Monitron User Manual
Contents
1. IN6 Fault In Bussed Fault In External Disable Outputs If the 1000M bit in Option is off this input disables the labelling when on and displays the External Fault message If the 1000M bit in Option2 is set this input becomes the External Disable input In this mode the Labelling Disabled by External Input message is displayed and it automatically resets when the input is tuned off See J6 for input polarity selection TB1 8 on a Monitor adapter board T1 6 on a Unitron adapter board All outputs signals that are available on a Servotron are present however only some are wired to the connectors on the rear This is to maintain compatibility with the original Monitor The signals not brought out to the rear panel are available on the adapter board They are selectable for NPN or PNP however they must all be one or the other Selection is made by changing IC9 For NPN use ULN2803A for PNP use UDN2981A Jumpers J9 and J10 must be set to suit In a Monitron the IC is PNP but the main outputs have slave transistors on the adapter board that provide a NPN output STEP Step Signal This output is used to drive the pulse input of the stepper drive Internally connected to the drive in a Monitron OUTI1 Coder Printer This output is the start trigger for a date coder etc Option Menu selects whether the coder is of the type that prints while the web is stationary e g hot stamp or moving e g ink jet2. Near the bottom corner of the InStep II PCB there is a small adjustment potentiometer to adjust the liquid crystal displays contrast The display contrast is directly affected by the ambient temperature and as such may require adjustment in extreme temperature environments Monitron Version Update Summary As the firmware installed in the current model stepper drive Monitrons is the same as the Servotron please refer to the Servotron User Manual Integrated Drive Stepper Motor Notes When this type of motor is used there is a small adapter board fitted in place of the stepper drive in the Monitron control box This is wired across to a small board fitted onto the pin headers on the Monitron adapter board on the floor of the box On the adapter board there are two jumpers to set the direction of the motor They must BOTH either be set to the right or BOTH set to the left to select the appropriate motor direction The old motor cable is usually reused and wired into the new motor The following table shows the new usage and the entire connection from the old drive connector through to the new connections inside the new motor The switch settings inside the motor are shown here also Page 16 of 18 Monitron User Manual doc Industronics Monitron Integrated Drive Stepper Motor Cable This chart is used when wiring an integrated drive stepper motor to a Monitron controller D550 Socket Rear Panel Socket Cable Wire Colour Cable Wire Number New BL Motor Si
3. Terminal 6 on a Monitron OUT2 Servo Enable Stepper Boost This output is connected internally to the stepper drive to control the boost function on the D550 OUT3 Feedscrew Enable Monitron OK Output As of V3 08 this output is provided to enable the feedscrew It is on whenever there are no faults and no level pauses from the high outfeed and low infeed sensors As of version 3 14 this output becomes an OK output whenever the level control are not enabled in the Analogue setup It is on whenever there are no faults present TB1 9 on a Monitor adapter boards T2 1 on a Unitron adapter board OUT4 Jig Solenoid Knife Up Solenoid This output controls the solenoid that closes the orient jig Implemented in V3 02 As of version 3 18 this output can be used for a cutter knife up solenoid if Knife Mode is selected in the Option2 menu A Monitor did not support jig mode so this output is connected to the Flap Adapter Output CON4 on the Monitor Adapter Board It was very rarely used and is not supported in this version of firmware T2 2 on a Unitron adapter board Page 11 of 18 Monitron User Manual doc Industronics OUTS Air Blast Knife Down Solenoid When an air blast time is entered in the menu or with the K command this output is turned on at the end of the product delay and before the servo starts to move As of version 3 18 this output can be used for a cutter knife down solenoid if Knife Mode is selected in the Option2 menu
4. In orient jig mode the cycle is initiated by a sensor connected to the Jig In input This initiates the spin up delay When this is complete the sensor connected to the Colour Sensor input is enabled When the colour sensor sees a leading edge the normal dispense sequence is started A value of 0 turns both jig modes off Pressing the down arrow displays the following screen 5 Knife Down Time 0 The menu displayed here depends on whether Knife mode is selected in the Option2 menu If Knife mode is not set then the Air Blast Time is displayed this sets the air blast time in milliseconds The air blast is for machines with an air box attachment The air blast time occurs after the product delay and before the label starts to move If Knife mode is selected then the Knife Down Time is displayed this sets the knife down time in milliseconds As soon as the dispense stops the air blast output is turned on for the set time to bring the knife down Pressing the down arrow displays the following screen Air Blast Time Q Library Functions Pressing the down arrow displays the Level Three Menus selection screen further below Pressing Enter takes you into the Library sub menu and displays the following screen Save to Library No 0 This is the first menu in the library sub menu Pressing Enter allows you to select the library number to save to with the arrow keys After selecting pressing Enter saves all of the data from the cu
