Service manual

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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. When the “Primary” applicator encounters a critical alarm condition, the
“Secondary” labeler is activated and continues to apply labels to the product. Possible critical alarm
conditions include: no labels found, web break, and primary offline.
The crossover sequence operates in the following manner. With the applicators powered and setup, they
are brought online with no products in between the primary and secondary heads. The primary head will
begin labeling. At the same time, it will send its product detect signal to the secondary labeler. A counter
in the secondary labeler will count up for each primary product detect signal while it will count down for
each secondary product detect signal. Initially, the secondary will not generate any product detects because
no products are in between the two heads. When the first labeled product reaches the secondary applicator,
the counter will decrement with each secondary product detect but the secondary labeler will not apply a
label. At this point, the secondary knows how many products are in between the heads. When an alarm
condition occurs in the primary labeler, it is taken offline and the secondary labeler is enabled. When the
first unlabeled product reaches the secondary applicator, it will start applying labels incrementing the
counter for each product passing the primary and decrementing for each product passing the secondary. It
will continue in this fashion until the primary applicator’s alarm condition is cleared and “ALARM
RESET” is pressed. When the primary applicator is brought back online, the secondary will continue to
label the products in between the heads but it will become disabled once the first labeled product from the
primary labeler reaches the secondary applicator.
CROSSOVER SETUP
1. Configure the label sensor, label length, label stop, label placement, and encoder (see General
Setup Procedure) with the crossover option off.
2. Make sure that the crossover cable is connected to both applicators.
3. Make sure that CRTL TO: ANLG is selected in the primary applicator’s special options menu (see
special options section). Also, if an offline condition in the primary labeler is to trigger an alarm,
select OFFLINE CRTL: ON.
4. From the “APPLICATOR OPTIONS” menu, enable the desired alarm conditions (i.e.: web break,
no labels found is always enabled).
5. From the “APPLICATOR OPTIONS” menu, select “3) X-OVER”.
6. Select “1) CROSSOVER: ON” to enable the crossover option.
7. Select “2” to toggle between “PRIMARY LABELER” and “SECONDARY LABELER”. The
primary labeler serves as the main or upstream applicator. The secondary labeler is the backup or
downstream applicator.
8. Press “ENTER” to return to the applicator options menu and “HOME” to return to the main menu
9. Bring both applicators “ONLINE” with no products between the heads.
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