ISHIDA WPL-3000 Service Manual
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ISHIDA WPL-3000 Service Manual

ISHIDA WPL-3000 Service Manual

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IMPORTANT
• Do 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.
Manual No. 0077B
WPL-3000
SERVICE MANUAL
48725

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Summary of Contents for ISHIDA WPL-3000

  • Page 1 WPL-3000 SERVICE MANUAL IMPORTANT • Do 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. Manual No. 0077B...
  • Page 2 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 SAFETY CONSIDERATIONS These safety measures must be followed to ensure the safe servicing of this machine: Servicing is to be done by qualified service personnel only These service instructions are for use by qualified service personnel who fully understand the potential hazards involved. To avoid any possible danger, do not perform any service procedures unless qualified to do so.
  • Page 4 ETTING TARTED This service manual contains the procedures for servicing the WPL-3000 Index Conveyor. It is strongly advised that you read and clearly understand the contents of this manual before beginning any maintenance to this machine. AINTENANCE RECAUTIONS To insure the safety and long operating life of this machine, it is important to observe the following precautions: Keep the area around the machine clear of any dust and debris.

  • Page 5: Table Of Contents

    2.4.4 Stand Fastening Method 2 ..... 2.5 Connecting Cable ........... 2.6 Setup Procedures ........... 2.7 Method for Threading Labels ......2-10 2.8 WPL-3000 USA Rescue Mode ....... 2-11 3.1 Menu Directory Diagram ......... 3. Test Mode 3.2 Test Mode 3.2.1 Starting Test mode .........

  • Page 6: Overview

    3.2.10 Machine ID No. Setting (C09) ....3-13 3.2.11 Preset Function Setting (C10) ....3-14 3.2.12 Password (C11) ........3-14 3.2.13 Data Transmission (C99) ....... 3-15 4.1 Menu Directory Diagram........4. Setting Mode 4.2 Setup Mode 4.2.1 Label Format (b01) ......... 4.2.2 Bar Code Setting (b02) ......
  • Page 7 7.1 Overview ............7. Printer / Label 7.2 Block Diagram ..........Applicator Unit 7.3 Electronic Components ........7.3.1 Printer Unit (Thermal head, label sensor adjustment) ... 7.3.2 Label Applicator Unit ......7-10 7.4 Adjustment Position of the Label Applicator Unit ......... 7-14 7.5 Movement Test ..........
  • Page 8 Contents...

  • Page 9: External Parts And Names (I Line Type)

    Chapter 1.1 External Parts and Names (I Line Type) ..1.2 External Parts and Names (L Line Type) ..1.3 Location of Safety Stickers ......verview...
  • Page 10 DISCHARGE ROLLER UNIT (OPTION) CONVEYOR WEIGH UNIT CONVEYOR STAND (OPTION) POWER SWITCH Fig. 1. 2 WPL- 3000 ( I Line Type) front view.* * IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm. WPL-3000 SERVICE MANUAL 0077B...
  • Page 11 CONTROLLER UNIT PRINTER UNIT LABEL APPLICATOR DISCHARGE ROLLER UNIT (OPTION) SCALE POWER SWITCH Fig. 1.4 WPL-3000 ( L Line Type) front view.* * IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm. WPL-3000 SERVICE MANUAL 0077B...

  • Page 12: Location Of Safety Stickers

    Overview 1 1.3 L OCATION OF AFETY TICKERS IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm. Fig. 1.5 Location of external stickers. Disconnect from before opening Fig. 1.6 Internal safety sticker. WPL-3000 SERVICE MANUAL 0077B...

  • Page 13: Confirm Before Delivery

    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 ......2-10 2.8 WPL-3000 USA Rescue Mode ....... 2-11...

  • Page 14: Location

    (20 in.) Fig. 2.1 Allow adequate space for WPL-3000. IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm. 2.1.2 Installation Route The WPL is 446mm (17.5 in.) x 1085mm (42.75 in.) and requires an entrance and delivery route wider than 446mm (17.5 in.).

