Omnivision II-Operation-English-45721-0215 - CCv0001 PDF

Omnivision II Operation Guide
Document 45721-0215
Industrial Dynamics Company, Ltd.
Document 45721-0215 Copyright 2015. 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Topics That This Guide Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Audience of This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii
Conventions That Appear in This Guide . . . . . . . . . . . . . . . . . . . . . . . . . .viii
1. Overview of Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Section Page
1.1 Omnivision II Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
1.3 How Omnivision II Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
1.4 Overview of Omnivision II Components . . . . . . . . . . . . . . . . . . . . . . . . .1-26
1.5 Base Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
1.6 Outer Sidewall Inspection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
1.7 Polycarbonate Safety Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
1.8 Monitor Station: Screen, Keypads, and Track Pad . . . . . . . . . . . . . . . . . .1-30
1.9 Signal Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
1.10 Container Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
1.11 Starwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
1.12 Main Power Switch and Emergency Stop Button . . . . . . . . . . . . . . . . . . .1-43
2. Turning On and Turning Off Omnivision II . . . . . . . . . . . . . . 2-1
Section Page
2.1 Turning On Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Turning Off Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Table of Contents iii

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3. Using Omnivision II System Software. . . . . . . . . . . . . . . . . . 3-1
Section Page
3.1 Common Parts of Omnivision II Screens . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Status Overview Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3 Status System Current Period and Previous Period Screens. . . . . . . . . . . 3-8
3.4 Status Base Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3.5 Status ISW Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3.6 Status Finish Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3.7 Status Thread Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
3.8 Status OSW Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3.9 Status Test Bottle Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
3.10 Status Reject History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3.11 Status CCRP History Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
3.12 Control Test Bottle Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
3.13 Control Test Bottle Test Results Dialog Box . . . . . . . . . . . . . . . . . . . . . .3-45
3.14 User Logon Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
4. Commissioning Omnivision II . . . . . . . . . . . . . . . . . . . . . . . 4-1
Section Page
4.1 Testing Containers and Analyzing Results . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Determining the Cause of a Failed Test Run . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3 Changing Over Containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
5. Maintaining, Servicing, and Troubleshooting Omnivision II . . . 5-1
Section Page
5.1 Routine Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Alarms and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
Documentation Feedback . . . . . . . . . . . . . . . . . . . .Feedback-1
Help Us Improve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-1

Ways to Submit Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-1
Documentation Feedback Form . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-2
iv Omnivision II Operation Guide

Document 45721-0215
List of Figures
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
1. Overview of Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-1. Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Figure 1-2. Typical Press or Crown Finish Container . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-3. Overpress Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Figure 1-4. Image of an Overpress on a Screen . . . . . . . . . . . . . . . . . . . . . . .1-14
Figure 1-5. Inspection Setup OSW Camera/Display Screen . . . . . . . . . . . . . . .1-15
Figure 1-6. A Typical ROPP Finish Container . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Figure 1-7. A Scuffed Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18
Figure 1-8. A Typical Twist Off Finish Container . . . . . . . . . . . . . . . . . . . . . . .1-20
Figure 1-9. Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-22
Figure 1-10. Major Components of Omnivision II . . . . . . . . . . . . . . . . . . . . . . .1-26
Figure 1-11. Base Unit With the Optional Door Feature. . . . . . . . . . . . . . . . . . .1-27
Figure 1-12. Outside the Outer Sidewall Inspection Unit . . . . . . . . . . . . . . . . . .1-28
Figure 1-13. Opened Front Polycarbonate Doors on the Omnivision II Base Unit. . .1-29
Figure 1-14. Monitor Station on Recent Models of Omnivision II . . . . . . . . . . . . .1-30
Figure 1-15. Monitor Station on Earlier Models of Omnivision II . . . . . . . . . . . . .1-31
Figure 1-16. Signal Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
Figure 1-17. Container Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Figure 1-18. Outer Sidewall (Rotator) Guides . . . . . . . . . . . . . . . . . . . . . . . . .1-34
Figure 1-19. Rolling and Staggering of Containers in the Outer Sidewall Guides. . .1-34
Figure 1-20. Progression of Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
Figure 1-21. Infeed Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Figure 1-22. Components in the Starwheel Area . . . . . . . . . . . . . . . . . . . . . . .1-37
Figure 1-23. Neck and Body Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Figure 1-24. Starwheel, Starwheel Motor, and the High Resolution Encoder . . . . .1-39
Figure 1-25. Deadplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
Figure 1-26. Air Knife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Figure 1-27. Outfeed Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Figure 1-28. Starwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
List of Figures v
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Figure 1-29. Main Power Switch and Emergency Stop Button . . . . . . . . . . . . . . .1-43
2. Turning On and Turning Off Omnivision II . . . . . . . . . . . . . . 2-1
3. Using Omnivision II System Software. . . . . . . . . . . . . . . . . . 3-1
Figure 3-1. Common Parts of Omnivision II Screens . . . . . . . . . . . . . . . . . . . . 3-2
4. Commissioning Omnivision II . . . . . . . . . . . . . . . . . . . . . . . 4-1
5. Maintaining, Servicing, and Troubleshooting Omnivision II . . . 5-1
Documentation Feedback . . . . . . . . . . . . . . . . . . . .Feedback-1
vi Omnivision II Operation Guide

Document 45721-0215
Preface
Introduction
The Omnivision II documentation provides operators, technicians,

and service personnel with complete information about
Omnivision II. Other documents that describe Omnivision II that
you can consult include:
• The first volume of the Omnivision II Service and Installation

Guide, which is titled Volume 1 Installing and Starting,
describes how to install the Omnivision II, associated
equipment, configure, and start Omnivision II.
• The second volume of the Omnivision II Service and Instal-
lation Guide, which is titled Volume 2 Software, describes the
Omnivision II software that you use keep Omnivision II 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 II 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 II.
• Omnivision II Drawing Pack contains system drawings and
schematics that you might need to complete procedures.
• Omnivision II Parts Catalog contains a pictorial parts catalog
of spare and service parts that you might need to maintain
and service Omnivision II.
Topics That This Guide Covers
Omnivision II Operation Guide tells you how to use and maintain

Omnivision II.
Preface vii
Document 45721-0215
Audience of This Guide
This guide is intended for use by operators who use Omnivision II

on a daily basis.
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 II Operation 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 II.
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 II, turn off
strictly observe the power and disconnect all
information that is provided. electrical power cables from
Omnivision II.
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 II, 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.
viii Omnivision II Operation Guide

Document 45721-0215
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. Omnivision II stores all user data and passwords
in the file users.mdb.
Preface ix
Document 45721-0215
x Omnivision II Operation Guide
Document 45721-0215
1. Overview of Omnivision II
This chapter presents an overview of Omnivision II.
Topics that this chapter covers include definitions of terms and

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

Document 45721-0215
1.1 Omnivision II Concepts
1.1.1 Definition: Alarm Message
An alarm message is diagnostic information that Omnivision II

displays in red in the lower left corner of all Omnivision II
screens, which are described later.
If you turn on the Omnivision II beacon, and Omnivision II

encounters a problem, Omnivision II also stops the conveyor.
Omnivision II continues to display the message until you clear it.

Omnivision II also adds this type of message to the list of
messages on the screen, which is described
later.
1.1.2 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.
1.1.3 Definition: Base
A base is the bottom rim of a container.
1.1.4 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.
1.1.5 Definition: Base Inspection
Base inspection is the inspection system on Omnivision II that

uses a charge-coupled device (CCD) camera to inspect the base of
containers.
1.1.6 Definition: Bottle
A bottle is referred to as a container in this documentation.
1-2 Omnivision II Operation Guide

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1.1.7 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.
1.1.8 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.
1.1.9 Definition: Bottles Per Hour
Bottles per hour, or BPH, is the number of containers that

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

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

Omnivision II.
1.1.12 Definition: CCW
CCW, or counter clockwise, is the direction in which you turn a

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

in mass and combines them into single file on a conveyor.
1.1.14 Definition: Container
A container refers to a bottle, can, or jar.

Document 45721-0215
1.1.15 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 II declares a defect for that
zone or lane.
1.1.16 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.
Special crowning heads on high speed fillers crimp containers.
No. Description
1
1 Crimping
Figure 1-1. Crimping
1.1.17 Definition: Crown Finish
A crown finish is a type of closure that is attached to a container

by crimping.

Document 45721-0215
Crown finish closures are often used on glass bottles.
Figure 1-2. Typical Press or Crown Finish Container
1.1.18 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.
1.1.19 Definition: CW
CW, or clockwise, is the direction in which you turn a knob,

screw, or other piece of hardware to tighten it.
1.1.20 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.
1.1.21 Definition: Detection
Detection is the process of identifying a flaw in a container and

possibly the reason an inspection system rejects that container.
1.1.22 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.

Document 45721-0215
A detection point is one pixel from the raw inspection image that
has been flagged as a fault.
1.1.23 Definition: Diagnostic Message
A diagnostic message, which Omnivision II displays in orange in

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

Omnivision II also adds this type of message to the list of
later.
1.1.24 Definition: Diffuser Spot
A diffuser spot is a stain or blot caused by soap or another liquid

or debris that has become attached to the surface of the diffuser
panel or camera window on the outer sidewall inspection unit,
and consequently detected by the outer sidewall camera during
inspection.
1.1.25 Definition: Downstream
Downstream is any point away from a fixed reference point,

along the direction of flow.
Flow
Reference point ---------------> Downstream
1.1.26 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 II 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.

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

depicts an emblem or logo.
1.1.28 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.
1.1.29 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.
1.1.30 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.
1.1.31 Definition: Finish
The finish is the type of sealing surface that is used to enclose

the contents of a container with an air tight seal.
1.1.32 Definition: Finish Image
The finish image is the reflected light from the crown finish of a
container that is received by the camera.

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1.1.33 Definition: Finish Inspection
Finish inspection is a subsystem of Omnivision II that inspects the

sealing area of a container.
Note: filtec formerly referred to finish inspection as UltraLine.
1.1.34 Definition: Fluting
Fluting is the curved parallel grooves on the outer sidewall

surface of a container.
1.1.35 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.
1.1.36 Definition: Housekeeping
Housekeeping is the tasks or operations that you or Omnivision II

needs to complete on a regular or scheduled basis.
1.1.37 Definition: Infeed
The infeed is the entrance (upstream) side of a container

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

II displays in green in the lower left corner of all Omnivision II
screens.
Omnivision II does not add this type of message to the list of

later.

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1.1.39 Definition: Inner Sidewall Inspection
Inner sidewall inspection is a subsystem of Omnivision II that

inspects the inner sidewall of containers.
1.1.40 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.
1.1.41 Definition: Inspection Donut
An inspection donut is the circular area within two rings on the

image of a container that Omnivision II inspects for defects.
No. Description
1 Inner ring of an inspection donut
2 Outer ring of an inspection donut
1.1.42 Definition: Knurling
Knurling is small ridges found on the bottom of a container.

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1.1.43 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 II can use up to five lanes to inspect the finish that

makes up a container.
Use this table to determine how the terms window and lane
correspond to the finish inspection that Omnivision II performs or
performed at one time.
Lane... Inspects for...
A Dropouts or marks
B Dropouts or marks
C Dropouts or marks
D Dropouts or marks, whichever you choose
E Dropouts or marks, whichever you choose
1.1.44 Definition: Last Detect
A last detect is the last value that exceeded the detection point
threshold that you specified for a zone or lane.
1.1.45 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.
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).

Document 45721-0215
1.1.46 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.
1.1.47 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.
1.1.48 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 II 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.
1.1.49 Definition: Marker
A marker is the colored highlight or highlights that Omnivision II

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 II uses or turns on for that container.
No. Description
1 Green marker
2 Purple marker
3 Blue marker
1
2
3
1.1.50 Definition: Mask
A mask is an area of a container that Omnivision II does not

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

protuberance on a container interferes with Omnivision II’s
accurate inspection of a container zone.
1.1.51 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 rejection
verification is turned off.
Also see False Accept.

