Omnivision III ASEBI-Service and Installation Guide-English-47751-0316 - CCv0002

Volume 1 Installing and Starting
Omnivision III Service and Installation Guide
Document 47751-0316
Omnivision III Service and
Installation Guide
Document 47751-0316
Industrial Dynamics Company, Ltd.
Document 47751-0316 Copyright 2016. 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, Ltd.
filtec and Industrial Dynamics are registered trademarks of Industrial Dynamics Company,
Ltd. All other trademarks are the property of their respective owners.
Contact Information
Corporate Headquarters 3100 Fujita Street,

Torrance, California
90505-4007
U.S.A.
Telephone:(310) 325-5633
FAX: (310) 530-1000
Internet: www.filtec.com
Mailing Address P.O. Box 2945,

90509-2945
U.S.A.
Shipping Address 3100 Fujita Street,

90505-4007
U.S.A.
Customer Service (800) 733-5173

Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Topics That This Guide Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Audience of This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Conventions That Appear in This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii
1. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section Page
1.1 Safety Notices and Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Compliance of Omnivision III to Standards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 International Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2. Overview of Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Section Page
2.1 Omnivision III Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
2.3 How Omnivision III Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
2.4 Overview of Omnivision III Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
2.5 Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
2.6 Outer Sidewall Inspection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
2.7 Polycarbonate Safety Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
2.8 Monitor Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
2.9 Signal Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
2.10 Radio Frequency Residual Liquid Detection Inspection Subsystem . . . . . . . . . . .2-41
2.11 Container Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
2.12 Starwheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
2.13 Suction Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
2.14 Strobe Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54
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2.15 Test Container Detection Photocell Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .2-56
2.16 Inspection Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
2.17 External Ethernet and PS/2 Keyboard Ports. . . . . . . . . . . . . . . . . . . . . . . . . .2-59
2.18 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
2.19 Solid State Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
2.20 Card Cage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62
2.21 Central Processing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
2.22 Inspection Processor Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
2.23 Camera Link Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
2.24 Universal Serial Bus Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
2.25 Reject Verifier Ultrasonic Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
2.26 Inspection Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
2.27 Servo Motors for Zoom and Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70
2.28 Infrared Residual Liquid Detection Sensor and Card . . . . . . . . . . . . . . . . . . . .2-71
2.29 Servo Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72
2.30 Finish Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-73
2.31 Encoders Inside Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74
2.32 Conveyor Chain Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75
2.33 Down and Jam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77
2.34 Sonic Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-80
2.35 Resynchronization Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82
2.36 Main Power Switch and Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . .2-83
2.37 Color Sort Inspection Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-85
2.38 Base Unit Lower Cabinet: Starwheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86
2.39 Air and Vacuum Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87
2.40 Air Regulating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88
2.41 Power Supply Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
2.42 Line Control Module Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90
2.43 Isolation Step-Down Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-91
2.44 Finish and Reject 48 Volt Direct Current Power Supply . . . . . . . . . . . . . . . . . .2-92
2.45 Base Unit Lower Cabinet: Operator Side. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93
2.46 Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94
2.47 Rotating Glass and Brush Drive Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95
2.48 Opto Isolated Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97
2.49 High Voltage Base Strobe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-99
2.50 Uninterruptable Power Supply Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
2.51 Starwheel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
2.52 Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
2.53 How the Vacuum System Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
2.54 Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
2.55 Water Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
2.56 Auxiliary Subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
2.57 Rejectors That You Use With Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
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Document 47751-0316
2.58 Bottle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
2.59 Omnivision III Utility Requirements and Specifications . . . . . . . . . . . . . . . . . 2-113
2.60 How Inspection Subsystems Interact With Each Other . . . . . . . . . . . . . . . . . . 2-120
2.61 How the Base Subsystem Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
2.62 How the Inner Sidewall Subsystem Works . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122
2.63 How the Finish Subsystem Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
2.64 How the Thread Inspection Subsystem Works . . . . . . . . . . . . . . . . . . . . . . . 2-124
2.65 How the Outer Sidewall Subsystem Works. . . . . . . . . . . . . . . . . . . . . . . . . . 2-125
2.66 How the Bright Field Analyzer Subsystem Works . . . . . . . . . . . . . . . . . . . . . 2-126
2.67 How the Infrared Residual Liquid Subsystem Works. . . . . . . . . . . . . . . . . . . . 2-127
2.68 How the Radio Frequency Residual Liquid Detection Subsystem Works . . . . . . . 2-128
2.69 How Base Inspection Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
2.70 How Inner Sidewall Inspection Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132
2.71 How Finish and Thread Inspection Work . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134
2.72 How Outer Sidewall Inspection Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136
2.73 How Infrared Residual Liquid Detection Inspection Works . . . . . . . . . . . . . . . 2-138
2.74 How Radio Frequency Residual Liquid Detection Inspection Works. . . . . . . . . . 2-140
2.75 Comparison of IR and RF Residual Liquid Detection . . . . . . . . . . . . . . . . . . . 2-142
3. Turning On and Turning Off Omnivision III. . . . . . . . . . . . . . . . 3-1
Section Page
3.1 Turning On Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Turning Off Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4. Installing Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section Page
4.1 Guidelines to Follow As You Install Omnivision III . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Determining the Space That You Need for Omnivision III . . . . . . . . . . . . . . . . . 4-3
4.3 Unpacking Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.4 Raising the Base Unit and Outer Sidewall Unit . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.5 Installing Omnivision III on Your Production Line . . . . . . . . . . . . . . . . . . . . . .4-14
4.6 Installing the Starwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4.7 Installing Container Guides and Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4.8 Installing Optional Reject Conveyor and Guide Assemblies . . . . . . . . . . . . . . . .4-20
4.9 Attaching the Reject Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
4.10 Installing Splice Plates Between a Production Conveyor and Omnivision III . . . . .4-23
4.11 Installing the Upstream Container Washer Assembly . . . . . . . . . . . . . . . . . . . .4-24
4.12 Mounting the Sonic Sensor Assemblies and Washer . . . . . . . . . . . . . . . . . . . . .4-26
4.13 Adjusting the Air Knife Blow Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4.14 Installing the Rotating Diffuser and Glass . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4.15 Installing the Mirror on the Optional Outer Sidewall Unit. . . . . . . . . . . . . . . . .4-30
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Document 47751-0316
4.16 Attaching the Polycarbonate Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
4.17 Connecting Air to Your Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
4.18 Connecting Water to Your Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35
4.19 Grounding Your Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
4.20 Connecting a Power Regulator to Omnivision III . . . . . . . . . . . . . . . . . . . . . . .4-38
4.21 Connecting Power to Your Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40
4.22 Installing the Uninterruptable Power Supply . . . . . . . . . . . . . . . . . . . . . . . . .4-43
4.23 Connecting Omnivision III to Your Programmable Logic Controller Line . . . . . . . .4-46
4.24 Final Installation Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
5. Adjusting, Aligning, and Calibrating Omnivision III . . . . . . . . . . 5-1
5.1 Adjusting the Starwheel Top Plate to the Container Finish . . . . . . . . . . . . . . . . 5-2
5.2 Generally Adjusting the Inspection Head . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Finely Adjusting the Inspection Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Adjusting the Dead Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.5 Adjusting the Conveyor Chain Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5.6 Aligning the Reject Takeaway Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5.7 Adjusting the Infeed and Outfeed Guides . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
5.8 Adjusting the Orange Body Guide Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5.9 Adjusting the Green Neck Guide Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
5.10 Adjusting the Diffuser Glass Drive and Rotating Brush . . . . . . . . . . . . . . . . . . .5-17
5.11 Verifying the Correct Vacuum Flow Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
5.12 Connector Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
6. Turning On Omnivision III for the First Time . . . . . . . . . . . . . . 6-1
6.1 Turning On Omnivision III for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Verifying That Systems Are Working Correctly . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.3 Checking and Adjusting the Air Knife Blow Off Assembly Pressure . . . . . . . . . . .6-12
6.4 Checking the Thread Blow Off System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
6.5 Checking the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6.6 Checking the Diffuser Glass Drive and Brush Cleaning System . . . . . . . . . . . . . .6-19
6.7 Pinning the Starwheel to the Inspection Head . . . . . . . . . . . . . . . . . . . . . . . .6-20
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
Documentation Feedback . . . . . . . . . . . . . . . . . . . . . .Feedback-1
Help Us Improve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-1

Ways to Submit Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-1
Documentation Feedback Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-2
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List of Figures
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. Overview of Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-1. Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Figure 2-2. Typical Press or Crown Container . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-3. Overpress Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Figure 2-4. Image of an Overpress on a Screen . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Figure 2-5. Inspection Setup OSW Image Screen . . . . . . . . . . . . . . . . . . . . . . . .2-19
Figure 2-6. A Typical ROPP Finish Container . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Figure 2-7. A Scuffed Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Figure 2-8. A Typical Twist Off Finish Container . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Figure 2-9. Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
Figure 2-10. Major Components of Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Figure 2-11. Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Figure 2-12. Outside the Outer Sidewall Inspection Unit . . . . . . . . . . . . . . . . . . . .2-35
Figure 2-13. Inside the Outer Sidewall Inspection Unit . . . . . . . . . . . . . . . . . . . . .2-36
Figure 2-14. Inside the Outer Sidewall Lower Cabinet . . . . . . . . . . . . . . . . . . . . .2-37
Figure 2-15. Polycarbonate Doors on the Omnivision III Base Unit . . . . . . . . . . . . . .2-38
Figure 2-16. Monitor Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
Figure 2-17. Signal Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
Figure 2-18. Radio Frequency Residual Liquid Detection Inspection Subsystem . . . . .2-41
Figure 2-19. Container Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Figure 2-20. Outer Sidewall (Rotator) Guides . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Figure 2-21. Rolling and Staggering of Containers in the Outer Sidewall Guides. . . . .2-43
Figure 2-22. Progression of Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Figure 2-23. Infeed Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Figure 2-24. Components in the Starwheel Area . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Figure 2-25. Neck and Body Belt Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Figure 2-26. Starwheel, Starwheel Motor, and the High Resolution Encoder . . . . . . .2-48
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Figure 2-27. Deadplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
Figure 2-28. Air Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Figure 2-29. Outfeed Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Figure 2-30. Starwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Figure 2-31. Various Types of Suction Cups . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
Figure 2-32. Strobe Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54
Figure 2-33. Strobe Light Emitting Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Figure 2-34. Test Container Detection Photocell Sensor . . . . . . . . . . . . . . . . . . . .2-56
Figure 2-35. Inside and Outside the Inspection Head . . . . . . . . . . . . . . . . . . . . . .2-58
Figure 2-36. External Ethernet and PS/2 Keyboard Ports on the Inspection Head . . . .2-59
Figure 2-37. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Figure 2-38. Omnivision III Solid State Drive (SSD) . . . . . . . . . . . . . . . . . . . . . . . .2-61
Figure 2-39. Card Cage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62
Figure 2-40. Central Processing Unit for Omnivision III . . . . . . . . . . . . . . . . . . . . .2-63
Figure 2-41. High Speed Inspection Processor Cards . . . . . . . . . . . . . . . . . . . . . . .2-64
Figure 2-42. Camera Link Interface Card (CLIC) . . . . . . . . . . . . . . . . . . . . . . . . .2-65
Figure 2-43. Universal Serial Bus (USB) Ports . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
Figure 2-44. Reject Verifier Photocell From Above and Below . . . . . . . . . . . . . . . .2-67
Figure 2-45. Inspection Cameras and Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Figure 2-46. Servo Motors for Zoom (Top) and Brightness (Bottom) . . . . . . . . . . . . .2-70
Figure 2-47. Infrared Residual Liquid Detection Sensor and Card . . . . . . . . . . . . . .2-71
Figure 2-48. Two Servo Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72
Figure 2-49. Finish Strobe Light Emitting Diode (LED) +48 Volt Power Supply . . . . . .2-73
Figure 2-50. Conveyor Chain Encoder and Drive Sprocket Wheel . . . . . . . . . . . . . .2-75
Figure 2-51. View of Down and Jam Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77
Figure 2-52. Close Up View of Down and Jam Sensor . . . . . . . . . . . . . . . . . . . . . .2-78
Figure 2-53. How the Down and Jam Sensor Works . . . . . . . . . . . . . . . . . . . . . . .2-79
Figure 2-54. Transmitter and Receiver Sonic Sensors . . . . . . . . . . . . . . . . . . . . . .2-80
Figure 2-55. Resynchronization Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82
Figure 2-56. Main Power Switch and Emergency Stop Button . . . . . . . . . . . . . . . . .2-83
Figure 2-57. Color Sort Inspection Module Inside and Out . . . . . . . . . . . . . . . . . . .2-85
Figure 2-58. Inside the Base Unit Lower Cabinet: Starwheel Side . . . . . . . . . . . . . .2-86
Figure 2-59. Base Strobe, Starwheel System Air Filters, and Starwheel Vacuum Filter 2-87
Figure 2-60. Air Regulating Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88
Figure 2-61. Power Supply Drawer From Above, Looking Down . . . . . . . . . . . . . . . .2-89
Figure 2-62. Line Control Module (LCM) Card . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90
Figure 2-63. Isolation Step-Down Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . .2-91
Figure 2-64. Finish and Reject 48 Volt Direct Current (VDC) Power Supply . . . . . . . .2-92
Figure 2-65. Inside the Base Unit Lower Cabinet: Operator Side . . . . . . . . . . . . . . .2-93
Figure 2-66. Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-94
Figure 2-67. Rotating Glass and Brush Assemblies . . . . . . . . . . . . . . . . . . . . . . . .2-95
Figure 2-68. Rotating Glass and Brush Drive Motors . . . . . . . . . . . . . . . . . . . . . . .2-96
Figure 2-69. Input/Output Access Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97
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Document 47751-0316
Figure 2-70. Programmable Logic Controller Module . . . . . . . . . . . . . . . . . . . . . .2-98
Figure 2-71. High Voltage Base Strobe Assembly . . . . . . . . . . . . . . . . . . . . . . . . .2-99
Figure 2-72. Uninterruptable Power Supply System . . . . . . . . . . . . . . . . . . . . . . 2-100
Figure 2-73. Starwheel Motor and Motor Control Unit. . . . . . . . . . . . . . . . . . . . . 2-103
Figure 2-74. Components of the Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . 2-105
Figure 2-75. Vacuum System Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Figure 2-76. Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
Figure 2-77. Water Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
Figure 2-78. Proline, Slimline, and Servotec II Rejectors . . . . . . . . . . . . . . . . . . . 2-111
Figure 2-79. Bottle Position Sensor (Front and Back) . . . . . . . . . . . . . . . . . . . . . 2-112
Figure 2-80. Omnivision III Utility Requirements and Specifications. . . . . . . . . . . . 2-117
Figure 2-81. Container Handling Rate Relative to Container Diameter . . . . . . . . . . 2-119
Figure 2-82. How Inspection Subsystems Interact With Each Other . . . . . . . . . . . . 2-120
Figure 2-83. How the Base Subsystem Works. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
Figure 2-84. How the Inner Sidewall Subsystem Works . . . . . . . . . . . . . . . . . . . . 2-122
Figure 2-85. How the Finish Subsystem Works . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123
Figure 2-86. How the Thread Inspection Subsystem Works. . . . . . . . . . . . . . . . . . 2-124
Figure 2-87. How the Outer Sidewall Subsystem Works . . . . . . . . . . . . . . . . . . . . 2-125
Figure 2-88. How the Bright Field Analyzer Subsystem Works. . . . . . . . . . . . . . . . 2-126
Figure 2-89. How the Infrared Residual Liquid Subsystem Works . . . . . . . . . . . . . . 2-127
Figure 2-90. How the Radio Frequency Residual Liquid Detection Subsystem Works . 2-128
Figure 2-91. How Base Inspection Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129
Figure 2-92. Images That Base Inspection Captures . . . . . . . . . . . . . . . . . . . . . . 2-131
Figure 2-93. How Inner Sidewall Inspection Works . . . . . . . . . . . . . . . . . . . . . . . 2-132
Figure 2-94. Image That Inner Sidewall Inspection Captures . . . . . . . . . . . . . . . . 2-133
Figure 2-95. How Finish and Thread Inspection Work . . . . . . . . . . . . . . . . . . . . . 2-134
Figure 2-96. Image That Finish Inspection Captures . . . . . . . . . . . . . . . . . . . . . . 2-135
Figure 2-97. Images That Thread Inspection Captures . . . . . . . . . . . . . . . . . . . . 2-135
Figure 2-98. How Outer Sidewall Inspection Works. . . . . . . . . . . . . . . . . . . . . . . 2-136
Figure 2-99. Image That Outer Sidewall Inspection Captures . . . . . . . . . . . . . . . . 2-137
Figure 2-100. How Infrared Residual Liquid Detection Inspection Works . . . . . . . . . 2-138
Figure 2-101. How Radio Frequency Residual Liquid Detection Inspection Works . . . . 2-140
Figure 2-102. Comparison of Effectiveness of IR and RF Residual Liquid Detection . . 2-142
3. Turning On and Turning Off Omnivision III. . . . . . . . . . . . . . . . 3-1
4. Installing Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-1. Determining the Floor Space for the Base Unit . . . . . . . . . . . . . . . . . 4-4
Figure 4-2. Determining the Floor Space for the Base Unit and OSW Units . . . . . . . 4-5
Figure 4-3. Preparing to Raise the Base Unit and OSW . . . . . . . . . . . . . . . . . . . .4-10
Figure 4-4. Raising the Base Unit and OSW . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Figure 4-5. Raising the Base Unit and OSW to an Upright Position . . . . . . . . . . . . .4-12
List of Figures ix
Document 47751-0316
Figure 4-6. Lifting the Base Unit and OSW After Raising Them Upright . . . . . . . . . .4-13
Figure 4-7. Installing Splice Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Figure 4-8. Aligning the Upstream Container Washer . . . . . . . . . . . . . . . . . . . . .4-24
Figure 4-9. Mounting the Sonic Sensors and Washer . . . . . . . . . . . . . . . . . . . . . .4-26
Figure 4-10. Utility Connections on the Lower Cabinet of the Base Unit. . . . . . . . . .4-33
Figure 4-11. Installing a Ground Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
Figure 4-12. Access Panel Inside the Lower Cabinet of the Base Unit. . . . . . . . . . . .4-42
Figure 4-13. PLC Input Connections for Brake Output, Machine Ready . . . . . . . . . . .4-49
Figure 4-14. PLC Output Connections for Throughput (Pin) . . . . . . . . . . . . . . . . . .4-50
5. Adjusting, Aligning, and Calibrating Omnivision III . . . . . . . . . . 5-1
Figure 5-1. Vertical Alignment of Starwheel Top Plate to Finish Reinforcement Ring. 5-2
Figure 5-2. Aligning the Inspection Head to the Starwheel. . . . . . . . . . . . . . . . . . 5-6
Figure 5-3. Air Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
6. Turning On Omnivision III for the First Time . . . . . . . . . . . . . . 6-1
Figure 6-1. Air Knife Blow Off Assembly for the Bottom of Containers . . . . . . . . . .6-12
Figure 6-2. Thread Blow Off System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
Figure 6-3. Thread Blow Off Air Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Figure 6-4. Checking the Upstream Container Washer. . . . . . . . . . . . . . . . . . . . .6-17
Documentation Feedback . . . . . . . . . . . . . . . . . . . . . .Feedback-1
x Omnivision III Service and Installation Guide

Document 47751-0316
Preface
Introduction
Omnivision III, or OV-III, documentation provides operators,

technicians, and service personnel with complete information
about how to install and service Omnivision III All Surface Empty
Bottle Inspector (ASEBI). Other documents that you can consult
include:
• Omnivision III Operation Guide tells you how to use and

maintain Omnivision III to inspect containers.
• Omnivision III Drawing Pack contains system drawings and
schematics that you might need to complete procedures.
• Omnivision III Parts Catalog contains a pictorial parts catalog
of spare and service parts that you might need to maintain
and service Omnivision III.
• The second volume of the Omnivision III Service and Instal-
lation Guide, which is titled Volume 2 Software, describes the
Omnivision III software that you use keep Omnivision III
running and the screens that you use to set up, configure, and
monitor the inspection of containers on your production line.
• The third volume of the Omnivision III Service and Installation
Guide, which is titled Volume 3 Commissioning, describes how
to set up downstream rejection, set up inspection functions,
and service, maintain, and troubleshoot your Omnivision III.
Topics That This Guide Covers
This guide describes how to install, configure, and calibrate an

Omnivision III, associated equipment, and system software.
This guide also provides maintenance procedures, trouble-

shooting suggestions, and service procedures.
Preface xi
Document 47751-0316
Audience of This Guide
This guide is intended for use by filtec service personnel or

customer service personnel who have received training from
filtec who need to install, service, and configure an Omnivision
III.
Conventions That Appear in This Guide
Use the following chart to learn about the typographic conven-

tions that appear in this guide.
This typeface or symbol... Indicates... Example...
abcd1234 A link to another document Omnivision III Service and Installation Guide
or page in the current
document, which, when you
click on it, displays the other
document or the other page.
Important: Important information that

you might find helpful or Important: Send oddly shaped
useful and best practice (non-round) and plastic containers
suggestions. to filtec for testing and evaluation
before you use them with
Omnivision III.
Caution: That there is a potential for

damage to the equipment. Caution: To ensure your complete
Depending on the particular safety, run all power cables
damage that can result, harm through liquid tight conduit.
to a person can also occur.
Warning: That there is a potential for

harm to an individual. As Warning: Before you attempt to
harm can be mild or severe, install Omnivision III, turn off
strictly observe the power and disconnect all
information that is provided. electrical power cables from
Omnivision III.
Failure to turn off power and
disconnect all cables can result in
serious injury or death from
electrocution.
abcd1234 Emphasis, a definition of a Before you attempt to install Omnivision III, turn
new concept, or a variable off power and disconnect all electrical power
for which you provide actual cables from the system.
text.
A text field is a set of alphanumeric characters
in a product code that do not change.
+x or -x
abcd1234 Text, including titles, menus, Press Key 5 until the inspection system displays
commands, and other Maximum Container Diameter on the screen.
information that you see or
type on a screen.
xii Omnivision III Service and Installation Guide

Document 47751-0316
This typeface or symbol... Indicates... Example...
abcd1234 A best practice to follow, a Best Practice:

note, an example, a range of
values that you can type in a Note:
field on a screen, and a
document to which to refer. Example:
Range:
See Also:
abcd1234 A file name or directory path. The system encrypts and internally stores the
encrypted password that you provide in the
configuration file file.cfg.
Preface xiii
Document 47751-0316
xiv Omnivision III Service and Installation Guide
Document 47751-0316
1. Safety Information
This chapter describes the safety mechanisms that are supplied

with your equipment and the safe operating procedures when you
use your filtec equipment.
This chapter also contains safety disclosure information and certi-

fications that are required by the government, or other governing
organizations, and voluntarily provided by filtec.
Safety Information 1-1

Document 47751-0316
1.1 Safety Notices and Safety Labels
To ensure your safety, filtec has included many safety notices

and labels within the product documentation and also within the
equipment. Always observe these safety instructions.
1.1.1 Safety Notices
This documentation contains two types of safety notices: cautions

and warnings. Always observe the safety notices. Cautions and
warnings indicate safety issues as follows:
Warning: A warning indicates that there is a potential for harm

to an individual. As harm can be mild or severe, strictly observe
the information that is provided.
Caution: A caution indicates that there is a potential for

damage to the equipment. Depending on the particular damage
that can result, harm to a person can also occur.
1.1.2 Safety Labels
filtec equipment contains various safety labels. These labels are

placed at strategic locations to help ensure your safety. Never
remove safety labels from the equipment.
1-2 Omnivision III Service and Installation Guide

Document 47751-0316
1.2 Compliance of Omnivision III to
Standards
1.2.1 Description
Omnivision III 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 affixed to it and is accompanied by an

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

Electrotechnical Commission (Commission Electrotechnique Inter-
nationale) International Standard for Graphical Symbols for use
on equipment as defined in CEI/IEC 417, amended in accordance
with these supplements:
• A (1974)
• B (1975)
• C (1977)
• D (1978)
• E (1980)
• F (1982)
• G (1985)
• H (1987)
• J (1990)
• K (1991)
• L (1993)
Safety Information 1-3

Document 47751-0316
1.3 International Symbols
1.3.1 Meaning of International Symbols
Use this chart and table to determine the meaning of interna-

tional symbols that filtec uses in this documentation and that is
affixed to your Omnivision III.
1 6 11
2 7 12
3 8 13
4 9 14
5 10
No. Description No. Description

1 Direct current 8 Equipotentiality
2 Alternating current 9 On (supply)
3 Both direct and alternating current 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
7 Frame or chassis terminal 14 Caution (refer to accompanying documents)

Document 47751-0316
2. Overview of Omnivision III
This chapter presents an overview of Omnivision III.
Topics that this chapter covers include definitions of terms and

definitions, descriptions, and diagrams of components that make
up the Omnivision III product. It also includes specifications of
Omnivision III.
Overview of Omnivision III 2-1

Document 47751-0316
2.1 Omnivision III Concepts
2.1.1 Definition: Alarm Message
An alarm message is diagnostic information that Omnivision III

displays in red in the lower left corner of all Omnivision III
screens, which are described later.
When an alarm occurs, Omnivision III puts the starwheel into

brake mode and sends a signal to your conveyor control system to
stop the conveyor chain.
Omnivision III continues to display the message until you clear it.
Omnivision III also adds this type of message to the list of
messages on the screen, which is described
later.
2.1.2 Definition: Applied Ceramic Label
An applied ceramic label, or ACL, is a notch on a container,

which sometimes looks like paint, that is used in the application
of labels to containers.
2.1.3 Definition: Asynchronous Transmission
Asynchronous transmission is the transfer of data from a trans-

mitter to a receiver asynchronously.
Transmission is controlled by start and stop bits at the beginning

and end of each data character.
2.1.4 Definition: Base
A base is the bottom rim of a container.
2.1.5 Definition: Base Backup Zone
The base backup zone is the inspection zone that is circular in

shape and is limited to the base area of the container in inner
sidewall inspection.

Document 47751-0316
2.1.6 Definition: Base Inspection
Base inspection is the inspection system on Omnivision III that

uses a camera to inspect the base of containers.
2.1.7 Definition: Birdswing
A birdswing is a specific type of glass flaw, which resembles a

birdswing in a bird cage, that can occur on the inside surfaces of
glass containers during the manufacturing process.
2.1.8 Definition: Bottle
A bottle is referred to as a container in this documentation.
2.1.9 Definition: Bottom Rim
A bottom rim is the same as base, or the bottom rim of a

container.
Bottom rim is sometimes abbreviated B/R.
2.1.10 Definition: Bottom Zone
The bottom zone is the inspection zone that is circular in shape

and limited to the center part of the container bottom.
2.1.11 Definition: Bottles Per Hour
Bottles per hour, or BPH, is the number of containers that

Omnivision III inspects per hour.
2.1.12 Definition: BPM
Bottles per minute, or BPM, is the number of containers that

Omnivision III inspects per minute.
2.1.13 Definition: Brightness
Brightness is the f-stop adjustment on the digital camera inside

Omnivision III.