  • Page 15: Work Clothes

    3.5 INCH 2DD FD MANUALS Fig. 2.2 Tools Note : Use a level with precision greater than 2/1000. 2.2.2 Manuals WPL-3000 Service Manual WPL-3000 Programming Manual (User’s Manual for Managers) WPL-3000 Operation Manual (User’s Manual for Operators) WPL-3000 SERVICE MANUAL 0077B...

  • Page 16: Package Confirmation

    Open carton and inspect contents to see that all items are accounted for and undamaged. Fig. 2.3 Items contained in carton IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm. Note : Infeed conveyor and stand are options.

  • Page 17: Fastening To Stand

    2.4.1 Fastening to Stand ANTI-VIBRATION PAD BOLT (X 6) STAND (M5 x 60mm) Fig. 2.4 Weigh conveyor unit (under side view) Bolt (X 4) (M5 x 60mm) Fig. 2.5 Infeed conveyor (under side view) STAND (OPTION) WPL-3000 SERVICE MANUAL 0077B...

  • Page 18: Fastening Stands

    Secure conveyor stands to floor using anchor bolts. Attach joint to stands so neither conveyor stand can move. METAL FITTING JOINT ANCHOR BOLT Tightly fasten the nuts securing the leveling leg. LEVELING LEG Fig. 2.6 Fastening Stands WPL-3000 SERVICE MANUAL 0077B...
  • Page 19 Fasten stand to floor. ANCHOR BOLT AND WASHER(4) LEVELING LEG Fig. 2. 7 Method 1 2.4.4 Stand Fastening Method 2 Fasten anchor bolt and leveling leg to anchor plate ADJUSTABLE PRESSURE FITTING (EXAMPLE) Fig. 2. 8 Method 2 WPL-3000 SERVICE MANUAL 0077B...

  • Page 20: Connecting Cable

    POWER CORD Fig. 2.9 Connecting Cable TIE UP AND SECURE EXCESS PRINTER CABLE AND FASTEN COVERS WITH SCREWS. IMPORTANT NOTE: Later versions of the WPL-3000 use a front mounted printer arm. Fig. 2.10 Printer Stand Case WPL-3000 SERVICE MANUAL 0077B...

  • Page 21: Setup Procedures

    THERMAL HEAD , section 3.2.4. 6. Performing Total Clear Refer to Programming Manual . 7. Backing Up Data Back up registered data to a floppy disk. Refer to Test Mode 99: DATA SAVE/LOAD , section 3.2.13. WPL-3000 SERVICE MANUAL 0077B...

  • Page 22: Method For Threading Labels

    Setup 2 2.7 M ETHOD FOR HREADING ABELS 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. WPL-3000 SERVICE MANUAL 0077B 2-10...

  • Page 23: Wpl-3000 Usa Rescue Mode

    To eliminate this problem, it is neces- sary to either delete the data or correct the data responsible for this hitch. When WPL-3000 cannot enter standard mode after power is turned ON, the machine cannot enter setting or registration mode.
  • Page 24 Setup 2 WPL-3000 SERVICE MANUAL 0077B 2-12...

  • Page 25: Menu Directory Diagram

    Chapter 3.1 Menu Directory Diagram ......... 3.2 Test Mode 3.2.1 Starting Test mode ......... est Mode 3.2.2 Hardware Test (C01)......3.2.3 RAM Clear (C02) ........3.2.4 Thermal Head Setting (C03) ....3.2.5 Sensor Check (C04) ....... 3.2.6 Extra Memory (C05) ....... 3.2.7 Setting ROM Switch (C06) .....

