LABEL-AIRE Write-up 3138NV-DAT Manual Download Page 37 | Manualshive

Page: 37 / 53

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37

SEMI-ANNUAL MAINTENANCE

Disconnect

the

power

from

the

machine

before

you

perform

the

following

procedures

or

you

may

be

injured

by

the

moving

drive

belts

and

pulleys,

or

receive

an

electric

shock

.

1.

Replace

the

air

filter

elements

and

clean

the

filter

bowl.

2.

Clean

the

inside

and

outside

the

machine

enclosure

using

an

industrial

vacuum

cleaner.

NOTE

:

Do

not

use

air

pressure

from

the

shop

air

supply

to

blow

dust

from

the

machine.

There

is

a

good

possibility

that

this

air

will

contain

water

and

emulsified

oil,

which

could

damage

the

electrical

components

in

your

machine.

3.

Check

the

venturi

muffler

for

debris

accumulation.

Replace

if

necessary.

4.

Check

the

venturi

for

debris

build

‐

up.

Clean

if

required.

5.

For

long

stroke

tamps,

check

the

function

of

the

tamp

back

switch.

Adjust

if

necessary.

6.

For

DAT

machines,

check

the

shock

absorbers

and

stop

plates

for

wear.

Adjust

or

replace

if

necessary.

7.

For

DAT

machines,

check

the

tamp

stops.

Tighten

or

adjust

as

needed.

8.

Perform

the

Daily

and

Weekly

maintenance

.

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Summary of Contents for Write-up 3138NV-DAT

Page 1: ...08 Write up 3138NV DAT Manual with Write Up P N 7408815 150 ...

Page 2: ...cator A In the Advanced Menu dual tamp mode must be set to Yes B The first product detector to encounter the product is Product Detector 1 Product Detector 1 must be connected to the Product Detector 1 connector on the applicator C In the Advanced Menu the SWING TAMP FIRST setting must be set so the appropriate tamp will apply the first label to the product When using a single tamp for front rear ...

Page 3: ...hen the machine is first powered ON the display will read LABEL AIRE PRINT APPLY DAT Software Version 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 1 X denotes a numeric value ...

Page 4: ...ssage after the error condition has been cleared The HELP button has no function at this time MENU LEVELS There are three menu levels Operator Advanced and Service When first powered ON the machine is at the Operator level This level offers only the basic functions that may need to be changed during a product run To change the menu level from Operator to either Advanced or Service simultaneously p...

Page 5: ...oduct detection and the application of the label by the side tamp This value is expressed in distance This value can be set from 00 01 to 40 00 inches SWING TAMP LABEL POSITION When SPECIFIC ACTION TAMP is set to YES this sets the delay between product detection and the application of the label by the swing tamp This value is expressed in distance This value can be set from 00 01 to 40 00 inches L...

Page 6: ...tivate the swing tamp function first and NO will activate the side tamp first When DUAL TAMP MODE is set to NO setting this to YES will activate the swing tamp only Setting this to NO will activate the side tamp only SWING TAMP INVERTED Available only when DUAL TAMP MODE is set to YES Set this to YES for Inverted Swing Tamp operation or to NO for Tamp Blow Swing Tamp operation SWING TAMP EXTEND TI...

Page 7: ...oprocessor the amount of time in milliseconds it takes the tamp to move from the retracted position to the extended position This is required for the Air Blast to occur at the right time This value can be set from 1 to 3000 milliseconds TAMP RETRACT TIME Available only when DUAL TAMP MODE is set to NO This tells the microprocessor the amount of time in milliseconds it takes the tamp to move from t...

Page 8: ...ABELING PRODUCTS is set to YES in the Service menu this value sets the number of products st skip between applying labels This value can be set from 1 to 99 NUMBER OF PRODUCTS TO LABEL If SKIP LABELING PRODUCTS is set to YES in the Service menu this value is set to the number of products to label LABELS PER PRODUCT If MULTIPLE LABELS ON PRODUCT is set to YES in the Service menu this value is set t...

Page 9: ...oder resolution is changed LOW LABEL INSTALLED If set to YES will allow the setting of the LOW LABEL STOP COUNT in the Advanced menu ZERO DOWN TIME INSTALLED Set this to YES if the machine is being used in a Zero Down Time situation or NO otherwise When set to YES it allows the setting of the ZERO DOWN TIME function in the Advanced menu DUAL TAMP INSTALLED Set to YES SPECIFIC ACTION TAMP When set ...

Page 10: ...10 RESTORE FACTORY DEFAULTS Pressing ENTER will restore this menu level Service to the default values UPGRADE SYSTEM Pressing ENTER will install new microprocessor software ...

