LSI - Labeling Systems, Inc.

Let Off Brake Adjustment

The let-off brake (sometimes referred to as the unwind brake) on the Series 3000 head is used for multiple functions. Its primary function is a brake which will prevent the unwind from free-wheeling. The second purpose of the brake is to maintain a constant tension on the web.

To adjust, remove the labels from the machine. When the unwind is set correctly, the tension arm will travel about one inch before the brake belt releases. The release point of the brake is achieved when the let-off disc rotates freely. Rotate the outer cam arm (located on the tension arm shaft internally on the labeler) in either direction, as required. Re-install the labels and run the machine. Make certain to install the outer unwind disc. If you are successful, a constant tension will be maintained on the web.

Labeling Head Rewind Adjustment

The rewind on most of our labeling heads utilize a felt disc for a slip clutch. When set correctly, this disc will provide continuous and proper operation. If the rewind slip clutch is set incorrectly, the life cycle of the felt disc may be reduced to 25% of the normal life expectancy.

On the series 2000 and series 3000 with a clutch brake, the most wear caused to the rewind occurs when the machine is sitting idle. On these machines the rewind clutch should be set to the minimum tension required to rewind the backing material from a full roll of labels.

The tension adjustment is easily made by rotating the threaded collar located inside the machine on the rewind shaft.. Sometimes you may also find it helpful to apply a few drops of oil to the felt disc.

New Controller

As most of you are aware, Labeling Systems, Inc. now offers a PLC controller with a keypad interface for our Series 2000 labeler. For most applications, this controller offers improved performance and flexibility over our standard controller. However, one of the features this controller does not currently offer is the ability to easily convert from Print & Apply to Apply & Print. We are exploring the possibility of adding this revision to a future software upgrade, which will be at least several months away.

To ensure a trouble free installation, be specific on the type of application required when placing an order for a new Series 2000.

Power Rewind on 16" Head

LSI has recently redesigned the power rewind assembly used on the Series 3000 with the 16" unwind option. The new design uses a belt drive instead of a chain. The belt requires less maintenance, runs quieter, and will provide a longer life cycle than the chain drive. This revision will be standard on all Series 3000 labeling heads with the 16" unwind. In addition we are currently offering a conversion kit which will allow the belt drive to be installed in our older machines. For information regarding this update, please contact our Customer Service Department at Extension # 264.

Series 300 Controller

The electronics provided on the Model 300 head is different from the standard controller provided on our other labeling heads because it uses 24VDC to power the boards, sensors and valves. Our other labeling heads use 6VDC for most of the sensors and outputs. In addition, the Series 300 labeling head uses an infrared solid state label sensor, which works well and has proven to be very reliable. However, because it does not use an incandescent light, it can be more difficult to trouble shoot.

The easiest way to diagnose a problem with the label sensor is to remove the receiver (mounted over the peeler bar) and hold it up to a bright incandescent florescent light. Look for the green LED on the microcontroller board to illuminate. If it lights, the problem is most likely a defective infrared transmitter; if it doesn’t light, the machine probably has a defective receiver or micro-controller board.

Stepper Drive Variations

LSI offers two different versions of stepper drive controllers for the Model 3000 head. One style controller, Part No. ETA1000060AA, is used for operating the head at a fixed speed only. The second, Part No. ETA1000061AA, is used for operating the machine with an encoder.

When troubleshooting a labeler equipped with an encoder, it is sometimes useful to bypass the encoder to verify the correct operation. This can be accomplished by changing the dip switch positions on the indexer board (this is the board with Power, Receive, and Transmit LED’s).

Turn dip switches #7 and #8 to the “Off” position. This turns off the encoder input. Next turn on any combination of dip switches #1-#4 (refer to the operating manual for specific speed settings). This will allow the machine to operate at a fixed speed without the encoder. If the machine is equipped with a follower micro-process circuit board, the encoder will still control the label stop and product delay functions. The machine should now run at a fixed speed without using the encoder for speed match.

Failed Circuit Boards

One problem we frequently see is failed circuit boards being returned for repairs. Although periodic failures of electronic components are inevitable, many of the failures we see are preventable. A common cause of circuit board damage can be traced back to the product sensor, or the boards themselves, being installed or removed with the machine powered up. When removing or installing any electrical component, make sure power is turned off. This is a good practice and will help prevent damage to the machine.

Website Recommendations

A good source of technical information for printers and software used in our equipment is the World Wide Web. Zebra (www.Zebra.com) and Tharo (EZ-LABEL) (www.Tharo.com) both have web sites, which provide access to technical support data bases. Sato’s technical support data base is under construction and should be available in the future. These web sites can be searched by entering keywords. If you cannot find the information you are looking for in your manual, try the Web.