5. Terminal 11 on a Monitron OUT6 Air Assist This output is turned on at the start of the servo moving and off at the beginning of deceleration Terminal 9 on a Monitron OUT7 Bussed Fault Out This output is turned on when there is a labeller fault printer fault servo fault end of reel or Fault In is on It only goes off when the fault has been reset or labelling is re enabled TB1 10 on a Monitor adapter board T2 3 on a Unitron adapter board Rear Panel Connectors Tuchel 16 way Rear Panel Connector Pin Number Hea ti Product Scanner _ ee lt P 3 Ground 4 NoConnection 6__ 5 5 volts for old gap scanner not supported PS Gow O 5 S O PG Printer O OT S O 8 No Connection 24 Volts in an ex Unitron Po Air Assist O J o o o O 10 24 Volts for above 8 Special unregulated voltage in an ex Monitor u o fAirBat n ee O 13 NoConnection 14 NoConmection O 15 NoConnection Page 12 of 18 Monitron User Manual doc Industronics Stepper Motor Rear Panel Connector for original 5 phase motor Pin Number Drive Pin a WE _ 20e Winding Start O i O PS we Wining Sia O D Wa _ 26c Winding 3 Finish E TWA 28c Winding5Finish F WE 20a WindingiSat o O G WE 2 Winding 3 Start H8 WE _ 24a Winding Start o O po wa 26a Winding2Finish O LO J WA 28a Winding 4 Finish Monitor Adapter Board Connectors Monitor Adapter Board Termina
6. Therefore the timing is always controlled by the Product Sensor Input When using Jig Control Mode you must select either Jig Only or Orient Jig Mode as well If not the sequence will stall after the Jig Solenoid is turned on The sense of the Jig In Sensor Input has been changed so that off jig in This was done to allow the use of a more standard N O proximity sensor in the orient jig mechanism Because the Product Gate and Jig In share the same input it is not practical to have both enabled at the same time However this is not normally a limitation as gating is usually only used on a rotary type machine where an orientation jig cannot be fitted The Spin Up Delay is used to ensure the product is spinning smoothly in the jig before the Colour Sensor Prod 2 is enabled This prevents false triggers from the Colour Sensor Sending anything over serial port or pressing any button while waiting for the colour sensor input to be activated will cause the sequence to reset without dispensing As of version S3 17C re activation of product scanner while the previous product is still in the jig will cause an Orientation Error 7 In Fixed pull mode steps 15 and 16 are bypassed and the advance is loaded with the fixed pull length minus the acceleration length It is not intended that it be used in conjunction with the jig modes or two label mode Page 18 of 18
7. and J13 1 to 2 for NPN output encoders Jumper J13 2 to 3 and J12 1 to J13 1 for PNP output encoders J14 to J24 These jumpers set the master encoder divisor J14 is divide by J18 installed one J15 is divide by 2 through to J24 which is divide by 1024 Only one jumper in this set to be installed J25 O Selects the function on pin 28 on P1 Refer to option manual 2 to 3 jumpered J25 J26 Selects whether to bypass the encoders optocoupler to 2 is to 1 to 2 jumpered use optocoupler 2 to 3 is to bypass the optocoupler A B Monitor Adapter Board Jumpers Description Default Jump A to provide NPN output on CON2 pin 16 for stepper boost A jumpered signal Jump B to provide PNP 14 volt output on CON2 pin 16 for TFM enable 14 volts must be brought in on CON2 pin 8 Only one jumper to be installed CON3 IN4 Provided to copy original PCB Not sure what it was used for Possibly gap edge select not supported in software Is actually the printer OK input in the current firmware N A CON4 OUT4 Flap Adapter Output Has BD681 NPN driver Flap N A adapter not supported is actually Jig Solenoid in current firmware A CON5 OUTS Air Assist Output Often used to drive label counter Stepper Drive DIP Switch CBergerLahrss0 Laysom L550 3 Direction Off Counter Clockwise NotUsed 4 Step Angle Off Half Step 1000 step NotUsed Rotary switch on D550 set to F for maximum current LCD Contrast
8. first one is displayed If subsequent faults are still present when earlier ones are reset they will then be displayed If the fault is rectified the screen can be cleared and the labeller re enabled by presssing Enter If you would like to review your settings without resetting the first press of either arrow key will bring back the menu that was present before the fault occurred You can then move around the menus as usual Afterwards you can re enable the labelling by using the Labelling Enable menu in Level 1 Labeller Error Press Enter to Reset This screen indicates that the servomotor has moved further than that set by the missing label length It is usually caused by a wrongly setup gap sensor or slipping drive rollers It can always be reset immediately Refer to the Missing Label Length menu in level two for adjustment Consec Miss Regist Prec a AINE Sie vO dS This screen indicates that the labeller has had to simulate the gap sensor more than three times in a row It is usually caused by a wrongly setup gap sensor or slipping drive rollers It can always be reset immediately Refer to the Missing Label Length menu in level two for adjustment iPAPabianueNemdiieetonen Press Enter to Reset Whenever the printer is enabled and the 1000M bit in Option2 menu is off the printer fault signal is also enabled The sense of the input is controlled by a bit in option port 2 or by the D co
