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Diagraph  - an ITW Company              LA/4700 User Manual - Revision B

Troubleshooting

Page 48

Tr

oubleshooting

Servo Controller Board (4700-350) Test Points 

WARNING These measurements must be taken with the top cover removed, where 
High-Current DC voltages are present. Please use caution when measuring test point 
voltages and never attempt to disconnect cabling while the unit is powered on.

Test Point

Expected Signal

How to Fix

Servo

 

Controller

 

Board

 

4700

‐

350

TP

 

1

BLDC

 

Hall

 

Sensor

 

Power

6.2

 

VDC

 

+/

‐ 

0.5

 

VDC

Check

 

TP5

 

for

 

correct

 

voltage.

 

If

 

TP5

 

is

 

correct,

 

replace

 

board

 

due

 

to

 

driver

 

IC

 

failure.

TP

 

2

Power

 

Supply

 

Ground

0

 

VDC

TP

 

3

5

 

VDC

 

Logic

 

Supply

5

 

VDC

 

+/

‐ 

0.25

 

VDC

Check

 

TP5

 

for

 

correct

 

voltage.

 

If

 

TP5

 

is

 

correct,

 

replace

 

board

 

due

 

to

 

5

 

VDC

 

regulator

 

failure.

TP

 

4,

 

6

Chassis

 

Ground

0

 

VDC

TP

 

5

VBUS

 

Regulated

35

 

VDC

 

+/

‐ 

0.5

 

VDC

Check

 

TP7

 

for

 

correct

 

voltage.

 

If

 

TP7

 

is

 

correct,

 

replace

 

board

 

for

 

VBUS

 

regulator

 

failure.

TP

 

7

VBUS

48

 

VDC

 

+/

‐ 

0.5

 

VDC

With

 

power

 

off,

 

check

 

ohms

 

across

 

D2.

 

If

 

0

 

ohms,

 

replace

 

board

 

due

 

to

 

transzorb

 

high

 

voltage

 

damage.

 

If

 

D2

 

ok,

 

check

 

power

 

supply

 

cable

 

and

 

power

 

supply

 

voltage

 

at

 

terminals.

TP

 

8

RSENSE

 

MONITOR

<

 

200

 

mVDC

 

RMS

 

when

 

running

 

servo

If

 

voltages

 

are

 

measured

 

above

 

200

 

mVDC

 

RMS,

 

replace

 

board

 

due

 

to

 

current

 

control

 

failure.

Содержание LA/4700

Страница 1: ...4700 010 Revision B...

Страница 2: ...n tinue specifications and designs shown in this manual without notice and without incurring obligation Diagraph has made every effort to verify the informa tion contained in this manual but reserves...

Страница 3: ...00 UL 60950 using Diagraph an ITW Company approved items Units are only tested and qualified with Diagraph an ITW Company approved parts and accessories Use of other parts or accessories may introduc...

Страница 4: ...ns In compliance with UL safety standards the stand must be secured to the surface where it is located Additionally this type of securing will result in greater product application accuracy 1 3 Docume...

Страница 5: ...arrow Web 5 in Wide Web 9 in 0 5 in 12 7 mm Min to 4 0 in 101 6 mm Max 0 5 in 12 7 mm Min to 9 0 in 228 6 mm Max Product Rate LA 4700 800 PPM Max Temperature 41 F 104 F 5 C 40 C Humidity 10 to 85 RH N...

Страница 6: ...mm Tamp Stroke 20 in cylinder 3 19 in 76 482 mm 3 in 76 mm 19 5 in 495 3 mm Air Consumption while running 2 5 CFM at 80 PSI 2 0 CFM at 80 PSI 5 CFM at 80 PSI Tamp Blow Distance Pad to product blow dis...

Страница 7: ...d P N 4700 800W9L Wide Web WIPE Left Hand P N 4700 800W9R Wide Web WIPE Right Hand P N 4700 800T5L Narrow Web TAMP Left Hand P N 4700 800T5R Narrow Web TAMP Right Hand P N 4700 800T9L Wide Web TAMP Le...