Document 47751-0316
2.1.14 Definition: Bus
A bus is the data path that is shared by many devices with one or
more conductors for transmitting signals, data, or power.
2.1.15 Definition: CCW
CCW, or counter clockwise, is the direction in which you turn a

knob, screw, or other piece of hardware to loosen it.
2.1.16 Definition: Combiner
A combiner is an upstream device that takes containers that are

in mass and combines them into single file on a conveyor.
2.1.17 Definition: CFM
CFM, is the measure of cubic feet per minute (1 cfm equals 0.472
liters per second).
2.1.18 Definition: Center Line
A center line is a real or imaginary line that is equidistant from

the surfaces or sides of an object.
2.1.19 Definition: Clock
A clock is the timing signals used in synchronous transmission, or

more generally, the source or sources of timing signals that
sequence electronic events.
2.1.20 Definition: Collimator
A collimator is a device for producing a beam of parallel rays (as

of light) or for forming an infinitely distant virtual image that can
be viewed without parallax.
2.1.21 Definition: Communication Interface Card
A communication interface card, or CIC, is a card or board that

enables the transmission of a number of different signals simulta-
neously over a single channel.

Document 47751-0316
On filtec systems, it is generally a card that makes it possible to
switch between different inspection systems.
A communication interface card is called a multiplexer, or MUX,

card.
2.1.22 Definition: Communication Protocol
A communication protocol is the rules that govern the exchange

of information between two or more devices on a data link.
2.1.23 Definition: Contact Circle
A contact circle is the part of a plastic container that contacts

the surface on which the container rests.
2.1.24 Definition: Container
A container refers to a bottle, can, or jar.
2.1.25 Definition: Count
A count is an instance where the number of detection points

within a particular zone or lane exceeds a threshold value that
you have defined and Omnivision III declares a defect for that
zone or lane.
2.1.26 Definition: Crimping
Crimping is the pressing and fastening of an airtight metal closure

or crown onto the lip or flange of a container by compressing it
into small folds or ridges.

Document 47751-0316
Special crowning heads on high speed fillers crimp containers.
No. Description
1
1 Crimping
Figure 2-1. Crimping
2.1.27 Definition: Crown
A crown is a type of closure that is attached to a container by

crimping.
Crown closures are often used on glass bottles.
Figure 2-2. Typical Press or Crown Container
2.1.28 Definition: Current Value
A current value is the value based on the actual number of

detection points that occur in a zone or lane in real time.

Document 47751-0316
2.1.29 Definition: CW
CW, or clockwise, is the direction in which you turn a knob,

screw, or other piece of hardware to tighten it.
2.1.30 Definition: DCE
DCE, or data communications equipment, includes the devices

that provide the functions that are required to establish,
maintain, and terminate a data transmission connection, that is,
a modem.
2.1.31 Definition: Defect (or Detect)
A defect, or detect, is a flaw on a container that an inspection

system detects and possibly the reason that the inspection system
rejects that container.
2.1.32 Definition: Detection
Detection is the process of identifying a flaw in a container and

possibly the reason an inspection system rejects that container.
2.1.33 Definition: Detection Point
A detection point is a combination of black and white or red dots

that appears on or along the edges of an object when that object
is detected as a flaw within an inspection zone.
A detection point is one pixel from the raw inspection image that
has been flagged as a fault.
2.1.34 Definition: Diagnostic Message
A diagnostic message, which Omnivision III displays in orange in

the lower left corner of all Omnivision III screens, is a message
that indicates that something is wrong with Omnivision III, an
incorrect entry has been made, or that data files are missing or
defective.
Omnivision III continues to display the message until you clear it.
Omnivision III also adds this type of message to the list of
later.

Document 47751-0316
2.1.35 Definition: Digital Data
Digital data is information that is transmitted in a coded form

from a computer that is represented by discrete signal elements.
2.1.36 Definition: DIP Switch
A dual in-line package, or DIP, switch is an electronic device

package with a rectangular housing and two parallel rows of
electrical connecting pins, each representing a separate contact
point, that is used to open and close leads between two or more
devices.
2.1.37 Definition: Downstream
Downstream is any point away from a fixed reference point,

along the direction of flow.
Flow
Reference point ---------------> Downstream
2.1.38 Definition: Drop or Dropout
A drop or dropout is the decrease of light or a dark area on a

particular area on the finish of a container that should be bright.
Omnivision III detects this decrease of light in a particular area as

a dropout in the inspection lane on the finish of a container.
Example: An outer chip or broken neck.
2.1.39 Definition: Digital Signal Processor
A digital signal processor, or DSP, is a multipurpose processor

that runs a real-time operating system and can simultaneously
execute programs and algorithms that can be dynamically loaded
at any time into on-board, non-volatile memory.
DSPs are used for processing the images from the video cameras
inside the inspection head.

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2.1.40 Definition: Embossing
Embossing is the raised surface on a container that usually

depicts an emblem or logo.
2.1.41 Definition: Erasable Programmable Read-Only

Memory (EPROM)
Erasable programmable read-only memory, or EPROM, is

read-only, nonvolatile, semiconductor memory that is erasable
via ultraviolet light and therefore reprogrammable.
A machine’s operating software is usually programmed into these

devices.
2.1.42 Definition: Exception Points
An exception point is a combination of black and white or red

dots that appears on or along the edges of an object when that
object is detected as a flaw within an inspection zone.
An exception point is another name for a detection point.
2.1.43 Definition: False Accept
A false accept is a bad container which is accepted by an

inspection system as a good container.
Also see Missed Reject.
2.1.44 Definition: False Reject
A false reject is a good container that is rejected by an inspection

system as a bad container.
You use false rejects to establish the performance capability of

an inspection system.
2.1.45 Definition: Finish
finish is the term that describes the top sealing surface of a glass
container.

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2.1.46 Definition: Finish Image
The finish image is the reflected light from the finish of a

container that is received by the camera.
2.1.47 Definition: Finish Inspection
Finish inspection is a subsystem of Omnivision III that inspects the

sealing area of a container.
Note: filtec formerly referred to finish inspection as UltraLine.
2.1.48 Definition: Flint
Flint refers to a clear glass container that is used in production.
2.1.49 Definition: Fluting
Fluting is the strait vertical grooves on the outer sidewall surface

of a container.
2.1.50 Definition: FPM
FPM, or feet per minute, is the number of feet per minute at

which a conveyor travels as it passes an inspection system.
2.1.51 Definition: Hertz (Hz)
Hertz, which is abbreviated Hz, is a measure of frequency or

bandwidth.
Hertz is the same as cycles per second.
2.1.52 Definition: Housekeeping
Housekeeping is the tasks or operations that you or Omnivision III

needs to complete on a regular or scheduled basis.

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2.1.53 Definition: Infeed
The infeed is the entrance (upstream) side of a container

inspector or any system.
2.1.54 Definition: Information Message
An information message is diagnostic information that Omnivision

III displays in green in the lower left corner of all Omnivision III
screens.
Omnivision III does not add this type of message to the list of
later.
2.1.55 Definition: Inner Sidewall Inspection
Inner sidewall inspection is a subsystem of Omnivision III that

inspects the inner sidewall of containers.
2.1.56 Definition: Inspection
Inspection is a complete process, which consists of scanning and

identifying (or detecting) a flaw in a container, tracking the
container, and rejecting it from the production line.
Also see Detection.

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2.1.57 Definition: Inspection Donut
An inspection donut is the circular area within two rings on the

image of a container that Omnivision III inspects for defects.
No. Description
1 Inner ring of an inspection donut
2 Outer ring of an inspection donut
2.1.58 Definition: Kernel
A kernel is a grouping, or matrix, of pixels on an image shown on

a screen.
For example, a kernel whose width is 4 and whose height is 4 is a

4 by 4 kernel and equals 16 pixels. A kernel whose width is 2 and
whose height is 2 is a 2 by 2 kernel and equals 4 pixels.
The size of a kernel defines the divisions of area on which the

system carries out the normalization functions.
2.1.59 Definition: Knurling
Knurling is small ridges found on the bottom of a container.

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2.1.60 Definition: Lane
A lane is a ring, which a user specifies and positions, that defines

an inspection area on a finish image.
Note: filtec formerly used the term window to refer to the

inspecting of a particular area of the finish that makes up a
container. filtec now uses the term lane in place of the term
window.
Omnivision III can use up to five lanes with which to inspect the
finish.
Use this table to determine how the terms window and lane
correspond to the finish inspection that Omnivision III performs or
performed at one time.
Lane... Inspects for...
A Dropouts
B Dropouts or marks
C Dropouts or marks
D Dropouts or marks, whichever you choose
E Dropouts or marks, whichever you choose
2.1.61 Definition: Last Detect
A last detect is the last value that exceeded the detection point
threshold that you specified for a zone or lane.
2.1.62 Definition: Light Level Compensation
Light level compensation is an automatic process that the system

uses to maintain a consistent container image intensity despite
color variation on a container-to-container basis.
Light level compensation is sometimes referred to as intensity

compensation.

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2.1.63 Definition: Line Control Module (LCM)
The line control module, or LCM, is a card that monitors the

conveyor speed and adjusts the speed of the starwheel to run
slightly slower to create a little slippage on the containers.
The line control module (LCM) also generates the “pin signal” and
tells the strobe to fire when a starwheel pocket is aligned. The
signal to the camera is also generated by the line control module
(LCM). All of the line sensors, solenoids, and lights are controlled
by the line control module (LCM).
Omnivision III routes all input and output signals through this
card.
2.1.64 Definition: Lower Rim Zone
The lower rim zone is an inspection zone that is shaped like a

donut just outside the bottom zone in base inspection.
2.1.65 Definition: Lower Sidewall Zone
The lower sidewall zone is the inspection zone that is shaped like
a donut just outside the bottom, or base, backup zone in inner
sidewall inspection.
2.1.66 Definition: Mark
A mark is a surface defect that causes a surplus of light in a

particular area on the finish of a container that should be dark.
Omnivision III detects this surplus of light in a particular area as a

bright spot in a “mark” inspection lane on the finish of a
container.
Example: An inner chip or a surface scuff.
2.1.67 Definition: Marker
A marker is the colored highlight or highlights that Omnivision III

overlays on the monitor station screen to identify particular
elements in an image.

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These markers represent the different inspection zones that
Omnivision III uses or turns on for that container.
No. Description
1 Green marker
2 Purple marker
3 Blue marker
2.1.68 Definition: Mask
A mask is an area of a container that Omnivision III does not

inspect and ignores.
You mask an area on a container usually because an element or

protuberance on a container interferes with the ability of
Omnivision III to accurately inspect a container zone.
2.1.69 Definition: Missed Reject
A missed reject is a bad container that is accepted by an

inspection system as a good container or a bad container that an
inspection system misses and fails to reject because of a system
failure.
Also see False Accept.
2.1.70 Definition: Modbus
Modbus is a serial communications protocol that is published by

Modicon for use with programmable logic controllers (PLCs).

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filtec products use the Modbus protocol to communicate with
host computers.
2.1.71 Definition: Module
A module is an assembly that is a component of a larger unit.
Typically, a plug-in type electronics assembly that might consist

of one or more cards, components, a front panel, and similar
hardware.
2.1.72 Definition: Multiple Triggering
Multiple triggering refers to a condition in which a sensor triggers

twice on a single container. This signal indicates an abnormality
such as a high sensor sensitivity, high object reflectivity, or the
failure of a sensor’s hardware.
2.1.73 Definition: Multiplexer
A multiplexer (or MUX) is a device that enables the transmission

of a number of different signals simultaneously over a single
channel.
On filtec systems, a multiplexer is usually a card that enables the

switching between different systems.
Also see Communication Interface Card.
2.1.74 Definition: Normalization
Normalization is a process that is used to change the range of

pixel intensity values in a specified area, that is, kernel, in an
effort to achieve a consistent and controlled dynamic range for
an image.
A pixel area that is normalized typically exhibits smaller average

variations in contrast and intensity within that area while its
more prominent features stand out in comparison.
2.1.75 Definition: Operator Menu
An operator menu is an Omnivision III screen that any assigned

person can view on Omnivision III by entering this unique
password.

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2.1.76 Definition: Outer Radius (Base) or Upper Rim Zone
The outer radius (base) or upper rim zone is the inspection zone
that is shaped like a donut just outside the lower rim zone in base
inspection.
2.1.77 Definition: Outer Radius (Sidewall) or Upper

Sidewall Zone
The outer radius (sidewall) or upper sidewall zone is the

inspection zone that is shaped like a donut just outside the lower
sidewall zone in inner sidewall inspection.
2.1.78 Definition: Outer Sidewall
The outer sidewall is the outside wall of a container.
2.1.79 Definition: Outfeed
The outfeed is the exit or downstream side of a container

inspector.
2.1.80 Definition: Overpress
Overpress is a defect on a container where excessive glass

protrudes or projects upward from the inside edge of the finish.
No. Description 1
1 Overpress
Figure 2-3. Overpress Finish

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An image of an overpress looks like this on a screen:
Figure 2-4. Image of an Overpress on a Screen
2.1.81 Definition: Parallel Transmission
Parallel transmission is a transmission mode, which is usually

unidirectional, that sends a number of bits simultaneously over
separate lines.
2.1.82 Definition: PET
PET is an acronym for plastic containers that are made of

polyethylene terephthalate.

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2.1.83 Definition: Phase
A phase is one of three outer sidewall image acquisitions that

occurs for a single base image acquisition as a container passes
through the inspection tunnel in Omnivision III.
At three outer sidewall acquisition phases for one base container

pitch and four views for each phase, a total of 12 outer sidewall
image acquisitions is possible.
Each phase includes up to four views.
These views are shown in Figure 2-5 and labeled V1 through V4.
These views have several inspection windows. In Figure 2-5, the
setting lane in View 1, Phase 1 is detecting an object.
V1 V2 V3 V4
Figure 2-5. Inspection Setup OSW Image Screen

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2.1.84 Definition: Plug
A plug is a type of container imperfection that usually describes a

condition where a container's neck is blocked by a foreign object.
2.1.85 Definition: PRB
PRB is an acronym for plastic returnable bottle.
2.1.86 Definition: Programmable Logic Controller
A programmable logic controller, or PLC, is a micro-processor

based device, which you can program, that controls assembly
lines and electromechanical machinery on a shop floor in a
manufacturing plant.
2.1.87 Definition: Racetrack
A racetrack is the oval shaped bubble that surrounds a

component’s part number on filtec engineering drawings.
2.1.88 Definition: Radial
A radial is a division of a circular image along its radii.
Note: The system uses 192 sectors, or radials, when inspecting a

container’s finish.
No. Description
1 Radial 3 212 3
2 Finish inspection window
3 Sector
Also see Sector.

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2.1.89 Definition: Reject History
Reject history is the listing on an Omnivision III screen of the

most recent causes of rejects and the number of consecutive
occurrences for each reject cause that Omnivision III has
detected.
2.1.90 Definition: Reject or Rejector Segment
The reject or rejector segment is the distance between the last,

or resynchronization 2, sensor and the first rejector downstream
from Omnivision III.
2.1.91 Definition: Rejector Timing
Rejector timing is the physical distance, which you specify in

millimeters, from the reject sensor to the center line of the
reject pad.
When you set the timing correctly, the rejector pad contacts a
container exactly at center, maximizing the efficiency of the
rejector stroke.
2.1.92 Definition: Flint
Flint refers to a clear glass container that is used in production.
2.1.93 Definition: Ribbing
Ribbing is the curved circular rings on the outer sidewall surface

of a container.
2.1.94 Definition: Roll On Pilfer Proof Finish
A roll on pilfer proof finish, or ROPP finish, is a type of closure

whose seal breaks when you twist it off.

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ROPP finish closures are often used on glass, plastic, and metal
liquor and pharmaceutical containers.
Figure 2-6. A Typical ROPP Finish Container
2.1.95 Definition: RS-232
RS-232 is a technical standard that defines the interface between

data terminal equipment (DTE) and data communication
equipment (DCE) that employs a serial binary data interchange.
2.1.96 Definition: RS-485
RS-485 is a technical standard that specifies the electrical

characteristics of balanced-voltage digital signalling circuits.
2.1.97 Definition: Scuffing
Scuffing is the scratching, chipping, or roughened wear that

glass, and sometimes plastic, containers exhibit.

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Scuffing is usually caused by friction from containers rubbing
against each other.
No. Description
1 Scuffing ring around
the middle of the
container
2 Various scuff marks
3 Scuffing ring around
the base of the
container
Figure 2-7. A Scuffed Container

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2.1.98 Definition: Sector
A sector is a part of a circle bounded by any two radii and the arc
between them.
No. Description
1 Radial 3 212 3
2 Finish inspection window
3 Sector
Note: The system uses 192 sectors, or radials, when inspecting a

container’s finish.
Also see Radial.
2.1.99 Definition: Shielding
Shielding is the protective covering on a device that eliminates

electromagnetic and radio frequency interference.
2.1.100 Definition: Slip Rate (or Slip Ratio)
Slip rate, or slip ratio, is the difference between the production

conveyor speed and the starwheel speed divided by the conveyor
speed, expressed as a percentage.
2.1.101 Definition: Spot
A spot is a stain or blot caused by soap or another liquid or debris

that has become attached to the surface of the camera window
on the outer sidewall inspection unit, and consequently detected
by the outer sidewall camera during inspection.

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2.1.102 Definition: Start Bit
In asynchronous transmission, the start bit is the first bit or

element in each character, normally a space, that prepares the
receiving equipment for the reception and registration of the
character.
2.1.103 Definition: Stippling
Stippling is the engraved dots, painted dots, or letters that

produce a graded image on a container.
2.1.104 Definition: Stop Bit
In asynchronous transmission, the stop bit is the last bit, used to

indicate the end of a character that serves to return the line to
its idle state.
2.1.105 Definition: Stress Cracking
Stress cracking is a circular area on the bottom of a plastic

container, that is located on both sides of the contact circle, that
is caused primarily by recycling through the washer and other
exposures to light, heat, and caustic materials.
2.1.106 Definition: Stroke
Stroke is the maximum amount of movement that a cylinder shaft

on a rejector is displaced when the system actuates it, by using
either air electro-magnetics or oil as the actuating medium.
2.1.107 Definition: Swing Gate
A swing gate is a circular protrusion in the middle of the bottom

of a plastic bottle that causes a dark spot to appear on the base
image.
The base inspection subsystem in Omnivision III performs a

different kind of inspection in this area to compensate for this
dark spot.

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2.1.108 Definition: Synchronous Transmission
Synchronous transmission is the synchronized sending of data bits

at a fixed rate from a transmitter to a receiver.
Synchronized transmission eliminates the need for start bits and

stop bits.
2.1.109 Definition: Test Container
A test container is a container with specific defects that you use

to test the inspection capabilities of Omnivision III.
2.1.110 Definition: Thread
A thread is the diagonal embossed or raised lines on the finish

portion of a container on a which a twist closure is twisted and
tightened.
2.1.111 Definition: Thread Image
A thread image is the reflected light from the threaded area of a

container finish that is received by the camera in Omnivision III.
2.1.112 Definition: Tracking Segment 1
Tracking segment 1 is the distance between the starwheel

rejection point and the resynchronization sensor 1.
The distance that the tracking segment 1 covers includes the

crossover conveyor, the crossover point, and part of the customer
rejection conveyor up to resynchronization sensor 1.
2.1.113 Definition: Tracking Segment 2
Tracking segment 2 is the distance between the tracking segment

1 and the resynchronization 2 sensor.
2.1.114 Definition: Twist Off Finish Closure
A twist off finish is a type of closure that is attached to a

container by a set of threads on the container’s neck.

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Twist off finish closures are often used on glass, plastic, and
metal jars and bottles.
Figure 2-8. A Typical Twist Off Finish Container
2.1.115 Definition: Upstream
Upstream is any point away from a fixed reference point, against

the direction of the flow of containers.
Flow
Upstream ---------------> Reference Point
2.1.116 Definition: Warning Message
An warning message is diagnostic information that Omnivision III

displays in yellow in the lower left corner of all Omnivision III
screens.
Omnivision III does not log warning messages.
2.1.117 Definition: Window
A window is a trapezoidal, rectangular, or square, user-defined

area that Omnivision III superimposes on the image of a container
when inspecting a container.

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2.1.118 Definition: Zone
A zone is a circular, user-defined area that Omnivision III super-

imposes on the image of the container.
2.1.119 Definition: Wash Out
A wash out is an effect that occurs when Omnivision III strobes an

object inside a container with a very intensive light, and the light
blends in with, hides, or washes out, that object on the image
taken by the Omnivision III cameras.
This effect tends to occur when the aperture of the Omnivision III
camera is set too wide and a thin layer of consistent dirt, oil, or
any material that absorbs light adheres to the inside of a
container.
Wash out is bad for any inspection. Ensure that the aperture of
your cameras is set correctly.

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2.2 Omnivision III
2.2.1 Definition
Omnivision III All Surface Empty Bottle Inspector (ASEBI) is a

product manufactured by filtec that inspects—for defects—the
finish, threads, bases, inner sidewalls, and outer sidewalls of
empty glass or plastic bottles and jars.
Omnivision III also detects plugs, residual liquid, and foreign

objects in, and scuff marks on, empty glass or plastic bottles.
2.2.2 Purpose
Omnivision III ensures that all containers that your cleaning

system washes are clean before they are filled, and those that
are not, are separated and removed from the production line
before they are filled.
2.2.3 Diagram
This diagram shows Omnivision III.

No. Description
1 Outer sidewall inspection unit
2 Inspection head
3 Base unit
2
1
Figure 2-9. Omnivision III

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2.2.4 Subsystems That Comprise Omnivision III
Omnivision III consists to two primary categories of inspection

subsystems:
Subsystems in the Inspection Head
• Base inspection (base)

• Inner sidewall (ISW)
• Finish inspection (finish)
• Thread inspection (thread)
• Residual liquid inspection
Upstream Subsystems
• Radio frequency residual liquid detection (RF-RLD) inspection

subsystem
• Outer sidewall inspection (OSW)
• One or two auxiliary inspections (Aux)

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2.3 How Omnivision III Works
2.3.1 Introduction
The standard Omnivision III provides accurate container base and

residual liquid detection (RLD) inspection.
Depending upon the configuration of your Omnivision III, it may

also be equipped with the following capabilities:
• High container detection

• Down container detection
• Unsalvageable container removal
• Reject sorting
• Test container verification system
• Upstream radio frequency residual caustic carry-over
detection (RF RLD)
• Container finish inspection
• Thread inspection
• Inner sidewall inspection (ISW)
• Outer sidewall inspection (OSW)
• Container jam detection
• Bright field inspection/cellophane polarizing plastic detection
• Color sorting
2.3.2 Description
In general, the container handling system of Omnivision III

enables containers to flow smoothly:
1. On the production conveyor.
2. Through the outer sidewall inspection station (if your

Omnivision III is equipped with this option).
3. Through the Omnivision III starwheel infeed guides.
4. To the vacuum starwheel for inspection.
5. Back onto the production line or reject crossover conveyor

and reject takeaway conveyor, table, or reject area.

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Specifically, if your Omnivision III includes the optional outer
sidewall inspection system, Omnivision III first inspects containers
for contamination on containers’ outer sidewall.
Using a digital camera, Omnivision III inspects the outer sidewall

of rotating containers moving on the production conveyor chain
through the outer sidewall enclosure.
This camera takes 12 snapshots as the container moves through

the outer sidewall enclosure.
After Omnivision III inspects containers for residual caustic,

Omnivision III guides containers towards the base unit.
The vacuum starwheel then holds containers by suction and

secures them firmly as they pass through the inspection head.
There, Omnivision III uses the motor drive and encoder-based

trigger system to inspect the base, inner sidewall, and the
bottom of containers for residual liquid. These inspections occur
at almost the same moment.
The starwheel continues to rotate, carrying the containers to the

second inspection position, which examines the container's finish
and threads.
The Omnivision III software issues a timing signal that flashes a

solid state strobe light to illuminate the containers from above to
enable the Omnivision III software to capture an image correctly.
Light emanates from above the container to inspect the finish

(reflected light). Light emanates from below the container to
inspect the threads (transmitted light).
Omnivision III transmits the light through the threads and the
thread areas are then examined by the finish and thread
inspection systems.
The vacuum starwheel releases the good bottles when they are
securely positioned in the outfeed guides, enabling them to
return to the production conveyor. If the Omnivision III inspection
system detects a defective container, the Omnivision III
inspection system releases the defective container onto the
reject conveyor.

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2.4 Overview of Omnivision III Components
2.4.1 Diagram
Use this diagram to learn the major components of Omnivision III.

12 3 4 5 6 7 8 9
14 13 12 11 10
No. Description
1 Down and jam sensor
2 Sonic sensor 1
3 Sonic sensor 2
4 Infeed guides
5 Outer sidewall inspection unit and color detection (shown in blue)
6 Caustic residual caustic detection (RF-RLD) transmitter and receiver
7 Starwheel
8 Monitor station
9 Production conveyor
10 Reject crossover conveyor
11 Reject takeaway conveyor (also includes encoder, resynchronization sensor, and
downstream rejectors)
12 Base unit (shown in yellow)
13 Base and finish/thread inspection point leaders
14 Rotating glass or diffuser (under cover)
Figure 2-10. Major Components of Omnivision III

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2.5 Base Unit
2.5.1 Description
Omnivision III uses cameras inside the inspection head to inspect

the finish, thread, base, and inner sidewall.
Omnivision III uses an infrared light detector and optional radio

frequency detector to inspect the inside of the container for the
presence of residual liquid.
2.5.2 Diagram
1
No. Description
1 Signal beacon
2 Monitor station
3 Starwheel
4 Inspection head 2
4
3
Figure 2-11. Base Unit

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2.6 Outer Sidewall Inspection Unit
2.6.1 Description
The outer sidewall (OSW) inspection unit contains components

that rotate the containers through special guide rails and a
high-speed digital camera that captures images of containers as
they rotate and pass through.
2.6.2 Diagram
No. Description
1 Outer sidewall camera cabinet
2 Outer sidewall lighting cabinet (one on
each side of, and perpendicular to, the
conveyor, two in all) 1
3 Your production or throughput conveyor 2 2
4 Outer sidewall lower cabinet
3
4
Figure 2-12. Outside the Outer Sidewall Inspection Unit

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3
1 5
2
7
1 8
No. Description
1 Light emitting diode (LED) strobe sub-panel, which illuminates the outer sidewall inspection area
2 24 volt direct current power supply for outer sidewall LED strobe sub-panel central processing units (CPUs)
3 Camera, which takes a digital snapshot of a container and sends it to Omnivision III software for processing
Note: Omnivision III captures multiple images as the containers rotate past the inspection window.
4 Protective, acrylic windows (two, on each side)
5 Mirror, which is angled at 45 degrees and reflects the image of containers at the digital camera
6 Metal frame that holds and positions the mirror
7 12 volt direct current power supply for the outer sidewall digital camera
8 Outer sidewall LED strobe sub-panel central processing unit (CPU)
Figure 2-13. Inside the Outer Sidewall Inspection Unit

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No. Description
1 Outer sidewall unit
2 Cables from the base unit
Figure 2-14. Inside the Outer Sidewall Lower Cabinet
2.6.3 How the Outer Sidewall Inspection Unit Works
The outer sidewall inspection unit inspects the entire outer

surface of each container.
As a container passes through the outer sidewall unit, patented

rotator guides rotate the container 360 degrees through the
inspection area. A black and white digital camera takes several
snapshots of each container during this period.
Omnivision III software then processes and evaluates the images.

