M-412-073 Rev B T4000 APX Setup Manual

TapTone T4000 APX
Installation
Manual
M-412-073
Rev. B
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TapTone T4000 APX

Installation Manual
M-412-073
Rev. B
(English)
TELEDYNE TAPTONE
49 Edgerton Drive
North Falmouth, Massachusetts
02556-2828 USA
Phone: 508-563-1000
Fax: 508-564-9945
www.taptone.com
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M-412-073
Table of Contents
Table of Contents
1.0
Introduction ................................................................................... 1
1.1 T4000 ACX Acoustic / Cocked Crown / X-Ray Inspection System .. 1

1.2 T4000 PX Proximity / X-ray Inspection System ................................ 2
1.3 T4000 SSV-X Fill_xr Level Inspection System ................................. 3
2.0
Safety Precautions ........................................................................ 4
2.1 General Safety Precautions ............................................................. 4

2.2 Specific Cautions and Warnings ...................................................... 5
2.3 Safety Label Descriptions ................................................................ 5
2.4 System Lockout / Tag-out Procedure ............................................... 7
3.0
Installation Instructions ................................................................ 8
3.1 T4000 Sensor Configurations .......................................................... 8

3.1.1 Acoustic Configuration (T4000 A) .............................................. 8
3.1.2 Acoustic/Cocked Crown Configuration (T4000 AC) ................... 9
3.1.3 Proximity Configuration (T4000 P) ........................................... 10
3.1.4 Dual Proximity Configuration (T4000 DP) ................................ 11
3.1.5 X-ray Configuration (T4000 X) ................................................. 12
3.1.6 Acoustic/X-ray Configuration (T4000 AX) ................................ 13
3.1.7 Proximity/X-ray Configuration (T4000 PX) ............................... 14
3.1.8 Acoustic/Cocked Crown/X-ray Configuration (T4000 ACX) ..... 15
3.1.9 Acoustic/Proximity/X-ray Configuration (T4000 APX) .............. 16
3.2 T4000 AC, P Stand Installation ...................................................... 17
3.2.1 RTV Crank Stand Installation .................................................. 17
3.2.2 Conveyor Mount Frame Installation (CMS) .............................. 19
3.3 T4000 X-ray Installation ................................................................. 21
3.3.1 Key Points to X-ray Sensor Installation.................................... 21
3.3.2 Stand Tube Cutting Procedure ................................................ 21
3.3.3 Stand Assembly Procedure ..................................................... 22
3.3.4 X-Ray Sensor Installation Procedure ....................................... 23
3.3.5 X-ray Detector Mask Installation .............................................. 24
3.4 Rejector Assembly Installation ....................................................... 25
3.4.1 Ram Installation....................................................................... 26
3.4.2 Air Regulator Installation ......................................................... 27
3.4.3 Connecting the Air ................................................................... 28
3.4.4 Rejector Electrical Connection................................................. 29
3.5 Shaft Encoder Installation ............................................................. 30
3.5.1 Shaft Encoder Mechanical Specifications ................................ 30
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Table of Contents
3.5.2 Shaft Encoder Electrical Specifications ................................... 30

3.5.3 Shaft Encoder Installation Instructions..................................... 31
3.5.4 Electrical Connections ............................................................. 32
3.6 Electrical Power Connections ........................................................ 33
3.6.1 AC Power Connections ........................................................... 33
3.6.2 Sensor Cable Connections ...................................................... 35
3.7 Initial Mechanical Setup ................................................................ 37
3.7.1 Acoustic Sensor Setup ............................................................ 37
3.7.2 Cocked Crown Sensor Setup .................................................. 37
3.7.3 Proximity Sensor Setup ........................................................... 37
3.7.4 X-ray Setup ............................................................................. 38
3.7.5 Reject Acknowledge Sensor Setup ......................................... 39
3.7.6 Trigger Sensor Setup .............................................................. 39
3.7.7 Trigger Timing Setup ............................................................... 40
Appendix A Warranty .......................................................................... 42
Appendix B Technical Specifications ................................................ 43
B.1 Electronic Control Box Specifications ............................................ 43
B.2 Fill_xr Sensor Specifications .......................................................... 44
Appendix C X-Ray Safety Survey Plot B-412-119 ........................... 45
Reference Manuals
M-412-102
M-412-073
M-412-074
M-412-066
TapTone T4000 Operations Manual

TapTone T4000 ACX Installation Manual
TapTone T4000 ACX Operations & Maintenance Manual
TapTone T4000 Users Manual
(English)
(English)
(English)
(English)
Preface
All information within this manual is a copyright of Teledyne TapTone and may not be
duplicated without the written consent or approval from Teledyne TapTone.
Teledyne TapTone reserves the right to make changes to the manual without obligation to
notify any person(s) or entities of revisions. It is recommended that the installation of your
Teledyne TapTone equipment is performed or supervised by an authorized Teledyne
TapTone representative.
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List of Figures
Table of Figures
Figure 1-1 T4000 ACX System .............................................................................................................................. 1
Figure 1-2 T4000 PX System ................................................................................................................................. 2
Figure 1-3 T4000 SSV-X System ........................................................................................................................... 3
Figure 2-1 Safety Labels ........................................................................................................................................ 5
Figure 2-2 X-ray Safety Labels .............................................................................................................................. 6
Figure 3-1 Transducer Stand Assembly (RTV) .................................................................................................... 17
Figure 3-2 Conveyor Mount Stand Dimensions (CMS) ........................................................................................ 19
Figure 3-3 Conveyor Mounted Transducer Assembly ......................................................................................... 20
Figure 3-4 Stand Tube Cutting Diagram .............................................................................................................. 21
Figure 3-5 X-ray Mechanical Assembly Diagram ................................................................................................. 22
Figure 3-6 X-ray Mechanical Installation Diagram ............................................................................................... 23
Figure 3-7 X-ray Detector Mask ........................................................................................................................... 24
Figure 3-8 Rejector Specifications ....................................................................................................................... 25
Figure 3-9 Rejector Assembly Adjustment Points ................................................................................................ 26
Figure 3-10 Rejector Regulator / Lubricator Mounting ......................................................................................... 27
Figure 3-11 Rejector Regulator / Lubricator Air Connections .............................................................................. 28
Figure 3-12 Rejector Power Connection .............................................................................................................. 29
Figure 3-13 Shaft Encoder Specifications ............................................................................................................ 30
Figure 3-14 Shaft Encoder Warnings ................................................................................................................... 30
Figure 3-15 Shaft Encoder Mounting Drawing ..................................................................................................... 31
Figure 3-16 Shaft Encoder Wiring ........................................................................................................................ 32
Figure 3-17 AC Power Selector Switch ................................................................................................................ 33
Figure 3-18 AC Power Wiring Diagram ................................................................................................................ 34
Figure 3-19 Proximity Head Cable Connections .................................................................................................. 35
Figure 3-20 Acoustic Head Cable Connections ................................................................................................... 35
Figure 3-21 X-ray Head Cable Connections ........................................................................................................ 36
Figure 3-22 X-ray Height Adjustment ................................................................................................................... 38
Figure 3-23 Trigger Sensor Adjustments ............................................................................................................. 40
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1.0
Chapter 1: Introduction
Introduction
1.1 T4000 ACX Acoustic / Cocked Crown / X-Ray Inspection System

