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DC Monitron User Manual

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1. arrow causes the next menu to be displayed as follows Enter Pressed Do Nothing This is the third choice in the initialisation menus Pressing Enter simply displays the first menu in level one and as the menu suggests does nothing If the entry into the initialisation menus was caused by invalid data you can t use this option but must select reinitialise Pressing the up arrow causes the first initialisation menu to be redisplayed Inputs All inputs are selectable for NPN 1 to 2 or PNP 2 to 3 input devices The function of each input follows PRODSENS Product Sensor This input initiates the labelling sequence It starts with a transition from off to on of this input See jumper J7 for input polarity selection Terminal 1 on a Monitron GAPSENS Gap Sensor This is the registration input It is normally connected to a fork sensor that detects the gap between the labels on the backing paper The label advance starts counting with an off to on transition of this input See jumper J8 for input polarity selection Terminal 2 on a Monitron ENC Master Encoder This is where the encoder for the product speed is connected The encoder is usually coupled to the conveyor or vacuum belt of the machine See jumper J12 and J13 for input polarity selection and J11 for voltage The pulses per rev of the encoder and its gearing to the conveyor belt should be selected so that the rate is the same as the step rate of the motor It is best to
2. 14 volts must be brought in on CON2 pin 8 Only one jumper to be installed CON3 IN4 Provided to copy original PCB Not sure what it was used N A for Possibly gap edge select not supported in software CON4 OUT4 Flap Adapter Output Has BD681 NPN driver CONS OUTS Air Assist Output Often used to drive label counter DC Drive Jumpers Located just under adjustment potentiometers Near Edge of Board Away from Edge Velocity Mode Away from Edge Bottom It limit not active It limit active Near Edge I peak 6A I peak 12A Note On some drives the incorrect pin has been cut off and the link made with a solder bridge underneath LCD Contrast Near the bottom corner of the InStep II PCB there is a small adjustment potentiometer to adjust the liquid crystal displays contrast The display contrast is directly affected by the ambient temperature and as such may require adjustment in extreme temperature environments Page 10 of 11 DC Monitron User Manual doc Industronics Baldor TFM DC Drive Adjustment Potentiometers 1 Uppermost Tacho Voltage Scaling Adjust to set the maximum desired motor speed when the speed is set to 255 CW is slower Beware of going to far CCW as uncontrolled speed can occur 2 Second top Velocity Loop Gain Turn full CCW then turn CW until very soft grumble can be heard in motor Then back of slightly until it stops Often about 25 3 Second bottom Turn full clockwise for maxim
3. be on the low side of one to one if this cannot be achieved The encoder should have an open collector 5 or 24VDC output Terminal 16 on an ex Unitron IN1 Colour Sensor Product Sensor 2 This input only functions in Orientation Mode It triggers the labelling cycle just as the normal product scanner does however only after the orient part of the cycle is complete See jumper J1 for input polarity selection Terminal 4 on a Monitor adapter boards TB1 IN2 Jig In Sensor Product Gate This input is usually a proximity detector mounted on the orientation jig to indicate when the jig is closed It initiates the spin up delay in orient jig mode If option port jumper J31 is installed this input becomes the product sensor gate input In this mode this input must be on before a product detection will start the dispense cycle See jumper J2 for input polarity selection Terminal 5 on a Monitor adapter boards TB1 IN3 End of Reel This input is usually connected to a sensor that detects a low level of labels on the unwind reel When this input is on labelling is disabled and the End of Reel screen is displayed See jumper J3 for input polarity selection Terminal 6 on a Monitor adapter boards TB1 Page 7 of 11 DC Monitron User Manual doc Industronics IN4 Printer OK This input is connected to the printer OK fault output of the printer controlled by the InStep module When the printer is enabled by the Coder Delay D command with an odd value t