If Omnivision III software determines that the container does not
meet the required criteria, it rejects the container.

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2.7 Polycarbonate Safety Doors
2.7.1 Definition
The polycarbonate safety doors, which are made of a trans-

parent, practically unbreakable, polycarbonate resin that is used
in shatterproof and bullet-resistant windows, windshields, and
other similar applications, are barriers that protect both the
inside and outside of Omnivision III.
2.7.2 Diagram
No. Description
1 Middle polycarbonate
door
2 Side polycarbonate
doors
2 2
Figure 2-15. Polycarbonate Doors on the Omnivision III Base

Unit

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2.8 Monitor Station
2.8.1 Definition
The monitor station, which rotates 270 degrees and includes a

touch screen, is the means by which you interact with Omnivision
III software, that is, how you tell Omnivision III what to do and
how to do it.
2.8.2 Diagram
No. Description
1 Touch screen
Figure 2-16. Monitor Station

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2.9 Signal Beacon
2.9.1 Definition
The signal beacon, which is located at the top of your Omnivision

III, is a stack of five different colored signal lights that indicate
the current machine status of Omnivision III.
2.9.2 Diagram
No. Description
1 Red beacon, which, if lit, indicates that Omnivision III has generated a 1
critical alarm
2 Yellow (or amber) beacon, which, if lit, indicates that Omnivision III has 2
generated a warning
3 Green beacon, which, if lit, indicates that power is applied to Omnivision III 3
and that Omnivision III is ready and working satisfactorily
4 Blue beacon, which, if lit, indicates that you are inspecting a test container
or running a test 4
5 White beacon, which, if lit, indicates that power is applied to Omnivision III
5
Note: If beacons are not lit, power to Omnivision III is turned off.
Figure 2-17. Signal Beacon

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2.10 Radio Frequency Residual Liquid
Detection Inspection Subsystem
2.10.1 Definition
The radio frequency residual liquid detection inspection

subsystem or RF RLD is an optional product that detects water or
caustic liquids in containers.

subsystem consists of a radio frequency transmitter and receiver
that are located between the outer sidewall and the base unit.

subsystem is equipment that filtec provides optionally.
2.10.2 Diagram
No. Description
1 Outer sidewall
2 Cover of the radio frequency
residual liquid detection
inspection system (RF RLD)
Important: If your
Omnivision III includes
the color sort
inspection module,
you also connect the
cables from the
module to points
inside this box.
1 2
3 Radio frequency residual
liquid detection receiver,
filtec part number 36148
4 Radio frequency residual
liquid detection transmitter
filtec part number 36149
3
Figure 2-18. Radio Frequency Residual Liquid Detection

Inspection Subsystem

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2.11 Container Handling System
2.11.1 Definition
The container handling system is that part of Omnivision III that

transports all containers through the system reliably, so that the
inspection and rejection actions can perform seamlessly without
affecting the efficiency of your production line.
2.11.2 Description
The container handling system includes the outer sidewall guides,

infeed guides, neck and body belt guides, starwheel, neck and
body belts, reject conveyor and guide rails, vacuum system,
through conveyor, and outfeed guides.
2.11.3 Diagram
1 2 3 4 5 6 7
No. Description
1 Outer sidewall guides, also known as the rotator guides
2 Infeed guides
3 Deadplate, which is located underneath the starwheel
4 Neck and body belt guides
5 Starwheel, starwheel motor, and high resolution encoder
6 Reject conveyor system
7 Outfeed guides
Figure 2-19. Container Handling System

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2.11.4 How the Container Handling System Works
Outer Sidewall (Rotator) Guides
First, containers enter the outer sidewall (rotator) guides.
The outer sidewall (rotator) guides are positioned in such a way

that they support the neck and the heel of each container as it
passes.
No. Description
1 Rotator guides
Figure 2-20. Outer Sidewall (Rotator) Guides
The guides get wider as the containers enter the outer sidewall
inspection area and return to their original width as they exit the
outer sidewall inspection area.
As the containers enter this wider area, they travel outward and
begin to roll against each other in a staggered formation, as
shown here.
1 No. Description 2
1 Upstream rotation area
2 Downstream re-combination area
Figure 2-21. Rolling and Staggering of Containers in the Outer

Sidewall Guides

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This rolling motion occurs due to a slight backup pressure
produced by the rotation system itself. The speed of each
container in the rotator section is slightly slower than when they
are in single-file.
Omnivision III acquires the image of each container as it passes

through the outer sidewall area in three phases, each having up
to four views.
Each container that traverses through the inspection tunnel

receives an independent inspection in up to 15 camera windows
that you define, for each view of each phase.
Figure 2-22. Progression of Images

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The preceding diagram shows four views per phase, enabling
Omnivision III to acquire a total of 12 images on which to perform
inspection (3 phases x 4 views of image acquisitions = 12 acquired
images).
Each acquisition is separated by approximately 30 degrees of

rotation, which enables Omnivision III to inspect the entire
surface of the container (30 degrees x 12 acquisitions = 360
degrees).
Infeed Guides
The infeed guides direct containers from the production conveyor

line through the outer sidewall station (if your Omnivision III is
equipped) or directly into the base system, and then to the
outfeed guides.
No. Description
1
1 Infeed guides
Figure 2-23. Infeed Guides

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Starwheel Area
After containers pass through the infeed guides, they enter the
starwheel area, which consists of the rubber neck and body belts,
air knife, diffuser or rotating glass, and the water drip valve.
1
No. Description
1 Test container sensor, which sends a signal to
the line control module (LCM) when the sensor
detects the reflective tape that you have taped
to a test container 2
2 Green neck belt
3 Orange body belt
4 Air knife blow off valve and assembly 3
(obscured), which blows and removes any soap
or water drops from the bottom of each
container
5 Diffuser or rotating glass, which protects the
base strobe unit from liquid and debris
6 Strobe lamp
7 Water drip valve, which provides water on the
rotating glass for cleaning by the rotating brush
4
5 6 7
Figure 2-24. Components in the Starwheel Area
Neck and Body Belt Guides
The neck belt guide and body belt guide, which are constructed
with a flexible rubber band that is mounted on rotational pulleys,
support and transport the containers as they pass through the
starwheel.

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As shown in Figure 2-24. Components in the Starwheel Area, the
neck belt guide is suspended over the body belt guide, just
underneath the inspection head and parallel with the necks of
containers. The body belt guide is suspended below the neck belt
guide, just above the base cabinet and parallel with the bodies of
containers.
No. Description
1 Starwheel 1
2 Green neck belt
3 Orange body belt
4 Container
3 4
Figure 2-25. Neck and Body Belt Guides
Starwheel
The two belts of the neck and body belt guides, which are critical
container handling parts, assist the vacuum system to stabilize
the containers during the inspection process.
The starwheel, which is driven by a servo motor and directly

controlled by, and synchronized with, the speed of the
production conveyor chain by a high resolution encoder,
accurately, reliably, and repeatedly places the container over or
under the inspection zone.

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The starwheel then moves containers through the base, inner
sidewall, infrared, finish, and thread inspection zones and back
to the production line or reject takeaway conveyor after
inspection is complete.
1 1
6 4
No. Description
1 Starwheel
5
2 Suction cups
3 Starwheel motor control unit
4 Starwheel motor
5 High resolution starwheel encoder (16000 pulses per
revolution)
6 Embossing that identifies pocket 1 on the starwheel
Note: The starwheel motor control unit (3),
starwheel motor (4), and high resolution encoder (5)
are all attached and supported by a mounting
bracket and is represented by a single part number.
Figure 2-26. Starwheel, Starwheel Motor, and the High

Resolution Encoder

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The indexed high resolution encoder that is located under the
starwheel motor provides a reference for all subsystems.
One complete revolution of the starwheel equals 16000 encoder

pulses, which Omnivision III divides according to the number of
container pockets in your particular starwheel (for example, 36
for 341 milliliter containers).
The absolute reference of the trigger for pocket 1, or the offset

from the index for pin 1, is set for each starwheel.
Note: For high altitude (more than 2435 feet above sea level)
applications, or for use with containers that are heavily fluted,
swirled, or ribbed, the vacuum option can be equipped with a
pump instead of the standard pressure vacuum converter. The
vacuum pump provides a greater vacuum flow rate.
Deadplate
When containers pass through the infeed guides, starwheel, and

outfeed guides, they pass over the deadplate, which is made of
high-grade stainless steel.

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The deadplate ensures that containers pass smoothly from the
infeed to the outfeed guides.
1
2
3 4 5
No. Description
1 Deadplate
2 Lock knob
3 Downstream support bracket
(obscured underneath)
4 Middle support bracket
(obscured underneath)
5 Upstream support bracket
Figure 2-27. Deadplate

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Air Knife Blow Off Assembly
As each container passes over the deadplate, the air knife blow
off assembly blows and removes soap and water from the bottom
of each container.
No. Description
1 1
1 Air knife
Figure 2-28. Air Knife
Outfeed Guides
After Omnivision III completes inspection, the starwheel releases

containers that pass inspection into the outfeed guides, which
guide the good containers back onto the production conveyor.
Figure 2-29. Outfeed Guides

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2.12 Starwheel
2.12.1 Definition
A starwheel is a custom-made change part that holds, positions,

and transports each container through Omnivision III.
2.12.2 Description
filtec custom manufactures the starwheel for each particular

type of container that you run through Omnivision III.
The starwheel is composed of a vacuum sealing ring, an upper

and lower ring, a hub, tubes, and suction cups. The starwheel
does not have pins to synchronize with the cameras. Rather, the
starwheel motor encoder synchronizes the cameras.
The starwheel uses vacuum that is passed through the hub and
tubes to secure each container in place at high speeds.
2.12.3 Diagram
No. Description
1 Suction cups
2 Starwheel hub
3 T knob
4 Tubes
5 Identifier for pocket
1 on the starwheel
1 4
2 3
5
Figure 2-30. Starwheel

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2.13 Suction Cup
2.13.1 Definition
A suction cup is the component on a starwheel that attaches to a

container through suction and keeps a container in place in the
starwheel as the starwheel rotates.
2.13.2 Storage Guidelines
Keep these guidelines about suction cups in mind.
• Always keep the suction cup or cups that you need in stock, as
you need to replace them frequently.
• Store suction cups in a cool, dark place that is free of sunlight
and fluorescent lighting.
Note: The black sucker cup (part number 04204) is particularly

sensitive to light in the ultraviolet wavelength, hardens, and
develops a white coating with time.
2.13.3 Diagram
1 2 3 4 5
No. Part No. Description
1 04204 Black suction cup, which is durable and works well with most heavy, light, and smooth
sided containers
2 12530 Gray suction cup, which is the most often used soft cup, and is used with embossed or
fluted neck containers, but not used with very large or heavy containers, as it tends to fold
3 43382 Tall blue suction cup, which is made of the softest material available and is usually used
with embossed containers when the gray suction cup does not reliably hold containers
4 24052 Red or orange suction cup, which is slightly softer than the black sucker cup, heat
resistant, and usually used in high temperature applications where containers are hot
5 24663 Squat blue suction cup, which is used with small containers and jars
Figure 2-31. Various Types of Suction Cups

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2.14 Strobe Lamp
2.14.1 Definition
A strobe lamp is a device inside the Omnivision III base unit that
generates a high intensity beam of light onto and through a
container so that cameras and sensors inside the Omnivision III
inspection head can capture an image of the container for
inspection purposes.
2.14.2 Diagram
No. Description
2 Light emitting diode strobe
lamp, including its convex
lens roundel, that is used
in Omnivision III
2
Figure 2-32. Strobe Lamp

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2.14.3 Description
The actual strobe in the newer model of the strobe lamp includes
three independently controlled sets of concentric zones of visible
light emitting diodes and two independently controlled
concentric rings of infrared light emitting diodes.
1
No. Description
2
1 Outer zone of light
emitting diodes 3
2 Middle zone of light
emitting diodes
3 Inner or center zone of
light emitting diodes
4 Outer ring of infrared
5 Inner ring of infrared
4
5
Figure 2-33. Strobe Light Emitting Diodes
You independently control each zone by setting parameters in the

Omnivision III system software.
Strobe settings that you can control include the duration of the
light pulse, which determines the intensity of light in the image
and infrared detector, and the trigger delay, which determines
the amount of time after the camera shutter opens before
Omnivision III turns on the light emitting diodes.

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2.15 Test Container Detection Photocell
Sensor
2.15.1 Definition
The test container detection photocell sensor is a

retro-reflective sensor that is mounted to the underside of the
inspection head that looks for reflective tape on a test container.
When you pass a test container past this sensor, Omnivision III
rejects this container and looks at the varying defects that it
detects. Omnivision III then compares those results to a test
container that you defined previously.
2.15.2 Diagram
No. Description
1 Test container detection
photocell sensor (detail)
2 Mounting location of the
test container detection
photocell sensor
1 2
Figure 2-34. Test Container Detection Photocell Sensor

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2.16 Inspection Head
2.16.1 Definition
The inspection head is the part of Omnivision III that contains the
cameras, cards, sensors, and software that processes images,
triggers inspections, and performs other inspection tasks.
Components in the inspection head that perform these inspec-

tions and tasks are:
• Base (camera)
• Inner sidewall (ISW) (camera)
• Infrared (IR) residual liquid detection (RLD) (sensor)
• Finish (camera)
• Thread (camera)
• Reject verification (sensor)

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2.16.2 Diagram
17 16 15 14 13 12
4 5 6 7 8 9 10 11
No. Description
1 Finish, thread, base, inner sidewall (FTBI) card
2 Outer sidewall processor and processor daughter card that perform outer
sidewall inspections
3 Fan (two)
4 Central processing unit (CPU) backplane card
5 Sonic gap sensor
6 Programmed solid state drive (SSD) (under protective cover) 18
7 Camera link interface card (CLIC)
8 Finish, thread, base, inner sidewall (FTBI) camera assembly
9 Infrared residual liquid detection sensor (inside protective cover)
10 Base camera
11 Inner sidewall camera
12 Infrared residual liquid detection card
13 Camera servo controller card (SCC1 and SCC2)
14 Finish interface card
15 Basic input/output system (BIOS) keyboard connector (obscured)
16 Universal serial bus (USB) and Ethernet ports
17 Inspection head power supply module assembly behind the card cage)
18 Inspection head, exterior
Figure 2-35. Inside and Outside the Inspection Head

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2.17 External Ethernet and PS/2 Keyboard
Ports
2.17.1 Definition
The external Ethernet port and Personal System/2 (PS/2)

keyboard port are connectors on the outside of the inspection
head.
You use these ports to connect an Ethernet network cable and

external keyboard to Omnivision III.
2.17.2 Diagram
No. Description
1 Back side of the inspection
head, including support brace
2 External Ethernet and PS/2
keyboard port (closed)
Note: The arrangement of the

ports on your inspection head 1
might appear as a mirror image
of that shown here depending
on whether your Omnivision III
is right or left sided. 2
3 External Ethernet and PS/2
keyboard port (close up, open)
Figure 2-36. External Ethernet and PS/2 Keyboard Ports on the

Inspection Head

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2.18 Cooling System
2.18.1 Definition
The cooling system is a thermal transfer cooling, rather than an

air conditioning, system. This system cools the inside of the
inspection head by using a glycol cooling thermal heat transfer
system. Two glycol coolers cool the electronics circuitry.
If you choose, you can instead purchase a vortex air cabinet

cooler. This cooling system uses a vortex to create cool air, which
then circulates over the electronic cards.
2.18.2 Diagram
3
Heat exchanger
cooling system 1
4 6
No. Description
1 Ambient air
2 Warmed air
3 Warm air
2
4 Heat tube
5
5 Cooled air
6 Inspection head
7 Hot air out
8 Compressed air in
6
7
Optional vortex 8
cooling system
Figure 2-37. Cooling System

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2.19 Solid State Drive
2.19.1 Definition
The solid state drive (SSD) is a storage device on which the

software and database files that run Omnivision III are stored.
Omnivision III uses a solid state drive (SSD) to improve longevity

and reliability.
2.19.2 Diagram
No. Description
1 Solid state drive
(SSD)
1
Figure 2-38. Omnivision III Solid State Drive (SSD)

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2.20 Card Cage
2.20.1 Definition
The card cage is the enclosure inside the inspection head into
which printed circuit boards, or cards, are inserted.
The card cage is exposed at the front to enable you or other

authorized personnel to insert and remove cards quickly and
easily.
2.20.2 Diagram
No. Description
1 Card cage housing
2 Finish, thread, base, inner sidewall
(FTBI) processor card
3 Outer sidewall processor and
processor daughter card that perform
outer sidewall inspections
4 Central processing unit (CPU)
backplane card
5 Universal serial bus (USB) and
Ethernet ports (accessed from above)
6 Programmed solid state drive (SSD)
(under protective cover)
7 Basic input/output system (BIOS)
keyboard connector (accessed from
above)
8 Camera link interface card (CLIC)
1 2 3 4 5 6 7 8
Figure 2-39. Card Cage

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2.21 Central Processing Unit
2.21.1 Definition
The central processing unit (CPU) is a card that runs the

Omnivision III user interface and communicates with the
inspection processor cards through the peripheral component
interconnect (PCI) bus on the backplane.
2.21.2 Diagram
No. Description
1 Communication section,
to which ribbon cables
from CLIC connect
Figure 2-40. Central Processing Unit for Omnivision III

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2.22 Inspection Processor Card
2.22.1 Description
Omnivision III includes two identical high speed inspection

processor cards in the card cage.
The first inspection processor card in the card cage (from the
left) receives the video signal from the camera breakout card and
performs base, inner sidewall, finish, and thread inspections on
the image according to the inspection parameters that you
specify.
The second inspection processor card in the card cage also

receives the digital camera signal from the camera breakout card
and performs outer sidewall inspections on the image according
to the inspection parameters that you specify.
The finish, thread, base, and inner sidewall cameras connect to

the finish, thread, base, and inner sidewall (FTBI) inspection
processor card (AL1). The outer sidewall video card is connected
to the outer sidewall inspection processor card (AL2).
2.22.2 Diagram
Figure 2-41. High Speed Inspection Processor Cards

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2.23 Camera Link Interface Card
2.23.1 Description
The camera link interface card (CLIC) interfaces with all of the
Omnivision III cameras and connects them to the corresponding
inspection processor card.
2.23.2 Diagram
Figure 2-42. Camera Link Interface Card (CLIC)

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2.24 Universal Serial Bus Ports
2.24.1 Definition
The universal serial bus (USB) ports is a component of Omnivision

III that enables you to communicate with the central processing
unit (CPU) through a universal serial bus (USB) keyboard.
2.24.2 Description
You plug a USB keyboard cable into a port at the top of the card
cage inside the inspection head. If necessary, you also use a USB
drive to back up machine data or download new software.
Caution: Always scan your USB device with antivirus software

before you insert it, as you might otherwise infect and corrupt
your Omnivision III system and void your warranty.
If you fail to scan your USB device and inadvertently infect your
Omnivision III system, contact filtec Customer Support.
2.24.3 Diagram
No. Description
1 Card cage
2 Two universal serial bus (USB)
3.1 Gen 1 ports (blue)
3 Single, unused universal serial
bus (USB) 2.0 port (black)
Note: Always use this port to 1

connect your device.
2
3
Figure 2-43. Universal Serial Bus (USB) Ports

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2.25 Reject Verifier Ultrasonic Sensor
2.25.1 Definition
The reject verifier ultrasonic sensor is a component inside the

inspection head, in between the reject conveyor and the
discharge of the throughput conveyor, that sends a signal to the
line control module (LCM) card to stop Omnivision III if Omnivision
III fails to reject a faulty container.
When Omnivision III rejects a container, this sensor detects if

there is an open space in the current pocket of the starwheel. In
other words, this sensor checks that a container to be rejected
was in fact rejected onto the reject conveyor.
If this sensor detects that a container is present in a pocket and

that container should have been rejected, the line control
module (LCM) issues a stop signal and Omnivision III turns on the
brake.
2.25.2 Diagram
No. Description
3
1 Location of reject verifier
ultrasonic sensor
2 Reject verifier ultrasonic
sensor, from above
3 Reject verifier ultrasonic
sensor, from below
Figure 2-44. Reject Verifier Photocell From Above and Below

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2.26 Inspection Cameras
2.26.1 Introduction
The cameras inside the inspection head and the outer sidewall
unit are black and white digital cameras.
In most cases, Omnivision III uses video cameras to inspect

containers. The configuration of the video cameras inside the
inspection head ensure that base, inner sidewall, and residual
liquid infrared detection inspections all occur at the same time.
2.26.2 Diagrams
2
No. Description 3 45 6
1 Base, inner sidewall, and finish camera
2 Outer sidewall inspection camera
3 Inner sidewall camera
4 Base camera
5 Infrared residual liquid detection sensor
6 Finish camera
Note: The thread camera is not shown.
Figure 2-45. Inspection Cameras and Sensors

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2.26.3 How the Inspection Cameras Work
Omnivision III sends the video signal from the cameras inside the
inspection head to the camera link interface card (CLIC), which
then passes the signal on to an inspection processor card to be
digitized.
The outer sidewall guide rails rotate the containers so that the
camera takes up to 12 images of the same container. Rotating the
containers in this way enables the outer sidewall unit to inspect
360 degrees on the outer surface of the container.

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2.27 Servo Motors for Zoom and Brightness
2.27.1 Definition
The servo motors are the part of Omnivision III that control the
zoom and brightness apertures on the camera lenses. Inside
Omnivision III, up to two servo controllers control up to eight
servo motors.
2.27.2 Diagram
No. Description
1 Inner sidewall servo motors for zoom
and brightness
2 Base servo motors for zoom and
brightness
3 Infrared residual liquid detection servo
motors for zoom and brightness
4 Finish servo motor for zoom and
brightness
Note: The thread servo motors for zoom

and brightness are not shown, but are
located to the left of the finish servo
motors for zoom and brightness.
1 23 4
Figure 2-46. Servo Motors for Zoom (Top) and Brightness

(Bottom)

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2.28 Infrared Residual Liquid Detection
Sensor and Card
2.28.1 Definition
The infrared residual liquid detection sensor is an electronic card

that calculates the amount of infrared light that is emitted from
a strobe lamp.
2.28.2 Diagram
No. Description 1 2
1 Infrared residual liquid
detection sensor assembly
2 Infrared residual liquid
detection card
Figure 2-47. Infrared Residual Liquid Detection Sensor and Card

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2.29 Servo Controller
2.29.1 Definition
The servo controller is an electronic card that provides power

and signal controls for up to eight servo motors inside the
inspection head.
2.29.2 Diagram
No. Description
1 Servo controllers
Figure 2-48. Two Servo Controllers

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2.30 Finish Interface Card
2.30.1 Definition
The finish interface card (finish or thread option only) boosts the
48 volts direct current (VDC) for the finish light emitting diode
(LED) strobe.
2.30.2 Diagram
No. Description 1
1 Finish interface card
(finish or thread option
only)
Figure 2-49. Finish Strobe Light Emitting Diode (LED) +48 Volt
Power Supply

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2.31 Encoders Inside Omnivision III
2.31.1 List
Here is a list of encoders inside Omnivision III.
• Main conveyor encoder, which produces 500 pulses per

revolution, is mounted on the conveyor chain.
This encoder supplies Omnivision III with a speed reference of
your production line.
• Starwheel encoder, which produces 16000 pulses per
revolution, is mounted on the bottom of the vector drive.
This encoder enables Omnivision III to precisely track
containers though the system and provides the machine with
timing signals.
• Takeaway encoder, which produces 500 pulses per revolution,
is mounted on the reject takeaway motor that is mounted to
the reject takeaway conveyor.
This encoder enables Omnivision III to track the rejected
container from the time that the starwheel rejects it.
• Reject encoder, which produces 500 pulses per revolution, is
mounted on your facility’s reject line.
This encoder tracks each container from the start of the
reject line to the rejecter. The tracking of the containers on
this conveyor is essential to sorting the rewash and cullet
containers.

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2.32 Conveyor Chain Encoder
2.32.1 Definition
The conveyor chain encoder is the part of Omnivision III that

modulates the drive, brake systems, the down, and jam function.
2.32.2 Diagram
1 3 3 4 5
No. Description
1 Drive sprocket wheel
2 Conveyor chain encoder, covered, top view
3 Starwheel spindle housing
4 Conveyor chain encoder, covered, side view
5 Conveyor chain encoder, uncovered
Figure 2-50. Conveyor Chain Encoder and Drive Sprocket Wheel
2.32.3 How the Conveyor Chain Encoder Works
The conveyor chain encoder assembly is mounted on the side of

the conveyor, underneath the starwheel shaft assembly.
The conveyor chain encoder consists of a high resolution encoder

attached to a special drive sprocket (wheel). The production
chain link pins drive the sprocket, which in turn drives the
encoder.

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The signal from the conveyor encoder modulates the drive and
brake system and the drives down container or jam functions.
Note: On occasion, you might need to adjust the encoder

sprocket. You might also need to check the bearings regularly.

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2.33 Down and Jam Sensor
2.33.1 Definition
A down and jam sensor is an upstream photoelectric sensor

assembly that detects jammed, downed, or optionally, “too high”
containers.
The primary purpose of the down and jam sensor is to prevent

fallen or foreign containers from entering Omnivision III.
Note: You can also use the optional “too high” detection
feature and use it with the down and jam sensor assembly. In
this case, an additional sensor is included with the down and
jam sensor assembly.
2.33.2 Diagram
No. Description
1 Down and jam sensor
2 Sonic sensor 1, which detects large gaps, applies the
brake, and detects fallen containers
3 Container washer
4 Sonic sensor 2, which slows the starwheel to gently close
the remaining small gaps
5 Omnivision III outer sidewall assembly
1 2 3 4 5
Figure 2-51. View of Down and Jam Sensor

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No. Description
1 Height adjustment knob
2 Beam reflector
3 Down and jam sensor transmitter 1
4 Sonic sensor 1 transmitter
5 Sonic sensor 1 receiver 2
Note: You must mount the down 3
container sensor over the center
line of the sonic sensor 1. When the
sonic sensor 1 turns on, the down
bottle sensor needs to turn on at
the same time.
Figure 2-52. Close Up View of Down and Jam Sensor
2.33.3 How the Down and Jam Sensor Works
If both the sonic sensor 1 as well as the jam sensor turn on when
the line is running, Omnivision III counts this condition as a good
condition. A good condition is:
1. When sonic sensor 1 is blocked.
2. Alternating signal states from the down bottle sensor are

being generated (that is, the conveyor and starwheel are
moving and consequently issuing encoders).
If the bottom sensor turns on for a predetermined number of

encoder pulses and the top jam sensor fails to turn on, the line
control module (LCM) determines that there is a fallen container.
Omnivision III subsequently stops the starwheel so that you can

remove the downed or foreign container and restart the line.

