Labeljet 210 Service Manual · 2019-12-13 · Labeljet 210 ii Rev AA Pour la Clientèle du Canada...

LABELJET 210

Service Manual

P/N 361627-01

Revision: AA, August 2006

Copyright 2004, Videojet Technologies Inc. (herein referred to as Videojet). All rights reserved.

This document is the property of Videojet Technologies Inc. and contains confidential and proprietary information owned by Videojet. Any unauthorized copying, use or disclosure of it without

the prior written permission of Videojet is strictly prohibited.

Videojet Technologies Inc.1500 Mittel Boulevard Phone: 1-800-843-3610 Offices - USA: Atlanta, ChicagoWood Dale, IL Fax: 1-800-582-1343 Int’l: Canada, France, Germany, Ireland, Japan, Spain, 60191-1073 USA Int’l Fax: 630-616-3629 Singapore, The Netherlands, and The United Kingdom www.videojet.com Distributors Worldwide

Rev AA i

Compliance InformationFor Customers in the U.S.A.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: 1) this device may not cause harmful interference, and 2) this device must accept any interference received, including interference that may cause undesired operation.

Warning

Changes or modifications to this unit not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide responsible protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference. In such cases, users will be required to correct the interference at their own expense.

Shielded cables must be used with this unit to ensure compliance with Class A FCC limits.

The user may find the following booklet prepared by the Federal Communications Commission helpful: How to Identify and Resolve Radio-TV Interference Problems. This booklet is available from the U.S. Government Printing Office, Washington, DC 20402, Stock No. 004-00-00345-4.

This equipment is UL listed.

For Customers in CanadaThis digital apparatus does not exceed the Class A limits for radio noise emissions from digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications.

This equipment is UL listed.

Labeljet 210

ii Rev AA

Pour la Clientèle du CanadaLe present appareil numerique n’emet pas de bruits radioelectriques depassant les limites applicales aux appareils numerique de las class A prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada.

Cet équipement est certifié CSA.

For Customers in the European UnionThis equipment displays the CE mark to indicate conformance to the following legislation:

Warning

The FCC warns the users that changes or malfunctions to the unit not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.

Support and Training

Contact InformationIf you have any questions or need assistance, please contact Videojet Technologies Inc. at 1-800-843-3610 (for all customers within the United States). Outside the U.S., customers should contact their Videojet Technologies Inc. distributor or subsidiary for assistance.

Videojet Technologies Inc.1500 Mittel BoulevardWood Dale, IL 60191-1073 U.S.A.Phone: 1-800-843-3610Fax: 1-800-582-1343International Fax: 630-616-3629Web: www.videojet.com

Labeljet 210

Rev AA iii

Service Program

About Total Source CommitmentTotal Source® TOTAL SERVICE PLUS RELIABILITY, is the Videojet Technologies Inc. commitment to provide you - our customer - the complete service you deserve.

The Total Source CommitmentThe Videojet Total Source® Service Program is an integral part of our business in providing marks, codes, and images where, when, and how often customers specify for packages, products, or printed materials. Our commitment includes:

• Applications support

• Installation services

• Maintenance training

• Customer response center

• Technical support

• Field service

• Extended hours phone assistance

• Parts and supplies

• Repair service

Customer TrainingIf you wish to perform your own service and maintenance on the printer, Videojet Technologies Inc. highly recommends you to complete a Customer Training Course on the printer.

Note: The manuals are intended to be supplements to (and not replacements for) Videojet Technologies Inc. Customer Training.

For more information on Videojet Technologies Inc. Customer Training Courses, call 1-800-843-3610 (within the United States only). Outside the U.S., customer should contact a Videojet subsidiary office or their local Videojet distributor for further information.

Rev AA 1

Table of ContentsCompliance Information

For Customers in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iFor Customers in Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iPour la Clientèle du Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiFor Customers in the European Union. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Support and TrainingContact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiService Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiCustomer Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Chapter 1 — IntroductionAbout the Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2Language Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Hazard Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3General Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3General Caution Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Abbreviations Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5Conventions for Figures and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

Chapter 2 — InstallationMounting the Labeljet 210 Label Applicator . . . . . . . . . . . . . . . . . . . . 2–2Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Assembling the Operator Control Panel and Mounting Tube . . 2–4Assembling the Label Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5Assembling the Wipe-down Brush . . . . . . . . . . . . . . . . . . . . . . . . . 2–8Assembling the Unwind Reel Flanges . . . . . . . . . . . . . . . . . . . . . . 2–9Assembling the Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . 2–10Assembling the Label Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10Assembling the Shaft Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

Setting up the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12Aligning the Label Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12Setting up Password Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13Connecting the Machine’s Mains Supply. . . . . . . . . . . . . . . . . . . 2–14Setting up the Engineering Menu . . . . . . . . . . . . . . . . . . . . . . . . . 2–15Setting up the Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . 2–20Adjusting the Web Tension and Product Detector . . . . . . . . . . . 2–20

Labeljet 210

2 Rev AA

Chapter 3 — Machine DescriptionWeb Drive Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2Web Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3Unwind and Rewind Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7Friction Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

Electronics Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8

Foldout 1: CPU Circuit Diagram (Sheet 1 of 5). . . . . . . . . . . . . . . . . . 3–15Foldout 2: CPU Circuit Diagram (Sheet 2 of 5). . . . . . . . . . . . . . . . . . 3–17Foldout 3: CPU Circuit Diagram (Sheet 3 of 5). . . . . . . . . . . . . . . . . . 3–19Foldout 4: CPU Circuit Diagram (Sheet 4 of 5). . . . . . . . . . . . . . . . . . 3–21Foldout 5: CPU Circuit Diagram (Sheet 5 of 5). . . . . . . . . . . . . . . . . . 3–23

CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25Toroidal Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36

Sensors and Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36Label Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36Product Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37Label Low Microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37

Mains Input and DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . 3–38Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41Foldout 6: Control Panel PCB Circuit Diagram . . . . . . . . . . . . . . . . . 3–43

Functional Description of the Control Panel . . . . . . . . . . . . . . . . 3–45Interface between the Control Panel and Electronics Module. . 3–45

Chapter 4 — Cleaning and MaintenanceCleaning the Web Path. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1Inspecting the Connections and Fittings . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Chapter 5 — TroubleshootingMachine Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1Label Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

Breaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3Slipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4Advancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7Applying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8Rewinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Password Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9Adjustment and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

Labeljet 210

Rev AA 3

Adjusting the Hold-down Spring . . . . . . . . . . . . . . . . . . . . . . . . . 5–10Inspecting the Connector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11Adjusting the Dancer Arm Tension . . . . . . . . . . . . . . . . . . . . . . . 5–12Adjusting the Rewind Reel Drive Belt . . . . . . . . . . . . . . . . . . . . . 5–13Resetting Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14Checking the Control Panel Cable. . . . . . . . . . . . . . . . . . . . . . . . . 5–17

Replacing Faulty Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17Replacing the Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18Replacing the Label Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19Replacing the Control Panel PCB . . . . . . . . . . . . . . . . . . . . . . . . . 5–20Replacing the CPU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22Replacing the Toroidal Transformer. . . . . . . . . . . . . . . . . . . . . . . 5–24Replacing the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25Replacing the Brake Band. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28Replacing the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29Replacing the Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31Replacing the Mains Input Module. . . . . . . . . . . . . . . . . . . . . . . . 5–32Replacing Fuse 2 on CPU PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34Replacing the Capacitors C19 and C20. . . . . . . . . . . . . . . . . . . . . 5–35Replacing the Mains Input Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . 5–38

Chapter 6 — Consumables and OptionsConsumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1

Appendix A — Applicator SpecificationsOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1

Appendix B — Illustrated Parts ListHow to Use this Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–1Labeljet 210 - Major Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–2Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–3Foldout 7: Web Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–7Web Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–9Electronic Components and Mounting Bracket. . . . . . . . . . . . . . . . . B–11Electronics Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–12

Index

Rev AA About the Service Manual 1-1

1Introduction

This chapter contains:

• information on what this manual is about, who this manual is intended for, and how it is organized

• a description of other manuals associated with this applicator

• safety and hazard information

• a list of abbreviations

• conventions used for figures and tables

About the Service ManualThe Service Manual is intended as a reference guide for trained service personnel, and contains the following:

• Introduction - contains information about this manual, hazard information on the applicator, and abbreviations used

• Installation - contains information on installing the applicator

• Machine Description - provides a mechanical and electrical overview of the applicator

• Cleaning and Maintenance - contains details of cleaning the applicator and maintaining it

• Troubleshooting - contains information on applicator failure symptoms, and steps to solve the problem by diagnosing it

• Illustrated Parts List - provides a labelled description of each part of the applicator

• Index - an alphabetical subject index of topics in this manual

Labeljet 210

1-2 About the Service Manual Rev AA

Related DocumentsLabeljet 210 Operator Manual (P/N 361626-01). This manual is supplied to operators to serve as a ready reckoner, while they operate the applicator.

Language CodesWhen ordering manuals, be sure to add the 2-digit language code to the end of the part number. For example, the part number for the Spanish version of this manual would be 361627-04.

Note: Initial availability of the Operator Manual is indicated by an asterisk (*). Availability of the Service Manual is indicated by a plus sign (+). Availability of the Illustrated Parts Breakdown is indicated by the number sign (#). For more information, consult your Videojet distributor or subsidiary.

Code Language Availability (see note)

01 English (US) * + #

02 French

03 German

04 Spanish

05 Portuguese

06 Japanese

07 Russian

08 Italian

09 Dutch

10 Chinese (Simplified)

11 Arabic

12 Korean

13 Thai

14 Icelandic

15 Norwegian

16 Finnish

17 Swedish

18 Danish

19 Greek

20 Hebrew

21 English (UK) * + #

23 Polish

Labeljet 210

Rev AA Hazard Information 1-3

Hazard InformationThis section contains important hazard notices. You must read these notices before using the Labeljet 210 Label Applicator.

The hazard information is prioritized into typographically distinct warning and caution notices as follows:

Warning

WARNING NOTICES. Warning notices denote a potential hazard to the health and safety of the users. These notices clearly state the nature of the respective hazard and the means by which it can be avoided.

Warning notices, together with the warning symbol shown on the left, appear in full in this chapter and at their points of application in the manual. They are presented in the typographical style of this notice.

Caution

CAUTION NOTICES. Cautionary notices denote a potential hazard to the physical integrity of the equipment/software, but not a danger to personnel. These notices clearly state the nature of hazard and the means by which it can be avoided.

Cautionary notices appear in full in this chapter and their points of application in the manual. They are presented in the typographical style of this notice.

General Warning NoticesThe following warnings supplement the specific warnings appearing elsewhere in the manual. These are general warnings which must be read, completely understood, and applied by all personnel involved with the operation and/or maintenance of the machine.

Warning

LETHAL HAZARD. When carrying out maintenance work, switch off the machine at the mains on/off switch and disconnect it from the electrical supply.

Labeljet 210

1-4 Hazard Information Rev AA

Warning

LETHAL HAZARD. When working on electrical equipment, observe all statutory electrical safety codes and practices.

Warning

PERSONAL INJURY. The Labeljet 210 Label Applicator has exposed rotating parts. Keep hands, long hair, ties, loose clothing and so on, away from the machine at all times, when it is switched on.

General Caution NoticesThe following cautions supplement the specific cautions appearing elsewhere in the manual. These are general warnings which must be read, completely understood, and applied by all personnel involved with the operation and/or maintenance of the machine.

Caution

EQUIPMENT DAMAGE. Do not fit or remove any connector on the Labeljet 210 Label Applicator while the power is switched on.

Labeljet 210

Rev AA Abbreviations Used 1-5

Abbreviations UsedThis manual contains the following abbreviations:

Abbreviation Expansion

A Ampere

AC Alternating Current

CPU Central Processing Unit

CTR Current Transfer Ratio

DC Direct Current

DIN Deutsches Institut fur Normung (German Stan-dards Institute)

DMA Direct Memory Access

DVM Digital Volt Meter

EMC Electro Magnetic Compatibility

EPROM Erasable Programmable Read Only Memory

ESD Electrostatic Sensitive Device

Hz Hertz

kg Kilograms

LCD Liquid Crystal Display

LED Light Emitting Diode

m Meter

min Minute

mm Millimeters

MOSFET Metal Oxide Semiconductor Field Effect Transis-tor

mV milliVolt

No. Number

OCP Operator Control Panel

PCB Printed Circuit Board

PROM Programmable Read Only Memory

PWM Pulse Width Modulation

RAM Random Access Memory

SRAM Static Random Access Memory

Labeljet 210

1-6 Conventions for Figures and Tables Rev AA

Conventions for Figures and TablesThe illustrations used in the manual are numbered according to the chapter they are used in. For example, Figure 1-3 is the third figure in Chapter 1.

Tables are numbered in a similar manner.

TP1 Test Point 1

USART Universal Synchronous/Asynchronous Receiver Transmitter

V Volt

+ve Positive

-ve Negative

Abbreviation Expansion

Rev AA 2-1

2Installation


• the installation procedures including assembly instructions

• the machine setup procedures

Warning

LETHAL HAZARD. Ensure that the Labeljet 210 Label Applicator is disconnected from the mains supply during the installation procedure. Connect the mains supply, only when the machine is fully assembled and all electrical connections are made.

Warning

LETHAL HAZARD/SERIOUS EQUIPMENT DAMAGE. Only personnel trained by Videojet Technologies Inc. should attempt this installation procedure.

Warning

PERSONAL INJURY. The Labeljet 210 Label Applicator has exposed rotating parts. Keep hands, long hair, ties, loose clothing and so on, away from the machine at all times, when it is switched on.

Warning

PERSONAL INJURY. The Labeljet 210 Label Applicator is heavy (23kg). Use suitable lifting equipment to install the machine.

Labeljet 210

2-2 Mounting the Labeljet 210 Label Applicator Rev AA

Note: Each installation must be approached on an individual basis due to variations in production line build specifications. Supposedly, identical production lines can vary significantly due to customer requirements or modifications. Therefore, all the installation criteria should be established before attempting the installation. Missing or ambiguous information should be clarified by telephone or fax before beginning the installation procedure.

Mounting the Labeljet 210 Label ApplicatorTo mount the Labeljet 210 Label Applicator on a production conveyor, proceed as follows:

1 Position the Mounting Stand (supplied by Videojet Technologies, Inc.) such that the Labeljet 210 Label Applicator can be installed correctly, for applying labels to the product.

2 Support the Labeljet 210 Label Applicator on the floor mounting stand.

Note: A 'U' arm Mounting Bracket is fitted to the Labeljet 210 Label Applicator as standard, and is used to attach the Label Applicator to its mounting stand.

3 Position the applicator (as shown in Figure 2-1 on page 2-3), with the bottom edge of the chassis parallel to the product surface. The Peel Tip should be as close to the product as possible, with enough gap between them to prevent any contact.

4 Tighten all mounting bolts, when the machine is in the correct position.

Note: The machine can be used to apply the labels either to the top, side or bottom of the product.

