LabelMill LM1012 User manual

LM1012
TABLE-TOP LABEL
APPLICATOR SYSTEM
OPERATIONS MANUAL
Manufactured in USA by:
LabelMill, Inc.
2416 Jackson St.
Savanna, IL 61074
[phone]
[email protected]
www.labelmill.com

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 2
TABLE OF CONTENTS
SECTION
PAGE
1. SYSTEM OVERVIEW
Introduction
4
General System Specifications
5
Inventory List
6
User Responsibility & Safety
7
2. SETUP AND OPERATION
LM1012TTS Component Description
9
Web Routing
10
Label Sensor Adjustment
11
Label Sensor Calibration
12
Mechanical Clear Label Detector
13
Electronic Clear Label Detector
14
Drive Motor Pack
15
3. PROGRAMMING & CONTROL OPERATION
System Controls / Operator Interface
17
Control Accessory Connections
18
Programming
19
Quick Programming Flow Chart
22
Key Definitions
32
Set Up of Key Features
33
Input & Output Description
35
4. OPTIONAL APPLICATION MODULES
Tamp Applicator Module Installation
39
Flag Applicator Module Installation
41
Round Product Applicator Module Installation
43
Auto Round System Module Installation
45
Remote Start Module
46
Valve Pack
47
Module Air Connections
48
Peeler Plate Adjustment
49
External Printer Interface Connection
50
5. TROUBLESHOOTING & MAINTENANCE
Troubleshooting
52
Fault Codes
53
Storage Spool Brake Adjustment
54
Replacing the Main Power Fuse
55

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 3
SECTION 1
SYSTEM OVERVIEW
Introduction
4
General System Specifications
5
Inventory List
6
User Responsibility & Safety
7

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 4
INTRODUCTION
The LabelMill LM1012TTS is a microprocessor controlled, variable speed, heavy-duty industrial table- top
label application system. Label dispensing speeds up to 1400 linear inches of label web per minute is
combined with exceptional label position repeatability. Automatic feed on label removal. Outboard-
supported drive roller to minimize vibration induced label misplacement. Heavy-duty hybrid-servo motor
drive. Hardened steel peeler plate for reduced wear. Adjustable label sensor for expediting changeover
without sacrificing accuracy. The LM1012TTS will accept a wide variety of label sizes without the need for
part changes. This system can be quickly and easily configured to meet your labeling needs. There is no
need for multiple machines with this design. The unique rail mounted application modules makes
changeover from one module to another in 5 minutes or less.
STANDARD FEATURES
Modular Design
Easy Set-Up
Electronic Label Sensor
OPTIONAL APPLICATOR MODULES
Tamp Applicator
Flag Applicator
Round Product Applicator
Auto-Round Module

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 5
LM1012TTS SPECIFICATIONS
LABEL SPEED
0 - 1400 linear inches of web per minute standard
LABEL ROLL
CAPACITY
12" Max. outside diameter wound on a 3" diameter core. Die cut waste removed with a
minimum of 1/8" separation between labels in running direction.
LABEL SIZE
Minimum: 1/2" wide x 1/2" long - Maximum: 4.5" wide x 10" long
LABEL PLACEMENT
ACCURACY
Up to 1/32" (1mm) when labels are produced to specifications and product handling is
controlled.
INTERFACE
SENSORS
Product Sensor-Photo Eye-Limit Switch, Label Sensor Switch, Head Up Limit Switch,
and Round Product Tamp Switch.
ELECTRICAL
115 V AC/60 Hz - 2A
AIR REQUIREMENT
80p.s.i. / 3 cfm
SIZE
26"H x 20"W x 24"D
WEIGHT
40 lb.
ENVIRONMENT
Operating Temp. 50-95 F. (10-15 C.) - 15-85% RH. non-condensing
*Options Available

