 Belt, Diffuser Brush Drive, Lower (120 T) 1
*26794 Brush, Diffuser Glass Scrubber 1
*26818 Touchpad, 10-key 1
*30493 Lamp, Helical Strobe 2
31572 Dual Helical Strobe Housing, Base/ISW 1
31959 Motor, Gearhead, DC, Starwheel Drive with Tachometer 1
*32176 Solenoid Valve, 110 VAC 1
*32794 Encoder, Star Drive 1
(Contact Engineering to determine which type should be ordered)
*33635-1 Plate, Valve, Large Diameter Bottles, RH 1
*33635-2 Plate, Valve, Glass Bottles, RH 1
*33635-3 Plate, Valve, Plastic Bottles, RH 1
*33636-1 Plate, Valve, Large Diameter Bottles, LH 1
*33636-2 Plate, Valve, Glass Bottles, LH 1
*33636-3 Plate, Valve, Plastic Bottles, LH 1
*33775 Gasket, Silicon Rubber (If Bright Field Option Is Not Ordered) 1
*33816 Power Supply, Linear, 48 V 1
*34483 Vent Fan, Base Cabinet 1
*35164 Smart Encoder 1
(Contact Engineering to determine which type should be ordered)
*92722 Relay, DPDT, 12 VAC Coil, 10 Amp 1
Industrial Dynamics Company, Ltd. © Form 3056 (05/99) C-1


BRIGHT FIELD ANALYZER OPTION
*34859 Glass, Rotating, Tempered 2
STANDARD VACUUM PUMP

11171 Vacuum Pump 1
*11800 Jar, Intake Filter, 1 Pint 1
*11801 Jar, Exhaust Mufßer, 1 Quart 1
*12206 Service Kit, Vacuum Pump 1
*12532 Coupling, Vacuum Pump 1
*13327 Oil Vacuum Pump 1
INSPECTION HEAD
*17125 Strobe Lamp, Single Finish 1
*17126 Trigger Beam, Single, Base and Finish 1
24984 Card, RLD 1
25821-3 CCD Camera Black and White 1
*30245 Servo Motor 1
*30619 Sensor, Reject VeriÞer 1
31195 Card, Pin Trigger 1
*32415 Widow, Protective, Optical 1
32578-1 Power Supply, Dual Ring Strobe with Dual Trigger 1
*93068 Power Supply, Inspection Head, 15 VDC 1
STARWHEEL AND GUIDES

*04204 Cup, Suction, Bellows, Standard 35
*15394 Belt, Bottle Retainer (Lower) 2
*26498 Wear Strip, Bottle Guides 8
*26781 Wear Strip Conveyor, Upper 2
*26786 Wear Strip Conveyor, Lower 2
*31852 Belt, Bottle Retainer (Upper) 2
CONVEYOR
*34156 Air Blowoff Nozzle, RH 1
*34157 Air Blowoff Nozzle, LH 1
*91241 Transmitter, Microsonic 1
*91242 Receiver, Microsonic 1
ELECTRONICS
*16449 RectiÞer, Strobe Power Supply 1
27890 Servo Cable Adapter 1
28513-1 **Card, I/O (See Following Note) 1
*28533-2 **Card, Line Control Module (See Following Note) 1
28648 Card, RLD Isolation 1
28694 **Servo Controller Card and Cover (See Following Note) 1
*29054-1 Takeaway Motor Controller 1
29154 Card, Multiplexer 1
29242 Card, Connector 1
C-2 Industrial Dynamics Company, Ltd. © Form 3056 (05/99)


29360-1 **Card, Video (See Following Note) 1
29442-2 Card, DSP 1
*31239-4 Starwheel Motor Controller 1
32729 Beacon Assembly 1
35117 Modbus Card (If Modbus Option Is Ordered) 1
36488-3 **CPU Card, Carrier, 20MB, ConÞgured (See Following Note) 1
*92713 Power Supply, 4 Output, 200 W, LCM 1
92893 Color Monitor 1
93387 LED, High Visibility, Red 1
*94381 Power Supply, Switching 350 Watts, A/B Chassis 1
*94452 Optical Coupler, PLC, Input, IDC 15 1
*94454 Optical Coupler, PLC, Output, ODC 15 1
Note: If ordering parts identiÞed with (**) after the machine is shipped,
contact IDC Engineering or Field Service for assistance. These parts are
software and/or revision sensitive. Specify both when ordering.
UPSTREAM RF RLD OPTION

35195-X Cover, Sensor, RF, Small 1
35196-X Cover, Sensor, RF, Large 1
93358 Card, Control and LED Display, RLD 1
93359 Kit, Emitter/Receiver, RLD 1
93360 Impulse Board, RLD 1
93361 Power Supply, RLD 1
DOWNSTREAM RF RLD OPTION

33967 Plate, Wear, Receiver, RF RLD 1
34005 Plate, Wear, Transmitter, RF RLD 1
35388 Card, Control & LED Display, RLD 1
93359 Kit, Emitter/Receiver, RLD 1

Omnivision 1200/D1200 Recommended Spare Parts

BASE CABINET
*01795 O-Ring, Valve Plate 4
02709 Regulator, Pressure, 0-100 PSI 1
*10238 Lens, Convex, Base Strobe (If Bright Field Option Is Not Ordered) 1
*13241 Reject Solenoid Valve, 4 Way, MAC 1
*13243 Solenoid Valve, Water, 110 VAC 1
13269 Clutch/Brake, Starwheel Drive 1
*14178-1 Glass, Diffuser (If Bright Field Option Is Not Ordered) 2
15544 Takeaway DC Drive Motor, 1/4 HP 1
16269 Diffuser Glass Gear Motor, LH 1
16270 Diffuser Glass Gear Motor, RH 1
*16514 Kit, Repair, Starwheel Drive DC Motor Brush 1
21575 Belt, Encoder Drive, (Dual) Starwheel 1
*25500 Belt, Diffuser Brush Drive, Upper (65T) 1
*25501 Belt, Diffuser Brush Drive, Lower (120 T) 1
*26794 Brush, Diffuser Glass Scrubber 1
*26818 Touchpad, 10-key 1
27591 Valve Plate, Starwheel, RH 1
27592 Valve Plate, Starwheel, LH 1
*27601 Belt, Clutch/Brake, Dual Drive 1
*30493 Lamp, Dual Helical Strobe 2
31054 Belt, Encoder Drive, (Dual) Conveyor 1
31572 Dual Helical Strobe Housing, Base/ISW 1
31959 Motor, Gearhead, DC, Starwheel Drive with Tachometer 1
*32176 Solenoid Valve, Air, 110 VAC 1
*33775 Gasket, Silicon Rubber (If Bright Field Option Is Not Ordered) 1
*33816 Power Supply, 48 VDC, Reject Valve 1
34483 Base Cabinet Vent Fan 1
*35164 Smart Encoder 1
*92722 Relay, DPDT, 12 VAC Coil, 10 Amp 1
BRIGHT FIELD ANALYZER OPTION

*34859 Glass, Rotating, Tempered 2
STANDARD VACUUM PUMP

11171 Vacuum Pump 1
*11800 Jar, Intake Filter, 1 Pint 1
*11801 Jar, Exhaust Mufßer, 1 Quart 1
*12206 Service Kit, Vacuum Pump 1
*12532 Coupling, Vacuum Pump 1
*13327 Oil, Vacuum Pump 1


INSPECTION HEAD
17125 Strobe Lamp, Single Finish 1
24984 Card, RLD 1
25821-3 CCD Camera Black and White 1
29172 Strobe Lamp, Dual Finish 1
29267 Trigger Beam, Base & Finish 1
*30245 Servo Motor 1
*30619 Sensor, Reject VeriÞer 1
31195 Card, Pin Trigger 1
*32415 Widow, Protective, Optical 1
32578-1 Power Supply, Dual Finish Strobe with Dual Trigger 1
*32948 Sensor, Test Bottle 1
STARWHEEL AND GUIDES

*04204 Cup, Suction, Bellows-Type 50
*26498 Wear Strip, Bottle Guides 8
*26781 Wear Strip Conveyor, Upper 2
*26786 Wear Strip Conveyor, Lower 2
*27746 Belt Bottle Retaining (Lower) 2
*31853 Belt, Bottle Neck Retainer 2
CONVEYOR SPARE PARTS

*33508 Air Blowoff Nozzle, RH 1
*33509 Air Blowoff Nozzle, LH 1
*91241 Transmitter, Microsonic 1
*91242 Receiver, Microsonic 1
ELECTRONICS
*16449 RectiÞer, Strobe Power Supply 1
27890 Servo Cable Adapter 1
28513-1 **Card, I/O (See Following Note) 1
*28533-2 **Card, Line Control Module (See Following Note) 1
28648 Card, RLD Isolation 1
28694 **Servo Controller Card and Cover (See Following Note) 1
*29054-1 Takeaway Motor Controller 1
29154 Card, Multiplexer 1
29242 Card, Connector 1
29360-1 **Card, Video (See Following Note) 1
29442-3 Card, DSP 1
*31239-4 Starwheel Motor Controller 1
35117 Modbus Card (If Modbus Option Is Ordered) 1
36488-3 **CPU Card, Carrier, 20MB, ConÞgured (See Following Note) 1
*92713 Power Supply, 4 Outputs, 200 Watts 1
92893 Color Monitor 1
93387 LED, High Visibility, Red 1


*94381 Power Supply, Switching 350 Watts, A/B Chassis 1
*94452 Optical Coupler, PLC, Input, IDC 15 1
*94454 Optical Coupler, PLC, Output, ODC 15 1
Note: If ordering parts identiÞed with (**) after the machine is shipped,
contact IDC Engineering or Field Service for assistance. These parts are
software and/or revision sensitive. Specify both when ordering.
UPSTREAM RF RLD OPTION

35195-X Cover, Sensor, RF, Small 1
35196-X Cover, Sensor, RF, Large 1
35408 Kit, Mod, Sensor, Quick Disconnect, RLD 1
93358 Card, Control & LED Display 1
DOWNSTREAM RF RLD OPTION

33967 Plate, Wear, Receiver, RF RLD 1
34005 Plate, Wear, Transmitter, RF RLD 1
35408 Kit, Mod, Sensor, Quick Disconnect, RLD 1
93358 Card, Control & LED Display 1

Outer Sidewall Inspection (Dual Station)

Recommended Spare Parts
OUTER SIDEWALL ENCLOSURE
27974-2 Ribbon Cable, Servo 1
28133 Filter, Air, Dual Sidewall 1
28580 Servo Motor, Tilt Mirror, ModiÞed 1
28610 Window, Protective, OSW Tunnel 2
29025 Diffuser, OSW 2
30040 Lamp Supports 2
30245 Servomotor 1
31131 Pot, Linear 1
34483 Vent Fan, OSW Cabinet 1
91692 Relay, 8-pin 1
92607 Power Supply, Power One 1
92762-1 Fuse, KLK-3/10A 2
92878 Lamp, Deluxe, Fluorescent 8
92879 Ballast, Osram, HF 1
94283 Motor, DC, Gearhead, 24V 1
94423-2 Servo Extension Cable, 12 Inches 1
94423-3 Servo Extension Cable, 16 Inches 1
OUTER SIDEWALL GUIDERAILS

28837 Guiderail, Upper 2
32198 Wearstrip, Conveyor, OSW, Upper 1
32199 Wearstrip, Conveyor, OSW, Lower 1
33686-X Wearstrip, Bottle Guide, Lower Guide Rail 2
33466 Guiderail, Lower, RH 1
33467 Guiderail, Lower, LH 1
35211-1 Guiderail, RH 1
35211-2 Guiderail, LH 1

PARTS ORDERING
This section is intended to facilitate parts ordering. Provided here
is a list of the most common replacement parts with numbered
pictorial references.
When ordering replacement parts, give the Serial Number of your

machine as well as the Part Numbers and full descriptions of the
parts. If there is any doubt about the identiÞcation of a part, refer
to the following pictorial details and the Drawings section as
required.
Parts are categorized and described in alphabetical order. The line

items from left to right are: Figure Numbers, Part Descriptions and
Part Numbers.
Figures are not shown to scale; they are intended to give a visual
representation of parts to facilitate the ordering process.
The parts categories addressed in this section are as follows:
• Belts
• Cameras/Monitors
• Cards/Modules
• Diffusers/Lenses/Mirrors/Windows
• Electrical, Miscellaneous
• Encoders
• Fans
• Guiderails/Wear Plates/Wearstrips
• Lamps/Light Sources
• Mechanical, Miscellaneous
• Motors/Motor Controllers
• Power Supplies
• Rejectors and Accessories
• Relays/Sockets
• Sensors and Accessories
• Solenoid Valves
• Switches
• Transformers

Belts
1 Belts (Toothed):
1
Clutch/Brake, Dual Drive 27601
Conveyor Encoder, Dual 31054
Diffuser Brush, Lower, 120T 25501
Diffuser Brush, Upper, 65T 25500
OSW Camera 28628 BELTS
Starwheel Encoder, Dual 21575

Starwheel Encoder, Single 11104 2
2 Belts (Smooth):
Bottle Retainer, Lower, OV 1200 27746
Bottle Retainer, Lower, OV 900 15394
Bottle Retainer, Upper, OV 1200 31853
Bottle Retainer, Upper, OV 900 31852
Cameras/Monitors
1 CCD Camera 25821-3

2 Monitor, Color, Earlier Model 92893
2 Monitor, Color, Later Model 94502
3 Monitor Reversing Switch 31601
1
P/N
2
RE
V
1-X
S/
N
82
25
TO MON Y VIDEO MONITOR REVERSING SWITCH

J4 TO MON X
J3
J2 J1 31601
SYS B SYS A
Mo
nit
or

Cards/Modules
1
1 Connector Card 29242 2
TOP 29242
2 CPU Card/Carrier (No Sandisk) 33046-1 TOP
2 CPU Card/Carrier (With Sandisk) 33046-3

2 CPU Card/Carrier (With Sandisk) 36486-3
33348
2 CPU Card/Carrier, ConÞgured 36488-3

3 DSP Card, 33 MHz 29442-2
4 I/O Card, Early Model 28513-1
4 I/O Card, Later Model 36324-1
5 IR RLD Card 24984
6 IR RLD Isolation Card 28648
7 Line Control Module, Logic Card 28533-2
8 Modbus Card 35117 CPUMem
9 Multiplexer Card 29154

10 Pin Trigger Card 31195
11 PLC Encoder Buffer Card 25922
12 PLC I/O Card 92313
5 3
13 RAM/ROM Card with Carrier 31854
14 EPROM Kit for RAM/ROM Card 31880 24984 S/N
29442
(See Field Engineer for Software Version)

MADE IN USA
U55
1.
15 RectiÞer Card, Strobe Pwr Supply 16449 1.
16 RF RLD Control/LED Displ. Card 93358

INDUSTRIAL DYNAMICS CO.,
1
.
U17
16 RF RLD Control/Level Shift Card 35388 1.

1
.
17 RF RLD Impulse Board 93360 C51 1.
1
.
18 Servo Cable Adapter Card 27890

66MHZ
6
19 Servo Control Card 28253
74ABT574
TOP 28648 74ABT574
P1 J1
20 Servo Control Card & Cover 28694

21 Video Card 29360-1 1.
1
.
1
.
1
.
C56
TOP 28533
7
4
TOP IOCd
8
35117

Cards/Modules Continued...
9 10 11
29154 TOP 31195 TOP
13
UNIVERSAL MULTIPLEXER CARD
INDUSTRIAL DYNAMICS CO., LTD.
TORRANCE, CA.
MADE IN U.S.A.
ASSY
S/N
REV
SN
12
1 2 3 4 5 6 7 8 9
1
2
3
4
92313 5 31
85
4
1 2 3 4 5 6 7 8 9
14
P/N: 31880 - XXX
15
CR1 CR3
POS. NO: UXX

CR2 CR4
1 2 3 4 5 6 7 8 9 VC: XXX CS:
TB
16449
16 17 15
18
0
89
27
35219
1
93358
93360
35388
21 TOP
19
29360 TOP 28
69
4
20 28253

Diffusers/Lenses/Mirrors/Windows
1 Base Strobe Lens 10238

2 Clear Glass, Rotating, Bright Field 34859 1
2 Diffuser Glass, Rotating, Standard 14178-1 10238
3 OSW Diffuser Glass 29025

3 Window, Display Monitor 25505
3 Window, Inspection, OSW 28610
4 Window, Finish, Inspection Head:
Dual, Press/Twist, ROPP (Single) 32415
Single, Press/Twist (T Bottle) 16796
Diffuser
4
2
WINDOW
DiffWind

Electrical, Miscellaneous
1 Air Conditioner, Early Model 25728

1 Air Conditioner, Current Model 35500
2 Ballast, Fluorescent Lamp, OSW 92879 1
Replacement Bulb (Lamp) 93496
4 Blower, Base Cabinet 30526
5 Circuit Breaker, Fuse Type, OSW 92686-2
6 Circuit Breakers: Air
Co
nd
Cabinet 91353
Starwheel Motor 91342
2-pole, 7-amp 92500
4-amp 91341 2
7 Clutch/Brake, Starwheel Drive 13269
8 Filter, EMI, Surge, Base Cabinet 33727
9 Filter, Inline, 120/230 VAC 92272 92
87
9
10 Fuse, KLK3/10A, OSW 92762-1

11 Potentiometer, Linear, OSW 31131
12 Servo Exten. Cable, 12 in., OSW 94423-2
12 Servo Exten. Cable, 16 in., OSW 94423-3 3
13 Servo Ribbon Cable, OSW 27974-2 4
14 Touchpad Panel 26818 32729
7
Cc 92
tBr
kr
6
68
6
5
30
52
6
9
10
13269
92762
92272
7
72
33
A 26818
B
94423 11
12 31131
14
13
JX/PX JY/PX
27974

Encoders
1 Starwheel/Conv. Encoder, Smart 93473

1
2 Starwheel Drive Encoder 24963
Replacement Encoder 93493 93
47
3 Starwheel Drive Encoder 32794 3
2 2496
3
Replacement Encoder 93493

3 Starwheel Drive Encoder, Smart 35164
Replacement Encoder (Item #1) 93473
3 EncS
tar
Fans
1 Fan, Air Conditioner, Electronics 35515

2 Fan, Base Cabinet 13268
3 Fan, Base Cabinet and OSW 34483 1
P311
4 Fan, Inspection Head 32877
5 Fan, Power Control Motor 13415
5
51
35
8
26
13
3
34
48
3
5
4 32
87
7
13415

Guiderails/Wear Plates/Wearstrips
1
1 Guiderail, Lower, OSW, LH 33467
1 Guiderail, Lower, OSW, RH 33466 GRLwrOSW
2 Guiderail, Upper, OSW 28837

2 Guiderail, Upper, OSW, LH 35211-2 2
2 Guiderail, Upper, OSW, RH 35211-1 GRUprOSW
3 RF RLD Emitter Wear Plate, D/S 34005

