Manual Tap Tone 500

TapTone 500 Series
Installation, Operation and Maintenance Manual

M-407-005
Rev. F
TapTone Package Inspection

49 Edgerton Drive
North Falmouth, Massachusetts
02556-2828 USA
Phone: 508-563-5920 or 1-800-423-4044 (USA Only)

Fax: 508-564-9945
www.taptone.com
Singapore contact:
Phone: 065-6-2927033
Fax: 065-6-2970125
M-407-005 Table of Contents
Table of Contents
1.0 Preface..............................................................................................................1
2.0 Introduction.....................................................................................................2
2.1 System Introduction & Theory of Operation..................................................2
2.1.1 TapTone 500 RTV Model .......................................................................4
2.1.2 TapTone 500 CMS Model .......................................................................5
2.2 System Configurations....................................................................................6
2.2.1 Single Inspection and Dual Rejection T500 ............................................6
2.2.2 Dual Inspection and Dual Rejection T500 ..............................................7
2.2.3 Triple Inspection and Dual Rejection T500 ............................................8
2.3 System Specifications .....................................................................................9
3.0 Safety Precautions ........................................................................................11

3.1 General Safety Precautions...........................................................................11
3.2 Specific Cautions and Warnings ...........................................................11
3.3 Safety Label Descriptions.............................................................................12
4.0 Installation Instructions ...............................................................................13

4.1 Installation Location .....................................................................................13
4.2 Sensor Head Configurations .........................................................................14
4.2.1 Single Sensor Configurations ................................................................15
4.2.2 Dual Sensor Configurations...................................................................16
4.2.3 Triple Sensor Configurations.................................................................21
4.2.4 Junction Box Cable Configurations.......................................................23
4.3 Control Enclosure Assembly ........................................................................24
4.4 Remote Transducer Stand Assembly (RTV) ................................................25
4.5 Conveyor Mounted Transducer Assembly (CMS) .......................................27
4.5.1 Transducer Frame Installation ...............................................................27
4.5.2 Junction Box Installation .......................................................................28
4.6 Rejector Assembly ........................................................................................29
4.7 Shaft Encoder Kit..........................................................................................30
4.8 Power and Air Connections ..........................................................................32
4.8.1 T500 Controller Power Connections .....................................................32
4.8.2 X-ray Sensor Connections .....................................................................32
4.8.3 PLC Board Connections ........................................................................33
4.8.4 Acoustic Power Board ...........................................................................34
TapTone Division of Benthos, Inc. i

4.8.5 Air Connection.......................................................................................35
4.9 Initial Sensor Setup.......................................................................................35
4.9.1 Acoustic Sensor Setup ...........................................................................35
4.9.2 Cocked Crown Sensor Setup .................................................................35
4.9.3 Proximity Sensor Setup .........................................................................36
4.9.4 Laser Sensor Setup ................................................................................36
4.9.5 X-ray Sensor Setup ................................................................................36
5.0 System Operating Procedures .....................................................................37

5.1 System Shut-Down Procedure ......................................................................37
5.2 Cleaning Requirements and Precautions ......................................................37
5.3 Controls and Displays...................................................................................37
5.4 System Programmable Parameters ...............................................................40
5.4.1 Parameter Menu Tree.............................................................................40
5.5 Operator Parameters......................................................................................41
5.5.1 Main .......................................................................................................42
5.5.2 Statistics .................................................................................................46
5.5.3 Diag........................................................................................................51
5.5.4 Change Prod...........................................................................................55
5.5.5 Setup ......................................................................................................55
5.6 Maintenance Parameters ...............................................................................56
5.6.1 Limits 1 ..................................................................................................57
5.6.2 Inspect 1.................................................................................................61
5.6.3 Limits 2 ..................................................................................................67
5.6.4 Inspect 2.................................................................................................70
5.6.5 Limits 3 ..................................................................................................77
5.6.6 Inspect 3.................................................................................................80
5.6.7 Rejector 1...............................................................................................83
5.6.8 Rejector 2...............................................................................................85
5.6.9 Encoder ..................................................................................................87
5.6.10 I/O ........................................................................................................87
5.6.11 Alarm ...................................................................................................93
5.6.12 Prod Type.............................................................................................94
5.6.13 Password ..............................................................................................96
5.7 Initial Setup Procedure..................................................................................97
5.7.1 Inspection #1 (proximity) Setup Procedure...........................................98
5.7.2 Inspection #1 (laser) Setup Procedure ...................................................99
5.7.3 Inspection #1 (cocked crown) Setup Procedure ..................................100
5.7.4 Inspection #2 (proximity) Setup Procedure.........................................101
5.7.5 Inspection #2 (X-ray) Setup Procedure ...............................................102
TapTone Division of Benthos, Inc. ii
5.7.6 Inspection #3 (acoustic) Setup Procedure ...........................................102
6.0 System Troubleshooting Guide .................................................................103

6.1 No Rejection Check List.............................................................................103
6.2 False Rejection Check List .........................................................................103
6.3 No Sensor Signal Check List ......................................................................103
6.4 System Error Messages...............................................................................104
6.5 Diagnostics Procedure ................................................................................105
6.6 System Wiring ............................................................................................106
6.6.1 Control Box Wiring Diagram ..............................................................106
6.6.2 Junction Box Wiring Diagram.............................................................107
6.6.3 Laser Control Box Wiring Diagram ....................................................108
6.6.4 Laser Junction Box Wiring Diagram...................................................109
6.6.5 X-ray Sensor Wiring Diagram (1 of 2)...............................................110
6.7 DSP Board Jumper Settings........................................................................111
6.7.1 DSP LED Designations .......................................................................111
6.7.2 DSP Jumper Designations ...................................................................112
6.7.3 Factory Default DSP Jumper Settings .................................................112
6.7.4 DSP Input Jumper Configurations.......................................................113
6.7.5 DSP Output Jumper Configurations ....................................................113
6.7.6 X-ray Jumper Configurations ..............................................................114
6.6.7 I/O Board Jumper Configurations .......................................................115
6.6.8 I/O Board Pinout..................................................................................116
6.8 Proximity Sensor Tuning Procedure...........................................................118
6.9 Acoustic Sensor Microphone Replacement Procedure ..............................119
6.10 X-Ray Transmitter Tuning Procedure ......................................................121
7.0 Preventative Maintenance..........................................................................122
8.0 Warranty .....................................................................................................123
9.0 Parts Replacement ......................................................................................124

9.1 Recommended Spare Parts List ..................................................................124
9.1.1 TapTone Core Spares Kit (A-407-42-SPK) .......................................124
9.1.2 Acoustic Spares Kit (A-407-27-SPK) ................................................124
9.1.3 Acoustic / Cocked Crown Spares Kit (A-407-31-SPK) .....................124
9.1.4 Proximity Sensor Spares Kit................................................................125
9.1.5 Laser Sensor Spares Kit.......................................................................125
9.1.6 X-ray Sensor Spares Kit (A-407-37-SPK) .........................................125
9.1.7 Rejector Spares Kit, ½” Stroke (A-407-28-SPK)...............................125
TapTone Division of Benthos, Inc. iii
9.1.8 Rejector Spares Kit, 1” Stroke (A-407-29-SPK)................................126
9.1.9 Rejector Spares Kit, Heavy Duty 8: Stroke (A-407-30-SPK)............126
9.2 Parts List .....................................................................................................126
9.2.1 Control Enclosure Assembly Parts List...............................................127
9.2.2 Remote Transducer Head Assembly Parts List ...................................128
9.2.3 CMS Transducer Head Assembly Parts List .......................................129
9.2.4 Crank Stand Assembly Parts List ........................................................130
9.2.5 Conveyor Clamp Assembly Parts List.................................................131
9.2.6 Rejector Assembly Parts List...............................................................132
9.2.7 Shaft Encoder Kit Parts List ................................................................133
9.2.8 Laser Sensor Parts List ........................................................................134
9.2.9 X-ray Sensor Parts List........................................................................136
9.2.10 X-ray Stand Assembly Parts List.......................................................137
9.3 Ordering Procedure.....................................................................................139
Appendix A - Parameter List..............................................................................140
Appendix B - Power Conditioner Installation...................................................141
Appendix C – Merit Value Scale Factor Chart.................................................142
TapTone Division of Benthos, Inc. iv

M-407-005 Table of Figures
Table of Figures
Figure 2-1 TapTone 500 RTV System............................................................................ 4
Figure 2-2 TapTone 500 CMS System........................................................................... 5
Figure 2-3 TapTone 500 Single Inspection System and Dual Rejection ........................ 6
Figure 2-4 TapTone 500 Dual Inspection and Dual Rejection System ........................... 7
Figure 2-5 TapTone 500 Triple Inspection with Dual Rejection System ......................... 8
Figure 3-1 Safety Labels .............................................................................................. 12
Figure 4-1 Inspection / Photo Beam Selection Chart.................................................... 14
Figure 4-2 Acoustic Inspection Layout ......................................................................... 15
Figure 4-3 Proximity Inspection Layout ........................................................................ 15
Figure 4-4 Laser Inspection Layout .............................................................................. 16
Figure 4-5 Acoustic with Cocked Crown Inspection Layout.......................................... 16
Figure 4-6 Acoustic & Proximity Inspection Layout ...................................................... 17
Figure 4-7 Proximity & Proximity Inspection Layout ..................................................... 17
Figure 4-8 Dual Proximity Inspection Layout................................................................ 18
Figure 4-9 Laser & Proximity Inspection Layout ........................................................... 18
Figure 4-10 Acoustic & X-ray Inspection Layout .......................................................... 19
Figure 4-11 Proximity & X-ray Inspection Layout ......................................................... 19
Figure 4-12 Laser & X-ray Inspection Layout ............................................................... 20
Figure 4-13 Acoustic, Cocked Crown & X-ray Inspection Layout ................................. 21
Figure 4-14 Acoustic, Proximity & X-ray Inspection Layout.......................................... 22
Figure 4-15 Junction Box Cable Configuration ............................................................. 23
Figure 4-16 Control Enclosure Specifications .............................................................. 24
Figure 4-17 Transducer Stand Assembly ..................................................................... 25
Figure 4-18 Conveyor Mounted Transducer Dimensions ............................................. 27
Figure 4-19 Conveyor Mounted Transducer Assembly ................................................ 28
Figure 4-20 Rejector Station Layout............................................................................. 29
Figure 4-21 Rejector Station Rail Specification ............................................................ 29
Figure 4-22 Remote Rejector Assembly....................................................................... 30
Figure 4-23 Shaft Encoder Specifications Drawing ...................................................... 31
Figure 4-24 Shaft Encoder Mounting Drawing ............................................................. 31
Figure 4-25 PLC Interface Board Connections............................................................. 33
Figure 4-26 Power Board Layout ................................................................................. 34
Figure 5-1 TapTone 500 Key Pad ................................................................................ 37
Figure 5-2 Enclosure Controls and Indicators .............................................................. 38
Figure 5-3 Regulator Assembly Controls and Indicators .............................................. 39
Figure 5-4 Photo Beam Module Controls and Indicators.............................................. 39
Figure 5-5 System Menu Tree...................................................................................... 40
Figure 5-6 Operator Menu Tree ................................................................................... 41
Figure 5-7 Maintenance Menu Tree ............................................................................. 56
Figure 6-1 Chassis Wiring Diagram............................................................................ 106
Figure 6-2 Junction Box Wiring Diagram.................................................................... 107
Figure 6-3 Laser Control Box Wiring Diagram............................................................ 108
Figure 6-4 Laser Junction Box Wiring Diagram .......................................................... 109
Figure 6-5 X-ray Sensor Wiring Diagram ................................................................... 110
Figure 6-7 DSP Board Layout .................................................................................... 111
Figure 6-8 DSP Board Factory Jumper Settings ........................................................ 112
Figure 6-9 Shaft Encoder and Photo Beam #2 Jumper Settings................................ 113
Figure 6-10 Rejector and Lamp Jumper Settings....................................................... 113
Figure 6-11 X-Ray Jumper Settings ........................................................................... 114
TapTone Division of Benthos, Inc. v

M-407-005 Table of Figures
Figure 6-12 I/O Board Jumper Settings...................................................................... 115
Figure 6-13 I/O Board Pinout ..................................................................................... 117
Figure 6-14 Proximity Sensor Adjustments ................................................................ 118
Figure 6-15 Acoustic Sensor Assembly...................................................................... 119
Figure 6-16 X-Ray Source Module Power Supply Board ........................................... 121
Figure 9-1 Control Enclosure Assembly ..................................................................... 127
Figure 9-2 Remote Transducer and Junction Box Assemblies................................... 128
Figure 9-3 Conveyor Mount Transducer and Junction Box Assemblies ..................... 129
Figure 9-4 Crank Stand Assembly.............................................................................. 130
Figure 9-5 Conveyor Mount Assembly ....................................................................... 131
Figure 9-6 Rejector Assembly .................................................................................... 132
Figure 9-7 Shaft Encoder Kit ...................................................................................... 133
Figure 9-8 Laser Sensor Kit ....................................................................................... 134
Figure 9-9 X-ray Sensor Kit........................................................................................ 136
Figure 9-10 X-ray Stand Assembly............................................................................. 137
TapTone Division of Benthos, Inc. vi

M-407-005 Chapter 1: Preface
1.0 Preface
All information within this manual is a copyright of TapTone and may not be duplicated without
the written consent or approval from the TapTone Division of Benthos Inc.
TapTone reserves the right to make changes to the manual without obligation to notify any
person(s) or entities of revisions.
It is recommended that the installation of your TapTone equipment is performed or supervised

by an authorized TapTone representative.
TapTone Division of Benthos, Inc. 1

M-407-005 Chapter 2: Introduction
2.0 Introduction
2.1 System Introduction & Theory of Operation
The TapTone 500 is a powerful control platform that monitors up to three independent on-line
inspections at line speeds up to 2000 containers per minute. The inspection sensors are based on
four different technologies.
Control Platform - The TapTone 500 controller incorporates the latest technology in
digital signal processing. A menu driven keypad with thirteen keys provides a simple to use
operator interface. A digital height indicator provides visual feedback for accurate and
repeatable sensor set-up. On-screen self-diagnostics are incorporated for continuous monitoring
of system performance. Unique parameter settings for up to 10 different product types can be
stored in the system by name and/or number. Additional capabilities of the system include dual
independent programmable reject outputs for sorting rejects by defects. There are four
programmable PLC output modules with the following choices: system status, reject container,
good container, photo beam, shaft encoder, reject lamp, alarm and rejector status outputs. The
four programmable input modules provide monitoring of external faults and reject signals from
other inspection equipment. The I/O board provides inputs for digital sensors such as label
detection.
Acoustic – This technology was developed by TapTone to inspect containers with rigid lids
for loss of pressure or vacuum. The sensor monitors the acoustic response of the container lid
when excited by a high-energy magnetic pulse. The frequency of vibration is directly related to
the pressure or vacuum inside the container. The patented method for analyzing the spectral
response of the lid provides for a high degree of accuracy and unmatched repeatability.
Proximity – This technology was perfected by TapTone for measuring the curvature of the
container lid to determine the vacuum or pressure level. The sensor is a high-speed analog
proximity sensor that can measure the curvature of a lid at line speeds to 2000 containers per
minute. Sophisticated algorithms determine the relative curvature, which varies based on the
pressure or vacuum level inside the container.
Laser – TapTone is using the latest state-of-the-art CCD laser technology to accurately
measure the deflection changes in non-metallic containers. The laser sensor will work on paper,
transparent foils, plastic and rubber lids of all colors, shapes and sizes. Sophisticated algorithms
determine the relative curvature, which varies based on the pressure or vacuum level inside the
container.
X-Ray – This sensor uses x-ray technology to measure the product fill level on steel,
aluminum, glass, plastic and paper products. The X-ray tube is energized at high voltage to
produce a low energy X-ray beam. This X-ray beam is focused to look through the container in
the expected fill level region. As the X-ray beam penetrates the container, it is attenuated by the
amount of product blocking the beam. The beam is monitored by a scintillation detector, which
counts the X-ray intensity after it goes through the container. The level of intensity is
proportional to the fill level of the container.

Features:
Non-contact Inspection Flash Memory for Easy Software
Reliable High Speed Rejection Upgrades
Inspection Speeds to 2,000 containers On-Screen Diagnostics for
per minute Troubleshooting
Clear LCD Graphic Display Menus in Seven Languages
Menu Driven Keypad NEMA 4X, IP65 Rated Enclosure
Memory for 10 Product Types Consecutive and Percent Reject Alarms
Digital Signal Processing Swing-away Transducer Assembly
RS-232 Serial Interface Port Programmable Merit Value Scaling
TapTone PC Software Display Last Four Rejects
(4) Optional PLC Inputs (2 Fault Diagnostics Feedback
programmable functions) Two Independently Programmable
(4) Optional PLC Outputs (8 Reject Outputs
programmable functions) I/O Board for Digital Input and Output
Shaft Encoder for Accurate Reject Functions
Timing
TapTone PC Software - The TapTone 500 is supplied with our latest TapTone PC
Windows based software package for use on a personal computer. This user-friendly tool
provides real-time production data and graphical reporting to assist in monitoring production
quality. The histograms provide vital statistical data on how the production equipment is
operating in regards to pressure, vacuum or fill level.
Strip Charts Histograms

2.1.1 TapTone 500 RTV Model
The RTV model uses two tripod stands, one for the control enclosure and the other for the
transducer and junction box assembly. This system provides convenient placement of the
control enclosure in walkways or operator platforms. The transducer assembly may be located in
hard to reach locations such as between conveyors or wet areas where operators would not
normally stand. The standard length of the cable between the junction box and the control
cabinet is 10 feet (3 meters). The rejector assembly mounts directly to the side of the inspection
conveyor.
REJECT
CRANK HANDLE LAMP
CONTROL
HEIGHT BOX
INDICATOR
JUNCTION
BOX
SENSOR
ASSEMBLY
TRIPOD BASE
Figure 2-1 TapTone 500 RTV System

2.1.2 TapTone 500 CMS Model
The CMS model provides mounting of the transducer bridge assembly onto the inspection
conveyor. This allows for installation where the conveyor height may be over six feet high or
where floor space is minimal. The junction box is also mounted to the side of the conveyor. The
control enclosure comes standard with a three-foot tripod stand for easy operator access in a
remote location away from the conveyor. The standard length of the cable is ten feet and
optional lengths up to thirty feet are available. The rejector assembly mounts directly to the
sidewall of the inspection conveyor.
Figure 2-2 TapTone 500 CMS System

2.2 System Configurations
2.2.1 Single Inspection and Dual Rejection T500
The single inspection T500 can be configured for one of the following inspections:
1. Acoustic - inspection for pressure or vacuum detection on rigid metal lid containers.
2. Proximity - inspection for curvature measurement on metal pressure or vacuum

containers.
3. Laser - inspection for curvature measurement on plastic pressure or vacuum containers.
4. Rejection #1 / Rejection #2 – single or dual rejection stations may be configured for

sorting rejects by specific defects.
MISSING LID REJECTS
INSPECTION
SENSOR #1
LEAKER REJECTS
REJECTOR #1 REJECTOR #2
TT500
CONTROL BOX
Figure 2-3 TapTone 500 Single Inspection System and Dual Rejection

2.2.2 Dual Inspection and Dual Rejection T500
The dual inspection T500 can be configured in any of the following combinations:
1. Acoustic / Cocked Crown - inspection for pressure detection on rigid metal lids with
cocked crown detection with a single head assembly.
2. Acoustic / Proximity - inspection for pressure or vacuum detection on rigid metal lids
with curvature measurement detection with dual head assemblies.
3. Proximity / Proximity - inspections for curvature measurements on metal pressure or

vacuum containers with different resolution sensors with dual head assemblies.
4. Laser / Proximity - inspections for curvature measurements on metal and plastic

pressure or vacuum containers with dual head assemblies.
5. Acoustic / X-Ray - inspections for pressure and vacuum detection and fill level
detection on rigid metal lid containers with dual head assemblies.
6. Proximity / X-Ray – inspection for curvature measurement and fill level detection on
metal pressure or vacuum containers with dual head assemblies.
7. Laser / X-Ray – inspection for curvature measurement and fill level detection on plastic
pressure or vacuum containers with dual head assemblies.
8. Rejection #1 / Rejection #2 – single or dual rejection stations can be configured for

COCKED CROWN REJECTS
INSPECTION INSPECTION
SENSOR #2 SENSOR #1
LEAKER REJECTS
TT500
CONTROL BOX
Figure 2-4 TapTone 500 Dual Inspection and Dual Rejection System

2.2.3 Triple Inspection and Dual Rejection T500
The dual inspection T500 can be configured in any of the following combinations:
1. Acoustic / Cocked Crown / X-Ray - inspection for pressure or vacuum detection on

rigid metal lids with cocked crown detection with a single head assembly for the acoustic and
cocked crown sensors. A separate stand is used for the x-ray assembly.
2. Acoustic / Proximity / X-Ray - inspection for pressure or vacuum detection on rigid

metal lids with cocked crown detection with triple head assemblies.
3. Rejection #1 / Rejection #2 – single or dual rejection stations can be configured for

