AFINIA LABEL AF200 User manual

AF200
FLAT SURFACE
APPLICATOR
USER MANUAL
V.2.02

Contents
1. Introduction.......................................................................................................................5
Using the applicator .............................................................................................................5
2. Setting up the Applicator...................................................................................................6
In the box.............................................................................................................................6
Specification ........................................................................................................................6
Parts of the Applicator - Figure 1.1.......................................................................................6
3. General safety instructions ...............................................................................................8
4. Operating instructions.......................................................................................................9
Setup...................................................................................................................................9
Power up..............................................................................................................................9
Determination of parameter value ‘Offset stop’.....................................................................9
Loading a label roll and calibrating the label sensor.............................................................9
Container positioning .........................................................................................................10
Working with the menu and changing parameters..............................................................10
Testing and fine tuning settings..........................................................................................10
Labeling.............................................................................................................................11
Errors.................................................................................................................................11
Adjusting the display..........................................................................................................11
Information service menu...................................................................................................11
5. Offset stop - 1 label mode...............................................................................................12
6. Offset stop 1, Offset stop 2 - 2 label mode......................................................................13
7. Loading labels ................................................................................................................15
8. Calibrating the label sensor ............................................................................................16
9. Adjusting the height of the Upper Applicator Assembly...................................................17
10. Container positioning and magnet adjustment ............................................................18
11. User menu and changing parameters..........................................................................19
Select mode ‘ONE LABEL’.................................................................................................19
Select mode ‘TWO LABELS’..............................................................................................19
12. Working with the service menu and setting parameters ..............................................20
13. Errors and Troubleshooting .........................................................................................22
14. Adjusting the brightness and the contrast of the display..............................................24
15. Information Menu - Counters.......................................................................................25
16. Information Menu - Inputs...........................................................................................25
17. Maintenance and cleaning ..........................................................................................26
18. Service........................................................................................................................26
19. Warranty.....................................................................................................................27
20. Transportation.............................................................................................................28
21. Disposal of the machine..............................................................................................28
22. Regulatory Details.......................................................................................................29
23. Technical Support.......................................................................................................30

4
Following symbols are found in this user manual
Read the User Manual!
Follow safety warnings and instructions!
Protect yourself from electric shock. Danger to life!
Keep children away from the machine while in operation!
Risk from electric shock when a power cord or plug is damaged!
Dispose the packaging and the appliance in accordance with
environmental regulations!
!

5
1. Introduction
Before using the machine for the first time, get acquainted with the
functions of the machine and be informed about the correct operation with
electrical appliances. Read the following operating instructions. Follow the
instructions in the manual. When handing over the machine to third
parties, hand over all documentation.
Using the applicator
This applicator is designed to apply one or two self-adhesive labels (front and back) on
containers/boxes with flat surfaces or slightly curved surface. Labels should be on one roll, and
in case of 2 label applications, front and back labels should be in correct order.
Place the container on the machine table and adjust the guides to position the container.
Adjust the start and stop position and press start the button or use the foot pedal. The machine
applies labels to the container.
Any other use is considered unlawful and generates significant risks of accidents. The
manufacturer accepts no responsibility for faults and damages caused by use contrary to the
indicated instructions.
The electrical protection of the machine is accomplished by a protective sheath of the
current-carrying parts and bygrounding ofthe metal housing. This requires the useof a straight
electrical outlet (socket). Overcurrent protection is provided by fuses built into the machine.
Their replacement should be performed byqualified personnel.
Attention!
Do not place any larger or smaller containers on the machine than
those specified in the technical data! Do not use damaged
containers or containers which have irregular shapes. There is a
danger of being injured.
Do not use labels with sizes beyond those specified in the
specifications! Loading labels, maintenance and cleaning should
only be performed with the power off!
Do not cover the ventilation openings of the machine! Be careful not to
spill liquid on the machine!
Do not insert objects into the openings of the machine! There is a
danger of electric shock!
Do not place your hand or fingers on the shafts of the machine!
There is a danger of injury!
Attention!
In case of electric shock, immediately disconnect power from the
machine.
!
!

