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WPL-3000 SERVICE MANUAL 0077B

5-2

Controller Unit 5

5.1 O

VERVIEW

The WPL-3000 display (GP1046A01AA)

uses a Fluorescent dot display for

characters and a fluorescent digital

display for numbers. The keyboard uses

membrane keys.

Refer to the

Operation Manual

for an

explanation of the function keys.

Fig. 5.1

Controller Unit

Registration Keyboard

Layout

Operation Keyboard

Layout

Summary of Contents for WPL-3000

Page 1: ... not carry out installation operation service or maintenance until thoroughly understanding the contents of this manual Keep this manual available at all times for instal lation operation service and maintenance SERVICE MANUAL WPL 3000 ...

Page 2: ...g improvements Please express your comments to the nearest Ishida Company representative Thank you Copyright 2001 by Ishida Co Ltd All Rights Reserved No part of this manual may be reproduced in any form by photocopy or any other means without written permission from the publisher ...

Page 3: ...e precautions against the danger of electrical shock or other potential hazard involved Take precaution against residual electrical charge hazard Capacitors inside the machine may still hold an electrical charge even after power is disconnected Use same type fuses and components for replacement parts To avoid the potential hazards involved do not replace fuses or components with types other than t...

Page 4: ... the machine clear of any dust and debris Do not leave screws or other foreign objects in the machine after performing routine maintenance since this can cause major damage to the machine when the electrical switch is turned on Always remove wires by holding the connector and pulling to disconnect Do not disconnect by pulling on the wires themselves since this may cause a wire to snap or damage th...

Page 5: ... Conveyor Stands 2 4 1 Fastening to Stand 2 4 2 Fastening Stands 2 4 3 Stand Fastening Method 1 2 4 4 Stand Fastening Method 2 2 5 Connecting Cable 2 6 Setup Procedures 2 7 Method for Threading Labels 2 8 WPL 3000 USA Rescue Mode 2 2 2 2 2 2 2 2 2 3 2 3 2 3 2 4 2 5 2 6 2 7 2 7 2 8 2 9 2 10 2 11 3 Test Mode 3 1 Menu Directory Diagram 3 2 Test Mode 3 2 1 Starting Test mode 3 2 2 Hardware Test C01 3 ...

Page 6: ...Registration Select b11 4 2 8 Total Mode Select b12 4 2 9 Password b13 4 2 10 Tray Master Registration b15 4 2 11 Conveyor Setup b16 4 2 4 5 4 7 4 8 4 9 4 11 4 12 4 14 4 15 4 15 4 16 4 16 5 Controller Unit 5 1 Overview 5 2 Block Diagram 5 3 Electronic Parts 5 3 1 Display Board 5 3 2 Junction Buzzer Board 5 4 Display and Key Check 5 5 Disassembly Diagram 5 2 5 3 5 3 5 4 5 6 5 7 6 Weigh Conveyor 6 1...

Page 7: ...t 8 2 Block Diagram 8 3 Electronic Components 8 3 1 Power Supply Unit 8 3 2 Drive Board P 854 8 3 3 Electromagnetic Valve 8 3 4 Air Cylinder 8 3 5 Application Timing Sensor 8 4 Elevator Check and Parts Adjustment 8 4 1 Weigh Conveyor 8 4 2 Conveyor Fall Prevention Screw Adjustment 8 5 Disassembly Diagram 8 2 8 3 8 4 8 4 8 5 8 5 8 6 8 7 8 8 8 8 8 9 8 10 9 Troubleshooting 9 1 Periodic Parts Replacem...

Page 8: ...Contents ...

Page 9: ...Chapter 1 Overview 1 1 External Parts and Names I Line Type 1 2 External Parts and Names L Line Type 1 3 Location of Safety Stickers 1 2 1 3 1 4 ...

Page 10: ...TAND PRINTER UNIT CONVEYOR WEIGH UNIT LABEL APPLICATOR DISCHARGE ROLLER UNIT OPTION POWER SWITCH 1 1 EXTERNAL PARTS AND NAMES CONVEYOR STAND OPTION Fig 1 1 WPL 3000 I Line Type top view INFEED CONVEYOR UNIT OPTION PRINTER UNIT SCALE LABEL APPLICATOR I LINE TYPE IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm ...

Page 11: ...p view L LINE TYPE SCALE PRINTER UNIT INFEED ROLLER UNIT OPTION Fig 1 4 WPL 3000 L Line Type front view IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm LABEL APPLICATOR PRINTER STAND PRINTER UNIT LABEL APPLICATOR DISCHARGE ROLLER UNIT OPTION POWER SWITCH CONTROLLER UNIT SCALE ...

Page 12: ...7B 1 4 Overview 1 1 3 LOCATION OF SAFETY STICKERS Disconnect from before opening Fig 1 5 Location of external stickers Fig 1 6 Internal safety sticker IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm ...

Page 13: ...lation 2 2 1 Tools 2 2 2 Manuals 2 3 Package Confirmation 2 4 Positioning and Adjusting Conveyor Stands 2 4 1 Fastening to Stand 2 4 2 Fastening Stands 2 4 3 Stand Fastening Method 1 2 4 4 Stand Fastening Method 2 2 5 Connecting Cable 2 6 Setup Procedures 2 7 Method for Threading Labels 2 8 WPL 3000 USA Rescue Mode 2 2 2 2 2 2 2 2 2 3 2 3 2 3 2 4 2 5 2 6 2 7 2 7 2 8 2 9 2 10 2 11 ...

Page 14: ...oise and voltage changes can affect performance so connect plug to a dedicated outlet and place in an appropriate environment 2 1 4 Setup Environment Installation site should 1 Be stable and level 2 Not be exposed to moisture 3 Not be exposed to direct sunlight for long periods 4 Not be exposed to wind or strong vibration 5 Have sufficient area for installation and maintenance 6 Allow power cord n...

