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Datamatrix StationXMV

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Table of Contents

1 General information 51.1 Service ....................................................................................................................... 51.2 Formatting and Meaning .............................................................................................. 51.3 Visibility of Buttons and Screens .................................................................................... 5

2 Intended Use 6

3 Safety Notes 73.1 Safety Labels............................................................................................................... 7

3.1.1 Hazard Notifications ...................................................................................... 73.1.1.1 Definitions of Signal Words ...................................................................... 73.1.1.2 Meaning of Hazard Alert Symbols.............................................................. 73.1.2 Mandatory Procedures................................................................................... 93.1.3 Prohibited Procedures.................................................................................... 9

3.2 General Protective Procedures ....................................................................................... 93.3 Safety Notes for Various Activities................................................................................... 10

3.3.1 Transporting and Setting the Equipment in Place............................................... 103.3.2 Installing...................................................................................................... 103.3.3 Operating the Equipment and Monitoring the Inspection Process......................... 103.3.4 Testing and Verifying the Equipment ................................................................ 103.3.5 Maintaining, Cleaning and Sanitizing the Equipment ......................................... 10

3.4 Special Hazards .......................................................................................................... 113.4.1 Electricity ..................................................................................................... 113.4.2 Pneumatics .................................................................................................. 113.4.3 Moving Parts ................................................................................................ 113.4.4 Rejectors...................................................................................................... 113.4.5 Noise........................................................................................................... 123.4.6 Strobe Lights ................................................................................................ 123.4.7 Lights and Laser Sensors ............................................................................... 12

4 System Description 134.1 Overview of an XMV System.......................................................................................... 134.2 Optional Mechanical Equipment .................................................................................... 17

4.2.1 Overview of Optional Mechanical Equipment .................................................... 174.2.2 Full Housing................................................................................................. 174.2.3 Detection of Open Flaps ................................................................................. 184.2.4 Wheeled Option ............................................................................................ 184.2.5 Rejection System Options............................................................................... 184.2.6 Conveyor Options.......................................................................................... 19

5 Installation 20

6 Storing the System, Accessories and Spare Parts 21

7 Operating Procedures 227.1 Adjusting the Input Conveyor ......................................................................................... 227.2 Adjusting the Open Flap Detector (Optional Equipment).................................................... 227.3 Adjusting the Rejection System for the Product's Weight ................................................... 227.4 Starting Production....................................................................................................... 237.5 Ending Production ....................................................................................................... 237.6 Switching off the XMV................................................................................................... 23

8 Cleaning and Maintenance 248.1 Visual Inspection and Cleaning of the System.................................................................. 248.2 Maintenance of the Gaskets .......................................................................................... 248.3 Maintenance of the Rejection System.............................................................................. 248.4 Maintenance of the Conveyor Belts................................................................................. 258.5 Maintenance of the Rejection Bin ................................................................................... 27

8.5.1 Exchanging a Damaged Rejection Bin ............................................................. 288.6 Maintenance of the Toothed Belt .................................................................................... 28

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8.7 Cleaning and Maintenance of Optional Mechanical Equipment .......................................... 298.7.1 Cleaning the Cover ........................................................................................ 298.7.2 Maintenance of the Light Barriers .................................................................... 29

8.8 Spare Parts and Warranty ............................................................................................. 29

9 Malfunctions / Emergency Operation Mode 309.1 System Messages ........................................................................................................ 309.2 Emergency Run ........................................................................................................... 30

10 Technical Data 3110.1 System ....................................................................................................................... 3110.2 External Components and Connections........................................................................... 31

11 Further Information 32

12 Disposal 33

13 Spare Part Kits 34

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1 General informationScopeThis manual describes how to operate the XMV Mark and Vision System. It is intended for personnel whooperate the XMV system for printing and print inspection (serialized or non-serialized).

1.1 ServiceIf you wish to contact the Service Department, please have as much information on hand as possible:• Machine type• Serial number• Line name• METTLER TOLEDO PCE order number and date• Software version• Precise wording of the displayed error message or detailed fault description• Your contact detailsThe Service Department will send you a technical questionnaire to analyze your technical request.Completing this questionnaire will help us to solve your technical issue in an efficient way.

Country E-Mail Address PhoneAustria [email protected] +43 1 6041990

France [email protected] +33 825 00 15 15

Germany [email protected] +49 5121 933 160

Korea [email protected] +82 2 3498 3566

Switzerland [email protected] +41 44 944 47 47

USA, Mexico [email protected] +1 630-446-7716

Rest of the World [email protected] +49 6251 8545-555

1.2 Formatting and MeaningThe formats used in this manual have determined meanings. If they are used they denote the following:

Format MeaningPC Menu Paths, Buttons at the screen surface, fixed tab

names, names of screens and dialogs

'apostrophes' Names of fields, checkboxes, modes, parameters

<angle brackets> wildcard for tab names of devices (individualnames can be assigned)

1.3 Visibility of Buttons and ScreensAlways remember that many PLM features need certain user rights. This means if your screen does not offerbuttons shown in the operator manual it is likely that you need more user rights which have to be assignedto your profile by an administrator. The usual way to assign user rights is to add a user to a user group.Thus the user obtains all user rights belonging to that group.