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 6
INVENTORY LIST
Standard Equipment - LM1012
QTY.
Description
1
Dispenser Assembly
1
12" Diameter Blue Plastic Spools w/ Quick Release Collar
1
12' Power Cord
1
Adjustable Electronic Label Sensor
1
Take-Up Spool Clip
2
Module Mounting Knobs
1
Model LM1012 Operators Manual
Optional Tamp Module - LM1012TM
QTY.
Description
1
Tamp Module Assembly
Optional Flag Module - LM1012FM
QTY.
Description
1
Flag Module Assembly
Optional Round Product Module - LM1012RM
QTY.
Description
1
Round Product Module Assembly
Optional Auto Round System Module - LM1012ARS
QTY.
Description
1
Auto-Round Product Module Assembly

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 7
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. This
equipment must be checked periodically. Defective equipment should not be used. Parts that are broken, missing,
plainly worn, distorted, or contaminated should be replaced immediately. Should such repair or replacement become
necessary, we recommend that a request for service advice be made.
This equipment or any of its parts should not be altered without the prior written approval of LABELMILL. The user of
this equipment shall have the sole responsibility for any malfunctions which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than LABELMILL or a service facility designated by
LABELMILL.
SAFETY
Only qualified personnel should use this equipment.
Before installing, inspecting or servicing equipment, turn OFF all power and air controls at the source and lock out in
accordance with OSHA Standards.
Be sure all external electrically conductive parts are connected to a good electrical ground.
Never handle live electrical equipment with bare hands while standing in water, or while hands and feet are wet.
Dangerous electrical shock can result.
Whenever the equipment is unattended, turn off all control and power supply switches.
Keep equipment clean and in good operating condition. Promptly repair or replace all worn or damaged hoses, cables
or parts.
Do not make any repairs to equipment unless you are fully qualified.
This equipment contains fast moving parts that may move without warning. Keep hands, loose hair and clothes clear of
machines at all times.
Never place hands or any other body parts under the label platen at any time.
This equipment uses compressed air. Proper care and maintenance must be taken when handling compressed air and
its components.
These precautions are further detailed and explained where specifically required in this manual.
WARNING
READ AND UNDERSTAND THESE INSTRUCTIONS
Protect yourself and others. Be sure this information is read and understood by all operators.
ELECTRICAL SHOCK CAN KILL!
Do not touch live electrical parts with bare skin or work with gloves or wet clothing.
NOISE CAN DAMAGE HEARING!
Wear proper ear protection.

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 8
SECTION 2
SETUP & OPERATION
LM1012TTS Component Description
9
Web Routing
10
Label Sensor Adjustment
11
Label Sensor Calibration
12
Mechanical Label Detector Setup
13
Electronic Clear Label Detector Setup
14
Drive Motor Pack
15

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 9
COMPONENT DESCRIPTION
Pinch Roller
Release Knob
Web Take-Up
Spool Lock
Label Storage Spool
Custom Product
Fixture
Spool Clip
Pinch Roller
Control Box
Valve Pack
Tamp Slide Assembly
Custom Nest Inserts
Push Button
Start Device
Tamp Pad

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 10
WEB ROUTING
Step
Operation
1
Load web onto label storage spool (A) so it unloads in a clockwise direction.
2
Insert the web under the first guide roller and over the second guide roller (B).
3
Wrap the web around the peeler plate (C), continuing on to the drive roller (D).
4
Turn the Pinch Roller Knob (G) 180deg. to open the pinch roller from the drive roller.
5
Feed the web over the top drive roller (D). Next, slip the web between the drive roller
and the pinch roller (E). Continue on by wrapping the web under the drive roller.
6
Finish the process by loading the waste backing paper onto the web take-up spool (F).
The take-up spool rotates in a counter-clockwise direction.
7
Turn the Pinch Roller Knob (G) 180deg. so that the pinch roller and drive roller contact
each other. When the roller is closed, roll the knob back and forth between your fingers
so that you can feel a “flat” on the shaft.
NOTE: This must be done to ensure proper label feeding.
8
Adjust the plastic web guide clips so the web is guided straight and even. Make sure the
clips do not bind the web.
9
Lock the wiper assemblies near roller (B) and at the peeler plate (C) with light pressure
to keep proper tension the system and to assist in peeling the label from the liner.
** To remove the label storage spool (A), turn the spool lock counter-clockwise (approx. 15 deg.) until you reach a stop.
The spool will now slide off. To secure the spool, simply turn the spool lock clockwise until snug. DO NOT over tighten
the spool lock!
Pinch Roller Knob (G)
(A)
(B)
(C)
(G)
Spool Lock
(D)
(F)
(E)

