FAQ

 

GENERAL

Why won’t my applicator turn on?
Check main fuse located at power connector and replace if necessary (refer to manual).
Why is my web tension so loose?
More than likely the Clutch tension is too low. (Consult manual for adjustment procedures.)
Why does the waste web keep breaking?

1) The most common reason for this to happen is that the applicator is webbed incorrectly. (Refer to manual for webbing instructions.)

2) A: Web braking can also be caused from the clutch being too tight. (Refer to manual for adjustment procedures.

My air system (tamp) doesn’t seem to be working. What could be wrong?

1) Check air supply and filter.

2) Check for a plugged hose. (If found, clear obstruction or replace.)

3) Check to make sure that Tamp duration is not set to zero.

4) Check all cable connections.

SEMI-AUTOMATIC

Why won’t my (Tamp, Flag or Round) module function correctly?

1) Check to make sure the Mode Switch is set correctly. (Refer to page 2-6 of the manual)

2) Make sure that all module hoses are connected correctly. (Refer to page 4-14 of the manual)

Why is my applicator feeding multiple labels?
The web sensor is probably out of adjustment. (Refer to manual for adjustment procedures)
Why is my applicator feeding multiple labels?
The web sensor is probably out of adjustment. (Refer to manual for adjustment procedures)
My applicator will not do anything at all. What’s going on?

1) Check to make sure the controller has not been disabled.

2) Disconnect the product trigger (photocell) from controller and press START button. If applicator functions correctly, photocell may need to be replaced or adjusted.

What does it mean if my Label Mill is displaying “Memory Checksum” on the controller display?
Data has been lost in battery SRAM. Contact your Label Mill service provider.
“Missing Label” is being displayed on the controller. Why?
Either your applicator is webbed incorrectly (missing the label sensor) or there is a spot in your label roll with a number of missing labels.
My applicator stopped running and is displaying “Following Fault”. What should I do?

1) Following Fault happens when the Servo Drive motor is stalled due to there being too high of a load. Check for proper label webbing and that the pinch rollers are closed.

2) Check the acceleration setting in the Label Speed menu. (See manual)

3) Lower label speed if necessary. (See manual)

My controller displays “Head Up Fault”. How do I fix it?
Check to make sure that the air is turned on and the tamp head is in the home position. With controller turned on check that the Head-Up limit switch (located at the top of the air cylinder) is displaying a red light. If red light is not on, loosen bracket on limit switch and move to the up most position where light comes on, secure sensor and try to cycle again.
My controller is displaying “Head Down Fault”. What should I do?

1) If tamp duration is too short the Head Up switch located at the top of the air cylinder will not change state causing a “Head Down Fault”. (Set duration longer)

2) Depress test button on the Tamp Valve to make sure air cylinder is functioning correctly.

3) Check the programmed state of the Head-Up switch. (See manual)

I continue to get a “Label Not Found” error. How can I correct it?
This happens only when running the Auto Set-up and is generally caused from either a dirty/blocked sensor or labels being routed improperly. Check and clean sensor if needed. Reload label stock and retry the Auto Set-up.

AUTOMATIC PRINT & APPLY

My printer/applicator tamps but will not print. (Printer Cycle Error) What’s going on?

1) Check to make sure that the print engine is ONLINE and not in an error condition.

2) Make sure that there is a print quantity on the printer display. If quantity is at zero, check software and connectivity between computer and print engine.

3) Make sure printer is set to correct applicator/interface mode. (Zebra = Mode 1) (Sato M84xxS engines=Mode 3)

Why isn’t my take-up spindle working?

1) The take-up motor only runs when the Label Mill printer/applicator is cycling and will not function when the operator simply presses the feed button on the print engine.

2) A: Check cable connections

My applicator will not do anything at all. What’s going on?

1) Check to make sure the controller has not been disabled.

2) Disconnect the product trigger (photocell) from controller and press START button. If applicator functions correctly, photocell may need to be replaced or adjusted

My controller displays “Head Up Fault”. How do I fix it?
Check to make sure that the air is turned on and the tamp head is in the home position. With controller turned on check that the Head-Up limit switch (located at the top of the air cylinder) is displaying a red light. If red light is not on, loosen bracket on limit switch and move to the up most position where light comes on, secure sensor and try to cycle again.
My applicator stopped running and is displaying “Following Fault”. What should I do?

1) Following Fault happens when the Servo Drive motor is stalled due to there being too high of a load. Check for proper label webbing and that the pinch rollers are closed.

2) Check the acceleration setting in the Label Speed menu. (See manual)

3) Lower label speed if necessary. (See manual)

My controller displays “Head Up Fault”. How do I fix it?
Check to make sure that the air is turned on and the tamp head is in the home position. With controller turned on check that the Head-Up limit switch (located at the top of the air cylinder) is displaying a red light. If red light is not on, loosen bracket on limit switch and move to the up most position where light comes on, secure sensor and try to cycle again.
My controller is displaying “Head Down Fault”. What should I do?