6
2. Setting up the Applicator
In the box
- AF200 Flat Surface Applicator
- Power cable
- Foot pedal
- Operation manual
Specification
Supply voltage: North America - 110V AC, 60 Hz —Europe, Middle
East, Asia - 220V AC, 50Hz
Power consumption: <100VA.
Dimensions: 11.8" (300mm) W, 16.8" (426mm) H, 27.5" (700mm) D
Machine weight: 50 lbs (23kgs)
Dimensions of platform: 11.8" (300mm) W, 11.8" (300mm) D
Field for labeling: 4.13" (105mm) W, 8.25" (210mm) D
Height of container: 1 to 7.87 inches (25 to 200mm) (thinner objects can be
labeled with a spacer
Label length: 1" (25mm) to 8.25" (210mm)
Width of label roll: 1" (25mm) to 4.13" (105mm)
Label Gap: > 0.1 inches (2.5mm)
Liner Thickness: < 0.07mm
Diameter of label roll: < 7.87 inches (200mm)
Corediameter: 2 to 3 inches (50 to 76mm)
Dispensing Speed: 0.1m/sec - programmable
Platform speed: 0.1m/sec - programmable
Noise information.
Noise level determined by analysis A.
Acoustic pressure level <70dB (A).
Noise level <70dB.
Parts of the Applicator - Figure 2.1
1. Magnet rails for adjusting 11. Container guide - rear
the start of the label. 12. Container guide - both sides
2. Foam roller 13. Power supply coupling
3. Label media guides 14. Power switch
4. Sensor for labels 15. Platform
5. Pull shaft 16. Foot pedal/ peripheral devices connector
6. Label media guides
7. Friction brush 17. Control panel
8. Moving arm 18. Start button
9. Label roll holder 19. Base
10. Label roll guides

7
9
8 10
7
6
5
4
3
2
1
11
12
13
14
17 15
18 16
19
Figure 2.1

8
Safe work.
3. General safety instructions
Attention! The following safety precautions must be observed when using
electrical devices to protect against electric shock, risk of injury and fire.
Read all of these instructions before using the machine.
-Keep your workplace in order. Clutter in the work area can lead to
accidents.
- Ensure good lighting in the workplace.
- Do not use the applicator in humid conditions.
- Do not use the applicator in places where there is a risk of fire or explosion.
- Keep bystanders, especially children, away from the applicator when
operating the device.
- Do not use the applicator for purposes other than those intended.
- Do not use the cord to pull the plug from the wall socket. Protect the cable
from oil, heat and sharp edges.
- Avoid unnatural postures of the body. Take care of a secure posture, keep
balance in every way.
- Carefully maintain your applicator.
- If you do not use the applicator, remove the plug from the socket.
- Do not use the applicator with a damaged power switch.
- An electrical device that cannot be switched on and switched off is dangerous
and needs to be repaired
- Inspect the machine for any damage. Check that the moving parts function as
designed and that there are no damaged parts. All parts must be installed
correctly and meet all conditions to ensure proper operation. Damaged safety
components and parts must be repaired or replaced by a certified technician,
unless otherwise stated in the instructions of the operation manual. Damaged
circuit breakers must be replaced by a certified electrician.
Specific safety instructions.
The container to be labeled is inserted and removed manually. The labeling
procedure is started by pressing the built-in 'Start' button, or by the external start pedal
connected to the device.
- Do not insert a container while the applicator is moving.
- Do not start the machine with a container that is incorrectly installed.
- Do not remove the container from the machine until the rollers have stopped.
- Failure to follow these instructions may result in injuries or damage.
!