  • Page 26: Menu Directory Diagram

    Test Mode 3 3.1 M IRECTORY IAGRAM WPL-3000 SERVICE MANUAL 0077B...
  • Page 27 The following hardware items are checked in this test mode operation. 1. A/D Converter Check 2. Key Check 3. Display Check (Dot and digital fluorescent display) 4. I NET Communication Check 5. Displaying Program Number 6. Conveyor Elevator and Label Applicator Test WPL-3000 SERVICE MANUAL 0077B...
  • Page 28 2): Once the membrane keyboard has been removed, it cannot be reused. Key 29= RESET key When RESET key is pressed, the display returns to sub-menu. CAUTION CAUTION When each key is pressed, the numerical value is displayed as shown in the above illustration. WPL-3000 SERVICE MANUAL 0077B...
  • Page 30 • Press PLU to test the conveyor’s up and down movement. Note: Compressed air must be supplied for these movement tests. 3.2.3 RAM Clear (C02) This initializes (clears) RAM, E ROM and sets Test PLU data. WPL-3000 SERVICE MANUAL 0077B...
  • Page 31 PLU’s 1 through 10 are created along with a dummy shop name. 3.2.4 Thermal Head Setting (C03) Use this step to set the Thermal Head resistance, check or reset usage, and set print density. WPL-3000 SERVICE MANUAL 0077B...
  • Page 32 Enter 0 and press ENTER to clear print usage distance. Always clear this setting when a new thermal head is installed. Print Density Setting (C03-03) This adjusts print density (1: light to 9: dark). Press PRINT to issue test labels. WPL-3000 SERVICE MANUAL 0077B...
  • Page 35 Note: Increase value for faster operation. * These changes must be registered to the A/D Board NV RAM. See WPL-3000 setup instructions (Appendix A.1). * Typical “Speed Up” settings are: 003C = 03, 003D = 03, and 003E = 03.
  • Page 36 Sales Mode (C08-01) This selects machine functions corresponding to customer sales configuration. Display 1 : IND, LABEL, W/O TL Standard issue of individual lablels without operators 2 : OPE, W TOTAL Enable operator functions WPL-3000 SERVICE MANUAL 0077B 3-12...
  • Page 37 3.2.10 Machine ID No. Setting (C09) This sets the Master Scale’s ID number for computer communications. Note: The maximum number of Master Scale connections to the computer may vary depending on the efficiency of the level converters used. WPL-3000 SERVICE MANUAL 0077B 3-13...
  • Page 40 Before using a new floppy disk for the first time, perform Step C99-03 to format the disk. Use 2DD type disks only. CAUTION CAUTION All IF-21FD operations are controlled from the WPL-3000. 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 .
  • Page 41 CAMPAIGN MASTER BATCH FILE SUB TOTAL NUTRITION FILE Verify (C99-02-04) This verifies WPL-3000 and IF-21FD data. Enter the selection number of the data to be verified and press ENTER . Press PRINT to begin verifying. ➝ Note: Select number using key.
  • Page 42 Executing (C99-03-03) Executing. Initialization Complete (C99-03-04) Initialization is complete when “OK” is displayed . P A S S Note: See Error Code list in Section 9.3 (Save & Load with IF-21FD Floppy Disk Unit) if necessary. WPL-3000 SERVICE MANUAL 0077B 3-18...
  • Page 43 Chapter 4.1 Menu Directory Diagram........4.2 Setup Mode 4.2.1 Label Format (b01) ......... etting 4.2.2 Bar Code Setting (b02) ......4.2.3 Code Settings (b03) ....... 4.2.4 Setting Initial Data (b04) ......4.2.5 PLU File (b08) ........4-11 4.2.6 Preset Report (b10) ........ 4-12 4.2.7 Registration Select (b11) ......

  • Page 47: Setup Mode

    Setting Mode 4 4.2 S ETUP 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. WPL-3000 SERVICE MANUAL 0077B...
  • Page 48 0-999.9 (0.1 increments) Length includes label length and space. (including gap) Maximum 175mm Note: Maximum length for automatic application is 85.0mm. b01-09 Label sensor distance 0-999.9 (0.1 increments) Default value 110.0. Adjust to fine tune print alignment. Fig. 4.1 Label Sensor Distance WPL-3000 SERVICE MANUAL 0077B...

  • Page 49: Bar Code Setting (B02)

    Barcode Type (b02-03) This sets bar code type. Select from the chart below: Setting No. Bar Code Type UPC 13* UPC 8 NON-PLU code 10 DIGIT 13 5 DIGIT 8 Source Marked Code *Default WPL-3000 SERVICE MANUAL 0077B...