LOW FILL REJECTS
SENSOR #3 SENSOR HEAD #2 SENSOR HEAD #1 LEAKER REJECTS
TT500
CONTROL BOX
Figure 2-5 TapTone 500 Triple Inspection with Dual Rejection System

2.3 System Specifications
General Specifications
Electrical: 115-240 VAC ± 10%, 47 - 85 Hz, single phase, 250 watts
Air: 30 - 150 psi., 6 cfm. (206.8 kPa - 1034.2 kPa, 2832 cm3/sec)
Operating Speed: Up to 2000-containers/minute or belt speed of 525 feet/min
(160 meters/min)
Temperature: 32º to 122º F (0º - 50º C)
Humidity: 0 - 90%, non-condensing
Altitude: Sea level to 10,000 feet (3035 m)
Fuses: 3.15 Amp, 250 VAC
Enclosure
Dimensions: 16” high x 16” wide x 6” deep (41 cm x 41 cm x15 cm).
Construction: Control enclosure with junction box
Material: Stainless steel, NEMA 4X, IP65 rated
Wash Down: High-pressure water
Mounting: Angled pedestal stand, stainless steel
Keypad: Watertight touch pad (13 keys)
LCD Display: LCD 240 x 128 pixels, back-lit
Reject Lamp: 24 VDC, 7 watt, orange lens, 1/2 second pulse per reject
Reject Signal: 24 VDC, 1 amp, variable pulse width and delay time
Communications: RS-232, 100 feet max.(30 meters max )
Transducer Stand
Type: Adjustable height with indicator, 9-1/2” (241 mm) travel
Construction: ABS plastic & stainless steel
Dimensions: Height-6 feet, 21.75” (552.4 mm) base diameter
Rejector/Regulator
Stroke: ½” or 1” (12 mm or 25 mm)
Construction: Stainless steel, conveyor mounted
Regulator Assembly: Filter/Regulator/Lubricator module with lockout
Pad: ABS plastic and black urethane
Operating Pressure: 40-80 psi (2.8-5.6 bars)
Maximum Line Pressure: 150 psi (11 bars)
Shaft Encoder
Resolution: 2540 pulses / revolution
Shaft Loading: Axial 40 lbs. (18.2 kg), radial 35 lbs. (15.8 kg)
Construction: Hard anodized aluminum, NEMA 4, IP65
Cable Type: 4 conductor, 20 AWG shielded
Cable Diameter: 0.182 inches (4.62 mm)
Cable Length: 25 ft. (7.62 m)
Supply Power: 5 VDC
Signal Output: 5 VDC, two channels

Sensor Input Specs.
Sensor #1: 0-10 VDC proximity, laser, cocked crown
Sensor #2: 0-10 VDC proximity, x-ray
Sensor #3: +/-10 VAC acoustic
Trigger Sensors
Photo Beam #1: Thru-beam fiber optic, high speed, 10-30 VDC (standard)
Photo Beam #2: Thru-beam fiber optic, high speed, 10-30 VDC (optional)
PLC Interface Board (Optional)

Input Modules Choices: Solid state, 3-30 VDC
Solid state, 140 VAC
Solid state, 280 VAC
Output Module Choices: Solid state, 60 VDC @ 3.5 amps, normally open
Solid state, 140 VAC @ 3.5 amps, normally open
Solid state, 280 VAC @ 3.5 amps, normally open
I/O Interface Board (Standard)

Input Modules Choices: Solid state, 3-30 VDC
Output Module Choices: Solid state, 60 VDC @ 3.5 amps, normally open
Laser Sensor Specifications

Laser Class: Laser Class II, wavelength of 670nm (visible red)
Laser optical output: <1 mW
Protection class sensor: IP65
Operation temperature: (0 to +50ºC) +32 to +104ºF
Measuring range: 10mm (.4”)
Reference distance: 35mm (1.4”) midrange (stand-off distance)
X-Ray Sensor Specifications

X-ray Source: X-ray tube, 60 kEV, < 0.1 mA
X-Ray Detector: Scintillation tube, 24 VDC
Fuses: 1.6 Amps, 3.15 Amps, 0.8 Amps
Dimensions:
Weight Approximate: 48.5 lbs. (22 kg)
Dimensions (WxHxD): 5.90” x 12.20” x 25.2” (150mm x 310mm x 640mm)
Tunnel Width: 4.72” (120mm) standard, 7.08” (180mm) wide
Material: Stainless steel, NEMA 4X, IP65 rated
System Mounting: Adjustable crank stand, stainless steel
X-ray Indicator: Yellow Lamp, 24 VDC, 4 watts
Electrical: 115-240 VAC ± 10%, 47 - 85 Hz, single phase, 250 watts

M-407-005 Chapter 3: Safety Precautions
3.0 Safety Precautions

3.1 General Safety Precautions
Please refer to the following safety instructions before and during operation of the system:
• Personnel trained in machine operations only must operate the system.
• Only personnel specifically trained should perform internal maintenance on the system.
• Make sure all safety guards and covers are properly installed before operating the system.
3.2 Specific Cautions and Warnings
DANGER! - High voltage components are used inside the enclosure during
operation. Do not operate the system with the enclosure door open. Turn power OFF
before opening the enclosure door for any reason.
DANGER! - Before removing the power board safety shield or disconnecting

the transducer wires, insure that LP1 (High Voltage Lamp) and LP2 (Cap Charge Lamp)
have gone out when ever the acoustic sensor is installed.
NOTICE! – Keep hands clear of X-ray tunnel when yellow X-ray lamp is on.
Do not operate the system with the power supply safety shield removed.
Do not operate the system with the enclosure open. Always turn power and air supply
OFF before opening the enclosure.
Keep hands clear of the rejector ram and inspection bridge whenever the system is in
operation.
Do not disconnect any electrical connections when the system power is on.
Damage to electrical components may occur.
Use lockout/tag-out equipment to prevent injury or damage when servicing the unit.
Before connecting an external device, power down both the TapTone 500 and the
external device. After power is off, connect device then turn power on.
The internal electronics of this equipment are sensitive to electrostatic discharge (ESD)
and proper precautions must be adhered to when handling any electrical components of
the system.
Do not place radial or axial load on the shaft encoder when mounting to the conveyor.
Internal damage to the encoder disk will occur.

M-407-005 Chapter 3: Safety Precautions
Laser Radiation: Do not stare into laser beam.
3.3 Safety Label Descriptions
Insert safety lock before getting in hazardous area.
Lock-out electrical power before servicing.
Stay clear.
General danger. (see manual)
Hazard hand crush.
Hazard electrical shock.
Protective earth.
Protective earth. (ground)
Figure 3-1 Safety Labels

M-407-005 Chapter 4: Installation Instructions
4.0 Installation Instructions

4.1 Installation Location
The following factors should be considered before installing the TapTone 500:
• A minimum of 12” (610 mm) of conveyor space (not including rejector station).
• The section of conveyor should be straight and smooth.
• The rails located at and immediately prior to the inspection area should be straight.
• There should be sufficient clearance in front of the TapTone 500 for an operator to safely and
comfortably stand.
• The AC power switch should be located between 2 feet (60 cm) and 6 feet (190 cm) from the
floor. This will allow operators to have easy access to the power switch in case of an
emergency.
• There should be sufficient space for a reject collection area.

4.2 Sensor Head Configurations
The T500 has a specific order to which the multiple inspections must be configured. The
following chart will establish the order in which the inspections must be installed. All inspection
timing is referenced to photo beam #1 which is the last inspection photo beam in the process
before the reject stations.
A = acoustic sensor
P = proximity sensor
L = laser sensor
C = cocked crown sensor
X = X-ray sensor
R = rejector (note a second rejector is available for all configurations)
ON = inspection is on for that specific sensor

OFF = inspection turned off, not used
AUTO = acoustic inspection automatically selects photo beam #1
Order of sensors = left to right where first letter is the most upstream sensor and the
rejector is always last.
Sensors Inspection Inspection Inspection Photo beam Photo beam Order of

Installed #1 #2 #3 #1 #2 Sensors
A OFF OFF ON-A AUTO-A OFF A-R
P ON-P OFF OFF ON-P OFF P-R
L ON-L OFF OFF ON-L OFF L-R
A/C ON-C OFF ON-A AUTO-A ON-C C-A-R
A/P ON-P OFF ON-A AUTO-A ON-P P-A-R
P/P ON-P1 ON-P2 OFF ON-P1 ON-P2 P2-P1-R
L/P ON-L ON-P OFF ON-L ON-P P-L-R
A/X OFF ON-X ON-A AUTO-A OFF X-A-R
P/X ON-P ON-X OFF ON-P OFF X-P-R
L/X ON-L ON-X OFF ON-L OFF X-L-R
A/C/X ON-C ON-X ON-A AUTO-A ON-C X-C-A-R
A/P/X ON-P ON-X ON-A AUTO-A ON-P X-P-A-R
Figure 4-1 Inspection / Photo Beam Selection Chart

4.2.1 Single Sensor Configurations
Acoustic Sensor – Set up the acoustic sensor on inspection #3. Inspection #3 will
automatically selects photo beam #1 for triggering the inspection. Connect photo #1 cable to
the acoustic photo beam module. Connect the microphone cable to the upper acoustic sensor
socket and the tap coil cable to the lower acoustic sensor socket.
Acoustic
Sensor Inspect #3
Conveyor
Direction
Photo #1
Rejector Rejector
#1 #2
Figure 4-2 Acoustic Inspection Layout
Proximity Sensor – Set up proximity inspection #1 then select photo beam #1 for triggering
the inspection. Connect photo #1 cable to the proximity photo beam module. Connect prox #1
cable to the proximity sensor socket.
Proximity
Sensor Inspect #1
Conveyor
Direction
Photo #1
Rejector Rejector
#1 #2
Figure 4-3 Proximity Inspection Layout

Laser Sensor – Set up laser inspection #1 then select photo beam #1 for triggering the
inspection. Connect photo #1 cable to the laser photo beam module. Plug in the laser sensor
cable to the laser sensor socket on the right side of the junction box.
Laser
Sensor Inspect #1
Conveyor
Direction
Photo #1
Rejector Rejector
#1 #2
Figure 4-4 Laser Inspection Layout
4.2.2 Dual Sensor Configurations
Acoustic & Cocked Crown Proximity Sensors – Set up the acoustic sensor on inspection
#3 with photo beam #1 automatically selected. Set up the cocked crown sensor on inspection #1
and select photo beam #2 then set the photo beam #2 offset value to program the distance
between the two inspections. Connect photo #1 cable to the photo beam module for the acoustic
sensor. Connect the microphone cable to the upper acoustic sensor socket and the tap coil cable
to the lower acoustic sensor socket. Connect prox #1 cable to the cocked crown proximity
sensor socket. Connect photo #2 cable to the cocked crown photo beam module.
Cocked
Crown Acoustic
Inspect #1 Inspect #3
Sensor Sensor
Conveyor
Direction
Photo Photo
#2 #1
Rejector Rejector
#1 #2
Figure 4-5 Acoustic with Cocked Crown Inspection Layout

Acoustic & Proximity Sensors - Set up the acoustic sensor on inspection #3 with photo
beam #1 automatically selected. Set up the proximity sensor on inspection #1 and select photo
beam #2 then set the photo beam #2 offset value to program the distance between the two
inspections. Connect photo #1 cable to the photo beam module for the acoustic sensor. Connect
the microphone cable to the upper acoustic sensor socket and the tap coil cable to the lower
acoustic sensor socket. Connect prox #1 cable to the cocked crown proximity sensor socket.
Connect photo #2 cable to the cocked crown photo beam module.
Proximity Acoustic
Inspect #1 Inspect #3
Sensor Sensor
Conveyor
Direction
Photo #2 Photo #1
Rejector Rejector
Figure 4-6 Acoustic & Proximity Inspection Layout # 1 #2
Proximity & Proximity Sensors - Set up the proximity sensor #1 on inspection #1 then
select photo beam #1. Set up proximity sensor #2 on inspection #2 and select photo beam #2
then set the photo beam #2 offset value to program the distance between the two inspections.
Connect prox #1 cable to proximity sensor #1 and photo #1 to photo beam module #1. Connect
prox #2 cable to proximity sensor #2 and photo #2 to photo beam module #2.
Inspect #2 Proximity Proximity Inspect #1

Sensor #2 Sensor #1
Conveyor
Direction
Photo #2 Photo #1
Rejector Rejector
#1 #2
Figure 4-7 Proximity & Proximity Inspection Layout

Dual Proximity Sensors - Set up the proximity sensor #1 (little foot) on inspection #1 and
select photo beam #1. Set up proximity sensor #2 (big foot) on inspection #2 and select photo
beam #2 then set the photo beam #2 offset value to program the distance between the two
inspections. Connect prox #1 cable to proximity sensor #1 and photo #1 to photo beam module
#1. Connect prox #2 cable to proximity sensor #2 and photo #2 to photo beam module #2.
Proximity Proximity
Inspect #2 Sensor #2 Sensor #1 Inspect #1
(big foot) (little foot)
Conveyor
Direction
Photo Photo
#2 #1
Rejector Rejector
#1 #2
Figure 4-8 Dual Proximity Inspection Layout
Laser & Proximity Sensors - Set up the laser sensor on inspection #1 and select photo beam
#1. Set up proximity sensor on inspection #2 and select photo beam #2 then set the photo beam
#2 offset value to program the distance between the two inspections. Connect photo #1 cable to
the laser photo beam module. Plug in the laser sensor cable to the laser sensor socket on the
right side of the junction box. Connect prox #2 cable to proximity sensor #2 and photo #2 to
photo beam module #2.
Proximity Laser
Inspect #2 Sensor Sensor
Inspect #1
Conveyor
Direction
Photo #2 Photo #1
Rejector Rejector
#1 #2
Figure 4-9 Laser & Proximity Inspection Layout

Acoustic & X-ray Sensors - Set up the acoustic sensor on inspection #3 with photo beam #1
automatically selected. Set up the x-ray sensor on inspection #2 then set the distance from the x-
ray sensor to photo beam #1. Connect photo #1 cable to the acoustic photo beam module.
Connect the microphone cable to the upper acoustic sensor socket and the tap coil cable to the
lower acoustic sensor socket. Connect the x-ray cable to the x-ray socket on the bottom of the
T500 control box.
X-ray
Inspect #2 Sensor Acoustic
Sensor Inspect #3
Conveyor
Direction
Photo #1
Rejector Rejector
#1 #2
Figure 4-10 Acoustic & X-ray Inspection Layout
Proximity & X-ray Sensors - Set up the proximity sensor #1 on inspection #1 then select
photo beam #1. Set up the x-ray sensor on inspection #2 then set the distance from the x-ray
sensor to photo beam #1. Connect photo #1 cable to the proximity photo beam module.
Connect prox #1 cable to the proximity sensor socket. Connect the x-ray cable to the x-ray
socket on the bottom of the T500 control box.
X-ray
Inspect #2 Sensor Proximity Inspect #1
Sensor #1
Conveyor
Direction
Photo #1
Rejector Rejector
#1 #2
Figure 4-11 Proximity & X-ray Inspection Layout

Laser & X-ray Sensors - Set up the laser sensor on inspection #1 then select photo beam #1.
Set up the x-ray sensor on inspection #2 then set the distance from the x-ray sensor to photo
beam #1. Connect photo #1 cable to the laser photo beam module. Plug in the laser sensor cable
to the laser sensor socket on the right side of the junction box. Connect the x-ray cable to the x-
ray socket on the bottom of the T500 control box.
X-ray
Inspect #2 Sensor Laser Inspect #1
Sensor
Conveyor
Direction
Photo #1
Rejector Rejector
#1 #2
Figure 4-12 Laser & X-ray Inspection Layout

4.2.3 Triple Sensor Configurations
Acoustic, Cocked Crown & X-ray Sensors - Set up the acoustic sensor on inspection #3
with photo beam #1 automatically selected. Set up the cocked crown sensor on inspection #1
and select photo beam #2 then set the photo beam #2 offset value to program the distance
between the two inspections. Set up the x-ray sensor on inspection #2 then set the distance from
the x-ray sensor to photo beam #1. Connect photo #1 cable to the photo beam module for the
acoustic sensor. Connect the microphone cable to the upper acoustic sensor socket and the tap
coil cable to the lower acoustic sensor socket. Connect prox #1 cable to the cocked crown
proximity sensor socket. Connect photo #2 cable to the cocked crown photo beam module.
Connect the x-ray cable to the x-ray socket on the bottom of the T500 control box.
Inspect #1
X-ray Cocked
Inspect #2 Sensor Crown Acoustic
Inspect #3
Sensor Sensor
Conveyor
Direction
Photo #2 Photo #1
Rejector Rejector
#1 #2
Figure 4-13 Acoustic, Cocked Crown & X-ray Inspection Layout

Acoustic, Proximity & X-ray Sensors - Set up the acoustic sensor on inspection #3 with
photo beam #1 automatically selected. Set up the proximity sensor #1 on inspection #1 and
select photo beam #2 then set the photo beam #2 offset value to program the distance between
the two inspections. Set up the x-ray sensor on inspection #2 then set the distance from the x-ray
sensor to photo beam #1. Connect photo #1 cable to the photo beam module for the acoustic
sensor. Connect the microphone cable to the upper acoustic sensor socket and the tap coil cable
to the lower acoustic sensor socket. Connect prox #1 cable to the cocked crown proximity
sensor socket. Connect photo #2 cable to the cocked crown photo beam module. Connect the x-
ray cable to the x-ray socket on the bottom of the T500 control box.
X-ray Inspect #1
Inspect #2 Sensor Proximity Acoustic
Sensor #1 Sensor Inspect #3
Conveyor
Direction
Photo #2 Photo #1
Rejector Rejector
#1 #2
Figure 4-14 Acoustic, Proximity & X-ray Inspection Layout

4.2.4 Junction Box Cable Configurations
Photo Beam #1 Photo Beam #2

T500 Junction Box
(front view)
Proximity Proximity
Sensor #1 Sensor #2
Acoustic Laser
Microphone Sensor
Sensor #3 Sensor #1
Acoustic Shaft
Tap Coil Encoder
Sensor #3
Reject #1 Reject #2
Conduit to
T500 Control
Enclosure
Figure 4-15 Junction Box Cable Configuration

4.3 Control Enclosure Assembly
The enclosure assembly contains all the circuit boards and power supplies for the system. This
assembly should be bolted to the floor where the operator can reach the keypad safely.
1. Assemble the controller stand as shown in Figure 4-16 below.
2. Select installation location where operators can safely reach the controls then mark three
holes to drill for the supplied lag bolts.
3. Drill three 5/8” (15.875mm) holes in the floor to a depth of 2” (50.8mm) then hammer in the
anchor drop-in part number 0219-313 into the holes.
4. Secure the tripod base to the floor using the ½-13 x 2” bolts, flat and split-lock washers
provided with the stand.
5. Rotate the control enclosure for easy access to the controls then secure the collar bolts.
13” (330mm)
Control Box Dimensions

Width = 16” (406mm)
Height = 16” (406mm)
Depth = 6” (152mm)
13” (330mm) Collar Bolts
Lag Bolts
Figure 4-16 Control Enclosure Specifications

4.4 Remote Transducer Stand Assembly (RTV)
9” (228m m)
6 Feet (1.82 m eters)
9-1/2” (241m m )
Lag Bolts
Figure 4-17 Transducer Stand Assembly
1. Select a location where the transducer stand will be mounted. Make sure the location is
smooth and straight. The rails must be straight and guide the containers smoothly through
the inspection head. The location should allow the rejector to be mounted on the conveyor
with an adequate size collection bin.
2. The transducer crank stand has 9-1/2 inches (241 mm) of travel. The stand is shipped with
the following inspection range:
Max. height: MXS = 67.375 inches (1711 mm)
Min. height: MNS = 57.875 inches (1470 mm)
3. Measure the conveyor tabletop height and the tallest and shortest containers. Enter the
values below.
CH - Conveyor Height =
TC - Tallest Container =
SC - Shortest Container =

If the difference between the TC and SC is greater than 9 1/2 inches (241 mm), contact TapTone
engineering for a custom stand tube.
Now calculate the inspection range for your containers as follows:
Max. test height: MXT = CH + TC =
Min. test height: MNT = CH + SC =
Calculate the amount of tube that needs to be cut off the bottom as follows:
CUTOFF = MXS - MXT =
4. Remove the (2) bolts holding the transducer head assembly.
5. Remove the (2) screws holding the junction box clamp for the RTV system.
6. Remove the tripod base by loosening the (4) bolts.
7. Mark and cut the bottom of the stand tube by the length calculated (CUTOFF).
8. Reassemble the tripod base to the stand by tightening the (4) bolts.
9. Reassemble the junction box to the stand with the (2) junction box clamp screws.
10. Reassemble the transducer head to the bracket with the (2) bolts.
11. Place the transducer stand along side the conveyor with the transducer head assembly
directly over the container flow at the location selected then mark three holes for drilling.
12. Drill three 5/8” (15.875mm) holes in the floor to a depth of 2” (50.8mm) then hammer in the
anchor drop-in part number 0219-313 into the holes.
13. Secure the tripod base to the floor using the ½-13 x 2” bolts, flat and split-lock washers
provided with the stand.

