LABEL-AIRE 3115NV Manual Download Page 3

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TABLE

CONTENTS

INTRODUCTION……………………………………………………………………………………………………………………………………………………………………

CAUTIONARY

SYMBOLS

AND

PICTOGRAMS…………………………………………………………………………………………………………………………..

INITIAL

WARNINGS…………………………………………………………………………………………………………………………………………………………...

APPLICATOR

POWER

CABLE……………………………………………………………………………………………………………………………………………..

MECHANICAL

PLACEMENT

THE

MACHINE…………………………………………………………………………………………………………………...

GENERAL

MACHINE

INFORMATION…………………………………………………………………………………………………………………………….

CONTROL

PANEL…………………………………………………………………………………………………………………………………………………………………

MICROPROCESSOR

MESSAGES……………………………………………………………………………………………………………………………………

MACHINE

SEQUENCE…………………………………………………………………………………………………………………………………………………..

TOOL

LIST…………………………………………………………………………………………………………………………………………………………………………..

CONNECTION

A.C.

POWER…………………………………………………………………………………………………………………………………….

INITIAL

SET

UP…………………………………………………………………………………………………………………………………………………………..

LABEL

SET

UP…………………………………………………………………………………………………………………………………………………………….

LABEL

SENSOR

EDGE…………………………………………………………………………………………………………………………………………………………

LABEL

REPEAT

LENGTH……………………………………………………………………………………………………………………………………………………..

LABEL

STOP

POSITION………………………………………………………………………………………………………………………………………………..

IMPRINTER

INSTALLED………………………………………………………………………………………………………………………………………………………

PRINTER

DWELL

TIME………………………………………………………………………………………………………………………………………………………..

ENCODER

PULSE

RESOLUTION…………………………………………………………………………………………………………………………………………..

SPEED

FOLLOWING……………………………………………………………………………………………………………………………………………………………

PRODUCT

SET

UP……………………………………………………………………………………………………………………………………………………………….

POSITIONING

THE

APPLICATOR…………………………………………………………………………………………………………………………………………

INITIAL

SET

UP………………………………………………………………………………………………………………………………………………………….

UPRIGHT

AND

ABOVE

ATTITUDE……………………………………………………………………………………………………………………………..

for parts & service call QLC (800) 837-1309

Summary of Contents for 3115NV

Page 1: ...2010 3115NV Manual 3115NV Rev 01 P N 7408830 100 for parts service call QLC 800 837 1309 ...

Page 2: ...2 for parts service call QLC 800 837 1309 ...

Page 3: ...PROCESSOR MESSAGES 21 MACHINE SEQUENCE 23 TOOL LIST 24 CONNECTION TO A C POWER 25 INITIAL SET UP 26 LABEL SET UP 27 LABEL SENSOR EDGE 31 LABEL REPEAT LENGTH 32 LABEL STOP POSITION 33 IMPRINTER INSTALLED 35 PRINTER DWELL TIME 36 ENCODER PULSE RESOLUTION 37 SPEED FOLLOWING 38 PRODUCT SET UP 40 POSITIONING THE APPLICATOR 41 INITIAL SET UP 41 UPRIGHT AND ABOVE ATTITUDE 43 for parts service call QLC 80...

Page 4: ...48 Figure 15 ALLEN BRADLEY 49 Figure 16 PEELER PLATE ALIGNMENT 51 Figure 17 PRODUCT DETECTOR POSITION 53 Figure 18 BRAKE ASY UNWIND 59 Figure 19 LABEL SENSOR PEEL TIP ASY 59 Figure 20 LOW LABEL ALARM ADJUSTMENT 62 Figure 21 Low Label Detector 64 Figure 22 WRAP UNIT ADJUSTMENT 68 Figure 23 PRESSURE BAR POSITION 69 Figure 24 PRESSURE BAR IN OUT POSITION 70 Figure 26 PEELER PLATE ALIGNMENT 73 Figure ...

Page 5: ...r safe trouble free operation the instructions in this manual must be carefully followed during set up operation change of rolls cleaning and maintenance Also the specified environmental conditions must be maintained ELECTRICAL SUPPLY 108 132 Volts 5 Amps 54 60 Hertz Single Phase A three meter long three wire cable with 1 00mm conductors rated at 10 amperes in accordance with CENELEC HD 21 is prov...

Page 6: ...oes take time Do not rush through the process careful work will produce good results TRY AGAIN IF SOMETHING DOES NOT WORK Although a machine malfunction is possible most problems happen because the machine is not set up right If the machine doesn t operate correctly back up and try again KNOW HOW TO FIND WHAT YOU NEED This manual contains all of the information needed including a Table of Contents...

Page 7: ...lers Read the text and follow the instructions carefully to avoid an injury This symbol indicates the presence of an uninsulated dangerous voltage within the applicators enclosure This symbol indicates a high noise level is present Ear protection must be worn to avoid hearing loss This symbol indicates that the machine should not be operated unless the covers guards are in place This symbol indica...