The T4000-ACX combines acoustic sensor to find low pressure or vacuum and cocked crown
to fine crown defects. The x-ray is used to detect both over and under-filled containers.
Acoustic/Cocked Crown
Acoustic Leak inspection detects low pressure or vacuum
RTV Floor stand for easy mounting
12 of travel for height adjustment
Digital indicator for accurate change-over
Fill_xr X-ray Features include:
Underfill and Overfill inspections with one head.
Angled or straight control box
Stainless steel design.
Digital counter for accurate product change-over.
X-ray lamp monitoring to turn off X-rays when bulb is burned out.
Up to 25 mm fill height detection range.
Tripod floor stand for easy installation
Options include:
Downed container rejection
High Cap Inspection
Missing Cap Inspection
Missing Label
UV Tamper Band Detection
Figure 1-1 T4000 ACX System
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1.2 T4000 PX Proximity / X-ray Inspection System

The T4000-PX combines proximity sensor with x-ray fill level inspections (Fill_xr) for food
cans, beverage cans and pop button glass containers.
Proximity
Proximity detects low pressure or vacuum
RTV Floor stand for easy mounting
12 of travel for height adjustment
Digital indicator for accurate change-over
Fill_xr Features include:
Options include:
High Cap Inspection
Missing Label
UV Tamper Band Detection
Figure 1-2 T4000 PX System
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1.3 T4000 SSV-X Fill_xr Level Inspection System

The T4000 stand-alone fill height inspection Sensor (T4000 SSV-X) Fill_xr is designed for the
inspection of fill height in a variety of containers. This model allows for mounting of the X-ray
head assembly over the inspection conveyor. The 0.9 meter (3 ft) tripod stand makes
installation easy. The X-ray sensor comes standard with a 4.5 meter (15 ft.) quick disconnect
water-proof cable. The X-ray lamp on sensor indicates when the X-ray module is transmitting.
Fill_xr Features include:
Options include:
High Cap Inspection
Missing Label
Reject air pressure monitoring kit
Figure 1-3 T4000 SSV-X System
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2.0
Chapter 2: Safety Precautions
Safety Precautions
2.1 General Safety Precautions

Please refer to the following safety instructions before and during operation of the system:
Only personnel trained in machine operations must operate the system.
Internal maintenance should only be performed by personnel specifically trained on the
system.
CAUTIONS!
PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT IF THE FOLLOWING
SAFETY PRECAUTIONS AND WARNINGS ARE NOT OBSERVED AT ALL TIMES.
Do not operate the system with the enclosure open. Always turn power and air
supply OFF before opening the enclosure.
Do not disconnect any electrical connections when the system power is on.
Damage to electrical components may occur.
Use lockout/tag-out equipment to prevent injury or damage when servicing the unit.
Before connecting an external device, power down both the TapTone system and the
external device. After power is off, connect device then turn power on.
The internal electronics of this equipment are sensitive to electrostatic discharge
(ESD) and proper precautions must be adhered to when handling any electrical
components of the system.
Do not place radial or axial load on the shaft encoder when mounting to the conveyor.
Internal damage to the encoder disk will occur.
Avoid high pressure spray with aggressive cleaning solvents on components like the
photo triggers, lamps and touch screen display.
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2.2 Specific Cautions and Warnings

WARNINGS! PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT IF THE
FOLLOWING SAFETY PRECAUTIONS AND WARNINGS ARE NOT OBSERVED AT ALL
TIMES.
Do not operate the system with the safety guards open. Failure to do so may cause
severe injury.
Keep hands clear of the rejector ram, conveyor belts and inspection bridges whenever
the system is in operation.
Do not operate this equipment with long hair or baggy loose clothing. Serious injury
may occur if it gets caught in any moving parts.
WARNING! - Keep hands clear of X-ray tunnel when X-ray lamp is on. X-ray energy is
transmitting when the X-ray lamp is ON.
WARNING! - This X-ray system MUST NOT be operated without the tunnel safety
shields installed.
2.3 Safety Label Descriptions

Denotes reject lamp.
Lock-out electrical power before servicing.
General danger. (see manual)
Hazard hand crush.
Protective Earth.
AC input ground wire
only.
Hazard electrical shock.
Stay clear.
General Chassis Earth Ground.