3 RF RLD Receiver Wear Plate, D/S 33967
4 Wear Plate, Bright Field Analysis 35392
5 Wearstrip, Bottle Guide 26498
6 Wearstrip, Bottle, Lower, DOSW 33686-1
6 Wearstrip, Bottle, Lower, SOSW 33686-2
7 Wearstrips:
Crossover Conveyor, MIDD 28647
Crossover Conveyor, RS 28670
Crossover Conveyor, Short 28669 35392
Main Conveyor, Lower 26786 WrPltRFRLD
Main Conveyor, Lower 26789 3 4

Main Conveyor, Upper 26781
OSW Conveyor, Lower 32199
OSW Conveyor, Upper 32198
Reject Conveyor 26708
5
26498
6
68
33

Lamps/Light Sources
1 Base Strobe Housing, Dual Point 31572

2 Dual Point Strobe Lamp 30493 2
3 Finish Strobe Lamp, Dual 29172
4 Finish Strobe Lamp, Single 17125 30493
5 LED, Red, High Visibility 93387

6 OSW Fluorescent Lamp 92878
Ring Strobe Lamp 16522
(Figure Not Shown)
3
1
29172
31572
17125
5
93387
92878

Mechanical, Miscellaneous
1 Air Blowoff: 1
“A” Manifold, LH, OV 1200 34157
“A” Manifold, RH, OV 900 33508
“B” Manifold, LH, OV 900 33509 Air
Blo
wo
ff
“B” Manifold, RH, OV 1200 34156
2 Air Filter, Dual OSW 28133
3 Ball Bearing, Bottle Neck Guide 11015
4 Counter, Height Indicator, Ins Hd 28194
5 Jar, Exhaust, Vacuum Pump 11801
5 Jar, Intake Filter, Vac. Pump 11800
6 Gasket, Light enclosure, Lower 10213 2
6 Gasket, Light enclosure, Upper 33775
7 Gauge, Pressure 91204
7 Gauge, Vacuum 91201
8 Lamp Supports, OSW 30040
9 Oil and Container, Ram Rejector 00177
9 Oil and Container, Vacuum Pump 13327 28133
10 Pressure Regulator, 0-100 psi 02709

11 Pulley, Bottle Neck Guide 19288
12 RF RLD Emitter Cover, Upstream 35195-0
12 RF RLD Receiver Cover, Upstream 35196-0 3
13 Scrubber Brush, Diffuser Glass 26794 5
11015
14 Suction Cup, Bellows Type 04204

15 Vacuum Pump 11171
16 Vacuum Pump Service kit 12206
17 Vacuum Pump Coupling 12532
18 Valve Plate “O” Ring 01795 4
19 Valve Plates:
Glass Bottles, LH, OV 900 33636-2 1180X
4
19
Glass Bottles, RH, OV 900 33635-2 28
Special Bottles, LH, OV 900 33636-1

Special Bottles, RH, OV 900 33635-1
Plastic Bottles, LH, OV 900 33636-3
Plastic Bottles, RH, OV 900 33635-3
Starwheel, LH, OV 1200 27592 6
Starwheel, RH, OV 1200 27591
Gasket
10 PART NO XXXXX
9
30040
02
70
7
9
91
20
X
8
Oil&Cntnr

Mechanical, Miscellaneous, Continued...
19288
11 12 14
26794 13 20
4
04
3519X
CARTRIDGE
(2)
15
BODY (SPACER)
GASKET VANE (4)
16
BEARING
SPACER
BALL
BEARINGS (3)
DIAPHRAGM
FEED
SHAFT WICK
11171
SEAL (2)
12206
17 01795 18
12532 19
VlvPltStar

Motors/ Motor Controllers
1 Gear Motor, Diffuser Glass, LH 16269 1

1 Gear Motor, Diffuser Glass, RH 16270
2 Gearhead Motor, 24 VDC, OSW 94283
162XX
3 Motor Controller, Starwheel 31239-4
3 Motor Controller, Takeaway 29054-1
4 Servo Motor 30245
5 Servo Motor, OSW Tilt Mirror 28580
6 Starwheel Gearhead Motor/Tach. 31959
7 Starwheel Motor Brush Repair Kit 16514
8 Takeaway Drive Motor, 1/4 HP 15544
9 Vacuum Pump Motor, 50 Hz 12562
9 Vacuum Pump Motor, 60 Hz 12561
9 Vacuum Pump Motor, 575V, 60 Hz 12560
10 Vacuum Pump Motor Starter: 2
6 - 10 A, 1 Phase 91400-1 94283
0.4 - 0.6 A, 1 Phase 91400-2
1.6 - 2.4 A, 3 Phase 91400-3
1.0 - 1.6 A, 3 Phase 91400-4
2.4 - 4.0 A, 3 Phase 91400-5 4 Mt
rC
ntr
l
30245
3
6
28580
9
95
31
7
RETAINER
(16512)
QTY 2
BRUSH
(16513)
QTY 2
16514
10
8 9
X 91
1256 40
0
4
54
15

Power Supplies
1 Chassis A/B Switching PS, 350W 94381

2 Dual Strobe/Dual Trig PS, Finish 32578-1 1
3 Four-output PS, 200W 92713
4 Inspection Head PS, 12 VDC 94495
4 Inspection Head PS, 15 VDC 93068
5 Monitors and Elect. PS, 48 VDC 33123
6 Outer Sidewall Power Supply 92607
7 Reject Valve PS, 48 VDC 33816
8 RF RLD Power Supply 93361
94
38
1
V4+
V4-
Fuse F1
LINE
V3
Adj
V4
Adj
V3+
V3- 2
V2+
NEU
GND
V2-
S-
3
V1-
TB1 V1-
V1+
ING
RN
115/230 VAC PFD Adj V1 Adj V1+
JUMPER
92713
S+ WA
TB2
8
57
32
5
49
94
3
12
33 60
7
92
J1
6
T2 T1
8
7
93361
33
81
6

Rejectors and Accessories
1 Air Controls, Impulse Rejector 34077

1 Air Controls, Proline Rejector 24326
2 Ram Rejector, Impulse 03048 1
3 Valve, Pilot and Guard 12565
(Used With Impulse Ram Rejector 03048)
4 Ram Rejector, ProLine 26030
(ProLine Top Assembly - 26039: Combines
26030, 24326 [Item #1], and Brackets)
5 Rejector Pads:
Soft Rubber (Tapered), 16 oz Btls. 19247
Soft Rubber, Short Pad Servotrec 34267-1
Soft Rubber, 48 oz Bottles 19245 Air Controls
Hard Rubber, Bottles Over 48 oz 03147
Soft Rubber, Long Pad Servotrec 34267-2
4
2
0
03
26
8
04
03
12
56
5
D
PA

Relays/Sockets
1 Relay, DPDT, 12 VAC, 10A 92722

6 5 4 3
24 22 12 14
1 Relay, Potter KRPA-11A-120 92735

2 Relay, PLC I/O Coupler, IDC15 94452 Relay 1
2 Relay, PLC I/O Coupler, ODC15 94454 2
3 Relay Socket, 8-pin, OSW 91692 94 5

4
3 91692
A2 21 11 A1
45
X
1 2 7 8 1 2
Sensors and Accessories
1 AmpliÞer for Sensor 21664 (Item 3) 31963

2 Microsonic Sensor, Receiver 91242
2 Microsonic Sensor, Transmitter 91241
3 Photoelectric Sensor, Ram Rejector 21664 1
4 Proximity Sensor, Doors, LH 33965 31963
4 Proximity Sensor, Doors, RH 33823

5 Reßector for Item 6, OV1200 32995-2
5 Reßector for Item 6, OV900 32995-1
6 Reject VeriÞer Sensor 30619
7 RF RLD Sensors 93359 2
8 RF RLD Sensors, Quick Disc. 34771
9 RF RLD Sensors, Quick Disc., Kit 35408
10 Test Bottle Sensor 32948 9124X
11 Trigger Sensor, Base/Fin, Dual 29267

11 Trigger Sensor, Base/Fin, Single 17126
3
4
7 5
6 21664
ns
xS
Pr
RECE
IVER
5
99
32
8
EMIT
TER
93359 9
61
30
10 Trig
Blk
11
3294
8

Solenoid Valves
1
1 Air Solenoid Valve, 110 VAC 32176
2 Reject Solenoid Valve, 24 VDC 13241
3 Water Solenoid Valve, 110 VAC 13243 32
17
4 Water Solenoid Valve, 110 VAC 94217 6
4
3
13
13
24
1 2
24
3
94
21
7
Switches
1 Door Interlock Switch 92728

2 Omnivision Main Power Switch 26669 92
72
8
3 OSW Main Power Switch 92803
4 Switch, Twist-release, Illum. 93266 1
Replacement LED for 93266 93387
4 Switch, Twist-release, Nonillum. 92365
3
80
92
3
Sw
Tw
4
ist
9
66
26

Transformers
1 2KVA Universal Transformer 92660

2 3KVA Transformer 93074
1
3 2 KVA, 575 VAC, Base Cabinet 91479
3 3 KVA, 575 VAC, Base Cabinet 93075
4 OSW Lamp Transformer 30045
5 Stepdown Transformers:
0.5 KVA, 50/60 Hz, OSW 91290-1
1 KVA, 50/60 Hz, Base Cabinet 91290-2
2 KVA, 50/60 Hz, Base Cabinet 91290-3
3 KVA, 50/60 Hz, Base Cabinet 91290-4 66
0
92
3
2
4
07
93
4 5
5
04
30
0
29
91

DRAWING TERMINOLOGY
The exploded view drawings use a speciÞc terminology for desig-
nating fasteners, parts and assemblies plus referenced parts from
other locations or other drawings. The terminology is as follows:
The circle code is used for fasteners. This

4
fastener list may be located on the drawing or
on a separate page.
Note: On the newer drawings, the circle code

is also used to identify the part numbers and
the assembly numbers. The number inside the
circle is the same as the Item Number in the
Parts List.
11071 Racetrack code for single parts.
12601 Rectangle code for Assemblies. These assem-

blies may be broken down on the same
drawing or another drawing. If the assembly
explosion cannot be found, then the parts
must be purchased as an assembly using that
number.
12610 or 12610 REF Denotes a “Reference” code which signiÞes

that part number has been used in an
assembly or as a separate part elsewhere on
the drawing. This method prevents dupli-
cation of parts or listing since each assembly
is exploded.
13291 Denotes a “Reference” Assembly which is not

a stocked item and cannot be ordered.
Industrial Dynamics Company, Ltd. © Form 3056 (05/99A) C-25

MAIN ASSEMBLY PART NUMBERS

This section contains the drawings and parts lists for various
assemblies used on the Omnivision 900, 1200, D1200, and the Dual
Station, 4-camera Outer Sidewall Systems.
The Top Assembly Drawing Numbers are:
• 29002 - Omnivision 1200/D1200 (Right Hand)

• 29003 - Omnivision 1200/D1200 (Left Hand)
• 33352 - Omnivision 900 (Right Hand)
• 33353 - Omnivision 900 (Left Hand)
• 27563 - Dual Stations Outer Sidewall Unit
NOTE
Only the drawings for the right-hand machines or those common
to both the right-hand and left-hand machines are included in
this appendix.
Refer to Figures C-1 through C-9 for Top Assemblies, Main Assem-
blies and Subassemblies. The table in each Þgure shows part
descriptions, part numbers, and where parts may be found by
referring to page numbers or “Z-fold” drawings or Form
Numbers. The Drawings Lists and Drawings follow this section.
C-26 Industrial Dynamics Company, Ltd. © Form 3056 (05/99A)

29002 (OV 1200) 29000 (OV 1200)

33352 (OV 900) 32865 (OV 900)
OMNIVISION
33293 (OV 1200)

33292 (OV 900)
27563 (DOSW) 31124 (OV 1200)

33256 (OV 900)
29034 (OV 1200)

OMNIVISION
33262 (OV 900)
OUTER SIDEWALL
INSPECTOR
29273 (OV 1200)

31708 (OV 900)
31068 (OV 1200)

26758 (OV 900)
29275 (OV 1200)

OVOSWAssy 33266 (OV 900)
OV 1200 OV 900
Part Description
P/N Page P/N Page
TOP ASSEMBLY, MAIN OMNIVISION, RH: 29002 C-61 33352 C-133
Monitors & Electronics 29000 Z-fold 32865 Z-fold
Columns & Doors 33293 Z-fold 33292 Z-fold
Inspection Head 31124 C-94 33256 C-126
Inspection Head & Star Drive 29034 C-62 33262 C-129
Conveyors & Air 29273 Z-fold 31708 C-104
Base Cabinet Exterior 31068 C-90 26758 C-50
Base Cabinet Interior 29275 Z-fold 33266 Z-fold
TOP ASSEMBLY, DUAL OSW UNIT 27563 Z-fold 27563 Z-fold
Note:
For Top Assembly parts and details, refer to Drawings 29002 (OV 1200), 33352 (OV 900)
and 27563 (DOSW).
Figure C-1. Omnivision Main Assembly Part Numbers (Right Hand System)

29000 (OV 1200) 35672-1 (OV 1200)

32865 (OV 900) 35672-2 (OV 900)
32729 (2)
OMNIVISION
OV 1200: OV 900:
29020-0 33584
32383-0 32383-0
94381 94381
28862
26818 (2)
A
B
Montr&Elect
OV 1200 OV 900
Part Description
P/N Page P/N Page
MONITORS AND ELECTRONICS: 29000 Z-fold 32865 Z-fold
Air Conditioner 35672-1 Z-fold 35672-2 Z-fold
Beacon 32729 See Note 32729 See Note
Card Cage 29020-0 See Note 33584 See Note
Dual Color Monitors 28862 Z-fold 28862 Z-fold
LCM Enclosure, Electronics 32383-0 C-116 32383-0 C-116
Power Supply 94381 Fm 3055 94381 Fm 3055
Touchpad 26818 See Note 26818 See Note
Note:
For other parts and details, refer to Drawings 29000 (OV 1200) and 32865 (OV 900).
Figure C-2. Monitors and Electronics - Subassembly Part Numbers

N
O
I
S
I
V
I
N
M
O
33293 (OV 1200)

33292 (OV 900)
s
Dr
s&
lm
Co
OV 1200 OV 900
Part Description
P/N Page P/N Page
COLUMNS AND DOORS: 33293 Z-fold 33292 Z-fold
Front and Rear Doors 33303 See Note 33295 See Note
Infeed Doors 33305, See Note 33296 See Note
33306
Outfeed Doors 33307, See Note 33298, See Note
33308 33299
Note:
Figure C-3. Columns and Doors - Subassembly Part Numbers

31124 (OV 1200) 28694 (2), OV 1200 28648 30167

33256 (OV 900) 28694 (1), OV 900
31533
OV 1200: OV 900: 93068

29107 (M.O.) 29107 (M.O.) Ins
pH
dO 94495
29267 (2) 17126 (2) V1
2
30315 30315
OV 1200 OV 900
Part Description
P/N Page P/N Page
INSPECTION HEAD (RH): 31124 C-94 33256 C-126
Isolation Card, IR RLD 28648 Fm 3055 28648 Fm 3055
Pin Trigger Card Assembly 31533 Fm 3055 Not Applicable
Power Supply, IR RLD Isolation 94495 Fm 3055 94495 Fm 3055
Power Supply, Trigger/Servo 93068 Fm 3055 93068 Fm 3055
Reject VeriÞer 30315 C-86 30315 C-86
Servo Card and Cover 28694 See Notes 28694 See Notes
Test Bottle Sensor (M.O.) 29107 C-74 29107 C-74
Trigger Beam, Emitter/Receiver 29267 See Notes 17126 See Notes
3-Tower Optical System, Right Hand 30167 C-79 30167 C-79
Notes:
The Figure shown above is for Omnivision D-1200.
Figure C-4. Inspection Head - Subassembly Part Numbers

29034 (OV 1200)

33262 (OV 900)
31124 (OV 1200)

33256 (OV 900)
OV 1200: OV 900:
13269 13269
21575 11104
27503 11065 28194
27601 None
31959 31959
35164 35164
InspHdStar
OV 1200 OV 900
Part Description
P/N Page P/N Page
INSPECTION HEAD AND STARWHEEL 29034 C-62 33262 C-129
DRIVE (RH):
Belt, Pulley, Star Drive 27601 Note Not Applicable
Belt, Timing, Encoder 21575 Note 11104 Note
Clutch, Brake, Star Drive 13269 Note 13269 Note
Counter, Position Indicator 28194 Note 28194 Note
Encoder, Smart, Star Drive 35164 Note 35164 Note
Inspection Head 31124 C-94 33256 C-126
Motor, Gear Head, DC With Tachometer 31959 C-111 31959 C-111
Spindle Housing 27503 Note 11065 Note
Note:
Figure C-5. Inspection Head and Starwheel Drive - Subassembly Part Numbers

29273 (OV 1200) 33508 (OV 1200)

31708 (OV 900) 34156 (OV 900)
29280 (OV 1200)

32509 (OV 900)
Air
nv
Co
OV 1200 OV 900
Part Description
P/N Page P/N Page
CONVEYORS AND AIR (RH): 29273 Z-fold 31708 C-104
Air Sprayer, Manifold 33508 Note 34156 Note
Belt, Bottle Retainer, Lower (Not Shown) 27746 Note 15394 Note
Main Conveyor, High Speed 29280 Z-fold 32509 Z-fold
Note:
Figure C-6. Conveyors and Air - Subassembly Part Numbers

27545
14178-1
34859
31068 (OV 1200)
26758 (OV 900) 26794
10238
16270
BsCabExt
OV 1200 OV 900
Part Description
P/N Page P/N Page
BASE CABINET EXTERIOR (RH): 31068 C-90 26758 C-50
Brush, Scrubber 26794 Note 26794 Note
Brush, Scrubber Assembly 27545 C-58 27545 C-58
Diffuser Glass (Clear Type) 34859 Note 34859 Note
Diffuser Glass (Diffused Type) 14178-1 Note 14178-1 Note
Gear Motor, Diffuser Glass 16270 C-42 16270 C-42
Lens, Convex 10238 Note 10238 Note
Note:
Figure C-7. Base Cabinet Exterior - Subassembly Part Numbers

29275 (OV 1200)

33266 (OV 900)
OV 1200: OV 900:
13241 13241
13268 13268
27520 26560
27766-0 None
32176 32176
33727 33727
BsCabInt
OV 1200 OV 900
Part Description
P/N Page P/N Page
BASE CABINET INTERIOR (RH): 29275 Z-fold 33266 Z-fold
Fan 13268 Note 13268 Note
Filter, EMI Surge 33727 Note 33727 Note
Filter/Gauge Panel 27520 C-55 26560 C-45
Reject Solenoid Valve, 4-way, Mac 13241 Note 13241 Note
Solenoid Valve, Air, 115VAC 32176 Note 32176 Note
Vacuum Kit 27766-0 C-59 None C-59
Note:
Figure C-8. Base Cabinet Interior - Subassembly Part Numbers

27563
92735 (2) O M N I V I S I O N
92607 (2)
27047 "A" "B"
30043 (2)
29086-0 (M.O.)
29100 (M.O.)
34483 (2)
28332 (2)
(M.O.)
DOSWAssy
30045 (2)
Description P/N Page

TOP ASSEMBLY, DUAL OUTER SIDEWALL UNIT: 27563 Z-fold
Fan 34483 Note
Guide Rail, Upper, Adjustable (M.O.) 29086-0 C-70
Guide Rail, Upper, Nonadjustable (M.O.) 29100 C-73
Lamp, Fluorescent, Single Sidewall 30043 Z-fold
Power Supply (5, ±12, 24 V) 92607 Note
Relay 92735 Note
Terminal Block Panel 27047 C-53
Transformer, Lamps 30045 C-78
TOP ASSY., MIRRORS/2 CAMERAS/MOVABLE TABLE (M.O.) 28332 Z-fold
Note: For other parts and details, refer to Drawings 27563 and 28332.
Figure C-9. Dual Station OSW - Subassembly Part Numbers

DRAWINGS
This section includes two drawings lists. The Þrst list shows the
drawings which are included in this manual (Form 3056). The
second list shows the drawings which are included in Start-up and
Technical Reference Manual (Form 3055).
The lists consist of Part Descriptions, Drawing Numbers, Revision

Numbers and Page Numbers where applicable. The lists are
categorized and arranged alphabetically to make it easy to locate
the drawings.
NOTE
For Installation Drawings refer to Form 3053. For additional
Outer Sidewall Inspection Drawings refer to Form 3057.
The actual drawings are organized numerically, either in the form

of “page-size” illustrations (with page numbers) or “Z-folded”
drawings which follow the “page-size” illustrations.
NOTE
The “page-size” illustrations are intended for identifying the
parts for ORDERING PURPOSES ONLY. These illustrations do
not contain instructions on how to assemble the parts.
To Þnd a part number, Þrst locate the part in the Description

column, and then go to the page number shown in the Page No./
Z-fold column.