Page 8: ...ndicates that you should read the Technical Manual before proceeding I This symbol on an electrical power switch indicates SWITCH ON O This symbol on an electrical power switch indicates SWITCH OFF This symbol indicates the protective EARTH connection for parts service call QLC 800 837 1309 ...

Page 9: ...determined to be The Web Drive Rollers The potential for finger pinch exists between the drive and pinch rollers Keep hands clear of the drive and pinch rollers whenever the machine is ONLINE Enclosure A potential for electrical shock exists if the cover is removed The cover must not be removed except by a qualified service person The power switch is to be turned OFF O and the power cord removed p...

Page 10: ...e of the applicator The other end connects to the customer s properly grounded and polarized power outlet Figure 1 115V Power Cable 220V applicators are shipped from the factory with an unterminated power cord An appropriate grounding polarized plug will need to be installed on the power cord Use the drawing below to wire in the appropriate grounding polarized plug for use in your facility Figure ...

Page 11: ...ort base that is mounted on casters the maximum overturning moment that can be experienced when the floor is non horizontal must be considered in the design of the support Some safety agencies specify that for a truly portable stand that the design should consider safely supporting the applicator in its worst orientation for a 10 degree tilt Also the casters should have locks to prevent inadverten...

Page 12: ...12 Figure 3 Applicator Support Structure for parts service call QLC 800 837 1309 ...

Page 13: ...ACHINE INFORMATION Figure 4 3115NV APPLICATOR Do not connect the machine to the AC power source or the compressed air service until directed to do so in the set up procedures for parts service call QLC 800 837 1309 ...

Page 14: ...14 i Figure 5 Electrical Panel Rear of Machine for parts service call QLC 800 837 1309 ...

Page 15: ... IMPAXX MACHINE SYSTEMS LABEL AIRE NEW 3000 SERIES Then OFFLINE PRODUCTS PER MINUTE XXXX 1 The ENABLE button will put the machine in ONLINE mode for normal operation or OFFLINE mode for set up The FEED button will feed a label The ENTER button 5 will select the displayed menu item 1 X denotes a numeric value for parts service call QLC 800 837 1309 ...

Page 16: ...ange the menu level from Operator to either Advanced or Service simultaneously press both the LEFT and RIGHT buttons then enter the ACCESS CODE for the desired menu level The Advanced level allows set up of the machine for different label and product types The Service level allows configuration of machine specific items such as the type of machine and activates any options the machine is equipped ...

Page 17: ... This adjusts the display contrast This value can be set from 0 to 50 CPU VERSION AND DATE This displays the CPU version number and the date of the software This is informational only these items cannot be changed ADVANCED LEVEL LABEL SENSOR TO PEEL TIP DISTANCE Enter the distance between the cross hairs on the label sensor to the tip of the peeler bar This value can be set from 1 0 to 40 0 inches...

Page 18: ...tween product detection and the application of the label This value can be set from 1 00 to 40 00 inches PRODUCT DETECTOR LOCKOUT This function allows you to set a distance during which the applicator will ignore any product inputs Use this function when the product detector is generating false detection signals and the applicator cycles more than once per product If not needed set this to its min...

Page 19: ...from 1 to 50 Label pages can be set up for each label type SERVICE MENU MACHINE TYPE This can be set to 3111NV 3114NV 3115NV 3125 3135 or 3155 This manual covers the 3115NV machine type UNITS Set this to IMPERIAL English or METRIC as desired LANGUAGE This can be set to ENGLISH SPANISH FRENCH PORTUGUESE or GERMAN Set as desired SPEED FOLLOWING Set this to YES if an encoder is being used NO otherwis...

Page 20: ...ed to each product or NO otherwise When set to YES it allows the setting of LABELS PER PRODUCT in the Advanced menu SKIP LABELING PRODUCTS Set this to YES if you do not wish to label every product or NO otherwise When set to YES it allows the setting of PRODUCT SKIP in the Advanced menu RESTORE FACTORY DEFAULTS Pressing ENTER will restore this menu level Service to the default values UPGRADE SYSTE...

Page 21: ...product UNWIND ERROR This message occurs only when the Powered Unwind option is installed and the unwind motor is constantly on This indicates a broken web REWIND ERROR This message occurs only when the Powered Rewind option is installed and the rewind motor is constantly on This indicates a broken web MISSING LABELS This message is displayed when CONSECUTIVE MISSING LABEL COUNT labels have not be...

Page 22: ...g label calibration SEARCH FAIL This message is displayed if the automatic label calibration fails LABEL PAGE X This message indicates the label page that the machine is set to use or change NO LABELS FOUND This message indicates that the label sensor isn t sensing labels This may be due to a break in the label stock CONSECUTIVE MISSING LABEL COUNT or more labels missing from the liner a malfuncti...