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2 Intended Use• This system is intended to be used solely for labeling (marking) and verification purposes.• Intended use also includes the compliance with the operating manual, including any maintenance

recommendations or instructions issued by the manufacturer.• This device is designed for indoor use only.• The mark and vision system is exclusively designed for industrial purposes.• Operation is allowed only if safety equipment is not by-passed or abrogated.• Inappropriate changes to the machine must be omitted.Any other use or use that exceeds the aforementioned scope is not in compliance with the intended use. Inparticular, the transportation of passengers is prohibited. The manufacturer/supplier is not liable for anydamage arising from misuse. Risk is borne solely by the user.

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3 Safety Notes

Important Safety NoteRead and understand all the safety notes in the following sections as well asthe safety messages in the rest of this manual.If you do not follow the safety notes and messages, this may lead to property damageand personal injury up to and including death.

3.1 Safety LabelsThe ISO 3864 safety labels are installed at potentially hazardous areas on the equipment. They give specialsafety-related notifications. The locations of these labels are given in the drawings supplied with yourequipment. There are three types of safety labels:• Hazard notifications• Mandatory procedures• Prohibitive proceduresThe meanings of the different kinds of safety labels are explained in the following sections.Before transporting, installing, operating or working on the equipment, find out about the location andmeanings of the safety labels. Maintain the safety labels so that they are clear of obstructions and arereadable. Do not remove any safety labels. Replace any label that is no longer readable.

3.1.1 Hazard NotificationsA hazard notification consists of the following:• Hazard alert symbol (yellow triangle with black symbol)

• Signal word (DANGER , WARNING or CAUTION )• Special notifications related to the hazard (as required)The signal word labels are attached next to the hazard alert symbol labels on the equipment.

3.1.1.1 Definitions of Signal Words

Signal words describe the level of risk of a particular hazard. The color of the safety label backgroundindicates the risk, as shown in the following table.

DANGER (red): Signal word used to indicate an imminently hazardous situationwhich, if not avoided, will result in death or serious injury

WARNING (orange): Signal word used to indicate a potentially hazardous situationwhich, if not avoided, could result in death or serious injury

CAUTION (yellow): Signal word used to indicate a potentially hazardous situationwhich, if not avoided, could result in minor or moderate injury

NOTICE (blue): Indicates important information that is not related to personal injurywhich, if ignored, could result in damage to the equipment, damage to property,malfunctions, erroneous results or loss of data

3.1.1.2 Meaning of Hazard Alert Symbols

The following hazard alert symbols may be installed on your equipment.

Crushing

Shearing

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Cutting

Entanglement

Drawing-in, trapping

Impact

Abrasion, friction

High pressure fluid ejection

Ejection of parts

Loss of stability

Slipping, tripping

Electrical shock

Electrostatic

Hearing impairment

Arc flash

Laser

UV light

Optical radiation

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3.1.2 Mandatory ProceduresMandatory procedures alert personnel to special required actions. The labels are round with a bluebackground and a white symbol describing the required action. The following table lists the mandatoryprocedures labels which may be installed on your equipment.

Read the manual

Read the technical manual

Wear ear protection

Lockout, tagout

Lift point

3.1.3 Prohibited ProceduresProhibited procedures alert personnel to particular actions to avoid. The labels are round with a circular redband and single diagonal cross bar. The black symbol describes the action to avoid. The following tablelists the prohibited procedure labels that may be installed on your equipment.

Do not operate without safeguards

Do not step on the equipment

3.2 General Protective Procedures

Important Safety NoteMake sure that all personnel who work on or near the equipment are correctlytrained.

• Keep the manual in a convenient location near the equipment. Replace the manual if it becomes lost ordamaged.

• Wear the applicable Personal Protective Equipment (PPE), in accordance with your plant's safetyprocedures.

• Understand the hazards of the equipment and the risks related to those hazards before working on ornear the equipment.

• Obey all safety procedures of the local plant.

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• Do not wear loose clothing, jewelry or long hair. Do not wear anything that can become entangled withthe equipment.

• Be careful around the equipment to avoid hitting your head, arms, or other body parts against theequipment.

• Be careful not to trip over cables or other parts of the equipment.• Do not move quickly in the area around the equipment.• Do not climb, hang onto, or use any of the part of the equipment as a support.

3.3 Safety Notes for Various Activities

Important Safety NoteRead and understand all parts of the manual before using or working on anyequipment.

The following sections list safety notes for particular activities or groups of activities. Refer to the correctsections in the manual for more detailed instructions.

3.3.1 Transporting and Setting the Equipment in Place• Only qualified personnel are allowed to transport the equipment.• Use safe moving procedures during transporting to maintain stability and to prevent the equipment from

tipping or falling.• Disconnect the equipment from the electrical power supply before moving.• Use the correct lifting devices.• If using a forklift, lift the equipment at the correct lift points as shown by the blue lift point labels.• Blue lift point labels are placed on the equipment to show correct locations for lifting. These lift point

locations were tested with the manufacturer's forklift trucks. A qualified rigger must make sure that the liftpoints are correct for your lifting equipment.

• When lifting by hand, obey the safe lifting procedures of your company.

