L3500PA Labeler - Shibuya Hoppmann

TM
L3500PA Labeler
Installation & Maintenance
Manual
Refer all servicing to qualified
personnel.
This manual is intended for use by
qualified mechanics and electricians
who install or service the Shibuya
Hoppmann L3500PA Print & Apply
Labeler.
Record your serial plate information
here for future reference
Ü
Second Edition, Revision 6, All Rights Reserved.
Copyright 2015 by Shibuya Hoppmann Corporation.
Duplication of this manual, in whole or in part, requires prior
written consent from Shibuya Hoppmann Corporation.
Model Number
Serial Number/Date
HeadquartersSales
Manufacturing
7849 Coppermine Dr.
1445 Brookville Way
291 Dillard Road
Manassas, VA
Suite F
Madison Heights, VA
20109
Indianapolis, IN 46239
24572
540.829.2564 t
317.322.0754 t
434.929.4746 t
800.368.3582 t
800.368.3582 t
800.543.0915 t
540.829.1726 f317.322.0794 f434.929.4959 f
www.ShibuyaHoppmann.com | publications@Hoppmann.com
Thank You!
Thank You for
Choosing Shibuya Hoppmann
Thank you for purchasing a labeler from Shibuya Hoppmann. Our
labelers, prefeeders, feeders, and automated systems possess an
industry-wide reputation of excellence for their quiet and rapid
handling of parts, ease of use and low maintenance requirements.
About This Manual
Who Should Read
Caution Symbols
and Messages
This manual is intended for those who install and/or operate the
L3500PA Labeler. The manual is not intended to meet the training
needs of persons new to labeling; nor is it intended to meet the
needs of personnel who wish to completely overhaul the unit.
These needs will require assistance of experienced personnel
and are outside the scope of this manual. Please read the entire
manual carefully before operating your labeler.
Caution symbols and messages in this manual call attention to
hazardous voltages, moving parts, and other hazardous
conditions.
The lightning bolt caution symbol denotes possible personal injury
and/or damage to the equipment from electrical hazards.
The exclamation point caution symbol denotes possible personal
injury and/or damage to the equipment.
Other Documentation
Equipment Improvements &
Document Revisions Notice
2
Product specifications and vendor subcomponents are
incorporated into this manual at the discretion of the
manufacturer.
Shibuya Hoppmann Corporation (SHC) continually improves its products, and reserves
the right to change or discontinue specifications and designs shown in this manual
without notice and without incurring obligation. Occasionally older versions of
equipment may have different spare parts/replacement parts requirements. Please be
sure to contact SHC before ordering specific parts for older style prefeeders. SHC has
made every effort to verify the information contained in this manual, but reserves the
right to correct any error at the time of the manual’s next revision. 10.2015.
L3500PA_Rev10_10.2015
Table of Contents
Chapter Name
1
Page
About this Manual
Other Documentation
Table of Contents
Terms and Definitions
Description The L3500PA Labeler
and Specifications L3500PA Labeler Specifications
Applicator Options and Upgrades Figures/Tables:
Table 1-1. L3500PA Available Options
Table 1-2. L3500PA Product Specifications
Figure 1-1. L3500PA Side and Front Views with Dimensions
Table 1-3. L3500PA Dimensions
Figure 1-2. L3500PA Labeler - Left Hand
Table 1-4. L3500PA Applicator Options and Upgrades
Table 1-1. Applicator Options and Upgrade Part Descriptions
2
2
2
3
6
7
7
8
7
8
8
8
9
10
10
Safety Precautions Safety Precautions
and Warnings Specific Warnings & Cautions
11
11
Applicator Installation Unpacking and Inspection
Labeler Positioning
Power Supply
Air Supply
Pneumatics
Label and Web Specifications
Figures/Tables:
Figure 3-1. Correct Positioning of Labeler
Figure 3-2. Incorrect Positioning of Labeler
Figure 3-3. U-Arm Mounting
Figure 3-4. L3500PA on T-Stand
Figure 3-5. Module Interface Panel
Figure 3-6. Printer I/O Ports (Example)
Figure 3-7. Filter Regulator
Figure 3-8. Pneumatic Valve Pack - Front View
Table 3-1. Label and Web Specifications Chart
13
13
16
17
18
19
3
14
14
15
15
16
17
18
18
19
L3500PA_Rev10_10.2015
3
Table of Contents (continued)
4
Chapter Name
Applicator Setup Ribbon Threading
Label Threading
Unwind, Rewind and Clutch Assemblies
Printer
Downloading Label Formats
Product Sensor
Figures:
Figure 4-1. Web Path (Left Hand Labeler)
Figure 4-2. Web Holding Pull-Pin on Rewind Wheel
Figure 4-3. Unwind and Rewind Assembly Location
Figure 4-4. Clutch Assembly for Rewind Assembly Figure 4-5. Product Sensor
Figure 4-6. Setup for Product Sensor
5
Page
21
22
25
27
28
29
22
24
26
26
29
29
Applicator Modules
Tamp Module
31
Blow-On Module
41
Testing48
Figures:
Table 5-1. Applicator Modules
31
Figure 5-1. Tamp Assembly
31
Figure 5-2. Tamp Clearance (Peeler Plate and Vacuum Pad)
32
Figure 5-3. Tamp Assembly Hose Attachments and Movement
33
Figure 5-4. Modification of Tamp Pad
35
Figure 5-5. Modification of Tamp Pad (Continued)
36
Figure 5-6. Tamp Adjustments When Feeding A Label
37
Figure 5-7. Air Assist Bar
37
Figure 5-8. Fine Tuning Label Placement
40
Figure 5-9. Blow Box
42
Figure 5-10. Blow-On Module Assembly
43
Figure 5-11. Valve Assembly Housing
44
Figure 5-12. Air Assist Bar for Blow-On Module
45
Figure 5-13. Grid Plate Cover
46
Figure 5-14. Fine Tuning Label Placement
47
6
Operator Interface
Operator Interface Map
Main Menu
Edit Parameter Menu
Figures:
Figure 6-1. Mapping of Operator Interface
4
49
50
52
49
L3500PA_Rev10_10.2015
Quick Start
7
Chapter Name
Page
Preventive Preventive Maintenance
Maintenance
61
Replacement Parts Replacement and Spare Parts
L3500PA Labeler - Replacement Parts
Tamp Module Spare Parts List
Figures:
Figure 8-1. Sample Serial Plate
Figure 8-2. L3500PA Replacement Parts Callouts
Figure 8-2. L3500PA Tamp Modules Callouts
63
65
66
Troubleshooting Unwind Assembly Troubleshooting
Power Supply/Electrical Components Troubleshooting
Printer (Print Engine) Troubleshooting
Label Placement Accuracy Troubleshooting
Tamp Pad Assembly Troubleshooting
Label Dispensing Troubleshooting
67
68
69
73
76
81
Appendix Pneumatic/Electrical Schematics
Figures:
Figure 10-1. Pneumatic Schematic
Figure 10-2. Labeler System Power/Control Wiring (Part 1)
Figure 10-2. Labeler System Power/Control Wiring (Part 2)
83
8
9
63
64
66
10
83
84
85
11
Warranty
L3500PA_Rev10_10.2015
Warranty 87
5
L3500PA Labeler Manual
Terms and Definitions
Term
Blow-On Module
Tamp-On Module
FR Filter
Peeler Plate
Product
Web
Flag
Labeler
PA
Print Engine
Print Head
6
Definition
Blow Module, Label Blow-On Applicator Module. Aids in applying
the label to product with the use of blowing air.
Tamp Module, Label Tamp-On Applicator Module. Aids in applying
the label to product with the use of pushing the label onto the
product with pneumatics.
Combination pneumatic pressure regulator and secondary particle
filter.
Peeler Bar; An edged, flat piece of metal around which the
backing or label web material is threaded–the prime function
being a mechanical device which causes a pressure-sensitive label
to be dispensed from the backing material.
Any medium to which the labels are applied (boxes, bottles,
containers, etc.)
Webbing; Backing; Label Strip; Label Ribbon; Waste; Continuous
Backing;
The part of the label with the adhesive exposed before the label is
completely removed from the webbing.
Label Applicator; Applicator; L3500PA
Print & Apply; Indicates the labeler has a print engine.
Thermal transfer printer; thermal printer; in-line printer.
Label applicator unit; Print & Apply label applicator; Labeler
L3500PA_Rev10_10.2015
Description & Specifications
1
The L3500PA Labeler
Function
The L3500PA Print & Apply Labeler integrates an industrial grade
printer with an engineer applicator design to maximize product
and to minimize maintenance and changeover time. This labeler
can be integrated into an in-line product handling system, be
used as a stand-alone unit, or dispense single labels as needed. It
is designed to dispense blank or pre-printed labels. The standard
L3500PA will dispense labels up to 5 1/2" wide.
Design features of the label applicator include:
Ü HMI touchscreen operator interface
Ü Standard 12" diameter label supply rolls
Ü Powered label drive and torque clutch adjustable rewind
Ü Rapid configuration and changeover of applicator modules
Ü Access to main components for maintenance and changeover
Ü Rugged stainless steel and black anodized construction
Ü Pneumatic assembly composed of ergonomic controls for
individual component air pressure adjustments and test port
access
Refer to Table 1-1 for applicator upgrades and options that will
expand the capabilities of the L3500PA Labeler.
Available Options for L3500PA
Tamp-On, Blow-On, Tamp-Blow, Wipe-On, LEC, TEC, and Dual Panel Tamp modules
Soft-Tamp module detects product locations
Extended length tamp modules (up to 24")
Remote operator panel
Low label level sensor & beacon fault upgrades
Horizontal positioning device
Auxiliary air valve for add-on modules or for product handling pneumatics
Powered unwind spools
Optional 18" (457mm) powered supply roll upgrade
Adjustable stands and machine mount supports
Table 1-1. L3500PA Available Options
L3500PA_Rev10_10.2015
7
L3500PA Labeler Manual
L3500PA Labeler Specifications
Accuracy
Controls
Unwind Roll Diameter
Product Detection
Machine Interface
Air Requirements
Power Requirements
Environment
±0.032" (±0.81mm)
PLC based control, HMI touchscreen interface
12" (305mm) OD x 3" (76mm) ID
Photo Eye
External sub-D connectors
80psi @ 2.2CFM
115 or 220VAC, 50/60 Hz, 6 amps
41-104˚ F (5-10˚C), 25-85% relative humidity
Table 1-2. L3500PA Product Specifications
Figure 1-1. L3500PA Side and Front Views with Dimensions
Dimension Specifications
A Applicator Width
B Overall Width (With Stand)
C Overall Depth (With Stand)
D Frame Depth
E Stand Height
F Applicator Height
G Applicator Depth
ANSI
30.38"
45.50"
38.4"
34.25"
62.52"
24.15
21.45"
Metric
772mm
1155mm
956mm
870mm
1588mm
613mm
545mm
Table 1-3. L3500PA Dimensions
8
L3500PA_Rev10_10.2015
Chapter 1 Description & Specifications
PNEUMATIC
VALVE
PACK
OPERATOR
HMI TOUCHSCREEN
UNWIND ASSEMBLY
FOR LABEL STOCK
50 100
0
150
psi
50 100
0
150
psi
50 100
0
150
psi
DANCER
ARM
PRINT ENGINE
OPERATOR
PANEL
PEELER
PLATE
REWIND
WHEEL
PRINT
ENGINE
IDLER
ROLLERS
*For illustration purposes only this labeler shows a "generic" print engine, print engine interface panel
and on/off switch. Location of the on/off switch and the size, layout and location of the print engine
interface panel will vary. Please refer to your print engine's manufacturer's documentation for specifics.
Figure 1-2. L3500PA Labeler - Left Hand
L3500PA_Rev10_10.2015
9
L3500PA Labeler Manual
Applicator Options & Upgrades
Part Number
L100FB001
L100LTB3CM
L100STP001
L100LECR01
L100LECL01
L100TECR01
L100TECL01
L100DPTR01
L100DPTL01
L100UKV3R1
L100UKV3L1
L100ROP001
L100VST001
L100GK6001
L100WVST01
L100UV3001
L100VA3601
L100VA6001
L100HLA001
L100BOMV3R
L100BOMV3L
L100TAV312
L100TAV318
L100TAV324
The manufacturer or distributor may have changed specifications
to match your desired application. Refer to the specifications listed
on page 7 for applicator specifications, and see Table 1-4 below
for Applicator Options and Upgrades.
Part Description
Tri-color light tower beacon with mounting bracket and terminal points
Low label detector sensor, tri-color beacon lamp for fault conditions
Soft tamp pad accessory for standard tamp on applicator
Leading edge, front and side panel wrap module (right hand)
Leading edge, front and side panel wrap module (left hand)
Trailing edge, side, and rear panel wrap module (right hand)
Trailing edge, side, and rear panel wrap module (left hand)
Dual panel tamp module for individual front/side or both panels (LH)
Dual panel tamp module for individual front/side or both panels (left hand)
18" (457mm) unwind kit upgrade (right hand)
18" (457mm) unwind kit upgrade (left hand)
Remote start/stop
T-Stand, light duty, 60" (1524mm) tall with 39" (990mm) of vertical adj.
T-Stand gusset kit to convert light duty stand to heavy duty
T-Stand, heavy duty, 60" (1524mm) tall with 39" (990mm) of vertical adj.
U-Arm
Machine mount label head stand 36" (914mm) tall with vertical adj.
Machine mount label head stand 60" (1524mm) tall with vertical adj.
Horizontal linear adjuster (single axis)
Blow-on module, 5" x 5" grid (right hand)
Blow-on module, 5" x 5" grid (left hand)
12" tamp stroke upgrade assembly
18" tamp stroke upgrade assembly
24" tamp stroke upgrade assembly
Table 1-4. L3500PA - Applicator Options and Upgrades
10
L3500PA_Rev10_10.2015
Safety Precautions
2
Safety Precautions
This labeler has been designed to be as safe as possible for
operators. However, even well-built machines can be installed
or operated in a hazardous manner. Safety precautions must be
observed by users.
