Roll Printer Sensor adjustment

As requested by the night shift technicians:

Roll Printer Sensor Set-up Adjustment Procedure

1. First determine if the "tick" mark is light or dark. You also have to consider whether the label media is a clear film or has a paper backing. For example, with a silver tick mark on clear media, you would want to choose the "light" switch setting and use a dark backing plate so that the colors contrast. See image.

 

 Also, one way to determine if the switch setting is correct is to align the tick mark on the sensor, then press foil pull/jog button. If the label stops immediately upon releasing the button, the switch setting may be incorrect-change it. It should pull for the fast time setting-whether or not it stops on the mark.

2. Second, the foil pull fast time must be set so that the label does not pass up the sensor in fast speed. Ideally, you will want to set the time so that once slow mode engages, you are about an inch to an inch and a half from the sensor.

This is so it can slowly approach the sensor and engage the brake. If it is moving too fast, it will not have time to stop accurately. For example, if you have the time set at 3.00 seconds and the label pulls very fast right past the tick mark, you should lower the time by a second or a half.

3. Set up the sensor so that it is approximately 3mm from the mark and be certain that the lens is pointed horizontally and not angled up or down. This provides the best range for "seeing" the mark.

4. To set the sensor sensitivity, release both label clamping brakes, roll the label back to the nearest mark until the sensor "sees" the mark. You will know because the LED's will react on the side of the sensor module. Set the brakes on both ends of the roll printer so it will stay on the mark. Now -using a small flat sensor adjustment screwdriver- adjust the screw in the middle hole until you get about a "5" reading. Depending on whether the mark is light or dark will determine whether or not the red "output" LED (on the side of the module) lights up. If it is on all the time, you will want to adjust it off. Similarly, if it is off when not on the mark, it should likely light up when it is on the mark. It all depends on the light or dark switch, but adjusting it until it functions flawlessly should not take very long if you remember these concepts.

Mp#12- I/O board

I changed out the board on Mp#12 as requested.  Dip switch settings match and all machine functions have been checked and are working.  Marty was told that he is welcome to start the press at his convenience but ghey may not have time today.

Triacs

We have several of the ITC brand temperature controllers that need new triacs for repair.

They are SanRex TG35E60.
They're about $8 each.

We have SCR's for the DME brand controllers but no triacs.

Have a great day!

Mp#1 Ejector Cylinder Leak

Mp#1 went down Thursday evening because of significant oil leaking from between the ram cylinder and the platen that the ejector cylinder is mounted to.

The mold is out now and oil has been cleaned up. I am not sure if the entire ejector block must be removed or if there is a trick to making an easier repair. When Kenny Hoskins comes in I will consult with his expertise on the matter.

I will post more soon.

Water system strainers

I went around and cleaned out the strainers. Most were not bad. About 70% had dirty water color such as this image.

Milacron 486 Valid Power issue

This is just a re-hash of the events regarding the power supply and battery issue we had with MP#5.

To summarize:

The symptoms we encountered were " Error E047" or no screen at all.

Initially, there was no screen at all. I changed the power supply with one from MRO to which it was not known to be good or bad...just another one. That brought up the E047 error.

Then upon checking power on the backplane at the test points, one of the +12 volt signals was not present.

We obtained another known to be new power supply and installed it and the +12 was then present on the backplane > however > the E047 would not clear.

We then replaced the back up lithium 3.6 volt battery and upon restarting the control, system booted as normal.

Checks of the analog circuits indicated that transducers were reading accurately at that point and we started the press for operational tests and production.

To summarize again:

1. battery must be good!
2. power supply must have all voltage signals present and testable on the backplane!

4.6.15 - Nissei control issues

MP#23-

We had a problem where somehow the upper range limit for setting the shot size got changed. We now presume that it may have been related to a low battery condition. The fix supposedly goes like this:

1. In manual operating mode > hold down the alarm reset button on the operator station (yellow).

2. While holding it down > manually retract the screw back until a prompt field appears on the controller screen. Follow its instructions.

This procedure has not been carried out as the priority of the machine has required it to run all night without interruption.

Additionally, we had an issue where one of our technicians inadvertently changed the dialog language from English over to Kanji writing. This was executed on the "shift>main data" page. Top right corner. To undo this event and return back to English, the language must be returned to bilingual or trilingual > then > go to the compile page and select English from the language field. Note: the language field may not be present initially and the process may have to be repeated with care.

The shift main data page is also where the units of measurement are located, in case someone changes from Fahrenheit to Centigrade.

For reference >According to Don Thornwald of Nissei North America, technical support:

"With barrel at oper. Temps. Hold alarm reset PB in and same time to screw backward with CS4 switch. Go back max. distance pump loading and hold there until message appears.

Release alarm PB & inject screw all the way fwd. then check SM range.

On compile screen, left side is language selection."