318 QUAKER CIRCLE PO BOX 589 SALEM, OHIO 44460 PHONE: 330-332-1800 FAX: 330-332-2144 DESIGNERS AND MANUFACTURERS OF PRESSURE SENSITIVE LABELING EQUIPMENT AND CUSTOM PRODUCT HANDLING 360 SERIES LABEL APPLICATOR MAINTENANCE & SERVICE MANUAL REVISION 360-2c.10.
___________________ TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION ......................................................................................................…...1 MACHINE TERMS ...................................................................................................…...4 DISPLAY PANEL ................................................................................................…….…8 MAIN MENU ………………………………………………………………………………………8 ONLINE …………………………………………………………………………………………….
___________________ TABLE OF CONTENTS CROSSOVER OPTION .....................................................................………………… 46 SETUP …………………………………………………………………………………………….46 MONITORING ……………………………………………………………………………………47 PRECAUTIONS …………………………………………………………………………………..47 PRINTER SETUP ……………………………………………………………………... 49 LOOSE LOOP SETUP ..............................................................................................…………….49 IMPRINTER SETUP .....................................................
___________________ TABLE OF CONTENTS ACCESSORIES .........................................................................................................…. 89 ELECTRONIC CROSSOVER ……………………………………………………………………89 IMPRINTER ………………………………………………………………………………………89 LOOSE LOOP …………………………………………………………………………………….89 LOW LABEL DETECTION ……………………………………………………………………...89 TAMP SWITCH …………………………………………………………………………………..89 WEB BREAK DETECTION ……………………………………………………………………...89 RECOMMENDED SPARE PARTS...............................
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________________ INTRODUCTION INTRODUCTION The CTM Integration 360 Series Modular Labeling System is a high-speed applicator used to apply pressure sensitive labels to moving products on a production line. It is essentially a self-contained module that may be mounted in almost any position to apply labels to the top, bottom, or sides of packages as they pass by on a production line.
________________ INTRODUCTION READ THE INSTRUCTIONS IN ORDER. The instructions are written as numbered steps that will take you safely and efficiently through the setup process. Any steps performed out of sequence may result in a hazard and the applicator may not operate properly. WORK CAREFULLY. Although setting up the applicator is not difficult, it does take time. Do not rush through the process. Careful work will produce good results. IF SOMETHING DOES NOT WORK PROPERLY, TRY SETTING IT UP AGAIN.
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_________________ MACHINE TERMS DEFINITION OF MACHINE TERMS AIR BLAST JETS: The flexible air blast jets press-fit into the inside face of the vacuum grid and can be re-arranged to provide an air stream pattern that transfers labels of various sizes and shapes to the product. The air jets are connected via a manifold to the output of the “Air Blast” solenoid valve located in the valve bank. The filter regulator assembly mounted upstream of the value controls the air pressure to this solenoid valve.
_________________ MACHINE TERMS BLOW BOX / VACUUM GRID: The blow box/vacuum grid is the cube shaped assembly located next to the peel edge on a blow box applicator. Two axial fans mounted above the grid create the vacuum needed to hold the label in place prior to application. DANCER ARM: The dancer arm is attached to the unwind block assembly with a shoulder bolt and a bushing. It appears immediately after the unwind mandrel in the web path.
_________________ MACHINE TERMS PEEL EDGE: The peel edge is the beveled plate located at the end of the applicator nose. When the label liner is pulled around the peel edge, the label separates from the liner and is transferred to the vacuum grid, tamp pad, or product depending on the applicator type. PEEL EDGE LABEL TENSION SPRING: This tension spring is attached to the bottom of the spring block assembly.
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_______________ DISPLAY PANEL DISPLAY PANEL MAIN MENU: The main menu or home page screen displays the applicator type, whether it is in a left or right-handed configuration, and the label rate. ONLINE: The ONLINE function indicates whether or not the applicator is active. When the online LED is on, the applicator can be jogged or cycled from the product detect signal. When the LED is off, the applicator is disabled and power is removed from the drive roll motor.
