CTM 360a series Maintenance And Service Manual Download Page 1

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1318 QUAKER CIRCLE P.O. BOX 589 SALEM, OHIO 44460

PHONE: 330-332-1800

FAX: 330-332-2144

www.ctmlabelingsystems.com

Designers and Manufacturers of Pressure Sensitive Labeling

Equipment and Custom Product Handling

360a LABEL APPLICATOR

CE VERSION

MAINTENANCE

SERVICE MANUAL

REVISION 360a-4a.1.X.XXX

Summary of Contents for 360a series

Page 1: ...0 PHONE 330 332 1800 FAX 330 332 2144 www ctmlabelingsystems com Designers and Manufacturers of Pressure Sensitive Labeling Equipment and Custom Product Handling 360a LABEL APPLICATOR CE VERSION MAINT...

Page 2: ...y of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13850 2008 Safety of Machinery Emergency stop equipment functional aspects Principles for design EN I...

Page 3: ...ide earth ground fault current protection if required The end user will provide any guarding needed after integration of the applicator Emergency Stop Actuators EN ISO 13850 2015 Clause 4 3 2 requires...

Page 4: ...3 10 Extended Air Assist 3 10 Web Speed 3 10 Pre Dispense 3 10 Over Speed 3 11 Label Profile 3 11 Multi Panel 3 15 PRODUCT SETUP 3 17 Label Placement 3 17 Detector Lockout 3 17 Encoder Option 3 17 CON...

Page 5: ...JOB SETUP 5 3 LABEL SENSOR SETUP 5 4 LABEL LENGTH SETUP 5 5 LABEL STOP SETUP 5 6 WEB SPEED SETUP 5 6 SLEW SPEED SETUP 5 6 LABEL STATIC TEST 5 7 LABELER TYPE SETUP 6 MERGE APPLICATOR 6 1 AIR BLOW APPLI...

Page 6: ...L INSTALLATION 12 3 MERGE NOSE ASSEMBLY REMOVAL INSTALLATION 12 4 TAMP NOSE ASSEMBLY REMOVAL INSTALLATION 12 5 NOSE ASSEMBLY CHANGEOVER 12 6 MERGE PEEL EDGE CHANGEOVER 12 6 BLOW BOX PEEL EDGE FAN GRID...

Page 7: ...dy included with each Applicator Nose to make the change using your existing Module Tamp Pad Manifolds as well as some Options are hand specific The labels should be supplied on a liner web with a min...

Page 8: ...the process Careful work will produce good results IF SOMETHING DOES NOT WORK PROPERLY TRY SETTING IT UP AGAIN Although an Applicator malfunction is possible most problems happen because the Applicat...

Page 9: ...el to the Blow Box Grid until it is dispensed onto the product The Nose Assembly is easily converted from left hand to right hand and vice versa using the same parts Also the Blow Box Nose Assembly ca...

Page 10: ...Mandrel Tension Disk with a spring The Dancer Arm maintains tension on the liner loop as it operates the brake on the Unwind Mandrel when labels are being dispensed The spring tension should be large...

Page 11: ...justable to accommodate varying label thickness and release properties REWIND MANDREL SLIP CLUTCH The Rewind Mandrel is provided to store the label liner after labels have been removed It is equipped...

Page 12: ...hange Outer Disc The Unwind Roll Mandrel and the Dancer Arm maintain proper web tension and prevent excessive run out of the label liner as labels are processed through the Applicator VALVE BANK The V...

Page 13: ...is key is for setting something like an Applicator Type jog or used as an Alarm Reset Key The color of keys will vary depending on the application This key is for bringing the Applicator on and offlin...

Page 14: ...Box will have a red background instead of yellow to signal the alarm condition Low Label This alarm occurs when the Low Label Sensor detects that the unwind roll is nearly out of labels Multi Label C...

Page 15: ...d by the applicator End Of Web This alarm occurs when the End Of Web sensor detects a break in the web No Labels Found This alarm occurs if the number of consecutive missing labels on the liner exceed...

Page 16: ...ontinue with password entry by touching within the box to the left to activate the keypad When you touch a number on the keypad it will highlight This is the only indication that a key was pressed sin...

Page 17: ...not change or erase Formats from here The Setup Key takes the operator to a password protected area to make changes to the operation of the Applicator The Display is equipped with a backlight saver fu...

