Home

WPL-3000 - Rice Lake Weighing Systems

1. CONTROLLER UNIT PRINTER STAND REIS LABEL APPLICATOR 71 DISCHARGE ROLLER UNIT OPTION SCALE POWER SWITCH j 92 Fig 1 4 WPL 3000 L Line Type front view IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm WPL 3000 SERVICE MANUAL 0077B Overview 1 1 3 LOCATION OF SAFETY STICKERS CAUTION Keep hand away from moving parts IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm Keep hands away from moving parts ELECTRIC SHOCK Disconnect from before opening Fig 1 6 Internal safety sticker 1 4 WPL 3000 SERVICE MANUAL 0077 2 Sete 2 1 Confirm Before Delivery 2 1 1 2 2 2 1 2 Installation 2 2 2 1 3 Electrical 2 2 2 1 4 Setup Environment 2 2 2 1 5 Work Clothes 2 3 2 2 Necessary Items for Installation TOO S 2 3 2 2 2 int deed dbi 2 3 2 9 Package Confirmation 2 4 2 4 Positioning and Adjusting Conveyor Stands 2 4 1 Fastening to Stand eco tate 2 5 2 4 2 Fastening Stands 2 6 2 4 3 Stand
2. 101 915 Jequinw lt py eoud 5 uodnoy 80Ud HUN 3oIHd WLOL ejeq Yd uonduoseq 14619H A UIPIM X 1u618H UPIM X enjeA M N yews04 PIO PIM X iuDieH UPIM X M N H 89160 0 0006 1 4 PIO SseJppy euleN eJoiS uonoun CO OO O uodnoy x 99 WPL 3000 SERVICE MANUAL 0077B A 12 Appendix 10 UPIM SHAEWNN 131 1919S Shay esn 199Jes 0 lt esn 910N 124 1101 spun 15 2101 129 12101 124 seuo e Jeurejuo Jad sunas 8ZIS 96 9 UIUEIA V UWE A euoninw SHUN 20 IM P8XIJ ZO 1M paxiJ 5 sueBns 7 pexi4 ql s iun 19914 aly 1M 1eqi4 20 1M pexi4 ayespAyoqued ZO E10 1M Pexi4
3. 4 15 4 2 10 Tray Master Registration b15 4 16 4 2 11 Conveyor Setup 016 4 17 4 1 Menu DIRECTORY DIAGRAM mmm Setting mode is used to adjust the machine to the needs of the customer For this reason a clear understanding of setting mode is needed before beginning operation Enter Setting mode using password 6000 followed by the MODE key Note that the password may be changed in Test mode C11 Section 3 2 12 ROUTE MENU SUB MENU KH LABEL FORMAT SETUP MODE b01 01 LABEL FORMAT NUMBER b01 03 W BACKING INDIVIDUAL b01 04 FIELD TITLE PRINT b01 05 STORE NAME b01 06 01 07 b01 089 COMMODITY LABEL LENGTH GAP SENSOR 2 DISTANCE b02 02 10 DIGIT FLAG b02 03 BARCODE TYPE b02 04 UPC TYPE 0 1 REGISTER CODE 0 2 DATE PRINT 0 3 P TIME 0 4 E TIME 05 06 DATA SET OPEN PRICE FORCED TARE b08 15 GROUP b08 17 POP b08 19 COUPON WPL 3000 SERVICE MANUAL 0077B ROUTE MENU piee neron SUB MENU 510 01 DAILY SALES TOTAL b10 28 DAILY OPERATOR TOTAL b10 02 MACHINE TOTAL b10 29 WEEKLY SALES TOTAL b10 03 DALYITEMITEM b10 30 WEEKLY MACHINE TOTAL b10 04 DALY PRICE b10 31 b10 05 DAILY ITEM ITEM WEIGHTABC b1
4. 3 15 4 Setting Mode 4 1 Menu Directory 4 2 4 2 Setup Mode 4 2 1 Label Format 601 4 5 4 2 2 Bar Code Setting b02 4 7 4 2 3 Code Settings 603 4 8 4 2 4 Setting Initial Data 604 4 9 4 2 5 PLU File 608 i ono RR 4 11 4 2 6 Preset Report 610 4 12 4 2 7 Registration Select 611 4 14 4 2 8 Total Mode Select b12 4 15 4 2 9 Password b13 4 15 4 2 10 Tray Master Registration 615 4 16 4 2 11 Conveyor Setup 016 4 16 5 Controller Unit 5 1 5 2 5 2 Block sso occa sta rA 5 3 5 3 Electronic Parts 5 3 1 Display Board 5 3 5 3 2 Junction Buzzer 5 4 5 4 Display and Key Check 5 6 5 5 Disassembly 5 7 6 Weigh Conveyor 6 1 ODIO 6 2 6 2 Block Diagrami dossier cete duae 6 3 6 3 Electronic Parts 6 3 1 Load Cell UM cscs aia rectores 6 4 6 3 2 A D Converter Board 6 5 6 4 Scale coc co 6 6 6 5 Disassembly 6 7
5. 11 01 PLUFILE 11 11 GROUP bl 1 02 COMMODITY NAME b11 12 OPERATOR 511 03 PRICE CHANGE b11 13 ADVERTISING MES b11 04 EXTRA MESSAGE 511 14 CAMPAIGN b11 05 COUPON 511 17 MACHINE NO 1 0 ore me b11 19 ONLINE SETUP 511 07 STORE b11 20 FILE DOWNLOAD b11 08 PRESET KEY b11 21 NUTRITION FILE b11 09 LIST b11 22 UNIT PRICE CHANGE b11 10 DEPARTMENT 511 23 LABEL SELECT b11 24 MASTER DELETE WPL 3000 SERVICE MANUAL 0077B Voll cvs 4 3 Setting Mode 4 ROUTE MENU SUB MENU TOTAL MODE SELECT DAILY TOTAL WEEKLY TOTAL b12 03 MONTHLY TOTAL REGISTRATION MODE TOTAL MODE SUBTRACTION MODE TRAY MASTER b15 01 b15 02 b15 03 Binch b15 04 Qinch b15 05 10 b15 06 111 b15 07 12inch 08 13inch 14inch 15inch Kj conveyor setup TIMER DELAY LABEL 60MM LUNGER TIMING SOLENOID ON BEL PLACING CONVEYOR DELAY TIMER LABEL PLACING TYPE 90 DEGREE b16 07 CONVEYOR TIMER L 516 08 DELAY TM NON WEIGH 60MM b15 09 b16 01 TIMER DELAY LABEL 60MM b16 02 b16 05 4 4 WPL 3000 SERVICE MANUAL 0077B Setting Mode 4 4 2 Setup The following pages contain explanations for each menu
6. sy y Jo 16199 eui uo 1uepuedep aue pue spjey sen eA eu episu 81 40 4 ZO ZO leio pue6e7 SOd uno seoeld ejo qns 1uBI9M 101 915 eoud 101 915 lt py 1M eiBuis 1M eoug pejunoosiq eur uMOpx1elN junoosiq eJ0Jeq eoug Jequinw eoud 8101 eoug HUN ejeq ejeq yoed 20 04 6 epooJeg episul ZO uonduoseq 01 1 09 5 1u618H UPIM A X uonoun piepuels anjeA UIpIAM X UIPIM X UPIM X yewo 89160 2 000 1dM PIO 8101S ejes x 9 A 15 WPL 3000 SERVICE MANUAL 0077B V ISHIDA ISHIDA CO LTD 44 SANNO CHO SHOGOIN SAKYO KU KYOTO 606 JAPAN PHONE 075 771 4141 FACSIMILE 075 751 1634 TELEX 05422065 SCALES J CABLE ADD SCALES KYOTO IW603P1005
7. ayespAyoquey pus6e7 LM LIN eoug pejunoosiq WNIPOS eoug pejunoosiq eur unipos eur 1019159945 eoug 10 SUN 0491591049 eoug 10 01915 0 7 ejeq PIPINS epooJeg sun ye4 panes uonduoseq 1uBioH A UIpIA X UPIM X anjeA M N G euuJ04 PIO ye4 panes uoljoun4 psepue s 1 1 P 9160 0 OO00E 1dM uonunw edeospue7 x 99 PIO 8101S O 13 WPL 3000 SERVICE MANUAL 0077B Appendix 1 10 UPIM X 0918 ex lt esn SH38INN 10918 4 esn 340N pejuud op se seseeJoui osje 9594 JO 5 1uBieu eu seseojJoui gaule 991 sy eu eui uo 1uepuedep pue spjey jo 146184 eu e10N UOJ s un 124 601 123 16101 Seuo e 1e J Jeurejuo Jad sunas 9715 96
8. osje jo uonisod SOSE9JOUI OU SY aui eui uo 2 pue jo 1 94 1 101 pexi 1195 Ag 195 SWEN Nld JequinN JequinN 04 6 20 WLOL LNNOWY 1M ZO Buipnjou 41 Ad pexi4 1M 81 Ad og loquiAS eoug pejunoosiq loquiAS eur 04 6 20 e10 eur ZO 18101 junoosiq eoug 104 0 eoud 8101 juno9 HUN uno eoelg seoeld ejo qns ejeq uoneJidx4 10 qnS 0 qng 5 uonduoseq 1uBi9H A UIpIAM X 1u618H UPIM X M N jeuuoJ PIO L abessa py piepuejs UIPIM X 14618 UPIM X anjeA M N H 89160 0 0006 14
9. 9 2 9 2 Breakdown and Countermeasure 9 3 9 3 Error Messages cea veo dta ve des 9 4 10 1 Location of Main Parts 10 2 10 2 Replacing the Load Cell Unit 10 3 10 3 Span Calibration Adjustment 10 6 Installation Notes A 2 A 2 Label Format Worksheets A 9 Chapter 1 1 1 External Parts and Names I Line 1 2 External Parts and Names L Line Type 1 3 Location of Safety Stickers Overview 1 1 1 EXTERNAL Parts AND NAMES LINE TYPE INFEED CONVEYOR UNIT OPTION PRINTER UNIT SCALE LABEL APPLICATOR Fig 1 1 WPL 3000 Line Type top view PRINTER STAND CONTROLLER UNIT PRINTER UNIT _ J LABEL APPLICATOR INFEED CONVEYOR UNIT OPTION DISCHARGE ROLLER UNIT OPTION CONVEYOR WEIGH UNIT CONVEYOR STAND OPTION POWER SWITCH Fig 1 2 WPL 3000 I Line Type front view IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm 12 WPL 3000 SERVICE MANUAL 0077B Overview 1 1 2 EXTERNAL Parts AND NAMES L LINE TYPE PRINTER UNIT LABEL APPLICATOR SCALE INFEED ROLLER UNIT OPTION Fig 1 3 WPL 3000 L Line Type top view
10. 6 Weigh NEG TT 6 2 6 2 Block Diagrami sac csse oda ces ae dna 6 3 6 3 Electronic Parts 6 3 1 Load Cell DIT 6 4 6 3 2 A D Converter Board 6 5 6 4 Scale 6 6 6 5 Disassembly 6 7 Weigh Conveyor 6 6 1 OVERVIEW The scale unit is installed in the weigh conveyor and uses a load cell resistance strain gage as a weigh sensor WEIGH UNIT CONTROL BOX ROLLER UNIT Fig 6 1 Weigh conveyor Fig 6 2 Items to be weighed roll across a sloping conveyor GUIDE BOARD ROLLER UNIT WEIGH PLATTER SEAL WIRE Fig 6 3 Roller Unit WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor 6 6 2 BLock DIAGRAM CONTROLLER UNIT KEYBOARD DISPLAY PRINTER UNIT LABEL APPLICATOR TIMING SENSOR ELECTROMAGNETIC AIR VALVE AID BOARD P 830B POWER SUPPLY UNIT SLS150PW t LOAD CELL UNIT CLC 25N CONNECTION FOR OPTIONAL 5IKAOGN ALU INFEED CONVEYOR Es E64197 WEIGH CONVEYOR MAIN POWER SWITCH Fig 6 4 Block Diagram Later designs incorporate a single P 854 Drive board tLater designs use two power supplies LSF100 24 36 3409 01 Main 24VDC LDA30F 24 46 3180 09 Fans WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor 6 6 3 ELECTRONIC PARTS mmm 6 3 1 LOAD CELL UNIT The load cell resistance strain gage converts power and load into direct elect
11. 2 3 2 2 2 Man alS xr hts 2 3 2 3 Package Confirmation 2 4 2 4 Positioning and Adjusting Conveyor Stands 2 4 1 Fastening to Stand 2 5 2 4 2 Fastening Stands 2 6 2 4 3 Stand Fastening Method 1 2 7 2 4 4 Stand Fastening Method 2 2 7 2 5 Connecting 2 8 2 6 Setup 222 2222 2 2 9 2 7 Method for Threading Labels 2 10 2 8 WPL 3000 USA Rescue Mode 2 11 3 1 Menu Directory 3 2 3 2 Test Mode 3 2 1 Starting Test mode 3 3 3 2 2 Hardware Test 01 3 3 3 2 3 RAM Clear 002 cet cies cds eds 3 6 3 2 4 Thermal Head Setting 3 7 3 2 5 Sensor Check 4 3 9 3 2 6 Extra Memory C05 3 9 3 2 7 Setting ROM Switch C06 3 9 3 2 8 Label Format Editing C07 3 12 3 2 9 Sales Mode Setting C08 3 12 3 2 10 Machine ID Setting 9 3 13 3 2 11 Preset Function Setting C10 3 14 3 2 12 Password C11 rette 3 14 3 2 13 Data Transmission C99
12. 7 4 WPL 3000 SERVICE MANUAL 0077B Printer Label Applicator Unit 7 When replacing the main board make sure the battery switch is ON BATTERY SWITCH LITHIUM BATTERY NON RECHARGEABLE lt gt Co qe Fig 7 6 Battery Switch board 892 Input signals from the CPU board P 834 are converted to 24VDC output signals Label applicator fan motors and electromagnetic air valves are controlled by the I O board 892 asterisk indicates latest version subsequent versions will be followed by letter e g A B C Junction Board 838 This board transmits peeling sensor reflective type and stepping motor signals through the cable from the J4 connector to the main board asterisk indicates latest version subsequent versions will be followed by letter e g A B C Fig 7 7 Junction Board 838 WPL 3000 SERVICE MANUAL 0077B 7 5 Printer Label Applicator Unit 7 Thermal Head The thermal head is constructed of 448 dot heating elements and made especially for printing labels When ink glue or other debris becomes stuck to the printing area of the thermal head heat to the label becomes uneven lowering print quality and shortening the operational life of the thermal head Overall dot count 448 dots Dot pitch 0 135 mm Required power 0 66 W dot Applied voltage 24 V DC Refer to Operation Manual for daily maintenance of thermal head Thermal Head Adjustment Fig 7 8 Ther
13. 3 2 4 Thermal Head Setting C03 Test Mode 3 Use this step to set the Thermal Head HEAD TENTER E THERMAL HEAD ENTER resistance check or reset usage and set print density C03 WPL 3000 SERVICE MANUAL 0077B 0 3 7 Test Mode 3 Setting Thermal Head Resistance Value C03 01 Set the thermal head resistance value according to the table below Refer to the value written on the underside of the thermal print head Note Press to automatically set the thermal head resistance value Resistance Value Entry Value 528 545 546 563 564 581 582 600 601 618 619 636 637 654 655 672 Print Usage Display C03 02 This shows the length in kilometers of label stock that has been issued This operation can also clear print usage length Enter 0 and press to clear print usage distance Always clear this setting when a new thermal head is installed Print Density Setting 03 03 3 8 This adjusts print density 1 light to 9 dark Press PRINT to issue test labels RESISTANCE 627 C03 01 627 PRINT USAGE IN km 0 0km 02 0 0 PRINT DENSITY ADJUST 1 9 5 C03 03 5 WPL 3000 SERVICE MANUAL 0077B 3 2 5 Sensor Check C04 This confirms that the peel and label sensors are operating The peeling sensor detects if a label is on the applicator It reads a low value when open and a high value when blocked There is no adjustm
14. Fig 5 7 Junction Buzzer Board P 887 WPL 3000 SERVICE MANUAL 0077B Controller Unit 5 5 4 DisPLAY AND CHECK When test mode 01 02 is activated all 120 keys on the keyboard may be C checked for functionality Refer to Test Mode Sec 3 2 1 and Sec 3 2 2 in this manual for entering the test KEY CHECK KEY DATA 1 2 3 4 5 7 8 o 12 13 DE 16 17 18 19 20 21 22 23 24 25 26 27 28 29 20 31 i 33 34 35 vee 99 40 46 47 48 49 50 51 52 53 54 55 56 61 62 63 64 65 66 67 68 69 70 71 76 77 78 79 80 81 82 83 84 85 86 91 92 93 94 95 96 97 106 107 108 109 111 112 Fig 5 8 Key Addresses Key 29 RESET is used to exit key check mode Test mode C01 03 is used for display check of the full dot and 7 segment digital displays 01 03 0 5 6 WPL 3000 SERVICE MANUAL 0077 Controller Unit 5 5 5 DISASSEMBLY DIAGRAM CONTROLLER UNIT mmm CABLE TO PRINTER UNIT DISPLAY FILTER TRANSPARENT KEYSHEET COVER JUNCTION BUZZER BOARD P 887 DISPLAY BOARD GP 1046A01A MEMBRANE KEYBOARD OPERATION KEY SHEET INSERT Fig 5 9 Controller Unit WPL 3000 SERVICE MANUAL 0077B 5 7 Controller Unit 5 WPL 3000 SERVICE MANUAL 0077B
