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LabelMill LM3560 Operation Manual

Servo drive print & apply automatic label applicator
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LM3560
SERVO DRIVE PRINT & APPLY
AUTOMATIC LABEL APPLICATOR
OPERATIONS MANUAL
Manufactured in USA by:
2416 Jackson St.
LabelMill, Inc.
Savanna, IL 61074
(800) 273-4707
info@labelmill.com
www.labelmill.com

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Summary of Contents for LabelMill LM3560

  • Page 1 LM3560 SERVO DRIVE PRINT & APPLY AUTOMATIC LABEL APPLICATOR OPERATIONS MANUAL Manufactured in USA by: 2416 Jackson St. LabelMill, Inc. Savanna, IL 61074 (800) 273-4707 info@labelmill.com www.labelmill.com...

  • Page 2: Table Of Contents

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL TABLE OF CONTENTS SECTION PAGE 1. APPLICATOR OVERVIEW Introduction General Applicator Specifications Inventory List User Responsibility/Safety 2. WEBBING, SETUP AND GENERAL OPERATION LM3560 Component Description Web Routing (Synchronous) Label Sensor Adjustment...

  • Page 3: Applicator Overview

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL SECTION 1 APPLICATOR OVERVIEW Introduction General Applicator Specifications Inventory List User Responsibility & Safety Page Made in the U.S.A. © 2019 LabelMill 11/01/2019 Model LM3560...

  • Page 4: Specifications

    SERVO PRINT & APPLY LABEL APPLICATOR The LabelMill LM3560 is a state of the art, high speed, heavy-duty industrial Label Applicator. High-speed label applications to 2300 linear inches of label web per minute is combined with an exceptional placement accuracy of up to +/- 1/32", with its wipe-on method of application.

  • Page 5: Inventory List

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL INVENTORY LIST QTY. Description Applicator Assembly Thermal Transfer Print Engine 12-½” dia. Blue Plastic Spools w/ Quick Release Collar 7-¾” dia. Blue Plastic Spool w/ screws ½” – 13 bolts w/ washers 6’...

  • Page 6: User Responsibility

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained, and repaired in accordance with the instructions provided.

  • Page 7: Webbing, Setup And General Operation

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL SECTION 2 WEBBING, SETUP AND GENERAL OPERATION LM3560 Component Description Web Routing (Synchronous Feed) Label Sensor Adjustment Drive Motor Pack T-150 Mounting Stand (option) T-Stand Adjustment Page Made in the U.S.A.

  • Page 8: Component Description

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL COMPONENT DESCRIPTION Control Box Print Engine (Behind Back Plate) Label Storage Spool U-Arm Brake Arm Label Sensor Take-Up Spool Clip Wipe Brush Web Take-Up Spool Pinch Rollers Dancer Arms Peeler Arms Page Made in the U.S.A.

  • Page 9: Web Routing (Synchronous)

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL WEB ROUTING (Left Hand Synchronous Feed Shown) Step Operation Load web onto label storage spool (A) so it unloads in a counter-clockwise direction. Feed the web to the right and under the brake arm (B), and over guide roller (C).

  • Page 10: Label Sensor Adjustment

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LABEL SENSOR ADJUSTMENT Sensor Peeler Arm Rail Manual adjustment of the label in relation to the peeler plate is achieved by loosening the thumbscrew on the backside of the label sensor and sliding the assembly up or down on the peeler arm rail.

  • Page 11: Drive Motor Pack

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL DRIVE MOTOR PACK (PN: AC-F-A0011) To increase waste web tension, move the lock collar 1/32” away from the take-up spool, compressing the spring. CAUTION! Too much web tension may cause web breakage, label drifting or premature failure of the take-up spool assembly.

  • Page 12: T-150 Mounting Stand (Option)

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL T-150 MOUNTING STAND (OPTIONAL) Page Made in the U.S.A. © 2019 LabelMill 11/01/2019 Model LM3560...

  • Page 13: T-Stand Adjustment

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL T-STAND ADJUSTMENT Column Crank Column Lock To adjust the T-150 mounting stand, simply loosen the headlocks and adjust to the desired height by turning the column crank. Be sure to lock the headlocks when finished.