9
!
4. Operating instructions
Attention!
Every operator working with the label applicator should be familiar
with this user manual.
Setup
Place the applicator on a flat, horizontal surface larger than its base. You should
provide space around the machine for maintenance, servicing and handling.
Install the power cord that is included with the applicator. Install the start petal
cable to the connector on the side of the applicator.
Power up
Plug in the included power cord and power on the machine using the on switch on the
right side of the machine. Machine boots up to its home screen.
Determination of parameter value ‘Offset stop’
The sensor which detects the end of the label is located at a distance 64mm before the
peel edge and its position cannot be changed. This requires the input of the 'Offset-
stop' parameter for single-label mode and 'Offset-stop 1' and 'Offset-stop 2' for two-
label mode.
These parameters determine the proper positioning of the subsequent label to the peel
edge. The values depend on the length of the labels and the distance between them.
For convenience, the measurement of the labels, the distance between them and the
calculation of the offsets are done before loading the label roll in the machine.
The online tool to calculate the values can be found on our website,
https://afinialabel.com/af200calc. This QR code will take you to the webpage.
When applying a single label, refer to section 5 to manually calculate the offset value.
When applying two labels, refer to section 6 to manually calculate the offset value.
Loading a label roll and calibrating the label sensor
The machine is loaded with label roll meeting the specifications described in the
technical data. For better access, the upper applicator assembly should be lifted up
and the platform pulled to the front position. The procedure is performed with the
machine powered off. Detailed instructions are listed in Section 7.
Refer to section 8 to calibrate the label sensor. This step does not need to be repeated
if the label roll material and size remains the same.

10
Container positioning
The dimensions of the container as well as the position of the label are specified in
the technical data. To apply labels to thinner containers than the minimum spec of 1
inch, a pre-made spacer with the necessary shape and height needs to be attached to
the platform.
To apply labels to irregularly shaped container, a suitable mold or jig must be attached
to the platform. For optimum results, it is necessary to adjust the height of the upper
applicator assembly based on the height of the container, using steps laid out in
Section 9.
Position of the applied label depends on correctly positioning the container on the
platform and adjusting the magnet screws to set start and end points. Detailed steps
are listed for this adjustment in Section 10.
Working with the menu and changing parameters
The menus in the machine are divided into two sections - user and service. They are
protected by passwords that cannot be changed. The password of the user menu is
deactivated by default.
The machine operator works within the user menu. The operator can change the
operating mode (one or two labels) and set the already calculated offset stop or offset
stop 1 and offset stop 2 for two label mode. Detailed instructions are in Section 11.
The technical staff works within the service menu. Technician can enable/disable user
menu password, change labelling speed and turn on/off fast platform movement
speed. Detailed instructions are in Section 12.
Testing and fine tuning settings
Test the machine and make precise adjustments:
- monitor position of the applied label, along with the peel edge. Adjust by
changing offset stop or offset stop 1 and offset stop 2 for two-label mode.
Decreasing its value causes the label to move inward.
- monitor the left / right position of the label. Adjust the position of the media guides
as needed.
- monitor the end of the applied label with respect to the foam roller at the end
of the cycle. In the case of two-label mode, monitor label with more rear
position. If needed, adjust the position of the rear guide.
- monitor the position of the beginning of the label. Adjust the position of the
right magnet. For two label mode adjust the right magnet for first label and the
left magnet for second label. The direction and distance of placement of the
magnet corresponds to the direction and distance of the placement of the
label.
- monitor the desired repeatability of labeling position. Adjust labeling speed.
Low speeds lead to better repeatability. When changing the labeling speed,
the positions of the magnets need to be adjusted and the position of the
beginning of the label also changes.

11
Labeling
The procedure is started by pressing the built-in 'Start' button or by an external 'Start'
pedal connected to the connector. Performance is indicated on the display. At the
completion of the labeling procedure, the label counter increases. Any time the
button is pressed and held for more than 3 seconds, the counter is reset.
Errors
When the machine is started or operated and a situation arises that can lead to
damage, the machine is stopped. A flashing message with an error code is displayed,
accompanied by a sound alarm. It is necessary to correct the problem and restart the
machine by turning the power off and on. Errors and troubleshooting steps are
described in Section 13.
Adjusting the display
The brightness and contrast of the display can be adjusted as needed. Menu access
and operation are described in Section 14.
Information service menu
Only qualified technicians should work with the information menus.
The first menu displays a record of the event counters, total cycle, error counter and
the machine serial number. The description of the counters and how to access is
described in Section 15.
The second menu allows diagnostics of all sensors and controller inputs. Details are
described in Section 16.