15. KEYS TIME LIST BARCODE BS Joerere 7 1 2680 DEPT GROUP E U LINE NsERT 4 END RESET MODE Jt Jt JL e JL JL N N J A o N NORMAL BOLD SIZE gt 24 5 lt gt J une J 4 5 E 5 ADV EDIT PAPER 3 amp PRICE PLU FEED a lt lt lt lt lt L pu IN AN PN 2 O 42 lt gt lt gt lt gt JL 5 LOWER N N N N KL JL JL SHIFT GRANDI DAILY PRICE PRESET C SPACE EDIT TARE ENTER A TOTAL SALES OVRDE _ Registration Keyboard Layout Operation Keyboard Layout 5 2 EXTRA PACK ZERO HELP COUNT MESSAGE MODE WPL 3000 SERVICE MANUAL 0077B VOID RESET f Y Y 5 LABEL LOWER BATCH PRESET lt Controller Unit 5 5 2 BLock DIAGRAM Controller Unit CONTROL DISPLAY UNIT GP104601A Printer Unit KEYBOARD UNIT Fig 5 2 Controller Unit 5 3 ELECTRONIC PARTS 1 5 3 1 Display Board GP1046A01AA The WPL 3000 utilizes a 256 X 16 horizonal x vertical full dot and 7 segment fluorescent digital displays Display data is received from and keyboard entries sent to the main CPU
16. ejo qans 210 ans 2101 qns d 18101 eoug euonoeJJ pue6e 4 8914 pext4 2 OWEN eoug pajunoosiq 2 eur 9 d BO 101 uonduoseq Nd UPIM X iuBieH UPIM X 04 9160 0 0006 1 PIO 8101S uonoun O jeqe7 wwo x WPL 3000 SERVICE MANUAL 00778 A 11 Appendix 14618H A 10 X 12 5 0 Kex lt esn SHAGWNN 07314 1919S 04 4 esn UOTEDIAEN 34 0N pejuud Aue op se osje eseu jo uonisod eui SOSESJOU Bale 1X9 SY eu eui uo 1uepuedep 2 pue jo senjeA 941 SWEN Nld SOds JequinN WLOL Buipnjou eoug junouy xe eoug pejunoosiq eur seoeld ejo qns eur 101 915
17. 2 ALLOW Open Price The operator 1 PROHIBIT Enter 1 may change the price in operat 2 ALLOW Enter 2 ing mode b04 06 FORCED TARE Default 2 NO key Forced Tare a tare weight Enter 1 bo pius 4 a label is Enter 2 allowed to print WPL 3000 SERVICE MANUAL 0077B to print current time 4 10 Setting Mode 4 4 2 5 PLU FILE b08 This prohibits or enables entry of the selected items in PLU programming Enter the numerical value 0 or 1 and press ENTER J for each selection 08 05 FIX PRICE 1 Enable FIX WEIGHT Show b 0 b 0 b 0 b08 07 b08 08 PACK QTY b 0 b 0 b 0 08 09 COST PRICE TARE 0 Prohibit Hide 08 17 POP BARCODE PREFIX WPL 3000 SERVICE MANUAL 0077B Setting Mode 4 Nub nho dM cc ee S M E 4 2 6 Preset Report b10 This selects which report will be printed when Preset Report F02 is selected from b10 0 the Total Mode menu See the WPL 3000 User s Manual Managers for printing de tails Enter numerical value and press ENTER for each selection DAILY SALES TOTAL b10 01 MENU NO SETTING ITEM ENTRY b10 01 DAILY SALES TOTAL b10 02 DAILYMACHNE TOTAL 510 03 oa neueren b10 04 DAILY ITEM ITEM PRICE ABC b10 05 DAILY ITEM TEM WEIGHTABC 0 0 6 DAILY ITEM ITEM COUNT b10 07 bALYITEMITEM 2 b
18. Contents 7 Printer Label Applicator Unit 8 Weigh Conveyor Unit 9 Troubleshooting 10 Load Cell Unit Appendix Contents 7 1 OVGrVIBW iiia e IU 7 2 7 2 Block Diagram 7 3 7 3 Electronic Components 7 4 7 3 1 Printer Unit Thermal head label sensor adjustment 7 4 7 3 2 Label Applicator Unit 7 10 7 4 Adjustment Position of the Label Applicator Unit 7 14 7 5 Movement 7 15 7 6 Disassembly Diagram Stand Unit 7 16 7 7 Disassembly Diagram Printer Unit 7 16 7 8 Disassembly Diagram Label Applicator Unit 7 17 8 1 Weigh Conveyor 8 2 8 2 Block Diagram 8 3 8 3 Electronic Components 8 4 8 3 1 Power Supply Unit 8 4 8 3 2 Drive Board P 854 8 5 8 3 3 Electromagnetic Valve 8 5 8 3 4 Air CVIIDOIBE 8 6 8 3 5 Application Timing Sensor 8 7 8 4 Elevator Check and Parts Adjustment 8 8 8 4 1 Weigh 8 8 8 4 2 Conveyor Fall Prevention Screw Adjustment 8 9 8 5 Disassembly 8 10 9 1 Periodic Parts Replacement
19. Fig 7 13 Rough Adjustmant Potentiometer fs la LS CEH 1 Turn FINE adjustment knob to cener position 2 Place backing paper only under gap sensor 3 Turn ROUGH adjustment until the point where the red LED turns on off this is point 4 Place label on backing paper under gap sensor 5 Turn ROUGH adjustment until the point where the red LED turns on off this is point B 6 Center the ROUGH adjustment between paints A and Projector Intrared Diode LN55 Racaivar Photo Transisiter PN150 Fig 7 14 Stepping Motor The labels are advanced using a stepping motor WPL 3000 SERVICE MANUAL 00778 7 9 Printer Label Applicator Unit 7 7 3 2 Label Applicator Unit APPLICATOR SHAFTS AIR CYLINDER SPEED CONTROLLE 1 alla 5 ELECTROMAGNETIC VALVE PEELING SENSOR LABEL ABSORPTION PLATE COVER Fig 7 15 Applicator Unit Disassembly Diagram Fan Motor The fan motors use suction to hold labels against the absorption plate until they are applied to a package 7 40 WPL 3000 SERVICE MANUAL 0077B Printer Label Applicator Unit 7 Electromagnetic Valve This electromagnetic valve controls the air supply to the air cylinder that pushes the labeling arm downward The electromagnetic valve also controls the air supply that moves the labeling arm up A port A TERMINAL NUMBER WIRE COLOR B TERMINAL NUMBER Fig 7
20. Medium standard 03 Fast fastest throughput Width of Stabilization Window Difference in number of internal counts from previous sample that will be accepted as the same weight Example 02 2 count difference from last sample Note Increase the value for faster operation These changes must be registered to the A D Board NV RAM See step 01 01 above for the procedure Typical Speed settings 003C 03 003D 03 and 003E 03 WPL 3000 SERVICE MANUAL 0077B A 7 Appendix PROGRAMMING MENU Access the Programming Mode by entering 9000 then pressing MODE key Use DOWN ARROW to move to the desired menu option then press ENTER Programming Menu 1 PLU FILE Use the ENTER and DOWN ARROW keys to navigate through PLU programming The following items have been added to PLU programming for the WPL 3000 Address Description Label Format 0 4 Label Print 0 Reference 1 Straight 2 Rotate Upper Weight Limit Lower Weight Limit Tray Number OPERATION Transfer Mode With no active PLU display reads KEY IN PLU NUMBER press the START func tion key to move packages across the conveyor system without weighing or labeling 8 WPL 3000 SERVICE MANUAL 0077 Appendix 1 A 10 PIM X 12 lt esn SH38INN 10919 shay 4 esn 10 e oqe pejuud Aue op se
21. PIO CO OO SseJppy euieN e401S x 9 SLAIFHSMYO A 1VWHOJ 13977 CV WPL 3000 SERVICE MANUAL 0077B A 9 Appendix epius WW p x yewo siU pesn eq Aew ui pue 5 ui 941 eu op se osje asaui 1 auj seseeJour 1X9 OU sy 1X9 JO eui uo 1uepuedep z pue spjay jo 1uBreu 94 910N 1 101 195 1M 7 Ag 195 SWEN Nld SOds 6666 ejes JequinwN 04 6 20 IV LOL LNNOWV 1M ZO Buipnjou 04 6 eiBuis 1M 87 Od loquiAS loquiAS eoug peiunoosiq 04 6 20 101 ZO leio eur 03 8 unoosiq eoug pue6e JequinN d 59 HUN
22. WPL 3000 SERVICE MANUAL 0077B 10 3 3 Removing the platter support 1 Unfasten the 4 screws holding the platter support 4 Removing the weigh mechanism cover 1 Unfasten the 4 screws holding the weigh mechanism cover 2 Slowly lift the weigh mechanism cover Fig 11 5 Weigh mechanism cover 5 Removing the A D board 1 Disconnect connector 1 and 2 from the A D board 2 Unsolder the load cell cable connections 5 places 3 Remove the A D board locking supports 4 places LOAD CELL CONNECTION CABLE Fig 11 6 A D board sure the main power is turned off and the power cord is removed 10 4 WPL 3000 SERVICE MANUAL 0077B Load Cell Unit 10 6 Removing load cell unit 1 Unfasten the load cell unit screws 3 2 Remove the load cell unit The load cell cell cable is soldered to the board Be careful to reattach the load cell cable wires to the correct position Confirming the four corner limit screws after replacing load cell With the roller unit weigh platter and platter support installed adjust and confirm position of four corner limit screws Place a weight equal to scale capacity plus 1096 33 Ib on each corner Rotate each of the four corner limit screws so that they just make contact with the limit bolts when the weight is loaded Gap in Fig 11 9 The four corner limit screws protect the load cell from being damaged when an excessive load is applied
23. 1 OVERVIEW Figure 7 1 is a side view of the PRINTER STAND printer and label applicator units The units are suspended from the printer stand and can be adjusted according to the height of the prod uct and the direction in which the label is applied The printer em ploys a 60mm wide thermal head ADJUSTMENT KNOB IMPORTANT NOTE Later versions of the WPL 3000 use a front mounted printer arm Fig 7 1 Printer Unit LABEL APPLICATOR ARM UNIT The labeling applicator arm in the LABELING ARM label applicator unit Figure 7 2 moves by electromagnetic valve and air cylinder The air cylinder is raised and low ered by the electromagnetic valve This movement of the air cylinder moves the labeling applicator arm downward applying the label to the product The stroke of the labeling applicator arm is 100mm 4 inches ELECTROMAGNETIC VALVE Fig 7 2 Label Applicator Unit 7 2 WPL 3000 SERVICE MANUAL 0077B Printer Label Applicator Unit 7 7 2 BLock DIAGRAM SUCTION FAN BOARD Controller Unit Keyboard Display JUNCTION BOARD Label Applicator Unit MAIN CPU BOARD P 834 Weigh Conveyor Fig 7 3 Block Diagram WPL 3000 SERVICE MANUAL 0077B 7 8 Printer Label Applicator Unit 7 7 3 ELECTRONIC COMPONENTS 7 3 1 Printer Unit Thermal head label sensor adjustment MAIN CPU BOARD P 834 JUNCTION BOARD P 838 Fig 7 4 Printer Unit Parts Main CPU Board
24. 16 Electromagnetic Valve WPL 3000 SERVICE MANUAL 0077B Air Cylinder Adjustment Method In the air cylinder there are adjustment screws for the cylinder speed controller which adjusts the air amount and air dumper which adjusts for shock Proce dures for adjustment ara listed below 1 Cylinder push side dumper 2 Cylinder pull side dumper 3 Cylinder push side speed controller 4 Cylinder pull side speed controller Adjustment Procedures 1 Adi Use the regulator mounted on the weigh conveyor unit to adjust air pressure be tween 0 4 and 0 6Mpa Turn clockwise to raise air pressure 7 12 Loosen the nut for turn the adjust Turn nut for 2 5 turns clockwise Loosen nut for and turn counter For and loosen the smaller nut 7 47 Air Cylinder af the double nut and turn adjustment screw counterclockwise as far as it will go clockwise three times and tighten double nut ment knob counterclockwise as far as it will ga and tighten nut clockwise until tight and fasten nut Fig 7 48 Air Adjustment WPL 3000 SERVICE MANUAL 00778 Printer Label Applicator Unit 7 Peeling sensor The peeling sensor uses a reflective photosensor Refer to Test Mode Section 3 2 1 and 3 2 5 in this manual for verifying Peeling Sensor operation of peeling label taken sensor Sensor Protectiv Cover 824 Fig 7 19 Peeling Sensor
25. 24V DC power supplies See previous CN2 page rm No Signals SLST50PW Voltage input 85 to 132 V AC 424 V DC 50 60 Hz Voltage output 24 V DC STAI Wi 3 4 GND he WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor Unit 8 8 3 2 Driver Board P 854 The driver board controls the electromagnetic valve that switches air pressure to raise and lower the weigh conveyor The drive motor for the infeed optional and weigh conveyors is also controlled by the driver board Control signals from the driver board are isolated by photocouplers Fig 8 6 Driver Board This driver board P 854 is installed in the control box located under the weigh conveyor 8 3 3 Electromagnetic Valve This electromagnetic valve drives the air cylinder which raises and lowers the weigh conveyor Fig 8 7 Electromagnetic Valve WPL 3000 SERVICE MANUAL 0077B 8 5 Weigh Conveyor Unit 8 A pot Remove rear panel cover to reach and 2 EP terminal number terminal number A port 1 TE B port Remove rear panel cover to reach B port1 and 2 8 3 4 Air cylinder A speed controller is installed on the air cylinder The following explains the method for adjusting the speed controller Raise Conveyor Speed Control Turn the nut and knob clockwise as far as they will go Turn the knob counterclockwise three rotations and tighten the nut Lower Conveyor Speed Control Turn the nut
