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LM3510 Manual

1. STOP DELAY gt 000 JOG TAKE UP gt ENTER TO JOG 4 COUNTERS PRESS ENTER Page 37 Made in the U S A gt TOTAL CNT RESET PRESS ENTER USER S MANUAL ARE YOU SURE YES PUSH ENTER gt BATCH CNT RESET PRESS ENTER ARE YOU SURE YES PUSH ENTER gt BATCH PRESET SET 0000000 gt LIFE COUNTER 0000000 3 10 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL 5 PRINT TYPE PRESS ENTER gt PRINT REPEAT OFF PRINT REPEAT gt 6 ENCODER PRESS ENTER i Page 38 Made in the U S A gt ENCODER ON ENCODER gt OFF gt OVERRIDE 150 0 gt TRIGGER DISTANCE 00 00 START COMP DIST 0 000 RANGE 0 5 000 LINES INCH 0025 0 RANGE 25 500 3 11 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL 7 CYCLE TYPE PRESS ENTER TAMP CYCLE TYPE gt TAMP CYCLE TYPE TAMP CYCLE TYPE NO TAMP BEFORE FEED gt AFTER FEED v gt BLOW LABEL BLOW LABEL OFF gt ON gt VARIABLE DATA VARIABLE DATA OFF gt ON 8 NOT SUPPORTED
2. LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL T STAND ADJUSTMENT cae Control Mounting Arm Column Lock 2 10 Page 19 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL TAMP UNIT OPERATION e Duration Tamp duration is used to provide an on timer for the solenoid valve on the main tamp cylinder The delay on standard versions can be from 0 to 30 000 seconds in 1 1000 of a second accuracy This allows for easy change over from one product height to another without physically changing the height of the unit It also allows for precise adjustments of how close the tamp head comes to the product refer to page 3 08 There is flow control adjustment for the valves It may be necessary to adjust the flow rate on the tamp solenoid for optimum performance after installation The adjustment is performed as shown below They are set at the factory The regulators on the vacuum air assist and flag valves are for increasing or decreasing the air pressure as necessary for proper operation Note Flag Regulator not shown below only supplied with flag applicators Vacuum Pump Flow Control B Flow Control Vacuum regulator Air assist regulator 2 11 Page 20 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL TAMP FLOW CONTROL ADJUSTMENT Regulator Ad
3. T j j js E REPEATPRINT O svor pj 4 J P STARTPRINT svor jJ j j js S PPRINTEND i svor de LABELOUT i svor j j 7 mBBONOUT i svor js PPRINTERGRD GROUND T T L L do o 3 21 Page 50 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL TAKE UP MOTOR CONNECTOR P1 ADDRESS 9 PIN AMP PIN TAKE UP MOTOR NEUTRAL TAKE UP MOTOR 1 eee E TAKE UP MOTOR 2 8 j _ VEI MAS LIGHT BAR AUXILIARY CONNECTOR P3 INPUT ADDITIONAL 14 PIN AMP PIN OUTPUT ADDRESS LOCATIONS SIGNAL IS p 24 VOLTS 1 24V COMMON _ ode U mE E LOWRIBBON LABEL HIGHCURRENT24AVOPTO 4 o ERRORLIGHT HIGHCURRENT24V0PTO CTS o v2 j RIBBON OUT 8 HIGH CURRENT 24V OPTO 6e o JY3a TAMP SYNC HIGH CURRENT 24V OPTO 7 O jY X AUXVODB5 RUN STATUS HIGH CUR 24V 8 O ve X A AUX ODE5 INHIBIT 24V OPTO INTERNAL 24V COM E I 1 xos PRE PRINT 24V INTERN 24V o I X04 LOW LABEL IN 24V OPTO INTERNAL 24V COM u 1 xo5 AUXVODB5 LAST LABEL REPEAT IN 24V OPTO INTERNAL 24V COM 12 1 x06 AUXVODB25 AUX IN 13 NO INTERNAL COMMON pi AUX IN 13 NO IN
4. 3 This feature requires the use of an encoder The appropriate encoder features should be setup prior to this feature 4 Set ENCODER to OFF 5 Set CONVEYOR LOCK to OFF if in ASYNCHRONOUS operation 6 If in SYNCHRONOUS operation PRODUCT DELAY WILL NOT WORK 7 Set Product delay to 00 000 8 Start system and apply label at the desired speed 9 Check the placement of the label on the product 10 Measure the OFFSET of the label placement Note A label CAN NOT be advanced on the product ONLY moved back since the applicator can only delay the product signal 11 Apply a small delay to the product delay or if too great it may be necessary to physically move the product switch Keep product delays to a minimum for best results 12 Operate system again and measure offset 13 Apply a small delay to the product delay or reduce if too much 14 Test again repeat if necessary until label is in proper registration 15 Turn back on any options that may have been disabled for setup of this particular feature 3 18 Page 45 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL HOW TO SET UP AN ASYNCHRONOUS APPLICATION TAMP WITHOUT A ENCODER Determine the following and select it in the software Type of application mode Tamp MENU 7 Tamp before or after feed before feed is standard MENU 7 Enter a value in the tamp duration start with 00 2
5. PROG KEY PASS NUMBER PRESS ENTER 1 PRODUCT SENSOR PRESS ENTER Y 2 TAMP SET UP PRESS ENTER Y 3 TAKEUP PRESS ENTER 3 05 Page 32 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL 4 COUNTERS PRESS ENTER 5 PRESS ENTER E 6 ENCODER PRESS ENTER I 7 CYCLE TYPE PRESS ENTER 4 8 NOT SUPPORTED PRESS ENTER 9 JOB STORAGE PRESS ENTER 4 DEFAULT SETTINGS LIS PRESS ENTER I O STATUS PRESS ENTER PRESS PROG KEY 3 06 Page 33 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL PASS NUMBER MAIN DISPLAYS gt ENTER PASS p PRESS ENTER 0000 gt CHANGE PASS CHANGE PASS NO gt YES 0000 gt LOCK WHAT MENUS gt LOCK WHAT MENUS gt LOCK WHAT MENUS 23456789 ALL 5678 Page 34 Made in the U S A Note When a pass number is used all menus not numbered are automatically locked as well as the selected locked menus 3 07 2003 MMI Automated Systems 12 23 03 Model LM 3501 1 PRODUCT SENSOR LM 3501 PRINT amp APPLY SYSTEM gt PRODUCT DELAY PRESS ENTER 00 000 SECONDS
6. SENSOR TYPE gt SENSOR TYPE SENSOR TYPE gt DISABLED NORMALLY OPEN gt NORMALLY CLOSED gt SENSOR TRIGGER SENSOR TRIGGER lt Page 35 Made in the U S A LEADING EDGE gt TRAILING EDGE v gt DEBOUNCE USED TO FILTER FAULSE 00 000 TRIGGERING Y gt OFF DEBOUNCE USED TO FILTER FAULSE 00 000 TRIGGERING gt MULTIPLE FEED MULTIPLE FEED QUANTITY 01 gt QUANTITY 02 ONLY ACTIVE 02 OR LARGER gt INTERVAL DELAY 00 00 SECONDS 3 08 2003 MMI Automated Systems USER S MANUAL Range 01 10 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL 2 TAMP SETUP gt TAMP DURATION PRESS ENTER 00 000 SECONDS gt FLAG DURATION 00 00 SECONDS HEAD UP SWITCH gt HEAD UP SWITCH HEAD UP SWITCH NORMALLY OPEN NORMALLY CLOSED gt NO TAMP SWITCH gt HEAD UP DBOUNCE 00 00 gt VACUUM RELEASE 00 00 Note this time can never be larger then the tamp duration gt VACUUM DELAY ON 00 00 TAMP SYNC LOGIC TAMP SYNC LOGIC gt NORMAL gt REVERSE AIR ASSIST DLY gt 00 00 3 09 Page 36 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 3 TAKEUP PRESS ENTER LM 3501 PRINT amp APPLY SYSTEM gt START DELAY 000