Figure 2-1 Safety Labels
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Denotes X-ray lamp.
Indicates X-ray caution

and emission direction.
Standard
CE
Figure 2-2 X-ray Safety Labels
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2.4 System Lockout / Tag-out Procedure

NOTICE! Technicians MUST use a Lockout / Tag-out pad lock on each system
power switch whenever service is required
DANGER! Never remove a pad-lock that was placed on the system by someone
else. Other technicians may be doing service to the system at the same time.
1. Turn the system main power switch to the OFF (0) position for both the inspection
electronics enclosure and the compression belt motor control enclosure.
2. Place a pad-lock through one of the three switch lock loops on both of the power
switches. A maximum of three pad-locks may be place on each switch.
3. Remove your pad-lock once your service is complete to resume normal operations. Do
not remove any other pad-locks that may be place on the system by other technicians as
they may be performing a different service procedure.
AC Power Switch
Figure 2-3 Lock-out Switch Locations

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3.0
Chapter 3: Installation Instructions
Installation Instructions
3.1 T4000 Sensor Configurations

3.1.1 Acoustic Configuration (T4000 A)
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3.1.2 Acoustic/Cocked Crown Configuration (T4000 AC)

Cocked
Crown
Sensor
DC-4
Acoustic
Sensor
AC-1
Flow
Cocked
Crown
Trigger
Trig-7
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Acoustic
Trigger
Trig-1
(Ref-1)
Reject #1
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3.1.3 Proximity Configuration (T4000 P)
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3.1.4 Dual Proximity Configuration (T4000 DP)

Prox
Sensor
DC-4
Prox
Sensor
DC-2
Prox 2
Trigger
Trig-7
Prox 1
Trigger
Trig-1
(Ref-1)
Flow
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3.1.5 X-ray Configuration (T4000 X)
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3.1.6 Acoustic/X-ray Configuration (T4000 AX)
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3.1.7 Proximity/X-ray Configuration (T4000 PX)
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3.1.8 Acoustic/Cocked Crown/X-ray Configuration (T4000 ACX)

X-ray
Sensor
DC-3
Cocked
Crown
Sensor
DC-4
Acoustic
Sensor
AC-1
Flow
X-ray
Trigger
Trig-6
TELEDYNE TAPTONE
Cocked
Crown
Trigger
Trig-7
Acoustic
Trigger
Trig-1
(Ref-1)
Reject #1
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3.1.9 Acoustic/Proximity/X-ray Configuration (T4000 APX)

X-ray
Sensor
DC-3
Prox
Sensor
DC-4
Acoustic
Sensor
AC-1
Flow
Prox
Trigger
Trig-7
X-ray
Trigger
Trig-6
TELEDYNE TAPTONE
Acoustic
Trigger
Trig-1
(Ref-1)
Reject #1
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3.2 T4000 AC, P Stand Installation

3.2.1 RTV Crank Stand Installation
9 (228mm)
9-1/2 (241mm)
6 Feet (1.82 meters)
Lag Bolts
Figure 3-1 Transducer Stand Assembly (RTV)
1. Select a location where the transducer stand will be mounted. Make sure the location is
smooth and straight. The rails must be straight and guide the containers smoothly
through the inspection head. The location should allow the rejector to be mounted on the
conveyor with an adequate size collection bin.
2. The transducer crank stand has 9.5 inches (241 mm) of travel. The stand is shipped with
the following inspection range:
Max. height: MXS = 66 inches (1676 mm)
Min. height: MNS = 56.5 inches (1435 mm)
3. Measure the conveyor tabletop height and the tallest and shortest containers. Enter the
values below.
CH - Conveyor Height =
TC - Tallest Container =
SC - Shortest Container =
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If the difference between the TC and SC is greater than 9.5 inches (241 mm), contact
TapTone engineering for a custom stand tube.
Now calculate the inspection range for your containers as follows:
Max. test height: MXT = CH + TC =
Min. test height: MNT = CH + SC =
Calculate the amount of tube that needs to be cut off the bottom as follows:
CUTOFF = MXS - MXT =
4. Remove the (2) bolts holding the transducer head assembly.
5. Remove the (2) screws holding the junction box clamp for the RTV system.
6. Remove the tripod base by loosening the (4) bolts.
7. Mark and cut the bottom of the stand tube by the length calculated (CUTOFF).
8. Reassemble the tripod base to the stand by tightening the (4) bolts.
9. Reassemble the junction box to the stand with the (2) junction box clamp screws.
10. Reassemble the transducer head to the bracket with the (2) bolts.
11. Place the transducer stand along the conveyor with the transducer head assembly directly
over the container flow at the location selected then mark three holes for drilling.
12. Drill three 5/8 (15.875mm) holes in the floor to a depth of 2 (50.8mm) then hammer in
the anchor drop-in part number 0219-313 into the holes.
13. Secure the tripod base to the floor using the -13 x 2 bolts, flat and split-lock washers
provided with the stand.
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3.2.2 Conveyor Mount Frame Installation (CMS)
1-1/2 (38mm)
Square Tube
26-1/2 (673mm)
17 (431mm)
Figure 3-2 Conveyor Mount Stand Dimensions (CMS)
1. Assemble the frame assembly as shown in Figure 3-3.

2. Place the frame assembly in the inspection area and mark the hole locations for the
frame mounting bolts. Make sure that holes are positioned where mounting hardware
is clear of any obstructions or working components of the conveyor.
3. Drill four 11/32 (8.73mm) diameter holes on each side of the conveyor for the frame
mounting bolts.
4. Install the frame assembly using the hardware listed below:
For conveyors 3 (76mm) to 7 (177mm) wide use both conveyor spacer blocks
and 5/16 x 1 hardware provided.
For conveyors over 7 (177mm) wide use the 5/16 x hardware provides
without the spacer blocks.
5. Make sure the vertical posts are perpendicular to the conveyor table top.
6. Place the junction box in the mounting location next to the frame assembly and mark
the hole for drilling.
7. Drill four 17/64 (6.75mm) holes in the conveyor for the junction box mounting
hardware.
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8. Mount the junction box using the -20 x hardware provided.

