ASTRO ATS-9900 Operator'S Manual Download

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ASTRO

ATS-9900

TABBER, LABELER,

AND STAMP AFFIXER

Operator Manual

Summary of Contents for ATS-9900

Page 1: ...ASTRO ATS 9900 TABBER LABELER AND STAMP AFFIXER Operator Manual ...

Page 2: ...er equipment 9 Make sure there is no strain on power cord caused by jamming it between equipment walls or furniture 9 DO NOT remove covers Covers enclose hazardous parts that should be accessed by a qualified service representative Report any cover damage to your service representative 9 This machine requires periodic maintenance Contact your authorized service representative for required service ...

Page 3: ...t 17 Version 18 Diagnostic 18 Notes before Programming 19 Job 19 Sensor 20 V Tab Tab Sensor Setup 20 Automatic Tab Sensor V Tab Adjustment 21 Manual Tab Sensor V Tab Adjustment 23 Tab Position Setup 25 Manual Tab Positioning 25 Manual Tab Positioning Features 25 Automatic Tab Positioning 28 Automatic Tab Positioning Features 28 Manual Product Length Input 30 Applying Roll Labels 31 Applying Fan Fo...

Page 4: ...__________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ ___________________________________________________________...

Page 5: ... labels or stamps on this Reel Assembly 5 Unwind Drive Roller Drives tab web 6 Head Lock Thumbscrew Locks Head Assembly in position for operating 7 Head Fine Adjustment Knob Used to make minute adjustments to tab or label side to side position 8 Applicator Head Applies tab label or stamp to media 9 Control Panel Control and program Tabber 10 Media Thickness Adjustment Operator can raise or lower H...

Page 6: ...ts Transport media through Tabber 6 Safety Interlock Switches Prevent Tabber from operating when Tab Pressure Cover is open DO NOT DISABLE THESE SWITCHES AS SEVERE INJURY CAN RESULT 7 Non Operator Side Tab Folding Guide Folds tab under media when tabbing from rear of Tabber 8 Media Forwarding Rollers Forward media while tab is being applied 9 Tab Pressure Rollers Press tab to underside of media to...

Page 7: ...rmed of Tabber status 7 KEYPAD Used to set adjustments and program the Tabber 8 EMERGENCY STOP BUTTON Stops Tabber Must be turned to release it so Tabber will start running 9 SOFT KEYS Used to step through various menu options to program Tabber 10 STOP KEY Stops Tabber and holds it in a ready state to resume operation 11 RUN KEY Use to start Tabber when running a job 12 INFO KEY Changes display to...

Page 8: ...RONGLY RECOMMENDED THAT TWO TECHNICIANS INSTALL TABBER HEAD TO BASE 1 Place open slot of Head Unit over nylon bushing on Base Unit Head Unit has to be tilted at an angle to accomplish this 2 Lower Head into position over Head Adjusting Guide There are two flats cut into Adjusting Guide One at top 1 and one on left hand side 2 Head Frame should rest in top flat 1 and against left hand flat 2 When H...

Page 9: ...2 wide up to 4 wide and Post it notes 1 Install Applicator Head by sliding it up into cutout between Head Frame and Head Adjusting Guide Attach Applicator Head to frame using two screws 4 supplied Mounting holes in frame are oval shaped When installing Applicator Head hold in uppermost position when tightening screws Slots in frame permit Head to be mounted in a lower position for thin media 2 Rou...

Page 10: ...TALLATION 6 3 Install grommet 8 in slot provided in Motor Cover 4 Connect Reel Brake Connector to two pin connector on top of Head Assembly 5 Mount Reel Assembly to top of Head and fasten it with three screws supplied ...

Page 11: ...le 2 Plug other end into a 115 220 Volt AC 50 60 Hz grounded outlet CAUTION DO NOT USE ADAPTER PLUGS OR EXTENSION CORDS TO CONNECT TABBER OR FEEDER TO WALL RECEPTACLE DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT WITH LARGE ELECTRICAL MACHINES OR APPLIANCES FF 14 Feeder and Feeder Base Install Feeder Base Guides Before using the FF 14 Feeder insta...