7. example PRODUCT SENSOR or TAMP SETUP 2 Access or Enter the data selection options line bottom line of display of the PROGRAM BLOCK Sub Menus 3 Store the selected data and return to the Sub Menu of the PROGRAM BLOCK top line of display Note that the carrot gt on the left hand side of the display will move line to line up down to indicate what line you are currently in PROG PROGRAM KEY IS USED TO 1 Enter Main program menu 2 Exit primary and secondary menus 3 Back out of the program menu one block at a time until you completely exit the program menu 4 Exita primary or secondary menu WITHOUT changing the data PROG key will not SAVE changes START KEY Start key will initialize the application cycle STOP CLEAR KEY 1 Stop key will abort the cycle only when not in the program menu and disable the system The system will be enabled only after the key is pressed again 2 Clear key will delete stored values while in the edit mode HOT KEY The Hot Key is used while in the primary program block to fast forward to the desired program block The number located in the upper left hand corner of the primary Program Block 0 9 identifies the Hot Key For example by depressing the 4 key you will automatically advance to the Program Block Counters 3 01 Page 27 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL e PASS NUMBER
8. key Set tamp duration to 00 200 Configure Head up limit switch standard is normally open Press 7 key Set tamp cycle to before feed Once manual set up is complete exit the programming menu by pressing the PROG key twice While in the display mode press the START key this will cycle the applicator System is now ready for set up of advanced features and options SETUP OF KEY FEATURES START COMP DIST START COMPENSATION DISTANCE Set basic applicator up first refer to quick setup Set ENCODER to ON Set TRIGGER DIST to 00 00 Set ENCODER LINES PER INCH refer to ENC LINES set up Start system and apply label at the fastest desired speed system should not exceed maximum rate of applicator Move product switch or use TRIGGER DIST to register label to desired position Keep trigger distance to a minimum for best results Change speed of system and operate it at the lowest speed desired Measure the offset in label placement Enter the measured offset into the START COMP DIST Operate system at the same low speed again and check label offset Make the necessary adjustments to the START COMP DIST Test again repeat if necessary until label is in proper registration System should now hold registration throughout speed range Turn back on any options that may have been disabled for setup of this particular feature Note there will be some label drift if speed range is
9. 24 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL OPTIONAL SIDEWINDER 2 15 Page 25 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL SECTION 3 Programming 3 01 Quick Reference Chart 3 05 Key Definitions 3 15 Set Up of Key Features amp Quick Start 3 16 Description of I O 3 21 Page 26 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL PROGRAMMING All programming is performed via the keypad and display as shown on page 2 6 All programmed settings are battery backed in nonvolatile memory and are not lost when the unit is powered off Upon power up of the control the screen will display MODEL NUMBER amp REVISION After this the screen will now display NITIALIZING The final screen in the wake up will display the counter TOTAL XXXXXX BATCH XXXXXX e KEY FUNCTIONS UP DOWN ARROW KEYS ARE USED TO Scroll up amp down through the primary menu PROGRAM BLOCKS Header name Scroll sub menus inside of PROGRAM BLOCKS top line of display while IN a PROGRAM BLOCKS Scroll data selection options bottom line of display after entering the selected PROGRAM BLOCKS Select different display views while in the RUN mode REO ENT ENTER KEY IS USED TO 1 Access or Enter the selected PROGRAM BLOCK
10. POWER FUSE Refer to section 3 5 of the enclosed SATO Operator s Manual for print head cleaning instructions or the appropriate section in the ZEBRA or DATAMAX Operator s Manual if so equipped 4 03 Page 57 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL MAINTAINING THE AIR SLIDE Very little maintenance is required to keep the Tamp Assembly s air slide in good working condition To maintain the air slide simply remove the air lines from the air slide and place 1 2 drops of any approved air motor oil into the air inlets at least once a month 1 2 drops of oil is also required for the incoming air supply WARNING The main air supply must be shut off before you remove the air lines from the air slide Airline 4 04 Page 58 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL REPLACING THE MAIN POWER FUSE The circuitry is protected from a current overload by GMA 10A a fast blow fuse Should the applier fail to operate the condition of this fuse should be checked If the fuse is open the cause of the overload condition must be determined and corrected prior to replacing the fuse NEVER replace the fuse with one of a greater AMP rating The specified rating has been selected to prevent damage and or injury ACTIONS TO REPLACE THE MAIN FUSE Set the main power switch to the OFF position D
11. The PASS NUMBER is used to lock the menus of the control at 4 different levels This option is used to prevent unauthorized access to variable data When shipped from the factory the pass number is set to 0000 and NO MENUS are locked If a different pass number is entered this number MUST BE MEMORIZED to be able to access the settings in the controller at a later time 1 PRODUCT SENSOR This is an external device that when activated starts the application cycle PROGRAMMABLE BLOCKS Product Delay delays the application of the label x seconds after the sensor has been activated Sensor Type used to designate the type of product sensor used Normally open is the standard Sensor Trigger designates whether the product sensor is activated at the leading or trailing edge of the product Multiple Feed how many labels are applied to one product with one signal reset when signal is toggled Interval Delay amount of time in seconds between multiple fed labels Note only active if quantity 2 or higher Note the product delay feature will not work when the Conveyor Lock feature is activated use TRIGGER DISTANCE e 2 TAMP SET UP This is used to adjust the different variables related to the tamp cycle PROGRAMMABLE BLOCKS Tamp duration used to adjust the time that the tamp cylinder valve is actuated 00 000 to 30 000 Flag duration used to adjust the time the flag jaws are held open after label application 00 00 to 99 99 H