4.5 Conveyor Mounted Transducer Assembly (CMS)
1-1 /2” (38m m )

S qu are T ub e
26-1/2” (67 3m m )
1 7” (431 m m )
Figure 4-18 Conveyor Mounted Transducer Dimensions
4.5.1 Transducer Frame Installation
1. Assemble the frame assembly as shown in Figure 4-19.
2. Place the frame assembly in the inspection area and mark the hole locations for the frame
mounting bolts. Make sure that holes are positioned where mounting hardware is clear of
any obstructions or working components of the conveyor.
3. Drill four 11/32” (8.73mm) diameter holes on each side of the conveyor for the frame
mounting bolts.
4. Install the frame assembly using the hardware listed below:

• For conveyors 3” (76mm) to 7” (177mm) wide use both conveyor spacer blocks and 5/16
x 1 ¾” hardware provided.
• For conveyors over 7” (177mm) wide use the 5/16 x ¾” hardware provides without the
spacer blocks.
Make sure the vertical posts are perpendicular to the conveyor table top.

Figure 4-19 Conveyor Mounted Transducer Assembly
4.5.2 Junction Box Installation
1. Place the junction box in the mounting location next to the frame assembly and mark the hole
for drilling.
2. Drill four 17/64” (6.75mm) holes in the conveyor for the junction box mounting hardware.
3. Mount the junction box using the ¼-20 x ¾” hardware provided.
4. Connect the sensor cables according to the junction box cable diagram Figure 4-15.

4.6 Rejector Assembly
The remote rejector is supplied with a 6-foot (1.8 meter) cable with molded connector. The
minimum mounting distance from the transducer head is two (2) can diameters. The maximum
mounting distance is the cable length. The rejector can be mounted directly on the conveyor
wall or on a tripod rejector stand. The following figure shows a suggested reject station.
24"deep tray(sloped)
36" to 48" reject tray opening

rail rail
rail rail
container flow
rejector
Figure 4-20 Rejector Station Layout
Line Speed (bottles / min) Guide Rail Opening

500 5.00 in. (127 mm)
750 7.50 in. (191 mm)
1000 10.00 in. (254 mm)
1250 12.50 in. (318 mm)
1500 15.00 in. (381 mm)
1750 17.50 in. (445 mm)
2000 20.00 in. (508 mm)
Figure 4-21 Rejector Station Rail Specification

1/16" GAP IN/OUT

4 BOLTS
CAN
UP/DOWN
4 BOLTS
SPACER
SHOP AIR SUPPLY

Figure 4-22 Remote Rejector Assembly
A. Select a location where the rails can be cut away to allow the rejects to leave the conveyor.
At faster line speeds, the conveyor cut-away must be larger. Refer to Figure 4-21 for cut-
away guidelines.
B. Drill four (4) holes for the mounting bolts.
C. Mount the rejector to the conveyor with the hardware provided. Use the spacer block
between the bracket and conveyor if required. Set the height so the reject pad hits the
container in the center.
D. Connect the shop air supply to the filter/regulator/lubricator assembly. Maximum shop air
pressure of 150 psi.
4.7 Shaft Encoder Kit
The shaft encoder kit includes the encoder, 3/8" rubber shaft coupler, and 25-foot cable with
connector and strain relief. The installer is required to mount the encoder to the conveyor shaft.
Dimensions are provided in the Figure 4-23.
Caution: Excessive side loads to the shaft will damage the watertight seal that could
lead to premature failure. Make sure the shafts line up and the coupling between them
is flexible.

2.650 ø.218
2.069 4 PLACES
1.035 2.600
.280
.3747
1.250 2.510
2.069
1.035
.75 FLAT
SET SCREW FLAT
.305 1.500
SHAFT DIA. 0.375
.910
1.480
Figure 4-23 Shaft Encoder Specifications Drawing
CONVEYOR
BELT
CONVEYOR SHAFT
CUSTOM BRACKET
CUSTOMER SUPPLIED
3/8" COUPLING
SHAFT ENCODER
Figure 4-24 Shaft Encoder Mounting Drawing

4.8 Power and Air Connections
DANGER! - High voltage components are used inside the enclosure during
operation. Do not operate the system with the door open. The power interlock switch
will turn the power OFF whenever the door is opened. The door must be closed before
turning the power on.
4.8.1 T500 Controller Power Connections
A 12-foot (3.6 meter) line cord with three-prong plug is standard with the TapTone 500. The
power requirements are 115 - 240 VAC+/- 10%, 47-85 Hz, 250 watts. The power connections
inside the control enclosure are as follows:
CONNECTION POINT WIRE COLOR WIRE COLOR FUNCTION

(POWER SWITCH) (USA) (EUROPE)
PIN-5 WHITE WIRE BLUE WIRE AC NEUTRAL (N)
PIN-3 BLACK WIRE BROWN WIRE AC LINE (L)
CONNECT TO (PE) CHASSIS GREEN WIRE GREEN/YELLOW GROUND (PE)
STUD ABOVE POWER
SWITCH
WIRE
If a power line conditioner is supplied with your TapTone 500 system, follow the installation
instructions located in Appendix B of this manual.
4.8.2 X-ray Sensor Connections
1. A 12-foot (3.6 meter) line cord with three-prong plug is standard with the TapTone 500 X-ray
sensor. The power requirements are 115 - 240 VAC+/- 10%, 47-85 Hz, 250 watts. The power
connections inside the X-ray control box are as follows:
WIRE COLOR WIRE COLOR FUNCTION

(USA) (EUROPE)
WHITE WIRE BLUE WIRE AC NEUTRAL (N)
BLACK WIRE BROWN WIRE AC LINE (L)
GREEN WIRE GREEN/YELLOW GROUND (PE)
WIRE
2. Connect the X-Ray 12-pin communication cable into the bottom of the T500 control box.

4.8.3 PLC Board Connections
The PLC interface board provides digital inputs and outputs to monitor the conditions of the
inspection system. Refer to section 5.6.11 I/O menu for specific details on input or output
function. The optically isolated I/O modules can be specified in the following voltage ranges:
Input Modules 3-30VDC or 140VAC or 280VAC
Output modules 60VDC or 140VAC or 280VAC

3.5 Amps, normally open contacts
M0 M1 M2 M3
M4 M5 M6 M7
Figure 4-25 PLC Interface Board Connections
Output Functions: System Status, Alarm, Lamp, Shaft Encoder, Photo Beam-1, Good
Container, Reject Output-1, Rejector Status
OUTPUT MODULE OUTPUT LED JSOUT PINS

M0 LED1 Pin 1 is (+) and Pin 2 is (-)
Input Functions: External Fault-Low, External Fault-High, Reject-Low, and Reject-

High
INPUT MODULE OUTPUT LED JSIN PINS


4.8.4 Acoustic Power Board
The power board shown below generates the high voltage for the acoustic transducer to transmit
the tap pulse. This board is only installed when the acoustic sensor is required. Make sure the
AC selector switch is set to the proper AC power supplied by the plant. TapTone recommends
using a power conditioner supplied with the unit and operating the T500 from the 110 VAC
terminals. Refer to Appendix B for power conditioner installation instructions. The power level
may be adjusted using the Jumper JH6 on the display board where 8 is lowest and 14 is highest
power level for the tap coil. Use power level 14 for most applications.
DANGER! - High voltage components are used on this board during operation.
Do not operate the system with the door open. Do not operate the system with the
protective safety shield removed.
115 / 230 VAC Transducer

Selector Switch Output Connector
Line Fuses
2 Amps
Figure 4-26 Power Board Layout
NOTICE! – To protect this board from AC power surges the power conditioner
provided must be installed onto the AC power line. See Appendix B for installation and
wiring procedures for the power conditioner.

4.8.5 Air Connection
A. The air supply should be clean and dry with a maximum line pressure of 150 psi (10.3 bar).
B. Connect the air supply to the input side of the regulator assembly supplied with the TapTone
500. Refer to Figure 5-3 Regulator Assembly Controls and Indicators.
C. Fill the lubricators bowl with 5-weight petroleum based oil and set the lubrication rate to the
minimum position. See Section 5-3 for control descriptions.
D. Turn air supply ON and set regulators pressure to approximately 40 psi (2.7 bar) on the
gauge. The regulator pressure may be adjusted as required to achieve proper removal of
rejected containers.
4.9 Initial Sensor Setup
The following procedures are based on every sensor offered by the TapTone 500. Setup the
TapTone 500 according to the sensors installed on your system.
NOTICE! – The rail gap MUST be less than 1/8” (3mm) to achieve maximum
system performance. Larger gaps or absence of rails may effect the overall
performance of the system. This statement is true for each of the T500 sensors.
4.9.1 Acoustic Sensor Setup
A. Adjust the conveyor rails to the container for a gap of 1/8” (3mm) maximum. The containers
should pass smoothly through the inspection head.
B. Place a good container under the acoustic sensor head and lower the head until it just touches
the highest point on the container. Note the value on the digital indicator then crank the head
up 150 values which is equal to .150” (4mm) above the container. Lock the brake knob and
take note of the final digital indicator value.
C. Center the acoustic sensor over the container and lock down the red wing clamps.
D. Set the photo beam fiber optic lenses to break the cap of the container or in a position that
will break even when the containers are touching.
4.9.2 Cocked Crown Sensor Setup
A. Set up the acoustic sensor first when using the combination acoustic/cocked crown kit.
B. Adjust the conveyor rails to the container for a gap of 1/8” (3mm) maximum. The containers
C. Set the height of the cocked crown sensor to be flush (level) with the acoustic sensor using
the adjustable knob on top of the sensor housing. This will set the cocked crown sensor
.150” (4mm) above the container. The sensor will be fine tuned at a later time.
D. It is very important that the container is center directly over the cocked crown sensor for
maximum performance.
E. Set the photo beam fiber optic lenses to break the cap of the container or in a position that

4.9.3 Proximity Sensor Setup
B. Place a good container under the proximity sensor head and lower the head until it just
touches the highest point on the container. Note the value on the digital indicator then crank
the head up 150 values which is equal to .150” (4mm) above the container. Lock the brake
knob and take note of the final digital indicator value.
C. Center the proximity sensor over the container and lock down the red wing clamps.
4.9.4 Laser Sensor Setup
B. Place a bad container under the laser sensor head and lower the head until the outer sensor
mounting plate just touches the highest point on the container. Note the value on the digital
indicator then crank the head up 1,400 values which is equal to 1.400” (35mm) above the
container. Lock the brake knob and take note of the final digital indicator value.
CAUTION – Make sure you do not scratch or damage the glass windows on the
laser sensor face.
C. Center the laser sensor over the container and lock down the red wing clamps. The laser
beam is visible for easy alignment.
4.9.5 X-ray Sensor Setup
B. Adjust the height of the X-ray sensor with the crank handle on the top of the stand. Set the
height so the arrow on the side of the X-ray transmitter box is level with the fill height level
in the container. This is just a rough setting to get you X-ray beam in the area of the fill
level.
C. Adjust the trigger sensors as required. If proximity sensors are provided, adjust them to be
about 5/64” (2mm) away from the cans. Make sure the sensors are not looking at the rails.

M-407-005 Chapter 5: System Operating Procedures
5.0 System Operating Procedures

5.1 System Shut-Down Procedure
A. Turn the system power OFF with the switch on the right side of the control enclosure.
B. Turn the rejector air supply OFF with the regulator air cut-off switch.
5.2 Cleaning Requirements and Precautions
CAUTION: Ensure the enclosure front door is securely fastened before washing
the enclosure.
WARNING: Do not spray directly on the keypad at close range. Damage to the
LCD screen may occur.
5.3 Controls and Displays
Keypad - located on the front door of the TapTone 500. The keypad is the main operator
interface to the machine. The yellow up/down, left/right arrow keys located at the bottom of the
display are used for navigation through the menu selections. Press the enter key to save values
to memory. The two symbolic keys turn the rejector on and off. The green key enables the
reject function. The red key disables the reject function. The six unmarked keys are universal
keys defined by text on the screen directly next to each key. Any key without text next to it is
unused in that screen.
LCD - located on the front door of the TapTone 500. The LCD gives the operator visual access
to all of the counters and parameters.
Function
Keys
Menu
Navigation
Keys
LCD
Display
Reject Enter
On/Off TapTone 500 Key
Keys
Figure 5-1 TapTone 500 Key Pad

Power Switch - located on the right side of the TapTone 500 control enclosure. This controls
the AC power to all circuitry inside the control enclosure. There are two lockout slots that lock
the power switch in the off position for maintenance requirements.
Reject Lamp - located on the top of the enclosure. The lamp will light for ½ second every time
a container is rejected. The lamp will flash continuously if the rejector is disabled or an alarm
condition occurs.
RS-232 - located on the left side of the enclosure. The communications port is used for RS-232
communications with the TapTone 500. It is used to upgrade the system software and
communicate with the TapTone PC software.
Figure 5-2 Enclosure Controls and Indicators
Air Pressure Gauge - located on the front of the rejector air regulator assembly. The gauge
displays the air pressure going to the reject valve and cylinder. The gauge displays values
between 0 and 150 psi (10.3 bar).
Air Pressure Adjust Knob - located on top of the regulator assembly. The knob is used to
adjust the pressure going to the reject valve and cylinder.
Air Cutoff Switch - located on the left side of the rejector air regulator assembly. This switch
disconnects the air going into the reject valve and cylinder that disables the rejector. Push down
to turn air supply off and push up to turn air on.
Lubricator Flow Control - to adjust the lubricator flow rate turn the knob labeled + and - on top
of the lubricator module. Turn clockwise (CW) to increase the amount of lubrication and
counter clockwise (CCW) to decrease the amount of lubrication. It is recommended to have the
lubricator just slightly opened.

Filter and Lubricator Bowl Drains - to drain any filtered water from the air supply or remove
lubricating oil use the ¼ turn manual drain located on the bottom of the regulator assembly
bowls.
Filter/Lubricator Bowl Level Indicators - the transparent nylon level indicators located on the
bowls of the regulator assembly display the level of water separated from the air supply and the
remaining lubricant in the lubricator reservoir bowl.
Air Shut-off Regulator Pressure Control
Lubricator Flow Control
To Rejector
Shop Air Supply
Gauge
Level Indicators
Bowl Drains
Figure 5-3 Regulator Assembly Controls and Indicators
Photo Beam Module Adjustments and Indicators - The photo beam output control should be
set to Dark Operate (DO.). The output LED will flash faster as the gain is increased.
GAIN +
OUTPUT -
GAIN ADJUST
D.O.
OUTPUT CONTROL L.O. QUICK

DARK/LIGHT OPERATE DISCONNECT
CONNECTOR
Figure 5-4 Photo Beam Module Controls and Indicators

Operator Menu
Change Prod Diag Statistics Main Setup
Product Sensor Sensor #1 Summary Passw ord
Type Signal Histogram Counters Screen
Last -4 Sensor #2 Sensor #1

M-407-005
Rejects Histogram Merit Values
Photo Beam Sensor #3 Sensor #2

Diagnostics Histogram Merit Values
Shaft
Encoder Sensor #3
Diagnostics Merit Values
Force I/O
Reject Counters
Optional I/O
Diagnostics
PLC
5.4.1 Parameter Menu Tree
Diagnostics
TapTone Division of Benthos, Inc.

X-ray
Diagnostics
System
Values
explain each menu selection in more detail.
Maintenance Menu
Limits 1 Inspect 1 Limits 2 Inspect 2 Limits 3 Inspect 3 Rejector 1 Rejector 2 Encoder I/O Alarm Prod Type Password
Shaft
High/Low Inspection High/Low Inspection High/Low Inspection Sensor Sensor Encoder Screen Text Consecutive Product Type Passw ord
Limits Selection Limits Selection Limits Selection Selection Selection On/Off Selection Alarm Select Control
5.4 System Programmable Parameters
Auto Track Photo Beam Auto Track Photo Beam Auto Track Algorithm Pulse Width Pulse Width Shaft Divider LCD Contrast Percent Product Name Passw ord
Offset Selection Offset Selection Offset Selection Adjust Adjust Adjust Adjust Alarm Adjust Change
Missing Lid Product

Missing Lid Photo Beam Photo Beam High/Low Gate Time/ Reject Delay Reject Delay PLC Input 1-4 Default
Limit -2 Offset Limit -2 Offset dB Limit Gate Delay Adjust Adjust Mode Select Reset
Sw elled Can Algorithm Sw elled Can Algorithm High/Low Modulation Can Width Can Width PLC Input 1-4 Product Copy
Limit Selection Limit Selection dB Offsets Filter On/Off Adjust Adjust Fault Select Select
Figure 5-5 System Menu Tree

Reject Reject
Cocked Cap Vac / Press Cocked Cap Vac / Press Auto Track Glass Distance Distance Opt Input 1-7 Bridge Height
Limit Mode Limit Mode Mode/Sample Filter On/Off Adjust Adjust Mode Select Adjust
Auto Track Window Auto Track Window Speed Comp Speed Comp Opt Input 1-7
Mode/Sample Adjustment Mode/Sample Adjustment Adjust Adjust Distance
Opt Output
Height Midpoint Midpoint 1-6 Function
Mode % % Select
Midpoint Midpoint Baud Rate

Height RS-232
Method Method
Profile Profile Baud Rate

Adjustment Adjustment RS-485
RS-485
X-ray Address
Distance Select
follows gives a road map to where all of the parameters are located. The following sections
All system parameters are accessible through the LCD/keypad interface. The menu tree that
Underfill/
Overfill
X-ray
Chapter 5: System Operating Procedures
40
Window
5.5 Operator Parameters
The operator can access all parameters located to the left of the main menu. These menus are not
password protected. There is one parameter that can effect the operation of the machine from
this screen. This parameter is the Product Type parameter. It is recommended to copy the final
product type settings to the unused product types using the copy menu function located in the
Product Type Menu.
Operator Menu
Change Prod Diag Statistics Main Setup
Product Sensor Sensor #1 Summary Password
Type Signal Histogram Counters Screen
Last -4 Sensor #2 Sensor #1

Rejects Histogram Merit Values
Photo Sensor #3 Sensor #2

Diagnostics
B Histogram Merit Values
Shaft
Sensor #3
Encoder
Merit Values
Diagnostics
Force I/O
Reject Counters
Optional
Diagnostics
I/O
PLC
Diagnostics
X-ray
Diagnostics
System
Values
Figure 5-6 Operator Menu Tree

5.5.1 Main
The numbers 1/5, 2/5 ..etc. refer to the page number and total number of screens in the menu
selected. Some pages may not appear when that particular menu function is not activated.
1/5 Summary Counters - Displays the ( Total, Pass, Fail, Rej1, Rej2 ) counters. Press the
Clear Counts button to reset all summary counters.
Statistics Main Setup

TapTone 500 - Version 3.0
Summary Counters
Total = 0
Pass = 0
Fail = 0
Rej 1= 0
Rej 2= 0
Clear
Counts
1/5
Total – Total containers inspected since last counter clear.

Pass – Total accepted containers inspected since last counter clear.
Fail – Total rejected containers inspected since last counter clear.
Rej 1 – Total rejected containers by reject #1 since last counter clear.
Rej 2 – Total rejected containers by reject #2 since last counter clear.
Clear Counts - Resets all counters and histograms to zero.
2/5 Sensor #1 Merit Values - Displays the merit values for each inspection on sensor #1. The
clear key resets the reject counters and histograms. Sensor #1 will display the proximity, laser or
the cocked crown inspection as selected in the inspection #1 menu.
Proximity Laser
Statistics Main Setup Statistics Main Setup
0<=pass<=1023 0<=pass<=1023
Profile Mean Sdev Skew Profile Mean Sdev Skew

0 0 0.0 0.00 0 0 0.0 0.00
Missing Swelled Cocked Missing Swelled Cocked
0 0 0 0 0 0
Rejects Rejects
Profile = 0 Missing = 0 Profile = 0 Missing = 0
Swelled = 0 Cocked = 0 Swelled = 0 Cocked = 0
Clear Sensor #1 - Proximity Clear Sensor #1 - Laser
2/5 2/5
Proximity and Laser Screen

0<=pass<=1023 - High and Low reject limits for profile inspection.
Profile - Merit value for curvature inspection (0-1023).
Missing - Merit value for missing lid inspection (0 - 1023).
Swelled - Merit value for swelled can inspection (0-1023).

