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Manual de Uso MLP4000/6000 V-1.S.1
MLP SP 4000/6000 User Manual
Version 1.S.5
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Quick Guide Installation – Operation - Maintenance
MLP SP 4000/6000
Date: October 2013 Version: 1.S.5
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Table of contents
1. GENERAL DESCRIPTION ....................................................................................................................................... 3
OBJECTIVE ............................................................................................................................................................... 3 PRECAUTIONS ........................................................................................................................................................... 3 SAFETY .................................................................................................................................................................... 4 GUARANTEE ............................................................................................................................................................. 4 COMPLIANCE WITH THE DIRECTIVES .............................................................................................................................. 4 TRANSPORT AND STORAGE .......................................................................................................................................... 4 DEVICE DELIVERY ....................................................................................................................................................... 5
2. TECHNICAL CHARACTERISTICS ............................................................................................................................. 6
3. COMPONENT DESCRIPTION ................................................................................................................................. 7
DISPENSER BODY ....................................................................................................................................................... 8 BLANK LABEL UNWINDER ............................................................................................................................................ 8 BACKING PAPER COLLECTOR ........................................................................................................................................ 9 ROLLER GUIDES ....................................................................................................................................................... 10 CONTROL UNIT ....................................................................................................................................................... 11
4. INSTALLATION INSTRUCTIONS ........................................................................................................................... 12
PRELIMINARIES ....................................................................................................................................................... 12 LOADING MEDIA ..................................................................................................................................................... 12 PREPARATION FOR USE ............................................................................................................................................. 13
Electrical power supply................................................................................................................................... 13 Air supply - Pneumatics .................................................................................................................................. 14 Presence signal & labelling trigger ................................................................................................................. 14
5. OPERATIONS AND PROCEDURES ....................................................................................................................... 15
WORKING CYCLE ..................................................................................................................................................... 15 ERROR SIGNALS ....................................................................................................................................................... 15
6. MAINTENANCE .................................................................................................................................................. 16
PREVENTIVE MAINTENANCE ....................................................................................................................................... 16
7. ANNEX 1. APPLICATORS. .................................................................................................................................... 17
LINEAR APPLICATOR (20) ......................................................................................................................................... 17
8. ANNEXE 2. PIN-OUT CONNECTORS. ................................................................................................................... 21
APPLICATOR CONNECTORS: INTERNAL INPUT & OUTPUT. SUB37 FEMALE. ......................................................................... 21 EXTERNAL CONNECTORS: EXTERNAL INPUTS & OUTPUTS. SUBD37 FEMALE ....................................................................... 22
9. ANNEXE 3. PARAMETERS AND SETTINGS MENUS .............................................................................................. 23
MAIN SCREEN ......................................................................................................................................................... 23 ACTIONS ............................................................................................................................................................... 23 MENUS & PARAMETERS ........................................................................................................................................... 24
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1. General description
Objective
This manual aims to inform the operator in the use of the Macsa ID self-adhesive print-and-apply labelling devices, models MLP 4000 and MLP 6000 (in order to refer to the device from now on, the designation “MLP device” shall be used).
Its task is to offer the operator of the MLP device all the necessary information on installation, operation and basic maintenance for the proper functioning of the printer-applicator. To complement the information in this manual, the manual of the printer that will be adapted to the MLP device is required. All the information that appears in this manual referring to the printer unit is manufactured by Datamax. Before proceeding to use the device, it is important to follow the instructions in this manual. Macsa is not responsible for any misuse of the device. The copying of this manual for third parties is prohibited. This device is designed to offer the maximum flexibility and adaptation to the most demanding production lines in order to carry out the automatic labelling of products.
Precautions
In this manual and on the device itself, the following international symbology will be used as a precaution, to inform or to warn of possible danger.
General caution Warning:
Warning to act with precaution
Electric shock hazard Warning:
Presence of electrical voltage. Disconnect the device, work with no power.
Risk of trapping hands Warning:
Risk of trapping upper limbs.
To identify important information in the manual, it will be indicated in a grey background with the inscription “Note”. The following shows an example: NOTE: Indications to take into account
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Safety
For intrinsic conditions of an automatic print-and-apply labelling system, the device in itself is not totally safe. It is for this reason that the handling of moving parts must be gauged in order to avoid possible personal injury.