Page 15: ...SSARY ITEMS FOR INSTALLATION 2 2 1 Tools Phillips head screwdriver Slotted screwdriver Monkey wrench more than 30mm 1 3 16 in jaw extension Open ended wrench 30mm Allen wrench key set metric Box wrench 7mm 8mm 10mm Electrician s pliers Level 200 to 250mm 8 to 10 in IF 21 FD 3 5DD inch floppy disk 2 2 2 Manuals WPL 3000 Service Manual WPL 3000 Programming Manual User s Manual for Managers WPL 3000 ...

Page 16: ...roper product flow or imprecise labeling may result To prevent these conditions from occurring follow the procedures outlined below 1 Securely fasten each unit to stand Reference Section 2 4 1 Using a level adjust the leveling legs to the desired height Cas tors should be set to rise at least 1 cm 3 8 inch from the ground Note Infeed conveyor and stand are options Note Use a level to set within 2 ...

Page 17: ...Loosely tighten anchor bolts to conveyor stands Confirm that all legs are stable with no movement and tighten down anchor bolts until bolts are tight 2 4 1 Fastening to Stand Fig 2 4 Weigh conveyor unit under side view BOLT X 6 M5 x 60mm STAND ANTI VIBRATION PAD Fig 2 5 Infeed conveyor under side view Note To prevent rust apply machine grease to legs Bolt X 4 M5 x 60mm STAND OPTION ...

Page 18: ...Fastening Stands Secure conveyor stands to floor using anchor bolts METAL FITTING JOINT ANCHOR BOLT NUT LEVELING LEG Tightly fasten the nuts securing the leveling leg Attach joint to stands so neither conveyor stand can move Fig 2 6 Fastening Stands ...

Page 19: ...2 4 4 Stand Fastening Method 2 Fasten anchor bolt and leveling leg to anchor plate 2 4 3 Stand Fastening Method 1 Fasten stand to floor Fig 2 7 Method 1 Fig 2 8 Method 2 ADJUSTABLE PRESSURE FITTING EXAMPLE ANCHOR BOLT AND WASHER 4 LEVELING LEG ...

Page 20: ...S WITH SCREWS 2 5 CONNECTING CABLE Connect each cable as shown below Tie up and secure excess printer cable PRINTER UNIT CONTROLLER UNIT POWER CORD Fig 2 9 Connecting Cable Fig 2 10 Printer Stand Case WEIGH CONVEYOR UNIT IMPORTANT NOTE Later versions of the WPL 3000 use a front mounted printer arm ...

Page 21: ...tting Mode 1 LABEL FORMAT section 4 2 1 3 Registering Date and Time This is performed in registration mode Refer to Programming Manual 4 Program PLU file This is performed in registration mode Refer to Programming Manual 5 Making Test Print Thread labels and confirm that printing is normal Refer to Test Mode 3 THERMAL HEAD section 3 2 4 6 Performing Total Clear Refer to Programming Manual 7 Backin...

Page 22: ...VICE MANUAL 0077B 2 10 Setup 2 2 7 METHOD FOR THREADING LABELS Thread labels as shown below For a detailed explanation of threading the label reel refer to Operation Manual Fig 2 11 Arrows indicate thread direction ...

Page 23: ...0 cannot enter standard mode after power is turned ON the machine cannot enter setting or registration mode For these situations when the machine does not enter standard mode after starting it is necessary to use Rescue Mode Rescue Mode by passes standard mode to enter another mode 1 With the HELP key pressed turn ON the machine 2 Rescue Mode appears after the display check sequence 3 In Rescue Mo...

Page 24: ...WPL 3000 SERVICE MANUAL 0077B 2 12 Setup 2 ...

Page 25: ...Thermal Head Setting C03 3 2 5 Sensor Check C04 3 2 6 Extra Memory C05 3 2 7 Setting ROM Switch C06 3 2 8 Label Format Editing C07 3 2 9 Sales Mode Setting C08 3 2 10 Machine ID No Setting C09 3 2 11 Preset Function Setting C10 3 2 12 Password C11 3 2 13 Data Transmission C99 3 2 3 3 3 3 3 6 3 7 3 9 3 9 3 9 3 12 3 12 3 13 3 14 3 14 3 15 ...

Page 26: ...WPL 3000 SERVICE MANUAL 0077B 3 2 Test Mode 3 3 1 MENU DIRECTORY DIAGRAM ...

Page 27: ... Check 5 Displaying Program Number 6 Conveyor Elevator and Label Applicator Test To enter test mode turn off the machine and restart while pressing any key exclud ing RESET to enter test mode When test mode appears on screen release the pressed key Use to scroll through the menu choices or enter corresponding menu number and press to jump to desired test mode operation Use ENTER to select test mod...

Page 28: ...is pressed the numerical value is displayed as shown in the above illustration Fig 3 1 Key Address CAUTION CAUTION Key 29 RESET key When RESET key is pressed the display returns to sub menu Note 1 If any keys do not work check cable connections at the buzzer board located inside the keyboard display unit Also check connections at the printer unit Note 2 Once the membrane keyboard has been removed ...

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Page 30: ...to test the label applicator s movement Press PLU to test the conveyor s up and down movement Note Compressed air must be supplied for these movement tests Program No Display C01 05 This displays program number and program version of ROM on main board Press to display FONT program number and version 3 2 3 RAM Clear C02 This initializes clears RAM E2 ROM and sets Test PLU data h ...

Page 31: ...ion programmed in the Setup Menu and Test Menu Setting Test Data C02 03 Set test data after performing RAM Clear and E2 ROM Clear Press ZERO twice to set test data OK is displayed after test data has been successfully set Note This operation is the same as step C02 01 RAM clear and step C02 02 E2 ROM clear plus test PLU s 1 through 10 are created along with a dummy shop name All RAM Clear C02 01 T...