  • Page 50: Code Settings (B03)

    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 WPL-3000 SERVICE MANUAL 0077B...

  • Page 51: Setting Initial Data (B04)

    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. WPL-3000 SERVICE MANUAL 0077B...
  • Page 52 Select by arrow or numerical entry Default = 2 : NO ¡ Numerical Forced Tare — a tare weight must be used before a label is 1 : YES Enter [1] allowed to print. 2 : NO Enter [2] WPL-3000 SERVICE MANUAL 0077B 4-10...

  • Page 53: Plu File (B08)

    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. WPL-3000 SERVICE MANUAL 0077B 4-11...

  • Page 56: Registration Select (B11)

    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. WPL-3000 SERVICE MANUAL 0077B 4-14...

  • Page 57: Total Mode Select (B12)

    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. WPL-3000 SERVICE MANUAL 0077B 4-15...

  • Page 58: Tray Master Registration (B15)

    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. WPL-3000 SERVICE MANUAL 0077B 4-16...

  • Page 59: Conveyor Setup (B16)

    Delay Timer (Non-Weigh > 60mm) Increase if product reaches labelling position before printing is completed. Time between A and B where: A = Label begins printing, B = Conveyor lifts to move product Note: 10 = 1/10th second delay WPL-3000 SERVICE MANUAL 0077B 4-17...
  • Page 60 Setting Mode 4 WPL-3000 SERVICE MANUAL 0077B 4-18...
  • Page 61 Chapter 5.1 Overview ............5.2 Block Diagram ..........5.3 Electronic Parts ontroller 5.3.1 Display Board ......... 5.3.2 Junction/Buzzer Board ......5.4 Display and Key Check ........5.5 Disassembly Diagram ........
  • Page 62 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.

  • Page 63: Controller Unit

    ARTS 5.3.1 Display Board (GP1046A01AA) The WPL-3000 utilizes a 256 X 16 (horizonal x vertical) full dot and 7 segment fluorescent digital displays. Display data is received from and keyboard entries sent to the main CPU board (P-834x) located in the printer unit. Power is supplied by the power supply unit SLS100PW in the contol box located in the weigh conveyor unit.

  • Page 64: Junction/Buzzer Board

    Fig. 5.5 DIP Switch 5.3.2 Junction/Buzzer Board (P-887) Keyboard entries are sent to the main CPU board (P-834x) in the printer unit via the Junction/Buzzer board (P-887). MEMBRANE KEYBOARD JUNCTION/BUZZER BOARD P-887 KEY SHEET Fig. 5.6 Keyboard WPL-3000 SERVICE MANUAL 0077B...
  • Page 65 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. BUZZER Fig. 5.7 Junction/Buzzer Board P-887 WPL-3000 SERVICE MANUAL 0077B...

