ISHIDA WPL-3000 User manual

Manual No. 0077B 48725
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.
SERVICE MANUAL
WPL-3000

You can help improve this manual by calling
attention to errors and recommending
improvements. Please express your
comments to the nearest 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.

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.
Perform only the specified service procedures
To ensure personal safety, do not perform any service procedures which are not
specifically mentioned in this service manual.
Properly ground machinery
As a Class 1 electrical device, this machine requires protective grounding for safe
operation.
Avoid servicing while power is being supplied
Machine servicing while power is being supplied and covers or enclosures are
opened or removed should be avoided as much as possible. When servicing cannot
be performed by any other means, service personnel should take precautions against
the danger of electrical shock or other potential hazard involved.
Take precaution against residual electrical charge hazard
Capacitors inside the machine may still hold an electrical charge even after power is
disconnected.
Use same type fuses and components for replacement parts
To avoid the potential hazards involved, do not replace fuses or components with
types other than those specified in the parts list for this machine.
Power supply to the machine is disconnected only when the electrical plug
is removed from the electrical outlet. For protection against electrical shock,
remove plug before performing any servicing to the machine.
WARNING
The following symbols are used to alert service personnel of potential danger or
special circumstances related to the safe and proper servicing of this machine:
WARNING
WARNING
Precautions which must be followed to prevent the possibility
of death or serious injury.
Precautions which must be followed to prevent the possibility
of light or moderately severe injury to personnel or damage to
the equipment.
Important information for the operation of the machine.
NOTE:

GETTING STARTED
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.
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.
Do not leave screws or other foreign objects in the machine after
performing routine maintenance since this can cause major damage to the
machine when the electrical switch is turned on.
Always remove wires by holding the connector and pulling to disconnect.
Do not disconnect by pulling on the wires themselves since this may cause a
wire to snap or damage the connection.
Before assembling or adjusting this machine, make sure you thoroughly
understand and follow each step in the order indicated in this manual.
MAINTENANCE PRECAUTIONS

Contents
Table of Contents
1. Overview 1.1 External Parts and Names (I Line Type) .........
1.2 External Parts and Names (L Line Type) ........
1.3 Location of Safety Stickers .............................
1-2
1-3
1-4
2. Setup 2.1 Confirm Before Delivery
2.1.1 Location..................................................
2.1.2 Installation Route ...................................
2.1.3 Electrical Power .....................................
2.1.4 Setup Environment.................................
2.1.5 Work Clothes ..........................................
2.2 Necessary Items for Installation
2.2.1 Tools .......................................................
2.2.2 Manuals..................................................
2.3 Package Confirmation ....................................
2.4 Positioning and Adjusting
Conveyor Stands
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 ..........................
2.8 WPL-3000 USA Rescue Mode .......................
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-4
2-5
2-6
2-7
2-7
2-8
2-9
2-10
2-11
3. Test Mode 3.1 Menu Directory Diagram .................................
3.2 Test Mode
3.2.1 Starting Test 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) .....................
3.2.8 Label Format Editing (C07) ....................
3.2.9 Sales Mode Setting (C08) ......................
3-2
3-3
3-3
3-6
3-7
3-9
3-9
3-9
3-12
3-12

Contents
3.2.10 Machine ID No. Setting (C09) ................
3.2.11 Preset Function Setting (C10) ................
3.2.12 Password (C11) .....................................
3.2.13 Data Transmission (C99) .......................
3-13
3-14
3-14
3-15
4. Setting Mode 4.1 Menu Directory Diagram..................................
4.2 Setup Mode
4.2.1 Label Format (b01).................................
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) ........................................
4.2.6 Preset Report (b10)................................
4.2.7 Registration Select (b11) ........................
4.2.8 Total Mode Select (b12) .........................
4.2.9 Password (b13) ......................................
4.2.10 Tray Master Registration (b15)...............
4.2.11 Conveyor Setup (b16) ............................
4-2
4-5
4-7
4-8
4-9
4-11
4-12
4-14
4-15
4-15
4-16
4-16
5. Controller Unit 5.1 Overview .........................................................
5.2 Block Diagram.................................................
5.3 Electronic Parts
5.3.1 Display Board .........................................
5.3.2 Junction/Buzzer Board............................
5.4 Display and Key Check ..................................
5.5 Disassembly Diagram .....................................
5-2
5-3
5-3
5-4
5-6
5-7
6. Weigh Conveyor 6.1 Overview .........................................................
6.2 Block Diagram ................................................
6.3 Electronic Parts
6.3.1 Load Cell Unit.........................................
6.3.2 A/D Converter Board ..............................
6.4 Scale Check ...................................................
6.5 Disassembly Diagram .....................................
6-2
6-3
6-4
6-5
6-6
6-7