To achieve higher safety levels, closing off or protecting access areas to stop anybody from getting near the moving parts is recommended. Depending on the location of the device and the production line, protection should be carried out accordingly. Modifying the inside of the device must be carried out by qualified personnel who have received training from Macsa ID. Besides the safety signs on the device, placing more directions on the production line near the device is recommended.
Guarantee
Intervention into the device that modifies any of the mechanical, electronic or electro-pneumatic parts will render the guarantee invalid. The fitting of spare parts to the device that are not recommended by Macsa ID could make the device malfunction. Always use accessories passed by Macsa or the authorized distributor.
Compliance with the directives
This device has been manufactured to comply with Directives:
89-336-CEE (2004-108-CE) Electromagnetic Compatibility
98/37/CE (2006-042-CE) Relating to Machinery.
73-23-CEE (2006-095-CE) Low tension electrical material.
Transport and storage
Packing The delivery of the device can be carried out by way of one of the following options or formats: - Format 1: Device assembled on floor stand with all device components and communications
connected up, ready to run. The whole system will be situated on top of a pallet base of 800x1200mm and will be completely stretch-wrapped.
- Format 2: Device not fitted to floor stand and mechanically assembled components. Accessories
and interconnecting elements are found apart beside the device. This device will be placed inside a wooden box of dimensions 800x1200x700 and will have a protective lining.
Packing check format 1:
- Verify that the device has not slipped from the pallet and that it is in a vertical position. - Verify that the packing has not suffered any knocks or breakages of the stretch-wrapping.
Packing check format 2: - Verify that the box has not suffered any knocks.
Moving the package Take special care in transporting the packed device in format 1. Use a forklift. Owing to the position of the stand, the device could become unsteady on lifting. Carry out the relocation holding the upper part of the device to avoid it falling to one side. Moving format 2 between two people is recommended or using a forklift.
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Unpacking To unpack format 1, remove the stretch wrapping using a Stanley knife and cut the anchors of the stand to the pallet base. To remove the pallet and position the stand with the device on the ground, lift the device among several people or use a forklift truck while the pallet is removed. To unpack format 2, take the device out from inside the box. It is recommendable to keep the box in case the device needs sending back for repair. Storage In case of the device being unused, it is necessary to verify the following points for proper storage:
Remove the ribbon from the printing unit
Remove the label roll from the unwind unit and the backing paper from the collector
Keep the heads clean and the rest of the labels applicator
Keep the printing unit anchors closed
Device delivery
Verify that the MLP device is delivered with the following elements:
Dispenser unit (with internal control unit)
Applicator unit
User interface
Power cord
Interface cable
MLP4000/6000 user manual If it includes a printer:
Printer unit OEM
Printer user manual OEM
Power cord
If it includes accessories:
Presence sensor kit (photoelectric cell, cable and stand)
Pneumatic maintenance group (filter and valve manual)
Stack beacon lights
Device start up requires:
Self-adhesive labels
Ribbon
Label design software
Communication cable PC-printer
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2. Technical characteristics
MLP SP 4000 MLP SP 6000
Device dimensions
Height 600 mm 600 mm
Width 745 mm 745 mm
Depth 395 mm 446 mm
Electrical specifications
Power supply 110V-230VAC 50Hz
Consumption 2 A
Pneumatic specifications
Input pressure 5 bar.
Weight
Gross (without printer) 32 Kg. 40 Kg.
Consumables
Maximum diameter of label reel 300 mm
Inner diameter of chuck 3” (76,2mm)
Maximum label width 110 mm 160 mm
Maximum label length 110 mm 210 mm
Environment conditions
Temperature +5…+40ºC
Relative humidity 30…80% sin condensation
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3. Component description
The following sets out the different elements of the dispenser unit:
Dispenser body (1)
Blank label roll unwinder (2)
Backing paper collector (3)
Roller guides (4)
Control unit (5)
1
2
3
5
4
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Dispenser body
The body of the dispenser is formed by a plate of aluminium 15mm thick, offering great robustness to all the elements that it has to support. It possesses the location to place the OEM printing unit, which is fixed with 5 screws M5x30. On one of the ends of the body plate the anchors can be found for fixing the applicator unit. The dispenser body is completed with a cover where the control unit and a connection card for the communication of external signals are located.