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1.1.52 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.
1.1.53 Definition: Operator Menu
An operator menu is an Omnivision II screen that any person can

view on Omnivision II without entering a password.
1.1.54 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.
1.1.55 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.
1.1.56 Definition: Outer Sidewall
The outer sidewall is the outside wall of a container.
1.1.57 Definition: Outfeed
The outfeed is the exit or downstream side of a container

inspector.

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1.1.58 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 1-3. Overpress Finish
An image of an overpress looks like this on a screen:
Figure 1-4. Image of an Overpress on a Screen

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1.1.59 Definition: PET
PET is an acronym for plastic containers that are made of

polyethylene terephthalate.
1.1.60 Definition: Phase
A phase is a stage of four to six snapshots that the digital camera

in the Omnivision II outer sidewall subsystem takes as the
container passes through the inspection tunnel in Omnivision II.
Each phase includes up to four views.
These views are shown in Figure 1-5 and labeled V1 through V4.
These views have several inspection lanes. In Figure 1-5, the
setting lane in View 1, Phase 1 is detecting an object.
V1 V2 V3 V4
Figure 1-5. Inspection Setup OSW Camera/Display Screen

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1.1.61 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.
1.1.62 Definition: Reject History
Reject history is the listing on an Omnivision II screen of the most

recent causes of rejects and the number of consecutive occur-
rences for each reject cause that Omnivision II has detected.
1.1.63 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 II.
1.1.64 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.
1.1.65 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 1-6. A Typical ROPP Finish Container
1.1.66 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 1-7. A Scuffed Container
1.1.67 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.
1.1.68 Definition: Stippling
Stippling is the engraved dots, painted dots, or letters that

produce a graded image on a container.

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1.1.69 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.
1.1.70 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 II performs a

different kind of inspection in this area to compensate for this
dark spot.
1.1.71 Definition: Test Container
A test container is a container with specific defects that you use

to test the inspection capabilities of Omnivision II.
1.1.72 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.
1.1.73 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 II.
1.1.74 Definition: Tracking Segment 1
Tracking segment 1 is the distance between the base unit

inspection 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.

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1.1.75 Definition: Tracking Segment 2
Tracking segment 2 is the distance between the tracking segment

1 and the resynchronization 2 sensor.
1.1.76 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.
Twist off finish closures are often used on glass, plastic, and
metal jars and bottles.
Figure 1-8. A Typical Twist Off Finish Container
1.1.77 Definition: Upstream
Upstream is any point away from a fixed reference point, against

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

displays in yellow in the lower left corner of all Omnivision II
screens.

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Omnivision II does not log warning messages.
1.1.79 Definition: Window
A window is a trapezoidal, rectangular, or square, user-defined

area that Omnivision II superimposes on the image of a container
when inspecting a container.
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.
1.1.80 Definition: Zone
A zone is a circular, user-defined area that Omnivision II superim-

poses on the image of the container.

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1.2 Omnivision II
1.2.1 Definition
Omnivision II, or OV-II, 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 II also detects plugs, residual liquid, and foreign

objects in, and scuff marks on, empty glass or plastic bottles.
1.2.2 Purpose
Omnivision II 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.
1.2.3 Diagram
This diagram shows Omnivision II.
No. Description
1 Inspection head
2 Base unit
3 Outer sidewall inspection unit 3
1
Figure 1-9. Omnivision II

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1.2.4 Subsystems That Comprise Omnivision II
Omnivision II 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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1.3 How Omnivision II Works
1.3.1 Introduction
The standard Omnivision II provides accurate container base and

residual liquid detection (RLD) inspection.
Depending upon the configuration of your Omnivision II, 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
1.3.2 Description
In general, the container handling system of Omnivision II enables

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

Omnivision II is equipped with this option).
3. Through the Omnivision II 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 II includes the optional outer
sidewall inspection system, Omnivision II first inspects containers
for contamination on containers’ outer sidewall.
Omnivision II 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 II inspects containers for residual caustic,

Omnivision II 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 II 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 II software issues a timing signal that flashes a

solid state strobe light to illuminate the containers from above to
enable the Omnivision II 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).
The reflected light from the sealing rim 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 II inspection
system detects a defective container, the Omnivision II inspection
system releases the defective container onto the reject
conveyor.

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1.4 Overview of Omnivision II Components
1.4.1 Diagram
Use this diagram to learn the major components of Omnivision II.

1 23 4 5 6 7 8 9 10
15 14 13 12 11
No. Description
1 Down and jam sensor
2 Sonic sensor 1
3 Container washer
4 Sonic sensor 2
5 Infeed guides
6 Outer sidewall inspection unit and color detection (shown in blue)
7 Residual liquid detection (RLD) transmitter and receiver
8 Starwheel
9 Production conveyor
10 Monitor station
11 Reject crossover conveyor
12 Reject takeaway conveyor (also includes encoder, resynchronization sensor, and
downstream rejectors)
13 Base unit (shown in yellow)
14 Inspection points
15 Rotating diffuser
Figure 1-10. Major Components of Omnivision II

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1.5 Base Unit
1.5.1 Description
Omnivision II uses charged coupled device (CCD) cameras inside

the inspection head to inspect the finish, thread, base, and inner
sidewall. Omnivision II uses an infrared light detector and
optional radio frequency detector to inspect the inside of the
container for the presence of residual liquid.
1.5.2 Diagram
5
No. Description
1 Monitor station
2 Inspection head
1
4 Starwheel
5 Signal beacon
2
Figure 1-11. Base Unit With the Optional Door Feature

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1.6 Outer Sidewall Inspection Unit
1.6.1 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.
1.6.2 Diagram
No. Description
1 Outer sidewall camera cabinet
2 Outer sidewall lighting cabinet (one on
each side, two in all) 1
3 Area through which your production or
throughput conveyor (which is not shown 2
in this diagram) passes
4 Outer sidewall lower cabinet 3
Figure 1-12. Outside the Outer Sidewall Inspection Unit
1.6.3 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 II software then processes and evaluates the images.

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

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1.7 Polycarbonate Safety Doors
1.7.1 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 II.
1.7.2 Diagram
No. Description
1 Polycarbonate doors
1 1
Figure 1-13. Opened Front Polycarbonate Doors on the

Omnivision II Base Unit

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1.8 Monitor Station: Screen, Keypads, and
Track Pad
1.8.1 Definition
The monitor station, which rotates 270 degrees, includes a touch

screen or a screen, keypad, buttons, and track pad, is the means
by which you interact with Omnivision II software, that is, how
you tell Omnivision II what to do and how to do it.
Earlier models of Omnivision II include the screen, keypads,

buttons, and track pad. More recent models include the touch
screen only.
1.8.2 Diagrams
No. Description
1 Touch screen
Figure 1-14. Monitor Station on Recent Models of Omnivision II

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No. Description
1 Screen
2 Numeric keypad, which you use to
enter numbers on dialog boxes
and screens
1
3 Track or mouse pad, including a
left and right track pad buttons
4 Navigation keypad
5 At present, this button is not used
6 Stop-the-starwheel button
7 Clear to Run button, which clears
an error condition that you have
resolved or repaired
Note: Even after applying power

and resolving the error condition,
Omnivision II brakes the 10
starwheel until you press this 9
button. 2
8 At present, this set of buttons is
not used
9 Clear-all-alarms button
10 Machine status indicator
3 4 5 6 7 8
Figure 1-15. Monitor Station on Earlier Models of Omnivision II

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

II, is a stack of five different colored signal lights that indicate
the current machine status of Omnivision II.
1.9.2 Diagram
No. Description
1 Red beacon, which, if lit, indicates that Omnivision II has generated a 1
critical alarm
2 Orange beacon, which, if lit, indicates that Omnivision II has generated a 2
warning
3 Green beacon, which, if lit, indicates that power is applied to Omnivision II 3
and that Omnivision II 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 II
5
Note: If beacons are not lit, power to Omnivision II is turned off.
Figure 1-16. Signal Beacon

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1.10 Container Handling System
1.10.1 Definition
The container handling system is that part of Omnivision II 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.
1.10.2 Description
The container handling system includes the outer sidewall guides,

infeed guides, neck and body guides, starwheel, neck and body
belts, reject conveyor and guide rails, vacuum system, through
conveyor, and outfeed guides.
1.10.3 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 guides
5 Starwheel, starwheel motor, and high resolution encoder
6 Reject conveyor system
7 Outfeed guides
Figure 1-17. Container Handling System

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1.10.4 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 1-18. 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 1-19. 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 II 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 10 camera windows
that you define, for each view of each phase.
Figure 1-20. Progression of Images

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The preceding diagram shows four views per phase, enabling
Omnivision II 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 II 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 II is
equipped) or directly into the base system, and then to the
outfeed guides.
No. Description
1
1 Infeed guides
Figure 1-21. 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
guides, 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 guide belt
3 Orange body belt 3
4 Air knife blow off assembly, 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
4
7 Water drip valve, which provides water on
the rotating glass for cleaning by the rotating
brush
5 6 7
Figure 1-22. Components in the Starwheel Area
Neck and Body Guides
The neck guide and body 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 1-22. Components in the Starwheel Area, the
neck guide is suspended over the body guide, just underneath the
inspection head and parallel with the necks of containers. The
body guide is suspended below the neck guide, just above the
base cabinet and parallel with the bodies of containers.
No. Description
1 Starwheel
1
2 Green container neck belt
3 Orange container body belt
4 Container
3 4
Figure 1-23. Neck and Body Guides
Starwheel
The two belts of the neck and body 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 (1600 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.
Figure 1-24. 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 II 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.
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.
The deadplate ensures that containers pass smoothly from the

infeed to the outfeed guides.
1
2
3
3
No. Description
1 Downstream height adjustment
2 Lock knob
3 Support brackets
4 Upstream height adjustment
Figure 1-25. 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 1-26. Air Knife
Outfeed Guides
After Omnivision II completes inspection, the starwheel releases

containers that pass inspection into the outfeed guides, which
guide the good containers back onto the production conveyor.
Figure 1-27. Outfeed Guides

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1.11 Starwheel
1.11.1 Definition
A starwheel is a custom-made change part that holds, positions,

and transports each container through Omnivision II.
1.11.2 Description
filtec custom manufactures the starwheel for each particular

type of container that you run through Omnivision II.
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.
1.11.3 Diagram
No. Description
1 Suction cups
2 Starwheel hub
3 Hub knob
4 Tubes
5 Identifier for pocket
1 on the starwheel
1 4
2 3
5
Figure 1-28. Starwheel

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

ately stop Omnivision II and production in an emergency.
The main power switch is a device that you use to turn off and
power down Omnivision II.
1.12.2 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 II
includes two emergency
stop buttons, one on the
front and one on the back
Figure 1-29. Main Power Switch and Emergency Stop Button
1.12.3 How the Emergency Stop Button Works
To immediately stop production in an emergency, you press in

the emergency stop button.
After you resolve the emergency and want to restart production,

you pull out or turn the emergency stop button clockwise.
To clear error messages, you press the button in the lower

right corner of the screen, and then select .

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

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2. Turning On and Turning Off
Omnivision II
This chapter tells you how to turn on and turn off Omnivision II.
Turning On and Turning Off Omnivision II 2-1

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2.1 Turning On Omnivision II
2.1.1 Steps
Follow these steps to turn on Omnivision II.
1. Ensure that both emergency stop buttons are pulled out.
Caution: Omnivision II 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 II starts. After a few minutes, Omnivision

II displays the screen on the monitor
station screen.
Turning On and Turning Off Omnivision II 2-3

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2.2 Turning Off Omnivision II
2.2.1 Steps
When you are finished using Omnivision II or when you need to

perform maintenance or an upgrade, follow these steps to turn
off Omnivision II.
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 II displays the message On Battery.
• The Omnivision II software closes.
• Omnivision II displays a shut down message on the
monitor station screen.
• Omnivision II shuts down the operating system.
• Omnivision II displays a blue screen for up to 20 seconds.
Important: During this period of time, Omnivision II continues

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

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 II.