2

1

1. Chassis2. Peel Tip

Figure 2-1. 210 Label Applicator Mounting Position

Labeljet 210

Rev AA Assembling Components 2-3

Assembling Components Certain items are supplied with the machine as separate components and need to be assembled. The following paragraphs describe the assembly procedures for each of the components listed below:

• Operator Control Panel (OCP) and Mounting Tube

• Label Sensor

• Wipe-down Brush

• Unwind Reel Flanges

• Product Detector

• Label Roll

• Shaft Encoder

Labeljet 210

2-4 Assembling Components Rev AA

Assembling the Operator Control Panel and Mounting TubeTo assemble the OCP (also called as Control Panel) and the Mounting Tube, proceed as follows:

1 Fit one end of the Mounting Tube (Figure 2-2) into the clamp at the rear of the Labeljet 210 Label Applicator chassis.

2 Position the tube in the required position and tighten the clamp.

3 Fit the clamp on the rear of the Control Panel, over the other end of the mounting tube and tighten the clamp.

4 Ensure that both the clamps are fully tightened.

5 Make the final adjustments to the position of the Control Panel, to ensure that it is in the most convenient position.

6 Connect the 8 pin DIN plug on the Control Panel cable, to the Control Panel connector (Figure 2-3 on page 2-5) on the Connector Panel, at the rear of the machine.

1

4

2 3

1. Control Panel2. Mounting Tube3. Clamp4. Wipe-down Brush

Figure 2-2. Control Panel and Mounting Tube

Labeljet 210


Assembling the Label SensorThe new Label Sensor should be calibrated before assembly.

Equipment required for calibration:

• Digital Volt Meter (DVM)

• Potentiometer Adjusting Tool

Note: The new Label Sensor should be plugged in with no label or web in position.

1. Product Detector Plug 6. Mains On/Off Switch2. Label Sensor Plug 7. Mains Voltage Selector3. Shaft Encoder Connector 8. Control Panel Connector4. Mains Inlet Connector 9. Lamp Stack Connector5. Mains Fuse Holder 10. General Alarm Connector

Figure 2-3. Connector Panel Components

1

2

34

5

6

7

8 9 1 0

Labeljet 210


To calibrate the new Label Sensor, proceed as follows:

Caution

EQUIPMENT DAMAGE. Electrostatic Sensitive Device (ESD) precautions must be taken when performing this procedure.

1 Switch off the power supply to the Labeljet 210 Label Applicator.

2 Remove the Connector Panel along with Central Processing Unit (CPU) Printed Circuit Board (PCB) from the machine, and support it such that the PCB does not short on the Labeljet 210 Label Applicator casing.

3 Connect the mains supply to the Connector Panel and switch on the power supply.

4 Set the DVM to Direct Current (DC) volts.

5 Connect the + ve lead to the Test Point 1 (TP1) on the CPU (Figure 2-4 on page 2-7).

6 Connect the -ve lead to the ground point, between X1 and SW1 on the CPU.

7 Adjust RV2, until a value of between 3.45 and 3.48 volts is obtained. The Label Sensor calibration is now set.

Note: The potentiometer only moves in an arc of 270 degrees, care must be taken not to damage the stops.

8 Switch off the power supply and disconnect the mains lead.

9 Refit the Connector Panel to the Labeljet 210 Label Applicator casing.

10 Reconnect the power supply and set up operating values as necessary.

Labeljet 210


To assemble the Label Sensor, proceed as follows:

1 Slide the Label Sensor (Figure 2-5 on page 2-8) onto its mounting shaft.

2 Position the Label Sensor such that the groove is in the center of the label width and tighten the locking screw.

Figure 2-4. Label Sensor Calibration

Labeljet 210


3 Connect the 6 way Amphenol socket on the Label Sensor cable to the Label Sensor plug (Figure 2-3 on page 2-5) on the Connector Panel.

Assembling the Wipe-down BrushTo assemble the Wipe-down Brush, proceed as follows:

1 Fit the Wipe-down Brush (Figure 2-5) to the Wipe-down Brush bracket, and secure it using the securing screw.

2 Adjust the angle and position of the Wipe-down Brush such that it makes light contact with the product.

Figure 2-5. Label Sensor

1. Mounting Shaft 4. Securing Screw2. Wipe-down Brush 5. Label Sensor3. Wipe-down Brush Bracket 6. Locking Screw

2

3

1

6

4

5

Labeljet 210


Assembling the Unwind Reel FlangesTo assemble the Unwind Reel Flanges, proceed as follows:

1 Identify the inner Unwind Reel Flange by the type of Grubscrew fitted to its hub (the Inner Flange has a steel socket headed Grubscrew and the Outer Flange has a nylon Grubscrew [Figure 2-6 on page 2-9]).

2 Slide the Inner Flange onto the Unwind Shaft, with the steel Grubscrew over the flat portion of the shaft, and the hub facing forward, as shown in Figure 2-6.

3 Position the Inner Flange such that, when a label roll is loaded onto the Unwind Reel, the center of the label web runs over the web driver rollers.

2

3

1

Figure 2-6. Unwind Reel Flange

1. Steel Grubscrew2. Unwind Reel Flange (Inner)3. Unwind Shaft

Labeljet 210


4 Secure the Inner Flange by tightening the Grubscrew onto the flat portion of the Unwind Shaft.

5 Check if the nylon Grubscrew on the Outer Flange just protrudes beyond the inner face of the hub.

<Procedure ends abruptly. Is there a concluding step?>

Note: The Outer Flange need not be fitted until the label roll has been loaded (“Loading the Label Roll” on page 2-10).

Assembling the Product DetectorTo assemble a Product Detector, proceed as follows:

1 Fit the Product Detector alongside the product conveyor.

2 Connect the 4 way Amphenol socket on the Product Detector cable, to the Product Detector plug (Figure 2-3 on page 2-5), on the Connector Panel.

Assembling the Label RollAssembling the Label Roll involves loading the Label Roll and threading the Label Web.

Loading the Label RollTo load a Label Roll, proceed as follows:

1 Switch off the machine and disconnect it from the mains supply.

2 Push the roll of labels (Figure 2-7 on page 2-11) onto the Unwind Shaft and ensure that the core of the roll fits tightly over the hub on the Inner Flange.

3 Fit the Outer Flange Reel onto the Unwind Shaft with the hub facing out and the nylon Grubscrew over the flat portion of the shaft.

4 Push the Outer Flange against the label roll and lock it in place by twisting it.

Threading the Label WebThread the label web through the machine (Figure 2-7 on page 2-11). While threading the label web, ensure the following:

• pull approximately 800 mm of label from the end of the web

• pass the web between the Drive Roller and the Nip Roller, operating the Cranked Nip Arm to separate the two rollers

Labeljet 210


• remove the Lock Pin from the Rewind Reel

• wind the label web two or three times around the Rewind Reel and secure it with the Lock Pin

• the web passes between the Friction Block and the Peel Plate

• the web passes through the slot in the Label Sensor

1

2

3

456

7

8

9

1. Unwind Shaft 6. Nip Roller2. Lock Pin 7. Friction Block3. Rewind Reel 8. Label Sensor4. Cranked Nip Arm 9. Label Roll5. Drive Roller

Figure 2-7. Label Web Path

Assembling the Shaft EncoderIf you want to use a Shaft Encoder to synchronize the machine speed, connect the Shaft Encoder lead to the Shaft Encoder connector (4 pin DIN connector [Figure 2-3 on page 2-5]) on the Connector Panel. Pinout details of the Shaft Encoder interface are described in Chapter 3, “Machine Description”.

Labeljet 210

2-12 Setting up the Machine Rev AA

Setting up the MachineSetting up the machine for correct operation, after installation, involves the following:

• Aligning the Label Web

• Setting up Password Levels

• Connecting the Machine’s Mains Supply

• Setting up the Engineering Menu

• Setting up Operator Controls

• Adjusting the Web Tension and Product Detector

Aligning the Label WebTo align the Label Web, proceed as follows:

1 Move the Inboard and Outboard Web Guide Collars (Figure 2-8) away from the label web.

2 Rotate manually the Rewind Reel in the direction shown in Figure 2-8.

3 Check if the label web is positioned at the center on the web drive rollers. If necessary, adjust the position of the Unwind Reel Flanges and the position of the web on the Rewind Reel, to achieve this.

4 Switch the machine on and cycle it for 500 mm, to settle the web in its correct path.

5 Set the Inboard Guide Collar, such that it is at a distance of 1 mm from the edge of the label web.

Labeljet 210

Rev AA Setting up the Machine 2-13

6 Set the Outboard Guide Collar, such that it is at a distance of 1 mm from the edge of the label web.

7 Position the Label Sensor, such that the label web passes through the slot and under the groove on the sensor.

8 Loosen the Thumb Knob on the Label Sensor.

9 Move the Label Sensor to the required position, and tighten the Thumb Knob to secure it.

Note: When using very narrow label webs, it may be necessary to remove the Label Sensor from the shaft, turn it through 180 degrees, and refit it.

Setting up Password LevelsThe machine functions of Labeljet 210 can be restricted by setting the password levels as shown below:

• Password Level 1 allows the operator to access and select stored machine operating parameters. The operator cannot modify any of the existing machine operating parameters.

• Password Level 2 provides full access to the operator. The operator can modify the machine operating parameters and/or the engineering setup.

Figure 2-8. Label Web Alignment

1. Rewind Reel2. Outboard Guide Collar3. Label Sensor4. Inboard Guide Collar

2

3

4

1

4

321

5

6

7

8

91011121314151617

18

Figure 2-9. Controls and Indicators

1. Liquid Crystal Display 7. Label Detected Indicator 13. label Stop Position Key2. Increment Key 8. General Alarm Indicator 14. Label Sensitivity Key3. Decrement Key 9. Air Assist Delay Key 15. Motor Speed Control key4. Machine On Indicator 10. Tamp/Blow Dwell Time Key 16. Memory Recall Key5. Product Detect Indicator 11. Hot Foil Coder (HFC) Dwell Key 17. Memory Store Key6. Label Out indicator 12. Product Delay Key 18. Numeric Keypad

Labeljet 210


Note: The machine is supplied without any passwords. You have to set the passwords to restrict access to the machine functions.

To set or change a password, proceed as follows:

1 Press the and keys on the Control Panel, to set or change a

Level 1 password, or press the and keys, to set or change a Level 2 password (Figure 2-9 on page 2-14).

2 Enter an active password (if it exists) or enter the new password for Level 1 or Level 2, as required.

Note: The password should comprise three numbers entered using the numeric keypad on the Control Panel.

3 Press the memory store key to save the password in memory. The password is set.

Connecting the Machine’s Mains SupplyWhen connecting the Labeljet 210 Label Applicator to the mains electrical supply, ensure the following:

Labeljet 210


• Connect a correct electrical supply, either 110 to 120 VAC or 220 to 240 VAC at 50 to 60 Hz. The supply should, if possible, be dedicated to the Labeljet 210 Label Applicator.

• Do not tee off a supply from a line which supplies to heavy machinery, as voltage fluctuations may adversely affect the performance of the Labeljet 210 Label Applicator.

• Do not use extension leads, as the connections may be unreliable and the supply may be disconnected by mistake.

To connect the Labeljet 210 Label Applicator to the mains supply, proceed as follows:

1 Ensure that the mains voltage selector switch (Figure 2-3 on page 2-5) is set correctly for the national mains supply voltage.

2 Ensure that the mains input fuses in the fuseholder (Figure 2-3 on page 2-5) are of the correct rating for the mains supply voltage, that is 230V - 3.15A and 115V - 5A.

3 Connect one end of the mains supply cable to the Mains Inlet Connector on the Connector Panel (Figure 2-3 on page 2-5).

4 Connect the other end to a suitable mains outlet.

Note: If no outlets are available, remove the plug from the cable, and hardwire the cable into a junction box.

Setting up the Engineering MenuThe engineering menu, described in the following paragraphs, is used to set up certain operating parameters for the machine.

Note: The engineering menu parameters require entry of the Level 2 password, before accessing the menu options. The following paragraphs assume that Level 2 password access is enabled.

Note: To locate keys on the Control Panel, see Figure 2-9 on page 2-14

• Use the engineering menu to match the machine to the devices that are connected to it, such as Product Detectors and Label Sensors. This also helps to put the machine into specific modes of operation.

• Press the and keys on the Control Panel simultaneously, to

access the engineering menu. The first item on the menu appears on the Control Panel Liquid Crystal Display (LCD).

- Use the and keys to select other menu items.

Labeljet 210


- Use '0', '1' and '2' to select options; enter values from the numeric keypad.

• Table 2-1 on page 2-16 lists the setup instructions for the following functions in the engineering menu:

- Applicator type

- Retract time

- Detector 2 to applicator distance

- Detector 1 to detector 2 distance

- Product Detector type

- Encoder resolution

- Encoder sample time

- Encoder type

- Reverse cycle

- Product Detector 2 polarity

- Product Detector 1 polarity

- Label Sensor polarity

- Direction

Table 2-1: Engineering SetUp

S.No Menu Item

Display Options Remarks

1 Applica-tor type

APPLICA-TOR TOUCH/BLOW/TAMP

0: Touch (Default)

For standard wipe-on configuration

1: Blow When optional Blow unit is fitted

2: Tamp When optional Tamp unit is fitted

Labeljet 210


2 Retract time

RETRACTX X X X

1-9999 millisec-onds (default value 500) 1 unit on display = 10 millisec-onds. Enter required value using Numeric Keypad

If the Labeljet 210 Label Applicator is fitted with an optional Tamp unit, set this time to allow the tamp to retract before the next label is dis-pensed.(The “Retract time” is a period within the total Tamp/Blow time that is set from the operator menu [Figure 2-10 on page 2-20]).

3 Detector 2 to applica-tor dis-tance

DET2-APPLICX X X X

1-9999 (Default value 0100) Enter required value using Numeric Key-pad

If two Product Detec-tors are in use, enter the distance (in mm) between the Product Detector 2 and the Label Applicator Peel Tip

4 Detector 1 to Detector 2 dis-tance

DET1 - DET2X X X X

1-9999 millime-ters (default value 0001) Enter required value using Numeric Key-pad

If two Product Detec-tors are in use, enter the distance in 0.1mm increments between Product Detector 1 and Product Detector 2

5 Product Detector type

PROD-UCT SIN-GLE/DUAL

0: Single (Default)

For normal operation (product speed is con-stant or speed is set from Shaft Encoder)

1: Dual If the speed is to be cal-culated using two Prod-uct Detectors

2: Encoder If the speed is to be controlled by an exter-nal, screened, Shaft Encoder.