Page 12: ...e 3 Attach Feeder Guide using rubber feet removed in Step 1 Install Feeder Base Guide on Tabber Feeder Guide 1 Fit channel on Feeder Base Guide over the flange on the Tabber Feeder Guide A NOTE Make sure the Feeder Base and Tabber are at the same level 2 Place the Feeder on the Feeder Base Insert the Feeder s rubber feet into the recesses on the surface of the Feeder Base B 3 Slide the Feeder and ...

Page 13: ...wer head is used for tabbing and stamp affixing Wider head is used for labels over 2 wide up to 4 wide and Post it notes 1 Raise Head Assembly to its uppermost position Unplug Applicator Head Connector from rear of Tabber 2 Remove cable and gromet from Rear Top Cover 3 Remove two Allen screws that attach Applicator Head to Head Assembly Frame and remove Head Assembly Install other Head and reassem...

Page 14: ...pring so it lightly touches tab backing 4 Continue threading leader under Idler Roller then through slot in Tab Label Sensor and Applicator 5 Bring leader back up and under Idler Roller 6 Lift Drive Roller Cover and Drive Press Roller Thread leader under Driver Cover Guide Roller over Drive Roller and under Drive Press Roller Close Drive Roller Cover and bring Drive Press Roller into contact with ...

Page 15: ...into position for tabbing To adjust these Guides 1 Place one of the two Media Guides next to Fixed Media Guide Then place Adjustable Guide next to it as shown at right 2 Two Media Guides 1 should be just resting on Belts Too much pressure will cause media to stall while being fed Additionally Guides should be positioned between 1 8 and 1 4 from edge of media to prevent edges from curling Center Me...

Page 16: ...djustable Guide so Rollers push media against Fixed Media Guide and media travels straight along Fixed Guide Turning Knob on this Guide counterclockwise causes Adjustable Rollers to push media against Fixed Guide Turning Adjustment Knob clockwise causes Rollers to exert less push on media toward Fixed Guide When running media on opposite side of Tabber adjustment is reversed Adjusting Tab Position...

Page 17: ...6 Check positioning of tab or tabs on piece and adjust Fine Positioning Knob 2 to center tab on piece Turning Knob clockwise will place more of tab on bottom of piece Turning Knob counterclockwise will place more of tab on top of piece 7 When you are satisfied with tab positioning run the job Operating Tabber Start up Tabber in the following sequence 1 Check that Emergency Stop button is released ...

Page 18: ...ct Automatic Tab Sensing Program and to access more information regarding soft key menus 4 Press RUN key located below soft keys on Control Panel to start Tabber Adjust Speed Control to set Tabber speed Press STOP key located below soft keys to stop Tabber Pressing large Emergency Stop button shuts down entire Tabber and locks out other keys To restart from an Emergency Stop release button by turn...

Page 19: ...gency Stop Button then 1 Press Job soft key 2 Select Job 1 4 you wish to run For this example select Job 2 3 Select Option to Edit screen appears Press RUN key on Control Panel to start Tabber NOTE To check setup press and hold INFO key on Tabber Control Panel and a screen appears containing settings and adjustments for the job you are running ...

Page 20: ...n mail piece measures from leading edge of mail piece to leading edge of tab stamp TabV Voltage on Sensors when a tab is present under Sensors Clear and Opaque Tabs will have different voltage readings Trip Voltage used to determine threshold activation point between Tab and Backing to cause tab to feed Tab Type Two tab types Clear and Opaque See Appendix B for samples 1 Pressing RUN key changes s...

Page 21: ...keys They are as follows Control Panel Backlight Control Panel Backlight intensity can be controlled from the Advanced soft key To access Backlight Control screen press Advanced key then Backlight key Use two arrow keys to adjust intensity of backlight Click BACK key to return Tabber to operating mode 50 is normal setting ...