Blank label unwinder
The blank label unwinder is comprised of the following parts:
Unwinder spindle (1)
Spool stop disc 400mm (2)
Spool break lever (3)
The unwinder can hold spools of up to 400mm diameter with a width of 160mm for the MLP6000 model. It is necessary to fit an adapter on the unwinder spindle in order to hold the tube inside the reel of labels. This cardboard tube is 3” (76,4mm).
To keep the spool in the right position, the stop disc must be anchored once the blank label spool is fitted.
The spool break lever carries out the function of freeing the blank label spool when labels are needed for printing and straight afterwards breaks the spool to keep it still.
3 2
1
Spool adapter 3” inside dia. (76,2 mm)
Stop disc with lever to anchor the spool
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Depending on the weight of the spool, the labelling rate and the length of the label, it may be necessary to fit a motor that joins the spool at the time of each print.
Backing paper collector
The collector of backing paper is comprised of 3 parts:
Collector spindle (1)
Activation lever (2)
Collector motor (3)
The backing paper is held to the collector spindle by means of a hook-shaped part. This part keeps the paper loose to the spindle allowing for easy removal.
The tension lever carries out the function of activating the collector motor. On printing a label, the remaining backing paper causes the displacement of the tension lever which activates the motor so that the paper stays wound onto the spindle.
1
2
3
Tension roller guides Fastening the backing paper
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Roller guides
There are 4 rollers able to guide the labels and the backing paper from the unwinder, through the inside of the printing unit and on to the collector. Each roller possesses a plastic ring for adjusting the width of the label or the backing paper and aligning them with the rest of the elements along the way.
Rings for guiding the labels
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Control unit
Control Unit is the name given to the set of main electronics formed by the following cards:
ME1620020: Dedicated CPU & Input& Output board
MME1620033: External elements interconnection card.
Power supply.
This unit is held to the body of the labeller using 3 screws which allows for easy fixture and removal and is also versatile and does not vary for either left or right-handed devices.
MLP SP´s Control Unit
It exist a main Power Supply that delivers 45Vdc to the main CPU board and driver motor.
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4. Installation instructions
Preliminaries
Environmental conditions The device is designed for being installed in industrial environments within the following range:
Temperature +5…+40ºC
Relative humidity 30…80% not condensed
The device is not prepared for being installed on the outside buildings. Avoid the placement of the device in areas with exterior heating. The device is not prepared for antideflagrant environments.
In environments with a great deal of dust, special attention in cleaning is required to maintain proper labelling.
Ask at our technical department to clarify if addition protection is necessary for special environments.
Necessary space The device must be installed in an area with access for the operator and for maintenance. The device must have an access area around 600mm on all sides.
Loading media
Label and ribbon path
Right Hand MLP SP OUT winding (continous lines) IN winding (discontinous line)
Left Hand MLP SP OUT winding (continous lines) IN winding (discontinous line)
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Preparation for use
The following sets out the necessary conditions for setting up and running the device.
Before turning the device on, check all the start up conditions:
1. Electrical power: The MLP device and the printing unit have independent power supply so two electric cables are needed.
2. Pneumatic power: The MLP device has pneumatic power. The intake of air must be done via a tube of external diameter 8.
3. Signal of presence (EI1): The MLP device has the signal of presence or cycle start wired
up. Several signals can be used or photoelectric cells for the start of the cycle, for example, when the work cycle requires cutting (Printing on one side and application on the other).
4. Fitting accessories:
The device has the labels fitted.
The printer has the ribbon fitted.
5. Sending information to the printer: The printing unit has labels loaded in the buffer.
6. External connections interface: The MLP device has the necessary external signals wired up to the PC/Host and thus permit the right synchronization with the production line.
7. Applicator interface connections: The MLP device has the signals of the applicator
connected.
Electrical power supply
The electrical requirements for the power supply of the device are two plugs type IEC female of 110V-230VAC 50Hz. One of the plugs is for the Dispenser-applicator power supply and the other for the printer unit power supply.
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Air supply - Pneumatics
The pneumatic requirements for the device are related to the applicator to be used. As a general requirement 1 inlet of compressed air of 6 bar of pressure with tube of external diameter of 8mm is necessary. With each device it is recommended to place at the inlet a maintenance unit of compressed air consisting of a filter and a manual valve.