Page 18: ...but when Label Sop is moving with Web Speed it was found making changes to it can make the label stop position better Label stop compensation is a number that shortens the Label Stop value the higher...

Page 19: ...h function not only sets the Label Sensor Sensitivity but also calculates the Label Length and Label Stop values When the Auto Teach function is selected the operator is prompted to move the label gap...

Page 20: ...last Format loaded If no Formats had been loaded the value in the box would be 0000 Saving a Format If the current setup in the Applicator is performing correctly and you want to save it press Label...

Page 21: ...at but will allow the operator to view the values within that Format After reviewing the values the operator may press Load Format to load the Format If the wrong format was selected the operator can...

Page 22: ...feeding another label If this value is too small a label will feed into the Pad or Manifold Allowed values are between 01 5 seconds Note In a Tamp Applicator the Tamp Slide action may be disabled or...

Page 23: ...r the remainder of the move The reason for this action is that convex products start out farther away from the Peel Edge than it will be by mid product The label is dispensed at normal speed at the be...

Page 24: ...nning at Web Speed during this distance Flat Area This is the distance the label travels while at the mid product labeling speed Enter a value between 1 and 20 The Applicator will be running at a perc...

Page 25: ...easure the length of the Flat Area Use the diagram below as an example 2 Use these numbers when inputting values to the Display 3 When using this type of product Web Ratio is set less than 100 This wi...

Page 26: ...lied at the required position on the product 4 If there are no wrinkles or bubbles in the first half of the applied labels go on to step 5 If a wrinkle or bubbles appear from the top to the bottom of...

Page 27: ...y the Peel Edge before moving the next label to the flagged out position Label Stop at Slew Speed The figure below illustrates an example setup with four labels between the Peel Edge and the Label Sen...

Page 28: ...to when the product clears the Peel Edge to the Product Clearance box The distance should be approximately equal to the product length 6 Go back to the Main Menu and press LABEL SETUP then LABEL SENS...

Page 29: ...be restored after the ENT key is pressed The allowed range of values in seconds if time based or in inches if encoder based are shown below the Label Placement Box The Label Placement value may be ch...

Page 30: ...tor to the change in Encoder Speed is proportional to the number of Scans The lower scan numbers are more responsive to speed changes while the higher number produces a smoother quieter application wi...

Page 31: ...position Merge Compensation Setup When selecting a value for rate compensation start at 0 008 Apply labels to the product at a slower speed Then run the product at production speeds or faster If the...

Page 32: ...uration NOTE If the Apply Hand Right or Left is changed the user will be forced to cycle power to the Applicator There is a Status Box on the right hand side of the screen that displays the current se...

Page 33: ...When the Applicator is properly set up under normal operating conditions the arm will not reach the Alarm Prox position If the Alarm Prox is active the 360a Applicator is dispensing faster than what...

Page 34: ...al When the Product Detect Input turns on the Primary sends a signal to the Secondary to start the transfer sequence When the product has traveled the On Distance the Secondary will start labeling The...

Page 35: ...lamp indicates the current setup 4 If the Applicator is going to be the Secondary measure the distance between the two application points subtract inch and enter this as the On and Off Distances 5 Bri...

Page 36: ...lower than the suggested value in some Applicator configurations One of these configurations would be a Time Based Inverted Tamp Applicator with both Tamp Home and Tamp Return Sensors Missing Label T...

Page 37: ...leave liner only conditions at the Peel Edge The next label will be moved into position as the current label is applied If the Applicator is taken offline with a missing label on the liner between the...

Page 38: ...to be applied and fold station to cycle based on a single Product Detect Sensor If Mode 1 is going to be used the Product Detect Sensor MUST be set to leading edge The Applicator will apply the label...

Page 39: ...er product rate and a higher Label Placement amount so that the Applicator has enough time to completely dispense the label and activate the Tamp Valve If the product rate is too high for the labeling...

Page 40: ...coder Option is used If the Max Speed is set too high the label dispense will be sluggish but if set too low the Applicator will be stiff and unstable In many cases the motor will lose enough power to...

Page 41: ...en where the user can setup the Label Sensor again SPECIAL OPTIONS SECTION This section is for changing the Motion Parameters changing the Password adjusting the number of consecutive missing labels b...

Page 42: ...ers will not be supported If the Password was changed and no one can remember what it is the operator can touch the upper right hand corner of the power up software screen Then they can select the Res...

Page 43: ...plicator has finished its power up sequence the Applicator will automatically be placed Online If the Applicator Type is set to anything other than a Merge the operator will be responsible for jogging...