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 11
Z-Z-ELS-100 LABEL SENSOR ADJUSTMENT
*Note that the control must be programmed for the label sensor to work properly. The Z-Z-ELS100 label sensor
must be set to the "Clear" setting in the Label Sensor menu.
LABEL PLACEMENT IN RELATION TO THE PEELER PLATE
Loosen the lock screw on the photo eye rail assembly and slide it forward or backward on the rails to achieve placement
of the label with the peeler plate nose (+/- 1/32). After adjustment, cycle the labeler to verify new label placement.
Label Sensor
Assembly
Sensor Adjustment
Rails
Label Sensor
Thumbscrew
Label Sensor
Rail Thumbscrew

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 12
Z-Z-ELS100 LABEL SENSOR SETUP INSTRUCTIONS
Teach Mode Setup Procedure:
1. Place the web liner in the sensor (remove a label or use the label gap).
Press the [+] and [-] buttons at the same time for less than one second.
The red LED will begin to flash.
2. Place the web liner, with a label, in the sensor.
Press the [-] button for less than one second.
The red LED will stop flashing.
3. The automatic setup is complete. (Steps 1 and 2 can be reversed)
Manual Sensitivity Adjustments:
The "Teach Mode Setup" should always be successful. However, the sensitivity can be adjusted manually by
pressing the [+] or [-] buttons. The red LED will flash with each button press.
Locking/Unlocking the Setup:
Press and hold the [+] and [-] buttons for three seconds (but less than six seconds). The red LED will
change state. When the buttons are released, the red LED will then indicate locked (red LED on) or unlocked
(red LED off).
Light/Dark Switching:
Press and hold the [+] and [-] buttons for six seconds. When the mode is changed, the red LED will begin to
flash slowly until the buttons are released.

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 13
OPTIONAL MECHANICAL CLEAR LABEL DETECTOR
The Mechanical Clear Label Detector comes preset from the factory and should require no adjustment. If there is a need
to readjust the sensor, the following is a guide: Move the label stock until the gap between the labels is centered under
the Star Wheel and the star wheel is laying flat on the label stock as shown above. This can be accomplished by
unwinding the label storage spool enough to make the web “loose". To test adjustment, move the label stock gap back
and forth under the photo eye slowly. The STAR WHEEL catches the edge of the label stock and flips from one flat to the
next. The STAR WHEEL detects the gap between the labels by catching the edge of the label as it is fed. When the star
wheel catches the edge of the label, the wheel will quit sliding and rotate. The diameter across the flats of the star wheel
is smaller than the diameter across the points. When the star wheel rotates, the micro switch is activated indicating the
gap in the label stock.
If double or multiple label feeding occurs, and the micro switch is always activated, loosen the adjustment nuts and slide
the micro switch up away from the label.
If double or multiple label feeding occurs and the micro switch never activates, loosen the adjustment nuts and slide the
micro switch down towards the label.
LABEL PLACEMENT IN RELATION TO THE PEELER PLATE:
Loosen the lock screw on the Mechanical Label Sensor Assembly and slide it forward or backward on the
adjustment rails to achieve placement of the label with the peeler plate nose (+/- 1/32). After adjustment, cycle the labeler
to verify new label placement.
Mechanical
Clear Label
Detector
Lock Screw
Star Wheel
Adjusting Nuts
Storage Spool