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The down and jam sensor is located directly above sonic sensor 1.
Normal Container Too High Container Too Short Down

Note: If your Omnivision II includes the optional
“too high” detection feature, the down and jam
sensor includes an additional sensor and uses two
beams, as shown above.
Figure 2-53. How the Down and Jam Sensor Works

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2.34 Sonic Sensor
2.34.1 Definition
A sonic sensor is an upstream device that transmits and receives a

photoelectric signal that Omnivision III uses to detect the
presence of, and close gaps between, upstream containers.
2.34.2 Diagram
No. Description
1 Receiver (RX) sonic sensor, which
includes a yellow light emitting
diode (LED), part number 95169
2 Transmitter (TX) sonic sensor,
part number 95170
3 Sonic sensors mounted on the
infeed conveyor
1 2
You mount sensor 1 at

an angle of approximately
30 degrees across the
conveyor and sensor 2 at
an angle of approximately
45 degrees across the conveyor
Figure 2-54. Transmitter and Receiver Sonic Sensors
2.34.3 How Sonic Sensors Work
Due to the slight pressure on containers at all times on the infeed

conveyor, Omnivision III always expects the sonic sensors to be
blocked.
If the line surges and Omnivision III detects a gap that is larger
than an encoder count that you specify (that is, the sensor
becomes unblocked) the line control module (LCM) either puts
the starwheel into brake mode or puts the starwheel into free
wheel mode until the sonic sensors are blocked again.

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The Omnivision III software uses the sonic sensor signals as well as
the conveyor encoder to determine how to modulate the
starwheel. The goal of these sensors is to ensure that a positive
container pressure is maintained at the starwheel infeed.

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2.35 Resynchronization Sensors
2.35.1 Definition
A resynchronization sensor is a photo sensitive sensor trigger that

ensures that Omnivision III correctly tracks the position of
rejected containers over conveyor transfers.
Omnivision III uses up to two synchronization sensors and two

encoders for this purpose. The primary purpose of resynchroni-
zation sensors is to identify containers and correctly flag them for
automatic disposal without a human intervening.
2.35.2 Diagram
3 5 8
1 2
4 6 7 9 10
No. Description
1 Container infeed, where containers enter Omnivision III
2 Omnivision III
3 Your facility’s main production or throughput conveyor
4 Omnivision III reject conveyor, which filtec supplies with Omnivision III
5 Resynchronization sensor 1
6 Crossover point from the Omnivision III reject conveyor to the reject takeaway
conveyor
7 Proline trigger sensor, which is located from 1.5 container diameters to 5 container
diameters upstream from your rejector and which resynchronizes the position of the
container so that the rejecter’s timing to the container is accurate
8 Your Proline or Slimline rejector
Note: You can also add an optional filtec Servotec II rejector downstream from your
Proline or Slimline rejector.
9 Unsalvageable container bin, chute, cullet, or secondary reject conveyor
10 Reject takeaway conveyor, which you provide
Figure 2-55. Resynchronization Sensors

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2.36 Main Power Switch and Emergency Stop
Button
2.36.1 Definition
The emergency stop button is a device that you use to immedi-

ately stop Omnivision III and production in an emergency.
The main power switch is a device that you use to turn off and
power down Omnivision III.
2.36.2 Diagram
No. Description
1 Three lock out, tag out
slots, in which you insert
a lock to lock the system
power switch in the off
position, if your company
1 maintains a lock out, tag
out policy 3
2 Main power switch
2
1 3 Emergency stop button
Note: Omnivision III

includes two emergency
stop buttons, one on the
front and one on the back
Figure 2-56. Main Power Switch and Emergency Stop Button
2.36.3 How the Emergency Stop Button Works
To immediately stop production in an emergency, you press in

the emergency stop button.
When you press in the emergency stop button, Omnivision III puts
the starwheel motor in shutdown mode. Shutdown mode means
that the starwheel is “free wheel”, that is, running at 0 torque
and 0 speed.
Omnivision III commands your conveyor to stop by setting the PLC

machine ready signal to off.
After you resolve the emergency and want to restart production,

you pull out or turn the emergency stop button clockwise.

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To clear alarms, you press the button in the lower right
corner of the screen, and then press .
Important: You might need to provide a password to clear some

alarms.
2.36.4 How the Main Power Switch Works
To turn off Omnivision III, you turn the power switch counter-
clockwise and to turn on Omnivision III, you turn clockwise.
On Off

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2.37 Color Sort Inspection Module
2.37.1 Definition
The color sort inspection module is an optional component of

Omnivision III that sorts containers based on their color.
2.37.2 Diagram
9
8
10
7
1 2
5 6 To power supply
No. Description 3 4 in the base unit
1 Cover
lower cabinet
2 Channel selector switch (A through D)
3 Cable that connects to the sensor side
of the color sort (or RF RLD) guide plate
4 Power cable that connects inside the
base cabinet
5 Cable that connects to the light side of
the color sort (or RF RLD) guide plate
6 Cable that connects to the auxiliary
input (J7 Aux 1 or J8 Aux 2 on SB1)
7 Color evaluation control unit
1
8 Color sort logic card assembly
9 Sensor side of the color sort guide plate 2
10 Light side of the color sort guide plate
11 Outer sidewall lower cabinet 11
Figure 2-57. Color Sort Inspection Module Inside and Out

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2.38 Base Unit Lower Cabinet: Starwheel Side
2.38.1 Definition
The base unit lower cabinet: starwheel side inside Omnivision III
houses the:
• Air regulating panel, which provides information about and

enables you to regulate air that your facility provides to
Omnivision III and service filters for air and vacuum.
• Power supply drawer, which contains transformers and power
supplies that supply voltage requirements to Omnivision III.
• 220 to 110 volt isolation, step-down transformer, which
powers Omnivision III.
2.38.2 Diagram
No. Description 1 23 4 5 6 78
1 Base strobe air filter
2 Line control module (LCM) card, which monitors the speed of the conveyor and adjusts the speed of the
starwheel to run slightly slower, generates the “pin signal” that tells the strobe to fire and the camera to
capture an image when a starwheel pocket is aligned, tracks all containers, rejects containers, and
controls all the sensors, solenoids, and lights
3 Starwheel system air filter
4 Power supply drawer, which slides in and out and houses power supplies and LCM card
5 Starwheel reject pressure regulator knob, which you use to regulate the pressure to the reject valve
6 Bottom diffuser blow off pressure regulator knob, which you use to regulate air pressure to the air knife
blow off assembly and the air brush on the rotating glass
7 Isolation step-down transformer, which converts 220 volts to 115 volts power to Omnivision III
8 Machine pressure regulator knob, which you use to regulate the main air pressure to Omnivision III
Figure 2-58. Inside the Base Unit Lower Cabinet: Starwheel Side

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2.39 Air and Vacuum Filters
2.39.1 Definition
The air and vacuum filters are five micron filters that are used on
Omnivision III to filter the air supply system.
2.39.2 Diagram
Figure 2-59. Base Strobe, Starwheel System Air Filters, and

Starwheel Vacuum Filter

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2.40 Air Regulating Panel
2.40.1 Definition
The air regulating panel displays the status of the air that your
facility is providing to Omnivision III and enables you, by turning
knobs, to regulate the amount of air that Omnivision III receives.
2.40.2 Diagram
Figure 2-60. Air Regulating Panel

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2.41 Power Supply Drawer
2.41.1 Definition
The power supply drawer, which is located inside, and slides into
and out of the lower cabinet of the base unit, houses power
supplies for all fans, the line control module (LCM), the reject
valve, the finish power supply unit, and the lamp transformer.
2.41.2 Diagram
No. Description
1 Line control module (LCM)
2 Fan 1
3 Transformer for the stack 2
lamp and valve
4 Finish and reject 48 volt 3
direct current (VDC) power
supply 1 4
5 Lamps, inspection head 5
raising mechanism, and fans
24 volt direct current (VDC) 6
power supply 12
7
See Also: Drawing D48827
6 Connection points 8
See Also: Drawing D40413 9
7 Line control module (LCM) 12
volt direct current (VDC)
power supply 4 10 11
8 Line control module (LCM) 5
volt direct current (VDC)
power supply 5
9 Light emitting diode (LED)
strobes 24 volt direct current
(VDC) power supply 3
10 Base cabinet and roof LED
light bar relays
11 LCM fuse block
See Also: Drawing D45357
Figure 2-61. Power Supply Drawer From Above, Looking Down

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2.42 Line Control Module Card
2.42.1 Description
The line control module (LCM) is one of the most important cards
in Omnivision III. The line control module card monitors the
conveyor speed and modulates the speed of the starwheel
accordingly.
The starwheel is a slave to the production through conveyor.
The line control module also generates the pin trigger signal,
loads all essential line control software, generates all tracking
registers for rejection, and stores these programs on the card.
The line control module (LCM) card generates the signal for the
camera to acquire an image, controls all infeed sensors,
solenoids, and stack lamp lights, and processes all of the line
inputs and output signals.
2.42.2 Diagram
Figure 2-62. Line Control Module (LCM) Card

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2.43 Isolation Step-Down Transformer
2.43.1 Definition
The isolation step-down transformer converts, or steps down,

and isolates 220 volts to 115 volts for Omnivision III power.
2.43.2 Diagram
Figure 2-63. Isolation Step-Down Transformer

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2.44 Finish and Reject 48 Volt Direct Current
Power Supply
2.44.1 Definition
The finish and reject 48 volt direct current (VDC) power supply is
a component inside the lower cabinet of the base unit, at the
rear of the power supply drawer, that provides power to the
finish inspection and reject interface card.
2.44.2 Diagram
Figure 2-64. Finish and Reject 48 Volt Direct Current (VDC)

Power Supply

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2.45 Base Unit Lower Cabinet: Operator Side
2.45.1 Description
The base unit lower cabinet: operator side houses the:
• Circuit breaker panel

• Rotating glass and brush drive motors
• Base strobe assembly
• Raising mechanism and gearbox
• Main 24 volt direct current (VDC) battery charging power
supply
• UPS card, 30 volt direct current (VDC) power supply and
battery pack
• Starwheel motor, motor controller, and starwheel motor
power supply
• Vacuum and rejects system
2.45.2 Diagram
No. Description
1 Circuit breakers
2 Rotating glass and brush drive
motors
3 Opto isolated outputs that
interface to your line control
4 Older model high voltage base
strobe assembly
5 Raising mechanism gearbox
6 Uninterruptable power supply
7 Uninterruptable power supply
battery pack
8 Starwheel motor power supply
1 2 3 4 5 6 7 8
Figure 2-65. Inside the Base Unit Lower Cabinet: Operator Side

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2.46 Circuit Breakers
2.46.1 Definition
A circuit breaker is an automatic device for stopping the flow of

current in an electric circuit as a safety measure.
2.46.2 Description
All circuit breakers for Omnivision III are located inside the lower
cabinet of the base unit, to the left and above the programmable
logic controller output, which is located on the opposite side of,
or behind the power supply drawer.
2.46.3 Diagram
No. Description
1 Circuit breakers
Figure 2-66. Circuit Breakers

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2.47 Rotating Glass and Brush Drive Motors
2.47.1 Definition
The rotating glass motor and rotating brush drive motor are
drive motors that rotate the diffuser glass and brush assemblies,
either clockwise or anti clockwise depending on whether you
have a right hand or left hand Omnivision III.
The rotating glass or diffuser, is the component in Omnivision III

that protects the strobe lamp dome glass assembly from liquid,
soap, dirt, and debris deposits. This component reduces human
intervention and ultimately keeps false rejects to a minimum due
to contamination issues.
The brush drive is the component in Omnivision III that brushes

and cleans the rotating glass to ensure that the rotating glass is
kept clean.
2.47.2 Description
The rotating glass and brush drive assembly incorporates a water

spray, rotating scrubber brush, and air deflector brush. Often you
need to clean the diffuser glass once per shift, but the frequency
depends on actual line conditions and the local glass population.
2.47.3 Diagram
No. Description
1 Scrubber brush assembly
2 Rotating glass
Figure 2-67. Rotating Glass and Brush Assemblies

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2.47.4 Diagram
No. Description
1 Brush drive motor
2 Rotating glass motor
Figure 2-68. Rotating Glass and Brush Drive Motors

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2.48 Opto Isolated Output Module
2.48.1 Description
The Omnivision III opto isolated output module is located inside

the lower cabinet of the base unit, on the operator side.
This module is connected to Omnivision III electronics through the

J11 connector on the input/output access panel in the lower
cabinet of the base unit.
You use the green terminal connectors on the programmable logic

controller module, which is also located on the input/output
access panel, to connect the cables from the programmable logic
controller (PLC) to your panel.
2.48.2 Diagram
1 3 4
No. Description
1 J1 Receptacle, 220 volts
alternating current,
4 amps, 50/60 Hertz
2 J2 Receptacle, 115 AC, 4A,
50/60 Hz
3 J4 Outer sidewall strobe
trigger (outer sidewall
sensors)
4 J5 Outer sidewall power
supplies connector
5 J6 Ethernet connector
6 J7 Industrial Dynamics Net
connector, RS-485 (DB9,
female cable)
7 J8 Outer sidewall lamps and
fan
8 J9 Modbus RS232 (DB9, male
cable)
9 J10 Programmable logic
controller module (rail
only shown)
controller (PLC) interface
module junction box
connector (DB25, female
cable) 9 2 8 5 6 10 7
Figure 2-69. Input/Output Access Panel

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1
3 4 5 6 7 8 9 10 11 12 13 15 16
14
No. Description Input or Green
Output terminal
block
1 J10 PLC interface module, which is attached to the rail on the
input/output access panel
2 Green positive and negative terminal connectors
3 K1 Starwheel encoder Output 1+, 2-
4 K2 Brake output, machine ready Output 3+, 4-
5 K3 Downstream gap (filler demand) Output 5+, 6-
6 K4 Reject output Output 7+, 8-
7 K5 Throughput (pin) Output 9+, 10-
8 K6 Jam Output 11+, 12-
9 K7 Fallen container Output 13+, 14-
10 K8 Reject failure Output 15+, 16-
11 K9 Brake output, machine ready, reject motor stop Output 17+, 18-
12 K10 Brake input Input 19+, 20-
13 K11 Run out Input 21+, 22-
14 Emergency stop dry contacts Switch closure 25, 26
15 K12 Reject inhibit Input 23+, 24-
16 J11 PLC interface module junction box connector cable (DB25,
female)
Figure 2-70. Programmable Logic Controller Module

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2.49 High Voltage Base Strobe Assembly
2.49.1 Diagram
No. Description
2 Light emitting diode (LED)
base strobe assembly
Figure 2-71. High Voltage Base Strobe Assembly

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2.50 Uninterruptable Power Supply Card
2.50.1 Definition
The sole purpose of the Omnivision III uninterruptable power

supply (UPS) card is to switch power from the 24 volts direct
current (VDC) power supply to the 24 volts direct current (VDC)
battery pack in the base unit lower cabinet for a period of one
minute.
Switching power to the battery pack enables the Omnivision III

operating system to shut down gracefully when you power off
Omnivision III by switching off the main power switch.
2.50.2 Diagram
No. Description
1 Uninterruptable
power supply
circuit breaker
CB11
2 Uninterruptable
power supply
card
3 Uninterruptable
power supply
battery pack
1
Figure 2-72. Uninterruptable Power Supply System
2.50.3 Components
The Omnivision III uninterruptable power supply (UPS) consists of

three basic components:
• 30 volts direct current (VDC) power supply, which provides

power to the battery pack and keeps it fully charged
• Uninterruptable power supply control board, which manages
the operation of the power supply, switches to backup power
if necessary, and maintains the charge on the battery

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• Battery pack, which provides temporary backup power in the
event of power loss or system shutdown for a period of one
minute to enable the Omnivision III software to safely shut
down
2.50.4 Description of How the Battery Pack Works
A 30 volts direct current (VDC) power supply that is mounted

inside the base unit lower cabinet charges the lead-acid 24 volts
direct current (VDC) uninterruptable power supply battery pack.
The circuit breaker, which is marked CB11, is connected directly

to the incoming 220 volts alternating current (VAC) mains line to
enable your uninterruptable power supply to charge continuously
whether Omnivision III is turned on or off.
Warning: Even after you shut down the main isolator, power is
still live inside the base cabinet. Always use caution when
accessing the inside of the base cabinet or injury or death can
result.
2.50.5 How the Uninterruptable Power Supply System

Works
Omnivision III constantly monitors the state of the 24 volts direct

current (VDC) output on the main 24 volts direct current (VDC)
power supply unit.
When the uninterruptable power supply detects a loss of power or

you turn off the main power switch on Omnivision III, Omnivision
III executes the battery backup function, which signals the
uninterruptable power supply to stop charging the battery and
switch to battery power.
The uninterruptable power supply control board continues to

provide battery power for up to 30 seconds while it waits for a
shutdown command from the Omnivision III software.
If you restore power before the uninterruptable power supply

receives a shutdown command and before 30 seconds has passed,
the uninterruptable power supply returns to normal operation.
The Omnivision III continues to operate normally if power is
restored.

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Otherwise, the uninterruptable power supply starts a timer and
waits another 15 seconds to allow the Omnivision III software
application and operating system to close. At the end of 15
seconds, the uninterruptable power supply control board
sequences off the chassis power supply outputs in 300 millisecond
intervals.
Note: Once the 15 second timer starts, you cannot stop it.
The uninterruptable power supply control board waits the
entire 15 seconds and sequences the power supply outputs off
regardless of whether you turn on the main power switch or you
restore input power before the 15 seconds expire.
Even during this 15 second interval, if alternating current (AC)

power is present, the uninterruptable power supply continues to
charge the battery.
The uninterruptable power supply control board uses two

charging methods. The initial battery charge method consists of
applying a constant 300 milliampere charge current to the
battery. The uninterruptable power supply control board raises
the charge voltage to maintain the constant charge current.
When the battery is completely charged, or close to completely

charged, the uninterruptable power supply control board
switches to a constant voltage charge method. When using the
constant voltage (float voltage) method, the uninterruptable
power supply control board maintains a constant voltage and
applies just enough charge current to maintain the target float
voltage.
Both of these battery-charging methods provide the maximum

possible battery life.

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2.51 Starwheel Motor
2.51.1 Diagram
2
3
No. Description
1 Starwheel hub and starwheel
2 Starwheel dedicated motor control unit, which interfaces
with the advanced line control system
3 Starwheel servo motor
4 Starwheel motor high resolution encoder
5 Location of starwheel motor inside the lower cabinet
Figure 2-73. Starwheel Motor and Motor Control Unit
2.51.2 How the Starwheel Motor Works
The starwheel is controlled by a servo motor that is located inside

the lower cabinet of the base unit.

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The speed of your production line directly controls the starwheel
vector drive motor, which interfaces with the line control module
(LCM) to ensure that no gaps are created at the starwheel infeed.
The production line speed is monitored by the conveyor encoder

that is mounted just under the starwheel, and the conveyor
encoder forces the starwheel vector drive motor to become a
slave to the line speed.
The line control module (LCM) ensures, through special

algorithms, how fast to rotate the starwheel drive motor to
ensure that there is always a slight infeed bottle pressure at the
machine infeed.

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2.52 Vacuum System
2.52.1 Diagram
1
2
No. Description
1 Venturi pump
4
2 Vacuum buffer tank (from the back side)
3 Vacuum filter 5
4 Reject valve
3
5 Vacuum buffer tank (from the front or
starwheel side)
Figure 2-74. Components of the Vacuum System

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2.53 How the Vacuum System Works
2.53.1 Flow Diagram
Figure 2-75. Vacuum System Flow Diagram
2.53.2 Description
Air that is regulated at 80 pounds per square inch (psi) from your
facility passes through a filter.
The air line then splits into two legs.
• The first leg supplies blow off pressure to the reject valve.
• The second leg supplies air to the vacuum generator.
From the vacuum generator, the vacuum air is filtered and split
at the spreader into three legs.

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• The first leg goes into a vacuum buffer and supplies vacuum
to the reject valve.
• The second leg supplies vacuum to the first vacuum port on
the starwheel.
• The third leg supplies vacuum to the second vacuum port on
the starwheel.

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2.54 Valve Plate
2.54.1 Definition
The valve plate is the component in Omnivision III that provides

air and vacuum to the starwheel to hold containers in the
starwheel as they are being inspected.
2.54.2 Diagram
1 2 3 4 5
No. Description
1 Atmosphere
2 Vacuum
3 Reject port vacuum/
pressure
4 Four cap screws
5 Vacuum
6 Air purge, 5 to 7 psig
4 4 6 4
Figure 2-76. Valve Plate

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2.55 Water Control Box
2.55.1 Definition
The water control box, which is located in the lower cabinet of

the outer sidewall unit, regulates and delivers water to various
components on Omnivision III.
2.55.2 Diagram
1 2 3 4
No. Description
1 Water outlet to upstream container washer
2 Outlet to rotating glass water dripper
3 Connector to J373 on the side of the lower
cabinet of the base unit
4 Water supply inlet
Figure 2-77. Water Control Box

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2.56 Auxiliary Subsystems
2.56.1 Definition
The auxiliary subsystems are optional independent inspection

devices that are located upstream from Omnivision III.
You can install from one to two auxiliary subsystems.
You can set up Omnivision III to receive reject signals from these
devices and you can specify that you want to Omnivision III to
perform rejection for these devices.
2.56.2 Examples
An example of an auxiliary subsystem that you can use with

Omnivision III is the filtec Spectrovision inspection system.

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2.57 Rejectors That You Use With
Omnivision III
2.57.1 Description
You use the Proline or Slimline rejector to remove containers

from the product line.
You can also optionally use the filtec Servotec II rejector to sort
and reject containers into lanes and a collection bin in addition
to the standard Proline or Slimline rejector.
Note: The chapter Setting Up Downstream Rejection describes

how to install and configure the Proline and Slimline rejectors.
The filtec document Servotec II Service and Installation Guide,
part number 40777, describes how to install and configure the
Servotec II rejector.
2.57.2 Diagram
Figure 2-78. Proline, Slimline, and Servotec II Rejectors

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2.58 Bottle Position Sensor
2.58.1 Description
You use the bottle position sensor with the Servotec II rejector.
This sensor detects a container as it passes on the reject

conveyor and signals the Servotec II rejector to reject a
particular container depending on its distance from the Servotec
II rejector pad.
2.58.2 Diagram
Figure 2-79. Bottle Position Sensor (Front and Back)

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2.59 Omnivision III Utility Requirements and
Specifications
2.59.1 Omnivision III Utility Requirements
Use this table to determine Omnivision II utility requirements and

specifications.
Utility Requirement Location on Omnivision II Description
Alternating current Access hole, whose diameter Computer grade, 220 volts, that is, a sinusoidal wave
(AC) power measures 1.13 inches or 28.70 form, free from input disturbances, ± 10 percent,
millimeters on the downstream single phase, VAC, 50 or 60 hertz (Hz), at 15 amps
side of your Omnivision II base
unit
Important: You must provide correct
Note: You supply the fitting or power line circuit breakers to protect
conduit connection for this your Omnivision II from input power
hole. damage. Power circuit protection must
adhere to all local electrical codes.
If the AC power that your facility provides exhibits

any of the following AC input disturbances, you must
install a power correction system in addition to the
uninterruptable power supply inside Omnivision II.
1 2
Disturbance Description
Swells The root mean square voltage exceeds
the nominal voltage by 10 percent to
80 percent for 0.5 cycle to one minute
Sags The root mean square voltage remains
below the nominal voltage by 10
percent to 90 percent for 0.5 cycle to
one minute
Flicker Random or repetitive root mean
square voltage variations between 90
percent and 110 percent
Under The nominal voltage drops below 90
voltage percent for more than one minute
Over voltage The nominal voltage rises above 110
percent for more than one minute
No. Description
Spikes Brief increases in voltage due to large
1 Alternating current inductive loads switched on or off or
power connectors due to nearby lightning strikes
2 Access hole, with a Harmonics Variations in waveform shape
1.13 inch or 28.70
millimeter diameter Frequency Brief or chronic variation from the
variations nominal value for the region
Non-zero low When a load draws more power, the
frequency voltage sags
impedance
Non-zero When a load demands a large amount
high of current, then stops demanding it
frequency suddenly, there will be a dip or spike
impedance in the voltage due to the inductance in
the power supply line

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Alternating current
(AC) power Note: filtec offers a regulator option,
(continued) which isolates and conditions the
power and enables you to maintain
tighter control over small variations in
voltage (improve a ± 15 percent
variation to ± 3 percent).
If you purchase this option, your

facility must provide a predictable and
consistent level of power to the
Omnivision II.
This option is not an external

Uninterruptable Power Supply (UPS).
You can also provide your own uninterruptable power

supply (UPS). If you provide your own UPS, your UPS
must:
• Provide an output rating of 220 VAC, 3 kVA, 50

Hz (or 60 Hz as applicable)
• Provide computer grade (isolated and condi-
tioned) power with no greater than a ± 3 percent
variation in voltage
• Adhere to the true-line design, that is, must
incorporate an uninterruptable AC power source
whose load-side power is provided strictly by
means of a battery source that is isolated from
the primary alternating current (AC) line
Important: Although much less

expensive, the non-online type of UPS
system does not provide an acceptable
level of protection and power stability
for Omnivision II.
Water 1/4 inch national pipe thread Omnivision II requires clean water, running at 20
(NPT) bulkhead fitting in the liters per hour (lph) at 276 kilopascals (kPa), or 5.5
water controls box, which you gallons per hour (gph) at 40 pound-force per square
access inside the outer side- inch gauge (psig).
wall unit, if you have one, or
conveyor sidewall if you do not Note: If you are running a heavily lubricated
production line, you might need to provide a higher
flow rate.
Water temperature must be 80 degrees Fahrenheit,

or 27 degrees Celsius.
Note: If you cannot provide water at a constant

temperature of 80 degrees Fahrenheit, or 27 degrees
Celsius, contact filtec Customer Support.
Important: Check your local building

or environmental codes to determine
if you are required to install a check
1 2 valve at the Omnivision II water inlet
to prevent possible contamination of
No. Description local drinking water.
1 Water controls box

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Air 3/8 inch national pipe thread Omnivision II requires clean, dry, compressed air,
(NPT) bulkhead fitting on the preferably 5 cubic feet, or 142 liters, per minute at
interface block SB3, which you 448 kilopascals (kPa), but up to 682 kilopascals (kPa),
access on the downstream side or 8.5 standard cubic feet per minute (scfm) at 65
of your Omnivision II base unit pound-force per square inch gauge (psig), up to a
maximum of 99 psig.
The line that you provide must be at least 0.51

inches, or 13 millimeters, in diameter.
Omnivision II uses a pressure-vacuum converter. If

you configure your Omnivision II to use the vacuum
system at your facility instead of the standard filtec
pressure-vacuum converter, the vacuum
requirements are as follows:
• With starwheel sucker pipes blocked, ensure that

the vacuum ranges from 22 to 26 inches, or 559
to 660 millimeters, of mercury (Hg).
Note: Larger containers require vacuum levels at
the upper end of this range.
• If your facility is located at an altitude higher
than 4,000 feet, or 1,220 meters, the nominal
operating vacuum is approximately 20 inches, or
1 508 millimeters, of mercury (Hg).
No. Description Allow a vacuum loss of approximately 1 inch, or
25.4 millimeters, of mercury (Hg), for every
1 3/8 inch NPT 1,000 feet, or 305 meters, that you increase your
bulkead fitting altitude.
Vacuum level Flow rate

Inches Hg mm Hg Cubic feet Liters per
per minute minute
10 254 5.5 155.7
18 457 4.0 113.3
25+ 635 1.2 34

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Upstream and Interface block SB1, which you The cables, which filtec provides, come with molded
downstream access on the upstream side of connectors at each end.
peripheral sensor your Omnivision II base unit or
connections through the outer sidewall unit,
if you have one, and SB3, which
you access on the downstream
side of your Omnivision II base
unit
1 2
No. Description
1 SB1 interface block,
which you access
upstream
2 SB3 interface block,
which you access
downstream
Operating The minimum operating temperature for Omnivision

temperature II is 32 degrees Fahrenheit, or 0 degrees Celsius.
The maximum operating temperature for Omnivision

II is 113 degrees Fahrenheit, or 45 degrees Celsius.
Note: If you anticipate using Omnivision II in an

operating environment that is above 104 degrees
Fahrenheit, or 40 degrees Celsius, filtec recommends
that you use a vortex cooling system with Omnivision
II.