1) If tamp duration is too short the Head Up switch located at the top of the air cylinder will not change state causing a “Head Down Fault”. (Set duration longer)

2) Depress test button on the Tamp Valve to make sure air cylinder is functioning correctly.

3) Check the programmed state of the Head-Up switch. (See manual)

Why is my display showing a “Label Out” condition when I have a fresh roll of labels loaded?

1) Reload labels through print engine making sure the labels are passing through the label sensor.

2) Check label sensor to make sure it is sitting over the top of the label. (See Sato manual)

3) Print engine label sensor may need to be recalibrated. (See Sato manual)

My printer/applicator tamps but will not print. (Print Time Out Error) What’s going on?

1) Check to make sure that the print engine is ONLINE and not in an error condition.

2) Make sure that there is a print quantity on the printer display. If quantity is at zero check software and connectivity between computer and print engine.

3) Make sure printer is set to correct applicator/interface mode (SatoLT408/412=Mode 1)

4) Check Interface Cable that runs between the print engine and the Label Mill.

Why isn’t my take-up spindle working?

1) The take-up motor only runs when the Label Mill printer/applicator is cycling and will not function when the operator simply presses the feed button on the print engine.

2) Check cable connections.

My applicator will not do anything at all. What’s going on?

1) Check to make sure the controller has not been disabled.

2) Disconnect the product trigger (photocell) from controller and press START button. If applicator functions correctly, photocell may need to be replaced or adjusted

What does it mean if my Label Mill is displaying “Memory Checksum” on the controller display?
Data has been lost in the serial EPROM. Contact your Label Mill service provider.
My handheld displays “Tamp Up Flt”. How do I fix it?

1) Check to make sure that the air is turned on and the tamp head is in the home position. With applicator turned on check that the Head-Up limit switch (located at the top of the air cylinder) is displaying a red light. If red light is not on, loosen bracket on limit switch and move to the up most position where light comes on, secure sensor and try to cycle again.

2) Depress test button on the Tamp Valve to make sure air cylinder is functioning correctly.

3) Check the programmed state of the Head-Up switch. (See manual)

My handheld is displaying “Tamp Down Flt”. What should I do?

1) If tamp duration is too short the Head Up switch located at the top of the air cylinder will not change state causing a “Head Down Fault”. (Set duration longer)

2) Depress test button on the Tamp Valve to make sure air cylinder is functioning correctly.

3) Check the programmed state of the Head-Up switch. (See manual)

I keep getting a “2nd Trigger FLT”. What’s wrong?
This fault will only occur if the “Variable Data” feature is turned on and the trigger signal was not received before the timer expired. If this feature is supposed to be on check photo eyes and product delay.
Why is my display showing a “Label Out” condition when I have a fresh roll of labels loaded?

1) Reload labels through print engine making sure the labels are passing through the label sensor.

2) Check label sensor to make sure it is sitting over the top of the label. (See Sato manual)

3) Print engine label sensor may need to be recalibrated. (See Sato manual)

AUTOMATIC APPLY

Why is my applicator feeding multiple labels?
The web sensor is probably out of adjustment. (Refer to manual for adjustment procedures)
My applicator will not do anything at all. What’s going on?

1) Check to make sure the controller has not been disabled.

2) Disconnect the product trigger (photocell) from controller and press START button. If applicator functions correctly, photocell may need to be replaced or adjusted.

What does it mean if my Label Mill is displaying “Memory Checksum” on the controller display?
Data has been lost in the serial EEPROM. Contact your Label Mill service provider.
My Label Mill controller is displaying “Label Not Found” after I run the Auto Set Up. What should I do?

1) Check for proper webbing of label stock. A: Check and clean label sensor if necessary.

2) Label Stock must have a minimum of 1/8” gap between labels (industry standard) in order for the applicator to work correctly.

The controller says “Gap Not Detected”, what’s wrong?

1) If there are too many labels missing on the web, the controller thinks that it cannot see a gap between labels.

2) Make sure that the applicator is properly webbed. (Running through the gap sensor)

3) Web sensor might not be set correctly for label material. Run the “Auto Gap Set”. (See manual if necessary)

My controller displays “Head Up Fault”. How do I fix it?
Check to make sure that the air is turned on and the tamp head is in the home position. With controller turned on check that the Head-Up limit switch (located at the top of the air cylinder) is displaying a red light. If red light is not on, loosen bracket on limit switch and move to the up most position where light comes on, secure sensor and try to cycle again.
My controller is displaying “Head Down Fault”. What should I do?

1) If tamp duration is too short the Head Up switch located at the top of the air cylinder will not change state causing a “Head Down Fault”. (Set duration longer)

2) Depress test button on the Tamp Valve to make sure air cylinder is functioning correctly.

3) Check the programmed state of the Head-Up switch. (See manual)