Страница 8: ...inch shaft P N 4700 630 9 inch shaft P N 4700 630W The nip assembly holds the label liner in constant contact with the drive roller It uses a non stick coating to avoid label build up This assembly i...

Страница 9: ...is an optional device that allows the feed speed and label placement to be synchronized with changing linespeeds The Photocoder uses two photosensors that are spaced a fixed distance apart By measurin...

Страница 10: ...holding torque The rewind is belt driven using an automatic tensioner This belt should be inspected for wear at the recommended service intervals The tamp pad captures the label from the drive module...

Страница 11: ...operation of the tamp cylinder and the delivery of the label from the drive module to the product The manifold has two pressure regulators one for tamp pressure and the other controls both vacuum and...

Страница 12: ...of the cylinder air assist or vacuum to change The Main Controller Assembly III is a third generation of Diagraph designed micro controller coupled with an interface board The Microcontroller Unit MCU...

Страница 13: ...d durability elimination of any clutch or dancer arm and limit switch The control current set by the system in accordance to the state of operation directly controls the rewind s tension The system el...

Страница 14: ...DC NPN type 6000 903 as shown 4600 903 is the older style with a flat lens The tamp pad sensors auto retract and label present and the label low sensor are diffuse light sensors All three sensors are...

Страница 15: ...simplicity in design The sensor should not require adjustments since the threshold levels are set at the factory The sensor constantly monitors pressure and triggers an error on the system if the air...

Страница 16: ...les and features which adds a great deal of diversity to the product line In this simplification the same MCU firmware and GUI memory run both the Printer Applicators PA 4600 PA 6000 and the Label App...

Страница 17: ...e orientation for application The LA 4700 are capable of rotating and pitching about various axes to accommodate a wide range of label placement opportunities Select the best orientation from the give...

Страница 18: ...odate a wide range of label placement opportunities Select the best orientation from the given measurements and desired label locations Top Down Side Apply Nose Down Nose Up Top Down TAMP FASA 50 in 1...

Страница 19: ...edicated AC line drop is preferred This eliminates problems caused by other AC loads on the same line such as motors which create back EMF Disturbances such as these can cause erratic behavior system...

Страница 20: ...Connect the clean dry compressed air line supplying 60 psi or greater at 2 5 CFM or better to the inlet air filter regulator of the system with the OSHA valve closed The air should be free of oil lubr...

Страница 21: ...s the conveyor using the supplied mounting bracket Sub Step b Adjust the sensor s sensitivity to detect just the product and ignore the background This can be done by placing the actual product in the...

Страница 22: ...ng OTS Screens on page 33 Power On Step 6 Enter Values for the System Settings Goal Enter System information pertaining to Application Mode Serial Baud Rate and Passcode Map Beginning in the Offline m...

Страница 23: ...formation on how to make these selections Wipe or WASA System For a typical one wipe application the following settings provide a good start Tamp or FASA System For a typical one tamp application the...

Страница 24: ...e correct pressure is set press down on the knob to lock it in position Remove the knob entirely by lifting it up past the unlock point if there is concern about system tampering TAMP FASA Step 9 Posi...

Страница 25: ...m the liner to create a leader Route the liner around the dancer arm B and feed into the drive module Feed the liner under the gap sensor E and around the peel blade F Open the nip roller arm lever D...

Страница 26: ...cer arm B and feed into the drive module Feed the liner through the gap sensor D and around the peel blade E Be sure to avoid webbing over the air assist tube F Open the nip roller arm lever C Take th...

Страница 27: ...ose to the inner guide and slide the outer guide B to the edge of the liner and tighten the knurled screw Sub Step c 1 Loosen knob C and adjust the brush clamp across the label width to the mid positi...

Страница 28: ...hat the label dispensed covers the ported vacuum holes and covers the label present sensor if equipped These screws adjust the tamp pad height in relation to the peel blade edge 2 Before locking the s...

Страница 29: ...ed Conversely turning the setscrew counter clockwise increases the speed Sub Step c The air cushion absorbs the shock of the tamp returning to the fully retracted or home position To increase the amou...