Table 2-1: Engineering SetUp (Continued)

S.No Menu Item


Labeljet 210


6 Encoder resolu-tion

ENCODERX X X X

10-5000 pulses per millimeter (Default 0001) Enter required value using Numeric Key-pad

Input the number of out-put pulses x 2 per mm from the Shaft Encoder for single phase type (if fitted)

Input the number of out-put pulses x 4 per mm from the Shaft Encoder for dual phase type (if fitted)

7 Encoder sampletime

ENCODER SLOW/FAST

0: Fast (Default) If the Shaft Encoder input frequency is below 3 kHz

1: Slow If the Shaft Encoder input frequency is above 3 kHz

8 Encoder type

ENCODER 1 PHASE/2 PHASE

0: 2 Phase (Default)

For the dual channel or quadrature Shaft Encoders

1: 1 Phase For single channel Shaft Encoders

9 Reverse cycle

REVERSE +VE/-VE

0: +ve (Default) If the optional Tamp unit is fitted, the cycle is: detect-tamp-dispense-code

1: -ve If the optional Tamp unit is fitted, the cycle is: detect-dispense-tamp- code

10 Product Detector 2 polarity

PROD-UCT 2+VE/-VE

0:+ve (Default) If a standard Product Detector is used to detect the leading edge of the product

1: -ve If the trailing edge of the product is to be detected or if a non standard detector is used


S.No Menu Item


Labeljet 210


11 Product Detector1 polarity

PROD-UCT 1+VE/-VE

0: +ve (Default) If a standard Product Detector is used to detect the leading edge of the product

1: -ve If the trailing edge of the product is to be detected or if a non standard detector is used

12 Label sensor polarity

LABEL+VE/-VE

0: +ve (Default) If a standard Label Sen-sor is fitted and dark-on-light labels are used

1: -ve If a non-standard Label Sensor is fitted or if it should detect light marks on a dark back-ground

13 Direction DIREC-TION+VE/-VE

0: +ve (Default) If the unit dispenses labels from right to left as viewed from the front of the machine

1: -ve If the unit dispenses labels from left to right


S.No Menu Item


Blow/Tamp time period

Retract time

Extended

Tamp position

Home

Figure 2-10. Chart2.1 Tamp Movement

Labeljet 210


Setting up the Operator Controls• To set up the operator controls, start up the machine and the

production line, as described in Chapter 4 of the Labeljet 210 Label Applicator Operator Manual.

• Make adjustments that are necessary, as described in Chapter 4 of the Labeljet 210 Label Applicator Operator Manual, until the machine operates correctly.

Adjusting the Web Tension and Product DetectorOnce all the parameters for the machine are set, and the machine starts running, you may encounter problems with the Web Drive mechanism. The likely problems and the adjustment procedures are described below.

Web Tension If you face problems with the label web breaking, or slipping in the drive, it may be necessary to adjust the web tension. The two components that affect the web tension, are:

• Hold-down Spring

• Dancer Arm Tension

To adjust the Hold-down Spring, refer the topic “Adjusting the Hold-down Spring” on page 5-10.

Labeljet 210


The Dancer Arm Tension should be adjusted such that the Unwind Reel brake is applied with just enough force, to stop labels from unwinding after the dispense cycle is completed. If it is too loose, the labels will continue to unwind after the machine stops. If it is too tight, the brake will not be released sufficiently and the web may slip or break during the dispense cycle.

To adjust the Dancer Arm Tension refer “Adjusting the Dancer Arm Tension” on page 5-12.

Product DetectorAfter setting up the machine, if the Product Detector does not function (Product Detector not activated), it may need calibrating. Refer the manual supplied with the Detector.

Rev AA 3-1

3Machine Description


• description and operation of various components of web drive mechanism

• description of connectors on the connector panel

• information on the operation of the CPU

• construction and functional description of the control panel

The Labeljet 210 Label Applicator, shown in Figure 3-1, consists of a cast aluminium chassis and sub-assemblies such as Web Drive Mechanism, Electronics Module, and Control Panel that are mounted on the chassis.

1

3

2 1. Web Drive2. Electronics Module3. Control Panel

Figure 3-1. 210 Label Applicator

Labeljet 210

3-2 Web Drive Mechanism Rev AA

Web Drive MechanismThe Web Drive (Figure 3-2 on page 3-3) is a motor-driven mechanism, controlled by the CPU module. As the label web passes through the Web Drive, the labels are peeled from the web, and applied to the product. The blank web returns to the Rewind Reel.

Stepper MotorThe Stepper Motor (Figure 3-2 on page 3-3) is connected directly to the CPU PCB through a four-way cable. It drives the label web through the web drive at the same speed as that of the product conveyor. The speed of the motor is either set by the operator at the Control Panel, or is automatically synchronized to the input from a Shaft Encoder (if fitted).

Labeljet 210

Rev AA Web Drive Mechanism 3-3

Web Drive

As a product approaches the machine (Figure 3-2) it passes in front of a Product Detector mounted next to a product conveyor. The Product Detector produces an output pulse, which is fed to the CPU through the Connector Panel. Following this, the CPU starts a label application cycle, as described below:

1

3

4

4

5

6

2

11

7

12

9

10

8

1. Unwind Reel 5. Nip Roller 9. Friction Block2. Dancer Roller 6. Drive Roller 10. Label Sensor3. Rewind Reel 7. Peel Tip 11. Stepper Motor4. Product 8. Label 12. Label Web

Figure 3-2. Web Drive

Labeljet 210


1 An adjustable delay called the “Product Delay” built into the sequence, allows the product to travel to the correct position beneath the Peel Tip, before a label is dispensed (Figure 3-2 on page 3-3).

2 When the “Product Delay” timing ends, the CPU transmits a drive signal to the Stepper Motor, which turns the Drive Roller.

3 The label web is pinched between the Drive Roller and the Nip Roller and is pulled through the Web Drive, over the Peel Tip.

4 As the label web passes over the Peel Tip, the self adhesive label separates from the web and is applied to the product. This is aided by the Wipe-down Brush ahead of the Peel Tip.

5 As the web is pulled through the machine, the tension on the Dancer Roller pulls it forwards. This releases a brake on the Unwind Reel, allowing more label web to be unwound. The blank label web is wound on to the Rewind Reel, which is driven by a belt between it and the Drive Roller.

The label application cycle is now complete and the machine waits for the next product to be detected.

Caution

INCORRECT LABEL APPLICATION. When changing from long labels to short labels, it is possible that the label stop value is larger than the new label length. If this happens, multiple labels will be dispensed on each application.

Note: The label web passes through a Label Sensor (Figure 3-2 on page 3-3) which detects the presence or absence of label material on the web. The sensor determines whether a label has been fully dispensed or not, by detecting the next inter-label gap.

The Stepper Motor continues to turn the Drive Roller until the label web stops in a position where the next label to be dispensed has its leading edge aligned with the peel tip. The motor pauses for a while before resuming the cycle.

The period for which the Stepper Motor continues to run is determined by the label stop delay, which is set by the operator to obtain the correct label alignment.

Labeljet 210

Rev AA Web Drive Mechanism 3-5

The figures below show the timing diagrams for a label dispense cycle:

Product detect

Product delay

Label feed

New label detect

Label stop

Print dwell

Wait for product to reachpeel tip.

Drive web and apply label.Web and conveyor synch.

Detect new label on web.

Align new label with edgeof peel tip.

'Dead time' to nextapplication cycle.

Figure 3-3. Dispense Cycle Timing (Conventional Application)

Product detect

Product delay

Label feed

New label detect

Label stop peeltip distance

Print dwell

Count encoder pulses totrack product distance frompeel tip.

Drive web position, gearedto conveyor position, to applylabel




Figure 3-4. Dispense Cycle Timing (Shaft Encoder Mode)

Labeljet 210


Product detect

Product delay

Label feed

Air assist delay

Blast duration

Label detect


Print dwell

Count encoder pulses totrack product distance fromapplication location.

Apply label, blast timeset byOCP.

Drive web at speed set byOCP.

Delay start of air assist for ?mm set by OCP. Start airassist. Stop on end of feed.




Figure 3-5. Dispense Cycle Timing (Blow Application)

Product detect

Product delay

Label feed

Air assist delay

Tamp cycle

Tamp retract

Label detect


Print dwell

Count encoder pulses totrack product distance fromapplication location.

Extend tamp. Apply label.Dwell. Retract tamp. Cycletime set by OCP.

Drive web at speed set byOCP.

Retract time. Engineeringset-up adjustment on OCP.

Delay start of air assist for ?mm set by OCP. Start airassist. Stop on end of feed.




Figure 3-6. Dispense Cycle Timing (Tamp Application)

Labeljet 210

Rev AA Electronics Module 3-7

Unwind and Rewind ReelThe process of label application is supported by label movement that occurs on both the Unwind and Rewind Reels, as described below:

1 The label stock is held on a roll, and is loaded onto the Unwind Reel (Figure 3-2 on page 3-3). When the Stepper Motor operates, the tension on the label web pulls the Dancer Roller. The Dancer Roller moves forward, releasing a brake at the rear of the Unwind Reel and allowing more label web to be unwound.

2 The label web travels through the Web Drive, and the blank web from which the label has been dispensed, is taken up by the Rewind Reel (Figure 3-2 on page 3-3). The Rewind Reel is driven by the Drive Roller, through a small vee belt.

3 When the Stepper Motor stops, the Dancer Roller returns to its previous position, thus applying the brake to the Unwind Reel. This stops the label web from running on and keeps it taut in the drive.

Friction BlockThe Friction Block (Figure 3-2 on page 3-3) is fitted with a Hold-down Spring plate, which holds the label web firmly against the Peel Plate. The pressure of the Hold-down Spring is adjustable and is set for correct peeling of the labels from the web.

Electronics ModuleThe Electronics Module (Figure 3-7 on page 3-8) is located in a case called Electronics Housing, at the rear of the chassis. The Electronics Module consists of a Connector Panel, a CPU PCB and a Toroidal Transformer that is mounted on top of the Electronics Module.

Labeljet 210

3-8 Electronics Module Rev AA

Connector Panel The Connector Panel is mounted on the rear of the Electronics Housing and controls the mains supply (through On/Off switch) and voltage selection. It supports the connections to the Control Panel, Label Sensor, Product Detector, Shaft Encoder, Alarm output and the Traffic Light status output.

The mains components (Figure 3-8 on page 3-9) of the Connector Panel are as follows:

• The Mains Inlet connector that connects the mains input to the machine

• The Mains Input Fuse holder that houses the two mains input fuses

• The Mains on/off switch that controls the mains input to the power supply

• The Mains Voltage Selector that is used to set the machine for a mains input voltage of 115 or 230 volts AC

3

4

1

2

1. Electronics Housing2. CPU PCB3. Connector Panel4. Toroidal Transformer

Figure 3-7. Electronics Module

Labeljet 210


The standard and optional system connectors (Figure 3-8) on the Connector Panel are as follows:

Control Panel Connector

The Control Panel Connector is labelled with the icon shown above. It is an eight pin DIN connector used to connect the Control Panel to the CPU. Information on the pins of the connector is given in Table 3-1.

1

2

3456

7

8

9

1 0 1 1 1 2

1. Product Detector Connector 7. Mains Fuse Holder2. Label Sensor Connector 8. Mains On/Off Switch3. Shaft Encoder Connector 9. Mains Voltage Selector4. Tamp/Blow Module Connector (optional)5. HFC Connector (optional) 10. Control Panel Connector6. Mains Inlet Connector 11. Lamp Stack Connector

12. General Alarm Connector


Labeljet 210


Lamp Stack Connector

The Lamp Stack Connector is labelled with the icon shown above. It is a six pin DIN connector that is used to connect an optional Lamp Stack, to indicate the machine’s status. Information on the pins is provided in Table 3-2.

Table 3-1: Control Panel Pin Outs

S.No Pin Task Cable Color

1 1 TXD Green

2 2 RXD Yellow

3 3 Screen -

4 4 RXD Blue

5 5 Not connected -

6 6 TXD Red

7 7 +12V Red

8 8 0V Blue

Table 3-2: Lamp Stack Connector Pin Outs


1 1 Lamp 1 Green

2 2 Lamp 2 Yellow

3 3 Lamp 3 Red

4 4 40V Blue

5 5 Not connected -

6 6 Not connected -

Labeljet 210


General Alarm Connector

Table 3-3: General Alarm Connector Pin Outs


1 1 Alarm Red

2 2 0V Blue

3 3 Not connected -

4 4 Not connected -

5 5 Not connected -

6 6 Not connected -

7 7 Not connected -

The General Alarm Connector is labelled with the icon shown above. It is a seven pin DIN connector that is used to connect the General Alarm signal from the CPU to a warning device. Information on the pins is provided in Table 3-3.

Product Detector Connector

The Product Detector Connector is labelled with the icon shown above. It is a four pin circular connector that connects the Product Detector to the CPU. An additional Product Detector can be connected to this connector. Information on the pins is provided in Table 3-4.

Table 3-4: Product Detector Connector Pin Outs


1 A Product detector 2 Green

2 B Product detector 1 Yellow

3 C 0V Blue

4 D +12V Red

Labeljet 210


Label Sensor Connector

The Label Sensor Connector is labelled with the icon as shown above. It is a six pin circular connector that connects the Label Sensor in the web path to the CPU. Information on the pins is provided in Table 3-5.

Shaft Encoder Connector

The Shaft Encoder Connector is labelled with the icon as shown above. It is a four pin DIN connector that transmits signals received from a Shaft Encoder (if fitted) to the CPU. Information on the pins is provided in Table 3-6.

Table 3-5: Label Sensor Connector Pin Outs


1 A 0V Blue

2 B 0V Green

3 C Label sensor 1 Yellow

4 D +12V (for LED) Red

5 E Not connected -

6 F Not connected -

Table 3-6: Shaft Encoder Connector Pin Outs


1 1 +12V Red

2 2 Encoder B1 Green

3 3 Encoder A1 Yellow

4 4 0V Blue

Labeljet 210


Tamp or Blow Module Connector

A blank connector is labelled with the icon as shown above. This can be used to connect an optional Tamp or Blow module with an Air Assist, to the CPU.

Hot Foil Coder Connector

A blank connector is labelled with the icon as shown above. This can be used to connect an optional Hot Foil Coder (HFC) to the CPU.

Labeljet 210

Rev AA Foldout 1: CPU Circuit Diagram (Sheet 1 of 5) 3-15

Foldout 1: CPU Circuit Diagram (Sheet 1 of 5)

Labeljet 210

3-16 Foldout 1: CPU Circuit Diagram (Sheet 1 of 5) Rev AA

Figure 3-9. CPU Circuit Diagram (Sheet 1 of 5)

Labeljet 210



Labeljet 210



Labeljet 210



Labeljet 210



Labeljet 210



Labeljet 210


Figure 3-12. CPU Circuit Diagram (sheet 4 of 5)

Labeljet 210



Labeljet 210



Labeljet 210

Rev AA 3-25

CPU PCBThe CPU PCB and the OCP together control and monitor the operation of the machine. The power supply components on the CPU PCB produce DC voltages for the CPU PCB, the Control Panel, and the devices connected to the Connector Panel such as the Product Detector, the Label Sensor, and the Shaft Encoder.

The following paragraphs describe the various interfaces and components of the CPU PCB.

InterfacesThe CPU PCB interfaces with various components of the machine, such as the Toroidal Transformer (as described in the topic “Mains Input and DC Power Supplies” on page 3-38), the Stepper Motor, and the Connector Panel (Figure 3-14 on page 3-28). The description of each interface with details is given below:

• Stepper Motor: The interfaces J29 and J30 on the CPU are connected to the Stepper Motor. The pin to pin connection information is given in Table 3-7.

• Label Sensor: The interface J26 on the CPU is connected to the Label Sensor plug on the Connector Panel. The Label Sensor detects the gap between labels on the web such that, the CPU can correctly position the edge of the next label to be dispensed, at the Peel Tip.

This interface carries +12V DC for the Label Sensor Light Emitting Diode (LED), and the output pulses from the Label Sensor to the CPU. The pin to pin connection information is given in Table 3-8 on page 3-26.