9. mode you must move the cursor back to the arrow at the right of the value and press Enter Pressing the down arrow displays the following screen Page 6 of 18 Monitron User Manual doc Industronics Master Speed 0 The speed of the master encoder is displayed here It is used to check the operation of the master encoder If the master encoder rate is too fast fast will be shown Extremely slow encoder rates cause Slow to be displayed If a dispense has been attempted when the master encoder is stopped it will display Stopped The display is not live you need to press Enter to update display Pressing the down arrow displays the following screen Options GSGEC421 00000000 The option status is displayed here A value of 1 indicates the option is on 0 is off The letters above the value indicate what the input is used for G Gate Signal Required S Servo Mode Not Stepper On for speed compensation and servo enable Off for stepper drives G SIG drive compensation Must select servo mode above as well E Enable at Power On C Moving Type Coder e g inkjet 0 Stationary Type e g stamping hot foil 421 Serial Address Select Set bits to total to desired address all off 8 Pressing Enter takes you into bit edit mode Refer to the output menu for details on bit edit mode Pressing the down arrow displays the following screen Option2 EMCKBSPF 00000000 The second option stat
10. Mode Only Man Dispense starts here AB Time gt 0 10 Air Blast Time Air Blast Mode Only Air Blast Time gt 0 11 Air Blast Output Off Air Blast Mode Only Air Blast Time gt 0 12 Air Assist Output On All modes 13 Acceleration All modes Except 2 label of two label set as of V3 07 14 Printer Output Off On Only if Printer enabled D gt 1 Off On selected on option port 15 Run in Sync or Set Speed All modes 16 Gap Sensor Input On All modes 17 Label Advance All modes Gets setting from t command on 1 label of 2 label 18 Air Assist Output Off All modes 19 Two Label Spacing Delay Two Label Mode Only Two Label Spacing gt 0 20 Back to step 9 on first pass Two Label Mode Only Two Label Spacing gt 0 21 Deceleration All modes Prior to V1 18C was done on 1 label of 2 label set 22 Knife Down On Up Off Knife Mode Only Option bit 4 on and Knife Down Time gt 0 23 Knife Down Time Knife Mode Only Option bit 4 on and Knife Down Time gt 0 24 Knife Up On Down Off Knife Mode Only Option bit 4 on and Knife Down Time gt 0 25 Jig Hold Delay Jig Control Mode Only Jig Delay gt 0 26 Jig Solenoid Output Off Jig Control Mode Only Jig Delay gt 0 27 Printer Output On Off Only if Printer enabled D gt 1 Off On selected on option port 28 Product Input Enabled Only if labelling still enabled E 1 If selected the Gate Input must be on at the instant of the product sensor coming on or the sequence will restart
11. de Pressing the down arrow displays the following screen HNodke Olwhe S ACHKONP VICE Options 00000000 The analogue output option status is displayed here The settings are only relevant if the Analogue Output Option Board has been fitted A value of 1 indicates the option is on 0 is off The letters above the value indicate what the input is used for G Guarding closed input monitored Not implemented I Infeed Low Sensor monitored Not implemented O Outfeed High Sensor monitored Spare V Vacuum Belt Speed Adjustment enabled C Conveyor Speed Adjustment enabled F Feedscrew Speed Adjustment enabled When the speed adjustments are disabled they are shutdown and the menu screens removed Refer to the Analogue Output Option Board manual for further details Pressing Enter takes you into bit edit mode Refer to the output menu for details on bit edit mode Page 7 of 18 Monitron User Manual doc Industronics Pressing the down arrow displays the following screen Level Two Menus Pressing Enter takes you to level two menus and displays the Manual Dispense menu Pressing the down arrow displays the following screen Level One Menus Pressing Enter takes you to level one menus and displays the Label Counter menu Pressing the down arrow rolls around and displays the Acceleration menu Fault Screens The following screens appear when the fault occurs If multiple faults occur only the
12. ed into the motor The firmware does not differ for this conversion but be sure to use the correct tables at the end of this manual as significant hardware differences exist Menu Structure If your Monitron has firmware later than S3 22C then use the Servotron Manual for the menu structure For all other details use this manual INStepsZaVereS s726 By Industronics This is the opening screen If Enter is pressed and held during this screen the controller will display the initialisation menu Refer to the end of this section for details If Enter is not pressed the following menu is displayed after a ten second delay Level One Menus Label Counter The Label Counter is displayed here This shows the total number of labels dispensed since the last count reset Pressing Enter will reset the label count As at Version 3 18 if the counter memory option is installed and enabled in Option2 menu the count will be retained through a power down otherwise it is lost Pressing the down arrow displays the following screen Label Position The Label Position setting is displayed here This sets the delay in steps between the product sensor activation and the start of dispense effectively changing the position of the label on the product Press Enter to enter Edit Mode a flashing arrow is displayed to the right of the value when in edit mode Whilst in edit mode the arrow keys can be used to adjust the value When the correct value is displayed
