Adjusting Your Label Sensor

 

Gain Adjustment

Gain/Span adjustments change the distance between the Gap and Label measurements and change the amount of noise in the measurement.

 

Shift Adjustment

Shift/Offset/Zero adjustments move the Gap and Label measurements up and down relative to the Trip Point.

Adjustment Basics

Adjusting a label sensor is easier than most people think.

Sensors are often adjusted when it isn't necessary.

Triggering the Sensor

Optical sensors measure light; capacitive sensors measure electric fields; ultrasonic sensors measure sound waves. No matter what your label sensor measures, the measurement is different for the gap than it is for the label, and the measurement includes some unwanted noise.

The sensor is adjusted so the gap measurement is on one side of a trip point, and the label measurement is on the other side of the trip point - and so the noise won't accidentally trip the sensor.

These measurements are adjusted to change the difference between the label and the gap and to shift them relative to the trip point.

Changing The Difference

On some sensors, the Gain (or Span, or Sensitivity) can be adjusted to be sure there is enough distance between the label measurement and gap measurement. Turning the gain too high can amplify noise in the sensor and cause a false trigger; so more is not always better.

Shifting the Measurement

The position of the label and gap measurements can be shifted relative to the trip point to get the trip point in the center. This adjustment may be called "Shift" or "Offset" or "Zero."

 

Adjusting Ultrasonic Label Sensors (LRD8200)

Ultrasonic label sensors usually only have Shift adjustments. The sensor is adjusted by shifting the measurement to center the Trip Point between the label and gap measurements. Your sensor may have some type of automatic setting.

Automatic Setting

On most ultrasonic sensors, a combination of buttons or press-and-hold technique activates an automatic adjustment. The LRD8200 Gap Quickset is activated by pressing both the up and down adjustment buttons at the same time when a gap is centered in the sensor. The light bar will sequence the lights until they reach the Gap Setup light at the bottom of the gray highlighted area.

The Gap Setup light should be on when the gap between labels is centered in the sensor.

  1. Center a gap in the sensor, or remove a label and place the liner only in the sensor.
  2. Press both the Up and Down adjustment buttons at the same time.
  3. The light bar will sequence the lights until they reach the Gap Setup light at the bottom of the gray highlighted area
  4. Move a few labels through the sensor and verify that the Gap Setup light is on during the gap between labels. If it isn't then adjust the sensor manually until it is.

Manual Adjustments

The LRD8200 has a fixed gain setting. The only adjustment to be made is the Offset.

  1. Center a gap in the sensor, or remove a label and place the liner only in the sensor.
  2. Use the Up and Down adjustment keys to move the light bar to the Gap Setup light which is at the bottom of the gray highlighted area.
  3. Move a few labels through the sensor and verify that the Gap Setup light is on during the gap between labels. If it isn't then adjust the sensor until it is.

Video: Ultrasonic Label Sensor (LRD8200) Basic Adjustment

LRD6110 Capacitive Label Sensor SetupAdjusting Single-Ended Capacitive Label Sensors (LRD6300)

The LRD6300 has both Gap Set and Gain adjustments.

The LRD6300 Single-Ended Capacitive Label Sensor has an automatic setup and manual adjustments:

  1. Remove a label fromthe liner
  2. Place liner only in the sensor
  3. Press and hold the "G" button for one second until lights begin to move back and forth, then release the button
  4. Setup complete
  5. Verify that a light is on in the LABEL section during a label and in the GAP section during a gap. The manual UP and DOWN arrows can be used to adjust the light bar should it be required.

If the light bar is not moving more than three lights between label and gap, turn on the High Gain setting and repeat the steps above.

Video: Single-Ended Capacitive Label Sensor (LRD6300) Basic Adjustment

 

Adjusting Single-Ended Capacitive Label Sensors (LRD6110)

The LRD6110 has both both Shift and Span (Gain) adjustments. For most labels, the Span adjustment can just stay in the center position. The only adjustment usually needed is a Shift adjustment.

LRD6110 Capacitive Label Sensor SetupThe Trip Point

The Trip Point is at the center of the light bar, between the two center lights under the middle of the big "X" on the sensor label. The objective is to adjust the sensor so the Gap is below the trip point - near the Web end of the light bar, and the Label is above the trip point - near the Label end of the light bar.