_______________ DISPLAY PANEL LABEL STOP: The label stop key lets you enter the label stop distance value. The label stop value is the distance from the label edge to the label sensor. If the entered value is incorrect, an out-of-range message is displayed and the label stop menu is re-displayed so that a different value may be entered. Allowed values are between 0.03” and (label length – 0.06”). The label stop value may be changed while the applicator is running. Note: After software version 360-2b.
_______________ DISPLAY PANEL LEADING EDGE APPLY: The leading edge apply option is used to merge a label onto two or three panels of a product. An example might include the leading, top, and bottom panels of a CD case. The applicator is initially setup so that the label is flagged out in front of the product but is still supported on the liner. When the product reaches the peel edge, the flagged out portion of the label is applied to the bottom edge of the product.
_______________ DISPLAY PANEL APPLICATOR OPTIONS: The applicator option menu will let you view and choose which options you’ll be using in a particular application. For example: If you have a loose loop configuration, simply select the loose loop option and press the HOME key to take you back to the main menu.
_______________ DISPLAY PANEL NOTE: If you press the applicator options key, the first screen shows all of the available options and which ones are currently active. Selecting a particular option for the first time requires a password. The password is 1800. Subsequent selections do not require a password as long as you remain within an option menu. Going back to the home screen will disable the last password entry. LABEL PLACEMENT: The label placement key lets you enter a label placement value.
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_____________ REAR PANEL REAR PANEL CONNECTORS VALVE: When using a Tamp, Blow Box, or a Merge applicator with an imprinter, a valve bank is mounted to the side of the machine. This plug is used to power the valves. ENCODER: The encoder is connected to this plug. The encoder is enabled through the product setup menu. ALARM: This connector is for an alarm light.
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_______________________________ GENERAL SETUP PROCEDURES 360 SERIES SETUP PROCEDURES 16
_______________________________ GENERAL SETUP PROCEDURES !!CAUTION!! DISCONNECT THE AIR AND POWER FROM THE MACHINE BEFORE YOU THREAD LABELS OR YOU MAY BE CAUGHT BETWEEN THE DRIVE AND NIP ROLLERS IF THE MACHINE CYCLES UNEXPECTEDLY! JOB SETUP NOTE: When reading through this section of manual, refer to the web path diagram section. THREADING LABELS 1. With the power off remove the outer unwind disk. 2. Make sure the inside of the inner disk is at least 1 1/4” away from the faceplate of the applicator.
_______________________________ GENERAL SETUP PROCEDURES LABEL SENSOR SETUP The label sensor is a “U”-shaped optical sensor that is connected to the sensor electronics with fiber optic cable. To insure proper operation of the label sensor, there should be no sharp bends in the fiber optic cable from the sensor to the applicator housing. The two sensor forks contain a light emitter and a receiver.
_______________________________ GENERAL SETUP PROCEDURES message is displayed indicating that the label stop may need adjusting. The operator may override the controller’s value using the “LABEL STOP” menu. MANUAL SETUP The manual setup function is provided for those instances where auto setup does not work. The following steps summarize the manual setup sequence: 1. With the applicator offline, select “2” from the LABEL SETUP menu. 2.
_______________________________ GENERAL SETUP PROCEDURES LABEL LENGTH SETUP 1. Measure the distance from the leading edge of one label to the leading edge of the next. This will be the “label length” value. 2. From the LABEL SETUP menu press “3” to adjust the “LABEL LENGTH” value. 3. Enter the length and press “ENTER”. If the value is less than 0.375” or more than 20”, the display will show an out-of-range message for 2 seconds then switch back to the label length menu.
_______________________________ GENERAL SETUP PROCEDURES LABEL STOP 1. The label stop value is the distance from the label edge to the label sensor. Allowed values are between 0.03” and (label length – 0.06”). NOTE: After software version 360-2b.25 any value less than .06 comes with a warning that says the label stop can move when the web speed changes. 2. Press the “LABEL STOP” key. Enter a new value and press “ENTER”.
_______________________________ GENERAL SETUP PROCEDURES LABEL FORMATS (cont.) Load Format This option will allow the operator to load the values of a previously stored format in to the system as current values. Pick “2” at the label format menu and select the number of the format you want to load. If you want to exit without loading any format, press “ENTER”. Continue to press “ENTER” to exit to the label setup menu.