3.3.2 InstallingOnly qualified personnel are allowed to install the equipment.

3.3.3 Operating the Equipment and Monitoring the Inspection Process• Before beginning operation, make sure that the area is safe.• Know the location and effect of each emergency stop button that controls the equipment.• Do not operate the equipment without protective guards and doors in place.• Make sure the safety circuit is working correctly.• Do regular inspections of the equipment.• If there is a fault or change in the equipment behavior, stop the equipment and inform responsible

personnel.

3.3.4 Testing and Verifying the EquipmentOnly qualified personnel are allowed to test and verify the equipment.

3.3.5 Maintaining, Cleaning and Sanitizing the Equipment• De-energize the equipment before doing any work.• Keep the equipment in good working order.• Follow a preventative maintenance program.• Replace parts when needed.• Obey the lockout tagout (LOTO) procedures of the plant.• Test (validate) the safety circuit after parts are replaced.

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• Only use METTLER TOLEDO approved spare parts and accessories.• Do not make any unauthorized modifications to the equipment.• Replace safety labels if damaged, missing, or unreadable.• Do a visual check of the equipment at least once during a shift to identify any visual damage or faults.

Report any equipment changes to the responsible supervisor immediately.• When required for a hygienic production environment, do regular sanitizing of the equipment according

to your company's procedures.• After cleaning or sanitizing, check all cables connectors and compressed air hoses for leakage, loose

connections, rub marks and damage. Tighten, repair or replace any faulty cables and air tubing, asnecessary.

3.4 Special HazardsThe following sections describe special instructions for equipment that may have special hazards.

3.4.1 Electricity• Only a qualified electrician is allowed to work on electrical systems or any parts inside the electrical

enclosure.• Keep all electrical enclosure doors closed. If the doors have locks on them, keep them locked.• Disconnect the equipment from the power supply before working on it.

3.4.2 Pneumatics• Only personnel with the necessary knowledge and experience are allowed to work on the compressed

air system.• Check pneumatic parts for visible damage.• Before any repair or maintenance work, relieve the pressure of compressed air pipes, tubing or

pneumatic system parts.• Make sure that there is a consistent compressed air supply when you operate the equipment.• If a pneumatic pipe becomes loose during the operation of the equipment, keep your eyes away from

the loose pipe.

3.4.3 Moving Parts• Product inspection equipment moves automatically, intermittently and without notice. Some surfaces

may get hot. Do not place hands or any other body parts on or near the equipment. The following areexamples of moving parts:– Conveyor belts and rollers– Rejectors– Motors– Gearboxes– Side grips– Automatic position adjusters– Encoders

• Only operate the equipment with all safeguards in place.• Make sure that all safeguards are in correct operating condition.• Do not climb, sit, stand, walk or ride on the conveyor.• Obey the lockout tagout (LOTO) procedures of the plant.• If there is a malfunction when you are operating the equipment, press the emergency stop button. Tell

the responsible supervisor, and follow the applicable steps approved by your company to fix themalfunction.

3.4.4 Rejectors• Avoid the area around rejectors because they move quickly and without notice.• Do not reach into the rejector area or reject bin while the rejector is operating.

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• Make sure the rejector is installed correctly.• Supply a safe rejected product collection area to prevent rejected products harming someone.• Keep your eyes and other body parts away from air blast nozzles when the equipment is operating.

3.4.5 Noise• Make sure that all noise-absorbing parts of the equipment are present and in the correct position.• Wear hearing protection as directed by your local safety authority.

3.4.6 Strobe Lights• Strobe lights can cause seizures in individuals with photosensitive epilepsy.• Individuals with photosensitive epilepsy must not operate the equipment.• Do not operate the equipment when excessively fatigued or after consuming alcohol.• Do not look directly at the lights, especially at close distances.• Avoid placing the equipment in areas with reduced lighting.• If lights are inside of an enclosure, do not open the enclosure doors when lights are flashing.

3.4.7 Lights and Laser Sensors• Do not stare directly at any lights or lasers.• Avoid prolonged exposure to UV-A and IR light.

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4 System Description

4.1 Overview of an XMV SystemThe Datamatrix station XMV offers a complete printing and print verification system for printing on cartons.The feeding direction of the print and control station is from left to right (standard) or from right to left (non-standard). Thereby the product will be forwarded into the print- and inspection area consisting of twotransfer conveyers. The product will be directed close to the printing head, so that the print job can be done.After the application of the printing the product will be forwarded and the imprint will be inspected andevaluated with a Smart Camera.The evaluation takes place by the means of the „Good-Principle”, this yields to it, that only productsevaluated as GOOD through all kinds of inspection will pass the machine. All products which have beenfound bad will be ejected (missing print), respectively the machine will stop (no match). The ejection of theproducts is realized by pressure controllable blowing nozzles, controlled by the PLC, which exactly knowsat each time where the products are. The ejection will be controlled via a ejection counter check sensor(ECC), which checks, that no BAD product will pass to the downstream machine, and that a GOOD productreally passes by to the downstream machine.The following illustration shows the standard layout of an XMV system:

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Schematic view of an XMV system (may differ from order-specific design)