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3. Using Omnivision II System
Software
This chapter describes screens that you use to administer,

configure, and monitor Omnivision II.
Using Omnivision II System Software 3-1

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3.1 Common Parts of Omnivision II Screens
3.1.1 Diagram
Here is a diagram of typical Omnivision II screens.
4
5 6 7 8 9 10 11 12 13 14
15 16
Figure 3-1. Common Parts of Omnivision II Screens

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3.1.2 Description
Use this table to learn about the common parts of Omnivision II

screens, as shown in the previous diagram.
No. Description Example
1 Rows of tabs that you select to perform an operation or display an

Omnivision II screen
2 Enable or disable switch, which you use to switch on or switch off a

field
3 Numeric spinner, which you use to increment or decrement a value for

a parameter, or, after pressing the numeric spinner box, type a value
in the dialog box with the graphic keyboard that Omnivision II displays
4 Image of the container that Omnivision II is currently inspecting
5 The current date and time or a diagnostic message, as shown below
If a container fails inspection, Omnivision II displays a code that

represents the type of inspection that it failed in the diagnostic
message.
Code Description
RLD Residual liquid detection
FIN Finish inspection
THR Thread inspection
BASE Base inspection
ISW Inner sidewall inspection
OSW Outer sidewall inspection
T Test container
6 Button that cycles the display of a container by the current subsystem

to the display of the container by the next subsystem, in the following
order:
• Base
• Inner sidewall
• Finish
• Thread
• Outer sidewall 1
• Outer sidewall 1/2/3
7 Icon that represents the subsystem, or inspection, that is currently

selected

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8 Button that executes a command
9 Button that indicates that you want to hold, or freeze, rejected

containers
10 The number of seconds that you want Omnivision II to hold, or freeze,

a rejected container image
11 Button that displays a pop-up window that lists status messages that
Omnivision II generates
12 Color coded icon that represents the status of Omnivision II, as

described in Signal Beacon
13 Button that saves, in three separate files on the Omnivision II hard

drive, the next image that the currently active subsystem acquires
Note: Omnivision II saves the three images as full-resolution, 16-bit,

grayscale, tagged image format file (TIFF) images in the directory
C:\Data\Images on your Omnivision II hard drive.
Best Practice: Use this button to diagnose problems.
14 Icons that represent the particular type of defect for which Omnivision
II rejects a container
ntaTest
ew r
ew r
all
r
all
RF ectio l
tec al
2
se
ish
n
a
ine
Sid Inne
Sid ute
rea
tio
ct
ct
De idu
De sidu
Ba
Fin
eje
eje
O
Th
s
Re
Re
t
xR
xR
Co
IR
Au
Au
When Omnivision II detects a defect, it changes the green background
to red
ntaTest
se
ish
n
ew r
ew r
all
all
RF ectio l
tec al
r
1
2
a
ine
Sid Inne
Sid ute
tio
rea
ct
ct
De idu
De sidu
Ba
Fin
eje
eje
O
Th
s
Re
Re
t
xR
xR
Co
IR
Au
Au
15 “Traffic light” icons that represent whether rejection of containers is

turned on (green) or turned off (red)
16 “Trigger” icons that represent whether Omnivision II is currently

examining a zone or detecting a defect on the container that is passing
on the conveyor.
Bright red indicates that, at present, Omnivision II is detecting a

defect or active state. Dark red or burgundy indicates that, at present,
Omnivision II is not detecting a defect or active state.

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Radio button, which you press to select a particular field.
Note: When you select a radio button, a black dot appears in the
center.

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3.2 Status Overview Screen
3.2.1 Diagram
Here is the screen.
3.2.2 Purpose
You use this screen to determine the basic rejection percentage

values.
This screen includes the current number of good containers,

current number of rejected or bad containers, and the total
percentage of bad containers that Omnivision II has detected in
relation to good containers that it has detected.
You also use this screen as the jumping off point for all
Omnivision II menus and screens.

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3.2.3 Fields on the Status Overview Screen
Use this table to determine the purpose of the fields on this

screen.
Use this field... To...
Good Bottles Determine the current number of containers

that Omnivision II has inspected that have
passed inspection during the time period since
the counters were last reset.
Rejects Determine the current number of containers

that Omnivision II has rejected because the
containers do not meet inspection criteria
during the time period since the counters were
last reset.
% Determine the total percentage of bad

containers that Omnivision II has detected in
relation to good containers that it has
detected, to two decimal places, during the
time period since the counters were last reset.

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3.3 Status System Current Period and
Previous Period Screens
3.3.1 Diagram
Here is the screen.

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Here is the screen.
3.3.2 Purpose
You use these screens to determine the count and corresponding

percentage of containers that Omnivision II has rejected up to the
present time during the current shift or during the period since
the counters were last reset.
These screens include counts and percentages for each

subsystem.
Important: The total reject percentage is not typically the sum

of the subsystem rejects, since multiple subsystems can detect
the same defects.

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3.3.3 Fields on the Status System Current Period and
Previous Period Screens
Use this table to determine the purpose of the fields on these

screens.
Total Bottles Determine the total number and percentage of

containers that Omnivision II has inspected thus
far in the current period.

passed inspection in the current period.
Total Rejects Determine the total number and percentage of

containers that Omnivision II has rejected due
to flaws or foreign objects that all Omnivision II
subsystems have detected in the current
period.
Bottles Per Minute Determine the current speed of your conveyor,

in containers per minute (CPM).
Range: Omnivision II displays a value between 0

and 1350 containers per minute (CPM)
inclusive.
Conveyor Slip Ratio Determine the current slip ratio for the
starwheel versus the conveyor speed, in
percent.
Range: Omnivision II displays a value between 0

and 20 percent inclusive.
Note: Slip ratio is the difference between the

speed of the conveyor and the speed of your
starwheel, both in feet or meters per minute,
divided by the speed of the conveyor,
expressed as a percentage.
Reject Type (box) Determine the current number and percentage

of containers that Omnivision II has rejected for
each of the four virtual rejector types.
Note: You assign the names

of the four virtual rejector
types (shown as VR1 through
VR4 in the preceding
diagrams) on the
screen.
System Reject Status Determine the total number and percentage of

(box) containers that Omnivision II has rejected
altogether, and that each listed subsystem has
Subsystems Reject Status rejected individually.
(box)
All Subsystems Determine the total number and percentage of

containers that all Omnivision II inspection
subsystems have rejected altogether.

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Base Determine the total number and percentage of

containers that the base inspection subsystem
has rejected.
Inner Sidewall Determine the total number and percentage of

containers that the inner sidewall inspection
subsystem has rejected.
Finish Determine the total number and percentage of

containers that the finish inspection subsystem
has rejected.
Thread Determine the total number and percentage of

containers that the thread inspection
OSW Determine the total number and percentage of

containers that the outer sidewall inspection
RF RLD Determine the total number and percentage of

containers that the radio frequency residual
liquid detection inspection subsystem has
rejected.
Note: RF RLD stands for radio

frequency residual liquid
detection.
IR RLD Determine the total number and percentage of

containers that the infrared residual liquid
detection inspection subsystem has rejected.
Note: IR RLD stands for

infrared residual liquid
detection.
Auxiliary 1 Determine the total number and percentage of

containers that the first optional installed
auxiliary subsystem that you define has
rejected.

of the two optional
subsystems (shown as
Auxiliary 1 and Auxiliary 2 in
the preceding diagrams) on
on the
screen.

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Auxiliary 2 Determine the total number and percentage of

containers that the second optional installed
auxiliary subsystem that you define has
rejected.

of the two optional inspection
on the
screen.
Reject Filter Determine the number and percentage of

rejects that Omnivision II detects.
Note: You can limit the

scuffing rejects that
Omnivision II detects to a
percentage that you select.
3.3.4 Unique Buttons on the Status System Current

Period Screen
Use this table to determine the purpose of the unique buttons on

this screen.
Use this button... To...
Save Current Period Counters Save copies of all counter values for
containers that Omnivision II has recorded
during the current period.
Note: You can use the values of these

counters to diagnose problems.

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3.4 Status Base Screen
3.4.1 Diagram
Here is the screen.
3.4.2 Purpose
You use this screen to determine the more detailed statistics for
the base inspection subsystem.
This screen lists the total number of inspected containers, the

current number of good containers, and the current number of
bad containers that Omnivision II has rejected due to defects in
the base.

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3.4.3 Fields on the Status Base Screen

screen.
Overall Statistics (box) Determine the total number of containers that

Omnivision II has inspected, good containers
that Omnivision II has inspected, and the
number and percentage of base rejects that
Omnivision II has detected.
Total Bottles Determine the total number of containers that

Omnivision II has inspected thus far in the
current period.

passed base inspection in the current period.
Base Defects Determine the total number and percentage of

to flaws or foreign objects that the Omnivision
II base subsystem has detected in the current
period.
Status & Sensitivity (box) Determine the current sensitivity settings for
the center, inner rim, inner mid rim, middle
rim, outer mid rim, and outer rim, plug/color
base inspection zones.
You set the sensitivity settings for all of the

base inspection zones on the
screen.
Reject Enable Determine if the rejection of containers due to

defects in a base inspection zone is turned on
or turned off.

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Detection Level Determine whether inspection of a particular

inner sidewall inspection zone is turned on or
turned off as well as the total number of
detection points on the last rejected container
that Omnivision II logged when it inspected the
rejected container.
Columns under Detection Level list include:
• Count, which lists the total number of

containers that Omnivision II has rejected
due to flaws or foreign objects that it
detected in a particular inner sidewall
inspection zone since the counters were
last reset.
• Current, which lists the most recent
container that Omnivision II rejected due
to flaws or foreign objects that it detected
in a particular inner sidewall inspection
zone since the counters were last reset.
• Last Detect, which lists the previous
container that Omnivision II rejected due
to flaws or foreign objects that it detected
in a particular inner sidewall inspection
zone since the counters were last reset.
Note: The values that Omnivision II displays
under the Current field increase as the size or
the darkness of the object increases.
Center Determine whether inspection of the center

base inspection zone is turned on or turned off.
You also use this field to determine the number

and frequency of containers that Omnivision II
has rejected due to defects in the center
inspection zone for the current or some
temporary period of time.
Inner Rim Determine whether inspection of the inner rim


has rejected due to defects in the inner rim
Inner Mid Rim Determine whether inspection of the inner mid

rim base inspection zone is turned on or turned
off.

has rejected due to defects in the inner mid
rim inspection zone for the current or some
Middle Rim Determine whether inspection of the middle

off.

has rejected due to defects in the middle rim

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Outer Mid Rim Determine whether inspection of the outer mid

off.

has rejected due to defects in the outer middle
rim inspection zone for the current or some
Outer Rim Determine whether inspection of the outer rim


has rejected due to defects in the outer rim
Plug/Color Determine whether inspection of the plugged

neck or color base inspection zone is turned on
or turned off.

has rejected due to defects in the neck or
color.
Note: The color sort feature

uses the same information
and the same adjustment that
you use in plugged neck
detection.
The color sort feature detects
a container whose color
grossly differs from the color
of the container that
Omnivision II is currently
inspecting.
Example: When inspecting
amber containers, Omnivision
II detects any intermixed flint
container. When running flint
containers, Omnivision II
detects any intermixed amber
container.

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3.5 Status ISW Screen
3.5.1 Diagram
Here is the screen.
3.5.2 Purpose
the inner sidewall (ISW) inspection subsystem.

bad containers that Omnivision II rejected due to defects on the
inner sidewall.

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3.5.3 Fields on the Status ISW Screen

screen.

number and percentage of inner sidewall
rejects that Omnivision II has detected.

current period.

passed inner sidewall inspection in the current
period.
ISW Defects Determine the total number and percentage of

II inner sidewall subsystem has detected in the
current period.
the bottom, lower, lower mid, middle, upper
mid, upper, large object, and plug/color inner
sidewall inspection zones.
You set the sensitivity settings for all of the

inner sidewall inspection zones on the
screen.
Reject Enable Determine if the rejection of containers due to

defects in an inner sidewall inspection zone is
turned on or turned off.