Page 32: ...Resistance Value Entry Value 528 545 537 546 563 555 564 581 573 582 600 591 601 618 609 619 636 627 637 654 645 655 672 663 Print Usage Display C03 02 This shows the length in kilometers of label stock that has been issued This operation can also clear print usage length Enter 0 and press ENTER to clear print usage distance Always clear this setting when a new thermal head is installed Print Dens...

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Page 35: ...3C 04 reading is accepted Note Decrease value for faster operation A D Conversion Speed 01 Slow slower throughput most reliable 003D 02 02 Medium standard 03 Fast fastest throughput Width of Stabilization Window Difference in number of internal counts from previous sample that will be accepted as the same weight 003E 02 Example 02 2 count difference from last sample Note Increase value for faster ...

Page 36: ... Enable operator functions Dot Display This is used to edit label formats There are seven default label formats 1 to 7 See Section 4 2 1 1 Enter the label format number 1 7 then press PLU 2 Select X or Y coordinate using 3 Select Print Field numbers using or 4 Enter the new coordinate value then press ENTER 5 Press PRINT to print a test label 6 Press END to return to the main Test Menu Note Refer ...

Page 37: ...f Master Scale connections to the computer may vary depending on the efficiency of the level converters used MSCU3000 option is necessary for MASTER SCALE CAUTION CAUTION Note Refer to AC 3000 System Setup Manual for details of configuring a scale communication network Entry CSIS Mode Condition 1 ALONE Used for stand alone 2 MASTER SCALE Used for setting as a master scale See caution below 3 SATEL...

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Page 40: ...ew floppy disk for the first time perform Step C99 03 to format the disk Use 2DD type disks only CAUTION CAUTION 3 2 13 1 Data Transfer Select IF21 File No C99 02 01 Enter the IF 21FD file number 1 8 to be used then press ENTER Note 1 Master File contains all data programmed in Registration Mode E2 ROM File contains all configuration setting changes made in Setup and Test Modes 2 Master File conta...

Page 41: ...OUPON MASTER 7 MESSAGE MASTER 8 OPERATOR 9 PRESET KEY 10 LABEL FORMAT 11 SETUP FILE 12 AD MESSAGE 13 TAX MASTER 14 TITLE FILE 15 DEPARTMENT 16 GROUP 17 CAMPAIGN MASTER 18 BATCH FILE 19 20 SUB TOTAL 21 NUTRITION FILE SELECTION NO FILE FOR VERIFICATION 1 ALL FILE 2 MASTER FILE 3 E2ROM FILE 4 ITEM MASTER 5 STORE MASTER 6 COUPON MASTER 7 MESSAGE MASTER 8 OPERATOR 9 PRESET KEY 10 LABEL FORMAT 11 SETUP ...

Page 42: ... all data contained on floppy disk Press CHAR DELETE to begin deleting file Press any key other than CHAR DELETE to cancel delete Execute C99 03 02 Press CHAR DELETE again to confirm and begin execution Press any key other than CHAR DELETE to cancel execution Executing C99 03 03 Executing Initialization Complete C99 03 04 Initialization is complete when OK is displayed Note See Error Code list in ...

Page 43: ... Setting b02 4 2 3 Code Settings b03 4 2 4 Setting Initial Data b04 4 2 5 PLU File b08 4 2 6 Preset Report b10 4 2 7 Registration Select b11 4 2 8 Total Mode Select b12 4 2 9 Password b13 4 2 10 Tray Master Registration b15 4 2 11 Conveyor Setup b16 4 2 4 5 4 7 4 8 4 9 4 11 4 12 4 14 4 15 4 15 4 16 4 17 ...

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Page 47: ...UAL 0077B Setting Mode 4 4 2 SETUP MODE The following pages contain explanations for each menu 4 2 1 Label Format b01 Label format settings are performed in this mode See the table below for a detailed explanation of each step ...

Page 48: ... printing Select if scale will print legends 1 Title printing Example TOTAL PRICE b01 05 Print Store Name 0 No printing Select if scale will print store name 1 Printing and address b01 06 Product Description 0 99 5 0 5 increments area Includes name ingredients and messages b01 07 Label length 0 999 9 0 1 increments Length includes label length and space including gap Maximum 175mm Note Maximum len...

Page 49: ...1 Enter a 3 digit number and press ENTER The first digit is for 8 digit barcode type and the next two digits are for 13 digit barcode type 10 Digit Flag b02 02 Enter a 4 digit number and press ENTER The first two digits are for the 8 digit barcode type and the last two digits are for the 13 digit barcode type Barcode Type b02 03 This sets bar code type Select from the chart below Setting No Bar Co...

Page 50: ...ion Sets digits for UPC 8 position Sets digits for UPC 13 position Code is used to set the code positions for department group etc for totals accumula tion Enter numerical value and press ENTER for each selection Note Item Code format 12345678 step P01 16 in PLU programming Example Group set to 42 starts at the fourth digit and uses two digits 1 2 3 4 5 6 7 8 UPC Type b02 04 This sets the 13 digit...

Page 51: ...ERVICE MANUAL 0077B Setting Mode 4 4 2 4 Setting Initial Data b04 This is used to set initial data Enter numerical value and press ENTER for each selection See the table below for a detailed expla nation of each step ...

Page 52: ...NO Forced Tare a tare weight must be used before a label is allowed to print MENU NO SETTING ITEM ENTRY REFERENCE b04 01 Initial data for 3 digits N A in USA version register code b04 02 DATE PRINT Select by arrow then make numeric entry b04 03 PACK TIME Select by arrow then make numeric entry b04 04 EXPIRE TIME Select by arrow then make numeric entry key Numerical 1 PROHIBIT Enter 0 2 INSTALLED E...

Page 53: ... WPL 3000 SERVICE MANUAL 0077B Setting Mode 4 4 2 5 PLU FILE b08 This prohibits or enables entry of the selected items in PLU programming Enter the numerical value 0 or 1 and press ENTER for each selection ...