1 Input conveyor 15 Height adjustment of top mounted cameraand printer

2 Smart Camera 16 Rejection system3 Height adjustment for camera and printer

mounted at the front17 Countercheck light barrier

4 Print heads 18 Output conveyor5 Height adjustment for camera and printer

mounted at the rear19 Rejection bin with lock

6 Input conveyor motor 20 Foot screw (adjustable)7 Height adjustment for input conveyor 21 Lateral adjustment for the entire system8 HMI – Human Machine Interface 22 Handscanner9 Control cabinet 23 Emergency stop button10 Indicator light 24 Start/stop buttons for conveyor belts11 "Disconnect" switch* 25 "Confirm" button12 UPS (uninterrupted power supply)

indicator light26 Lateral adjustments of cameras and print

heads13 Bypass key switch 27 Product sensor (reflector)14 USB interfaces

* Mounted in different positions according to the unit's design.

1 Input conveyorThe conveyor belts insure a smooth and safe transport of the products. The conveyor belts are free frommaintenance.

2 Smart CameraThe Smart Camera system consists of an intelligent camera with integrated signal processor and a softwarewhich is able to control different characteristics. Furthermore, the camera hardware contains a memory, anetwork interface, an optical component and illumination.

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3 Height adjustment for camera and printer mounted at the frontBy using the height adjustment, you can move the camera and the print heads on the front side of themachine up and down independently from the conveyor height. Camera and print heads can only be movedsimultaneously, therefore it is not necessary to adapt the camera field of view to the print heads.

4 Print headsThe print heads of the continuous ink jet printer are part of the marking system and belong to the maincomponents of the XMV. With these print heads you can print alphanumeric texts, bar codes, 2D codes,Data Matrix codes and logos with a print height of 12.7 mm per cartridge. If you require greater printheights, you can cascade several print heads.

5 Height adjustment for camera and printer mounted at the rearBy using the height adjustment, you can move the camera and the print heads on the backside of themachine up and down independently from the conveyor height. Camera and print heads can only be movedsimultaneously, therefore it is not necessary to adapt the camera field of view to the print heads.

6 Input conveyor motorThe motor is part of the conveyor system.

7 Height adjustment for input conveyorYou can adjust the pass-through size of the product by using the height adjustment of the top conveyor belt.For good print quality, it is recommended that products run through the machine tightly without the productsbeing squeezed.

8 HMI – Human Machine InterfaceThe HMI is the only interface which you need to operate the machine. The HMI is connected to the IPCwhere either the PCE Line Manager (PLM) software or a virtual network computing (VNC) connection to thePLM software runs.

9 Control cabinetThe control cabinet contains the following electronic components:• Main power supply• 24V power supply• IPC• PLC• Print controller

10 Indicator lightThe indicator light provides visual and audible signals of the state or process event to machine operatorsand technicians:

Red Machine is stopped. This can be the case either whenthe machine detects a fatal error or when such an errorhas been solved and the machine has not been re-started again.

Yellow Warning

Green (steady) Machine runs in production mode

Green (flashing) Jam

11 "Disconnect" switchThe "Disconnect" switch connects/disconnects the main power of the machine. It may be mounted indifferent positions according to the units design.

12 UPS (uninterrupted power supply) indicator lightThe UPS (uninterrupted power supply) indicator light shows the status of the UPS:

On UPS working

Off UPS not working

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13 Bypass key switchThe bypass key switch enables the emergency run. When the emergency mode is enabled, the conveyersrun in a pre-defined speed. For the emergency mode, only power is required, no other components such asthe PLM software are needed. This ensures that you can run the conveyors in the emergency mode even ifother components broke down.

14 USB interfacesUsage: To connect external USB devices to the built-in IPC (industrial PC).

15 Height adjustment of top mounted camera and printerBy using the height adjustment, you can move the camera and the print heads of the machine up and downindependently from the conveyor height. Camera and print heads can only be moved simultaneously,therefore it is not necessary to adapt the camera field of view to the print heads.

16 Rejection systemIf one of the print inspection devices sends the signal of a bad reading, the rejection system ejects theproducts. Possible configurations:

Use case ConfigurationFor small / light products Blowing nozzles

For big / heavy products Pusher cylinder

For combined rejection system / switchable Blow pusher

17 Countercheck light barrierThe countercheck light barrier checks whether the product passes the light barrier at the correct position afterthe print inspection devices have checked the print quality of the product. If the print inspection devices havefailed to eject one bad product, the countercheck light barrier produces an error.

18 Output conveyorAfter printing, inspecting and sorting, the good products leave the machine via the output conveyor belt.

19 Rejection bin with lockThe machine contains a rejection bin, which can be locked with a key. In this rejection bin all the rejectedproducts are gathered. The rejection bin is made out of acrylic glass.

20 Foot screw (adjustable)You can adjust the machine with the four foot screws.Fine adjustments to the conditions of use are essential when installing the system. When the machine isinstalled, these fine adjustments are adapted by a service technician to the surrounding conditions. Onlytrained service technicians may perform fine adjustments. To make these fine adjustments, detailed profes-sional knowledge is necessary.

21 Lateral adjustment of the entire systemWith the lateral adjustment, you can move the complete machine forwards and backwards.