  • Page 66: Display And Key Check

    3.2.2 in this manual for entering the test mode. Fig. 5.8 Key Addresses Note : Key 29 (RESET) is used to exit key check mode. Test mode C01-03 is used for display check of the full dot and 7 segment digital displays. WPL-3000 SERVICE MANUAL 0077B...
  • Page 67 Controller Unit 5 5.5 D ISASSEMBLY IAGRAM CONTROLLER UNIT CABLE TO PRINTER UNIT DISPLAY FILTER TRANSPARENT KEYSHEET COVER JUNCTION/BUZZER BOARD P-887 DISPLAY BOARD(GP-1046A01A) MEMBRANE KEYBOARD OPERATION KEY SHEET INSERT Fig. 5.9 Controller Unit WPL-3000 SERVICE MANUAL 0077B...
  • Page 68 Controller Unit 5 WPL-3000 SERVICE MANUAL 0077B...
  • Page 69 Chapter 6.1 Overview ............6.2 Block Diagram ..........6.3 Electronic Parts eigh 6.3.1 Load Cell Unit ......... 6.3.2 A/D Converter Board ......6.4 Scale Check ........... onveyor 6.5 Disassembly Diagram ........
  • Page 70 WEIGH UNIT CONTROL BOX ROLLER UNIT ITEMS TO BE WEIGHED Fig. 6.1 Weigh conveyor Fig. 6.2 Items to be weighed roll across a sloping conveyor GUIDE BOARD ROLLER UNIT SEAL WIRE WEIGH PLATTER Fig. 6.3 Roller Unit WPL-3000 SERVICE MANUAL 0077B...
  • Page 71 5IK40GN-ALU INFEED E64197 CONVEYOR WEIGH CONVEYOR MAIN POWER SWITCH Fig. 6.4 Block Diagram *Later designs incorporate a single P-854 Drive board. ✝Later designs use two power supplies: LSF100-24 (36-3409-01) – Main 24VDC LDA30F-24 (46-3180-09) – Fans WPL-3000 SERVICE MANUAL 0077B...
  • Page 72 Load cell type CLC-25N Load (maximum) 25 kg within ±5% Standard output Insulated resistance over 5M Ohm Applied voltage -12V Fig. 6.5 Load cell RECEIVING PLATTER A/D BOARD (P-830B) LOAD CELL UNIT Fig. 6.6 Disassembly of scale unit WPL-3000 SERVICE MANUAL 0077B...
  • Page 73 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) Red (+V White (-V Green (+Signal) Blue (-Signal) Shield Fig. 6.7a Load Cell Connections WPL-3000 SERVICE MANUAL 0077B...
  • Page 74 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. WPL-3000 SERVICE MANUAL 0077B...

  • Page 75: Disassembly Diagram

    Weigh Conveyor 6 6.5 D ISASSEMBLY IAGRAM WEIGH PLATTER UNIT SEALING WIRE ROLLER UNIT FOUR-CORNER ADJUSTMENT SCREW SCALE UPPER CASE A/D CONVERTER BOARD (P-830B) LOAD CELL UNIT WEIGH CONVEYOR BASE Fig. 6.8 Disassembly Diagram WPL-3000 SERVICE MANUAL 0077B...
  • Page 76 Chapter 7.1 Overview ............7.2 Block Diagram ..........7.3 Electronic Components ........rinter/ abel 7.3.1 Printer Unit (Thermal head, label sensor adjustment) .. 7.3.2 Label Applicator Unit ......7-10 7.4 Adjustment Position of the Label pplicator Applicator Unit ..........7-14 7.5 Movement Test ..........
  • Page 77 The printer em- ploys a 60mm wide thermal head. IMPORTANT NOTE: LABEL APPLICATOR UNIT Later versions of the WPL-3000 PRINTER UNIT use a front mounted printer arm. Fig. 7.1 Printer Unit LABEL APPLICATOR ARM UNIT...