Specific Warnings & Cautions
Turn Power Off! Before servicing the labeler, make sure you
have turned off compressed air and electrical power in a way
that prevents accidental reactivation. Padlock, and clearly tag,
the appropriate electrical and pneumatic disconnects. After
disconnecting the electrical power, wait at least two minutes for
the motor capacitor to discharge.
Dress Properly and Wear Safety Glasses! To reduce the risk of
injury from moving parts, secure loose clothing. Do not wear jewelry
or neckties near the machine. Wear safety glasses or other protective
eye wear at all times. Never place hands or tools in the tamp, corner
wrap, print head, or other movable parts of the labeler when the
machine is operating.
Avoid Pinch Points! Exposed pinch points include the unwind
and rewind assemblies, dancer arm, idler rollers, pull pins, the
peeler plate and the different modules.
Avoid Dangerous Conditions! The standard labeler should
not be placed in washdown environments nor is it designed to
be used in explosive conditions. The L3500PA Applicator will be
damaged when sprayed by a fire suppressant sprinkler system.
Dry conditions are critical for long life duration of the machine.
Potentially explosive environments, such as areas where flammable
gas and vapors are present, should be avoided due to static
electricity caused by normal operations.
L3500PA_Rev10_10.2015
11
L3500PA Labeler Manual
Notes
12
L3500PA_Rev10_10.2015
Installation & Start-Up
3
This chapter covers unpacking, inspection, positioning and power
and air hookups for the L3500PA Print & Apply Labeler.
Unpacking
Step 1.
and Inspection
Check the Shipping Container. Make a visual check of the inside
of the shipping box. The box and packing in which the unit ships
has been carefully designed to prevent damage during shipping.
However, if you do find a problem, report any damage to the
Shipping Carrier immediately and follow their instructions.
The applicator can weigh in excess of 115 pounds (53kg).
Step 2.
Unpack the Labeler. Remove the top and sides of the shipping
crate to expose the labeler. Remove the packing material.
Inventory the container.
Labeler
L3500PA_Rev10_10.2015
The standard labeler is shipped with two 12mm threaded
mounting holes for custom attachments. One is located on each
side of the labeler. An optional U-Arm and/or T-stand are available
for mounting.
Note: Positioning of the labeler may vary if an application module
was purchased with your unit. Refer to Chapter 6: Application
Modules, for more information.
Positioning
The labeler must be positioned so that printed labels are applied
to the product with the proper orientation. Once the correct
orientation is obtained, the labeler is ready to be placed into
position. The product and labeling surface should be parallel with
each other at the point of contact (see Figure 3-1 and 3-2 on the
following page).
Note: The labeler needs to be mounted in such a way that there is
minimum vibration and rotation, or else the accuracy of the
labeling may be compromised. It is also suggested that fine tuning
adjustments be made after mounting the labeler.
13
L3500PA Labeler Manual
CORRECT POSITIONING
TWO SURFACES
SHOULD BE
PARALLEL
PRODUCT
PRODUCT
Figure 3-1. Correct Positioning of Labeler
INCORRECT POSITIONING
TWO SURFACES
ARE NOT
PARALLEL
PRODUCT
PRODUCT
Figure 3-2. Incorrect Positioning of Labeler
14
L3500PA_Rev10_10.2015
Chapter 3 Applicator Installation
HANDLE FOR
VERTICAL
MOVEMENT
U-ARM
MOUNTING
BOLT
Figure 3-3. U-Arm Mounting
U-Arm and T-Stand
If a U-Arm and/or T-stand is/are purchased with your unit, refer
to Figure 3-3 and Figure 3-4 for proper positioning. To pivot
the labeler up or down, loosen the large hex nut which fastens
the U-Arm to the T-stand. This allows the unit to rotate the
peeler plate up or down. Tighten the same nut to secure the
labeler's position (see Figure 3-4).
The labeler may also be positioned for top, side or bottom
panel labeling. Loosen the two large socket head bolts that
fasten the U-Arm to the labeler. Rotate the labeler into a
position where the application module is parallel to the surface
of the product to be labeled.
Use the handle at the top of the T-stand to raise or lower the
labeler to the desired height relative to the product (see Figure
3-4). To change the horizontal position of the unit, simply
unlock the casters on the bottom of the T-stand and roll the
unit to the desired location. Lock the casters down once in
position. HANDLE FOR
VERTICAL
MOVEMENT
CASTERS/
LEVELING FEET
Figure 3-4. L3500PA on T-Stand
L3500PA_Rev10_10.2015
15
L3500PA Labeler Manual
Power Supply
Verify Main Power
Supplying the unit with the correct supply voltage permits safe
and efficient operation. Refer to specification chart on page 8.
The labeler is supplied with a power cord for AC operation. Plug
the power cord into an outlet with the proper voltage (115 VAC,
see Voltage Selection section if different voltage is required) and
ground. Make sure the power cord is securely connected to the
labeler (see Figure 3-5) and the outlet.
Due to the wide variety of plugs used world wide, the
power cord that is shipped with the labeler has a standard
U.S. plug. If you need a power cord with a different type of
plug, purchase a power cord approved by local government
or identified with an HAR (Harmonized Standard) label.
PRINTER
INTERFACE
ELECTRICAL
AUXILIARY 3
MAIN AIR
ELECTRICAL
AUX 1
ON/OFF
SWITCH
POWER CORD
CONNECTION
P-AUX
AIR ASSIST
PRINTER
POWER
ELECTRICAL
AUX 1
PRODUCT
SENSOR
LIGHT
TOWER
Figure 3-5. Module Interface Panel
16
L3500PA_Rev10_10.2015
Chapter 3 Applicator Installation
To test the connection, turn the main power switch "ON" and
then the print engine power switch "ON". The print engine will
illuminate to verify the power connection.
Verify that the Sub-D connector is attached to the proper I/O port
at the rear of the labeler. It should be firmly seated in the lowest
of the three I/O ports (refer to Figure 3-6). The Sub-D connector
interfaces with the controller.
*For illustration purposes
only this Printer's I/O ports
show locations of different
connections. Location of
the same ports – layout and
location – on your print engine
will vary. Please refer to your
print engine's manufacturer's
documentation for specifics.
SUB-D
CONNECTION
PARALLEL
PRINTER
PORT
CONNECTION
TO MODULE
INTERFACE PANEL
POWER
CORD/
PLUG
Figure 3-6. Printer I/O Ports (Example)
Air Supply
Connect Shop Air
L3500PA_Rev10_10.2015
Locate the FR (Filter-Regulator) that was shipped with the labeler.
Mount the FR (the optional U-Arm provides a mounting position
for the FR). Attach one end of the 3/8" main air line (hose) to the
quick disconnect on the FR. Connect the other end of the host to
the quick disconnect labeled "MAIN AIR" on the module interface
panel (see Figure 3-5).
17
L3500PA Labeler Manual
The moisture collected in the filter should be removed daily or as
needed. To do this, press the bottom pin of the filter and allow the
moisture to drain (refer to Figure 3-7).
This FR is intended to be used as a secondary filtration
system to supplement existing facility water removal
and filtration. It is not designed to be the primary filter/
regulator system. Be sure plant-supplied air is clean and dry.
DEPRESS
TO DRAIN
MOISTURE
PNEUMATIC
GAUGES
(each of the
three
pneumatic
subsystems
can be
viewed
separately.)
VALVE LED
WINDOW
50 100
0
150
psi
50 100
0
150
psi
Figure 3-7. Filter Regulator
50 100
0
150
psi
AIR PRESSURE
ADJUSTMENT KNOBS
(Hand adjusted with
screw lock down)
Figure 3-8. Pneumatic Valve Pack (Front View)
Pneumatics
The pneumatic valve pack and module interface panel are used
for hookup and adjustment of various components on the labeler
and any attached modules. These will be discussed in depth in
Chapter 6: Applicator Modules.
For an overview of the pneumatic valve pack, refer to Figure 3-8.
Ü Set line supply pressure at FR to 80psi.
Ü The air pressure adjustment knobs are for adjusting air pressure
to the various components.
18
L3500PA_Rev10_10.2015
Chapter 3 Applicator Installation
Ü The pneumatic valve settings can be locked by tightening the
nut located on the threads of the adjustment knob.
Ü The pneumatic gauges read the actual amount of air pressure
supplied to the listed components.
Ü The valve override test points are used to activate and isolate
the components for setup and troubleshooting.
Ü The valve pack can be easily removed for servicing.
Label and Web Specifications
LABEL STYLE
ACCURACY
ROLL PUT-UP
SPLICES
LABEL
TOLERANCE
Label and Web Specifications
Stripped out form only. Minimum spacing of 0.125" (3mm). Remove all
die cut waste (skeleton). Label backing must have a release agent such as
silicon. Label must free peel when pulled around a standard peeler plate
with a minimum label gap of 0.125" (3mm).
(A) Linear position of label relative to web or backing must be centered.
(B) Die cutting and edge slitting must be controlled to avoid cutting or
nicking of the web backing. Failure to regulate this will result in web failure
and label dispensing problems.
(C) Web must be a minimum of 0.25" (6mm) wider than label to be
dispensed.
Maximum O.D. of roll is 12" (305mm) with a core I.D. of 3" (76mm). Label
orientation is based on equipment and product orientation. Wind labels to
the outside of the roll.
Splices should be avoided as much as possible, but when splices are needed,
please use "angle-style", flush to the edge on both sides of backing, using
1" (25mm) cellophane splice tape. Replace the label in the spliced area.
A label tolerance of ±0.032" (0.81mm) can be maintained provided that:
(A) Labels are manufactured to the right label specification with no die cuts
into the webbing.
(B) Lateral position of labels is within 0.0025" (0.06mm) on the x and y
axes.
CAPACITANCE Capacitance sensors will be damaged by metal or foil labels.
Table 3-1. Label and Web Specifications Chart
L3500PA_Rev10_10.2015
19
L3500PA Labeler Manual
Notes
20
L3500PA_Rev10_10.2015
Applicator Setup
4
This chapter covers mechanical setup of the labeler and printer,
downloading label formats, label specifications and sensor setup.
Ribbon Threading
Before attempting to thread the print engine supply ribbon,
consult your authorized supplier for precise ribbon specifications.
Different print engines use different styles of ribbon. The wrong
ribbon may cause damage to the print engine.
Most print engines use carbon as the print medium. The
print medium can be on the outside or inside of the roll
depending on the manufacturer or the model. Using the
wrong ribbon will damage the printer. Only use the OEM
replacement ribbon to maintain the warranty.
For details on ribbon threading instructions, refer to the printer
operation manual which was shipped with your machine. A
diagram of proper ribbon threading is also provided on most print
engine's lift cover.
Note:
Make sure the ribbon core is pressed all the way to the rear wall
of the printer. To insure proper alignment, also make sure that the
ribbon is threaded squarely through the printer.
After the supply roll has run out, use the empty supply roll as the
rewind core. Always use a rewind core to collect the ribbon; it is
very difficult to remove the ribbon if it is directly rewound on the
rewind drum.
Not using a core on the rewind drum could cause the ribbon
to ripple, resulting in poor print quality.
L3500PA_Rev10_10.2015
21
L3500PA Labeler Manual
Label Threading
It is very important that the correct labels be used on the labeler.
More information on label and web specifications is available later
in this chapter.
It is also very important that the labels are threaded through
the print engine correctly. Improper threading will result in poor
operation. Refer to Figure 4-1 to assist in proper label threading. A
label threading diagram is supplied on the front cover of the print
engine.
1
2
3
4
5
6
7
1
3
2
4
5
7
6
Figure 4-1. Web Path (Left Hand Labeler Shown)
22
L3500PA_Rev10_10.2015
Chapter 4 Applicator Setup
Before installing a label roll, please read Tables 5-1 to insure
the selection of proper label stock.
Heat damage may occur if label rolls are not stored in a cool,
dry place.
Avoid contamination, edges of labels will pick up debris
which could damage print head. Using contaminated label
or ribbon stock will void print engine warranty.
Always use ribbon that is wider than the label stock. Failure
to do so will cause print head damage.
Procedure Refer to the circled numbers (1 through 7) specifically positioned in
Figure 4-1 to assist you in following this label threading procedure.
To thread the label on a left hand unit, reverse the directions.
(For example, if right hand unit is threaded "counterclockwise",
reverse to clockwise for the left hand unit.)
Step 1.
Remove Locking Collar. With the power off, remove the locking
collar from the unwind and rewind assembly. Remove the locking
collar by releasing the levers which hold the locking collar in
position, and pull the outer disk assembly off the core.
Step 2.
Install Label Core. Install the label core onto the unwind
assembly, removing the previous core if applicable. Make sure
supply roll is pushed to the inside disk of the unwind assembly.
Replace the outer disk assembly by aligning the pins on the
locking collar with the grooves on the unwind core. Lock by
pushing the levers parallel to the outer disk.
Step 3.
Secure Label Stock. Holding the unwind assembly, grab the label
stock and tug to make sure the roll doesn’t slip. Once secure, pull
the label from the top and loop around the dancer arm clockwise
[1 and 2].
Step 4.
Guide Label Stock into Print Engine. From the dancer arm pull
the label down, counterclockwise around the first idler roller [3]
and clockwise around the second idler roller [4]. Then, loop the
L3500PA_Rev10_10.2015
23
L3500PA Labeler Manual
label into the print engine, keeping the stock above the alignment
pin and press against the inside guides on the printer.
At this point, the label stock is in position to be threaded through
the printer. Refer to the appropriate section in the print engine
manual for instructions. The printer's operator manual supplies
detailed instructions on threading through the printer. There is
also a diagram, for label threading, supplied on most print engines
inside the lift cover. Route the label around the peeler plate of the
print engine [5]. Do not block air assist bar when routing label
through print engine.
The label stock must not loop around the air assist tube
located under the peeler plate. If the air assist tube is
blocked, proper alignment of labels will not be achieved,
and/or the web will break.