  • Page 14: Setup And Adjustment

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL SECTION 3 SETUP & ADJUSTMENT Valve Pack Tamp Assembly & Factory Setup Flag Assembly & Factory Setup Synchronous Feed (Wipe-On) Assembly Corner Wrap Unit Operation Page Made in the U.S.A.

  • Page 15: Vacuum Regulator

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL VALVE PACK (Not Included in Synchronous Feed Configuration) There are solenoid valves associated with applicators using pneumatics. They are supplied with pre-wired cables that connect to the necessary components. There is an adjustment for airflow for each valve. This will change the rate at which air will flow through each valve. It may be necessary to adjust each valve for optimum performance after installation.

  • Page 16: Tamp Assembly & Factory Setup

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL Tamp Assembly & Factory Setup NOTE: PICTURES SHOWN MAY NOT RESEMBLE YOUR MODEL Hinge Thumbscrew Tamp Pad (T) Peeler Plate (P) Air Assist Tube (B) Tamp pad adjustment 1. To adjust the tamp pad (T) in relationship to the peeler plate (P) in the horizontal plain, loosen the (2) button- head screws and move the peeler plate forward or backward in the slots.

  • Page 17: Flag Assembly & Factory Setup

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL Flag Assembly & Factory Setup NOTE: PICTURES SHOWN MAY NOT RESEMBLE YOUR MODEL Shaft Collars (S) Cylinder Mounting Plate (C) Flag Assembly (F) Peeler plate (P) Label jaws (J) Air assist tube (B)

  • Page 18: Synchronous Feed & Factory Setup

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL Synchronous Feed Assembly & Factory Setup Peeler Arm (A) Mounting Screw (S) Peeler Plate (P) Peeler Plate Adjustment (used to adjust tracking) 1. Loosen the mounting screws (S) and slide the peeler plate (P) in the direction needed to make the label web track in the desired direction.

  • Page 19: Corner Wrap Unit Operation

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL CORNER WRAP UNIT OPERATION The LM-3560 control unit is equipped to support the optional corner wrap unit. (Pictures may not show your actual model) Page Made in the U.S.A. © 2019 LabelMill...

  • Page 20: Programming And Control Operation

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL SECTION 4 PROGRAMMING AND CONTROL OPERATION Operator Interface Console Accessory Connections T-50 Photo Eye Programming Programming Flow Chart Main Displays 4-10 Key Definitions 4-21 Set Up of Key Features 4-23 Quick Start &...
  • Page 21 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL HAND HELD LABELER INTERFACE HLI-100 Operator LCD Display Interface Interface Port Page Made in the U.S.A. © 2019 LabelMill 11/01/2019 Model LM3560...

  • Page 22: Accessory Connections

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL ACCESSORY CONNECTIONS LOCATED ON BACK OF CONTROL BOX Main Power Power Switch Remote Trigger Print Engine (Photoeye) Port Print Engine Power Cable Light Bar / Auxiliary Ports Label Sensor Printer Interface...
  • Page 23 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL T-50 PHOTOEYE Trigger Cable Wiring Page Made in the U.S.A. © 2019 LabelMill 11/01/2019 Model LM3560...

  • Page 24: Programming

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL PROGRAMMING All programming is performed via the HLI-100 keypad and display as shown on page 4-1. All programmed settings are backed in nonvolatile memory and are not lost when the unit is powered off.
  • Page 25 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • PASSWORD The PASSWORD is used to lock the menus of the control. This option is used to prevent unauthorized access to variable data. When shipped from the factory, the password is to 7074 and NO MENUS are locked. The password cannot be changed.
  • Page 26 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • COUNTERS Used to reset and set the internal counters of the control. PROGRAMMABLE BLOCKS: Total counter – resets the total counter to zero. Batch counter – resets the batch counter to zero.
  • Page 27 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • CYCLE TYPE Determines the application type and sequence in relation to the label. PROGRAMMABLE BLOCKS: No Tamp (Used for Synchronous Feed (Wipe-On) Applications) Tamp Before Feed - Tamp Cylinder will cycle before a label is fed onto vacuum platen...