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 14
OPTIONAL ELECTRONIC CLEAR LABEL DETECTOR (ECLD)
Description
The Z-Z-ELC300 Label Sensor uses capacitive technology to sense label edges for registration, counting, splice detection
or other applications. Capacitive technology provides the fastest and most accurate edge detection method available. The
Z-Z-ELC300 has an integral cable, and uses an M12 connector.
Setup
1. Web must remain in contact with the base/mounting plate during operation.
2. Label must pass under the [-SENSOR-] indicator.
3. Small labels should be centered under the [-SENSOR-] indicator.
4. When properly setup, the lights in the gray LABEL area will be on when a label is
present, and lights in the gray GAP area will be on when a gap is present.
5. All lights flashing rapidly indicates over-current condition, likely caused by wiring error.
AutoGap Setup
1. Start with High Gain off.
2. Remove a label from the web.
3. Place the area of the missing label in the sensor (liner only).
4. Press for at least 1 second (lights begin to move back and forth).
5. Release the button.
6. Setup complete.
7. Verify the light bar goes into the gray GAP area during gaps between labels and into the gray LABEL area
during labels. If necessary, use arrow keys to adjust manually. If the light bar is not moving at least three or
four lights, turn on High Gain.
Manual Adjustment
When running, the light bar should extend from the gray LABEL area to the gray GAP area. The up and down arrows can
be used to fine tune the adjustment if necessary. If the adjustments reach the end of their range, the last light in the GAP
or LABEL area will flash three times when the button is pressed. The light bar may move toward LABEL while the Up
arrow is pressed. This is because the sensor body is deflecting and making the slot smaller. It will return when the button
is released and will not affect setup.
Sensor Configuration
Light/Dark Switching In “Light” switching mode, the sensor outputs are active/on during the gap. In “Dark”
switching mode, the sensor outputs are active/on during the label. Switch modes by pressing the button.
Do not change while running.
High Gain Mode
Only use High Gain mode when necessary. Very small or very thin labels may not consistently move the light
bar between the LABEL and GAP areas. In this case, use the High Gain mode by pressing the button.
Do not change while running. AutoGap must be performed after activating High Gain.
Metal/Foil Label Setup
AutoGap Setup on a missing label area may not work reliably for rectangular metallic labels (foil or metalized Mylar). In
this case, place an actual gap in the sensor (use alignment groove on the sensor). Then hold the Gap button down for
AutoGap as above. Move labels slowly through the sensor. Use manual adjustments if necessary to ensure the light bar
is in the LABEL area during labels and GAP area during gaps.

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 15
DRIVE MOTOR PACK
To reduce waste web tension, move the lock collar 1/32" away from the take-up spool. To increase web tension, move
the lock collar 1/32" toward the take-up spool.
CAUTION! Too much web tension may cause web breakage, label drifting, or premature failure of the take-up spool
assembly.

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 16
SECTION 3
PROGRAMMING AND CONTROL OPERATION
System Controls / Operator Interface
17
Control Accessory Connections
18
System Programming
19
Programming Flow Charts
22
Key Definitions
32
Set Up of Key Features
33
Input & Output Description
35

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 17
SYSTEM CONTROLS / OPERATOR INTERFACE
LCD DISPLAY
OPERATOR
KEYPAD
INTERFACE
ENTER
PROGRAMMING
MENU
MANUAL TRIGGER
DISABLE SYSTEM
ENABLE SYSTEM

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 18
ACCESSORY CONNECTIONS
LOCATED ON BACK OF CONTROL BOX
MAIN POWER
POWER SWITCH
MAIN DRIVE MOTOR
EXTERNAL
PRINTER
INTERFACE
START INPUT
FUSE
HEAD UP
SWITCH
SMART TAMP
INPUT
SOLENOIDS
LABEL SENSOR
OPTIONAL
KEYPAD
LOW LABEL
LIGHT KIT /
AUXILIARY #1
LOW LABEL
LIGHT KIT /
AUXILIARY #2
ROUND
MODULE