Presence signal & labelling trigger
The standard way of working with MLP devices is to use the present signal EI1 that triggers the cycle of Print and Apply.
Photocell External board MME1620004 Board
Description Colour Binder
M12 - 4 pins Colour
CN-12 XH 4 wire
Colour Description
+ 24V Brown 1 Brown 1 Brown + 24V
Dark / Light White 2 White 2 Black Signal – IE1
0 V Blue 3 Blue 3 White -
Signal – IE1 Black 4 Black 4 Blue 0 V
Presence signal - IE1
Pressure gauge
Pressure regulator
Manual valve
Filter
Air inlet Air outlet
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5. Operations and procedures
The CPU, apart from running the different application programs, also carries out other processes of great importance that guarantee correct functioning. These processes are listed and set out in the following:
Working cycle
Once the diameters have been calculated, the labeller stays in wait of the order to start the cycle. Once received, the labeller synchronises the action of the dispenser, printer and applicator units:
1. Once the order to start the cycle is received and if the printer has data ready to print in its
buffer (there is an active label) the print order is sent to the printing unit. Otherwise, the error message "Printer Ready Error” will be shown and the printing process will be aborted.
2. As the label is being printed, the rewinder motor starts up in order to collect the backing paper that is being fed into it.
3. While printing the label, it positions itself on the blade with the help of blown air (blower tube) and the vacuum that is created in the blade itself (it will depend on the applicator used).
4. When the printing ends the rewinder motor continues working until the breather recovers and the sensor of the rewinder lever II5 is activated.
5. When the label is in the blade, the application cycle is initiated, which will depend on the active program (See details of the programs).
Error signals
The signals and causes of errors are constantly checked and generate an interruption/alarm if necessary.
Error messages and alerts, give warning in three ways:
Screens/Displays.
External outputs that notify that there is a printer or applicator error.
Signal lights (not necessarily present).
Solving errors
Once the incidence has been shown on the screen and/or in the signal lights, the labeller, based on the severity of the incidence, will wait for its resolution in order to restart the work cycle. Depending on the origin of the incidence, its resolution will depend on if the error has occurred in the printing unit or rather in the labeller.
If the origin of the error is the Printing Unit, the incidence will be signalled both in the display of the printer itself and in the labeller (display and signal lights). In this case, the operator must resolve the incidence via the printer unit and its display. Once the incidence is resolved, the signal that indicates the error in the printer to the labeller, it will automatically reset, with which the labeller will reset its alarm without the operator’s aid.
If the origin of the error is in the Labeller, the incidence will only be signalled in the display and lights of the labeller. The labeller will go from On-line to Off-line. The operator must resolve the incidence via the labeller itself and once resolved, finish it off pressing the key of the display destined to such purpose (ACTION from RESET or pass from Offline to Online).
Once the incident is resolved and the alarm reset manually on the display, the labeller must restart the machine to ensure that everything is correct leaving the outputs in a state of rest/deactivated.
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6. Maintenance
Preventive maintenance
Before proceeding to modify the device, be sure the device is disconnected from the electric current and the pneumatic supply.
- To disconnect from the electrical power, you must do so from the printer and the labeller as they both receive power separately.
- To disconnect the pneumatic supply, you must close the general valve in-take to the device. To access the interior of the MLP device it is necessary to unscrew the screws of the cover.
General cleaning For the cleaning and maintenance of the printer, refer to the manual that comes with the unit. The printer is the most important element of the device, so you must pay special attention to maintaining it in a perfect state.
Regular cleaning is necessary in order to maintain the long life of the MLP device. It is recommendable to keep the applicator clean, with no scraps of label or adhesive on the elements where the labels circulate. Clean the pad with alcohol with a cloth that does not leave threads or fluff. Do not use knives or sharp tools to remove adhesive. Mechanical maintenance Check the tension of the unwinder break, checking that with the compensator lever in the highest position, the unwinder spindle breaks and the label roll does not turn. Verify that on moving the compensation lever downwards the unwinder lever is freed and it turns without difficulty. Check the alignment of the labels from the unwinder to the printer entry point, placing the guiding flanges with respect to the width of the label being used. Electrical maintenance
Check that the SubD connectors of the signal cables are well connected and that the signal does not have poor contacts.
Check that the MLP device entry detectors work properly, verifying their action on the 5.4” display test screen.