13. f it is on usually caused by large products in the jig then this failure checking is disabled as there is no way to check for subsequent products coming Whether this checking is disabled or not you can always release a jig stuck in due to failure of the colour sensor to detect the mark by pushing any button Safety Circuit Open Press Enter to Reset This screen appears when the 1000M bit in Option is set and the Print OK input is on In this setup a N C contact on a safety contactor is connected to what is usually the Print OK input You must reset the safety circuit before you can re enable Labelling Disabled By External Input When the 1000M bit is set the Fault In input becomes the External Disable Input This message is displayed when the input is on and automatically returns to the previous menu when turned off In this mode this input can also be used to reset other faults Other fault screens may appear depending on the option card fitted and which functions are enabled Initialisation Menu This menu can only be entered during power up It will automatically appear if the controller detects invalid data in the current data memory or it can be forced to appear if Enter is pressed and held during the initial screen that displays the version number information It will appear as either of the two following screens T Enter Pressed EPROM Data Invalid Use to make choice Use to make c
14. ge The pulses per rev of the encoder and its gearing to the conveyor belt should be selected so that the rate is the same as the step rate of the motor It is best to be on the low side of one to one if this cannot be achieved The encoder should have an open collector 5 or 24VDC output The Monitor had no support for a master encoder but the input is available on TB1 11 It is terminal 16 on an ex Unitron IN1 Colour Sensor Product Sensor 2 This input only functions in Orientation Mode It triggers the labelling cycle just as the normal product scanner does but only after the orient part of the cycle is complete See jumper J1 for input polarity selection TB1 4 on a Monitor adapter board T1 1 on a Unitron adapter board IN2 Jig In Sensor Product Gate This input is usually a proximity detector mounted on the orientation jig to indicate when the jig is closed It initiates the spin up delay in orient jig mode If the Gate Input is selected on the option port this input becomes the product sensor gate input In this mode this input must be on before a product detection will start the dispense cycle See jumper J2 for input polarity selection TB1 5 on a Monitor adapter board T1 2 on a Unitron adapter board IN3 End of Reel This input is usually connected to a sensor that detects a low level of labels on the unwind reel Refer to the description of End of Reel Count menu See jumper J3 for input polarity selection TB1 6 on a Mon
15. gnal C 4 Z 20c 22c 24c 26c 28c 20a 22a 24a 26a 28a OVDC La O o T bl id o Q uja jA jo iS Z Q w amp Z A S1 selects motor for 1000 pulses per revolution The layout of the four switches in the table above represents the physical layout in the motor itself For CN1 Ov is the top of the T and VDC is the leg of the T For CN4 pin 1 is in the top left then 1 2 3 across the 4 is next to 1 This makes 5 near the key For CN2 pin 1 is on the top right then count down Start again at the top for pin 7 This makes 9 and 10 near the key Page 17 of 18 Monitron User Manual doc industronics InStep Labelling Modes and Sequence Chart Step No Step Comments 1 Product Input On All modes except Jig Only Orient and Man Dispense 2 Product Gate Input On Only if selected on option port InStep I J31 or InStep II bit 7 3 Jig Delay Jig Control Mode Only Jig Delay gt 0 4 Jig Solenoid Output On Jig Control Mode Only Jig Delay gt 0 5 Jig In Input Off Jig In Jig modes only Jig Only Orient Mode starts here S U D gt 0 6 Spin Up Delay Orient jig mode only Spin Up Delay gt 1 7 Colour Sensor Prod 2 Input Orient jig mode only Spin Up Delay gt 1 8 Label Position Delay All modes except manual release 9 Air Blast Output On Air Blast
16. hoice Q c Enter Pressed Erase Libraries ia et eg oO Hae i A Q jas n gel 5 oO n n a ek eg oO S 2 5 ga n QO p Oo oO 5 z w H ge oO R This is the first choice in the initialisation menus Pressing Enter causes all of the Library data to be erased then the first initialisation menu is shown again Pressing the up arrow causes the next menu to be Enter Pressed Reinitialise Qa iy ZA ue A fes e io a fes n sj E This is the second choice in the initialisation menus Pressing enter drops into the type selection sub z 5 4 gt 4 3 5 n D n g j n Select Type Use to make choice If the up arrow is pressed the following screen will appear Select Type Sservotron Pressing Enter causes all of the current data to be reset to default values and then display the first menu in level one Because of this if you want to erase libraries and reinitialise you must erase libraries first Pressing the up arrow will cycle through the following selections Servotron 2001 Model 500 Monitron etc Do Nothing and back to Servotron Pressing the up arrow causes the next menu to be displayed as follows Enter Pressed Do Nothing Page 9 of 18 Monitron User Manual doc Industronics This is the third choice in the initialisation menus Pressing Enter simpl
