ASTRO ATS-309 User manual

ASTRO
ATS-309
MULTI-TABBER/
STAMP AFFIXER
OPERATOR MANUAL

SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. OBSERVE
SAFETY RULES WHEN OPERATING TABBER, LABELER, AND STAMP AFFIXER.
BEFORE USING TABBER, READ MANUAL CAREFULLY AND FOLLOW
RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS:
9 Keep hands, hair, and clothing clear of rollers and other moving parts.
9 Avoid touching moving parts or materials while machine is in use. Before clearing a jam, be sure machine
mechanisms come to a stop.
9 Always turn machine off before making adjustments, cleaning, or performing any maintenance covered in
this manual.
9 Always use power cord supplied with the machine and plug it into a properly grounded, easily accessible
wall outlet located near the machine. Failure to properly ground the machine can result in
severe personal injury and/or fire.
9 Power cord and wall plug are primary means of disconnecting machine from power supply.
9 DO NOT use an adapter plug on line cord or wall outlet.
9 DO NOT remove ground pin from line cord.
9 DO NOT route power cord over sharp edges or trap it between furniture.
9 Avoid using wall outlets controlled by wall switches or shared with other equipment.
9 Make sure there is no strain on the 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 schedules.
9 To prevent overheating, do not cover the vent openings.
9 Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Astro Machine Corp., its designated agents,
customers, and their employees. The information in this guide was obtained from several different
sources that are deemed reliable by all industry standards. To the best of our knowledge, that information
is accurate in all respects. However, neither Astro Machine Corp. nor any of its agents or employees shall
be responsible for any inaccuracies contained herein.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher.

TABLE OF CONTENTS
i
TABLE OF CONTENTS
SECTION 1 – Getting Acquainted 1
Front View 1
Exit End View 2
Tabber Electrical Connections 3
Feeder and Connections 4
Tabber Control Panel 5
SECTION 2 - Assembly and Installation 6
Assembly 6
Connecting 7
SECTION 3 - Operating Tabber 10
Mechanical Set-up 10
Narrow Media Set-up 13
Running Tri-Fold Long Edge 13
Applying Stamps to #10 Envelopes 14
Applying Three Tabs to a Narrow Piece 14
Media Thickness Adjustment 15
Adjusting Feeder 16
Setting Media Length 17
Loading Tabs (Head 1 or Head 2) 17
Head 1 Adjustment – General 18
Head 1 Adjustment – Side Tabbing 19
Head 1 Adjustment – End Tabbing 21
Head 1 Adjustment – Applying Stamps 24
Head 2 Adjusting for Side Tabbing 26
Operating Tabber 28
Understanding Start-up Screen 29
Exceeding Tabbing Rate 30
Select and Run a Pre-Programmed Job 30
Fine Tuning Adjustments 32
Side Tab Positioning 32
Head 1 Side Tab Adjustment 33
Head 1 Tabbing at Lead Edge of a Piece 33
Head 2 Side Tab Adjustment 34
SECTION 4- Programming Tabber 36
Notes before Programming 36
Advanced Soft Key 36
Job # 37
Manual Tab/Stamp Positioning Features 38
Head #2: 39
Head #1: 40
Pitch 41
Automatic Tab Positioning Features 42
Manual Product Length Input: 44

ii
Tab Sensor (V-Tab) Adjustment 45
Manual V-Tab Adjustment: 47
Programming Jobs 48
Programming: Tabs with Automatic Setup 49
Programming: Stamps with Manual Setup 54
Placing Multiple Stamps 58
Programming: Tabs on Opposite Sides 59
Programming: Tabs on Perpendicular Sides 65
SECTION 5 – Maintenance 72
Cleaning 72
Rollers and Transport Belts 72
Shafts with Movable Parts 72
Cleaning Sensors 73
Sensor locations: 73
Media Sensor Test: 73
Tab Sensor Test 74
Cleaning Tab Wrap Guides 74
Lubrication 75
SECTION 6 – Troubleshooting 76
Jams 76
Tab Placement Problems 77
Stamp Placement Problems 79
Tabber Operation Problems 80
Diagnostics 80
Appendix A – Specifications 83
Appendix B – Identifying Tab Types 84
Appendix C – Tab Placement Capabilities 85
Index 91

GETTING ACQUAINTED
1
SECTION 1 – Getting Acquainted
Front View
1
Control Panel – Control and program Tabber from this panel.
2
Head 1 Fine Tuning Adjustment – Permits fine positioning of tabs on Head 1.
3
Head 2 Fine Tuning Adjustment – Permits fine positioning of tabs on Head 2.
4
Head 1 – Applies stamps or tabs on either edge or end of media.
5
Head 2 – Only applies tabs on edge of media.
6
Take-up Reels – Winds up tab web after tab is applied.
7
Left Media Guide Assembly – Transports media to tabbing area.
Guide is not adjustable.
8
Main Power Switch & Receptacle-Tabber – Power cord plugs in here.
Switch turns Tabber ON and OFF.
9
Center Support Plate – Used to support media 6.5" wide or larger. This plate also
contains slot used when tabbing at lead edge of a piece.
10
Right Media Guide Assembly – Transports media to tabbing area and is adjustable
for media width.
11
Media Thickness Adjustment Knob – Adjusts Heads and Pressure Rollers to
thickness of media.
12
Media Width Fine Adjustment – Fine tunes Media Guide to media width.