Pneumatic maintenance
Check that the pneumatic maintenance set works correctly at a pressure of between 4 and 5 bars of pressure and that the air filter is clean. In the case of the air of the installation being dirty, it is advisable to empty the tank on purging.
Check that there are not any air leaks in the tubes and in the joint fittings with the pneumatic elements.
Clean the silencer filters of the set of valves and the breather nozzle with soapy water.
Verify the working of the cylinder, checking that the movement does not offer resistance when it is moved with the general air in-take disconnected and carrying out the movement by hand.
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7. Annex 1. Applicators.
Linear Applicator (20)
MLP SP 4020 o MLP SP 6020: Lineal. This applicator is the most common automatic labelling applicator. A pneumatic circuit is used to create the vacuum that holds the label, the air blower in order to apply the label to the product and a linear cylinder to displace the label.
The functioning of the Linear applicator is the following:
In rest position the printed label is collected from the printer.
The displacement of the applicator is done by means of the linear cylinder.
When the product makes contact with the applicator, the label is applied.
The applicator returns to the position of rest. The Linear applicator is composed of the following elements:
Applicator pad (1)
Linear cylinder (2)
Blow tube (3)
The applicator pad is the set of elements that collect the label when it has been printed and apply it to the product. The dimensions of the pad can vary depending on the label to apply (the standard dimensions are 110x110 y 148x210).
2 1
3
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The elements that comprise a standard pad are:
Compression springs (1)
Compression detector (2)
Pneumatic circuit (3)
Pad board (4)
The compression springs along with the compression detector allow the pad to make contact with the product. On making contact, the springs compress and the detector sends a signal so that the linear cylinder returns to the state of rest. In order to hold the label on the pad while the linear displacement is carried out and to blow the label on making contact with the product, the pad possesses a pneumatic circuit for the in-take and out-let of air. The pad board has a special mechanism to hold the label to the surface by creating a vacuum and applies the label by blowing. The linear applicator is composed of the following elements:
Pneumatic cylinder (1)
Cable carrier chain (2)
Set of electro valves (3)
Breather nozzle (4)
Air cavity (5)
1
2 3 3
4
2
3
4
1
5
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The pneumatic linear displacement cylinder causes the applicator arm to move. The sensors and the pneumatic circuit air tubes are channelled by a cable carrier chain. The set of electro valves takes care of activating each device in order to complete the labelling cycle. The breather nozzle creates the vacuum in the air circuit in the pad to keep the label still while the displacement is carried out. The air cavity accumulates a volume of air in each labelling cycle so that when the applicator makes contact with product it blows this volume through the pad and a better label application is achieved. The blow tube is situated under the dispensation point and its function consists in injecting a curtain of air over the label while it is being printed with the aim of steering the label towards the pad applicator.
Blow tube
Pad
Dispensation point
Tube fitting for air inlet
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8. Annexe 2. PIN-OUT connectors.
Applicator connectors: Internal Input & Output. Sub37 Female.
Internal signal are the ones used in order to automate the applicator device and the rewinder. All of them are opt coupled and are PNP. The connection of the applicators is done through the Subd37 female connector situated in the front side of the machine
The pinout of the connectors is shown below and:
Internal Inputs (II): Opto PNP and without configuration jumpers / straps.
Description SubD 37 Female
OI1 – Cil1 1
OI2 – Cil2 2
OI3 – Air assist tube 3
OI4 – Vacuum 4
OI5 – Blow ejection 5
OI9 – Belts motor CC 6
OI10 – TBD 7
OI11 – Scanner trigger 8
+24V 9 a 11
II1 – Cil1 home 12
II2 – Cil1 o 2 End 13
II3 – Cil2 home 14
II4 – Peel pos Belts 15
GND 16
GND 17
GND 18
GND 19
+24V 20 a 29
II5 – Sensor pad 30
II6 – Sensor label on pad 31
II7 – Scanner Good Read 32
II8 – TBD 33
GND 34 a 37
SubD37 Female. Internal Input & Output
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External connectors: External Inputs & Outputs. SubD37 Female
Inputs and output available in order to interface the machine externally from the host machine (PLC, etc)..