12
Label
L < 64mm
64mm
Label
Gap
64mm
Label
L > 64mm
Label
5. Offset stop - 1 label mode
This value needs to be determined when applying one label. The easiest way to do this is
to use the online tool on our website, https://afinialabel.com/af200calc. This QR code will
take you to the webpage.
To manually determine these values, follow these steps
Examples are shown on Figure 5.1.
Situation 1:
Label >= 64 mm.
1. The value of Offset is 64:
Offset stop = 64.
Situation 2:
Label < 64mm.
The offset value is determined by
subtracting from 64 length of the label
and half the gap:
Offset stop = 64 - Label - Gap/2.
Situation 3:
Label << 64mm.
The offset value is determined by
subtracting from 64 the sum of all
lengths of the labels and gaps, and
2. adding half of the gap.
For the specific example:
Offset stop = 64 - Label - Gap - Label
- Gap - Label - Gap + Gap/2.
3.
64mm
Note: Measured offset results are a
good start. Several adjustments may be
needed to better position the start of the
label.
Figure 5.1
L << 64mm
Label
Label
Label
Label
64mm
Label
L = 64mm
Label

13
6. Offset stop 1, Offset stop 2 - 2 label mode
These values need to be determined when applying two label. The
easiest way to do this is to use the online tool on our website,
https://afinialabel.com/af200calc. This QR code will take you to the
webpage.
To manually determine these values, follow these steps.
Depending on the length of the labels the following situations are possible:
Situation 1:
Front label >= 64mm
Back label - regardless of the
size - Figure 6.1.
The value of Offset stop 1 is
determined by adding to 64 half the gap:
Offset stop 1 = 64 + Gap/2.
The value of Offset stop 2 is
determined by adding half the gap to the
back label length:
Offset stop 2 = Back label + Gap/2.
Front label must be applied first.
Figure 6.1 Situation 2:
Front label < 64mm
Back label >= 64mm -
Figure 6.2.
The value of Offset stop 1 is
determined by adding to 64 half the gap:
Offset stop 1 = 64 + Gap/2.
The value of Offset stop 2 is
determined by adding half the gap to
the front label length:
Offset stop 2 = Front label + Gap/2.
Back label must be applied
first.
Figure 6.2
64mm
Label
front
L = 64mm
Label
back
Gap
Label
back
64mm
L < 64mm
Label
front
Gap
64mm
Label
back
L = 64mm
Label
front
Gap
64mm
Label
back
L > 64mm
Label
front
Gap
64mm
Label
front
L > 64mm
Label
back

14
c).
Figure 6.3
61mm
L < 61mm
Label
long
Label
short
Label
long
Label
short
a).
b).
Gap
67mm
Situation 3:
Front label < 64mm
Back label < 64mm -
Figure6.3.
Three situations are possible:
a). Sum of the two labels and gap is
>= 67mm. Then the value of Offset
stop 1 is determined by subtracting the
length of the shorter label and half the
gap:
Offset stop 1 = 64 - Small label-Gap/2.
The value of Offset stop 2 is
determined by adding the Small Label
length to half the gap:
Offset stop 2 = Small label + Gap/2.
Big label must be applied first.
b). Sum of the lengths of the two labels
and the gap is < 67mm but > 61mm.
Then the Offset Stop 1 value is equal to half the gap:
Offset stop 1 = Gap/2 .
The value of Offset stop 2 is determined by adding Small Label length to half the gap:
Offset stop 2 = Small label + Gap/2.
Big label must be applied first.
c). Sum of the lengths of the two labels and the gap is <= to 61mm. Then the value of Offset
stop 1 is determined by subtracting from 64 the length of the two labels with the gap between
them and the length of another half gap:
Offset stop 1 = 64 - Big label - Gap - Small label - Gap/2.
The value of Offset stop 2 is determined by adding the Small Label length to half the
gap:
Offset stop 2 = Small label + Gap/2.
Big label must be applied first.
Note: Measured offset results are a good start. Some adjustments may be needed to
better position the start of the label.
Gap
67mm
Label
long
Label
short
L > 67mm
Label
long
61mm
Label
long
61< L < 67mm
Label
long
Label
short