Cocked - Merit value for cocked cap inspection (0-1023).
Mean - Mean value calculated from the profile inspection (0-1023).
Sdev - Standard of Deviation calculated from the profile inspection (0-99.9).
Skew - Skew of histogram calculated from the profile inspection (0-9999.99).
Rejects Profile - Total rejects for profile inspection.
Rejects Missing - Total rejects for missing lid inspection.
Rejects Swelled - Total rejects for swelled can inspection.
Rejects Cocked - Total rejects for cocked cap inspection.
Sensor #1 Proximity - Identifies the sensor number and sensor type.
Clear - Resets all counters and histograms to zero.
Cocked Crown
Dimple=0
Sym.=0
Height=0
Rejects
Dimple= 0
Symmetry= 0
Height= 0
Clear Sensor #1 – Cocked Crown

2/5
Cocked Crown Screen

Dimple – Merit value for cocked crown dimple inspection (1-1023).
Symmetry – Merit value for cocked crown symmetry inspection (1-1023).
Height – Merit value for cocked crown height inspection (1-1023).
Rejects Dimple - Total rejects for dimple inspection.
Rejects Symmetry - Total rejects for symmetry inspection.
Rejects Height - Total rejects for height inspection.
3/5 Sensor #2 Merit Values - Displays the merit values for each inspection on sensor #2. The
clear key resets the reject counters and histograms. Sensor #2 will display either the proximity
or the x-ray inspection as selected in the inspection #2 menu.
Proximity
0<=pass<=1023
Profile Mean Sdev Skew

0 0 0.0 0.00
Missing Swelled Cocked
0 0 0
Rejects
Profile = 0 Missing = 0
Swelled = 0 Cocked = 0
Clear Sensor #2 - Proximity
3/5

Proximity Screen
0<=pass<=1023 - High and Low reject limits for profile inspection.
Profile - Merit value for curvature inspection (0-1023).
Missing - Merit value for missing lid inspection (0 - 1023).
Swelled - Merit value for swelled can inspection (0-1023).
Cocked - Merit value for cocked cap inspection (0-1023).
Mean - Mean value calculated from the profile inspection (0-1023).
Sdev - Standard of Deviation calculated from the profile inspection (0-99.9).
Skew - Skew of histogram calculated from the profile inspection (0-9999.99).
Rejects Profile - Total rejects for profile inspection.
Rejects Missing - Total rejects for missing lid inspection.
Rejects Swelled - Total rejects for swelled can inspection.
Rejects Cocked - Total rejects for cocked cap inspection.
Sensor #2 Proximity - Identifies the sensor number and sensor type.
X-Ray
Fill= 0
Rejects
Fill Level= 0
Sensor #2 – X-Ray
Clear
3/5
X-Ray Screen
Fill – Merit value for the X-ray fill level inspection (0 – 160).
Fill Level Rejects – Total rejects for fill level inspection.
Sensor #2 X-Ray - Identifies the sensor number and sensor type.
4/5 Sensor #3 Merit Values - Displays the merit values for acoustic inspection #3.
Acoustic
0<=Freq pass<=1023
0<= dB pass <=1023
Freq Mean SDev Skew

0 0 0.00 0.00
dB Mean SDev Skew
0 0 0.00 0.00
Rejects
Freq = 0 dB = 0
Clear Sensor #3 - Acoustic

4/5

Sensor #3 Acoustic - Identifies the sensor number and sensor type.
Freq - Merit value of the frequency inspection (0-511).
Mean - Mean frequency value calculated from the frequency inspection (0-100).
dB - Merit value of the dB inspection (0-100).
Mean - Mean dB value calculated from the dB inspection (0-511).
Rejects Freq - Total rejects for frequency inspection.
Rejects dB - Total rejects for dB inspection.
5/5 I/O Counters - Displays the digital input reject counters.

Rejects
Input #1 = 0
Input #2 = 0
Input #3 = 0
Input #4 = 0
Input #5 = 0
Input #6 = 0
Input #7 = 0
Clear Inputs
5/5
Input Screen
Input =# - Number of rejected containers for this input.

5.5.2 Statistics
1/3 Sensor #1 Histogram - Graphic display of the histogram for inspection #1. The four
proximity and laser choices are profile, missing lid, swelled can and cocked cap. The three
cocked crown choices are dimple, symmetry and height.
Proximity (4 screens)
Diag Statistics Main Diag Statistics Main
L/F L/F
Adj Adj
Sensor 1 - Profile Sensor 1 – Missing Lid

Type Zoom Type Zoom
1/3 1/3
L/F L/F
Adj Adj
Sensor 1 – Swelled Can Sensor 1 – Cocked Cap

Type Zoom Type Zoom
1/3 1/3
Proximity Screens
Adj - Select one of four histograms (profile, missing lid, swelled can, cocked cap) for sensor #1.
Type - Select short term histogram or long term histogram.
S or L - Designates short-term histogram (2,000) or long-term histogram (1,000,000).
Zoom - Select zoom in on limits or zoom out to full screen.
F or Z – Designates full screen or zoom screen for the histogram.

Cocked Crown (3 screens)
L/F L/F
Adj Adj
Sensor 1 - Dimple Sensor 1 – Symmetry

Type Zoom Type Zoom
1/3 1/3
Diag Statistics Main
L/F
Adj
Sensor 1 – Height
Type Zoom
1/3
Cocked Crown Screens

Adj - Select one of four histograms (dimple, symmetry, height) for sensor #1.
S or L - Designates short-term histogram(2,000) or long-term histogram (1,000,000).
Zoom – The zoom feature is not used for the cocked crown screens.

Laser (4 screens)
L/F L/F
Adj Adj

Type Zoom Type Zoom
1/3 1/3
L/F L/F
Adj Adj

Type Zoom Type Zoom
1/3 1/3
Laser Screens
S or L - Designates short-term histogram (2000) or long-term histogram (1,000,000).

2/3 Sensor #2 Histogram - Graphic display of the histogram for inspection #2. The four
proximity choices are profile, missing lid, swelled can and cocked cap. The X-ray histogram
displays the fill height merit values.
Proximity (4 screens)
L/F L/F
Adj Adj

Type Zoom Type Zoom
2/3 2/3
L/F L/F
Adj Adj

Type Zoom Type Zoom
2/3 2/3
Proximity Screens
S or L - Designates short-term histogram or long-term histogram.

X-ray (1 screen)
Diag Statistics Main
L/F
Adj
Sensor 2 – Fill Level

Type Zoom
2/3
X-ray Screen
Adj -
3/3 Sensor #3 Histogram - Graphic display of the histogram for inspection #3. The two
choices are frequency and dB.
Acoustic (2 screens)
L/F L/F
Adj Adj
Sensor 3 - Frequency Sensor 3 - dB

Type Zoom Type Zoom
3/3 3/3
Adj - Select one of two histograms (frequency or dB) for sensor #3.

5.5.3 Diag
1/9 Sensor Signal – This screen displays the sensor profiles, signal and spectrum for the active
sensors. Press the sensor key to select the desired signal.
Sensor #1 - Profile Sensor #2 - Profile

Change Prod Diag Statistics Change Prod Diag Statistics
P=289 P=124
M=674 M=789
S=325 S=488
C=501 C=463
View View
Sensor #1 Sensor #2
Sensor Last Container Sensor Last Reject
1/9 1/9
P= - The profile merit value for the proximity inspection of the last container (0-1023).
M= - The missing lid merit value for the proximity inspection of the last container (0-1023).
S= - The swelled can merit value for the proximity inspection of the last container (0-1023).
C= - The cocked cap merit value for the proximity inspection of the last container (0-1023).
View - Select the display for last container profile or display the last reject profile only.
Sensor - Select the sensor signal to be viewed, profile, signal and frequency spectrum.
Sensor #3 - Signal Sensor #3 - Spectrum

F=324 F=324
D=72 D=72
View View
Sensor #3 Sensor #3
Sensor Last Container Sensor Last Container
1/9 1/9
F= – The frequency merit value for the acoustic inspection of the last container (0-511).
D= – The dB merit value for the acoustic inspection of the last container (0-511).
View - Select the display for last container signal or display the last reject signal only.
Sensor - Select the sensor signal to be viewed, profile, signal and frequency spectrum.

2/9 Last 4-Rejects - This screen displays the last four reject containers. Number 1 is always the
last container to be rejected.
Change Prod Diag Statistics

Last Rejects
Sensor Inspect Value
------ ------ -----
1 Sensor #1 Profile 48
2 Sensor #3 Frequency 271
3 Sensor #3 dB 52
4 Sensor #1 Missing 12
2/9
Sensor - Displays which sensor detected the reject. (proximity, acoustic, cocked crown, laser,
X-ray, inputs)
Inspect - Displays which inspection failed.
Value - Displays the rejected merit value.
3/9 Photo Beam Diagnostics - This screen displays the status of photo beam #1 and #2. It
monitors the state (free or blocked), can passing time, maximum and minimum can passing time
in both milliseconds and shaft encoder clicks. The measurement in shaft encoder clicks will be
displayed as zero if the encoder is not enabled.

Photobeam #1 is Blocked
Pass Min Max
ms 60 57 63
cks 47 44 50
Photobeam #2 is Free
Pass Min Max
ms 60 57 63
cks 47 44 50
Clear
3/9
Clear - Reset Max and Min values to zero.

Pass – Last container passing time.
Min – Minimum container passing time since last clear.
Max – Maximum container passing time since last clear.
ms – Container passing time in milliseconds.
cks – Container passing time in shaft encoder pulses.

4/9 Shaft Encoder Diagnostics - This screen displays the shaft encoder state (Stop or Turn),
shaft divider value, shaft time in microseconds and encoder enabled/disabled.

Shaft Encoder is Disabled
Shaft Shaft Shaft
Time Divider Status
----- ------ -----
0 2 Stop
4/9
5/9 Force Reject - This screen allows the user to select the number of containers to be rejected
(0-100). This feature works for both rejector #1 and rejector #2 by selection keys.
Rejector 1 Rejector 2
Force Reject of Force Reject of
Adj 0 Sel Adj 0 Sel
Containers Containers
to start rejecting to start rejecting

5/9 5/9
Adjust – Select the number of forced reject containers.

Sel – Selects the rejector (1 or 2) for the forced rejection operation.
Enter to start rejecting – Force reject the selected amount of containers in sequence now.
6/9 I/O Diagnostics - This screen displays the status of the seven I/O inputs and the six I/O
outputs.
Change Diag Statistic
I/O Diagnostics
Inputs
1 2 3 4 5 6 7
L L L L L L L
Outputs
1 2 3 4 5 6
H L H L H L
6/9
I/O Inputs I/O Outputs
H = input state is high H = output state is closed
L = input state is low L = output state is open

7/9 PLC Diagnostics - This screen displays the status of the four PLC inputs and the four PLC
outputs. A message (PLC board not installed) will appear when the PLC board is not installed.
PLC Diagnostics
Input
1 2 3 4
L L L L
Output
1 2 3 4
H L H L
7/9
PLC Inputs PLC Outputs
H = input state is high H = output state is closed
L = input state is low L = output state is open
8/9 X-ray Diagnostics - This screen displays the status of the X-ray sensor. A message (X-ray
not configured) will appear when the X-ray sensor is not connected or powered up.

X-ray Diagnostics
Pulse Rate
150
Pulse status is OK
Source status is OFF
Detector status is OK
Percent Insp is 50
Over / Under fill is Under
Update
8/9
Pulse Rate – Displays the current pulse rate every time you press the Update key. Use this
mode for static setup of the system.
Pulse status – This indicates the status of the pulse rate reading.
Detector status – This indicates the status of the X-ray detector.
Percent Inspection – Displays the percent inspection window (50% or 100%).
Over/Under – Displays the inspection mode of (overfill or underfill).
Update – Updates the pulse rate value once every time it is pressed.
9/9 System Values (15 screens) - Displays all stored parameter values for the current product
type. Scroll through the 15 pages using the up / down adjust buttons on the left side of the
screen. The screens will change based on the functions that are activated.

5.5.4 Change Prod
1/1 Product Type - Select the product type value with the pre-stored inspection parameters.
The name and bridge height is displayed for the selected product type. There are 10 product
types. The following T500 parameters are global and do not change when switching between
product type 1-10 from the change product menus.
SHAFT ENCODER ON/OFF SENSOR 3 TYPE

SHAFT DIVIDER PHOTO BEAM #2 DISTANCE
LANGUAGE REJECTOR MASK
LCD CONTRAST I/O BOARD INPUTS
BAUD RATE RS-232 I/O BOARD OUTPUTS
BAUD RATE RS-485 PLC INPUTS
RS-485 ADDRESS PLC OUTPUTS
SENSOR 1 TYPE ALL INSPECTION COUNTERS
SENSOR 2 TYPE
Main Change Prod Diag
Product Type = 1
Name = Good Stuff

Adj
Bridge Height = 0
to increase value
to decrease value
to save value
1/1
5.5.5 Setup
1/1 Password Entry Screen - This screen is where the four-digit password is entered for to
access maintenance menus. The default password is 0 0 0 0. Numbers 0-9 are valid for each
character. Press adjusts up/down arrows to select digit then press enter to move to the next digit.
Main Setup Limits 1
Enter Password
0___
Adj
1/1

M-407-005
Maintenance Menu
Limits 1 Inspect 1 Limits 2 Inspect 2 Limits 3 Inspect 3 Rejector 1 Rejector 2 Encoder I/O Alarm Prod Type Password
Shaft
High/Low Inspection High/Low Inspection High/Low Inspection Sensor Sensor Encoder Screen Text Consecutive Product Type Passw ord
Limits Selection Limits Selection Limits Selection Selection Selection Selection Alarm Select Control
On/Off
Auto Track Photo Beam Auto Track Photo Beam Auto Track Algorithm Pulse Width Pulse Width Shaft Divider LCD Contrast Percent Product Name Passw ord
Offset Selection Offset Selection Offset Selection Adjust Adjust Adjust Adjust Alarm Adjust Change
Missing Lid Product

Missing Lid Photo Beam Photo Beam High/Low Gate Time/ Reject Delay Reject Delay PLC Input 1-4
TapTone Division of Benthos, Inc.

Limit -2 Offset Limit dB Limit Gate Delay Adjust Adjust Default
-2 Offset Mode Select Reset
5.6 Maintenance Parameters
Sw elled Can Algorithm Sw elled Can Algorithm High/Low Modulation Can Width Can Width PLC Input 1-4 Product Copy
Limit Selection Limit Selection dB Offsets Filter On/Off Adjust Adjust Fault Select Select
Reject Reject
Cocked Cap Vac / Press Cocked Cap Vac / Press Auto Track Glass Distance Distance Opt Input 1-7 Bridge Height
Limit Mode Limit Mode Mode/Sample Filter On/Off Adjust Adjust Mode Select Adjust
Auto Track Window Auto Track Window Speed Comp Speed Comp Opt Input 1-7
Mode/Sample Adjustment Mode/Sample Adjustment Adjust Adjust Distance
Opt Output
Height Midpoint Midpoint 1-6 Function
Mode % % Select
Midpoint Midpoint Baud Rate

Height RS-232
Method Method
Figure 5-7 Maintenance Menu Tree

Profile Profile Baud Rate
Adjustment Adjustment RS-485
RS-485
X-ray Address
screen. All parameters to the right of the main screen are password protected.
Distance Select
Underfill/
Overfill
X-ray
Window
The maintenance menus include all operator parameters and all menus to the right of the setup
Chapter 5: System Operating Procedures
56
5.6.1 Limits 1
1/8 High/Low Limits - Set the high and low rejection limits for profile inspection #1 (0-1023).
Adjust values with the up/down keys on each side of the screen. The dashed lines mark the
limits on the histogram screen. You must press the enter key to activate and store new value.
Setup Limits 1 Inspect 1
Low High
Low = 0 High = 1023

1/8
Low - Any value below this limit will be rejected (0-1023).

High - Any value above this limit will be rejected (0-1023).
2/8 Autotrack Offsets - Set the high/low autotrack offset limits for inspection #1. The two
dotted lines are the high/low offset values that are adjustable using the up/down keys on the sides
of the display. The two dashed lines are the fixed high/low reject limits. The single dot/dash
line in the center is the calculated mean value. Menu 6/8 is where the autotrack offset feature is
turned on/off and the selection for mean or standard of deviation calculation is selected.
High and Low Offset values range from (0-1023) and the Std Dev Offset range is (3-10).
Setup Limits 1 Inspect 1 Setup Limits 1 Inspect 1
Low High Adj
Low High Std Dev Offset=3

Offset = 50 Offset = 50
2/8 2/8
This feature is used for applications where the pressure or vacuum levels may vary during the
production process. This method of tracking the production pressure or vacuum trends allows
the system to remain at maximum sensitivity regardless of production fluctuations from the
cookers, pasteurizes, coolers and CO2 plates.

3/8 Missing Lid Limit (proximity) or Dimple Limit (cocked crown) - Set the reject limit for
the missing lid or dimple inspection. Press enter to store and activate new value. Setting the
value to 0 will disable this inspection.
Missing Lid – The missing lid inspection measures the merit value at the center of the container.
Any missing lid value below the limit will be rejected. The range of missing lid values is (0 –
1023).
Dimple – The dimple inspection measures the crown for dents where 100% is good and the
greater the dent the lower the dimple value. The range of dimple values is (0-100).
Adj Adj
Missing Lid = 0 Dimple = 0

3/8 3/8
4/8 Swelled Can Limit (proximity) or Symmetry Limit (cocked crown) - Set the reject limit
for the swelled can or symmetry inspection. Press enter to store and activate new value. Setting
the value to 0 will disable this inspection.
Swelled Can – The swelled can inspection measures the merit value at the center of the
container. Any missing lid value below the limit will be rejected. The range of swelled can
value is (0 – 1023).
Symmetry – The symmetry inspection compares the first half of the curvature to the second half
of the curvature and compares the percentage of symmetry of the crown. Any crown with a
symmetry value below the limit will be rejected. The range of missing lid values is (0 – 100).
Adj Adj
Swelled Can = 0 Symmetry = 0

4/8 4/8

5/8 Cocked Cap Limit - Set the reject limit for the cocked cap inspection. Any cocked cap
value below this limit will be rejected (0 - 1023). Press enter to store and activate new value.
Setting the value to 0 will disable this inspection.
Adj
Cocked Cap = 0
5/8
6/8 Autotrack Mode / Sample - Set the auto track mode for the inspection #1. The choices are
as follows:
Autotrack mode
Adj fixed Mode
Sample size = 50
to save value
6/8
Mode selections:
off - auto track not used
fixed - auto track values based on fixed offset values from the mean value
sdev - auto track values based on the offset value times the standard of deviation.
Sample Size - Use the adjust keys to set the sample size (25-5000) in steps of 25.

7/8 Height mode Selection - Select the height mode to reject or accept crowns out of range of
the cocked crown sensor. Use adjust keys to select mode and press enter to save selection.
Limits 1 Inspect 1 Limits 2
Height mode
Adj Reject
Accept
to save value
7/8
Reject – This mode will reject any crown height value below the height limit set in menu
8/8. This allows all crowns outside the range of the sensor or below the height limit to
be rejected.
Accept – This mode will accept all crowns outside the range of the sensor. This allow short
bottle to pass all three of the cocked crown inspections if outside the range of the
sensor. The height limit value determines the height range for accepting all crowns
below this value. The dimple, symmetry and height calculations will be ignored for
crowns below the height limit value.
8/8 Height Limit (cocked crown) - Set the reject limit for the height inspection. Press enter to
store and activate new value. Setting the value to 0 will disable this inspection. The height
inspection measures the height of the crown in relation to the sensor. The range is (0-1023)
where 1023 is touching the sensor and 0 is out of range of the sensor. Set the value to zero to
disable the inspection.
Adj
Height = 0
7/7

5.6.2 Inspect 1
1/9 Inspection Selection - Select inspection #1 based on the sensor currently wired to analog
input #1.
Inspection #1
Off
Adj Proximity
Laser
Cocked crown
to save value
1/9
• Off – Select off when no sensor is wired to inspection #1. Selecting this choice will disable
the Limits #1 menus.
• Proximity – Select this inspection to access the proximity algorithms. This inspection
should be used whenever one of the three analog proximity sensors are connected. The
analog proximity sensor choices are: Minifoot (18mm), Littlefoot (30mm), and Bigfoot
(54mm) which is related to the diameter of the sensor. This inspection is used for all
curvature measurement inspections such has food cans, beverage cans, pop-button glass
bottles and jars.
• Laser – Select this inspection to access the laser algorithms. This inspection should be used
whenever the laser sensor is connected to inspection #1. The laser sensor is used to inspect
non-metallic containers for vacuum or pressure.
• Cocked crown – Select this inspection to access the cocked crown algorithms. This
inspection should be used whenever the cocked crown detection sensor (18mm proximity
sensor) is connected to inspection #1. This inspection is used to measure the curvature of
the crowns for beer and beverage bottles.

2/9 Photo Beam Selection - Select the photo beam input used to trigger inspection #1. The
default is photo beam 1 for inspect 1. Refer to the Figure 4-1 for detailed explanation as to
which inspections and photo beam selection to choose based on the system configuration.
Photobeam
Adj Photobeam 1
Photobeam 2
to save value
2/9
3/9 Photo Beam-2 Offset - This screen sets the distance value from photo beam 1 to photo
beam 2. Photo beam 2 must be located before photo beam 1 in the inspection process. Adjust
the set value to equal the distance value shown in the screen. Pass only one container at a time
when setting this value. Press enter to save the set value. Photo beam 2 is typically used with
inspection 1 or inspection 2. A shaft encoder must be used whenever photo beam 2 is used. The
maximum offset is 10,000 encoder pulses.
This screen only appears when photo beam 2 is selected in the Inspect 1 menu 2/9.
Encoder disabled – This message will appear inside the signal box if the shaft encoder is
turned off. You must turn the shaft encoder on and set the shaft divider value before
programming the photo beam 2 offset value.