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___________________________________ LABELER TYPE SETUP PROCEDURE MERGE APPLICATOR SETUP The merge applicator is used to apply labels to products moving on a conveyor. A label is feed onto the surface of the product at the same speed that the product is moving. 1. On the display, under “APPLICATOR TYPE” select “MERGE” applicator. Also, indicate whether it is in a right-hand or left-hand configuration using the “RT/LT HAND” selection. 2. Go through the general label setup procedure. 3.
___________________________________ LABELER TYPE SETUP PROCEDURE ENTERING LABEL PROFILING VALUES 1. Press “LABEL SETUP” then select “LABEL PROFILING”. 2. The label profiling menu shows the following three items: Profile Rise Area Profile Flat Area Web Ratio 3. Press “1) PROFILE RISE AREA”. This is the distance the label travels before changing to the mid-product labeling speed. Enter a value between 0.5 and 20. A valid entry will send you back to the label profiling menu. 4.
___________________________________ LABELER TYPE SETUP PROCEDURE ESTIMATING RISE AREA AND FLAT AREA This process will give you a starting point for profile variables. Some experimentation is necessary for best results. The example shown is for a convex or oval product. 1. Apply a label by hand to the product. Measure the rise area by looking at the beginning of the label to where it starts to flatten out. Also measure the length of the flat area. Use the diagram below as an example. 2.
___________________________________ LABELER TYPE SETUP PROCEDURE RISE AREA AND FLAT AREA FINAL ADJUSTMENT The system will work best with the smallest rise area value and the largest flat area value that properly applies the label. Use the instructions below to find these values. 1. With the applicator online, send several products down the conveyor and observe the labels that are applied. 2. If the leading edges of the labels were all applied at the same position on the products, go on to step #3.
___________________________________ LABELER TYPE SETUP PROCEDURE MERGE LEADING EDGE APPLY The leading edge apply option is used to merge a label onto two or three panels of a product. An example might include the leading, top, and bottom panels of a CD case. The applicator is initially setup so that the label is flagged out in front of the product but is still supported on the liner.
___________________________________ LABELER TYPE SETUP PROCEDURE CONFIGURING LEADING EDGE APPLY WITH AUTO SETUP 1. Make sure the applicator is powered and offline. 2. Press “LABEL SETUP” and select “5) LEADING EDGE APPLY” 3. Select “1) LEADING EDGE OPTION IS: ON” from the leading edge submenu. 4. Select “3) PRODUCT CLEARANCE TIME / DISTANCE” and enter the time or distance after the label is dispensed to when the product clears the peel edge.
___________________________________ LABELER TYPE SETUP PROCEDURE AIR BLOW APPLICATOR SETUP The air blow applicator is a versatile labeler in the sense that many different label sizes can be used without buying a new pad or manifold. Products can also be labeled at a stand still without contact. The blow box consists of two axial fans mounted in the top of the assembly that produce the vacuum needed to hold the label.
___________________________________ LABELER TYPE SETUP PROCEDURE AIR BLOW PEEL EDGE ALIGNMENT 1. Turn power on to the applicator and make sure it’s offline. 2. Advance the web using the drive roller and notice how the label feeds onto the grid. A normal paper label should deflect 5-10 degrees to the bottom surface of the label grid. A stiffer label should feed straight onto the grid. 3. To adjust the peel edge, loosen the two 1/4 S.H.C.S.
___________________________________ LABELER TYPE SETUP PROCEDURE AIR BLOW AIR ASSIST The air assist tube blows a stream of air onto the label to force it up against the blow box grid during the label feed. The air assist starts to blow when the web starts to move and stops when the label is on the grid. The extended air assist time allows the air assist to blow after the label feed to help stabilize the label. 1. Adjust the air assist tube so it’s blowing into the center of the label.
___________________________________ LABELER TYPE SETUP PROCEDURE TAMP APPLICATOR SETUP The tamp applicator consists of a tamp slide, label manifold, and a label pad. The label is fed out onto the label pad and is tamped within 1/8” of the labeling surface. The label is then blown off by an air blast. The tamp applicator has higher placement accuracy and is less dependent on product movement. NOTE: Before proceeding, make sure you’ve selected tamp under “APPLICATOR TYPE” on the display.