  • Page 28: Programming Flow Chart

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL PROGRAMMING FLOW CHART MODEL NUMBER LM MODEL 3560 & REVISION INITIALIZING UP & DOWN ARROW KEYS WILL SCROLL THROUGH THE PROGRAM BLOCKS AND SUB MENUS TOTAL 0000000 BATCH 0000000 PRESS "PROG"...
  • Page 29 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL ENCODER PRESS "ENTER" CYCLE TYPE PRESS "ENTER" PRINTER SETUP PRESS "ENTER" ALARMS PRESS "ENTER" JOB STORAGE PRESS "ENTER" DEFAULTS PRESS "ENTER" I/O STATUS PRESS "ENTER" NETWORK SETTING PRESS "ENTER" PRESS "PROG"...

  • Page 30: Main Displays

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL MAIN DISPLAYS PASSWORD 0000 PASSWORD PRESS ENTER PASSWORD PASSWORD Note: use UP and DOWN arrows to toggle between "ON" and "OFF". The enter key will save selection. AUTO SET UP...
  • Page 31 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL PRODUCT SENSOR PRODUCT DELAY PRODUCT DELAY 00.00 PRESS ENTER PRESS ENTER SENSOR TRIGGER SENSOR TRIGGER PRESS ENTER LEADING EDGE SENSOR TRIGGER TRAILING EDGE ON DEBOUNCE ON DEBOUNCE 0.000 USED TO FILTER FALSE...
  • Page 32 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL TAMP SETUP TAMP DURATION TAMP DUR 0.000 PRESS ENTER PRESS ENTER FLAG DURATION FLAG DUR 00.00 PRESS ENTER HEAD UP SWITCH HEAD UP SWITCH PRESS ENTER N.O. HEAD UP SWITCH...
  • Page 33 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LABEL SPEED/ACC SET SPEED SPEED-IPM 0650 PRESS ENTER PRESS ENTER SET ACCERELERATION SET ACCERELERATION ACCEL-MS 0060 PRESS "ENTER" PRESS ENTER COUNTER ENTER TO CLEAR TOTAL CNT RESET PRESS ENTER PRESS ENTER...
  • Page 34 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LABEL SENSOR I-MARK/GAP/CLR I-MARK/GAP/CLR PRESS ENTER PRESS ENTER I-MARK/GAP/CLR CLEAR I-MARK/GAP/CLR I-MARK MANUALSET GAP SET MIN, ENTER PRESS ENTER 0.000 SET MAX, ENTER 0.000 GAP VOLTS 0.000 GAP THRESHOLD GAP VOLTS 0.000...
  • Page 35 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LABEL AUTO POSN AUTO-POSITION PRESS ENTER AUTO-POSITION STOP COMP DIST STOP COMP 0.000 PRESS ENTER LABEL STOP POSN STOP POSN 0.000 PRESS ENTER MISSG LABEL DET MISSING LBL DET PRESS ENTER...
  • Page 36 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL ENCODER ENCODER ON/OFF PRESS ENTER PRESS ENTER ENCODER ON/OFF ENCODER ON/OFF CONVEYOR LOCK CONVEYOR LOCK >ON ENC OVERRIDE % & OVERRIDE 100.00 Range PRESS ENTER 50-150% TRIGGER DISTANCE TRIG DIST 00.00...
  • Page 37 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL CYCLE TYPE NO TAMP PRESS "ENTER" (WIPE-ON) TAMP BEFORE FEED TAMP AFTER FEED BLOW BEFORE FEED BLOW AFTER FEED PRE-PRINT TAMP PRE-PRINT BLOW CLAM SHELL BEFORE CLAM SHELL AFTER 4-17 Page Made in the U.S.A.
  • Page 38 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL PRINTER SETUP > = PRINT LABEL PRESS "ENTER" < = CYCLE NO PRINT PRINTER ENABLE ON / OFF PRESS "ENTER" PRINT REPEAT ON / OFF PRESS "ENTER" PRINT FLT TIMER PRINT FLT TIMER PRESS "ENTER"...
  • Page 39 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL Range 01-06 Jobs JOB STORAGE PRESS ENTER RESTORE JOB JOB NUMBER 1 ARE YOU SURE? PRESS ENTER < = NO > = YES SAVE JOB JOB NUMBER 1 ENTER: OVERWRIGHT...
  • Page 40 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL I/O STATUS S P H I A F V T PRESS ENTER O O O O O O (XO) O O O O O O O O (X1) O O O O O O O O...