Photobeam 2 Offset
P1
Adj
P2
Distance Set
1022 0
3/9

4/9 Algorithm Selection - Select the algorithm that best fits your container application. The
default selection is the point algorithm. These algorithms are available for the proximity and
laser inspections only.
Algorithm
Point
Adj Can
Beverage
Special
to save value
4/9
• Point – This is the universal algorithm for pressure or vacuum food can applications with or
without pull-tab ends. The point algorithm uses the following parameters to adjust for
optimum performance:
Vacuum / Pressure Mode
Window %
Midpoint Method
Midpoint %
Profile Adjustment
• Can – This algorithm is specifically designed for two or three piece cans with vacuum only.
The can algorithm compensates for cans without spacing or conveyor height variations. The
can algorithm uses the following parameters to adjust for optimum performance:
Window %
Midpoint Method
Midpoint %
Profile Adjustment
• Beverage – This algorithm is specifically designed for two piece pressurized aluminum
beverage cans with centered pull-tabs. This algorithm compensates for the random
orientation of the pull-tab and conveyor height variations. The beverage algorithm uses the
following parameters to adjust for optimum performance:
Midpoint Method
Midpoint %
Profile Adjustment
• Special – Reserved for future use.

5/9 Vacuum / Pressure Mode - Select the mode of inspection for vacuum or pressure detection
when using the point algorithm. Vacuum is the default selection.
Vac / Press Mode
Adj Vacuum
Pressure
to save value
5/9
• Vacuum – Select vacuum for pop-button lids or cans that have drawn sufficient vacuum.
• Pressure – Select pressure for cans with positive pressure such as after a steam flush seamer
or before and after the cooker where the lids are bulging with pressure.
6/9 Window Adjustment - The window percentage designates the location for the outer
inspection points used by the point and can algorithm. Use the adjust keys to move the dashed
lines until they are on the highest point of the chines. Press enter to activate and store new value.
The window % range is 1% to 100% of the signal in 1% increments. The default value is 80%.
The window % menu is active for the following proximity algorithms: Point, Can
The window % menu is active for the cocked crown inspection.
Adj
Window = 80
6/9

7/9 Midpoint Method - Select the midpoint inspection value that best fits your application.
The midpoint method menu is active for the following algorithms: Point, Can, Beverage
Midpoint Method
Middle
Adj Minimum
Maximum
Average
Median
to save value
7/9
• Middle - Center sample value.
• Minimum - Lowest sample value inside midpoint percent window.
• Maximum - Highest sample value inside midpoint percent window.
• Average - The average value of all samples inside the midpoint percent window.
• Median - The middle sample of the sorted values in order from low to high inside the
midpoint percent window.
8/9 Midpoint Percent - Select the midpoint percentage value to show the greatest change in
deflection between good and bad containers. The midpoint search will occur only inside this
percentage window. The range for the midpoint inspection is 0% to 50% in 1% increments. The
default midpoint % value is 50%. The midpoint % menu is active for the following algorithms:
Point, Can, Beverage
Adj
Midpoint % = 30
8/9

9/9 Profile Adjustment - This menu is used to scale the actual profile merit value to a desired
profile scale value. Pass one good container by the system and observe the actual merit value.
Adjust the desired profile merit value to equal the new merit value that will be assigned to the
actual merit value. Press enter to save and activate the desired profile merit value. This
parameter is good for spreading the merit value scale between good and bad containers for
greater rejection resolution. The profile adjustment menu is active for the following algorithms:
Point, Can, Beverage
Example: Pass a good container with actual merit value of 68. Adjust desired value to 200 and
press enter. Pass the same good container again, and observe the new merit value will read 200.
All containers that are inspected will be scaled by the new value selected.
Caution: Once the enter key is pressed, all merit values will be scaled based on the
desired profile value. The only way to get back to the original merit value is to press the
default key. This will set the actual merit values back to zero scaling factor.
Desired profile value range is 50-1023.
Actual profile=50
Adj Desired profile = 100
to save value
Default
9/9
Default – Press this key to reset the merit value back to the original scale.

5.6.3 Limits 2
The limits 2 menu is used to set up all limit functions for inspection sensor #2. This menu is
only activated if an inspection sensor is selected in inspect 2 menu 1/12. All parameters in this
menu are exactly the same as in limits 1.
1/6 High/Low Limits - Set the high and low rejection limits for profile inspection #2 (0-1023).
Adjust values with the up/down keys on each side of the screen. You must press the enter key to
activate and store new value.
Inspect 1 Limits 2 Inspect 2
Low High
Low = 0 High = 1023

1/6
Low - Any value below this limit will be rejected (0-1023).
High - Any value above this limit will be rejected (0-1023).
2/6 Autotrack Offsets - Set the high/low autotrack offset limits for inspection #2 (0-1023). The
two dotted lines are the high/low offset values that are adjustable using the up/down keys on the
sides of the display. The two dashed lines are the fixed high/low reject limits. The single
dot/dash line in the center is the calculated mean value. You must press the enter key to activate
and store the new value. Menu 6/6 is where the autotrack offset feature is turned on/off and the
selection for mean or standard of deviation calculation is selected.
Fixed Std Dev
Inspect 1 Limits 2 Inspect 2 Inspect 1 Limits 2 Inspect 2
Low High Adj

2/6 2/6
Low Offset - Any value below this limit will be rejected (0-1023).
High Offset - Any value above this limit will be rejected (0-1023).
This feature is used for applications where the pressure or vacuum levels may vary during the
production process. This method of tracking the production pressure or vacuum trends allows
the system to remain at maximum sensitivity regardless of production fluctuations from the
cookers, pasteurizes, coolers and CO2 tanks.

3/6 Missing Lid Limit / Underfill or Overfill Height- Set the reject limit for the missing lid
inspection or underfill / overfill height based on Inspection #2 sensor selection and under/overfill
mode selection. Press enter to store and activate new value.
Proximity Sensor
Adj
Missing Lid = 0
3/6
Missing Lid – Any container missing lid value below the set limit will be rejected. (0-1023)
X-ray Sensor (Underfill) X-ray Sensor (Overfill)

Inspect 1 Limits 2 Inspect 2 Inspect 1 Limits 2 Inspect 2
Adj Adj
Underfill Height = 92 Overfill Height = 75

3/6 3/6
Underfill Height – Any container fill height value above the set limit will be rejected. (0-255)
Overfill Height – Any container fill height value below the set limit will be rejected. (0-255)
4/6 Swelled Can Limit - Set the reject limit for the swelled can inspection. Any swelled can
value below this limit will be rejected (0-1023). Press enter to store and activate new value.
Adj
Swelled Can = 0
4/6

5/6 Cocked Cap Limit - Set the reject limit for the cocked cap inspection. Any cocked cap
value below this limit will be rejected (0 - 1023). Press enter to store and activate new value.
Adj
Cocked Cap = 0
5/6
6/6 Autotrack Mode / Sample - Set the autotrack mode for the inspection #2. The choices are
as follows:
Autotrack mode
Adj fixed Mode
Sample size = 50
to save value
6/6
Mode selections:
off - autotrack not used.
fixed - autotrack values based on fixed offset values from the mean value.
sdev - autotrack values based on the offset value times the standard of deviation.
Sample Size - Use the adjust up/down keys to set the sample size (25-5000) in steps of 25.

5.6.4 Inspect 2
1/12 Inspection Selection – Select inspection #2 based on the sensor currently wired to analog
input #2.
Inspection #2
Off
Adj Proximity
X-Ray
to save value
1/12
• Off – Select off when not sensor is wired to inspection #2.
• Proximity – Select this inspection whenever one of the three analog proximity sensors is
connected to inspection #2. The three sensors are the Minifoot (18mm), Littlefoot (25mm),
and Bigfoot (42mm) which is related to the diameter of the sensor. This inspection is used
for all curvature measurement inspections such has food cans, beverage cans and pop-button
glass bottles and jars.
• X-Ray – Select this inspection whenever the X-ray sensor is connected to inspection #2.
This inspection is used to measure fill level in all types of containers.
2/12 Photo Beam Selection – Select the photo beam input used to trigger inspection #2. The
default photo beam is #1 for inspection #2. Refer to Figure 4-2 for a detailed explanation as to
which inspections and photo beam selection to choose based on the system configuration.
Photobeam
Adj Photobeam 1
Photobeam 2
to save value
2/12
• Photo beam 1 – last photo beam before rejection.
• Photo beam 2 – First photo beam in line before photo beam #1 when used.

3/12 Photo Beam-2 Offset – This screen sets the distance value from photo beam 1 to photo
beam 2. Photo beam 2 must always be located before photo beam 1 in the inspection process.
Adjust the set value to equal the distance value shown in the screen. Pass only one container at a
time when setting this value. Press enter to save the set value. Photo beam 2 is typically used
with inspection 1 or inspection 2. A shaft encoder must be used whenever photo beam 2 is used.
The maximum offset is 10,000 encoder pulses. This screen only appears when photo beam 2 is
selected from Inspect 1 menu 2/12.
programming the photo beam 2 offset value.

Photobeam 2 Offset
P1
Adj
P2
Distance Set
1022 0
3/12
4/12 Algorithm Selection – Select the algorithm that best fits your container style. The default
algorithm is point. These algorithms are only available for the proximity inspection.
Algorithm
Point
Adj Can
Beverage
Special
to save value
4/12
• Point – This is the universal algorithm for pressure or vacuum food can applications with or
without pull-tab ends. The point algorithm uses the following parameters to adjust for
optimum performance:
Vacuum / Pressure Mode
Window %
Midpoint Method
Midpoint %
Profile Adjustment

• Can – This algorithm is specifically designed for two or three piece cans with vacuum only.
The can algorithm compensates for cans without spacing or conveyor height variations. The
can algorithm uses the following parameters to adjust for optimum performance:
Window %
Midpoint Method
Midpoint %
Profile Adjustment
• Beverage – This algorithm is specifically designed for two piece pressurized aluminum
beverage cans with centered pull-tabs. This algorithm compensates for the random
orientation of the pull-tab and conveyor height variations. The beverage algorithm uses the
following parameters to adjust for optimum performance:
Midpoint Method
Midpoint %
Profile Adjustment
• Special – Reserved for future use.
5/12 Vac / Press Mode – Select the inspection mode for vacuum or pressure detection.
Vacuum mode is for vacuum cans and pop-button lids on glass. Pressure mode is for beverage
cans or three-piece cans under positive pressure at the point of inspection.
Vac / Press Mode
Adj Vacuum
Pressure
to save value
5/12
• Vacuum – Select vacuum for pop-button lids or cans that have drawn sufficient vacuum.
• Pressure – Select pressure for cans with positive pressure such as after a steam flush seamer
or before and after the cooker where the lids are bulging with pressure.

6/12 Window Adjustment – The window percentage designates the location for the outer
inspection points used by the point and can algorithms. Use the adjust keys to move the dashed
lines until they are on the highest point of the chines. Press enter to activate and store new value.
The window % range is 1% to 100% of the signal in 1% increments. The default value is 80%.
Adj
Window = 80
6/12
7/12 Midpoint Method – Select the midpoint inspection value that best fits your application.
The midpoint method menu is activate for the following algorithms: Point, Can, Beverage
Midpoint Method
Middle
Adj Minimum
Maximum
Average
Median
to save value
7/12
• Middle – Center sample value.
• Minimum – Lowest sample value inside midpoint percent window.
• Maximum – Highest sample value inside midpoint percent window.
• Average – The average value of all samples inside the midpoint percent window.
• Median – The middle sample of the sorted values in order from low to high inside the
midpoint percent window.

8/12 Midpoint Percent – Select the midpoint percentage value to show the greatest change in
deflection between good and bad containers. The midpoint search will occur only inside this
percentage window.
Adj
Midpoint % = 30
8/12
The midpoint % menu is activate for the following algorithms:
• Point
• Can
• Beverage
9/12 Profile Adjustment – This menu is used to scale the actual profile merit value to a desired
profile scale value. Pass one good container by the system and observe the actual merit value.
Adjust the desired merit value to equal the new merit value that will be assigned to the actual
merit value. Press enter to save and activate the desired merit value. This parameter is good for
spreading the merit value scale between good and bad containers for greater rejection resolution.
The profile adjustment menu is activate for the following algorithms: Point, Can, Beverage
Example: Pass a good container with actual merit value of 68. Adjust desired value to 200 and
press enter. Pass the same good container again, and observe the new merit value will read 200.
All containers that are inspected will be scaled by the new value selected.
Caution: Once enter key is pressed, all merit values will be scaled based on the desired
profile value. The only way to get back to the original merit value is to press the default
key. This will set the actual merit values back to zero scaling factor.
Actual profile=50
Adj Desired profile = 100
to save value
Default
9/12
Desired profile value range is 50-1023.

Default – Press this key to reset the merit value back to the original scale of 1.

10/12 X-ray Distance – This screen sets the distance value from photo beam 1 to X-ray sensor
reject signal. The X-ray sensor must always be located before photo beam 1 in the inspection
process. Adjust the set value to equal the distance value shown in the screen. Pass only one low
filled (to activate reject signal) container at a time when setting this value. Press enter to save
the set value. A shaft encoder must be used whenever the X-ray sensor is used. The maximum
offset is 10,000 encoder pulses. This screen only appears when the X-ray sensor is selected from
Inspect 2 menu 2/12.
programming the X-ray sensor offset value.

X-ray Distance
P1
Adj
X-Ray
Distance Set
1019 1019
10/12
11/12 Underfill / Overfill Mode – Select the inspection mode for the X-ray sensor (Underfill or
Overfill) detection. Underfill mode is for detecting containers with a fill level below the selected
height. Overfill mode is for detecting containers with the fill level above the selected height.
Underfill / Overfill Mode
Adj UF
OF
to save value
11/12
• UF– Select underfill to detect and reject containers with fill level merit values above the set
reject limit.
• OF – Select overfill to detect and reject containers with fill level merit values below the set
reject limit.

12/12 X-ray Window – Select the X-ray window based on the trigger location and fill level of
container. Some container and trigger schemes require the following x-ray window:
• 100% - proximity trigger for food or beverage cans.

• 50% - photo beam trigger for plastic containers with tapered in necks like PET bottles.
• 100% - photo beam trigger for straight plastic containers.
• 50% - photo beam trigger for glass bottles.
X-ray Window
Adj 50%
100%
to save value
12/12

5.6.5 Limits 3
1/6 High / Low Limits- Set the high and low rejection limits for the acoustic inspection #3 (0-
1023). Adjust values with the up/down keys on each side of the screen. You must press the
enter key to activate and store new value.
Low High
Low = 0 High = 1023

1/6
Low – Any value below this limit will be rejected (0-1023).
High – Any value above this limit will be rejected (0-1023).
2/6 AutoTrack Offsets – Set the high/low autotrack offset limits for the acoustic inspection #3
(0-1023). The two dotted lines are the high/low offset values that are adjustable using the
up/down keys on the sides of the display. The two dashed lines are the fixed high/low reject
limits. The single dot/dash line in the center is the calculated mean value. Menu 5/6 is where
the autotrack offset feature is turned on/off and the selection for mean or standard of deviation
calculation is selected. Adjust values with the up/down keys on each side of the screen. You
must press the enter key to activate and store new value.
Fixed Std Dev

Low High Adj

2/6 2/6
Low Offset – The merit value difference from the mean for the autotrack low reject limit (0-
1023).
High Offset – The merit value difference from the mean for the autotrack high reject limit (0-
1023).

3/6 High / Low dB Limits – Set the high and low dB rejection limits for the acoustic inspection
#3 (0-1023). Adjust values with the up/down keys on each side of the screen. You must press
the enter key to activate and store new value.
Low High
Low dB = 0 High dB =1023

3/6
Low – Any value below this limit will be rejected (0-1023).
High – Any value above this limit will be rejected (0-1023).
4/6 High / Low dB Offsets – Set the high/low dB autotrack offset limits for the acoustic
inspection #3 (0-1023). The two dotted lines are the high/low offset values that are adjustable
using the up/down keys on the sides of the display. The two dashed lines are the fixed high/low
reject limits. The single dot/dash line in the center is the calculated mean value. You must press
the enter key to activate and store the new value.
Low High
Low dB High dB
4/6
Low dB Offset – The merit value difference from the mean for the autotrack low dB limit (0-
1023).
High dB Offset – The merit value difference from the mean for the autotrack high dB limit (0-
1023).

5/6 AutoTrack Mode / Sample – Set the autotrack mode for the acoustic inspection #3. The
choices are as follows:
Autotrack mode
Adj fixed Mode
Sample size = 25
to save value
5/6
Mode selections:
off – autotrack not used.
Fixed – autotrack values based on fixed offset values from the mean value.
Sdev – autotrack values based on the offset value times the standard of deviation.
Sample Size – Use adjust up/down keys to set the sample size (25-5000) in steps of 25.
6/6 dB AutoTrack Mode / Sample – Set the dB autotrack mode for the acoustic inspection #3.
The choices are as follows:
dB
Autotrack mode
Adj fixed Mode
Sample size = 25
to save value
6/6
Mode selections:
off – autotrack not used.
Fixed – autotrack values based on fixed offset values from the mean value.
Sdev – autotrack values based on the offset value times the standard of deviation.
Sample Size – Use adjust up/down keys to set the sample size (25-5000) in steps of 25.

5.6.6 Inspect 3
1/5 Inspection #3 On / Off- Turn the acoustic inspection #3 On or Off with the adjust keys.
Press enter to save the value. Turning this inspection on automatically selects photo beam 1 as
the trigger beam for this inspection.
Limits 3 Inspect 3 Rejector 1
Inspection #3
Off
Adj On
to save value
1/5
2/5 Algorithm Selection – Select the acoustic algorithm for inspection #3. Peak is the default
selection. Special is reserved for future development and should not be selected at this time.
Inspection #3
Peak
Adj Special
to save value
2/5
The peak inspection detects the maximum point in the frequency spectrum and assigns that point
as the merit value for that container. The frequency spectrum can be viewed in the DIAG menu.
The following example shows the frequency spectrum screen:
Change Prod Diag Statistics Peak Frequency
F=324
D=72
View
Sensor #3
Sensor Last Container
1/7

3/5 Gate Time / Gate Delay Adjust – This menu sets the gate time and the gate delay values
for the microphone signal in the time domain.
Gate Delay – The gate delay is the number of samples that the microphone will be turned off in
the beginning of the data samples collected. Typically the first 40 samples are not used as they
do not contain frequency information relevant to the acoustic response of the lid or crown. The
gate delay value is displayed graphically for easy adjustment. Press enter to save the new value.
The default value is 40. The range is (0-128).
Gate Time – The gate time is the number of samples that the microphone signal will be turned
ON during the collection of data. This value is adjusted for the point where the signal is just
starting to dampen out. Do not use too much of the signal at the end as it typically does not
contain frequency information relevant to the acoustic response of the lid or crown. The gate
time value is displayed graphically for easy adjustment. Press enter to save the new value. The
default value is 80. The range is (0-128).
Del Time
Gate del=40 Gate time=80

3/5
• Beer Bottle application – Gate Delay=40 and the Gate Time=70.
• Food Can application – Gate Delay=40 and Gate Time=120
4/5 Modulation Filter On / Off – This parameter smooths out the effects of multiple peaks in
the frequency spectrum. It detects dual peak within 25 merit values and averages them together
to select the calculated merit value. The second peak must be a minimum of 50% amplitude to
the amplitude of the largest peak. This parameter is typically used for glass beer bottles with
PVC free liner. The default setting is off.
Modulation Filter
Off
Adj On
to save value
4/5

5/5 Glass Filter On / Off – This filter only works when the modulation filter is turned on. This
parameter filters out the selection of the second peak for the modulation filter if it is below a
merit value of 260. The filter is typically used for glass beer bottles where the glass vibration
affects the inspection results. The default setting is off.
Glass Filter
Off
Adj On
to save value
5/5

5.6.7 Rejector 1
1/6 Sensor Selection – Select which inspections will be rejected by rejector 1. Use the select
up/down key to scroll through each sensor inspection and press the set button to turn the
inspection reject function on or off. A dot in the circle means that any reject container detected
by that inspection will be rejected by rejector #1.
Acoustic, Cocked Crown Acoustic, Proximity
Inspect 3 Rejector 1 Rejector 2 Inspect 3 Rejector 1 Rejector 2
Sensor 1 Sensor 2 Sensor 1 Sensor 2
-Dimple
------ -Missing
------
Sym. Swelled
Height Sel Profile Sel
Cocked
Set Set Sensor 3
Sensor 3
Freq Freq
dB dB
1/6 1/6
2/6 Pulse Width – This parameters sets the reject pulse signal time in milliseconds for rejector
#1 (5-1000 ms). Press the force reject key to test and reject the next container to pass by.
Inspect 3 Rejector 1 Rejector 2
Pulse Width = 25
Adj
to increase value
to decrease value
to save value
Force
Reject
2/6
3/6 Reject Delay – This parameter controls when the rejector #1 is fired using shaft encoder
pulses. The distance is measured in shaft encoder pulses from the trigger photo beam (5-9999).
This parameter is only visible and active when the shaft encoder control is turned on. Press the
force reject key to test and reject the next container to pass by.
Reject Delay = 2500
Adj
to increase value
to decrease value
to save value
Force
Reject
3/6