___________________________________ LABELER TYPE SETUP PROCEDURE TAMP LABEL STOP 1. With the applicator online, jog a couple of labels. 2. Label stop position should be 1/32” from the peel edge tip. 3. If needed change the label stop value. (Refer to label stop setup in the general job setup) TAMP VACUUM The tamp vacuum is generated by a vacuum venturi located on the applicator. This vacuum is used to hold the label on the label pad until the air blast releases it.
___________________________________ LABELER TYPE SETUP PROCEDURE TAMP AIR ASSIST The air assist tube blows a stream of air onto the label to force it up against the tamp pad during the label feed. The air assist starts to blow when the web starts to move and stops when the label is on the pad. The extended air assist time allows the air assist to blow after the label feed to help stabilize the label. 1. Adjust the air assist tube so it’s blowing in the center of label.
___________________________________ LABELER TYPE SETUP PROCEDURE TAMP SLIDE The tamp slide is used to move the label pad and manifold toward the product. The speed at which it travels is a function of air pressure and airflow. The valve and regulator for the tamp assembly is part of the valve bank mounted to the side of the applicator. Typically, the air pressure should be set between 40 and 50 PSI but it may be changed as necessary.
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_____________________________ PRODUCT SETUP PROCEDURE PRODUCT SENSOR The factory product sensor is a reflective type. Other types can be used but the following setup procedure is for a reflective sensor. 1. Make sure the sensor is plugged into the applicator. 2. Turn the power on and leave the applicator offline. 3. Set the sensor to DO (dark operation) by gently turning the output select screw completely counter-clockwise. 4. Make sure the sensor is aligned with the reflector.
_____________________________ PRODUCT SETUP PROCEDURE PRODUCT SETUP 1. Make sure the power is on and the applicator is offline. 2. Press “PRODUCT SETUP” on the display. 3. The product setup screen will show the status of the detector lockout function, whether the encoder is on or off and its speed, the label counter value, and whether the product sensor is detecting a product or not.
_____________________________ PRODUCT SETUP PROCEDURE LABEL PLACEMENT (cont’d) NOTE: 1) The applicator will be slower and less accurate for larger label placement values. Keep this value to a minimum by moving the product sensor closer to the peel edge. 2) If the encoder option is on, the label placement value is in inches. If the encoder is off, the label placement value is in seconds. 3) This adjustment can be made while the machine is running.
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_____________ ENCODER SETUP ENCODER OPTION The encoder option is useful when the product velocity varies during the application cycle. An example of such an application is forms on a forms table. With the encoder installed and enabled, the labeler adjusts the label dispense speed to insure accurate label placement on the product. The applicator has a differential quadrature incremental encoder interface with times four interpolation built into the controller board.
_____________ ENCODER SETUP ENCODER SETUP 1. Select “ENCODER SETUP” at the product setup menu. NOTE: This area is password protected. The password is 1800. Going back to the home screen will disable the last password entry. 2. Turn the encoder on by pressing “1”. NOTE: If the encoder was already enabled, you would turn off the encoder by pressing “1”. 3. Select “PULSE LENGTH” and enter the distance the product travels per pulse of the encoder.
_____________ ENCODER SETUP ENCODER SETUP (cont.) 5. Rate Compensation for Air Blow and ITB Tamp Applicators: When selecting a value for rate compensation, start at 0.025. Apply labels to the product at a slower speed. Then run the product at production speeds or faster. If the labels are applied in the same place, the compensation is correct. If labels move back the faster you go, INCREASE RATE COMPENSATION. If the labels move forward, DECREASE RATE COMPENSATION.
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_______________ CROSSOVER SETUP CROSSOVER OPTION The crossover option allows for “zero downtime” operation by interconnecting two applicators with identical setup configurations. Both applicators are placed on the conveyor system one upstream of the other. The upstream applicator is the “Primary” labeler while the downstream applicator is the “Secondary” labeler.