26. Err 03 first line for POP mes first line by removing sage to print excess characters AD MESSAGE OVER CHARACTER Too many characters Edit Ad message by Err 04 one line in Ad message removing excess charac ters per line STORE NAME ADDR OVER CHARACTER Too many characters on Edit Store Name Address Err 07 one line in Store Name by removing excess Address characters per line LABEL SIZE ERROR Incorrect labels installed Install correct labels Err 09 in printer Check label size Label size settings are settings incorrect Re thread labels Mis threaded labels EXCESS ON SCALE ITEM Discount price is equal to Check the discount price Err 10 or greater than the registration original price MAX ITEM NUMBER OVERFLOW Accumulated operator Clear operator totals by Err 12 totals have exceeded 30 printing a total label Use transactions or 100 000 the TOTAL key per operator or 100 total transactions 13 SAME OPR TOTALING ON MAC Same operator number Wait and restart opera Err 13 used within one second tion 14 OPERATOR IN USE Same operator number Wait and restart opera Err 14 used within one second tion WPL 3000 SERVICE MANUAL 0077B Note To clear error messages from display press CLR key OPERATION WEIGHT IS OVER LIMIT Err 17 WEIGHT IS BELOW LIMIT Err 18 LABEL REMAINING ON APPLICATOR Err 19 WEIGHT EXCEEDS CONVERYOR CAP Err 20 MEMORY NOT INITIAL SET
27. FORMAT NO PLU C07 00 0 NO 01 0 AXIS POSITION 0000 C07 01 0 01 0000 PRINT FIELD NUMBER COORDINATE POSITON S LES MODE ENTER C08 0 MODE gt 1 IND LABEL T L 1 08 01 1 1 1 IND LABEL W O TL Standard issue of individual lablels without operators Dot Display IND 2 W TOTAL Enable operator functions WPL 3000 SERVICE MANUAL 0077B 3 12 Test Mode 3 CSIS Mode C08 02 This selects either stand alone or CSIS mode CSIS MODE 1 ALONE 1 08 02 1 1 CSIS Mode Condition 1 ALONE Used for stand alone 2 MASTER SCALE Used for setting as a master scale See caution below 3 SATELLITE SCALE Used for satellite scales Note Refer to AC 3000 System Setup Manual for details of configuring a scale communication network MSCU3000 option is necessary for MASTER SCALE 3 2 10 Machine ID No Setting C09 This sets the Master Scale s ID number for computer communications Note The maximum number of Master Scale connections to the computer may vary depending on the efficiency of the level EMAC HIENE STD NUMB ERSO pe converters used C09 01 1 WPL 3000 SERVICE MANUAL 0077B 3 1 Test Mode 3 3 2 11 Preset Function Setting C10 This programs functions for each function key PF 1 to PF 4 Use to select PF setting 1 4 Enter the number corresponding to the Eup ESTART i desired
28. adjustment Is the A D Converter amount change within 30000 2 Remove weigh from scale i Saving data Press the A D board switch Fig 11 10 Span Flowchart 1 A D converter initial value Press with no weight on the scale rollers The A D converter initial value is displayed in the unit price column Confirm that the initial value is within 2000 1 count If it is within 20001 count perform span adjustment If it is not within 2000 1 count press and confirm 2 Span Adjustment Place 30 lbs of calibrated weights on the scale rollers The A D converter weight change is shown in the weight column Confirm that the span adjustment is within 3000022 count If it is within 3000022 save data If span adjustment is not within 3000042 count press and remove the weights Repeat the procedure beginning with step 7 A D converter initial value 3 Saving data Save data to E7ROM Remove weights from scale rollers and remove the roller unit Remove cap and press the memory switch on the A D board See Fig 11 11 WPL 3000 SERVICE MANUAL 0077B 10 7 Load Cell Unit 10 4 Completion Replace the cap and scale roller unit 5 Check After reassembly recheck scale calibration and return to zero Also verify clearance by pressing key to activate the conveyor If A D counts are not the same when the conveyor is up and down check for binding between conveyor and scale rollers Fig 11 11 A D boar
29. ahigher value moves the label to the trailing edge of the package ii a lower value moves the label to the leading edge of the package WPL 3000 SERVICE MANUAL 0077B Appendix ALTERING WEIGHT STABILIZATION PARAMETERS Enter Test Mode by turning the POWER ON while holding down the 1 key Use DOWN ARROW to move to the desired menu option then press ENTER Test Menu 1 HARDWARE TEST Step C01 01 1 Make changes in Test Mode 6 ROM SWITCH to addresses 003C 003D 003E see table below for details D uos Enter the weight calibration step 1 01 A D CHECK Press ZERO to set counts to 0 and 2000 Press FEED to send ROM SWITCH data to the A D board Press the Memory Switch on the A D board same as during calibration Exit Test Mode turn WPL off on and check operation Test Menu 6 ROM SWITCH Use RIGHT ARROW to move to the desired address Enter the new data then press ENTER Address Default Description Conveyor Time Out 00 No Conveyor runs continuously 01 Yes Conveyor stops after 10 minutes of non use Configuration 00 Straight through In Line 01 L shape Shelf Life 00 Today counted as one day 01 Today not counted add one day to shelf life Stabilization Lock Count Number of samples that must match before weight reading is accepted Note Decrease the value for faster operation A D Conversion Speed 01 Slow slower throughput most reliable 02
30. board P 834x located in the printer unit Power is supplied by the power supply unit SLS100PW in the contol box located in the weigh conveyor unit FULL DOT DISPLAY 7 SEGMENT DIGITAL DISPLAY DISPLAY BOARD GP1046A01AA JUNCTION BUZZER BOARD P 887 Fig 5 3 Display Board 1 Handle the display modules with care since they are made of glass 2 Do not remove the electrical plug when the machine is on CAUTION WPL 3000 SERVICE MANUAL 0077B 5 3 Controller Unit 5 Fuses are soldered on the board to protect the full dot and 7 segment digital displays FLUORESCENT DOT MATRIX DISPLAY cei N 7 SEGMENT DIGITAL DISPLAY FLUORESCENT DOT MATRIX DISPLAY FUSE 1 0 6A P N 42 1452 05 7 SEGMENT DIGITAL DISPLAY FUSE F2 0 5A P N 42 1451 01 Fig 5 4 Display Board All DIP switches on the display unit must remain in the OFF position If any switches are set to ON the display will not work properly Fig 5 5 DIP Switch 5 3 2 Junction Buzzer Board P 887 Keyboard entries are sent to the main CPU board P 834x in the printer unit via the Junction Buzzer board P 887 MEMBRANE KEYBOARD JUNCTION BUZZER BOARD P 887 KEY SHEET Fig 5 6 Keyboard WPL 3000 SERVICE MANUAL 0077B Controller Unit 5 A single confirmation beep is made every time a key is pressed A buzzer attached to the Junction Buzzer board emits a series of beeps when a key entry error is made
31. function then press ENTER i3 x C10 0 Ec renpseq quine PresetFunction Key Locations 2 EAC OOE a bron 5 1 Cals up POF graphis message Sets special price Setsdicountamount Enter operator ID number 19 ROTATE Apply label to leading or trailing corner Activates tray call up Sets lower weight check limit Selects printing no printing of barcode Note Default settings are PF 1 START PF 2 STOP PF 3 LOWER LIMIT PF 4 TARGET QTY 3 2 12 Password C11 Use to change the Setup Menu password from the default value of 6000 C11 0 Enter a one to four digit number then press ENTER C11 01 6000 3 2 13 Data Transmission C99 This allows memory data to be copied to a floppy disk when IF 21FD backup tool is connected Transferring data from a floppy disk back to WPL 3000 is also possible DATA SAVE LOAD ENTER c99 0 Before transferring the data by IF 21 FD check the cable connecting WPL 3000 and IF 21 FD Before the cable is connected both machine and CAUTION floppy drive should be turned off Note The ROM program version for the IF 21 FD is J 209N or later Confirm that the ROM version is correct before using Use the 9 pin cable pro vided with the IF 21FD Note Confirm only switches 2 and 5 are down before turning the IF 21FD on RES
32. to Rotate label position a Turn the printer 90 degrees b Press the ROTATE function key 10 Label Placement 90 degree Placement SETUP MENU b16 06 Section 4 2 11 a Test label placement b Adjust b16 06 setting as needed i ahigher value moves the label to the trailing edge of the package ii a lower value moves the label to the leading edge of the package 11 Lower Conveyor as soon as possible SETUP MENU b16 07 Section 4 2 11 a Test lowering time of conveyor using the widest tray available b Adjust b16 07 as low as possible to allow the tray to be moved off the scale area Note Lowering quickly ensures the scale is ready to accept the next package 1 Configuration 1 Memory Clear TEST MENU C02 Section 3 2 3 a C02 01 Ram Clear b C02 02 E ROM Clear c C02 03 Test Set Optional 2 Configuration TEST MENU C06 ROM Switch A 7 Set address 003A 00 3 Assign ROTATE function key TEST MENU C10 Section 3 2 11 Assign PF4 19 rotate 4 Label Format a SETUP MENU b01 Section 4 2 1 i Select format number b01 01 ii Set text area b01 06 iii Set label length gap b01 07 iv Set Sensor 2 b01 09 to ensure label comes free of the backing paper b TEST MENU C07 Section 3 2 8 i Modify label format as needed WPL 3000 SERVICE MANUAL 0077B A 5 Appendix A 6 10 11 Set Applicator Stroke TEST MENU b16 03 Section 4 2 11 a Applicators i Standard 08 typica
33. to test the conveyor s up and down movement Note Compressed air must be supplied for these movement tests 3 2 3 RAM Clear C02 This initializes clears RAM E7ROM and sets Test PLU data PROGRAM No ENTER C01 05 0 MAIN BOARD PROG Ver C0916E C01 05 00 0916 MAIN BOARD FONT Ver F0211 01 05 01 0211 conveyor TEST ENTER 01 06 0 PLUNGER PRINT ELEVATOR PLU 01 06 00 CLEAR 02 WPL 3000 SERVICE MANUAL 00778 3 6 All RAM Clear C02 01 This clears all RAM data Press ZERO twice to start clearing XADE RAM O GEEAR RAM C02 01 is displayed after RAM has cleared and self checked Note RAM data consists of all information programmed in the Registration Menu E ROM Clear C02 02 This resets all E7ROM data to default values Press ZERO twice to start clearing E7ROM OK is displayed after has been reset and self checked E2ROM CLEAR C02 02 Note E ROM data consists of all configuration information programmed in the Setup Menu and Test Menu Setting Test Data C02 03 Set test data after performing RAM Clear and E ROM Clear Press twice to set test data is displayed after test data has been successfully set Note This operation is the same as step 02 01 RAM clear and step C02 02 E7ROM clear plus test PLU s 1 through 10 are created along with a dummy shop name TEST SET C02 03
34. to test the label applicator s movement ees 0 Refer to TEST MODE Section 3 2 2 for additional information PLUNGER PRINT ELEVATOR PLU 01 06 00 0 Peeling Sensor Test This tests the sensitivity of the peeling sensor and the label gap sensor Refer to Test Mode Section 3 2 5 for additonal information D SENSOR CHECK ENTER C04 Note Voltage values on the peeling sensor may PEEL 1 LABEL 255 be tested on the P 838 board connector C04 00 J2 Measure between pins 3 positive and 4 negative Note Use a label or white paper to test LABEL SENSOR SENSOR DISPLAY VALUE LABEL SENSOR RECEIVER VOLTAGE BEAM REFLECTED ABOVE 200 COUNTS BELOW 1 V DC BEAM OPEN BELOW 50 COUNTS OVER 4 V DC WPL 3000 SERVICE MANUAL 0077B 7 15 Printer Label Applicator Unit 7 7 6 DISASSEMBLY DIAGRAM STAND UNIT STORE CABLE UNDER COVERS Fig 7 24 Disassembly diagram stand unit IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm 7 7 DISASSEMBLY DIAGRAM PRINTER UNIT mmm BOARD P 892 STEPPING MOTOR LABEL APPLICATOR UNIT LABEL SENSOR THERMAL HEAD Fig 7 25 Disassembly diagram printer unit 7 16 WPL 3000 SERVICE MANUAL 0077B Printer Label Applicator Unit 7 7 8 DISASSEMBLY DIAGRAM LABEL APPLICATOR UNIT amm SPEED CONTROL AIR CYLINDER HINGE METAL FITTING FAN MOTORS ELECTROMAGNETIC VALVE COVER PEELING SENSOR LABEL
35. to the weigh platter Adjustment of the four corner limit screws is necessary when the load cell has been replaced or the main body has received a jolt LOAD CELL UNIT SCREW QS Fig 11 8 Load cell output cable FOUR CORNER LIMIT SCREW gt LIMIT BOLT MAIN BODY Fig 11 9 Confirming the four corner limit screws WPL 3000 SERVICE MANUAL 0077B 10 5 10 3 SPAN CALIBRATION ADJUSTMENT Span Adjustment is performed in test mode Refer to Test Mode Sec 3 2 1 and 3 2 2 in this manual for procedures for starting test mode CHECK ENTER 01 01 0 Note After entering the A D check mode confirm the conveyor does not touch the scale rollers Press COUPON TEXT key on the registration keyboard to raise and lower the conveyor Air must be supplied to move the conveyor Adjustment Pr r Confirm the present setting ZERO ZERO SPAN TARE A D CONVERTER A D CONVERTER AMOUNT CHANGE INITIAL VALUE 10 6 WPL 3000 SERVICE MANUAL 0077B Load Cell Unit 10 Span Adjustment Flowchart Is the A D A D converter initial converter initial value value setting within 2000 1 count Remove weigh from scale YES Place a 30 weight on the weigh platter Press A Span
36. uno eoelg seoeld ejo qns 101 915 10 qns uonduoseq 14618H A UIPIM X 1u618H UPIM X M N Z 1euu04 PIO abessa py uoloun 14619H A UPIM X 14618 UPIM X anjeA M N 9160 0 000 14 PIO 8101S 10 CO OO O ejes wwgg x WPL 3000 SERVICE MANUAL 0077B A 10 Appendix A 10 PIM X 19198 lt esn SY39WNN 10918 7 esn ajon eui pojuud Aue op se osje JO uonisod auj eui sy 1X9 aui 1 uo 1uepuedep z pue jo sen eA 1 99 910N iuDieH X uonoun PIO 14619H A UIPIM X 0 5 ZO 04 6 97 1u618M 87 04 6 70 101 1uB618M ZO 0 LM LAN seoeld