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Page 56: ...RVICE MANUAL 0077B 4 14 Setting Mode 4 4 2 7 Registration Select b11 This prohibits or enables menu items for selection on the registration menu Enter the numerical value 0 or 1 and press ENTER for each selection ...

Page 57: ...tals types Enter the numerical value 0 or 1 and press ENTER for each selection 4 2 9 Password b13 This allows passwords to be changed for registration total and subtraction modes Enter a 1 to 4 digit number and press ENTER to set password ITEMS IN PARENTHESES DENOTE DEFAULT SETTING Note A password of 6000 can not be entered ...

Page 58: ...eyor carries items a distance of 5mm in a time of 10 msec Use 10 msec intervals to set delay time Example A 6 inch tray with a set value of 50 would result in a delay time of 500msec Use this setting to center packages right to left on the weighing element Note Tray Master settings are only used when the WPL 3000 is configured for straight I line operation ...

Page 59: ...roduct breaks photo eye B Label Applicator fires Note 1 approx 1 8th inch distance Note Increase slower move label left b16 05 10 1 256 Conveyor Delay Timer Straight configuration only Time between A and B where A Trailing edge of product passes photo eye B Conveyor lowers package onto scale Note 1 approx 1 8th inch distance Note Increase package travels farther b16 06 1 1 256 Label Placing Type 9...

Page 60: ...WPL 3000 SERVICE MANUAL 0077B 4 18 Setting Mode 4 ...

Page 61: ...Chapter 5 Controller Unit 5 1 Overview 5 2 Block Diagram 5 3 Electronic Parts 5 3 1 Display Board 5 3 2 Junction Buzzer Board 5 4 Display and Key Check 5 5 Disassembly Diagram 5 2 5 3 5 3 5 4 5 6 5 7 ...

Page 62: ...y GP1046A01AA uses a Fluorescent dot display for characters and a fluorescent digital display for numbers The keyboard uses membrane keys Refer to the Operation Manual for an explanation of the function keys Fig 5 1 Controller Unit Registration Keyboard Layout Operation Keyboard Layout ...

Page 63: ...n the printer unit Power is supplied by the power supply unit SLS100PW in the contol box located in the weigh conveyor unit 5 2 BLOCK DIAGRAM FULL DOT DISPLAY 7 SEGMENT DIGITAL DISPLAY JUNCTION BUZZER BOARD P 887 1 Handle the display modules with care since they are made of glass 2 Do not remove the electrical plug when the machine is on CAUTION CAUTION Fig 5 2 Controller Unit Fig 5 3 Display Boar...

Page 64: ...a the Junction Buzzer board P 887 JUNCTION BUZZER BOARD P 887 KEY SHEET MEMBRANE KEYBOARD Fig 5 4 Display Board 7 SEGMENT DIGITAL DISPLAY FLUORESCENT DOT MATRIX DISPLAY FUSE F1 0 6A P N 42 1452 05 7 SEGMENT DIGITAL DISPLAY FUSE F2 0 5A P N 42 1451 01 All DIP switches on the display unit must remain in the OFF position If any switches are set to ON the display will not work properly FLUORESCENT DOT...

Page 65: ...077B Controller Unit 5 A single confirmation beep is made every time a key is pressed A buzzer attached to the Junction Buzzer board emits a series of beeps when a key entry error is made Fig 5 7 Junction Buzzer Board P 887 BUZZER ...

Page 66: ...ted all 120 keys on the keyboard may be checked for functionality Refer to Test Mode Sec 3 2 1 and Sec 3 2 2 in this manual for entering the test mode Test mode C01 03 is used for display check of the full dot and 7 segment digital displays Fig 5 8 Key Addresses Note Key 29 RESET is used to exit key check mode ...

Page 67: ...roller Unit 5 5 5 DISASSEMBLY DIAGRAM CONTROLLER UNIT JUNCTION BUZZER BOARD P 887 DISPLAY BOARD GP 1046A01A OPERATION KEY SHEET INSERT MEMBRANE KEYBOARD Fig 5 9 Controller Unit CABLE TO PRINTER UNIT DISPLAY FILTER TRANSPARENT KEYSHEET COVER ...

Page 68: ...WPL 3000 SERVICE MANUAL 0077B 5 8 Controller Unit 5 ...

Page 69: ...Chapter 6 Weigh Conveyor 6 1 Overview 6 2 Block Diagram 6 3 Electronic Parts 6 3 1 Load Cell Unit 6 3 2 A D Converter Board 6 4 Scale Check 6 5 Disassembly Diagram 6 2 6 3 6 4 6 5 6 6 6 7 ...

Page 70: ...d in the weigh conveyor and uses a load cell resistance strain gage as a weigh sensor ITEMS TO BE WEIGHED Fig 6 1 Weigh conveyor Fig 6 2 Items to be weighed roll across a sloping conveyor WEIGH UNIT CONTROL BOX ROLLER UNIT 6 1 OVERVIEW ROLLER UNIT WEIGH PLATTER SEAL WIRE Fig 6 3 Roller Unit ...

Page 71: ...MOTOR 5IK40GN ALU MAIN POWER SWITCH POWER SUPPLY UNIT SLS150PW POWER CORD SOCKET FUSED E64197 PRINTER UNIT WEIGH CONVEYOR CONTROLLER UNIT KEYBOARD DISPLAY P 854 DRIVE BOARD LOAD CELL UNIT CLC 25N CONNECTION FOR OPTIONAL INFEED CONVEYOR ELECTROMAGNETIC AIR VALVE LABEL APPLICATOR TIMING SENSOR Later designs use two power supplies LSF100 24 36 3409 01 Main 24VDC LDA30F 24 46 3180 09 Fans ...

Page 72: ...cell resistance strain gage converts power and load into direct electrical signals Load cell type CLC 25N Load maximum 25 kg Standard output within 5 Insulated resistance over 5M Ohm Applied voltage 12V A D BOARD P 830B RECEIVING PLATTER Fig 6 5 Load cell Fig 6 6 Disassembly of scale unit LOAD CELL UNIT ...