_______________ CROSSOVER SETUP CROSSOVER MONITORING If the applicator is a secondary labeler, the crossover sub-menu will have a MONITOR SECONDARY SETUP selection. This menu is provided to aid the operator in setting up the crossover network and is particularly helpful if the secondary applicator is not labeling or is double labeling products.
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____________ PRINTER SETUP LOOSE LOOP SETUP The loose loop option allows labels to be printed and applied from one system by tying a thermal printer into the web path of the applicator. As the labels exit the printer, they go around a dancer arm to maintain web tension. Three proximity switches monitor the dancer arm position. The lower switch turns the printer off while the upper two turn the printer on. If the upper switch is active, the applicator enters a “Tight Loop” alarm condition.
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__________________ LABEL OPTIONS SETUP LABEL OPTIONS This section will discuss options that control how the applicator dispenses a label or handles a missing label on the liner web. These options appear in the “APPLICATOR OPTIONS” menu and are password protected. The password is 1800. MULTIPLE LABEL: The multiple label option allows more than one label to be applied to a product from one product detect signal.
__________________ LABEL OPTIONS SETUP MISSING LABEL The applicator has the ability to track missing labels between the peel edge and the label sensor. When a missing label is detected on the label liner, the applicator will feed a new label to the peel edge at slew speed. 1. Press the “APPLICATOR OPTIONS” key and select “8) MISS LBL” to enter the missing label submenu. 2. Select “1) MISSING LABEL: ON” to enable the option. Pressing “1” repeatedly will toggle the missing label function on and off. 3.
__________________ LABEL OPTIONS SETUP SKIP COUNTER The applicator has the ability to skip products on the conveyor system. The skip counter submenu displays the CURRENT PRODUCT COUNT: the number of products remaining before a label will be applied, SKIP COUNTER: ON/OFF, and the LABEL EVERY “x” PRODUCTS value: the desired product labeling interval. 1. Press the “APPLICATOR OPTIONS” key and select “9) SKIP CNT” to enter the skip counter submenu. 2. Select “1) SKIP COUNTER: ON” to enable the option.
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___________________ CONFIGURATION MENU CONFIGURATION MENU Pressing “9” within the first five seconds of power-up will bring up the factory configuration menu. This screen is hidden from normal use and serves as a place for options that are not normally adjusted.
___________________ CONFIGURATION MENU 1) PRINT/PWR REWIND/CRTCL ALRM TO DO10 (pg. 1) Selecting “1” from the special options menu configures the source that drives digital output 10 (DO10). The display in 1) will toggle between PRINT TO DO10 and PWR REWIND TO DO10 each time “1” is pressed. Although the software drivers are supplied with the applicator, the hardware for a loose loop printer, an imprinter, or a powered rewind is an option that must be purchased separately.
___________________ CONFIGURATION MENU 5) CRITICAL TO: ALRM/ANLG/DO10 (pg. 1) The CRITICAL TO: ALRM/ANLG/DO10 selection allows the user to direct critical alarms to specific applicator outputs. The program cycles through ALRM, ANLG, and DO10 each time “5” is pressed. The following critical alarms are supported: no labels found, web break, tight loop at printer1, and applicator offline. 1Starting with software version 2c.10.3, tight loop at printer is no longer a critical alarm.
___________________ CONFIGURATION MENU WARNING: The factory default values should work in most cases and should not be changed. please consult factory before making changes.
___________________ CONFIGURATION MENU 2) I/O DIAGNOSTICS (pg. 2) The I/O DIAGNOSTICS menu provides a means to check devices connected to the applicator. From here, the operator can manually turn on valve outputs; monitor inputs such as: product detect, web break, and low label; and verify the operation of the analog input and output. 3) DEBOUNCE DELAY (pg. 2) The DEBOUNCE DELAY value helps eliminate false product detect signals that are electrical in nature.