External Input (IE): through jumpers they can be configured depending on the type of sensor connected. ‘Always On”, NPN or PNP (Default). External output(OE): through jumpers they can be configured as a free contact or to deliver +24V and if it´s normally open or closed. Jumpers/Straps:
OEi NO (normally open -default) or NC (normally closed )
OEi1 & OEi2 both jumper on the same side. o Pos1 free potential contact o Pos2 +24Vdc
Description SubD 37 Female
+24V 1
PHOTOCELL 1 - IE1 2
PHOTOCELL 2 - IE2 3
PHOTOCELL 3 - IE3 4
Emergency STOP- IE4 5
Reset - IE5 6
TBD 1 - IE6 7
TBD 2 - IE7 8
Encoder 1 - II12 9
Encoder 2 - II13 10
GND 11 y 12
Printer. Ready1 - OEA1 13
Printer Ready2 - - OEB1 14
Sensor Cil. Home - OEA2 15
Sensor Cil. Home - OEB2 16
TBD A1 - OEA3 17
TBD A2 - OEB3 18
+24V 19 a 21
Error 1 - OEA4 22
Error 2 - OEB4 23
Alarm 1 - OEA5 24
Alarm 2 - OEB5 25
GND 26 a 28
End cycle - OEA6 29
End cycle - OEB6 30
TBD B1 - OEA7 31
TBD B2 - OEB7 32
TBD C1 - OEA8 33
TBD C2 - OEB8 34
+24V 35 a 37
Subd37 FemaleExternal IOs
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9. Annexe 3. Parameters and settings menus
Main screen
When the MLP unit is started, if it is not in any configuration menu, the display shows the working display. This screen shows the status of the labelling machine and the summary of the configuration.
Main screen MLP SP
‘Stop’ button switches between START and STOP. The indicated action (START or STOP) is performed each time the button on the screen is pressed and the status is switched. When the equipment is started, the Action button shows the text START. When STOPPING, it is a controlled stop, i.e. the equipment does not stop immediately, but the current cycle is ended. The last line of the screen shows a text line indicating the equipment status. When there is an error, the equipment automatically switches to OFFLINE until the error is resolved and the Action button is pressed (START). The equipment performs a reset after an error. If the error is in the printer module, the labelling machine will automatically switch to Online once the error has been resolved, without working on the labelling machine. If the problem lies in the labelling machine/applicator, once the error has been corrected, press the “Start” button to restart
Actions
The actions button allows access to a screen with individual commands/actions. In this screen, the equipment
does not process the normal labelling cycle signals:
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Menus & Parameters
The configuration of the MLP can be carried out from the 4.3’’ QVGA display screen. This display may have the password lock enabled which requires a code to be entered in order to make any
modification to the parameters. The code to enter is “2605”.
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Timers
There are 4 timer screens, of which 3 enable the action times of different parts of the processes to be configured. The fourth screen is informative to see the time of the last printing/dispensing + application cycle, or only application. To access its configuration from the 4.3’’ Display: “Home Screen > Applicator > Timers”
Timers 1 of 4
t1 Cycle maximum: maximum application time before an error is triggered due to time-out.
Cycle T.: if other than 0, an error will be indicated if the printing and application time exceeds the established value.
t10 Application Maximum: label application time. When exceeded, the label is ejected and the label application is ended. There is no associated error.
t15 Application End Delay: enables the actions made after
the application to be delayed: delay cycle end signal, etc.
Timers 2 of 4
t8 Print & Apply: delay between the Printing and the
Application
t2 Ejection: extra ejection when the label application on the
product is complete.
t9 Additional blowing: extra blowing time after printing.
t14 Vacuum: delay time from when the label is dispensed to the action of the vacuum.
Timers 3 of 4
t4 Return Cylinder 2: maximum time that Cylinder 2 has to
return to its Home position after starting its action. if it is 0, it is not controlled.
t6 Delay Cylinder 1: delay between the start of the cycle
and the time when Cylinder 1 works.
t5 Delay Cyl2/Pusher: delay between the start of the cycle
and the time when Cylinder 2 works.
t7 Delay Cylinder 3: delay between the start of the cycle and the time when Cylinder 3 works.
Timers 4 of 4
T. Cylinder 2/Pusher (or t13): length of time for which Cylinder 2/Pusher works.
t11 Estimated cycle: time calculated by the MLP and which
reflects the duration of the last dispensing and application cycle made.
t12 Estimated Application: same as t11 but only reflects the
application time of the last cycle.