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Speed of conveyor Omnivision II can handle containers that are up to 65

millimeters diameter at 81000 bottles per hour (BPH)
and containers that are up to 110 millimeters in
diameter up to 50000 BPH.
Figure 2-80. Omnivision III Utility Requirements and

Specifications
2.59.2 Noise Specifications
When installed according to the instructions in this document, at

a one meter, or 3.28 foot, boundary, the Omnivision III generates
less than 80 decibels (dB).
2.59.3 Efficiency Specifications
The machine efficiency is a figure of merit (percentage) that

shows how much operating time is lost due to malfunctions of the
Omnivision III, according to this formula:
ME = (Net measured time - all stops that are caused by a malfunction of the OV-II)
= 99+ percent
Net measured time
Net measured time includes all stops that are not caused by a
malfunction of the Omnivision III.
2.59.4 Container Height and Diameter Requirements
The minimum and maximum height and diameter of containers

that Omnivision III can handle are shown in the following table.
Measurement Minimum Maximum
Diameter 45 millimeters or 114 millimeters or

1.77 inches 4.48 inches
Height 49 millimeters or 380 millimeters or

1.93 inches 14.96 inches
Table 2-1. Container Height and Diameter Requirements
Omnivision III can inspect containers that vary in height up to a

maximum of five millimeters. However, the smaller the variation
in height, the better Omnivision III can reliably and accurately
detect defects and reject containers correctly.

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2.59.5 Conveyor Chain Requirements
Omnivision III uses the production conveyor chain encoder to

drive and reference the starwheel system.
The Omnivision III conveyor section uses a standard 83 milli-

meter, or 3.25 inch, wide table top chain. You can also use a REX
type 815, 820, 863 Tab, 864, 866, 881, 881 Tab, 1873, or 1874
chain.
2.59.6 Conveyor Height Requirements
You specify the height of your conveyor from the top of the chain
to the production floor when you order your Omnivision III.
You can specify a height from a minimum of 953 millimeters, or

37.5 inches, to a maximum of 1511 millimeters, or 59.5 inches in
89 millimeter, or 3.5 inch, increments.
You can also vertically adjust the threaded feet on the bottom of
the Omnivision III an additional 114 millimeters, or 4.5 inches.

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2.59.7 Diagram: Container Handling Rates
Containers
Per hour Per minute
90000 1500
84000 1400
78000 1300 1 2
72000 1200
66000 1100
60000 1000
54000 900
48000 800
42000 700
36000 600
60 70 80 90 100 110
Bottle diameter in millimeters
No. Description
1 Steady state capacity (machine equipped
with an outer sidewall subsystem)
Note: Derate the values in this curve by 15

percent if you inspect fluted containers.
2 Steady state capacity (standard machine
without an outer sidewall subsystem)
Figure 2-81. Container Handling Rate Relative to Container

Diameter

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2.60 How Inspection Subsystems Interact
With Each Other
2.60.1 Block Diagram
Omnivision III employs a number of standard and optional

inspection subsystems that work together to ensure the quality of
your product.
Figure 2-82. How Inspection Subsystems Interact With Each

Other

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2.61 How the Base Subsystem Works
2.61.1 Diagram
The base inspection subsystem uses a high resolution digital

camera and multiple overlapping inspection zones.
Self-checking inspection algorithms ensure accurate defect

detection while maintaining a low false reject rate.
Figure 2-83. How the Base Subsystem Works

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2.62 How the Inner Sidewall Subsystem
Works
2.62.1 Diagram
The inner sidewall subsystem inspects behind labels and scuffing

where the outer sidewall system is blind.
Figure 2-84. How the Inner Sidewall Subsystem Works

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2.63 How the Finish Subsystem Works
2.63.1 Diagram
The chipped finish subsystem inspects the finish of containers for

chips, dings, blemishes, and other defects.
Figure 2-85. How the Finish Subsystem Works

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2.64 How the Thread Inspection Subsystem
Works
2.64.1 Diagram
The thread inspection subsystem inspects twist and roll on pilfer

proof (ROPP) threads of containers using a top view camera, light
emitting diode (LED) lighting, and special custom optics to focus
the camera on the thread and a dedicated high speed image
processor for full thread inspection.
The thread inspection evaluates up to 720 degrees of roll thread

and inspects the full length of all twist thread segments,
providing both thread integrity and thread “unwrap” evaluations.
Figure 2-86. How the Thread Inspection Subsystem Works

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2.65 How the Outer Sidewall Subsystem
Works
2.65.1 Diagram
The outer sidewall subsystem, which is mounted upstream of the

Omnivision III, rotates containers 360 degrees and generates 12
front views of each container and 10 inspection windows per
view.
Figure 2-87. How the Outer Sidewall Subsystem Works

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2.66 How the Bright Field Analyzer
Subsystem Works
2.66.1 Diagram
The bright field analyzer subsystem is a special optical technique

that enhances the overall inspection capabilities of Omnivision III.
Figure 2-88. How the Bright Field Analyzer Subsystem Works

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2.67 How the Infrared Residual Liquid
Subsystem Works
2.67.1 Diagram
The infrared residual liquid subsystem detects even the smallest

amount of water based liquids in containers by measuring the
amount of absorption of infrared radiation by the container.
Figure 2-89. How the Infrared Residual Liquid Subsystem Works

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2.68 How the Radio Frequency Residual
Liquid Detection Subsystem Works
2.68.1 Diagram
The radio frequency residual caustic detection subsystem

generates a high frequency radio signal through the base area of
the container that a receiver on the other side of the container
receives and measures.
Omnivision III reliably can detect even a single drop of caustic

carryover or dry caustic film by the change in this high frequency
radio signal.
Figure 2-90. How the Radio Frequency Residual Liquid

Detection Subsystem Works

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2.69 How Base Inspection Works
2.69.1 Diagram
1
2
3 7
4 5 6
No. Description
1 Outer rim on the image
2 Middle rim on the image
3 Center on the image
4 Outer rim from the base
5 Middle rim line from the base
6 Center line from the base
7 Polarization system, for the inspection
of transparent cellophane plastic
8 Protective window
Figure 2-91. How Base Inspection Works
2.69.2 Description
A camera acquires and processes the image of the base of a

container.

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The Omnivision III inspection software examines up to six
independent zones, which themselves are divided into segments
and radials.
By employing two polarizing filters, which comprises the bright

field option, Omnivision III can also detect the presence of trans-
parent plastic or cellophane.
2.69.3 Guidelines for Determining Segments and Radials

in a Zone
All inspections that Omnivision III performs require a radial and a

segment parameter. To obtain maximum resolution, the
parameter values that you specify for segments and radials are
dictated by the size of the inspection zone.
• When setting up inspection zones, use these calculations to

obtain the correct values for center or bottom.
Segments = 1.4 * (outer radius - inner radius of the container)
Radials = 8.8 * outer radius of the container
When a zone does not have an inner radius, Omnivision III
ignores the segments and radials because all pixels are
collected in the inspection process.
• You can configure the base for up to five discrete inspection
zones, but at a minimum of four, ensure that the base
inspection zone is made up of three concentric inspection
zones, called the center, middle, and outer zones.
• Align these zones to the center of the container.
• Ensure that the container is absolutely center of the camera
lens system when the strobe and camera are triggered to
capture a digitized image of the container.
• Center the inspection zones on the container when you pin
the starwheel pocket.
You can enable the remaining two inspection zones, if necessary,

to accommodate additional specific inspection requirements.
You specify these centering adjustments (horizontal position and

vertical position) on the screen that you use to configure the
camera and display.
Once you specify the centering adjustments you no longer need

to adjust these settings to compensate for other problems that
arise due to the mechanical alignment, triggering, and similar
functions of Omnivision III.

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2.69.4 Images That Base Inspection Captures
Figure 2-92. Images That Base Inspection Captures

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2.70 How Inner Sidewall Inspection Works
2.70.1 Diagram
1
2
3
No. Description
1 Upper inner sidewall on the image
2 Middle inner sidewall on the image
3 Bottom inner sidewall on the image
Figure 2-93. How Inner Sidewall Inspection Works
2.70.2 Description
A camera acquires and processes the image of the inner sidewall

of a container.
The Omnivision III inspection software examines up to six

independent zones placed on the image of the container to
maximize inspection versatility.

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When Omnivision III inspects the inner sidewall, it inspects both
the base of the container (as a backup system of the base
inspection subsystem) and the inner sidewall of the container.
Omnivision III analyzes the inner sidewall by evaluating the light

that is reflected from the inside of the container.
Omnivision III inner sidewall inspection also analyzes light levels,

which enable Omnivision III to recognize and reject containers
that contain dark areas, bright areas, or blocked areas, as well as
By employing two polarizing filters, which is known as the bright

2.70.3 Image That Inner Sidewall Inspection Captures
Figure 2-94. Image That Inner Sidewall Inspection Captures

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2.71 How Finish and Thread Inspection Work
2.71.1 Diagram
No. Description
1 Parabolic mirror
2 Light source for finish
inspection, which includes two
independent light emitting
diode rings, which is indicated
by the red arrows
3 Mirrors for thread inspection 2
4 Light source for thread 1
inspection, which is indicated
indicated by the green arrows)
Figure 2-95. How Finish and Thread Inspection Work
2.71.2 Description: Finish Inspection
A camera acquires and processes the 360 degree measurement of

the image of the press, roll, or twist finish of a container, and
looks for chip defects, cracked areas, and underchip defects.
Light from the long life light emitting diode strobe reflects off of
the sealing surface. The resulting image is a thin luminous circle.

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The light emitting diode strobe unit is capable of three modes of
operation that enable one or both of two independently
controlled rings to flash. This flash enables you to optimize the
setup of the light return characteristics for each type of
container.
2.71.3 Image That Finish Inspection Captures
Figure 2-96. Image That Finish Inspection Captures
2.71.4 Description: Thread Inspection
Thread inspection directs light through the container, which exits

through the finish threads. This light is transferred onto the
conical mirror arrangement of the thread inspection optics.
Thread inspection uses the light transmitting characteristics of

the container by using a light emitting diode strobe underneath
the container and evaluating the emitted light of the threads.
The threads appear as a spiral on the camera image.
2.71.5 Images That Thread Inspection Captures
Figure 2-97. Images That Thread Inspection Captures

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2.72 How Outer Sidewall Inspection Works
2.72.1 Diagram
No. Description
1 Light source
2 Mirror at 45 degrees
Figure 2-98. How Outer Sidewall Inspection Works
2.72.2 Description
A backlight passes light through each container as it passes

through Omnivision III on the conveyor. A mirror, which is angled
at 45 degrees, reflects the light into a high speed, digital high
resolution camera.
This camera then captures 12 views of each container as

Omnivision III rotates the container 360 degrees.

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By employing two polarizing filters, which is known as the bright
2.72.3 Image That Outer Sidewall Inspection Captures
Here are the types of images that outer sidewall inspection

captures.
Figure 2-99. Image That Outer Sidewall Inspection Captures

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2.73 How Infrared Residual Liquid Detection
Inspection Works
2.73.1 Diagram
1
No. Description
1 Infrared light (IR) detector
and signal amplifier 2
2 Lensing system, which filtec
has designed to concentrate
on the area of the base of
the container where most
residual liquid collects
3 Bottom light source, which
produces infrared light
energy that water or other
liquid collected in the base
attenuates
Figure 2-100. How Infrared Residual Liquid Detection Inspection

Works
2.73.2 Description
Omnivision III performs infrared residual liquid inspection at the

same time that it performs base and inner sidewall inspection.
Infrared residual liquid inspection also uses the same triggering
circuitry, zoom lens, and strobe light source assembly (which
emits both visible and infrared energy) that the base and inner
sidewall camera assemblies use.

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From below, Omnivision III illuminates the base of the container
with infrared light. Any liquid, such as water, oil, paint, or
varnish inside the base absorbs this infrared light.
The infrared detector includes a mask in the middle that blocks

light that emanates from the center of the container. Most
containers have a raised center in the base and, as a result, liquid
forms a ring in the base of the container.
Omnivision III employs an infrared sensor that is located inside

the inspection head to measure the incoming quantity of infrared
light. Excessive liquid levels transmit significantly less infrared
energy and can therefore be detected.
The Omnivision III infrared residual liquid detection inspection

system then evaluates the signal from the sensor and if the
measured value falls below a threshold value that you specify,
Omnivision III registers a fault and Omnivision III subsequently
activates the rejection system.
Because infrared residual liquid does not use video, Omnivision III
automatically displays the base image when you display the
infrared residual screens.
The base strobe light includes the infrared wavelength to which

the infrared photocell is sensitive. When a container is empty, a
great amount of the infrared wavelength reaches the photocell
and a large signal count is generated.
When a container contains liquid, the liquid absorbs the infrared

wavelength and a smaller amount of the infrared wavelength
reaches the photocell and a smaller signal count is generated.
When the signal count is above a certain level, or above a

threshold count, Omnivision III deems the container good. If the
signal count drops below the threshold count, Omnivision III
deems the container bad and rejects it.

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2.74 How Radio Frequency Residual Liquid
Detection Inspection Works
2.74.1 Diagram
No. Description
1 Radio frequency transmitter
2 Radio frequency receiver
1 2 1 2
Container without Container with 2 milliliters

caustic liquid in it of aqueous solution of caustic,
0.5 percent concentration
Figure 2-101. How Radio Frequency Residual Liquid Detection

Inspection Works
2.74.2 Description
Omnivision III performs radio frequency residual liquid inspection

upstream of base inspection and downstream from the outer
sidewall, in other words, between base inspection and the outer
sidewall.
First, the container passes between the high frequency trans-

mitter and receiver.
The transmitter delivers a radio signal of fixed frequency.
The receiver converts the radio signal to a proportional pulse

width modulated (PWM) signal for the line control module (LCM)
to examine.

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A normal container causes a small attenuation in the radio signal
that correlates to a smaller pulse-width reading at the LCM.
A container that contains caustic (NaOH) material causes a signif-

icant attenuation in the radio signal that correlates to a much
smaller pulse-width reading at the LCM.
The line control module (LCM) of Omnivision III checks this pulse
width and compares it to the detection threshold that you specify
on the screen, which is described later.
If the value that Omnivision III measures falls below the limit
value that you specify, Omnivision III registers a fault and
activates the rejector.
The reference point that Omnivision III uses for this inspection is
the base trigger. Omnivision III waits for the container to get to
the radio frequency inspection point (that is, the value that you
specify in the Trigger Offset field on the
screen) and inspects the width of the bottle, which you specify in
the Inspection Window field on the
screen, which is described later.
The distance from the radio frequency inspection point to the

base inspection point is measured in number of containers, which
you specify in the Bottle Delay field on the
screen, which is described later.

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2.75 Comparison of IR and RF Residual Liquid
Detection
2.75.1 Diagram
Radio Frequency Detection of Residual Liquid

Infrared
(Logarithmic scale)
Relative Sensitivity
Figure 2-102. Comparison of Effectiveness of IR and RF Residual

Liquid Detection

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3. Turning On and Turning Off
Omnivision III
This chapter tells you how to use the stop buttons and main
power switch to turn on and turn off Omnivision III.
Turning On and Turning Off Omnivision III 3-1

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3.1 Turning On Omnivision III
3.1.1 Steps
Follow these steps to turn on Omnivision III.
1. Ensure that both emergency stop buttons are pulled out.
Caution: Omnivision III comes equipped with two emergency

stop buttons, which are located on the front and rear left
corners of the base unit.
Both buttons are identical and have lighted push buttons. The
buttons are in the released or “pulled out” position during
normal operating conditions.
Under emergency conditions, you push in either button to stop
the starwheel and the reject takeaway conveyor.
The red light on each push button indicates that the button is
activated. You can release the buttons by twisting them to the
right or pulling them out to the normal operating position.
2. Does your company maintain a lock out, tag out policy?
If yes, remove the lock from all (up to three) lock out, tag
out slots.
Note: The section Main Power Switch and Emergency Stop

Button contains more information about these buttons and lock
out, tag out locks.
If no, go to the next step.

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3. At the base unit, turn the red main power switch clockwise
from the off position to the on position.
Result: Omnivision III starts. After a few minutes,

Omnivision III displays the screen on the
monitor station screen.
Turning On and Turning Off Omnivision III 3-3

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3.2 Turning Off Omnivision III
3.2.1 Steps
When you are finished using Omnivision III or when you need to
perform maintenance or an upgrade, follow these steps to turn
off Omnivision III.
1. At the base unit, turn the red main power switch counter-
clockwise from the on position to the off position.
Result: After you turn off the red main power switch:
• The signal beacon power indicator goes off.

• For three to five seconds, in the diagnostics message
area at the bottom of the monitor station screen,
Omnivision III displays the message On Battery.
• The Omnivision III software closes.
• Omnivision III displays a shut down message on the
monitor station screen.
• Omnivision III shuts down the operating system.
• Omnivision III displays a blue screen for up to 20
seconds.
Important: During this period of time, Omnivision III continues

to power the card cage inside the inspection head.
• The Omnivision III monitor station goes off and

Omnivision III turns off all power.
2. Does your company maintain a lock out, tag out policy?
If yes, insert a lock into at least one or all three lock out,
tag out slots.
If no, stop, as you have successfully turned off Omnivision

III.

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4. Installing Omnivision III
This chapter tells you how to install and connect utilities to your
Omnivision III.
Installing Omnivision III 4-1

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4.1 Guidelines to Follow As You Install
Omnivision III
4.1.1 Before You Begin
Before you install Omnivision III, read and understand all instruc-
tions and referenced drawings in this chapter.
Also, to ensure that you use the latest drawing updates, check
the configuration sheet that filtec ships with Omnivision III.
Caution: Do not turn on your Omnivision III after you finish

installing it. Ensure that an authorized filtec representative
turns on your Omnivision III.
4.1.2 Guidelines
A correctly installed Omnivision III promotes long-term, trouble

free operation. When installing Omnivision III, follow these
guidelines.
• Keep the shipping crate or crates horizontal as you move

them to the area in which you intend to install them.
If you must stand them up, ensure that they do not strike any
objects, such as service pipes or lighting, hanging from your
facility’s ceiling.

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4.2 Determining the Space That You Need
for Omnivision III
4.2.1 Determining the Floor Space That You Need for the
Shipping Crates
The base unit ships in one crate. The optional outer sidewall
(OSW) unit ships in a separate crate. Use this chart to ensure that
you have enough room to receive, move, and store the
Omnivision III shipping crates at your facility.
Omnivision III Length Width Depth

system
Base unit 2.29 meters 2.14 meters 1.41 meters
90.16 inches 84.25 inches 55.51 inches
Outer sidewall 2.29 meters 1.29 meters 1.40 meters

unit
90.16 inches 50.78 inches 55.12 inches
4.2.2 Determining That You Can Lift the Shipping Crates
The shipping crate in which the base unit weighs a minimum of

approximately 1362 kilograms, or 3003 pounds.
The shipping crate in which the optional outer sidewall unit

weighs a minimum of approximately 273 kilograms, or 602
pounds.

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4.2.3 Diagram: Determining the Space for the Base Unit
1
3 6
No. Description
1 Infeed
2 Machine length, which measures 0.85 meters or 33.46 inches
3 Machine width, which measures 0.97 meters or 38.19 inches
4 Service access, which measures 0.92 meters, or 36.22 inches, all sides
5 Minimum length, floor space, which measures 2.68 meters or 105.51 inches
6 Minimum width, floor space, which measures 2.80 meters or 110.23 inches
Figure 4-1. Determining the Floor Space for the Base Unit

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4.2.4 Diagram: Determining the Space for the Base Unit
and OSW Units
1
3 6
Outer Sidewall Base Unit

Unit
No. Description
1 Infeed
2 Machine length, which measures 1.70 meters or 66.93 inches
3 Machine width, which measures 0.97 meters or 38.19 inches
4 Service access, which measures 0.92 meters, or 36.22 inches, all sides
5 Minimum length, floor space, which measures 3.53 meters or 139 inches
6 Minimum width, floor space, which measures 2.80 meters or 110.24 inches
Figure 4-2. Determining the Floor Space for the Base Unit and
OSW Units

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4.2.5 Calculating the Height That You Need for
Omnivision III
Omnivision III Component Meters Inches
Bottom of the lower cabinet of the base unit 2.28 89.76

to the top of Omnivision III, including
support columns and lamps
Clearance at the top for servicing +0.92 +36.22

Omnivision II
Length of the Omnivision III legs and See your See your
extensions configuration configuration
sheet for this sheet for this
information information
Total height required See your See your

configuration configuration
sheet for this sheet for this
information information

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4.3 Unpacking Omnivision III
4.3.1 Introduction
The crate that contains the base unit includes the base machine,
which is shipped in a horizontal position, and all other
unassembled parts, such as the starwheel, guide assemblies, and
the reject takeaway conveyor. The machine is attached to a rigid
wood frame and is secured with strong banding straps.
The crate that contains the optional outer sidewall unit also ships
in a horizontal position and includes all other unassembled parts.
The optional outer sidewall unit is mounted on a rigid frame, but
the outer sidewall unit is not attached to the frame.
Mounting hardware such as bolts, nuts, and lock washers are

either:
• Bagged in plastic and taped to the component on which they

are used, or
• Installed at the time of shipment and require temporary
removal while reassembling components
Ensure that you have the following items before you begin.
• All Omnivision III installation drawings

• A fork or pallet lift
• Two or more rubber or no-skid pads, which measure at least a
meter or a yard long
• Four support legs and jam nuts for the base unit
• Two support legs and jam nuts for the optional outer sidewall
unit, if you ordered it
4.3.3 Steps
Complete these steps to unpack the base unit and the optional
outer sidewall unit.
1. Place the rubber or no-skid pads at the spot where you

intend to position the pallets, as close as possible to the
spot where you intend to position Omnivision III.

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2. Move the crate that contains the base unit, and the optional
outer sidewall unit, if you ordered it, as close as possible to
the spot where you intend to position it.
Note: Ensure that you correctly position the pallet on the

rubber or no-skid pads, that is, at the base or bottom end of
the base unit and outer sidewall unit.
3. Strip away all packing material and carefully inspect it to

ensure that you do not throw away any parts.
4. Attach the four support legs and jam nuts to the base of the
base unit and adjust the back support legs to their shortest
possible height.
5. If you also have the optional outer sidewall unit, attach the
two support legs and jam nuts to the base of the heavier
side of the optional outer sidewall unit, that is, the side on
which the outer sidewall tunnel is located.
Note: The other, lighter side connects to the base of the

base unit and so does not need support legs.
6. Check all parts against the shipping documents.
Note: If any parts are missing or incorrect, or if damage

occurred during shipment, immediately notify the freight
company and contact filtec Customer Support.
7. Store all unassembled parts in a safe place until you need to

install them later.
Note: Do not remove the pallets, banding straps, braces, or

safety securing boards, or unbolt any items that secure the base
unit or optional outer sidewall unit. These pallets, straps,
braces, boards, and bolts keep the machine stable as you raise
it to an upright position.
Note: Do not use the conveyor segments to maneuver the base

unit as you move it to its final position.

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4.4 Raising the Base Unit and Outer Sidewall
Unit

• Chains, strong cables, nylon moving straps, ropes, or slings
capable of lifting over 1362 kilograms, or 3003 pounds
• Five to ten large wooden blocks
• Rubber or no-skid pad
• Four support legs and jam nuts for the base unit
• Two support legs and jam nuts for the optional outer sidewall
unit, if you ordered it
• Optional extension legs, if you ordered them
4.4.2 Steps
Complete these steps to raise the base unit and optional outer
sidewall unit to an upright position.
1. Remove all other boxes, containers, and components.
Caution: Do not attempt to raise the base unit or optional outer

sidewall unit by the door support columns.
2. Insert as many large wooden blocks as you can between the

back support legs and under and butt against the base of the
base unit and outer sidewall unit.

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3. Carefully loop a cable or chain through the holes that filtec
has drilled into the pallet’s support beams, and loop the
other end of the cable or chain to your fork or pallet lift.
Base Unit or Main Machine
A 1 2
9 3
4
8
5
A 6 No. Description
7 1 Unit attached to the pallet
2 Support legs, four for the base
unit, two for the outer
sidewall unit
AA
3 Attached wooden blocks, two
for each unit
4 Pallet
5 Rubber or no-skid pad
6 Base unit support beams and
blocks
7 Straps
8 8 Chain or other cable through

hole for lifting and stability
9 Fork or pallet lift
1
Outer Sidewall Unit
3
9
4
8
5
Figure 4-3. Preparing to Raise the Base Unit and OSW

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4. A few inches at a time, gradually raise the pallet off the
floor.
Base Unit
Outer Sidewall Unit
Figure 4-4. Raising the Base Unit and OSW
Note: Keep the pallet as stable as possible.
Caution: As you raise the pallet a few inches at a time, also

move the fork or pallet lift forward a few inches at a time as
well. Ensure that the pallet does not bounce, rock, or lunge
forward when you get close to raising it fully upright.

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5. When you have raised the pallet high enough to make it easy
to maneuver, carefully maneuver the pallet into a
completely upright position.
9
8
No. Description
4 Pallet
8 Chain or other cable through
hole for lifting and stability
4 9 Fork or pallet lift
B B
Figure 4-5. Raising the Base Unit and OSW to an Upright

Position
6. Adjust all support legs until they match in height.
Caution: Do not remove the wooden blocks under the base of

the base unit or optional outer sidewall unit until you have
permanently installed the units on your production line.