4. canner not supported po S Ground e a E o o PG Printer o O 7 24 Volts 1 Use for scanner power 8 NoConnection 24V in a Unitron Boost in some DC Monitor s oos Air Assist S OOo o o 10 24 Volts for above 8 Special unregulated voltage in an ex Monitor E A a e a a a a l 12 1 24 Volts for above 0 Special unregulated voltage in an ex Monitor 13 NoConnection o S y 14 NoConmection OP S y 15 No Connection Only wired to adapter board in an ex Unitron DC Motor Rear Panel Connector Comment TFM Pin 14c and 16c B Tachometer Yellow___ TFM Pin 12c E al sc ee TFM Pin 20a and 20c TFM Pin 22a and 22c N C Earth Green Yellow Adapter Board Terminal Strip TB1 Description a ee Ss O OS DC Drive analogue command signal Spare Depends on Option Board RS 232 RxD 8 Spare3 Depends on Option Board PAINT E Colour Sensor Product Sensor 2 po SIND Jig In Sensor Product Gate po TING Fixed Pull i es a 8 A _ a aa a ae a na Servo OK Disable Missing Label Fault Master Encoder Flap Adapter Driven by OUT4 PB Ade i O O See O E Note Terminal strip not normally fitted 1 2 3 4 5 gj 10 11 12 13 14 Page 9 of 11 DC Monitron User Manual doc Industronics Configuration InStep II Jumper Descriptions Default J1 to J8 These three point jumpers select the polarity of the signal required 1 to 2 jumpered to operate the i
5. e the value indicate what the input is used for G Guarding closed input monitored I Infeed Low Sensor monitored O Outfeed High Sensor monitored Spare V Vacuum Belt Speed Adjustment enabled C Conveyor Speed Adjustment enabled F Feedscrew Speed Adjustment enabled Used for Motor Speed on a DC Monitron When the speed adjustments are disabled they are shutdown and the menu screens removed Refer to the Analogue Output Option Board manual for further details Pressing Enter takes you into edit mode The display counts up and down in binary Pressing the down arrow displays the following screen Level Two Menus Pressing Enter takes you to level two menus and displays the Manual Dispense menu Pressing the down arrow displays the following screen Level One Menus Pressing Enter takes you to level one menus and displays the Label Counter menu Pressing the down arrow rolls around and displays the Acceleration menu Page 5 of 11 DC Monitron User Manual doc Industronics Fault Screens The following screens appear when the fault occurs If the fault is rectified the screen can be cleared and the labeller re enabled by presssing Enter If you would like to review your settings without resetting the first press of either arrow key will bring back the menu that was present before the fault occurred You can then move around the menus as usual Afterwards you can re enable the labelling by usin
6. en Page 2 of 11 DC Monitron User Manual doc Industronics Manual Dispense Press Enter to Start m lt e lt Dn Pressing Enter starts a labelling cycle Pressing the down arrow displays the following screen Printer Disabled The Printer menu is shown here Pressing Enter cycles between Disabled and Enabled Use the Option Menu to select the type of printer fitted and the Option2 Menu to select the type of printer fault signal Pressing the down arrow displays the following screen Missing Label Length If a label is dispensed and a gap sensor input is not detected before the time set here the labeller will disable show Labeller error and turn on the Bussed Fault Output A value of 0 allows infinite length 1 0 07 sec 2 0 14 sec 3 0 28 sec 4 0 56 sec 5 1 12 sec 6 2 25 sec 7 4 5 sec and 8 9 seconds Pressing the down arrow displays the following screen Brake On Time 100 The time that the servomotor brakes for is set here The setting should be such that it is sufficiently long enough to bring the web to a complete stop but not so long as to allow any speed drift to effect the stopping position Pressing the down arrow displays the following screen Library Functions Pressing the down arrow displays the Level Three Menus selection screen further below Pressing Enter takes you into the Library sub menu and displays the following screen Save to Libra
7. ervo Mode Not Stepper On for speed compensation and servo enable Off for stepper drives G SIG drive compensation Must select servo mode above as well E Enable at Power On C Moving Type Coder e g inkjet 0 Stationary Type e g stamping hot foil 421 Serial Address Select Set bits to total to desired address all off 8 Pressing Enter takes you into edit mode The display counts up and down in binary Pressing the down arrow displays the following screen Option2 BSPF 00000000 The second option status menu is displayed here A value of indicates the option is on 0 is off The letters above the value indicate what the input is used for B Stepper Boost When on changes the servo enable output function to a stepper drive boost S Servo OK input polarity When on here the Servo OK input is off OK Can be used when no servo ok signal is available i e in a Monitron P Printer Fault polarity When the printer is enabled in level 2 the Printer Fault input becomes active The level that causes labelling to be stopped is entered here 0 on 1 off F Fixed Pull Mode This is different from InStep I fixed pull mode it is triggered by the product scanner AnlgOut GIO VCF Options 00000000 The analogue output option status is displayed here The settings are only relevant if the Analogue Output Option Board has been fitted A value of 1 indicates the option is on 0 is off The letters abov