Drawings Included In This Manual (Form 3056)
Description Dwg. Rev. Page No./

No. No. Z-fold
Air Conditioner, SK 3290100 35672-0 5 Z-fold
Base Cabinet, Exterior, Right Hand, OV 1200 31068 12 C-90
Base Cabinet, Exterior, Right Hand, OV 900 26758 13 C-50
Base Cabinet, Interior, Right Hand, OV 1200 29275 26 Z-fold
Base Cabinet, Interior, Right Hand, OV 900 33266 12 Z-fold
Brush Scrubber 27545 3 C-58
Camera, B/W CCD 25821-0 5 C-44
Camera, Mounted, Dual 29185-0 1 C-75
Change Parts, OV 1200, Right Hand 30224-0 1 C-82
Columns and Doors, Right Hand, OV 1200 33293 5 Z-fold
Columns and Doors, Right Hand, OV 900 33292 5 Z-fold
Conveyors and Air, Right Hand, OV 1200 29273 7 Z-fold
Conveyors and Air, Right Hand, OV 900 31708 4 C-104
Crossover Conveyor, Omnivision, Right Hand 28726 11 Z-fold
Filter/Pressure Gauge Panel, OV 1200 27520 3 C-55
Filter/Pressure Gauge Panel, OV 900 26560 6 C-45
Gear Motor, Diffuser Glass, Right Hand 16270 7 C-42
Inspection Head and Starwheel Drive, RH, OV 1200 29034 15 C-62
Inspection Head and Starwheel Drive, RH, OV 900 33262 10 C-129
Inspection Head, Right Hand, OV 1200 31124 5 C-94
Inspection Head, Right Hand, OV 900 33256 7 C-126
Kits:
--- Base Cabinet, Option, 190-460 VAC, OV 900 33136 4 C-125
--- Bright Field Inspection System 35643-0 3 Z-fold
--- Finish, Option, Dual, Right Hand 31371 5 C-100
--- Finish, Option, Dual, 40-55 Degrees, RH, OV D1200 33023 3 C-124
--- Illuminator, Dual Strobe, Press, 40°-55°, RH, OV D1200 32565 4 C-120


No. No. Z-fold
Kits Continued ...
--- Illuminator, Dual Strobe, Twist Finish, RH, OV D1200 29096 5 C-71
--- Illuminator, ROPP, 28 mm, Single, 20°, OV 900/1200 32453-2 8 C-117
--- Optical Collimator, Press, Single, 62°, RH, OV 900/1200 26586 8 C-48
--- Ram Rejector, Impulse 32070-2 14 C-114
--- Ram Rejector, Proline 32070-1 14 C-112
--- “T” Bottle Coll., Single, Twist Fin., 40°, RH, OV900/1200 29532-0 9 C-76
---Vacuum, Option 27766-0 8 C-59
Line Control Module, Electronics Enclosure 32383-0 7 C-116
Line Control Module, Heat Sink, Power Supplies 32517-0 3 C-119
Line Sensors, Ultrasonic 35750-0 4 Z-fold
Main Conveyor, Right Hand, OV D1200 29280 15 Z-fold
Main Conveyor, Right Hand, OV 900 32509 11 Z-fold
Monitor, Color, 14" (Assembly and RetroÞt Kit) 37014-0 1 Z-fold
Monitors and Electronics, OV 1200 29000 21 Z-fold
Monitors and Electronics, OV 900 32865 16 Z-fold
Monitors, Color, Dual Assembly 28862 11 Z-fold
Motor Drive, Starwheel 31239-0 6 C-97
Motor Drive, Takeaway Conveyor 29054-0 4 C-66
Motor, Gearhead, DC, W/Tach, Starwheel Drive 31959 5 C-111
Neck Guide, OV 1200, Right Hand 31914 2 C-110
Neck Guide, OV 900, Right Hand 31911 0 C-109
Optical Tower, Base Inspection 30203-0 5 C-80
Optical Tower, Inner Sidewall Inspection 30205-0 5 C-81
Optics, Three-Tower, Right Hand 30167 4 C-79
Outer Sidewall Inspection:

--- Elevator, Plate, Camera 30615 2 C-87
--- Guide Rail, Lead Screw, Upper, Dual 29059 4 C-67


No. No. Z-fold
Outer Sidewall Inspection Continued...
--- Guide Rail, Upper, Adjustable, Dual 29086-0 3 C-70
--- Guide Rail, Upper, Nonadjustable, Dual 29100 2 C-73
--- Lamp, Fluorescent 30043 4 Z-fold
--- Mirror, Elevated, Third View 32778 2 C-122
--- Mirror, 2 Cameras, Movable Table 28332 9 Z-fold
--- Terminal Block Panel, Dual 27047 2 C-53
--- Transformer, Lamps, Set Up 30045 1 C-78
Overheight Bottle Detector 31353 8 C-98
Reject Conveyor, Extended Tray, Right Hand 26712 2 Z-fold
Reject VeriÞer Sensor 30619 5 C-89
Reject VeriÞer Sensor, Assembly, Right Hand 30315 4 C-86
Strobe, Dual Point, Omnivision 900/1200 31572 8 C-101
Tank, Lube, Vacuum Pump 16883 4 C-43
Test Bottle Sensor 32948 4 C-123
Test Bottle Sensor, Assembly, Option 29107 7 C-74
Top Assembly, Omnivision 1200, Series 3000, Right Hand 29002 6 C-61
Top Assembly, Omnivision 900, Series 3000, Right Hand 33352 5 C133
Top Assembly, OSW Unit, Dual Station, 4 Cameras 27563 9 Z-fold
Ultrasonic Line Sensors 35750-0 4 Z-fold
Voltage Option, Base Cabinet, 208-440 VAC, OV 1200 31752 7 C-106
Voltage Option, Base Cabinet, 460-480 VAC, OV 1200 31753 5 C-107
Voltage Option, Base Cabinet, 575 VAC, Omnivision 1200 31754 4 C-108

Drawings Included In Start-up And Technical Reference Manual

(Form 3055)
Description Dwg. No. Rev. No.

ASSEMBLIES
Back Plane/Motherboard, Card Cage A/B 28509 9
Camera, CCD, A/B 25821-0 5
Line Control Module (LCM) Enclosure, Electronic 32383-0 7
PLC Interface, Junction Box 27567 8
Power Supply, 48V, OV 900 33123 5
Power Supply, Inspection Head, ACC107 (5V, ±12V, 50W) 94495 3
Power Supply, Inspection Head, ACC108 (5V, ±15V, 50W) 93068 1
Power Supply, SQM350 94381 2
Starter, Vacuum Pump Motor 91400-0 11
CABLES
Adapter, Pin Trigger 31357 2
Kit, Adaptor, DC, Power, Dual 32738 3
Kit, Power, AC, LED Strobe, Omnivision 32736 1
LCM, AC Distribution 32555-0 4
LCM, Motor/Brake/Clutch 32556-0 9
LCM/PLC/Sensors 32559-0 7
LCM, P1, Reject/Beacon 32558-0 8
LCM, Sonic/Encoder/Overtemperature 32557-0 9
Ring Strobe, Power, 48 VAC/VDC 32554-0 3
SCHEMATICS
Connector Card 29243 5
Dual Ring Strobe, Logic 31308 0
Dual Ring Strobe, Trigger 32580 1
I/O Card 28514 16

Description Dwg. No. Rev. No.

SCHEMATICS Continued ...
IR RLD Card 24987 3
Line Control Module, Card 28534 13
Motherboard/Back Plane 28510 3
Multiplexer Card 29155 0
Quad Pin Buffer Card, OV D-1200 31196 0
Servo Control Card 28254 7
Strobe Logic, OV D-1200 31573 2
Strobe Quench, OV 1200 28001 0
Strobe Trigger Card, OV 900 25868 2
Video Card 29361 4
Video Monitor Reversing Switch 31602 0
WIRING DIAGRAMS
Fluorescent Lamp, OSW 30058 1
Input Power, 208-440VAC, 50/60 Hz, OV 1200 31765 2
Input Power, 575 VAC, 60 Hz, OV 1200 31772 2
Input Power, 575VAC, 60 Hz, OV 900 33132 1
LCM Power, OV 1200 31155 11
Network, RS485, Routing 28989-0 10
PLC Junction Box, OV 1200 29192 2
Power System, Omnivision 32601-0 9
System Cable, Omnivision 32600-0 5

P/N 16270 ASSEMBLY, GEAR MOTOR, DIFFUSER GLASS, RIGHT HAND
Item No. Part No. Description Qty

1 25325 Bracket, Mounting, Fan Cover 2
2 25350 Spacer, Hex, M/F 4
3 91302 Connector, Cap Housing 1
4 91305 Contact, Cap or Plug Socket 2
5 91549 Motor, Gearhead, Right Hand 1
6 92399 Guard, Fan, Finger 1
7 None Tie Wrap A/R
0A
27
16
5
4 (2)
7 A 3
1 (2)
1
2 (4)
2
A-A

P/N 16883 ASSEMBLY, TANK, LUBE, VACUUM PUMP

1 00512 Connector, Male, Brass 2
2 11316 Adhesive, RTV, Silicone Rubber A/R
3 13834 Oil Lubricator A/R
4 16876 Pipe, Copper, Water 1
5 18933 Fitting, Tube, Equalization 1
6 18934 Fitting, Tank, Lube, Vacuum Pump 1
7 18941 Pipe, Copper 1
8 28594 Fitting, Hose, Barb, 5/8 - 3/8 1
9 91295 Contact Cap or Plug Socket 2
10 91303 Connector, Plug Housing 1
5
4 7
Gast Gast
Washer "O" Ring
1 (2)
Detail "A"
See Detail "A"

8
14.00
Red Wire (2)

6 (Ref) 9 (2)
10
2
5
(Seal All Around)
Wick (Ref) Plastic Cap (Ref)

(Shipping Only)

P/N 25821-1 ASSEMBLY, CAMERA, BLACK & WHITE, BLACK & WHITE CCD

1 24404 Label, Part Number, Revision, Serial Number 1
2 25816 Camera, Black & White CCD 1
1 (CAMERA WITH
LABEL 2
COVER ON)
552
REV
P/N
S/N
XXXXXX
XX
XXXXX-X
GP-MF
NOTE: REFER TO DWG 25821-0 FOR

CAMERA CONFIGURATION
AND SWITCH SETTINGS.

P/N 26560 ASSEMBLY, FILTER/GAUGE PANEL, OV 900

1 00511 Close, Nipple, Brass 3
2 00666 Elbow, Male, Brass 1
3 01185 Filter, Vacuum Pump 1
4 01726 Nipple, Brass 1 1/2 inch 2
5 02709 Regulator, Pressure 1
6 04356 Tubing, Plastic 2
7 05905 Washer, PolyÞbre 2
8 10034 Fitting, Elbow, Female 3
9 10240 Connector, Male, Compression 1
11 10242 Connector, Female, Compression 2
12 10250 Fitting, Elbow, Male 2
13 10253 Adapter, Bulkhead, ModiÞed 1
14 10486 Adapter, Bulkhead 2
15 10500 Fitting, Elbow 1
16 10645 Tee, Female, Brass 1
16A 10911 Clamp, Hose, Worm Drive 1
17 10957 Nut, Panel 2
18 11121 Seal, Hole 3
19 11122 Fitting, Long, Nipple, 3/8 2
20 11130 Fitting, 3/8, Street Elbow 2
21 11169 Adapter, Brass, Bulkhead 2
22 11188 Fitting, Close Nipple 1
23 11189 Fitting, Bush, 3/8 Pipe 1
24 11399-2 Washer, Fiber 2
26 11951 Tee, Female, Brass, 3/8 1
27 16866 Pipe, Air, Copper, Gauge 1
28 16884 Regulator, Air, Fixed 1
29 17960 Label, Filter Service 1
30 21506 Nipple, 1/4 Hex 2
31 24081 Connector, Male, 3/8 Tubing 1
32 25571 Tube, Oval 1
33 25572 Tube, Press 1
34 25577 Tube, Regulator, Air Filter 1
35 25641 Panel, Gages, Filters 1
36 25890 Connector, Male 2
38 27765 Tubing, Poly 36 inches
39 33453 Connector, Male, 1/2 Tube x 3/8 1

P/N 26560 ASSEMBLY, FILTER/GAUGE PANEL, OV 900, CONTINUED

40 33454 Elbow, Male, Swivel, 1/2 Tube x 3/8 1
41 33456 Tubing, Polyurethane 48 inches
42 33457 Elbow, Male, 1/2 Tube x 1/4 NPT 1
43 34067 Filter, Air, 1/4 NPT 1
44 91201 Gauge, Vacuum Switch 1
45 91204 Gauge, Pressure, Switch 1

TO PURGE TO SOLENOID VALVE TO MANIFOLD
SEE DWG 26550 SEE DWG 6550 SEE DWG 26550
SHT 2, DETAIL EE SHT 3, DETAIL B (2-C) SHT 2, AT "DD" (3-D) 23 10 31
40 41
(1-D)
14 26
11
(PANEL BKT)
12 38 15
24 14 21 (PANEL BKT)
16A 33 4 22 7 21
C
C
8 19
27 39
D
30 H 44
14
37 D
24 30
12 14
1 35 21
4 TO VACUUM PUMP
13 8 SEE DWG 26766
9 7 20
28 16 DETAIL D, AT "F"
G
43 21
(ALSO 26766, DETAIL A)
6 19
32 3
1 36 20
Industrial Dynamics Company, Ltd. © Form 3056 (05/99A)

TO MAC VAVE (PANEL BKT) DETAIL "B'
SEE DWG 26550 11 8
6 VACUUM FILTER INSTALLATION
SHT 2, AT "FF" E (SEE HOLE CONFIGURATIN)
(4-D) 25 13 36
60
80
41 0
40
600
F 300
2
17 SEE DETAIL "C" PART OF
C
42 C ITEM 18
5 C
45 C (PANEL HOLE)
17
A
A
DETAIL "A" B H 18 (3)
D B SEE DETAIL "A"
AIR FILTER INSTALLATION J D B D H
(SEE HOLE CONFIGURATION) D J G G
J (PANEL BKT)
35 DETAIL "C"
E E
29 PLUG INSTALLATION
F (A AND B HOLES)
F
SEE DETAIL "B"
FILTER / GAUGE 26560

ASSEMBLY ASSY, FILTER/GAUGE PANEL, OV 900
C-47
26586 KIT, OPTICAL COLLIMATOR, SINGLE, PRESS FINISH, 62 DEGREES, RH

1 16787 Retainer, Diffuser, Strobe 1
2 16788 Spacer, Diffuser, Strobe 4
3 16793 Cover, Bottom, Housing, Strobe 1
4 16796 Window, Inspection, Camera 1
5 16797 Housing, Terminal, Strobe 1
6 16800 Shield, Annular, Outer, Inspection Head 1
7 16803 Shield, Annular, Inner, Inspection Head 1
8 16861 Ring, Support, Window, Flash 1
9 16908 Assembly, Knurled Knob, #6-32 2
10 16921 Label, Warning, Lethal V, Trilingual 1
11 16922 Label, Warning, High Voltage, Inspection Head 1
12 16950 Label, Shock, Hazard, Power Supply 2
13 17125 Assembly, Strobe Lamp, UltraLine 1
14 25820 Assembly, Strobe Housing, High Resolution, Inspection Head 1
15 26389 Assembly, Tower, UltraLine 1
16 26552 Label, Warning, Shield, Power Supply, German 2
17 26554 Label, Electrical Hazard, German 2
18 26585 Label, Warning, High Voltage, Shield, German 1
19 32506 Diffuser, 56 Degree, Collimator 1
20 32578-1 Assembly, Power Supply, Dual Strobe 1

15
BRACKET 2 PL
SEE VIEW "A"

REF 15
18
FLAT
2 PL
25810 2 PL
(PART OF 14
ITEM 14) 10
5
REF 7
TOP
2 PL
SURFACE
11
4 PL
VIEW "A" 3
(ITEMS 1, 14 & 19 NOT
SHOWN FOR CLARITY) 1
BLK 13
(4) 2 RED
12 17
16 19
6 9 (2)
17
12 7 SEE VIEW "A"
20
16
4 PL
4
NOTE:
REFER TO DWG 26586 FOR
ASSEMBLY INSTRUCTIONS. 8
4 PL 6 PL
26586
KIT, OPTICAL COLLIMATOR, SINGLE,
PRESS FINISH, 62 DEGREES, RH, OV 900/1200