Page 73: ... board P 834x board installed in the printer unit Power regulators are installed on the A D converter board for IC and load cell electrical power levels These power regulators convert electricity supplied from the power supply unit located in the weigh conveyor to lower more stable voltages Fig 6 7 A D Converter Board P 830B Fig 6 7a Load Cell Connections Red VEX White VEX Green Signal Blue Signal...

Page 74: ...he test mode Use to scroll down and press ENTER to select Selection can also be made by numeric en try and pressing ENTER 1 Select hardware test mode C01 and press ENTER 2 Select A D check C01 01 and press ENTER 3 Press ZERO Confirm that the A D converter initial value is stabilized within 2000 1 count Note See Section 10 3 for calibation procedure 6 4 SCALE CHECK h ...

Page 75: ...L 0077B Weigh Conveyor 6 6 5 DISASSEMBLY DIAGRAM WEIGH PLATTER UNIT ROLLER UNIT SEALING WIRE FOUR CORNER ADJUSTMENT SCREW SCALE UPPER CASE LOAD CELL UNIT A D CONVERTER BOARD P 830B WEIGH CONVEYOR BASE Fig 6 8 Disassembly Diagram ...

Page 76: ...ter Unit Thermal head label sensor adjustment 7 3 2 Label Applicator Unit 7 4 Adjustment Position of the Label Applicator Unit 7 5 Movement Test 7 6 Disassembly Diagram Stand Unit 7 7 Disassembly Diagram Printer Unit 7 8 Disassembly Diagram Label Applicator Unit 7 2 7 3 7 4 7 4 7 10 7 14 7 15 7 16 7 16 7 17 ...

Page 77: ...applicator arm is 100mm 4 inches Figure 7 1 is a side view of the printer and label applicator units The units are suspended from the printer stand and can be adjusted according to the height of the prod uct and the direction in which the label is applied The printer em ploys a 60mm wide thermal head LABELING ARM LABEL APPLICATOR ARM UNIT AIR CYLINDER ELECTROMAGNETIC VALVE ADJUSTMENT KNOB LABEL AP...

Page 78: ...cator Unit 7 7 2 BLOCK DIAGRAM Fig 7 3 Block Diagram I O BOARD P 892 JUNCTION BOARD P 838A MAIN CPU BOARD P 834 THERMAL HEAD Printer Unit Weigh Conveyor Controller Unit Keyboard Display Label Applicator Unit SUCTION FAN LABEL TAKEN SENSOR Label Gap Sensor ...

Page 79: ...r and label taken sen sor input 7 Conveyor control 8 I 2 NET output 7 3 ELECTRONIC COMPONENTS 7 3 1 Printer Unit Thermal head label sensor adjustment IC12 PD70208G 10 CPU V40 F1 1A 5V POWER FUSE IC15 Main EPROM BATTERY SWITCH LITHIUM BATTERY IC14 Font EPROM Main CPU Board P 834 Fig 7 5 Main CPU Board asterisk indicates latest version subsequent versions will be followed by letter e g A B C Note IC...

Page 80: ...lled by the I O board P 892 Junction Board P 838 This board transmits peeling sensor reflective type and stepping motor signals through the cable from the J4 connector to the main board LITHIUM BATTERY BATTERY SWITCH CAUTION CAUTION J4 J2 J1 J3 Fig 7 6 Battery Switch Fig 7 7 Junction Board P 838 asterisk indicates latest version subsequent versions will be followed by letter e g A B C asterisk ind...

Page 81: ...l head attachment screws 2 by a 1 4 turn Type LH3124 Overall dot count 448 dots Dot pitch 0 135 mm Head resistance value 528 to 672 Ohm Required power 0 66 W dot Applied voltage 24 V DC Thermal Head The thermal head is constructed of 448 dot heating elements and made especially for printing labels When ink glue or other debris becomes stuck to the printing area of the thermal head heat to the labe...

Page 82: ... is com plete tighten the two attachment screws 3 Set the thermal head resistance value Setting are performed in test mode C03 THERMAL HEAD Refer to Test Mode Sec 3 2 1 and 3 2 4 for starting test mode CAUTION CAUTION Avoid touching the surface of the head If the surface is touched clean using head cleaner made especially for thermal heads Lower print density before adjusting for more precise adju...

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Page 85: ...Unit Fan Motor The fan motors use suction to hold labels against the absorption plate until they are applied to a package AIR CYLINDER SPEED CONTROLLER ELECTROMAGNETIC VALVE FAN MOTORS PEELING SENSOR LABEL ABSORPTION PLATE Fig 7 15 Applicator Unit Disassembly Diagram APPLICATOR SHAFTS COVER ...

Page 86: ...gnetic valve controls the air supply to the air cylinder that pushes the labeling arm downward The electromagnetic valve also controls the air supply that moves the labeling arm up A TERMINAL NUMBER WIRE COLOR B TERMINAL NUMBER A PORT 1 RED 1 A PORT 2 BLACK 2 Fig 7 16 Electromagnetic Valve A port A B 1 2 ...

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Page 88: ... Mode Section 3 2 1 and 3 2 5 in this manual for verifying operation of peeling label taken sensor A K E C Connector UL tube Peeling sensor Peeling Sensor Sensor Protective Cover 1 A anode green 2 K cathode blue 3 C collector purple 4 E emitter gray Connector No Connection Terminal Color Fig 7 19 Peeling Sensor Fig 7 20 Peeling Sensor J2 P 838 ...

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Page 90: ...r s movement Refer to TEST MODE Section 3 2 2 for additional information Peeling Sensor Test This tests the sensitivity of the peeling sensor and the label gap sensor Refer to Test Mode Section 3 2 5 for additonal information Note Voltage values on the peeling sensor may be tested on the P 838 board connector J2 Measure between pins 3 positive and 4 negative Note Use a label or white paper to test...