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7. Detach and remove the pallet.
8. Cut and remove all banding straps, support and packing

materials, temporary ties, and the cover to the inspection
head.
Caution: Once you raise the base unit and optional outer
sidewall unit to an upright position and you cut the banding
straps, you can no longer lower the base unit and optional outer
sidewall unit to a horizontal position.
9. Do you want to install the optional extension legs?
If yes, slide the fork or pallet lift under the wooden blocks
that are attached to the base of the unit and lift it high
enough to unscrew the support legs and screw in the
extension legs.
Base Unit Outer Sidewall Unit
Figure 4-6. Lifting the Base Unit and OSW After Raising Them
Upright
10. Using the fork or pallet lift, transport the upright unit to the
point on the conveyor in which you intend to install
Omnivision III.

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4.5 Installing Omnivision III on Your
Production Line
4.5.1 Introduction
Now that you have unpacked, raised, and moved your Omnivision
III to the approximate location at which you intend to install it,
you are ready to install Omnivision III on your production line.
This section tells you how.

• Level
4.5.3 Steps
Complete these steps to install the Omnivision III base unit and
outer sidewall unit on your production line.
1. Separate or “break” the production conveyor chain.
2. Are you installing the base unit only or both the base unit
and outer sidewall unit?
If only the base unit, install supports under both sides of the
conveyor, approximately 0.9 to 1.2 meters, or 3 to 4 feet
from the center line of the starwheel.
If both the base unit and outer sidewall unit, install

supports under both sides of the conveyor, approximately
0.9 to 1.2 meters, or 3 to 4 feet upstream from the outer
sidewall unit and downstream from the center line of the
starwheel.
Note: The base unit and outer sidewall unit are not designed to
support a production conveyor.

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3. Using the applicable filtec installation drawing listed in the
table below for reference, cut out a section from your
conveyor.
If you intend to install a... Then refer to drawing...
Right handed Omnivision III I00801
Flow
Right-hand Reject
conveyor
Operator side
Left handed Omnivision III I00802
Flow
Reject Left-hand
conveyor
Operator side
4. Move the base unit into position on the conveyor line.
5. Raise the base unit to its highest position.
6. Lower or heighten the base unit by turning the threaded

support or optional extension legs until the base unit
conveyor stub matches the height of your production
conveyor.
Important: Ensure that you evenly distribute the load on each

support leg.
7. Position the outer sidewall unit on the upstream side of the

base unit so that the outer sidewall tunnel is facing away
from the base unit.
8. Push the lower cabinet of the outer sidewall unit against the
lower cabinet of the base unit so that the screw holes line
up.

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9. Insert the four bolts through the matching holes in both of
the lower cabinets, but do not tighten them at this time.
10. Lower or heighten the outer sidewall unit by turning the

threaded support or optional extension legs until the outer
sidewall conveyor stub matches the height of the base unit
conveyor stub as well as your production conveyor.
Important: Ensure that you evenly distribute the load on each

support leg.
11. Using the four conveyor splice plates for the base unit and
the two conveyor splice plates for the outer sidewall unit,
bolt, but do not tighten, all conveyor stubs together.
Note: If the height of the bottom return of the conveyor

channels do not match, use the optional brass wear plates
and mounting hardware that filtec provides to guide the
chain into the base unit and outer sidewall unit conveyor
stubs.
12. Adjust the height of the base unit and outer sidewall unit
and conveyor stubs so that all wear strips line up correctly.
Best Practice: Use a straight edge and a level to verify that

they line up.
13. Turn the support or optional extended legs on both the base
unit and outer sidewall unit until the top surface of each
lower cabinet is level and both the base and outer sidewall
units are flush with each other.
14. Tighten all jam nuts on the support or optional extended

legs, the bolts that hold the lower cabinets together, and
the bolts that hold the conveyor splice plates together until
snug.
15. Remove the wooden blocks from under the lower cabinets.
16. Install the two brace panels that hold the top of the outer
sidewall and base unit door support frames together.
17. Check the junction of the outer sidewall unit and the base
unit conveyor stubs with each other and with the production
conveyor system to ensure that there is smooth conveyor
chain transition through the base unit and outer sidewall
unit.

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18. Relink the production conveyor chain.

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4.6 Installing the Starwheel
4.6.1 Steps
Complete these steps to install the starwheel.
1. Ensure that the seal ring inside the starwheel is correctly

seated and clean, and wipe with a damp cloth if necessary.
2. Ensure that the valve plate, where the seal ring is seated on
the spindle assembly on the lower cabinet of the base unit,
is clean.
Important: If it is not clean, the starwheel does not work

correctly.
3. Make sure that the springs under the valve plate allow the
plate to return when you press on the valve plate assembly.
Ensure that the plate does not catch when the plate comes
back up.
4. Place the starwheel on the shaft.
5. Engage the starwheel and spindle shaft registration plates

by completing these steps:
a. Press the emergency stop button.
b. Pull out the emergency stop button on both sides of

your Omnivision III.
Caution: Ensure that you pull out both emergency stop buttons
on your Omnivision III.
c. Gently rotate the starwheel until it drops into place.
6. Securely tighten the starwheel T knob.

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4.7 Installing Container Guides and Belts
4.7.1 Steps
Complete these steps to install the container guide.
1. Attach the guide rails.
2. Ensure that the guide rails on the outer sidewall are parallel
and securely attached to the guide rails on the base unit.
3. Ensure that containers flow correctly between the guide

rails.
4. Ensure that the containers overlap uniformly inside the

outer sidewall tunnel.
5. Ensure that you correctly attach the Omnivision III guide

rails to your production guide rails.
Best Practice: Use sample containers from a production

float to adjust the spacing of the guide rails.
Ensure that the guide rails allow a smooth, continuous

container flow into the outer sidewall tunnel and through
the base unit with no container gapping.
6. Cut the production conveyor rails so that they clear the

infeed and outfeed guide rails by 0.118 to 0.20 inches, or 3
to 5 millimeters, to avoid container handling problems.
7. Ensure that the conveyor rails are supported firmly so that

they cannot flex where they meet the Omnivision III guide
rails.
8. Install the green container guide belt on top pulleys and the
orange container guide belt on the bottom pulleys and
ensure that they are level.

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4.8 Installing Optional Reject Conveyor and
Guide Assemblies
4.8.1 Steps
Install the reject conveyor and guide assemblies according to the

drawing I00801 or I00802 for your particular configuration.

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4.9 Attaching the Reject Conveyor
Before you being, obtain the following tools:
• Tape measure that extends at least 10 feet or 3 meters

• Permanent marker
• Level
• Adjustable wrench or wrench set
4.9.2 Steps
Complete these steps to attach the reject conveyor.
1. Slide the reject conveyor into place so that the adjustment

slots align with the threaded holes in the bracket.
No. Description
1 Threaded hole
2 Adjustment slot
1 2 1 2 1 2
Slide the reject
conveyor into place
2. Insert the washers and bolts underneath the conveyor and

finger tighten them.
3. Adjust the height of the reject conveyor so that it aligns

correctly with the dead plate and your conveyor.

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4. Insert the washers and bolts into the bracket underneath the
conveyor and finger tighten them.
No. Description
1 Bolt
2 Adjustment slot
3 Bracket
1 2 3
5. Ensure that the conveyor is level, correctly positioned, and

correctly adjusted so that the dead plate is not obstructed.
Note: The reject conveyor must be level. If the reject conveyor

is not level, you might not be able to adjust the dead plate
correctly.
6. Using a permanent marker, mark the floor at which you

intend to drill the 3/8th inch floor sleeve anchors.
7. At each of the marks that you made on the floor, using a

power drill and a 3/8 inch drill bit, drill holes for the 3/8
inch floor sleeve anchors.
8. Attach the sleeve anchors.
9. With a wrench, tighten all bolts.

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4.10 Installing Splice Plates Between a
Production Conveyor and Omnivision III
4.10.1 Steps
Install the splice plates, which filtec provides with the reject
takeaway conveyor, between your production conveyor and the
reject takeaway conveyor according to the diagram here and
either drawing I00801 or I00802 for your configuration.
Figure 4-7. Installing Splice Plates
Note: The splice plates provide stability to the reject conveyor.

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4.11 Installing the Upstream Container
Washer Assembly
4.11.1 Diagram
Refer to this diagram as you follow the steps in this section.
2
4
5
3
No. Description
1 Upstream container washer
2 Water spray
3 Mounting bracket
4 Mounting angle, which is approximately 15 to 20 degrees
5 Container washer water line
Figure 4-8. Aligning the Upstream Container Washer
Before you begin, obtain the following tools:
• Tape measure that extends at least 10 feet or 3 meters

• Masking tape or permanent marker that marks stainless steel
satisfactorily
• Level
• Electric drill with 3/8 inch bits

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4.11.3 Steps
Complete these steps to install the upstream container washer

assembly.
1. On either side of the production conveyor, using the tape

measure, identify the location on the conveyor wall where
you intend to attach the mounting bracket for the upstream
container washer, according to this chart.
If you are installing the... Measure and mark...
Base unit only Approximately 1532 millimeters, or

60.31 inches from the center line of the
starwheel
Both the base unit and the Approximately 2438 millimeters, or 96

outer sidewall unit inches from the center line of the
starwheel
2. At the location you measured, hold the mounting bracket

against the conveyor wall and mark the location of the
mounting bracket holes on the conveyor wall.
3. Drill holes in the conveyor wall at the locations you marked.
4. Attach the bracket, the bolts, the nuts, and tighten the nuts
firmly.
5. Attach the container washer to the bracket.
6. Align the nozzle of the container washer slightly upstream

into the flow of containers, and at a downward angle of
between 15 and 20 degrees at the point at which the
container heels touch the conveyor chain.
7. Connect the container washer water line to the water outlet

on the side of the Omnivision III water control box.
Note: If your Omnivision III includes an outer sidewall unit, the

water control box is located inside the outer sidewall lower
cabinet.

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4.12 Mounting the Sonic Sensor Assemblies
and Washer
4.12.1 Diagram
Refer to Figure 4-9 and one of the following installation drawings

as you follow the steps in this section.
• Right hand Omnivision III I00801

• Left hand Omnivision III I00802
3
4
5
1 2
No. Description
1 Sensor sensor 1 (start/stop)
2 Sensor sensor 2 (modulate)
45°
30° 3 Container washer
Right hand 4 Down and jam sensor

5 Production conveyor
3 6 Container flow
4 5
Left hand
2 1
45°
30°
Figure 4-9. Mounting the Sonic Sensors and Washer

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4.12.2 Guidelines
Keep these guidelines in mind as you mount the sonic sensor

assemblies.
1. If your Omnivision III includes an outer sidewall unit, ensure

that you mount the sonic sensor 1 on the conveyor that
feeds directly into Omnivision III, a minimum of 9.25 feet, or
2.82 meters, and a maximum of 18 feet, or 5.49 meters,
2. If your Omnivision III does not include an outer sidewall unit,

ensure that you mount the sonic sensor 1 on the conveyor
that feeds directly into Omnivision III, a minimum of 7 feet,
or 2.13 meters, and a maximum of 15 feet, or 4.57 meters,
3. Mount the sonic sensor 2 3 feet, or 0.91 meters, closer to

the starwheel than the distance at which you mounted sonic
sensor 1.
4. You can mount the sonic sensor 1 transmitter or receiver on

either side of the conveyor. The position in relation to
oncoming containers does not matter.
4.12.3 Steps
Complete these steps to mount the sonic sensors.
1. Do you need to position the sensors further upstream than is

indicated in the installation drawing for your particular
configuration (I00801 or I00802?
If yes, extend the wire.
Note: When you extend the sonic sensor cable, ensure that you
use filtec sensor cable sets or an equivalent cable.
2. Mount the two sonic sensor assemblies as shown in your

installation drawing and in Figure 4-9.

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4.13 Adjusting the Air Knife Blow Off
Assembly
4.13.1 Steps
Complete these steps to adjust the air knife blow off assembly.
1. To raise or lower the air knife blow off assembly, loosen the
two bolts that secure it in place, as shown here.
No. Description
1 Loosen these bolts
2 Needle valve air
adjustment knob
2. Adjust the air valve so that all soap and water is removed
from the base of the container.
Best Practice: Make sure that you do not turn the air so high
that the air knife blows soap or water onto the base or finish
lens assemblies.
3. Set the height of the top of the air knife to just below the
dead plate.
Best Practice: Make sure that you do not raise the air knife
so high that containers collide with the air knife, back up,
and jam the conveyor.

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4.14 Installing the Rotating Diffuser and
Glass
4.14.1 Steps
Complete these steps to install the diffuser and glass.
1. Loosen the thumbscrew on the rotating brush assembly

column.
2. Lift and remove the brush assembly.
3. Lift and pull out the rotating glass blow off assembly and lay
it safely on top of the lower cabinet of the base unit.
4. Carefully remove the rotating glass from its packaging.
5. Gently slide the rotating glass (diffuse side up), at an angle,

from the direction of the door support column, onto the
drive spindle.
6. Set the nut and the washer group on and screw it down
finger tight.
Best Practice: Do not use a wrench.
7. Install the rotating glass blow off assembly by aligning it

with its mounting slots and pushing it down in place.
8. Attach the rotating brush.
Best Practice: Ensure that it bottoms out correctly on its

support post and set it so that the brush does not touch the
washer on the diffuser and glass disk.
9. Tighten the thumbscrew tightly.

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4.15 Installing the Mirror on the Optional
Outer Sidewall Unit
4.15.1 Steps
Complete these steps to install the mirror on the optional outer

sidewall unit.
1. Remove the cover to the outer sidewall camera.
2. Loosen the screws on the two side brackets that hold the
mirror in place.
Note: You do not need to remove the brackets.
No. Description
1 2
1 Rails without mirror
2 Rails with mirror and
brackets installed
3. Lift up the brackets and gently slide the mirror all the way
onto the rails.
Caution: You must angle the mirror quite sharply to get it into
the outer sidewall unit cabinet. Be extra careful not to bend
the mirror or plate, as bending can crack the mirror.
4. Gently push the brackets down to sandwich the mirror.
5. Tighten the screws.

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6. Clean the mirror with lens tissue or a soft cloth.
Caution: Do not use caustic or abrasive cleaning fluid.
7. Replace the cover to the outer sidewall camera.

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4.16 Attaching the Polycarbonate Doors
4.16.1 Steps
Complete these steps to attach the polycarbonate doors that

enclose the Omnivision III.
1. Pick up and lift each polycarbonate door carefully and align

the hinges with the matching hinge post on the column of
the Omnivision III.
No. Description
1 Hinge post
2. Lower the door into place on the hinge posts.
Note: No fasteners or screws are required.
3. Ensure that the door locks are in place.
No. Description
1 Door lock

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4.17 Connecting Air to Your Omnivision III
4.17.1 Introduction
The air tubing connection, which you use to connect air to your
Omnivision III, is located in the lower cabinet of the outer
sidewall unit.
Best Practice: Connect a 13 millimeter or wider diameter air

supply pipe to Omnivision III.
4.17.2 Diagram
Refer to Figure 4-10 as you complete the steps in this section.

No. Description
1
1 Lower cabinet, downstream, left
hand, upstream right hand
2 Lower cabinet, upstream, left hand, 2
downstream right hand
3 Quick connect ports: 3
• J344=Downstream down container
• J345=Downstream gap
• J347=Bottle position sensor
• J368=Air knife blow off assembly
• J371=High container
• J372=Down container
• J373=Water control box
• J374=RF residual liquid detection
receiver 4 7
• J375=RF residual liquid detection
transmitter 5 8
• J376=Sonic sensor 1 6
• J377=Sonic sensor 2
• J386=Crossover sensor
• J387=Encoder #3
• J388=Rejector (ram #2)
• J389=Rejector (ram #1)
• J394=Thread blow off sensor
• J395=Thread blow off #1
• J396=Thread blow off #2
• J397=Auxiliary input
4 Air inlet
5 Servotec II rejector conduit
6 Motorized reject tray conduit
7 Outer sidewall camera conduit
8 Outer sidewall lamp conduit
Figure 4-10. Utility Connections on the Lower Cabinet of the

Base Unit

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4.17.3 Steps
Complete these steps to connect air to your Omnivision III.
1. Using tubing whose inner diameter measures a minimum of

13 millimeters or 0.51 inches, connect the air supply line to
a stub near your Omnivision III.
2. Install a manual shut off valve at the stub.
3. Install a length of flexible plastic air line at the valve long

enough to reach the labeled air inlet fitting on the lower
cabinet of the base unit, as shown in Figure 4-10.
4. Purge the air line.
5. Do you expect that your facility’s air supply might be

contaminated?
If yes, attach a high-volume air filter to the air line between

the labelled Omnivision III air inlet fitting and your air
supply.
6. Connect the air supply to the labeled air inlet fitting.
7. Momentarily open the valve and inspect the tubing and all
connections for leaks, and if you find one, repair it and
repeat this step until all leaks are repaired.
Note: Omnivision III also uses the air supply to produce a

vacuum through the pressure and vacuum converter inside the
lower cabinet of the base unit. You do not need to make
vacuum connections.

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4.18 Connecting Water to Your Omnivision III
4.18.1 Steps
Complete these steps to connect water to your Omnivision III.
1. Obtain and have ready tubing that is capable of transporting

200 liters or more per minute to the water control box.
2. Purge all water from the tubing.
3. Connect the tubing to the water control box.
1 2 3 4
No. Description
1 Water outlet to upstream container washer
2 Outlet to rotating glass water dripper
3 Connector to J373 on the side of the lower cabinet of the base unit

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4. If possible, install a water line valve that is controlled by
your production line’s programmable logic controller (PLC)
so that the PLC shuts down the water supply 30 seconds
after your production line stops running.
5. Do you expect that your facility’s water supply might be

contaminated?
If yes, attach a high-volume water filter to the water line

between the labelled Omnivision III water inlet fitting and
your water supply.
6. Momentarily open the valve and inspect the tubing and all
connections for leaks, and if you find one, repair it and
repeat this step until all leaks are repaired.
7. Plug the connector into the matching socket J373 on the

utility panel inside the lower cabinet of the base unit, as
shown in Figure 4-10.

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4.19 Grounding Your Omnivision III
4.19.1 Introduction
You must connect Omnivision III to protective earth ground (PE

GND). This section shows you how.
4.19.2 Steps
Complete these steps to ground your Omnivision III.
1. Is the surface where you intend to install Omnivision III

above, at, or below ground level?
If above or at ground level, connect the PE GND wire to a

dedicated grounding rod that you drive into the earth, as
shown in Figure 4-11.
If below ground level, connect the PE GND wire to a nearby

grounded water pipe.
2
3
1.83 meters
No. Description
or 6 feet
1 Ground rod, which filtec supplies
2 Omnivision III ground wire
3 Omnivision III PE GND
Figure 4-11. Installing a Ground Rod

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4.20 Connecting a Power Regulator to
Omnivision III
Refer to page 3 of wiring diagram D38168 and installation drawing

I00760 as you complete the steps in this section.
Also, refer to the wiring diagram on the backside of the power

panel cover plate inside the lower cabinet of the base unit.
Warning: The main power switch on the Omnivision III is tagged

and secured in the OFF position. Do not touch the main power
switch at this time.
If your company maintains a lock out, tag out policy, ensure

that you insert a lock into at least one or all three lock out, tag
out slots.
High voltages are present inside all regulators. Do not reach
inside a unit when it is turned on.
4.20.2 Steps
Complete these steps to connect a power regulator to Omnivision

III.
Note: All power cables are color coded and marked with tags.
1. Verify that all circuit breakers on the power panel on your

Omnivision III are set to the OFF position.
2. Verify that all power is turned off and all power cables to
the regulator are removed.

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3. Locate and mount the power regulator at the location that
you want.
Best Practice: Ensure that you mount the power regulator

with 12 inches or 30 centimeters space on either side and 24
inches or 60 centimeters space above to provide adequate
ventilation.
4. Connect the power cable wires according to this diagram.
Up to 440 VAC
Omnivision II
220 VAC
Power Regulator

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4.21 Connecting Power to Your
Omnivision III
Refer to page 3 of wiring diagram D46231 and installation drawing

D48811 as you complete the steps in this section.
Also, refer to the wiring diagram on the backside of the power

panel cover plate inside the lower cabinet of the base unit.
Warning: The main power switch on the Omnivision III is tagged

and secured in the OFF position. Do not touch the main power
switch at this time.
If your company maintains a lock out, tag out policy, ensure

that you insert a lock into at least one or all three lock out, tag
out slots.
4.21.2 Steps
Complete these steps to connect power to your Omnivision III.
Note: All power cables are color coded and marked with tags.
1. Verify that all circuit breakers on the power panel on your

Omnivision III are set to the OFF position.
2. Ensure that your facility’s power matches the power

requirements for the Omnivision III:

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Computer grade 220 volts, ± 10 percent, single phase, alter-
nating current (VAC), 50 or 60 hertz (Hz), at 15 amp
Warning: If you connect your facility’s voltage to the

Omnivision III and your facility’s voltage does not match the
voltage that is required by Omnivision III, you might cause
serious bodily injury or death and you might damage to
Omnivision III.
The input voltage that you provide to Omnivision III must
remain between 198 VAC and 242 VAC or you might damage
Omnivision III.
The power monitor that filtec builds into Omnivision III
automatically disconnects power to Omnivision III when power
levels drops below 198 VAC.
3. Route the incoming alternating current (AC) power cable

through the indicated bulkhead fitting that is located on the
wall of the lower cabinet of the base unit.
4. Wire the cable to the terminal block 1 (TB1) inside the

power panel.
5. Attach the incoming protective earth ground (PE GND) wire

to the ground stud that is welded next to the lower left
corner of the power panel inside the lower cabinet of the
base unit.
Warning: Follow filtec’s grounding requirements for Omnivision

III or you risk voiding your warranty.
6. Route the outer sidewall cables through the bulkhead

fittings on the lower cabinet of the base unit.
7. Connect the outer sidewall cables to the matching

connectors on the I/O access panel, which is located just
below the power panel, as shown in Figure 4-11.
Note: Ensure that you route the outer sidewall camera cable
and servo cables through separate conduits from the power
cables.

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Caution: Do not turn on or apply power to Omnivision III at this
time.
1 2 3
No. Description
1 J1 Receptacle, 220 volts
alternating current,
4 amps, 50/60 Hertz
9 J2 Receptacle, 115 AC, 4A,
50/60 Hz
2 J4 Outer sidewall strobe
trigger (outer sidewall
sensors)
3 J5 Outer sidewall power
supplies connector
7 J6 Ethernet connector
6 J7 Industrial Dynamics Net
connector, RS-485 (DB9,
female cable)
4 J8 Outer sidewall lamps and
fan
8 J9 Modbus RS232 (DB9, male
cable)
controller module (rail
only shown)
controller (PLC) interface
module junction box
connector (DB25, female
cable) 10 9 8 7 6 5 4
Figure 4-12. Access Panel Inside the Lower Cabinet of the Base
Unit

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4.22 Installing the Uninterruptable Power
Supply
4.22.1 Steps: Installing and Starting the Uninterruptable

Power Supply
filtec installs the uninterruptable power supply at the factory.

However, filtec disconnects the connector to the uninterruptable
power supply before Omnivision III leaves the factory.
When you install your Omnivision III, you need to connect the
battery’s connector cable on the uninterruptable power supply
control board.
You also need to ensure that the one amp circuit breaker on the
alternating current (AC) input to the uninterruptable power
supply control board is switched to the on or up position.
Complete these steps to plug in the connector and ensure that

the one amp circuit breaker is switched on.
1. On the starwheel side of the base unit lower cabinet, on

which is located both an emergency stop knob and the
Omnivision III main power switch, remove the cover to the
lower cabinet of the base unit.
Starwheel side
(rear, not shown)
Operator
side

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2. Remove the screw for the battery pack and rotate the
battery pack forward to move it out of the way and gain
access to the uninterruptable power supply control board.
3. On the uninterruptable power supply control board, insert

the P11 cable connector from the uninterruptable power
supply into the connector on the uninterruptable power
supply control board.
No. Description
1 Connector on
uninterruptable
power supply
control board
2 P11 male cable
connector
Note: The P11 cable is labeled 41954.
4. Inspect the one amp circuit breaker on the AC input to the

uninterruptable power supply control board.
No. Description
1 Circuit breaker
2 Uninterruptable
power supply
control board
3 Uninterruptable
power supply
battery pack

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Is the circuit breaker positioned in the up, or on, position?
If yes, go to step 5.
If no, switch it to the up, or on, position.
5. On the uninterruptable power supply control board, press

the white reset button, which is labeled S1, as shown here.
Result: Omnivision III resets the uninterruptable power

supply control board, which then turns on the chassis power
supplies in 300 millisecond intervals to start up the uninter-
ruptable power supply smoothly.
The control board then detects the presence of current and

immediately starts charging the batteries.

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4.23 Connecting Omnivision III to Your
Programmable Logic Controller Line
4.23.1 PLC Interface Module Inputs
Omnivision III provides the following optically isolated PLC

interface module inputs.
Use this PLC input... To... Green terminal

block
Brake input Apply the starwheel brake unconditionally. 19 (+)
BRAKE IN 20 (-)
Clutch input Force the clutch on Omnivision III to remain engaged 21 (+)
RUN OUT regardless of the conditions that are present at 22 (-)
sensors 1 and 2.
Best Practice: Use this programmable logic controller

input to enable Omnivision III to run the remaining
containers through inspection without stopping when
the trailing upstream gap at the end of the container
queue passes the line sensors.
Reject inhibit Disable the rejector unconditionally. 23 (+)
REJECT INHIBIT 24 (-)
Note: These inputs, which are activated by signals from your

programmable logic controller unit, are buffered using
solid-state direct current (DC) relays.
Each programmable logic controller input is usually high and is
switched by an active low (or low going) signal from your PLC
unit.
4.23.2 PLC Interface Module Outputs
Omnivision III provides the following optically isolated PLC

outputs, which enable you to set up the interface between your
PLC and Omnivision III.
Note: The outputs on terminal block TB1 inside Omnivision III

are normally high (open) when Omnivision III is not generating a
PLC signal.
When Omnivision III generates a programmable logic controller
signal, the respective output goes low (closed), thus presenting
a signal to your PLC unit.

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This PLC output... Indicates that... Green terminal block
Starwheel encoder Omnivision III has generated a buffered encoder 1 (+)
ENCODER starwheel output signal. 2 (-)
Best Practice: Use this programmable logic

controller output signal to synchronize external
devices to Omnivision III.
Brake output, machine Omnivision III has applied the starwheel brake, 3 (+)
ready except when sensors 1 and 2 have detected an 4 (-)
BRAKE OUT/MACHINE upstream gap.
READY
Under the following conditions, Omnivision III applies
Note: You must invert the starwheel brake when Omnivision III:
( ) the PLC Machine
Ready signal on the • Detects an over height container
• Generates a reject verifier fault signal
screen.
• Generates a major diagnostic fault signal or
alarm message
Downstream gap (filler Omnivision III has detected an extended gap in the 5 (+)
demand) infeed area. 6 (-)
DWNSTRM GAP (FILLER
DEMAND) Best Practice: Use this programmable logic
controller output signal to slow the downstream
conveyors that feed the filler when an extended
infeed gap occurs so that the filler is not starved.
Note: This signal mimics the sensor 1 gap signal.