9. Connect the sensor cables according to the junction box cable diagram Figure 3-3.
Figure 3-3 Conveyor Mounted Transducer Assembly
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3.3 T4000 X-ray Installation

3.3.1 Key Points to X-ray Sensor Installation
Do not mount system on or just after a curve in the transportation conveyor. System must
be at least 1 meter (3 ft.) from nearest conveyor curve or transfer. This gives the product
contents time to settle before fill height measurement.
For accurate measurement, the conveyor flow should be as smooth as possible.
The X-ray tunnel must be level with the conveyor deck.
The floor tripod base must be lag bolted to the floor.
3.3.2 Stand Tube Cutting Procedure
1. Measure the conveyor chain height from the floor to the chain top =
2. X-Ray frame tube length is equal to the conveyor height minus 20.3 cm (8 in.).
Pole length = chain top height 20.3 cm (8 in.)
Figure 3-4 Stand Tube Cutting Diagram
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3.3.3 Stand Assembly Procedure
Figure 3-5 X-ray Mechanical Assembly Diagram
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3.3.4 X-Ray Sensor Installation Procedure

1. Select location based on criteria mentioned in Section 3.5.1 - Key Points to Installation.
2. Place the X-ray system over the conveyor with the crank stand height indicator numbers
facing the operator side of the conveyor. Raise the crank stand to the maximum height
for ease in lifting the unit over the conveyor.
3. Center the container flow within the X-ray tunnel.
4. Level the system to the conveyor with the stand leveling pads.
5. Bolt system feet to the floor.
6. Adjust or remove rails blocking the X-ray detector and transmitter windows.
7. The trigger photo beam must not block the X-ray beam path.
8. Connect the X-ray yellow control cable to the 16-pin socket on the right side of the
junction box. Reference Figure 3-18 for electrical connections.
Figure 3-6 X-ray Mechanical Installation Diagram
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3.3.5 X-ray Detector Mask Installation

NOTICE! The X-Ray system is shipped with the permanent 25.4 mm x 25.4 mm
detector mask installed. The optional 25.4 mm x 12.7 mm or 7.6 mm x 12.7 mm mask may
be installed if a smaller fill height range is required.
(25.4 mm x 25.4 mm) Detector Mask
The fill height detection range is 25.4 mm (1 in).
This mask is used for maximum fill height measurement range where head space may
vary due to filler operations or container variations.
Use the Plastic algorithm when the 25.4 mm permanent window is used.
The Plastic algorithm automatically sets the X-ray beam intensity for the 25.4 mm mask
opening.
(25.4 mm x 12.7 mm) or (7.6 mm x 12.7 mm) Detector Mask Installation
The fill height detection range is 12.7 mm (1/2 in.).
These masks are used when the space between the top of the product and the container
lid is small, or when greater resolution is desired over the shorter range.
1. Turn the system power OFF.
2. Remove the control cabinet receiver assembly by removing the base plate mount screws.
3. Place the CAN or GLASS detector mask into the slot at the face of the detector frame and
secure with the included mount screws.
4. Replace the control cabinet receiver assembly and secure with the base plate mount
screws.
5. Adjustment of the X-ray energy may be required when the smaller windows are installed.
This adjustment must be performed by factory trained TapTone technicians.
CAN WINDOW
1.00 x 0.50
(25.4mm x 12.7mm)
GLASS WINDOW
0.30 x 0.50
(7.62mm x 12.7mm)
PERMANENT
ENCLOSURE
WINDOW
1.00 x 1.00
(25.4mm x 25.4mm)
Figure 3-7 X-ray Detector Mask
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3.4 Rejector Assembly Installation

CAUTION! - Pinch point hazard, keep hands clear of moving parts during operation.
Rejector/Regulator Specifications
Stroke:
Construction:
Wash Down:
Regulator Assembly:
Reject Pad:
Operating Pressure:
Maximum Line Pressure:
Voltage:
12.7 mm or 25.4 mm (1/2in. or 1in.)

Stainless steel, conveyor mounted
High-pressure water
Filter/Regulator/Lubricator module with lockout
Stainless steel and molded black urethane
2.8-5.6 bars (40-80 psi)
11 bars (150 psi)
24 VDC, 17 Watts, 0.7 Amps
Figure 3-8 Rejector Specifications
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3.4.1 Ram Installation

1. The rejector should be mounted as close as possible to the last sensor relative to the
product flow. The rejector should be mounted directly to the side of the inspection
conveyor. Pneumatic rejectors are available in 12.7 mm (1/2 in.), 25.4 mm (1 in.), and
203.2 mm (8 in.) stroke models.
2. Select a location where the rails can be cut away to allow the rejects to leave the
conveyor. At faster line speeds, the conveyor cut-away must be larger as shown in
figure x-x.
Line Speed (bottles / min)
Guide Rail Opening
000 749
3 x Can Diameter Minimum
750 1249
1250 2000
Figure 3-9 Rejector Assembly Adjustment Points
3. Drill four 8 mm (5/16 in.) holes for the bracket mounting bolts.
4. Mount the rejector to the conveyor with the hardware provided. Use the spacer block
between the bracket and conveyor if required. Set the height so the reject pad hits the
container at the center of gravity.
5. Position the rejector horizontally on the bracket as close as possible to the product
flow without hitting.
6. Tighten all bolts!
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3.4.2 Air Regulator Installation

1. Mount the rejector regulator/lubricator to the conveyor side wall, next to the rejector in
a location that allows it to be easily serviceable.
2. Fill the bowl of the lubricator with 5-weight petroleum based oil, and set the lubrication
rate to the minimum position.
Figure 3-10 Rejector Regulator / Lubricator Mounting
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3.4.3 Connecting the Air

STEPS:
1. The air supply should be clean and dry with a maximum line pressure of 10.3 bar (150
psi).
2. Connect the shop air supply to the input side of the regulator assembly supplied with
the system.
3. Turn air supply ON and set the pressure of the regulator to a reading of approximately
2.7 bar (60 psi). The regulator pressure may be adjusted as required, to achieve
proper removal of rejected containers.
Figure 3-11 Rejector Regulator / Lubricator Air Connections
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3.4.4 Rejector Electrical Connection