Page 22: ... Stamps applied by tab head BIOS Version Software version currently loaded into Tabber BACK Returns you to Advanced features screen Diagnostic Diagnostic function is for use by Technical Representative to diagnose possible problems with Tabber Each screen performs a specific check of a function of Tabber It should only be used by a trained technician See Diagnostics at end of Troubleshooting Secti...

Page 23: ...amming a job Job When Job soft key is pressed jobs 1 4 already programmed and saved can be selected Or select 1 4 to set up a new job Up to four jobs can be programmed into Tabber s memory NOTE Overwrite any programmed jobs by simply reprogramming Job selected with new job parameters Once desired Job is selected Select Setup Options screen appears V Tab Used to set Tab Sensor Voltages for your tab...

Page 24: ...up Option screen NOTE If wrong Sensor is selected media will run through Tabber without being tabbed or stamped V Tab Tab Sensor Setup Every time a new Tab stock is used or a new job is set up you must also set up Tab Sensors for Tab stock From Select Setup Option screen press V Tab Tab Sensor Setup screen appears You can set up Tab Sensors automatically using Automatic key or manually First we ll...

Page 25: ...o tab using Job screen 3 Select Job Number 1 4 to use In this example select Job Number 1 4 From Select Setup Option screen select V Tab 5 Select Automatic from Tab Sensor setup screen 6 Select Tab Type before calibration screen appears Select type of tab either Opaque or Clear based on table below In this example select Opaque ...

Page 26: ... the liner between each tab Once Tab Type is selected Tabber Transport starts and screen at right appears Adjust Speed Control on Tabber up or down until Feed 1 Product now appears in display Feed one piece from Feeder into Tabber Two or three tabs will be applied to the piece then Tabber will stop and display new V Tab values Tab Sensor is now set up for this tab stock IMPORTANT IN ORDER FOR TABB...

Page 27: ...ct Setup Option screen Select V Tab 5 Manually programming V Tab voltage Begin by finding Gap V or voltage return from space between tabs in this case Release Hold Down Roller Latch so tabs can slide easily through Sensor Move tab web through Sensor until you obtain the lowest voltage reading then press Gap V key 1 Continue moving tab web through Sensor until you obtain the highest reading then pr...

Page 28: ...rify proper threading transport setup media length tab type and tab pitch settings IMPORTANT WHEN SETTING GAP VOLTAGE AND TAB VOLTAGE MANUALLY SOFTWARE WILL DETERMINE IF TAB TYPE IS OPAQUE OR CLEAR BASED ON VOLTAGE READINGS YOU SELECT Tab Type Description Gap V Level Tab V Level Opaque Tabs in which the space between tabs is lighter than the tab even if the tab is white Low High Clear Tabs with a ...

Page 29: ...omatic key follows Manual Tab Positioning Manual Tab Positioning Features Pressing Manual soft key from Select Setup Option screen puts Tabber into manual positioning mode In this mode operator manually sets offset value position for each tab being applied Select option to edit screen appears Tabs Select to set number of tabs to apply to media Position Select to set position offset values for each...

Page 30: ... Allows individual adjustment of each tab position via Offset Value Together Used for Stamps Stamps are placed next to each other starting at Offset Value see below set for Tab 1 BACK Returns to previous screen Pressing Position prompts you to set Offset Value for each Tab starting with Tab 1 Offset Value Distance from leading edge of mail piece to leading edge of Tab NOTE If you only set Tabs for...

Page 31: ...ess SAVE key Press BACK Repeat this process for each tab position IMPORTANT TAB POSITION IS BASED ON PLACEMENT OF THE BEGINNING OF TAB WITH RESPECT TO LEAD EDGE OF THE PIECE WHEN PLACING TABS LENGTH OF THE TAB IS NOT CALCULATED Set Pitch Pitch is very important Pitch setting is how software determines how far to advance tab When Pitch soft key is pressed display prompts you to Enter Tab Pitch and ...

Page 32: ...n 0 5 from each edge 3 Tabs Two tabs are applied within 0 5 from each edge and one tab is centered When Automatic is selected the following choices appear Tabs Allows you to choose Number of Tabs to apply to media Product L Set Paper Length of media you are using Pitch Set Tab Pitch distance from top of one tab to top of next tab for Tab stock used BACK Returns to previous screen When Tabs soft ke...