4/6 Can Width – This parameter sets the can diameter in millimeters (5-1000 mm). Press the
force reject key to test and reject the next container to pass by. The measurement point should
be where the container breaks the photo beam. This parameter is only visible and active when
the shaft encoder control is turned off.
Can Width = 10
Adj
to increase value
to decrease value
to save value
Force
Reject
4/6
5/6 Reject Distance – This parameter controls the firing of the rejector based on time in
milliseconds. This distance is measured in millimeters from the trigger photo beam to the reject
pad (0-1000 mm). This parameter is only visible and active when the shaft encoder control is
turned off. The delay time is calculated based on the can passing time, can width and the reject
distance values. Press the force reject key to test and reject the next container to pass by.
Reject Distance = 500
Adj
to increase value
to decrease value
to save value
Force
Reject
5/6
6/6 Speed Comp – This parameter sets the response time in milliseconds for the rejector to be
fired. This value is used to establish a lead-time for the rejector pulse to compensate for the
mechanical inertia of the reject valve and cylinder (0-100 ms). The normal setting is 20 for the
standard TapTone reject system. Press the force reject key to test and reject the next container to
pass by.
Speed Comp = 15
Adj
to increase value
to decrease value
to save value
Force
Reject
6/6

5.6.8 Rejector 2
1/6 Sensor Selection – Select the inspections that will be rejected by rejector 2. Use the select
up/down key to scroll through each sensor inspection and press the set button to turn the
inspection reject function on or off. A dot in the circle means that any reject container detected
by that inspection will be rejected by rejector #2.
Acoustic, Cocked Crown Acoustic, Proximity
Rejector 1 Rejector 2 Encoder Rejector 1 Rejector 2 Encoder
Sensor 1 Sensor 2 Sensor 1 Sensor 2
-Dimple
------ -Missing
------
Sym. Swelled
Height Sel Profile Sel
Cocked
Set Sensor 3 Set Sensor 3
Freq Freq
dB dB
1/6 1/6
2/6 Pulse Width – This parameters sets the reject pulse signal time in milliseconds for rejector
#2 (5-1000 ms). Press the force reject key to test and reject the next container to pass by.
Rejector 1 Rejector 2 Encoder
Pulse Width = 25
Adj
to increase value
to decrease value
to save value
Force
Reject
2/6
3/6 Reject Delay – This parameter control when rejector #2 is fired using shaft encoder pulses.
The distance is measured in shaft encoder pulses from the trigger photo beam (5-9999). This
parameter is only visible and active when the shaft encoder control is turned on. Press the force
reject key to test and reject the next container to pass by.
Reject Delay = 2500
Adj
to increase value
to decrease value
to save value
Force
Reject
3/6

4/6 Can Width – This parameter sets the can diameter in millimeters (5-1000 mm). Press the
force reject key to test and reject the next container to pass by. The measurement point should
be where the container breaks the photo beam.
Can Width = 10
Adj
to increase value
to decrease value
to save value
Force
Reject
4/6
5/6 Reject Distance – This parameter controls the firing of the rejector based on time in
milliseconds. This distance is measured in millimeters from the trigger photo beam to the reject
pad (0-5000). This parameter is only visible and active when the shaft encoder control is turned
off. The delay time is calculated based on the can passing time, can width and the reject distance
values. Press the force reject key to test and reject the next container to pass by.
Reject Distance = 500
Adj
to increase value
to decrease value
to save value
Force
Reject
5/6
6/6 Speed Comp – This parameter sets the response time in milliseconds for the rejector to be
fired (0-100 ms). This value is used to establish a lead-time for the rejector pulse to compensate
for the mechanical inertia of the reject valve and cylinder. The normal setting is 20 for the
standard TapTone reject system. Press the force reject key to test and reject the next container to
pass by.
Speed Comp = 15
Adj
to increase value
to decrease value
to save value
Force
Reject
6/6

5.6.9 Encoder
1/2 Shaft Encoder On / Off – This parameter controls the shaft encoder function. Select ON to
use shaft encoder pulses for inspection and rejection timing. Select OFF to use the internal timer
for inspection and rejection timing.
Rejector 2 Encoder I/O
Shaft Encoder
Adj Off
On
to save value
1/2
2/2 Shaft Divider – This parameter sets the value by which the shaft encoder pulses or clicks
are divided down (0-100). The faster the number of pulses that the encoder generates per
revolution the higher the divider should be set. The divider should be set such that the shaft time
(viewable in the Shaft Encoder Diagnostics Menu 4/9) is between 1000 and 1500 with the
conveyor running at full speed. If the shaft time drops below 1000 the divider is automatically
increased (operator intervention is not required).
Rejector 2 Encoder I/O
Shaft Divider = 2
Adj
to increase value
to decrease value
to save value
2/2
5.6.10 I/O
1/10 Screen Text Selection – This parameter selects the language for the screen text. There are
seven languages to choose from: English, Spanish, German, French, Dutch, Portuguese, and
Italian. Select the specific language by the adjust buttons and then press enter to activate all
displays in that language.

Encoder I/O Alarm
Screen Text
English
Adj Spanish
German
French
Dutch
Portuguese
Italian
to save value
1/10
2/10 LCD Contrast – This parameter adjust the LCD contrast of the display. The range of
contrast is 0=darkest and 15=lightest with 14 as the normal setting.
Encoder I/O Alarm
LCD Contrast = 14
Adj to increase value

to decrease value
to save value
2/10
3/10 PLC Input 1-4 Mode Select – This parameter selects the function for each of the four
PLC inputs. Press select buttons to choose inputs 1-4. Press the adjust buttons to choose one of
the five input functions to activate.
Encoder I/O Alarm
PLC Input 1
Off
Adj Ext fault -Low Sel
Ext fault - High
Reject - Low
Reject - High
to save value
3/10
Ext fault – Low – This function turns the rejector off and flashes the reject lamp when
input x is Low. The external Fault message will appear on the screen until the fault is
reset. Reset the rejector function by the reject enable key (green).
Ext fault – High – This function turns the rejector off and flash reject lamp when input x
is High. Reset the rejector function by the reject enable key (green). An example would
be a pressure switch to monitor the air pressure set by the regulator assembly that
supplies air to the TapTone 500 reject system.

Reject – Low – This function will cause the container under photo beam #1 to be
rejected whenever this input is activated low. The input is monitored during 100% of the
photo beam #1 blocked period.
Reject – High – This function will cause the container under photo beam #1 to be
rejected whenever this input is activated high. The input is monitored during 100% of
the photo beam #1 blocked period. An example would be a reject signal from an outside
source such as another piece of inspection equipment to reject the container that is being
inspected by photo beam #1.
4/10 PLC Output 1-4 Function Select – This parameter sets the function for each of the four
PLC outputs. Press select buttons to choose outputs 1-4. Press the adjust buttons to choose one
of the eight output functions to activate.
Encoder I/O Alarm

PLC Output 1
System Status
Alarm
Adj Lamp Sel
Shaft Encoder
Photo beam
Good Container
Reject
Rejector Status
to save value
4/10
System Status – This output is closed whenever the system is operational and opens whenever
there is a system fault or system power is off.
Alarm – This output is closed whenever one of the two alarm condition (consecutive or percent)
rejects occurs. Press the enter key to reset alarm condition which will open the output.
Lamp – This output selection will function exactly the same as the reject lamp on top of the
control enclosure. It will close for 1/2 second during each rejected bottle, flash open and closed
when rejector is disabled or an alarm condition occurs.
Shaft Encoder – This output will mimic the divided down shaft encoder pulse.
Photo beam – This output will mimic the output function of photo beam #1 by closing
whenever photo beam #1 is blocked and open when photo beam #1 is free.
Good Container – This output will close for 20 milliseconds after every good container is
inspected and passes all inspections.
Reject – This output mimics the reject #1 signal in both reject delay and pulse width with a
closed signal during the reject pulse.
Rejector Status – This output is closed when the rejector is enabled. The output is open when
the rejector is disabled or the system power is off.

5/10 Optional Input 1-7 Mode Select – This parameter selects the function for each of the
seven optional inputs. Press select buttons to choose inputs 1-7. Press the adjust buttons to
choose one of the seven input functions to activate.
Encoder I/O Alarm

Optional Input 1
Off
Active High
Adj Active Low Sel
Active High All
Active Low All
Active High Any
Active Low Any
to save value
5/10
Off – This function turns off the optional input x.
Active High – This function will activate a reject if the optional input sees a high signal
at the set distance. This input function should only be used when the sensor is before the
photo beam #1 signal and the correct distance offset value set.
Active Low – This function will activate a reject if the optional input sees a low signal at
the set distance. This input function should only be used when the sensor is before the
photo beam #1 signal and the correct distance offset value set.
Active High All – This function will activate a reject if the optional input sees a high
signal for the entire photo beam #1 block time. This input function should only be used
for an optional input signal that occur during the photo beam #1 break. The optional
input offset distance must be set to zero.
Active Low All – This function will activate a reject if the optional input sees a low
signal for the entire photo beam #1 block time. This input function should only be used
for an optional input signal that occur during the photo beam #1 break. The optional
input offset distance must be set to zero.
Active High Any – This function will activate a reject if the optional input sees a high
signal any time during photo beam #1 block time. This input function should only be
used for an optional input signal that occur during the photo beam #1 break. The
optional input offset distance must be set to zero.
Active Low Any – This function will activate a reject if the optional input sees a low
signal any time during photo beam #1 block time. This input function should only be
used for an optional input signal that occur during the photo beam #1 break. The
optional input offset distance must be set to zero.

6/10 Optional Input (1-7) Offset - This screen sets the distance value from photo beam 1 to
optional sensor input (1-7). The optional sensor must be located before photo beam 1 in the
inspection process. Adjust the set value to equal the distance value shown in the screen. Pass
only one container at a time when setting this value. Press enter to save the set value. A shaft
encoder must be used whenever an optional input is used. The maximum offset is 10,000
encoder pulses.
Notice: The teaching of the distance can only be performed when the input signal is the same as
the mode selection value. Example – if the select mode is active high than a high signal must be
used to teach the distance value. The distance value that appears on the screen when no input
signal is received is the maximum distance value for that particular shaft encoder divider value.
This distance value can be increased by increasing the shaft divider value. The maximum
allowable distance is 10,000.
programming the optional input offset value.
Encoder I/O Alarm

Input 1 Offset
Adj Sel
Distance Set
1022 0
6/10
7/10 Optional Output 1-6 Function Select – This parameter sets the function for each of the
six optional outputs. Press select buttons to choose outputs 1-6. Press the adjust buttons to
choose one of the eight output functions to activate.
Encoder I/O Alarm

Output 1
System Status
Alarm
Adj Lamp Sel
Shaft Encoder
Photo beam
Good Container
Reject
Rejector Status
to save value
7/10
System Status – This output is closed whenever the system is operational and opens whenever
there is a system fault or system power is off.
Alarm – This output is closed whenever one of the two alarm condition (consecutive or percent)
rejects occurs. Press the enter key to reset alarm condition which will open the output.
Lamp – This output selection will function exactly the same as the reject lamp on top of the
control enclosure. It will close for 1/2 second during each rejected bottle, flash open and closed
when rejector is disabled or an alarm condition occurs.
Shaft Encoder – This output will mimic the divided down shaft encoder pulse.
Photo beam – This output will mimic the output function of photo beam #1 by closing
whenever photo beam #1 is blocked and open when photo beam #1 is free.
Good Container – This output will close for 20 milliseconds after every good container is
inspected and passes all inspections.
Reject – This output mimics the reject #1 signal in both reject delay and pulse width with a
closed signal during the reject pulse.
Rejector Status – This output is closed when the rejector is enabled. The output is open when
the rejector is disabled or the system power is off.
8/10 Baud Rate RS-232 – This parameter sets the baud rate for the RS-232 serial port.
Encoder I/O Alarm
RS-232 Baud Rate

300
Adj 600
1200
2400
4800
9600
19200
to save value
8/10
9/10 Baud Rate RS-485 – This parameter sets the baud rate for the RS-485 serial port. This
port is used for X-ray communications only. It is not an external port for data communications.
The default Baud Rate is 9600 for the X-ray system.
Encoder I/O Alarm
RS-485 Baud Rate

300
Adj 600
1200
2400
4800
9600
19200
to save value
9/10

10/10 RS-485 Address – This parameter set the individual address for the RS-485 serial port.
The range of addresses is (0-127). This port is used for X-ray communications only. It is not an
external port for data communications. The default address is 0 for the X-ray system.
Encoder I/O Alarm
RS-485 Address = 0
Adj
to increase value
to decrease value
to save value
10/10
5.6.11 Alarm
1/2 Consecutive Alarm – This parameter sets the number of consecutive rejects for the
consecutive alarm (0-100). When the number of consecutive rejects is equal one greater than the
set value, the alarm output will close and the reject lamp will flash. Press the enter key to reset
the alarm condition. Note that the inspection and rejection functions are still operational during
any alarm condition.
I/O Alarm Prod Type
Consecutive = 0

to decrease value
to save value
1/2
2/2 Percent Alarm – This parameter set the percentage of rejects based on the last 100
containers inspected (0-100). When the percentage of rejects equals the set value the alarm
output will close and the reject lamp will flash. Press the enter key to reset the alarm condition.
Note that the inspection and rejection functions are still operational during any reject condition.
I/O Alarm Prod Type
Percent = 0

to decrease value
to save value
2/2

5.6.12 Prod Type
1/5 Product Type – This parameter selects from 1 of the 10 product types that store preset
parameters required for the container to be inspected. The following T500 parameters are global
and do not change when switching between product type 1-10 from the change product menus.
SHAFT ENCODER ON/OFF SHAFT DIVIDER

LANGUAGE LCD CONTRAST
BAUD RATE RS-232 BAUD RATE RS-485
RS-485 ADDRESS SENSOR 1 TYPE
SENSOR 2 TYPE SENSOR 3 TYPE
PHOTO BEAM #2 DISTANCE REJECTOR MASK
PLC INPUTS PLC OUTPUTS
ALL INSPECTION COUNTERS I/O BOARD INPUTS
I/O BOARD OUTPUTS
Alarm Prod Type Password
Product Type = 1
Name = Good Stuff
Adj
to increase value
to decrease value
to save value
1/5
2/5 Product Name – This menu is used to set a user-selected name for the product type. The
product name can be up to 10 characters long. The characters can be alphabetic, numeric, or a
space. The arrows are used to scroll through these characters. When the desired character is
displayed on the screen, pressing enter key will save that character. The cursor will then move
to the next position. When enter key is pressed after the 10th character the new name will be
saved. Leaving this screen before the 10th character is saved will default to the original name
that was saved.
Product Type = 1
Name = Good Stuff
Adj
New = A _ _ _ _ _ _ _ _ _
2/5

3/5 Product Default Reset – This parameter resets all parameters in the current product type to
factory default settings.
Set current product type

to default values
to save value
3/5
4/5 Product Copy – This parameter allows a copy of the current parameters to be saved in one
of the other 9 product types.
Copy Product Type 1
Adj to
Product Type 1
to save value
4/5
5/5 Bridge Height – This parameter stores the bridge height value as read off the adjustable
crank stand digital indicator. This value is just a reminder for when you switch product types
with containers of different heights. The range is 0-9999.
Bridge Height = 0

to decrease value
to save value
5/5

5.6.13 Password
1/2 Password Control – This parameter sets the password function on/off. If this parameter is
set to ON then no access to the Setup Menu is allowed unless the 4 digit numeric password is
entered correctly. If the password is not entered correctly, the user is returned to the Main
Screen. When the password is off, users have full access to all menus and parameters.
Prod Type Password Time / Date
Password Control
Adj Off
On
to save value
1/2
2/2 Password Change – This screen allows the user to change the 4 digit numeric password to a
number of their choosing. The default password is ‘0000’. Follow the instructions presented on
each screen and use the up and down arrow keys to scroll the 4 digits 0-9 until the desired digit
is displayed on the screen. Pressing the ENTER will accept this value. After all 4 digits are
entered; the new password is saved.
Prod Type Password Time / Date
Enter Current Password

0___
Adj
to save value
2/2

5.7 Initial Setup Procedure
This section describes the procedure for initial setup of a TapTone 500 with a single proximity
sensor on inspection #1. This section can only be performed once Chapter 4 Installation
Instructions has been completed. The number in parenthesis denote the menu page and number
of pages in the menu. Example: (3/6) means page 3 of 6 pages.
1. Go to the Setup menu and enter the password “0 0 0 0” to access the maintenance parameters
for system setup.
2. Go to the Password menu and turn the password control off. This allows easy access in and
out of the maintenance parameters during the setup procedures.
3. Go to the Product Type menu and select the number of the product type you wish to store all
parameters for this particular container setup. Then enter the Product Name menu and set the
name associated with this container setup. The name can be alphanumeric up to ten
characters long. Use a name that best describes the container for future reference.
4. Stop the conveyor and place a container under the sensor head. Adjust the bridge height so
the sensor is .150” (4 mm) above the highest point on the container. Note that .150” is equal
to 150 counts on the bridge height indicator. Then go to the bridge height menu and enter
the bridge height value shown on the digital indicator.
5. Make sure the sensor head is centered over the containers on the conveyor. Adjust the
conveyor guide rails for 1/8” (3 mm) spacing between the container and the guide rails for
best inspection results.
6. Adjust the photo beam lenses to trigger on a portion of the container where triggering is
possible even when containers are back to back.
7. Turn the rejector air pressure ON and set the regulator pressure for 40 psi.
8. Go to the Encoder menu and run the conveyor at full production speed.
(1/2) Select encoder function to on or off. If you select OFF, the reject timing is done by the
internal timer.
(2/2) If you select ON, run the conveyor to the maximum production speed then set the shaft
divider value until the shaft time is between 1000 and 1500. You can view the shaft
time value in the shaft encoder diagnostics menu 4/9.
9. Go to the Rejector 1 menu and set-up the following parameters.
For ENCODER ON:
(1/6) Choose the sensor 1 selections for rejection by rejector #1.
(2/6) Set the reject cylinder Pulse Width in milliseconds for clear rejection of the container.
Press the force reject key to test function on the next container passed.
(3/6) Set the Reject Delay value to hit the middle of the can based on shaft encoder pulses.
(6/6) Set the Speed Compensation value to 20 for most lines. This parameter varies the
reject timing based on speed of the line. Press the force reject key to test function on
the next container passed.
For ENCODER OFF:
(1/6) Choose the sensor 1 selections for rejection by rejector #1.
(2/6) Set the reject cylinder Pulse Width in milliseconds for clear rejection of the container.
(4/6) Enter the Can Width value for the container where the photo beam is blocked by the
container. Press the force reject key to test function on the next container passed.
(5/6) Set the Reject Distance in millimeters to hit the middle of the container. The reject
timing is calculated using the photo beam passing time and the can width value entered
above. Press the force reject key to test function on the next container passed.
(6/6) Set the Speed Compensation value to 15 for most lines. This parameter varies the
reject timing based on speed of the line. Press the force reject key to test function on
the next container passed.
10. Go to the Password menu and set a new password if required then turn the password control
to on. The default password is 0 0 0 0.
11. Proceed to the following section based on the type and number of inspections installed on
your system.
5.7.1 Inspection #1 (proximity) Setup Procedure
Inspection # 1 can be configured for Proximity, Laser or Cocked Crown inspection depending on
which sensor is installed in the system. The following steps are to set-up inspection #1 for
proximity sensor.
1. Proceed to Inspection #1 menu: Use yellow up/down navigation keys to scroll though
following menu functions:
(1/9) Select proximity inspection.
(2/9) Select photo beam #1 when for single inspection. Select photo beam #2 whenever
inspection #3 (acoustic) is used. Proceed to menu 3/9 photo beam offset whenever photo
beam #2 is selected. Note that photo beam #2 is always before photo beam #1 in the
inspection process.
(3/9) Set the photo beam #2 offset distance. Pass a single container then adjust the set value
to equal the distance value shown. Press enter to save new set value.
(4/9) Select the algorithm that best fits your container type:
• Point – pressure or vacuum containers with pop buttons or foil lids.
• Can – steel or aluminum vacuum filled cans.
• Beverage – steel or aluminum pressure filled beverage cans with pull-tabs.
• Special – Reserved for future applications, do not use this algorithm.
(5/9) Select vacuum or pressure mode when using the point algorithm.
(6/9) Pass good container then set the window percent value so the dotted lines are on the
maximum outside chines of the container.
(7/9) Select the midpoint method to best fit the selection of the midpoint data.
• middle – center point of data samples for beverage cans.
• minimum – lowest data point in midpoint % value for food cans, pop-tops
• maximum – highest data point in midpoint % value for foil lids.
• average – average data point of all midpoint % values.
• median – middle point of sorted data points from lowest to highest.
(8/9) Select the midpoint % to best fit the selection of the middle data.
(9/9) Pass containers and monitor the actual profile merit values, select one container for
your standard then set the desired profile value then press enter. Now all container
profile values will be scales relative to the desired profile value. To return to the
original profile values, press the default key. Make sure you adjust all profile limits or
false rejects may occur when you press the default key.
2. Go to Limits 1 menu and adjust reject limits for the following inspections:
(1/8) Adjust the fixed high and low profile limits.
(3/8) Adjust the missing lid low reject limit for all types of containers. Leave the value set
to zero when not using this parameter.
(4/8) Adjust the swelled can low reject limit for vacuum and pressure cans. Leave the value
set to zero when not using this parameter.