12. counter expires the batch done output is activated e 5 PRINT TYPE The print type command is used to activate the print repeat cycle in the supplied print engine Sato only This feature will continue to print the last label in the buffer after the buffer count has expired PROGRAMMABLE BLOCKS Print Repeat turn repeat print option ON or OFF e 6 ENCODER Provides a more consistent way to apply labels to a product With this option a distance from the trigger point can be set at which the label is to be applied Note optional encoder must be used with this feature PROGRAMMABLE BLOCKS Encoder used to turn the encoder option on or off Enc Override Allows fine tuning of the ratio of applicator speed to conveyor speed Trigger Distance used to apply the label a certain distance away from the trigger point Start Comp Dist Start Compensation Distance used to compensate for variable speed applications Enc lines inch tells how many pulses the encoder will count with 1 inch of travel 25 to 500 counts per inch 3 03 Page 29 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL e 7 CYCLE TYPE Determines the application type and sequence in relation to the label PROGRAMMABLE BLOCKS Tamp cycle type Before feed standard after feed No tamp changes tamp cycle in relation to label feeding Blow label turns the blow on option on or off Note In
13. product switch is activated 5 The PRODUCT DELAY should be kept to a minimum BON Determine the following and select it in the software TAMP WITHOUT AN ENCODER Type of application mode Tamp MENU 7 Select Tamp after feed before feed is not active MENU 7 Select Blow Label OFF MENU 7 Select Variable Data ON MENU 7 Enter a value in the tamp duration start with 00 20 MENU 2 Set head up limit switch normally open is standard MENU 2 Use the product delay to MOVE the label on the product DUO OI ow The asynchronous application mode is used to apply labels to products that are either stationary or moving at a constant speed when the label application is to take place e BLOW WITHOUT AN ENCODER Determine the following and select it in the software Type of application mode Tamp MENU 7 Select Tamp after feed before feed is not active MENU 7 Select Blow Label ON MENU 7 Select Variable Data ON MENU 7 Enter a value in the tamp duration start with 00 20 MENU 2 Set head up limit switch TAMP SWITCH MENU 2 Use the product delay to MOVE the label on the product N orgi e O P The asynchronous application mode is used to apply labels to products that are either stationary or moving at a constant speed when the label application is to take place 3 19 1 Page 47 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SY
14. the BLOW mode a tamp cycle must also be enabled and a tamp duration entered program block 2 TAMP Variable data on or off When turned on the preprint port is activated this allows a optional product trigger to print the label the second standard trigger would activate the tamp cycle only This is used primarily with variable data being gathered for example when the applicator is being interfaced with a scale e 8 NOT SUPPORTED 9 JOB STORAGE Used to store frequently used settings pertaining to different labeling jobs PROGRAMMABLE BLOCKS Job store stores settings for last job Job select allows operator to select 1 of the optional 10 stored jobs Job delete allows operator to delete a stored job e DEFAULT SETTINGS This setting will return the controller to the default settings e O STATUS Displays the status of the inputs and outputs Page 30 Made the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL 3 04 Page 31 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL QUICK PROGRAMMING CHART MODEL NUMBER amp REVISION kuq LM MODEL 1501 INITIALIZING UP AND DOWN ARROW KEYS WILL SCROLL THROUGH THE PROGRAM BLOCKS V AND THE SUB MENUS TOTAL 000000 gt BATCH 000000 PRESS
15. value START Comp is used to compensate for label drift when speed of conveyor changes To calculate this refer to the section on Start Compensation ENC LINES INCH enter the proper lines per inch to match encoder output to conveyor speed To calculate lines per inch refer to the section on Gearing NOOR ON gt 3 19 Page 46 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL HOW TO SET UP AN VARIABLE DATA APPLICATION e TAMP WITHOUT AN ENCODER WITH TWO TRIGGER PHOTO EYES Variable data application is utilized when the LM3501 is interfaced with a scale or other equipment that will be transmitting a DIFFERENT label format to the applicator for every label that is applied When this option is activated the use of the pre print photo eye option is required The pre print photo eye will trigger the printing of the label The product photo eye switch will trigger the application tamp of the label The reason for two triggers is to improve the accuracy of the label placement when printing before applying General set up The PRE PRINT photo eye connects to the LIGHT BAR AUX port The PRE PRINT photo eye should be set to trigger on the leading edge of the product The PRE PRINT photo eye should be set to trigger BEFORE the product switch The PRE PRINT photo eye should be set to allow the printer enough time to print the format before the
16. 0 MENU 2 Set head up limit switch normally open is standard MENU 2 Use the product delay to MOVE the label on the product The asynchronous application mode is used to apply labels to products that are either stationary or moving at constant speed when the label application is to take place e BLOW WITHOUT AN ENCODER Determine the following and select it in the software Type of application mode Tamp MENU 7 Tamp before or after feed before feed is standard MENU 7 Note Tamp before or after must be activated for this option to operate BLOW LABEL must be turned ON MENU 7 Enter a value in the tamp duration start with 00 10 MENU 2 Set head up limit switch to NO TAMP SWITCH MENU 2 Use the product delay to MOVE the label on the product The asynchronous application mode is used to apply labels to products that are either stationary or moving at constant speed when the label application is to take place e TAMP OR BLOW WITH A ENCODER Determine the following and select it in the software Type of application mode Tamp or Blow refer to above Tamp or blow before or after feed before feed is standard Enter a value in the tamp duration start with 00 200 Turn encoder ON in menu 6 Encoder OVERRIDE is used to fine tune the GEARING RATIO between applicator and conveyor Trigger distance is used to MOVE label on product product delay is disabled Enter a Start Comp