P/N 26758 ASSEMBLY, EXTERIOR CABINET, TOP, RIGHT HAND

1 00116 O-ring, Starwheel, Hub 1
2 00512 Connector, Male, Brass, 1/4 1
3 04356 Tubing, Plastic 1 foot
4 09016 Nipple, Brass 1
5 10212 Gasket, Light Enclosure, Upper 2
6 10213 Gasket, Light Enclosure, Lower 1
7 10238 Lens, Convex Roundel 1
9 10498 Valve, Flow Control 1/8 NPT 1
10 10516 Assembly, Tubing, Water Dripper 1
11 10517 Bracket, Water Dripper Mounting 2
12 10624 Gasket, Mounting Diffuser Glass 1
13 10719 Ring, Retaining 2
14 13284 Washer, Spring Cup 1
15 14178-1/34859Assembly, Diffuser Glass/Clear Glass (Reference) 0
16 16270 Assembly, Gear Motor, Diffuser Glass 1
17 16386 Coupling, Diffuser Glass 1
18 24065 Elbow, Male, Swivel, 3/8 TBG x 1/4 1
19 25498 Pulley, 12 Grooves 1
20 25501 Belt, 120 Grooves 1
21 25534 Mounting, Scrubber 1
22 25603 Pulley, Driver, Coupling, Diffuser Glass 1
23 25709 Bearing, Diffuser Glass 1
24 25727 Assembly, Tee Knob 1
25 25891 Connector, Male, 90°, 1/8 NPT 1
26 25969 Gasket, Mounting Scrubber 1
27 26793 Bracket, Gear Motor, Diffuser, Glass 1
28 26794 Brush, Scrubber, Machining 1
29 26795 Flange, Holder, Brush 1
30 27545 Assembly, Brush, Scrubber, Omni 1
31 27841 Enclosure, Light 1
32 27842 Assembly, Shield, Light Enclosure 1
33 28227 Assembly, Shaft, Diffuser Glass 1
34 28235 Assembly, Mount, Diffuser Glass 1
35 31495 Bracket, Support, Tube, Dripper, Right Hand 1
36 32172 Manifold, Pedestal 1
37 32175 Nipple, Close, Male, 1/4 NPT 1
38 32177 Valve, Needle, Miniature, 1/4 NPT 1
40 33918 Coupling, V-Retaining, ModiÞed 1

See See
Detail B Detail A
See
Detail C
See
Detail E To Water Control
Box (35780-2) 24
14
See
Detail D
15
33
See
Detail F (Part of 34)
30
34
29 (2) 13
12 23 REF
(Top of Cabinet)
21
28
26
(Top of Cabinet) 22
17
DETAIL B
Diffuser Glass Assembly
REF 13 23
NOTE: SEE DWG 26758 FOR
OTHER DETAILS.
19
20
DETAIL A
Brush Scrubber Assembly 26758
Assembly, Exterior Cabinet, Top, RH, OV 900
Sheet 1 of 2

40
37 7
36 18
39
1
32
(Top of Cabinet) 25
38 31
Part of Interior Base
Cabinet Assy 26550
DETAIL D
Air Valve Assembly
6
(Top of Cabinet)
DETAIL C
Lamp Housing Assembly
10
2
35
(Top of Cabinet)
11
Plate
4 27
3 16
8 To Water Control
Box (35780-2)
DETAIL E
Spray Valve Assembly
DETAIL F
NOTE: SEE DWG 26758 FOR Diffuser Motor Assembly
OTHER DETAILS.
26758
Assembly, Exterior Cabinet, Top, RH, OV 900
Sheet 2 of 2

P/N 27047 ASSEMBLY, PANEL, TERMINAL BLOCK, OUTER SIDEWALL UNIT

1 23328 Label, TB2 1
2 23431 Label, TB1 1
3 27025-1 Rail, Mounting, ModiÞed 1
4 27025-2 Rail, Mounting, ModiÞed 1
5 27097 Bracket, Mounting, Relay Base 1
6 27098 Label, F2 1
7 27099 Label, F1 1
8 29848-3 Bridge Bar, ModiÞed 1
9 92701 Clamp, End, E/UK 3
10 92702 Cover, End, D-USK/10 1
11 92703 Terminal Block, Gray, USK 10 11
12 92704 Terminal Block, Yellow/Green, USLKG 10 2
13 92705 Terminal Block, Blue, UKN 10 3
14 92706 Marker Strip, Printed, White 4
15 92707 Marker Strip, Blank 12
16 92761 Fuse Holder, 571007P 2
17 92762-1 Fuse, KLK-3/10A 2

5 A
15
2 B
R REF
1 PW
A-
N
7 B-
N
U
1 NE
TB
L1
2
L2
TB
F1
ON
6 I
A
10
CT
3/ 0V
60
RE
DI
F2A
10
3/ 0V
60 Y
4 15 (12) 14 (4)
9
1
11 (11)
2 See Detail "C"
3
4 13 (3)
5
6
16 (2) 8
11
See Detail "A"
9 12 (2)
16
(See Detail "B")
17 (2) 11
See
16 Detail "C"
10
(End Cover)
Detail "A" 9 (3)
(End Clamp)
14 14 OR 15
Detail "B" Detail "C"
Label Assy Label Assy
Item 12 Items11 & 13
27047
Assembly, Panel, Terminal Block, OSW

P/N 27520 ASSEMBLY, FILTER/GAUGE PANEL, OV 1200

2 00666 Elbow, Male, Brass 1
3 01185 Filter, Vacuum Pump 1
4 01726 Nipple, Brass 1 1/2 inch 2
5 02709 Regulator, Pressure 1
6 04356 Tubing, Plastic 2
7 05905 Washer, PolyÞbre 2
11 10242 Connector, Female, Compression 2
13 10253 Adapter, Bulkhead, ModiÞed 1
14 10486 Adapter, Bulkhead 2
15 10500 Fitting, Elbow 1
16 10645 Tee, Female, Brass 1
17 10957 Nut, Panel 2
18 11121 Seal, Hole 3
19 11122 Fitting, Long, Nipple, 3/8 2
20 11130 Fitting, 3/8, Street Elbow 2
21 11169 Adapter, Brass, Bulkhead 2
22 11188 Fitting, Close Nipple 1
23 11189 Fitting, Bush, 3/8 Pipe 1
26 11951 Tee, Female, Brass, 3/8 1
27 16866 Pipe, Air, Copper, Gauge 1
28 16884 Regulator, Air, Fixed 1
29 17960 Label, Filter Service 1
30 21506 Nipple, 1/4 Hex 2
31 24081 Connector, Male, 3/8 Tubing 1
32 25571 Tube, Oval 1
33 25572 Tube, Press 1
34 25577 Tube, Regulator, Air Filter 1
37 27621 Panel, Gages, Filters 1
38 27765 Tubing, Poly 1
39 33453 Connector, Male, 1/2 Tube x 3/8 1

P/N 27520 ASSEMBLY, FILTER/GAUGE PANEL CONTINUED

41 33456 Tubing, Polyurethane 5
42 33457 Elbow, Male, 1/2 Tube x 1/4 NPT 1
43 34067 Filter, Air, 1/4 NPT 1
44 91201 Gauge, Vacuum Switch 1
45 91204 Gauge, Pressure, Switch 1

SEE DWG 27513
OR 27515 23 10 31
41
SEE DWG 27513 40
OR 27515 14 26
(PANEL BKT) 11
12
24 14 38 15
21 (PANEL BKT)
33 4
C 22 7 21
C
8
27 19
39
30 D
14 H 44
24 37 D
12 30
35 14
1 4
SEE DWG 27766, 21
13 8
9 27767 OR 27768
28 16 7 20
G
43
21
32 6 DETAIL "B' 19
1 34 3
VACUUM FILTER INSTALLATION 20
SEE DWG 8 (PANEL BKT)

11 (SEE HOLE CONFIGURATIN)
27513 OR 6
E
27515 25 13 34
PART OF
60 SEE DETAIL "C"
80
41 0
40
ITEM 18
600
F 300
C
0
C
2 (PANEL HOLE)
17 C C
42 5 A A 18 (3)
45
17 B H D B
D SEE DETAIL "A"
J D B H
DETAIL "A" G G
D J
AIR FILTER INSTALLATION J (PANEL BKT) DETAIL "C"
(SEE HOLE CONFIGURATION) PLUG INSTALLATION
36 E
E 29 (A AND B HOLES)
F F
SEE DETAIL "B"
27520
FILTER / GAUGE
ASSEMBLY
ASSY, FILTER / GAUGE PANEL
OV 1200
C-57
P/N 27545 ASSEMBLY, BRUSH, SCRUBBER

6 25500 Belt, 65 Grooves 1
7 25547 Guide, Bracket, Tensioner, Belt 1
8 25549 Bracket, Belt Tensioner 1
9 25550 Shaft, Brush 1
10 25709 Bearing, Diffuser Glass, ModiÞed 1
11 25734 Housing, Scrubber, Machining 1
12 25761 Spacer, Cover, Scrubber 1
13 25766 Cover, Scrubber, Housing 1
14 26778 Gasket, Cover, Scrubber 1
15 26779 Handle, Locking 1
16 27711 Shaft, Arm 1
17 36299 Bearing, Flanged 2
Note: Item Number 2 does not exist.
13
14
12
6
17
5
1 3
4 10
1 8
17 7
11
15
9
16

P/N 27766-0 OPTION, VACUUM

2 03160 Fitting, 90 Degree, Liquidtight 2
3 03162 Conduit, SealTite, 3/4 inch Diameter 1.5 feet
6 11113 Fitting, Elbow Male 1
7 11114 Fitting, Connector, Male, Tube 1
8 11170 Fitting, Brass, Bulkhead 3
9 11171 Pump, Vacuum A/R
10 11190 Washer, Fiber Conduit 3
11 12021 Locknut, 1/2 - 14 NPT 1
12 12561 Assembly, Motor, Vacuum Pump 1
13 12562 Assembly, Motor, Vacuum Pump 1
14 14098 connector, Strain Relief 1
15 16873 Hose, Polyvinance 44
16 16883 Assembly, Tank, Vacuum Pump 1
17 17120 Clamp, Hose, Thumbscrew, #8 6
18 18233 Elbow, Street 2
19 19551 Filter, Exhaust Mufßer 1
20 25582 Oil, Cup, Elbow 1
21 25834 Coupling, 1/2 NPT, Female 1
22 25845 Fitting, Nipple 3
23 25995 Tubing, Filter, Exhaust 1
24 26953 Hose Barb, 1/2 NPT 4
25 27777 Bushing, 3/8 NPT x 1/2 NPT 1
26 33454 Elbow, Male, Swivel, 1/2 Tubing x 3/8 1
27 33456 Tubing, Polyurethane 2.5 feet
28 91400-3 Starter, Motor, 1.6 - 2.4A, 3-Phase 1
Note: Item Numbers 1, 4 and 5 do not exist.

C-60
2 H 8 DASH VOLTAGE/ FREQ. MOTOR STARTER
HOLE NO
3 GAUGE PANEL 208V, 60 HZ
2 PL 27776-1 12 30
220/230V, 60 HZ
24 27776-2 220/230V, 50 HZ 13 28
14
18 10 380 - 415V, 50/60 HZ
27776-3 12 29
11 440, 460/480V, 60 HZ
8 7
2 27776-4 440/460V, 50 HZ 13 29
24 23
27776-5 575V, 60 HZ 12560 29
SEE
TABLE DETAIL "E"
STARTER ASSY 6
THROUGH HOLE 8
IN FLOOR
22 18
G HOLE DETAIL "B" 24

8 GAUGE PANEL EXHAUST FILTER ASSY 19 H
4 PL 16
4 PL (27765)
10
24
8
21
F
DETAIL "C" 15 G
OIL CUP ASSEMBLY
SEE DETAIL "C
G
SEE 22 SEE
H 25 26
DETAIL "D" TABLE
SEE 20
DETAIL "E" 17 9
F
DETAIL "D"
15 FILTER/ OIL PUMP ASSEMBLY
PRESSURE
ET
RES
PANEL
THROUGH
HOLE IN
FLOOR SEE DETAIL "B"
SEE DETAIL "A"
DETAIL "A" 27766-0
BASE CABINET FILTER/ GAUGE PANEL OPTION, VACUUM

P/N 29002 ASSEMBLY, TOP, OMNIVISION 1200, RH

1 27567 PLC Junction Box 1
2 29000 Monitors and Electronics 1
3 29034 Scanner Head and Star Drive, RH 1
4 29273 Conveyors and Air, RH 1
5 29275 Base Cabinet, Interior, RH 1
6 31068 Base Cabinet, Exterior, RH 1
7 33293 Columns and Doors 1
8 35750-3 Upstream Bottle Sensor #1 1
10 35780-2 Water Control, External 1
3 7 REF
BOTTLE WASHER
00
2 STARWHEEL PART OF ITEM 8
SI
ON
12 AND GUIDES 8
NI
VI M.O.
OM 9 D
7 EE
INF
6
CUSTOMER'S
REJECT CONVEYOR
CONVEYOR
ASSEMBLY 10
M.O.
UPPER STRUCTURE
1 ED 5
TFE
OU
T
ON
4 FR
NOTE: REFER TO DWG 29002
PART OF FOR OTHER DETAILS.
ITEM 3

P/N 29034 ASSEMBLY, INSPECTION HEAD AND STARWHEEL DRIVE, RH, OV 1200

1 03527-3 Pin, Roll, CRES 1
2 10427 Spring, Compression 1
3 10950 Handwheel, Raising Mechanism 1
4 11019 Collar, Inspection Head, Clamp 1
5 12298 Universal Joint, ModiÞcation 2
6 12429 Closed, Cell Foam Rubber 1
7 12564 Rivet Pop A/R
8 12659 Wedge, Inspection Head Support 1
9 12660 Collar, Inspection Head Support 1
10 12974 Key, Starwheel Drive 1
11 13269 Assembly, Clutch, Brake, Star Drive 2
12 16355 Shaft, Locking, Raising Mechanism 1
13 16357 Retainer, Gear Shaft, Raising 2
15 16362 Bearing, PL, Gear Shaft, Raising Mechanism 2
16 16366 Ring, Retaining, Raising Mechanism 1
17 16369 Worm, Raising Mechanism 1
18 16371 Screw, Set, 3/4-16 by 3/4 1
19 16372 Cover, Gear Box, Raising Mechanism 1
20 16373 Bearing, Flanged, Raising Mechanism 2
21 16419 Cam, Locking, Raising Mechanism 1
22 16420 Cam, Lock, Thread Raising Mechanism 1
23 16480 Bearing, Thrust, Needle 1
24 16481 Race, Thrust 2
27 16625 Gear, Worm, ModiÞed 1
28 16633 Shaft, Raising Mechanism 1
29 17007 Seal, Shaft, Handwheel, Raising 1
30 17008 Seal, Shaft, Locking, Raising 1
31 19516 Label, Barrier Strip, TB2 1
32 21575 Belt, Timing, 1/4 inch Wide 2
33 22617 Hub, Handle ModiÞcation 1
34 24960 Pulley, Encoder, Starwheel Drive 2
35 25698 Label, Lock 1
36 27503 Assembly, Housing Spindle, Right Hand 1
37 27595 Coupling, Flexible, ModiÞcation, 5/8 1
38 27600 Pulley, 5 mm P, 0.500 Bore 1
39 27601 Belt, Pulley 2
40 27602 Bracket, Mounting, Motor 1
41 27680 Pulley, 5 mm P., 0.625 Bore 2
42 27707 Shaft, Locking Mechanism, Right Hand 1

P/N 29034 ASSEMBLY, INSPECTION HEAD AND STARWHEEL DRIVE, RH, OV 1200, CONT.

43 27748 Plate, Mount, Connector 1
44 27762 Mount, Clutch, Dual, Mach, Right Hand 1
45 27845 Gasket, Tube, Scanner, Support 1
46 27847 Weldment, Tube, Scanner Head, RH 1
47 28193 Shaft, Raising Mechanism, Right Hand 1
48 28194 Counter, Indicator, Position 1
49 29395-1 Key, Coupling 1
51A 29395-5 Key, Coupling 1
51B 29395-7 Key, Coupling 1
52 29396 Insert, Coupling, 5/8 Bore 1
53 29397 Washer, Pulley, 5 mm 1
54 30863 Collar, 5/8 inch, Lower 1
55 31063-1 Bracket, Mounting Encoder, Upper 1
56 31063-2 Bracket, Mounting Encoder, Lower 1
57 31124 Assembly, Inspection Head, Right Hand 1
58 31959 Assembly, Motor, Gearhead, DC, W/Tachometer 1
59 32116 Gib, Rack, Raising Mechanism 1
60 32117 Retainer, Gib, Raising Mechanism 2
61 32118 Pusher, Rack, Raising Mechanism 1
62 32119 Assembly, Housing, Raising Mechanism 1
63 32161 Screw, Set, 1/4-20 3
64 32687 Pulley, Belt, Mod 1
66 32795 Pulley, Dual Belt 1
67 33448 Collar, two Piece 1
68 33449 Collar, Threaded, two Piece 1
69 33670 Assembly, Screw, Captive, 1/4-20 1
70 33760 Rack, Gear, Raising Mechanism 1
71 33941 Assembly, Couplings and Pulley 1
71A 35164 Assembly, Encoder, Smart, Star Drive 2
72 36737 Gear, Pinion, Raising Mechanism 1
73 36739 Shaft, Gear, Raising Mechanism 1
74 36740 Shaft, Worm, Raising Mechanism 1
75 36741 Spacer, Gear, Raising Mechanism 1
Note: Item Numbers 14, 25, 26 and 65 do not exist.