Page 23: ...Product detector detects the edge of the product 4 LABEL ON PRODUCT POSITION distance elapses 5 Label apply begins 6 Label detector detects the edge of the label 7 Label apply ends 8 Label feed ends LABEL STOP POSITION for parts service call QLC 800 837 1309 ...

Page 24: ...nch size Inch size tools are required as follows HEX HEAD WRENCHES OPEN END WRENCHES SCREWDRIVERS 1 16 inch 7 16 inch 1 Phillips 1 8 inch 3 32 inch flat blade 3 16 inch 3 32 inch 5 32 inch 7 64 inch 9 64 inch 11 4 inch for parts service call QLC 800 837 1309 ...

Page 25: ... before applying power or damage to the equipment may result 1 Turn OFF O the applicator POW ER switch 2 With both ends of the A C power cord disconnected connect one end of the A C power cord to the IEC receptacle on the side of the applicator 3 Connect the remaining end of the A C power cord to the electrical mains for parts service call QLC 800 837 1309 ...

Page 26: ...to YES only if an encoder is being used Set to NO otherwise Measure the distance between the cross hairs on the label sensor and the peeler bar tip Enter this value into LABEL SENSOR TO PEEL TIP DISTANCE Set LABEL STOP POSITION to 0 Set LABEL ON PRODUCT POSITION to 0 Set LABELING SPEED to 1000 Press the CUSTOM key until one label gap has passed the sensor then release the CUSTOM key The Applicator...

Page 27: ...ine as shown in Figure 9 or Figure 10 Make sure to thread the label liner through the label sensor 7 Lay the end of the liner over the quick release rewind mandrel and turn the mandrel by hand to take up any slack 8 Turn the rewind mandrel by hand Check that the inner edge of the label liner aligns with the inner unwinds disk and the rewind disk Adjust the positions of the inner unwind disk and th...

Page 28: ...28 Figure 7 Peeler Plate Detail for parts service call QLC 800 837 1309 ...

Page 29: ...29 Figure 8 Threading Diagram Right Hand for parts service call QLC 800 837 1309 ...

Page 30: ...30 Figure 9 Threading Diagram Left Hand for parts service call QLC 800 837 1309 ...

Page 31: ...AIL which designates for the leading or trailing edge of the label 3 The display should read LEAD unless the label has an odd shaped leading edge and a straighter trailing edge If this is the case select TRAIL 4 Set the LABEL SENSOR EDGE setting as required Go on to the Label Repeat Length Section for parts service call QLC 800 837 1309 ...

Page 32: ...abel is missing or the label sensor isn t working properly If CONSECUTIVE MISSING LABEL COUNT labels in a row are missing the microprocessor will stop the machine This item is set up automatically during label calibration but may be set manually if required 1 Place the machine ONLINE 2 Measure the label and gap between labels 3 Set the LABEL REPEAT LENGTH to the measured value Go on to the Label S...

Page 33: ...em 3 Press and release the FEED key to advance a label NOTE if the encoder is not turning while you re doing this step the SPEED FOLLOWING function of the microprocessor must be OFF or the label will not feed 4 Check the position of the label on the peeler plate One label should be completely dispensed and the leading edge of the next label should extend 1 16 inch beyond the peeler plate 5 Press a...

Page 34: ...el if the label isn t positioned correctly repeat step 4 NOTE If the label is still flagged out too far when the display is at its minimum value move the label sensor to the other position Go on to the Imprinter Installed Section for parts service call QLC 800 837 1309 ...

Page 35: ...ompleted before the next label feed begins 1 Place the machine OFFLINE 2 Select the IMPRINTER INSTALLED menu item 3 Set IMPRINTER INSTALLED to NO if the machine does not have an imprinter Set IMPRINTER INSTALLED to YES if the machine has an imprinter Go on to the Imprint Dwell Section if IMPRINTER INSTALLED was set to YES Otherwise go on to the Velocity Compensation Section for parts service call ...

Page 36: ...ard this section if IMPRINTER INSTALLED is set to NO Continue with the Product Set Up Section If IMPRINTER INSTALLED is set to YES refer to the Options Section of the manual for instructions for parts service call QLC 800 837 1309 ...

Page 37: ...ers If an encoder is used set this value to number of encoder pulses per inch of conveyor product travel This value only needs to be changed if the circumference of the encoder wheel changes or if the encoder resolution is changed Go on to the Product Set Up Section for parts service call QLC 800 837 1309 ...

Page 38: ... cause the Label on Product Position to fluctuate accordingly This function provides compensation for wide variations in web speed so that the Label on Product Position remains constant regardless of web speed An encoder must be installed to use this function Go on to the Product Set Up Section for parts service call QLC 800 837 1309 ...

Page 39: ...39 3115NV RH 3115NV RH for parts service call QLC 800 837 1309 ...

Page 40: ... the order that they are given PRODUCT SET UP Place the machine offline before you perform the following procedures or you may be injured by the moving drive roller This is a general outline to cover basic set up procedures when you are using your own product handling system and applicator mounting Make sure that the following items are correct before adjusting the position of the applicator for p...