Page 44: ...ulses based on the sensor inside the Applicator The Label Sensor Model setting must match the sensor model inside the Applicator Once the Label Sensor Model has been selected performing a Factory Defa...

Page 45: ...Factory Default Screen to appear Choosing Reset To Factory Default values causes the Select Restore Default Type menu to appear as shown above The Partial selection allows the operator to retain the s...

Page 46: ...light will be on when the Applicator is ready to label PRODUCT This is where the Product Detect Sensor is connected LOW LABEL When the Low Label Option is used the Sensor is connected here EOW This is...

Page 47: ...GENERAL SETUP PROCEDURES 5 1 360a SERIES SETUP PROCEDURES...

Page 48: ...by hand will take at least two people The U arm should be rotated down in the position shown to the left Have a person on each side of the applicator with the one on the applicator nose side lifting o...

Page 49: ...els through the Applicator referring to the web path diagram section that applies to your configuration a When going between the Nip and Drive rollers turn the knob on top of the Nip Assembly to sprea...

Page 50: ...or has two detection modes available for instances where the entire leading or trailing edge of the label is similar in contrast to the label gap The terms Leading and Trailing Edge refer to the first...

Page 51: ...details on Label Length and to page 3 3 for changing variables 3 Enter the length and press ENTER If a value of less than 0 125 or more than 32 is entered the display will automatically restore the p...

Page 52: ...eed is the velocity of the label web in inches per minute In a Merge application the Web Speed should be set at the velocity of the product In Tamp or Air Blow applications the Web Speed will vary dep...

Page 53: ...If the label falls off or moves after the label has left the liner the vacuum is too low If the label feed looks smooth go to the next step 5 Work with the air pressure and the position of the Air Ass...

Page 54: ...made 2 Go through the General Setup procedure which is starts on page 6 1 of this Manual 3 Position the Peel Edge so it s between 1 8 and 1 2 away from the product at approximately 20 degrees to the...

Page 55: ...cator Type Menu is exited the Applicator will force the operator to cycle the power to the Applicator before any other changes can be made 2 Place the Applicator as close to the product as you can wit...

Page 56: ...label onto the Grid and tape it in place 2 Turn the power off and remove the Blow Box Cover Arrange the Air Jet Tubes in a symmetrical pattern with most of the Tubes in the center of the label Insert...

Page 57: ...but it may be changed as needed 3 If a longer Air Assist is needed to help position the label enter the Applicator Setup Menu on the Display and press the Ext Air Assist Key here you can enter a valu...

Page 58: ...tion Tamp has a Swing Action to apply a label to the leading or trailing panel of the product and a Tamp Action to apply a label to a side panel of the product The DAT Applicator has three 3 Modes of...

Page 59: ...eded 4 If OK go to Tamp Label Stop 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 val...

Page 60: ...t between 30 and 40PSI This is a typical setting but it may be changed as needed 3 If a longer Air Assist is needed to help position the label enter the Applicator Setup Menu on the Display and press...

Page 61: ...Tamp Extend Time an air blast forces the label off of the Label Pad onto the product In order to keep cycle times low set the Extend Time so that the air blast occurs when the slide reaches the fully...

Page 62: ...l Placement Time or Distance When the First Label Placement is finished the Applicator will blow the label off the Pad onto the front of the product At the same time the Label Pad swings home and the...

Page 63: ...amp or Swing Times are selected both Extend and Retract Timers are accessible for changing The Extend Timers determine how long the Tamp or Swing valves are on before the air blast occurs The Extend T...

Page 64: ...Pump at 20 PSI 6 Air Blast Time is set through the Display and should be set long enough to apply a label firmly to the product Setting the time too high results in fewer labels min a value to start a...

Page 65: ...for Tamp Only Action Position the Applicator with the Tamp Assembly extended and the label pad approximately 1 8 away from the product Jog several labels onto the product If the label stack is within...

Page 66: ...st the Slide Body Some minor changes may be required before applying labels but this will get the label close to the desired position PRODUCT DETECT SENSRO POSITION Before going through this section m...

Page 67: ...CT SENSOR SETUP Banner SM312LV 1 Plug the Sensor into the back of the Applicator 2 Turn the power on and disable the Tamp if applicable 3 Remove the back cover of the Sensor and set the light dark swi...