2 PL
6
C-64
9 60
(3) 63
4 PL 8
59
4 (2) 15
2 PL
61 2 PL
13 62
28
2 PL 68
18
70
4 PL 4 PL
19
21 3 PL
6 PL
4 PL
27 51A
57 2
22
DETAIL "D" 60 13
12
SCANNER HEAD AND
RAISING SHAFT ASSY 51B
72
2 PL 2 PL
17 74 2 PL
73 15
2 PL 24 75
2 PL
2 PL 42 DETAIL "A"
5 (2) 67 16 24 23 RAISING MECHANISM ASSEMBLY
20 (2)
30
1 33
NOTE: REFER TO DWG 29034 FOR ASSEMBLY INSTRUCTIONS.
2 PL
2 PL
47
3
20 29034
DETAIL "C" ASSY, INSPECTION HEAD & STAR DRIVE, RH
29 SHEET 1 OF 2
RAISING MECHANISM SHAFTS
48 AND COUNTER ASSY

TO TOP
4 PL PLATE SEE DETAIL "D"
36 (SHEET 1)
4 PL
66 36 REF
44
PART OF 71
2 PL
46
4 PL
(2) 34
2 PL
4 REQD PART OF 71 11141
11 (2)
2 PL 49 45
32 (2)
SEE
TO TOP 39 51 41 DETAIL "C"
PLATE TO TOP (SHEET 1)
PLATE 50
41
55
53 52 2 EA
56 2 PL 7 (4)
(2) 71A
10

37
TB2
2 REQD 54
2 PL 4 PL
58
71 2 PL
P3 E
AK 2
9 PART OF 54 35
BR
P9 TCH
KE CLU
BRA
4 1
TCH
(2) 39 3
PST3AR
ENC
2 CLU
P 3STAR
1
ENC
P7R
STATO
R
MO
2 PL SEE
SEE DETAIL "B"
DETAIL "A"
2 PL (SHEET 1)
43
BASE CABINET
TB2
PART OF 71 13616
2 PL NOTE:
4 PL 2 PL REFER TO DWG 29034 FOR ASSEMBLY INSTRUCTIONS
38 31
DETAIL "B"
STAR DRIVE ASSY 4 PL 40
29034
ASSY, INSPECTION HEAD & STAR DRIVE, RH
SHEET 2 OF 2
C-65
P/N 29054-0 ASSEMBLY, ELECTRONICS, MOTOR DRIVE (TAKEAWAY CONVEYOR)

1 29054-1 Controller, Motor, 1/4 HP, KBMM (93152-1) 1
5 Form 3048 Label 1
NOTE: Refer to the Start-up & Technical Reference Manual (Form 3055) for application details.
1 2 3 4
S1
- 5
Plug-in
Horsepower
93152-1
Resistor

P/N 29059 ASSEMBLY, MECHANISM, GUIDE RAIL, UPPER

1 16373 Bearing, Flange, Raising Mechanism 1
2 27898 Bearing, Flange 1
3 27923 Plate, Nut 2
4 27924 Plate, Base, Block 2
5 27925 Screw, Lead, Upper 2
6 27926 Shaft, Guide, Upper 2
7 27927 Stop, Screw, Lead, Upper 2
8 27930 Weldment, Tube, Support 1
9 27932 Nut, Power, Lead, Screw, ACME 2
10 27933 Flange, Nut, ACME, Screw, Lead 2
11 27937 Plate, Mounting, Seal 1
12 27939 Coupling, Lead Screw 2
13 27941 Seal, Shaft 2
14 28194 Counter, Indicator 1
15 28441 Gear Box, 90 Degree, 3-Way 2
16 28458-2 Tube, Transfer, Drive 1
17 28479 Plate, Mounting, Counter 1
18 28481 Collar, Tube, Transfer 1
19 28482 Shaft, Counter 1
20 28491 Plate, Seal, Shaft 2
21 28687 Handle, Handwheel 1
22 28741 Assembly, Handwheel 1
23 28743 Screw, Shoulder 1
24 29037 Screw, Thumb, 1/4-20 1
25 29345-1 Coupling, Flexible, Jaw Type 1
26 29345-2 Coupling, Flexible, Jaw Type 1
27 29346 Spider, Coupling, Flexible, Jaw Type 1
28 29372 Bolt, Tube, Support, Guide Rail, Upper 2
29 34128 Bushing, Plain, 3/4 Shaft 4
30 34129 Retainer, Sleeving 2
31 34131 Block, Bearing, Shaft, Guide Rail, Upper 2

C-68
REF 5 5 REF
2 PL
2 PL
2 REQD, 2 PL
2 REQD, 2 PL
12 16 REF
2 PL 2 PL
15 APPROX. 1/8" GAP 12
REF 19 AFTER ASSEMBLY
18
25 15
27
C (2) 03257-3
26
DETAIL "B"
20
13 REF
2 PL 16 REF
REF
6 REF
C
NOTE: REFER TO DWG 29059 FOR
2 PL ASSEMBLY INSTRUCTIONS.
REF 20 13 REF
DETAIL "A"
8 REF
6
28 (2)
SEE GUIDE ASSY 2 PL

(29086 OR 29100) 29059
2 PL ASSY, MECHANISM, GUIDERAIL, UPPER
SHEET 1 OF 2

(U INF
PS E 21 22
TR ED 14 2 PL
EA
M) 24 7 (2)
17 2 PL
3 REQD
23 2 PL
1
10 (2)
2
3 (2)
4 PL
REF 6 3 REQD
(2) 9 2 PL
B OUTER SIDEWALL
A HOUSING (REF)
(28468 REF) 5 (2) 30 (2)
11
19
29 2 REQD

2 PL
A
3 REQD 31 (2)
B 2 PL
4 REQD
6 REF 2 PL
SEE DETAIL "A" A
(2) 13
(SHEET 1)
16
(27058 REF) 4 (2)
(2) 20
(27057 REF) B
4 REQD A
C
SEE SHEET 1 SEE DETAIL "B" 2 PL
4 REQD, 2PL (SHEET 1) 6 (2)
WHERE TO MOUNT ON
LOWER SHELF OF OSW C B
SEE SHEET 1
29059
NOTE: ASSY, MECHANISM, GUIDERAIL, UPPER
REFER TO DWG 29059 FOR ASSEMBLY INSTRUCTIONS.
SHEET 2 OF 2
C-69
P/N 29086-0 ASSEMBLY, GUIDE RAIL, UPPER, ADJUSTABLE

1 27912 Screw, Thumb, 10-32 8
2 27913-1 Bracket, Support, Adjustable Guide Rail, Upper, Long 8
3 27913-3 Bracket, Support, Adjustable Guide Rail, Upper, Short 8
4 27915 Weldment, Tube, Bracket, Guide Rail, Upper 1
5 28496 Shaft, Bracket, Support, Guide Rail, Upper 4
6 28497 Collar, Shaft, Bracket, Support 8
8 28837 Guide Rail, Upper, Upstream 2
(U INFE
PS E
TR D
EA
M)
27926
PART OF 29059
29372
27930
4 1 (8)
6 (8)
8 (2)
7 (2)
2 REQD, 4 PL 8 PL
SUPPORT
DASH SUPPORT BRACKET (8 PL)
LENGTH
NO. BRACKET (SEE TABLE)
-1 3 6.50 LG
5 (4)
-2 2 9.75 LG

P/N 29096 KIT, ILLUMINATOR, DUAL STROBE, TWIST FINISH, 50 DEG, RH, OV D1200

1 16908 Assembly, Knurled Knob, #6 - 32 4
4 27890 Assembly, Adapter, Servo Cable 1
5 28586 Nut Plate 1
6 28661 Reßector, Toroidial 1
7 29172 Assembly, Optical, Dual, Strobe 1
9 29184 Assembly, Toroidal, Mirror 1
10A 29185-1 Assembly, Camera, Mounted 1
10B 29185-2 Assembly, Camera, Mounted 1
11 29348 Housing, Terminal, Dual Strobe 1
12 29349 Cover, Terminal, Dual Strobe 1
13 29368 Housing, Strobe Lamp, Upper 1
14 30158 Assembly, Servo, Zoom, Right Hand 2
15 31200 Assembly, Bafße, Diffuser, 50% 1
16 31304 Heat Sink, Housing, Terminal, Dual Ring 1
17 31690 Gasket, Transfer, Thermal 1
18 32414 Ring, Support, Window, Strobe 1
19 32415 Window, Protective, Optical 1
20 32564 Housing, Strobe, Lower 1
22 32725 Bumper, Stem, Rubber 4
Note: Item Numbers 2 and 3 do not exist.

21
10B
10A
2 REQD
4 PL 2 PL
2 REQD
2 PL
4 PL 2 PL
2 PL
14 (2)
2 PL
Power Supply
Mtg Bracket 16 4 PL
(Ref)
4 5
17
8
2 PL 11
4 PL
7
13
6
4 PL
SCANNER HEAD (4) 1
( Ref) 9 15
12
19
3 PL 2 PL
18 22
2 REQD 20
3 PL 2 PL
4 PL
NOTES: 1. ITEM NUMBERS 2 & 3 DO NOT EXIST.
2. REFER TO DWG 29096 FOR

ASSEMBLY INSTRUCTIONS.
29096
KIT, ILLUMINATOR, DUAL STROBE,
TWIST FINISH, 50 DEG, RH, OV D-1200

P/N 29100 ASSEMBLY, GUIDE RAIL, NONADJUSTABLE, UPPER, OSW

1 27949 Machining, Support, Guide Rail, Upper 4
2 28832 Weldment, Tube, Bracket, Guide Rail, Upper 1
4 28837 Guide Rail, Upper, Upstream 2
(U INFE 27926
PS E
TR D
EA
M)
29372 PART OF 29059
27930
1 (4)
2
4 (2)
3 (2)
2 REQD, 4 PL
2 REQD, 4 PL

P/N 29107 OPTION, ASSEMBLY, TEST BOTTLE SENSOR

1 17293 Reßector, Contour, Color 8
2 20660 Connector, 3/8 NPT, Squeeze 1
3 21348 Nut, Jam, 3/8-18 NPT 1
4 28819 Bracket, Sensor, Test Bottle 1
5 32948 Assembly, Sensor, Test Bottle 1
7)
7(R
10
29
DISCARD COVER RIGHT HAND

PLATE 29103 MOUNTING
(PART OF INSP. HEAD) (See Notes)
SCANNER HEAD
ASSY
2
5
2 PL
4 LEFT HAND
MOUNTING
(See Notes)
2 PL
4 PL
RE-USE SAME
HARDWARE NOTES:
1. INCLUDE ITEM #1 (REFLECTOR 17293 ,8 EA.) ,
WITH EACH OPTION.
2. FOR WIRING REFER TO SENSOR DWG 32948.
CNNECTOR
(PART OF ITEM 5)
WHT SIGNAL OUT

1
+V (10 TO 30VDC) RED or BRN

SENSOR (ITEM 5) 2
0V BLK or BLU
3
WIRING DIAGRAM

P/N 29185-0 ASSEMBLY, CAMERA, MOUNTED, DUAL

1 25803 Lens, Zoom, 12.5 x 6 1
2 25812 Adapter, Camera, Panasonic 1
3 25821-3 Assembly, Camera, B/W CCD 1
4 26594 Bracket, Support, Camera 1
5 28763 Ring, Adapter 1
6 30624 Lens, Extender, x1.5 1
DASH EXTENDER
NO LENS NO
CAMERA
FRONT P/
29185 - 1 NONE
N
RE
V
S/
N
29185 - 2 6
6
SEE TABLE NOTE:
REFER TO DWG 29185-0 FOR
ASSEMBLY INSTRUCTI0NS.
1
2 PL

P/N 29532-0 KIT, COLLIMATOR, TWIST (T) FINISH, SINGLE, 40 DEGREES, RH

1 16788 Spacer, Diffuser, Strobe Lamp 4
2 16793 Cover, Bottom, Terminal Housing, Strobe 1
3 16796 Window, Inspection, Camera 1
4 16797 Housing, Terminal, Strobe Lamp 1
5 16861 Ring, Support, Window, Flash 1
7 16921 Label, Warning, Lethal Voltage, Trilingual 1
8 16922 Label, Warning, High Voltage, Inspection Head 1
9 17125 Assembly, Strobe Lamp, UltraLine 1
10 25820 Assembly, Strobe Housing, High Resolution, Inspection Head 1
12 29179 Assembly, Jumper, Thermo 1
13 29531-1 Assembly, Tower, Panasonic 1
14 29531-2 Assembly, Tower, NEC 1
15 30136 Retainer, Diffuser, Outer 1
16 30138 Shield, Annular, Outer 1
17 30210 Retainer, Diffuser, Inner 1
18 30211 Shield, Annular, Inner 1
19 32501 Diffuser, Illuminator, “T” Bottle 1

DASH CAMERA CAMERA 13 14 (SEE TABLE)

NO TYPE NO
29532-1 PANASONIC 13
29532-2 NEC 14
SEE VIEW "A"

BRACKET
11
10
12
CAMERA 7
(SEE TABLE) FLAT 4
16790
(98" Lg)
25810 8
(PART OF
ITEM 10) 2
30211 TOP
REF SURFACE
BLK 9
VIEW "A" 15 RED

17
(ITEMS 10, 15, 17, & 30212 NOT
SHOWN FOR CLARITY)
(4) 1 6 (2)
19
16
18 SEE VIEW "A"
Power Supply Mtg
Bracket (Ref)
20
9)
2(R
53
29
NOTE:
3
5
29532-0
KIT, COLLIMATOR, TWIST (T) FINISH,
SINGLE, 40 DEGREES, RH, OV 900/1200

P/N 30045 ASSEMBLY, TRANSFORMER, LAMPS, SETUP, OSW

1 00157 Washer, Fiber 1
2 12021 Locknut, 1/2 - 14 NPT 1
3 14098 Connector, Strain Relief 1
4 91290-1 Transformer, 50/60 Hz 1
7 91306 Contact, Cap or Plug Pin 4
8 91731 Lug, Solderless, Insulated, 1/4 Inch 2
9 92800 Wire Joint, Crimp, Large 5
5 3
PIN 2
1
Pin #1
7 (4)
P1
WHITE
BLACK
(2) 8
BLACK
(GND)
Pin #1
GRN/YEL
P2 GRN/YEL
BLUE 6 4
7 PIN
9 (5)
5 6
P1 Black Black Black Black

X1-X3 H1-H3 P2
1
1
TRANSFORMER
2 2
4
3 N/C White Black
X2-X4
Grn/Yel Black Black Blue
H2-H4
9
WIRING DIAGRAM

P/N 30167 ASSEMBLY, 3-TOWER OPTICAL SYSTEM, RIGHT HAND
Item Qty P/N Description 1

1 1 30202-1 Camera, RLD
P/
RE
N
2/3
See
S/V
N
2 30203-1 Camera, Base

Table
See Camera, Base,
3 30203-3 4/5
Table BFA
See
4 30205-1 Camera, ISW
Table
See Camera, ISW,
5 30205-3
Table BFA
See
6 30204-1 Tower Base
Table
See Tower Base,
7 30204-2
Table BFA
See
*8 29442-3 DSP Card
Table
See
*9
Table
29360-1 Video Card 6/7
See Assy, Strobe
*10 37211
Table Housing
30
16
Assy, Bright 7(R
4)
See
*11 36121-2 Field Analyzer,
Table
RH
*Note: Items 8 through 11 not shown.
Nonbright Field Option

Dash No Camera Item 2 Item 4 Item 6 Item 8 Item 9 Item 10
30167-1 RLD, Base 1 ---------- 1 1 1 1
30167-2 RLD, Base, ISW 1 1 1 2 2 1
Bright Field Option

Dash No Camera Item 3 Item 5 Item 7 Item 8 Item 9 Item 11
30167-3 RLD, Base 1 ---------- 1 1 1 1
30167-4 RLD, Base, ISW 1 1 1 2 2 1

P/N 30203-0 ASSEMBLY, TOWER, OPTIC, BOTTOM RIM, PANASONIC

1 04840 Seal, Lead, Wire, Security 1
2 25796 Clamp, Lens Tube 1
3 25797 Retainer, Objective Lens 1
4 25803 Lens, Zoom, 12.5 x 6 1
5 25808 Lens, Achromatic, 100 mm, UltraLine 1
7 See Table Assembly, Camera, Black & White, CCD 1
9 30157 Tube, Close-up, Lens 1
10 30158 Assembly, Servo, Zoom 1
11 30817 Screw, ModiÞed, 8-32 x 1, Hex Head 2
12 See Table Filter, Neutral Density 1
7 8
30624 M.O.
(Zoom
Extender
Lens)
Camera Camera
Filter
Dash No Type P/ N
4 10 (12)
(7) (7)
30203-1 Panasonic 25821-3 33695-2

12 30203-2 NEC 28760-2 33695-2
30203-3 Panasonic 25821-3 35191
3 Notes:
30203-3 is used on Bright Field Analysis (BFA)
5 11 Option.
Item #1 not shown on the Figure.
Refer to DWG 30203-0 for assembly details.
9
2 30203(R5)

P/N 30205-0 ASSEMBLY, TOWER, OPTIC, INNER SIDEWALL, PANASONIC

1 04840 Seal, Lead, Wire, Security 1
2 25796 Clamp, Lens, Tube 1
3 25797 Retainer, Objective Lens 1
4 25803 Lens, Zoom, 12.5 x 6 1
6 See Table Assembly, Camera, Black & White, CCD 1
8 30156 Lens, Achromatic, 180 mm, UltraLine 1
9 30157 Tube, Close-up, Lens 1
10 30158 Assembly, Servo, Zoom 1
11 30817 Screw, ModiÞed, 8-32 x 1, Hex Head 2
12 See Table Filter, Neutral Density 1
7
6
Camera Camera
Filter
10 Dash No Type P/ N
(12)
4 (6) (6)
30205-1 Panasonic 25821-3 33695-2

12 30205-2 NEC 28760-2 33695-2
30205-3 Panasonic 25821-3 35191
3 Notes:
30205-3 is used on Bright Field Analysis (BFA)
Option.
8 11 Item #1 not shown on the Figure.
Refer to DWG 30205-0 for assembly details.
2 30205(R5)

P/N 30224-0 ASSEMBLY, CHANGE PARTS, RH, OV 1200

1 02542 Bearing, Flanged 1
2 03527-4 Pin, Ross, CRES A/R
3 04204 Cup, Suction, Bellows, Standard A/R
4 10287-0 Seal, Ring 1
5 10289-0 Spacer, Top, Hat, Hub, Starwheel A/R
6 10342 Knob, 5 Lobe, Guide Rail Assembly 1
7 10446 Pulley, Guide 1
8 10451 Washer, Bearing, Mounting 1
9 10453-0 Shaft, Starwheel Knob 1
10 11006-0 Pin, Dowel A/R
11 11015 Bearing, Ball 1
12 11072-0 Pin, Dowel 4
13 11309-1 Pin, Dowel, 0.625 1
14 12325 Label 1
15 12518 Ring, Shield 1
16 14477-0 Hub, Starwheel 1
17 14514 Washer, 1/4 Flat 1
18 14986-0 Spacer, Hub, Lower 1
19 15657-0 Shaft, Pulley 1
20 15658 Nut, Hex, ModiÞed 8
21 15662-0 Shaft, Guide Rail 16
22 16144 Pin, Grooved 8
23 21694-0 Spacer, Hub, B, Starwheel 0
24 22617 Hub, Handle, ModiÞcation 8
25 25380-0 Shaft, Guide Rail, Lever 8
26 26110 Bar, Support, Lower Divider 1
27 26111 Mount, Infeed Guide Rail Support 2
28 26113 Bar, Support, Upper 1
29 26450-0 Plate, Bottle, Starwheel 1
30 26452-0 Plate, Guide Rail Infeed, Lower 1
31 26453-0 Plate, Guide Rail, Infeed, Upper 1
32 26454-0 Plate, Pulley, BTM 1
33 26455-0 Plate, Pulley, Upper 1
34 26456-0 Plate, Guide Rail, Outfeed 1
35 26457-0 Plate, Guide Rail, Outfeed 1
36 26458-0 Plate, Divider, Upper 1
37 26459-0 Plate, Divider, Lower 1
38 26460-0 Spacer, Guide Rail, Pulley, RH 1
39 26461-0 Spacer, Guide Rail, Lower 1
40 26462-0 Spacer, Guide Rail, Upper 1

P/N 30224-0 ASSEMBLY, CHANGE PARTS, RH, OV 1200 CONTINUED

45 26467-0 Block, Spacer, Divider, Lower 1
46 26469 Mount, Outfeed, Upper 1
47 26481 Bar, Support, Outfeed, Upper 1
48 26482 Bar, Support, Infeed, Upper 2
49 26496 Insert Stop Plate, Guide Rail 2
50 26497 Plate, Insert 2
51 26498 Insert, Guide Rail 8
52 26502-0 Tube, Suction A/R
53 26523-0 Disc, Starwheel, Upper 1
54 26525 Disc, Starwheel, Lower A/R
55 27674 Disc, Starwheel, Lower, Cast. 1
56 27784-0 Tube, Suction, Insert, Short A/R
57 33018 Plate, Intermediate, Starwheel 1
58 34120-0 Ring, Pocket, Starwheel 1

(2) 24 (2) 20 24 (2)
25 (2) (2) 25
(2) 22 22 (2)
33
(2) 2
38
48 28
32
49
(2) 2 36
39
7
8 45
44
11 51 (2)
19 (4) 21
17 27 37
26
51 (2)
(4) 21
30581-0 30583-0
REF REF
(2) 24 20 (2)
25 (2) (2) 25 24
(2) 20
(2) 22 47
31 22 (2)
(2) 51
40 51 (2)
(2) 48 42
30
(2) 2 (2) 50
41 35
27
(4) 21
(4) 21 34
46 43
30579-0
REF
30580-0
REF

30224-0
ASSY, CHANGE PARTS, 1 IN, RH, OV 1200
SHEET 1 OF 2

9 6
6 PL
58
57
12 PL
3 PL
14
53
REF 1 10
12
REF
12 (4)
1
5 16
32763-0 (REF)
23
4
52
13
3 15
12
REF
18
54 55
3 PL
29
NOTE:
6 PL
12 PL
30224-0
ASSY, CHANGE PARTS, 1 IN, RH, OV 1200
SHEET 2 OF 2

P/N 30315 ASSEMBLY, REJECT VERIFIER, RIGHT HAND, OV 900
Part Number Description Qty

1 29232 Bracket, Mounting, Reject VeriÞer, Right Hand 1
2 30619 Assembly, Sensor, Reject VeriÞer, Right Hand 1
3 32995-1 Assembly, Reßector, ModiÞcation, Reject VeriÞer 1
Inspection Head
Note:
For wiring refer to
Drawing 30619.