22 HandscannerThe scanner reads machine-readable codes. You can configure the scanner according to the machineconfiguration. For configuration instructions, refer to the PCE Line Manager User Manual.

23 Emergency stop buttonIf you push the emergency stop button, the conveyor belts of the XMV stop immediately. If you push theemergency stop button, connected machines next to the XMV stop as well.

24 Start/stop buttons for conveyor belts• The "Start" button restarts the suspended work order. This button has the same functionality as the

“Continue” button in the "Production" menu of the PCE Line Manager software.• The "Stop" button suspends the current working work order. This button has the same functionality as

the “Suspend” button in the "Production" menu of the PCE Line Manager software.

25 "Confirm" buttonUse the "confirm" button to confirm warnings and errors. This button has the same functionality as the"Confirm” button in "Main" menu of the PCE Line Manager software.

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26 Lateral adjustments of cameras and print headsBy using the lateral adjustment, you can move the camera and the print heads of the machine forwards andbackwards to handle different sized cartons. Camera and print heads can only be moved simultaneously,therefore it is not necessary to adapt the camera field of view to the print heads.

27 Product sensor (reflector)Tracking every single product is done by a shift register which is implemented by the programmable logiccontroller (PLC). The shift register realizes the triggers of all devices. The tracking process for every singleproduct is started when the sensor detects the product.

4.2 Optional Mechanical Equipment

4.2.1 Overview of Optional Mechanical EquipmentThe system can be combined with different types of optional equipment. The following accessory optionsare offered:• Full housing with door and safety switch• Detection of open flaps• Wheeled option• Different types of rejectors:

– High-performance double air nozzle– Pusher– Blow-pusher

• Different types of additional in-feed conveyors incl. guiding rails:– 400mm– 600mm– 800mm– 1200mm

• Different types of spare part kits

4.2.2 Full HousingWith the acrylic housing option, the risk of injury is minimized. The cover is protected with safety guardsagainst unauthorized opening, because it is locked during the running production.

Installation1 Place the cover over the system.2 Make sure that the cover does not touch the belt.

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Cover

4.2.3 Detection of Open FlapsWith this device, you can detect open folding cartons and protruding flaps by measuring the box length. Theopen flap detector checks the height/width of a product with a light sensor and rejects products that haveopen flaps and thus do not meet the height/width requirement. You can adjust the length measurement ofthe open flap detector to the size of your product. For instructions on how to adjust the open flap detector tothe size of your product, refer to chapter [Adjusting the Open Flap Detector (Optional Equipment) } 22].

4.2.4 Wheeled OptionIt is possible to move the XMV easily from one production line to another by using the optional availablewheels.

WARNINGDuring the production, the machine must have a firm stand.Therefore it is not allowed to use the wheels while the machine is in production. Beforethe machine is in production, set the machine onto the four foot screws. Adjust the footscrews of the machine so that it fits the surrounding conditions and the machine has afirm stand.

Fine adjustments to the conditions of use are essential. Fine adjustments may only be performed by trainedservice technicians.For temporary parking of the machine, use the breaks of the wheels.

4.2.5 Rejection System OptionsThe XMV is available with different types of rejection systems, depending on the weight of your product.Available options are:




The rejection system is pre-configured. No additional configuration is necessary.

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4.2.6 Conveyor OptionsDifferent types of additional in-feed conveyors including guiding rails, and optional in-feed conveyors areavailable for the XMV. You can purchase the system with different sizes of the conveyor belts:• 400mm• 600mm• 800mm• 1200mmThe electrical connection for the conveyor belt is provided by the XMV. When production is started by thePCE Line Manager software, the in-feed conveyor starts running simultaneously. You can start the conveyoras well when the machine runs in bypass mode. To adjust the guiding rails, unscrew the knurled screwsand move guiding in desired position. After positioning, fasten the screws to fix the guiding rails.You can adjust the top belt to the size of your product. For instructions on how to adjust the top belt, refer tochapter [Adjusting the Input Conveyor } 22].

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5 InstallationConnect the XMV to the power supply. Consult the XMV nameplate to check the required input voltage.The PCE Line Manager (PLM) software is installed on the XMV before delivery. Adapt the PLM softwareaccording to the desired formats. Take the necessary steps detailed in the PLM User Manual.

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6 Storing the System, Accessories and Spare PartsStore the system upright in the original packaging in a clean and dry place until it is to be installed.Keep all electronic parts delivered in antistatic bags in their bags until the parts are to be used. This ensuresthat they are optimally protected.

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7 Operating ProceduresOperating the XMV is done via the PCE Line Manager (PLM) software. For detailed instructions on how tooperate systems via the PLM software, refer to the PLM Manual.

7.1 Adjusting the Input ConveyorThe input conveyor belt system either with a top and bottom belt or with a side grip provides optimalproduct guiding. You can adjust the top belt to prevent that products slip or drift through the top and bottombelt.

Adjusting the Top BeltTo adjust the height of the top belt to the size of your product, follow these instructions:1 Turn the hand wheel and set the pass-through size to the height or width of the product.2 Define the pass-though size adequately: The pass-through size setting should allow the product to be

gripped securely and moved further along the conveyor, but without being crushed.