Step 5. Thread Label Stock. Pull about 18" (457 mm) excess label stock
through the top of the print engine to allow sufficient slack to
thread to rewind assembly. At this point, align all the spring collar
guides on the dancer and idler rollers in accordance with the inner
printer guides to insure proper label stock alignment.
UNWIND
ASSEMBLY
ROUNDED
NOTCHES ON
HUB
DANCER
ARM
LONGER PIN
END HOLDS
LABEL WEB
"WASTE" IN
PLACE ON
WHEEL
REWIND ASSEMBLY
WEB
WASTE
Figure 4-2. Web Holding Pull Pin on Rewind Wheel
24
L3500PA_Rev10_10.2015
Chapter 4 Applicator Setup
Step 6.
Secure Excess Stock. Once the label stock is threaded through
the printer and aligned properly, pull the excess and loop around
the return idler bar [6], then counterclockwise around the rewind
assembly [7] (see Figure 4-2). Push the pull pin onto the rewind
core to secure the label stock.
Step 7.
Remove Excess Label Stock. The threading process is complete,
now turn the power "ON" and remove any excess label slack by
pulling the dancer arm down and rotating the supply assembly
counterclockwise until tension is achieved.
Step 8.
Set Sensitivity and Label Pitch. To adjust the label on the peeler
plate, refer to the specific print engine manual as each type of
engine has a different procedure.
Step 9.
Adjust the Label Position (if necessary). Adjust the Label
Position (if necessary). Observe the label to make sure it is
protruding over the edge of the peeler plate tip approximately
0.016" (0.41 mm). If adjustment is needed refer to the specific
print engine manual.
Step 10.
Completed Threading. Once you have achieved the proper
alignment and positioning of the label stock, you have completed
the label threading process.
Unwind, Rewind and Clutch Assemblies
The following is an overview of how new labels are fed from the
unwind assembly around the dancer arm, through the printer, and
finally onto the rewind assembly.
The unwind assembly cannot dispense web (label backing) while
the mechanical brake is engaged. When the machine is turned
ON, the brake is automatically engaged.
Initially, the dancer arm holds a buffer of fresh labels under
tension. As this supply is pulled into and consumed by the print
engine, the additional tension on the web pulls the dancer arm in
a clockwise direction (for a left hand unit; clockwise direction for
L3500PA_Rev10_10.2015
25
L3500PA Labeler Manual
a right hand unit). At a certain point, the
dancer arm mechanically releases the brake,
allowing the unwind assembly to dispense
additional labels as needed. The feed rate of
the unwind assembly is dependent on the
printer speed.
UNWIND
ASSEMBLY
DANCER
ARM
REWIND
ASSEMBLY
IDLER
ROLLERS
Figure 4-3. Unwind and Rewind Assembly Locations
Adjusting the
Clutch Assembly
Step 1.
As labels are dispensed, empty web leaves
the print engine and is collected on the
rewind assembly. Constant tension is applied
by the rewind assembly to the ejected web
to ensure it does not interfere with the
dispensing of new labels. This tension is
applied by a motor and can be manually
adjusted by a clutch located inside the
labeler (see Figure 4-3).
The manually adjusted clutch controls the amount of tension an
electric motor applies to the Rewind Assembly. This adjustment
should be done during initial setup of the machine.
Remove the Back Cover. Remove the cover from the back of the
labeler, loosening and removing the screws holding it in place.
MOTOR DRIVE
PULLEY
DRIVE
BELT
SLIP
CLUTCH
1/30hp
REWIND
ASSEMBLY
GEAR
MOTOR
REWIND
SHAFT
Figure 4-4. Clutch Assembly for Rewind Assembly (Rear of Labeler)
26
Step 2. Locate Clutch
Assembly. The clutch assembly
is on the end of the rewind shaft
on the back side of the labeler. A
drive belt connects a pulley on the
rewind shaft to a pulley on the
motor spindle (see Figure 4-4).
The motor pulley is located above
the rewind pulley.
Step 3. Adjust Clutch Tension.
The operator can manually adjust
the amount of rewind tension. If
this dial is turned clockwise, the
clutch applies more grip to the
rewind shaft (less belt slippage).
L3500PA_Rev10_10.2015
Chapter 4 Applicator Setup
The more grip to the rewind spindle, the greater the amount of
tension the rewind exerts on the ejected web.
If the clutch is turned counterclockwise, it will apply less grip to
the rewind shaft, increasing belt slippage. Less grip to the rewind
shaft means less tension the rewind wheel exerts on the ejected
web.
Make sure the tension is loose enough not to snap or tear
the ejected web but tight enough to exert tension on the
ejected web as the rewind assembly fills up. (When the
rewind assembly fills with empty web it can become quite
heavy.)
Printer
Note:
The unit is a versatile labeler in that it can accommodate various
styles/models of print engines. These print engines are easy
and quick to change out. The different manufacturer's print
engines can easily bolt up to the labeler without any additional
modifications. Refer to the OEM manual for answers to any
questions regarding the print engine.
Right or left justified printer can only be exchanged in like
housing.
It is important to note that the documentation supplied
with your print engine should be reviewed before operating
the labeler.
See the general settings for SATO and ZEBRA print engines below
which are required to communicate with the L3500PA. Please note
these settings may different based on specific models:
SATO: DSW3 dip switch bank, switch #7 and #8 to "ON".
Cycle the print engine for this to take effect.
ZEBRA: Applicator Port: MODE 1; Print Mode: APPLICATOR;
Start Print Signal: LEVEL MODE; Reprint Mode:
ENABLED.
L3500PA_Rev10_10.2015
27
L3500PA Labeler Manual
Downloading Label Formats
Several software packages are available to produce multiple types
of labels. Once a label is generated on your software, the format
must be loaded into the print buffer of the print engine. Once in
the printer, the label may be printed on demand. The following
information is generic instructions on downloading a label from a
personal computer or device which labels are stored.
Step 1.
Select the Desired Communication Interface. There is typically
a parallel port and/or serial port provided on print engines. Refer
to the Operator’s Manual of the particular printer that is provided
on your labeler for more information.
Step 2.
Connect Cables. Connect the correct cable between the printer
and personal computer or other device used. Be sure that these
cables are connected securely.
Step 4.
Turn on Main Power Supply. Turn "On" the main power of the
unit and the power to the print engine. Make sure the printer is
“On-line” before attempting to download any labels.
Step 4.
Download Generated Labels. Now you are ready to download
the generated label. If PC software is used, typically, the print
command is used to download a label. This queue typically
prompts you to give quantities (or the number of "copies" you
desire) along with various other information. Download more
quantities than needed so the labeler does not stop before
complete production is finished. Setting up the labeler may use up
several of the quantities downloaded.
Step 5.
Verify Label Count. Once "Print" or another command is used
to download the label into the print buffer, the LCD of the printer
will display the quantity of labels downloaded. If the quantity
reads 000, the label was not downloaded correctly; try again. If
the quantity displayed is correct, then you are ready to print your
labels. The labeler can be set up to print the same label multiple
times. Refer to Chapter 7: Operator Interface. Also refer to printer
manual for dip switch settings (SATO printers only).
28
L3500PA_Rev10_10.2015
Chapter 4 Applicator Setup
GREEN LED
INDICATOR
(stable)
SHORT RANGE
DETECTION
(refelective)
LIGHT-ON/DARK-ON
ADJUSTMENT
RED LED
INDICATOR
(light receiving)
GAIN
SENSITIVITY
ADJUSTMENT
Figure 4-5. Product Sensor
Product Sensor
The sensor supplied with the labeler should be connected directly
to the Module Interface Panel via a quick disconnect connector
(refer to Figure 3-5, Module Interface Panel). This allows for quick
changeover of sensor style as applications dictate.
This sensor (Figure 4-5) is shipped with a mounting bracket that
should be mounted slightly upstream from the module that was
purchased for your labeler (i.e. tamp pad applicator or blow
module). Refer to the Sensor Setup section of your particular
applicator module.
MAXIMUM
15 INCHES
OBJECT TO BE
DETECTED
SENSOR
Beam is reflected back
to sensor as edge of
object breaks beam
The alignment and method
of mounting is critical to
the performance of the
sensor (refer to Figure
4-6.) Excessive vibration
may cause false readings.
Anything behind the
product that could cause a
false sensor reading should
be moved or placed as far
away as possible.
Figure 4-6. Setup for Product Sensor
L3500PA_Rev10_10.2015
29
L3500PA Labeler Manual
To select between sensing the leading edge or the trailing edge of
a product, use the following directions. Leave the sensor operate
switch set to "light operate" at all times. In the operator interface,
select Trail product to detect the trailing edge, or select Lead
Product to detect the leading edge. (See Chapter 7, Operator
Interface, for more details).
The standard sensor that is shipped with the labeler is set up for
"light operate." Refer to Figure 4-5 for locations to adjust the
sensor (gain control and light-on/dark-on adjustments).
Changing the sensor setting from light operate to dark operate
will drastically affect the operation of the labeler and any modules
being used.
Once the sensor is mounted and the product is in place, apply
power and advance the GAIN control to maximum (clockwise
rotation). If the sensor is “seeing” its reflected light, the sensor
alignment red LED should be on. If a red pulse is not observable,
reduce the GAIN control (counterclockwise rotation) to obtain a
countable pulse rate.
Once you feel comfortable with the set GAIN, test by removing
the object from the sensing position. The red LED indicator should
go “off”. If the LED indicator does not go “off”, the sensor is
reacting to light reflected from a background surface. Reduce the
GAIN until the indicator goes “off”, and check the sensor with
the object once again. If the sensor indicator does not come “on”
when the object is placed in position, then the sensor is receiving
more light energy from the background than the object. Consider
the following alternatives:
aMove the sensor closer to the object, and reduce the sensitivity
(GAIN).
aReduce the background reflectiveness by painting the
background with flat-black paint, scuffing the background or
cutting a hole through it.
aTilt the sensor or the background so that the sensing beam is
not perpendicular to the background.
30
L3500PA_Rev10_10.2015
Applicator Modules
5
Module Style
TAMP
SOFT TAMP/
TAMP BLOW
SOFT TAMP
BLOW ON
WIPE ON
TAMP-BLOW
LEADING EDGE,
CORNER WRAP
TRAILING EDGE,
CORNER WRAP
DUAL TAMP
This chapter covers the change out and setup of individual
applicator modules. This includes installation, setup and
maintenance for each module. Table 5-1 suggests which model
machine and module to use with a particular application.
Description of Label Application
Single label up to 9.5" (241mm) long on the top/bottom/side of container
Single label on fragile parts
Single label as product travels around a 90˚ turn
Label applied without touching product (accuracy is not critical)
Label applied to top, side or bottom as product moves by at a high rate of
speed (can accommodate long labels)
Single label applied by extending tamp towards the product surface then
blowing the label on the surface
Label application on the front corner of a product to 5" (127mm) width,
6" (152mm) to 16" (406mm) long
Label application on the trailing corner of a product to 5" (127mm) width,
6" (152mm) to 12" (305mm) long
Applying two labels on back and side of product, maximum label size 5"
(127mm) x 8" (203mm)
Table 5-1. Applicator Modules
Tamp Module
Labeling Process
L3500PA_Rev10_10.2015
The tamp module assembly (see Figure 5-1)
is a mechanism used to apply a label to a
product. The tamp module consists of a
cylinder, tamp pad, vacuum pad, vacuum
generator and various other components.
The position of the tamp pad assembly is
critical for proper label placement.
Once the tamp assembly is set up, labels
should slide smoothly from the printer peeler
plate to underneath the vacuum pad. The
product sensor then detects the edge of
the product, and the tamp extends to place
VACUUM
PORT
Figure 5-1. Tamp
Assembly
31
L3500PA Labeler Manual
the label onto the product in the preferred location. The label is
securely applied without damaging the product. The tamp retracts
for another label. This whole process should occur with minimal
vibration or erratic motion.
Installation
Step 1.
If your labeler does not already have a tamp module installed, use
the following instructions for installation.
Align Mounting Holes. Align the mounting holes of the tamp
body with the two slotted holes in the machine housing near the
print engine. Once aligned, insert the bolts and tighten to secure
the tamp body. Make sure that the distance between the tamp
body and the peeler plate is a minimum of 0.125" (3 mm) (refer to
Figure 5-2).
PRINT ENGINE
TAMP
ASSEMBLY
VACUUM
PAD
PEELER PLATE
0.125"
CLEARANCE
*Print Engine shown is for illustration purposes only.
Figure 5-2. Tamp Clearance (Peeler Plate and Vacuum Pad)
32
Step 2.
Attach Red Air Hose. Remove the cover and attach the read air
hose (refer to Figure 5-3 on the next page) to the top of the air
cylinder (extend). Plumb the hose through the hole in the housing
into the "A" port of the solenoid valve marked "Tamp".
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
TAMP MODULE
MOVEMENT IS UP
AND DOWN, AND
ROTATION WITH
RESPECT TO THE
PEELER PLATE
AIR ASSIST BAR
HAS ABILITY TO
ROTATE AND MOVE
UP AND DOWN FOR
DESIRED LOCATION
Figure 5-3. Tamp Assembly Hose Attachments and Movement
Step 3.
Attach Black Air Hose. Attach the black air hose to the bottom
of the air cylinder (retract). Plumb the hose through the supplied
hole in the housing and into the "B" port of the solenoid valve
marked "Tamp" (refer to Figure 5-3).
Step 4.
Plumb Green Air Hose. Attach the green air hose into the quick
disconnect fitting on the vacuum generator. Then plumb the hose
through the hole in the housing and into the "A" port of the
solenoid valve marked "Vac Valve."
Step 6.
Install Home Sensor. Locate the tamp home sensor (with
mounting clamp) supplied with the unit. It is found tied to the
machine housing inside the labeler. Install the sensor on the top of
the tamp air cylinder by using the instructions found below.
L3500PA_Rev10_10.2015
Position the tamp pad by adjusting the air for the tamp module
so that the slide is fully retracted. Loosely clamp the tamp home
sensor at the extreme top of the air cylinder and slowly move the
sensor down the cylinder until the LED on the sensor illuminates.