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Detection Level Determine whether inspection of a particular

Count turned off as well as the total number of
detection points on the last rejected container
Current that Omnivision II logged when it inspected the
rejected container.
Last Detect
Columns under Detection Level list the:
• Total number of containers that

Omnivision II has rejected due to flaws or
foreign objects that it detected in a
particular inner sidewall inspection zone
(under Count) since the counters were last
reset.
• Most recent container that Omnivision II
rejected due to flaws or foreign objects
that it detected in a particular inner
sidewall inspection zone (under Current)
since the counters were last reset.
• Previous container that Omnivision II
rejected due to flaws or foreign objects
that it detected in a particular inner
sidewall inspection zone (under Last
Detect) since the counters were last reset.

Bottom Determine whether inspection of the bottom

turned off.

has rejected due to defects in the bottom
Lower Determine whether inspection of the lower

turned off.

has rejected due to defects in the lower
Lower Mid Determine whether inspection of the lower mid

turned off.

has rejected due to defects in the lower mid

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Middle Determine whether inspection of the middle

turned off.

has rejected due to defects in the middle
Upper Mid Determine whether inspection of the upper mid

turned off.

has rejected due to defects in the upper mid
Upper Determine whether inspection of the upper

turned off.

has rejected due to defects in the upper

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Large Object Determine whether inspection for a large

object in the inner sidewall inspection zone is

has rejected due to the presence of a large
object in the inner sidewall inspection zone for
the current or some temporary period of time.
Plug/Color Determine whether inspection of the plugged

neck or color base inspection zone is turned on
or turned off.

has rejected due to defects in the neck or
color.
Note: The color sort feature

uses the same information
and the same adjustment that
you use in plugged neck
detection.
The color sort feature detects
a container whose color
grossly differs from the color
of the container that
Omnivision II is currently
inspecting.
Example: When inspecting
amber containers, Omnivision
II detects any intermixed flint
container. When running flint
containers, Omnivision II
detects any intermixed amber
container.

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3.6 Status Finish Screen
3.6.1 Diagram
Here is the screen.
3.6.2 Purpose
the finish inspection subsystem.

finish.

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3.6.3 Fields on the Status Finish Screen

screen.

number and percentage of finish rejects that

current period.

passed finish inspection in the current period.
Finish Defects Determine the total number and percentage of

II finish subsystem has detected in the current
period.
the bottom, lower, lower mid, middle, upper
mid, upper, large object, and plug/color inner
sidewall inspection zones.
You set the sensitivity settings for all finish

inspection zones on the screen.
Rejects Enabled Determine if the rejection of containers due to

defects in a particular finish inspection zone is
Last Result Determine whether the inspection of a

particular finish inspection zone passed or
failed.
Period Defects Determine the number of defects that

Omnivision II has detected for a particular
finish inspection zone since the counters were
last reset.
Finish Rejects Determine if the rejection of containers due to

defects in the finish inspection zone is turned
on or turned off.
Track Locator Determine if the finish ring is found or not.
Tracking Length Determine if the finish ring is incomplete or

not.
Lane A Inspection Determine the number of defects that

Omnivision II has detected for lane A.
Lane B Inspection Determine the number of defects that

Omnivision II has detected for lane B.
Lane C Inspection Determine the number of defects that

Omnivision II has detected for lane C.

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Lane D Inspection Determine the number of defects that

Omnivision II has detected for lane D.
Lane E Inspection Determine the number of defects that

Omnivision II has detected for lane E.
Light Level Determine the average light level for the

containers that the Omnivision II finish
subsystem has inspected.
Best Practice: Typically, you set the value for

Lower Limit to a value that is less than 100.
The value in the Light Level field for a rejected
container is displayed under the heading Last
Detect.
For normal containers, specify a value in the

Light Level field that ranges from 150 to 250,
although in some cases, you can specify a
higher limit of 500.

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3.7 Status Thread Screen
3.7.1 Diagram
Here is the screen.
3.7.2 Purpose
the thread inspection subsystem.

bad containers that Omnivision II rejected due to thread defects.

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3.7.3 Fields on the Status Thread Screen

screen.

number and percentage of thread rejects that

current period.

passed thread inspection in the current period.
Thread Defects Determine the total number and percentage of

II thread subsystem has detected in the current
period.
Status & Sensitivity Determine the current sensitivity settings for

Sensitivity (box) the centering, tracking, lane A, lane B, lane C,
lane D, and lane E thread inspection zones.
You set the sensitivity settings for all thread

inspection zones on the screen.
Reject Enabled Determine if the rejection of containers due to

defects in thread inspection zones is turned on
or turned off.
Last Inspection Results Determine whether the:

Period Detects
• Inspection of a particular thread inspection
zone passed or failed (under Last
Inspection Results).
• Number of defects that Omnivision II has
detected for a particular thread inspection
zone since the counters were last reset
(under Period Detects).
Centering Determine if Omnivision II detects centering

errors.
Tracking Determine if Omnivision II detects for parts of

an image that are not found.
Lane A Determine the number of detects that

Omnivision II has detected for lane A.
Lane B Determine the number of detects that

Omnivision II has detected for lane B.
Lane C Determine the number of detects that

Omnivision II has detected for lane C.

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Lane D Determine the number of detects that

Omnivision II has detected for lane D.
Lane E Determine the number of detects that

Omnivision II has detected for lane E.

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3.8 Status OSW Screen
3.8.1 Diagram
Here is the screen.
3.8.2 Purpose
the outer sidewall (OSW) inspection subsystem.

outer sidewall.

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3.8.3 Fields on the Status OSW Screen

screen.

number and percentage of outer sidewall
rejects that Omnivision II has detected.

current period.

passed thread inspection in the current period.
OSW Defects Determine the total number and percentage of

II outer sidewall subsystem has detected in the
current period.
Algorithm 1 Display statistical information for algorithm 1,

which includes detection counters during the
current period for each window that your
Omnivision II administrator has defined.
Your Omnivision II administrator can define

from 1 to 15 unique windows for inspection.
Algorithm 2 Display statistical information for algorithm 2,

which includes detection counters during the
current period for each window that your
Omnivision II administrator has defined.
Your Omnivision II administrator can define

from 1 to 15 unique windows for inspection.
Window Results (box) Determine the number of times that Omnivision

II has detected a flaw or foreign object within a
lane in the current period since the counters
were last reset.

the
screen.
Window Determine the particular lane in which

Omnivision II detected a flaw or foreign object.
Period Determine the number of times that Omnivision

II has detected a flaw or foreign object within a
particular lane.

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3.8.4 Unique Buttons on the Status OSW Screen

this screen.
Select Phase to Display Display each phase separately.
Note: You press the button each time to display

the particular phase that you want.

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3.9 Status Test Bottle Screen
3.9.1 Diagram
Here is the screen.
3.9.2 Purpose
You use this screen to determine the expected inspection results

by each subsystem on each test container.
Omnivision II matches these expected inspection results against

the actual results in determining a pass or fail test for each
inspection.
This screen also indicates those inspections that you specified

that Omnivision II is to ignore.

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3.9.3 Fields on the Status Test Bottle Screen

screen.
ID # Determine the identification number, from 1 to

10, that you have assigned to a particular test
container.
Bottle Defects Determine whether a particular Omnivision II

inspection subsystem that is listed in this
column detected a defect in a test container.
IR Detected Liquid Determine whether the infrared residual liquid

subsystem correctly detected a defect in one or
more test containers.
RF Detected Liquid Determine whether the radio frequency

residual liquid subsystem correctly detected a
defect in one or more test containers.
Auxiliary 1 Determine whether the first auxiliary

subsystem, which you define, correctly
detected a defect in one or more test
containers.

the
screen.
Auxiliary 2 Determine whether the second auxiliary

subsystem, which you define, correctly
detected a defect in one or more test
containers.

the
screen.
Finish Determine whether the finish subsystem

correctly detected a defect in one or more test
containers.
Thread Determine whether the thread subsystem

containers.
Base Determine whether the base subsystem

containers.

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Zone Determine whether the base subsystem

correctly detected a defect in the center,
inner, inner mid, middle, outer mid, or outer
zone in one or more containers.
Note: You select the particular zone that you

want.
Light Level Determine whether the base subsystem

correctly detected the correct light level in one
or more test containers.
ISW Determine whether the inner sidewall

Zone Determine whether the inner sidewall

subsystem correctly detected a defect in the
bottom, lower, lower mid, middle, upper mid,
or upper zone in one or more containers.
Note: You select the particular zone that you

want.
Light Level Determine whether the inner sidewall

subsystem correctly detected the correct light
level in one or more test containers.
Large Object Determine whether the inner sidewall

subsystem correctly detected a large object in
one or more test containers.
Outer Sidewall Determine whether the outer sidewall

Window Determine whether the outer sidewall

subsystem correctly detected a defect in any of
the possible 15 lanes in one or more containers.
Note: You select the particular lane that you

want.
3.9.4 Icons on the Status Test Bottle Screen
Use this table to determine the purpose of the icons on this

screen.
This icon... Indicates that Omnivision II...
Green plus Correctly detected an object in the zone, as

you or your supervisor specified on the
screen.
Green minus Correctly did not detect an object in the zone,

as you specified on the screen.
Red plus Detected an object in the zone that you or your

supervisor did not specify on the
screen.

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This icon... Indicates that Omnivision II...
Red minus Did not detect an object in the zone that you or
your supervisor specified on the
screen.
Ignore Ignored results in the zone, as you or your

supervisor specified on the
screen.
3.9.5 Unique Buttons on the Status Test Bottle Screen

this screen.
Print Results Print the results of container test runs on a

printer that you have connected to Omnivision
II.
Note: Qualified filtec service personnel or

customer personnel who have received training
from filtec install, connect, and set up the
printer or printers that you use with Omnivision
II.
3.9.6 See Also
The section Status CCRP History Screen describes another

screen that you can use to determine the expected inspection
results by each subsystem on each test container.

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3.10 Status Reject History Screen
3.10.1 Diagram
Here is the screen.
3.10.2 Purpose
You use this screen to view a scrolling list of rejects by subsystem

as Omnivision II encounters them.
You use this screen to determine which inspection zones are the
source of the most recent rejects.
Each row represents a single container.

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3.10.3 How This Screen Works
If inspection of a container by a particular subsystem passes, the

Omnivision II subsystem displays the green traffic icon .
If inspection of a container by a particular subsystem fails, the

Omnivision II subsystem displays the red traffic icon .
3.10.4 Fields on the Status Reject History Screen

screen.
Digit Determine the unique tracking identifier of a

container that failed to pass inspection.
Omnivision II assigns this unique tracking

identifier to each container to track it as it
passes through Omnivision II.
Omnivision II displays only the container

tracking identifier for containers that fail to
pass inspection.
Range: 0 to 255, inclusive
Note: Omnivision II restarts the count from 0

after assigning 255 to a container.
Omnivision II displays a maximum of 200

containers on this screen at one time.
Note: At present, you cannot scroll down the

list, as the scroll buttons do not work in the
current release.
Total Messages Determine the total number of rejected

containers that are displayed on the Status
Reject History screen.
Note: The only time that you will see the value
that is shown in this field change from 200 is
when Omnivision II detects fewer than 200
rejected containers on your production line and
when you start and stop your conveyor.

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3.10.5 Icons on the Status Reject History Screen
Use this table to determine the purpose of the icons on this

screen.
This icon... Represents...
Infrared residual inspection
Radio frequency inspection
Finish inspection
Thread inspection
Base inspection
Inner sidewall inspection
Outer sidewall inspection
Scuff filtering
Auxiliary 1 inspection
Note: You assign the names of the two

optional inspection subsystems (shown as
Auxiliary 1 and Auxiliary 2 in the
preceding diagrams) on the Machine
Configuration Subsystems screen.

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This icon... Represents...
Auxiliary 2 inspection
Note: You assign the names of the two

optional inspection subsystems (shown as
Auxiliary 1 and Auxiliary 2 in the
preceding diagrams) on the
screen.
Test container detected

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3.11 Status CCRP History Screen
3.11.1 Diagram
Here is the screen.
Note: CCRP stands for consumer complaint reduction program.
3.11.2 Purpose
You use this screen to view and print events that Omnivision II
generates.