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______________________ WEB PATH DIAGRAMS 360 SERIES LEFT HAND MERGE Web Path Diagram and Machine Parts 60
______________________ WEB PATH DIAGRAMS 360 SERIES RIGHT HAND MERGE Web Path Diagram and Machine Parts 61
______________________ WEB PATH DIAGRAMS 360 SERIES LEFT HAND TAMP Web Path Diagram and Machine Parts 62
______________________ WEB PATH DIAGRAMS 360 SERIES RIGHT HAND TAMP Web Path Diagram and Machine Parts 63
______________________ WEB PATH DIAGRAMS 360 SERIES LEFT HAND AIR BLOW Web Path Diagram and Machine Parts 64
______________________ WEB PATH DIAGRAMS 360 SERIES RIGHT HAND AIR BLOW Web Path Diagram and Machine Parts 60
______________________ WEB PATH DIAGRAMS 360 SERIES LEFT HAND MERGE (With 16” Unwind) Web Path Diagram and Machine Parts 66
______________________ WEB PATH DIAGRAMS 360 SERIES RIGHT HAND MERGE (With 16” Unwind) Web Path Diagram and Machine Parts 67
______________________ WEB PATH DIAGRAMS 360 SERIES LEFT HAND TAMP (With 16” Unwind) Web Path Diagram and Machine Parts 68
______________________ WEB PATH DIAGRAMS 360 SERIES RIGHT HAND TAMP (With 16” Unwind) Web Path Diagram and Machine Parts 69
______________________ WEB PATH DIAGRAMS 360 SERIES LEFT HAND AIR BLOW (With 16” Unwind) Web Path Diagram and Machine Parts 70
______________________ WEB PATH DIAGRAMS 360 SERIES RIGHT HAND AIR BLOW (With 16” Unwind) Web Path Diagram and Machine Parts 71
___________________________ GENENRAL MAINTENANCE 360 SERIES GENERAL MAINTENANCE PROCEDURES 72
___________________________ GENENRAL MAINTENANCE !!CAUTION!! DISCONNECT THE AIR AND POWER FROM THE MACHINE BEFORE DOING THE FOLLOWING PROCEDURES. FAILURE TO FOLLOW THIS PRECAUTION COULD RESULT IN INJURIES FROM MOVING PARTS OR ELECTRICAL SHOCK. MAINTENANCE NOTE: Since all three types of applicator are covered in this section, some items discussed will not pertain to your application. DAILY MAINTENANCE 1. Examine the peel edge, vacuum grid, label pad and rollers for excessive adhesive build-up.
___________________________ GENENRAL MAINTENANCE SEMI-ANNUAL MAINTENANCE 1. Replace air filter and clean collection bowl. 2. Clean inside and outside of machine using an industrial vacuum cleaner. NOTE: Do not use compressed air to blow dust off of the electrical section of the applicator. 3. Replace slip clutch disk. Clean both friction surfaces. 4. Check roller clutch on the rewind shaft for correct operation. 5. Examine pulleys for wear. 6. Perform the monthly maintenance section.
___________________________ GENENRAL MAINTENANCE !!WARNING!! DISCONNECT THE POWER AND AIR TO MACHINE BEFORE DOING THE FOLLOWING PROCEDURES. INJURIES COULD OCCUR FROM MOVING PARTS OR ELECTRICAL SHOCK. REWIND SLIP CLUTCH ADJUSTMENT More or less tension may be needed on the rewind if the liner is being wound too loose or tight. Different conditions will warrant this adjustment: 1. Change in label width or length. 2. Applicator attitude. 3. Web speed changes. 4.
___________________________ GENENRAL MAINTENANCE !!WARNING!! DISCONNECT THE POWER AND AIR TO MACHINE BEFORE DOING THE FOLLOWING PROCEDURES. INJURIES COULD OCCUR FROM MOVING PARTS OR ELECTRICAL SHOCK. DRIVE BELT ADJUSTMENT 1. Remove all AC power and air to the machine. 2. Remove the lower stainless cover. 3. Remove the air lines interconnecting the two sides of the applicator to gain access to the drive belt. 4. Remove both splice plates that are mounted on either side of the motor.