Contents
7. Printer / Label
Applicator Unit
7.1 Overview .........................................................
7.2 Block Diagram ................................................
7.3 Electronic Components ..................................
7.3.1 Printer Unit
(Thermal head, label sensor adjustment) ...
7.3.2 Label Applicator Unit ..............................
7.4 Adjustment Position of
the Label Applicator Unit .................................
7.5 Movement Test ...............................................
7.6 Disassembly Diagram (Stand Unit) ................
7.7 Disassembly Diagram (Printer Unit). ..............
7.8 Disassembly Diagram (Label Applicator Unit) ..
7-2
7-3
7-4
7-4
7-10
7-14
7-15
7-16
7-16
7-17
8. Weigh Conveyor
Unit
8.1 Weigh Conveyor Unit ......................................
8.2 Block Diagram ................................................
8.3 Electronic Components ..................................
8.3.1 Power Supply Unit..................................
8.3.2 Drive Board (P-854) ...............................
8.3.3 Electromagnetic Valve ............................
8.3.4 Air Cylinder.............................................
8.3.5 Application Timing Sensor......................
8.4 Elevator Check and Parts Adjustment ............
8.4.1 Weigh Conveyor .....................................
8.4.2 Conveyor Fall Prevention Screw
Adjustment .............................................
8.5 Disassembly Diagram......................................
8-2
8-3
8-4
8-4
8-5
8-5
8-6
8-7
8-8
8-8
8-9
8-10
9. Troubleshooting 9.1 Periodic Parts Replacement ...........................
9.2 Breakdown and Countermeasure ...................
9.3 Error Messages ..............................................
9-2
9-3
9-4
10. Load Cell Unit
Appendix
10.1 Location of Main Parts ....................................
10.2 Replacing the Load Cell Unit ..........................
10.3 Span Calibration Adjustment ..........................
A.1 Installation Notes ............................................
A.2 Label Format Worksheets...............................
10-2
10-3
10-6
A-2
A-9

Contents

Chapter 1
Overview
1.1 External Parts and Names (I Line Type) .........
1.2 External Parts and Names (L Line Type) ........
1.3 Location of Safety Stickers .............................
1-2
1-3
1-4

WPL-3000 SERVICE MANUAL 0077B
1-2
Overview 1
Fig. 1. 2 WPL- 3000 ( I Line Type) front view.*
CONTROLLER UNIT
INFEED CONVEYOR UNIT (OPTION)
PRINTER STAND
PRINTER UNIT
CONVEYOR WEIGH UNIT
LABEL APPLICATOR
DISCHARGE ROLLER UNIT
(OPTION)
POWER SWITCH
1.1 EXTERNAL PARTS AND NAMES
CONVEYOR STAND
(OPTION)
Fig. 1.1 WPL- 3000 ( I Line Type) top view.*
INFEED CONVEYOR UNIT (OPTION) PRINTER UNIT
SCALE
LABEL APPLICATOR
( I LINE TYPE )
* IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm.

1-3
WPL-3000 SERVICE MANUAL 0077B
Overview 1
1.2 EXTERNAL PARTS AND NAMES
Fig. 1.3 WPL-3000 ( L Line Type) top view.*
( L LINE TYPE )
SCALE
PRINTER UNIT
INFEED ROLLER UNIT (OPTION)
Fig. 1.4 WPL-3000 ( L Line Type) front view.*
* IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm.
LABEL APPLICATOR
PRINTER STAND
PRINTER UNIT LABEL APPLICATOR
DISCHARGE ROLLER UNIT
(OPTION)
POWER SWITCH
CONTROLLER UNIT
SCALE

WPL-3000 SERVICE MANUAL 0077B
1-4
Overview 1
1.3 LOCATION OF SAFETY STICKERS
Disconnect from
before opening
○○○○
○○○○○○
Fig. 1.5 Location of external stickers.
Fig. 1.6 Internal safety sticker.
IMPORTANT NOTE – later versions of the
WPL-3000 use a front mounted printer arm.

Chapter 2
Setup
2.1 Confirm Before Delivery
2.1.1 Location..................................................
2.1.2 Installation Route ...................................
2.1.3 Electrical Power .....................................
2.1.4 Setup Environment.................................
2.1.5 Work Clothes ..........................................
2.2 Necessary Items for Installation
2.2.1 Tools .......................................................
2.2.2 Manuals..................................................
2.3 Package Confirmation ....................................
2.4 Positioning and Adjusting
Conveyor Stands
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 ..........................
2.8 WPL-3000 USA Rescue Mode .......................
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-4
2-5
2-6
2-7
2-7
2-8
2-9
2-10
2-11

WPL-3000 SERVICE MANUAL 0077B
2-2
Setup 2
2.1 CONFIRM BEFORE DELIVERY
2.1.1 Location
Maintain adequate space for setup and maintenance as shown below:
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.).
The route should be maintained at all times.
2.1.3 Electrical Power
Electrical voltage as well as electrical plug and standards vary according to coun-
try. Always use the appropriate voltage and plug. In addition, noise and voltage
changes can affect performance, so connect plug to a dedicated outlet and place in
an appropriate environment.
2.1.4 Setup Environment
Installation site should:
1. Be stable and level.
2. Not be exposed to moisture.
3. Not be exposed to direct sunlight for long periods.
4. Not be exposed to wind or strong vibration.
5. Have sufficient area for installation and maintenance.
6. Allow power cord not to be pinched between objects or receive force from
other objects.
7. Be connected to an outlet with a circuit breaker capable of detecting short
circuits.
500mm
(20 in.)
Fig. 2.1 Allow adequate space for WPL-3000.
500mm
(20 in.)
IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm.