17. 01 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL TAKE UP UNIT ASSEMBLY A TAKE UP SPOOL B BEARING BODY C GEAR MOTOR D CLUTCH ASSEMBLY The Take Up Assembly is located on the backside of the main panel To adjust the clutch the side panels must be removed to gain access To remove the Clutch Assembly you must first remove the Web Take Up Spool The mounting bolts for the Take Up Assembly can be found directly behind the plastic spool WARNING Be sure power is off before performing any service TAKE UP ASSEMBLY 2 04 Page 12 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL CLUTCH ADJUSTMENT WWW A DRIVE DOG B SHAFT WHEEL C FRICTION DISC D PRESSURE PLATE E THRUST BEARING F PRESSURE SPRING G TENSION ADJ COLLAR H SHAFT LOCK COLLAR To increase waste web tension move the Tension Adjustment Collar G 1 32 toward the motor To reduce web tension move the Tension Adjustment Collar G 1 32 toward the spool CAUTION Too much web tension may cause web breakage print drifting or premature failure of the Take Up Assembly 2 05 Page 13 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL OPERATOR INTERFACE TERMINAL LCD OPERATOR INTERFAC MODULAR MICRO PROCESSOR CONTROL MAIN POWER 2 06 Page 14 Made th
18. 2 7 are on Y VO STATUS m PORT Y1 gt PORT Y1 00000000 VO STATUS EN PORT Y2 gt PORT Y2 00000000 PORT Y2 76543 210 XOXOXOX X 3 20 Page 49 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL SIGNAL NAMES TYPE MOTOR WEB LIGHT TRIG TAMP PRINTER AUX I O PINS PINS PINS PINS PINS PINS PINS 1 2 P3 P4 P5 P6 P9 a 1t Ji s j Ji CTO pase 1 1 d js q e j c c T TAKEUP J jJ j p j j J PVELREF to 78 jJ jJ j jJ DRIVE o J rr Jj 12 j j j jJ MOTOR O FT 34 j j j j RES o OT RES ss j j DRIVECOM OT SHIELD o j T DRIVE __ i4 X ene j Jj jJ SENSE i fos jJ cL jJ j Jj jJ jJ vacuum OH awor j j j TAMPSW ji 2vorr js Fraa 1 AMVOPT 0 j s _ p PAIRASSIST OH 2vOPT 7 p SMARTTAMP 4 pn j j js j o PAUXOUT 1 on awot j J J T L j jJ PINHIBITCYCLE J 24woPT ds j PRE PRINT 24vOo
19. LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL TABLE OF CONTENTS SECTION PAGE 1 APPLICATOR OVERVIEW Introduction 1 01 General Printer Specifications 1 02 Inventory List 1 03 Print amp Apply Component Description 1 04 User Responsibility 1 05 Safety 1 05 2 SETUP AND OPERATION Web Routing 2 01 Thermal Print Head Label Loading 2 03 Thermal Ribbon Loading 2 03 Label Sensor Adjustment 2 03 Take Up Unit Assembly 2 04 Clutch Assembly Adjustment 2 05 Operator Interface Terminal 2 06 Accessory Connector Panel 2 07 T 50 Photo Eye 2 07 5 Air assist tube 2 08 T 150 Mounting Stand optional 2 09 T stand adjustment 2 10 Tamp Unit Operation 2 11 Tamp Flow Control Adjustment 2 12 Optional Adjacent Panel Labeler APL 2 13 Optional Corner Wrap 2 14 3 CONTROL BOX Programming 3 01 Quick Reference Chart 3 05 Key Definitions 3 15 Set Up Of Key Features 3 16 Description of I O 3 20 4 CLEANING amp MAINTENANCE Troubleshooting 4 01 Fault Codes 4 02 Cleaning of the Print Head 4 03 Cleaning the Platen Demand Plate and Rollers 4 03 Replacing the Print Head Power Fuse 4 03 Maintaining The Air Slide 4 04 Replacing Main Power Fuse 4 05 Page 1 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL SECTION 1 APPLICATOR OVERVIEW Introduction 1 01 General Printer Specifications 1 02 Inventory List 1 03 Print amp Apply Component Description 1 04 User Responsibil
20. OVERRIDE This feature is used in conjunction with ELECTRONIC GEARING This feature is used to fine tune the ratio of the applicator to the product conveyor e TRIGGER DIST TRIGGER DISTANCE is used in conjunction with the encoder feature Trigger distance is similar to product delay in that it is used to electronically move the placement of the label on the product When the encoder feature is used the product delay feature is rendered inactive Trigger distance will move the label placement in inches 00 00 e PRODUCT DELAY is NOT used in conjunction with the encoder feature Product delay is similar to trigger distance in that it is used to electronically move the placement of the label on the product Product delay will move the label placement in time 00 000 seconds Because the product delay feature utilizes time the speed of the product MUST remain constant A product traveling at a higher velocity will travel further in a given time thus effecting the placement of the label 3 15 Page 42 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 O O a D LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL QUICK START Inspect applicator system and verify all cables are installed properly Web system with labels Turn power switch on Press PROG Press 9 and then the down arrow DEFAULT SETTINGS press ENTER Hold CLEAR button down for 5 seconds Press 2
21. PRESS ENTER 3 12 Page 39 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL 9 JOB STORAGE PRESS ENTER gt JOB STORE PRESS ENTER gt JOB SELECT PRESS ENTER gt JOB DELETE PRESS ENTER gt STORE CURRENT 00 1 10 gt SELECT JOB FROM 00 DELETE JOB gt 00 Range 01 10 Jobs Range 01 10 Jobs ENTER OVERWRITE CLEAR ABORT ARE YOU SURE YES PUSH ENTER DELETE THE JOB YES PRESS ENTER ARE YOU SURE YES PUSH ENTER THE JOB SELECTED IS EMPTY SELECT JOB FROM RANGE 1 10 DEFAULT SETTINGS EN SET DEFAULTS PRESS ENTER CLEAR 5 SECONDS 3 13 Page 40 Madein the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM I O STATUS PRESS ENTER Page 41 Made in the U S A USER S MANUAL gt l O STATUS I O STATUS STATUS PANEL gt STATUS PANEL DISPLAY I O VO STATUS PORT X0 PRESS ENTER gt PORT X0 00000000 XPSIYAFVT VO STATUS PORT X1 00000000 gt PORT X1 00000000 I O STATUS PORT X2 gt PORT X2 00000000 I O STATUS PORT YO gt PORT YO 00000000 I O STATUS PORT Y1 gt PO
22. PT jJ dbo J LOWLABELIN jJ 2voer REPEAT LAST LABEL 24vOPT 0 de j j e PAUXIN 6 a 2vorr j jJ eM AUXINO e 0 0 j j 15 PAUXIN 8 i vor jJ e AUXIN I 0 j j j t7 X5 AUXIN O i owoer j jJ w ie AUXIN I T1 2MvOPT jJ j tT PAUXIN 12 t1 vor j o PAUXIN 13 1 041334 0 PAUXIN 14 t j 9100 INPLO as Ji svor j j T a kf NPLO Q jJ svor JX 2 PINPLO 17 Ji svo j j iNPLOCOM sVCOM J 2 J TAMPSYNC evot 0 7 j O j t RUN STATUS OK 2voPT d e j J p BATCHDONE vot 0 j j j js 4 aux JO voT j j js O LOW RIBBON LABEL OL 24vOPT de j J6 J PERRORLITE ___ evot _ p s j RIBBONOUT OL wort 6 j O j j PAUXOUT 9 X oL awot 0 j j 4 qw AuxoUTQ0 OL evot 0 vq j j js PAUXOUT 11 vor j js J AuxoUT 2 _ evot 0 j j Lo j Ww T j qp Ji js j j j ji PRIBBONLOW i svor j e ERROR CTT svor