Top and Bottom Belt

7.2 Adjusting the Open Flap Detector (Optional Equipment)The open flap is not included in the standard configuration of the XMV system, but is an option you canpurchase additionally. The open flap detector checks the height/width of a product with a light sensor andrejects products that have open flaps and thus do not meet the height/width requirement. You can adjust theopen flap detector the size of your product:1 Turn the knurled wheels and adjust the light barriers laterally in relation to the conveyor belt.2 Set the light barriers to the length of a properly closed folding carton.

Length-measuring Equipment

NOTICEProtruding flaps increase the folding carton length and screen and are thus detected byone of the light barriers.

− Make sure that the properly closed folding carton does not screen any of the light barriers.

7.3 Adjusting the Rejection System for the Product's WeightThe rejection system ejects "bad" products. Three possible configurations of the rejection system areavailable and need to be ordered when purchasing the XMV:

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The rejection system is pre-configured. No additional configuration is necessary. However, depending onyour product's material, weight and the speed of the conveyors, you may adapt the air pressure of therejection system. For blowing nozzles, the air pressure must be between 3 bar and 6 bar.

7.4 Starting ProductionTo start the production of a product, follow these instructions:Preconditions:• All devices (cameras, printers etc.) are configured correctly and work properly.• A lineformat is already created• The work order is assigned to a lineformatTo operate the XMV:• Turn on the system using the Disconnect button. The PCE Line Manager software starts automatically.• Log on as a user with appropriate user rights. For details on PLM user rights, refer to the PLM User

Manual.• Switch to production screen.• Start production via order• Select and start work order

7.5 Ending ProductionTo finish the production of a product, click the “Finish” button in the PCE Line Manager (PLM) software onyour touch monitor. For detailed instructions on how to operate systems via the PLM software, refer to thePLM Manual.The XMV is then ready for further tasks.

7.6 Switching off the XMVPreconditions:• Production is currently not running• Switch off system by using "Disconnect" button.The XMV shuts down in a controlled way defined by the UPS.

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8 Cleaning and Maintenance

DANGERRisk of fatal injury from electrocutionBefore starting any work, i.e. prior to cleaning or maintenance, the system must bedisconnected from the power supply by a qualified electrician.

The cleaning steps and simple maintenance tasks described below can be performed by operatingpersonnel with sufficient technical experience.

8.1 Visual Inspection and Cleaning of the System

Recommended InspectionInterval

What Needs to Be Done?

Daily Perform a general visual inspection.

WARNINGCleaning the system when it is hot may cause severe damage.Only clean the system with moisture when it is cold.Before cleaning, allow the drive motors to cool down completely.

WARNINGNever use a high pressure jet to hose down the system.Do not use caustic cleaning agents containing solvents to clean the system and theterminal. Never use pure alcohol or concentrated acid or lye.Use particular care when cleaning in order to avoid damage and, above all, to preventwater from entering the system.

Clean the system and terminal using soft cloths dampened with a mild solution of soap and water or acommercially available glass and plastic cleaner.

8.2 Maintenance of the Gaskets



Monthly • Perform a general visual inspection.• If necessary, replace the gaskets.

Make sure that gaskets on covers such as flaps and doors, or also on (optional) glass light covers, are ingood condition. If the gaskets need to be replaced, contact the METTER TOLEDO Service. You find contactdetails for the METTLER TOLEDO Service at [Service } 5].

8.3 Maintenance of the Rejection SystemCompressed air must be free of contaminants, i.e. it must be clean and dry, otherwise the performance ofpneumatic devices (e.g. ejectors, sorting switches) can be impacted and pneumatic parts may undergopremature wear.

WARNINGRisk of injuryTurn off the compressed air supply before starting work on the pneumatic cylinder orsolenoid valve, or prior to loosening any screw connections, connectors, etc.

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Weekly • Perform a general visual inspection of the rejectionsystem.

• Inspect the compressed air system for contaminants,leaks in the hoses and in the connections of thehoses.Replace damaged or worn connecting hosesimmediately.

• Check the pressure gauge for the correct pressuresetting: at least 3 bar, depending on the product(maximum of 6 bar!).

Checking the Sight GlassRegularly check the sight glass of the water separator on the device's compressed-air supply.



Monthly • Perform a general visual inspection of the sightglass.

• Drain the condensate.

1 If condensate has accumulated in the sight glass, turn off the compressed air supply, unscrew the drainplug at the bottom of the sight glass, and let the water drain into a container.

2 Then, screw the plug back in and tighten it by hand.

8.4 Maintenance of the Conveyor Belts

DANGERRISK OF FATAL INJURY FROM ELECTROCUTIONBefore starting any work, i.e. prior to cleaning or maintenance, the system must bedisconnected from the power supply by a qualified electrician.

The cleaning steps and simple maintenance tasks described below can be performed by operatingpersonnel with sufficient technical experience.

Cause or RecommendedInspection Interval


Excessive wear of top andbottom belt

Have equipment replaced by Technical Service.

Significant elongation ofthe belts

Weekly Make sure that the top belt and bottom belt are cleanand do not show any signs of wear.If necessary, correct the setting of the top and bottombelt.