P/N 30615 ASSEMBLY, PLATE, CAMERA, ELEVATOR, OSW

1 27867 Shaft, 3/8, 2-Camera Mirror Assembly 1
2 27868 Block, Bushing, Upper 1
3 27885 Lead Screw, 2-Camera Mirror Assembly 1
4 28544 Plate, Mounting, Elevator Assembly 1
5 28545 Block, Bushing, Lower 1
6 28546 Shaft, 3/8, 2-Camera Mirror Assembly 1
7 28570 Tensioner, Anti-Rotation 1
8 28629 Nut, Power, Lead Screw 1
9 28774 Bearing, Linear, Ball Bushing 2
10 28776 Assembly, Servo, Elevator, Camera, Left 1
11 28777 Assembly, Servo, Elevator, Camera, Right 1
12 28792 Retainer, E-Ring, 5/8 Inch Shaft 2
13 30609 Assembly, Swivel Mirror, Upper 1
14 30651 Assembly, Camera, Elevator 1
15 31241 Spring, Detention, Focus, Camera 1
16 32595-1 Spacer, Camera, 0.063 2
17 32595-2 Spacer, Camera, 0.125 1
18 32595-3 Spacer, Camera, 0.250 2
19 32778 Assembly, Mirror, Elevated, Third View 1

14
6
2 PL
12 (2)
N
P/
V
8
REN
S/
2
3 11
9 (2)
4 2 PL
4 PL
2 PL
7
15
10
2 PL
5
(2) 18
13
17
4 PL
(2) 16
1
19
30615
ASSY, PLATE, CAMERA, ELEVATOR, OSW

P/N 30619 ASSEMBLY, SENSOR, REJECT VERIFIER

1 30621 Label, Sensor, Reject VeriÞer 1
2 35964 Sensor, Reßective, Reject VeriÞer, PZ2-61 1
3 91608 Pin, Crimp, Male 3
4 92249 Connector, Receptacle, Power Supply 1
1 2
NOTES:
1 CRIMP PINS TO WIRES .
2 BAG CONNECTOR HOUSING (ITEM #4) AND

2 VENDOR PROVIDED SCREWDRIVER WITH CABLE.
4 3 (3)
BLK SIGNAL
1
BRN +V SENSOR
2
(35964)
BLU GND
3
18.00 WIRING DIAGRAM

P/N 31068 ASSEMBLY, BASE CABINET, EXTERIOR, RIGHT HAND

1 00116 O-ring, Starwheel, Hub 1
2 00512 Connector, Male, Brass, 1/4 1
3 04356 Tubing, Plastic 1 foot
4 09016 Nipple, Brass 1
6 10213 Gasket, Light Enclosure, Lower 1
7 10238 Lens, Convex Roundel 1
8 10248 Fitting, Elbow, Female, 1/4 x 1/8 1
9 10498 Valve, Flow Control 1/8 NPT 1
10 10517 Bracket, Water Dripper Mounting 2
11 10624 Gasket, Mounting Diffuser Glass 1
13 13284 Washer, Spring Cup 1
15 14178-1/34859Assembly, Diffuser Glass/Clear Glass (Reference Only) 0
16 16270 Assembly, Gear Motor, Diffuser Glass 1
17 16386 Coupling, Diffuser Glass 1
18 24065 Elbow, Male, Swivel, 3/8 TBG x 1/4 1
20 25501 Belt, 120 Grooves 1
21 25534 Mounting, Scrubber 1
22 25603 Pulley, Driver, Coupling, Diffuser Glass 1
23 25709 Bearing, Diffuser Glass 1
24 25727 Assembly, Tee Knob 1
25 25891 Connector, Male, 90°, 1/8 NPT 1
26 25969 Gasket, Mounting Scrubber 1
27 26793 Bracket, Gear Motor, Diffuser, Glass 1
28 26794 Brush, Scrubber, Machining 1
29 26795 Flange, Holder, Brush 1
30 27545 Assembly, Brush, Scrubber, Omni 1
31 27729 Assembly, Tubing, Water Dripper 1
32 27743 Block, Support, Cover, Diffuser Glass 1
33 27841 Enclosure, Light 1
34 27842 Assembly, Shield, Light Enclosure 1
35 28227 Assembly, Shaft, Diffuser Glass 1
36 28235 Assembly, Mount, Diffuser Glass 1
37 31491 Plate, Base, Support, Cover, Right Hand 1
38 31494 Spacer, Plate, Base, Right Hand 1
39 31495 Bracket, Support, Tube, Dripper, Right Hand 1
40 32172 Manifold, Pedestal 1

P/N 31068 ASSEMBLY, BASE CABINET, EXTERIOR, RIGHT HAND CONTINUED
Part Number Description Qty

41 32175 Nipple, Close, Male, 1/4 NPT 1
42 32177 Valve, Needle, Miniature, 1/4 NPT 1
43 33539 Plate, Drip Shield Switch 1
44 33775 Gasket, Light Enclosure 1
45 33918 Coupling, V-Retaining, ModiÞed 1

C-92
38 2 PL 37
31 42
32 41
2 18 40
9 39 2 PL 25
2 PL 1
10 (2) PART OF
DETAIL "E" SEE DETAIL "B" TOP OF INTERIOR
DIFFUSER COVER SUPPORT (SHEET 2) CABINET BASE
2 PL CABINET
4 2 PL
DETAIL "D"
3 AIR VALVE ASSEMBLY
8
To Water Control SEE DETAIL "D"
Box (35780-2)
DETAIL "H" TOP COVER
SEE DETAIL "C"
SPRAY VALVE ASSY (SHEET 2) SEE DETAIL "E"
43
SEE DETAIL "A"
(SHEET 2)
POWER
SWITCH
SEE DETAIL "H" To Water Control
BASE
Box (35780-2) CABINET
NOTE:
REFER TO DWG 31068 FOR DETAIL "G"
DRIP PLATE
SEE DETAIL "G" INSTALLATION
SEE DETAIL "F"

ASSY, BASE CABINET, (SHEET 2) 31068
INTERIOR, RH
(29275) ASSY, BASE CABINET, EXTERIOR, RH, OV 1200
SHEET 1 OF 2

13 24
30
45
15 TOP PLATE
29 (TOP COVER
7 NOT SHOWN
FOR CLARITY) G
2 PL 35 44
36
28 34
21
12
3 PL TOP OF SHOWN FOR
CABINET REFERENCE

4 PL
26 TOP OF 11 33 ONLY
CABINET
4 PL
27
6
23 3 PL 22
16
TOP OF
CABINET 2 PL
12 19 17
4 PL
20
G
DETAIL "A" DETAIL "B" DETAIL "C" DETAIL "F"
BRUSH SCRUBBER ASSY DIFFUSER GLASS ASSY LAMP HOUSING ASSY DIFFUSER MOTOR ASSY
NOTE: 31068
REFER TO DWG 31068 FOR ASSEMBLY INSTRUCTIONS.
ASSY, BASE CABINET, EXTERIOR, RH, OV 1200
SHEET 2 OF 2
C-93
P/N 31124 ASSEMBLY, INSPECTION HEAD, RIGHT HAND, OV 1200

1 04265-2 Grommet, Rubber, 3/16 inch Inner Diameter 8
2 10492 Pin, Locating 2
3 10494 Label, Indicator 2
4 10825 Cover, Vertical Column 1
5 13286 Post, Mounting, Circuit Card Assembly 8
6 14128 Retainer, Cover, Vertical Column 1
7 16786 Pointer, Adjustment Trigger 2
8 16950 Label, Shock, Hazard Power, SP 1
9 17212 Screw, Trigger, Pointer 4
10 25588 Plate, Retainer, Cable, Inspection Head 1
11 25644 Bracket, Mounting, Power Supply, Finish Inspection 1
12 26552 Label, Warning, SH, PS, German 2
14 27533 Assembly, Cover, Inspection Head 1
15 27633 Skin, Back, Cover, Inspection Head 1
16 27636 Plate, Inspection Head, Left Side 2
17 None None 0
18 27726 Plate, Back, Inspection Head, Right Hand 1
20 28648 Assembly, Circuit Card, Universal, Isolation 1
21 28694 Assembly, Servo Card and Cover 2
22 28846 Plate, Mounting, Servo 1
23 29081 Screw, Captive, 8 - 32 5
24 29103 Plate, Cover, Test Bottle Sensor 1
25 29105 Plate, Mounting, RLD, OV 1200 1
26 29106 Shield, RLD, OV 1200 1
27 29111 Standoff, Quick Release 10
28 29118 Bracket, Reject Verify 1
29 29267 Assembly, Trigger Beam, Emitter/Receiver 2
30 29270 Plate, Base, Inspection Head, Right Hand 1
31 30167 Assembly, 3-Tower Optical System 1
32 30315 Assembly, Sensor, Reject VeriÞer 1
33 31336 Plate, Mounting, LVPS, Right Hand 1
34 31533 Assembly, Mounting, SW Pin Trigger 1
35 31815 Plate, Neck Guide, OV1200, Right Hand 1
36 32995-2 Reßector, Reject Verify 1
37 93068 Power Supply, Inspection Head, ACC 1 1
38 94495 Power Supply, Inspection Head 1
NOTE: No part number is assigned to Item No 17.

2 PL 10 A 4 PL
13
18 11
16 (2) 8
REF
8 PL
12
ING
30 RN
WA
11 REF G
UN
RN
WA
6 PL
3 PL 2 (2)
30
4 LABEL APPLICATION
6
3 PL
CHASSIS ASSEMBLY
38

14 37
(5) 23
15
35
33
6 PL
11 REF
5 PL
NECK GUIDE
8 PL
ASSY PER M.O.
31914
31816-0
27773-0
COVERS
A
NOTES: 31124
1. ITEM NO17 DOES NOT EXIST.
2. REFER TO DWG 31124 FOR ASSEMBLY INSTRUCTIONS. ASSY, INSPECTION HEAD, RH, OV 1200
SHEET 1 OF 2
C-95
C-96
2 PL 36
32 9
2 REQD 23 REF 27 REF
31 PART OF 2 PL
ITEM 29
2 PL 31195
6 PL
19 28
31075
VIEW A-A
2 PL REJECT VERIFY ASSEMBLY
(ROTATED FOR CLARITY) 34
8 PL
5 (8)
4 PL
7 (2)
CONN 92249
(PART OF
ITEM 32)
3 (2)
2 PL
A
A
29 (2)
25
26
24
27 (10) 29107 M.O.
20 1 (8)
28819 (OPTION, TEST
REF BOTTLE SENSOR)
2 PL
4 PL
21 (2)
22
31124
ASSY, INSPECTION HEAD, RH, OV 1200
NOTE: REFER TO DWG 31124 FOR ASSEMBLY INSTRUCTIONS.
SHEET 2 OF 2

P/N 31239-0 ASSEMBLY, ELECTRONICS, MOTOR DRIVE (STARWHEEL)

5 Form 3047 Label 1
NOTE: Refer to the Start-up & Technical Reference Manual (Form 3055) for application details.
1 2 3 4
S1
KB - 6
MM
Plug-in
Horsepower
Resistor
93151 - 4

P/N 31353 ASSEMBLY, DETECTOR, OVERHEIGHT BOTTLE

1 17340 Assembly, Bracket, Spt, Hi Bottle Reject 1
2 17914 Plug, End, 1.5 square by 0.12 wide 1
3 18412 Block, Clamp, Trigger 1
4 21664 Assembly, Photo Switch, Impulse 1
5 22616-5 Assembly, Handle, Locking 1
6 30112 Gib, Clamp 1
7 30113 Bracket, Support, Mounting, Sick Sensor 1
8 30114 Block, Clamp 1
9 30117 Bracket, Support, Mounting, Sick Sensor 1
10 31352 Assembly, Weldment, Mounting, TMG & H Bottle 1
11 31963 Assembly, Box, AmpliÞer, Reject Sensor 1
12 31966 Bracket, Mounting, Junction Box 1
13 31967 Assembly, Cable, High Bottle Detector 1
14 32548 Bracket, Mounting, Sensor, Overheight Bottle 1
15 90945 Lug, Fork, Terminal 6

2
8
14 6
7
10
3
5
13
P46
P46
15 (6)
11
12
AMPLIFIER BOX RED +12V
WHT SIG
ITEM 11 BLK GND
.
SHLD
BLUE
BLK
BRN
31353
ASSY, DETECTOR, BOTTLE, OVERHEIGHT
SENSOR CABLE
ITEM 4
ITEM 13
#1
WIRING DIAGRAM

P/N 31371 KIT, FINISH, TWIST, OPTION, DUAL, RIGHT HAND, OV D1200

2 16922 Label, Warning, High Voltage, Scanner 1
3 26585 Label, Warning, High Voltage, German 1
4 26951 Kit, UltraLine, Base Cabinet, Option 1
5 29096 Kit, Illuminator, Dual Strobe, Twist Finish, RH, OV D1200 1
6 31372 Kit, Finish, Cards 2
7 32877 Assembly, Fan, Inspection Head 1
93068 32578-1 5
-12V G +12
INSPECTION
HEAD
BLK RED
TO FAN ASSY
ITEM 7
7
1
3
EA
SID T)
ON
(FR
BASE CABINET
TOP PLATE ASSEMBLY SID
UPSIDE DOWN SID

(FR
ON
EA
EB
BASE
T)
CABINET
4
EB
SID

P/N 31572 ASSEMBLY, DUAL POINT STROBE, OMNIVISION 900/1200

2 17821 Cap, Capacitor 2
3 None None 0
4 25867 Assembly, Circuit Card, Strobe Trigger 1
6 27851 Plate, Reßector, Strobe 1
7 27852 Spacer, Hex, Aluminum, #6-32 by 3.5 2
8 28000 Assembly, Card, 1200 Quench 1
9 28063 Assembly, Res, Bleeder, 1 Megabyte 1
10 29017-4 Assembly, Jumper Cable, Red, 7.1" 1
10A 29017-5 Assembly, Jumper Cable, Black, 7.1" 1
11 29017-6 Assembly, Jumper Cable, Red, 3" 1
11A 29017-7 Assembly, Jumper Cable, Black,3” 1
12 29026 Assembly, High Voltage, BNC 1
13 29334 Assembly, Thermometer, 140 degrees Overtemperature 1
14 30474 Enclosure, Strobe Interface 1
15 30475 Cover, Enclosure, Strobe Interface 1
16 30476 Assembly, Wire, Ground 1
17 30477 Bafße, Weldment 1
18 30478 Air Inlet, Weldment 1
19 30479 Bracket, Mounting, Capacitor 2
20 30480 Bracket, Mounting, Strobe, Interface 4
21 30481-1 Spacer, Hex, SS, #6-32 by 5/8 4
22 30481-2 Spacer, Hex, SS, #6-32 by 1/2 4
23 30482 Plate, Strobe, Receptor 1
24 30493 Assembly, Lamp, Dual Strobe 2
25 30788-1 Assembly, Wire, Quench, OV 1200 2
26 31571 Assembly, Circuit Card, OV 1200, Logic 1
27 92458 Cap, Power Supply, 5 F, 2 KVD 1
28 92476 Connector, Banana, Female 2
29 93767-1 Connector, Banana, Female, White 4
30 93767-2 Connector, Banana, Female, Black 2
31 93767-3 Connector, Banana, Female, Yellow 2

C-102
NOTES: SEE DETAIL "C"
SHEET 2 15
1.ITEM NO 3 DOES NOT EXIST.
2.REFER TO DWG 31572 FOR
OTHER DETAILS. 23
T101
(Yel)
T102 (Wht)
4 SEE DETAIL "A"
20 (4) SHEET 2
17
(4) 21 TO PIN 8
(Red)
26 TO PIN 7
18 8 (Blk)
25 REF
(4) 22
ON RH J201
13
2 (2)
J2
01 1- 3
-5 0
J2 PART OF
-1
01 ITEM 27
J2
14
25 (2)
PART OF
ITEM 12 9
27
1
16
31572
12 ON LH 13 19 (2)
5
ASSY, DUAL POINT STROBE, OV 900/1200
SHEET 1 OF 2

PART OF
7 10A 6
ITEM 30
5 24
FROM "GNDHV"(Blk) 11A
(ITEM 4, SHT 1)
(2) 7
FROM "1200VDC"(Red)
(ITEM 4, SHT 1)
8 10
FROM T101(Yel)
6
(ITEM 4,SHT 1)
11 29
10
FROM T102 (Wht)
REF 23
(ITEM 4, SHT 1)

9
28 (2)
Good for Red
10 8
Banana Plug Nos 6, 8
7 4
9 6 3 23 REF CABLE ASSY
PART OF SEE DETAIL "A"
5 2 ITEM 29
1
31 (2)
Good for Yellow 29 (4)
DETAIL "C"
Banana Plug Good for White Banana STROBE LAMP ASSEMBLY
Nos 9,10 30 (2) Plug Nos 1, 2, 3, 4
Good for Black
BananaPlugs Nos 5, 7
DETAIL "A"
CABLE ASSEMBLIES
(SHOWN UPSIDE DOWN FOR CLARITY)
(TERMINAL DESIGNATIONS ARE PICTORIAL ONLY) 31572
NOTES: ASSY, DUAL POINT STROBE, OV 1900/200
1.DETAIL "B" DOES NOT EXIST. SHEET 2 OF 2
2.REFER TO DWG 31572 FOR OTHER DETAILS.
C-103
P/N 31708 ASSEMBLY, CONVEYORS AND AIR, HIGH SPEED, RIGHT HAND