37. 0 32 WEEKLYITEMITEM PRABC REGISTRATION SELECT 510 06 DAILY ITEM ITEM couNrABc 1 0 33 WEEKLY ITEMITEM WT ABC b10 07 DAILY ITEM ITEM PRICE Z b10 34 WEEKLY ITEM ITEM b10 08 DAILY ITEM ITEM WeIGHTz b 1 0 35 WEEKLY ITEM TEM PRZ 510 09 DALY ITEMITEM COUNTZ b 10 36 _ WEEKLY ITEM TEM WT Z 10 10 b10 37 WEEKLYITEMITEM CT Z 10 11 DAILY ITEM DPT PR ABC 510 38 wEEKLYITEWDPT 510 12 DAILY ITEM DPT WT ABC b10 39 PRABC b10 13 b10 40 WEEKLYITEMDPT WT ABC b10 14 J payvirewpPr PRZ b 10 41 WEEKLYITEMDPT b10 15 panyiremorr wrz b10 42 WEEKLY ITEM DPT PRZ b10 16 DAILY ITEM DPT CT Z b10 43 WEEKLYITEWDPT WT Z b10 17 DAILY ITEM GR b10 44 WEEKLYITEMDPT CT 510 18 panvitewar PRABC b10 45 WEEKYITEMWGR b10 19 _ DpAILYtrem ar wT aBc 510 46 WEEKLY ITEMGR PRABC 10 20 panyiremar b10 47 WEEKLYITEM GR WT ABC 1 22 _ 10 49 510 232 owrmeemors _ 50 wesntvrewan wr 10 25 oauvoeranmenr b10 52 weexiveronrrora b10 26 b 10 53 weexvoeranrwent 10 27 510 54
38. 00 SERVICE MANUAL 0077B Display Check C01 03 This mode tests the dot fluorescent display and digital fluorescent display operation by lighting both displays to indicate normal condition Press to start display check Press END to exit display check NET Check C01 04 This test confirms whether NET circuitry is working properly 1 RAM check 01 04 01 This performs RAM check of internal communications chip between scales Press to start test OK is displayed after self test is complete 2 Loop Back Test 01 04 02 This tests the transceiver driver and receiver Press to start test OK is displayed after self test is complete 3 PNET Program No Display C01 04 03 This displays the program version of the PNET circuitry e Press to exit FNET check WPL 3000 SERVICE MANUAL 0077B erate CHECE ENTER CON 03 tener Eu TER 1 04 2HET chack PRINT C0O1 04 01 LOOP BACK TEST PRINT 201 04 02 n 0 1 0 4 05 184 Test Mode 3 Program No Display C01 05 This displays program number and program version of ROM on main board to display FONT program number and version Conveyor Elevator and Applicator Test 01 06 This tests the label application arm opera tion and weigh conveyor elevator Press to test the label applicator s movement e Press
39. 01 0 nation of each step DATE PRINT 4 BOTH 1 4 1 b04 02 P TIME 1 PROHIBIT 1 1 0 b04 03 E TIME 1 PROHIBIT 100 b04 04 1 100 OPEN PRICE gt 2 ALLOW 2 2 b04 05 2 FORCED TARE 2 NO 2 b04 06 2 2 WPL 3000 SERVICE MANUAL 0077B 4 9 Setting 4 MENU SETTING ITEM ENTRY REFERENCE b04 01 Initial data for 3 digits N A in USA version register code 604 02 DATEPRINT Select by arrow then make numeric entry Select by arrow When number of days equals 1 the shelf life is key Numerical xS limited to the present day 1 PROHIBIT Enter 0 2 PACK DATE Enter 0 3 EXPIRE 3 digits for shelf life 4 BOTH Default 4 BOTH 1 b04 03 PACK TIME Select by arrow then make numeric entry Designated time from 0 11 is Numerical a m and 12 23 is p m 1 PROHIBIT Enter 0 2 INSTALLED Enter 0 3 DESIGNATED Enter 4 digits Note Select 2 INSTALLED designated time e g for AM 8 enter 800 Default 1 PROHIBIT 0 b04 04 EXPIRE TIME Select by arrow then make numeric entry Designated time from 0 11 is Numerical a m and 12 23 is p m 1 PROHIBIT Enter 0 2 DESIGNATED Enter 4 digits designated time e g for AM 8 enter 800 3 RELATIVE Enter time in minutes e g for a 3 hour increase in internal time enter 180 Default 1 PROHIBIT 100 b04 05 OPEN PRICE Select by arrow or numerical entry N m rical Default
40. 1 1 5 msec RESET key operation 00 Enable 01 Disable Receive to transmit turn around timer 01 1 5 msec Decimal Point Position Total Price Position from right 01 no decimal point Decimal Point Position Weight Position from right 01 no decimal point Decimal Point Position Unit Price Position from right 01 no decimal point Second Nutrition Label Label Format 1 00 None 01 Short 02 Long Second Nutrition Label Label Format 2 00 None 01 Short 02 Long Second Nutrition Label Label Format 3 00 None 01 Short 02 Long Second Nutrition Label Label Format 4 00 None 01 Short 02 Long Second Nutrition Label Label Format 5 00 None 01 Short 02 Long Second Nutrition Label Label Format 6 00 None 01 Short 02 Long WPL Conveyor Time Out 00 No Conveyor runs continuously 01 Yes Stop after 10 minutes of non use ROM Address Default Value WPL 3000 SERVICE MANUAL 0077B 3 10 Test Mode 3 ROM Switch List Test Menu 6 ROM SWITCH WPL Configuration 00 Straight through In Line 01 L shape Shelf Life 00 Today counted as one day 01 Today not counted add one day to shelf life Sta
41. 10 08 DALYITEMITEM WEIGHT Z b10 09 DAILY ITEM ITEM COUNT Z b10 10 DAILY ITEM DPT b10 11 DAILY ITEM DPT b10 13 519215 mwmworwz EXCLUDE b 10 16 DALYITEMDPT 2 0 18 DALYITEM GR PRABC 1 0 19 DAILY ITEM GR WT ABC b10 20 bALYITEM GR 0 21 0 22 0 23 DAILY ITEM GR CT Z DAILY ITEM GR PRZ DAILY ITEM GR WT Z 0 24 DAILY PROFIT TOTAL 0 25 0 26 DAILY GROUP DAILY DEPARTMENT 0 27 DAILY HOURLY TOTAL b10 28 DAILY OPERATOR TOTAL b10 29 WEEKLY SALES TOTAL b 10 30 WEEKLY MACHINE TOTAL b10 31 WEEKLY ITEM TEM 0 32 WEEKLYITEM TEM PR ABC 0 33 WEEKLY WT ABC 0 34 WEEKLY ITEM TEM CT ABC 0 35 WEEKLY ITEM TEM PR Z 0 36 WEEKLY ITEM TEM WT Z 0 37 WEEKLY ITEM TEM CT Z 0 38 0 39 WEEKLYITEM DPT PRABC 0 40 WEEKLYITEM DPT WT ABC Q 4 1 WEEKLY ITEMDPT 0 42 _ WEEKLY 4 12 WPL 3000 SERVICE MANUAL 0077B MENU NO SETTING ITEM ENTRY b10 43 WEEKLY ITEM DPT WT Z b1 0 44 WEEKLYITEM DPT CT Z 10 45 WEEKLY ITEM GR b10 46 WEEKLY ITEM GR PRABC 0 EXCLUDE 10 47 WEEKLY ITEM GR WT ABC b10 48 WEEKLY ITEM GR
42. 2 4 for starting test mode RESISTANCE 627 C03 01 627 PRINT USAGE km 0 0km C03 02 0 0 PRINT DENSITY ADJUST 1 9 5 C03 03 5 4 Print a test label WPL 3000 SERVICE MANUAL 0077B NX PONEV Urn Label Sensor The label sensor utilizes a photo interrupter Gaps between labels are detected to ensure labels are issued one at a time Label sensor adjustment is performed to compensate for differences in light transmission which vary according to the type of label paper being used SENSOR BOARD STEPPING MOTOR Fig 7 11 Label Sensor SENSOR FINE ADJUSTMENT KNOB ROUGH ADJUSTMENT POTENTIOMETER SENSITIVITY Fig 7 12 Adjustment Controls label sensor T The LED flashes as the gap between labels passes through the CAUTION 7 8 WPL 3000 SERVICE MANUAL 0077B 1 Align the fine adjustment knob to center 2 Turn the rough adjustment potentiometer counterclockwise as far as it will go 3 Press the Paper Feed key once and adjust the rough adjustment potentiometer clockwise to the position where a single lable is issued This point is A 4 Turn the rough adjustment potentiometer clockwise as far as it will go 5 Press the Paper Feed key once and adjust the rough adjustment potentiometer counterclockwise to the position where a single label is issued This point is B 6 Set the rough adjustment potentiometer midway between points A and B
43. 2 Err 2 Floppy disk does not verify Reload data to from disk Create new master disk 3 Err 3 No disk in IF 21FD floppy disk recorder Install DS DD floppy disk into recorder Bad IF 21FD disk drive Repair IF 21FD 4 Err 4 Cannot record to floppy disk because it is Switch write protect tab on the disk to write protected correct position 5 Err 5 Attempting to overwrite existing file Select an unused file number floppy disk Attempting to receive verify or delete Select an existing file number a nonexistent file on floppy disk Err 6 IF 21FD floppy disk unit not configured Check that only DIP switches 2 and 5 correctly are in the down position Check that the IF 21FD has the latest firmware version J 209N Use 9 pin cable not 25 pin cable 7 Parity error in communication protocol error in communication protocol Parity error in communication protocol Check scale CPU board Check scale CPU board CPU board Err 8 Floppy disk memory overflow Restart with a blank floppy disk Erase unused files from floppy disk Err 9 Operation error Begin SAVE LOAD procedure again following correct procedure Refer to Section 3 2 13 if needed Floppy disk format error Reformat floppy disk Err 66 Data on disk is corrupted Create new master disk Scale memory is corrupted Clear scale memory reload disk File is too large for scale memory Reduce f
44. 4 2 1 Label Format b01 Label format settings are performed in this mode b01 0 LABEL FORMAT NUMBER b01 01 See the table below for a detailed explanation of each step W BACKING 0 INDIVIDUAL 1 b01 03 FIELD TITLE PRINT Yz1 b01 04 No 1 STORE NAME ADDRESS 1 YES 0 NO b01 05 COMMODITY 0 5 2 7mm 10 8 b01 06 LABEL LENGTH GAP 46 5 b01 07 SENSOR 2 DISTANCE 108 5 b01 09 WPL 3000 SERVICE MANUAL 0077B 4 5 Setting Mode 4 MENU SETTING ITEM ENTRY NOTES Label Format Number 0 Receipt 1 Format 1 60 x 44 2 Format 2 64 x 85 Safe Handling Setable to 47mm 3 Format 3 64 x 110 Bakery 4 Format 4 64 x 85 Coupon 5 Format 5 66 x 145 Bakery 3 part 6 Format 6 64 x 90 Vertical Nutrition 7 7 64 x Safe Handling Peel off type 1 Peel off type paper or peel off one at a time b01 04 Print Field Titles No title printing Select if scale will print legends Printing and address Product Description 0 99 5 0 5 increments One line of character size 3 1 0 area Includes name One line of character size 120 5 Must enter values in increments of 0 5 ingredients and 0 5 2 7mm 1 0 5 4mm messages 2 0 10 8mm 4 0 21 6mm Label length 0 999 9 0 1 increments Length includes label length and space including gap Maximum 175mm Note Maximum length for automatic application is 85 0mm b01 09 Label sensor distance 0 999 9 0 1 incre
45. 834 A 16 bit microprocessor is installed on the main board controlling data man agement for the entire machine A lithium battery is used as a power source for backing up memory data This lithium battery is not rechargeable The CPU board monitors and controls the following functions 1 N Main body control 14 A D conversion input Keyboard data input IC15 Output to display board Wan FPROM Label feed motor and thermal head printing output Label sensor and label taken sen sor input Conveyor control output BOARD 892 STEPPING MOTOR LABEL SENSOR THERMAL HEAD BATTERY SWITCH LITHIUM BATTERY IC12 PD70208G 10 CPU V40 F1 1A 5V POWER FUSE Fig 7 5 Main CPU Board asterisk indicates latest version subsequent versions will be followed by letter e g A B C Note 15 CHIPO socket contains the Main Program EPROM It begins with the letter B C Z based on the program function IC14 CHIP1 contains the Font Program It begins with the letter F
46. 9 Jeu Jamol jeuonuinN 96 V UILJEMHA jeuonuinN SHUN 8101 416 ulejoJg en qi 1u619M syun sreBng enr siun 18q14 1eqi4 96 SayespAyoquey spun sayespAyoquea Jequinw WNIPOS eoug pejunoosiq unipos junoosiq eoug 01915 2 BO 210 1019121049 0 150 049 HUN 184 Syun ye4 papens payeinyes uonduoseq 3 146189H A UIPIM X X M N 9121 04 PIO 18 8101 uoloun4 99160 9 14619H A UPIM X iuDieH UPIM X M N OO0E 1dM PIO SseJppy euieN uoloun4 pJepuels WPL 3000 SERVICE MANUAL 0077B Appendix 10 YIPIM X 1091 lt esn SH38gINN 12 0 Shey 4 esn ajon e oqe pejuud op se seseeJoui osje eseu seseeJoui
47. ABSORPTION PLATE Fig 7 26 Disassembly Diagram label applicator unit WPL 3000 SERVICE MANUAL 0077B 7 47 8 Weigh Convers 8 1 Weigh Conveyor 222 8 2 8 2 Block Diagram soa ihid nhe deep Rd 8 3 8 3 Electronic Components 8 4 8 3 1 Power Supply Unit 8 4 8 3 2 Drive Board 854 8 5 8 3 3 Electromagnetic Valve 8 5 8 3 4 sp cep 8 6 8 3 5 Application Timing Sensor 8 7 8 4 Elevator Check and Parts Adjustment 8 8 8 4 1 Weigh Conveyor 8 8 8 4 2 Conveyor Fall Prevention Screw A justmoent eerte bienes 8 9 8 5 Disassembly Diagram 8 10 Weigh Conveyor Unit 8 8 1 Conveyor Unit When the scale has weighed a product the weigh conveyor on the intake side rises to transport the weighed product to the printer unit where labels are issued and attached by the label applicator unit WEIGHED PRODUCT WEIGH CONVEYOR WEIGHER UNIT THE END OF THE WEIGH CONVEYOR RAISES AND LOWERS To remove the Weigh Conveyor Unit 1 Remove the conveyor belt from pulley as shown below 2 Grip the handles and lift the weigh conveyor straight up Fig 8 1 Weigh conveyor unit CONVEYOR BELT WEIGH CONVEYOR PULLEY CON