Страница 30: ...sure and counter clockwise to increase it Since the blow valve has an additional trim of a dedicated flow control set the pressure as high as necessary for vacuum Typically a pressure range between 30...

Страница 31: ...to set the material for operation During the calibrate process the Status LED will flash green while calibrating 5 When calibration is complete the Status LED will either be green if the process was s...

Страница 32: ...ng home but can impact the final return time of the tamp pad to the home position Increase the air cushion adjustment so that no metallic clank is heard when the cylinder retracts but not so much that...

Страница 33: ...ll for the beginning 80 of the roll but equally as well for the remaining 20 If the vacuum is too high it will be most notable when the transfer to the product suffers It will also be noticeable over...

Страница 34: ...e button below the text until it displays Yes The choices are left and right handed based on the direction of the drive module on the baseplate This is determined by facing in the direction of the fee...

Страница 35: ...blank area of liner without interpreting this as a missing label GUI Version 1 29 and higher only The rewind profile changes the speed and tension to match the application requirement In five incremen...

Страница 36: ...rate product delay distance 1 Blow 1 product trigger to 1 blow on a blow box application 2 Blows 1 product trigger to 2 blows on a blow box application 1 Wipe 1 product trigger to 1 label feed Wipe or...

Страница 37: ...linespeed the more important the exact setting is entered ALL APPLY MODES PHOTO SPEED ENCODER ENABLED When the system is running with the Photo Speed Encoder enabled the product speed is automatically...

Страница 38: ...ct surface before contact This allows the lightest touch of the label to the product which can accomplish nearly the same effect as a tamp blow on many products and have the benefit of positive contac...

Страница 39: ...d far enough away from the system to allow for the label feeding to finish in time for application This works well for applications where each label is unique A final choice of Product Sensor 2 allows...

Страница 40: ...active and a white background if no signal is present The Rewind Diagnostic screen will allow the user to test the motor by pressing the TEST button This will activate the motor briefly to verify oper...

Страница 41: ...PA Unit Gap Sensor LA Unit LOW Label Low PD2 Product Detector 2 AUX Auxiliary Input CYL Cylinder Home PD1 Product Detector 1 The Pneumatics Diagnostic screen permits testing of the various valves on t...

Страница 42: ...is offline due to error This includes Media Out Air Pressure Out Drive Errors Repeat Label or Tamp Threshold Exceeded etc Steady Warning Unit has experienced a condition that requires attention but it...

Страница 43: ...input event Screen Functionality Input Event Description None No input event assigned Online Enter online mode Level activated Cannot enter online mode if there is an error Deactivate signal for offl...

Страница 44: ...n B User Interface Page 43 User Interface 5 6 Information Screens Map Note Information screens can be entered while running online or offline The below columns indicate the menu structure for the give...

Страница 45: ...itched 24 VDC supply are turned off Once off the screen will transition to the next following screen for turning it back on If this screen is entered but no selection is made within 10 seconds the scr...

Страница 46: ...tion trigger but could not start timing sequence since the apply cycle was not complete On a FASA system this could mean that the second apply cycle has a product delay that is too short Label on Dete...

Страница 47: ...m Errors Note Any of the following errors will place the unit in offline thus stopping operation Screen Screen Screen E02 Repeat Label Cycle E03 Repeat Tamp Cycle E04 Cylinder Not Home E06 Air Pressur...

Страница 48: ...evision B Troubleshooting Page 47 Troubleshooting 6 3 Electrical Test Points Power Supply Terminals Measure these tests with a VOLT METER and the cables disconnected from the pc board Test Expected Re...

Страница 49: ...tage If TP5 is correct replace board due to driver IC failure TP 2 Power Supply Ground 0 VDC TP 3 5 VDC Logic Supply 5 VDC 0 25 VDC Check TP5 for correct voltage If TP5 is correct replace board due to...

Страница 50: ...T METER and the cables connected from the pc board Test Expected Result Coil A to Coil B Less than 2 Coil B to Coil C Less than 2 Coil C to Coil A Less than 2 Test Expected Result HALL A and Ground 0...