Page 33: ...pieces through Tabber NOTE Feeding more than one mail piece will cause an incorrect length to be measured and set After piece is fed through Tabber Tabber will stop and display piece length Verify measurement It must be accurate or 0 250 If Tabber measures piece to be longer than the actual piece length then media may be slipping or hesitating as it feeds Check Adjust transport system If Tabber me...

Page 34: ...n Control Panel 2 Enter this Value in inches and tenths of an inch using numeric key pad 3 Press SAVE key to accept and save this value 4 Press BACK soft key to return to previous screen Pitch Pitch is very important Pitch setting is how software determines how far to advance tab When Pitch soft key is pressed display prompts you to Enter Tab Pitch and press SAVE key Pitch Distance measured from t...

Page 35: ...ay has to be installed in order to run fan folded labels on Tabber Follow these steps 1 Remove any labels or tabs that may be installed on machine 2 If Labels are Over 2 Wide up to 4 Wide Replace 2 Tab Label Applicator Head with 4 Tab Label Applicator Head 3 Remove Roll Guide 1 and Roll Core Support 2 from Tabber Roll Core Support is held in place by an Allen screw 4 Install Label Tray over spindl...

Page 36: ...am job refer to Program Job Single Tab instructions Fan Folded Labels Over 2 Long CAUTION WHEN RUNNING LABELS OVER 2 LONG TABBER SPEED MUST BE SET TO 10 000 PIECES PER HOUR OR LESS Install Long Fan Folded Label Tray to run fan folded labels over 2 long up to 4 long on Tabber Steps required are below 1 Remove any labels or tabs that may be installed on Tabber 2 If Labels are Over 2 Wide up to 4 Wid...

Page 37: ...Tray Adjust Side Guide 4 to within 1 16 of labels 7 Thread labels over top of Tray in direction of arrows and then down through two Guide Rods 5 as shown Hook Label Plate 6 over Top Guide and behind Lower Guide but in front of labels 8 Thread labels behind Tab Bin 7 down and around Applicator Head then up and over Feed Drum to Take up Spool NOTE DO NOT THREAD LABELS THROUGH TAB UNWIND ROLLER AND D...

Page 38: ...pplying a stamp to an envelope is similar to applying labels Main difference is in positioning of the stamp in the proper place on the envelope Applying Multiple Stamps Multiple stamps should be treated the same as applying a single stamp or label Use the same programming procedure as with applying multiple tabs Select up to three Tabs Stamps then select Together instead of Separate This permits y...

Page 39: ...___________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ __________________________________________________...

Page 40: ...t free cloth using any standard nonabrasive household cleaner that does not contain plastic harming solvents CAUTION NEVER SPRAY OR POUR CLEANERS DIRECTLY ON OR INTO THE TABBER EXCESS LIQUID COULD HARM ELECTRONIC PARTS ALWAYS DAMPEN A RAG WITH THE CLEANER AND APPLY IT TO PARTS TO BE CLEANED Rollers and Transport Belts Belts and Rollers can become glazed with paper lint and ink from media Clean reg...

Page 41: ...AB SENSOR TAB WEB SENSOR Located under this plate Lubrication Several locations on Tabber require regular lubrication 1 Apply white lithium grease to four Head Raising Cams 2 Apply white lithium grease to Head Raising Drive Assembly Gears as shown ...

Page 42: ...MAINTENANCE 38 NOTE Access Gears shown at right by removing Front Cover Panel from Tabber 3 Lightly apply a thin coat of light machine oil to two Tabber Head Guide Rods to insure smooth operation ...

Page 43: ..._________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ ______...

Page 44: ...Guides are not pressing down too firmly on media 3 Check that Adjustable Center Guide is not pushing paper tightly against Fixed Side Guide 4 Check that head pressure is not too tight Tab Placement Problems CONDITION SOLUTION Tabs are not placed in same spot on media Tabs should be placed within 1 8 1 Check pitch setting for tab It should be slightly more than tab size plus space between tabs 2 Ch...