Table 3-7: Stepper Motor Interface

S.No CPU Connector Pin Signal Stepper Motor Cable

J29

1 1 MP1-2 Red

2 2 GND Not connected

3 3 MP1-1 Yellow

J30

1 1 MP2-2 Orange

2 2 GND Not connected

3 3 MP2-1 Blue

Labeljet 210

3-26 Rev AA

• Shaft Encoder: The interface J28 on the CPU is connected to the Shaft Encoder socket on the Connector Panel. This interface carries +12V DC from the CPU to the Shaft Encoder, and one or two inputs from the Shaft Encoder to the CPU. The pin to pin connection information is given in Table 3-9.

• Product Detector: The interface J27 on the CPU is connected to the Product Detector plug on the Connector Panel. The Product Detector produces a pulse each time a product passes under it. This pulse is fed to the CPU and is used to initiate a label dispense cycle.

This interface carries +12V DC from the CPU to the Product Detector and the output pulses produced by the Product Detector to the CPU.

Table 3-8: Label Sensor Interface

S.No CPU Connector Pin

Signal Cable Core Color

Connector Panel Plug

J26

1 1 LAB_SENS_LED(+12V DC)

Red Pin D

2 2 0VD Green Pin B

3 3 LAB_SENS_1

Yellow Pin C

4 4 0V Blue Pin A

5 5 GND - Not connected

Table 3-9: Shaft Encoder Interface



Connector Panel Socket

J28

1 1 VCCA (+12V DC)

Red Pin 1

2 2 ENC_B_1 Yellow Pin 2

3 3 ENC_A_1 Green Pin 3

4 4 0VD Blue Pin 4


Labeljet 210

Rev AA 3-27

The pin to pin connection information is given in Table 3-10 on page 3-27.

Table 3-10: Product Detector Interface



Connector Panel Plug

J27

1 1 VCCA (+12V DC)

Red Pin D

2 2 PROD_SENS_2

Green Pin A

3 3 PROD_SENS_1

Yellow Pin B

4 4 0VD Blue Pin C


Labeljet 210

3-28 Rev AA

• Alarm: The interface J20 on the CPU is connected to the Alarm socket on the Connector Panel. An alarm signal is generated by the CPU in response to certain hardware faults. This signal can be used to activate a warning device. The pin to pin connection information is given in Table 3-11.

Table 3-11: Alarm Interface

S.No CPU Connector Pin Signal Cable Core Color


J20

1 1 Alarm Red Pin 1

M

CPUPCB

CONNECTORPANEL

STEPPERMOTOR

J29 J30 J33OCP

J28ENCODER

J26LABEL SNSR

J27PRODUCT SNSR

J20ALARM

J22LAMP 1

J23LAMP 2

J24LAMP 3

J18TAMP/BLOW

J19AIR ASSIST

Control panelsocket

Shaft encodersocket

Label sensorsocket

Product sensorsocket

Alarmsocket

Traffic lightsocket

Tamp/blowsocket (optional)

Hot foil coder(optional)

J21PRINT

Figure 3-14. CPU Interfaces

Labeljet 210

Rev AA 3-29

• Traffic Lights: The interfaces J22, J23 and J24 on the CPU are connected to the Traffic Light socket on the Connector Panel. The Traffic Light beacon (if connected) indicates the operational status of the Labeljet 210 Label Applicator. This interface carries the lamp signals from the CPU to Traffic Light beacon. The pin to pin connection information is given in Table 3-12.

• Tamp/Blow: The interface J18 on the CPU is connected to the Tamp/Blow socket on the Connector Panel. The machine can be fitted with an optional Tamp or Blow module. This interface carries the activation signal for the fitted applicator. The pin to pin connection information is given in Table 3-13.

2 2 0VP Blue Pin 2

3 3 GND - Pin 3 to 7 not con-nected

Table 3-12: Traffic Light Interface



J20

1 1 Lamp 1 Green Pin 1

2 2 0VP Blue Pin 4

3 3 GND - not connected

J23

4 1 Lamp 2 Yellow Pin 2

5 2 0VP - not connected


J24

7 1 Lamp 3 Red Pin 3

8 2 0VP - not connected


Table 3-11: Alarm Interface (Continued)



Labeljet 210

3-30 Rev AA

• Air Assist: The interface J19 on the CPU is connected to the Tamp/Blow socket on the Connector Panel to help with the positive placement of labels on to the Tamp or Blow module. This interface carries the activation signal for the Air Assist device. The pin to pin connection information is given in Table 3-13.

• Print: The interface J21 on the CPU carries the drive signal for an optional Hot Foil Coder. J21 connections are made directly to the CPU module through an optional connector on the Connector Panel. The pin to pin connection information is given in Table 3-14 on page 3-30.

• Control Panel: The interface J33 is connected to the Control Panel socket on the Connector Panel. This interface provides a +12V DC supply to the Control Panel, and a serial communications interface. The pin to pin connection information is given in Table 3-15.

Table 3-13: Tamp/Blow Interface



J18

1 1 Tamp/Blow

Red Not yet allocated

2 2 0VP Blue Not yet allocated

3 3 GND - Not yet allocated

J19

4 1 Air Assist Red Not yet allocated

5 2 0VP Blue Not yet allocated

6 3 GND - Not yet allocated

Table 3-14: Print Interface

S.No CPU Connector Pin Signal

J21

1 1 Print (24VDC)

2 2 0VP

3 3 GND

Labeljet 210

Rev AA 3-31

Note: Figure 3-9 on page 3-16 to Figure 3-13 on page 3-24, show the circuit diagrams of various components on the CPU PCB.

Table 3-15: Control Panel Interface




J33

1 1 RXD (Receive data)

Blue 4

2 2 RXD Yellow 2

3 3 TXD (Trans-mit data)

Red 6

4 4 TXD Green 1

5 5 Screen - 3

6 6 Not connected - -


8 8 0V Blue 8


10 10 VCC02 (+12V) Red 7

Labeljet 210

3-32 Rev AA

Functional Description The functional description of the CPU PCB is given below:

• The Control Processor is the PM3003 that uses a Hitachi H8/300H Micro Controller. The PM3003 has the features listed in Table 3-16.

Table 3-16: Control Processor Functions

S.No PM3003 Facility Label Applicator Function

1 128 Kb EPROM(Erasable Program-mable Read Only Memory)

Operating System and Pro-gram Memory

2 512 bytes CPU RAM

Program variables

3 2 Kb non-volatile battery backed RAM

Setup parameters store

4 8 channel, 10 bit analogue A/D

Sensors

5 48 generic digital inputs and outputs

General I/O, Control Panel serial bus

6 2 USART (Univer-sal Synchronous/Asynchronous Receiver/Transmit-ter) serial data communications channels

Debug and diagnostic port

7 16-bit Integrated Timer Pulse Unit (ITU)

Timers and Encoder interface

8 8 channel DMA Velocity profile control algo-rithm

9 Programmable Timing Pattern Controller (TPC)

Transport Drive control

• The PM3003 is reset by the following:

- Power up

- Reset pushbutton

- Watchdog timer

• The PM3003 memory map is listed in Table 3-17 on page 3-33

Labeljet 210

Rev AA 3-33

The CPU PCB components and their features are listed in Table 3-18 below.

Table 3-17: Control Processor Memory Map

S.No Address (hex) Resource Size (bytes)

1 00000 to 0F7FF Operating system, devices drivers, vector table Pro-grammable Read Only Memory (PROM)

62K

2 0F800 to 0FFFF External battery backed Static Ran-dom Access Mem-ory (SRAM)

2K

3 10000 to 1FCFF Operating system and devices drives PROM

63.5K

4 1FE00 to 1FEFF High speed inter-processor serial communications bus

256K

5 FFD10 to FFF00 Internal SRAM 512K

Table 3-18: CPU Components

S. No Component Features

1 Micro Controller • 12 bytes static RAM• Address decoding and chip select gener-

ation for external devices• Interrupt controller• Ten bit, eight channel multiplexed ana-

logue to digital conversion with integral sample and hold

• Timer counters for waveform generation, five pulse width modulators and encoder interface

• Two serial data communications USARTs• Watchdog timer

2 Clock Crystal Parallel resonant, the Crystal Frequency (fc) is 16 MHz

Labeljet 210

3-34 Rev AA

3 PSD4 x 3A1 This is a PROM device that provides:• 28 Kb EPROM• 2 Kb SRAM• Power Management Unit (PMU) to switch

the battery to SRAM in the event of power failure

4 Analog to Digital (A/D) Converter

• Ten bit resolution• Conversion time of 8.4 micro sec with 16

MHz clock at a bandwidth of 30 KHz• Eight input channels• Sample and hold• Input range to the A/D multiplexer of 0V to

5V• A/D converter reference (AV ref) is 5 VDC

at 0.2 mA• A/D converter supply is 5 VDC at 2 mA

5 Timer Pulse Unit (ITU)

• PWMs (Pulse Width Modulations) can be synchronized for Stepper Motor control

• Two phase encoder interface (ITU chan-nel 2) which produces both positive going and negative going edges counted up to 6.4 MHz with a 16 MHz clock

6 Serial communica-tion (SCI)

• Two full duplex USARTs• Each USART with own baud rate genera-

tor, note that Tx = Rx baud rate• Multidrop communications bins; ninth bit

operation to generate receive interrupt if data is identified

• Break detection• DMA (Direct Memory Access) operation

7 SCI channel 0 This is equipped with RS232D receivers and drivers

8 SCI channel 1 • Not allocated • Equipped with either RS232D receivers

and drivers or RS422/485 receivers and drivers. For RS422 communications, driver and receiver selection is connected to the Operator Control Panel through a jumper. The RS422/485 driver is capable of multidrop operation and is enabled by a logic 1 on port P9.5

9 SCI channel 2 Serial communications link to the Operator Control Panel

Table 3-18: CPU Components (Continued)


Labeljet 210

Rev AA 3-35

Specific CPU PCB Functions for the Stepper Motor The specific CPU PCB functions for the Stepper Motor are given below:

• The Control Processor PM3003, generates all the Stepper Motor signals required for half step control of the bipolar two phase Stepper Motor. A special purpose Drive Amplifier powers the Stepper Motor.

• The Drive Amplifier (Figure 3-11 on page 3-20) provides bipolar current control using fixed frequency PWM, for a two phase Stepper Motor.

The Drive Amplifier design is optimized for half step operation. In normal operation, the phase currents are ± 4, ± 4 A at the full step positions, and 0, ± 5.6 A at the half step positions. A boost input increases the current levels by approximately 20%, and a cut input decreases the levels to approximately 50% of the normal.

• Each phase is controlled using two inputs-DIRECTION and SHUT DOWN. These inputs, together with the boost and cut inputs are galvanically isolated from the processor to provide optimum noise immunity. Six opto-couplers, driven from a darlington buffer, provide the isolation.

• Control is provided by a logic IC. Timing is provided by a timer IC which provides a PWM period of approximately 50 micro sec.

• The required current level for each phase is determined by voltages set by a potential divider (starting from 5V), the output of which is buffered by an op-amp.

The boost and cut signals are provided by opto-coupled transistors which introduce additional resistors into the divider circuit. The current control voltage is further buffered, and the output again is divided down to a level compatible with the current sense comparator.

10 Watchdog Timer • Eight bit counter• Eight bit counter clock sources are from 8

MHz to 3.9 KHz with a 16 MHz clock• Watchdog timer overflow generates a

reset signal to reset the CPU• The backup battery is connected to Vsby.

The PMU automatically switches the SRAM supply from Vcc to Vsby when Vcc fails. SRAM current consumption is typi-cally 0.5 micro A or 1 micro A if Vsby> 2.7V.

Table 3-18: CPU Components (Continued)


Labeljet 210

3-36 Sensors and Actuators Rev AA

• The phase current is sensed using a low value resistor in series with the amplifier output. The current sense comparators compare the voltage across the sense resistor to the current demand voltage.

• Two identical N-channel power MOSFET bridges control the flow of current in each winding. These are driven by a pair of half bridge driver ICs.

Toroidal TransformerA 250VA nominal rated Toroidal Transformer supplies the AC voltages required by the power components of the Labeljet 210 CPU PCB (Figure 3-13 on page 3-24). The transformer winding details are listed in Table 3-19.

Sensors and Actuators The specifications of various sensors on the CPU PCB are given below:

Label Sensor• The Label Sensor conditioning circuit (Figure 3-12 on page 3-22),

contains two optical devices, one Infra Red (IR) emitting diode and one Phototransistor.

Table 3-19: Toroidal Transformer Windings

S.No Winding Voltage Design Load Remarks

1 Primary 1 0-100-115V, 50/60Hz

- Input voltage

2 Primary 2 0-100-115V, 50/60Hz

- Input voltage

3 Secondary 1 0-51.0VAC 3.6 Amp Output voltage @ load current




Labeljet 210

Rev AA Sensors and Actuators 3-37

• The Label Sensor input circuit uses an operational amplifier configured as a current to voltage convertor. The conversion gain is adjustable to compensate for a wide range of sensor Current Transfer Ratio (CTR).

• The output of the circuit is digitized by the micro controller on A/D chip to a resolution of 10 bits (1:1024).

Product Detector • Two identical Product Detector conditioning circuits are provided

(Figure 3-12 on page 3-22) for Product Detector 1 and Product Detector 2.

• These circuits use an inverting low gain voltage operational amplifier with diode feedback limiting the output voltage swing. The operational amplifier is biased such that the Product Detectors with either current sink (npn) or current source (pnp) transistors can be used. The output of the circuit is digitized by the micro controller on chip A/D to a resolution of 10 bits (1:1024).

Label Low MicroswitchThe label low microswitch conditioning circuit (Figure 3-12 on page 3-22) uses a voltage follower operational amplifier, to buffer the microswitch input. The output of the circuit is digitized by the micro controller on A/D chip, to a resolution of 10 bits (1:1024).

EncoderThe two phase (quadrature) encoder interface conditioning circuit (Figure 3-12 on page 3-22) uses a dual comparator, one for each encoder phase, with positive feedback to provide hysteresis. The output of the circuit is processed by an on chip counter pair in the micro controller capable of pulse edge detection and counting

The Labeljet 210 Label Applicator drives the following actuators:

• Tamp or Air Blast or Pneumatic Flap

• Air Assist

• Vacuum Box Fan

• Print Request

• General Alarm

• Lamp Stack - Green

• Lamp Stack - Orange

Labeljet 210

3-38 Mains Input and DC Power Supplies Rev AA

• Lamp Stack - Red

The actuator and indicator interfaces are given in Table 3-20

The actuators and indicators are driven by short circuit protected high side drivers (one end of the load is connected to chassis/return). The driver inputs are connected to an on-chip micro controller I/O port.

Mains Input and DC Power SuppliesGiven below are the mains input and DC power supply specifications for the Labeljet 210 Label Applicator:

Table 3-20: Actuator and Indicator Interfaces

S.No Actuator Power (W) Supply (V) Current (A) Remarks

1 Tamp/air Blast/pneu-matic Flap

1.5 24 0.1 Solenoid

2 Vacuum Box Fan

4.8 24 0.2 DC motor

3 Air Assist 1.5 24 0.1 Solenoid

4 Print Request

1.5 24 0.1 Solenoid

5 General Alarm

1.5 24 0.1 DC buzzer

6 Lamp Stack - Green

9 24 0.35

7 Lamp Stack - Orange

9 24 0.35 Only one active at a time

8 Lamp Stack - Red

9 24 0.35

Labeljet 210

Rev AA Mains Input and DC Power Supplies 3-39

• The Applicator can be set to accept a mains input of either 115V AC or 230V AC.