23. Power Cord Model 3500 Operators Manual Extra Cardboard Ribbon Core Product Switch specified a Manual Limit Switch optional b Photo Switch optional 1 Take up Spool Clip 1 Head Cleaning Kit optional Part No SA070 JN TOOLS REQUIRED FOR ASSEMBLY 3 32 ALLEN WRENCH 34 WRENCH 1 1 8 WRENCH 1 03 Page 5 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL COMPONENT DESCRIPTION LABEL SPOOL CYLINDER SPOOL LOCK THERMAL PRINTER WEB GUIDE ROLLERS WEB TAKE UP SPOOL 1 04 Page 6 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Defective equipment should not be used Parts that are broken missing plainly worn distorted or contaminated should be replaced immediately Should such repair or replacement become necessary we recommend that a request for service advice be made This equipment or any of its parts should not be altered without the prior written approval of MMI Automated Systems The user of this equipment shall have the sole responsibility
24. RT Y1 00000000 I O STATUS PORT Y2 gt PORT Y2 00000000 I O Ports are numbered as follows 76543210 Ports are numbered from right to left 3 14 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL KEY DEFINITIONS e ASYNCHRONOUS OPERATION The term ASYNCHRONOUS OPERATION is used because the speed of the printer applicator motor label speed does not necessarily match the speed of the product conveyor In other words their speed is set independently of one another and has NO interrelation The 3501 can only be configured in asynchronous operation e SYNCHRONOUS OPERATION The term SYNCHRONOUS OPERATION is used because the speed of the applicator motor label speed is matched to the speed of the product conveyor In order to accomplish this an encoder is used to monitor the speed and distance the product conveyor travels In order for this feature to function the CONVEYOR LOCK mode must be turned on In synchronous operation the applicator motor is ELECTRONICALLY GEARED to the product conveyor The 3501 can NOT be configured in synchronous operation e START COMPENSATION Start compensation compensates for the reaction time of the Label Mill control and start signal from the product switch The purpose of start compensation is to maintain label placement on a product that is traveling at different speeds An example of this is a conveyor that accelerate
25. STEM USERS MANUAL TAMP WITH AN ENCODER Determine the following and select it in the software Type of application mode Tamp MENU 7 Select Tamp after feed before feed is not active MENU 7 Select Blow Label OFF MENU 7 Select Variable Data ON MENU 7 Enter a value in the tamp duration start with 00 20 MENU 2 Set head up limit switch normally open is standard MENU 2 Turn encoder ON in menu 6 Encoder OVERRIDE is used to fine tune the GEARING RATIO between applicator and conveyor Trigger distance is used to MOVE label on product product delay is disabled 0 Enter a Start Comp value START Comp is used to compensate for label drift when speed of conveyor changes To calculate this refer to the section on Start Compensation 11 ENC LINES INCH enter the proper lines per inch to match encoder output to conveyor speed To calculate lines per inch refer to the section on Gearing agouopggsitomc e BLOW WITH AN ENCODER Determine the following and select it in the software Type of application mode Tamp MENU 7 Select Tamp after feed before feed is not active MENU 7 Select Blow Label ON MENU 7 Select Variable Data ON MENU 7 Enter a value in the tamp duration start with 00 20 MENU 2 Set head up limit switch NO TAMP SWITCH MENU 2 Turn encoder ON in menu 6 Encoder OVERRIDE is used to fine tune the GEARING RATIO between applicator and conveyor Trigge
26. TERNAL COMMON p14 REMOTE TRIGGER CONNECTOR P4 PRODUCT SWITCH PIN ADDRESS 4 PIN AMP 244AVCOMMON 3 O NO CONNECTION 4 L O 3 22 Page 51 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL TAMP SOLENOIDS CONNECTOR P5 INPUT 9 PIN AMP SMALL PIN OUTPUT ADDRESS TAMP SOL 24V 0 O 1 xo l p O O AUX1OUT24VHIGHCURRENT 9 o 4s PRINT AND APPLY P6 PRINTER 5V INPUT 5V OPTO Ji PRINT END INPUT 5V OPTO 6G x2 LABELS OUT INPUT 5V OPTO RIBBON OUT INPUT 5V OPTO l8 x4 Es PRINTER GROUND AUX I O INPUT ADDITIONAL DB25 CONNECTOR PIN OUTPUT ADDRESS LOCATIONS SIGNAL IS AVAILABLE X0 0 1 0 Y1 2 Yiz o v24 Yus Ye Y27 r Po AUXIN 14 NO INTERNAL COM XT rC l 2 _ 3 4 6 7 00 1 xte O 12 _ 24 VOLTS i4 15 i6 i7 18 19 j 20 21 2 23 24 OOO LIGHT BAR AUX LIGHT BAR AUX 24V GROUND 25 j polo 1 xozr Xto 0 0 0 0 0 EXEC o x2 0 0 0 0 0 0 xia 1 Xt4 0 0 0 0 0 0 xt5 PT x25 C x26 Io y x27 0 0 0 0 Eo Pn 3 2 P9 1 2 4 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 4 25 3 23 Page 52 Madein the U S A 2003 MMI Automated Sys
27. appropriate encoder features should be setup prior to this feature 4 Set ENCODER to ON 5 Set ENODER LINES XXXX X Refer to CALCULATING ENCODER LINES PER INCH section 6 Set TRIGGER DIST to 00 00 7 Start system and apply label at the desired speed 8 Checkthe placement of the label on the product 9 Measure the OFFSET of the label placement Note A label CAN NOT be advanced on the product ONLY moved back since the applicator can only delay the product signal 10 Apply the measured offset to the TRIGGER DISTANCE or if too great it may be necessary to physically move the product switch Keep trigger distances to a minimum for best results 11 Operate system again and measure offset 12 Enter the measured offset IF ANY into the TRIGGER DISTANCE 13 Test again repeat if necessary until label is in proper registration 14 Turn back on any options that may have been disabled for setup of this particular feature e PRODUCT DELAY PRODUCT DELAY is NOT used in conjunction with the encoder feature Product delay is similar to trigger distance in that it is used to electronically move the placement of the label on the product Product delay will move the label placement in time 00 000 Because the product delay feature utilizes time the speed of the product MUST be constant and consistent Set basic applicator up first refer to quick setup 2 Ensure that applicator is operating properly before starting this procedure