Daily Perform a general visual inspection of the conveyorbelts.Replace worn belts immediately.

Clean the conveyor belts (and, if installed, the transition plates) using soft cloths dampened with a mildsolution of soap and water or a commercially available glass and plastic cleaner. Keep the conveyor beltsand any installed transition plates clean. This also keeps the metal slider bed plates under the belts cleanand smooth.Frequently check any installed safety devices to ensure that they are correctly positioned and in goodcondition.

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NOTICEThere are no points on the conveyors that require lubrication.

WARNINGRisk of injuryNever loosen or remove the fastening screws of the conveyor belt on the columnar baseframe.

CAUTIONConveyor belt grinding causes increased wear and excessive vibrations.Avoid contact between conveyor belts and any safety devices or transition plates installed.

Checking the Tension of the Conveyor BeltsOver time, most belt types will stretch as a result of use.



Weekly Check the conveyor belts for a tight fit.

NOTICEThe tension of elastic belts (rubber belts) does not need to be checked in this mannersince it is not possible to tauten them using the belt tensioners. Belts of this type must bereplaced when they show visible signs of wear or a noticeable loss of elasticity.

The following indicators can be used to monitor the belt tension:1 Switch off the conveyor belts.2 If it is possible to lift the belt's edge section by sliding one fingertip under the belt at about the midpoint

of the conveyor, then the belt is still sufficiently taught.

Sufficient belt tension (one-finger rule)

If it is possible to slide two fingers under the belt, then the belt is just barely taut enough.

Belt tension still sufficient (two-finger rule)

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Slippage (drift) under normally occurring loads (product weights) is a sign that there is too much slack inthe belt.

Tensioning the Conveyor Belt

NOTICEThe belts should only be tensioned on the belt-tensioning devices as much asis absolutely necessary to keep them from slipping (no drift) under normallyoccurring loads. Excessive tautening results in rapid wear of the belts anddeflection pulley bearings.

• The conveyor belt must run centered and straight.

• It is not necessary to disassemble the belt frame in order to tension the conveyor belt.

METTLER TOLEDO recommends having Technical Service conduct an annual inspection of the drive system(pulleys, belts, etc.).A tensioning screw for tensioning the conveyor belt is located on each side of the idler (on the side panel ofthe belt frame).

Tensioning screws

Turn both belt-tensioning screws evenly (initially one full turn per screw) in a clockwise motion. This movesthe deflection pulley slightly further outwards, thereby increasing the tension of the belt. If necessary, repeatthe procedure.

Important Safety NoteIf tensioning is not performed evenly on both sides, then the belt will not runcentered and straight.

8.5 Maintenance of the Rejection BinClean the rejection bin using soft cloths dampened with a mild solution of soap and water or a commer-cially available glass and plastic cleaner.

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8.5.1 Exchanging a Damaged Rejection BinThe rejection bin collects rejected products.

Rejection bin

If the rejection bin is damaged, replace it with a new one.

Important Safety NoteOnly use METTLER TOLEDO approved spare parts and accessories.For detailed information on how to order spare parts, refer to chapter [Service } 5].

To replace a damaged rejection bin, follow these instructions:1 Loosen the four or six M5 or M6 hex bolts (depending on the design) using a (metric) size-8 or size-10

wrench and remove them from the fastening plate. Be careful not to lose any of the washers.2 Take off the damaged rejection bin.3 Position the new rejection bin in front of the fastening plate so that the four/six holes on the rear panel of

the bin line up perfectly with the four (six) threaded holes on the fastening plate. This step is best doneby a second person.

4 Insert the four/six hex bolts – using a washer for each bolt – into the four/six holes on the rear panel ofthe bin and tighten the bolts hand-tight.

Important Safety NoteManually tighten the bolts to a sufficient extent with a wrench, but refrainfrom applying excessive force, since the bin is made of plastic (acrylic).

8.6 Maintenance of the Toothed Belt



Monthly or at least every250 hours of operation

Immediately replace worn toothed belts.

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Important Safety NoteMake sure that the toothed belt does not grind against anything, that no teethare missing on the inside of the belt, and that the belt is not dirty. Ifnecessary, replace the toothed belt.

Make sure that the toothed belts are in good condition. If the toothed belts need to be replaced, contact theMETTER TOLEDO Service. You find contact details for the METTLER TOLEDO Service at [Service } 5].

8.7 Cleaning and Maintenance of Optional Mechanical Equipment

8.7.1 Cleaning the CoverClean the cover using soft cloths dampened with a mild solution of soap and water or a commerciallyavailable glass and plastic cleaner.

8.7.2 Maintenance of the Light Barriers


What Needs to be Done?

Weekly Perform a general visual inspection for dust, dirt, finger-prints or moisture condensation. If necessary, clean thelight barriers.

Weekly Perform a general visual inspection on th cables andcheck whether cables are tightly screwed. If they arenot, tighten the cable screws.

Important Safety NoteAlways keep the light barriers (light sensor, photocells, and if necessary, thereflectors) clean. Dust, dirt or moisture condensation on the optical parts maylead to malfunctions.If necessary, clean the light barriers using a soft, slightly damp towel or with cottonswabs.