8. g the Labelling Enable menu in Level 1 Labeller Error Press Enter to Reset This screen indicates that the motor has moved too far in its search for the gap sensor activation It is usually caused by a wrongly setup gap sensor or slipping drive rollers It can always be reset immediately Refer to the Missing Label Length menu in level two for adjustment Printer Error ss apie pee Lie ld ee te Whenever the printer is enabled the printer fault signal is also enabled The sense of the input is controlled by a bit in option port 2 or by the D command If no printer fault signal is available it should be set to off OK default The fault signal must be removed to reset External Fault Press Enter to Reset This screen appears when the Fault In input is activated This input is usually tied together with all of the other Fault In Fault Outs on the machine so that a fault on one label head will disable all heads Stepper Drive Error Press Enter to Reset This screen appears when the connected stepper drive has indicated a fault You usually must power down the stepper drive to reset the fault If the fault occurs often it will be necessary to open the enclosure to check the fault code indicated on the front of the stepper drive Refer to the stepper drive manual for the fault codes meaning and its remedy It is usually caused by a web jam up End of Label Reel Press Enter to Reset This screen appears when the senso
9. he front of the TFM drive control card Irrespective of where this setting is left it will be corrected during the first dispense cycle Pressing the down arrow displays the following screen Mme S PO PETC 00000000 This is the third menu in level three The input status is displayed here A value of 1 indicates the input is on 0 is off The letters above the value indicate what the input is used for P Product Sensor G Gap Sensor D Disable Input Fault In S Servo OK J Jig In Product Gate Input C Colour Sensor The display is not live pressing Enter updates the display Pressing the down arrow displays the following screen Outputs XFABJSEC 00000000 The output status is displayed here A value of 1 indicates the output is on 0 is off The letters above the value indicate what the output is used for X Spare F Fault Output A Air Assist Output B Air Blast Output J Jig Solenoid Output S Feedscrew Enable Output E Servo Enable Stepper Boost Output C Coder Printer Output The display is not live pressing Enter updates the display Pressing the down arrow displays the following screen Page 4 of 11 DC Monitron User Manual doc Industronics Options GSGEC421 00000000 The option status is displayed here A value of 1 indicates the option is on 0 is off The letters above the value indicate what the input is used for G Gate Signal Required S S
10. his input must be on otherwise the InStep is disabled and the bussed fault output is turned on If an even value is used in D the input must be off for printer OK See jumper J4 for input polarity selection Pin 2 of CON3 on a Monitor adapter Board INS Drive OK Polarity controlled by a bit in Option 2 menu When signal active labelling is disabled and the drive error menu is displayed Terminal 7 on a Monitor adapter boards TB1 IN6 Disable Bussed Fault In This input disables the labelling on a transition from off to on Even if the input is left on the unit may be re enabled via the E1 command See J6 for input polarity selection Terminal 8 on a Monitor adapter boards TB1 Outputs All outputs are selectable for NPN or PNP however they must all be one or the other Selection is made by changing IC9 For NPN use ULN2803A for PNP use UDN2981A Jumpers J9 and J10 must be set to suit In a Monitron the IC is PNP but the main outputs have slave transistors that provide a NPN output STEP Step Signal This output is used to drive the pulse input of the stepper or servo drive Connected internally Unused in a DC Monitron OUT1 Coder This output is the start trigger for a date coder etc Option Menu selects whether the coder is of the type that prints while the web is stationary e g hot stamp or moving e g ink jet Terminal 6 on a Monitron OUT2 Servo Enable Stepper Boost This output is connected internally to the