(5/8) Adjust the cocked cap low reject limit for bottles and jars with screw top closures.
Leave the value set to zero when not using this parameter.
(6/8) Select the auto track mode:
• off – autotrack feature not used.
• fixed – based on offset high and low values from the mean value.
• std dev – based of standard deviation on profile histogram
Select the sample size for calculation and updating of the mean value.
(2/6) Adjust the autotrack offset values for best rejection.
3. Go to Main Menu and clear total counters then go to Sensor #1 merit value screen and clear
counters and histograms.
5.7.2 Inspection #1 (laser) Setup Procedure
The following steps are to set-up inspection #1 for laser sensor.

(1/9) Select laser inspection.
(2/9) Select photo beam #1 for laser sensor.
(3/8) Adjust the missing lid low reject limit for all types of containers. Leave the value set
to zero when not using this parameter.
(4/8) Adjust the swelled can low reject limit for vacuum and pressure cans. Leave the value
set to zero when not using this parameter.
• fixed – based on offset high and low values from the mean value.
• std dev – based of standard deviation on profile histogram
(2/8) Adjust the autotrack offset values for best rejection.
5.7.3 Inspection #1 (cocked crown) Setup Procedure
Inspection # 1 can be configured for Proximity, Laser or Cocked Crown inspection depending on
which sensor is installed in the system. The following steps are to set-up inspection #1 for
cocked crown sensor.
(1/9) Select cocked crown inspection.
(2/9) Select photo beam #2 for the cocked crown inspection. Note that photo beam #2 is
always before photo beam #1 in the inspection process.
(3/9) Set the photo beam #2 offset distance. Pass a single container then adjust the set value
to equal the distance value shown. Press enter to save new set value.
(3/8) Adjust the dimple low reject limit to reject bottles with crushed or dented crowns.
(4/8) Adjust the symmetry low reject limit to reject bottles with crowns that are damaged or
misapplied. Leave the value set to zero when not using this parameter.
(7/8) Select the height mode to accept or reject crowns outside the range of the sensor.
(8/8) Adjust the height low reject limit to accept or reject short bottles or missing crowns.

5.7.4 Inspection #2 (proximity) Setup Procedure
Inspection # 2 can be configured for Proximity or X-ray sensor inspections.
(1/12) Select proximity inspection.
(2/12) Select photo beam #2.
(3/12) Set the photo beam #2 offset distance from photo beam #1 by passing a single
container then adjust the set value to equal the distance value shown. Note that photo beam
#2 is always before photo beam #1 in the inspection process. Press enter to save new set
value.
(3/6) Adjust the missing lid low reject limit for all types of containers.
(4/6) Adjust the swelled can low reject limit for vacuum and pressure cans.
• fixed – based on fixed high and low values from the mean value.
• std dev – standard deviation on profile histogram
(2/6) Adjust the autotrack offset for best rejection.

5.7.5 Inspection #2 (X-ray) Setup Procedure
Inspection # 2 can be configured for proximity or X-ray sensor inspections.

(1/12) Select x-ray inspection.
(10/12) Set the x-ray offset distance from photo beam #1 by passing a single empty
container then adjust the set value to equal the distance value shown. Note that photo beam
#2 is always before photo beam #1 in the inspection process. Press enter to save new set
value.
(11/12) Select the X-ray inspection mode for overfill or underfill detection.
(12/12) Select the X-ray inspection window for 50% or 100% of the container width.
2. Go to Limits 2 menu and adjust reject limits for the x-ray inspection:
(3/6) Adjust the overfill or underfill reject limit.
5.7.6 Inspection #3 (acoustic) Setup Procedure
Inspection # 3 is for the Acoustic inspection only.

(1/5) Turn Inspection #3 acoustic sensor ON.
On – activates the acoustic inspection.
Off – select off when no sensor is installed on inspection #3.
(2/5) Select the Peak detection algorithm. Special is reserved for future development.
(3/5) Select the Gate Time and Gate Delay for the most useful signal data.
Beer Bottles – Gate Delay=40 and Gate Time=70
Food Cans – Gate Delay=40 and Gate Time=120
(4/5) Set the Modulation Filter to Off unless you are testing beer bottles with PVC free
liners on the crowns.
(5/5) Set the Glass Filter to Off unless the modulation filter is on and you observe multiple
peak frequencies with one peak below 260 merit value.
(1/6) Adjust the fixed high and low frequency merit value limits.
(3/6) Adjust the fixed high and low dB limits.
(5/6) Select the frequency autotrack mode:
• fixed – based on fixed high and low frequency values from the mean value.
• std dev – standard deviation of the frequency histogram.
(2/6) Set the high and low offset limits for the frequency merit values.
(6/6) Select the dB autotrack mode and sample size:
• fixed – based on fixed high and low dB values from the dB mean value.
• std dev – standard deviation of the dB histogram.
(4/6) Set the high and low dB offset limits for the dB values.

M-407-005 Chapter 6: System Troubleshooting Guide
6.0 System Troubleshooting Guide

6.1 No Rejection Check List
Is reject lamp flashing (reject is disabled)? Enable rejector.

Are counters updating? Clean photo beam lenses.
Is photo beam looking over or through the container? Adjust sensor height.
Is rejector air supply off? Turn air supply on.
Is rejector air pressure set properly? Set air pressure 30-60psi.
Does reject merit value fall outside pass limits? Adjust reject limits.
Is reject cable plugged into the correct socket reject #1 or #2? Check reject cable plug.
Is reject pulse too short? Increase reject pulse value.
Is reject cylinder stuck or clogged? Rebuild reject cylinder.
Check 24V power supply? Replace if required.
Is the sensor selection correct for that rejector?
6.2 False Rejection Check List
Is reject limit too high or low? Adjust reject limits.

Is sensor too high? Adjust sensor height.
Is reject delay timing correct (shaft encoder mode)? Adjust delay value.
Is can width value correct (timer mode)? Measure and adjust value.
Is reject distance value correct (timer mode)? Measure and adjust value.
Is reject pulse too short or long? Adjust reject pulse.
6.3 No Sensor Signal Check List
Is sensor too high? Adjust sensor height.

Is the inspection turned on for that sensor? Turn inspection on.
Is the sensor plugged in correctly? Check connection.

6.4 System Error Messages
Error Message Probable Cause Solution

short photo beam #1 photo beam #1 looking over or adjust fiber optic lens positions,
break through the container adjust photo beam gain
short photo beam #2 photo beam #2 looking over or adjust photo beam position,
break through the container adjust photo beam gain
photo beam break >5 photo beam lenses dirty of clean fiber optic lenses,
seconds blocked by rail or container, remove obstruction from lenses,
photo beam output control set set photo beam module output control to
incorrectly dark operate (D.O.) position
encoder slipping or shaft encoder coupling loose, tighten shaft encoder coupling, replace if
conveyor start conveyor has just started from worn out
stopped position
merit value buffer too many containers between make the distance between head #1 and
overflow head #1 and head #2 head #2 closer together. 16 cans
maximum distance.
reject buffer overflow too many rejects between can width not set properly, make the
head #1 and the rejector #1 distance between head #1 and rejector
#1 closer together. 16 cans maximum
distance.
external fault one of the PLC inputs are check PLC inputs and reset external fault
activated situation
rejector too close reject pulse too close to exit of Reject delay must be at least twice the
inspection head can passing time in clicks.
Reject distance must be at least twice
the can width value.
Reject pulse must be less than the can
passing time in milliseconds.
Mean outside reject mean value is not between adjust high and low reject limits so the
limits high and low reject limits mean value is between them
X-ray communication X-ray power off, Check AC power to X-ray sensor.
error check X-ray power communication link open Check X-ray communication cable.
Check 24VDC signal to X-ray sensor
relay for switching power.

6.5 Diagnostics Procedure
The following diagnostics screens will help in troubleshooting all aspects of the system. Refer to
Section 5.5.3 Diag menu for full detail of each function.
(1/9) Sensor Profile display the graphic representation of the data collected of the last container
and the merit values for each inspection sensor. The last reject profile can also be viewed as it
occurs.
(2/9) Last 4-Rejects displays which sensor found reject, what inspection algorithm and the reject
merit value. Number 1 is always the latest container to be rejected.
(3/9) Photo Beam Diagnostics displays photo beam function for each photo beam used.
(4/9) Shaft Encoder Diagnostics displays the status of the encoder functions.
(5/9) Force Reject may select a consecutive number of rejects for a sample check or test rejector
function.
(6/9) I/O diagnostics screen displays the current state of the inputs and outputs for the I/O board.
(7/9) PLC diagnostics displays the current status of the four PLC inputs and outputs.
(8/9) X-ray diagnostics screen displays the status of the X-ray sensor.
(9/9) System Values screens display all stored parameter values for the current product type.
There are 15 pages of parameters to view by pressing the adjust keys.

6.6 System Wiring
6.6.1 Control Box Wiring Diagram
Figure 6-1 Chassis Wiring Diagram

6.6.2 Junction Box Wiring Diagram
Figure 6-2 Junction Box Wiring Diagram

6.6.3 Laser Control Box Wiring Diagram
Figure 6-3 Laser Control Box Wiring Diagram

6.6.4 Laser Junction Box Wiring Diagram
Figure 6-4 Laser Junction Box Wiring Diagram

6.6.5 X-ray Sensor Wiring Diagram (1 of 2)
Figure 6-5 X-ray Sensor Wiring Diagram

6.7 DSP Board Jumper Settings
Figure 6-7 DSP Board Layout
6.7.1 DSP LED Designations
LED1 - System status will flash when DSP processor is functioning properly
LED2 - Photo Beam Input #1 goes on when triggered
LED3 - Shaft Encoder (high) will be on when encoder running
LED4 - Shaft Encoder (low) will be on when encoder running
LED5 - Photo Beam Input #2 goes out when triggered
LED6 - (+24V) Supply present when lit
LED7 - (-12V) Supply present when lit

6.7.2 DSP Jumper Designations
JH1 - Reject #1 output switch configuration (24V sinking standard)

JH2 - Lamp output switch configuration (24V sourcing standard)
JH3 - Reject #2 output switch configuration (24V sinking standard)
JH4 - Shaft encoder input voltage configuration (5V and GND standard)
JH5 - Photo beam #2 input configuration (12V sourcing standard)
JH6 - Power Level to acoustic head sensor coil assembly, (tap energy)
JH7 - LCD Mode, contrast control. Black on white or white on black
JP10 - I/O memory allocations, (factory set)
JP15 - Watchdog timer, (factory set)
JP16 - Serial port configuration, (factory set)
6.7.3 Factory Default DSP Jumper Settings
Display Board Jumper Settings:

JH6
JH7 8 7 Power = 14
White Background, Black Background, 6 5 Power = 12
Black Text White Text
4 3 Power = 10
LDC (Default)
Display 2 1 Power = 8
Tap
Power
DSP Board Jumper Settings:
JH1 JH2 JH3 JH4 JH5

8 7 8 7 8 7 5V 1 2 5V 1 2
6 5 6 5 6 5 12V 3 4 12V 3 4
4 3 4 3 4 3 24V 5 6 24V 5 6
2 1 2 1 2 1 GND 7 8 GND 7 8
Reject #1 Lamp Reject #2 Shaft Photo #2
Encoder
JH10 JH15 JH16

RX 1 2
FS- 3 4
FS+ 5 6
TX 7 8
Memory WatchDog Serial
Type Timer Port
Figure 6-8 DSP Board Factory Jumper Settings

6.7.4 DSP Input Jumper Configurations
Shaft Encoder Input JH4 – select one of three voltage settings 5, 12 or 24 VDC. Position 7
and 8 should be bridged for using internal ground and open for external isolated grounds. The
default value for a TapTone supplied shaft encoder is 5 VDC internal ground.
Photo Beam #2 Input JH5 – Select one of three voltage settings 2, 12 and 24 VDC. Position 7
and 8 should be bridged for using internal ground and open for external isolated grounds. The
default value for a TapTone supplied photo beam #2 is 12 VDC with isolated ground.
5V 12V 24V
5V 1 2 5V 1 2 5V 1 2
12V 3 4 12V 3 4 12V 3 4
24V 5 6 24V 5 6 24V 5 6
GND 7 8 GND 7 8 GND 7 8
Figure 6-9 Shaft Encoder and Photo Beam #2 Jumper Settings
6.7.5 DSP Output Jumper Configurations
Rejector #1 Output JH1 - The rejector output #1 can be set in one of the four configurations.
The Sinking 24VDC configuration is the default setting.
Lamp Output JH2 - The reject lamp should set to the Source 24 VDC configuration.
Rejector #2 Output JH3 – The rejector output #2 can be set in one of the four configurations.
The Sinking 24VDC configuration is the default setting.
Sinking Sinking Source Dry-Switch

External 24VDC 24VDC 0-60VDC
8 7 8 7 8 7 8 7
6 5 6 5 6 5 6 5
4 3 4 3 4 3 4 3
2 1 2 1 2 1 2 1
Figure 6-10 Rejector and Lamp Jumper Settings

6.7.6 X-ray Jumper Configurations
Jumper default settings shown in Figure below.
Chassis Board J1
(bottom)
1 2 3 4 5 6 7 8
SW1 J5
J4
J6
J3
OPEN
OPEN
Control Board
(top)
J1
1 2 3 4 5 6 7 8
0 0 0 0 1 1 0 0
J2
J4
J2
SW2
1 2 3 4 5 6 7 8
Figure 6-11 X-Ray Jumper Settings

6.6.7 I/O Board Jumper Configurations
Input 1-8 Jumper Key
Input # Jumper # Logic Level Select

Jumper Pin-Out
1 JP1 Voltage Jumper
2 JP2 5V 1-2 1 2
3 JP3 12V 3-4 3 4
4 JP4 24V 5-6 5 6
5 JP5 7 8
Isolation Select
6 JP6
Mode Pos 7 - 8 JP1-JP8
7 JP7
Grounded Shorted
8 JP8
Isolated Open
Mixed Output 1-6 Jumper Key
Function Jumper #
Jumper Pin-Out
Output4/Lamp1 JP9
Output5/Lamp2 JP10 2 4 6
Output6/Lamp3 JP11
Function Select 1 3 5
Mode Jumper
Output 3-5 & 4-6 24VDC only!
Lamp 1-3 & 2-4
Digital Output 7,8 Jumper Key

(Jumper # JP12)
Logic Level Select Jumper Pin-Out

Voltage Jumper
5V 1-2 1 2
12V 3-4 3 4
24V 5-6 5 6
Figure 6-12 I/O Board Jumper Settings
JP1-JP8 (Inputs 1-8) Default setting is 12VDC and grounded. (jump 3-4 and 7-8)
JP9-JP11 (Outputs 4-6) Default setting is set to Output. (jump 3-5 and 4-6)
JP12 – (Digital Output 12) Default setting is 5VDC. (jump 1-2)

6.6.8 I/O Board Pinout
J1 – Internal Lamp Plug Function Specifications

Pin-1 Lamp 1 Sinking 5,12,24VDC
J2 – X-Ray Plug Function Specifications

Pin-1 Power Supply (+) 24VDC
Pin-2 X-Ray Reject Input 24VDC
Pin-3 Encoder Output 24VDC
Pin-4 Power Supply (-) GND 24VDC
J3 – Optional Input Plug Function Specifications

Pin-1 Input 1 (+) 5,12,24VDC selectable
Pin-2 Input 1 (-) Internal GND
Pin-17 No connection
Pin-18 No connection
Pin-19 Power Supply +5VDC
Pin-20 Power Supply 5V GND

J4 – Optional Input Plug Function Specifications
Pin-1 Output 1 (+) Isolated 5,12,24VDC selectable
Pin-2 Output 1 (-)
Pin-4 Output 2 (-)
Pin-6 Output 3 (-)
Pin-8 Output 4 (-)
Pin-10 Output 5 (-)
Pin-12 Output 6 (-)
Pin-13 Output 7 (+) High Speed 5,12,24VDC
selectable
Pin-14 Output 8 (+) High Speed 5,12,24VDC
selectable
Figure 6-13 I/O Board Pinout

6.8 Proximity Sensor Tuning Procedure
Trained technicians should perform this tuning procedure only! All sensors are tuned at
TapTone prior to shipping.
1. Remove the brass plug from the top of proximity sensor #1.
2. Open the door and turn system power on, pull out the interlock switch to turn power on with
the door open.
3. Turn the OFFSET potentiometer fully (CCW) counterclockwise until it clicks at the end.
4. Place a DC voltmeter across pins 1 (+white) and 2 (-black) of JP1 which is the 12-pin
connector at the bottom of the DSP board. Adjust the GAIN potentiometer until the
voltmeter reads 10.00 volts +0.00/-0.03 with no metal present at the face of the sensor.
5. Turn power off and replace the brass plug in the top of the sensor.
Connector
Sensor
Body
Gain Offset
Adjust Adjust
Proximity
Sensor
Wires
Figure 6-14 Proximity Sensor Adjustments

6.9 Acoustic Sensor Microphone Replacement Procedure
The following procedure is provided to assist in the proper replacement of microphones in

TapTone 500 Acoustic Inspection Systems. Microphones are designed with a specialized
waterproofing screen. The screen has a very small mesh to block liquids from penetrating the
microphone diaphragm. The mesh is however, small enough to clog with beer or soap residue.
If the performance of the microphone has degraded (dB value is low), the screen can be cleaned
using a cotton swab and alcohol. If this does not improve the dB reading to an acceptable level,
the microphone should be replaced. Microphone replacements can only be purchased from
TapTone or an authorized TapTone agent.
Apply RTV Glue Here
White Wire (red dot) Black Wire
Microphone
Apply RTV Glue Here
Figure 6-15 Acoustic Sensor Assembly
Replacement Steps:
1. Turn the TapTone system power OFF.
2. Disconnect the two yellow cables from the transducer head. These cables are keyed for
proper reconnection later.
3. Remove the four screws holding the transducer body to the mounting plate then remove the
head from the body.
4. Using long nose pliers carefully grab the top of the microphone body inside the transducer
head and move ¼ turn to break glue seal. Pull the microphone out of the body.
5. Unsolder the two wires from the microphone terminals. Note the red/white wire goes to the
terminal with the red dot to indicate the positive terminal.
6. Solder the red/white wire to the new microphone terminal with the red dot. Solder the
red/black wire to the other terminal.

7. Place a small amount of silicone RTV around the outer edge of microphone and half way
down body. Keep RTV off microphone face.
8. Carefully place the microphone back into the transducer body and press in place until the
microphone is completely seated on the bottom of the body. Note the microphone will have
reduced dB values if not completely seated into the transducer body.
9. Place the transducer body up to the mounting plate and replace the four screws. Use RTV
sealant on top of the transducer head to seal.
10. Connect the two yellow cables to the transducer head. The three conductor cable is the top
connector and the four conductor cable is the bottom connector.
11. Check for proper alignment of transducer head with production bottles.
12. Turn the TapTone system power back ON.

6.10 X-Ray Transmitter Tuning Procedure
Trained technicians should perform this tuning procedure only! All X-Ray modules are tuned at
TapTone prior to shipping.
1. Turn system power OFF.
2. Remove the eight screws holding the back plate to the x-ray transmitter box (small box side)
and remove the back plate. Unplug the ground connection before removing the plate
completely.
3. Turn system power ON.
4. Go to the X-Ray Diagnostics screen page (8/9) and monitor the Pulse Rate value. Press the
Update button to update the pulse rate value on the screen.
Normal value for Pulse Rate = 160 (+/- 8)
5. Adjust the pulse rate using the fine adjust potentiometer RT3 until the pulse rate is equal to
the normal value of 160 (+/-8). RT3 potentiometer is located in the top right hand corner of
the x-ray board mounted on the brass box. Refer to the chart mounted on the x-ray module.
The course adjust potentiometer is RT2 and should only be adjusted if the fine adjust RT3
can not get the pulse rate value to 160.
6. Turn the system power OFF.
7. Plug the ground connection to the back plate and secure the back plate to the X-Ray module.
(HV) Volt Meter
+ -
- +
TP6
TP7 TP3 IA FINE ADJUST
4321
S11
RT3 HV ADJUST
1.6A + -
1=N.C. RT1
2=+24V
3=GND
4=LAMP
RT2 TP5
- IA COURSE ADJUST
+
-
TP1
(IA) Volt Meter
TP2 +
S12
3.5A
Figure 6-16 X-Ray Source Module Power Supply Board

M-407-005 Chapter 7: Preventative Maintenance
7.0 Preventative Maintenance

This section describes the maintenance procedures that are required to keep the TapTone 500 in
top operating condition.
DAILY
• Wipe photo beam transmitter and receiver lens clean.
• Drain any water that has accumulated in filter bowl. To drain any water, shut off the air and
open the drain valve on the bottom of the bowl.
WEEKLY
• Check the sensor bracket mounting hardware to insure that it is tight.
• Check the rejector pad for damage and replace as required.
MONTHLY
• Check the lubricator bowl for an adequate oil level. If the oil level is low, fill the lubricator
bowl with only 5-weight petroleum based oil. Ensure that the air supply is disabled before
opening the lubricator bowl.