17. iIndustronics Design Application and Service of Electronics in Industry Monitron User Manual For Version S 3 26E 12 September 2010 27 Wanganui Road Kirrawee NSW Australia 2232 Phone 02 9545 6181 Fax 61 29545 6181 Mobile 0419 267 889 Email info industronics biz WWW hitp Awww industronics biz A division of D H Enterprises Pty Limited A B N 72 087 000 995 Monitron User Manual doc Industronics Overview The Monitron is an upgrade for either an Impresstik Monitor on Unitron Control Box The entire front panel and control board is replaced providing a more reliable and fully featured controller If an older type incandescent label gap sensor was used this must be upgraded to a 24 volt fork type sensor Apart from this it is simply a matter of plugging the upgraded box into the old position and learning the new controls All of the adjustments are made with three pushbuttons on the front panel There is a two line by twenty character LCD display for viewing the settings Settings can also be adjusted via a serial port if this option is installed The firmware used is exactly the same as in the current Servotron controller On a re initialise simply select Monitron The menu structure below is lifted directly from the Servotron User Manual Other sections have changes to suit the different hardware Starting from August 2010 Monitrons may be converted to suit the newer Bergher Lahr Stepper motor that has the drive electronics integrat
18. ion Board fitted Ne Unitron Adapter Board Terminal Strip T2 PUTA i ig Solenoid Output PUT Busse Fault Output o i O Depends on Option Board fitted Depends on Option Board fitted es Note T1 and T2 are to duplicate the terminal strips on the Layson External I O Board Although T1 is inputs and T2 is outputs the features they supported are not necessarily supported by the Monitron Configuration InStep II PCB Jumper Descriptions Default J1 to J8 These three point jumpers select the polarity of the signal required J1 to J7 2 to 3 to operate the inputs jumpered Jump 1 to 2 for sinking NPN type input devices J8 1 to 2 jumpered Jump 2 to 3 for sourcing PNP type input devices J1 to J6 correspond to input 1 to 6 respectively J7 is for the product sensor input J8 is for the label sensor input J9 and J10 These jumpers are set to match the type of output driver IC 2 to 3 jumpered installed in position IC9 Jump both 1 to 2 for NPN type IC ULN2803A Jump both 2 to 3 for PNP type IC UDN2981A Note jumpers must be set correctly or damage will result Install Jumper 11 when 5 volt encoder is used J12 13 must be in Page 15 of 18 Monitron User Manual doc Industronics ip __ PNP configuration when this jumper is installed as J12 and J13 These jumpers are set to match the polarity of the output of the J12 1 to 2 jumpered master encoder connected to terminal 11 J13 1 to 2 jumpered Jumper J12
19. itor adapter board T1 3 on a Unitron adapter board IN4 Printer OK Safety Circuit Monitor If the 1000M bit in Option is off this input is connected to the printer OK fault output of the printer controlled by the Monitron When the printer is enabled by the printer menu or the D command with an odd value this input must be on otherwise labelling is disabled and the Printer Error is displayed If an even value is used in D the Page 10 of 18 Monitron User Manual doc Industronics input must be off for printer OK The P bit in Option Port 2 also controls the polarity As of V3 19A the printer fault input is only checked just after the label dispense is completed This allows it to possibly serve as an actual print confirmation input from a contrast scanner for instance or just a simple printer fault signal monitor If the 1000M bit in Option is set this input becomes the Safety Circuit Monitor In his mode if the input is on labelling is disabled and the Safety Circuit Open fault is displayed See jumper J4 for input polarity selection Pin 2 of CON3 on a Monitor adapter board T1 4 on a Unitron adapter board IN5 Drive OK This input is normally connected to the drive fitted inside the Monitron It disables labelling and shows a fault screen when it is off However it is not wired in a Monitor or Unitron but is still available on TB 1 7 of the Monitor adapter board or T1 5 on a Unitron adapter board