1. Connect the 4-pin yellow rejector plug into the rejector #1 socket located in the bottom
(Left) side of the junction box.
Figure 3-12 Rejector Power Connection
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3.5 Shaft Encoder Installation

3.5.1 Shaft Encoder Mechanical Specifications
Figure 3-13 Shaft Encoder Specifications
CAUTION! - Excessive side loads to the shaft will damage the encoder and could lead to
premature failure. Make sure the shafts line up and the coupling between them is flexible.
Figure 3-14 Shaft Encoder Warnings
3.5.2 Shaft Encoder Electrical Specifications

Input Voltage:
Output:
Count Resolution:
5-26VDC (24VDC used)

Follows input voltage (24VDC used)
2,500 Pulses Per Revolution
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3.5.3 Shaft Encoder Installation Instructions

STEPS:
1. Select the transport conveyor shaft on the drive end of the belt for encoder installation.
2. Drill and tap the conveyor shaft that the encoder coupling will be mounted to. The
encoder shaft is 9.5mm (3/8) diameter.
3. Each mounting location is different so a custom designed bracket will need to be
designed. Fabricate a bracket to mount the shaft encoder over the conveyor shaft.
4. Mount the shaft encoder to the fabricated bracket. Next, align the shaft of the encoder
with the conveyor shaft and mark the location for the mounting holes.
5. Secure the 3/8 in shaft coupling to conveyor and encoder shafts.
Figure 3-15 Shaft Encoder Mounting Drawing
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3.5.4 Electrical Connections

STEPS:
1. Connect the shaft encoder female plug into the socket on the shaft encoder. Make
sure the connector is tight to prevent water intrusion.
2. Note the electrical wiring diagram for reference to pinout of shaft encoder connector.
Figure 3-16 Shaft Encoder Wiring
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3.6 Electrical Power Connections

WARNING! All AC power electrical connections should be done by a certified
electrician. Improper connections may cause serious injury or death.
3.6.1 AC Power Connections
NOTICE! All T4000 systems ship from the factory set to 115V power input. Follow the
procedures below to select the AC power input for you installation.
AC Power Requirements: 100-120VAC OR 200-240VAC, 1-Phase, 3.0Amps, 275Watts
1. Set the 24V power supply ac input power selector switch to the appropriate setting
based on you AC power source. This supply is located in the control box.
115V = (100 to 120VAC)
230V = (200 to 240VAC)
24V Power Supply
Power Source Input

Select: 115V or 230V
Figure 3-17 AC Power Selector Switch
2. Connect the (neutral L1) wire to L1 terminal on the top of the AC power switch.
Connect the (line L2) wire to L2 terminal on top of the AC power switch.
3. Connect the (PE earth ground) to the upper right box stud labeled PE. This ground
wire must be the only wire placed on this box stud for PE.
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DATE
09/14/09
10/02/09
Conduit #1 TO J-BOX
013210
013210
0411-095
0411-137
0411-137
011830
CABLE-A
CABLE-B
CABLE-C
CABLE-D
CABLE-E
GRN/YEL 14
REV
A
B
DESCRIPTION
APP
RELEASE VERSION
RAC
REMOVE EARTH GROUND TERMINALS
BRN-16
BLU-16
TB-3
Power Requirements: 100-120VAC or

200-240VAC, 1-phase, 3.0 amps, 275 watts
AC MAIN SWITCH
2/T1
3/L2
4/T2
5/L3
6/T3
BRN-16
011837
011832
GRN/YEL-14
Com 2
O2
Com 1
O1
DOOR INTERLOCK SWITCH
5 Amp
F2
BRN-16
011832
BLU-16
011837
BRN-16
011832
PE
0218-010
003066
AC DOOR SWITCH ASSEMBLY

C-412-109
GRN/YEL-14 011830
0147-031
0418-008
DOOR STUD
BLU-16
BRN-16
GND
Line
0218-010
16FTLB TORQUE
003066
0147-031
GRN/YEL-14011830
0418-008
0147-031
011830
GRN/YEL-14
TYPICAL
003066
Conduit #1
TO J-BOX
GND STUD
(BLACK) Denotes 16AWG Ferrule part number 013285.
0147-031
WHT (from B-412-210)
DRAWN BY :
RAC
CHECKED BY :
TAS
APPROVED BY :
RDS
0147-031
0147-031
0418-008
GRN/YEL-14011830
GRN-YEL-14011830
0147-031
0418-008
TYPICAL
49 Edgerton Driv e, North Falmouth, MA 02556 USA

Tel (508)563-1000 FAX (508)563-6444
TITLE:
SCHEMATIC, WIRING DIAGRAM FOR T4000

A-P-X
AC LINE POWER
FOR ELECTRICAL REFERENCE ONLY. DO NOT USE FOR MECHANICAL ASSEMBLY PURPOSES.
SHEET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
DATE:
08/31/09
A, AP, APP
SCALE:
N/A
P, PP
WARNING: This drawing contains critical

information, printed in color. Do not use this
drawing if the color of the text you are now
reading is not in RED.
16FTLB TORQUE
DOOR STUD
Notes:
TYPICAL
BOX STUD
Lower Right Box Stud
0218-010
0418-008 0418-008
BOX STUD
Lower Lef t Box Stud
0418-008
PE
WHT 0418-008
GRN/YEL-14
011830
DOOR STUD
PE
FROM
B-412-210
CABLE
SHEET 5 TO DOOR
GND STUD
16FTLB TORQUE
Neutral
AC LINE FILTER
0147-031
BOX STUD
Upper Right PE Stud
5 Amp
009239
PE
FL1
F1
BLU-16
011837
POWER SWITCH
Pow er ground PE w ire

only on this box stud.
GRN/YEL-14
011830
BRN-14 (line)
1/L1
BLU-16
L L N N
SW2
SW1
BLU-14 (neutral)
011832
011837
(AC Neutral)
Switched AC Power
All wires must be rated for 600 Volts @ 105C.
DWN CHK
TAS RDS
TAS
(AC Line)
M-412-064
FILENAME:
CAGE CODE
26858
A412249B.DSN
DRAWING NUMBER:
REV
A-412-249
SHEET
1 OF 15
Figure 3-18 AC Power Wiring Diagram
TELEDYNE TAPTONE
34
M-412-064
3.6.2 Sensor Cable Connections