33
L3500PA Labeler Manual
Once the LED illuminates, continue to move the sensor down an
additional 0.125" (3 mm). Tighten the sensor clamp to prevent
movement.
Tie the air hose and wire so that the linear shafts of the
tamp will not hit through its full travel.
Be sure the sensor is located in the correct position. Failure
to do so may cause the placement of a double label or no
label placement. Check periodically to make sure the clamp
is tight on the cylinder to eliminate movement during
production.
Step 6.
Replace Cover. Replace back cover.
Step 7.
Verify Module Interface Panel Setup. Make sure that the
Module Interface Panel is set up with the correct connections (refer
back to Figure 3-5). The tamp module is now installed and is ready
for setup.
Modification of
Tamp Pad
If your tamp module was shipped with a standard tamp pad (one with no
holes), the pad will have to be modified to accommodate the label
used on the labeler. The following instructions and illustrations are
guidelines for modifying the tamp pad. For special applications/
labels call your authorized distributor for assistance.
Step 1.
Verify Tamp Pad Setup. First, check that the tamp pad is parallel
with the bottom of the front plate, and the bottom of the vacuum
pad is approximately 0.031" – 0.125" (0.79 mm – 3 mm) below
the peeler plate. Also, check that the tamp module assembly is a
minimum distance of 0.125" (3 mm) from the peeler plate. This
eliminates any interference during cycling (refer to Figure 5-2).
Step 2.
Thread Labels. Thread the desired labels for the tamp pad
you are modifying. Adjust the stop position so that the label is
approximately 0.016" (0.41 mm) past the end of the peeler plate.
Please refer to your specific print engine manual for instructions
on how to adjust the stop position.
34
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
4.50 (114.3mm)
4
LABEL
PROCEDURE:
When the label being used covers the
entire vacuum bore area, including the
three vacuum bore holes drilled in the side,
then use the following procedure:
VACUUM BORE
1.13
(28.6mm)
0.062
(1.6mm)
THRU TO
VACUUM
BORE
1.50
(38.1mm)
5.25
(133.4mm)
VACUUM
BORE
1.50
(38.1mm)
0.38
(9.7mm)
TYP.
LABEL
TRAVEL
1.13
(28.6mm)
0.40
(10.2mm)TYP.
PROCEDURE:
When the label being used does not cover
the entire vacuum bore area, then use the
following procedure:
• Start by drilling three (3) 0.062" holes
at 0.38" from the leading edge of the
vacuum pad. The outer rows should be
spaced 0.25" from the side edge of the
label. The middle row will be half the
distance between the outer rows.
• Space additional holes .40" apart in
the travel direction of the label (do not
exceed the label travel onto the vacuum
pad).
• Test the label on the pad. Additional
holes in the direction of travel may be
necessary to insure the label is fed far
enough onto the pad.
LABELER
HOUSING
• Start by drilling three (3) 0.062" holes
at 0.38" from the leading edge of the
vacuum pad. The space between the
rows of holes should coincide with the 3
vacuum bores in the side of the pad.
• Space additional holes .40" apart in
the travel direction of the label (do not
exceed the label travel onto the vacuum
pad).
• Test the label on the pad. Additional
holes in the direction of travel may be
necessary to insure the label is fed far
enough onto the pad.
4.50 (114.3mm)
VACUUM BORE
LABEL
TRAVEL
1.13
(28.6mm)
2
LABEL
VACUUM
BORE
0.40
(10.2mm)
TYP.
.25
(6.4mm)
0.062
(1.6mm)
THRU TO
VACUUM
BORE
0.38
(9.7mm)
TYP.
1/2X
.25
(6.4mm)
1.50
(38.1mm)
5.25
(133.4mm)
1.50
(38.1mm)
1.13
(28.6mm)
LABELER HOUSING
Figure 5-4. Modification of Tamp Pad
L3500PA_Rev10_10.2015
35
L3500PA Labeler Manual
VACUUM
BORE
LABEL
LABEL
TRAVEL
TRAVEL
STANDARD VACUUM PAD
VACUUM
BORE TYP
(3) PLACES
Figure 5-5. Modification of Tamp Pad (Continued)
Step 5.
Step 3. Mark Label for Modification.
Make sure the print engine is "offline", and feed a label onto the tamp
pad on the printer. Use your index
fingers to hold the label in place. This
allows you to see approximately how
the label will be dispensed onto the
vacuum pad. Make initial marks on
the vacuum pad. This will assist in the
modification process.
Step 4. Modify Vacuum Pad.
Refer to Figures 5-4 and 5-5 as general
guidelines to modify the vacuum pad.
The number and position of holes will
vary depending on your label. Test the
pad after the initial holes are drilled
and modify as needed.
Determine Sufficient Vacuum. To determine the sufficient
vacuum for a particular label, use the tip of your index finger
to guide a dispensed label onto the vacuum pad. Use the same
finger tip to alternately hold the label against, and pull the label
away from the tamp pad while adjusting the vacuum regulator
so that there is slightly more vacuum than necessary to hold the
label on the pad. Make sure that the label covers all the holes on
the vacuum pad surface equally. The entire label should adhere to
the vacuum pad when the vacuum is on. If the label is falling off
the vacuum pad or erratic placement is being observed, additional
vacuum holes may need to be added.
Make sure there is no interference between the tamp
assembly and the peeler bar throughout the stroke of the
air cylinder.
36
Feed a Label
Once the tamp pad position is initially set, it is now time to feed a
label onto the vacuum pad. Download a formatted label into the
printer. Make sure the labeler is in STOP mode before going to the
Jog mode (refer to Chapter 7). Press the "green" (+) button to
feed a label one by one. The goal is for the label to feed straight
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
TAMP MODULE
MOVEMENT
UP/DOWN
AND
ROTATION
WITH RESPECT
TO THE PEELER
PLATE
HOUSING
TAMP
PAD
AIR
FITTING
VACUUM
PAD
AIR
ASSIST
BAR
AIR ASSIST ROTATE &
MOVE UP/
DOWN FOR
OPTIMAL
ASSISTANCE
AIR DISTRIBUTION
HOLES
Figure 5-6. Tamp Adjustments When Feeding A Label
HORIZONTAL
ADJUSTMENT SET
Figure 5-7. Air Assist Bar
from the peeler bar onto the vacuum pad without any flapping.
You may need to adjust the tamp pad assembly up or down using
the mounting slots in the housing (refer to Figure 5-6).
Air Assist Tube
Adjustments
L3500PA_Rev10_10.2015
The air assist tube's flow is used to help the transition of the
label from the peeler plate to the vacuum pad. The air assist tube
can be rotated (refer to Figure 5-6) or adjusted in or out (refer
to Figure 5-7) after loosening the set screw located under the
housing. The air assist can move up or down after loosening the
bolts attaching the mounting bracket to the plate housing. The
angle of the air assist tube is generally set upwards toward the
front of the vacuum pad. The air holes in the air assist tube are
generally centered on the width of the label. Air assist tubes with
several holes are generally set to evenly distribute the air flow onto
the label. Unused air ports not located under the label or tamp
pad may be covered with tape if not required. The actual position
of the air assist tube is determined by the size of the label.
The label should feed onto the vacuum pad as far from the
peeler plate as possible. This will eliminate possible label jams
37
L3500PA Labeler Manual
as the tamp assembly extends. There are many adjustments to
accomplish this; it may require one or more of the following:
Ü Decrease the vacuum supplied using the appropriate flow knob
on the pneumatic panel.
Ü Increase the air flow to the air assist bar using the appropriate
flow knob on the pneumatic panel.
Ü Adjust the angle of the air assist bar.
Ü Decrease the air assist delay (AIR AST DEL) found in the
operator's panel. Refer to Chapter 7. The air from the air assist
bar starts sooner to push the label onto the vacuum pad.
Ü Increase the air assist dwell (AIR AST DWL) using the operator's
panel. The air from the air assist bar stays on longer to push the
label further away from the peeler plate.
Note:
The air assist bar should be activated for as long as the label is
moving.
Ü Increase the vacuum delay (VACUUM DEL) using the operator's
panel. This delays the vacuum from being applied to the label
through the tamp pad allowing the label to feed further onto
the pad before being set by the vacuum.
Ü Drill additional vacuum holes in the tamp pad in the direction
the label is traveling onto the tamp. This allows the label to
feed further onto the vacuum pad and still adhere flat to the
pad.
Excessive vacuum holes may cause loss in vacuum suction
which will affect the label positioning. Add only one row of
holes at a time. Ü Adjust the angle of the tamp assembly with respect to the
peeler plate. This allows the label to feed onto the pad further.
The entire unit will have to be rotated in the opposite direction
to accommodate the angle of the tamp, or the label will not be
applied to the product squarely.
38
Apply Label
to Product
Once the label is properly positioned onto the vacuum pad, it is
now time to apply the label to the product. Position the labeler
such that the tamp pad is parallel with the surface of the product
to be labeled. Position the labeler so that when the tamp pad
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
contacts the desired product, it is as close to the tamp pad as
possible– but not past the full extension of the tamp cylinders. If
the tamp pad is fully extended when it applies the label, the label
may only be partially applied to the product. To optimize cycle
time, position the tamp as close to the product as possible.
Adjust Striking Force
Once the labeler is in position to apply the label, adjustment of the
tamp pad contacting the product may be necessary. One or more
of the following methods may be used in adjusting the striking
force onto the product:
Ü Adjust the pressure to the cylinder using the appropriate
knob (TMP/BLW) on the pneumatics panel. Increasing the
flow causes the tamp pad to strike the product with more
force. Decreasing the flow softens the applied force onto the
product.
Ü Adjust the intake/exhaust flow controls for the tamp found
on the air cylinder. Closing the intake (flow control which
red airline is attached) decreases the speed extension, while
opening it increases the rate the tamp pad extends. Closing
the exhaust (flow control which black airline is attached)
decreases the rate of return, while opening it increases the rate
of the tamp pad return.
Ü Adjust the TMP DWL at the operators panel. TMP DWL is the
amount of time the tamp will be away from its home position
(retracted). This setting allows you to control the length of
stroke by adjusting the time of dwell. Use this parameter to
minimize or maximize the amount of force the tamp exerts on
the product. A higher value extends the tamp longer. A lower
value decreases the tamp extension time. Refer to Chapter 7:
Operator Interface.
Ü Physically locate the labeler unit closer to or further away from
the product. Lowering the unit will cause the tamp pad to
apply more force onto the product, while raising the unit will
decrease the force.
Note:
Make above adjustments until the application of the label to the
product is a smooth, non-vibrating process.
Label Placement
The final adjustment for the tamp pad assembly is the placement
of the label on the product with respect to the edge of the
L3500PA_Rev10_10.2015
39
L3500PA Labeler Manual
PLACE LABEL
CLOSE TO
LEADING EDGE
FOR TAMP/
BLOW DELAY
(LOW VALUE)
PLACE LABEL FURTHER
FROM LEADING EDGE REQUIRES HIGH VALUE
FOR LABEL PLACEMENT
LABEL
LABEL
PRODUCT SENSOR
(DETECTS LEADING
EDGE OF PRODUCT)
Direction of
Travel
Figure 5-8. Fine Tuning Label Placement
product (refer to Figure 5-8). One or more of the following
methods may be used for the desired adjustment.
Ü Adjust the TMP/BLW DEL found in the operators panel. Refer
to Chapter 7. A higher value delays the tamp assembly from
extending causing the label to be placed closer to the trailing
end of the product. A lower value extends the tamp sooner
and places the label closer to the leading edge.
Ü Adjust the ProdUCT Lockout found in the operators panel.
This adjustment prevents applying multiple labels or false hits
on the same product. Increasing the value locks out the input
from the product sensor for a longer amount of time, while
decreasing the value shortens the time. Too long of a product
lockout could cause a product to be missed.
Ü Adjust the Product DETECTION found in the operators panel.
This activates the labeler on the leading or trailing edge of the
product. Refer to Chapter 7: Operator Interface.
Removing Tamp When removing the tamp module, follow the steps below. The
Module tamp assembly will fall off the machine if not supported as
you remove the cap screws.
Step 1.
Remove Cover. Remove the back cover.
Step 2.
Remove Tamp Sensor. Remove the tamp home sensor attached
to the air cylinder and wire tie it inside the housing.
40
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
Step 3.
Step 4.
Troubleshooting
Remove Air Pressure. Remove the pressure from the Tamp/Blow
valve by turning the adjustment knob until the meter reads zero
PSI.
Remove Air Lines. Remove the two air lines on the air cylinder
and the one vacuum line from the tamp pad.
Step 5. Remove Mounting Screws. Remove the two M6 socket head
cap screws which mount the tamp to the housing.
Replacing Worn Parts From time to time you may need to replace:
Ü Air cylinder
Ü Slide bushings
(Refer to the Spare Parts list in Chapter 9).
To isolate pneumatic problems to the Tamp Module, activate the
"Tamp Assist Valve Override Test Point" found on the pneumatic
panel. Confirm that the tamp extends and retracts properly. Refer
to the Troubleshooting section in Chapter 10 for additional help.
Blow-On Module
L3500PA_Rev10_10.2015
The Blow-On Module is a mechanism used to apply a label when
contact with the product is not desirable, or when labels need to
be applied very rapidly. The Blow-On Module consists of a blow
box with a fan to create a vacuum that holds the label until such
time that the label is blown onto the product. A baffle knob on
the front of the cover can be turned clockwise or counterclockwise
to open or close a series of 1/2" holes to bleed off unwanted
vacuum. A series of blow pipes connected to a manifold are
located on the inside rear of the blow box with connector nozzles
located on the other ends. These connector nozzles are inserted
into the grid plate on the bottom of the blow assembly. They are
simply pushed in until a snug fit has been attained. Any unused
blow pipes must be inserted into the back plate when not used or
there will be inconsistency when blowing the labels. A grid plate
cover that slides in over the bottom grid plate (that you customize)
is provided to stop vacuum loss when it blocks the holes on the
41
L3500PA Labeler Manual
grid plate. The position of the Blow-On Module is critical for
proper label placement.