20. l Strip CON1 INC 3 ov Po vots from Power Supply Sd po OV volts from Power Supply PSV volts from Power Supply Used for SV Pp Vf A volts from Power Supply NC po Vf 24 volts from Power Supply Pp Ext 24V 9 and 10 should be bridged on rearof PCB a _ Monitor Adapter Board Terminal Strip CON2 a G O 24V Ext24V G Ext24V0 i G POV OE gene G GapSense Label Gap Sensor Input Po TMH I4V Only used in DC Monitrons _ _ _ PD StepOut_ Step Output to Stepper Drive eS SS eel a alata o O Page 13 of 18 Monitron User Manual doc Industronics Monitor Adapter Board Terminal Strip TB1 Pp INS Fixed Pull po ING sable i O Pp OUTS Missing abel o Fig O a Sa a Note This terminal strip not normally fitted Unitron Adapter Board Connectors Unitron Adapter Board Terminal Strip TB1 a i I ies E E Unitron Adapter Board Terminal Strip TB2 Boost Output to Stepper Drive Page 14 of 18 Monitron User Manual doc Industronics Unitron Adapter Board Terminal Strip TB3 Pp OV volts from Power Supply PSV Sots from Power Supply po Gnd SV Ground from Power Supply PS SV 15 volts from Power Supply POV volts from Power Supply pSV 15 volts from Power Supply Unitron Adapter Board Terminal Strip T1 PND Vig In Sensor Input Product Gate Pp s UO EndofReel Sensor Input Po a Ne Printer OK Input PINS rive OK Input PING alt Imps S O Pp 8 Spare Depends on Opt
21. missing label function worked like this If a label dispense takes more than the number of steps set here the labeller will disable show Labeller error and turn on the Bussed Fault Output A value of 0 allows infinite length 1 256 2 512 3 1024 4 2048 5 4096 6 8192 7 16384 and 8 32768 steps From version 3 20 on it can work in either of two ways If the value entered here is less than 64 the missing label function works as above except that the number of steps is set differently The number of steps at which the labeller will stop is 256 times the value set here So a value of 16 gives the same as the old default value of 5 256 x 16 4096 This gives a much more precise way to set the trip point If the value is greater than 63 the no gap skip style of missing label is implemented This allows the labeller to skip past missing labels or blocked label gaps as if they never happened It works by simulating the label gaps presence at the number of counts specified here So the number entered here should be the label length minus the label advance setting You can enter this manually or by pressing Enter after the length is displayed in the previous menu If the actual gap occurs after the gap is simulated the actual gap position will override the simulated one to maintain correct registration If you change the advance after setting this value you should redo this setting to cater for the new advance value If the ga
22. mmand If no printer fault signal is available it should be set to off OK default The fault signal must be removed before it can be reset External Fault Press Enter to Reset This screen appears when the Fault In input is activated the 1000M bit in Option2 menu must be off This input is usually tied together with all of the other Fault In Fault Outs on the machine so that a fault on one label head will disable all heads Servodrive Error Press Enter to Reset This screen appears when the connected servo drive has indicated a fault You usually must power down the servodrive to reset the fault If the fault occurs often it will be necessary to open the enclosure to check the fault code indicated on the front of the servodrive Refer to the servodrive manual for the fault codes meaning and its remedy It is usually caused by a web jam up End of Label Reel Press Enter to Reset This screen appears when the End of Reel has been detected It can be reset straight away Refer to Option2 menu and End of Reel Count menu for correct type setup and count setting Page 8 of 18 Monitron User Manual doc Industronics Orientation Error Press Enter to Reset As of version 3 17C and when in Jig Control and Orient Mode the product sensor is monitored while the jig is closed and should it be activated again the jig opens and this fault is displayed At the time of jig closure the product sensor input is checked I
23. nu to select the type of printer fitted and the Option2 Menu to select the type of printer fault signal Pressing the down arrow displays the following screen End of Reel Count 3 3 How the end of reel count functions is determined by a bit in the Option2 menu With this bit on the setting here is the number of labels that can be dispensed in between operations of the end of reel sensor The sensor detects the movement of the label reel In this mode the number set here is usually quite low With the bit off it sets the number of labels that can be dispensed while the end of reel sensor is on The sensor detects that the label reel is low in diameter The setting is usually larger in order to allow the reel to become very close to finished before the head stops In both modes the setting depends on the label length The number on the left is the actual count It is a live value and is provided to assist in establishing the correct setpoint Pressing the down arrow displays the following screen Length Measure Whilst this menu is displayed the actual dispensed label length in steps is displayed at the completion of every cycle Pressing Enter when there is a length displayed will calculate the missing label length and load it into the next menu Pressing the down arrow displays the following screen Page 3 of 18 Monitron User Manual doc Industronics Missing Label Length From version 3 06 to 3 19A the