PROXIMITY or COCKED CROWN SENSORS
Figure 3-19 Proximity Head Cable Connections
ACOUSTIC SENSOR
Microphone
Cable
Acoustic
Trigger
Tap Coil
Cable
Figure 3-20 Acoustic Head Cable Connections
TELEDYNE TAPTONE
35
M-412-064
X-RAY SENSOR
1. Connect the X-ray power cable to the large socket on the bottom of the control box.
2. Connect the X-ray trigger sensor to the photo beam module.
X-ray
Trigger
X-ray
Power
Cable
Figure 3-21 X-ray Head Cable Connections
TELEDYNE TAPTONE
36
M-412-064
3.7 Initial Mechanical Setup

NOTICE! The rail gap MUST be less than 1/8 (3mm) to achieve maximum system
performance. Larger gaps or absence of rails may affect the overall performance of the
system. This statement is true for each of the T4000 sensors.
3.7.1 Acoustic Sensor Setup
1. Adjust the conveyor rails to the container for a gap of 1/8 (3mm) maximum. The
containers should pass smoothly through the inspection head.
2. Place a good container under the acoustic sensor head and lower the head until it just
touches the highest point on the container. Note the value on the digital indicator then
crank the head up 150 values which is equal to .150 (4mm) above the container.
Lock the brake knob and take note of the final digital indicator value.
3. Center the acoustic sensor over the container and lock down the red wing clamps.
4. Set the photo beam fiber optic lenses to break the cap of the container or in a position
that will break even when the containers are touching.
3.7.2 Cocked Crown Sensor Setup
1. Set up the acoustic sensor first when using the combination acoustic/cocked crown kit.
3. Set the height of the cocked crown sensor to be flush (level) with the acoustic sensor
using the adjustable knob on top of the sensor housing. This will set the cocked crown
sensor .150 (4mm) above the container. The sensor will be fine tuned at a later time.
4. It is very important that the container is center directly over the cocked crown sensor
for maximum performance.
3.7.3 Proximity Sensor Setup
2. Place a good container under the proximity sensor head and lower the head until it just
touches the highest point on the container. Note the value on the digital indicator then
crank the head up 150 values which is equal to .150 (4mm) above the container.
Lock the brake knob and take note of the final digital indicator value.
3. Center the proximity sensor over the container and lock down the red wing clamps.
TELEDYNE TAPTONE
37
M-412-064
3.7.4 X-ray Setup
WARNING! - Keep hands clear of X-ray tunnel when X-ray lamp is on. X-ray energy is
transmitting when the X-ray lamp is ON.
1. Adjust the conveyor rails to allow for a maximum of a 3 mm (1/8 in.) gap on either side
of the container. Containers should pass smoothly through the X-ray tunnel.
2. Adjust the height of the X-ray sensor with the crank handle on the top of the stand.
Set the X-ray sensor height so that the line on the tunnel side of the X-ray transmitter
box is level with the anticipated fill height of the container. This is just an approximate
setting to align the X-ray beam in the region of the fill level.
3. Adjust the height and position of the trigger sensors as necessary. Ensure that the
photo sensors are not blocking the X-ray beam windows.
Vertical Height
Adjustment
Figure 3-22 X-ray Height Adjustment
TELEDYNE TAPTONE
38
M-412-064
3.7.5 Reject Acknowledge Sensor Setup

1. Mount your reject acknowledge sensor at the opening to the reject station. The sensor
should be blocked as the container enters the reject station. Make sure the rejected
container does not bounce back and block the reject sensor.
2. Connect the reject sensor to Input #1 of the I/O Board.
3. Go to the Reject Acknowledge On/Off menu in Rejector #1 menu. Turn the reject
acknowledge function On.
4. Go to the Reject Acknowledge Distance menu in Rejector #1 menu. Press the force
reject button to reject the next container. Note the Measured Distance value then set
the Reject Sensor Distance to be the same as the Measured Distance. Repeat
several times to ensure the proper distance value is set.
5. Connect any of the four PLC output modules to the conveyor stop, lamp or alarm
signal that will identify a missed reject. Select reject acknowledge function for the
desired PLC output. When the output is activated press the ENTER key to clear the
alarm condition.
3.7.6 Trigger Sensor Setup
1. Output Selection Switch This switch controls the output operation for the sensor. Set
the output selection switch to the D.O. (Dark Operate) position. This means the output
of the sensor will go high when the beam is blocked. Make sure the switch is all the
way to the D.O. position stop. Use care when adjusting this control, as the stop can
break if turned too far.
2. Output LED When the sensor beam is free, this LED will continuously flicker to
indicate the photo beam gain adjustment. The LED will turn off when the beam is
blocked or if the gain is set too low.
3. Gain Adjust This 15 turn potentiometer is adjusted clockwise (CW) to increase the
photo beam receive gain. Adjust counter clockwise (CCW) to reduce the receive gain.
To set the gain, rotate CCW until the LED turns off, then rotate CW just until the LED
comes ON. Once the LED lights, adjust the gain two full rotations CW.
TELEDYNE TAPTONE
39
M-412-064
Figure 3-23 Trigger Sensor Adjustments
3.7.7 Trigger Timing Setup