Page 91: ...BLY DIAGRAM PRINTER UNIT STORE CABLE UNDER COVERS CPU BOARD P 834 LABEL APPLICATOR UNIT I O BOARD P 892 JUNCTION BOARD P 838 LABEL SENSOR THERMAL HEAD STEPPING MOTOR Fig 7 24 Disassembly diagram stand unit Fig 7 25 Disassembly diagram printer unit IMPORTANT NOTE later versions of the WPL 3000 use a front mounted printer arm ...

Page 92: ...licator Unit 7 7 8 DISASSEMBLY DIAGRAM LABEL APPLICATOR UNIT LABEL ABSORPTION PLATE SPEED CONTROL AIR CYLINDER ELECTROMAGNETIC VALVE HINGE METAL FITTING APPLICATOR SHAFTS FAN MOTORS PEELING SENSOR Fig 7 26 Disassembly Diagram label applicator unit COVER ...

Page 93: ...ower Supply Unit 8 3 2 Drive Board P 854 8 3 3 Electromagnetic Valve 8 3 4 Air Cylinder 8 3 5 Application Timing Sensor 8 4 Elevator Check and Parts Adjustment 8 4 1 Weigh Conveyor 8 4 2 Conveyor Fall Prevention Screw Adjustment 8 5 Disassembly Diagram 8 2 8 3 8 4 8 4 8 5 8 5 8 6 8 7 8 8 8 8 8 9 8 10 ...

Page 94: ...tached by the label applicator unit 8 1 WEIGH CONVEYOR UNIT WEIGHED PRODUCT WEIGH CONVEYOR WEIGHER UNIT THE END OF THE WEIGH CONVEYOR RAISES AND LOWERS To remove the Weigh Conveyor Unit 1 Remove the conveyor belt from pulley as shown below 2 Grip the handles and lift the weigh conveyor straight up Fig 8 1 Weigh conveyor unit HANDLE Fig 8 2 Removing Weigh Conveyor PULLEY WEIGH CONVEYOR PULLEY CONVE...

Page 95: ...LU Main Power Switch TERMINAL POWER SUPPLY UNIT SLS150PW Power Cord Socket Power Filter Board E64197 PRINTER UNIT WEIGH CONVEYOR INFEED CONVEYOR Optional INDEXING PHOTO SENSOR ELECTROMAGNETIC AIR VALVE LABEL APPLICATOR TIMING SENSOR CONTROLLER UNIT Keyboard Display Later designs incorporate a single P 854 Drive Board Later designs incorporate two 24V DC power supplies LSF 100 24 36 3409 01 Main 24...

Page 96: ...in the printer unit Note Later designs use two 24V DC power supplies See previous page 8 3 ELECTRONIC COMPONENTS The control box inside the weigh conveyor contains the power supply driver board and other electronic components regulating the machine Fig 8 4 Inside of Control Box CONTROL BOX Product name SLS150PW Voltage input 85 to 132 V AC Frequency 50 60 Hz Voltage output 24 V DC Current output 6...

Page 97: ...olled by the driver board Control signals from the driver board are isolated by photocouplers This driver board P 854 is installed in the control box located under the weigh conveyor 8 3 3 Electromagnetic Valve This electromagnetic valve drives the air cylinder which raises and lowers the weigh conveyor Fig 8 6 Driver Board Fig 8 7 Electromagnetic Valve SSR PHOTO COUPLER TRANSISTOR WEIGH CONVEYOR ...

Page 98: ...r Conveyor Speed Control Turn the nut and knob clockwise as far as they will go Turn the knob counterclockwise four rotations and tighten the nut For decreasing speed Turn knob clockwise For increasing speed Turn knob counterclockwise Fig 8 8 Air Cylinder B A A terminal number color B terminal number A port 1 black 1 A port 2 black 2 B port 1 black 3 B port 2 black 4 A port B port RAISE CONVEYOR S...

Page 99: ...GROUND OBJECT Place the item to be detected in position Start with the potentiometer fully CCW Turn the potentiometer CW until the orange lamp is OFF This is position A If the orange lamp does not turn off position A is fully CW CW clockwise CCW counter clockwise Remove the detected item From position A turn the potentiometer CCW until the orange lamp turns ON This is position B Turn the potentiom...

Page 100: ...ode At step C01 06 00 press PLU to perform the elevator test 8 4 1 Weigh conveyor To confirm and adjust the tension of the conveyor drive belt follow the procedures below 1 Confirm belt tension When pressed with a force of 1kgf 2 2 LBF in the middle of the belt the belt should give 9 11mm 3 8in 7 16in Fig 8 10 Conveyor Belt 2 Belt tension can be adjusted by changing motor position To adjust tensio...

Page 101: ...s shown in Fig 8 12 Adjust so that there is a 0 5mm 1 64 inch gap between screw and brace CONVEYOR FALL PREVENTION SCREW Fig 8 12 Conveyor Fall Prevention Screw Fig 8 11 Adjusting Belt Tension BRACE Conveyor belts must be tight to prevent slipping To adjust tension loosen the roller screw and raise or lower the roller as shown in Fig 8 11 ...

Page 102: ... DIAGRAM AIR CYLINDER POWER SWITCH APPLICATION TIMING SENSOR ELECTROMAGNETIC VALVE DRIVER BOARD P 854 POWER SUPPLY UNIT SLS150PW WEIGH CONVEYOR DRIVE MOTOR POWER FILTER BOARD P 859 Fig 8 13 Disassembly Diagram DRIVE PULLEY Later designs incorporate two 24 VDC power supplies ...

Page 103: ...Chapter 9 Troubleshooting 9 1 Periodic Parts Replacement 9 2 Breakdown and Countermeasure 9 3 Error Messages 9 2 9 3 9 4 ...

Page 104: ... Thermal head LH3124 Replacement period When label distance reaches 60 km Check this value in Test Mode C03 02 Section 3 2 4 2 Display Display board Expected life over 30 000 hours using standard rated drive 3 Print roller Replacement period When label distance reaches 300 km Check this value in Test Mode C03 02 Section 3 2 4 MTBF Mean Time Between Failures 9 1 PERIODIC PARTS REPLACEMENT MTBF ...