Page 45: ...le tabbing one tab is not placed properly on edge of media 1 Media may not be traveling along Fixed Side Guide Adjust angle of Guide Rollers by turning Knob on Skew Guide 2 Check pressure between Head and Transport Too much pressure causes media to flex as it is transported 3 Too little pressure can cause media to skew as tab is being applied Two or three tabs applied next to each other Programmin...

Page 46: ...d label is not aligned on media 1 Media may not be traveling along Fixed Side Guide Adjust angle of Guide Rollers by turning Knob on Skew Guide 2 Check pressure between Head and Transport Too much pressure will cause media to flex as it is transported Two or three labels applied evenly spaced Programming issue When applying labels make sure that you select one label rather than two or three Severa...

Page 47: ... on media 1 Media may not be traveling along Fixed Side Guide Adjust angle of Guide Rollers by turning Knob on Skew Guide 2 Check pressure between Head and Transport Too much pressure causes media to flex as it is transported Two or three stamps applied evenly spaced Programming issue When programming multiple stamps Separate was selected instead of Together Reprogram the job More than three stamp...

Page 48: ...sts in order are 1 Voltage Test Displays voltages in power supply and logic When you press Test ON V 1 should be 12 0 volts for main power supply V 2 V 3 and V 4 are voltages on logic board Press EXIT to return to Voltage Test screen or Next to proceed to next test 2 Encoder Test Tests if Encoder is working When you click Test ON a number will display in Reading Rotate Exit Roller if number change...

Page 49: ... OFF Pressing Test ON causes Servo Motor to turn ON You should be able to hear this action Press Next to proceed to next test 4 Tab Supply Test Tests function of Tab Web Sensor In Test OFF Drive is OFF Motor not running and Brake is ON Tab Brake is locked Clicking Test ON turns Drive ON Motor running and turns Brake OFF Tab Brake unlocked Click Next to go to next test ...

Page 50: ...ange from UNCOVERED to COVERED Press Next to proceed to Media Sensor Test 7 Media Sensor 1 Test Tests that Media Sensors 1 and 2 are working properly Pressing Sensor key toggles between Sensor 1 and Sensor 2 Insert a piece of paper between Sensor and reflective lens Display should change from UNCOVERED to COVERED Press Next to proceed to Keyboard Test 8 Keyboard Tests keyboard function Each time y...

Page 51: ...ber of Tabs 1 2 or 3 Tab Accuracy 1 8 3 mm Production Counters and Displays Life and Job Count and Production rate and speed Error Reporting YES Features Right to Left or Left to Right Operation Specify when ordering Can apply multiple stamps Safety Interlocks on all adjustments Emergency Stop Switch Dimensions ATS 9900 27 W x 33 D x 37 H 67 cm x 84 cm x 94 cm ATS 9950 27 W x 33 D x 71 H w Console...

Page 52: ...Sensor Test 46 Motor Test 45 Tab Sensor Test 46 Tab Supply Test 45 Voltage Test 44 Web Loop Sensor Test 46 E Emergency Stop Button 3 Encoder Test 44 F Fan Folded Labels Applying 31 Fan Folded Labels Over 2 Long 32 Fan Folded Labels Up to 2 Long 31 Feeder Guides 7 Install 7 Feeder Aligning 11 H Head and Reel Assembly 2 Head Fine Adjustment Knob 1 Head Lock Thumbscrew 1 Head Power Switch 3 I Info Ke...

Page 53: ...or Automatic Adjustment 21 Manual Adjustment 23 Tab Sensor Test 46 Tab Supply Test 45 Tab Label Applicator Head Install 5 Tabber Applicator Head 9 Automatic Tab Positioning 28 Cleaning 36 Diagnostics 44 Feeder Guides 7 Install 7 Lubrication 37 Maintenance 36 Manual Product Length Input 30 Manual Tab Positioning 25 Multiple Stamps Applying 34 Operate 9 13 Program 17 Single Stamps Applying 34 Specif...

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