Page 41: ...e inconsistently presented to the label applicator Out feed rails should be set to allow the products to exit smoothly and quickly with no backlog If you re using only one applicator to label the side of a product the rails should be positioned to move the product to the applicator Front and back applicator systems should have the products oriented in the center of the conveyor d Adjust the Hold D...

Page 42: ...e adjustments go on to the Applicator Nose Alignment Section This section explains how to prepare the applicator for set up with labels There are two common operation attitudes for the 3115NV applicator Reels Up and Upright and Above A Reels Up machine labels the side of a product while an Upright and Above machine labels the top of the product Follow the instructions below for your machine NOTE I...

Page 43: ...p of the product 3 Adjust the side to side angle of the applicator so that the peeling edge of the peeler plate is parallel to the surface of the product that will be labeled Re check the angle after you have tightened the U arm bolts NOTE Whenever you adjust the applicator or the applicator peeler plate position make sure that the conveyor and the conveyor chain top never touch the peeler plate C...

Page 44: ...8 inch away from the highest point of the product labeling surface Tighten the noise assembly height adjustment screws If necessary use the U arm to reposition the entire applicator See Figure 13 Figure 10 Nose Tilt Adjustment NOTE It is important that the peeler plate be at a 15 25 angle to the top of the product and that the peeling edge of the peeler plate be 1 8 inch from the tallest point of ...

Page 45: ...r s angles and distances are correct and secure go on the Product Sensor Section Figure 12 Nose Height Adjustment Figure 11 Nose Height Adjustment Figure 12 Upright and Above Attitude for parts service call QLC 800 837 1309 ...

Page 46: ... plate at the approximate height that you want labels applied 3 Position the applicator nose at a 15 25 angle to the side of the conveyor see Figure 14 Adjust the angle by loosening the kip lever shown in Figure 11 moving the peeler plate to the proper angle and then tighten the kip lever 4 Adjust the applicator so that the peeler plate edge is parallel to the side wall of the product Loosen the m...

Page 47: ...ck to see that both peeler plate tips are even and in line with each other If they re not choose either the right or left hand applicator loosen the kip lever and move the peeler plate to the correct position The angles on both nose assemblies should still be at the initial 15 25 set up If they re not both applicator noses must be re set until they have the correct angle are even and in line with ...

Page 48: ...ay be injured by the moving drive roller Figure 14 Wiring for PNP and NPN Detectors The following instructions are for the Label Aire standard product detector P N 7600005 802 Follow the manufacturer s instructions for set up if another model product detector is used for parts service call QLC 800 837 1309 ...

Page 49: ...he detector will indicate that the detector and reflector are in alignment Secure in position 6 If the orange indicator is also lit use a 1 16 inch flat blade screwdriver to turn the sensitivity adjustment screw counterclockwise until the orange indicator goes out 7 Use the screwdriver to turn the sensitivity adjustment screw clockwise until the orange indicator just goes on 8 Place a product betw...

Page 50: ...r a low value i e 0 4 for PRODUCT DETECTOR LOCKOUT Exercise caution when cycling the machine Keep hands away from the drive rollers 4 Try running products at this low value If the false detections are not eliminated increase the value for PRODUCT DETECTOR LOCKOUT and try again Continue to slowly increase the setting until the false detections are eliminated NOTE If the value for PRODUCT DETECTOR L...

Page 51: ...roduct handling system is adjusted to present the products to the applicator in a repeatable manner at a steady pace 2 The applicator peeler plate tip is parallel to the product surface to be labeled See Figure 17 3 The peeler plate tip is 1 8 inch from the surface to be labeled See Figure 17 Figure 16 PEELER PLATE ALIGNMENT for parts service call QLC 800 837 1309 ...

Page 52: ...o close the leading edge of the product early either reposition the product detector further downstream or increase the LABEL ON PRODUCT POSITION setting Refer to Figure 15 5 Place one product on the conveying system 6 Place the machine ONLINE and watch as the label is applied 7 Stop the conveyor Check where the beginning of the label was applied to the product 8 If the label was applied too close...

Page 53: ...nu item Set PRODUCT DETECTOR LOCKOUT as low as it will go The PRODUCT DETECTOR LOCKOUT value is always a minimum of 0 25 inch greater than the LABEL ON PRODUCT POSITION The LABEL ON PRODUCT POSITION is measured in 0 01 inch increments 12 Place one product on the conveyor Place the machine ONLINE 13 Start the conveyor and watch as the label is applied to the product Stop the conveyor for parts serv...

Page 54: ...he product in inches Multiply that measurement by 100 Example 8 inches x 100 800 Set PRODUCT LOCKOUT to the calculated value 15 Repeat steps 12 13 and 14 Re adjust the PRODUCT DETECTOR LOCKOUT if needed 16 Place two properly spaced products on the conveyor Make sure that the machine is ONLINE 17 Start the conveyor and apply labels to both products If the DETECTOR LOCKOUT message remains on the dis...