1. From initial power-up the trigger sensors MUST be blocked at least one time to
initialize the trigger sensor inputs. This means after power-up the first container will not
be inspected. Pass one container through all inspection sensors to initiate proper
timing input function.
2. Go to the Trigger Setup screen as shown below.
3. The Trigger Setup screen will show the Inspection Triggers that are activated with
green check marks.
4. Now pass one (1) container through the entire system and notice the Detected values
will appear in the lower box of this screen. Pass one (1) container again to confirm the
values are the same.
5. Now once satisfied with the Detected values then press Store Values to save the
detected values to memory. The Sorted values will be saved forever even when the
TELEDYNE TAPTONE
40
M-412-064
power is turned off. This procedure DOES NOT need to be done ever again unless
you add new inspection sensors.
6. Trigger sensor programming is now complete, press Exit to return to the system home
screen. This process may be repeated at any time if sensor timing needs to be
adjusted.
TELEDYNE TAPTONE
41
M-412-073
Appendix A: Warranty
Appendix A Warranty
Approved 12/18/12
Teledyne TapTone*
Warranty, Limitation of Liability, and Intellectual Property Rights Statement
LIMITED WARRANTY.
Teledyne TapTone warrants that all goods delivered under Buyers order shall be free from defects in material and workmanship,
and conform to Teledyne TapTones specifications for a period of twelve (12) months from the date of original shipment. The
warranty period for spare parts is ninety (90) days from the date of original shipment. The warranty period for repair work performed
on goods that are not covered by the original warranty is ninety (90) days from the date of return shipment and applies only to that
portion of the goods that was repaired. Teledyne TapTone warrants all services for ninety (90) days after completion unless
otherwise mutually agreed under a separate service contract. This warranty does not apply to any goods that, upon examination by
Teledyne TapTone, are found to have been (a) mishandled, misused, abused, or damaged by Buyer or Buyers customer, (b)
altered from their original state, (c) repaired without Teledyne TapTones prior written approval, or (d) improperly stored, installed,
operated, or maintained in a manner inconsistent with Teledyne TapTones instructions. This warranty does not apply to defects
attributed to normal wear and tear. Teledyne TapTone, at its sole option, shall either repair or replace defective goods, or issue
Buyer a credit for the original price of the defective goods. In the case of defective services, Teledyne TapTone shall re-perform
such services. Such repair, replacement, credit, and re-performance by Teledyne TapTone shall be Buyers sole remedy for
defective goods and services. Under no circumstances is Teledyne TapTone liable for recall, retrieval, removal, dismantling, reinstallation, redeployment, or re-commissioning of any defective goods or any costs associated therewith. Consumables obtained
from third parties shall bear the warranty of their manufacturer. The warranty period for repaired or replaced goods or re-performed
services shall be the unexpired portion of the original warranty period. THESE EXPRESS WARRANTIES, INCLUDING THE
REMEDIES SET FORTH HEREIN, ARE EXCLUSIVE AND ARE IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED. NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS INTENDED OR
GIVEN. IN THE CASE OF GOODS OTHER THAN THOSE OF TELEDYNE TAPTONES OWN MANUFACTURE, TELEDYNE
TAPTONE MAKES NO WARRANTIES, EXPRESS, STATUTORY, OR IMPLIED.
LIMITATION OF LIABILITY.
Notwithstanding any other provision herein, under no circumstances shall either Party be liable to the other for any consequential,
special, incidental, indirect, multiple, administrative, or punitive damages, or any damage of an indirect or consequential nature
arising out of or related to its performance under Buyers order, including, without limitation, loss of use, loss of revenues, loss of
anticipated profits, and cost of capital, whether based upon breach of Buyers order, warranty, negligence, or any other type of
claim, and whether grounded in tort, contract, civil law, or other theories of liability, including strict liability, even if advised in
advance of the possibility of such damages. Each Partys total liability to the other Party arising from or related to Buyers order,
including, but not limited to, its liability for indemnity, defense, and hold harmless obligations, is limited to no more than the amount
paid by Buyer to Teledyne TapTone under Buyers order. To the extent that this limitation of liability conflicts with any other Section
or provision herein, such provision shall be regarded as amended to whatever extent required to make such provision consistent
with this clause.
INTELLECTUAL PROPERTY RIGHTS. Teledyne TapTone shall retain all rights, title, and interest in and to any data,
information, software programs, tools, specifications, templates, scripts, ideas, concepts, inventions, works of authorship, products, know-how, processes,
techniques, and the like used or developed by Teledyne TapTone, its employees, and its subcontractors in connection with Buyers order. Buyer agrees
that Teledyne TapTone retains all proprietary rights in and to all products, specifications, designs, discoveries, inventions, patents, copyrights, trademarks,
trade secrets, and other proprietary rights relating to goods or services. Unless otherwise identified in writing to Teledyne TapTone, no information or
knowledge heretofore or hereafter disclosed to Teledyne TapTone in the performance of, or in connection with, the terms hereof, shall be deemed to be
confidential or proprietary and any such information or knowledge shall be free from restrictions, other than a claim for patent infringement, as part of the
consideration hereof.
*This Statement applies to the products of Teledyne TapTone, a Business Unit of Teledyne Instruments, Inc.
TELEDYNE TAPTONE
42
M-412-073
Appendix B: Technical Specifications
Appendix B Technical Specifications

B.1 Electronic Control Box Specifications
General Specifications
Electrical:
Control Box:
100-120VAC 47 - 85 Hz, single phase, 275 watts
Or 200-240VAC 47-85Hz, single phase, 275 watts
3
Air:
206.8 kPa - 1034.2 kPa, 2832 cm /sec (30 150 psi., 6 cfm.)
Room Temperature:
0 - 50 C (32 to 122 F)
Humidity:
0 - 90%, non-condensing
Altitude:
Sea level to 3,035 m (10,000 feet)
Control Enclosure
Dimensions:
Construction:
Material:
Wash Down:
Mounting:
HMI:
Reject Lamp:
Reject Signal:
Communications:
41 cm high x 41 cm wide x 18 cm deep (16 in. x 16 in. x 7 in.).