Page 11: ...ply position See Figure 1 When using two product detectors product Detector 2 must be positioned downstream of Product Detector 1 and should be positioned upstream2 of the retracted side tamp Product Detector 2 must be positioned far enough upstream to allow the side tamp time to reach the fully extended position or the side of the product as the product arrives at the apply position See Figure 1 ...

Page 12: ... REAR APPLI CATOR Product Detector 1 should be positioned upstream3 of the retracted side tamp Product Detector 1 must be positioned far enough upstream to allow the side tamp time to reach the fully extended position or the side of the product as the product arrives at the apply position See Figure 2 When using two product detectors product Detector 2 must be positioned downstream of Product Dete...

Page 13: ...t an appropriate position relative to the fully extended swing tamp and downstream from Product Detector 1 FRONT APPLICATOR Product Detector 1 must be positioned far enough upstream to at least allow the swing tamp time to reach the fully extended position slightly before the product arrives at the apply position See Figure 3 1 Press the custom button till the tamp disable appears on the menu scre...

Page 14: ...e swing tamp time to reach the fully extended position as the product arrives at the apply position See Figure 4 1 Press the CUSTOM button till the disable appears on the menu screen Position product detector 1 at an appropriate position relative to the fully extended swing tamps Figure 4 ...

Page 15: ...ide of the product as the product arrives at the apply position See Figure 5 and Figure 6 1 Press the custom button till the DISABLE appears on the menu screen 2 Refer to Figure 5 or Figure 6 Position Product Detector 1 at an appropriate position relative to the retracted side tamp Figure 5 4 Product Detector 1 can be downstream of the retracted side tamp if the label is applied further towards th...

Page 16: ...16 Figure 6 Product Detector 1 Side Application ...

Page 17: ...ust be opened before any adjustments can be made See Figure 7 Press the flexible retaining clip against the cable to open the cover window 5 Gently slide the UN Operate switch on the back of the detector to L towards the retaining clip for Light Operation 6 Align the product detector with the reflector The yellow light on the rear of the detector will indicate that the detector and reflector are i...

Page 18: ...t Remove the product 10 Snap the window cover closed on the product detector The detector is ready for use PRODUCT DETECTOR 2 In specific mode operation product detector 2 operates the second tamp in the apply sequence Follow the same set up instructions for Product Detector 1 except connect the second detector to the Product Detector 2 connector ...

Page 19: ...t and side the side and rear and single tamp configurations Follow the appropriate instructions below FRONT AND SIDE CONFIGURATION Refer to Figure 8 1 Press the CUSTOM button till the tamp disable appears on the menu screen 2 Enter the advanced menu Figure 8 Label Placement Front ...

Page 20: ...e the distance X by the conveyor speed per second The resulting number is the approximate LABEL ON PRODUCT POSITION Use the UP and the DOWN buttons to set the LABEL ON PRODUCT POSITION to slightly less than the calculated number 8 Set the swing tamp air regulator to 60 P S I 40 bar 9 Manually apply a label at the required position on the side of the product 10 Position the lead edge of the product...

Page 21: ... Placement Side 13 Remove the label from the product and move the product upstream on the conveyor 14 Press the CUSTOM button until tamp ENABLE appears on the menu screen Press FEED to dispense a label onto the tamp pad ...

Page 22: ...ncrease the air blast air pressure to attain a full lay down of the label The SWING TAMP AIR BLAST DWELL may also be increased Setting of the SWING TAMP AIR BLAST DW ELL in excess of 40 milliseconds may not be effective due to the speed of the swing arm 17 Repeat step 15 and watch as the tamp returns to the printer for another label If there is a delay between the swings tamp returning to the stop...

Page 23: ...Press the CUSTOM button till the tamp disable appears on the menu screen 2 Enter the advanced menu 3 Position the lead edge of a product at product detector 1 stop conveyor See figure 10 4 Manually apply a label to the required position on the side of the product 5 Refer to figure 10 Measure the distance between the upstream edge of the tamp pad to the upstream edge of the label on the side of the...

Page 24: ...ure the distance from Product Detector 2 to just beyond the fully extended swing tamp Record the distance B NORMAL MODE 9 Manually extend the swing tamp Measure the distance from Product Detector 1 to just beyond the fully extended swing tamp Record the distance B Distance B is slightly greater than the distance that the product will travel during the SECOND LABEL POSITION time Figure 10 Label Pla...