Labeling Process
Installation
Step 1.
Disconnect Power. Disconnect power and air to the labeler.
Remove any other modules installed.
Step 2.
Install Blow-On Module. Install the Blow-On Module to the
labeler with the two M6 x 30mm long socket head cap screws,
flat washers and lock washers provided (refer to Figure 5-9 and
Figure 5-10). The falt washers go against the housing and the
lock washers go against the socket head cap screw. The Blow-On
module grid plate should be level with the print engine peel plate.
Once the Blow-On Module is set up, the printer will print the label.
As the label slides smoothly across the peeler plate and through
a series of timing sequences, the label is assisted onto the grid
plate by the air assist bar and held to the grid plate by the vacuum
generated by the fan. Next, the product sensor detects the edge
of the product. Then, through another set of timing sequences
started by the product sensor, the label is blown onto the product
as the product passes under the blow box.
If your labeler does not already have a Blow-On Module installed,
use the following instructions for installation.
INCOMING
LABELS
AIR
AIR
GRID
PLACE
AIR
WASTE
AIR ASSIST
BAR
LABEL
Figure 5-9. Blow Box
42
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
Step 3.
Connect Fan. Connect the fan cord to the fan receptacle (110V
Auxiliary power) on the module interface panel (refer to Figure
5-12).
Step 4.
Install Valve Assembly. Install the valve assembly with the M10
x 20mm long socket head cap screws and flat washers provided.
This assembly has the tag labeled "Blow-On Module Pressure"
(refer to Figure 5-10).
Step 5.
Connect Red Tubing. Connect the red 3/8" diameter tubing from
the Blow-On Module to the port on the valve assembly labeled
"Blow-On Module Pressure" (refer to Figure 5-10).
SHOP AIR
"T" FITTING
TUBING TO
MAIN AIR
SUPPLY
3/8" RED
TUBING
50 100
150
psi
BLOW-ON MODULE PRESSURE
VALVE
ASSEMBLY
FAN
CORD
BLOW BOX
(CAN MOVE UP/DOWN)
AIR ASSIST BAR CAN
ROTATE/MOVE UP-DOWN
Figure 5-10. Blow-On Module Assembly
L3500PA_Rev10_10.2015
43
L3500PA Labeler Manual
STRAIN
RELIEF
VALVE ASSEMBLY
COVER
VALVE
REGULATOR
KNOB
TO INSIDE OF
LABELER
GAUGE
Figure 5-11. Valve Assembly Housing
Step 6.
Connect Air. The main air hose will require a tee to supply the
Blow-On Module with air. The tee fitting and hose are in the kit.
Disconnect the 3/8" diameter air line from the Main Air port,
insert it into the open port on the tee fitting, then insert the short
hose from the tee fitting into the Main Air port on the labeler
(refer to Figure 5-10).
Step 7.
Other Connections. Remove the cover from the blow box
valve housing (refer to Figure 5-11). Disconnect the Tamp Valve
Connector found inside the labeler. This is the quick connect plug
attached to the tamp valve (upper most valve) on the pneumatic
valve pack. Route this connector through the opening in the front
of the case (same opening as airlines are routed through), there
is excess wire supplied for routing to the required location. At
this point wrap the wire with the supplied spiral wrap and route
through the strain relief on the blow box valve housing (refer to
Figure 5-11). Plug the connector into the supplied valve as shown
and tighten the strain relief. Confirm all connections are routed
properly and tighten. Install cover.
Step 8.
Connect Air and Power. Connect plant air (80 PSI min). and plug
in power cord to the labeler.
44
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
Step 9.
Feed a Label
Air Assist Tube
Connect Nozzles. Insert the Blow-On Module nozzles in the grid
plate (more nozzles for larger labels, less for smaller labels) (Refer
to Blow Nozzle Placement). Modify the lexan grid plate cover (refer
to Grid Plate Cover) and adjust the blow and air assist pressures to
meet the application needs.
Once the Blow Box position is initially set, it is now time to feed
a label onto the grid plate. Download a formatted label into the
printer. The goal is for the label to feed straight from the peeler
bar onto the grid plate without any flapping. You may need to
adjust the Blow Box assembly up or down using the mounting
slots in the housing (refer to Figure 5-10).
The air assist tube's flow is used to help the transition of the label
from the peeler plate to the grid plate. The air assist tube can be
rotated (refer to Figure 5-10) or adjusted in or out (refer to Figure
5-12). Loosen the set screw located under the housing before
rotating the air assist bar. The air assist can move up or down after
loosening the bolts attaching the mounting bracket to the plate
housing. The angle of the air assist tube is generally set upwards
toward the front of the vacuum grid. The air holes in the air assist
BLOW-ON
MODULE
AIR
FITTING
AIR
ASSIST
BAR
AIR DISTRIBUTION HOLES
Figure 5-12. Air Assist Bar for Blow-On Module
L3500PA_Rev10_10.2015
45
L3500PA Labeler Manual
tube are generally centered on the width of the label. Air assist
tubes with several holes are generally set to evenly distribute the
air flow onto the label. Unused air ports not located under the
label or tamp pad may be covered with tape if not required. The
actual position of the air assist tube is determined by the size of
the label.
Troubleshooting
To isolate pneumatic problems to the Blow-On Module, activate
the "Blow Assist Valve Override Test Point" found in the Valve
Assembly. Confirm that the Blow Module blows properly. Refer to
the Troubleshooting section in Chapter 10 for additional help.
Adjustments
The label should feed onto the grid plate as far from the peeler
plate as possible. There are many adjustments to accomplish this;
it may require one or more of the following:
Ü Increase the air flow to the air assist bar using the appropriate
flow knob on the pneumatic panel.
Ü Adjust the angle of the air assist bar.
Ü Decrease the AIR AST DEL found in the operators panel. Refer
to Chapter 7. This blasts air from the air assist bar sooner to
push the label onto the vacuum pad.
Ü Increase the Air AST DWL by using the operator panel. The
air from the air assist bar is activated longer to push the label
further away from the peeler plate.
Note: The air assist should blow as long as the label is moving.
Blow Nozzle Blow pipes are supplied to blow
Placement the label onto the product. Use
CUSTOM MADE NOTCH
as many as needed to sufficiently
MATCHES THE SIZE OF THE
blow the label onto the product.
LABEL
Smaller labels will need fewer
blow pipes, larger labels need
more. They are simply pushed
into the bottom grid plate until
a snug fit has been attained.
Arrange the blow pipes in a
symmetrical pattern that matches
the size and shape of the label.
Figure 5-13. Grid Plate Cover
46
L3500PA_Rev10_10.2015
Chapter 5 Applicator Modules
Finding the optimal pattern is more art than science; it may take
several tries before locating an optimal pattern for your label. Any
unused blow pipes must be inserted into the back plate when not
used or there will be inconsistency when blowing the labels.
Grid Plate Cover
Apply Label
to Product
Label Placement
A grid plate cover made of clear lexan that slides in over the
bottom grid plate is provided to stop vacuum loss when it blocks
the holes on the grid plate. You will need to customize it by
cutting it to fit the size of your specific label (refer to Figure 5-13).
Once the label is properly positioned onto the grid plate, it is now time
to apply the label to the product. Position the labeler such that the
blow box is parallel with the surface of the product to be labeled.
Position the labeler so that product is as close to the grid plate
as possible. The closer the product is to the grid plate, the more
accurate the label placement.
The final adjustment for the Blow-On Module assembly is the
placement of the label on the product. One or more of the
following methods may be used for the desired adjustment.
Ü Adjust the TMP/BLW DEL using the operator panel. Refer to
Chapter 7. A higher value delays the blowing, causing the label
to be placed closer to the trailing end of the product. A lower
value blows sooner and places the label closer to the leading
edge.
LABEL CLOSE TO
LEADING EDGE: LOW VALUE
FOR "SET PRODUCT"
LABEL
Direction of
Travel
LABEL
PLACE LABEL FURTHER
FROM LEADING EDGE:
HIGH VALUE FOR "SET
PRODUCT"
PRODUCT SENSOR (DETECTS
LEADING EDGE OF PRODUCT)
Figure 5-14. Fine Tuning Label Placement
L3500PA_Rev10_10.2015
47
L3500PA Labeler Manual
Ü Adjust the LABEL PLACE found in the operators panel. This is
a fine tuning adjustment of the Tamp/Blow Delay described
above. A higher value delays the tamp assembly from
extending and the label is placed closer to the trailing end
of the product. A lower value extends the tamp sooner, and
places the label closer to the leading edge.
Ü Adjust the PROD LOCKOUT using the operator panel. This
adjustment prevents applying multiple labels or false hits on the
same product. Increasing the value locks out the input from the
product sensor for a longer period of time, while decreasing
the value shortens the lockout time. A long lockout time could
cause a product to be missed.
Ü Adjust the TRAIL/LEAD PRODUCT found in the operators panel.
This activates the labeler on the leading or trailing edge of the
product. Refer to the Operator Interface in Chapter 7.
Testing
The following is a checklist for starting your labeler. After this
list is complete, you will be ready to move forward to Chapter 7:
Operator Interface to learn about the actual controls of the labeler.
❑ All safety cautions are adhered to for safe operation.
❑ Verify all accessories and modules purchased are installed.
❑ Insure that the labeler is positioned properly and secured for
proper performance.
❑ Air and power are properly supplied and attached.
❑ The proper ribbon is used and is threaded through the printer
correctly.
❑ The label stock is properly threaded through the
labeler.
❑ The desired labels are downloaded into the printer supplied.
❑ The product sensor is in position and properly adjusted for the
required product.
48
L3500PA_Rev10_10.2015
Operator Interface
6
Operator Interface Map
MODE
JOG
To go back to the previous screen
when in the MODE (Main Menu)
screen, use the left or right arrow
keys
RESET LOW LABEL
COUNT
DESCRIPTION
EDIT PARAMETERS
When EDIT PARAMETER is
pressed, a keypad will appear
where the password [1-1]
is then entered. Then hit
ENT. Once returned to Edit
parameter screen, press the
plus button.
TAMP / BLOW DELAY
TAMP / BLOW DWELL
VACUUM DELAY
VACUUM DWELL
AIR ASSIST DELAY
AIR ASSIST DWELL
ADVANCED PARAMETERS
When ADVANCED PARAMETERS
is pressed, a keypad will appear
where the password [2-2] is
then entered. Then hit ENT.
Once returned to ADVANCED
PARAMETERS screen, press the
plus button.
BLOW MODULE
SOFT TAMP SELECT
SOFT TAMP DELAY
SOFT TAMP RESET
SOFT TAMP RESET TIMER
PRODUCT EDGE
PRODUCT LOCKOUT
PRINT TYPE
REMOTE OPERATOR
PRINT ENGINE
TOTAL COUNT
To move within the
menus, use the up and
down arrow keys.
To return from any screen to the
main menu (EXCEPT main menu) use
the right and left arrow keys.
Figure 6-1. Mapping of the Operator Interface
L3500PA_Rev10_10.2015
49
L3500PA Labeler Manual
The following pages of information explain the different
parameters found within the operator panel. These parameters
are extremely important in obtaining a reliable labeling operation.
The operator should take time to sample various settings and
observe how they affect the performance of the labeler. The more
the operator understands the following information, the easier the
transition from application to application will become. Below is a
brief illustration of the program layout (Figure 6-1).
Read the entire Operator Interface chapter before setting
the operating mode.
Main Menu
Mode: APPLICATOR ON/APPLICATOR OFF
APPLICATOR ON
Starts and stops the labeler and auxiliary equipment. Only when
APPLICATOR OFF is displayed, can the Jog mode be turned on or
off using the Jog screen.
After turning on the machine, the display reads the Mode screen.
The default setting is APPLICATOR OFF.
APPLICATOR OFF pauses the labeler. The machine is stopped
indefinitely. The labeler can only be jogged when in APPLICATOR
OFF mode.
APPLICATOR ON locks out jog mode and lets the labeler run
normally. Use the Plus (+) Minus (-) keys to toggle between
APPLICATOR ON and APPLICATOR OFF.
The down key (▼) scrolls to the next screen.
The up key (▲) scrolls to the previous screen.
Ü APPLICATOR ON/APPLICATOR OFF switches the auxiliary
equipment on or off. Ü This selection is used to start and stop the labeler unless a
separate stop button has been installed.
50
L3500PA_Rev10_10.2015
Chapter 6 Operator Interface
▼
▼
Ü Defaults to APPLICATOR OFF after power is cycled.
Ü In this screen only, to return to the previous screen, use the left
).
or right arrow key(
JOG
JOG
Turns jog mode on or off.
Off lets the labeler run normally.
On runs the labeler manually one cycle at a time or continuously
and locks out other screens.
To cycle the machine one time, press the plus key once.
Ü Use Jog for troubleshooting or after loading labels or printer
ribbon. Jog is only available after you choose APPLICATOR OFF
on the “Run” screen.
Ü Defaults to Off after power is cycled.
RESET LOW LABEL
LOW LABEL (Reset Low Label)
For use with a Low Label Sensor and Light Tower. This parameter
resets a low label sensor "fault" which is displayed as an amber
light on the Light Tower. After replenishing the label stock on the
Unwind Assembly, press the (+) key.
Count
COUNT
123456
Counts the cycles since the counter was reset.
Ü Max: 99,999 units of product. The setting is retained when
power is turned off.
Ü Min: 0 units of product.
L3500PA_Rev10_10.2015
51
L3500PA Labeler Manual
SHIBUYA HOPPMANN
SHIBUYA
HOPPMANN
L3500
L3500
Indicates the model and operating system for the labeler.
Edit Parameter Menu
Edit Parameters
EDIT PARAMETERS
The Edit PARAMETERS menu customizes the way the labeler
operates. Press the EDIT PARAMETER key, and an keypad will
apprear. Enter the password (1-1), and hit ENT.
▼
▼
Ü To enter this menu, press the plus key (+) when the Edit
Parameters screen is displayed.