Page 105: ...attery 2 External noise static electricity 3 Defective main board 1 Unstable voltage 2 Defective power supply unit 3 Defective display board 4 Defective main board 1 Dirty thermal head 2 Defective thermal head 3 Defective thermal head cable 4 Defective main board 5 Defective power supply unit COUNTERMEASURE 1 Reinsert power plug 2 Replace fuse 3 Check replace power switch 4 Check replace main boar...

Page 106: ...abel size settings are incorrect Mis threaded labels Discount price is equal to or greater than the original price Internal data base has become corrupted Accumulated operator totals have exceeded 30 transactions or 100 000 per operator or 100 total transactions Same operator number used within one second Same operator number used within one second Solution Edit product description by removing exc...

Page 107: ...ain program does not start up Memory in E2ROM has been corrupted A D board is discon nected or malfunctioning NV RAM calibration data in A D board has been corrupted Scale is unstable or was powered up with some object on the platter Scale was powered up with some object on the platter Solution Remove package from scale Change weight limit Remove package from scale Change weight limit Remover labe...

Page 108: ...ransmis sion of transaction results to Total area of memory No communication with second printer at initial power up of main unit No communication with second printer Too many characters per PLU Too many characters per line Solution Clear scale totals Power scale off ater RAM clear do NOT use RESET key Re initialize Master Satellite system Press PLU key to resend data Press VOID key to cancel tran...

Page 109: ...ed 30 transactions or 100 000 per operator or 400 total transactions Master scale is Off Line Master scale is in Totals Mode or Test Mode Satellite cannot report Totals data back to Master scale Satellite does not receive requested data from Master Board Solution Check Master Board replace if necessary Check all cable connec tions Check for incorrectly wired cables Wait and restart opera tion Wait...

Page 110: ...er not connected Incorrect disk format Solution Reload data to from disk Create new master disk Install DS DD floppy disk into recorder Repair IF 21FD Switch write protect tab on the disk to correct position Select an unused file number Select an existing file number Check that only DIP switches 2 and 5 are in the down position Check that the IF 21FD has the latest firmware version J 209N Use 9 pi...

Page 111: ...Chapter 10 Load Cell Unit 10 1 Location of Main Parts 10 2 Replacing the Load Cell Unit 10 3 Span Calibration Adjustment 10 2 10 3 10 6 ...

Page 112: ...WPL 3000 SERVICE MANUAL 0077B 10 2 Load Cell Unit 10 Fig 11 1 Location of main parts 10 1 LOCATION OF MAIN PARTS ...

Page 113: ...base seal wire unnecessarily since it is necessary to replace the sanction seal when the seal wire is cut 2 Cutting seal wire and removing weigh platter 1 Cut seal wire 2 Unfasten seal screws screw 1 screw 2 and remove weigh platter Fig 11 2 Scale unit Fig 11 3 Seal wire and weigh platter CAUTION CAUTION WEIGH PLATTER PLATTER SUPPORT ROLLER UNIT WEIGH PLATTER MAIN BODY OF WEIGHING MECHANISM SCREW ...

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Page 115: ...t screws so that they just make contact with the limit bolts when the weight is loaded Gap in Fig 11 9 The four corner limit screws protect the load cell from being damaged when an excessive load is applied to the weigh platter Adjustment of the four corner limit screws is necessary when the load cell has been replaced or the main body has received a jolt The load cell cell cable is soldered to th...

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Page 117: ...30000 2 count If it is within 30000 2 save data If span adjustment is not within 30000 2 count press TARE and remove the weights Repeat the procedure beginning with step 1 A D converter initial value 3 Saving data Save data to E2 ROM Remove weights from scale rollers and remove the roller unit Remove cap and press the memory switch on the A D board See Fig 11 11 Span Adjustment Flowchart Fig 11 10...

Page 118: ...g COUPON TEXT key to activate the conveyor If A D counts are not the same when the conveyor is up and down check for binding between conveyor and scale rollers CAP CAUTION CAUTION Do not press the switch with a screw driver or other metallic object Do not cut the base seal wire unnecessarily since it is necessary to replace the sanction seal when the seal wire is cut Fig 11 11 A D board memory sav...

Page 119: ...Appendix A 1 Installation Notes A 2 A 2 Label Format Worksheets A 9 ...

Page 120: ...silicone or double backed tape Note Be sure to align holes in strips with holes in stand WPL Assembly 1 Place the WPL on the stand Note Main power switch faces the side with printer arm mounting plates 2 Bolt WPL to stand 4 corners from under side Note Bolts provided in stand hardware kit 3 Attach infeed roller assembly brackets L configuration only 4 Bolt printer arm to stand 6 bolts Note Bolts p...

Page 121: ...m underside 3 Connect cable to WPL located behind the WPL infeed end panel Programming 1 Install and configure labels 2 Load PLU file General Settings ROM Switches See page A 7 for details a Select conveyor timeout switch 0039 b Select if shelf life calculations will count today as one day switch 003B c For use with an automatic wrapper set the following switch values i 003C 03 ii 003D 03 iii 003E...

Page 122: ...cking paper b TEST MENU C07 Section 3 2 8 i Modify label format as needed 5 Set Applicator Stroke SETUP MENU b16 03 Section 4 2 11 a Applicators i Standard 08 typical setting ii Extended 05 typical setting b Test and adjust as necessary for maximum travel but no delay in up stroke 6 Delay Package on Scale SETUP MENU b16 01 b16 02 Section 4 2 11 a Set b16 01 100 b Set b16 02 100 Note These delays a...