28. e U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL ACCESSORY CONNECTOR LOCATED ON THE REAR PANEL OF THE OPERATOR INTERFACE TERMINAL 2 07 Page 15 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL T 50 PHOTO EYE 1 24VDC BROWN 3 24VDC BLUE 2 SINKING WHITE gt CONNECTOR SHOWN FROM WIRE SIDE 2 07 5 Page 16 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL AIR ASSIST TUBE The Air Assist Tube must be adjusted to x clear the trailing edge of the printed labels and Label Platen An adjustment screw is used to adjust the position of the air holes in relation to the labels An angle of 45 degrees is required One slot is provided to make the appropriate adjustments desired o Pr al N Label Platen Air Assist M N Tube Airflow Blow tube Adjustment mounting Screw bracket Clamp screw 2 08 Page 17 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL OPTIONAL T 150 MOUNTING STAND 2 09 Page 18 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501
29. ead up limit switch type normally open standard normally closed none Head up Dbounce Debounce is used to allow time for the tamp cylinder to settle on return 00 00 to 01 00 Vacuum Release Used to release label when tamping on light products Vacuum Delay On Used to reduce label flutter when feeding large labels while tamping Tamp Sync Logic Used to interface external equipment in relationship to the tamp cycle Air Assist DLY Used to delay the air assist from turning off after feeding the label 00 00 to 01 00 e 3 TAKEUP This is used to delay the start and stop of the take up motor PROGRAMMABLE BLOCKS Start delay delays x seconds after start print before starting take up motor Stop delay take up runs x seconds after end print signal is received from printer Jog take up press the ENT key to jog the take up motor Note If acceleration is set too low Quick following errors may occur 3 02 Page 28 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL e 4 COUNTERS Used to reset and set the internal counters of the control PROGRAMMABLE BLOCKS Total counter resets the total counter to zero Batch counter resets the batch counter to zero Batch counter set sets the total number of labels to be applied in 1 batch Life counter displays the total number of controller cycles can not be reset Note that when the batch
30. etermine the number of lines per revolution 2 Determine the gear ratio of the encoder to the conveyor 3 Measure diameter of conveyor drive wheel 4 Multiply diameter of wheel by Pi this will give circumference 5 Divide encoder lines per revolution by circumference this will net lines per inch of wheel 6 Multiply this number by the gear ratio this will net lines per inch 7 Enter this number into menu 6 ENC LINES INCH note that this number needs to be between 25 amp 500 EXAMPLE 1 Encoder lines per revolution 1000 2 Gear ratio is 2 to 1 3 Conveyor drive wheel diameter 6 00 4 6 00x3 14 18 84 5 1000 18 84 53 079 6 53 079 x 2 106 2 rounding number to the 10 7 Enter 106 2 into ENC LINES INCH 3 17 Page 44 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL e TRIGGER DIST TRIGGER DISTANCE TRIGGER DISTANCE is used in conjunction with the encoder feature Trigger distance is similar to product delay in that it is used to electronically move the placement of the label on the product When the encoder feature is used the product delay feature is rendered inactive Trigger distance will move the label placement in inches 00 00 Set basic applicator up first refer to quick setup 2 Ensure that the applicator is operating properly before starting this procedure 3 This feature requires the use of an encoder The
31. f and others Be sure this information is read and understood by all operators ELECTRICAL SHOCK CAN KILL Do not touch live electrical parts with bare skin or work with gloves or wet clothing NOISE CAN DAMAGE HEARING Wear proper ear protection 1 05 Page 7 Madein the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL SECTION 2 SETUP AND OPERATION Web Routing 2 01 Thermal Print Head Label Loading 2 03 Thermal Ribbon Loading 2 03 Label Sensor Adjustment 2 03 Take Up Unit Assembly 2 04 Clutch Assembly Adjustment 2 05 Operator Interface Terminal 2 06 Accessory Connector Panel 2 07 T 50 Photo Eye 2 07 5 Air Assist Tube 2 08 1 150 Mounting Stand option 2 09 T stand adjustment 2 10 Tamp Unit Operation 2 11 Tamp Flow Control Adjustment 2 12 Optional Adjacent Panel Labeler APL 2 13 Optional Corner Wrap 2 14 Page 8 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 Step LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL WEB ROUTING Operation Load web onto label storage spool A so it unloads in a clockwise direction refer to pg 2 2 Feed the web to the left and below roller guide B to the right of roller C and to the left and below roller guide D Feed the web into the thermal printer for a detailed description of thermal printer routing see page 2 3 Finish the process by loading the waste backing paper onto the web take up spo
32. for any malfunctions which results from improper use faulty maintenance damage improper repair or alteration by anyone other than MMI Automated Systems or a service facility designated by MMI Automated Systems SAFETY Only qualified personnel should use this equipment Before installing inspecting or servicing equipment turn OFF all power and air controls at the source and lock out in accordance with OSHA Standards Be sure all external electrically conductive parts are connected to a good electrical ground Never handle live electrical equipment with bare hands while standing in water or while hands and feet are wet Dangerous electrical shock can result Whenever the equipment is unattended turn off all control and power supply switches Keep equipment clean and in good operating condition Promptly repair or replace all worn or damaged hoses cables or parts Do not make any repairs to equipment unless you are fully qualified This equipment contains fast moving parts which may move without warning Keep hands loose hair and clothes clear of machines at all times Never place hands or any other body parts under the label platen at any time This equipment uses compressed air Proper care and maintenance must be taken when handling compressed air and its components These precautions are further detailed and explained where specifically required in this manual N WARNING READ AND UNDERSTAND THESE INSTRUCTIONS Protect yoursel
33. isconnect the AC power cable from the rear of the console Locate the fuse holder power cord assembly Gently press down the fuse holder cover while pulling away from the console Replace with the spare fuse provided in the holder gs ON 4 05 Page 59 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501