) to return to the MAIN
Ü To exit, press the arrow keys (
MENU while in any screen
The down key (▼) scrolls to the next screen.
The up key (▲) scrolls to the previous screen.
Note: The parameters are retained even after power is turned off.
Incorrect changes in the Edit PARAMETERS menu may cause
the machine to operate improperly.
TAMP/BLOW
DELAY
0132
Tamp / Blow_Delay
Sets delay between sensing the product and activation of tamp or
blow assembly.
Increase (+) to position label closer to trailing end of product.
Decrease (-) to position label closer to leading end of product.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. Setting is retained when power is turned off.
52
L3500PA_Rev10_10.2015
Chapter 6 Operator Interface
Tamp / Blow_Dwell
TAMP/BLOW
DWELL
0134
Sets dwell time for the tamp or blow assembly.
Increase (+) to extend the time the tamp is extended or the blow
box is activated.
Decrease (-) to reduce the time the tamp is extended or the blow
assembly is activated.
Ü Maximum: 9999 (99.99sec) Minimum: 1 (0.01sec) Units: 0.01
sec.
Ü The setting is retained when power is turned off.
Vacuum Delay
VACUUM
DELAY
3456
Delays activation of the vacuum that pulls the label onto the tamp
pad. Used to smooth the transition of the label from the peeler
bar to the tamp pad. See Air Assist Delay screen.
Increase (+) to turn the vacuum on later.
Decrease (-) to turn the vacuum on earlier.
Ü Delay starts when label begins printing. If the leading edge of
the label does not arrive all the way to the edge of the tamp,
then increase this setting.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. Setting is retained when power is turned off.
Ü Vacuum delay is normally set to expire at the same time the
label is finished feeding.
L3500PA_Rev10_10.2015
53
L3500PA Labeler Manual
VACUUM
DWELL
Vacuum Dwell
0132
Sets a time value to keep the vacuum activated as the tamp is
applying the label.
Increase (+) to keep the vacuum activated for more time.
Decrease (-) to keep the vacuum activated for less time.
Ü When a tamp is installed, Vacuum Dwell is used to prevent
the label or a lightweight product to remain attached to the
pad as the tamp retracts.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. Setting is retained when power is turned off.
The value cannot exceed tamp dwell or the labeler will not
function properly.
Air Assist Delay
AIR ASSIST
DELAY
0134
Smooths the transition of the label from the peeler bar to the
tamp pad or blow box. See Vacuum Delay screen.
Increase (+) to turn the air assist on later.
Decrease (-) to turn the air assist on earlier.
Ü Delays activation of the air assist valve. Delay starts when the
label begins printing.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. Setting is retained when power is turned off.
54
L3500PA_Rev10_10.2015
Chapter 6 Operator Interface
AIR ASSIST
DWELL
Air Assist Dwell
3456
Helps push the label further onto the tamp pad or blow box.
Increase (+) to keep the air assist activated for more time.
Decrease (-) to keep the air assist activated for less time.
Ü Sets how long air assist valve stays activated to blow the label
up onto the tamp pad or blow box.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. Setting is retained when power is off.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. Setting is retained when power is turned off.
Advanced Parameter
Menu
The ADVANCED PARAMETERS menu further customizes the way
the labeler operates. Press the ADVANCED PARAMETER key, and
an keypad will appear. Enter the password (2-2), and hit ENT.
▼
▼
Ü To enter this menu, press the plus key (+) when the
ADVANCED Parameters screen is displayed.
Ü To exit, press the arrow keys (
) to return to the MAIN
MENU while in any screen
The down key (▼) scrolls to the next screen.
The up key (▲) scrolls to the previous screen.
BLOW MODULE
BLOW
MODULE
ÜSelect YES when the blow-on module is installed.
OFF
The setting is retained after the power is turned off.
Note: When setting this module to YES, all other modules must
be set to NO.
L3500PA_Rev10_10.2015
55
L3500PA Labeler Manual
SOFT_TAMP_SELECT
Soft Tamp requires the installation of an optional sensor.
YES
SOFT TAMP
SELECT
If SOFT TAMP is active, the tamp assembly retracts as soon as
the soft tamp sensor is blocked. Retraction of the tamp may be
delayed by entering a time into the Soft Tamp Delay screen.
Soft tamp can be used:
Ü To apply labels to fragile parts.
Ü To apply labels on products as they travel through a 90º
transfer.
Ü To apply labels at various heights and widths.
Ü Choose Yes when the soft tamp is installed. The setting is
retained after the power is turned off.Note: When setting
this module to YES, all other modules must be set to NO.
SOFT TAMP DELAY
SOFT TAMP
DELAY
The
Soft Tamp Delay delays retraction of the tamp assembly.
1234
The delay starts when the soft tamp sensor is blocked.
Increase (+) to delay return of tamp assembly after sensor
activation.
Decrease (-) to speed return of tamp assembly after sensor
activation.
Ü Maximum: 9999 (99.99 sec) Minimum: 0 (0 sec) Units: 0.01
sec. The setting is retained when the power is turned off.
Ü Soft Tamp requires the installation of an additional (optional)
sensor.
56
L3500PA_Rev10_10.2015
Chapter 6 Operator Interface
SOFT TAMP RESET
SOFT
TAMP
OFF
RESET
The
Soft Tamp RESET will allow the tamp assembly to
automatically retract if the soft tamp sensor doesn't see the
product in the amount of time set in the SOFT TAMP RESET TIMER.
This time starts from when the tamp first starts extending, until
the sensor detects the product.
SOFT TAMP RESET TIMER
The Soft Tamp RESET TIMER is the time that the tamp assembly
will take to retract automatically if no product is detected. SOFT
TAMP RESET must be enabled for this function.
1234
SOFT TAMP
RESET TIMER
product edge
TRAILING PRODUCT
EDGE
The PRODUCT EDGE activates the labeler on the leading or trailing
edge of the product.
LEADING activates the labeler on the leading edge of the product.
TRAILING activates the labeler on the trailing edge of the product.
The setting is retained after the power is turned off.
Ü Correct operation of this feature depends on the proper setting
of the product sensor. The light/dark operate switch on the
sensor itself must be set to "L.O." (light operate).
Ü If this switch is reversed, operation of the Product Edge will be
reversed.
L3500PA_Rev10_10.2015
57
L3500PA Labeler Manual
Product lockout
PRODUCT
LOCKOUT Product Lockout sets a time value to activate the labeler after a
1234
product sensor input signal is received. The labeler will not cycle
again until this time value expires.
Increase (+) to lock out input from the product sensor for a longer
time period.
Decrease (-) to lock out input from the product sensor for a shorter
time period.
Ü Prevents accidentally placing an extra (or extra) labels on the
same product.
Ü Maximum; 9999 (99.99 seconds). Minimum; 1 (0.01 second).
Units: 0.01 second. Setting is retained when power is turned
off.
Ü The product lockout settings affect the rate at which the
labeler will cycle continuously in jog mode.
A high PRODUCT LOCKOUT value may cause the labeler to
miss product(s).
58
A low PRODUCT LOCKOUT value may cause the labeler to
apply multiple labels to the same product if false product
senor inputs are received.
L3500PA_Rev10_10.2015
Chapter 6 Operator Interface
PRINT TYPE
PRINT
PRINT TYPE
Print type allows the operator to choose between two types of
printing modes (PRINT and REPRINT).
PRINT is used when label information changes for each label.
Note: If the product sensor detects a product before a label is
finished printing, the product will not be labeled.
When PRINT is active, the machine prints the number of labels
loaded in the queue and then stops. The printing begins once the
data is received by the print engine. If more than one label is sent,
the labeler will print the first one and store the remaining labels in
the queue. The label will stay on the vacuum pad until it is cycled. *For more information on individual printer Engine settings, refer to the manufacturer's
operations manuals.
REPRINT is used when label information does not change.
When REPRINT is active, the machine finishes printing all the labels
in the queue, then reprints the last label over and over. If only one
label is loaded, the same label will be reprinted over and over.
Ü On SATO printers, for REPRINT to operate, "DSW3 switch #8"
must be set to ON.
Ü On ZEBRA printers, for REPRINT to operate, "REPRINT MODE"
in the print engine's operator screen must be set to ENABLED.
*For more information on the DSW3 switch, refer to the Installation and Configuration
section of the SATO printer manual, Section 3.
L3500PA_Rev10_10.2015
59
L3500PA Labeler Manual
ReMOTE OPERATOR
REMOTE
OPERATOR
YES
REMOTE OPERATOR allows the labeler to be stopped manually
with an optional remote stop button.
Ü Leave NO selected unless a remote stop button is installed on
the equipment.
Ü Choose YES if the optional remote stop button is installed.
Setting is retained when the power is turned off.
If you select YES but have no optional remote stop button
installed, the machine is NOT RUN.
PRINT ENGINE
PRINT
ENGINE
The PRINT ENGINE allows you to set the printer associated with
SATO
the labeler (SATO or ZEBRA).
TOTAL
COUNT
X100
TOTAL counT
60
TOTAL COUNT displays the lifetime total number of labels printed.
This value cannot be reset. Counts are in increments of 100.
L3500PA_Rev10_10.2015
Preventive Maintenance
7
Preventive Maintenance
Preventative maintenance should be scheduled regularly based
on the working environment. Operators or technicians may add
additional items to the PM list provided. If there are any service
questions, contact your distributor.
The maintenance information is suggested for the base unit.
Maintenance instructions for the print engine are included in the
printer manual.
Ü Examine the drive rollers, vacuum pad, air assist bar, and peeler
plate for adhesive buildup or dust collection. Isopropyl alcohol
or mineral spirits may be used to clean problem areas. Do not
use compressed air to blow dust from the labeler. Damage to
the printer's electronics may occur.
Ü Check all electrical plugs for secure connections.
Ü Verify that all components and modules are securely fastened.
Ü Drain the filter regulator. Replace filter element if necessary.
Ü Inspect the unit for loose screws, guides or covers and tighten
as necessary.
Ü Inspect the tamp cylinder guide rods for proper alignment. The
tamp cylinder should extend and retract without hesitation.
Ü Inspect the pads on the clutch assemblies for excessive wear.
Adjust the friction by using the clutch tool. Replace the clutch
when the proper adjustment cannot be achieved.
Ü With the regulator set to the proper pressure, listen for air
leaks. Reconnect air lines and tighten fittings as necessary.
L3500PA_Rev10_10.2015
Ü Clean any dust from the lens of the product sensor.
61
L3500PA Labeler Manual
62
Ü Inspect all air hoses for wear. Replace as necessary.
Ü Use the manual override switch on the solenoid valves to verify
smooth operation.
Ü Remove the vacuum pad, and clean any contamination within
the vacuum chamber.
Ü Inspect the air assist bar for proper flow.
L3500PA_Rev10_10.2015
Replacement Parts
8
Replacement Parts
Replacement parts lists for the Shibuya Hoppmann L3500PA Print
& Apply Label Applicator are listed on the following pages. When
ordering replacement parts, please reference the model name
and number of your labeler located on the serial plate (see Figure
6-1). This helps in making sure you receive the correct replacement
parts.
TM
SERIAL #
MODEL #
INVENTORY #
PROJECT NUMBER
DATE
Having the serial number in addition to the
part number you wish to order will help us to
accurately assist you in getting the correct parts.
You may order your labeler's spare parts directly
from Shibuya Hoppmann by e-mail, phone or
fax (see the contact information listed below).
www.shibuyahoppmann.com • (800) 368-3582
Figure 8-1. Sample Serial Plate
Shibuya Hoppmann Spares and Service Department
Ü
E-mail:Spares@Hoppmann.com
Ü
Phone: 434.929.4746 (1.800.543.0915)
Ü
Fax:434.929.4959
Ü
Mail:
Shibuya Hoppmann Corporation
Attn: Spares Department
29 Dillard Road, P.O. Box 879
Madison Heights, Virginia 24572 USA
www.ShibuyaHoppmann.com
L3500PA_Rev10_10.2015
63
L3500PA Labeler Manual
L3500PA Labeler Replacement Parts
5
2
6
1
7
3
11
4
9
10
12
8
Figure 8-2. L3500PA Replacement Parts Callouts
64
L3500PA_Rev10_10.2015
Chapter 8 Replacement Parts
L3500PA Labeler - Replacement Parts
Loc.
1
Part Number
Description
Qty.
BRNGBALL18
Ball Bearing, 5/8" Bore
6
CA809C1024D
Contactor
1
L050500046
Brake Drum
1
L080130203
Vacuum Cube
1
MDL-6
Fuse, 6 Amp
1
PZG42CB
Product Sensor
1
3
SPRE000001
Extension Spring, Brake
1
4
BELTJ4V160
Clutch Belt, Poly-V, 16"
1
L050600049
Locking Collar Assembly
1
5
L050603092
Drive Brake Belt
1
6
L050500071
Unwind Shaft
1
7
BRNG00031
Bearing, 5/8" Bore
1
8
TORQPOLY01
Slip Clutch, 2 Disc
1
9
L050600016
Clutch Pulley
1
Gear Motor, 1/30 hp, 10:1
1
Rewind Pull Pin
1
11 L050603063
Drive Pulley
1
12 L050500070
Rewind Shaft
1
2
10 MTRG000008
L050601134
L3500PA_Rev10_10.2015
65
L3500PA Labeler Manual
Tamp Module Spare Parts List
Loc.
Part Number
Description
Qty.
1
MAGSWITCH1
Magnetic Reed Switch
1
2
MAGWIREC30
Magnetic Reed Switch Wire
1
3
BUSHBALL15
Linear Tamp Bushing
4
4
L050120718
Linear Tamp Shaft, 7" Stroke
2
5
ORING42518
Vacuum Pad O-Ring Seal
1
6
L080510420
Air Cylinder, 7" Stroke
1
7
AIRF000058
Air Fitting with Flow Control
2
8
L040800005
Stop Washer
4
9
AIRFITN034
Air Fitting, Vacuum
1
6
7
2
8
1
9
3
3
8
5
Figure 8-3. L3500PA Tamp Module Parts Callouts
66
L3500PA_Rev10_10.2015
Troubleshooting
9
Unwind Assembly Troubleshooting
Problem
Unwind Assembly
Does Not Limit Label
Feed
Possible Cause
Solution
Check to make sure the rocker
The electric brake is not working
arm is properly set to initiate the
properly.
brake.