  • Page 78: Weigh Conveyor

    7.2 B LOCK IAGRAM SUCTION FAN I/O BOARD P-892 Controller Unit JUNCTION (Keyboard/Display) BOARD Label P-838A Applicator Unit Label THERMAL HEAD Sensor MAIN CPU BOARD P-834 "LABEL TAKEN" SENSOR Printer Unit Weigh Conveyor Fig. 7.3 Block Diagram WPL-3000 SERVICE MANUAL 0077B...
  • Page 79 * asterisk indicates latest version, subsequent versions will be followed by letter (e.g.,A,B,C) Note: IC15 (CHIP0) socket contains the Main Program EPROM. It begins with the letter B, C or Z based on the program function. IC14 (CHIP1) contains the Font Program. It begins with the letter F. WPL-3000 SERVICE MANUAL 0077B...
  • Page 80 This board transmits peeling sensor (reflective type) and stepping motor signals through the cable from the J4 connector to the main board. * asterisk indicates latest version, subsequent versions will be followed by letter (e.g., A,B,C) Fig. 7.7 Junction Board (P-838*) WPL-3000 SERVICE MANUAL 0077B...
  • Page 81 Print a test label to test printing. If print quality is unsatisfactory, adjust according to the following procedure : (1) Loosen the thermal head attachment screws (2) by a 1/4 turn. ATTACHMENT SCREWS Fig. 7.9 Locations of screws WPL-3000 SERVICE MANUAL 0077B...
  • Page 82 Lower print density before adjusting for more precise adjustment. (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. (4) Print a test label. WPL-3000 SERVICE MANUAL 0077B...
  • Page 85 ELECTROMAGNETIC VALVE PEELING SENSOR LABEL ABSORPTION PLATE COVER Fig. 7.15 Applicator Unit Disassembly Diagram Fan Motor The fan motors use suction to hold labels against the absorption plate until they are applied to a package. WPL-3000 SERVICE MANUAL 0077B 7-10...
  • Page 86 The electromagnetic valve also controls the air supply that moves the labeling arm up. A port A TERMINAL NUMBER WIRE COLOR B TERMINAL NUMBER A PORT 1 A PORT 2 BLACK Fig. 7.16 Electromagnetic Valve WPL-3000 SERVICE MANUAL 0077B 7-11...
  • Page 88 (“label taken”) sensor. Sensor Protective Cover Fig. 7.19 Peeling Sensor Peeling sensor Connector UL tube J2 P-838 Connector No. Connection Terminal Color anode green cathode blue collector purple emitter gray Fig. 7.20 Peeling Sensor WPL-3000 SERVICE MANUAL 0077B 7-13...
  • Page 90 Note: Use a label or white paper to test. LABEL SENSOR SENSOR DISPLAY VALUE LABEL SENSOR RECEIVER VOLTAGE BEAM REFLECTED ABOVE 200 COUNTS BELOW 1[V] DC BEAM OPEN BELOW 50 COUNTS OVER 4 [V] DC WPL-3000 SERVICE MANUAL 0077B 7-15...

  • Page 91: Disassembly Diagram

    ISASSEMBLY IAGRAM STAND UNIT STORE CABLE UNDER COVERS KNOB BOLT Fig. 7.24 Disassembly diagram (stand unit) IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm. 7.7 D ISASSEMBLY IAGRAM PRINTER UNIT CPU BOARD (P-834) I/O BOARD (P-892)
  • Page 92 Printer/ Label Applicator Unit 7 7.8 D ISASSEMBLY IAGRAM LABEL APPLICATOR UNIT SPEED CONTROL AIR CYLINDER FAN MOTORS HINGE METAL FITTING APPLICATOR SHAFTS ELECTROMAGNETIC VALVE COVER PEELING SENSOR LABEL ABSORPTION PLATE Fig. 7.26 Disassembly Diagram (label applicator unit) WPL-3000 SERVICE MANUAL 0077B 7-17...
  • Page 93 Chapter 8.1 Weigh Conveyor Unit ........8.2 Block Diagram ..........8.3 Electronic Components ........eigh 8.3.1 Power Supply Unit ........8.3.2 Drive Board (P-854) ....... 8.3.3 Electromagnetic Valve ......Onveyor 8.3.4 Air Cylinder ..........8.3.5 Application Timing Sensor ...... 8.4 Elevator Check and Parts Adjustment .... 8.4.1 Weigh Conveyor.

  • Page 94: 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 CONVEYOR BELT WEIGH CONVEYOR PULLEY CONVEYOR BELT HANDLE PULLEY Fig. 8.2 Removing Weigh Conveyor WPL-3000 SERVICE MANUAL 0077B...

  • Page 95: Block Diagram

    Main Power Switch Fig. 8.3 Block Diagram * Later designs incorporate a single P-854 Drive Board. ✝ Later designs incorporate two 24V DC power supplies: LSF 100-24 (36-3409-01) – Main 24V DC LDA 30F-24 (46-3180-09) – Fans WPL-3000 SERVICE MANUAL 0077B...

  • Page 96: Power Supply Unit

    Note: Later designs use two 24V DC power supplies. See previous page. Signals Product name SLS150PW Voltage input 85 to 132 [V] AC +24 [V] DC Frequency 50/60 [Hz] Voltage output +24 [V] DC Current output 6 [A] Power output 144 [W] WPL-3000 SERVICE MANUAL 0077B...