48. C02 01 Ram Clear b 02 02 E ROM Clear c 02 03 Test Set Optional Set L Configuration TEST MENU C06 ROM Switch Page A 7 Set address 003A 01 Assign ROTATE function key TEST MENU C10 Section 3 2 11 Assign PF4 19 rotate Label Format a SETUP MENU b01 Section 4 2 1 i Select format number 601 01 ii Set text area b01 06 iii Set label length gap b01 07 iv Set Sensor 2 b01 09 to ensure label comes free of the backing paper b TEST MENU C07 Section 3 2 8 i Modify label format as needed Set Applicator Stroke SETUP MENU b16 03 Section 4 2 11 a Applicators i Standard 08 typical setting ii Extended 05 typical setting b Test and adjust as necessary for maximum travel but no delay in up stroke Delay Package on Scale SETUP MENU b16 01 b16 02 Section 4 2 11 a Set b16 01 100 b Set b16 02 100 Note These delays are necessary to set the correct times for the next step Label Placement Standard SETUP MENU b16 04 Section 4 2 11 a Test label placement b Adjust b16 04 setting as needed i alower value moves the label to the leading edge of the package ii a higher value moves the label to the trailing edge of the package Set Delay of package on scale to minimum SETUP MENU b16 01 b16 02 Section 4 2 11 a Test delay WPL 3000 SERVICE MANUAL 0077B Appendix b Set b16 01 to the minimum time that allows the label to be completely printed c Set b16 02 by the same method 9 Switch
49. C99 3 15 Test Mode 3 3 1 Menu Directory DIAGRAM BR HARDWARE TEST EN CHECK 5 CHECK I2NET CHECK BH PROGRAM conveyor TEST ALL RAM CLEAR E2ROM CLEAR TEST SET RESISTANCE PRINT USAGE THERMAL HEAD IN km SENSOR CHECK EXTRA MEMORY Ed ABEL FORMAT EJ SALES CSIS MODE NODE NUMBER PRESET FUNCTION KEY PAssworp DATA SAVE LOAD EH TRANSFER FILE PRINT DENSITY ADJUST 1 9 SELECT SEND RECEIVE VERIFY DELETE IF21 FILE No INITIALIZE DISK WPL 3000 SERVICE MANUAL 0077B 3 2 Test Mode 3 3 2 Test Move 3 2 1 Starting Test Mode To enter test mode turn off the machine and restart while pressing any key exclud ing to enter test mode When cee test mode appears on screen release the pressed key J to scroll through the menu choices or enter corresponding menu number and press to jump to desired test mode operation Use ENTER to select test mode opera tion or enter menu number and press to select test mode operation directly 3 2 2 Hardware Test CO1 The following hardware items are checked in this test mode operation 1 A D Converter Check Key Check Display Check Dot and digital fluorescent display PNET Communication Che
50. CT ABC 510 49 WEEKLY ITEM GR PRZ 1 PRINT b10 50 WEEKLYITEM GR WT Z b10 51 WEEKLY ITEM GR CT Z b10 52 WEEKLY PROFIT TOTAL b10 53 WEEKLY DEPARTMENT b10 54 WEEKLY GROUP WPL 3000 SERVICE MANUAL 0077B 4 13 Setting 4 4 2 7 Registration Select b11 This prohibits or enables menu items for selection on the registration menu Enter the numerical value 0 or 1 and press for each selection REGISTRATION SELECT ENTER b11 0 PLU FILE 1 ENABLE b11 01 1 ONLINE SETUP FILE DOWNLOAD NUTRITION FILE UNIT PRICE CHANGE LABEL SELECT MENU NO SETTING ITEM 52511 01 PLU FILE b11 02 COMMODITY NAME b11 0 3 PRICE CHANGE b11 04 EXTRA MESSAGE 611 05 COUPON b11 06 DATE TIME b11 07 STORE NAME b11 08 PRESET KEY 611 09 LIST b11 10 DEPARTMENT 11 11 GROUP b11 12 OPERATOR b11 1 3 ADVERTISING MES 611 14 CAMPAIGN 11 17 MACHINE NO b b b b b b 11 24 4 14 1 ENABLE Show 0 PROHIBIT Hide WPL 3000 SERVICE MANUAL 0077B 4 2 8 Total Mode Select b12 This prohibits or enables access to report totals types Enter the numerical value 0 or 1 and press for each selection Setting Mode 4 BAR CODE ENTER b02 0 MENU NO SETTING ITEM ENTRY 12 01 DA
51. Connector Peeling sensor UL tube J2 P 838 A E Connector No 1 Fig 7 20 Peeling Sensor WPL 3000 SERVICE MANUAL 0077B 7 13 7 4 ADJUSTMENT POSITION OF THE LABEL APPLICATOR Un sum Misadjustment of the applicator unit can be a cause of misapplied labels This section will explain the procedure for adjusting the posi tion of the applicator unit 1 Parallel adjustment Loosen the hinge screws 3 and the snap lock screw 2 Adjust the label applicator to be parallel with the peeling bar Refer to Figure 7 21 2 Height Position Adjustment Loosen the hexagonal stop screw holding the shaft with an Allen wrench Turn the shaft with a screwdriver and adjust the distance between the absorption plate and peeling bar within 0 5 10 2mm Reter to Figures 7 22 and 7 23 3 Labeling Confirmation Issue labels and test application If misapplication does not occur after issuing more than 50 labels than adjust ment is complete 7 14 A Ey F OMM al ABSORPTION PLATE 0 5 Zmm Fig 7 22 Hasght Adjustment APPLICATOR UNIT HINGE Fig 7 23 Height Adjustment detail WPL 3000 SERVICE MANUAL 00778 Printer Label Applicator Unit 7 7 5 Movement TEST Labeling arm test and peeler sensor and label sensor test can be performed from the Test Mode Refer to Test Mode Section 3 2 1 for starting test mode Labeling arm test When the screen to the right is shown in the display press
52. Conveyor lowers for next product Note 10 1 10th second delay WPL 3000 SERVICE MANUAL 0077B Delay Timer Non Weigh gt 60mm Increase if product reaches labelling position before printing is completed Time between A and B where A Label begins printing B Conveyor lifts to move product Note 10 1 10th second delay 4 17 Setting 4 4 18 WPL 3000 SERVICE MANUAL 0077B Chapter 5 Controle U nit dde 5 2 5 2 Block Diagram ertt 5 3 5 3 Electronic Parts 5 3 1 Display ehe 5 3 5 3 2 Junction Buzzer Board 5 4 5 4 Display and Key Check 5 6 5 5 Disassembly Diagram oerte 5 7 Controller Unit 5 5 1 OVERVIEW The WPL 3000 display GP1046A01AA uses a Fluorescent characters and a fluorescent digital display for numbers The keyboard uses membrane keys Refer to the Operation Manual for an explanation of the function keys dot display for a 4 4 4 4 4 44 44 ig 5 1 Controller Unit WEIGHT b UNIT PRICE TOTAL PRICE _ ZERO SAVE AUTO WPL 3OOO C PLU ei Scale capacity 30 X 0 01 Ib Conveyor capacity 10 X 0 01 lb MESSAG Y Y Y Y EXTRA COUPON DISPLAY SPEED DATE PLU STORE RECEPT CHAR TEXT TEXT TEXT
53. Defective thermal head Defective thermal head cable Defective main board Defective power supply unit WPL 3000 SERVICE MANUAL 0077B Reinsert power plug Replace fuse Check replace power switch Check replace main board Check replace power unit Check replace keyboard Check replace main board Check change installation site Check replace load cell Check replace main board Check replace power unit Adjust weigh platter position Perform four corner test Remove foreign matter Adjust replace load cell Check replace main board Check connectors Check replace main board Check replace display board Check Junction Board P 887 Check replace keyboard Replace battery Check change installation site Check replace main board Check power source voltage Check replace power unit Check replace display board Check replace main board Clean thermal head Adjust replace thermal head Check replace cable Check replace main board Checkthermal head applied voltage Check replace power unit Troubleshooting 9 9 3 Error MESSAGES Note To clear error messages from display press CLR key OPERATION CHARACTER OVER Too many characters Edit product description Err 02 one line in product by removing excess description characters per line POP MESSAGE OVER CHARACTER Too many characters Edit product description s
54. E MANUAL 0077B 2 5 Setup 2 2 4 2 Fastening Stands Secure conveyor stands to floor using anchor bolts Attach joint to stands so neither conveyor stand can move METAL FITTING JOINT ANCHOR BOLT Tightly fasten the nuts securing the leveling leg NUT LEVELING LEG Fig 2 6 Fastening Stands 2 6 WPL 3000 SERVICE MANUAL 0077B Setup 2 2 4 3 Stand Fastening Method 1 Fasten stand to floor ANCHOR BOLT AND WASHER 4 LEVELING LEG Fig 2 7 Method 1 2 4 4 Stand Fastening Method 2 Fasten anchor bolt and leveling leg to anchor plate ADJUSTABLE PRESSURE FITTING EXAMPLE 74 5 Fig 2 8 Method 2 WPL 3000 SERVICE MANUAL 0077B 2 7 Setup 2 2 5 CONNECTING CABLE Connect each cable as shown below Tie up and secure excess printer cable PRINTER UNIT CONTROLLER UNIT WEIGH CONVEYOR UNIT Fig 2 9 Connecting Cable TIE UP AND SECURE EXCESS PRINTER CABLE AND FASTEN COVERS WITH SCREWS IMPORTANT NOTE Later versions of the WPL 3000 use a front mounted printer arm WPL 3000 SERVICE MANUAL 0077B Setup 2 WEIGH CONVEYOR UNIT INFEED CONVEYOR UNIT OPTION Fig 2 11 Connecting Cable 2 6 SETUP PROCEDURES Refer to Appendix A 1 Installation Notes for more information 1 Performing RAM Clear Insert electrical plug into electrical outlet Refer to Test Mode 2 RAM CLEAR in this manual section 3 2 3 and perform initialization of all RAM data 2 Formatting Label
55. ET SWITCH PRESS DOWN TO TURN Switch Set only 2 and 5 down WPL 3000 SERVICE MANUAL 0077B 3 15 Test Mode 3 T Before using a new floppy disk for the first time perform Step C99 03 to format the disk Use 2DD type disks only CAUTION All IF 21FD operations are controlled from the WPL 3000 3 2 13 1 Data Transfer Select IF21 File No C99 02 01 Enter the IF 21FD file number 1 8 to be used then press ENTER SELECT IF21 FILE NO 0 99 02 01 0 0 Send C99 02 02 This sends data from WPL 3000 to SEND 1 ALL FILES 1 IF 21FD C99 02 02 nol Enter selection number of the data to be sent and press ENTER ALL FILE Press PRINT to begin sending Note Select number using key Receive C99 02 03 This receives data from IF 21FD to WPL 3000 Enter selection number of the data to be received and press ENTER Press PRINT to begin receiving Note Select number using key Note 1 Master File contains all data programmed in Registration Mode E ROM File contains all configuration setting changes made in Setup and Test Modes 2 Master File contains file numbers 4 9 and 12 21 3 E ROM file contains file numbers 10 Label Format and 11 Setup File RECEVE 1 ALL FILES 1 99 02 03 nol 1 IMPORTANT When upgrading firmware or transferring files from one model to other DO NOT load 11 SETUP FILE This file is incompatible and will cause u
56. Err 40 SYSTEM ERROR Err 42 NO POWER SCALE SCALE ERROR Err 51 REMOVE ITEM ON THE PLATTER Err 56 REMOVE ITEM ON THE PLATTER Err 57 WPL 3000 SERVICE MANUAL 0077B Package exceeds programed upper weight limit Package does not reach programmed lower weight limit Label cannot be printed until previous label is removed from label applicator Package weight exceeds conveyor capacity Standard capacity is 10 pounds Memory in FAT area has been corrupted Malfunction in main program does not start up A D board is discon nected or malfunctioning NV RAM calibration data in A D board has been corrupted Scale is unstable or was powered up with some object on the platter Scale was powered up with some object on the platter Troubleshooting 9 Remove package from scale Change weight limit Remove package from scale Change weight limit Remover label from applicator Check clean label sensor Reduce weight of the package Change to Manual weighing labeling with the PREPACK key Re initialize all memory including RAM and E2ROM Check possible CPU board failure Check firmware chips Re initialize with clear Check A D board cabling Replace A D board Recalibrate scale Remove internal external cause of instability Power up the scale with nothing on the platter Power up the scale with nothing o
57. Fastening Method 1 2 7 2 4 4 Stand Fastening Method 2 2 7 2 5 Connecting Cable eerta aon 2 8 2 6 Setup 2 9 2 7 Method for Threading Labels 2 10 2 8 WPL 3000 USA Rescue Mode 2 11 Setup 2 2 1 CONFIRM BEFORE DELIVERY 2 1 1 Location Maintain adequate space for setup and maintenance as shown below Fig 2 1 Allow adequate space for WPL 3000 IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm 2 1 2 Installation Route The WPL is 446mm 17 5 in x 1085mm 42 75 in and requires an entrance and delivery route wider than 446mm 17 5 in The route should be maintained at all times 2 1 3 Electrical Power Electrical voltage as well as electrical plug and standards vary according to coun try Always use the appropriate voltage and plug In addition noise and voltage changes can affect performance so connect plug to a dedicated outlet and place in an appropriate environment 2 1 4 Setup Environment Installation site should 1 Be stable and level Not be exposed to moisture Not be exposed to direct sunlight for long periods Not be exposed to wind or strong vibration Have sufficient area for installation and maintena
58. ILY TOTAL ENABLE 0 PROHIBIT 12 02 WEEKLY TOTAL ENABLE 0 PROHIBIT 512 03 MONTHLY TOTAL ENABLE 0 PROHIBIT 4 2 9 Password b13 This allows passwords to be changed for registration total and subtraction modes Enter a 1 to 4 digit number and press ENTER to set password PASSWORD ENTER b13 0 REGISTRATION MODE 9000 b13 01 MENU NO SETTING ITEM DEFAULT 13 01 REGISTRATION 9000 13 02 TOTAL MODE 8000 b13 0 3 SUBTRACTION MODE 7 0 0 0 ITEMS IN PARENTHESES DENOTE DEFAULT SETTING Note A password of 6000 can not be entered WPL 3000 SERVICE MANUAL 0077B 9000 4 15 Setting 4 4 2 10 Tray Master Registration b15 4 16 The infeed conveyor delay time may be set by tray size The infeed conveyor carries items a distance of 5mm ina time of 10 msec Use 10 msec intervals to set delay time Example A 6 inch tray with a set value of 50 would result in a delay time of 500msec Use this setting to center packages right to left on the weighing element margeng e iwek CMM 15 11 teineh o E TRAY MASTER ENTER b15 6 inch Trey b15 01 Note Tray Master settings are only used when the WPL 3000 is configured for straight I line operation WPL 3000 SERVICE MANUAL 0077B Setting Mode 4 4 2 11 Conveyor Setup b16 Use this step to set the timing for package mo