Page 55: ...the machine Keep hands away from the drive rollers 1 Place the machine ONLINE 2 Turn the conveyor ON and apply labels to products 3 Observe the label registration on the products Make any adjustments required 4 After the machine set up is verified place the machine OFFLINE Go on to the Set Up Record Section for parts service call QLC 800 837 1309 ...

Page 56: ...56 for parts service call QLC 800 837 1309 ...

Page 57: ...ou perform the following procedures or you may be injured by the moving drive roller 1 Make sure that the current microprocessor settings consistently apply the label accurately on the product 2 Place one label in the space provided 3 Fill in the date name of the person who set up the applicator and the product to be labeled 4 Measure and record the distance from the peeler bar tip to the product ...

Page 58: ...esired position or proximity 1 o clock and then slightly tighten the Allen screws so the collar will still move on the shaft then using 5 32 T handle push collar clockwise slightly to set into position tighten the screws back down As shown on page 59 figures 1 2 NOTE The outer collar has no adjustments the break tension is set with the dancer arm adjustment for parts service call QLC 800 837 1309 ...

Page 59: ...59 BRAKE BAND SPRINGS Figure 18 BRAKE ASY UNWIND Figure 19 LABEL SENSOR PEEL TIP ASY for parts service call QLC 800 837 1309 ...

Page 60: ...60 OPTIONS The following pages contain the instructions for the set up and operation of the optional equipment available on this machine for parts service call QLC 800 837 1309 ...

Page 61: ...pply the loss of label detection or other problems SET UP LOW LABEL DETECTOR The low label detector is a photoelectric sensor which triggers the alarm light when the supply of labels is almost exhausted Use the following procedure to check the function of the Low Label Detector Exercise caution when cycling the machine Keep hands away from the drive rollers 1 Place the machine ONLINE NOTE The alar...

Page 62: ...nt of label supply remaining on the unwind roll when the alarm light activates 1 Place the machine OFFLINE 2 Rotate the unwind roll of labels until the slot in the inner unwind disk is directly in front of the low label detector Notice the red spot on the label supply The red spot is generated by the detector and is the alarm trigger point 3 Use a 9 64 inch hex head wrench to loosen the low label ...

Page 63: ... clip against the cable to open the window 4 Gently slide the L D Operate switch on the back of the detector to D away from the retaining clip for Dark Operation 5 Use a 3 32 inch hex head wrench to loosen the detector Slide the detector in or out until the red spot is sharply focused on the label stock Secure in position The green light on the rear of the detector will light A The green LED on th...

Page 64: ...cted onto the label roll Remove the outer unwind disk and move the label roll away from the low label detector The green LED on the rear of the detector must go out and the yellow LED will light Adjust the gain adjustment if necessary and repeat this procedure 10 Snap the window cover closed on the detector 11 Perform the Low Label Alarm Trigger Point procedure The only set up involved for the web...

Page 65: ...ly when the supply of labels is exhausted or the LOW LABEL STOP COUNT is reached WEB BREAK The web break alarm occurs when the label sensor does not detect the number of labels entered in CONSECUTIVE MISSING LABEL COUNT or when the label detector does not see a gap during one LABEL REPEAT LENGTH When the microprocessor detects this fault condition it will shut down the applicator s labeling functi...

Page 66: ... 500 encoder pulses All speed matching calculations are based on this relationship When mounting the encoder it is imperative to maintain this relationship Five inches of product travel equals one revolution of the encoder shaft wheel In installations where the Label Aire encoder wheel cannot be used another drive arrangement is useable only if the five inch of product travel per encoder shaft rev...

Page 67: ...ot equipped with the encoder option the LABEL WEB SPEED must be set to match the wrap belt speed not the conveyor speed WRAP UNIT ALIGNMENT The wrap unit must be positioned so that the wrap belt is parallel to the product See Figure 21 Place a product on the conveyor next to the wrap belt If necessary loosen the mounting screws Adjust the jack screws to position the wrap belt parallel to the side ...

Page 68: ...68 Figure 22 WRAP UNIT ADJUSTMENT for parts service call QLC 800 837 1309 ...

Page 69: ...that provides proper product guidance into the wrap unit The point where the bend begins should be directly across or slightly before the in feed radius of the wrap belt See Figure 19 The proper positioning of the pressure bar will ensure stable product position at the entrance of the wrap unit Figure 23 PRESSURE BAR POSITION for parts service call QLC 800 837 1309 ...

Page 70: ...l to the product 5 If necessary loosen the mounting screws and adjust the jack screws so that the pressure bar is parallel to the side of the product Tighten the mounting screws 6 Position the pressure bar 1 3 to the height of the product See Figure 24 7 Make sure that the pressure bar is parallel with the conveyor chain top from in feed to out feed See Figure 24 8 Position the pressure bar agains...