• When the Mains Selector Switch is set to 115V, the primary windings of the Toroidal Transformer are connected in parallel. When it is set to 230V, the primary windings are connected in series.

• The output from the secondary windings is same for either of the mains input voltage. The circuit diagrams of mains input and Toroidal Transformer, and a block diagram of the DC power supplies on the CPU PCB is given in Figure 3-15.

Labeljet 210

3-40 Mains Input and DC Power Supplies Rev AA

• The outputs from the secondary windings of the transformer are connected to interfaces J31 and J32 on the CPU PCB.

• Bridge rectifiers BD1 to BD4, and the associated voltage regulators produce the DC power supplies as mentioned in Table 3-21.

MAINS INLETMODULE

N

L

E

MAINS SELECTORSWITCH

BLUE BLACK

RED

RED

ORANGEGREENBROWN

115V

230V

TOROIDAL TRANSFORMER

BLACK

P1

P2

RED

GREY

BLUE

ORANGE

RED

BROWN

WHITE

YELLOW

GREEN

51V

0V

15V

0V

21V

0V

15V

0V

~

~

~

~

ORANGE

GREEN

J324

32

1

4

32

1

J31

RECTIFIER/REGULATORCIRCUITS

+70V DC

+12V DC

+5V DC

+24V DC

+12V DC

+5V DC

PART OF CPU PCB

Figure 3-15. Mains Input and DC Power Supplies

Labeljet 210

Rev AA Control Panel 3-41

• Circuit diagram of the DC power supplies is shown in Figure 3-13 on page 3-24.

Control PanelThe Control Panel, shown in Figure 3-16, is mounted in a cast aluminium housing. It is assembled to the Labeljet 210 Label Applicator by means of a 'U' shaped mounting tube. One end of the mounting tube fits into a clamp at the rear of the Control Panel housing, and another end into a clamp on the Labeljet 210 Label Applicator main chassis. The mounting tube allows the operator to access the Control Panel easily by placing it in the best possible operating position.

The electrical connection between the Control Panel and the Labeljet 210 Label Applicator Electronics Module consists of a six way screened cable.

Table 3-21: DC Power Supplies

Voltage Power Supply Type

0V unregulated

12V regulated (VCC A2)

5V regulated (VCC 02)

24V regulated (VCC P)

12V regulated (VCC A)

5V regulated

1

2

Figure 3-16. Control Panel

1. Control Panel2. Housing

Labeljet 210

3-42 Control Panel Rev AA

One end of the six way screened cable is terminated with a 10 way socket, which connects to plug J1 on the Control Panel PCB (Figure 3-18 on page 3-44). The other end is terminated with an 8 way DIN plug which connects to the Control Panel socket on the Connector Panel.

The Control Panel PCB is mounted behind a keypad plate which has cutouts to accommodate the keypad switches, indicator LEDs, and the LCD on the PCB. A self-adhesive keypad overlay is fixed on the front side of the keypad plate (Figure 3-17 on page 3-42).

The Control Panel contains an LCD, a keypad and various status indicators. It performs the following functions:

• Enables the operator to monitor the status of the machine

• Enables the operator to recall operating parameters from memory

• Provides facilities for setting up the operating parameters of the machine

• Gives access to the engineering setup menu

1

2

3

4

Figure 3-17. Control Panel Components

1. Cable2. Control Panel PCB3. Keypad Plate4. Keypad Overlay

Labeljet 210

Rev AA Foldout 6: Control Panel PCB Circuit Diagram 3-43

Foldout 6: Control Panel PCB Circuit Diagram

Labeljet 210

3-44 Foldout 6: Control Panel PCB Circuit Diagram Rev AA

Figure 3-18. Control Panel PCB Circuit Diagram

Labeljet 210

Rev AA 3-45

Functional Description of the Control PanelThe Control Panel along with the CPU PCB controls and monitors the Labeljet 210 Label Applicator.

• The Microprocessor IC1, on the Control Panel PCB performs the following functions (Figure 3-18 on page 3-44):

- Acts as an interface between the Electronics Module and the Control Panel, transmitting and receiving data through the transceiver IC3

- Scans the keypad switches - SW1 to SW21

- Drives the LED indicators - D1 to D12

- Drives the LCD

• IC4 on the Control Panel PCB is a 5V, 1A regulator, with an input voltage of 12 volts from the Electronics Module through J1

Interface between the Control Panel and Electronics ModuleTable 3-22, gives the pin to pin connection information of the cable that connects J1 on the Control Panel PCB to the Control Panel DIN socket on the Connector Panel.

Table 3-22: Control Panel to Electronics Module Interface

S.No 10 Way Connector (Control Panel End)

Signal DIN Plug (Electronics Module End)

1 Pin No. 1 RXI (Receive data)

Pin No.6 (Blue)

2 RXI 1 (Brown)

3 TXD (Trans-mit data)

4 (Yellow)

4 TXD 2 (White)

5 Screen 3

6 Not con-nected

-

7 Not con-nected

-

8 0V 8 (Black)

Labeljet 210

3-46 Rev AA

9 Not con-nected

-

10 VCC02 (+12V)

7 (Red)

Table 3-22: Control Panel to Electronics Module Interface (Continued)

S.No 10 Way Connector (Control Panel End)

Signal DIN Plug (Electronics Module End)

Rev AA Cleaning the Web Path 4-1

4Cleaning and Maintenance

In this chapter, you will learn how to clean and visually inspect the Labeljet 210 Label Applicator.

Warning

LETHAL HAZARD. Disconnect the Labeljet 210 Label Applicator from the mains supply before carrying out any maintenance tasks.

Warning

PERSONAL INJURY. Do not use compressed air for cleaning.

To retain optimum performance, the Labeljet 210 Label Applicator must be cleaned and inspected regularly. The following maintenance tasks must be performed:

• Cleaning the Web Path, each time a label roll is changed

• A daily visual inspection of connections and fittings

Cleaning the Web PathTo clean the web path, proceed as follows:

1 Remove the old label roll, as described below:

a. On the Unwind Reel (Figure 4-1 on page 4-2) rotate the Outer Flange, until the hub is released from the shaft. Pull the flange from the shaft.

Labeljet 210

4-2 Inspecting the Connections and Fittings Rev AA

b. Remove the empty label roll from the Unwind Reel.

c. Pull the U shaped lock pin from the Rewind Reel.

d. Remove the roll of label web from the Rewind Reel.

2 Clean all paper dust from the web path using a soft brush and a damp lint-free cloth.

3 Clean any label adhesive from the web path components using a lint-free cloth, moistened with a suitable solvent.

4 Clean the bristles of the Wipe-down Brush.

Inspecting the Connections and FittingsVisually inspect the following:

• Electrical cables and connectors for signs of damage and wear

1

2

3

456

7

8

9

10

11

1. Unwind Shaft 7. Friction Block2. Lock Pin 8. Label Sensor3. Rewind Reel 9. Guide Rollers4. Cranked Nip Arm 10. Label Roll5. Drive Roller 11. Unwind Reel6. Nip Roller

Figure 4-1. Label Web Path

Labeljet 210

Rev AA Inspecting the Connections and Fittings 4-3

• Mechanical components for security of attachment and any signs of damage or wear

Note: Report any faults to the maintenance department for rectification.

Rev AA Machine Problems 5-1

5Troubleshooting

In this chapter, you will learn:

• how to diagnose a failure and resolve it

• how to remove and refit the applicator parts

Machine ProblemsThe table below contains a list of fault symptoms that may arise during machine setup, possible causes of these faults, and the remedial action that you can take.

Table 5-1: Machine Problems

S. No Symptom Possible Cause

Remedial Action

1 Machine is not opera-tional. Power indi-cator on the Control Panel is not lit.

Mains supply not switched on

Check if the mains supply is switched on at the Wall Socket or the Junction Box

Set the mains On/Off switch on the Connector Panel to On

Mains Supply Lead defec-tive or not connected

Check if the Mains Supply Lead is connected

Mains Input Fuses failed

Replace fuses. To know how to replace fuses, see the topic “Replacing the Mains Input Fuse” on page 5-38.

Labeljet 210

5-2 Machine Problems Rev AA

2 Machine cycles occur at random with no product flow

Product Detector vibrating

Mount the Product Detector on a vibration-free support

Product Detector not calibrated

Refer the manual supplied with the Product Detector

Loose wiring connection

Check if all the cables are secured properly

3 Power 'On' light not lit, but mains supply present and Mains Input Fuses ser-viceable

Mains Input Module faulty

Replace the Mains Input Module, as described in the topic “Replac-ing the Mains Input Module” on page 5-32

Control panel PCB faulty

Replace the Control Panel PCB, as described in the topic “Replacing the Control Panel PCB” on page 5-20

CPU PCB faulty

Replace the CPU PCB, as described in the topic “Replacing the CPU PCB” on page 5-22

Toroidal Transformer faulty

Replace the Toroidal Transformer, as described in the topic “Replac-ing the Toroidal Transformer” on page 5-24

Cable between the Control Panel and the CPU, faulty, or dis-connected

Check the cable and repair it if nec-essary, as described in the topic “Checking the Control Panel Cable” on page 5-17

4 Machine not responding to keypad

Cable between the Control Panel and the CPU faulty, or dis-connected

Check the cable and repair it if nec-essary, as described in the topic “Checking the Control Panel Cable” on page 5-17

Control Panel PCB faulty

Replace the Control Panel PCB, as described in the topic “Replacing the Control Panel PCB” on page 5-20

CPU PCB faulty


Table 5-1: Machine Problems

S. No Symptom Possible Cause

Remedial Action

Labeljet 210

Rev AA Label Problems 5-3

Label ProblemsThe tables below (Table 5-2 to Table 5-8) list all the fault symptoms that may arise during label application, possible causes of these faults, and remedial action that you can take.

Breaking

Table 5-2: Label Breaking Problems

S. No Symptom Possible Cause Remedial Action

1 Label web breaking

Incorrectly threaded labels

Thread the label web cor-rectly, as described in the topic “Threading the Label Web” on page 2-10

Damaged or defec-tive roll of labels

Load a new roll of label as described in the topic “Load-ing the Label Roll” on page 2-10

Guide Collars not correctly aligned with label path

Adjust the Guide Collars as described in the steps 1-6 of the topic “Aligning the Label Web” on page 2-12

Guide Collars too close to label web

Adjust the Guide Collars, as described in the steps 1-6 of the topic “Aligning the Label Web” on page 2-12

Adhesive build-up on the peel tip or label Hold-down spring

Clean the web path as described in the topic “Clean-ing the Web Path” on page 4-1

Label Hold-down spring too tight

Adjust the Hold-down spring, as described in the topic “Adjusting the Hold-down Spring” on page 5-10

2 Label web breaking or running on after dispense cycle

Dancer Arm ten-sion incorrect

Adjust the Dancer Arm tension, as described in the topic “Adjusting the Dancer Arm Tension” on page 5-12

Labeljet 210

5-4 Label Problems Rev AA

Slipping

Dispensing

Table 5-3: Label Slipping Problems

S.No Symptom Possible Cause Remedial Action

1 Label roll slipping on web drive

Label web path dirty

Clean the label path, as described in the topic “Cleaning the Web Path” on page 4-1

Drive Roller worn out

Replace the Drive Roller, as described in the topic “Replacing the Drive Roller” on page 5-31

Table 5-4: Label Dispensing Problems

S. No Symptom Possible Cause Remedial Action

1 Two or more labels consistently being dispensed for each product

Label stop adjust-ment too high

Adjust the label stop setting, as described in the topic “Label Stop” of Chapter 3 in the Opera-tor Manual

Label sensitivity not adjusted properly

Adjust the label sensi-tivity, as described in the topic “Label Sensi-tivity” (Chapter 3 in the Operator Manual)

2 Labels not being dispensed

Product Detector not calibrated

Refer the manual sup-plied with the Product Detector

Product Detector defective

Replace the Product Detector, as described in the topic “Replacing the Product Detector” on page 5-18

3 Label dispensed, but web does not stop, or stops errat-ically

Label Sensor defective

Replace the Label Sen-sor, as described in the topic “Replacing the Label Sensor” on page 5-19

Labeljet 210


Advancing

Table 5-5: Label Advancing Problems


1 Label advance does not occur

Fuse 2 on CPU PCB unserviceable

Replace Fuse 2, as described in the topic “Replacing Fuse 2 on CPU PCB” on page 5-34

Stepper Motor unserviceable

Replace the Stepper Motor, as described in the topic “Replacing the Stepper Motor” on page 5-29

CPU PCB unser-viceable


Toroidal Trans-former unservice-able

Replace the Toroidal Transformer, as described in the topic “Replacing the Toroidal Transformer” on page 5-24

2 Label advance occurs, but does not stop, or is erratic

Label sensitivity set up incorrectly

Set up the label sensitiv-ity, as described in the topic “Label Sensitivity” of Chapter 3 in the Oper-ator Manual



3 Label not applied on the product and “Product Detected” indicator function erratic

Use of NPN sen-sors

Change NPN sensors to PNP output type

Labeljet 210


The C19 and C20 capacitors on CPU PCB are fitted to the summing node of the product detector condition-ing amplifiers, and cause the signal feed to the CPU analog input to have large damped oscillations at each transition. This occasionally causes the CPU to establish an incor-rect reference volt-age and miss the next few signals before reestablish-ing the correct ref-erence voltage.

Remove C19 and C20 capacitors on the CPU PCB, as described in the topic “Replacing the Capacitors C19 and C20” on page 5-35

Table 5-5: Label Advancing Problems (Continued)


Labeljet 210


Positioning

Table 5-6: Label Positioning Problems


1 Label placement on the product is con-sistently poor

Label sensitivity set up incorrectly

Set up the label sensitiv-ity, as described in the topic “Label Sensitivity” (Chapter 3 in the Opera-tor Manual)

Incorrect product delay

Adjust the product delay as described in the topic “Product Delay” of Chap-ter 3 in the Operator Manual

The speed of the label feed is not the same as the pro-duction line speed

Adjust the machine speed as described in the topic “Machine Speed”of Chapter 3 in the Oper-ator Manual

Production line speed fluctuates

Call a maintenance engi-neer

Poor quality of label adhesive

Load a new roll of labels as described in the topic “Loading the Label Roll” on page 2-10

Product Detector not properly posi-tioned

Move the Product Detec-tor to a position where it operates correctly



Labeljet 210


Applying

Table 5-7: Label Application Problems

S.NO Symptom Possible Cause Remedial Action

1 Label application does not occur

Machine is set up incorrectly

Check the machine set-tings, as described in the topic “Controls” of Chap-ter 3 in the Operator Manual

Product Detector not connected or faulty

Check for the correct connection, as described in the topic “Inspecting the Connec-tor Panel” on page 5-11

Two products touching

Ensure that there is a gap between products

2 Label application rate cannot keep up with product rate

Product delay too long

Set the product delay to minimum. To know how to set the product delay, see Chapter 4 in the Operator Manual. Also, reposition the Product Detector for correct label placement.