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3.11.3 Types of Events That Omnivision II Displays
Omnivision II displays events on this screen when an:
• Operator runs a test container through Omnivision II

• Error occurs
• Operator changes a parameter or setting
3.11.4 Fields on the Status CCRP History Screen

screen.
Report Type (box) Specify the types of events that you want
Omnivision II to display in the list of events on
this screen.
You can switch on or switch off one or

more of the following fields:
• Test Bottle History

• Diagnostic Status Log
• Parameter Change Log
Test Bottle History Switch on or switch off the display of the date,
time, and the results of runs on this screen that
Omnivision II has performed on test containers
during the time frame that you specify.
Diagnostic Status Log Switch on or switch off the display of the date,
time, and error messages that Omnivision II has
generated during the time frame that you
specify.
Parameter Change Log Switch on or switch off the display of the date,
time, name of the operator, and the parameter
that that operator changed while using
Omnivision II during the time frame that you
specify.
Show Changes for All Switch on or switch off the display of container
Bottle Types types that are affected by an operator’s
changing a parameter.
Report Time Frame (box) Specify the number of previous events or period
of time during which Omnivision II generated
events that you want to display on this screen.
Previous Specify the number of previous events that you

want to display on this screen.
Range: You can specify a value between 0 and

99999 events inclusive in this field.

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Range of Dates Select the time period during which Omnivision

II generated events that you want to display on
this screen.
You can select three time periods:
• Hours
• Days
• Weeks
All Specify that you want Omnivision II to display

all events since Omnivision II was last restarted
on this screen.
3.11.5 Unique Buttons on the Status CCRP History Screen

this screen.
Print Print the list of events that Omnivision II

currently displays on the
screen.

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3.12 Control Test Bottle Screen
3.12.1 Diagram
Here is the screen.
3.12.2 Purpose
You use this screen to start, verify, or abort a test run or to print
test run results.

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3.12.3 Fields on the Control Test Bottle Screen

screen.
Summary (box) Determine the status of a test container run.
Total Test Bottles Determine the number of containers that you

intend to test.
Range: Omnivision II displays a value from 0 to

10 containers in this field, inclusive.
Current Time Determine the current time, in 24-hour format.
Test Bottle State Determine whether you are currently running a

test on containers or stopped.
Range: Omnivision II displays the values

Stopped or Inspecting in this field.
Next Scheduled Test Determine the number of containers inspected

or number of minutes until Omnivision II has
scheduled the next test container run.

99999 in this field, inclusive.
Important: If Omnivision II displays the period

of time until the next scheduled test in
containers rather than in minutes, the actual
period of time that elapses until the next test
depends on the speed of your conveyor.
Note: 99999 minutes equals approximately

69.44 days or 2.28 months.
Bottles Determine whether you are measuring the

Minutes period of time until the next scheduled test
container run in number of containers or in
number of minutes.
Range: Omnivision II displays the values Bottles

or Minutes in this field.
Operator Timeout Determine the number of seconds that

Omnivision II is going to wait after starting a
test container run before stopping because it
has not received a container at the inspection
point.
Note: This period of time enables you to insert

all test containers in the line and all containers
to get to the inspection point.

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Time to Complete Test Determine the number of minutes until

Omnivision II is expected to complete the test
container run.

Test Bottles to Go Determine the number of test containers

Omnivision II expects to inspect before it
completes the currently running test container
run.

3.12.4 Unique Buttons on the Control Test Bottle Screen

this screen.
Run Test Display the Control Test Bottle test results dialog box
and manually initiate a test run.
Abort Stop the test container run that Omnivision II is

currently running.
Test Verifier Test the functionality of the verifier system as a

whole.
Print Print results of the container test run.

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3.13 Control Test Bottle Test Results Dialog
Box
3.13.1 Introduction
Omnivision II displays this screen when you press the Run Test
button on the screen.
3.13.2 See Also
The section Status Test Bottle Screen describes another screen

that you can use to determine the expected inspection results by
each subsystem on each test container.
3.13.3 Diagram
Here is the test results dialog box.

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3.13.4 Purpose
You use this dialog box to determine the results of a test

container run.
3.13.5 Fields on the Control Test Bottle Test Results

Dialog Box

dialog box.
Auto PopUp Specify whether you want Omnivision II to

automatically display the Control Test Bottle
test result dialog box whenever Omnivision II
generates an error message.
Best Practice: Always switch on this switch .
3.13.6 Unique Buttons on the Control Test Bottle Test

Results Dialog Box

this dialog box.
Refresh List Update the display with any results that Omnivision II
has generated since you updated the list.
Clear to Run Clear all alarms
Hide Close the Control Test Bottle test results dialog box.
Red Display alarms.
Tan Display warning messages.

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Green Display only informational messages.
Blue Display test container requests.
White Display messages that indicate that an operator turned

on Omnivision II.

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3.14 User Logon Screen
3.14.1 Diagram
Here is the screen.
3.14.2 Purpose
You use this screen to log into Omnivision II.

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3.14.3 Fields on the User Logon Screen

screen.
Enter User ID Specify your user identification number, that

is, your one to four digit password.
Note: A user name and security level is

associated with each user identification
number.
Range: You can specify a value between 0 and

9999, inclusive, in this field.
3.14.4 Unique Buttons on the User Logon Screen

this screen.
Change Enter your user

identification number.
Logout/Change to Default User Revert to the lowest level

of security access on
Omnivision II.

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4. Commissioning Omnivision II
This chapter tells you how to set up inspection functions,

including base, inner sidewall, finish, thread, residual liquid
detection, and outer sidewall inspection.
Commissioning Omnivision II 4-1

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4.1 Testing Containers and Analyzing
Results
4.1.1 Steps
To verify that Omnivision II is operating correctly, you need to

run maintenance test runs at regularly scheduled intervals. Your
service department determines these intervals.
Follow these steps to test containers and analyze the results.
1. Gather the test containers that your service department

provides.
2. In your production line, insert the test containers a

minimum of 5 to 8 feet, or 1.8 to 2.4 meters, upstream from
the gap sensors.
Best Practice: Ensure that the test containers do not disturb

the normal production flow through the Omnivision II.
Inserting them into the combiner is a good choice. However,

always follow your plant operating procedures.
Also ensure that production line surges do not occur on the

line on which Omnivision II is installed.

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3. Display the screen.
4. Press the button.

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Result: Omnivision II runs the test and displays the test
results dialog box.
Important: If the Omnivision II does not detect the test

containers within the time limit, the starwheel stops turning
and Omnivision II generates an alarm message that instructs you
to run the test containers. If you see this error message, press
the button and reset the sequence.
You can abort testing at any time by pressing the

button.
5. As Omnivision II continues to run the test, press the

button.
Result: Omnivision II updates the number of containers

tested.

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6. When the number of tests run equals 0, display the
screen.
Result: Omnivision II displays the results of the test run.
Note: In the preceding example of the

screen, every test container passed.
7. Did the containers pass?
If yes, is this the first time that you have run the test?
If yes, repeat from step 2.

If no, stop, you have successfully finished testing
containers.
If no, go to the section Determining the Cause of a Failed
Test Run.

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4.2 Determining the Cause of a Failed Test
Run
4.2.1 Steps
If Omnivision II fails to complete a test run, you need to

determine if the failure occurred because you are using a
defective test container or if there is a problem with Omnivision
II.
Follow these steps to determine the cause of the failure.
2. Tap each folder to expand it, as shown below.

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3. Using this screen as a guide, determine which test or tests
are failing.
Note: Each test container that you use in the preceding sections
is configured to test a specific inspection function.
4. Visually inspect the failed test container or containers for

obvious defects, wear, and tear.
Note: Sometimes, after extended use, a test container becomes

damaged or worn and no longer works correctly as a result.
5. Does the container that you visually inspected appear to be

damaged or worn?
If yes, contact your service department and obtain a

replacement container to test.
If no, go to step 6.
6. Repeat the steps in Testing Containers and Analyzing

Results.
7. Did Omnivision II complete all maintenance test runs?
If yes, stop, you have successfully completed a maintenance

test run.
If no, contact your service department for assistance as your

Omnivision II might be malfunctioning.

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4.3 Changing Over Containers
4.3.1 Steps
Complete these steps to changeover a container.
2. On the screen, press the icon of the

container to which you want to change over.

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Result: Omnivision II displays the Bottle Changeover
Requirements dialog box.
3. As you confirm that the number shown in the Guide IF/OF

Number, Deadplate Dash Number, Starwheel Number, and
Spacer Number (if included in your Omnivision II), and
Inspection Head Height (counts) field is correct, press the
, ,
, and
button.

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Result: Omnivision II displays, in the lower left corner of the
screen, the
button, as shown below.
4. Press the
button.
Result: Omnivision II loads and activates all parameters for

the container that you selected.

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5. Maintaining, Servicing, and
Troubleshooting Omnivision II
This chapter tells you how to maintain, troubleshoot, and service

your Omnivision II.
Maintaining, Servicing, and Troubleshooting Omnivision II 5-1

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5.1 Routine Preventative Maintenance
Schedule
5.1.1 Introduction
filtec has designed Omnivision II to operate without requiring

intensive maintenance. Follow the maintenance procedures in
this chapter as closely as possible.
Routine preventative maintenance procedures ensure that

Omnivision II continues to operate safely and reliably throughout
its entire lifespan.
Note: The camera, mirrors, servos, and mirror heaters inside

the optional outer sidewall system are enclosed and sealed.
They are designed to operate on a long-term basis without
regular maintenance.
None of the outer sidewall system components require
lubrication.
Do not open the outer sidewall system enclosure unless
necessary. Opening the outer sidewall enclosure allows dirt,
product, water, and other fluids and gases to contaminate the
optical components.
5.1.2 Ideal Preventative Maintenance Schedule
Use this table to determine the ideal routine preventative

maintenance schedule for Omnivision II.
Component Interval Procedure
Diffuser glass Daily With a non-caustic, non-abrasive, commercially

available glass cleaner, such as Windex,
thoroughly clean both the top and the bottom of
the glass.
Also, adjust the diffuser glass wiper brush and

water drip system.
Important: A dirty diffuser

glass can cause false rejects.
Water drip Daily Inspect, and if necessary, adjust for slow drip.
system

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Inspection Daily With a non-caustic, non-abrasive, commercially

head lens and available lens tissue or soft cloth, clean the
optical inspection head lens and external cover glass
window glass surface.
Important: A dirty window

causes loss of light to the
inspection head systems.
Starwheel Daily Inspect for splits, cuts, hardened, or dried out

suction cups cups, or other damage, and replace any cups if
they are worn or detective.
Important: Defects cause loss

of vacuum and the rejection of
good containers.
Purge air Daily Inspect for air flow by holding your hand in front
(suction of the suction cups as the starwheel rotates past
pipes) the purge ports, and replace them if necessary.
Upstream Daily Inspect and adjust for the correct spray pattern
container and coverage.
washer
Important: If not set
correctly, a malfunctioning
upstream container washer
causes false rejects due to
soap from the conveyor
adhering to the bottom of the
container.
Air blow off, Daily Inspect and adjust for the correct flow.
diffuser glass
Important: The air blow off
and diffuser glass removes
water, pulp, and other objects
from glass surface before
inspection.
Air blow off, Daily Inspect and adjust for the correct flow and
container pattern.
bottom
Important: If not set
correctly, a malfunctioning air
blow off causes false rejects
due to soap from the conveyor
adhering to the bottom of the
container.
Sonic sensors Daily Inspect and adjust the operation of the line
control by blocking and unblocking the beams
with a container.
Ensure that the red indicator on the receiver

turns on when no container is present and off
when a container is present.