24. own here otherwise the Sync Ratio setting is displayed here This sets the sync ratio between the master encoder and the output pulse rate 0 is 50 239 is 800 A value of 255 causes the master encoder to be ignored and the set speed value to take effect Always use 255 in a converted Monitor as no encoder connection is present Pressing the down arrow displays the following screen e 5 B gq 5 Dn fo D 5 D aa a Labelling is Enabled Pressing Enter cycles between Enabled and Disabled This menu is provided to allow for re enabling after an ignored fault of to disable so that the product sensor is ignored or the drive roller can be turned by hand Other menus may appear here This depends on the option card that has been fitted and which options have been enabled Refer to the appropriate option manual for further details Otherwise pressing the Level Two Menus a j Q o Dn gel D lt Dn ct oO S x oa n QO id fo oO 5 Pressing the down arrow rolls around to the Label Counter menu Pressing Enter takes you to level two menus and displays the following screen Level Two Menus Manual Dispense Press tNCer FOr obart Pressing Enter starts a labelling cycle Pressing the down arrow displays the following screen PEINE Disabled The Printer menu is shown here Pressing Enter cycles between Disabled and Enabled Use the Option Me
25. p skip is done four times consecutively the labeller will disable show Consec Miss Regist and turn on the Bussed Fault Output Pressing the down arrow displays the following screen Set Speed If the sync ratio has been set to 255 to ignore the master encoder the Sync Ratio menu will be shown here otherwise the Set Speed setting is displayed here This is the dispense speed when no master encoder is used i e Sync Ratio set to 255 Values less than 5000 give a very slow dispense speed while values approaching 9999 give a very fast speed Pressing the down arrow displays the following screen Note the following six menus may not appear here but in the top level menu if they are enabled Two Label Spacing The Two Label Spacing setting is displayed here This setting sets the number of steps to pause between the first and second label of a set A value of 0 turns this function off Pressing the down arrow displays the following screen 2 Label 1st Advance i The advance setting for the first label of a two label set is displayed here When two label spacing is turned on in the previous menu this setting controls the stopping position after the first label is dispensed The normal advance setting is used for the second label Pressing the down arrow displays the following screen Jig Delay The Jig Delay setting is displayed here This setting sets the number of steps between product sensor activation and the activation of
26. press Enter to leave Edit Mode Whilst not in edit mode pressing the arrow keys moves to another menu item Pressing the down arrow displays the following screen Label Advance Or Fixed Move Length 100 100 This is the second menu in level one The Label Advance or the Fixed Move length setting is displayed here Which is displayed is determined by bit 0 in the Option 2 menu in level three The label advance menu sets the number of steps to move after the gap sensor has activated If the deceleration is adjusted this value must be entered again to subtract the deceleration steps from the entered advance value The fixed move length menu sets the total length of the fixed move when that mode is selected Both of these menus use the same memory location for value storage so changing one changes the other Other menus may appear here These can be Two Label Spacing together with 2 Label 1 Advance and or Jig Delay together with Jig Hold Delay and or Spin Up Delay and or Air Blast Time in this order They appear here in the top level menu when they are enabled and down in the second level if disabled This allows the menus to self customise to the application and prevents clutter of the top level menu Refer to the appropriate menus in the second level for further details Page 2 of 18 industronics Sync Ratio 128 If the sync ratio has been set to 255 to ignore the master encoder the Set Speed menu will be sh
27. rrent data memory and displays the Library Functions menu There is no library number zero it is provided to allow a way to escape without saving Pressing the down arrow displays the following screen Read from Lib No 0 This is the second menu in the library sub menu Pressing Enter allows you to select the library number to read from After selecting pressing Enter reads the library and saves it to the current data memory If after pressing Enter the Library Functions menu is not displayed the data in the selected menu was invalid Select another library number or select 0 to escape from this menu Pressing the down arrow displays the Library Functions menu Level Thr Menus Pressing Enter takes you to level three menus and displays the Acceleration menu Pressing the down arrow displays the following screen Page 5 of 18 Monitron User Manual doc Industronics Level One Menus Pressing Enter takes you to level one menus and displays the Label Counter menu Pressing the down arrow displays the Printer menu Level Three Menus Acceleration The Acceleration setting is displayed here This menu selects one of six acceleration ramp profiles A value of 5 is the softest 3 is normal Pressing the down arrow displays the following screen Deceleration 10 This is the second menu in level three The Deceleration setting is displayed here This menu adjusts the number of steps to decelera