The required rate of application is faster than the Labeljet 210 Label Applica-tor’s application cycle

Check if the Product Conveyor specification is within the operational limits of the Label Appli-cator

Rewinding

Table 5-8: Label Rewinding Problems


1 Rewind Reel not taking up label web

Drive Belt worn or broken

Replace the Drive Belt, as described in the topic“Replacing the Drive Belt” on page 5-25

Labeljet 210

Rev AA Password Problems 5-9

Password Problems

Adjustment and Repairs

Warning

LETHAL HAZARD. Ensure that the mains supply to the Labeljet 210 Label Applicator is switched off and disconnected before replacing any component.

Warning

LETHAL HAZARD. If it is essential to keep the machine switched on during the repair and maintenance work, ensure that all statutory electrical safety codes and practices are observed.

2 Label web running from the Rewind Reel after cycle stops

Brake Band worn or broken

Replace the Brake Band, as described in the topic “Replacing the Brake Band” on page 5-28

Requires Brake Band adjustment

Adjust the Brake Band

Table 5-9: Password Problems


1 Machine operating parameters cannot be accessed

Password forgotten Reset the Pass word, as described in “Resetting Pass-words” on page 5-14

Table 5-8: Label Rewinding Problems (Continued)


Labeljet 210

5-10 Adjustment and Repairs Rev AA

Warning

PERSONAL INJURY. The Labeljet 210 Label Applicator has exposed rotating parts. Keep hands, long hair, ties, loose clothing and so on away from the machine at all times, when it is switched on.

Adjusting the Hold-down SpringTo adjust the Hold-down spring, proceed as follows:

1 Loosen the Friction Block securing screw (Figure 5-1), and position the Friction Block, such that the Hold-down spring is in the center of the label web.

2 Tighten the Friction Block securing screw, to hold the Friction Block in this position.

3 Adjust the Hold-down spring screw, such that the label is held firmly (but not tightly) against the Peel Tip.

1

2

3

4

5

Figure 5-1. Hold-down Spring Adjustment

1. Peel Tip2. Hold-down Spring3. Friction Block4. Spring Adjusting Screw 5. Friction Block Securing Screw

Labeljet 210

Rev AA Adjustment and Repairs 5-11

If the spring is too tight, the label web could break or slip in the web drive as it is pulled along. If it is not tight enough, the labels are not peeled, and applied correctly on to the product. Adjust the spring mid way between these two extremes.

Inspecting the Connector Panel

Warning

LETHAL HAZARD. Ensure that the mains supply to the machine is switched off and disconnected, before checking any connections.

Caution

EQUIPMENT DAMAGE. Ensure that the machine is switched off, before connecting or disconnecting any cables.

Figure 5-2 shows the Connector Panel at the rear of the machine. Use this figure to check if all the components are connected correctly.

Labeljet 210


Note: Connectors for an optional Tamp/Blow module and/or a Hot Foil Coder can be fitted to the Connector Panel.

Adjusting the Dancer Arm Tension

Caution

EQUIPMENT DAMAGE. Do not disconnect or connect any connector on the machine, when it is switched on.

The Dancer Arm tension should be adjusted, such that the Unwind Reel brake is applied, with just enough force to stop the labels from unwinding, after the dispense cycle is completed. If it is too loose, the labels will continue to unwind after the machine stops. If it is too tight, the brake will not be released sufficiently and the web may slip or break during the dispense cycle.

To adjust the Dancer Arm Tension, proceed as follows:

1

2

345

6

7

8

9 1 0 1 1


1. Product Detector Connector 6. Mains Fuse Holder2. Label Sensor Connector 7. Mains On/Off Switch3. Shaft Encoder Connector 8. Mains Voltage Selector4. Optional Connector 9. Control Panel Connector5. Mains Inlet Connector 10. Lamp Stack Connector

11. General Alarm Connector

Labeljet 210


1 Locate the Spring Anchor Collar (Figure 5-3) situated behind the Unwind Reel, at the rear of the machine.

2 Loosen the Grubscrew.

3 Rotate the Spring Anchor Collar clockwise to reduce the spring tension or rotate counter-clockwise to increase it.

4 Tighten the Grubscrew, when the spring gains the required tension.

Adjusting the Rewind Reel Drive Belt To adjust the Rewind Reel Drive Belt tension, proceed as follows:

1 Loosen (do not remove) the Socket Head Screw (Figure 5-4).

12

Figure 5-3. Dancer Arm Tension Adjustment

1. Spring Anchor Collar2. Grubscrew

Labeljet 210


2 Slide the Rewind Reel into the elongated hole, such that the Drive Belt is neither too tight nor too loose.

3 Tighten the Socket Head Screw when the Drive Belt tension is satisfactory.

4 Test the machine operation, and readjust the Rewind Drive Belt tension, if necessary.

Resetting PasswordsThere are two levels of password protection on Labeljet 210 Label Applicator:

• Password Level 1 allows the operator to access and select stored machine operating parameters. The operator cannot modify any of the existing machine operating parameters.

• Password Level 2 provides full access to the operator. The operator can modify the machine operating parameters and/or the engineering setup

The machine operating parameters cannot be accessed if the passwords are forgotten. The Labeljet 210 Label Applicator can however, be reset to the parameters which were initially set in its non-password state (that is before the entry of any password), by removing the battery back up supply from the Integrated Circuit (IC) “WSI PSD413A1”.

1

2

Figure 5-4. Rewind Reel Drive Belt Adjustment

1. Clamp Washer2. Socket Head Screw

Labeljet 210


Note: The customized setup features are lost when the Labeljet 210 Label Applicator is set to the original parameters of its non-password state.

To gain full control of the machine and to re-enter the passwords, proceed as follows:

1 Switch off the Labeljet 210 Label Applicator, and leave the Power Cord attached, such that the machine is grounded for static dissipative effects. If possible, use “a ground only power cord lead” to ensure that no potential, on either the live or the neutral wire is attached to the machine.

2 Unscrew the four crosshead screws that secure the Connector Panel to the Electronics Housing, and pull out the Connector Panel along with the CPU PCB from the Electronics Housing (Figure 5-6 on page 5-16).

Figure 5-5. Password Re-entry Equipment

1. Allied Part 675-0022. 2371. Plcc-extractor Or RS Part Number 404-727 Smt Plcc Extractor2. Anti Static Wrist Band and Lead 3. No. 1 Cross Head Screw Driver

1

3

2

Labeljet 210


3 Attach the antistatic wrist band to your wrist, and attach the grounding wire to the power outlet or clip it to the edge of the Connector Panel.

4 Disconnect or move the various plug assemblies from the PCB to allow access to the IC as shown in Figure 5-7.

5 Insert the IC extractor with extreme care into the socket, and close the arms until they are correctly positioned.

Figure 5-6. Cross Head Screws

Cross Head Screws

Figure 5-7. CPU PCB - Plug Assemblies

Labeljet 210

Rev AA Replacing Faulty Components 5-17

6 Apply the squeezing action to the extractor and extract the IC WSI PSD413A1, taking care not to damage the legs of the device or the socket.

7 Lift the extracted IC from its socket.

8 Install the extracted IC back into its socket.

9 Check if any cable/wire is affected by the above process and fix it.

10 Push the CPU PCB back into the Electronics Housing.

11 Fasten the four crosshead screws, to secure the Connector Panel to the Electronics Housing.

12 Plug the power supply cord back and switch on the Labeljet 210 Label Applicator.

13 Reset all parameters for all the programs and the password also.

14 Write down the password for future reference and keep it safely.

Checking the Control Panel CableTo perform the checks on the cable located between the Control Panel and the CPU, proceed as follows:

1 Remove the Control Panel, as described in steps 1 and 2 of the procedure, “To remove the Control Panel PCB, proceed as follows:” on page 5-20.

2 Disconnect the cable and the DIN plug from the Control Panel socket on the Connector Panel.

3 Check the cable, by referring the pin-to-pin connection information given in the topic “Control Panel Connector” on page 3-9.

Replacing Faulty ComponentsThe following paragraphs describe the procedures for replacing faulty components.

Warning

LETHAL HAZARD. Ensure that the mains supply to the Labeljet 210 Label Applicator is switched off and disconnected, before replacing any components.

Labeljet 210

5-18 Replacing Faulty Components Rev AA

Warning

LETHAL HAZARD. If it is essential to keep the machine switched on during repair and maintenance work, ensure that all statutory electrical safety codes and practices are observed.

Warning

PERSONAL INJURY. The Labeljet 210 Label Applicator has exposed rotating parts. Keep hands, long hair, ties, loose clothing and so on away from the machine, when it is switched on.

Caution

EQUIPMENT DAMAGE. Do not disconnect or connect any connector on the machine, when it is switched on.

Caution

EQUIPMENT DAMAGE. The PCBs in the Labeljet 210 Label Applicator contain Electrostatic Sensitive Devices (ESDs). An antistatic wrist strap must be worn, when working on PCBs.

Replacing the Product DetectorReplacing the Product Detector involves removing and refitting the Detector.

To remove the Product Detector, proceed as follows:

1 Locate the Product Detector. If necessary, stop the Production Conveyor, to gain access to the Product Detector.

2 Disconnect the Product Detector lead from the Product Detector connector (Figure 5-8 on page 5-19) on the Connector Panel.

Labeljet 210


3 Remove the Product Detector from its mounting.

To refit the Product Detector, proceed as follows:

1 Mount the Product Detector in its correct position next to the Product Conveyor.

2 Connect the Product Detector lead to the Product Detector connector (Figure 5-8 on page 5-19) on the Connector Panel.

Replacing the Label SensorReplacing the Label Sensor involves removing and refitting the Sensor.

To remove the Label Sensor, proceed as follows:

1 Remove the labels from the Label Sensor (not from the Web Drive).

2 Disconnect the Label Sensor lead from its connector (Figure 5-8) on the Connector Panel.

3 Loosen the Thumbscrew on the Label Sensor (Figure 5-9 on page 5-20) and slide it from the Mounting Shaft.

1

2

3

Figure 5-8. Product Detector and Label Sensor Connectors

1. Product Detector Connector2. Label Sensor Connector3. Connector Panel

Labeljet 210


To refit the Label Sensor, proceed as follows:

1 Slide the Label Sensor (Figure 5-9) onto its Mounting Shaft and fix it by tightening the Thumbscrew.

2 Thread the label web through the Web Drive, as described in the topic “Threading the Label Web” on page 2-10, and fasten the end of the web to the Rewind Reel.

3 Ensure that the mark on the Label Sensor is in the center of the label web path. If necessary, loosen the Thumbscrew and reposition the sensor.

4 Connect the Label Sensor lead to its connector (Figure 5-8 on page 5-19) on the Connector Panel.

5 Adjust the label sensitivity, as described in the topic “Label Sensitivity” (Chapter 3 in the Operator Manual).

Replacing the Control Panel PCBReplacing the Control Panel PCB involves removing and refitting the Control Panel PCB.

To remove the Control Panel PCB, proceed as follows:

3

2

1

Figure 5-9. Label Sensor Replacement

1. Label Web2. Rewind Reel3. Label Sensor

Labeljet 210


1 Remove the two screws (Figure 5-10 on page 5-21) that secure the Control Panel to the Control Panel casting.

2 Carefully separate the Control Panel from the casting and pull it forward.

3 Disconnect the 8-way socket from the plug on the Control Panel PCB.

4 Lay the Control Panel down with the PCB facing upwards, as shown in Figure 5-11.

2

1

3

Figure 5-10. Control Panel Removal and Refitting

1. Control Panel Securing Screws2. Control Panel Casting3. Control Panel

Labeljet 210


5 Remove the seven nuts that secure the PCB to the supporting pillars.

6 Carefully lift the PCB away from the keypad plate and remove it.

To refit the Control Panel PCB, proceed as follows:

1 Hold the PCB (Figure 5-11 on page 5-22) in the correct position over the keypad plate, and lower it onto the supporting pillars.

2 Secure the PCB to the pillars, using the seven nuts.

3 Hold the assembled Control Panel upto the Control Panel casting (Figure 5-10 on page 5-21) and reconnect the 8-way socket to the plug on the PCB.

4 Secure the Control Panel to the casting with the two screws.

Replacing the CPU PCBReplacing the CPU PCB involves removing and refitting the CPU PCB.

To remove the CPU PCB, proceed as follows:

Caution

SERIOUS EQUIPMENT DAMAGE. Do not allow the underside of the CPU PCB to make contact with the Electronics Housing, when removing or refitting the CPU PCB.

1

4

1 2

1

4

3

Figure 5-11. Control Panel PCB

1. Securing Nuts2. Control Panel PCB3. Keypad Plate4. Supporting Pillar

Labeljet 210


1 Remove the four screws (Figure 5-12 on page 5-23) that secure the Connector Panel to the Electronics Housing.

2 Pull the Connector Panel, along with the CPU PCB, away from the Electronics Housing.

3 Support the Connector Panel, to prevent its weight being taken by the cabling.

4 Remove all connections from the CPU PCB. As each cable is removed, make a note of its position, such that it can be reconnected correctly.

5 Remove the Connector Panel and the PCB from the Electronics Housing.

6 Remove the three screws that secure the PCB to the Connector Panel, and separate the two.

To refit the CPU PCB, proceed as follows:

1 Place the CPU PCB (Figure 5-12) in its position behind the Connector Panel, and secure it to the Connector Panel using the three screws.

2 Position the Connector Panel, along with the CPU PCB, close to the Electronics Housing and reconnect the cables.

3

1

1

45

2

Figure 5-12. CPU PCB Replacement

1. Screws2. Connector Panel3. Electronics Housing4. CPU PCB5. PCB Securing Screws

Labeljet 210


Note: While reconnecting the cables, ensure that adequate support is provided to the Connector Panel and the CPU PCB.

3 Reconnect all the cables from the Connector Panel to the CPU PCB.

4 Refit the Connector Panel to the Electronics Housing and secure it with the four screws.

Replacing the Toroidal TransformerReplacing the Toroidal Transformer involves removing and refitting the Transformer.

To remove the Toroidal Transformer from the Electronics Housing, proceed as follows:

1 Remove the Connector Panel and CPU PCB from the Electronics Housing, as described in steps 1 to 5 of the procedure “To remove the CPU PCB, proceed as follows:” on page 5-22.

Note: Do not separate the PCB from the Connector Panel.

2 Remove the nut and the washer from the bottom of the Toroidal Transformer, while supporting the transformer (Figure 5-13).

1

2

3

3

45

6

7

8

Figure 5-13. Toroidal Transformer Replacement

1. Bolt 5. Electronics Housing2. Washer 6. Nut3. Protection Pad 7. Washer4. Toroidal Transformer 8. Dished Washer

Labeljet 210


3 Remove the bolt and washer from the top of the Electronics Housing.

4 Remove the transformer along with the Dished Washer and two Protection Pads.

To refit the Toroidal Transformer, proceed as follows:

1 Place the Toroidal Transformer and its associated components - that is Dished Washer and two Protection Pads, inside the Electronics Housing.