34. ity 1 05 Safety 1 05 Page2 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL LABEL MILL 3501 THERMAL PRINTER APPLICATOR SYSTEM INTRODUCTION The Label Mill 3501 is a state of the art THERMAL PRINTER amp APPLICATOR SYSTEM created with maximum flexibility for your AUTOMATIC LABELING NEEDS The unit will print and apply high quality labels and bar codes to your product at print speeds up to 10 sec and apply at speeds up to 80 labels min OPERATION The standard configuration is External Computer Mode The configuration allows label formats to be sent to the standard Centronics Parallel Interface Port or serial port on the Printer Applicator Once the format is downloaded to the Printer Job Buffer the system 3501 can print and apply as normal Standard industry label software packages can be used in conjunction with a PC to design and load label design 1 01 Page 3 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 USERS MANUAL PRINT SPEED BAR CODES BAR CODE RATIOS HUMAN READABLE FONTS LABEL ROLL CAPACITY LABEL SIZE MAXIMUM PRINT AREA LABEL PLACEMENT ACCURACY PRINTING METHOD INTERFACE INTERFACE SENSORS ELECTRICAL AIR REQUIREMENT SIZE ENVIRONMENT WEIGHT Options available Page 4 Made in the U S A LM 3501 PRINT amp APPLY SYSTEM SPECIFICATIONS Up to 10 second and approx 80 labels min Varies depe
35. justment Clockwise Increase pressure Counterclockwise Decrease pressure MAIN AIR REGULATOR Controls maximum air pressure available to entire applicator Should be set between 40 and 80 PSI FLAG REGULATOR The flag regulator is used to adjust the pressure that the flag jaws apply to the label as it is applied VACUUM REGULATOR only used on the flag and tamp applicator system The vacuum regulator is used to control the vacuum that is used to hold the label to the flag jaws or the tamp pad AIR ASSIST REGULATOR The air assist regulator is used to change the pressure that is applied to the blow tube The blow tube is below the front edge of the peeler plate and is used to help push the label onto the bottom of the tamp pad or the flag jaws FLOW CONTROLS tamp and flag applications Control A This is used to adjust the pressure that controls the tamp cylinder in the upward direction Control B Controls the tamp cylinder in the downward direction Page 21 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL 2 12 Page 22 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL OPTIONAL ADJACENT PANEL LABELER APL 2 13 Page 23 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL OPTIONAL CORNER WRAP 2 14 Page
36. nding on label and product size UPC A UPC E EAN 8 EAN 13 Code 39 Int 2 of 5 Code 128 MSI 2 of 5 UPC Bookland and CODABAR 1 2 1 2 5 1 3 or individually programmable bar code widths Eight fonts including OCR A and OCR B representation and an outline font American and European fonts Upper case and lower case with decendors plus memory available for custom fonts 12 Max outside diameter wound on a 3 diameter core Die cut waste removed with a minimum of 1 8 separation between labels in running direction Minimum 1 wide x 34 long Maximum 7 2 wide x 14 long 6 5 wide x 14 long Up to or 1 32 1mm when labels are produced to specifications and product handling is controlled Thermal Transfer and Direct Thermal Print application method Standard Tamp Optional Blow On and Wipe On Standard Centronics Parallel Port Standard RS 232C Serial Port Ribbon out Product Sensor Photo Eye Limit Switch PLC input 115V AC 60 Hz 250 W idle 600 W running 80 p s i 3 cfm 21 W x 28 1 4 L x 23 3 8 D Operating Temp 50 95 F 10 35 C 15 8596 RH non condensing 60 Ib with U Arms 1 02 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL INVENTORY LIST QTY Description Print amp Apply Assembly 12 7 dia Blue Plastic Spools w Quick Release Collar 7 34 dia Blue Plastic Spool w screws 1 2 13 bolts w washers
37. ol E The take up spool rotates in a clockwise direction Adjust the 2 plastic web guide clips so the web is guided straight and even Make sure clips do not bind the web For a detailed illustration of this procedure see Figure 2 1 below FIGURE 2 1 LABEL MILL D Page 9 Made in the U S A 2 01 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL WEB ROUTING SPOOL LOCK LABEL MILL b gt SPOOL LOCK REMOVAL To remove the label storage spool A turn the spool lock counterclockwise until you reach a stop The spool will now slide off To secure the spool simply turn the spool lock clockwise until snug DO NOT over tighten 2 02 Page 10 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL LOADING THERMAL PRINT HEAD REFER TO PRINTER MANUAL LABEL amp RIBBON ROUTING REFER TO PRINTER MANUAL THERMAL RIBBON LOADING REFER TO PRINTER MANUAL NOTE The printer will not operate unless the front cover is in the fully closed position For your continued safety do not override the front cover interlock switch LABEL SENSOR ADJUSTMENT REFER TO PRINTER MANUAL 2 03 Page 11 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 35
38. ory 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL FAULT CODE Printer Cycle Head Up Head Down Ribbon Out Label Out Page 56 Made in the U S A D gt D gt gt OWS gt FAULT CODES FAULT Printer Off Line No Label Formats Loaded Check Printer Interface Cable Tamp Cylinder Is Not Up No Air Faulty Valve Flow Control Miss Adjusted Miss Adjusted Reed Switch Faulty Reed Switch Tamp Cylinder Did Not Move No Air Faulty Valve Flow Control Miss Adjusted Faulty Reed Switch Low Tamp Duration Low Ribbon In Printer Printer Out of Ribbon Labels Out Of Printer Printer Miss Adjusted 4 02 2003 MMI Automated Systems REFER TO Printer Manual Page 2 11 to 2 12 Light on reed switch should be on when cylinder is up Tamp duration is too low Page 2 11 to 2 12 Page 3 02 and 3 08 Printer Manual Printer Manual 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL CLEANING THE PRINT HEAD Refer to section 3 2 of the enclosed SATO Operator s Manual for print head cleaning instructions or the appropriate section in the ZEBRA or DATAMAX Operator s Manual if so equipped CLEANING THE PLATEN DEMAND PLATE AND ROLLERS Refer to section 3 3 of the enclosed SATO Operator s Manual for print head cleaning instructions or the appropriate section in the ZEBRA or DATAMAX Operator s Manual if so equipped REPLACING THE PRINT HEAD