GETTING ACQUAINTED
2
Exit End View
1
Head 2 Fine Tuning Adjustment – Permits fine positioning of tabs on Head 2.
2
Head 1 Securing Knob – Locks in position of Head 1.
3
Right Media Guide Securing Knob – Locks Right Media Guide in position.
4
Head 1 Transport Belt and Guide – Adjustable for media width.
5
Center Plate – Supports media wider than 6.5".
Slot in middle is used when tabbing on end of a piece.
6
Exit Foot – Holds media down as it travels under Exit Rollers. Adjusted with Head 1.
7
Tab Wrap Guide / Head 1 – Wraps tab around media when Side Tabbing.
8
Exit Pressure Rollers – Provide pressure to transport media and seal tabs.
9
Tab Wrap Guide / Head 2 – Wraps tab around media when Tabbing.
10
Exit Roller Assembly Securing Latches – Locks down Exit Roller Assembly.
11
Exit Foot Knob – Used to position and secure Exit Foot (6).
12
Exit Roller Assembly Pinch Guard – Prevents operator's fingers from being
pinched by Exit Rollers.

GETTING ACQUAINTED
3
Tabber Electrical Connections
1
Emergency Stop Input – When wired into an existing safety circuit, this connector
per
mits an emergency stop from existing circuit to stop Tabber. Jumper Plug is
required when this feature is not used.
2
Emergency Stop Output – Permits Tabber to control emergency stopping
of another machine.
3
Tabber/Feeder Connection – Feeder connects here to permit automatic operation
of Feeder when used with Tabber.
4
Main Power Switch-Tabber – Turns Tabber ON and OFF.
5
Fuse – Main power fuse (2.5A / 250V) for Tabber.
CAUTION! Disconnect power before replacing fuse.
6
Power Inlet Tabber – Power cord plugs in here.

GETTING ACQUAINTED
4
Feeder and Connections
1
Tabber/Feeder Control Cable – Permits Tabber to control Feeder when Mode Switch
is in Automatic position.
2
Power Inlet-Feeder – Power cord plugs in here.
3
Fuse – Feeder fuse is located here.
4
Main Power Switch-Feeder – Turns Feeder ON and OFF.
5
Mode Switch – Permits selection of either Automatic Mode (Tabber controls Feeder)
or Manual Mode (Feeder speed is controlled manually by Feeder Speed Control).
6
Feeder Speed Control – Controls Feeder speed when Feeder mode switch is in
Manual position.
7
Media Thickness Adjustment-Feeder – Adjusts Exit Rollers of Feeder for thicker
media (Loosen knob and repositioning lever).

GETTING ACQUAINTED
5
Tabber Control Panel
1
Transport Power Switch – Turns Tabber transport power ON.
NOTE: Transport Power will not activate unless all safety and emergency
switches are closed.
2
Speed Control – Adjusts speed of Tabber.
NOTE: M
aximum speed of Tabber is controlled by software.
Tabber s
peeds for applying tabs:
x Single tabs to one side of a piece – 20,000 pieces per hour;
x Double tabs to one side of a piece – 12,000 pieces per hour;
x Triple tabs to one side of a piece – 8, 000 pieces per hour.
Exceeding these speeds will cause Tabber to stop
.
(Tab placed on end of piece is not counted in the above.)
3
LED Display – Informs operator of Tabber status.
4
Key Pad – Used to enter data to program Tabber.
5
Emergency Stop – When Tabber is properly connected to Feeder and/or other
pieces of equipment, activating this button stops machines.
6
Soft Keys – Used to step through various menu options to program Tabber.
7
Stop Key – Pressing this key stops Tabber and holds it in a ready state to
resume operation.
8
Run Key – Pressing this key starts Tabber when running a job.
9
Info Key – Pressing this key changes Display to Information Mode.
10
Save Key – Saves entries into memory.
11
Clear Key – Clears any incorrect entry before it is saved in memory.
12
Measuring Scale – Use scale to determine where to place tabs.