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_____________________ TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION WITH THE POWER SWITCH ON, POWER CORD DEFECTIVE OR UNPLUGGED INSPECT AND CORRECT AC FUSE BLOWN DETERMINE CAUSE AND REPLACE FUSE WITH THE POWER SWITCH ON, DISPLAY CABLE NOT PLUGGED IN TO RECONNECT CABLE COOLING FAN ON; NO DISPLAY THE BACK OF THE APPLICATOR NO COOLING FAN; NO DISPLAY DISPLAY PORT SETTINGS INCORRECT LOCATE SW1 NEAR THE AIR FILTER MAKE SURE SWITCHES 1 & 6 ARE UP LABEL LINER BREAKING LOSS OF 12 VDC CALL A FAC
_____________________ TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LABEL DOES NOT ADVANCE NIP ROLLER NOT ENGAGED INSPECT AND CORRECT AND DISPLAY IS WORKING AGAINST DRIVE ROLLER DRIVE BELT IS BROKEN LOST KEY IN DRIVE PULLEY REPLACE BELT FOLLOW PROCEDURE FOR SLIP CLUTCH ADJUSTMENT. WHEN YOU GET TO STEP #6 AND HAVE REMOVED THE PULLEY GOING TO THE REWIND, GO AHEAD AND REMOVE THE DRIVE PULLEY.
_____________________ TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LABEL LINER NOT WINDING UP REWIND SLIP CLUTCH NEEDS SEE SLIP CLUTCH ADJUSTMENT TENSIONING OR REPLACED IN THE MAINTENANCE SECTION ONE-WAY CLUTCH BEARING REPLACE REWIND SHAFT ASSEMBLY NOT WORKING BROKEN BELT REPLACE BELT LABELS ARE NOT HELD ON LABEL AIR BLOW CHECK FOR BLOWN FUSE GRID OR LABEL PAD VACUUM FAN NOT WORKING OBSTRUCTION IN FAN REPLACE FANS TAMP INSPECT FOR CLOGGED OR NOT ENOUGH VACUUM ON PAD DEFECTIVE VENTU
_____________________ TROUBLESHOOTING PROBLEM POSSIBLE CAUSE SOLUTION LABEL PLACEMENT ON GRID OR AIR BLOW YOU MAY HAVE TO MASK OFF LABEL PAD NOT CONSISTENT IMPROPER VACUUM THE HOLES NOT USED BY THE LABEL ON THE INSIDE OF THE VACUUM BOX YOU CAN ADD MORE VACUUM BY TURNING THE VAC SWITCH TO HIGH TAMP ADJUST AIR PRESSURE IMPROPER VACUUM BOTH REPLACE LABEL ROLL ADHESIVE STRINGS ON LABEL AND LINER BOTH REFER TO PEEL EDGE ALIGNMENT PEEL EDGE OUT OF ADJUSTMENT IN THE LABELER SET UP SECTION BOTH
_____________________ TROUBLESHOOTING FAULT CODE REGISTER Following a fault condition, the controller runs a section of code to determine the cause of the fault. The display will show a fault type message, its corresponding fault code value, and the fault code register value. If a fault occurs, record these three values and contact the factory for assistance. The display will only show the first error condition encountered but the fault code register value encodes the status of all fault conditions.
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______________ FLOWCHARTS AIR BLOW SEQUENCE OF OPERATION 84
______________ FLOWCHARTS TAMP SEQUENCE OF OPERATION 85
______________ FLOWCHARTS ITB TAMP SEQUENCE OF OPERATION 86
______________ FLOWCHARTS MERGE SEQUENCE OF OPERATION 87
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______________ ACCESSORIES ACCESSORIES ELECTRONIC CROSSOVER: The Electronic Crossover accessory is an electronic interface between two labeling heads positioned in series that will monitor labeling head fault conditions and switch to a secondary applicator to prevent interruption of production flow. Includes control with all interface cabling. IMPRINTER: The Imprinter accessory is a Hot Stamp Imprinter device mounted on special bracketry attached to the labeling head.
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______________________________ RECOMMENDED SPARE PARTS 360 SERIES RECOMMENDED SPARE PARTS 91
RECOMMENDED SPARE PARTS 360 AIR BLOW APPLICATOR PART NO.
RECOMMENDED SPARE PARTS 360 MERGE APPLICATOR PART NO.
RECOMMENDED SPARE PARTS 360 TAMP APPLICATOR PART NO.