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Container Daily 1. Inspect and ensure that the guide belts are
guide belts tight and positioned correctly and adjust
them if they are too loose.
2. Inspect the brackets and ensure that they
are aligned correctly.
Inspection Daily 1. Display the

head height screen and check the value in the Inspection
Head Height (counts) field.
2. Using a mechanical counter, measure the
height of the inspection head above the
starwheel.
Important: When raising

or lowering the inspection
head, make sure that the
container neck guide belt
is pulled away and clear
from the starwheel top
plate.
3. Verify that there is a 0.5 inch or 13 milli-

meter clearance between the bottom of the
finish inspection lens and the crown on a
container.
Note: Be sure to lock the raising mechanism
after each adjustment.
4. Run containers through Omnivision II and
verify the inspection height.
5. Repeat this procedure for each container
type.
Infeed and Daily 1. Inspect and confirm that you are using the
outfeed correct guides.
container 2. Check all knobs and if necessary tighten
guides them.
3. Ensure that guides blend smoothly with
production conveyor guide rails.
Outer Daily 1. Inspect the inspection area for any debris,

sidewall such as broken glass, labels, or other foreign
inspection matter.
area 2. Clear debris out of the inspection area.
Outer Daily 1. Check and ensure that the correct tension is

sidewall used in the cord.
guide rails
2. If necessary, tighten the cord.
3. Inspect for labels, glass, and other debris
that might be stuck to the guide rails.
4. If necessary, remove the debris.
5. Inspect for any damage to the guide rails and
wear strips.

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Outer Daily 1. Inspect for scratches or other damage.

sidewall
diffuser 2. With a non-caustic, non-abrasive, commer-
panels (on cially-available glass cleaner, such as
the light Windex, thoroughly clean the diffuser
source panels.
enclosure)
Important: Every six
months, replace the
phenolic diffuser panels to
ensure consistent light
levels for inspection.
Outer Daily 1. Inspect for scratches or other damage.

sidewall
camera 2. With a non-caustic, non-abrasive, commer-
window (on cially- available glass cleaner, such as
the camera Windex, thoroughly clean the camera
enclosure) window panels.

months, replace the
phenolic diffuser panels to
ensure consistent light
Vacuum Weekly 1. Check the vacuum filter for debris or other

system obstructions.
2. With the pressure and vacuum converter
running, check the efficiency of the system
by seating containers firmly in all pockets.
3. Ensure that the vacuum gauge on the
Omnivision II panel reads at least 22 inches
Hg.
If the gauge reads less, check the suction
cups and ensure that all containers are
seated firmly.
If the reading remains low, check the piping
for leaks.
Reject Weekly Cycle by pressing the small button on the body of

solenoid valve.
valve
Diffuser glass Weekly 1. Stop the glass disk and ensure that it slips
correctly.
2. Ensure that the glass disk runs true and does
not bind against adjacent components.
3. Check for cracks, deep scratches, and other
damage.
4. With a non-caustic, non-abrasive, commer-
cially available glass cleaner, such as
Windex, thoroughly clean both the top and
the bottom of the glass.

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Infeed and Weekly 1. Check the alignment and tighten all knobs
outfeed securely.
container
guides 2. Ensure that containers have approximately
0.125 inch or 3 millimeters clearance on
each side as they pass through the guides.
3. Ensure that the guides merge smoothly with
the conveyor guide rails and provide a
smooth transition into the starwheel.
4. If necessary, check and replace all plastic
wear inserts.
Takeaway Weekly Use any good grade of bearing grease to lubricate

system the grease fittings that are located on the side of
the reject conveyor channel.
Suction cups Weekly 1. Check for cracks, hardened, or dried out

on the cups, and, if necessary, replace damaged,
starwheel hardened, or dried out cups.
2. Check for bent vacuum tubes (caused when
the pipes are not aligned to the starwheel).
3. If necessary, replace and align vacuum
tubes.
Light source Weekly With a non-caustic, non-abrasive, commercially-

lens available glass cleaner, such as Windex,
thoroughly clean the top surface thoroughly.
Important: Do not remove the

lens.
Outer Weekly Inspect and ensure that the fluorescent lighting

sidewall light units are working correctly.
source

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All starwheels Monthly Check as follows:
1. Inspect the valve seal ring, which is located

in the bottom of the starwheel hub, for
scratches and any other imperfections that
might prevent a seal with the valve plate.
If you discover excessive wear, scratching,
or other flaws, replace it.
2. Remove each suction cup and check each for
damage and that the material of which the
suction cup is made is not hardened.
3. Replace any damaged cups.
4. Locate the small restrictor at the end of
each vacuum pipe that measures approxi-
mately 0.060 inch or 1.5 millimeters in
diameter.
5. Check the restrictors to ensure that they are
not clogged.
If they are clogged, remove the starwheel,
and using a paper clip or other small
diameter wire, clean them or use a
compressed air nozzle to blow through the
restrictors down through the hub.
Result: Any debris in the restrictors and
pipes is flushed out.
6. Using non-caustic, non-abrasive soap,
ordinary water, and a soft brush, rinse the
entire starwheel.
7. After you finish cleaning it, reassemble the
starwheel.
Caution: Do not rinse the

starwheel or any component
with a high pressure nozzle
and do not steam clean,
pressure wash, or immerse in
liquid any Omnivision II
component.
Air and water Monthly Run and check air and water solenoid valves and
solenoid water flow.
valves
Air filter Monthly Examine filter for... And if necessary...

Main air Replace it
Base strobe Replace it
Cabinet purge (if Replace it
your Omnivision II is
equipped with one)
Thread blow off Replace it
Outer sidewall lamp Clean it
box

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Starwheel Monthly 1. Pass a container through the entire

system starwheel system.
2. As the container passes through, ensure that
the clearance of the guide assemblies, the
dead plate, the crossover points, and the
entry back onto the conveyor is correct, and
that movement is as smooth as possible.
Lower Monthly 1. Check inside the lower cabinet of the base

cabinet of the unit for signs of water leakage or other
base unit corrosion.
2. Remove corrosion immediately.
3. If you find evidence of water leakage, inves-
tigate to discover its source.
Guide Monthly 1. Inspect the plastic container set plates on

assemblies the starwheel and the plastic guides on the
plastic wear infeed and outfeed guide assemblies for
strips damage.
2. Are the guide assembly plastic wear strips
worn or damaged to the point that they
interfere with container handling?
If yes, order new ones from filtec and
replace them.
Important: When ordering

replacements for these parts,
check for the dash number
that is stamped on each plate.
This dash number positively
identifies the starwheel and
guide assembly sections (with
accompanying plastic wear
strips).
When ordering starwheels and

guide assemblies, indicate
whether top or bottom plates
are needed and provide the
dash number.
Container Monthly 1. Inspect the container guide belts and upper

guide belts and lower pulley assemblies.
and upper
and lower 2. Ensure that the pulleys turn freely and do
pulley not wobble excessively and ensure that the
assemblies belts have strong tension and run smoothly
in the pulleys.
Encoder Monthly 1. Inspect the encoder system on both the main

system and the reject conveyor.
2. Tighten all bolts and set screws as
necessary.
3. Lift the conveyor chain under the starwheel
(or remove the starwheel if necessary) and
check the encoder drive sprocket. Ensure
that the drive sprocket turns freely and does
not bind in any way.
4. Check the sprocket height and ensure that
the chain is not lifted or that the sprocket is
not too low.

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Outer Monthly 1. Inspect for scratches or other damage.

sidewall
diffuser 2. With a non-caustic, non-abrasive, commer-
panels (on cially-available glass cleaner, such as
the light Windex, thoroughly clean the diffuser
source panels.
enclosure)
months of operation time,
replace the phenolic
diffuser panels to ensure
consistent light levels for
inspection.
Outer Monthly Ensure that the cooling fan is correctly blowing

sidewall lamp air out of the top of the enclosure.
box cooling
fan Ensure that the filter is clean.
If the filter is not clean, remove and wash the

filter in soapy, hot water. If the filter is too
clogged to clean and wash with soapy, hot water,
replace the filter.
Outer Monthly Ensure that the fluorescent lighting units are

sidewall light working correctly.
source
months, replace the
fluorescent lighting units
to ensure consistent light
Spindle Monthly 1. Remove the starwheel.

assembly
2. Inspect the spindle assembly.
3. Ensure that the valve plate is smooth and
free from defects. If it is scratched or worn
excessively, replace it.
4. Ensure that the valve plate assembly moves
freely in the vertical direction or it will
impart excessive drag to the starwheel.
5. Ensure that the valve plate slides easily up
and down on the four alignment pins in the
hub.
Important: Do not use an

oil-based lubricant in this
area, as it might clog the
valve plate.
6. Inspect the flexible hoses that are connected

to the vertical port tubes to ensure that they
are not binding against the starwheel drive
components.
7. Also run the starwheel in manual mode and
hold onto the reject hose. If the reject hose
is split, you will be able to feel the air
leaking out.
8. If the flexible hoses assembly is binding and
you cannot free it, disassemble it.

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Starwheel Monthly Examine the female part on the drive spindle,

registration and look for burrs or deformation that could
plate compromise the mating accuracy.
Ensure that the “Tang” protrusion is not

damaged.
If it is worn or damaged, replace it with a new

kit, filtec part number 42928-1 or 42928-2.
Takeaway Monthly Check the takeaway system for loose parts and
system excessive wear. Tighten all bolts securely.
Conveyor Monthly 1. Inspect the strips, which are located under

wear strips the production chain, for excessive wear or
damage.
2. If they are excessively worn or damaged,
replace them.

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5.2 Alarms and Error Messages
5.2.1 List
Use this table to determine the cause of an alarm or error

message that Omnivision II displays.
Error code... Has severity Includes this message... Indicates that...
1 1 Bottle jam detected A container has jammed at some

point inside Omnivision II, either on
the conveyor, at the starwheel, or
some other location.
To resolve the problem, clear the

jammed container and reset
Omnivision II.
2 3 Run stop button on keypad On earlier models of Omnivision II,

pressed you or someone pressed the
Stop-the-starwheel button on the
monitor station touchpad.
3 1 Host not communicating with LCM A fault has occurred in line control
for 20 seconds module (LCM) communications or
one or more of the other
components that are serviced by
the IDC net RS-485 network are
causing excessive data traffic.
To resolve the problem, consult

your supervisor or, if you have
access, check the Diagnostics IDC
Net Comms screen for more
information.
4 1 Upstream down bottle detected Omnivision II has detected a fallen

container upstream of sonic sensor
2.
To resolve the problem, clear or

remove the fallen container and
clear the error.
5 1 Downstream bottle gap detected Omnivision II has detected a gap in

the queue of containers at the
discharge of Omnivision II.
6 1 Downstream down bottle Omnivision II has detected a fallen

detected container downstream of sonic
sensor 2 or after the discharge of
the Omnivision II.

container and clear the error.

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7 1 High bottle detected The high container sensor has

detected a “too high” container,
that is, a container that is too tall
to traverse under the inspection
head.
To resolve the problem, remove

the container from the conveyor
and clear the error.
8 1 LCM restarted, line stopped Omnivision II has reset the line

control module (LCM) main
processor after a power failure or
after the card itself malfunctioned,
or possibly because the base
cabinet line voltage monitor
momentarily disengaged.

alarm. If the alarm condition
persists, contact maintenance
personnel.
9 1 Emergency stop button pushed One or both emergency stop

buttons are pushed in and engaged
or you or someone has not yet
pressed the Clear to Run button.
To resolve the problem, pull out

the emergency stop button or
buttons and then press the
button.
10 3 Sonic 1 gap detected Omnivision II has detected a gap in

the queue of containers on the
conveyor at sonic sensor 1.
11 1 Base cabinet door interlock At least one of the polycarbonate

opened up safety doors is open.
To resolve the problem, close the

polycarbonate safety door or doors.

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12 2 OSW downlink port received Communication between the line

invalid subsystem control module (LCM) or between
the camera breakout card and the
outer sidewall inspection processor
card has failed.
Most likely one of the cables

between these components is
broken, frayed, or incorrectly
inserted.
To resolve the problem, inspect

and:
1. Reseat, reinsert, or replace

the green Category-5 (CAT-5)
cable between the line control
module (LCM) in the drawer in
the base unit and the camera
breakout card inside the
inspection head.
the 50-pin ribbon cable
between the J18 connector on
the camera breakout card and
the P4 connector on the outer
sidewall inspection processor
card.
3. Test the line control module
(LCM) card and ensure that it is
operating correctly.
4. Test the camera breakout card
and ensure that it is operating
correctly.
Note: If you need to test the LCM
or the camera breakout card,
contact filtec Customer Support.
13 2 PLC brake in active The production line programmable

logic controller (PLC) system has
remotely activated the starwheel
brake on Omnivision II.
14 3 PLC run out active The production line programmable

logic controller (PLC) system has
remotely activated the Omnivision
II runout signal.
As a result, Omnivision II has

disabled the upstream sonic
sensors.
15 3 PLC reject inhibit active The programmable logic controller

(PLC) system has remotely disabled
the Omnivision II starwheel
rejector.
16 3 PLC spare in An Omnivision II emergency

condition exists.
As a result, Omnivision II has

stopped the crossover (reject)
conveyor.