ASSEMBLY AND INSTALLATION
6
SECTION 2 - Assembly and Installation
Tabber is shipped in a single carton.
Assembly
Choose a Location
Place Tabber with its Feeder on a sturdy worktable or cabinet at least 12" from any walls.
Allow enough room to place Feeder on same work surface. Protect Tabber from excessive
heat, dust, and moisture – avoid placing it in direct sunlight.
CAUTION
UNIT IS HEAVY. STRONGLY RECOMMENDED THAT TWO TECHNICIANS
REMOVE TABBER FROM CARTON AND PLACE IT ON WORKING SURFACE.
Install Reel Supports
Two Reel Supports have to be installed. Remove upper mounting screw and loosen lower
mounting screw. Slide Reel Supports over Frame until they bottom on lower mounting screw.
Install and tighten upper screw and lower screw.

ASSEMBLY AND INSTALLATION
7
Install Optional Feeder
1. Pin [A] on Feeder should mate with hole
[B] on Tabber body.
2. When Feeder is properly aligned with Tabber body,
it looks like picture shown at right.
Connecting
Plugging in Feeder and Tabber
Make sure that Tabber Emergency Stop Switch is turned
OFF and Main Power Switch above Power Cord
Receptacle is turned OFF. Make sure that Power Switch
on Feeder is turned OFF.
1. Connect one end of Tabber power cord [1] to
rear of Tabber in corresponding receptacle.
2. Connect one end of Feeder power cord [2] to
rear of Feeder in corresponding receptacle.
3. Plug other cord ends into a 115 Volt AC (220
VAC International), 50/60 Hz, grounded outlet.

ASSEMBLY AND INSTALLATION
8
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 SAME CIRCUIT WITH LARGE
ELECTRICAL MACHINES OR APPLIANCES.
4. Connect Feeder Interface Cable [3] to Feeder and to lower connector on Tabber.

ASSEMBLY AND INSTALLATION
9
NOTES
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OPERATING TABBER
10
SECTION 3 - Operating Tabber
Tabber is capable of applying up to three tabs or stamps on each of two sides of media in one
pass. To set-up Tabber for applying tabs or stamps:
x
Determine type of tabbing and number of tabs
x
Determine orientation that media must feed to accommodate application
x
Set-up Tabber and Feeder to feed media
x
Load tabs or stamps in proper Head
x
Adjust Head positions (side tab or end tab) for application
x
Program Job
x
Run Job
Mechanical Set-up
Once you determine tab location and number of tabs, you are ready to set up Tabber for handling
media and placing tabs.
IMPORTANT
TO PERMIT PROPER FEEDING THROUGH TABBER, MEDIA USED TO
TAB/STAMP MUST HAVE SQUARE, TIGHT FOLDS, AND BE NEARLY
UNIFORMLY
THICK. IF
MEDIA DOES NOT FEED PROPERLY, IT WILL
NOT BE TABBED/STAMPED PROPERLY.
Turn OFF Tabber and Feeder using Main Power Switches.
1. Loosen Exit Foot Knob located on top
of Exit Roller Assembly and move it
toward back of Tabber (toward Head 2),
(as shown).

OPERATING TABBER
11
2. Measure width of piece using
scale on Tabber. If media width
is less than 6.5", Center Support
Plate must be removed from
Tabber. This is done to allow
Right Media Guide to be
positioned closer to Left Media
Guide. (See “Narrow Media
Set-up” for more information.)
To remove Center Support Plate,
first remove Hold-down Guide,
then lift up on Center Support
Plate to remove it, (as shown).
IMPORTANT
CENTER SUPPORT PLATE AND HOLD-DOWN GUIDE MUST BE
INSTALLED WHEN USING MEDIA THAT MEASURES 6.5
" OR WIDER.
FOR MEDIA LESS THAN 6.5"
GO TO “NARROW MEDIA SET-UP” ON
PAGE 13.
3. Loosen securing knob for
Right Media Guide.
NOTE: Right Media Guide is movable.
Left Media Guide is fixed.
4. Turn ON Tabber's Main Power Switch.
Verify that Exit Roller Assembly is closed
and secured (lock latches). Verify that
Emergency Stop Button is released. Press
green Transport Power Button.
5. Press soft key labeled:
“Pass-Thru” to set Tabber
in Pass-Thru Mode.
NOTE: When Tabber is in
“Pass-Thru” mode it displays
“Press-Run for pass-thru
mode” and soft key changes to
“Operate”.