Thread labels correctly. Refer
Labels are not correctly threaded. to Figure 4-1 for proper label
threading.
Web Tears
Label Supply Roll
Feeds Erratically or
Not At All
Nicks and die cuts in the liner
may cause the label to break at
Quality of the labels (label stock)
lower than expected tensions.
is poor.
See "Web Specification" section
in appendix.
Remove label stock and re-thread
the labels correctly. See Figure
4-1 for proper label threading.
Labels are not correctly threaded
If not correctly threaded, the
around the dancer arm.
unwind brake will not release
during dispensing and the supply
roll will not rotate.
The clutch is not supplying
enough friction to turn the
supply roll.
Labels Do Not Track
Squarely Around the
Dancer Arm
When loading labels onto the
Label supply roll is not positioned unwind assembly, make sure to
adjust the roll so it is positioned
on the unwind assembly
squares. Make sure locking collar
squarely.
is tightly fit.
Adjustable guides are not used
or are improperly positioned.
L3500PA_Rev10_10.2015
Tighten the clutch on the unwind
assembly for proper friction.
Adjust the spring collars so
that the web path is uniform
throughout.
67
L3500PA Labeler Manual
Unwind Assembly Troubleshooting
Label Roll Does Not
Fit Onto the Unwind
Assembly
Previous supply roll core has not
been removed from the roller.
When the supply roll of labels is
empty, remove the core before
loading the new roll.
Inner diameter of label roll core
is deformed.
Inspect the inner surface and
edges of the core for damage.
Straighten if possible.
Inner diameter of label roll core
is undersized.
Rewind the roll of labels onto
a core with the correct inner
diameter: 3.0" (76mm) in
diameter.
Power Supply / Electrical Components Troubleshooting
Problem
Labeler (Applicator)
Does Not Turn On
Printer (Print Engine)
Does Not Turn On
68
Possible Cause
Solution
Turn the main switch on. Do not
confuse the labeler power switch
The main power switch is not
with the print engine power
on.
switch.
Power cord is not plugged in.
Plug in the cord to the labeler.
Unplug the unit. Replace the
Main fuse is blown.
main fuse located on the
electrical DIM rail.
Refer to Table 1-1 for power
Power supply is the wrong voltrequirements. Consult distributor
age, phase, or frequency.
for possible solutions.
Turn the printer power on. Do
The power switch for the printer not confuse the printer power
switch with the labeler power
is not turned on.
switch.
The plug may only be inserted
Power cord is not plugged into
one way. May sure the plug is
the rear of the print engine
fully inserted into the receptacle.
(printer).
Disconnect the power. Replace
Printer fuse is blown.
the fuse if blown (refer to printer
manufacturer's manual).
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Printer (Print Engine) Troubleshooting
Problem
Possible Cause
Label roll is not threaded
correctly.
Labels Do Not Track
Squarely Through the
Printer
Labels in the printer are
threaded wrong.
Label guides are positioned
wrong.
The printer is not threaded
correctly.
The printer drive roller needs to
be cleaned.
Labels are Jammed in
the Printer
Printer Error LED
Signal is Lit
L3500PA_Rev10_10.2015
Labels are curled and peeling
from the web.
Solution
Thread labels correctly. See Figure
4-1 for proper label threading.
Thread labels correctly through
the printer - refer to the printer's
documentation.
Correctly position the adjustable
label guides. Refer to the Label
Threading section in Chapter 4.
Thread labels correctly through
the printer - refer to the printer's
documentation.
Label material may have built up
on the printer drive roller. Refer
to the Printer Manual for more
information.
Old and thick labels may curl
from the web as they wind
through the labeler. Use new
labels with correct specifications.
Label sensor is positioned
wrong.
Position the sensor so it does
not interfere with the web path.
Refer to the Printer Manual.
Label adhesive is weak.
Make sure the label adhesive
quality is acceptable.
One or more of the printer error
conditions exist.
A label-out or ribbon-out
condition may exist. Refer to
the Printer Manual for replacing
ribbon and the Label Threading
section of this manual for
replacing label supply.
69
L3500PA Labeler Manual
Printer (Print Engine) Troubleshooting
Problem
Labels Feed Through
Printer but Do Not
Print
Possible Cause
Printer has "just been" turned
on.
The printer may print a couple
blank labels when first started.
Label data has not been
downloaded to the printer.
Make sure the downloaded label
data is present in the printer.
Printer is "off-line".
The printer only prints a label if it
is "on-line". Press the line button
on the control panel.
Ribbon is depleted/torn/jammed
or not threaded properly.
Ribbon is not advancing.
Label software is not set up for
the printer.
Labels Feed Through
Printer But Do Not
Print
70
Solution
If the red warning LED on the
printer face is lit, the ribbon
supply is depleted. Open the
cover of the printer to check error
condition.
If the ribbon is torn, jammed or
incorrectly threaded, the ribbon
fault may not light even though
there is an error. Check the
condition of the ribbon.
Configure the software so that is
corresponds with the make and
model of the printer.
Some software packages are not
Label software is not compatible compatible with all makes and
models of printers. Contact the
with the printer.
software manufacturer.
The elements of the print head
are not heating to the required
temperature to supply carbon
Temperature setting is too low
to the label. Increase the
and the print speed too fast.
temperature and decrease the
print speed.
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Printer (Print Engine) Troubleshooting
Problem
Possible Cause
Printer is not turned on.
Green printer on-line LED is not
lit.
Printer Does Not Feed
or Print Labels
At least one label format is not
present in the print buffer.
Printed images for label are
outside the printing area.
Printer Prints
Labels with Missing
Information
Ribbon has run out.
Only a portion of the ribbon is
contacting the label.
Label Printing is
Compressed
L3500PA_Rev10_10.2015
Solution
Turn power on.
Check that the cover to the
printer is closed, the print head
latch is locked and the printer
error LED is not lit. Make sure the
printer is on-line and press the
feed button on the control panel
to test feed a label.
Press the line button for the
printer. Once on-line, download
a label format to the printer. The
display should not read 0000
after a label is downloaded.
Refer to the Downloading Labels
section of this manual.
The label format file may be
too large for the label stock.
Reposition the label or reformat
the label file.
Make sure the ribbon LED on
the printer control panel is lit.
Refer to the Printer Manual on
replacing the Printer ribbon.
Make sure the ribbon extend
across the entire width of the
desired portion of the label to be
printed.
Printer is not correctly threaded.
Refer to the Printer Manual for
label threading instructions.
Drive roller for the printer is not
locked into place.
Refer to the Printer Manual
for instructions on how to
manipulate the drive roller.
71
L3500PA Labeler Manual
Printer (Print Engine) Troubleshooting
Problem
Possible Cause
Print image darkness is not set
correctly.
Poor Print Clarity
Wrong label and/or ribbon
combination has been selected.
Drive roller for the printer is not
locked into place.
Unwind tension is too tight.
Labels Advance
Erratically in Printer
Solution
Refer to the Printer Manual
for image control adjustment
instructions.
Consult suppliers for correct
combinations. Certain
combinations of labels, ribbons
and printers are required.
Refer to the Printer Manual
for instructions on how to
manipulate the drive roller.
Loosen Unwind Clutch (see
"Adjusting Clutch Assembly" in
Chapter 4.)
Drive mechanism of the printer
needs to be cleaned.
Refer to the Printer Manual for
cleaning instructions.
Printer drive belts are worn/
damaged.
Replace printer drive belts.
Platen rollers are worn/damaged. Replace platen rollers.
The printer is not threaded
correctly.
Labels Do Not
Advance in the Printer
Drive roller for the printer is not
locked into place.
Printer drive belts are worn/
damaged.
Thread labels correctly through
the printer - refer to the printer's
documentation.
Refer to the Printer Manual
for instructions on how to
manipulate the drive roller.
Replace printer drive belts.
Platen rollers are worn/damaged. Replace platen rollers.
72
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Printer (Print Engine) Troubleshooting
Problem
Possible Cause
Correct print speed for the
printer is not set.
Print Engine is Not
Printing Quickly
Enough
Drive mechanism for the printer
is slipping.
Drive motor for the printer is
damaged.
Printer is not receiving the
correct power supply.
Solution
Refer to the Printer Manual
regarding instructions on how to
adjust the print speed of the print
engine.
Inspect the internal drive
components of the printer for
wear. Replace parts as needed.
Verify that the drive motor for the
printer is spinning smoothly. If
not, replace motor.
Verify that the labeler is
connected to the correct power
supply. Refer to the power
requirements listed in Table 1-1.
Label Placement Accuracy Troubleshooting
Problem
Possible Cause
Solution
Reposition the labeler and the
tamp pad as directed in Figure
Tamp pad is not parallel with the
3-1. The tamp pad must contact
product surface.
the entire product for proper
label impressions.
A Section of the Label
is Not Fully Impressed Tamp pad barely contacts the
onto the Product
product at maximum extension.
Tamp pad is too large for label.
L3500PA_Rev10_10.2015
The tamp pad should contact
the product a minimum of
0.125" (3.18mm) from maximum
extension. Refer to Chapter 3
and Chapter 5 for tamp pad and
labeler positioning.
Order a custom size tamp pad to
fit the label.
73
L3500PA Labeler Manual
Label Placement Accuracy Troubleshooting
Problem
Possible Cause
Strength of vacuum may vary.
Vacuum dwell time is too short.
Label Falls From Tamp
Pad Before Application
Air assist pressure is incorrectly
adjusted.
Air assist pressure remains on
after label has been dispensed.
At Some Point After
Application, Label Falls
From Product
Label is not fully applied to the
product when the tamp pad
begins to retract.
Label adhesive is not strong
enough to stick to dusty or
porous surfaces.
Label does not contact the
product when the tamp pad
begins to retract.
After Tamp Cycles,
The Label Remains on
the Vacuum Tamp Pad
Tamp Dwell setting is too low.
Vacuum Dwell is too high.
74
Solution
Increase the pressure supplied to
the vacuum of the tamp pad.
Increase vacuum dwell time (see
Chapter 6 regarding changing
dwell time values).
Refer to the Tamp Module
section for the proper adjustment
of the air assist pressure.
Refer to Air Assist Dwell section
in the Operator's Interface
(Chapter 6). Adjust as necessary.
The tamp pad should contact
the product at a minimum of
0.125" (3.18") from maximum
extension. Refer to the Tamp
Module section for proper setup.
Industrial labeling applications
require strong adhesives to stick
labels to pallets, cases and other
irregular or dusty surfaces. Check
the label specifications.
The tamp pad should contact
the product a minimum of
0.125" (3.18mm) from maximum
extension. Refer to Chapter 3
and Chapter 5 for tamp pad and
labeler positioning.
Increase Tamp Dwell setting. See
Operator's Interface in Chapter 6
for more information.
Decrease Vacuum Dwell setting.
See Operator's Interface in
Chapter 6 for more information.
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Label Placement Accuracy Troubleshooting
Problem
Solution
Products must be properly
aligned for the labels to be
Products are not properly
applied (within the positioning
controlled at the point of label
tolerances). Guide rails may be
application.
required for smaller products.
Even if products are positioned
repeatedly, the surfaces to be
labeled may differ between
Product surface is inconsistent.
products. Labels are applied to
Accurate Label
within the surface tolerance of
Placement is Not
the product.
Repeatable
Refer to the Product Sensor
Product sensor is set up wrong. section (Chapter 4) and make
sure the sensor is set up correctly.
Adhesive buildup may cause the
label to stick (remain on the tamp
Label is sticking to the tamp pad.
pad after extension). Clean the
tamp pad.
Compressed air supply is not
Provide constant air supply (see
constant.
Table 1-1, Specifications).
Increase spacing between
Products are too close together. products and/or increase print
speed of the print engine.
Refer to the Product Sensor
Product sensor is not properly
Product Passes
section (Chapter 4) and make
calibrated.
Without Being Labeled
sure the sensor is set up correctly.
If the quantity of labels supplied
to the printer drops to 0000, the
Quantity of labels downloaded
labeler will not operate unless in
into the printer is 0000.
the "reprint" mode.
Increase Tamp Delay setting.
Label is Positioned Too
Refer to the Operator's
Close to the Leading
Tamp delay is not long enough.
Interface in Chapter 6 for more
Edge
information.
L3500PA_Rev10_10.2015
Possible Cause
75
L3500PA Labeler Manual
Label Placement Accuracy Troubleshooting
Problem
Possible Cause
Label is Positioned Too
Close to the Trailing
Tamp delay is too long.
Edge
Solution
Decrease Tamp Delay setting. See
Operator's Interface in Chapter 6
for more information.
Refer to the Positioning section
Tamp pad is skewed with respect
in Chapter 3 and reposition the
to the product surface being
labeler so that the pad is parallel
Label is Skewed on the labeled.
with the surface to be labeled.
Product
See the Tamp Module section
Tamp pad is parallel with the
(Chapter 5) and reposition the
surface to be labeled, but the
label on the tamp pad correctly.
label is skewed on the pad.
Tamp Pad Assembly Troubleshooting
Problem
Solution
Refer to the Tamp Setup section.
Leading edge of the tamp pad is
Align the vacuum tamp pad
not parallel with the dispensing
with the dispensing edge of the
edge of the printer.
printer.
Label Skews as it is
Dispensed Onto the
Refer to the Tamp Setup to
Ports of the air assist bar are
Pad
not centered below the vacuum correctly position the air assist
bar.
tamp pad.
Adhesive has built up along the
Clean the tamp pad.
bottom surface of the tamp pad.
Connect an adequate air supply
Air supply is not attached.
to the inlet of the labeler (see
Table 1-1 for specifications).