28. te for This setting is read only at present Pressing the down arrow displays the following screen TEUR RCO PEJE 00000000 This is the third menu in level three The input status is displayed here A value of 1 indicates the input is on 0 is off The letters above the value indicate what the input is used for P Product Sensor G Gap Sensor D Disable Input Fault In S Servo OK P Printer OK E End of Reel Input J Jig In Product Gate Input C Colour Sensor The display is not live pressing Enter updates the display Pressing the down arrow displays the following screen Outputs XFABJSEC 00000000 The output status is displayed here A value of 1 indicates the output is on 0 is off The letters above the value indicate what the output is used for X Spare F Fault Output A Air Assist Output B Air Blast Output J Jig Solenoid Output S Feedscrew Enable Output E Servo Enable Stepper Boost Output C Coder Printer Output The display is not live pressing Enter updates the display As of version 3 21 set reset of outputs for testing is allowed This uses the new bit editing method introduced in this version With this new version pressing Enter takes you into edit mode as usual however the arrow keys move the cursor up and down through the different bit positions When the Enter key is pressed it alternatively set resets the highlighted bit To exit edit
29. the jig solenoid A value greater than zero enables Jig Control Mode If you select this mode you must select a mode in the Spin Up Delay as well If Knife mode is selected in the Option2 menu this value cannot be changed from off Pressing the down arrow displays the following screen Page 4 of 18 Monitron User Manual doc Industronics Jig Hold Delay i The Jig Hold Delay setting is displayed here This setting sets the number of steps between the completion of the dispense and the deactivation of the jig solenoid It is up to the operator to ensure correct product spacing You must ensure the product is released before the following product is detected by the product sensor or that product will be ignored This setting is only used when in Jig Control Mode which is enabled by the menu above so you can leave the value in here when it is disabled Pressing the down arrow displays the following screen Spin Up Delay The Spin Up Delay setting is displayed here This setting can enable one of two modes In both modes the sequence is started by the Jig In input A value of puts the InStep into Jig Only Mode In this mode the Jig In sensor simply triggers the normal cycle instead of the product sensor When a larger value is entered the Orient Jig Mode is turned on This command sets the number of steps to pause before the registration scanner is enabled This is to ensure the product is spinning in the jig at the correct speed
30. us menu is displayed here A value of indicates the option is on 0 is off The letters above the value indicate what the input is used for E End of Reel Mode When on selects reel turning detection type and when off selects reel diameter low or no web type detection Set to 0 if no end of reel sensor is fitted Refer to EOR menu M 1000M Mode When on changes the functions of the Printer OK and Fault In inputs Print OK changes to Safety Circuit Activated and Fault In changes to External Enable C Counter Memory If the counter memory option is installed it should be enabled here Enabling this function prevents serial communications from working Was labelled M in V3 18 K Knife Mode Changes the air blast function into a label cutter function Normally used in a Reeltek Protag application machine B Stepper Boost When on changes the servo enable output function to a stepper drive boost S Servo OK input polarity When on here the Servo OK input is off OK Can be used when no servo ok signal is available i e in a Monitron P Printer Fault polarity When the printer is enabled in level 2 the Printer Fault input becomes active The level that causes labelling to be stopped is entered here 0 on 1 off F Fixed Pull Mode This is different from InStep I fixed pull mode it is triggered by the product scanner Pressing Enter takes you into bit edit mode Refer to the output menu for details on bit edit mo
31. y displays the first menu in level one and as the menu suggests does nothing If the entry into the initialisation menus was caused by invalid data you can t use this option but must select reinitialise Pressing the up arrow causes the first initialisation menu to be redisplayed Inputs All inputs signals that are available on a Servotron are present however only a few are wired to the connectors on the rear This is to maintain compatibility with the original Monitor The signals not brought out to the rear panel are available on the adapter board In an ex Monitor at TB land in an ex Unitron at T1 and T2 All inputs are selectable by jumpers on the InStep II PCB for NPN 1 to 2 or PNP 2 to 3 input devices The function of each input follows Product Sensor This input initiates the labelling sequence It starts with a transition from off to on of this input See jumper J7 for input polarity selection Terminal 1 on a Monitron Gap Sensor This is the registration input It is normally connected to a fork sensor that detects the gap between the labels on the backing paper The label advance starts counting with an off to on transition of this input See jumper J8 for input polarity selection Terminal 2 on a Monitron Master Encoder This is where the encoder for the product speed is connected The encoder is usually coupled to the conveyor or vacuum belt of the machine See jumper J12 and J13 for input polarity selection and J11 for volta
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