15
7. Loading labels
To load a roll of labels, pull up the Label roll holder and remove the magnetic roll
guides. Place the roll on the holder and use the magnetic guides to locate the roll in the
desired position.
Before routing the media, unlock the Press shaft. Use your thumbs to push the
unlock/lock tab down on both sides.
Now route the label media as shown in the schematic (Figure 7.1) below.
- slips under friction brush
- passes between media guide 1. Position both guides against the edge of the media
- passes over Pull shaft
- goes through the slot of the Label sensor
- passes under media guide 2. Position both guides against the edge of the media
- Peel label to expose about 12” of liner. Route the liner under and back from the Peeling
edge
- passes under Pull shaft and over Press shaft
- over the bracket shielding the stepper motor
- passes under Label roll and falls back freely
Label roll is adjusted in the left/right position so a peeled label is aligned with the container
on the table. Pull the label media such that the start of a label (first label if 2 label option is
being used) is positioned on the Peeling Edge. There should be no labels past the peeling
edge. Use ruler markings on the label roll holder and under pull shaft to ensure media is
aligned through the applicator. Lock the Press Shaft by pushing up the unlock/lock tab on
both sides. If needed, readjust the Magnetic label roll guides, Media Guides 1 and Media
Guides 2 against the edge of the media, ensuring there is a slight clearance and the media
edges are not pinched. Manually move the label roll to make sure media is taut.
Figure 7.1
Label roll
Scheme of label movement
Label roll guide
Label roll holder
Path of the label Friction brush
Media Guide 1
Pull shaft
Label sensor
Media Guide 2
Foam
roller
Press shaft
Unlock
Lock
Peeling edge

16
8. Calibrating the label sensor
The label stock and matrix must travel through the sensor
area. If irregular shaped label stock is used, the sensor will
not register the gap correctly. When calibrating, the label
stock cannot be moving.
1. Position the stock so that the gap is under the sensor,
as shown in figure 8.1
2. Press and hold the TEACH button for 3 seconds. The
yellow LED under T will be lit. When the button is released,
the LED will be blinking. Sensor calibration takes place and
the sensor level will be displayed on the LEDs under L. Once
calibration is completed, the T LED will turn off.
3. Position the stock so a label is under the sensor, as
shown in figure 8.2.
4. Press the TEACH button. The LED under T will turn on
and will blink briefly. Sensor calibration takes place and the
sensor level will be displayed on the LEDs under L. Sensor
calibration is complete
5. If there is not enough signal difference between the label
stock and the liner, the level LED indicators will blink,
indicating an error. If this occurs repeat these steps again,
with another section of the label material or try different label
stock.
6. Exiting the error state can also be done by powering off
the applicator.
Figure 8.2
Figure 8.1

17
9. Adjusting the height of the Upper Applicator Assembly
For correct operation, the distance H between the top surface of the container and the
foam roller must be under 5mm. It is measured when the upper applicator assembly
position is set after homing on initial startup - Fig.9.1.
The position of the upper applicator assembly is fixed on a tooth comb in 20mm steps and
can be adjusted up or down.
Rough Adjustment
- Power off the machine.
- Turn the adjusting screw (4) counter clockwise until it is in the outmost position
- Tilt the upper applicator assembly back (1) and slide the 2 pins (pivot points) on
both sides out of the tooth comb (1) and into the vertical channel.
- Keeping the upper applicator assembly in this position move the whole assembly up or
down (2) in the vertical channel as needed based on the container height.
- Once the desired height is reached slide the 2 pins (pivot points) on both sides into one
of the tooth combs (3) from the vertical channel and tilt the upper applicator assembly
forward (3) until the pins rest in the tooth comb.
Precision Adjustment
- If necessary, use the adjustment screw to set the correct height. Clockwise (tightening)
movement of the screw will raise the upper applicator assembly and counter clockwise will
lower it.
Be careful not to damage the wiring harness.
If the container is thinner than the 1” minimum spec, the upper applicator assembly
can be set to the minimum height, and a prefabricated pad with the necessary shape and
height is secured to the platform. In case of an irregular shape container, it is necessary to
make a suitable mold which is attached to the platform.
Figure 9.1
Upper app
assembly
Guide
<5mm
Adjusting
screw