2 Insert the bolt and the washer (Figure 5-13 on page 5-24) into the Toroidal Transformer through the hole on the top of the Electronics Housing

3 Secure the transformer with the nut and washer from below.

Caution

Do not over tighten the nut as the transformer windings may get damaged.

4 Fit the Connector Panel, along with the CPU PCB onto the Electronics Housing, as described in the procedure “To refit the CPU PCB, proceed as follows:” on page 5-23.

Replacing the Drive BeltReplacing the Drive Belt involves removing and refitting the Belt.

To remove the Drive Belt of the Rewind Reel, proceed as follows:

1 At the rear of the machine, unhook the Nip Roller Tensioning Spring (Figure 5-14 on page 5-26) from the Spring Post.

Labeljet 210


2 Remove the Socket Head Screw and Clamp Washer, while supporting the Rewind Reel.

3 Pull the Rewind Reel away from the front side of the machine, releasing the Drive Belt from the pulley at the end of the reel.

4 Remove the two screws (Figure 5-15 on page 5-27) securing the belt cover and remove the cover. It may be necessary to move the Cranked Nip Arm to one side, to gain access to the left-hand screw.

12

3

4

Figure 5-14. Rewind Reel and Tensioning Spring Removal

1. Nip Roller Tensioning Spring2. Spring Post3. Clamp Washer4. Socket Head Screw

Labeljet 210


5 Remove the Drive Belt.

To refit the Drive Belt, proceed as follows:

1 Fit the Drive Belt in the position shown in Figure 5-15, and ensure that the left-hand end is correctly placed in the groove at the end of the Drive Roller.

2 Refit the Belt Cover and secure it using the two screws.

3 Fit the Rewind Reel into the slot in the chassis, and ensure that the Drive Belt fits onto the pulley on the Rewind Reel shaft.

4 Tension the belt, by sliding the rewind reel in the slot, before finally tightening the screw.

5 Secure the Rewind Reel to the chassis, using the Socket Head Screw and Clamp Washer (Figure 5-14 on page 5-26).

6 Hook the end of the Nip Roller Tensioning Spring over the groove in the Spring Post.

1 2

45 3 3

Figure 5-15. Drive Belt Replacement

1. Belt Cover2. Drive Belt3. Screw4. Cranked Nip Arm5. Drive Roller

Labeljet 210


Replacing the Brake BandReplacing the Brake Band involves removing and refitting the Band.

To remove the Brake Band (located behind the Unwind Reel), proceed as follows:

1 On the Brake Assembly, unhook the spring from the Spring Post (Figure 5-16).

2 Remove the screw and washer that secure the Brake Band to the Brake Band collar.

3 Pull the loop at the other end of the Brake Band off the Brake Band anchor (if necessary, rotate the Spring Anchor Collar, to gain access to the loop).

4 Remove the Brake Band.

To refit the Brake Band, proceed as follows:

1 Form a loop at one end of the Brake Band and secure it with the screw, washers and nut.

1

2

3

45

6

7

8

9

4

1. Friction Boss 5. Spring2. Brake Band 6. Spring Post3. Screw, Washers and Nut 7. Screw and Washer4. Brake Band Anchor 8. Brake Band Collar

9. Spring Anchor Collar

Figure 5-16. Unwind Reel Brake Assembly

Labeljet 210


2 Secure the other end of the Brake Band to the Brake Band collar, using the screw and washer and ensure that the dark green rubberized surface faces the collar.

3 Pass the Brake Band around the Friction Boss and fit the loop over the Brake Band anchor.

4 Refit the spring to the Spring Post, and ensure that the hook on the spring is located in the groove at the end of the post.

5 Adjust the Brake Band.

Replacing the Stepper Motor Replacing the Stepper Motor involves removing and refitting the Motor.

To remove the Stepper Motor, proceed as follows:

1 Remove the four screws (Figure 5-12 on page 5-23) that secure the Connector Panel to the Electronics Housing and pull the Connector Panel and the CPU PCB away from the housing.

2 Support the Connector Panel to prevent its weight being taken by the cabling.

3 Remove the four Stepper Motor connections from the terminal blocks J29 and J30 on the CPU PCB.

Note: Note the orientation of the connections to use as reference when refitting.

4 Remove the retaining washer from the Electro Magnetic Compatibility (EMC) gland through which the stepper motor cable passes, at the bottom of the Electronics Housing.

5 Pull the cable down through the hole in the Electronics Housing.

Note: The whole cable should come out of the hole.

6 Loosen the Socket Head screw (Figure 5-14 on page 5-26), which secures the Rewind Reel to the chassis.

7 Slide the Rewind Reel as far as it can go towards the center of the machine.

8 Unhook the end of the Nip Roller tensioning spring (Figure 5-14 on page 5-26) from the Spring Post.

9 Remove the nuts and washers from the rear of the Stepper Motor.

10 Remove the securing screws (Figure 5-17 on page 5-30) while supporting the Stepper Motor.

Labeljet 210


11 Withdraw the Stepper Motor, along with the Drive Roller from the rear of the chassis.

To refit the Stepper Motor, proceed as follows:

1 Position the Stepper Motor, along with the Drive Roller, into the rear of the chassis.

2 Refit the Stepper Motor securing screws (Figure 5-17), nuts and washers.

3 Hook the end of the Nip Roller tensioning spring (Figure 5-14 on page 5-26) onto the Spring Post.

4 Tension the Drive Belt by sliding the Rewind Reel away from the center of the machine.

5 Tighten the Socket Head screw (Figure 5-14 on page 5-26), which secures the Rewind Reel to the chassis.

6 Pass the cable through the hole in the base of the Electronics Housing and fit the EMC gland to the hole, and ensure that there is approximately 25 mm of braiding, protruding from the gland.

7 Fold the braiding back over the gland, and fit the Retaining Washer to secure the EMC gland.

1

2

1

Figure 5-17. Stepper Motor Removal

1. Stepper Motor Securing Screws2. Drive Roller

Labeljet 210


8 Trap the braiding between the Retaining Washer and the base of the Electronics Housing.

9 Connect the ends of the Stepper Motor cable to J29 and J30 on the CPU PCB and fit them in their respective positions noted during step 2 of the stepper motor removal procedure.

10 Support the Connector Panel and the CPU PCB, and place them in the Electronics Housing.

11 Refit the Connector Panel (Figure 5-12 on page 5-23) to the Electronics Housing, using the four screws.

Replacing the Drive RollerReplacing the Drive Roller involves removing and refitting the Roller.

To remove the Drive Roller, proceed as follows:

1 Remove the Stepper Motor along with the Drive Roller, as described in steps 1-11 of the procedure “To refit the Drive Roller, proceed as follows:” on page 5-32.

2 Separate the Drive Roller (Figure 5-18 on page 5-32) from the Stepper Motor, as described below:

Note: Before separating the Drive Roller from the Stepper Motor, measure the distance between the end of the Drive Roller and the end plate of the Stepper Motor. Make a note of this measurement for reference, when refitting.

Caution

EQUIPMENT DAMAGE. Do not use excessive force or mechanical devices to grasp the Drive Roller.

Labeljet 210


3 Grasp the Drive Roller firmly (see Caution above), and using a spanner, loosen the coupling nut by turning it clockwise (as viewed from the drive shaft end of the motor).

4 Pull the Drive Roller and the coupling off the motor Drive Shaft.

To refit the Drive Roller, proceed as follows:

1 Fit the Drive Roller (Figure 5-18), along with the coupling, onto the Drive Shaft of the Stepper Motor.

2 Position the Drive Roller, such that the distance between the end of the Drive Roller and the end plate of the motor is the same as the value noted while separating the Drive Roller from the Stepper Motor.

3 Grasp the Drive Roller firmly, and using a spanner, tighten the coupling nut by turning it in the anti-clockwise direction (as viewed from the Drive Shaft end of the motor).

Replacing the Mains Input ModuleReplacing the Mains Input Module involves removing and refitting the Module.

To remove the Mains Input Module, proceed as follows:


13

2

Figure 5-18. Drive Roller Removal

1. Coupling Nut2. Drive Roller3. Stepper Motor

Labeljet 210


2 Pull the Connector Panel away from the housing and support it to prevent its weight being taken by the cabling.

3 Pull the Insulating Boot (Figure 5-19) off the Mains Input Module, and slide it back along the cable.

4 Unsolder the earth wire from the terminal at the rear of the Mains Input Module.

5 Pull the live and neutral wires off the other two terminals.

Note: Make a note of the positions of the live and neutral wires, as they are removed, and use it as reference when refitting.

6 Remove the Plug Retaining Clip from the securing screws.

7 Remove the securing screws, and withdraw the Mains Input Module from the Connector Panel.

To refit the Mains Input Module, proceed as follows:

1 Fit the Mains Input Module (Figure 5-19) to the Connector Panel and secure it with securing screws.

2 Fit the Plug Retaining clip to the securing screws.

3 Solder the earth wire to its terminal at the rear of the Mains Input Module.

3

4

5

2

1

Figure 5-19. Mains Input Module Removal

1. Insulating Boot2. Plug Retaining Clip3. Securing Screws4. Mains Input Module5. Connector Panel

Labeljet 210


4 Fit the live and neutral wires to the other two terminals, in their respective positions.

5 Fit the insulating boot over the body of the Mains Input Module.

6 Refit the Connector Panel to the Electronics Housing and secure it using the four screws.

Replacing Fuse 2 on CPU PCBTo replace Fuse 2 on the CPU PCB, proceed as follows:


2 Pull the Connector Panel along with the CPU PCB away from the housing, and support the Connector Panel to prevent its weight being taken by the cabling.

3 Locate the Fuse 2 fuseholder on the CPU PCB (Figure 5-20).

4 Pull out the fuseholder.

5 Check the fuse and replace it.

6 Refit the fuseholder.

7 Refit the Connector Panel, along with the CPU PCB into the Electronics Housing, and secure it using the four screws.

2

1

Figure 5-20. Fuse 2 Replacement

1. CPU PCB2. Fuse 2 Fuseholder

Labeljet 210


Replacing the Capacitors C19 and C20

Warning

LETHAL HAZARD. Ensure that you are fully earthed using the appropriate static dissipative equipment.

To remove the Capacitors C19 and C20 on the CPU PCB, proceed as follows:

1 Switch off the Labeljet 210 Label Applicator and disconnect it from the mains supply by removing the power cord.

2 Disconnect the CPU PCB, as described in the procedure “To remove the CPU PCB, proceed as follows:” on page 5-22 (Figure 5-21).

Figure 5-21. CPU PCB Removal

1. CPU PCB2. Connector Panel3. PCB Securing Screws

1

2

3

3 Locate the Capacitors C19 and C20 on the CPU PCB (Figure 5-22 on page 5-36).

Labeljet 210


4 Place a fine-tipped soldering iron and the tip of tweezers at the base of the capacitor as shown in Figure 5-23.

Note: The soldering iron should be fully tinned with self fluxed, regular melting point, lead tin solder.

5 Touch the soldering iron tip quickly as shown in Figure 5-24 on page 5-37, across both the ends of the capacitor at the same time, to apply the heat and melt the solder.

Note: The solder melts almost instantaneously, if the iron is tinned enough.

Figure 5-22. Capacitors C19, C20

Figure 5-23. Capacitor Removal Equipment

1. Soldering Iron2. Tweezers3. Capacitor

123

Labeljet 210


Caution

EQUIPMENT DAMAGE. Do not apply too much heat, as it may cause damage to the CPU PCB.

6 When the solder melts, push the capacitor (Figure 5-25) off the pads using tweezers (the capacitor usually sticks to the soldering iron’s tip).

7 Remove the Capacitors from the CPU PCB area.

Caution

EQUIPMENT DAMAGE. Ensure that the capacitor is completely removed and it has not fallen back onto the PCB.

To refit the CPU PCB, proceed as follows:

1 Place the CPU PCB (Figure 5-12 on page 5-23) in the required position behind the Connector Panel, and secure it to the Connector Panel using the three screws.

2 Position the Connector Panel, along with the CPU PCB, close to the Electronics Housing and reconnect the cables.

Figure 5-24. Unsolder the Capacitor

Figure 5-25. Capacitor Removal

1. Soldering Iron2. Capacitor

1

2

Labeljet 210


Note: While reconnecting the cables, ensure that adequate support is provided to the Connector Panel and the CPU PCB.

3 Reconnect all the cables from the Connector Panel to the CPU PCB.

4 Refit the Connector Panel to the Electronics Housing and secure it with the four screws.

Replacing the Mains Input Fuse

Warning

LETHAL HAZARD. Ensure that the mains supply to the Labeljet 210 Label Applicator is disconnected before replacing fuses or any other component.

To replace the mains input fuse, proceed as follows:

1 Identify the fuseholder on the Power Entry Module (Figure 5-26). This module is located at the bottom left hand corner of the Connector Panel.

2 Withdraw the fuseholder from the Power Entry Module and allow it to drop down to the vertical position.

3 Remove the mains fuse and check them for continuity.

12

Figure 5-26. Mains Input Fuse Replacement

1. Fuseholder2. Power Entry Module

Labeljet 210


4 Replace the fuse, if necessary or refit the old ones, if they are serviceable.

5 Position the Fuseholder in the horizontal position and push it fully into the Power Entry Module.

6 Reconnect the mains supply and switch on the machine.

Rev AA Consumables 6-1

6Consumables and Options


• information on the consumables required by the Labeljet 210 Label Applicator

• information on the optional components that can be fitted to the applicator

ConsumablesContact your Videojet subsidiary office or local Videojet distributor for information on the supply of label stock.

OptionsThe Labeljet 210 Label Applicator can be fitted with the following optional components (Table 6-1).

Table 6-1: Options

S.No Part Number Description Remarks

1 527-0001-126 Shaft Encoder 2500 pulses per revolu-tion

2 527-0001-127 Shaft Encoder 5000 pulses per revolu-tion

3 NYA Measuring Wheel (200 Mm)

Used with Serial 1/2

4 527-0001-129 Diaphragm Coupling Used with Serial 1/2

5 527-0001-130 Flange Adaptor Plate Used with Serial 1/2

6 527-0001-131 Angle Bracket Used with Serial 1/2

Labeljet 210

6-2 Options Rev AA

Note: NYA means that a part number is not yet allocated, contact your local Videojet Technologies Inc., sales company or distributor for details.

<Review comment: I found in the technical manual a couple of part numbers that are obsolete. On page 129 (6-2) number 11 should be part number 28000179. For item number 14, we quote part num-ber 80100045 or 80100047, which are standard labeling reflex or proximity photocell. Those two num-ber should be added instead of 200-0042-004. I would also like to see the sizes added to the description of the tamp and blow box, on that same page. >

7 527-0001-132 Shaft Encoder Cable (3 M)


8 527-0001-133 Shaft Encoder Cable (5 M)


9 500-0036-581 Four Way DIN Plug Used with Serial 1/2

10 NYA Low Label Sensor

11 28000179 Mounting Stand

12 200-0390-117 Lamp Stack Module

13 NYA Hot Foil Coder Con-nector Kit

14 80100045 or 80100047

Standard Labeling Reflex or Proximity Photocell

Product detector

15 200-0210-115 Tamp Final Left hand 50



18 200-0210-118 Tamp Final Left hand special

19 200-0210-119 Tamp Final Right hand 50



22 200-0210-122 Tamp Final Right hand special

23 200-0210-123 Blowbox Final Left hand 100

24 200-0210-124 Blowbox Final Left hand 200

25 200-0210-125 Blowbox Final Right hand 100

26 200-0210-126 Blowbox Final Right hand 200

Table 6-1: Options (Continued)

S.No Part Number Description Remarks

Labeljet 210

Rev AA Options 6-3

Rev AA Overview A-1

AApplicator Specifications

Overview

Machine data for Labeljet 210 Label Applicator is given in Table A-1.