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 19
SYSTEM SETUP
PROGRAMMING
All programming is performed via the keypad located on the front of the control box. All programmed settings are backed
in nonvolatile memory and are not lost when the unit is powered off.
Upon power up of the control, the screen will display MODEL NUMBER & REVISION of the control box and then the
MODEL NUMBER & REVISION of the labeler system. After this, the screen will now display the main screen and
counters.
KEY FUNCTIONS:
“PROG” PROGRAM KEY IS USED TO:
1. Enter and exit the program menu.
“ENTER” KEY IS USED TO:
1. Access or “Enter” the selected “PROGRAM BLOCK”. (example TAMP SETUP)
2. Access or “Enter” the data selection/options line of the “PROGRAM BLOCK” Sub Menus.
3. Store the selected data.
UP / DOWN ARROW KEYS ARE USED TO:
1. Scroll up & down through the primary menu “PROGRAM BLOCKS” . (Header name)
2. Scroll sub menus inside of “PROGRAM BLOCKS”.
START KEY:
1. Start key will initialize the application cycle.
STOP KEY:
1. Stop key will abort the application cycle.
ENABLE KEY:
1. Enable key will “Enable” the drive after it has been disabled.
DISABLE KEY:
2. Disable key will “Disable” the drive if it is currently enabled.
CLEAR KEY:
1. Clear key will delete stored values while in the edit mode.
ESC (escape) KEY:
1. Will back out of the sub programming menu without saving changes.

LM1012TTS Table-Top Label Applicator System
USER'S MANUAL
Made in the U.S.A.
© 2022 LABELMILL
01/01/2022 Model LM1012TTS
Page 20
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 factory
password cannot be changed. An alternate user password can be set to lock specific menus in the control.
I/O STATUS
Displays the status of the inputs and outputs.
AUTO SET GAP ***NO LONGER USED IN SYSTEMS MANUFACTURED AFTER 2020***
The AUTO SET GAP function is used to set label sensor values. (Note that when using a Clear label detector the sensor
values are not relevant) The label speed (IPM) can be set to fine tune this option. It is recommended to leave the IPM
set to 300 or set it at the current application speed.
PRODUCT SENSOR
This is an external device that when “activated” starts the application cycle.
PROGRAMMABLE BLOCKS:
Product Delay –Delays the application of the label (x) seconds after the sensor has been activated.
Sensor Trigger –Programs system to be activated at the leading or trailing edge of the trigger signal.
On Debounce - Programs how long (seconds) a trigger signal must be received to activate system.
Off Debounce - Used to ignore trigger signals (in seconds) after a cycle has completed.
Multiple Feed –Programs how many system cycles occur with a single trigger signal.
Interval Delay –Amount of time in seconds between multiple fed labels. Note: Active with quantity 2+
TAMP SETUP
This is used to adjust the different variables related to the tamp cycle.
PROGRAMMABLE BLOCKS:
Tamp Duration –Used to adjust the time that the tamp cylinder valve is actuated.
Flag Duration –Used to adjust the time the flag jaws are held open after label application.
Head Up Limit Switch –Type: normally open-standard, normally closed, none
Head Up Debounce –Debounce is used to allow time for the tamp cylinder to settle on return.
Vacuum Release –Used to release label when tamping on light products.
Vacuum Delay On –Used to reduce label flutter when feeding large labels onto the vacuum platen.
Tamp Sync - Used for "Normal" or "Reverse" Tamp signal operation.
ROUND MODULE SETUP
This is used to adjust the system parameters when using the Round Module attachment.
PROGRAMMABLE BLOCKS:
Roller Stop Delay - Delays the wrap roller from stopping after the label feed.
Label Feed Delay - Delays the start of the label feed after the carriage pivots up.
Roller Speed - Used to program how fast the Round Module rotates.
Roller Acceleration - Used to control how fast the motor reaches the programmed speed.
Jog Round Motor - Used to manually jog the motor on the Round Module.
LABEL SPEED
PROGRAMMABLE BLOCKS:
Label Speed –Used to control the speed that the label is fed through the system
Label Acceleration - Used to control how fast the motor reaches the programmed feed speed.