Connect an adequate air supply
Tamp Pad Does Not
Air supply is not at an adequate
to the inlet of the labeler (see
Extend With Jog
pressure level.
Table 1-1 for specifications).
Button/Product Signal
Two 0.25" (6.35mm) diameter air
Air lines to the tamp cylinder are lines should be connected to the
tamp cylinder. Refer to Figure 5-1
not connected.
and 5-3.
76
Possible Cause
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Tamp Pad Assembly Troubleshooting
Problem
Solution
Refer to the Operator's Interface
Timer for the tamp pad return
section for setting the tamp
is too quick. The tamp does
cylinder dwell time. If the dwell is
not have enough dwell time to
too short, the tamp cylinder will
extend.
not extend.
Make sure that the 4-pin
connector for the product sensor
is securely fastened to the labeler.
Product sensor is not connected.
See Product Sensor instructions
in Chapter 4 and electrical
schematics for the sensor.
Tamp Pad Does Not
Extend With Jog
Press the Tamp/Blow valve
Button/Product Signal
override switch found on the
Solenoid valve has seized.
pneumatic panel. This will
activate the tamp cylinder.
Turn off the labeler. Disconnect
air and remove both flow control
Sliding rod of the tamp cylinder ports on the tamp cylinder.
Inspect both rods for deformities
is damaged.
when the pad is extended and
retracted. Replace if necessary.
Tamp home sensor is not located See Tamp Module section
properly.
regarding proper installation.
Refer to the Tamp Module
Air tamp pressure is too great.
instructions to adjust air tamp
Tamp Pad Extends
pressure.
Too Quickly
Air flow control ports are open
See Tamp Module instructions to
too far.
adjust air flow control ports.
Refer to the Tamp Module
Air tamp pressure is too light.
instructions to adjust air tamp
pressure.
Tamp Pad Extends
Too Slowly
Refer to the Tamp Module
Air flow control ports are closed
instructions to adjust air flow
too far.
control ports.
L3500PA_Rev10_10.2015
Possible Cause
77
L3500PA Labeler Manual
Tamp Pad Assembly Troubleshooting
Problem
Tamp Pad Returns
Too Quickly
Possible Cause
Air tamp pressure is too light.
Air flow control ports are closed
too far.
Air tamp pressure is too light.
Tamp Pad Returns
Too Slowly
Air flow control ports are closed
too far.
Air tamp pressure is too light.
Air flow control ports are closed
too far.
Tamp Pad Does Not
Extend or Return
Smoothly
Air supply flow is not sufficient
or dependable.
One of the sliding rods of the
tamp cylinder is damaged.
One or both of the sliding rods
of the tamp cylinder require
lubrication.
Next Label Partially
Dispenses Onto the
Tamp Pad
78
Printer pitch offset setting is
incorrect.
Tamp home sensor is not
positioned properly.
Solution
See Tamp Module instructions to
adjust air tamp pressure.
See Tamp Module instructions to
adjust air flow control ports.
Refer to the Tamp Module
instructions to adjust air tamp
pressure.
Refer to the Tamp Module
instructions to adjust air flow
control ports.
Refer to the Tamp Module
instructions to adjust air tamp
pressure.
Refer to the Tamp Module
instructions to adjust air flow
control ports.
Refer to the specifications for
air supply requirements. Provide
specified air supply.
Inspect the two steel rods for
damage. Manually extend and
retract the pad, checking for
rough sections of travel.
Lubricate as necessary.
Refer to the Printer Manual
for instruction on pitch offset
adjustment procedures.
Refer to installation of Tamp
Module (Chapter 5) for the
correct positioning of the tamp
home sensor.
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Tamp Pad Assembly Troubleshooting
Problem
Possible Cause
Label tamp pad vacuum is
insufficient.
Label is not completely
The Label Sticks to the dispensing from the web.
Air Assist Bar Instead
of Dispensing onto the
Tamp Pad
Air assist pressure is too low.
Solution
Refer to the Tamp Module
instructions on how to adjust the
vacuum for the tamp pad label.
Adjust the air assist pressure to
further separate the label from
the liner as it passes around the
peeler plate.
Refer to Tamp Module
instructions on adjustment
procedures (Chapter 5).
See Tamp Module instructions on
air assist delivery tube positioning
Ports on the air assist delivery
tube are not positioned correctly. and adjustment procedures
(Chapter 5).
Labels Do Not
Dispense onto the
Tamp Pad Accurately
L3500PA_Rev10_10.2015
Vacuum for the label tamp pad
is not adjusted correctly.
Refer to the Tamp Module
instructions on how to adjust the
vacuum for the label tamp pad.
Extreme air assist pressure is
blowing the label across the
tamp pad.
Refer to the Tamp Module
instructions on the proper setup
of the air assist delivery tube.
Vacuum for the tamp pad is
not sufficient to hold label into
place.
Refer to the Tamp Module
instructions on how to adjust the
vacuum for the label tamp pad.
Tamp pad is not positioned
properly.
Refer to the Tamp Module
instructions on how to set up the
label tamp pad.
79
L3500PA Labeler Manual
Tamp Pad Assembly Troubleshooting
Problem
Possible Cause
Tamp pad is positioned too low
below the dispensing edge of
the printer.
Leading Edge of the
Label Contacts the
Tamp Pad Side
Air assist pressure is too high.
Air assist delivery ports are
angled incorrectly.
Air assist delay is too short.
80
Solution
Refer to the Setup of Tamp
Module (Chapter 5) for
adjustment procedures to raise
the tamp pad to the correct
position in from the dispensing
edge of the printer.
Refer to the Tamp Module
instructions on how to regulate
the air assist delivery ports.
Refer to the Tamp Module
instructions for information on
how to adjust the angle of the air
assist delivery ports.
Increase air assist delay (refer to
Operator's Interface).
L3500PA_Rev10_10.2015
Chapter 9 Troubleshooting
Label Dispensing Troubleshooting
Problem
Solution
During the power up the printer
Multiple Labels
may feed a couple of blank
Dispense During
System has just been turned on.
labels. Remove the labels and
Power Up
continue with normal operations.
Die cuts may extend into the
Die cuts have perforated the
label web and weaken it. Replace
web.
Web Tears at the
the defective labels.
Dispensing Edge of the
Adjust the rewind speed on the
Printer
Rewind is set too fast.
rewind assembly. Lessens the pull
or tug on the label web.
Refer to Setup of Tamp Module
for adjustment procedures to
Pitch offset control has
positioned the label too far back raise the tamp pad to the correct
position in from the dispensing
from the normal stop position.
edge of the printer.
Make sure the dimensions of the
The wrong label format is
formatted label match the label
downloaded.
stock.
The label size must match the
Labels Do Not
dimensions of the label defined
The supplied labels are the
Dispense From the
in the formal file. Either replace
wrong size.
Web
the labels with the correct size or
reformat the label file.
Labels are not threaded around Thread labels correctly. See Figure
the peeler plate.
4-1 for proper label threading.
Replace the defective labels with
Die cuts do not completely
good ones. Refer to Label and
perforate the adhesive.
Web Specifications.
Air assist pressure is not strong
Increase air pressure.
enough.
L3500PA_Rev10_10.2015
Possible Cause
81
L3500PA Labeler Manual
82
L3500PA_Rev10_10.2015
Appendix
10
Pneumatic/Electrical Schematics
PLUG
AUX AIR
INPUT AIR
80psi
MAX
1/4"
RED
TUBE
1/4"
RED
TUBE
3/8"
RED
TUBE
TAMP
1/4"
RED
TUBE
1/4"
RED
TUBE
VACUUM
ASSIST
EA
EA
P
P
1
EB
3R2
1P
5A1
2B
4A
AB
1/4"
RED
TUBE
3R2
1P
5A1
3R2
1P
5A1
2B
4A
AB
1/4"
BLACK
TUBE
1/4"
RED
TUBE
Plug
EB
Plug
3
1/4"
RED
TUBE
2
2
TAMP CYLINDER
Plug
AB
1
3
2B
4A
1/4"
GREEN
TUBE
AIR ASSIST BAR
VACUUM PAD
1
2
SHC P/N: AIRFITN068
Mft. SMC# KQ2Z1135S
SHC P/N:
PIAB#M20A6-BN
Figure 10-1. Pneumatic Schematics
L3500PA_Rev10_10.2015
83
L3500PA Labeler Manual
FU
D
N
6A
115VAC
50/60HZ
SEE NOTE 1
A
L1
B
6A
C
GND
VOLTAGE SELECT
FU1
100
101
2A
POWER SUPPLY
24VDC
N
N
N
V+
V-
200
201
PRINT ENGINE
DB9S
FU2
1/2A
1CAP
(BLU)(BRN FOR 230VAC)
1C
103
(GRY)
UNWIND
MOTOR
(BLK)
1C
N1
*TO CHANGE ROTATION, SWAP THE BLU (BRN FOR 230VAC) AND BLK LEADS
102
N
Figure 10-2. Labeler System Power/Control Wiring (Part 1)
84
L3500PA_Rev10_10.2015
Chapter 10 Wiring Schematics
(COM)
200
102
(+24VDC)
201
(COM)
200
(+24VDC)
201
N
L
G
N
S/S
24V
S/S
OV
S/S
COM0
COM0
PRODUCT
SENSOR
X0
BLU
BRN
WHT
BRN
WHT
X1
BLU
X2
BLU
BRN
WHT
BRN
WHT
X3
BLU
PE3
PE1
INDEX
HOME
PRX2
PE3
TAMP HOME
XO
Y0
X1
COM1
X2
Y1
X3
COM2
X4
Y2
Y0
VIO
DB9S
PIN4
REPRINT
COM1
Y1
BLU
DB9S
PIN5
PRINT START
1SOL
TAMP
VALVE
Y3
2SOL
VACUUM
VALVE
Y4
3SOL
AIR
ASSIST
Y5
4SOL
Y6
1CR
AUX
VALVE
UNWIND
MOTOR RELAY
AUX INPUT
2PB
START
PUSHBUTTON
(IF REQUIRED)
3PB
X7
LOW LABEL
SENSOR
DB9S
PIN9
GRN
PRINTER
FAULT
X6
BRN
WHT
3PE
BLU
X10
X6
X7
X10
COM3
MITSUBISHI
FX1S-30MR-ES/UL
X5
STOP
PUSHBUTTON
(IF REQUIRED)
Y3
Y4
Y5
Y6
DB9S
PRINT ENGINE PIN3
PRINTER
LABEL OUT
RIBBON
OUT
RIBBON
NEAR END
END PRINT
Y7
BRN
DB9S
PIN7 ORN
DB9S
PIN8
DB9S
PIN2
X11
Y10
X12
Y11
YEL
Y7
Y10
Y11
G
1PL
A
2PL
R
3PL
RUN IND
LOW RIBBON/
LABEL
FAULT INDICATOR
X13
COM4
BLK
DB9S
PIN6 RED
X14
Y12
X15
X16
X17
Y13
Y14
Y15
Figure 10-2. Labeler System Power/Control Wiring (Part 2)
L3500PA_Rev10_10.2015
85
L3500PA Labeler Manual
Notes
86
L3500PA_Rev10_10.2015
Warranty
11
Warranty
Shibuya Hoppmann Corporation warrants that each item of
its own manufacture delivered hereunder shall, at the time of
delivery and for a period of twelve (12) months thereafter, be free
from defects in materials or workmanship; and if any such item
shall prove to be defective in material or workmanship under
normal intended usage and maintenance during the warranty
period, upon examination by Shibuya Hoppmann Corporation,
then Shibuya Hoppmann Corporation shall repair or replace, at
its sole option, such defective item at its own expense; provided,
however, that the owner shall be required to ship such defective
item, freight prepaid, to Shibuya Hoppmann Corporation's plant
in Virginia. The warranty on components not manufactured by
Shibuya Hoppmann Corporation, but a part of the system, is
limited to the warranty provided by the original manufacturer of
said components to the extent, and only to the extent, that such
original manufacturer actually honors such warranty.
ALL WARRANTIES HEREUNDER ARE EXPRESSLY LIMITED TO
THE REPAIR OR REPLACEMENT OF DEFECTIVE ITEMS AS SET
FORTH HEREIN, AND IN NO EVENT SHALL SHIBUYA HOPPMANN
CORPORATION BE LIABLE FOR SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES BY REASON OF ANY BREACH
OF WARRANTY OR DEFECT IN MATERIAL OR WORKMANSHIP.
SHIBUYA HOPPMANN CORPORATION SHALL NOT BE RESPONSIBLE
FOR REPAIR OR REPLACEMENT OF ITEMS WHICH HAVE BEEN
SUBJECTED TO NEGLECT, ACCIDENT OR IMPROPER USE, OR
WHICH HAVE BEEN ALTERED BY OTHER THAN AUTHORIZED
SHIBUYA HOPPMANN CORPORATION PERSONNEL.
THIS WARRANTY IS IN LIEU OF OTHER WARRANTIES, EXPRESS
OR IMPLIED. ALL IMPLIED WARRANTIES, INCLUDING BUT NOT
LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY
EXCLUDED.
L3500PA_Rev10_10.2015
87
TM
Shibuya Hoppmann offers a wide selection of products:
Ü
Ü
Ü
Ü
Ü
Ü
Hoppmann Centrifugal Feeders™
Prefeeders
Continuous Motion Assembly Turrets
Placement Systems
Fillers and Cappers
Conveyors
Ü
Ü
Ü
Ü
Ü
Ü
Product Handling Equipment
Aseptic Filling Systems
Labelers
Decontamination Equipment
Intermittent Motion Assembly Systems
Complete Integrated Product Lines
HeadquartersSales
Manufacturing
7849 Coppermine Dr.
1445 Brookville Way
291 Dillard Road
Manassas, VA
Suite F
Madison Heights, VA
20109
Indianapolis, IN 46239
24572
540.829.2564 t
317.322.0754 t
434.929.4746 t
800.368.3582 t
800.368.3582 t
800.543.0915 t
540.829.1726 f317.322.0794 f434.929.4959 f