OPERATING TABBER
12
WARNING!
DO NOT MOVE RIGHT-HAND MEDIA GUIDE IF TABBER IS NOT RUNNING.
TO DO SO RESULTS IN DAMAGE OR BREAKAGE TO TRANSPORT BELT.
6. Press RUN key and center Speed Control Dial so transport is running at a medium speed.
7. With Tabber Transport running,
adjust position of Right Media
Guide Assembly to match media’s
measured width. Scale (located at
entrance end of Tabber) can be
used to accomplish this step.
IMPORTANT
IF MEDIA IS NOT FOLDED SQUARE, MAKE INITIAL SETTING OF GUIDE
AT WIDEST POINT ON PIECE
.
ONCE INITIAL ADJUSTMENT IS MADE, MEDIA WIDTH FINE
ADJUSTMENT CAN BE USED TO FINE TUNE RIGHT-HAND GUIDE.
8. Secure Right Media Guide’s position using Locking Knob.
9. Press STOP button to stop Tabber.
10. Slide Exit Foot Knob towards operator
side until it stops against Right Media
Guide Assembly, then back off a small
amount (no more than 1/8"). Tighten
Exit Foot Knob to secure its position.
11. Turn Tabber OFF using Main
Power Switch.
12. Proceed to Media Thickness
Adjustment.

OPERATING TABBER
13
Narrow Media Set-up
Narrow Media Guide is designed to help you feed media that is less than 5-1/2" and place two
side tabs and one end tab on media 5-1/4" wide or more. Guide also permits tabbing long edge of
a Tri-Fold and improve Stamp application.
Narrow Media Guide has a Side Rail [1] held in place by two screws. Used for front tabbing
media between 5" and 6-1/2" and can be removed when running very narrow media and stamps.
Running Tri-Fold Long Edge
1. Remove Side Rail [1] (see photo above).
2. Remove Standard Support Plate.
3. Install Narrow Media Guide in place of Standard Support Plate.
4. Adjust Narrow Media Guide to width of Tri-Fold media, then move Transport Belt
against Narrow Media Guide.
5. Set up Tabber to side tab from Head 2.
6. Run Job.

OPERATING TABBER
14
Applying Stamps to #10 Envelopes
1. Remove Extra Side Guide from Narrow Media Guide.
2. Set Guide against Envelope.
3. Move Transport Belt Guide against Narrow Media Guide to hold it in place.
4. Set up Head 1 to apply stamps.
5. Run Job.
Applying Three Tabs to a Narrow Piece
1. Install Standard Media Guide in place.
2. Install Side Rail on Narrow Media Guide (if not already installed).
3. Place Narrow Media Guide with Side Rail against Standard Media Guide just
on edge of media.
4. Move Transport Belt Guide against Narrow Media Guide.
5. Set up Tabber to tab three tabs: two on Head 2 and one on front from Head 1.
6. Run Job.

OPERATING TABBER
15
Media Thickness Adjustment
IMPORTANT
TO PERMIT PROPER FEEDING THROUGH TABBER, MEDIA USED TO
TAB/STAMP MUST HAVE SQUARE, TIGHT FOLDS, AND BE NEARLY
UNIFORMLY THICK
.
IF MEDIA DOES NOT FEED PROPERLY, IT WILL
NOT BE TAB/STAMPED PROPERLY.
1. Close Exit Roller Assembly and lock two latches to secure it.
2. Turn Media Thickness Control Knob fully clockwise (raising Exit Roller Assembly).
3. Insert one piece of Media into
exit end of Tabber and adjust
Media Thickness Control Knob
counterclockwise (lowering Exit
Roller Assembly) until you start
to feel a drag on media.
4. Continue to turn Media
Thickness Control Knob
counterclockwise an additional
3 or 4 clicks, to obtain proper
transport pressure on media.
5. If installed, loosen thumbscrew
for Hold-Down Guide, and allow
Guide (strap) to relax. Then
retighten thumbscrew. This
prevents Guide from putting too
much pressure on media, possibly
causing it to stall.
6. Proceed to “Adjusting Feeder”
to complete setup.

OPERATING TABBER
16
Adjusting Feeder
Feeder is properly aligned with Tabber when it is installed. Non-operator Side Guide
(Right Side) on Feeder is fixed in position for proper alignment of media.
Adjust Feeder to feed media:
1. Open non-operator Side Guide to provide room
for media.
2. Loosen Separator Locking Knobs [1] and raise
Sheet Separators [2]. Install one sheet of media
under Separators and lower them into contact with
media. Tighten Locking Knobs.
NOTE: For media thicker than 1/2 folded sheets
you can add one sheet of material to the media
before tightening Locking Knobs. This gives
thicker media a little more room to feed.
3. Move non-operator Side Guide to within 1/32"
of media and tighten Locking Knob.
4. Adjust Rear Media Support Guide so media
is approximately 1/2" above Media Support
(as shown).
NOTE: The above is a starting guideline.
Height of media above Support Guide may
vary to obtain optimum feeding.
5. Forwarding Rollers on Feeder are adjustable
for media thickness. Particularly helpful when
feeding media over 1/8" thick. To adjust
Forwarding Rollers: Loosen Locking Knob
[3], place a piece of media under Forwarding
Rollers [4], then tighten Knob.
NOTE: To increase or decrease pressure
on Forwarding Rollers, adjust Lever [5]
while tightening Locking Knob [3].