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17 1 Air failure detected Omnivision II has received a signal

that indicates that the air pressure
level has dropped below the fault
value that is set on the gauge.
To resolve the problem, examine

the air system and ensure that it is
working correctly, and repair it if
necessary.
18 1 Vacuum failure detected Omnivision II has received a signal

that indicates that the vacuum
level of the starwheel vacuum
system has dropped below the fault
point that is set on the gauge.

the starwheel vacuum system and
ensure that it is working correctly,
and repair it if necessary.
19 1 Base cabinet interlock opened up One or more of the metal base

cabinet doors is open.
To resolve the problem, close the

metal base cabinet door or doors
and clear the error.
20 1 OSW interlock opened up The lamp enclosure inside the

outer sidewall unit is open.

the lamp enclosure and, if
necessary, remove any
obstructions.
21 1 Trigger failure - starwheel moving The signal that the pin trigger
with no inspection triggers processor inside the line control
module (LCM) generates has failed
or is not functioning correctly.
To resolve the problem, contact

your supervisor as you might need
to reload the pin trigger software
to the pin trigger processor.
22 1 Starwheel encoder failure - The encoder signal from the

starwheel moving with no starwheel motor is not getting to
encoders the line control module (LCM).

your supervisor, as you might need
to reload the line control module
(LCM) motor processor.
23 2 Pocket count incorrect - check You have installed the wrong

number of starwheel pockets starwheel in your Omnivision II or
the number of starwheel pockets
that you or someone specified on
the
screen is incorrect.
24 3 Sonic 2 gap detected Omnivision II has detected a gap in

the queue of containers at sonic
sensor 2.

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25 1 Pocket missing sucker cup - 5 There is a missing or damaged

bottles dropped from same pocket sucker cup on the starwheel.

all sucker cups and reseat, repair,
or replace the damaged sucker cup
if necessary.
26 2 FTBI downlink port received Communication between the line

invalid subsystem control module (LCM) or between
the camera breakout card and the
finish (F), thread (T), base (B), and
inner sidewall (I) inspection
processor card (AL1) has failed.
Most likely one of the cables

between these components is
broken, frayed, or incorrectly
inserted.
To resolve the problem, inspect

and:

the yellow Category-5 (CAT-5)
cable between the line control
module (LCM) in the drawer in
the base unit and the camera
breakout card inside the
inspection head.
the 50-pin ribbon cable
between the J18 connector on
the camera breakout card and
the P4 connector on the FTBI
inspection processor card
(AL1).
3. Test the line control module
(LCM) card and ensure that it is
operating correctly.
4. Test the camera breakout card
and ensure that it is operating
correctly.
Note: If you need to test the LCM
or the camera breakout card,
contact filtec Customer Support.
27 1 Bottle failed to reject! Check for The reject verifier has detected a
and remove bad bottles container that has not been
downstream rejected.
To resolve the problem, check and

remove containers at the discharge
area of your Omnivision II.
28 1 Consecutive incomplete All inspection processes have not

inspection limit exceeded been completely performed on the
successive number of containers
that you or someone specified in
the Incomplete Inspection box on
the
screen.

Document 45721-0215
29 1 Consecutive rejects limit The number of containers that is

exceeded specified in the Consecutive
Reject Alarm box on the
screen for this alarm function have

been rejected in succession.
To learn more, check the

screen for
additional information.
30 1 Reject verifier signal not The inspection head is too high or

changing. Check sensor. the reject verifier sensor is faulty.

your supervisor, or if you are
authorized, check the height of the
inspection head and ensure that it
is correct. Also, examine the reject
verifier sensor to ensure that it is
working correctly.
31 2 Reject tracker serial An excessive amount of signal

communications output buffer traffic has caused throughput
overflowed latency or termination in the line
control monitor (LCM) signal
processor.
To resolve the problem, check for

faulty peripheral components
(encoders and sensors, for
example).
32 1 Starwheel motor overheated, The temperature of the starwheel

freewheeling until reset motor processor or driver has
exceeded a safe level to continue
running without causing permanent
damage to the motor or driver.
To resolve the problem, check the

starwheel motor cooling fan in the
base cabinet, and repair or replace
it.
After you correct the condition,

reset the motor on the
screen.

Document 45721-0215
Index
Symbols definition 1-3

Bottles Per Minute field 3-10
% field 3-7 Bottom field 3-19
bottom rim
definition 1-3
bottom zone
A definition 1-3
BPH (bottles per hour)
ACL (applied ceramic label) definition 1-3
definition 1-2 BPM (bottles per minute)
alarm message definition 1-3
definition 1-2 brightness
Algorithm 1 field 3-29 definition 1-3
Algorithm 2 field 3-29 buttons
All Subsystems field 3-10 blue 3-47
analyzing test container results 4-2 Change 3-49
applied ceramic label (ACL) Clear To Run 3-46
definition 1-2 green 3-47
Auto PopUp field 3-46 Hide 3-46
Auxiliary 1 field 3-11, 3-32 Logout/Change to Default User 3-49
auxiliary 1 inspection icon 3-37 Print 3-34, 3-41
Auxiliary 2 field 3-12, 3-32 red 3-46
auxiliary 2 inspection icon 3-38 Refresh List 3-46
Run Test 3-44
Select Phase to Display 3-30
B tan 3-46
white 3-47
B/R (bottom rim)
definition 1-3
base
definition 1-2 C
base backup zone CCW (counter clockwise)
definition 1-2 definition 1-3
Base Defects field 3-14 Center field 3-15
Base field 3-11, 3-32 Centering field 3-26
base inspection Change button 3-49
definition 1-2 changing over
base inspection icon 3-37 containers 4-8
base unit 1-27 Clear To Run button 3-46
blue button 3-47 clockwise
bottle definition 1-5
definition 1-2 combiner
Bottle Changeover Requirements dialog box definition 1-3
3-45, 4-9 components
Bottle Defects field 3-32 Omnivision II 1-26
Bottles field 3-43 container
bottles per hour definition 1-3
definition 1-3 containers
bottles per minute analyzing test results 4-2
Index Index-1
Document 45721-0215
changing over 4-8 drop 1-6
testing 4-2 embossing 1-7
Control Bottle Selection screen 4-8 exception point 1-7
Control Test Bottle screen 3-42, 4-3 false accept 1-7
Control Test Bottle test results dialog box 3-45 false reject 1-7
Control Test Bottle test results screen 3-45 feet per minute 1-8
Conveyor Slip Ratio field 3-10 finish 1-7
count finish image 1-7
definition 1-4 finish inspection 1-8
Count field 3-15, 3-19 fluting 1-8
counter clockwise FPM (feet per minute) 1-8
definition 1-3 housekeeping 1-8
crimp infeed 1-8
definition 1-4 information message 1-8
crimping inner sidewall 1-9
definition 1-4 inspection 1-9
Current field 3-15, 3-19 inspection donut 1-9
Current Time field 3-43 knurling 1-9
current value lane 1-10
definition 1-5 last detect 1-10
CW (clockwise) LCM 1-10
definition 1-5 line control monitor 1-10
lower rim zone 1-11
lower sidewall zone 1-11
D mark 1-11
marker 1-11
defect mask 1-12
definition 1-5 missed reject 1-12
definition monitor station 1-30
dropout 1-6 normalization 1-13
definitions Omnivision II 1-22
ACL (applied ceramic label) 1-2 operator menu 1-13
alarm message 1-2 outer radius (base) 1-13
applied ceramic label (ACL) 1-2 outer radius (sidewall) 1-13
B/R (bottom rim) 1-3 outer sidewall 1-13
base 1-2 outfeed 1-13
base backup zone 1-2 overpress 1-14
base inspection 1-2 PET (polyethylene terephthalate) 1-15
bottle 1-2 phase 1-15
bottles per hour 1-3 plug 1-16
bottles per minute 1-3 polycarbonate doors 1-29
bottom rim 1-3 polyethylene terephthalate 1-15
bottom zone 1-3 press finish 1-4
BPH (bottles per hour) 1-3 reject history 1-16
BPM (bottles per minute) 1-3 reject segment 1-16
brightness 1-3 rejector segment 1-16
CCW (counter clockwise) 1-3 rejector timing 1-16
clockwise 1-5 roll on pilfer proof finish 1-16
combiner 1-3 ROPP (roll on pilfer proof) 1-16
container 1-3 screen 1-30
count 1-4 scuffing 1-17
counter clockwise 1-3 signal beacon 1-32
crimp 1-4 slip rate 1-18
crimping 1-4 spot
current value 1-5 diffuser 1-6
CW (clockwise) 1-5 stippling 1-18
defect 1-5 stress cracking 1-19
detect 1-5 swing gate 1-19
detection 1-5 test container 1-19
detection point 1-5 thread 1-19
diagnostic message 1-6 thread image 1-19
diffuser spot 1-6 tracking segment 1 1-19
donut 1-9 tracking segment 2 1-20
downstream 1-6 twist off finish 1-20
Index-2 Omnivision II Operation Guide