  • Page 41: Key Definitions

    An encoder uses “LINES or COUNTS” per revolution in order to track speed and distance. Note that lines per revolution are also referred to as counts per revolution. These counts are feed into the LabelMill control to be processed for the different features that require this feed back.
  • Page 42 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • ENCODER OVERRIDE – This feature is used in conjunction with ELECTRONIC GEARING. This feature is used to fine-tune the ratio of the applicator to the product conveyor. • TRIGGER DIST – TRIGGER DISTANCE is used in conjunction with the encoder feature. Trigger distance is similar to product delay in that it is used to electronically move the placement of the label on the product.

  • Page 43: Setup Of Key Features

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL SETUP OF KEY FEATURES • START COMP DIST – START COMPENSATION DISTANCE 1. Set basic applicator up first, refer to quick setup 2. Set up STOP COMP DIST, refer to STOP COMPENSATION DISTANCE setup 3.

  • Page 44: Label Stop Position

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • LABEL STOP POSITION LABEL STOP POSITION is used to electronically move the stop position of the label on the applicator ONLY. The setup below describes how to use the LABEL STOP POSITION in ASYNCHRONOUS operation ONLY.

  • Page 45: Wheel-Mounted

    CALCULATING ENCODER LINES PER INCH (gearing) There are two basic concepts utilized to interface the product ENCODER to the LabelMill control. One method utilizes a wheel mounted directly to an encoder. This wheel rests on the belt surface and rotates when the belt moves.
  • Page 46 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • TRIGGER DIST – TRIGGER DISTANCE TRIGGER DISTANCE is used in conjunction with the encoder feature. Trigger distance is similar to product delay in that it is used to electronically move the placement of the label on the product. When the encoder feature is used, the product delay feature is rendered inactive.
  • Page 47 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • BROKEN WEB BROKEN WEB feature is used to detect the breakage of the label web. Note this feature will not work with clear labels. The label sensor detects the broken web by comparing the difference in the opacity of the label liner to NO label liner.
  • Page 48 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • MANUAL-SET GAP MANUAL-SET GAP is used to manually set the label sensor to the label stock that is webbed in the applicator. This step is automatically taken care of in the AUTO SETUP mode covered in QUICK SETUP chapter. If the values the applicator calculated are in question, the following will allow manual calibration of the label.