18
10. Container positioning and magnet adjustment
Container positioning and adjustment on the platform determine where the label will
be applied. Follow the process below to set the correct container position.
- Power off the machine.
- Place the container on the platform. Position the center of the label roll to coincide
with the center of the desired label application position. Set the left and right container guide to
secure the containerbetween them (1) - fig.10.1. Tighten the screws on both guides.
- Manually pull the platform to the front position. Position the container so the end of
the label is below the start of the upper applicator assembly (2) - Fig. 10.2. This ensures
complete adhesion of the label. Secure the container in this position and set the rear guide
(3) - Fig. 10.1. In the case of a two-label mode, this procedure is performed for the label with
more rear position.
- Manually push the platform back to set the start of the labeling position. Starting
position of the label is indicated by arrow (4) in Fig.10.3. Without moving the platform, loosen
screw on the right and move it to about 1.25” in front of the label start position as indicated
by arrow (5) in Fig.10.3. Tighten the screw on the right. In two-label mode, for the second
label, repeat this procedure but with the left magnet screw. These adjustments provide a
rough starting point and once the machine is being tested, additional correction of the
position of the magnet screws might be needed (direction and distance of the magnet
location coincides with the direction and distance of the label placement).
When changing the labeling speed, the positions of the magnets may need to be adjusted.
Figure 10.1
Center label roll
Rear guide
Screw
rear guide
Screw
rear guide
Screw
left guide
Screw
right guide
Left guide
Right guide
Container
Label position
Platform

18
Figure 10.2
Figure 10.3

19
11. User menu and changing parameters
Figure 11.1
Figure 11.2
Figure 11.3
Figure 11.4
Figure 11.5
Figure 11.6
Access the parameter menu by holding down the button for 3 seconds.
Select mode ‘ONE LABEL’
Once 'ONE LABEL' mode is selected, next enter the Offset stop
parameter- Figure 11.4. This value determines the proper positioning of the
beginning of the label to the peeling edge. The value depends on the length
of the label and is explained in section 5.
Change the value by pressing the key. To go to the next
digit press the key. The process is cyclical.
By pressing the key, the set offset is set and the main screen
is displayed - Figure.11.1.
Select mode ‘TWO LABELS’
Once the 'TWO LABELS' mode - Figure 11.3, is selected and
confirmed, next enter - offset stop 1 - Figure 11.5. Its value determines the
proper positioning of the beginning of the front label to the peeling edge.
The value depends on the length of the two labels (front, back), and is
explained in section 6.
Change the value by pressing the key. To move to the next
digit, press the key. Pressing the key will reset the numbers.
Press the key to save the Offset stop 1 value. Next enter the Offset
stop 2 value, Figure 11.6. Again, use the key to change values and
the key to move to the next digit. Press the key to reset the
numbers. Press to save the Offset stop 2 value.
When staying in the parameter menu screen for more than 60
seconds without activity, the machine will return to the main screen (Figure
11.1). Any changes will be saved.
OFFSET STOP 2
------------------------------
64
^
------------------------------
[01 ... 70 mm]
OFFSET STOP 1
------------------------------
64
^
------------------------------
[01 ... 70 mm]
OFFSET STOP
------------------------------
64
^
------------------------------
[01 ... 70 mm]
SELECT MODE
------------------------------
ONE LABEL
>TWO LABELS
SELECT MODE
------------------------------
> ONE LABEL
TWO LABELS
MODE 1 LABEL
------------------------------
BANK NUMBER 0
WAIT START
NUMBER LABELS
0000 0,0s