1 01963 Casting, Bracket, Upper Guide 1
2 04356 Tubing, Plastic A/R
3 10420 Fitting, Nozzle 1
4 10428 Bracket, Nozzle Mounting 1
5 10475 Assembly, Pulley, Guide Rail, Right Hand 1
6 10679 Valve, Two-Way Shut-off 1
8 11609 Tubing, Flame Retardent 4 feet
9 15394 Assembly, Belt, Bottle Retainer, EBI 1
10 16253 Mount, Infeed, Conveyor, Right Hand 1
11 16260 Mount, Outfeed Conveyor, Right Hand 1
12 17351 Gasket, Mount, Outfeed Conveyor 2
13 23089 Tubing, Pneumatic, 75 PSI, 0.375 1 foot
15 32509 Assembly, Main Conveyor, High Speed 1
16 34156 Assembly, Manifold, Air Sprayer, RH 1

REF
ONLY 14 AIR BLOWOFF ASSY
REJECT CONVEYOR
(CROSSOVER OR 13
EXTENDED TRAY) 16 CONVEYOR
MOUNTING
25837-0 BLOCK
(SEE M.O.)
SE
E
DE
DW T-
G D
26 ,
75
8
2 PL
10
3 PL
9 2 PL
5
2 PL
11 12

2 PL 12
15
4
3
6
2 PL
7 2 PL
8
1
2 PL
UPSTREAM BOTTLE WASHER

4 PL
31708
ASSY, CONVEYORS AND AIR, HIGH SPEED, RH, OV 900
C-105
P/N 31752 OPTION, VOLTAGE, BASE CABINET, 208-440 VAC

1 03160 Fitting, 90 degrees Liquidtight 2
2 18591-3 Washer, Reducing, Conduit 2
4 31938 Bar, Support, Transformers 1
5 31943 Brace, Transformers, Shipping 1
6 31944 Stud, Transformers, Shipping 1
7 31945-2 Bar, Transformers, Shipping 1
8 33640 Bracket, Latch, Door Cabinet 1
9 92660 Transformer, 2KVA, Universal 1
10 93074 Transformer, 190-400/120VAC, 3KVA 1
PART OF BASE CABINET ASSY 6

29275 (RH) OR 29276 (LH) 5
Se
Ro e Co
7 29 uting ndui
t
3 (2) Se 275 o , DE
e D r 2 T-J
eta 92 ,
il B 76
10 1
Se
Ro e Co
29 uting ndui
t
Se 275 o , DE 4 PL
e D r 2 T-J
eta 92 ,
il A 76
4 PL
1
1 (2)
CONDUIT
9 9 2 (2)
2 PL
DETAIL A
2 PL
4
"T" FITTING
8
FILTER
10
1
DETAIL B 31915 31937
(PART OF 29275 OR 29276) (PART OF 29275 OR 29276)

P/N 31753 OPTION, VOLTAGE, BASE CABINET, 460-480 VAC

3 31938 Bar, Support, Transformers 1
4 31943 Brace, Transformers, Shipping 1
5 31944 Stud, Transformers, Shipping 1
6 31945-1 Bar, Transformers, Shipping 1
7 91290-3 Transformer, 50-60 Hz, 2 KVA 1
8 91290-4 Transformer, 50-60 Hz, 2KVA 1
PART OF BASE CABINET ASSY 5

29275 (RH) OR 29276 (LH) 4
Se
Ro e C
29 utin ond
Se 275 g, D uit
6 e D or ET
eta 292 -J,
il B 76
1
3-440
-T
8
Se 2 (2)
Ro e C
29 utin ond 4 REQD
Se 275 g, D uit 2 PL
e D or ET
eta 292 -J,
il A 76
1
1
CONDUIT
7 2 (2)
7
2 PL
DETAIL A
2 PL
3
"T" FITTING
FILTER
8
1
DETAIL B 31915 31937
(PART OF 29275 OR 29276) (PART OF 29275 OR 29276)

P/N 31754 OPTION, VOLTAGE, BASE CABINET, 575 VAC

1 00156 Connector, Conduit, 90 Degree, 3/8 4
3 03165 Connector, Conduit, Straight, 3/4 1
4 31497 Bracket, Mount, Transformer, 575 VAC 4
5 33640 Bracket, Mount, Transformer 1
6 91479 Transformer, Step Down, 2KVA 1
7 93075 Transformer, Step Down, 3KVA 1
SE
E
C
RO ONDU 4 (2)
UT
IN IT
G,
29
27
5
DE
T- SECONDARY SIDE
OR J,
29
27
MUST FACE THIS
6
DIRECTION
1 (4) 4 PL
SEE
7
DETAIL
SE
E
RO CON
UT
I
29 NG, T
DU
I XFMR INSTALLATION
27
5 DE
OR T-J, DETAIL (Item 6 or 7) (2)
29
27
6
SEE PART OF BASE CABINET ASSY

6 29275 (RH) OR 29276 (LH)
DETAIL
2 PL
3/8" CONDUIT
2 PL
5
2-575
-T
3-575
-T
PART OF BASE CABINET ASSY

29275 (RH) OR 29276 (LH)

31911 ASSEMBLY, NECK GUIDE, RIGHT HAND, OV 900

3 14514 Washer, 1/4 Flat 2
4 19288 Pulley, Guide Rail 2
5 27815 Retainer, Handle 2
6 31852 Belt, Neck Guide, OV 900 1
OV 900
INSPECTION
HEAD
(31812)
REF
2 PL
(2) 3
6 PL
31813-0
(2) 27773-0 MO
MO
(2) 2
(2) 1 5 (2)
2 PL
2 PL
27773-0
REF 2
4
6 4 (2)
1
SECTION VIEW OF PULLEY ASSY, ITEM 4

31914 ASSEMBLY, NECK GUIDE, RIGHT HAND, OV 1200

3 14514 Washer, 1/4 Flat 2
4 19288 Pulley, Guide Rail 2
5 27555 Assembly, Handle, Captive 2
6 31853 Belt, Neck Guide, OV 1200 1
(31124) (31815)
(27532) REF
2 PL
(2) 3
6 PL
(2) 27773-0
MO
31816-0
(2) 2 MO
(2) 1
2 PL
5 (2)
6
27773-0
REF
2
4
1
4 (2)
SECTION VIEW OF PULLEY ASSY, ITEM 4

P/N 31959 ASSEMBLY, MOTOR, GEARHEAD, DC, WITH TACHIOMETER

1 91297 Contact, Cap Or Plug Pin 3
2 91299 Connector, Plug Housing, 6 Contacts 1
4 91731 Lug, Solderless, Insulated 1
5 93110 Motor, Gearhead, With Tachiometer 1
J7
T+ T- 9.50" GRN/YEL
TACH+ 1 22 RED
TACH (12")
TACH- 22 BLK
2
SHIELD 3 BLK/WHT
A+ A-
A+STAR 4 16 WHT
MOTOR
A-STAR 5 16 BLK
(3) 1 J7
SPARE 6
18 GRN/YEL 2
6 3
5 2
4 1
(2) 3
4
WIRING DIAGRAM
NOTES: FOR REPLACEMENT BRUSHES USE IDC # 16514

P/N 32070-1 KIT, RAM REJECTOR, PROLINE

1 00177 Assembly, Oil and Container 1
1A 00830 Connector, Strain Relief 1
1B 11623 Connector, Strain Relief 1
2 19247 Assembly, Pad, Tapered, Soft 1
3 20556 Assembly, Knob, 1 inch, Locking 2
4 21082 Washer, Flat, 1/4 ID 2
5 21106-3 Assembly, Junction Box, Cable 1
7 21214 Connector, Butt Splice, Heat Shrink 5
8 21239 Bracket, Sensor Mounting, Impulse Rejector 1
9 21631 Channel, Mounting, Impulse Rejector 1
10 21664 Assembly, Photo Switch, Impulse Rejector 1
11 26039 Assembly, ProLine, Bottle, Conveyor Mount 1
12 90420 Tie-Wrap, Nylon, T0015A A/R
17 None Cable, 2-conductor, 18AWG, Type SJT, Carol Cable #86012 or Equiv. A/R
18 None Cable, 3-conductor, 22AWG, Dearborn or Equivalent A/R

(2) 3 9 2 PL 8
(2) 4 BOTTLE
2 PL
FLOW
12 2 PL
10
2 CUSTOMER
CONVEYOR
11
100
6 PL 0
PART OF
TO AIR SEE VIEW "A" ITEM 11
CONTROLS
18 SUGGESTED MOUNTING
PART OF 2 PL OF AIR CONTROLS

ITEM 11
4 PL 13 14 (3)
PART OF
ITEM 10 5 120.0 63.0
(+/-1.0) (+/-1.0)
7 P 47
(3)
6 5
1B RED BRN (RED) RAM
1
17 7 (2) WHT BLK (WHT) REJECT
CONVEYOR P 47 2 SENSOR
BLK BLU (BLK)
3 (ITEM 10)
.82
J 36 15 1.63
RAM
3.00 1 WHT WHT REJECT
2.25 J 36
16 (2) 2 BLK BLK SOLENOID
.343 O (ITEM 11)
1A
(6) 2.75
1.75 (5) 7 6
VIEW "A" WIRING DIAGRAM
NOTE: REFER TO DWG 32070-0 FOR 32070-1

ASSEMBLY INSTRUCTIONS. KIT, RAM REJECTOR, PROLINE
C-113
P/N 32070-2 KIT, RAM REJECTOR, IMPULSE

1 00177 Assembly, Oil and Container 1
4 01726 Nipple, Brass, 1 1/2 inch 1
5 03048 Assembly, Rejector, 3/4 inch Stroke 1
6 03390-2 Plug, Countersunk, 1/4 - 18 NPT 3
7A 11623 Connector, Strain Relief 1
8 12565 Assembly, Valve, Pilot and Guard 1
9 14587 Bracket, Ram Mounting 1
10 18288 Fitting, Conduit, 1/2 Male to Female, 90 Degree 1
11 20305 Weldment, Bracket, Rejector Mounting 1
12 20308 Plate, Rejector Spacer 1
13 20556 Assembly, Knob, 1 inch, Locking 2
14 21082 Washer, Flat, 1/4 ID 2
17 21214 Connector, Butt Splice, Heat Shrink 3
18 21239 Bracket, Sensor Mounting, Impulse Rejector 1
19 21466 Pipe, 1/4 NPT x 3" Long 1
20 21631 Channel, Mounting, Impulse Rejector 1
21 21664 Assembly, Photo Switch, Impulse Rejector 1
22 34077 Assembly, Air Controls, High Flow, 1/2 NPT 1
23 90420 Tie-Wrap, Nylon A/R
24 91294 Connector, Plug, Housing, 3 Contacts 1
28 92799 Wire Joint, Crimp, Small 2
29 None Cable, 2-conductor, 18AWG, Type SJT, Carol Cable #86012 or Equiv. A/R
30 None Cable, 3-conductor, 22AWG, Dearborn or Equivalent A/R
Note: Item Number 16 does not exist.

18 11
2 PL
20 12 5
BOTTLE 2 PL
FLOW 2 PL
2 PL
2 PL (3) 7
(2) 14 13 (2) 21
9 8
23
CUSTOMER
CONVEYOR
AIR
2 PL 2 PL
4 PL
(2) 2
(3) 6
SEE VIEW "B" 19
30 4 10
SEE PART OF 24 25 (3)
VIEW "C"
VIEW "C" ITEM 21 29

2 PL 7A REF
63.0 16 P 47
29 PART OF 3 28 (2)
(+/-1.0)
ITEM 22 17 (3)
15 120.0 63.0
(+/-1.0) (+/-1.0)
17 (2) 15
29
RED BRN (RED) RAM
1
WHT BLK (WHT) REJECT
26 P 47 2 SENSOR
J 36 BLK BLU (BLK)
3 (ITEM 21)
27 (2) CONVEYOR 17 (3)
3 RAM
.82 100 WHT WHT
0
1 REJECT
2.25 J 36 2 BLK BLK SOLENOID
3.00 (ITEM 8)
.343 O
2.00 22 28 (2)
(4)
2.125
WIRING DIAGRAM
VIEW "B"
ASSEMBLY INSTRUCTIONS. 32070-2
KIT, RAM REJECTOR, IMPULSE VERSION
C-115
P/N 32383-0 ASSEMBLY, LCM, ELECTRONICS ENCLOSURE

2 26748 Assembly, Cable, Ground Strap 1
3 28248 Mount, Shock, LCM 2
4 28533-2 Assembly, Card, LCM, Omnivision 1200 1
5 31991 Strap, Ground, Circuit Board 1
6 32386 Frame, LCM, Electronics Enclosure 1
7 32517-1 Assembly, Heat Sink, Power Supply, 1/4 HP 1
10 94491-5 Resistor, 2 Ohm, 25 W, Chassis Mount 1
EXISTING
HEAT SINK/ 10-32 UNC-2A STUD
DASH TAKEAWAY
POWER 2
NO MOTOR HP IN ELEC ENCL
SUPPLIES
32383-1 7 1/4
32383-2 8 1/2
32383-3 9 3/4 HEAT SINK/

POWER
SUPPLIES
(FOR GROUND (SEE TABLE)
(4) 1 CONNECTION)
2 Starwheel
Motor Controller
(Ref)
Takeaway
Motor Controller
(Ref)
4 PL
4 2 PL SEE DETAIL "A"
10
6 PL
6
2 PL
3 (2)
5
DETAIL "A"

WIRING INSTRUCTIONS.

P/N 32453-2 KIT, ILLUMINATOR, ROPP FINISH, 28MM, SINGLE, 20 DEG, STROBE

1 16793 Cover, Bottom, Housing, Strobe Lamp 1
2 16797 Housing, Terminal, Strobe Lamp 1
4 16921 Label, Warning, Lethal, Voltage, Trilingual 2
5 16922 Label, Warning, HV, Scanner Head 1
6 17125 Assembly, Strobe Lamp 1
7 26585 Label, Warning, HV, Scanner Head, German 1
8 28416-2 Spacer, Terminal, Housing 1
9 28586 Nut Plate 1
10 28656 Housing, Upper 1
11 28661 Reßector 1
12 29129 Assembly, Bafße, Diffuser 1
13 32400 Assembly, Lens, Toroidal, 28 mm, 20 Degrees 1
15 32414 Support, Window 1
16 32415 Window, Protective Cover 1
17 32436-2 Assembly, Camera 1
18 32437 Assembly, Window, Lens, Primary 1
19 32578-1 Assembly, Power Supply 1

17
7 2 PL
2 PL
2 PL
2
5
4
8
1
4 PL
10
6
12
(2) 3 11
13 RED
BLK
4 PL
19
4 PL
4 PL
14
4 PL
9
Power Supply Mtg
Bracket (Ref)
Inspection
Head (Ref)
NOTE:
REFER TO DWG 32453-0 FOR 18
16
15
4 PL 3 PL
3 PL
32453-2
KIT, ILLUMINATOR, ROPP FINISH, 28 MM,
SINGLE, 20 DEGREES, OV 900/1200

P/N 32517-0 ASSEMBLY, HEAT SINK, POWER SUPPLIES, LCM

1 29054-1 Assembly, Motor Controller, 1/4 HP, Takeaway Conveyor 1
4 31135 Gasket, Transfer, Thermal, 200 W 1
5 31136 Gasket, Transfer, Thermal, Control 2
6 31239-4 Assembly, Motor Controller, 1/8 HP, Starwheel 1
7 32385 Heat Sink, LCM, Electronics Enclosure 1
8 32389 Hanger, LCM, Electronics Enclosure 2
9 92713 Power Supply, 4 Output 1
4
8 (2)
9
7
DASH MOTOR TAKEAWAY

NO CONTROLLER MOTOR HP
32
51
7(R
03
32517-1 1 1/4 )
32517-2 2 1/2
32517-3 3 3/4 1 2 3
See Table

P/N 32565 KIT, ILLUMINATOR, DUAL STROBE, PRESS, 40-55 DEGREES, RH

1 16908 Assembly, Knurled Knob, #6 - 32 4
2 26552 Label, Warning, SH, PS, German 2
4 27574 Mirror, Toroidal, 40-55 Degrees 1
5 27577 Bezel 1
7 28586 Nut Plate 1
8 28661 Reßector, Toroidial 1
11 29185-1 Assembly, Camera, Mounted 1
11A 29185-2 Assembly, Camera, Mounted 1
12 29348 Housing, Terminal, Dual Strobe 1
13 29349 Cover, Terminal, Dual Strobe 1
14 29368 Housing, Strobe Lamp, Upper 1
15 30158 Assembly, Servo, Zoom, Right Hand 2
16 31304 Heat Sink, Housing, Terminal, Dual Ring 1
17 31600 Assembly, Bafße, Diffuser, 40-55 Degrees 1
18 31690 Gasket, Transfer, Thermal 1
19 32415 Window, Protective, Optical 1
20 32563 Assembly, Window, Lens, primary 1
23 32725 Bumper, Stem, Rubber 2

11A
4 PL
11
22
2 REQD
4 PL 2 PL
6
2 REQD
2 PL
2 PL
2 PL (2)
2 PL 15
2 PL
Power Supply
Mtg Bracket 16 4 PL
(Ref)
18
10
12
4 PL
7
9
14
SCANNER HEAD 8
( Ref) 20 4 PL
(4) 1
19 17
13
5 21
(2) 23
4 PL 3 PL
3 PL
NOTE: REFER TO DWG 32565 FOR 4

32565
KIT, ILLUMINATOR, DUAL STROBE,
PRESS FINISH, 40-55 Degrees, RH, OV D-1200

P/N 32778 ASSEMBLY, MIRROR, ELEVATED, THIRD VIEW, OSW

2 32460 Bracket, Mirror, 45 Degree 2
3 32465 Assembly, Mirror, Base, 45 Degree 1
4 32466 Assembly, Block, Mirror, Elevated 1
5 32643 Filter, Neutral Density 1
6 32645 Base, Filter, Neutral Density 1
2 (2)
6 PL
1 (2)
6
5
6 PL

P/N 32948 ASSEMBLY, SENSOR, TEST BOTTLE

1 91609 Pin, Crimp, Female 3
2 92248 Connector, Plug, Power Supply 1
3 93548 Sensor, Retro-Reßective 1
LED
(OUTPUT)
1 (3) 1
32948(R4)
24" LG
NOTES:
2 2
1 CRIMP PIN (ITEM 1) TO WIRE, 3 PLACES.
2 BAG CONNECTOR HOUSING (ITEM 2)

ALONG WITH SENSOR CABLE.
SENSOR (ITEM 3)
PIN (ITEM 1)
RED or BRN +V (10 TO 30VDC)
CONN (ITEM 2)
WHT SIGNAL OUT
1
2
BLK or BLU 0V
3
WIRING DIAGRAM

P/N 33023 KIT, FINISH, OPTION, DUAL, 40-55 DEGREES, RH, OV D1200

2 16922 Label, Warning, High Voltage, Scanner 1
4 26951 Kit, UltraLine, Base Cabinet, Option 1
5 31372 Kit, Finish, Cards 2
6 32565 Kit, Illuminator, Dual Strobe, 40-55 Deg, Press Finish, RH, OV D1200 1
7 32877 Assembly, Fan, Inspection Head 1
93068 32578-1 6
-12V G +12
INSPECTION
HEAD
BLK RED
TO FAN ASSY
ITEM 7
7
1
3
A
DE
SI )
NT
RO
(F
BASE CABINET
TOP PLATE ASSEMBLY SI
DE
UPSIDE DOWN SI
(F
DE
RO
A
B
BASE
NT
)
CABINET
4
B
DE
SI

P/N 33136 OPTION, TRANSFORMER, 190-460 VAC, BASE CABINET

2 03162 Conduit, Sealtite, 3/4” Diameter 29 Inches
3 03165 Connector, 3/4” Conduit, Straight 1
6 26945 Bar, Mounting, Transformer, Right 1
7 26946 Bar, Mounting, Transformer, Left 1
8 26947 Bracket, Transition, Securing 1
9 26948 Bar, Securing, Transformer 2
10 92660 Transformer, 2KVA, Universal 2
4 PL
2
9 (2)
3
2 PL
4 PL
2 PL
BASE CABINET
10
(2) 5
4 PL
NOTE:
4 (4)
WIRING INSTRUCTIONS.