Control enclosure with junction box
Stainless steel, NEMA 4X, IP65 rated
Low-pressure water
Angled pedestal stand, stainless steel
Watertight LCD touch screen 25.4 cm (10 in.)
24 VDC, 6.5 watt, orange lens, 1/2 second pulse per reject
24 VDC, 1 amp, variable pulse width and delay time
Molex watertight Ethernet socket RJ-45
Shaft Encoder
Resolution:
Construction:
Wash Down:
Cable Type:
Cable Diameter:
Cable Length:
Supply Power:
Signal Output:
2500 pulses / revolution

Stainless Steel or Aluminum, NEMA 4X, IP65
Low-pressure water
4 conductor, 20 AWG shielded
4.62 mm (0.182 in.)
7.62 m (25 ft.)
5-26VDC
5-26VDC, two channels, input voltage follower
Trigger Sensors
Photo Beams:
Thru-beam fiber optic, high speed, 10-30 VDC pnp output
I/O Interface Board

Input Modules:
Output Module:
Four solid state, 3-24 VDC

Four solid state, 0-24 VDC @ 3.5 amps, normally open
TELEDYNE TAPTONE
43
M-412-073
Appendix B: Technical Specifications
B.2 Fill_xr Sensor Specifications
X-Ray Sensor Specifications

ENCLOSURE
Dimensions:
Construction:
Material:
Environmental Rating:
Wash Down Rating:
Mounting:
STAND
Type:
Travel Range:
Construction:
X-ray Source:
X-ray Lamp:
X-ray Detector:
Trigger Sensor:
TELEDYNE TAPTONE
31.1 cm high x 17.15 cm wide x 64.77 cm deep (12.25 in. x 6.75 in. x 25.5 in.)
Single piece box w/ screw mount access panel
Brushed stainless steel
NEMA 4X, IP65
High-pressure water
Pedestal stand to floor secured to conveyor
Adjustable height
Crank handle fine adjust 304.8 mm (12 in.)
Overall floor to X-ray beam range (does not include fine adjust range) standard
post 50.8-228.6 cm (20-90 in.) Longer Lengths are available upon request
Brushed stainless steel
X-ray tube, 35-60 kV, 10-30uA, 24 VDC @ 2 A, +/- 15 VDC @
300 mA
Red lens (Green for CE), 24 VDC, 6.5 watt LED (monitored for
continuity)
Photo Multiplier Tube (PMT), 25.4 mm (1 in.) square window
Thru-beam pair, adjustable gain, 10-30 VDC, sourcing pnp output
44
M-412-073
Appendix C: X-Ray Safety Survey Plot
Appendix C X-Ray Safety Survey Plot B-412-119
TELEDYNE TAPTONE
45
M-412-073
TELEDYNE TAPTONE
46
M-412-073
TELEDYNE TAPTONE
47

M-412-073 Rev B T4000 APX Setup Manual

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TapTone T4000 APX

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TapTone T4000 APX

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1.1 T4000 ACX Acoustic / Cocked Crown / X-Ray Inspection System .. 1

Safety Precautions ........................................................................ 4

2.1 General Safety Precautions ............................................................. 4

Installation Instructions ................................................................ 8

3.1 T4000 Sensor Configurations .......................................................... 8

3.5.2 Shaft Encoder Electrical Specifications ................................... 30

TapTone T4000 Operations Manual

1.1 T4000 ACX Acoustic / Cocked Crown / X-Ray Inspection System

Figure 1-1 T4000 ACX System

1.2 T4000 PX Proximity / X-ray Inspection System

Figure 1-2 T4000 PX System

1.3 T4000 SSV-X Fill_xr Level Inspection System

Figure 1-3 T4000 SSV-X System

Chapter 2: Safety Precautions

2.1 General Safety Precautions

Chapter 2: Safety Precautions

2.2 Specific Cautions and Warnings

2.3 Safety Label Descriptions

Lock-out electrical power before servicing.

General danger. (see manual)

Hazard hand crush.

Hazard electrical shock.

General Chassis Earth Ground.

Chapter 2: Safety Precautions

Denotes X-ray lamp.

Indicates X-ray caution

Chapter 2: Safety Precautions

2.4 System Lockout / Tag-out Procedure

Figure 2-3 Lock-out Switch Locations

Chapter 3: Installation Instructions

3.1 T4000 Sensor Configurations

Chapter 3: Installation Instructions

3.1.2 Acoustic/Cocked Crown Configuration (T4000 AC)

Chapter 3: Installation Instructions

3.1.3 Proximity Configuration (T4000 P)

Chapter 3: Installation Instructions

3.1.4 Dual Proximity Configuration (T4000 DP)

Chapter 3: Installation Instructions

3.1.5 X-ray Configuration (T4000 X)

Chapter 3: Installation Instructions

3.1.6 Acoustic/X-ray Configuration (T4000 AX)

Chapter 3: Installation Instructions

3.1.7 Proximity/X-ray Configuration (T4000 PX)

Chapter 3: Installation Instructions

3.1.8 Acoustic/Cocked Crown/X-ray Configuration (T4000 ACX)

Chapter 3: Installation Instructions

3.1.9 Acoustic/Proximity/X-ray Configuration (T4000 APX)

Chapter 3: Installation Instructions

3.2 T4000 AC, P Stand Installation

6 Feet (1.82 meters)

Figure 3-1 Transducer Stand Assembly (RTV)

Chapter 3: Installation Instructions

Chapter 3: Installation Instructions

3.2.2 Conveyor Mount Frame Installation (CMS)

Figure 3-2 Conveyor Mount Stand Dimensions (CMS)

1. Assemble the frame assembly as shown in Figure 3-3.

Chapter 3: Installation Instructions

8. Mount the junction box using the -20 x hardware provided.

Figure 3-3 Conveyor Mounted Transducer Assembly

Chapter 3: Installation Instructions