Page 123: ...n 4 2 11 a Test lowering time of conveyor using the widest tray available b Adjust b16 07 as low as possible to allow the tray to be moved off the scale area Note Lowering quickly ensures the scale is ready to accept the next package I Configuration 1 Memory Clear TEST MENU C02 Section 3 2 3 a C02 01 Ram Clear b C02 02 E2 ROM Clear c C02 03 Test Set Optional 2 Set i Configuration TEST MENU C06 ROM...

Page 124: ... 4 2 11 a Set b16 01 100 b Set b16 02 100 Note These delays are necessary to set the correct times for the next step 8 Label Placement Standard SETUP MENU b16 04 Section 4 2 11 a Test label placement b Adjust b16 04 setting as needed i a lower value moves the label to the leading edge of the package ii a higher value moves the label to the trailing edge of the package 9 Set Delay of package on sca...

Page 125: ...se changes must be registered to the A D Board NV RAM See step C01 01 above for the procedure Typical Speed Up settings are 003C 03 003D 03 and 003E 03 Address Default Description Conveyor Time Out 0039 00 00 No Conveyor runs continuously 01 Yes Conveyor stops after 10 minutes of non use Configuration 003A 01 00 Straight through In Line 01 L shape Shelf Life 003B 00 00 Today counted as one day 01 ...

Page 126: ...eys to navigate through PLU programming The following items have been added to PLU programming for the WPL 3000 OPERATION Transfer Mode With no active PLU display reads KEY IN PLU NUMBER press the START func tion key to move packages across the conveyor system without weighing or labeling Address Description P01 26 Label Format 0 4 P01 28 Label Print 0 Reference 1 Straight 2 Rotate P01 29 Upper We...

Page 127: ...05 0106 Field Standard Function Code Value Old Value New Value X Width Y Height X Width Y Height 28 Ad Message 1 0E 9999 0000 29 Sign 0B 0340 0060 30 Sub Total Price 28 0342 0067 31 Sub Total Weight 27 0390 0211 32 Sub Total Pieces 26 0067 0051 33 Piece Count 2C 0156 0216 34 PCS Legend 2C 0224 0211 35 Legend 2B 0286 0211 36 Count 2B 0305 0216 37 Legend 2B 0372 0211 38 For Price 2D 0391 0216 39 Tot...

Page 128: ... 0139 Field Standard Function Code Value Old Value New Value X Width Y Height X Width Y Height 28 Ad Message 1 0E 9999 0000 29 Sign 0B 0348 0093 30 Sub Total Price 28 0351 0100 31 Sub Total Weight 27 0390 0271 32 Sub Total Pieces 26 0075 0084 33 Piece Count 2C 0164 0276 34 PCS Legend 2C 0232 0271 35 Legend 2B 0294 0271 36 Count 2B 0313 0276 37 Legend 2B 0380 0271 38 For Price 2D 0399 0276 39 Total...

Page 129: ...l Pieces 26 0067 0051 20 NET WT Legend 91 0024 0271 21 Total OZ Weight 32 0211 0271 22 Total OZ Legend 32 0264 0271 23 Symbol 32 0562 0271 24 LB Weight 31 0341 0271 25 LB Symbol 31 0394 0271 26 OZ Weight 30 0457 0271 27 OZ Symbol 30 0510 0271 Field Standard Function Code Value Old Value New Value X Width Y Height X Width Y Height 28 00 0016 0457 29 0B 30 28 31 27 32 26 33 2C 34 2C 35 2B 36 2B 37 2...

Page 130: ... Number 12 0029 0159 26 PCS 12 0074 0151 27 PLU Name 2 49 0008 0525 Field Standard Function Code Value Old Value New Value X Width Y Height X Width Y Height 28 62 0008 0402 29 lb Pack Date 63 0008 0402 30 8D 0008 0402 31 Weight lb 63 0008 0222 32 8D 0008 0222 33 TOTAL PRICE Legend 90 0202 0222 34 Coupon Area 64 0407 0522 35 Ingredients 0C 0008 0525 36 47 0008 0525 37 Ad Message 1 0E 9999 0000 38 0...

Page 131: ...at Calories 6F 0434 0307 25 Total Fat 70 0360 0390 26 Total Fat units 71 0360 0348 27 Total Fat 72 0360 0318 Field Standard Function Code Value Old Value New Value X Width Y Height X Width Y Height 28 Saturated Fat 73 0328 0390 29 Saturated Fat units 74 0328 0348 30 Saturated Fat 75 0328 0318 31 Cholesterol 76 0295 0390 32 Cholesterol units 77 0295 0348 33 Cholesterol 78 0295 0318 34 Sodium 79 026...

Page 132: ... Code Value Old Value New Value X Width Y Height X Width Y Height 28 Total Fat 72 0287 0412 29 Saturated Fat 73 0221 0375 30 Saturated Fat units 74 0260 0375 31 Saturated Fat 75 0287 0375 32 Cholesterol 76 0221 0339 33 Cholesterol units 77 0260 0339 34 Cholesterol 78 0287 0339 35 Sodium 79 0209 0303 36 Sodium units 7A 0260 0303 37 Sodium 7B 0287 0303 38 Carbohydrates 7C 0209 0268 39 Carbohydrates ...

Page 133: ...ght 27 0000 0130 20 Sub Total Pieces 26 0067 0051 21 Piece Count 2C 0000 0139 22 PCS Legend 2C 0067 0135 23 Total OZ 32 0349 0100 24 Symbol oz 32 0386 0090 25 Symbol 32 0426 0100 26 Symbol 32 0584 0100 27 LB inside 31 0445 0100 Field Standard Function Code Value Old Value New Value X Width Y Height X Width Y Height 28 Symbol lb 31 0484 0090 29 OZ inside 30 0526 0100 30 Symbol oz 30 0561 0090 31 32...

Page 134: ...IW603P1005 ISHIDA CO LTD 44 SANNO CHO SHOGOIN SAKYO KU KYOTO 606 JAPAN PHONE 075 771 4141 FACSIMILE 075 751 1634 TELEX 05422065 SCALES J CABLE ADD SCALES KYOTO ...

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