P/N 33256 ASSEMBLY, INSPECTION HEAD, RIGHT HAND, OV 900

3 10492 Pin, Locating 2
4 10494 Label, Indicator 2
5 10825 Cover, Vertical Column 1
7 14128 Retainer, Cover, Vertical Column 1
8 16786 Pointer, Adjustment Trigger 2
9 17126 Assembly, Trigger Beam, UltraLine 2
10 17212 Screw, Trigger, Pointer 4
11 21567 Label, BS1 1
12 25588 Plate, Retainer, Cable, Inspection Head 1
13 25610 Plate, Inspection Head, Right 1
14 25644 Bracket, Mounting, Power Supply, Finish Inspection 1
15 25988 Plate, Inspection Head, Left Side 1
16 26606 Strap, Ground, Chassis, RLD 1
17 27329 Skin, Back, Cover, Inspection Head 1
18 27330 Label, Barrier Strip, 8 Poles 1
20 28648 Assembly, Circuit Card, Universal, Isolation 1
21 28694 Assembly, Servo Card and Cover 1
22 28846 Plate, Mounting, Servo 1
23 29081 Screw, Captive, 8 - 32 3
24 29103 Plate, Cover, Test Bottle Sensor 1
25 29105 Plate, Mounting, RLD, OV 1200 1
26 29106 Shield, RLD, OV 1200 1
27 29111 Standoff, Quick Release 4
28 29232 Bracket, Mounting, Reject VeriÞer, Right Hand 1
29 29698 Assembly, Cover, Inspection Head 1
30 30167 Assembly, 3-Tower Optical System 1
31 30315 Assembly, Sensor, Reject VeriÞer 1
32 31336 Plate, Mounting, LVPS, Right Hand 1
33 31812 Plate, Neck Guide, OV 900, Right Hand 1
34 32995-1 Assembly, Reßector, ModiÞed, Reject VeriÞer 1
35 33249 Plate, Back, Inspection Head 1
36 33251 Plate, Base, Inspection Head 1
37 91033 Barrier Strip, 8 Terminals 1
38 93068 Power Supply, Inspection Head, ACC 1 1
39 94495 Power Supply, Inspection Head 1

38 12 35
39 27 (4) 2 PL
25
(3) 23 15
4 REQD
1 (8) 2 PL
32
20
8 PL 13
1 REF
14
4 PL 26
4 REQD
2 PL
8 PL
7 PL 36
GROUND STRAP
PART OF ITEM 30 2 PL 5
29107
M.O.
3 PL 7

10 (4) PART OF
3 (2)
ITEM 9
4 PL DETAIL "B"
37 CHASSIS ASSY
SEE 18
DETAIL "B"
SEE
DETAIL "A"
24 2
DETAIL "A"
30315 11
M.O. 33 (2) 8
4 PL (2)
4
9 (2)
4 PL
33256
ASSY, INSPECTION HEAD, RH, OV 900/ 3OOO
NOTE: REFER TO DWG 33256 FOR ASSEMBLY DETAILS.
SHEET 1 OF 2
C-127
29 2 PL
C-128
GROUND STRAP
SEE SHEET 1
17 31
30
34
19 28
6 PL
2 PL
COVERS 4 PL
2 PL
CONNECTOR 92249 VIEW C - C

(PART OF ITEM 31) REJECT VERIFY ASSY
(ROTATED FOR CLARITY)
22
26770 (STANDARD)
OR
29530 ("T" TYPE) 21
SEE M.O.
2 PL 3 PL
2 REF
C C
NOTE: REFER TO DWG 33256 33256

FOR ASSEMBLY DETAILS. ASSY, INSPECTION HEAD, RH, OV 900/ 3000
SHEET 2 OF 2

P/N 33262 ASSEMBLY, INSPECTION HEAD & STARWHEEL DRIVE, RH, OV 900

1 03527-3 Pin, Roll, CRES 1
2 10427 Spring, Compression 1
3 10950 Handwheel, Raising Mechanism 1
4 11019 Collar, Scanner Head, Clamp 1
5 11065 Assembly, Spindle Housing, Right Hand 1
6 11096 Bracket, Motor, Mounting 1
7 11104 Belt, Timing 1
8 11141 Gasket, Spindle Housing 1
9 11499 Bracket, Magnetic Clutch 1
10 12298 Universal Joint, ModiÞcation 2
11 12326 Label, Caution 1
12 12429 Closed, Cell Foam Rubber 1
13 12487 Coupling, Flexible, 5/8 Bore 1
14 12564 Rivet Pop 4
15 12659 Wedge, Inspection Head Support 1
16 12660 Collar, Inspection Head Support 1
17 12974 Key, Starwheel Drive 1
17A 13269 Assembly, Clutch/Brake, Starwheel Drive 1
18 14984 Key Starwheel Drive 1
19 16355 Shaft, Locking, Raising Mechanism 1
20 16357 Retainer, Gear Shaft, Raising Mechanism 2
22 16362 Bearing, Gear Shaft, Raising Mechanism 2
23 16366 Ring, Retaining, Raising Mechanism 1
24 16369 Worm, Raising Mechanism 1
25 16371 Screw, Set 3/4-16 x 3/4 1
26 16372 Cover, Gear Box, Raising Mechanism 1
27 16373 Bearing, Flanged, Raising Mechanism 2
28 16419 Cam, Locking, Raising Mechanism 1
29 16420 Cam, Lock, Raising Mechanism 1
30 16480 Bearing, Thrust, Needle 1
31 16481 Race, Thrust 2
34 16625 Gear, Worm, ModiÞed 1
36 17008 Seal, Shaft, Locking, Raising Mechanism 2
37 19516 Label, Barrier Strip, TB2 1
38 22617 Hub, Handle, ModiÞcation 1
39 24958 Bracket, Mounting, Encoder, Starwheel Drive 1
40 24960 Pulley, Encoder, Starwheel Drive 1
41 25584 Shaft, Locking 1

P/N 33262 ASSEMBLY, SCANNER HEAD & STARWHEEL DRIVE, RH, OV 900, CONTINUED

42 25698 Label, Lock 1
43 27330 Label, Barrier Strip 1
44 27845 Gasket, Tube, Scanner Support 1
45 27847 Weldment, Tube, Inspection Head, Right Hand 1
46 28194 Counter, Indicator 1
46A 29395-5 Key, Coupling 1
46B 29395-7 Key, Coupling 1
47 30863 Collar, 3/8 Lower, Omnivision 900 1
50 31959 Assembly, Motor, Gear head, DC 1
51 32116 Gib, Rack, Raising Mechanism 1
52 32117 Retainer, Gib, Raising Mechanism 2
53 32118 Pusher, Rack, Raising Mechanism 1
54 32119 Assembly, Housing, Raising Mechanism 1
55 32161 Set Screw, 1/4-28 Self-locking 3
57 33026 Spacer, Clutch-Brake 1
58 33119 Plate, Mount, Connector 1
59 33256 Assembly, Inspection Head, Right Hand 1
60 33448 Collar, Two Piece 1
61 33449 collar, Threaded, Two Piece 1
62 33760 Rack, Gear, Raising Mechanism 1
63 33961 Assembly, Couplings, W/Spider 1
63A 35164 Assembly, Encoder, Smart, Starwheel Drive 1
64 36737 Gear, Pinion, Raising Mechanism 1
65 36739 Shaft, Gear, Raising Mechanism 1
66 36740 Shaft, Worm, Raising Mechanism 1
67 36741 Spacer, Gear, Raising Mechanism 1
Note: Item Numbers 21, 32, 33, 49 and 56 do not exist.

41 2 PL 2 PL 4 PL
12
(2) 27
10 (2)
16
36
1 38 15
2 PL
4
36 48
2 PL
DETAIL "C"
35
RAISING MECHANISM SHAFTS
AND COUNTER ASSEMBLY
46 62
3 6 PL
SEE 4 PL
DETAIL "D" 59

45
2 PL
DETAIL "D"
SEE 44 INSPECTION HEAD ASSY
DETAIL "A"
SHEET 2 8
(4) 14 NOTE: REFER TO DWG 33262 FOR

42
SEE
DETAIL "C"
CABINET 33262
ASSEMBLY ASSY, INSPECTION HEAD &
SEE STAR DRIVE, RH, OV 900
DETAIL "B" SHEET 1 OF 2
SHEET 2
C-131
C-132
11 5
2 PL
(2) 52
PART OF
51 ITEM 63 7
(3) 55
2 PL
53 2 PL 4 PL
54 40
25 2 PL 39
63
61 2 PL
63A
4 PL 4 PL
28 26
2 46A 9
34
3 PL PART OF
4 PL
ITEM 63
29 20 (2) 2 PL
19 17
17A
2 PL
2 PL 64 13
66
67 46B 65 47
2 PL 22 (2)
24 50 18
30 58
23 DETAIL "A" PART OF
RAISING MECHANISM ASSY ITEM 47
60 31 (2)
57
2 PL
DETAIL "B" 13616
STARWHEEL DRIVE ASSY
NOTE: REFER TO DWG 33262 FOR 2 PL
TB2
2 PL
6
4 PL 37
33262
ASSY, INSPECTION HEAD &
STAR DRIVE, RH, OV 900
SHEET 2 OF 2

P/N 33352 ASSEMBLY, TOP, OMNIVISION 900 (SERIES 3000), RH

1 26758 Base Cabinet, Exterior, RH 1
2 27119 Diffuser Cover 1
3 27567 PLC Junction Box 1
4 32865 Monitors and Electronics 1
5 33262 Scanner Head and Star Drive, RH 1
6 33266 Base Cabinet, Interior, RH 1
7 33293 Columns and Doors 1
8 33433 Conveyors and Air, RH 1
11 35780-2 Water Control, External 1
BOTTLE
5 PART OF WASHER CUSTOMER'S
ITEM 7 PART OF 9 CONVEYOR
ITEM 11
10 D
EE
INF
1
1
2 11
26712 OR
28726 REF ASSY, STARWHEEL
AND GUIDERAILS, RH
BASE CABINET
4
PART OF ITEM 7
D
TF
EE 6
OU
8
3
7
NOTE:
BASE CABINET


Index
INDEX
A
Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21, B-1
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Air Jet Blowoff Nozzle, Repair & Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Air System Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Alignment and Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26, C-36
B
Base Cabinet, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Base Inspection Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Base Inspection Strobe Lamp, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Base Inspection Strobe Lamp Power Supply, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . 3-15
Base Inspection Trigger Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Base Inspection Trigger Sensor, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Belts, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Blowoff Nozzle, Air Jet, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Bottle Guides, Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Bottle Jams at Infeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bottle Jams at Outfeed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bottle Jams in the Inspection Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Bottle Sensors, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2, 3-11
Brake-clutch Unit, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Broken Diffuser Glass Disk, Repair & Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
C
Cameras, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Cards/Modules, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
CE Test Mark Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Cleaning or Replacing Diffuser/Clear Glass Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Clutch-brake Unit, Repair & Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Color Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20, A-12
Complete System Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Conveyor Chain Encoder Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Customer Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
D
Daily Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Dead Plate, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Diffuser Glass Disk, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Diffuser Glass Disk, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Diffusers, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Drawing Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-25
Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26
Drive System, Starwheel, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Dual Outer Sidewall Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Industrial Dynamics Company, Ltd. Form 3056 (05/99) Index-1

Dual Strobe Assembly, Base, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Dual Strobe Assembly, Finish, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Dual Strobe Power Supply, Base, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
E
Electrical, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Emergency Repair and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Encoder Alignment, Starwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Encoder Problems, Production Conveyor Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Encoders, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
F
False Rejects, Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Fans, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Faulty Bottles Detected, But not Rejected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Faulty Bottles Passing as Good Bottles (False Accepts or Missed Rejects) . . . . . . . . . . . . . . . . . 2-37
Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Finish Inspection Excessive False Rejects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Finish Inspection Strobe, Dual, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Finish Inspection Trigger Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Finish Inspection Trigger Sensor, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Fluorescent Lamps, OSW, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
G
Gast Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Gearhead Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10, A-11
Glass Disk, Diffuser, Cleaning or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Glass Disk, Diffuser, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Guide Positioning, Main Omnivision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Guide Positioning, OSW Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Guidelines for Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Guiderails, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
I
Identifying Software Version Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Infrared RLD Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Inner Sidewall Inspection Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Inspection Head and Timing Trigger Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Inspection Head, Repair or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Inspection/Rejection Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Inspection Trigger Sensors, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
International Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
L
Lamp Replacement, OSW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Lamps, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Large Percentage of Bottles Rejected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Lenses, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Light Sources, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Index-2 Industrial Dynamics Company, Ltd. Form 3056 (05/99)

Index
M
Main Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26, C-36
Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Manual List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Manufacturers Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Mechanical, Miscellaneous, Parts Ordering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
Microsonic Bottle Sensor Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Microsonic Bottle Sensors, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Microsonic Bottle Sensors, Repair or Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Microswitch Usage for Bottle Sensing, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mirrors, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Missed Rejects (Passing Faulty Bottles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Monitors, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Monitors, Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20, A-12
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Motor Controllers, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-19
Motor, Takeaway Conveyor, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Motors, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-19
Motors, Gearhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10, A-11
N
No Bottles Rejected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Norgren Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
O
Oiler, Vacuum, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Omnivision Bottle Handling Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Omnivision Guide Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Omnivision Manual List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Omnivision 1200/D-1200 Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Omnivision 900 Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Outer Sidewall Enclosure, Repair or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Outer Sidewall Guide Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Outer Sidewall Inspection Excessive False rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Outer Sidewall Inspection Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Outer Sidewall Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
P
Parts Lists, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-26
Parts Lists, Recommended Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Passing Faulty Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Plugged Neck/Color Sort Excessive False Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17, 2-20
Power Supplies, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-20
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Preventive Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Product Safety Test Mark Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Pump, Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8, A-1

R
Radio Frequency RLD Excessive False rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Recommended Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Reject Solenoid Valve, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Reject Takeaway Conveyor Motor, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Rejected Bottles Not Stable on the Takeaway Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Rejecting Incorrect Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Rejecting Large Percentage of Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Rejecting No Bottles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Rejectors, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-21
Relays, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22
Repair and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Rotating Diffuser Glass Disk, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5, 3-13
S
Sensors, Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2, 3-11
Sensors, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-22
Software Version Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Solenoid Valve, Reject, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Solenoid Valves, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23
Spare Parts, Recommended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Starwheel Drive and Line Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Starwheel Drive is Sluggish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Starwheel Drive Motor, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Starwheel Drive System, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Starwheel Encoder Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Starwheel Seal Ring, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Starwheel Vacuum System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Switches, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23
Symbols, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
System Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
T
Takeaway Conveyor Motor, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Timing Trigger Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Touchpads, Repair & Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Transformers, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-24
Trigger Sensors, Inspection Head, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
U
Ultrasonic Bottle Sensors, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2, 3-11
Using Microswitch for Bottle Sensing, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
V
Vacuum Oiler, Repair & Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8, A-1
Vacuum System Adjustment, Starwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Valve Plate, Repair & Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Valves, Solenoid, Parts Ordering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-23
Version Code, Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Index
Video Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20, A-12

Video Monitors, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
W
Wear Plates, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Wear Strips, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Windows, Optical, Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Wiring the Microswitch Into the System, Emergency Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2


30560599-MANUAL OV-1200-900 SERIE 3000-Ingles

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Omnivision Series 3000

Maintenance and Parts Manual

Maintenance and Parts

Software Version CFx

Form 3056 (05/99A)

Form 3056 (05/99A) Copyright. All rights reserved.

INDUSTRIAL DYNAMICS COMPANY, LTD.

2927 Lomita Boulevard,

Customer Service Center (800) 733-5173

Headquarters (310) 325-5633

Headquarters (310) 530-1000

Product Safety Test Mark Information . . . . . . . . . . . . . . . . . . . . . . vii

Chapter Topic Page

3 Repair and Replacement Procedures

4 Alignment and Calibration procedures

Industrial Dynamics Company, Ltd. © Form 3056 (05/99) iii

B Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

C Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

iv Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Maintenance and Parts Manual Overview

The Omnivision Systems may have the following conÞgurations:

Industrial Dynamics Company, Ltd. © Form 3056 (05/99) v

This manual is organized as follows:

Chapter 1 Periodic Maintenance.

The software is identiÞed by a version code. The version code

The version code may be viewed on the Omnivision Sign-on

When calling Industrial Dynamics for assistance, always have the

Omnivision Series 3000 Manuals

Other manuals include:

Installation Manual (Form 3053)

vi Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

PRODUCT SAFETY TEST MARK INFORMATION

The machine has a CE Mark afÞxed to it and is accompanied by an

The Omnivision machine labels conform to the International

For your convenience, the following is a table of International

Industrial Dynamics Company, Ltd. © Form 3056 (05/99) vii

No. Description No. Description

viii Industrial Dynamics Company, Ltd. © Form 3056 (05/99)

Periodic Maintenance Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Industrial Dynamics Company, Ltd. © Form 3056 (06/98)

Industrial Dynamics Company, Ltd. © Form 3056 (06/98)

PERIODIC MAINTENANCE OVERVIEW

The Omnivision system is designed to operate without requiring

PERIODIC MAINTENANCE PROCEDURES

ITEM DAILY MAINTENANCE

Industrial Dynamics Company, Ltd. © Form 3056 (06/98) 1-1

ITEM DAILY MAINTENANCE

1-2 Industrial Dynamics Company, Ltd. © Form 3056 (06/98)

ITEM DAILY MAINTENANCE

Industrial Dynamics Company, Ltd. © Form 3056 (06/98) 1-3

ITEM WEEKLY MAINTENANCE

Vacuum Pump Check oil level and Þll to 3/4 full.

1-4 Industrial Dynamics Company, Ltd. © Form 3056 (06/98)

ITEM WEEKLY MAINTENANCE

ITEM MONTHLY MAINTENANCE

Air Conditioner Check the Þlter element. Clean or replace as necessary.

Industrial Dynamics Company, Ltd. © Form 3056 (06/98) 1-5

ITEM MONTHLY MAINTENANCE