Page 71: ...71 Figure 25 Pressure Bar Position for parts service call QLC 800 837 1309 ...

Page 72: ...igure 21 and adjust as needed Figure 25 GUIDE RAIL SKEW APPLICATOR ADJUSTMENTS 1 Remove the peeler plate brush 2 Position the applicator so that the peeler plate tip is 1 4 to 3 8 inch from the tangent of the wrap belt See Figure 20 NOTE If necessary re locate and re align the wrap unit 3 Adjust the tilt of the applicator so that the peeler tip is parallel to the wrap belt See Figure 27 Lock in po...

Page 73: ...ITION so that the label stops at the end of the peeler plate tip See Figure 21 5 Adjust the position of the product detector so that the label contacts the wrap belt at the same moment that the product contacts the wrap belt for parts service call QLC 800 837 1309 ...

Page 74: ...74 APPENDICES The following appendices contain supplemental information that may be helpful for day to day operation of the machine for parts service call QLC 800 837 1309 ...

Page 75: ...rs 6 Thread the web through the machine as shown in Figure 28 or Figure 29 Make sure to thread the label liner through the label sensor 7 Lay the end of the liner over the quick release rewind mandrel and turn the mandrel by hand to take up any slack 8 Turn the rewind mandrel by hand Check that the inner edge of the label aligns with the inner edge of the vacuum grid Adjust the positions of the in...

Page 76: ...76 APPENDIX B SET UP RECORD SHEET for parts service call QLC 800 837 1309 ...

Page 77: ...77 for parts service call QLC 800 837 1309 ...

Page 78: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 79: ...79 for parts service call QLC 800 837 1309 ...

Page 80: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 81: ...81 for parts service call QLC 800 837 1309 ...

Page 82: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 83: ...83 for parts service call QLC 800 837 1309 ...

Page 84: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 85: ...85 for parts service call QLC 800 837 1309 ...

Page 86: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 87: ...87 for parts service call QLC 800 837 1309 ...

Page 88: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 89: ...89 for parts service call QLC 800 837 1309 ...

Page 90: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 91: ...91 for parts service call QLC 800 837 1309 ...

Page 92: ... LABELING SPEED LABEL STOP POSITION LABEL ON PRODUCT POSITION ADVANCED MENU LABEL SENSOR TO PEEL TIP DISTANCE FAST RISE LENGTH LABEL REPEAT LENGTH FLAT AREA LENGTH LABEL SENSOR SETTING WEB RATIO LABEL SENSOR EDGE SLEW SPEED CONSECUTIVE MISSING LABEL COUNT PRINTER DWELL TIME PRODUCT SENSOR EDGE PRODUCT DETECTOR LOCKOUT LOW LABEL STOP COUNT ZERO DOWN TIME NUMBER OF PRODUCTS TO SKIP NUMBER OF PRODUCT...

Page 93: ...tions exist the outputs are brought to zero volts PIN CONDITION SIGNAL NAME RESET BY 1 Low Label OFFLINE 2 End of Web OFFLINE 3 Unlabeled Product OFFLINE 4 Offline 5 24 Volts 6 Label on Pad 7 Web Break OFFLINE 8 Tamp Back 9 24 Volts CHASSIS GROUND for parts service call QLC 800 837 1309 ...

Page 94: ...94 Figure 27 I O WIRING Example for parts service call QLC 800 837 1309 ...

Page 95: ...ow PIN CONDITION SIGNAL NAME OUTPUT TYPE RESET BY 1 Ready PNP 2 Ready FET 3 Warning Low Label Unlabeled Product PNP OFFLINE 4 Warning Low Label Unlabeled Product FET OFFLINE 5 Fault End of Web Web Break Offline PNP OFFLINE 6 Fault End of Web Web Break Offline FET OFFLINE 7 24 Volts 8 Ground 9 Reserved for parts service call QLC 800 837 1309 ...

Page 96: ...s for which these speeds are used The distance that the label stock must travel at the line speed is the fast rise length Flat area length is the distance for which the label stock needs to travel at a slower speed Web ratio a percentage of the line speed is the speed at which the label will travel during flat area steps length Consider the elliptical product in Figure 31 Notice that the parts of ...

Page 97: ...that is large enough to compensate for the greater curvature of the product The value for Fast Rise Length will depend upon the length of the label applied to the curvature of the product Figure 33 shows two identical products with two different length labels Product 1 has a short label This means that very little of the label will be applied over the steeply curved portion of the product and that...

Page 98: ...ive roller 1 Select the WEB RATIO menu item 2 To begin set the WEB RATIO to 85 Remember that this value is only an estimate and may be changed later FAST RISE LENGTH FLAT AREA LENGTH ESTIMATION The FAST RISE LENGTH and FLAT AREA LENGTH are the values that the microprocessor uses to adjust the speed of the labels to compensate for the curvature of the product Some experimentation is necessary to fi...