  • Page 49: Manual Setup

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL QUICK START GENERAL SETUP 1. Inspect applicator system and verify all cables are installed properly. 2. Web system with labels. 3. Turn power switch on. 4. Press “PROG” 5. Press UP arrow 6.
  • Page 50 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL HOW TO SET UP AN ASYNCHRONOUS APPLICATION • “TAMP” WITHOUT AN ENCODER Determine the following and select it in the software 1. Type of application mode. (Tamp) 2. Tamp before or after feed (before feed is standard) 3.
  • Page 51 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL HOW TO APPLY MULTIPLE LABELS TO A SINGLE PRODUCT • WHEN UTILIZING A ENCODER This section will explain how to apply more than one label to a single product with a single start signal. TRIGGER DISTANCE will move the label placement in inches (00.00) for the FIRST LABEL.
  • Page 52 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL • WHEN NOT UTILIZING A ENCODER Product delay is similar to trigger distance in that it is used to electronically move the placement of the FIRST label on the product. Product delay will move the label placement in time (00.000). Because the product delay feature utilizes time, the speed of the product MUST be constant and consistent.
  • Page 53 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL DESCRIPTION OF I/O All user inputs and outputs are “SINKING” type, except for the special isolated ground I/O. Example in order for a status light to illuminate for “Run Status Ok” the light should be wired between pins #1 & #8 on the “Light Bar/Aux.”...
  • Page 54 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL REMOTE TRIGGER CONNECTOR P1-A REMOTE TRIGGER CONNECTOR P1-B (PRODUCT SWITCH) PIN # ADDRESS (Pre-Print PRODUCT SWITCH) PIN # ADDRESS 4 pin Am p 4 pin Am p +24 VDC +24 VDC...
  • Page 55 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LIGHT BAR/AUXILIARY CONNECTOR P5-A INPUT/ DB-15 FEMALE PIN # OUTPUT ADDRESS +24VDC +24VDC 24 COM 24 COM LOW LABEL IN X1,3 ERROR (Red light) Y0,7 LOW LABEL (Yellow light) Y1,0...
  • Page 56 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL AUX I/O P6-A INPUT/ DB25 Fem ale CONNECTOR #J1 PIN # OUTPUT ADDRESS +24VDC +24VDC 24V COM 24V COM Input Common Pin 5 and 1 tied for sinking inputs, pin 5 to pin 3 for...
  • Page 57 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL E-STOP Wiring (DB-25 FEMALE / J1 ONLY) E-STOP Wiring (J1 ONLY) DB25 +24 TO OUTPUTS POWER TO SERVO CARD 4-37 Page Made in the U.S.A. © 2019 LabelMill 11/01/2019 Model LM3560...
  • Page 58 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL P7-J3 P7-J4 Display COMM. PIN # Display COMM. PIN # 8 Pin RJ 6 Pin RJ 422 Touch Screen HLI-100 232 Hand Held Touch Sense (GND) Fault line O.C. COMM. 1 RS-232 COMM.

  • Page 59: How To Set Labeler Communications Address

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LM3560 SETUP DIP SWITCH COMMUNICATIONS ADDRESS HOW TO SET LABELER COMMUNICATIONS ADDRESS FOR A 3560 WHEN USING MULTIPLE LABELERS WITH ONE TS204 TOUCHSCREEN, EACH LABELER MUST BE SET UP WITH A UNIQUE COMMUNICATIONS ADDRESS.

  • Page 60: Cleaning And Maintenance

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL SECTION 5 CLEANING & MAINTENANCE General Cleaning & Maintenance Troubleshooting Fault Codes Replacing the Main Power Fuse Page Made in the U.S.A. © 2019 LabelMill 11/01/2019 Model LM3560...

  • Page 61: General Cleaning & Maintenance

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL GENERAL CLEANING & MAINTENANCE The system should be inspected and cared for properly before operation begins. Typical inspection includes confirming correct supply spool loading, web path, checking air pressure, ensuring rollers are clean and free of adhesives, checking pinch assembly operation, and label feed position.

  • Page 62: Troubleshooting Guide

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL TROUBLESHOOTING GUIDE If the system malfunctions, it is necessary to determine where the problem exists in a normal sequence of operation. Possible error conditions are listed in the left-hand column to provide a systematic approach to troubleshooting.

  • Page 63: Fault Codes

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL FAULT CODES DISPLAYED FAULT DESCRIPTION CORRECTIVE ACTION Memory Checksum Data lost in battery SRAM Consult factory or service provider Missing Label Too many labels missing on web Check label stock...

  • Page 64: Replacing The Main Power Fuse

    LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL REPLACING THE MAIN POWER FUSE The circuitry is protected from a current overload by GMA 15A a fast blow fuse. Should the applicator fail to operate, the condition of this fuse should be checked. If the fuse is open, the cause of the overload condition must be determined and corrected prior to replacing the fuse.
  • Page 65 LM3560 Servo Drive Print & Apply Label Applicator USER’S MANUAL LM3560 AUTOMATIC LABEL APPLICATOR OPERATIONS MANUAL Copyright and Trademarks Copyright ©2019 LabelMill All rights reserved. All trademarks and brand names are the property of their respective owners. LabelMill 2416 Jackson St.