39. r distance is used to MOVE label on product product delay is disabled 0 Enter a Start Comp value START Comp is used to compensate for label drift when speed of conveyor changes To calculate this refer to the section on Start Compensation 11 ENC LINES INCH enter the proper lines per inch to match encoder output to conveyor speed To calculate lines per inch refer to the section on Gearing 00 3 19 2 Page 48 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL DESCRIPTION OF I O LEGEND 24V SEP 24V OPTO INPUT WITH NO INTERNAL COMMON 24V OPT 24V OPTO INPUT WITH INTERNAL 24V COMMON 5V OPT 5V OPTO WITH EXTERNAL COMMON OH HIGH CURRENT OUTPUT Rated 1amp OL LOW CURRENT OUTPUT Rated 100 ma All user inputs and output are SINKING type except for the special isolated ground I O Example in order for a status light to illuminate for Run Status OK the light should be wired between pins 1 amp 8 on the Light Bar Aux Connector Status display legend INPUTS OUTPUTS EX s P F lt uM us QA M PRODUC TAMP AUX OUT AIR ASSIST FLAG VACUUM TAMP SENSOR 1 SOL SOL SOL SOL T SENSOR When using the I O status ports to verify if the inputs and outputs are on or off the ports are numbered as from right to left follows are as shown below In this sample port Y2 0 Y2 1 Y2 3 Y2 5 and Y
40. s on start up and decelerates to a stop At high speeds an uncompensated system would apply a label too late and the label would be placed too far back on the product Linear interpolation is used to correct this problem The start compensation corrects this error by adding an offset distance at LOW speeds since it is not possible to apply any correction at high speed Note Start compensation ONLY effects label placement on product e ELECTRONIC GEARING Electronic gearing is a function of the product encoder and the Label Mill control This is used to match the speed of the applicator to the product conveyor Electronic gearing is similar to mechanical gearing in that there is a gear ratio and the change of speed of one affects the speed of the other This feature is part of the Synchronous feed mode In order for this to operate properly the correct number of lines per inch of product travel must be entered into the ENC LINES INCH in menu 6 e ENCODER AN ENCODER is a device that is used to monitor the speed of an external device like a product conveyor The reason this speed is monitored is to match the speed of the label applicator to the product speed An encoder uses LINES or COUNTS per revolution in order to track speed and distance Note that lines per revolution are also referred to as counts per revolution These counts are feed into the LABEL MILL control to be processed for the different features that require this feed back e ENCODER
41. t or tamps will not print Take up unit does not turn Waste web tension to loose Waste web breaks or printing drifts on labels Page 55 Made in the U S A Possible Cause A Blown Main Fuse No air pressure Plugged hose Faulty valve No air Plugged hose Faulty valve Cable No tamp duration Sticky cylinder mmoom gt ODP Unit off line Incorrect label configuration No label format downloaded Wrong interface selected Interface cable Error on printer nmoomsmp Motor not running Friction plate failure in clutch Mechanical failure in clutch gt op Clutch tension too low Clutch adjusted to tight Machine Webbed wrong Low quality webbing Friction plate failure in clutch Mechanical failure in clutch moom 4 01 2003 MMI Automated Systems Corrective Action Check main power fuse and replace if necessary as shown on page Check printer fuse Check air supply and filter Fix or replace hose Consult factory Check air supply and filter Fix or replace hose Consult factory Check connection Reference to page 2 11 Consult factory Check printer cover limit switch Check software Check software Check mode 3 or dip switches Check connection Check printer manual Consult Factory Consult Factory Consult Factory Adjust clutch as shown on page 2 10 Adjust clutch as shown on page 2 10 Re web system as shown on page2 2 Consult label mfg Consult factory Consult fact
42. tems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL P7 P8 COMM 1 DB9 PIN COMM 2 PIN DB9 NO CONNECTION IN oO i RS232 XMIT 5232 XMIT 5232 RCV 5232 RCV PRCV o da RCV Je O RV 5 nv J5 XMT e 6 XMT e 8 PSHIELD 9 SHIELD jo SERVO CONNECTION IS NOT USED ON THE LM3501 ENCODER DB9 PIN GND 1 0e y f Drive Enable 1 8 O Doo SO CONVEYOR Pit O k 4 GND je Pd 3 24 Page 53 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL SECTION 4 CLEANING amp MAINTENANCE Troubleshooting 4 01 Fault Codes 4 02 Cleaning of the Print Head 4 03 Cleaning the Platen Demand Plate and 4 03 Rollers Replacing the Print Head Power Fuse 4 03 Maintaining the Air Slide 4 04 Replacing the Power Fuse 4 05 Page 54 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USER S MANUAL TROUBLESHOOTING GUIDE If the system malfunctions it is necessary to determine where the problem exists in a normal sequence of operation The procedure of the unit is outlined in the left hand column of the table below to provide a systematic approach to troubleshooting Problem Unit will not turn on Air system will not operate Tamp will not operate Unit will not prin
43. too great or top speed is out of range of applicator There is also the normal placement tolerance that will effect the accuracy of the system 3 16 Page 43 Made in the U S A 2003 MMI Automated Systems 12 23 03 Model LM 3501 LM 3501 PRINT amp APPLY SYSTEM USERS MANUAL CALCULATING ENCODER LINES PER INCH gearing There are two basic concepts utilized to interface the product ENCODER to the Label Mill control One method utilizes a wheel mounted directly to an encoder This wheel rests on the belt surface and rotates when the belt moves The second method is to mechanically slave the encoder to the conveyor utilizing belts or a chain etc Note that lines per revolution are also referred to as counts per revolution The following is only a small sample of the many ways there is to couple an encoder to a product conveyor WHEEL MOUNTED 1 Check encoder to determine the number of lines per revolution 2 Measure diameter of contact wheel 3 Multiply diameter of wheel by Pi this will give circumference 4 Divide encoder lines per revolution by circumference this will net lines per inch 5 Enter this number into menu 6 ENC LINES INCH note that this number needs to be between 25 amp 500 EXAMPLE 1 Encoder lines per revolution 1000 2 Contact wheel diameter 6 00 3 6 00x3 14 18 84 4 1000 18 84 53 1 rounding number to the 10 5 Enter 53 1 into ENC LINES INCH DIRECT DRIVE 1 Check encoder to d

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