M-407-005 Chapter 8: Warranty
8.0 Warranty
The warranty period is one (1) year and commences on the date of shipment from Benthos, Inc.
(one (1) year from date of installation on automatic equipment). A warranty extension of one (1)
month is allowed for exported equipment. The warranty obligation of Benthos, Inc. is limited to
providing repairs to any TapTone product ("Equipment") used in normal service and which has
been, during the warranty period, promptly reported by Purchaser as defective in workmanship
or material and is so found by Benthos, Inc. upon examination. Examination and repair will be
effected upon delivery of the Equipment to the facilities of Benthos, Inc., F.O.B. the Benthos,
Inc. plant in North Falmouth, Massachusetts, within the warranty period. If examined
Equipment is found not to be defective or is not for some other reason within the warranty
coverage, the service time expended by Benthos, Inc. will be charged to Purchaser. This
warranty is void if the Equipment has been disassembled by anyone other than the personnel of
Benthos, Inc., or operated other than in accordance with operating instructions of Benthos, Inc.
Benthos, Inc. will have no further obligation if the Equipment has been subjected to abuse,
misuse, negligence or accident or if the Purchaser fails to perform any of the duties of the
Purchaser set forth herein.
THE WARRANTY PRINTED ABOVE IS THE ONLY WARRANTY APPLICABLE TO THIS

PURCHASE OF THE EQUIPMENT. ALL OTHER WARRANTIES, WRITTEN OR ORAL,
EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE
DISCLAIMED.
BENTHOS, INC. MAKES NO WARRANTY OR REPRESENTATION WITH RESPECT TO

THE PERFORMANCE ABILITY OF THE EQUIPMENT OR ITS ABILITY TO FUNCTION
IN ANY RESPECT.
LIMITATION OF LIABILITY
IT IS UNDERSTOOD AND AGREED THAT THE LIABILITY OF BENTHOS, INC.,

WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY, IN NEGLIGENCE OR
OTHERWISE, SHALL NOT EXCEED THE RETURN OF THE AMOUNT OF THE
PURCHASE PRICE PAID BY PURCHASER AND UNDER NO CIRCUMSTANCES SHALL
SELLER BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES OR
LOSS OF USE, REVENUE OR PROFIT EVEN IF BENTHOS, INC. HAS BEEN ADVISED
OF THE POSSIBILITY OF SUCH DAMAGES. THE PRICE STATED FOR THE
EQUIPMENT IS A CONSIDERATION IN LIMITING THE LIABILITY OF BENTHOS, INC..
NO ACTION, REGARDLESS OF FORM, ARISING OUT OF THE TRANSACTIONS
UNDER THIS AGREEMENT MAY BE BROUGHT BY PURCHASER MORE THAN ONE
YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED.

M-407-005 Chapter 9: Parts Replacement
9.0 Parts Replacement
9.1 Recommended Spare Parts List
9.1.1 TapTone Core Spares Kit (A-407-42-SPK)
Quantity Part Number Description of Part
1 D-407-24 DSP Board
1 C-407-2 Display Board
1 0561-198 Photo Beam Module, Banner SM312 FMHSQD
1 008891 5/12V Power Supply
1 008890 24V Power Supply
5 0501-012 Fuse 2 Amp 250V, 5mm x 20mm
5 0501-026 Fuse 3.15 Amp 250V, 5mm x 20mm
1 0212-002 Box, Plastic
9.1.2 Acoustic Spares Kit (A-407-27-SPK)
1 D-401-126-2 Assembly, Transducer Body, Small - 40
1 B-401-34 Assembly, Microphone
1 C-401-12 Assembly, PCB, Power
9.1.3 Acoustic / Cocked Crown Spares Kit (A-407-31-SPK)
1 D-401-126-2 Assembly, Transducer Body, Small - 40
1 C-403-25-3 Assembly, Prox Sensor, Mini Foot
1 B-401-34 Assembly, Microphone
1 C-401-12 Assembly, PCB, Power

9.1.4 Proximity Sensor Spares Kit
1 C-403-25-2 Assembly, Big Foot Proximity Sensor
1 C-403-25-3 Assembly, Mini Foot Proximity Sensor
1 C-403-25-1 Assembly, Little Foot Proximity Sensor

* Select the proximity sensor to match the original sensor on your system.
9.1.5 Laser Sensor Spares Kit
1 008826 Laser Sensor
9.1.6 X-ray Sensor Spares Kit (A-407-37-SPK)
1 0561-342 X-ray Source Module
1 0516-334 X-ray Source Lamp
5 0501-135 Fuse 3.15A, 250V
5 0501-136 Fuse 1.8A, 250V
5 0501-137 Fuse 0.8A, 250V
1 0561-346 Control Board
1 009026 Power Supply 24Vdc
9.1.7 Rejector Spares Kit, ½” Stroke (A-407-28-SPK)
1 A-401-10-1 Cylinder, AVT 1 x ½ - B, ½” Stroke
1 B-401-209 Assembly, Pad & Base Rejector
1 0250-128 Valve, MAC, 912B – PM – 871CA - MCLSF

9.1.8 Rejector Spares Kit, 1” Stroke (A-407-29-SPK)
1 A-401-10-2 Cylinder, AVT 1 x 1 - B, 1” Stroke
1 B-401-209 Assy, Pad & Base Rejector
1 0250-128 Valve, MAC, 912B – PM – 871CA - MCLSF
9.1.9 Rejector Spares Kit, Heavy Duty 8: Stroke (A-407-30-SPK)
1 0250-182 Cylinder, TRD, W/SS Hardware
1 0250-128 Valve, MAC, 912 – B – PM – 871CA - MCLSF
9.2 Parts List
The following parts lists consist of all major replaceable components of the system. For more
details, see Section 9.3 on ordering procedures.

9.2.1 Control Enclosure Assembly Parts List
Figure 9-1 Control Enclosure Assembly

Ref. No. Part Number Description of Part
1 0219-205 Strain Relief Connector
2 0104-041 ½” Lock Nut
3 0411-005 12’ (4 meter) Line Cord
4 0219-211 Seal Ring
5 0118-002 Hex-cap Screw
6 0151-003 Sealing Washer
7 C-401-87 Interlock Switch
8 0503-129 Actuator Switch
9 008891 5/12 VDC Power Supply
10 008890 24 VDC Power Supply
11 0501-012 2 Amp Fuse, Mini
12 D-407-24 T500 DSP Board
13 C-401-12 Acoustic Power Board
14 0501-012 2 Amp Fuse, Mini
15 B-401-29 14-Pin Ribbon Cable
16 B-407-29 RS-232 Data Socket for T500
17 C-407-2 Interface Display Board
18 B-401-30 64-Pin Ribbon Cable
19 B-404-482 Lamp Assembly (orange)
20 0516-311 24V, 7 Watt Bulb
21 C-401-130-* PLC Board * 1=140VAC, 2=60VDC, 3=280VAC,
4=60VDC & 140VDC mixed
22 C-407-42 I/O Board

9.2.2 Remote Transducer Head Assembly Parts List
Figure 9-2 Remote Transducer and Junction Box Assemblies

1 0561-320 Fiber Optic Cable 1/16
3 0229-042 Transducer Lock Handle
4 0143-076 5/16 Flat Washer
5 0144-034 5/16 Split Lock
6 0411-416 Cable Tie
7 0118-215 5/16 – 18 Hex-cap
8 0144-034 5/16 Split Washer
9 0101-037 5/16 – 18 Hex Nut
10 0411-414 9/16 Cable Clamp
11 0118-003 ¼ - 20 Hex Cap
12 0143-044 ¼ Flat Washer
13 0405-153 Photo Beam Cable
14 0405-154 Proximity Cable
15 0405-154 Microphone Cable
16 0405-151 Coil Cable
17 0405-158 Rejector Cable 12 feet (4meter)

9.2.3 CMS Transducer Head Assembly Parts List
Figure 9-3 Conveyor Mount Transducer and Junction Box Assemblies

3 0411-416 Cable Tie
4 0118-215 5/16 – 18 Hex-cap
5 0144-034 5/16 Split Washer
6 0101-037 5/16 – 18 Hex Nut
7 0405-153 Photo Beam Cable
8 0405-154 Proximity Cable
9 0405-154 Microphone Cable
10 0405-151 Coil Cable
11 0405-158 Rejector Cable 12 feet (4meter)

9.2.4 Crank Stand Assembly Parts List
Figure 9-4 Crank Stand Assembly

1 0250-154 Bridge Height Indicator
2 B-401-8 Crank Handle
3 0249-016 Locking Knob
4 A-401-3 Brass Locking Brake
5 C-404-381 Transducer Bracket
6 C-401-31 Transducer Bracket Mounting Plate
7 0118-219 5/16 – 18 x 1-1/4” Hex Cap
8 0144-034 5/16” Split Lock Washer
9 0101-037 5/16 x 18 Hex Nut
10 0118-127 1/2 – 13 x 2” Hex Bolt
11 0143-043 ½” Flat Washer
12 0144-043 ½” Split Lock Washer
13 0219-313 Drop – In Anchor

9.2.5 Conveyor Clamp Assembly Parts List
Figure 9-5 Conveyor Mount Assembly

1 0118-052 Screw, Hex-cap x 1 ¾ “ Lg.
2 0144-034 Washer, Split lock
3 0101-037 Nut, Hex 5/16” -18
4 0118-051 Screw, Hex cap x ¾” Lg.
5 0218-097 Cap, insert
6 D-401-145 Precision Slide Assembly
7 0229-035 Adjustable Lever

9.2.6 Rejector Assembly Parts List
14 13 12 6 1 OR 2
3 15
4
11 10 9
Figure 9-6 Rejector Assembly

1 A-401-10-1 Cylinder ½” Stroke
2 A-401-10-2 Cylinder 1” Stroke
3 0250-136 Solenoid Valve 24VDC, 17 Watts
4 0250-136 Exhaust Muffler
5 0250-053 Pressure Gauge, 0-160 psi
6 B-401-209 Rejector Pad and Base Assembly
7 0250-189 Filter / Regulator / Lubricator Assembly
8 A-404-297 Conveyor Spacer
9 0118-219 Bolt 5/16-18 x 1-1/4”
10 0198-208 Flat Washer 5/16
11 0144-034 Split Washer 5/16
12 A-401-13 Guide Rod
13 0101-028 Nut, Guide Rod #10-32
14 0147-025 Star Washer #10
15 0405-156 Cable 2 meters
16 0250-147 Cylinder Rebuild Kit
17 0247-002 Cylinder Cap End Bumper
18 A-401-88 Cylinder Rod End Bumper

9.2.7 Shaft Encoder Kit Parts List
Figure 9-7 Shaft Encoder Kit

1 0561-333 Shaft Encoder
2 0219-307 Rubber Shaft Coupling
3 0403-699 Encoder Connector
4 0423-185 Encoder Cable Seal
5 0411-137 Shaft Encoder Cable 4-Conductor
6 B-401-104-2 Complete Cable & Connector Assembly 25 feet

9.2.8 Laser Sensor Parts List

13
18
17
16
2
7
15
1
11
10
9
4
23
14
21
22 19 5
12 6
20
23
Figure 9-8 Laser Sensor Kit

Laser Sensor Parts List (continued)

1 D-407-47 Laser Head Shroud
2 C-407-23 Laser Mounting Plate, Front
3 C-407-24 Laser Mounting Plate, Rear
4 A-401-140 Photo Beam Bracket
5 0561-198 Photo Beam Module SM312FMHS-QD
6 0561-315 Photo Beam Bracket SMB312S
7 D-407-60 Laser Sensor Assembly
8 0561-361 Fiber Optic Cable 1/8” Bundle
9 0229-042 Adjustment Lever
10 0144-034 Split Lock Washer, 5/16”
11 0198-208 Flat Washer, 5/16”
12 0904-015 TapTone Label
13 0904-107 Laser Safety Label
14 0199-120 Screw 10-32 x 3/8”
15 0199-121 Nut 10-32, Keps
16 0128-344 Screw 8-32 x 2-3/8”
17 0144-022 Split Lock Washer #8
18 0143-020 Flat Washer #8
19 0199-403 Screw 6-32 x 3/8”
20 0199-400 Nut 6-32
21 0199-148 Screw ¼-20 x ¾”
22 0144-031 Split Lock Washer ¼”
23 0900-021 Threadlocker, Loctite, 242-21

9.2.9 X-ray Sensor Parts List
11
1 3
2 4 5 6 7
8 9 10 13 14
Figure 9-9 X-ray Sensor Kit

1 0561-342 X-Ray Source Module with Power Supply Board Installed
2 0561-343 X-Ray Detector Module Complete
3 0561-344 X-Ray Module Power Supply Board
4 0561-345 2-Channel Controller Board with EPROM
5 0561-346 Main Chassis Board with Connectors
6 0561-347 Middle Board
7 009026 Power Supply 24V
8 0501-135 Fuse 3.15A / 250V
9 0501-136 Fuse 1.8A / 250V
10 0501-137 Fuse 0.8A / 250V
11 0516-334 X-Ray Source Lamp Bulb 24V, 4W
13 B-407-46 X-ray to T500 Cable Assembly
14 B-407-45 T500 Socket Assembly for X-ray Cable
15 D-407-52 X-ray Stand

9.2.10 X-ray Stand Assembly Parts List
1
19
18
4
11 2 25
7
23
3
6 15
16
5
24
20
8
27
26
37
38
36 9
13 12
17
22
21
34 39
33
32
35
31
29
30
14

X-Ray Stand Parts List (continued)

1 B-407-37 Crank Handle
2 C-407-35 Acme Rod
3 C-407-33 Super Nut Mount
4 C-407-32 Guide Rod
5 C-407-31 Bearing Block
6 C-407-30 End Cap
7 C-407-29 Counter Holder
8 C-407-28 Binder Wedge
9 C-407-27 Thrust Bearing
10 D-407-3 Mounting Bracket
11 B-404-5-2 Stand Tube 6 feet
12 D-407-50 Post Mount Assembly
13 D-407-51 Bearing Block Mount
14 D-401-46 Tripod Base
15 008880 Bronze Bearing
16 008881 Plastic Ball Screw Super Nut
17 008882 Radial Bearing
18 0250-207 Digital Indicator
19 0139-037 Spring Pin
20 0119-126 Screw ¼-28 x ½”
21 0118-215 Screw 5/16-18 x 1”
22 0144-034 Split Washer 5/16 x .079
23 0118-032 Screw ¼-28 x ½”
24 0144-031 Split Washer ¼ x .031
25 0125-257 Screw 10-32 x 5/8”
26 0118-053 Screw 5/16-18 x 3.25”
27 0198-208 Flat Washer 5/16 x ¾ x .050
28 0118-051 Screw 5/16-18 x ¾”
29 0101-048 Nut 3/8-24
30 0198-201 Split Washer 3/8
31 0118-307 Screw 3/8-24 x ¾
32 0143-043 Flat Washer ½”
33 0144-043 Split Washer ½”
34 0118-127 Screw ½-13 x 2”
35 0219-313 Drop-in Floor Anchor
36 C-407-36 Long Block Bearing
37 0101-037 Nut 5/16-18
38 008884 Shaft Collar 5/8” ID
39 0118-003 Screw ¼-20 x ¾”

9.3 Ordering Procedure
When ordering replacement parts for the system, have the following information available before
calling:
• Systems model number and serial number if applicable.

• Part number and quantity.
TapTone Package Inspection

49 Edgerton Drive
North Falmouth, Massachusetts 02556 U.S.A.
Phone: (508) 563-5920 or 1-800-423-4044 (USA Only)

Fax:(508) 564-9945
Hours: 8:00 a.m. - 5:00 p.m., Monday - Friday (eastern U.S. time zone)
E-mail: info@TapTone.com
Web page: www.TapTone.com

M-407-005 Appendix A: Parameter List
Appendix A - Parameter List

Parameter 1 2 3 4 5 6 7

M-407-005 Appendix B: Power Conditioner Installation
Appendix B - Power Conditioner Installation

The power conditioner regulates the AC voltage and provides surge suppression and isolation for
the TapTone 500 system. It also offers protection against voltage sags and brownouts.
Warning: A power conditioner MUST be used for every TapTone 500 with the acoustic sensor
and power board installed.
Installation:
1. Be sure the power conditioner shipped with the system matches the frequency (50Hz or
60Hz) of the AC power available.
50 Hz power conditioner: Part no. 063-00625-0800-23

60 Hz Power conditioner: Part no. 063-00125-0400-23
2. Install the power conditioner away from wet areas. This unit is not waterproof and damage
will occur if the unit gets wet. A good location for installation is high on a wall or support
column. Make sure the unit is open to airflow to provide sufficient cooling.
3. Make sure AC power is OFF before wiring the power conditioner.
4. Connect the AC power input of the power conditioner according to the line voltage (120VAC
or 240VAC) as supplied locally. Refer to the wiring diagram found in the power conditioner
manual supplied with the unit for actual pin assignments. Make sure the earth ground is
connected.
5. Connect the (120VAC ) output of the power conditioner to the TapTone 500 system. The
power conditioner will act as a step down transformer for those installations with 220VAC or
higher input. Make sure the earth ground is connected.
6. Set the power select switch SW1 on the power board (Acoustic Sensor) to (115VAC)
position.
7. Measure the output voltage of the power conditioner to assure 120 VAC is wired to the
TapTone 500 controller before turning system on.

M-407-005 Appendix C: Merit Value Scale Factor Chart
Appendix C – Merit Value Scale Factor Chart

Product Product Description Original Merit Value Scale Factor Notes
Type (good container) Value

Manual Tap Tone 500

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TapTone 500 Series

Installation, Operation and Maintenance Manual

TapTone Package Inspection

Phone: 508-563-5920 or 1-800-423-4044 (USA Only)

3.0 Safety Precautions ........................................................................................11

4.0 Installation Instructions ...............................................................................13

TapTone Division of Benthos, Inc. i

5.0 System Operating Procedures .....................................................................37

6.0 System Troubleshooting Guide .................................................................103

7.0 Preventative Maintenance..........................................................................122

8.0 Warranty .....................................................................................................123

9.0 Parts Replacement ......................................................................................124

Appendix A - Parameter List..............................................................................140

Appendix B - Power Conditioner Installation...................................................141

Appendix C – Merit Value Scale Factor Chart.................................................142

TapTone Division of Benthos, Inc. iv

TapTone Division of Benthos, Inc. v

TapTone Division of Benthos, Inc. vi

It is recommended that the installation of your TapTone equipment is performed or supervised

TapTone Division of Benthos, Inc. 1

TapTone Division of Benthos, Inc. 2

Strip Charts Histograms

TapTone Division of Benthos, Inc. 3

Figure 2-1 TapTone 500 RTV System

TapTone Division of Benthos, Inc. 4

Figure 2-2 TapTone 500 CMS System

TapTone Division of Benthos, Inc. 5

2.2.1 Single Inspection and Dual Rejection T500

2. Proximity - inspection for curvature measurement on metal pressure or vacuum

3. Laser - inspection for curvature measurement on plastic pressure or vacuum containers.

4. Rejection #1 / Rejection #2 – single or dual rejection stations may be configured for

MISSING LID REJECTS

TapTone Division of Benthos, Inc. 6

3. Proximity / Proximity - inspections for curvature measurements on metal pressure or

4. Laser / Proximity - inspections for curvature measurements on metal and plastic

8. Rejection #1 / Rejection #2 – single or dual rejection stations can be configured for

COCKED CROWN REJECTS

TapTone Division of Benthos, Inc. 7

1. Acoustic / Cocked Crown / X-Ray - inspection for pressure or vacuum detection on

2. Acoustic / Proximity / X-Ray - inspection for pressure or vacuum detection on rigid

3. Rejection #1 / Rejection #2 – single or dual rejection stations can be configured for

LOW FILL REJECTS

SENSOR #3 SENSOR HEAD #2 SENSOR HEAD #1 LEAKER REJECTS

TapTone Division of Benthos, Inc. 8

TapTone Division of Benthos, Inc. 9

PLC Interface Board (Optional)

I/O Interface Board (Standard)

Laser Sensor Specifications

X-Ray Sensor Specifications

TapTone Division of Benthos, Inc. 10

3.0 Safety Precautions

3.2 Specific Cautions and Warnings

DANGER! - Before removing the power board safety shield or disconnecting

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Laser Radiation: Do not stare into laser beam.

3.3 Safety Label Descriptions

Insert safety lock before getting in hazardous area.

Lock-out electrical power before servicing.

General danger. (see manual)

Hazard hand crush.

Hazard electrical shock.

Protective earth. (ground)

Figure 3-1 Safety Labels

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