Table A-1: Machine Data

Electrical supply 230 or 110 Volts AC 50-60 Hz, 250 VA.

Weight 50.8 lbs (23 Kg)

Operating temperature range 0° to 45° Centigrade (C)

Humidity 0% to 95% relative, non condensing

Storage range -0°C to + 45°C and up to 70°C for short periods not exceeding 24 hours.

Dimensions See Figure A-1. on page A-2

Operating speed 2 to 30 meters/min

Label width 1 - 12 mm minimum to 104 mm maxi-mum

Label length 2 - 12 mm minimum to 500 mm maxi-mum

Memory 10 Storage Locations

Labeljet 210

A-2 Overview Rev AA

9 32 6 0

5 6 5

3 5 0

1 4 5

3 2 8

6 1 0

22.2”

10.2” 3.6”

13.8”

5.7”

24.0”

12.9”

LEFT HAND ORIENTATION

Figure A-1. Machine Dimensions (mm)

Rev AA How to Use this Parts List B-1

BIllustrated Parts List

The illustrations and the associated tables given in this chapter, provide ordering information for the available spare parts of the Labeljet 210 Label Applicator.

How to Use this Parts List• The illustrations show the major sub-assemblies. For example, Figure

B-1. on page B-2 shows the major sub-assemblies of the Labeljet 210/205 Label Applicator.

• The table associated with illustration lists the sub-assemblies and the relevant detailed parts list. Wherever a component is not illustrated, the letters 'NI' appear in S. No column. For example, see Table B-1 on page B-2.

Labeljet 210

B-2 Labeljet 210 - Major Assemblies Rev AA

Labeljet 210 - Major Assemblies

Table B-1: 210/205 Label Applicator

S. No Part Number Description Remarks

Figure B-1 200-0210-201 210 Label Applicator

200-0205-201 205 Label Applicator

1 - Web Drive Components See Figure B-3. on page B-8

2 100-0210-149 Brush Rod

2

3

7

1

4

5

6

Figure B-1. 210/205 Label Applicator

Labeljet 210

Rev AA Operator Control Panel B-3

Operator Control PanelThe Operator Control Panel contains the parts shown in Figure B-2.

3 100-0210-155 Wipe Down Brush

4 100-0210-154 Brush Arm

5 - Electronic Components and Mounting Bracket

See Figure B-4. on page B-11

6 200-0210-210 Electronics Module See Figure B-5. on page B-12

7 200-0210-204 210/205 Operator Control Panel

See Figure B-2. on page B-4

Table B-1: 210/205 Label Applicator (Continued)

S. No Part Number Description Remarks

Labeljet 210

B-4 Operator Control Panel Rev AA

Table B-2: Operator Control Panel

S. No Part Number Description Qty Remarks

Figure B-2. on page B-4

200-0210-204 210/205 Operator Control Panel

1

1 100-0210-138 Control Panel Mounting Tube

1

2 500-0050-108 EMC Gland 1

3 100-0210-133 Control Panel cast-ing

1

4 200-0210-212 Control PCB 1

5 100-0210-140 Keypad Plate 1

1

2

3

4

5

6

Figure B-2. Operator Control Panel

Labeljet 210

Rev AA Operator Control Panel B-5

6 100-0210-143 Keypad Overlay 1

NI 501-0007-168 8 core Screened Cable

1m These items make up the cable betweenthe Control Panel and theConnectorPanel

NI 500-0036-132 10 way housing 1

NI 500-0036-133 Crimp Terminal 7

NI 500-0036-584 8 pin DIN plug 1

Table B-2: Operator Control Panel

S. No Part Number Description Qty Remarks

Labeljet 210

Rev AA Foldout 7: Web Drive Components B-7

Foldout 7: Web Drive Components

Labeljet 210

B-8 Foldout 7: Web Drive Components Rev AA

3

*

2

1

3

45

7

6

6

89

3938

10

6

11

13

16

18

24

25

26

23

2727

17

15

14

19

21

20

22

12

3736

35

40

34 33

32

30 28

31

29

Figure B-3. Web Drive Components

Rev AA Web Drive Components B-9

Web Drive ComponentsFigure B-3. on page B-8 and Table B-3 list the details of Web Drive components.

Table B-3: Web Drive Components

S. No Part Number Description Qty Rema-rks

Figure B-3. on page B-8

Web Drive Compo-nents

-

1 100-0210-110 Brake Band 1

2 100-0210-108 Spring Anchor Collar 1

3 500-0122-108 Extension Spring 1

4 100-0210-107 Brake Band Collar 1

5 100-0210-139 Brake Band Anchor 1

6 500-0045-125 12 Flanged Oilite Bush

3

7 500-0045-127 15 Single Row Ball Bearing

2

8 100-0210-146 Dancer Arm Shaft 1

9 100-0210-106 Dancer Arm 1

10 100-0210-147 Dancer Roller Shaft 1

11 100-0210-103 Unwind Shaft 1

12 100-0210-109 Dancer Roller 1

13 100-0210-130 Rewind Shaft 1

14 500-0064-106 Vee Belt 1

15 100-0210-156 Unwind Hub Assem-bly

2

16 100-0210-131 Rewind Roller 1

17 100-0210-157 Rewind Lock Pin 1

18 100-0210-129 Belt Cover 1

19 100-0210-148 Nip Arm Assembly, Left Hand

1

20 100-0210-126 Nip Roller Shaft 1

Labeljet 210

B-10 Web Drive Components Rev AA

21 100-0210-128 Nip Safety Bar 1

22 100-0210-127 Nip Roller 1

23 500-0045-129 Trantorque Coupling 1

24 100-0210-134 Idler Shaft 3

25 100-0210-122 Drive Roller 1

26 100-0210-112 Large Idler Roller 1

27 100-2610-103 Web Guide 3

28 100-0210-113 Small Idler Roller 1

29 200-0210-114 Label Sensor Assem-bly

1

30 100-0210-114 Label Sensor Shaft 1

31 100-0210-121 Peel Plate 1

32 100-0210-116 Friction Block Shaft 1

33 100-0210-160 Friction Block 1

34 100-2600-139 Hold Down Spring 1

35 100-0210-137 Mounting Block 1

36 518-0001-112 Stepper Motor 1

37 100-0210-136 Nip Spring Post 1

38 500-0122-121 Extension Spring 1

39 100-0210-124 Short Spring Post 1

40 500-0045-126 Ø 12 Plain Oilite Bush

1

NI 100-0210-145 Threading Label, Left-hand

1

NI 100-0210-151 Nip Arm Assembly, Right-hand

1

NI 400-0009-339 Threading Label, Right- hand

1

Table B-3: Web Drive Components (Continued)


Labeljet 210

Rev AA Electronic Components and Mounting Bracket B-11

Electronic Components and Mounting BracketFigure B-4 and Table B-4 list the details of Electronic Components and the Mounting Bracket.

Table B-4: Electronic Components and Mounting Bracket


Figure B-4

- Electronic Compo-nents and Mounting Bracket

-

1 500-0090-119 Toroidal Transformer 1

2 100-0210-141 'U' Bracket 1

3 200-0210-210 Electronics Module 1 see Fig 12.5

1

2

3

Figure B-4. Electronic Components and Mounting Bracket

Labeljet 210

B-12 Electronics Module Rev AA

Electronics ModuleThe Electronics Module of Labeljet 210 consists of the following parts:

Table B-5: Electronics Module


Figure B-5 200-0210-210 210 Electronics Module 1

200-0205-210 205 Electronics Module 1

1 500-0036-558 7 Pin DIN Socket 1

2 500-0076-133 Blanking Plug 2

3 500-0036-560 4 Pin DIN Socket 1

4 500-0079-130 Insulating Boot 1

5 200-0210-113 210 CPU Board 1

115V

11

12

1

2

43

10

9

867

5

Figure B-5. Electronics Module

Labeljet 210

Rev AA Electronics Module B-13

200-0205-113 205 CPU Board 1

6 500-0036-496 6 Pin Circular Connec-tor; Plug

1

7 500-0036-433 4 Pin Circular Connec-tor; Plug

1

8 500-0097-116 Plug Retaining Clip 1

9 500-0097-124 4a Power Entry Module 1

10 500-0082-141 Voltage Selector Switch 1

11 500-0036-566 8 Pin DIN Socket 1

12 500-0036-571 6 Pin DIN Socket 1

Table B-5: Electronics Module (Continued)


Rev AA 1-1

Index

AA/D Converter, 3-34A/D Multiplexer, 3-34Actuator

Print Request, 3-37Vacuum Box Fan, 3-37

Air Assist interface, 3-30Anti static wrist band, 5-15Applicator, 1-1

BBaud rate generator, 3-34Blow Applicator, 2-16Blow interface, 3-29Blow module connector, 3-13Brake band, 5-9, 5-28

refitting, 5-28Bridge rectifiers, 3-40

CCapacitors C19,C20, 5-6Central Processing Unit (CPU), 3-2Central Processing Unit-Printed Cir-

cuit Board (CPU PCB)damped oscillations, 5-6Fuse 2, 5-5interfaces, 3-25refitting, 5-23, 5-37

Chassis, 2-2Compressed air, 4-1Connector Panel, 2-5, 3-8Consumables, 6-1Control Panel, 2-4, 2-15

cable, 2-4cable check, 5-17casting, 5-21connector, 2-4connector pin outs, 3-9housing, 3-41interface, 3-30PCB removal, 5-20Printed Circuit Board (PCB), 3-42

Control Processor Memory map, 3-32Cranked Nip Arm, 2-10Cross head screws, 5-15Current Sense comparator, 3-35

DDancer arm tension, 2-20

adjustment, 5-12Dancer Roller, 3-7Digital Volt Meter, 2-5DMA, 3-32Drive Amplifier, 3-35Drive Roller, 2-10, 3-4

refitting, 5-31removal, 5-31

EElectrical Supply, 2-15Electronics Housing, 3-7Electronics Module, 3-1, 3-7Electrostatic Sensitive Device (ESD), 2-

6, 5-18EPROM, 3-32

FFriction Block, 2-11

Securing screw, 2-20

GGeneral Alarm

interface, 3-28General Alarm connector pin outs, 3-11Grounding wire, 5-16Grub Screw

Nylon, 2-9Steel socket head, 2-9

Guide CollarInboard, 2-12Outboard, 2-12

HHalf Bridge driver IC, 3-36Hold-down spring, 2-20

adjustment, 5-10plate, 3-7

Hot Foil Coder connector, 3-13

IIC WSI PSD413A1, 5-14Illustrated Parts Breakdown, 1-2Input fuses, 2-15

Labeljet 210

1-2 Rev AA

InspectingElectrical Cables, 4-2Mechanical Components, 4-3

Integrated Timer Unit, 3-32

JJunction box, 2-15

LLabel, 2-2

adhesive, 5-7Advancing, 5-5Dispense Cycle, 3-4Dispensing, 5-4long, 3-4Placement, 5-7Sensitivity, 5-4short, 3-4Stop adjustment, 5-4

Label low microswitch, 3-37Label Roll, 2-10

Slipping, 5-4Label Sensor, 2-5, 3-7

6 way Amphenol socket, 2-8cable, 2-8calibration, 2-6connector pin outs, 3-12interface, 3-25locking screw, 2-7mounting shaft, 2-7refitting, 5-20removal, 5-19thumb knob, 2-13

Label Web, 2-12Alignment, 2-12Breaking, 5-3path, 5-4

Lamp Stack connector pin outs, 3-10Light Emitting Diode (LED) indica-

tors, 3-45Liquid Crystal Display (LCD), 2-15lock pin, 2-11

MMachine Components, 3-1

Available options, 6-1Mains Inlet connector, 2-15, 3-8

Mains Input fuse, 5-10Mains Input fuse holder, 3-8Mains Input Module

removal, 5-32Mains On/Off switch, 1-3, 3-8Mains Outlet, 2-15Mains Supply, 2-14

Extension leads, 2-15lead, 5-1Voltage fluctuations, 2-15

Micro Controller, 3-32Microprocessor IC1, 3-45MOSFET, 3-36Mounting Bolts, 2-2Mounting Stand, 2-2Mounting Tube, 2-4

NNip Roller, 2-10, 3-4NPN sensors, 5-5Numeric Keypad, 2-17

Oop-amp, 3-35Operating System, 3-32Operator Controls, 2-20Operator Manual, 1-2

Availability in other languages, 1-2Ordering, 1-2Related documents, 1-2

PPassword, 2-13

Level 1, 2-13Level 2, 2-13Operating Parameters, 2-13

Peel Plate, 2-11Peel Tip, 2-2, 3-4PNP sensors, 5-5Polarity

Label Sensor, 2-19Product Detector 1, 2-19Product Detector 2, 2-18, 2-19

Potential divider, 3-35Potentiometer Adjusting Tool, 2-5Power indicator, 5-1Print interface, 3-30

Labeljet 210

Rev AA 1-3

Product, 2-2Product Delay, 3-4Product Detector, 2-10

4 way Amphenol socket, 2-10cable, 2-10Calibrating, 2-21connector pin outs, 3-11interface, 3-26Plug, 2-10product detector 1, 3-37refitting, 5-19

Production conveyor, 2-2Program Memory, 3-32

RRAM, 3-32Retract time, 2-17Rewind Reel, 2-12, 3-7

vee belt, 3-7

SSense resistor, 3-36Serial Communication

SCI Channel 2, 3-34Shaft Encoder, 2-15

connector, 2-11connector pin outs, 3-12interface, 2-11, 3-26lead, 2-11Resolution, 2-18Sample time, 2-18Type, 2-18

Soldering Iron, 5-36SRAM, 3-33Stepper Motor, 3-4, 3-7

Bipolar two phase, 3-35interface, 3-25

TTamp Applicator, 2-16Tamp interface, 3-29Tamp module connector, 3-13Timer counters, 3-33Timer Pulse Unit (ITU), 3-32Timing Pattern Controller (TPC), 3-32Toroidal Transformer, 3-7

Primary winding, 3-36, 3-39

removal, 5-24Secondary winding, 3-36, 3-39

Touch Applicator, 2-16Traffic light interface, 3-29Transceiver, 3-45Tweezers, 5-36

UUnwind Reel, 3-7

Brake, 2-21Unwind Reel Flange, 2-9

Inner Flange, 2-9Outer Flange, 2-9

Unwind Shaft, 2-9USART, 3-34

VVoltage Selector switch, 2-15, 3-8

WWeb Drive mechanism, 3-1Web Path

cleaning, 4-1Web tension, 2-20Wipe Down Brush, 2-8

Bracket, 2-8Securing Screw, 2-8

Date post:	31-Dec-2019
Category:	Documents
Upload:	others
View:	3 times
Download:	0 times