Page 25: ...E TAMP RETRACT TIME Reduction of this time will reduce the total machine cycle time 16 Repeat step 14 and watch as the label feeds onto the tamp pad If the tamp pad is bouncing when the label begins to feed the TAMP SETTLE TIME must be increased to prevent possible label jams Adjust until the tamp pad is stationary when the label begins to feed The side tamp should fully extend and immediately app...

Page 26: ...ry increase the air blast air pressure to attain a full lay down of the label The SWING TAMP AIR BLAST DWELL may also be increased Setting of the SWING TAMP AIR BLAST DW ELL in excess of 40 milliseconds may not be effective due to the speed of the swing arm 19 After both labels are applied correctly DISABLE the tamp ...

Page 27: ... fault condition 3138NGA ALARM CONDITIONS AND RESPONSES ALARM ONE LIGHT TWO LIGHT CE TWO LIGHT THREE LIGHT CONDITION YELLOW U S CE Low Label Slow Flash Yellow Yellow Yellow Slow Green Out of Label Fast Flash Blue Yellow Red Yellow Blue Low Ribbon Slow Flash Yellow Yellow Yellow Slow Green Out of Ribbon Fast Flash Blue Yellow Red Yellow Blue End of Web or Fast Flash Blue Yellow Red Yellow Blue Web ...

Page 28: ... 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 1 Place the machine ONLINE NOTE The alarm light will not function with the machine OFFLINE 2 Push the dancer arm toward the printer and rotate the unwind roll of labels until the slo...

Page 29: ...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 detector s adjustment screws See Figure 11 4 Decide how much label supply should remain When the low label alarm is triggered Slide the detector to put the red spot at the desired trigger point Tighten the adjustment screws ALLEN BRADLEY LOW LA...

Page 30: ...o 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 Rotate the unwind disk slightly so that the red spot is directed onto the unwind disk The detector s green LED must remain ON Adjust the sensitivi...

Page 31: ...nd the Output Status connectors if an I O card is used Load your label printing information into the printer and send several products down the conveyor Look at the position of the labels on the products to make sure that they are positioned consistently on each one If the labeling is not accurate make sure that the conveyor is presenting the products to the applicator consistently Then review the...

Page 32: ...NG TAMP FIRST PRINTER OPEN SIGNAL SWING TAMP INVERTED PRINTING SIGNAL SWING TAMP EXTEND TIME TAMP BACK SIGNAL SWING TAMP RETRACT TIME LABEL ON PAD SIGNAL SWING TAMP AIR BLAST DWELL LOW LABEL SIDE TAMP EXTEND TIME READY SIDE TAMP RETRACT TIME OFFLINE SIDE TAMP AIR BLAST DWELL ERROR OUTPUT ACTIVE PRODUCT SENSOR EDGE WARNING PRODUCT DETECTOR LOCKOUT REWIND FAILURE SERVICE MENU TAMP OUT SIGNAL TAMP BL...

Page 33: ...33 PRINTER SETTINGS Print the configuration of the printer on a label and affix the label to the back of the page or record the printer settings in the table below PRINTER PARAMETER SETTING ...

Page 34: ...TENANCE This section gives instructions for performing maintenance on the applicator portion of the 3138NVsystem Refer to the printer manual for maintenance instructions about the printer portion of the 3138NV ...

Page 35: ...en roller each time you change the ribbon Refer to the printer manual for detailed instructions 2 Examine air filter visually for evidence of excessive water or oil collection Drain and eliminate the source of oil water if possible 3 Examine the tamp pad and peeler bar for excessive adhesive build up Clean if necessary using alcohol or other similar solvent 4 Check the machine for any evidence of ...

Page 36: ... drive belts and pulleys or receive an electric shock 1 Clean the peeler bar and pad 2 Clean dust from the product detector lens 3 Examine the air supply connections for leakage correct if necessary 4 Wipe down the exterior surface of the machine 5 Examine all roller assemblies for free rotation excessive play etc and correct as necessary ...

Page 37: ... to blow dust from the machine There is a good possibility that this air will contain water and emulsified oil which could damage the electrical components in your machine 3 Check the venturi muffler for debris accumulation Replace if necessary 4 Check the venturi for debris build up Clean if required 5 For long stroke tamps check the function of the tamp back switch Adjust if necessary 6 For DAT ...

Page 38: ... an electric shock 1 Check all the items in the weekly and semi annual maintenance sections 2 Check the rewind drive belt for wear Replace if necessary 3 Examine moving parts for excessive wear Replace any worn parts 4 For long stroke tamps only Remove the tamp rods Clean the tamp rods and the tamp block bearings Re lubricate the tamp block bearings with Aero shell grease 7 ...