Reject output The starwheel has rejected a container (one pulse 7 (+)
REJECT per rejected container). 8 (-)
Throughput (pin) A good container has exited the Omnivision III. 9 (+)
THROUGHPUT (PIN) 10 (-)
Jam Omnivision III has detected a jam either upstream or 11 (+)
JAM downstream. 12 (-)
Fallen container Omnivision III has detected a fallen container either 13 (+)
FALLEN BOTTLE upstream or downstream. 14 (-)
Reject failure Omnivision III has discovered that it failed to reject a 15 (+)
REJECT FAILURE container. 16 (-)
Brake out, machine Omnivision III is ready to convey containers on a 17 (+)
ready, reject motor moving production conveyor. 18 (-)
stop
BRAKE OUT/MACH
READY/REJ MTR STOP
Note: These outputs, which send signals to your programmable

logic controller unit, are buffered using solid-state direct
current (DC) relays.
4.23.3 Input and Output Signal Requirements
Your programmable logic controller unit must provide power to

the Omnivision III programmable logic controller junction box so
that it can accept input signals from your programmable logic
controller unit.

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This power source for input signals can provide between 3.3 and
32 volts direct current (VDC).
Your programmable logic controller unit must provide power to

the Omnivision III programmable logic controller junction box, so
that it can generate the required output signal for your program-
mable logic controller unit.
This power source for output signals can provide between 3 and
60 volts direct current (VDC).
Note: You must connect a resistor of the correct value across

the load that is attached to the relay. This resistor can absorb
the 0.5 mA (milliampere) leakage current or to meet the
minimum load current requirement.

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4.23.4 Diagram of Input Connections
Use this diagram as reference as you connect your programmable

logic controller unit to Omnivision III.
1 5
6 7
4
2
No. Description
1 Your programmable logic controller unit
2 Your programmable signal out (typical)
3 Lower cabinet of the base unit
4 Green terminal block on the input/output access panel
5 Programmable logic controller module inside Omnivision III
6 Portion of the input/output module mounting board
7 Direct current (DC) input plug-in module
Figure 4-13. PLC Input Connections for Brake Output, Machine

Ready

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4.23.5 Diagram of Output Connections
Use this diagram as reference as you connect your programmable

logic controller unit to Omnivision III.
1 5
8
6 7
2
No. Description
1 Your programmable logic controller unit
2 Your programmable signal out (typical)
3 Lower cabinet of the base unit
4 Green terminal block on the input/output access panel
5 Programmable logic controller module inside Omnivision III
6 Portion of the input/output module mounting board
7 Direct current (DC) input plug-in module
8 Load resister, which uses these values:
Load resister value Operating voltage

3 kilohms at 1.5 watts 60 volts
1.8 kilohms at 1.0 watt 36 volts
1.2 kilohms at 1.0 watt 24 volts
750 ohms at 1/2 watt 15 volts
220 ohms at 1/2 watt 5 volts
Figure 4-14. PLC Output Connections for Throughput (Pin)

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4.23.6 Guidelines for Setting Up Your PLC for Jam Signals
Follow these guidelines when setting up your programmable logic

controller (PLC) for jam signals.
• Monitor the PLC jam output to initiate the line stop when a
jam occurs. Your PLC might need to monitor the line for a
high-to-low state change rather than a signal level.
• When the production line stops, your PLC needs to monitor
the line only for the PLC machine ready signal to reset the
conveyor start.

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4.24 Final Installation Checklist
4.24.1 Table
Use this checklist to confirm that you have performed all

mechanical and electrical installation and configuration
procedures.
Once you confirm that you have performed all these procedures,
you are ready to start Omnivision III.
Check this box... If the...

Production conveyor is supported at both the infeed and
outfeed side of the base unit and the supports are within
0.9 to 1.2 meters (3.0 to 4.0 feet) of the starwheel center
line.
Omnivision III stub conveyor is aligned to the production
conveyor, the wear strips match in height, the return wear
plates provide the correct guide for the chain return path.
Omnivision III’s threaded legs are locked in place by the
jam nuts and the weight is distributed evenly on all four
legs.
Spacer, which is supplied with the Omnivision III reject
takeaway conveyor, is installed between the production
conveyor and the reject takeaway conveyor.
Production conveyor guide rails are aligned with the
Omnivision III infeed and outfeed guides to allow a
smooth, continuous flow of containers.
A maximum gap of 5 millimeters or 0.197 inches is allowed

between the end of the production conveyor guide rails
and the start of the Omnivision III guides.
Production conveyor guide rails are supported within 25.4
millimeters or 1 inches from the ends that meet the
Omnivision III guides
Production conveyor is correctly railed for smooth
container handling for a minimum of 1.8 meters or 6 feet
on the infeed and outfeed sides of the Omnivision III.
Good railing means guide rail spacing should be set for

container diameter plus 5 to 9.5 millimeters or 0.197 to
0.374 inches.
If the customer is running multiple containers, and does

not readjust rails on a container changeover, set the rails
for 5 millimeters or 0.197 inches greater than the largest
container diameter that will run on the production
conveyor.

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Check this box... If the...
Upstream container washer assembly is mounted
correctly, which you confirm by ensuring that the:
1. Container washer assembly is installed according to

the installation drawing.
2. Nozzle is aimed at a downward angle of approxi-
mately 20 degrees to the point where the container
bottom and conveyor chain meet.
3. Nozzle is aimed slightly upstream into the flow of
containers.
Sonic sensors are mounted correctly, which you confirm by
ensuring that the:
1. Distances and angles match the distances and angles

shown in the installation drawings.
2. Sensors are mounted high enough so that container
guides do not block the sensor beam.
If you have the down container option installed, you
must ensure that the sonic sensor is able to see a
down container on the conveyor.
3. Distance between the transmitter and receiver is kept
between a minimum of 152 millimeters or 6 inches
and a maximum of 305 millimeters or 12 inches.
Air supply lines to the lower cabinet of the base unit are
flushed and clear, and the manual valve is turned off.
Water supply lines to the water control box are flushed
and clear, and the manual valve is turned off.
Your facility’s electrical service meets the requirements
of the Omnivision III electrical system and any applicable
local electrical codes. Ensure that the:
1. Voltages allocated to Omnivision III as shown on the

alternating current power distribution panel are
correct.
2. Customer must use proper circuit protection for AC
power feeding the Omnivision III.
3. Circuit breakers are set to the off position.
4. Facility’s single phase alternating current power input
matches Omnivision III requirements.
5. Unit is connected to the facility’s power supply as
instructed in drawing I00761.

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5. Adjusting, Aligning, and
Calibrating Omnivision III
Topics that this chapter covers include adjusting the:
• Starwheel top plate to the container finish

• Inspection head
• Dead plate
• Encoder
• Reject takeaway conveyor
• Infeed and outfeed guides
• Body and neck guide belts
• Diffuser glass drive and rotating brush
Caution: Only authorized, factory trained filtec representatives

can perform the procedures in this chapter. If you perform the
procedures in this chapter and you misalign or miscalibrate your
Omnivision III, you might void your warranty.
Adjusting, Aligning, and Calibrating Omnivision III 5-1

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5.1 Adjusting the Starwheel Top Plate to the
Container Finish
5.1.1 Diagram
3 1 6 4
2 5
No. Description
1 Press crown finish
2 Starwheel top plate
3 1.00 millimeter or 0.039 inch
4 Roll-On Pilfer Proof (ROPP) finish
5 Starwheel top plate
6 1.00 millimeters or 0.039 inch
Figure 5-1. Vertical Alignment of Starwheel Top Plate to Finish

Reinforcement Ring
5.1.2 Steps
Follow these steps to check and, if necessary, adjust the

starwheel top plate to the container finish.
Caution: Only authorized, factory trained filtec representatives

can perform the procedures in this section. If you perform the
procedures in this section and you misalign or miscalibrate your
Omnivision III, you might void your warranty.
1. Measure the distance between the starwheel top plate and

the start of the slope from the nominal reinforcement ring,
as shown in Figure 5-1.

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2. If your container finish is... Is the distance that you measured...
Press crown 1.00 millimeter
Roll-on pilfer proof (ROPP) 1.00 millimeter
If yes, stop as you have completed this procedure.

3. Raise the inspection head approximately 100 millimeters

above the top starwheel plate.
4. Loosen the six 9/16 hex bolts on top of the starwheel and
insert the shim plates that filtec provides to achieve the 1
millimeter height that is required.
5. Replace the six 9/16 hex bolts.
Caution: Do not over tighten the six 9/16 hex bolts because you
might damage the starwheel hub.
6. Run the starwheel to ensure that no warping has occurred.

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5.2 Generally Adjusting the Inspection Head
5.2.1 Steps
filtec aligns the inspection head to the starwheel assembly

(pinned and torqued) before it leaves the factory. Follow these
steps to generally align the inspection head.
1. Remove the cover to the inspection head and store it in a

safe place for the duration of the preproduction and
production start-up procedures.
2. Check and verify that the inspection head moves up and

down freely.
3. Place the first container type that you intend to run in the
starwheel pocket directly under the finish inspection
window.
4. Adjust the height of the inspection head so there is approxi-

mately a gap that measures:
• 13 millimeter or 0.5 inch between the finish and the

inspection head base plate, without the thread
inspection system.
• 10 millimeter or 0.375 inch between the finish and the
inspection head base plate, with the thread inspection
system.
Note: Always lower the inspection head about two counts below
the actual height that is indicated on the height counter and
then raise the inspection head to the actual height. This action
eliminates any inspection head backlash.
5. Lock the position of the inspection head.
6. Remove the container from the starwheel.
7. Check and verify that the optics and the cameras are
securely mounted, and that nothing is interfering with the
movement of the lens.
8. Check and verify that nothing is interfering with the servo

systems.

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9. Wipe off the inspection head windows by using a damp clean
soft cloth and follow up with a dry clean soft cloth.
Caution: Do not use any paper products on the inspection head

windows.

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5.3 Finely Adjusting the Inspection Head
5.3.1 Diagram
Refer to this diagram as you complete the steps in this section.
3 2 1
No. Description
1 Top: Alignment hole 1
(base or finish)
Bottom: Alignment pin 1

(base or finish)
2 Top: Alignment hole 2
(base only)
Bottom: Alignment pin 2

(base only)
4
3 Alignment hole 2 (finish
only)
4 Starwheel
Figure 5-2. Aligning the Inspection Head to the Starwheel
Obtain and have ready a digital protractor or bubble level and a

large adjustable wrench.

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5.3.3 Steps: Setting Up Adjustment
Follow these steps to install alignment pins in the “finish”

position.
Note: Refer to Figure 5-2 as you complete the steps in this

section.
1. Raise the inspection head above the starwheel top plate.
2. Screw in alignment pin 1 in hole 1 under the base plate.
3. Insert the alignment pin 2 in hole 3.
4. Rotate the starwheel until the number one pocket (the

number 1 is stamped in the container ring set or disk
casting) is aligned with the finish inspections window.
Note: This locates alignment pin 2.
Note: With the number one starwheel pocket directly below the
finish inspection camera window, alignment 1 and 2 pins only
align with two of the three holes in the starwheel top plate.
5. Lower the inspection head slowly, until both pins engage the
starwheel holes.
6. Continue lowering until there is a:
• 13 millimeter or 0.5 inch gap between the finish and the

inspection system.
• 10 millimeter or 0.375 inch gap between the finish and
the inspection head base plate, with the thread
inspection system.
Note: The locking handle is set too tightly when excessive
force is required to lower the inspection head.
Caution: Do not force the pins into the starwheel holes.

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7. Do the pins fit smoothly or align easily with the holes with
only a slight bend or twist of the starwheel?
If yes, raise the inspection head and replace the alignment

pins in the storage position.
If no, the alignment is greater than 1/8 of the pin diameter,

go to the next step.
8. Move the inspection head to a position where the pins are 1

millimeter or 0.031 inch above the top of the starwheel and
complete the next section.
5.3.4 Steps: Using a Protractor of Level to Align the

Inspection Head to the Starwheel
Complete these steps to use a protractor or bubble level to

ensure course alignment of the inspection head to the starwheel.
1. Place the digital protractor on the starwheel so that it is

parallel with the left and right sides of your Omnivision III.
2. Using the large adjustable wrench, adjust the left and right
base cabinet legs until the digital protractor reads less than
0.50 degrees.
3. Place the digital protractor on the starwheel so that it is

perpendicular with the left and right sides of your
Omnivision III.
4. Using the large adjustable wrench, adjust the front and back
base cabinet legs until the digital protractor reads less than
0.50 degrees.
5. Repeat step 1 and step 3.
6. Is your starwheel level?
If no, repeat from step 1.
7. Lower the inspection head slowly, until both pins engage the
starwheel holes.
8. Continue lowering until there is a:

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• 13 millimeter or 0.5 inch gap between the finish and the
inspection system.
• 10 millimeter or 0.375 inch gap between the finish and
the inspection head base plate, with the thread
inspection system.
Note: The locking handle is set too tightly when excessive
force is required to lower the inspection head.
Caution: Do not force the pins into the starwheel holes.
9. Do the pins fit smoothly or align easily with the holes with
only a slight bend or twist of the starwheel?
If yes, raise the inspection head and replace the alignment

pins in the storage position.
If no, the alignment is greater than 1/8 of the pin diameter,

go to the next step.
10. Move the inspection head to a position where the pins are 1
millimeter or 0.031 inch above the top of the starwheel and
repeat from step 1.
See Also: The sections Aligning the Starwheel’s Pocket One

to the Base Inspection Zone, Setting the Pin 1 Offset, and
Aligning the Starwheel Pockets by Using the Finish
Inspection Zone contain additional information.

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5.4 Adjusting the Dead Plate
5.4.1 Introduction
filtec sets the dead plate at the factory, so you need only verify
that it is configured correctly.
5.4.2 Steps
Follow these steps to verify that the dead plate is configured

correctly.
1. Is the dead plate at the infeed side approximately 0.031 to

0.062 inches or 0.8 to 1.6 millimeters below the top surface
of the main conveyor chain?
If yes, go to the next step.
If no:
a. Ensure that you have set and locked the height of

the starwheel to correctly intercept the container
finish reinforcement ring according to Figure 5-1.
b. Loosen the infeed dead plate mounting bracket

bolts.
c. Position the dead plate at the infeed so that it is

approximately 0.031 to 0.062 inches or 0.8 to 1.6
millimeters below the top surface of the main
conveyor chain.
2. Is the dead plate at the outfeed side approximately level

with the main conveyor chain?
If yes, stop, you have correctly configured the dead plate.
If no, on the discharge side, loosen the downstream

mounting bracket bolts and position the dead plate at the
same height as the top of the main conveyor chain.
A correctly-positioned dead plate contacts containers only when

the Omnivision III discharges them from the starwheel to the
conveyor. This contact ensures that Omnivision III transfers
containers without their stumbling or striking the conveyor chain
at the re-entry point.

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5.5 Adjusting the Conveyor Chain Encoder
5.5.1 Steps
Follow these steps to ensure that the encoder sprocket on the

encoder shaft are aligned correctly.
1. Remove the starwheel and the infeed and discharge guides.
2. Loosen the four 1/2 inch bearing housing bolts and lift the
encoder sprocket as high as possible.
3. Place the chain on top of the sprocket and ensure that a

chain link matches one of the sprocket teeth valleys.
4. Move the chain back and forth, ensuring that the sprocket
teeth are contacting the chain tabs correctly.
Note: Ensure that the conveyor drive chain does not lift at all
when you move the chain. Ensuring that the conveyor drive
chain does not lift ensures that you have found the correct
contact location.
5. Tighten the four 1/2 inch bolts on the two bearing blocks
and move the chain again, ensuring that the sprocket is
turning and the chain is not lifting.
Best Practice: Do not force the encoder pulley onto the

encoder shaft, as the encoder pulley, if configured
correctly, slides easily into position (slip fit).
Important: The encoder is a precision optical instrument. Do

not use a hammer to attach the drive pulley to the shaft, as you
might break the internal parts of the encoder.

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5.6 Aligning the Reject Takeaway Conveyor
5.6.1 Steps
Follow these steps to ensure that the dead plate makes a smooth
transition from the reject takeaway chain to the main conveyor
chain.
1. Measure the distance between the top of the takeaway

chain and the main conveyor chain.
2. Is the top of the takeaway chain approximately 5 to 10 milli-

meters below the main conveyor chain?
Note: Configuring the takeaway chain below the main conveyor

chain enables Omnivision III to deposit containers from the
starwheel onto the main conveyor without their dragging or
bumping across or falling onto the takeaway chain.
If yes, stop, you have successfully aligned your reject

takeaway conveyor.
3. Run containers through Omnivision III and stop the starwheel

with containers present over the reject conveyor.
4. Is there about a 5 millimeter gap between the reject

conveyor and the base of the container?
If no, adjust for that gap, wait for production, and see if
containers fall.
5. During production, do containers fall on rejection?
If yes, continue to raise the reject conveyor until containers

stop falling.
Important: Do not try to make this adjustment above the

sprocket of the takeaway system.

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6. Is the takeaway chain running parallel to the conveyor
chain?
If yes, stop, you have finished aligning the takeaway

conveyor.
If no, loosen the bolts that secure the takeaway mounting

bracket and adjust the chains so that they run parallel.

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5.7 Adjusting the Infeed and Outfeed Guides
Slotted guide rail support base plates are used for this task. Use
the largest container that you can find to adjust the base plate.
5.7.2 Steps
Follow these steps to ensure that the infeed (upstream) and

outfeed (downstream) guide sets are fixed in angle and location.
Note: You do not need to adjust the infeed and outfeed guides
when you change over containers.
1. Remove the adjustable guide rails.
Important: Only one side of the guide rails are adjustable. Do

not try adjust the opposite side.
2. Measure the clearance between the largest container

diameter and the guide set.
3. Is there 3 millimeters clearance?
If yes, stop, your guides are correctly configured.
If no, mark the current position and adjust the infeed or

outfeed guide so that there is a clearance of 3 millimeters.
Best Practice: Move the base support rail and plate evenly
so that the same gap is maintained over the full length of
the guide rail.

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5.8 Adjusting the Orange Body Guide Belt
5.8.1 Steps
Follow these steps to ensure that the orange neck guide belt is
tangent to the guide path and adjust the guide belt and guide
path if necessary.
1. Measure the clearance between the belt path and the

container at the reject position.
2. Is there a 9.5 to 13 millimeter clearance between the belt

path and the container at the reject position?
If yes, stop, you have successfully adjusted the orange neck

guide belt.
3. Move the pulley in the slotted mounting hole so that, with

containers in the starwheel, the belt is tangent to the guide
path.
4. Ensure that the container guide pulley, with belt installed,

does not extend beyond the face of the guide.
If the container guide pulley extends beyond the face of the

guide, containers will jam on the pulley and belt.
5. Horizontally adjust the outfeed pulley (towards the

conveyor) to the correct clearance.
6. Vertically adjust the pulley mounting bracket to the correct

height at the discharge side of Omnivision III.
Important: When you correctly configure the container guide

pulley, containers pass smoothly into the pockets on the
starwheel (with a minimum of friction).

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5.9 Adjusting the Green Neck Guide Belt
5.9.1 Steps
Follow these steps to ensure that the green neck guide belt is
adjusted correctly.
1. Is the green neck guide assembly mounted securely?

If no, adjust and tighten it securely.
2. Does the green neck guide belt contact the container just
below the crown?
3. If yes, go to the next step.

If no, adjust it or order a new green neck guide belt.
4. Does the green neck guide belt inhibit the flow of the
starwheel or containers?
If yes, stop, you have successfully adjusted the green neck

guide belt.
If no, examine the pulleys to ensure that they are mounted

about fifty percent in the adjustable mounting slots.
Note: If necessary, you can make adjustments for stability

later.

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5.10 Adjusting the Diffuser Glass Drive and
Rotating Brush
5.10.1 Steps
Follow these steps to ensure that the diffuser glass drive and
rotating brush cleaning system is adjusted correctly.
1. Is the diffuser glass and rotating brush cleaning system

securely mounted?

If no, adjust and tighten it securely.
2. Is anything interfering or obstructing their movement?
3. If yes, go to the next step.

If no, remove the interfering or obstructing object.
4. Does the rotating brush rub against the washer at the center
of the diffuser glass disk?
If yes, adjust the rotating brush and the washer to ensure

that they do not rub against each other.
If no, stop, you have successfully adjusted the diffuser glass

drive and rotating brush cleaning system.
5. Examine the diffuser glass and ensure that the diffuser glass
does not rub on the air knife below the dead plate.
6. Ensure that the diffuser glass rotates opposite the brush and
removes debris as designed.
7. Does the diffuser rotate opposite the flow of containers?
If yes, contact filtec Customer Support and notify them that

you need to swap the power cable inside the connection
plug to change the motor direction.
If no, stop as you have successfully adjusted the diffuser

glass drive and rotating brush.

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5.11 Verifying the Correct Vacuum Flow Rate
5.11.1 Diagram
1 2 3 4 5 6 7 8 9 10 11
No. Description
1 Base strobe air filter
2 Starwheel system air filter
3 Vacuum filter (inside base unit)
4 Starwheel reject pressure
5 Starwheel reject pressure regulator
6 Starwheel system pressure
7 Starwheel vacuum
8 Bottom/diffuser blow-off pressure
9 Bottom/diffuser blow-off pressure regulator
10 Regulated machine pressure
11 Machine pressure regulator
Figure 5-3. Air Panel
5.11.2 Steps
If you are using a central vacuum system, this test verifies the
correct vacuum flow rate and, thereby, that you can use this
central vacuum system with Omnivision III.
1. Check all flexible hoses on the valve plate and ensure that
all have internal springs and that all springs contact the
copper tubing at each end (that is, you see no gaps).
2. Ensure that the starwheel is not loaded with containers.

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3. Start the starwheel.
4. Does the vacuum gauge show a minimum pressure of 203

millimeters or 8 inches of mercury (Hg) and does the needle
fluctuate less than 51 millimeters or 2 inches of mercury
(Hg)?
If no, check the size of the inlet lines and, if they are too
small, ask the customer to increase the size of the inlet
lines.
5. Stop the starwheel.
6. Load the starwheel with containers
7. Start the starwheel.
8. Is your facility located at or more than 1220 meters or 4000

feet above sea level?
If yes, does your vacuum gauge show a pressure of approxi-

mately 508 millimeters or 20 inches of mercury (Hg)?
If yes, stop, you have completed this procedure.
If no, check the size of the inlet lines and, if they

are too small, ask the customer to increase their
size and repeat from step 1.
Note: A vacuum loss of approximately 25.4 millimeters or 1 inch

of mercury (Hg) occurs for every 305 meters or 1000 feet you
increase your altitude.
9. Does the vacuum gauge show a pressure between 609 and

660 millimeters or 24 to 26 inches of mercury (Hg) at sea
level?
If no, check the size of the inlet lines and, if they are too
small, ask the customer to increase their size and repeat
from step 1.

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5.12 Connector Abbreviations
5.12.1 List
Due to space limitations on the connector lists, some terms are

abbreviated. Refer to the following table for abbreviations and
their meanings.
This abbreviation... Stands for...
AC Alternating current
Assy Assembly
BS Barrier strip
CB Circuit breaker
CLIC Camera link interface card
COM Communication
CPU Central processing unit (card cage)
DC Direct current
E-stop Emergency stop
HV High voltage
I/O Input/output
IR RLD Infrared residual liquid detection
ISW Inner sidewall inspection
J J-numbered connector (jack)
LCD Liquid crystal display (monitor)
LCM Line control module
LED Light emitting diode
LH Left-hand assembly machine, and other components
OSW Outer sidewall inspection
P P-numbered connector (plug)
PLC Programmable logic controller
RF RLD Radio frequency residual liquid detection
RH Right-hand assembly, machine, and other

components
Servo Servomotor
TB Terminal block

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This abbreviation... Stands for...
VAC Volts alternating current
VDC Volts direct current

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6. Turning On Omnivision III for
the First Time
This chapter covers the following topics:
• Turning on Omnivision III for the first time

• Confirming that all systems are working correctly after you
turn on Omnivision III, including the air knife blow off
assembly, thread blow off system, water system, and diffuser
glass drive and brush cleaning system
• Pinning the starwheel to the inspection head
Turning On Omnivision III for the First Time 6-1

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6.1 Turning On Omnivision III for the First
Time
Obtain and have ready a voltmeter and a small and a large flat
head screwdriver.
6.1.2 Steps: Getting Ready
Complete these steps to prepare your Omnivision III for turning it

on for the first time.
1. Remove all covers from the inspection head, base unit lower
cabinet, and unsnap and remove the clear plastic cover from
the power supply drawer to gain access to components.
2. Store all covers in a safe place.
3. Check all components and cable connections to ensure that

they are seated correctly, tight, and you observe no loose
connections or dislodged, bent, or broken components.
4. Ensure that the CBMain circuit breaker is turned off.
No. Description
1 Circuit breakers
2 CBMain circuit
breaker

Document 47751-0316
5. Ensure that the uninterruptable power supply circuit
breaker CB11 is turned off.
No. Description
1 Uninterruptable
power supply
circuit breaker
CB11
6. Using a voltmeter, check the voltage at TB4.

No. Description
1 TB4 connection
point
7. Is your facility’s mains electricity nominally 220 to 230

volts ±10 percent?
If no, adjust your facility’s electricity so that it is nominally

220 to 230 volts ±10 percent.

Document 47751-0316
8. Unscrew the uninterruptable power supply battery pack,
slide the battery pack slightly forward out of the way, and
temporarily reinsert the screw so that you do not lose it.
No. Description
1 Connector on
uninterruptable
power supply 1
control board
2 Flat head
screw,
reinserted
3 Battery pack,
slid forward
2
3
9. On the uninterruptable power supply control board, insert

the P11 cable connector from the uninterruptable power
supply into the connector on the uninterruptable power
supply control board.
No. Description
1 Connector on
uninterruptable
power supply
control board
2 P11 male cable
connector
3 P11 cable from
uninterruptable
power supply
connected to
uninterruptable
power supply
control board
1
2
3
Note: The P11 cable is labeled 41954.

Document 47751-0316
6.1.3 Steps: Turning On Omnivision III for the First Time
Complete these steps to turn on your Omnivision III for the first
time.
1. Turn on the uninterruptable power supply circuit breaker

CB11.
2. On the uninterruptable power supply control board, press

the white reset button, which is labeled S1.
Result: Omnivision III resets the uninterruptable power

supply control board, which then turns on the chassis power
supplies in 300 millisecond intervals to start up the uninter-
ruptable power supply smoothly.
The control board then detects the presence of current and

immediately starts charging the batteries.
3. Examine the uninterruptable power supply control board

and ensure that the CHG (LD4) and AC (LD1) light emitting
diodes (LEDs) are lit.