Page 68: ...Time or Distance before the Applicator will apply a label Label Placement Value gives you the ability to adjust where the label is applied on the product More Label Placement label moves back on the p...

Page 69: ...sing the Compensated Label Placement to lag behind the current Label Placement a Warning will be given to raise the Label Placement Value ENCODER MOUNTING The method of coupling the Encoder to the con...

Page 70: ...GENENRAL MAINTENANCE 8 1 360a SERIES GENERAL MAINTENANCE PROCEDURES...

Page 71: ...for loose screws rollers etc WEEKLY MAINTENANCE 1 Clean rollers Blow Box Grid Label Pad and Peel Edge of adhesive build up and dust 2 Examine air lines and connections to make sure there are no leaks...

Page 72: ...tion 5 Examine Pulleys for wear 6 Perform the monthly maintenance section DANCER ARM ADJUSTMENT The Dancer Arm maintains tension on the label liner and operates the Brake on the Unwind Mandrel when la...

Page 73: ...nd Spring from the Drive Roller Shaft 5 If you re replacing the Slip Clutch Disk remove the Thrust Bearing and walk the Rewind Belt off of the Slip Clutch Pulley Slide the Pulley for the Rewind off th...

Page 74: ...Motor Mounting Plate using a 5 32 Allen wrench 6 Push the Motor Mount Assembly upward and re tighten mounting screws Make sure the Motor Assembly is 90 degrees from the Faceplate to insure proper angu...

Page 75: ...SPLAY BOARD REPLACE DISPLAY BOARD WITH THE POWER SWITCH ON COOLING FAN ON DISPLAY MAKE SURE THE DRIVE IS RUNNING CALL A FACTORY REPRESENTATIVE IS STUCK ON THE STARTUP SCREEN LABEL LINER BREAKING LABEL...

Page 76: ...T BACK TOGETHER LABEL DOES ADVANCE BUT DOES NOT LABEL SENSOR NEEDS SET UP REFER TO LABEL SENSOR SETUP STOP IN THE SAME PLACE EVERY IN THE LABEL SETUP DISPLAY TIME OR DOES NOT STOP IN THE SECTION OF TH...

Page 77: ...HAFT 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...

Page 78: ...BEL 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 EXAMINE AND CORRECT INCORRECT EXTENDED AIR ASSIST TIME BOT...

Page 79: ...r your application Amp Fault If this occurs there has been a failure on the Drive Board The factory should be consulted if this occurs E Stop In the future the operator will be allowed to enable the E...

Page 80: ...ering the unit off and restarting the system Typically this situation occurs when the Display Cable is loose or unplugged DISPLAY WRITE ERROR When necessary the Controller attempts multiple reads or w...

Page 81: ...L DETECTION The Low Label Detection Accessory is a Sensor that generates a signal when the Unwind is low on labels The Applicator will display an Alarm Status Box at the Main Menu it will also activat...

Page 82: ...LINE RATE COMPENSATION This Kit includes an Encoder and Interface Cable Splitter Cables may be purchased to allow one 1 Encoder to drive multiple Applicators CLEAR LABEL SENSOR A Label Sensor is avail...

Page 83: ...6 LONG PE CO1020 1 214 3508 16 3 X 10 POWER CORD BELDEN MP DR1007 1 STEPPER MOTOR CONTROLLER MP IN1013 1 APPLICATOR TOUCH SCREEN ASS 200A 1034 or 1 STEPPER MOTOR BLACK 5 amp ASS 200A 1036 1 HIGH TORQU...

Page 84: ...200 0134 1 UNWIND BEARING BLOCK ASSEMBLY RECOMMENDED SPARE PARTS 16 20 NON POWERED UNWIND Part Number Recommended Qty Description SAS 200 0135 or 2 5 TENSION ROLLER ASSEMBLY w o SHAFT SAS 200 2135 or...

Page 85: ...ASS 200 0460 1 PROXIMITY SWITCH PE FU2065 1 3 AMP FUSE PE MC1109 1 MOTOR DRIVER CONTROLLER PE MO1008 1 LEESON GEAR MOTOR PE PO1030 1 5K SPEED POTENTIONMETER PE RE1063 3 RELAY PE RE1013 1 SOLID STATE...

Page 86: ...tion PM T1000 or 1 UHMW TAPE FOR 5 PEEL EDGE 5 7 16 Wide x 7 Lg PM T1015 1 UHMW TAPE FOR 7 5 10 PEEL EDGE 8 Wide x 7 Lg ASS 215 0110X X or 1 5 WIPER ASSEMBLY specify length material ASS 215 2110X X or...