Page 99: ... The estimated Flat Area Length is the label length less two times the estimated Fast Rise Length See Figure 34 Example If the label length is 3 1 4 inches and the estimated Fast Rise Length is 5 8 inch 625 then the estimated Flat Area Length is 3 25 2 625 2 8 Multiply the estimated Flat Area Length by 100 to convert the measurement to hundredths of inches Example 2 x 100 200 9 Select the FLAT ARE...

Page 100: ...st Rise Length and run some more products Repeat until the leading edge label placement is consistent 3 If the leading edges of the label were applied at the required position on the product go on to step 4 If the leading edge of the label is applied at the incorrect position adjust the LABEL ON PRODUCT POSITION setting or re position the product detector Run some more products Repeat until the le...

Page 101: ...Web Ratio set the Web Ratio to the value noted above Go on to step 6 6 Increase the Flat Area Length slightly and run some more products Repeat until the wrinkle is removed 7 If the labels are applied wrinkle free from lead edge to trail edge go on to step 8 If small horizontal wrinkles appear on the trailing edge of the label the Flat Area Length is too long Slightly decrease the Flat Area Length...

Page 102: ...102 for parts service call QLC 800 837 1309 ...

Page 103: ...s instructions for performing ordinary maintenance and adjustments on the 3115NV applicator The procedures recommended in the periodic maintenance sections are detailed in the Adjustments Section for parts service call QLC 800 837 1309 ...

Page 104: ...he following procedures or you may be injured by the moving drive roller 1 Examine peeler bar and rollers for excessive adhesive build up Clean if necessary using alcohol or other similar solvent 2 Wipe down the exterior surface of the machine for parts service call QLC 800 837 1309 ...

Page 105: ...s and pulleys or receive an electric shock 1 Clean all rollers remove adhesive and paper dust using solvent alcohol or equivalent 2 Clean peeler bar 3 Clean dust from all photoelectric cells and lamps 4 Check generally around the machine for any evidence of loose screws rollers fixtures etc Tighten as necessary for parts service call QLC 800 837 1309 ...

Page 106: ... belts and pulleys or receive an electric shock 1 Examine dancer arm tension adjust if necessary 2 Check the Nolu tape on the peeler bar for wear cuts or other damage Replace if necessary 3 Examine the rewind slip clutch disk and o ring and clean or replace as necessary 4 Examine all roller assemblies for free rotation excessive play etc and correct as necessary 5 Check the motor drive shaft belt ...

Page 107: ...ean inside and outside machine enclosure using an industrial vacuum cleaner NOTE Using air pressure from the shop air supply to blow off dust etc can create more problems than it solves There is a good possibility that this air will contain water and emulsified oil If you must use compressed air be sure that it is adequately filtered and regulated to low pressure and remove the electronic module 2...

Page 108: ...ear Check the stability of roller mounts and motor mounts 2 Examine timing belts for damage Replace if necessary 3 Replace the rewind slip clutch disk and o ring in the rewind station assembly Clean all friction faces on the rewind and check for wear Replace the slip clutch disk and or o ring as necessary 4 Check the one way clutch on the rewind shaft for correct operation 5 Examine pulleys for we...

Page 109: ... should be added or subtracted one at a time until proper drive is achieved Conditions that may warrant adjustment of the rewind slip clutch are 1 A change in applicator attitude Example 1 Reels up 2 Upright and above 2 A change in label carrier size Example 1 one inch 25mm web Narrow 2 4 6 inch 101 152mm web Wide 3 A change in the manual speed of the applicator NOTE Depending on the attitude of t...

Page 110: ...ver Remove the enclosure cover 5 Use a 1 Phillips screwdriver to remove the screw from the end of the drive shaft 6 Carefully remove the flat washer and the compression spring 7 Install one flat washer P N 7101697 to increase the rewind drive or remove one flat washer to decrease the rewind drive 8 Carefully re install the compression spring the flat washer and the screw Tighten the Phillips screw...

Page 111: ...111 Figure 33Rewind Slip Clutch for parts service call QLC 800 837 1309 ...

Page 112: ...m the A C power 3 Disconnect the A C power cord from the IEC receptacle on the machine 4 Turn the four pinch roller set screws in clockwise by the same amount to increase the pinch roller pressure or out counterclockwise to decrease the pinch roller pressure The pinch roller tension should be just enough to feed the web through the machine without the web slipping 5 Reconnect the A C power cord to...

Page 113: ...rcuit board 4 Refer to Figure 38 Locate jumpers H2 and H3 Place jumpers on both pins 5 Connect a nine pin female to nine pin female straight through serial cable from the serial port on the computer to the comm port on the applicator 6 Start the Flash Simple program on the computer The first time you use Flash Simple you must set it up Device Name H8S 2357F 20 Mhz Interface Name Direct Connection ...