59. ISHIDA v WPL 3000 SERVICE MANUAL IMPORTANT e not carry out installation operation service or maintenance until thoroughly understanding the contents of this manual e Keep this manual available at all times for instal lation operation service and maintenance ISHIDA CO LTD Manual No 0077B 48725 You can help improve this manual by calling attention to errors and recommending improvements Please express your comments to the nearest Ishida Company representative Thank you Copyright 2001 by Ishida Co Ltd All Rights Reserved No part of this manual may be reproduced in any form by photocopy or any other means without written permission from the publisher SAFETY CONSIDERATIONS These safety measures must be followed to ensure the safe servicing of this machine Servicing is to be done by qualified service personnel only These service instructions are for use by qualified service personnel who fully understand the potential hazards involved To avoid any possible danger do not perform any service procedures unless qualified to do so Perform only the specified service procedures To ensure personal safety do not perform any service procedures which are not specifically mentioned in this service manual Properly ground machinery As a Class 1 electrical device this machine requires protective grounding for safe operation Avoid servicing while power is being supplied Machine servicing whi
60. NTER Col 0 2 Select A D check 01 01 and press BH CHECK ENTER ENTER 01 01 0 3 Press ZERO ZERO ZERO SPAN TARE Confirm that the A D converter initial value 0 2000 0 is stabilized within 2000 1 count Note See Section 10 3 for calibation procedure 6 6 WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor 6 6 5 DisAssEMBLY DIAGRAM WEIGH PLATTER UNIT E 756 77 7 7 l l l l l l l l l l l l ROLLER UNIT l l l l l u mm mm SCALE UPPER CASE A D CONVERTER BOARD P 830B Fig 6 8 Disassembly Diagram WPL 3000 SERVICE MANUAL 0077B 6 7 Chapter 7 TA HOVER MEET 7 2 7 2 Block Diagram 7 3 P 7 3 Electronic Components 7 4 ri n r 7 3 1 Printer Unit te abe Thermal head label sensor adjustment 7 4 7 3 2 Label Applicator Unit 7 10 A 7 4 Adjustment Position of the Label ppl ICator Applicator Unit n denotes 7 14 7 5 Movement Testi uer Fir bar turn nee pao 7 15 7 6 Disassembly Diagram Stand Unit 7 16 It 7 7 Disassembly Diagram Printer Unit 7 16 7 8 Disassembly Diagram Label Applicator Unit 7 17 Printer Label Applicator Unit 7 7
61. PC TYPE 1 UPC CODE 5 1 b02 04 1 SETTING NO CODE SYSTEM SETTING NO CODE SYSTEM 1 UPC CODE 5 10 EAN CD 4 WT 5 2 UPC CODE 6 11 0 COD 4 PR 5 3 EAN CODE 6 12 MN 3 CD 2 PR 5 4 UPC PRICE 5 13 MN 2 CD 3 PR 5 5 EANQ CD 4 PR 5 14 FG 1 COD 6 PR 4 6 EANQ PR 4 C P 5 15 FG 1 COD 6 PR 5 7 EAN CD 6 WT 4 16 FG 1 COD 6 WT 5 8 EAN CD 5 WT 5 9 EAN CD 4 PR 6 Default Note Layout of popular UPC formats 1 FFIIIII PPPP C D 2 C D 4 C D 6 C D 4 2 3 Code Settings b03 e Sets digits for Department position e Sets digits for Group position e Sets digits for UPC 8 position e Sets digits for UPC 13 position Code is used to set the code positions for department group etc for totals accumula tion Enter numerical value and press ENTER for each selection Note Item Code format DOOMOOM step 1 16 in PLU programming Example Group set to 42 starts at the fourth digit and uses two digits 12345678 E cope ENTER b03 0 DEPARTMENT 31 b03 01 31 GROUP 42 b03 02 42 UPC 8 REFERENCE 42 b03 03 42 UPC 13 REFERENCE 45 b03 04 45 WPL 3000 SERVICE MANUAL 0077B Setting Mode 4 4 2 4 Setting Initial Data b04 This is used to set initial data Enter numerical value and press for each selection See the table below for a detailed expla 504
62. Print Format Setting Refer to Test Mode 7 LABEL FORMAT section 3 2 8 Label Length Setting Refer to Setting Mode 1 LABEL FORMAT section 4 2 1 3 Registering Date and Time This is performed in registration mode Refer to Programming Manual 4 Program PLU file This is performed in registration mode Refer to Programming Manual 5 Making Test Print Thread labels and confirm that printing is normal Refer to Test Mode 3 THERMAL HEAD section 3 2 4 6 Performing Total Clear Refer to Programming Manual 7 Backing Up Data Back up registered data to a floppy disk Refer to Test Mode 99 DATA SAVE LOAD section 3 2 13 WPL 3000 SERVICE MANUAL 0077B 2 9 Setup 2 2 7 METHOD FoR THREADING LABELS Thread labels as shown below For a detailed explanation of threading the label reel refer to Operation Manual LABEL HOLDING SHAFT PRINT HEAD RELEASE LEVER LABEL SENSOR WINDING SLEEVE Fig 2 11 Arrows indicate thread direction 2 10 WPL 3000 SERVICE MANUAL 0077B Setup 2 2 8 WPL 3000 USA Rescue When the address and store name have been changed there is a possibility that the registered data is greater than the allocated space on the label As a result a hitch can develop when starting in standard mode To eliminate this problem it is neces sary to either delete the data or correct the data responsible for this hitch When WPL 3000 cannot enter standard mode after power is turned ON the machine c
63. This is position B operation Check that the stable green PROCEDURE orange lamp is OFF This is position A Turn the potentiometer CW until the lamp is lit in all cases If the orange lamp does not turn off position A is fully CW orange lamp is OFF and the green lamp is fully ON This is position C CW clockwise CCW counter clockwise WPL 3000 SERVICE MANUAL 0077B 8 7 Weigh Conveyor Unit 8 8 4 ELEVATOR CHECK AND PARTS ADJUSTMENT mm The elevator check for the weigh con veyor can be performed when the ma chine is in test mode Refer to Test Mode Section 3 2 1 and 3 2 2 for procedure for starting test PLUNGER PRINT ELEVATOR PLU mode 01 06 00 0 conveyor TEST 01 06 At step 01 06 00 press to perform the elevator test 8 4 1 Weigh conveyor To confirm and adjust the tension of the conveyor drive belt follow the procedures below 1 Confirm belt tension 9 11mm 3 8 7 16 F MOTOR PULLEY When pressed with a force of 1kgf 2 2 LBF in the middle of the belt the belt should give 9 11mm 3 8 7 16 Fig 8 10 Conveyor Belt 2 Belt tension can be adjusted by changing motor position To adjust tension loosen the four motor mounting bolts on the under side of the main body Move the motor as needed 8 8 WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor Unit 8 Conveyor belts must be tight to prevent slipping To adjust tension loosen the roller scr
64. VEYOR BELT PULLEY Fig 8 2 Removing Weigh Conveyor 8 2 WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor Unit 8 8 2 BLock DIAGRAM CONTROLLER UNIT Keyboard Display PRINTER UNIT INDEXING LABEL APPLICATOR PHOTO SENSOR TIMING SENSOR ELECTROMAGNETIC AIR VALVE INFEED CONVEYOR m P 854 POWER SUPPLY UNIT SCALE UNIT Drive Board SLS150PW t A D BOARD P 830B LOAD CELL UNIT CLC 25N P 854 Drive Board TERMINAL Power Cord P 859 Power Filter P Socket Board MOTOR MOTOR 5IK40GN ALU 5CGK 01 5IK40GN ALU E64197 WEIGH CONVEYOR Main Power Switch Fig 8 3 Block Diagram Later designs incorporate a single P 854 Drive Board t Later designs incorporate two 24V DC power supplies LSF 100 24 36 3409 01 Main 24V DC LDA 30F 24 46 3180 09 Fans WPL 3000 SERVICE MANUAL 0077B 8 3 Weigh Conveyor Unit 8 8 3 ELECTRONIC COMPONENTS 8 3 1 Power Supply Unit 84 The control box inside the weigh conveyor contains the power supply driver board and other electronic components regulating the machine Fig 8 4 Inside of Control Box SLS150PW The power supply unit supplies stable 24V DC power to the control ler unit printer unit and scale Electrical power to IC s 5V and the load cell 12V is stepped down by regulators located on the main CPU board in the printer unit Fig 8 5 Power Supply Unit Note Later designs use two
65. and knob clockwise as far as they will go Turn the knob counterclockwise four rotations and tighten the nut For decreasing speed Turn knob clockwise For increasing speed Turn knob counterclockwise RAISE CONVEYOR SPEED CONTROL KNOB LOWER CONVEYOR SPEED CONTROL KNOB Fig 8 8 Air Cylinder 8 6 WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor Unit 8 8 3 5 Application timing sensor This sensor detects products and initiates the timing for applying labels to the prod ucts Two LEDs in the sensor confirm that the sensor is working properly SENSITIVITY ADJUSTMENT POTENTIOMETER SIGNAL OPERATION DISPLAY LIGHT Fig 8 9 Application timing sensor The green LED indicates stability and should be on when power is supplied to the sensor The orange LED is off when the sensor is aligned with the reflector and on when the reflected beam is blocked or out of alignment lt Sensitivity Adjustment Method gt STEP 1 GRADUATION A 2 GRADUATION B 3 SETTING BACKGROUND PHOTO CELL SWITCH DETECTING TO CELL SWITCH OBJECT 50 lt DETECTING E CONDITION E TEM SENSITIVE B ADJUSTMENT VOLUME Place the item to be detected in position Remove the detected item From position Set the potentiometer half way between Start with the potentiometer fully CCW A turn the potentiometer CCW until the position A and position C Test the sensor ADJUSTMENT Turn the potentiometer CW until the orange lamp turns ON
66. annot enter setting or registration mode For these situations when the machine does not enter standard mode after starting it is necessary to use Rescue Mode Rescue Mode by passes standard mode to enter another mode 1 With the HELP key pressed turn ON the machine 2 Rescue Mode appears after the display check sequence 3 In Rescue Mode the Registration Menu and Setup Menu may be accessed by using the appropriate password followed by 4 When the temporary process is complete turn OFF power and restart 5 Machine should enter standard mode WPL 3000 SERVICE MANUAL 0077B Setup 2 2 12 WPL 3000 SERVICE MANUAL 0077B Chapter 3 3 1 Menu Directory Diagram 3 2 3 2 Test Mode 3 2 1 Starting Test mode 3 3 Taa Mode 3 2 2 Hardware Test 1 3 3 3 2 3 RAM Clear 02 3 6 3 2 4 Thermal Head Setting 3 7 3 2 5 Sensor Check C04 3 9 3 2 6 Extra Memory C05 3 9 3 2 7 Setting ROM Switch C06 3 9 3 2 8 Label Format Editing CO7 3 12 3 2 9 Sales Mode Setting C08 3 12 3 2 10 Machine ID No Setting C09 3 13 3 2 11 Preset Function Setting C10 3 14 3 2 12 Password 3 14 3 2 13 Data Transmission
67. bilization Lock Count Number of weight samples that must match before weight reading is accepted Note Decrease value for faster operation A D Conversion Speed 01 Slow slower throughput most reliable 02 Medium standard 03 Fast fastest throughput Width of Stabilization Window Difference in number of internal counts from previous sample that will be accepted as the same weight Example 02 2 count difference from last sample Note Increase value for faster operation These changes must be registered to the A D Board NV RAM See WPL 3000 setup instructions Appendix A 1 Typical Speed Up settings are 003C 03 0030 03 and 003E 03 WPL 3000 SERVICE MANUAL 0077B Test Mode 3 3 2 8 Label Format Editing C07 This is used to edit label formats There are seven default label formats 1 to 7 See Section 4 2 1 1 Enter the label format number 1 7 then press PLU 2 Select X or Y coordinate using gt 3 Select Print Field numbers using 4 Enter the new coordinate value then press ENTER 5 Press PRINT to print a test label 6 Press to return to the main Test Menu Note Refer to Appendix A2 for worksheets of all default label formats 3 2 9 Sales Mode Setting C08 This is used to set sales and CSIS modes Sales Mode C08 01 This selects machine functions corresponding to customer sales configuration LABEL FORMAT ENTER C07 0