Page 87: ...specify length material ASS 215 5110X X 1 10 WIPER ASSEMBLY specify length material RECOMMENDED SPARE PARTS Part Number Recommended Qty Description MP 211 0217 7 1 AIR ASSIST TUBE THIS IS JOB SPECIFIC...

Page 88: ...T DC SOLENOID PM VA2396M 1 60 PSI AIR ASSIST REGULATOR PM VA2397M 1 120 PSI TAMP BLOW REGULATOR ASS 211 0112M 1 RVB 2 STATION VALVE BANK ASSEMBLY WEAR ITEM Part Number Recommended Qty Description PM T...

Page 89: ...ber Recommended Qty Description MP 211 0217 7 1 AIR ASSIST TUBE THIS IS JOB SPECIFIC EXTENDED SPARE PARTS Part Number Recommended Qty Description PM FIL1010 1 WATTS FILTER PM VA2395M 1 5 4 WATT DC SOL...

Page 90: ...terial RECOMMENDED SPARE PARTS Part Number Recommended Qty Description MP 211 0217 7 1 AIR ASSIST TUBE JOB SPECIFIC EXTENDED SPARE PARTS Part Number Recommended Qty Description PM FIL1010 1 WATTS FILT...

Page 91: ...erial ASS 215 5110X X 1 10 WIPER ASSEMBLY specify length material RECOMMENDED SPARE PARTS Part Number Recommended Qty Description PM SA0950 2 SHOCK ABSORBER PM SA0990 1 SHOCK ABSORBER HOME PM SA1000 1...

Page 92: ...CHANGE SLIDE TRANSITION PLATE OPTIONS RECOMMENDED SPARE PARTS SMART TAMP PHOTOEYE Part Number Recommended Qty Description PE SE0985 1 SM312W QD SENSOR JOB SPECIFIC OPTIONS RECOMMENDED SPARE PARTS SMA...

Page 93: ...BALL BEARING PE FU2065 1 3 AMP FUSE PE MC1109 1 MOTOR DRIVER CONTROLLER PE MO1008 1 LEESON GEAR MOTOR PE PO1030 1 5K SPEED POTENTIONMETER PE RE1001 1 24VDC RELAY IDEC PE RE1012 1 CROUZET RELAY PE SI1...

Page 94: ...ANGEOVER 1 Remove the nose assembly See NOSE ASSEMBLY REMOVAL 2 Change the applicator nose assembly to the opposite hand dispense See NOSE ASSEMBLY CHANGEOVER 3 Remove the rewind assembly from the app...

Page 95: ...W BOX NOSE ASSEMBLY INSTALLATION 1 Make sure that the peel edge assembly is removed from the blow box nose assembly 2 Install the blow box nose assembly using the six 10 mounting screws making sure th...

Page 96: ...lding the nose assembly to the housing MERGE NOSE ASSEMBLY INSTALLATION 1 Rotate the first stage of the merge nose downward to gain access to the 10 mounting screws 2 Install the merge nose assembly u...

Page 97: ...bly to the housing TAMP NOSE ASSEMBLY INSTALLATION 1 Make sure that the peel edge assembly is removed from the tamp nose assembly 2 Install the tamp nose assembly using the six 10 mounting screws 3 In...

Page 98: ...ee APPLICATOR PEEL EDGE CHANGEOVER 3 Re mount the peel edge assembly to the opposite side of the nose assembly mounting plate On a merge applicator re install the bronze washers between the peel edge...

Page 99: ...adjustment stop must be reversed on the mounting bar as well 5 Remove the air assist tube and insert through the opposite side of the mounting plate and re attach BLOW BOX GRID FAN ASSEMBLY CHANGEOVE...

Page 100: ...facing the same direction as it was originally 4 Remove the label tension spring mounting bar and remount on the opposite side The tension spring and the adjustment stop must be reversed on the mount...

Page 101: ...d transition plate 2 Remove the pulley from the shaft making sure to note its position relative to the end of the shaft 3 Remove the snap ring from the pulley side of the assembly and push the rewind...

Page 102: ...13 1 360 APPLICATOR DRAWINGS 360a SERIES CE MECHANICAL AND ELECTRICAL DRAWINGS...

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Summary of Contents for 360a series

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CTM 360a series, Maintenance And Service Manual

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