  1. (The Span adjustment has a maximum of 4 turns. Turning the Span adjustment beyond the end of the adjustment range will not damage the sensor; the adjustment will continue to turn but no further adjustment will occur, and it may click.)
    Set the Span adjustment to its center position.
    1. Turn the Span adjustment 4 full turns clockwise
    2. Turn the Span adjustment 2 full turns counterclockwise
  2. Center a gap in the sensor, or remove a label and place the liner only in the sensor.
  3. (The Shift adjustment can NOT be turned beyond its adjustment without permanently damaging the sensor. If the adjustment gets difficult to turn, STOP.)
    Adjust the Shift until the light on the light bar is anywhere BUT the last light at the the "Web" end.
  4. Adjust the Shift unitl the light at the Web end just comes on; do not adjust very far past the point where the Web light comes on.
  5. If you removed a label for the adjustment, move a gap through the sensor and verify that the last light at the Web end lights. If it does not, make a small Shift adjustment until it does.

Video: Single-Ended Capacitive Label Sensor (LRD6110) Basic Adjustment

Adjusting Differential Capacitive Label Sensors (LRD2100)

The Zero adjustment on the LRD2100 is NOT a label adjustment and only needs to be adjusted once - when first put on the machine.
The Gain setting also rarely needs changing.

The LRD2100 ships with small black labels which can be placed over the adjustments (especially the Zero) to prevent unnecessary adjustment.

(The Zero and Gain adjustments have a maximum of 4 turns. Turning them beyond the end of the adjustment range will not damage the sensor; the adjustments will continue to turn, but no further adjustment will occur, and they may click.)

lrd2100 label sensor adjustmentAdjustments When First Intalled On A Machine

  1. Set the Gain adjustment to maximum.
    1. Turn the Gain adjustment at least 4 full turns clockwise
  2. With NO material in the sensor, turn the Zero adjustment to the point where the Zero light changes between On and Off. It doesn't matter whether it is On or Off when completed, as long as it is close to the point where it changes.
  3. Consider placing one of the included round black labels over the adjustment to prevent future unnecessary adjustments.
  4. Set the Gain to center of its range
    1. Turn the Gain adjustment 2 turns counterclockwise

The Zero may have to be adjusted again if the baseplate is ever replaced or the sensor is used without the baseplate.

Adjustments When Label Stock Is Changed

Usually None. The basic setting (Gain at center of its range) will work for most labels.

Very small labels may require an increase in Gain.

If, and ONLY if, the new labels aren't being detected correctly, use this procedure:

  1. Re-Set the Gain to center of its range
    1. Turn the Gain adjustment at least 4 full turns clockwise
    2. Turn the Gain adjustment 2 turns counterclockwise
  2. Run and see if the sensor works correctly. If it does, the Gain had been adjusted and needed to be re-centered.
    If NOT, then:
  3. Set Gain to Minimum
    1. Turn the Gain adjustment 4 turns counterclockwise
  4. Move labels through the sensor and increase Gain (turn clockwise) until the Output light ("Edge" on older models) just begins to flash.
    If possible, it may be easier to create some slack in the web and just move one gap back-and-forth through the sensor while adjusting.
  5. Turn the Gain adjustment another half-turn clockwise.

If the sensor doesn't detect labels reliably after this procedure, you may have label materials that don't work well with a differential capacitive label sensor. In which case you will need another type of sensor (Single-Ended Capacitive or Ultrasonic).

Video: Differential Capacitive Label Sensor (LRD2100) Basic Adjustment

Adjusting Optical Label Sensors (LionEye2)

Optical label sensors, because there are so many models, can vary on setup options and techniques. Some allow Gain and Zero adjustments, others only allow one of the two.

Automatic setup procedure for the LionEye2:

  1. Place web only in sensor (remove a label, or carefully center a gap in the sensor)
  2. Press [+] and [–] at the same time for less than one second
  3. The red LED will begin to flash
  4. Place a label in the sensor
  5. Press [–] for less than one second
  6. The red LED stops flashing
  7. Setup is complete

Fine Tuning

The "Automatic" mode setup should always be successful. However, the gain of the sensor can be
adjusted manually by pressing the [+] or [–] buttons. The red LED will flash with each button press.

The LionEye2 has many more options that can be accessed through the setup buttons. Consult the instruction manual for details.

 

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