68. ck Displaying Program Number Conveyor Elevator and Label Applicator Test KEH HARDWARE TEST ENTER C01 0 on WPL 3000 SERVICE MANUAL 0077B 3 3 Test Mode 3 A D Converter Check C01 01 See Section 10 3 for calibration procedure CHECK ENTER C01 01 0 ZERO ZERO SPAN TARE 0 2000 0 Key Check C01 02 Operation of all 120 keys on the keyboard can be checked in this mode C01 02 0 KEY CHECK KEY DATA 01 02 00 0 1000020200290535 17 18 19 20 21 22 23 24 25 26 27 28 29 30 pi SSS 41 42 43 44 45 32 33 34 35 36 37 38 39 40 Boon Bone Boon DOMO pooo 47 48 49 50 51 52 53 54 55 62 63 64 65 66 67 68 69 70 77 78 79 80 81 82 83 84 85 92 93 94 95 96 97 98 99 100 101 107 108 109 110 111 Fig 3 1 Key Address Note 1 If any keys do not work check cable connections at the buzzer board located inside the keyboard display unit Also check connections at the printer unit 2 Once the membrane keyboard has been removed it cannot be reused Key 29 RESET key When RESET key is pressed the display returns to sub menu e When each key is pressed the numerical value is displayed as shown in the above illustration 3 4 WPL 30
69. d leveling feet in place Note Be sure to also tighten set screws in each leg 8 Connect air lines WPL 3000 SERVICE MANUAL 0077B Appendix Roller Assemblies 1 Attach infeed roller assembly L configuration only 2 Attach exit roller assembly Infeed Power Conveyor 1 Mount infeed conveyor to stand 2 Connect 4 cables to WPL remove WPL infeed end panel to access connections Set height and level conveyor Exit Power Conveyor 1 Mount exit conveyor bracket to WPL stand 4 bolts 2 Mount exit conveyor to bracket 4 bolts from underside 3 Connect cable to WPL located behind the WPL infeed end panel Programming 1 Install and configure labels 2 Load PLU file General Settings ROM Switches See page A 7 for details a Select conveyor timeout switch 0039 b Select if shelf life calculations will count today as one day switch 003B For use with an automatic wrapper set the following switch values i 003C 03 ii 0030 03 iii 03 Note These changes MUST be registered to the A D Board NV RAM Weight Calibration Follow the procedure in Section 10 3 Span Calibration Adjustment Note Take care that the weights touch only the scale rollers and backstop WPL 3000 SERVICE MANUAL 0077B A 3 Appendix A 4 Conveyor Timing Follow the setup sequence listed below to optimize the conveyor timings L Configuration 1 Memory Clear TEST MENU C02 Section 3 2 3 a
70. d memory save switch Do not press the switch with a screw driver or other metallic object Do not cut the base seal wire unnecessarily since it is necessary to replace the sanction seal when the seal wire is cut 10 8 WPL 3000 SERVICE MANUAL 0077B IX A 1 Installation Notes uias roce i aces A 2 A 2 Label Format Worksheets A 9 Appendix 1 INSTALLATION NOTES WPL 3000 SYSTEM COMPONENTS Standard Main Conveyor Body Printer Unit Printer Arm Display Keyboard Unit Display Keyboard Mount Kit Power cord Stand w telescoping legs leveling legs casters and rubber anti vibration strips Optional Roller Conveyors Infeed amp Exit Power Exit Conveyor Power Infeed Conveyor w Stand I Line only Rotary Catch Bin Air Compressor INSTALLATION A 2 Stand Assembly 1 Secure rubber strips to stand using silicone or double backed tape Note Be sure to align holes in strips with holes in stand WPL Assembly 1 Place the WPL on the stand Note Main power switch faces the side with printer arm mounting plates 2 Bolt WPL to stand 4 corners from under side Note Bolts provided in stand hardware kit 3 Attach infeed roller assembly brackets 4 configuration only Bolt printer arm to stand 6 bolts Note Bolts provided in stand hardware kit 5 Bolt printer unit to printer arm 6 Adjust stand to proper height 7 Level stand and tighten all leg extensions an
71. e in Test Mode C03 02 Section 3 2 4 MTBF Mean Time Between Failures WPL 3000 SERVICE MANUAL 0077B Troubleshooting 9 9 2 BREAKDOWN AND COUNTERMEASURE mm SYMPTOM CAUSE COUNTERMEASURE No electrical power to scale Enters test mode at start up We will serve you shortly message re mains displayed in definitely Displayed weight is different from actual weight or displayed weight fluctuates Certain segments do not light or are continuously lit Ineffective key s Registration data changes All display segments disappear during op eration Partial or no printing Electrical plug is improperly inserted Fuse is blown Defective power switch Defective main board Defective power unit Defective keyboard Defective main board External vibration Defective load cell Defective main board Defective power supply unit Weigh platter unit rollers is touching conveyor frame Contact is made between four corner screw and limit bolt Foreign matter under weigh platter or load cell Defective load cell Defective A D board Incomplete data sent Defective main board Defective display board Loose connections Defective keyboard Defective battery External noise static electricity Defective main board Unstable voltage Defective power supply unit Defective display board Defective main board Dirty thermal head
72. ent for these values The label sensor reads the gap be tween labels It reads a low value when blocked and a high value when open See Section 7 3 1 for adjust ment procedures 3 2 6 Extra Memory C05 This displays initial memory amount and remaining available memory on the main board 3 2 7 Setting ROM Switch C06 This sets the ROM switch values which determine machine operation Press to select the ROM switch address number Enter the desired value then press ENTER Refer to the list on the following pages to set ROM switch values WPL 3000 SERVICE MANUAL 0077B D sensor CHECK ENTER C04 0 PEEL 1 LABEL 258 C04 00 1 255 EXTRA MEMORY ENTER cos MEMORY 128 N 102 C05 00 128 102 ENTER C06 0 ROM SWITCH SELECT lt C06 01 0000 00 e O rout ROM Switch List Test Menu 6 ROM SWITCH Move to the desired address using the key Input the new data then press ENTER Temporary date change type 00 Pack and Expire 01 Expire only FEED key function 00 blank label 01 reissue last label VOID key function 00 no label 01 print Void label Flashing message timer seconds 00 99 HEX Selection of Unit Pricing 00 kg 01 100g and Ib USA Computer communications speed 00 03 9600 baud 01 2400 baud 02 4800 baud 04 19200 baud Answer wait time for PC 0
73. ew and raise or lower the roller as shown in Fig 8 11 Fig 8 11 Adjusting Belt Tension 8 4 2 Conveyor Fall Prevention Screw Adjustment A conveyor fall prevention screw is shown in Fig 8 12 Adjust so that there is a 0 5mm 1 64 inch gap between screw and brace CONVEYOR FALL PREVENTION SCREW Fig 8 12 Conveyor Fall Prevention Screw WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor Unit 8 8 5 DisassEMBLY DIAGRAM DRIVE PULLEY BPPEISATIONITIMING SENSOR POWER SUPPLY UNIT SLS150PW DRIVER BOARD P 854 AIR CYLINDER ELECTROMAGNETIC VALVE Fig 8 13 Disassembly Diagram Later designs incorporate two 24 VDC power supplies WPL 3000 SERVICE MANUAL 0077B 8 10 Chapter 9 1 Periodic Parts Replacement 9 2 9 2 Breakdown and Countermeasure 9 3 9 3 Error Messages 9 4 Troubleshooting Troubleshooting 9 9 1 Periopic PARTS 9 2 This chapter describes periodic parts replacement repair procedures and error messages The following parts need to be replaced periodically 1 Thermal head LH3124 Replacement period When label distance reaches 60 km Check this value in Test Mode C03 02 Section 3 2 4 2 Display Display board Expected life over 30 000 hours using standard rated drive 3 Print roller Replacement period When label distance reaches 300 km Check this valu
74. ig 2 3 Items contained in carton IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm Note Infeed conveyor and stand are options 2 4 POSITIONING AND ADJUSTING CONVEYOR STANDS mmm For the WPL 3000 to weigh accurately it is essential that the machine be level Should the machine be unlevel or located on an unstable surface inaccurate measurements improper product flow or imprecise labeling may result To prevent these conditions from occurring follow the procedures outlined below 1 Securely fasten each unit to stand Reference Section 2 4 1 Using a level adjust the leveling legs to the desired height Cas tors should be set to rise at least 1 cm 3 8 inch from the ground Note Use a level to set within 2 1000 diagonal on right left and front back of weigh platter 2 4 WPL 3000 SERVICE MANUAL 0077B Setup 2 2 Loosely tighten nuts fastening the leveling legs Confirm that all legs are stable with no movement and tighten down the nuts until tight Note To prevent rust apply machine grease to legs 3 Loosely tighten anchor bolts to conveyor stands Confirm that all legs are stable with no movement and tighten down anchor bolts until bolts are tight 2 4 1 Fastening to Stand gt ANTI VIBRATION PAD BOLT X 6 M5 x 60mm SAND Fig 2 4 Weigh conveyor unit under side view Bolt X 4 M5 x 60mm Fig 2 5 Infeed conveyor under side view WPL 3000 SERVIC
75. ile size and reload into scale s memory Attempting to receive incompatible Select and receive only data files from data file similar scales 73 Err 73 F 21FD floppy disk recorder not Power off scale and connect IF 21FD connected floppy disk recorder Incorrect disk format Reformat floppy disk WPL 3000 SERVICE MANUAL 0077B Chapter 1 10 1 Location of Main Parts coser a canes 10 2 10 2 Replacing the Load Cell Unit 10 3 L C 10 3 Span Calibration Adjustment 10 6 oad Well Unit Load Cell Unit 10 10 1 Location Main Parts Fig 11 1 Location of main parts PARTS NO PARTS NAME LC UNIT CLC 25N HARNESS C 3 SCALE A D BOARD PWB 830B 10 2 WPL 3000 SERVICE MANUAL 0077B Load Cell Unit 10 10 2 REPLACING THE LOAD CELL UNIT 1 Removing the weigh conveyor and roller unit Refer to Weigh Conveyor Unit g Section 6 5 for detaching weigh conveyor E WEIGH EGATTER PLATTER SUPPORT Fig 11 2 Scale unit 2 Cutting seal wire and removing weigh platter 1 Cut seal wire 2 Unfasten seal screws WEIGH PLATTER 7 SCREW screw 1 screw 2 S remove weigh platter SEAL WIRE SCREW 2 MAIN BODY WEIGHING MECHANISM Fig 11 3 Seal wire and weigh platter Do not cut the base seal wire unnecessarily since it is necessary to replace the sanction seal when the seal wire is cut
76. l setting ii Extended 05 typical setting b Test and adjust as necessary for maximum travel but no delay in up stroke Set Conveyor timing to Lower packages on to Scale SETUP MENU b16 05 Section 4 2 11 a Test lowering time of conveyor using the widest tray available b Adjust b16 05 such that trays are fully on the scale roller assembly i ahigher value provides the package more travel on to the scale ii a lower value provides the package less travel on to the scale Note If sensors are mounted on the leading edge of the WPL 3000 typical set ting is O Delay Package on Scale SETUP MENU b16 01 Section 4 2 11 a Set b16 01 100 b Set b16 02 100 Note These delays are necessary to set the correct times for the next step Label Placement Standard SETUP MENU b16 04 Section 4 2 11 a Test label placement b Adjust b16 04 setting as needed i alower value moves the label to the leading edge of the package ii a higher value moves the label to the trailing edge of the package Set Delay of package on scale to minimum SETUP MENU b16 01 b16 02 Section 4 2 11 a Test delay b Set b16 01 to the minimum time that allows the label to be completely printed c Set b16 02 by the same method Switch to Rotate label position a Turn the printer 90 degrees b Press the ROTATE function key Label Placement 90 degree Placement SETUP MENU b16 06 Section 4 2 11 a Test label placement b Adjust b16 06 setting as needed i
77. le power is being supplied and covers or enclosures are opened or removed should be avoided as much as possible When servicing cannot be performed by any other means service personnel should take precautions against the danger of electrical shock or other potential hazard involved Take precaution against residual electrical charge hazard Capacitors inside the machine may still hold an electrical charge even after power is disconnected Use same type fuses and components for replacement parts To avoid the potential hazards involved do not replace fuses or components with types other than those specified in the parts list for this machine Power supply to the machine is disconnected only when the electrical plug is removed from the electrical outlet For protection against electrical shock WARNING remove plug before performing any servicing to the machine The following symbols are used to alert service personnel of potential danger or special circumstances related to the safe and proper servicing of this machine Precautions which must be followed to prevent the possibility of death or serious injury WARNING Precautions which must be followed to prevent the possibility of light or moderately severe injury to personnel or damage to WARNING the equipment NOTE Important information for the operation of the machine This service manual contains the procedures for servicing the WPL 3000 Index Conveyor It is strongl
