Mark 7 Bullet Sense Instructions Manual

Page 1

This document is proprietary and confidential.

™ Installation Instructions

Box Contents and General Setup:

1. First review the box contents to make sure all parts are included: a. Setup Insert b. 650 BulletSense® Bracket Assembly c. Mirror Bracket (Mirror Holder attached to Mirror Arm with 2X flat head screws) d. 2X ¼-20 x 3” socket head cap screws for mounting to case feeder pole e. Offloading bracket (modified for pistol calibers)

2. Check the software and firmware version installed on your machine and make sure it’s at

least the version listed below (or newer) before installing 650 BulletSense®. The latest updates are available on the software updates page.

650 X: SW 00.01.13 FW 18

650 PRO: SW: 00.01.13 FW 26

Figure 1: Package Contents

Page 2

This document is proprietary and confidential.

3. The mirror holder is shipped with a protective film over the surface, before starting setup,

peel off the film. If required the mirror surface should be cleaned with water or isopropyl alcohol, do not use any other types of solvents.

Installing BulletSense® Main Assembly:

1. Begin by clearing the shell plate and powering off the machine and tablet. Remove the

tablet, tablet holder, and offloading bin and set aside.

2. If Locate and remove the offloading bracket bolts (X2) with a 7-16” socket and set aside

(see Figure 2).

Figure 2: Removing offload bracket

Page 3

This document is proprietary and confidential.

3. The case feeder pole bolts need to be removed to install the BulletSense mounting

bracket. It is recommended to remove the case feeder or have an assistant hold the pole in place so the case feeder does tip over. Carefully remove the case feeder pole bolts with a 3/16” Allen wrench and with a 7/16” socket affixed on the opposite side of the press (see Figures 3 and 4).

Figure 3: Case Feeder Mounting Bolt Locations

Page 4

This document is proprietary and confidential.

4. Install the 650 BulletSense Bracket Assembly as shown in the figure below (Figure 4).

Use the longer ¼-20” bolts provided.

Figure 4: Installing BulletSense on XL 650.

Page 5

This document is proprietary and confidential.

5. Attach the Mirror Bracket to the top bracket mount with the 2X flat head 8-32 X 1.25” cap

screws. The mirror then can be adjusted using a 3/8” open ended wrench.

Figure 5: Installing Mirror Bracket

6. Attach the offloading bracket provided with the screws that came with the press if you

are loading pistol calibers. Note for rifle calibers: The standard bracket can still be used for rifle (it just covers the bottom of the mirror). This isn't an issue though because the laser head is mounted higher due to the taller cases and longer projectiles.

Page 6

This document is proprietary and confidential.

Adjusting BulletSense® Laser for Station 4 and Station 5:

1. BulletSense can be configured in either station #4 or #5 (depending on whether you

are using a PowderSense).

Station 4: BulletFeeder dropper in Station 3 with standard crimp and seat dies. Station 5: BulletFeeder dropper in Station 4. (using PowderSense® Powder check)

2. Once you decide which station, align the 650 BulletSense assembly with the mirror

holder by loosening the sensor head mount (middle arm) brass thumb screw and rotating the sensor head to meet the mirror (see Figure 6).

Figure 6: Lining Up Laser with Mirror (Crude Adjustment)

Page 7

This document is proprietary and confidential.

3. Plug in the Sensor into Port #3 and power on the console which will automatically turn

on the laser. When you first power on the sensor look at the mirror to see where the laser beam is directed. Use a thick white card/flat object to help find the exact position if it’s difficult to detect the position.

**Please do not look directly into laser beam or directly at reflection in mirror**

WARNING – Class 3R laser: Avoid eye contact at all times; do not look directly

into the laser when adjusting the laser alignment.

4. Adjust Laser beam onto the mirror with the 2X 6-32” set screws on the top of the

assembly with a Torx screwdriver size T6 x 40mm. Once the Laser diode is hitting the mirror surface rotate the mirror using a 3/8” wrench so the laser beam is reflected back to the sensor main body. Once the reflected laser beam appears on the sensor main body, continue adjusting the set screws a little at a time to direct the laser beam into the sensor hole as shown in Figure 7.

Figure 7: Adjusting Laser

Sensor hole

Page 8

This document is proprietary and confidential.

5. Next the sensor vertical height must set for the given caliber and projectile being used.

This must be performed when the platform assembly is in the home position. Before making the vertical adjustment perform a system calibration so the platform stops in the home position.

6. To set the vertical adjustment, place a case with the neck expanded (pistol only) in

Station #4 or #5 and place a bullet in the proper orientation into the case at the level where it would be when dropped from the Mr. Bulletfeeder drop tube.

7. Loosen the brass thumb screw and gently position the sensor head mount (on middle

curved arm) so the laser beam goes OVER the tip of the bullet and hits the mirror, the reflected beam should return and hit the tip of the bullet so the beam path is broken as shown below (Figures 8 and 9). Once the height has been set, remove the bullet and make sure the laser is still aimed at the sensor hole.

Figure 8: Setting Vertical height of laser

Page 9

This document is proprietary and confidential.

Figure 9: Beam Over Bullet (Left) the Reflected Beam Will Hit the Back of the Bullet (Right)

8. When the vertical height is correct a shadow will be cast on the sensor preventing the

sensor from “seeing” the laser beam. When the bullet is not present/upside down/ sideways the beam will pass over the bullet and contact the sensor triggering the machine to stop.

9. It may be required to loosen the brass thumbscrew under the sensor head to add a slight

angle on the laser body to achieve a proper line of sight between the laser, bullet tip, mirror and back to the sensor hole.

10. Once the proper height and adjustment has been achieved tighten the brass 2X thumb

screws located under the sensor head.

11. The sensor head assembly is designed to be rotated out of the way if you need to

access the shell plate or perform press maintenance. Use the plastic knob on top of the rod to lift and rotate the sensor away from the machine.

Page 10

This document is proprietary and confidential.

Figure 10: Bullet Properly Oriented - Beam Interrupted (Left)

vs.

Bullets Improperly Oriented – Beam not interrupted (Center and Right)

Operating 650 BulletSense®:

1. With a clear shell plate enter the Reloader application, confirm that you have the

required software and firmware version or newer as outlined in the first page of this document.

2. BulletSense® Plugged into I/O Port 3.

3. Confirm that the laser is aligned with the sensor opening.

4. Perform a system calibration then select the sensors tab and make sure BulletSense® is

enabled. (See Figure 11).

5. Press RUN or Single Cycle. With a clear shell plate the following notification should

appear “Bullet Not Properly Positioned.” (see Figure 12).

Page 11

This document is proprietary and confidential.

Figure 11: Enabling BulletSense® on Sensor tab

Figure 12: Bullet Not Properly Positioned Notification