11. iIndustronics Design Application and Service of Electronics in Industry DC Monitron User Manual For Version D 3 17C 7 March 2004 27 Wanganui Road Kirrawee NSW Australia 2232 Phone 02 9545 6181 Fax 61 2 9545 6181 Mobile 0419 267 889 Email dpayne industronics biz WWW hitp Awww industronics biz A division of D H Enterprises Pty Limited A B N 72 087 000 995 DC Monitron User Manual doc Industronics Overview This manual covers the Monitron version that controls a DC Servomotor and contains a Baldor TFM drive control The Monitron is an upgrade for either an Impresstik Monitor or Unitron Control Box The entire front panel and control board is replaced providing a more reliable and fully featured controller If an older type incandescent label gap sensor was used this must be upgraded to a 24 volt fork type sensor Apart from this it is simply a matter of plugging the upgraded box into the old position and learning the new controls All of the adjustments are made with three pushbuttons on the front panel There is a two line by twenty character LCD display for viewing the settings Settings can also be adjusted via a serial port if this option is installed Menu Structure io ep Se Bye ones This is the opening screen If Enter is pressed and held during this screen the controller will display the initialisation menu Refer to the end of this section for details If Enter is not pressed the following menu is disp
12. layed after a ten second delay Level One Menus Label Counter The Label Counter is displayed here This shows the total number of labels dispensed since turn on or the last count reset Pressing Enter will reset the label count As at version 3 17 the count is lost when the Monitron is powered down Pressing the down arrow displays the following screen Air Blast Time The Air Blast Time setting is displayed here This menu sets the air blast time in milliseconds The air blast is for machines with an air box attachment The air blast time occurs after the product sensor is activated and before the label starts to move On non airbox machines this setting may also be used to delay application of the label Pressing the down arrow displays the following screen Motor Speed The run speed of the DC servomotor is set here 0 is zero speed and 255 is maximum speed The uppermost adjustment on the front of the TFM drive control card can be used to change the maximum speed Pressing the down arrow displays the following screen Labelling is Enabled Pressing Enter cycles between Enabled and Disabled This menu is provided to allow for re enabling after an ignored fault of to disable so that the product sensor is ignored or the drive roller can be turned by hand Level Two Menus Pressing the down arrow rolls around to the Label Counter menu Pressing Enter takes you to level two menus and displays the following scre
13. nputs Jump 1 to 2 for sinking NPN type input devices Jump 2 to 3 for sourcing PNP type input devices J1 to J6 correspond to input 1 to 6 respectively J7 is for the product sensor input J8 is for the label sensor input J9 and J10 These jumpers are set to match the type of output driver IC 2 to 3 jumpered installed in position IC9 Jump both 1 to 2 for NPN type IC ULN2803A Jump both 2 to 3 for PNP type IC UDN2981A Note jumpers must be set correctly or damage will result PNP configuration when this jumper is installed J12 andJ13 These jumpers are set to match the polarity of the output of the J12 1 to 2 jumpered master encoder connected to terminal 11 J13 1 to 2 jumpered Jumper J12 and J13 1 to 2 for NPN output encoders Jumper J13 2 to 3 and J12 1 to J13 1 for PNP output encoders J14 to J24 These jumpers set the master encoder divisor J14 is divide by J14 installed one J14 is divide by 2 through to J24 which is divide by 1024 Only one jumper in this set to be installed 125 Selects the function on pin 28 on P1 Refer to option manual 1 to 2jumpered J25 J26 Selects whether to bypass the encoders optocoupler to 2 is to 1 to 2 jumpered use optocoupler 2 to 3 is to bypass the optocoupler B Monitor Adapter Board Jumpers Description Default A Jump A to provide NPN output on CON2 pin 16 for stepper boost B jumpered signal Jump B to provide PNP 14 volt output on CON2 pin 16 for TFM enable