  • Page 97: Electromagnetic Valve

    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. WEIGH CONVEYOR LIFT CONVEYOR SUPPORT AIR CYLINDER SPEED CONTROLLER ELECTROMAGNETIC VALVE Fig. 8.7 Electromagnetic Valve WPL-3000 SERVICE MANUAL 0077B...
  • Page 98 Turn the knob counterclockwise four rotations and tighten the nut. *For decreasing speed Turn knob clockwise. *For increasing speed Turn knob counterclockwise. RAISE CONVEYOR SPEED CONTROL KNOB LOWER CONVEYOR SPEED CONTROL KNOB Fig. 8.8 Air Cylinder WPL-3000 SERVICE MANUAL 0077B...

  • Page 99: Application Timing Sensor

    Turn the potentiometer CW until the If the orange lamp does not turn off, orange lamp is OFF and the green lamp position A is fully CW. is fully ON. This is position C. CW - clockwise CCW = counter clockwise WPL-3000 SERVICE MANUAL 0077B...

  • Page 100: Elevator Check And Parts Adjustment

    Fig. 8.10 Conveyor Belt 2. Belt tension can be adjusted by changing motor position. To adjust tension, loosen the four motor mounting bolts on the under side of the main body. Move the motor as needed. WPL-3000 SERVICE MANUAL 0077B...

  • Page 101: Conveyor Fall Prevention Screw Adjustment

    8.4.2 Conveyor Fall Prevention Screw Adjustment A conveyor fall prevention screw is shown in Fig. 8.12 Adjust so that there is a 0.5mm (1/64 inch) gap between screw and brace. BRACE CONVEYOR FALL PREVENTION SCREW Fig. 8.12 Conveyor Fall Prevention Screw WPL-3000 SERVICE MANUAL 0077B...
  • Page 102 POWER SUPPLY UNIT SLS150PW * DRIVER BOARD (P-854) WEIGH CONVEYOR DRIVE MOTOR POWER SWITCH AIR CYLINDER POWER FILTER BOARD (P-859) ELECTROMAGNETIC VALVE Fig. 8.13 Disassembly Diagram * Later designs incorporate two 24 VDC power supplies. WPL-3000 SERVICE MANUAL 0077B 8-10...
  • Page 103 Chapter 9.1 Periodic Parts Replacement ....9.2 Breakdown and Countermeasure .... 9.3 Error Messages ........roubleshooting...

  • Page 104: Periodic Parts Replacement

    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 WPL-3000 SERVICE MANUAL 0077B...

  • Page 105: Breakdown And Countermeasure

    2. Adjust, replace thermal head 3. Defective thermal head cable 3. Check, replace cable 4. Defective main board 4. Check, replace main board 5. Defective power supply unit 5. Check thermal head applied voltage Check, replace power unit WPL-3000 SERVICE MANUAL 0077B...

  • Page 106: Error Messages

    100 total transactions. Same operator number Wait and restart opera- SAME OPR. TOTALING ON MAC. used within one second. tion. Err--13 Same operator number Wait and restart opera- OPERATOR IN USE used within one second. tion. Err--14 WPL-3000 SERVICE MANUAL 0077B...
  • Page 107 • Power up the scale with nothing on the platter. Scale was powered up Power up the scale with REMOVE ITEM ON THE PLATTER with some object on the nothing on the platter. Err-57 platter. WPL-3000 SERVICE MANUAL 0077B...
  • Page 108 Err--204 • Check cabling between printers. — Too many characters per Check PLU name CHARACTER BUFFER OVER PLU. registration area. — Too many characters per Check PLU name CHARACTER DOTS OVER line. registration area. WPL-3000 SERVICE MANUAL 0077B...
  • Page 109 9330 SYSTEM ERROR (CHECK MASTER SCALE) Satellite does not receive • Check Master Board, requested data from replace if necessary. Err--9330 Master Board. • Check all cable connec- tions. • Check for incorrectly wired cables. WPL-3000 SERVICE MANUAL 0077B...
  • Page 110 • Select and receive only data files from data file. similar scales. • IF-21FD floppy disk recorder not • Power off scale and connect IF-21FD Err 73 connected. floppy disk recorder. • Incorrect disk format. • Reformat floppy disk. WPL-3000 SERVICE MANUAL 0077B...