Page 39: ... will not stop the unwind mandrel If the strap is too tight the printer s stepper motor must pull against the unwind brake especially near the end of a roll of labels Use the instructions below to adjust the tension of the strap The dancer arm and unwind brake are of little use if the label core spins on the unwind hubs If the label core slips on the unwind hubs apply several labels to the inside ...

Page 40: ...shaft 6 Position the spring retainer so that the strap is held snug on the dancer arm shaft but the tension releases when the dancer arm is pulled by the advancing label stock If the tension is too loose the unwind will not brake properly and a loop of loose label stock will form If the Tension is too tight the printer s stepper motor will be forced to pull against the unwind brake this will put u...

Page 41: ...set swing tamp extend time 500 4 From the Service Menu select tamp blow Yes 5 Press the FEED button to cycle the swing tamp several time and observe the tamp action The swing tamp should move quickly and smoothly without slamming to a stop at either end of travel If the tamp functions properly leave the tamp in Disable mode and press the enter button If the tamp does not move quickly and smoothly ...

Page 42: ...ly but does not crash to a stop and b Adjust the thumbscrew on the retract flow control until the swing tamp retracts quickly but does not crash to a stop NOTE If the tamp fails to fully extend increase the SWING TAMP EXTEND TIME setting 9 Tighten the swing tamp flow control lock nuts 10 Keep the TAMP in DISABLE mode and press the enter key ...

Page 43: ...43 Figure 14 Tamp Flow Control ...

Page 44: ...mming to a stop at either end of travel If the tamp functions properly leave the TAMP IN Disable mode and press the enter button If the tamp does not move quickly and smoothly or if it slams to a stop at either end of travel continue with step 5 5 Locate the side tamp flow controls located on the tamp support assembly 6 Loosen the side tamp flow control lock nuts with a 3 8 inch open end wrench 7 ...

Page 45: ...45 NOTE If the tamp fails to fully extend increase the SIDE TAMP EXTEND TIME setting 8 Tighten the side tamp flow control lock nuts 9 Keep the tamp in Disable mode and press the enter button ...

Page 46: ...beling products of different sizes or when products are presented in various positions relative to the applicator When the tamp extends and encounters the product before the tamp has fully extended the Tamp Interrupt Sensor detects the products When the tamp interrupt sensor detects the product the air cylinder is switched off to return the tamp and the air blast is initiated to apply the label Fi...

Page 47: ... inch from the tamp pad Secure in position The yellow light on the rear of the detector will light Figure 16 Tamp Interrupt Sensor Detail 5 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 6 Use the screwdriver to turn the sensitivity adjustment screw clockwise until the orange i...

Page 48: ...e Tamp Back Sensor signals the printer to print another label The tamp back sensor is mounted to the flow control plate Figure 17 Tamp Back Sensor NOTE An incorrectly adjusted Tamp Back sensor can override the function of the Tamp Interrupt sensor ...

Page 49: ...crewdriver to turn the sensitivity adjustment screw clockwise until the yellow light on the rear of the detector lights 4 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 5 Use the screwdriver to turn the sensitivity adjustment screw clockwise until the orange indicator just goes...

Page 50: ...ts for an 11 16 inch open end wrench The barrel of the shock absorber is designed to be used as a mechanical stop The barrels of the shock absorbers act as the travel limit for the retracted tamp assembly and for the extended swing tamp The cushioning setting is set by a lockable rotating dial at the end of the shock absorber The dial setting is locked in place by a set screw using a 1 16 inch hex...

Page 51: ...ly remove the set screw There is a nut plate inside the shock absorber that may be irretrievable Figure 20 Tamp Back Shock Absorber 6 Set the cushioning setting dial to 9 Lock the set screw 7 Thread the shock absorber into the mounting bracket Do not tighten the jam nut 8 Manually retract the tamp assembly Adjust the position of the shock absorber so that the fully retracted tamp pad has retracted...

Page 52: ... air service 2 Pull the tamp assembly to the extended position 3 Refer to Figure 21 Loosen the swing tamp shock absorber jam nut 4 Thread the shock absorber completely out of the mounting bracket 5 Loosen the locking set screw 1 4 to 1 2 turn on the shock absorber setting dial NOTE DO NOT completely remove the set screw There is a nut plate inside the shock absorber that may be irretrievable 6 Set...

Page 53: ...o that the fully extended swing tamp has rotated 900 when the shock absorber rod end button contacts the shock absorber barrel Tighten the jam nut in position 9 Connect the compressed air service and cycle the swing tamps to check the full extension Make additional adjustments as required ...

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