Document 47751-0316
4. Turn on the CBMain circuit breaker.
5. Ensure that both emergency stop buttons are pulled out.
Caution: Omnivision III comes equipped with two emergency

stop knobs, which are located on the front and rear left corners
of the base unit.
Both knobs are identical and have lighted push buttons. The
knobs are in the released or “pulled out” position during normal
operating conditions.
Under emergency conditions, you push in either knob to stop
the starwheel and the reject takeaway conveyor.
The red light on each push button indicates that the knob is
activated. You can release the knobs by twisting them to the
right or pulling them out to the normal operating position.
6. At the base unit, turn the red main power switch clockwise
from the off position to the on position.

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Result: Omnivision III starts. Omnivision III first displays the
Starting GUI dialog box on the monitor station screen.

Document 47751-0316
After a few minutes, Omnivision III then displays the
screen.

Document 47751-0316
6.2 Verifying That Systems Are Working
Correctly
6.2.1 Steps: Verifying the Starwheel and Air
Once you have turned on Omnivision III for the first time, follow
these steps to verify that systems are working correctly.
1. Verify that the pressure and vacuum converter is running

correctly by holding your finger over the vacuum ports on
the starwheel.
2. Using a strip of rubber, cover the sucker cups on the

starwheel.
No. Description
1 Starwheel
2 Strip of rubber
1
3 Sucker cups
(underneath the 2
strip of rubber)
3. Ensure that the starwheel is rotating.
4. While the starwheel is rotating, does the vacuum gauge read

609 to 660 millimeters or 24 to 26 inches Hg?

If no, adjust the air that your facility provides to Omnivision
III.
5. Remove the rubber strip or any containers that might

restrict air flow on the starwheel.

Document 47751-0316
6. As the starwheel continues to rotate, does the vacuum
gauge read a minimum of 203 millimeters or 8 to 10 inches
Hg, without fluctuating more than 51 millimeters or 2 inches
Hg?

III.
7. Does the reject air pressure gauge read 345 to 448 kPa or 50
to 65 psig?

III and push in the red ring to lock the pressure setting.
8. When you open circuit breaker CB1, does the air valve
solenoid momentarily close and does the air pressure gauge
drop to zero?

III.
9. Open the container air knife blow off nozzle.
10. Is air blowing and is the nozzle adjusted correctly?
If no, adjust the air knife blow off nozzle, or replace it, if
necessary, as described in the section Checking and
Adjusting the Air Knife Blow Off Assembly Pressure.
6.2.2 Steps: Verifying the Diffuser Glass, Scrubber, and

Water Nozzle
Complete these steps to verify the diffuser, scrubber, and water

nozzle.
1. Does the diffuser glass rotate in the correct direction, at

approximately seven revolutions per minute?

If no, adjust the diffuser glass.

Document 47751-0316
2. Does the glass scrubber brush rotate in the correct direction
and does the glass scrubber brush touch the diffuser glass?

If no, adjust the diffuser glass and glass scrubber brush.
3. Is the scrubber brush motor drive running freely without any

preload on motor?
If no, examine the brush motor drive and replace it if

necessary.
4. Open the diffuser glass water nozzle.
5. Does the water drip freely?
If no, adjust the diffuser glass water nozzle or replace it, if

necessary.
6. Open the diffuser glass air knife blow off nozzle.
7. Is the diffuser glass cleaning system operating correctly?
8. Under normal operating conditions, when under the dead

plate hole, is the diffuser glass clean and water-free?

If no, adjust the air, water, and brush for the diffuser glass.

Document 47751-0316
6.3 Checking and Adjusting the Air Knife
Blow Off Assembly Pressure
6.3.1 Diagram
Refer to this diagram as you complete the steps later in this

section.
1
2
Center line
4
No. Description
1 Container
2 Air blow off assembly
3 Air inlet
4 Air jet out
Figure 6-1. Air Knife Blow Off Assembly for the Bottom of
Containers
6.3.2 Steps
Follow these steps to check and, if necessary, adjust the air

system pressure of the Omnivision III.
1. Turn on the external air valve.
2. Check the air filters.
3. Check the diffuser glass air knife blow off (upper and lower
bars).
4. Do you detect good air flow across the glass?
If yes, adjust the needle valve so that water is not blowing

onto the inspection windows.

Document 47751-0316
5. Using Figure 6-1 as reference, check the air knife blow off
assembly, which cleans the bottoms of containers.
6. Is the air knife blow off assembly correctly aligned and does
it sufficiently blow off chain soap carry-over on the bottom
of test containers?
If yes, stop, you have successfully checked and adjusted the

air system pressure.
If no, increase the air flow until the air knife blow off
assembly sufficiently blows off chain soap carry-over from
the bottom of the container or adjust the position to
achieve the best results.

Document 47751-0316
6.4 Checking the Thread Blow Off System
6.4.1 Introduction
When you order the thread inspection option, filtec includes the
thread blow off system. You install the thread blow off system
upstream from the Omnivision III base unit or the outer sidewall
system.
6.4.2 Description
The thread blow off system consists of a pair of blow off air
nozzles. These nozzles are installed in a staggered manner
because two opposing air nozzles would cancel out any drying
effect.
One blow off air nozzle is located on one side of the conveyor and
faces the other across the conveyor. The air control valves enable
air to flow only when the starwheel is rotating (as does the
bottom blow off).
6.4.3 Diagrams
No. Description
1 Air nozzle
2 Air in
3 Pressure gauge
4 Thread blow off
solenoid relay
Air flow
1 2 3 4
Figure 6-2. Thread Blow Off System

Document 47751-0316
No. Description
3
1 Strobe cooling
1 orifice
2
2 Needle valve
3 Strobe blow off 4
4 Filter kit
5 Thread blow off
relay and valve
6 Input
7 Output
Lower cabinet of the base unit To thread

blow off
nozzle
Downstream Upstream assembly
#1
6 To thread
5 blow off
nozzle
assembly
7 #2
Figure 6-3. Thread Blow Off Air Routing
6.4.4 Steps
Follow these steps to check and, if necessary, adjust the air blow
off system of the Omnivision III.
1. Verify that the air blow off system is mounted securely.
2. Verify that containers can pass freely through the air blow
off system.
3. Turn on the external air valve.
4. Adjust the air pressure so that the gauge reads 345 to 448
kPa or 50 to 65 psig.

Document 47751-0316
5. Using your hand, carefully check the assembly for leaks.
Important: Using Omnivision III System Software describes how

to use Omnivision III software to adjust the air blow off system.

Document 47751-0316
6.5 Checking the Water System
6.5.1 Introduction
Omnivision III uses water to clean the diffuser glass disk and to
wash off the bottom of containers.
Note: The main water control for the upstream water spray is
located in the water control box.
6.5.2 Diagram
2
4
5
3
No. Description
1 Upstream container washer
2 Water spray
3 Mounting bracket
4 Mounting angle, which is approximately 15 to 20 degrees
5 Container washer water line
Figure 6-4. Checking the Upstream Container Washer
6.5.3 Steps
Follow these steps to check and, if necessary, adjust the water

system of the Omnivision III.
1. Ensure that the external water valve is turned off.

Document 47751-0316
2. Turn off both the upstream container washer and the
diffuser glass water valves.
3. Turn on the external water valve.
4. Check for leaks, particularly inside the lower cabinet of the

base unit.
5. Is there sufficient spray directed at the base of the

containers to break up soap as the containers pass along the
conveyor?

If no, adjust the valve on the upstream container washer.
6. Using the needle valve, adjust the diffuser glass water

dripper flow rate so that the flow is less than a continuous
flow, but more than 30 to 40 drops per minute.
7. Ensure that the air blow off across the diffuser glass always
removes all water on the diffuser glass plate.

Document 47751-0316
6.6 Checking the Diffuser Glass Drive and
Brush Cleaning System
6.6.1 Steps
Follow these steps to check and, if necessary, adjust the diffuser

glass drive and brush cleaning system of the Omnivision III.
1. Verify that the scrubber brush and top and bottom holders
are mounted correctly for good contact with the diffuser
glass.
2. Verify that diffuser drive shaft and drive motor shaft are in
correct alignment and that the set screw locking the coupler
to the motor shaft is secure.
3. Verify that the diffuser glass is rotating in line with the flow
of containers, that is, from the infeed side towards the base
inspection station (clockwise for a right hand Omnivision III
and counter clockwise for a left hand Omnivision III).
4. Grasp the outer edge of the diffuser glass with your fingers
to stop it from rotating.
5. Does a slip condition occur between the glass disk and motor
drive shaft, that is, does the beveled washer at the center
of the glass slip correctly?
If no, adjust the locking retainer above the bevelled washer

until the beveled washer slips correctly.

Document 47751-0316
6.7 Pinning the Starwheel to the Inspection
Head
6.7.1 Steps
Follow these steps to pin the starwheel to the inspection head of

Omnivision III.
Note: As you complete the steps in this section, refer to Figure

5-2, which shows you how the starwheel fits onto the inspection
head.
1. Verify that the power to the production conveyor chain is

turned off.
2. Raise the inspection head and insert both the primary and
secondary alignment pins into the proper inspection head
holes for base inspection timing alignment.
3. Rotate the starwheel until the number one pocket is located

directly below the base inspection camera window.
Note: With the number one starwheel pocket located directly

below the base inspection camera window, the primary and
secondary alignment pins align only with two of the five holes in
the starwheel top plate.
4. Insert a “good” sample container into the number one

pocket.
5. Lower the inspection head slowly until both pins engage into
the correct starwheel holes.
6. Continue to lower the inspection head until you see a 0.5

inch or 12.7 millimeters clearance between the container
finish and the inspection head base plate.
Best Practice: Use a gauge block with 0.5 inch or 12.7 milli-
meter thickness.

Document 47751-0316
Best Practice: Always lower the inspection head two counts
below the actual height that is indicated on the height
counter and then raise the inspection head to the actual
height. This action eliminates any inspection head backlash.
Note: You set the final vertical position of the inspection head
during production operation.
7. Lock the vertical column raising mechanism.
8. For later reference, note and record the height that the
height counter shows.
9. Remove the sample container from the number one pocket.

Document 47751-0316
Document 47751-0316
Index
A adjusting air knife 6-12

bottle
ACL (applied ceramic label) definition 2-3
definition 2-2 bottles per hour
adjusting definition 2-3
air knife blow off 4-28 bottles per minute
air knife blow off pressure 6-12 definition 2-3
dead plate 5-10 bottom rim
inspection head 5-4, 5-6 definition 2-3
starwheel encoder 5-11 bottom zone
air definition 2-3
connecting to Omnivision III 4-33 BPH (bottles per hour)
air knife blow off definition 2-3
adjusting 4-28 BPM (bottles per minute)
air knife blow off pressure definition 2-3
adjusting 6-12 brightness
air systems definition 2-3
verifying operation of 6-9 brush cleaning system
alarm message checking 6-19
definition 2-2 bus
aligning definition 2-4
reject takeaway conveyor 5-12
applied ceramic label (ACL)
definition 2-2
asynchronous transmission C
definition 2-2 cage
attaching reject conveyor 4-21 definition of card 2-62
camera link interface card (CLIC)
description 2-65
B description of 2-65
card cage
B/R (bottom rim) definition 2-62
definition 2-3 cards
base camera link interface (CLIC) 2-65
definition 2-2 central processing unit (CPU) 2-63
base backup zone CPU 2-63
definition 2-2 Caution 1-2
base inspection CCW (counter clockwise)
definition 2-3 definition 2-4
base unit 2-34 center line
raising 4-9 definition 2-4
belts central processing unit card 2-63
installing 4-19 definition 2-63
birdswing CFM (cubic feet per minute)
blow off checking
checking thread 6-14 brush cleaning system 6-19
blow off pressure diffuser glass drive 6-19
thread blow off system 6-14
Index Index-1
Document 47751-0316
water system 6-17
checklist D
final installation 4-52 data communications equipment
CIC (communication interface card) definition 2-7
definition 2-4 DCE (data communications equipment)
cleaning system definition 2-7
checking brush 6-19 dead plate
clock adjusting 5-10
definition 2-4 defect
clockwise definition 2-7
definition 2-7 definition
collimator dropout 2-8
definition 2-4 definitions
combiner ACL (applied ceramic label) 2-2
definition 2-4 alarm message 2-2
communication interface card applied ceramic label (ACL) 2-2
definition 2-4 asynchronous transmission 2-2
communication protocol B/R (bottom rim) 2-3
definition 2-5 base 2-2
components base backup zone 2-2
Omnivision III 2-33 base inspection 2-3
connecting air to Omnivision III 4-33 birdswing 2-3
connecting Omnivision III to PLC 4-46 bottle 2-3
connecting power regulator to Omnivision III 4-38 bottles per hour 2-3
connecting power to Omnivision III 4-40 bottles per minute 2-3
connecting water to Omnivision III 4-35 bottom rim 2-3
connections bottom zone 2-3
PLC input 4-49 BPH (bottles per hour) 2-3
PLC output 4-50 BPM (bottles per minute) 2-3
contact circle brightness 2-3
definition 2-5 bus 2-4
container CCW (counter clockwise) 2-4
definition 2-5 center line 2-4
container finish CFM (cubic feet per minute) 2-4
adjusting starwheel top plate to 5-2 CIC (communication interface card) 2-4
container guides clock 2-4
installing 4-19 clockwise 2-7
container washer collimator 2-4
installing upstream 4-24 combiner 2-4
mounting 4-26 communication interface card 2-4
conveyor communication protocol 2-5
aligning reject takeaway 5-12 contact circle 2-5
attaching reject 4-21 container 2-5
installing reject 4-20 count 2-5
count counter clockwise 2-4
definition 2-5 crimp 2-5
counter clockwise crimping 2-5
definition 2-4 cubic feet per minute 2-4
CPU current value 2-6
card 2-63 CW (clockwise) 2-7
crimp data communications equipment 2-7
definition 2-5 DCE (data communications equipment) 2-7
crimping defect 2-7
definition 2-5 detect 2-7
cubic feet per minute detection 2-7
definition 2-4 detection point 2-7
current value diagnostic message 2-7
definition 2-6 digital data 2-8
CW (clockwise) digital signal processor 2-8
definition 2-7 DIP switch 2-8
donut 2-12
downstream 2-8
drop 2-8
DSP (digital signal processor) 2-8
Index-2 Omnivision III Service and Installation Guide

Document 47751-0316
dual in-line package switch 2-8 reject history 2-21
embossing 2-9 reject segment 2-21
EPROM (erasable programmable read-only rejector segment 2-21
memory) 2-9 rejector timing 2-21
exception point 2-9 ribbing 2-21
false accept 2-9 roll on pilfer proof finish 2-21
false reject 2-9 ROPP (roll on pilfer proof) 2-21
feet per minute 2-10 RS-232 2-22
finish 2-9 RS-485 2-22
finish image 2-10 screen 2-39
finish inspection 2-10 scuffing 2-22
flint 2-10, 2-21 sector 2-24
fluting 2-10 shielding 2-24
FPM (feet per minute) 2-10 signal beacon 2-40
Hertz 2-10 slip rate 2-24
housekeeping 2-10 spot 2-24
Hz (Hertz) 2-10 start bit 2-25
infeed 2-11 stippling 2-25
information message 2-11 stop bit 2-25
inner sidewall 2-11 stress cracking 2-25
inspection 2-11 stroke 2-25
inspection donut 2-12 swing gate 2-25
kernel 2-12 synchronous transmission 2-26
knurling 2-12 test container 2-26
lane 2-13 thread 2-26
last detect 2-13 thread image 2-26
LCM 2-14 tracking segment 1 2-26
light level compensation 2-13 tracking segment 2 2-26
line control monitor 2-14 twist off finish 2-26
lower rim zone 2-14 upper rim zone 2-17
lower sidewall zone 2-14 upper sidewall zone 2-17
mark 2-14 upstream 2-27
marker 2-14 warning message 2-27
mask 2-15 wash out 2-28
missed reject 2-15 window 2-27
Modbus 2-15 zone 2-28
module 2-16 detect
monitor station 2-39 definition 2-7
multiple triggering 2-16 detection
multiplexer 2-16 definition 2-7
MUX (multiplexer) 2-16 detection point
normalization 2-16 definition 2-7
Omnivision III 2-29 diagnostic message
operator menu 2-16 definition 2-7
outer radius (base) 2-17 diagrams
outer radius (sidewall) 2-17 Omnivision III 2-29
outer sidewall 2-17 diffuser glass drive
outfeed 2-17 checking 6-19
overpress 2-17 digital data
parallel transmission 2-18 definition 2-8
PET (polyethylene terephthalate) 2-18 digital signal processor
phase 2-19 definition 2-8
plastic returnable bottle 2-20 DIP switch
PLC 2-20 definition 2-8
plug 2-20 donut
polycarbonate doors 2-38 definition 2-12
polyethylene terephthalate 2-18 doors
PRB (plastic returnable bottle) 2-20 installing polycarbonate 4-32
press finish 2-6 polycarbonate 2-38
programmable logic controller (PLC) 2-20 downstream
racetrack 2-20 definition 2-8
radial 2-20 drive
radio frequency residual liquid detection in- checking diffuser glass drive 6-19
spection subsystem 2-41 definition of solid state 2-61
Index Index-3
Document 47751-0316
drop Omnivision III 4-37
definition 2-8 guidelines
dropout installation 4-2
definitions 2-8 guides
DSP (digital signal processor) installing 4-20
definition 2-8 reject conveyor 4-20
dual in-line package switch installing container 4-19
definition 2-8
H
E head
embossing adjusting inspection 5-4, 5-6
definition 2-9 definition of inspection 2-57
encoder height
adjusting starwheel 5-11 calculating what you need for Omnivision III
EPROM (erasable programmable read-only memo- 4-6
ry) Hertz
erasable programmable read-only memory housekeeping
Ethernet port Hz (Hertz)
exception point
definition 2-9
I
F infeed
definition 2-11
false accept information message
false reject inner sidewall
feet per minute inputs
definition 2-10 PLC 4-46
final installation checklist 4-52 inspection
finish definition 2-11
adjusting starwheel top plate to 5-2 inspection donut
finish image inspection head
definition 2-10 adjusting 5-4, 5-6
finish inspection definition 2-57
definition 2-10 pinning starwheel to 6-20
flint installation checklist 4-52
definition 2-10, 2-21 installation guidelines 4-2
floor space installing
determining for base unit 4-4, 4-5 belts 4-19
determining for Omnivision III shipping crates container guides 4-19, 4-20
4-3 diffuser 4-29
determining for outer sidewall unit 4-5 guides 4-20
fluting mirror 4-30
definition 2-10 polycarbonate doors 4-32
FPM (feet per minute) rotating diffuser 4-29
definition 2-10 rotating glass 4-29
spacer 4-23
upstream container washer 4-24
G installing starwheel 4-18
installing uninterruptable power supply 4-43
glass
installing rotating 4-29
glass drive
checking diffuser 6-19
K
grounding kernel

Document 47751-0316
knurling diagram 2-29
definition 2-12 getting ready to turn on 6-2
how it works 2-31
installing 4-1
L installing on production line 4-14
requirements 2-113
lane specifications 2-113
definition 2-13 turning on 6-2, 6-5
last detect unpacking 4-7
definition 2-13 operator menu
LCM definition 2-16
definition 2-14 optional premium outer sidewall inspection unit
lifting 2-35
Omnivision III shipping crates 4-3 outer radius (base)
light level compensation definition 2-17
definition 2-13 outer radius (sidewall)
line control monitor definition 2-17
definition 2-14 outer sidewall
lower rim zone definition 2-17
definition 2-14 outer sidewall inspection unit 2-35
lower sidewall zone how it works 2-37
definition 2-14 outer sidewall unit
raising 4-9
outer sidewall unit mirror
installing 4-30
M outfeed
definition 2-17
mark outputs
definition 2-14 PLC 4-46
marker overpress
mask
definition 2-15
mirror
installing outer sidewall unit 4-30 P
missed reject
definition 2-15 parallel transmission
Modbus definition 2-18
definition 2-15 PET (polyethylene terephthalate)
module definition 2-18
definition 2-16 phase
monitor station definition 2-19
definition 2-39 pinning
mounting sonic sensor 4-26 starwheel to inspection head 6-20
mounting washer 4-26 plastic returnable bottle
multiple triggering definition 2-20
definition 2-16 plate
multiplexer adjusting dead 5-10
definition 2-16 PLC
MUX (multiplexer) connecting Omnivision III to 4-46
input connections 4-49
input signal requirements 4-47
inputs 4-46
N output connections 4-50
output signal requirements 4-47
normalization outputs 4-46
definition 2-16 plug
definition 2-20
polycarbonate doors
O definition 2-38
installing 4-32
Omnivision III polyethylene terephthalate
components 2-33 definition 2-18
Index Index-5
Document 47751-0316
port
definition of Ethernet 2-59 S
power safety
connecting to Omnivision III 4-40 labels 1-2
power regulator notices 1-2
connecting to Omnivision III 4-38 screen
PRB (plastic returnable bottle) definition 2-39
definition 2-20 scuffing
press finish definition 2-22
definition 2-6 sector
pressure definition 2-24
adjusting air knife blow off 6-12 segment 1
production line tracking 2-26
installing Omnivision III on 4-14 segment 2
tracking 2-26
shielding
R definition 2-24
shipping crates
racetrack determining floor space for 4-3
definition 2-20 lifting Omnivision III 4-3
radial signal
definition 2-20 input 4-47
radio frequency residual liquid detection inspec- output 4-47
tion subsystem signal beacon
raising base unit 4-9 Single Platform Technology (SPT)
raising outer sidewall unit 4-9 turning off 3-4
ram stroke slip rate
rejector 2-25 definition 2-24
regulator solid state drive (SSD)
connecting power 4-38 definition 2-61
reject conveyor sonic sensor
attaching 4-21 mounting 4-26
installing 4-20 spacer
reject history installing 4-23
definition 2-21 specifications
reject segment Omnivision III 2-113
definition 2-21 spot
reject takeaway conveyor definition 2-24
aligning 5-12 definition of 2-24
rejector segment start bit
rejector timing starwheel
definition 2-21 installing 4-18
requirements pinning to inspection head 6-20
Omnivision III 2-113 starwheel encoder
PLC input signal 4-47 adjusting 5-11
PLC output signal 4-47 starwheel top plate
ribbing adjusting to container finish 5-2
definition 2-21 steps
roll on pilfer proof finish turning off Single Platform Technology (SPT)
definition 2-21 3-4
ROPP (roll on pilfer proof) stippling
rotating diffuser stop bit
rotating glass stress cracking
RS-232 stroke
RS-485 rejector ram 2-25
definition 2-22 subsystems
radio frequency residual liquid detection
inspection 2-41

Document 47751-0316
swing gate
definition 2-25 V
synchronous transmission verifying operation of systems 6-9
definition 2-26
systems
air 6-9
checking brush cleaning 6-19 W
checking water 6-17
verifying operation of 6-9 Warning 1-2
warning message
definition 2-27
wash out
T definition 2-28
washer
takeaway conveyor installing upstream container 4-24
aligning reject 5-12 mounting 4-26
test container mounting upstream container 4-26
definition 2-26 water
thread connecting to Omnivision III 4-35
definition 2-26 water system
thread blow off system checking 6-17
checking 6-14 window
thread image definition 2-27
definition 2-26
timing
rejector 2-21
top plate Z
adjusting starwheel 5-2
tracking segment 1 zone
tracking segment 2
definition 2-26
turn on
Omnivision III 6-2
turning off Single Platform Technology (SPT) 3-4
turning on
Omnivision III 6-2, 6-5
twist off finish
definition 2-26
U
uninterruptable power supply
installing 4-43
unit
base 2-34
optional premium outer sidewall inspection
2-35
outer sidewall inspection 2-35
unpacking Omnivision III 4-7
upper rim zone
definition 2-17
upper sidewall zone
definition 2-17
UPS
see uninterruptable power supply
upstream
definition 2-27
upstream container washer
installing 4-24
mounting 4-26
Index Index-7
Document 47751-0316
Document 47751-0316
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Feedback-2 Omnivision III Service and Installation Guide

Document 47751-0316

Omnivision III ASEBI-Service and Installation Guide-English-47751-0316 - CCv0002

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Volume 1 Installing and Starting

Omnivision III Service and Installation Guide

Corporate Headquarters 3100 Fujita Street,

Mailing Address P.O. Box 2945,

Shipping Address 3100 Fujita Street,

Customer Service (800) 733-5173

1. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Overview of Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Table of Contents iii

iv Omnivision III Service and Installation Guide

3. Turning On and Turning Off Omnivision III. . . . . . . . . . . . . . . . 3-1

4. Installing Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. Adjusting, Aligning, and Calibrating Omnivision III . . . . . . . . . . 5-1

6. Turning On Omnivision III for the First Time . . . . . . . . . . . . . . 6-1

6.1 Turning On Omnivision III for the First Time . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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Help Us Improve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-1

vi Omnivision III Service and Installation Guide

1. Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Overview of Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Figure 2-1. Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

List of Figures vii

viii Omnivision III Service and Installation Guide

3. Turning On and Turning Off Omnivision III. . . . . . . . . . . . . . . . 3-1

4. Installing Omnivision III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. Adjusting, Aligning, and Calibrating Omnivision III . . . . . . . . . . 5-1

6. Turning On Omnivision III for the First Time . . . . . . . . . . . . . . 6-1

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x Omnivision III Service and Installation Guide

Omnivision III, or OV-III, documentation provides operators,

• Omnivision III Operation Guide tells you how to use and

Topics That This Guide Covers

This guide describes how to install, configure, and calibrate an

This guide also provides maintenance procedures, trouble-

This guide is intended for use by filtec service personnel or

Conventions That Appear in This Guide

Use the following chart to learn about the typographic conven-

This typeface or symbol... Indicates... Example...

Important: Important information that

Caution: That there is a potential for

Warning: That there is a potential for

xii Omnivision III Service and Installation Guide

abcd1234 A best practice to follow, a Best Practice:

This chapter describes the safety mechanisms that are supplied

This chapter also contains safety disclosure information and certi-

Safety Information 1-1

To ensure your safety, filtec has included many safety notices

1.1.1 Safety Notices

This documentation contains two types of safety notices: cautions

Warning: A warning indicates that there is a potential for harm

Caution: A caution indicates that there is a potential for

1.1.2 Safety Labels

filtec equipment contains various safety labels. These labels are

1-2 Omnivision III Service and Installation Guide

Omnivision III complies with all of the CE (Conformité

The machine has a CE mark affixed to it and is accompanied by an

The Omnivision III machine labels conform to the International

Safety Information 1-3

1.3.1 Meaning of International Symbols

Use this chart and table to determine the meaning of interna-

No. Description No. Description

1-4 Omnivision III Service and Installation Guide

This chapter presents an overview of Omnivision III.