78. mal Head HEAD RESISTANCE VALUE The thermal head prints one line at a time If the printing surface of the thermal head and the top edge crown of the print roller are not aligned the label will not print clearly across the entire width of the label Print a test label to test printing If print quality is unsatisfactory adjust according to the following procedure oQ 1 Loosen the thermal head attachment screws 2 by a 1 4 turn ATTACHMENT SCREWS Fig 7 9 Locations of screws WPL 3000 SERVICE MANUAL 0077B 7 6 Printer Label Applicator Unit 7 2 Manually adjust the position of the thermal head so that the top RIN SURFRACE edge crown of the roller and thermal head print surface are aligned Print out another test TOP EDGE CROWN label and adjust until all characters print clearly with the proper dark ness When adjustment is com plete tighten the two attachment screws PRINT ROLLER Fig 7 10 Thermal Head Print Surface T Avoid touching the surface of the head If the surface is touched clean using head cleaner made especially for thermal heads CAUTION Lower print density before adjusting for more precise adjustment 3 Set the thermal head resistance value Setting are performed in test mode C03 0 C03 THERMAL HEAD Refer to Test Mode Sec 3 2 1 and 3
79. ments Default value 110 0 Adjust to fine tune print alignment LABEL TAKEN SENSOR THERMAL HEAD LABEL LENGTH INCLUDING GAP pon GAP SENSOR LABEL BACKING PAPER gt X LABEL SENSOR DISTANCE Fig 4 1 Label Sensor Distance 4 6 WPL 3000 SERVICE MANUAL 0077B 4 2 2 Bar Code Setting b02 This sets default settings for barcode Enter selection number and press ENTER Setting Flag Code e Setting Flag Code for Source Marked Barcode Setting Bar Code Type Setting 13 Digit UPC Type format Barcode Flag b02 01 Enter a 3 digit number and press ENTER The first digit is for 8 digit barcode type and the next two digits are for 13 digit barcode type 10 Digit Flag b02 02 Enter a 4 digit number and press ENTER The first two digits are for the 8 digit barcode type and the last two digits are for the 13 digit barcode type Barcode Type b02 03 This sets bar code type Select from the chart below Bar Code Type UPC 13 10 DIGIT 13 Default WPL 3000 SERVICE MANUAL 0077B Setting Mode 4 BAR CODE ENTER b02 0 BARCODE FLAG 202 b02 01 202 10 DIGIT FLAG 0 b02 02 0 BARCODE TYPE 1 UPC 13 1 b02 03 1 UPC 8 NON PLU code 5 DIGIT 8 Source Marked Code 4 7 Setting 4 UPC Type b02 04 This sets the 13 digit code barcode format Select from the chart below for settings U
80. n the platter Troubleshooting 9 Note To clear error messages from display press CLR key 9 6 RESEND RESULT DATA Err 68 PRINTER POWER OFF OR NOT CONNECT Err 203 PRINTER COMMUNICATION ERROR Err 204 OPERATION Transaction results cannot be written in to memory due to corruption of Totals area Incorrect Memory clear procedure Incorrect Master Satellite setup proce dure Noise from RS 232 communications with PC Unsuccessful transmis sion of transaction results to Total area of memory No communication with second printer at initial power up of main unit No communication with second printer Clear scale totals Power scale off ater RAM clear do NOT use RESET key Re initialize Master Satellite system Press PLU key to resend data Press VOID key to cancel transmission Turn on second printer unit before main unit Check cabling between printers Check power at second printer Check cabling between printers CHARACTER BUFFER OVER Too many characters Check PLU name PLU registration area CHARACTER DOTS OVER Too many characters per line Check PLU name registration area WPL 3000 SERVICE MANUAL 0077B Troubleshooting 9 Note To clear error messages from display press CLR key SYSTEM COMMUNICATIONS SYSTEM ERROR CHECK CABLE Master Board malfunc Check Master Board Err oFFLin tion replace if necessary Faul
81. nce Allow power cord not to be pinched between objects or receive force from other objects 7 Be connected to an outlet with a circuit breaker capable of detecting short circuits O 2 2 WPL 3000 SERVICE MANUAL 0077B Setup 2 2 1 5 Work Clothes Care must be taken when working near moving parts Avoid wearing loose clothing that might be caught in the machine Shirt sleeves should be kept buttoned or rolled securely above the elbows To keep fingers or hands from being caught in the conveyor gears or other moving parts do not wear gloves Ties should be tucked inside shirts 2 2 NECESSARY ITEMS FOR INSTALLATION mm 2 2 1 Tools e Phillips head screwdriver LEVEL e Slotted screwdriver gt Monk h oS e Monkey wrenc PHILLIPS HEAD more than 30mm 1 3 16 in jaw extension Open ended wrench 30mm Allen wrench key set metric Box wrench 7mm 8mm 10mm Electrician s pliers Level 200 to 250mm 8 to 10 in IF 21 FD 3 5DD inch floppy disk SLOTTED SCREWDRIVER Fig 2 2 Tools Use a level with precision greater than 2 1000 2 2 2 Manuals e WPL 3000 Service Manual e WPL 3000 Programming Manual User s Manual for Managers e WPL 3000 Operation Manual User s Manual for Operators WPL 3000 SERVICE MANUAL 0077B 2 3 Setup 2 2 3 PACKAGE CONFIRMATION Open carton and inspect contents to see that all items are accounted for and undamaged F
82. ng file Press any key other than CHAR DELETE to cancel delete Execute C99 03 02 Press CHAR DELETE again to confirm and begin execution Press any key other than CHAR DELETE to cancel execution Executing C99 03 03 Executing Initialization Complete C99 03 04 Initialization is complete when OK is displayed Note See Error Code list in Section 9 3 Save amp Load with IF 21FD Floppy Disk Unit if necessary 3 18 DELETE c99 02 05 nol INITIALIZE DISK ENTER C99 03 0 CAUTION When a floppy disk is initialized all contents of the floppy disk are deleted By DELETE FILE Y DEL N ENT 99 03 00 m EXECUTE 99 03 02 7INITIALIZING 1 99 03 03 INITIALIZING OK C99 03 04 PASS WPL 3000 SERVICE MANUAL 0077B Chapter 4 4 1 Menu Directory 4 2 4 2 Setup Mode 4 2 1 Label Format 601 4 5 S etti ng 4 2 2 Bar Code Setting b02 4 7 4 2 3 Code Settings 603 4 8 4 2 4 Setting Initial Data 604 4 9 M ode 4 2 5 PLU File 608 4 11 4 2 6 Preset Report 610 4 12 4 2 7 Registration Select 611 4 14 4 2 8 Total Mode Select b12 4 15 4 2 9 Password 613
83. nintended configuration settings 3 16 WPL 3000 SERVICE MANUAL 0077B Test Mode 3 SELECTION NO TRANSMISSION TYPE ALL FILE MASTER FILE E2ROM FILE ITEM MASTER STORE MASTER COUPON MASTER MESSAGE MASTER OPERATOR PRESET KEY LABEL FORMAT SETUP FILE AD MESSAGE TAX MASTER TITLE FILE DEPARTMENT GROUP CAMPAIGN MASTER BATCH FILE SUB TOTAL NUTRITION FILE Verify C99 02 04 This verifies WPL 3000 and IF 21FD data Enter the selection number of the data to be oe ee verified and press ENTER Press ed to begin verifying Note Select number using key SELECTION NO FILE FOR VERIFICATION ALL FILE MASTER FILE E2ROM FILE ITEM MASTER STORE MASTER COUPON MASTER MESSAGE MASTER OPERATOR PRESET KEY LABEL FORMAT SETUP FILE AD MESSAGE TAX MASTER TITLE FILE DEPARTMENT GROUP CAMPAIGN MASTER BATCH FILE SUB TOTAL NUTRITION FILE WPL 3000 SERVICE MANUAL 0077B 3 17 Test Mode 3 Delete C99 02 05 This deletes the file selected in step C99 02 01 from the IF 21FD disk Press twice to delete the file 3 2 13 2 Disk Formatting Initialize Disk C99 03 This formats the 2DD floppy disk Note Before a disk is used for the first time it must be formatted Delete File C99 03 00 This initializes all data contained on floppy disk Press CHAR DELETE to begin deleti
84. rical signals Load cell type CLC 25N Load maximum 25 kg Standard output within 5 Insulated resistance over 5M Ohm Applied voltage Fig 6 5 Load cell RECEIVING PLATTER A D BOARD P 830B LOAD CELL UNIT d Re 1 Fig 6 6 Disassembly of scale unit 6 4 WPL 3000 SERVICE MANUAL 0077B Weigh Conveyor 6 6 3 2 A D Converter Board P 830B Analog signals from the load cell are amplified and converted to digital data A D converted data is transmitted to the CPU board P 834x board installed in the printer unit Power regulators are installed on the A D converter board for IC and load cell electrical power levels These power regulators convert electricity supplied from the power supply unit located in the weigh conveyor to lower more stable voltages LOAD CELL CABLE SOLDER TERMINALS IC1 PD75108CW X23 MEMORY SAVE SWITCH Fig 6 7 A D Converter Board P 830B Red Vex White Green Signal Blue Signal Shield Fig 6 7a Load Cell Connections WPL 3000 SERVICE MANUAL 0077B 6 5 Weigh Conveyor 6 6 4 ScaLE CHECK The A D converter can be checked from test mode TEST MENU PRESS 1 KEY 0 Refer to Test Mode Sec 3 2 1 and 3 2 2 in this manual for entering the test mode Use to scroll down and press ENTER to select Selection can also be made by numeric en try and pressing ENTER 1 Select hardware test mode C01 and press E
85. ty cable connec Check all cable connec tions tions Check for incorrectly wired cables 9305 SAME OPR TOTALING ON MAC Same operator number Wait and restart opera Err 9305 used within one second tion 9307 SAME OPR PROCESSING ON OTHER Same operator number Wait and restart opera Err 9307 used within one second tion 9309 ERROR ON COMM CROSSOVER Data transfer duplication Press CL key to reset Err 9309 error same data was sent twice transactions 9316 MASTER IS OFF LINE Master scale is Off Line Return master scale to Err 9316 Master scale is in Totals On Line mode Mode or Test Mode 9330 COMM ERROR ON RESULT TRANSFER Satellite cannot report Check Master Board Err 9330 Totals data back to replace if necessary Master scale Check all cable connec tions Check for incorrectly wired cables 9330 SYSTEM ERROR CHECK MASTER SCALE Satellite does not receive Check Master Board Err 9330 requested data from replace if necessary Master Board Check all cable connec tions Check for incorrectly wired cables 9311 MAX ITEM NUMBER OVERFLOW Accumulated operator Clear operator totals by Err 9311 totals have exceeded 30 printing a total label transactions or 100 000 Use the TOTAL key per operator or 400 total WPL 3000 SERVICE MANUAL 0077B 9 7 Troubleshooting 9 Note To clear error messages from display press CLR key SAVE amp LOAD WITH IF 21FD FLOPPY DISK UNIT
86. vement and label application position Default Description Delay Timer Label lt 60mm Increase if product reaches labelling position before printing is completed Time between A and B where A Weighing completed B Conveyor lifts to move product Note 10 1 10th second delay Delay Timer Label gt 60mm Increase if product reaches labelling position before printing is completed Time between A and B where A Weighing completed B Conveyor lifts to move product Note 10 1 10th second delay Plunger Timing Solenoid ON The length of the Label Applicator Stroke Note 1 approx 0 5 in default 2 in Label Placing Type Normal Time between A and B where A Product breaks photo eye B Label Applicator fires Note 1 approx 1 8th inch distance Increase slower move label left Conveyor Delay Timer Straight configuration only Time between A and B where A Trailing edge of product passes photo eye B Conveyor lowers package onto scale Note 1 approx 1 8th inch distance Increase package travels farther Label Placing Type 90 Degree Time between A and B where A Trailing edge of product passes photo eye B Label applicator fires Note 1 approx 1 8th inch distance Increase slower move label up Use ROTATION function key Conveyor Timer L Type L configuration only Time between A and B where A Conveyor lifts after weighing is completed B
87. y advised that you read and clearly understand the contents of this manual before beginning any maintenance to this machine MAINTENANCE PRECAUTIONS To insure the safety and long operating life of this machine it is important to observe the following precautions Keep the area around the machine clear of any dust and debris Do not leave screws or other foreign objects in the machine after performing routine maintenance since this can cause major damage to the machine when the electrical switch is turned on Always remove wires by holding the connector and pulling to disconnect Do not disconnect by pulling on the wires themselves since this may cause a wire to snap or damage the connection Before assembling or adjusting this machine make sure you thoroughly understand and follow each step in the order indicated in this manual Table of Contents 1 Overview 2 Setup 3 Test Mode Contents 1 1 External Parts and Names I Line Type 1 2 1 2 External Parts and Names L Line Type 4 3 1 3 Location of Safety Stickers 1 4 2 1 Confirm Before Delivery 2 1 1 Locations usas nee 2 2 2 1 2 Installation Route 2 2 2 1 3 Electrical Power 2 2 2 1 4 Setup Environment 2 2 2 1 5 Work Glotfigs casco 2 3 2 2 Necessary Items for Installation 2 21 AOS

WPL-3000 - Rice Lake Weighing Systems

Contents

Download Pdf Manuals

Related Search

Related Contents