Page 114: ...wer from the applicator 12 Disconnect the nine pin serial cable 13 Remove the two jumpers from H2 and H3 14 Replace the back cover 15 Apply power to the applicator SETTING UP THE APPLICATOR 1 Select the Machine Type from the Factory Menu 2 If the applicator has the Powered Rewind option set POWER REWIND to YES NO otherwise 3 Set the UNITS to the desired value 4 set the values in the Supervisor men...

Page 115: ...115 Figure 35 Control Board H2 H3 location for parts service call QLC 800 837 1309 ...

Page 116: ...ing correctly 131 11 Label liner breaking 131 8 Machine functions at random without being initiated 130 7 Applicator runs after missing CONSECUTIVE MISSING LABEL COUNT or more labels 130 6 Machine will not cycle Message reads BROKEN WEB 130 5 Label placement on the product is consistently poor 128 4 Label advance occurs but fails to stop or is erratic 127 TROUBLESHOOTING for parts service call QLC...

Page 117: ...ualified assistance to repair the defective unit Loose connectors Examine and correct POWER switch defective Examine and replace 2 Display board does not light Cable from the display not plugged into the microprocessor on back of the unit Inspect and reconnect Defective display Replace the display or request qualified assistance 3 Label advance does not occur Control motor defective Replace the co...

Page 118: ...correctly Refer to the set up procedures for instruction Label sensor out of alignment Refer to the set up procedures for instruction Label sensor lens blocked or contaminated Clean using a lens brush Marginal label detection point Move label sensor to alternate mounting hole Label sensor assembly loose Connecting wires to the label sensor loose or damaged Tighten to eliminate movement Check for d...

Page 119: ...of labels Label Stop Position is out of adjustment Investigate and correct Peeler bar angle is incorrectly positioned Refer to the set up procedures for alignment instructions Label sensor incorrectly positioned odd shaped labels Refer to the Label Sensor Detection Point Section Label sensitivity incorrectly adjusted Refer to the set up procedures for instruction Label detection edge setting incor...

Page 120: ...oduct Position setting delay Refer to the set up instructions Unsuitably positioned product detector Refer to the set up instructions Fluctuation of product conveyor speed Investigate and correct Inadequate product guidance Adjust product guides as necessary Mold release agent on products Check manufacturer for recommendations for mold release agent removal Shape variations from product to product...

Page 121: ...inch roller not engaged Engage the pinch roller 7 Applicator runs after missing CONSECUTIVE MISSING LABEL COUNT or more labels Incorrect Label Repeat Length Refer to the Label Repeat Length Set Up 8 Machine functions at random without being initiated Product detector loose or vibrating Investigate and repair as necessary Product detector alignment or adjustment marginal Refer to the set up procedu...

Page 122: ...amine and repair Refer to General Maintenance for information One way rewind clutch not operating Replace rewind shaft assembly Broken drive belt Replace as necessary On Powered Rewind version Potentiometer not set up or damaged Investigate and correct Encoder sensor blocked by contamination Investigate and correct 11 Label liner breaking Incorrectly threaded labels Thread the labels correctly Dan...

Page 123: ...correct Investigate and correct operation of unwind brake dancer arm Adjust dancer arm spring or adjust tension if necessary Peeler bar label tension spring too tight Adjust with knob Examine spring and replace if damaged Adhesive build up on the peeler bar or label tension spring Clean as necessary and examine the label roll for damage A damaged roll can cause excessive adhesive build up Replace ...

Page 124: ...ves through the machine Detection Points The point of the label or product that causes the label or product sensor to signal the machine Disk The flat plastic circle which holds the roll of labels on the supply mandrel Display Board The LED display above the keypad Display The portion of faceplate that shows the microprocessor messages Encoder Pulses The measurement of conveyor travel the number o...

Page 125: ...uipment that is not required to operate the machine but can be purchased and employed with the machine to accomplish some additional task e g imprinter P S I G Pounds per square inch gauge BAR PSIG 14 4 Peeler Bar The flat bar that the separates the label from the label liner as the label stock slides around it Photocell A device that varies the intensity of an electric current according to the am...

Page 126: ...tch A clutch that disengages by slipping when there is enough tension on the driven part Thread Sequence The manner in which the label stock is threaded through the machine rollers Trailing Edge The last edge of the product or label to leave the detection beam VAC Volts A C Alternating Current Web See Label Stock for parts service call QLC 800 837 1309 ...

Page 127: ...oder 23 25 30 38 42 43 56 71 72 127 131 133 Encoder pulses 23 42 71 133 Encoder wheel 23 42 71 Gain control 133 General machine information 15 Glossary i 8 133 Guide rails 46 Imprint dwell 40 Imprinter 22 23 39 41 134 Index i 8 137 Initial warnings 11 Introduction 7 Label adhesive 133 Label detect edge 32 Label detected 21 Label feed 26 27 40 Label lamp 133 Label liner 32 80 118 128 131 135 Label ...

Page 128: ...128 PRINTS for parts service call QLC 800 837 1309 ...

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LABEL-AIRE 3115NV, Manual

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