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___________ DRAWINGS 360 SERIES APPLICATOR ELECTRICAL AND MECHANICAL DRAWINGS 96
______________________________ CHANGEOVER INSTRUCTIONS CHANGING TO OPPOSITE HAND DISPENSE When performing an applicator changeover, the nose assembly, unwind assembly, rewind, and wiring are first changed to the opposite hand dispense. Then each component assembly is remounted on the opposite side of the applicator. The symmetry of the applicator main module and the individual parts facilitate the changeover process but it can be confusing if care is not exercised.
______________________________ CHANGEOVER INSTRUCTIONS NOSE ASSEMBLY REMOVAL AND INSTALLATION INSTRUCTIONS NOTE: DISCONNECT THE POWER CORD AND AIR SUPPLY FROM THE MACHINE BEFORE ATTEMPTING ANY OF THE FOLLOWING PROCEDURES. FAILURE TO FOLLOW THIS PRECAUTION COULD RESULT IN INJURIES FROM MOVING PARTS OR ELECTRICAL SHOCK! BLOW BOX NOSE ASSEMBLY REMOVAL 1) Remove the stainless steel cover from the bottom of the applicator. 2) Remove the air tubes interconnecting the two sides of the applicator.
______________________________ CHANGEOVER INSTRUCTIONS NOTE: DISCONNECT THE POWER CORD AND AIR SUPPLY FROM THE MACHINE BEFORE ATTEMPTING ANY OF THE FOLLOWING PROCEDURES. FAILURE TO FOLLOW THIS PRECAUTION COULD RESULT IN INJURIES FROM MOVING PARTS OR ELECTRICAL SHOCK! MERGE NOSE ASSEMBLY REMOVAL 1) Remove the stainless steel cover on the bottom of the applicator. 2) Remove the air tubes interconnecting the two sides of the applicator.
______________________________ CHANGEOVER INSTRUCTIONS NOTE: DISCONNECT THE POWER CORD AND AIR SUPPLY FROM THE MACHINE BEFORE ATTEMPTING ANY OF THE FOLLOWING PROCEDURES. FAILURE TO FOLLOW THIS PRECAUTION COULD RESULT IN INJURIES FROM MOVING PARTS OR ELECTRICAL SHOCK! TAMP NOSE ASSEMBLY REMOVAL 1) Remove the stainless steel cover from the bottom of the applicator. 2) Remove the air tubes interconnecting the two sides of the applicator.
______________________________ CHANGEOVER INSTRUCTIONS NOSE ASSEMBLY CHANGEOVER When changing the nose assembly to the opposite hand dispense, all parts are first transferred to the opposite side of the mounting plate. Then the entire nose assembly is rotated 180 degrees and remounted to the opposite side of the applicator. 1) Remove the peel edge assembly from the nose assembly mounting plate.
______________________________ CHANGEOVER INSTRUCTIONS BLOW BOX PEEL EDGE CHANGEOVER 1) Remove the label sensor from the peel edge assembly and remount on the opposite side making sure that the fiber cables are threaded through from the opposite side. The open end of the U-shaped sensor should face towards the inside. 2) Remove the guide rollers and remount to the opposite side of the peel edge mounting plate.
______________________________ CHANGEOVER INSTRUCTIONS TAMP PEEL EDGE CHANGEOVER 1) Remove the label sensor from the peel edge assembly and remount on the opposite side making sure that the fiber cables are threaded through the holes from the opposite side. The open end of the Ushaped sensor should face towards the inside. 2) Remove the guide rollers and remount to the opposite side of the peel edge mounting plate.
______________________________ CHANGEOVER INSTRUCTIONS REWIND REMOVAL 1) Remove the belt connecting the rewind clutch to the motor. 2) Remove the rewind mandrel from its drive shaft. 3) Remove the six #10 screws that hold the rewind mounting plate to the housing. REWIND INSTALLATION 1) Attach the rewind mounting plate to the housing using the six #10 screws. 2) Install the rewind mandrel on the mandrel drive shaft. 3) Install the belt connecting the rewind clutch to the motor.
______________________________ CHANGEOVER INSTRUCTIONS Power Entry Module Wiring 105
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