8.8 Spare Parts and Warranty

Important Safety NoteFor safety and warranty reasons, only Technical Service or technicalpersonnel authorized by METTLER TOLEDO are permitted to replace a motor orthe terminal.If you would like to perform these maintenance tasks yourself, please contact our servicehotline for information about the required training for your personnel.

NOTICEKeeping spare parts on hand – especially for wear parts – can help reducedowntime. Please contact us if you have any questions.

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9 Malfunctions / Emergency Operation ModeInformation on how to contact the METTLER TOLEDO Service line is available in chapter [Service } 5].

9.1 System MessagesYou find text messages that provide information about certain processes or malfunctions on the terminalbasic screen in the Info field.

9.2 Emergency RunIn case of any fault occurring at your METTLER TOLEDO system, an emergency run function can beactivated so that the products continue to be transported on a belt conveyor while the print function does notfunction. All XMV systems are equipped with a function for emergency running at a malfunction.

NOTICEThe functions of the system are deactivated during an emergency run. Only the productscontinue to be transported.

CAUTIONAfter the control cabinet has been opened, live parts become accessible!The system may only be opened by a qualified electrician.

Activating Emergency Operation ModeTo activate the emergency operation mode, set the key-switch to position (I).

Emergency operation mode activated

Deactivating Emergency Operation ModeTo deactivate the emergency operation mode, set the key-switch to position (0).

Emergency operation mode deactivated

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10 Technical Data

10.1 SystemMaterial of standard design Frame, control cabinet, support made of stainless

steel, other (customized) designs possible

Protection class of system instandard design

Protected against ingress of dust and splashingwater according to IP53

Compressed air supply 1/4", minimum of 3 bar

Permissible operating temperature 0 to +40 °C

Noise emissions Less than 70 dB(A)

System power supply 230/115 VAC ±10%, 50/60 Hz, 1 phase

System power consumption Approx. 400 VAFor designs with optional equipment: up to 775VA

10.2 External Components and Connections

Interfaces 2 * serial interfaces (RS232)4 * USB 3.01 * USB 2.01 * DVI1 * Display Port2 * Ethernet

Printers and external storagemedia

Connection via interfaces; technical designdepends on system configuration

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11 Further InformationInside the control cabinet of your equipment, you find the following further documentation:• EU Declaration of Conformity (CE)• Wiring diagramOperating the XMV is done via the PCE Line Manager (PLM) software. For detailed instructions on how tooperate systems via the PLM software, refer to the PLM Manual.

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12 DisposalIn compliance with European Directive 2002/96/EC on Waste Electrical andElectronic Equipment (WEEE), this instrument must not be disposed of together withdomestic waste. This also applies to countries outside the EU, per their specificrequirements.Please dispose of this product in accordance with local regulations at the collectingpoint specified for electrical and electronic equipment.If you have any questions, please contact the responsible authority or the distributorfrom which you purchased this instrument.Should this instrument be passed on to other parties (for private or professional use),the content of this regulation must also be related.Thank you for your contribution to environmental protection.

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13 Spare Part Kits

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Spare Part Kits XMV – Basic kit

For XMV the following spare parts are available:

1.01.1350.01.0000 XMV Spare part kit - Basic kit consisting of

Outfeed conveyor:

1 transport belt

1 tooth belt 2MR-130-9

1 drive roller

1 idle roller

TBB conveyor:

2 transport belts

2 tooth belts

2 drive rollers

2 idle rollers

For the Printer:

1 printer cartridge

Spare Part Kits XMV – Uptime kit


1.01.1350.01.0000 XMV Spare part kit - Uptime kit consisting of

Outfeed conveyor:

1 transport belt

1 tooth belt 2MR-130-9

1 drive roller

1 idle roller

TBB conveyor:

2 transport belts

2 tooth belts

2 drive rollers

2 idle rollers

For the Printer:

1 printer cartridge

Motors:

Motor for outfeed conveyor

Motor for TBB conveyor

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Spare Part Kits XMV – Electronics kit


1.01.1350.02.0000 XMV Spare part kit - Electronics kit consisting of

Electrical/Electronic Components:

- 2 x motor

- 1 x LPB XRTC

- 1 x Motor Connection Board

- 1 x printer head

- 1 x Light barrier

- 5 x fuses

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Spare Part Kits XMV – Complete kit


1.01.1350.03.0000 XMV Spare part kit - Complete kit consisting of

For the conveyor:

- 3 x full flat belt

- 3 x toothed belt

- 3x drive roller

- 3x idle roller

For the printer:

- 1 x printer cartridge

Electrical/Electronic components:

- 2 x motor

- 1 x LPB XRTC

- 1 x Motor Connection Board

- 1 x printer head

- 1 x Light barrier

- 5 x fuses

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Pharmacontrol Electronic GmbHGernsheimer Strasse 264673 Zwingenberg, GermanyTel. +49 6251 8545-0Fax +49 6251 8545-111www.mt.com

Subject to technical changes.© Pharmacontrol Electronic GmbH 9/1/2016B

For more informationwww.mt.com

intentionally left blank · • if using a forklift, lift the equipment at the correct lift points...

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