  • Page 111: Location Of Main Parts

    Chapter 10.1 Location of Main Parts........10-2 10.2 Replacing the Load Cell Unit ......10-3 10.3 Span Calibration Adjustment ......10-6...
  • Page 112 Load Cell Unit 10 10.1 L OCATION OF ARTS Fig. 11.1 Location of main parts WPL-3000 SERVICE MANUAL 0077B 10-2...
  • Page 113 MAIN BODY OF WEIGHING MECHANISM Fig. 11.3 Seal wire and weigh platter Do not cut the base seal wire unnecessarily since it is necessary to replace the sanction seal when the seal wire is cut. CAUTION CAUTION WPL-3000 SERVICE MANUAL 0077B 10-3...
  • Page 115 MAIN BODY platter. • Adjustment of the four-corner limit screws is necessary when the load cell Fig. 11.9 Confirming the four-corner limit screws has been replaced or the main body has received a jolt. WPL-3000 SERVICE MANUAL 0077B 10-5...
  • Page 117 Repeat the procedure beginning with step 1. A/D converter initial value . 3. Saving data Save data to E 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. WPL-3000 SERVICE MANUAL 0077B 10-7...
  • Page 118 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. CAUTION CAUTION WPL-3000 SERVICE MANUAL 0077B 10-8...
  • Page 119 ppendix A.1 Installation Notes..........A-2 A.2 Label Format Worksheets........ A-9...

  • Page 120: Installation Notes

    5. Bolt printer unit to printer arm. 6. Adjust stand to proper height. 7. Level stand and tighten all leg extensions and leveling feet in place. Note: Be sure to also tighten set screws in each leg. 8. Connect air lines. WPL-3000 SERVICE MANUAL 0077B...
  • Page 121 Note: These changes MUST be registered to the A/D Board NV RAM. Weight Calibration Follow the procedure in Section 10.3, Span Calibration Adjustment. Note: Take care that the weights touch only the scale rollers and backstop. WPL-3000 SERVICE MANUAL 0077B...
  • Page 122 8. Set Delay of package on scale to minimum: SETUP MENU b16-01/b16-02 [Section 4.2.11] a. Test delay WPL-3000 SERVICE MANUAL 0077B...
  • Page 123 Set text area: b01-06 iii. Set label length + gap: b01-07 iv. Set Sensor 2 (b01-09) to ensure label comes free of the backing paper b. TEST MENU C07 [Section 3.2.8] i. Modify label format as needed WPL-3000 SERVICE MANUAL 0077B...
  • Page 124 Note: If sensors are mounted on the leading edge of the WPL-3000, typical set- ting is 0.
  • Page 125 Note: Increase the value for faster operation. * These 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. WPL-3000 SERVICE MANUAL 0077B...
  • Page 126 Use DOWN ARROW to move to the desired menu option then press ENTER. Programming Menu 1: PLU FILE Use the ENTER and DOWN ARROW keys to navigate through PLU programming. The following items have been added to PLU programming for the WPL-3000. Address Description...
  • Page 127 Appendix WPL-3000 SERVICE MANUAL 0077B...
  • Page 128 Appendix WPL-3000 SERVICE MANUAL 0077B A-10...
  • Page 129 Appendix WPL-3000 SERVICE MANUAL 0077B A-11...
  • Page 130 Appendix WPL-3000 SERVICE MANUAL 0077B A-12...
  • Page 131 Appendix WPL-3000 SERVICE MANUAL 0077B A-13...
  • Page 132 Appendix WPL-3000 SERVICE MANUAL 0077B A-14...
  • Page 133 Appendix WPL-3000 SERVICE MANUAL 0077B A-15...
  • Page 134 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 IW603P1005...

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