Страница 51: ...roller is turning backwards liner is pulled from rewind Unit is incorrectly webbed Re web the label liner as seen on page 24 Unit is not correctly configured for left hand or right hand Confirm that...

Страница 52: ...rter labels require a steeper angle to the product surface page 26 Wipe on brush position is too close to peel edge For labels longer than 2 inches 50 8 mm move the brush away from the peel blade edge...

Страница 53: ...orted Open pad and check First column of holes should be open matching the width of the label Last column of holes matching the label s length should be open but only those matching the width of the l...

Страница 54: ...See Tamp Cylinder Adjustments on page 27 Cylinder home sensor position too low Move the cylinder home sensor to a position where the cylinder is detected home later Air cushion set too slow The air cu...

Страница 55: ...mentally simple as a roll of labels would appear there are a few key areas that can cause problems and these problems are sometimes falsely associated with the equipment and not the label The typical...

Страница 56: ...ed Start the MTool2 program and once the system s param eters are read select the tab to download new firmware This takes approximately one minute and concludes by re reading the parameters Maintenanc...

Страница 57: ...Supply 4700 505 Drive Module Power Capacitor 6146 617 YES Peel Blade Narrow Web 6146 617W YES Peel Blade Wide Web NIP ROLLER ASSEMBLIES Narrow and Wide Versions Contain Nip Roller Nip Roller Shaft Ni...

Страница 58: ...mbly III MCA III Includes MCU Board Interface Board User Interface Enclosure 4600 503 Rewind BLDC Motor 4600 950 YES MAINTENANCE KIT Wear Items Set Includes 2 Rewind Belts 3 Spindles 2 ea Springs 3 Un...

Страница 59: ...window 6000 903 new style sphere window YES Auto retract Label low or Label present sensor and PUR cable 1 sensor cable cover per kit 6000 420 Ethernet Module Wired and Wireless 4700 907 Photo Speed...

Страница 60: ...Diagraph an ITW Company LA 4700 User Manual Revision B Maintenance Page 59 Maintenance 7 4 Assembly Views and Part Numbers...

Страница 61: ...Diagraph an ITW Company LA 4700 User Manual Revision B Maintenance Page 60 Maintenance...

Страница 62: ...Diagraph an ITW Company LA 4700 User Manual Revision B Maintenance Page 61 Maintenance...

Страница 63: ...Diagraph an ITW Company LA 4700 User Manual Revision B Maintenance Page 62 Maintenance...

Страница 64: ...mation 8 1 Product Detector J2 J3 DB9 Female PIN Pin Description Pins 1 2 N C Pin 3 Ground Pins 4 5 N C Pin 6 24 VDC Supply Pin 7 N C Pin 8 Product Detector Input Pin 9 N C 8 2 Auxiliary Port Pin Out...

Страница 65: ...1 2 3 N C Pin 4 Red Ground Switched Pin 5 Yellow Ground Switched Pin 6 24 VDC Supply Pin 7 Green Ground Switched Pin 8 9 N C 8 4 Serial Communication Pin Out J1 DB25 Female PIN Pin Description Pin 1...

Страница 66: ...sures Detected In troubleshooting an application it may be desirable to determine if the supplied compressed air has caused an intermittent error condition Once the system detects that the pressure is...

Страница 67: ...3 23 EEC Standards Conducted Emissions EN55 011 Harmonics EN 61000 3 2 Flicker EN 61000 3 3 Radiated Emissions EN55 011 Electrostatic Discharge ESD EN 61000 4 2 Radiated Immunity EN 61000 4 3 Fast Tra...

Страница 68: ...ing Label Warning Error Label Shape Normal Irregular Product Detector Trailing Leading SYSTEM Apply Mode 1 Tamp 1 Tamp Blow 1 Blow 1 Wipe 2 Tamps 2 Tamp Blows 2 Blows 2 Wipes Passcode __ __ __ __ Phot...

Страница 69: ...__________________________ Output 2 ____________________________ Output 3 ____________________________ Output 4 ____________________________ Output 5 ____________________________ Output 6 ____________...

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