Document 45721-0215
upper rim zone 1-13 Base 3-11, 3-32
upper sidewall zone 1-13 Base Defects 3-14
upstream 1-20 Bottle Defects 3-32
warning message 1-20 Bottles 3-43
window 1-21 Bottles Per Minute 3-10
zone 1-21 Bottom 3-19
detect Center 3-15
definition 1-5 Centering 3-26
detection Conveyor Slip Ratio 3-10
definition 1-5 Count 3-15, 3-19
Detection Level field 3-15, 3-19 Current 3-15, 3-19
detection point Current Time 3-43
definition 1-5 Detection Level 3-15, 3-19
diagnostic message Enter User ID 3-49
definition 1-6 Finish 3-11, 3-32
diagrams Finish Defects 3-23
Omnivision II 1-22 Finish Rejects 3-23
Omnivision II screen 3-2 Good Bottles 3-7, 3-10, 3-14, 3-18, 3-23, 3-26,
dialog boxes 3-29
Bottle Changeover Requirements 3-45, 4-9 ID # 3-32
Control Test Bottle test results 3-45 Inner Mid Rim 3-15
test results 4-4 Inner Rim 3-15
diffuser spot Inner Sidewall 3-11
definition 1-6 IR Detected Liquid 3-32
donut IR RLD 3-11
definition 1-9 ISW 3-33
doors ISW Defects 3-18
polycarbonate 1-29 Lane A 3-26
downstream Lane A Inspection 3-23
definition 1-6 Lane B 3-26
drop Lane B Inspection 3-23
definition 1-6 Lane C 3-26
dropout Lane C Inspection 3-23
definitions 1-6 Lane D 3-27
Lane D Inspection 3-24
Lane E 3-27
E Lane E Inspection 3-24
Large Object 3-21, 3-33
embossing Last Detect 3-15, 3-19
definition 1-7 Last Inspection Results 3-26
Enter User ID field 3-49 Last Result 3-23
exception point Light Level 3-24, 3-33
definition 1-7 Lower 3-19
Lower Mid 3-19
Middle 3-20
Middle Rim 3-15
F Minutes 3-43
Next Scheduled Test 3-43
failed test run Operator Timeout 3-43
determining cause of 4-6 OSW 3-11
false accept OSW Defects 3-29
definition 1-7 Outer Mid Rim 3-16
false reject Outer Rim 3-16
definition 1-7 Outer Sidewall 3-33
feet per minute Overall Statistics 3-14, 3-18, 3-23, 3-26, 3-29
definition 1-8 Period 3-29
fields Period Defects 3-23
% 3-7 Period Detects 3-26
Algorithm 1 3-29 Plug/Color 3-16, 3-21
Algorithm 2 3-29 Reject Enable 3-14, 3-18
All Subsystems 3-10 Reject Enabled 3-26
Auto PopUp 3-46 Reject Filter 3-12
Auxiliary 1 3-11, 3-32 Reject Type 3-10
Auxiliary 1 field 3-11, 3-12 Rejects 3-7
Auxiliary 2 3-12, 3-32
Index Index-3
Document 45721-0215
Rejects Enabled 3-23
Report Time Frame 3-40 I
All 3-41 icons
Previous 3-40 auxiliary 1 inspection 3-37
Range of Dates 3-41 auxiliary 2 inspection 3-38
Report Type 3-40 base inspection 3-37
Diagnostic Status Log 3-40 finish inspection 3-37
Parameter Change Log 3-40 green minus 3-33
Show Changes for All Bottle Types 3-40 green plus 3-33
Test Bottle History 3-40 ignore 3-34
RF Detected Liquid 3-32 infrared residual inspection 3-37
RF RLD 3-11 inner sidewall inspection 3-37
Save Current Period Counters 3-12 outer sidewall inspection 3-37
Sensitivity 3-26 radio frequency inspection 3-37
Status & Sensitivity 3-14, 3-18, 3-23, 3-26 red plus 3-33, 3-34
Subsystems Reject Status 3-10 scuff filtering 3-37
Summary 3-43 test container detected 3-38
System Reject Status 3-10 thread inspection 3-37
Test Bottle State 3-43 ID # field 3-32
Test Bottles to Go 3-44 ignore icon 3-34
Thread 3-11, 3-32 infeed
Thread Defects 3-26 definition 1-8
Time to Complete Test 3-44 information message
Total Bottles 3-10, 3-14, 3-18, 3-23, 3-26, 3-29 definition 1-8
Total Messages 3-36 infrared residual inspection icon 3-37
Total Rejects 3-10 Inner Mid Rim field 3-15
Total Test Bottles 3-43 Inner Rim field 3-15
Track Locator 3-23 inner sidewall
Tracking 3-26 definition 1-9
Tracking Length 3-23 Inner Sidewall field 3-11
Upper Mid 3-20 inner sidewall inspection icon 3-37
Window 3-29, 3-33 inspection
Window Results 3-29 definition 1-9
Zone 3-33 inspection donut
finish definition 1-9
definition 1-7 IR Detected Liquid field 3-32
Finish Defects field 3-23 IR RLD field 3-11
Finish field 3-11, 3-32 ISW Defects field 3-18
finish image ISW field 3-33
definition 1-7
finish inspection
definition 1-8
finish inspection icon 3-37 K
Finish Rejects field 3-23
fluting knurling
FPM (feet per minute)
definition 1-8
L
G lane
definition 1-10
Good Bottles field 3-7, 3-10, 3-14, 3-18, 3-23, 3-26, Lane A field 3-26
3-29 Lane A Inspection field 3-23
green button 3-47 Lane B field 3-26
green minus icon 3-33 Lane B Inspection field 3-23
green plus icon 3-33 Lane C field 3-26
Lane C Inspection field 3-23
Lane D field 3-27
Lane D Inspection field 3-24
H Lane E field 3-27
Lane E Inspection field 3-24
Hide button 3-46 Large Object field 3-21, 3-33
housekeeping last detect
definition 1-8

Document 45721-0215
definition 1-10 outer radius (base)
Last Detect field 3-15, 3-19 definition 1-13
Last Inspection Results field 3-26 outer radius (sidewall)
Last Result field 3-23 definition 1-13
LCM Outer Rim field 3-16
definition 1-10 outer sidewall
Light Level field 3-24, 3-33 definition 1-13
line control monitor Outer Sidewall field 3-33
definition 1-10 outer sidewall inspection icon 3-37
Logout/Change to Default User button 3-49 outer sidewall inspection unit 1-28
Lower field 3-19 how it works 1-28
Lower Mid field 3-19 outfeed
lower rim zone definition 1-13
definition 1-11 Overall Statistics field 3-14, 3-18, 3-23, 3-26, 3-29
lower sidewall zone overpress
M P
maintenance Period Defects field 3-23
scheduling preventative 5-2 Period Detects field 3-26
maintenance schedule Period field 3-29
preventative 5-2 PET (polyethylene terephthalate)
mark definition 1-15
definition 1-11 phase
marker definition 1-15
definition 1-11 plug
mask definition 1-16
definition 1-12 Plug/Color field 3-16, 3-21
Middle field 3-20 polycarbonate doors
Middle Rim field 3-15 definition 1-29
Minutes field 3-43 polyethylene terephthalate
missed reject definition 1-15
definition 1-12 press finish
monitor station definition 1-4
definition 1-30 preventative maintenance
schedule 5-2
Print button 3-34, 3-41
N
Next Scheduled Test field 3-43
normalization
R
definition 1-13 radio frequency inspection icon 3-37
red button 3-46
red plus icon 3-33, 3-34
O Refresh List button 3-46
Reject Enable field 3-14, 3-18
Omnivision II Reject Enabled field 3-26
components 1-26 Reject Filter field 3-12
definition 1-22 reject history
diagram 1-22 definition 1-16
how it works 1-24 reject segment
Omnivision II screen definition 1-16
diagram 3-2 Reject Type field 3-10
operator menu rejector segment
Operator Timeout field 3-43 rejector timing
optional premium outer sidewall inspection unit definition 1-16
1-28 Rejects Enabled field 3-23
OSW Defects field 3-29 Rejects field 3-7
OSW field 3-11 Report Time Frame All field 3-41
Outer Mid Rim field 3-16 Report Time Frame field 3-40
Report Time Frame Previous field 3-40
Index Index-5
Document 45721-0215
Report Time Frame Range of Dates field 3-41 Status Reject History screen 3-35
Report Type Diagnostic Status Log field 3-40 Status System screen 3-8
Report Type field 3-40 Status Test Bottle screen 3-31, 4-5
Report Type Parameter Change Log field 3-40 Status Thread screen 3-25, 3-39
Report Type Show Changes for All Bottle Types steps
field 3-40 turning off Single Platform Technology (SPT)
Report Type Test Bottle History field 3-40 2-4
RF Detected Liquid field 3-32 stippling
RF RLD field 3-11 definition 1-18
roll on pilfer proof finish stress cracking
ROPP (roll on pilfer proof) Subsystems Reject Status field 3-10
definition 1-16 Summary field 3-43
Run Test button 3-44 swing gate
definition 1-19
System Reject Status field 3-10
S
Save Current Period Counters field 3-12
schedule
T
preventative maintenance 5-2 tan button 3-46
schedules Test Bottle State field 3-43
preventative maintenance 5-2 Test Bottles to Go field 3-44
screen test container
screens test container detected icon 3-38
Control Bottle Selection 4-8 test results dialog box 4-4
Control Test Bottle 3-42, 4-3 test run
Control Test Bottle test results 3-45 determining cause of failed 4-6
Status Base 3-13 testing containers 4-2
Status CCRP History 4-6 thread
Status Finish 3-22 definition 1-19
Status ISW 3-17 Thread Defects field 3-26
Status OSW 3-28 Thread field 3-11, 3-32
Status Overview 3-6 thread image
Status Reject History 3-35 definition 1-19
Status System 3-8 thread inspection icon 3-37
Status Test Bottle 3-31, 4-5 Time to Complete Test field 3-44
Status Thread 3-25, 3-39 timing
User Logon 3-48 rejector 1-16
scuff filtering icon 3-37 Total Bottles field 3-10, 3-14, 3-18, 3-23, 3-26,
scuffing 3-29
definition 1-17 Total Messages field 3-36
segment 1 Total Rejects field 3-10
tracking 1-19 Total Test Bottles field 3-43
segment 2 Track Locator field 3-23
tracking 1-20 Tracking field 3-26
Select Phase to Display button 3-30 Tracking Length field 3-23
Sensitivity field 3-26 tracking segment 1
signal beacon definition 1-19
definition 1-32 tracking segment 2
Single Platform Technology (SPT) definition 1-20
turning off 2-4 turning off Single Platform Technology (SPT) 2-4
slip rate twist off finish
spot
definition of diffuser 1-6
Status & Sensitivity field 3-14, 3-18, 3-23, 3-26
Status Base screen 3-13 U
Status CCRP History screen 4-6 unit
Status Finish screen 3-22 base 1-27
Status ISW screen 3-17 optional premium outer sidewall inspection
Status OSW screen 3-28 1-28
Status Overview screen 3-6 outer sidewall inspection 1-28

Document 45721-0215
Upper Mid field 3-20
upper rim zone
definition 1-13
upper sidewall zone
definition 1-13
upstream
definition 1-20
User Logon screen 3-48
W
warning message
definition 1-20
white button 3-47
window
definition 1-21
Window field 3-29, 3-33
Window Results field 3-29
Z
zone
definition 1-21
Zone field 3-33
Index Index-7
Document 45721-0215
Document 45721-0215
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Omnivision II Operation Guide

Corporate Headquarters 3100 Fujita Street,

Mailing Address P.O. Box 2945,

Shipping Address 3100 Fujita Street,

Customer Service (800) 733-5173

1. Overview of Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. Turning On and Turning Off Omnivision II . . . . . . . . . . . . . . 2-1

Table of Contents iii

4. Commissioning Omnivision II . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. Maintaining, Servicing, and Troubleshooting Omnivision II . . . 5-1

Documentation Feedback . . . . . . . . . . . . . . . . . . . .Feedback-1

Help Us Improve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback-1

iv Omnivision II Operation Guide

1. Overview of Omnivision II . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Figure 1-1. Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2. Turning On and Turning Off Omnivision II . . . . . . . . . . . . . . 2-1

3. Using Omnivision II System Software. . . . . . . . . . . . . . . . . . 3-1

Figure 3-1. Common Parts of Omnivision II Screens . . . . . . . . . . . . . . . . . . . . 3-2

4. Commissioning Omnivision II . . . . . . . . . . . . . . . . . . . . . . . 4-1

5. Maintaining, Servicing, and Troubleshooting Omnivision II . . . 5-1

Documentation Feedback . . . . . . . . . . . . . . . . . . . .Feedback-1

vi Omnivision II Operation Guide

The Omnivision II documentation provides operators, technicians,

• The first volume of the Omnivision II Service and Installation

Topics That This Guide Covers

Omnivision II Operation Guide tells you how to use and maintain

This guide is intended for use by operators who use Omnivision II

Conventions That Appear in This Guide

Use the following chart to learn about the typographic conven-

This typeface or symbol... Indicates... Example...

abcd1234 A link to another document Omnivision II Operation Guide

Important: Important information that

Caution: That there is a potential for

Warning: That there is a potential for

viii Omnivision II Operation Guide

abcd1234 A best practice to follow, a Best Practice:

This chapter presents an overview of Omnivision II.

Topics that this chapter covers include definitions of terms and

Overview of Omnivision II 1-1

1.1.1 Definition: Alarm Message

An alarm message is diagnostic information that Omnivision II

If you turn on the Omnivision II beacon, and Omnivision II

Omnivision II continues to display the message until you clear it.

1.1.2 Definition: Applied Ceramic Label

An applied ceramic label, or ACL, is a notch on a container,

1.1.3 Definition: Base

A base is the bottom rim of a container.

1.1.4 Definition: Base Backup Zone

The base backup zone is the inspection zone that is circular in

1.1.5 Definition: Base Inspection

Base inspection is the inspection system on Omnivision II that

1.1.6 Definition: Bottle

A bottle is referred to as a container in this documentation.

1-2 Omnivision II Operation Guide

A bottom rim is the same as base, or the bottom rim of a

Bottom rim is sometimes abbreviated B/R.

1.1.8 Definition: Bottom Zone

The bottom zone is the inspection zone that is circular in shape

1.1.9 Definition: Bottles Per Hour

Bottles per hour, or BPH, is the number of containers that

1.1.10 Definition: BPM

Bottles per minute, or BPM, is the number of containers that

1.1.11 Definition: Brightness