14. r connected to the End of Reel input is on It is usually a sensor setup to detect a low quantity of labels on the unwind reel Other fault screens may appear depending on the option card fitted and which functions are enabled Initialisation Menu This menu can only be entered during power up It will automatically appear if the controller detects invalid data in the current data memory or it can be forced to appear if Enter is pressed and held during the initial screen that displays the version number information It will appear as either of the two following screens Enter Pressed EEPROM Data Invalid Use to make choice Use to make choice or gt Enter Pressed Erase Libraries n et i oO i a w 3 we n gel 5 oO Nn Dn OQ a ew i oO Z 5 ga Dn O pn Oo oO 5 zZ S asi 5 oO 5 This is the first choice in the initialisation menus Pressing Enter causes all of the Library data to be erased then the first initialisation menu is shown again Pressing the up arrow causes the next menu to be displayed as follows Page 6 of 11 DC Monitron User Manual doc Industronics feo oe Reinitialise This is the second choice in the initialisation menus Pressing Enter causes all of the current data to be reset to default values and then display the first menu in level one Because of this if you want to erase libraries and reinitialise you must erase libraries first Pressing the up
15. ry No This is the first menu in the library sub menu Pressing Enter allows you to select the library number to save to with the arrow keys After selecting pressing Enter saves all of the data from the current data memory and displays the Library Functions menu There is no library number zero it is provided to allow a way to escape without saving Pressing the down arrow displays the following screen Read from Lib No This is the second menu in the library sub menu Pressing Enter allows you to select the library number to read from After selecting pressing Enter reads the library and saves it to the current data memory If after pressing Enter the Library Functions menu is not displayed the data in the selected menu was invalid Select another library number or select 0 to escape from this menu Pressing the down arrow displays the Library Functions menu Page 3 of 11 DC Monitron User Manual doc Industronics Level Thr Menus Pressing Enter takes you to level three menus and displays the Force Brake menu Pressing the down arrow displays the following screen Level One Menus Pressing Enter takes you to level one menus and displays the Label Counter menu Pressing the down arrow displays the Manual Dispense menu Level Three Menus Force Brake Off The brake can be forced on and off here Forcing the brake on allows adjustment of zero speed via the lowest adjustment on t
16. stepper drive to control the boost function on the D550 On a DC Monitron it is the DC Servo Enable signal OUTS3 Feedscrew Enable Servotron OK Output This output is provided to enable the feedscrew It is on whenever there are no faults and no level pauses from the high outfeed and low infeed sensors This output becomes an OK output whenever the level control are not enabled in the Analogue setup It is on whenever there are no faults present The analog output option board is required for the level sensor inputs Terminal 9 on a Monitor adapter boards TB1 OUT4 Jig Solenoid This output controls the solenoid that closes the orient jig Pin 2 of CON4 on a Monitor adapter board OUTS Air Blast When an air blast time is entered in the menu or with the K command this output is turned on at the end of the product delay and before the servo starts to move Terminal 11 ona Monitron OUT6 Air Assist This output is turned on at the start of the servo moving and off at the beginning of deceleration Terminal 9 on a Monitron Page 8 of 11 DC Monitron User Manual doc Industronics OUT7 Bussed Fault Out This output is turned on when there is a labeller fault or a printer fault Terminal 10 on a Monitor adapter boards TB1 Connectors Tuchel 16 way Rear Panel Connector Connector Signal Machine Comment Pin Number Terminal Product Scanner 3 Must be new 24 volt type 4 NoConnection 6 5 5 volts for old gap s
17. um current Offset Adjust With Force Brake ON adjust for no drift DC Monitron Version Update Summary Version D 3 17 6 12 2002 Changes First released version Fixes None Additions None Version D 3 17A 25 08 2003 Changes Changed default re initialise Brake On Time from 200 to 50 Which is a more typical value Fixes None Additions None Version D 3 17B 17 09 2003 Changes Changed range of Air Blast adjustment from 0 to 255 to 0 to 8191 Fixes None Additions None Version D 3 17C 26 02 2004 Changes None Fixes Fixed problem where if man dispense pushed while dispensing the cycle would re start This is the same fix made to the Servotron at 3 22C Refer to Servotron manual for further details Additions None Page 11 of 11

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