2-3
WPL-3000 SERVICE MANUAL 0077B
Setup 2
2.1.5 Work Clothes
●Care must be taken when working near moving parts.
●Avoid wearing loose clothing that might be caught in the machine.
●Shirt sleeves should be kept buttoned or rolled securely above the elbows.
●To keep fingers or hands from being caught in the conveyor gears or other
moving parts, do not wear gloves.
●Ties should be tucked inside shirts.
2.2 NECESSARY ITEMS FOR INSTALLATION
2.2.1 Tools
●Phillips head screwdriver
●Slotted screwdriver
●Monkey wrench
(more than 30mm (1 3/16 in.)
jaw extension)
●Open-ended wrench (30mm)
●Allen wrench key set (metric)
●Box wrench (7mm, 8mm, 10mm)
●Electrician's pliers
●Level (200 to 250mm (8 to 10 in.))
●IF-21 FD (3.5DD inch floppy disk)
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)
Note : Use a level with precision greater than 2/1000.
PHILLIPS HEAD
SCREWDRIVER (3MM,4MM)
IF-21FD
3.5 INCH
2DD FD MANUALS
LEVEL
SL TTED SCREWDRIVER
Fig. 2.2 Tools

WPL-3000 SERVICE MANUAL 0077B
2-4
Setup 2
Open carton and inspect contents to see that all items are accounted for and
undamaged.
2.3 PACKAGE CONFIRMATION
2.4 POSITIONING AND ADJUSTING CONVEYOR STANDS
For the WPL-3000 to weigh accurately, it is essential that the machine be level.
Should the machine be unlevel or located on an unstable surface, inaccurate
measurements, improper product flow, or imprecise labeling may result. To
prevent these conditions from occurring, follow the procedures outlined below:
1. Securely fasten each unit to stand. (Reference Section 2.4.1)
Using a level, adjust the leveling legs to the desired height. Cas-
tors should be set to rise at least 1 cm (3/8 inch) from the ground.
Note : Infeed conveyor and stand are options.
Note : Use a level to set within 2/1000 diagonal on right/left and front
/ back of weigh platter.
Fig. 2.3 Items contained in carton
IMPORTANT NOTE – later versions of the WPL-3000 use a front mounted printer arm.

2-5
WPL-3000 SERVICE MANUAL 0077B
Setup 2
2. Loosely tighten nuts fastening the leveling legs. Confirm that all legs are
stable with no movement and tighten down the nuts until tight.
3. Loosely tighten anchor bolts to conveyor stands. Confirm that all
legs are stable with no movement and tighten down anchor bolts
until bolts are tight.
2.4.1 Fastening to Stand
Fig. 2.4 Weigh conveyor unit (under side view)
B LT (X 6)
(M5 x 60mm) STAND
ANTI-VIBRATI N PAD
Fig. 2.5 Infeed conveyor (under side view)
Note : To prevent rust, apply machine grease to legs.
Bolt (X 4)
(M5 x 60mm)
STAND ( PTI N)

WPL-3000 SERVICE MANUAL 0077B
2-6
Setup 2
2.4.2 Fastening Stands
Secure conveyor stands to floor using anchor bolts.
METAL FITTING J INT
ANCH R B LT
NUT
LEVELING LEG
●Tightly fasten the nuts
securing the leveling leg.
●Attach joint to stands so
neither conveyor stand
can move.
Fig. 2.6 Fastening Stands

2-7
WPL-3000 SERVICE MANUAL 0077B
Setup 2
2.4.4 Stand Fastening Method 2
Fasten anchor bolt and leveling leg to anchor plate
2.4.3 Stand Fastening Method 1
Fasten stand to floor.
Fig. 2. 7 Method 1
Fig. 2. 8 Method 2
ADJUSTABLE PRESSURE FITTING (EXAMPLE)
ANCH R B LT AND WASHER(4)
LEVELING LEG

WPL-3000 SERVICE MANUAL 0077B
2-8
Setup 2
TIE UP AND SECURE EXCESS PRINTER
CABLE AND FASTEN C VERS WITH SCREWS.
2.5 CONNECTING CABLE
Connect each cable as shown below. Tie up and secure excess printer cable.
PRINTER UNIT
C NTR LLER UNIT
P WER C RD
Fig. 2.9 Connecting Cable
Fig. 2.10 Printer Stand Case
WEIGH C NVEY R UNIT
○○○
○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
IMPORTANT NOTE:
Later versions of the WPL-3000
use a front mounted printer arm.