ASTRO ATS-9800 User manual

ASTRO
ATS-9800
DUAL TABBER
OPERATOR MANUAL

SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
OBSERVE THE FOLLOWING SAFETY RULES WHEN OPERATING THE
ASTRO ATS-9800 TABBER.
BEFORE USING THE ATS-9800, YOU SHOULD READ THIS MANUAL
CAREFULLY AND FOLLOW THE 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 the machine is in use. Before clearing a jam, be
sure machine mechanisms come to a stop.
9 Always turn off the machine before making adjustments, cleaning the machine, or performing
any maintenance covered in this manual.
9 Use the power cord supplied with the machine. 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 The power cord and wall plug is the primary means of disconnecting the machine from the
power supply.
9 DO NOT use an adapter plug on the line cord or wall outlet.
9 DO NOT remove the ground pin from the line cord.
9 DO NOT route the 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 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, please 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 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 trademarks are the property of their respective holders.
All rights reserved. No part of this manual 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 Astro Machine Corp.

TABLE OF CONTENTS
Table of Contents
SECTION 1— GETTING ACQUAINTED 4
PACKAGING/SHIPPING 4
CONTENTS 4
FRONT VIEW 5
REAR VIEW 6
TAB DRIVE AND MEDIA SENSOR ASSEMBLY COMPONENTS 7
CONTROL PANEL 8
SECTION 2 — ASSEMBLY 9
STAND-ALONE MODE 9
IN-LINE MODE 10
In-Line Roller Assembly Removal 12
External Feeder Control Setup 13
CHOOSING A LOCATION 14
CONNECTING POWER 15
SECTION 3 — OPERATING THE TABBER 16
THEORY OF OPERATION: 16
Important Operating Tips: 16
LOADING/THREADING TABS: 17
Tab Stock Threading Diagram (Peel Bar Up) 21
Tab Stock Threading Diagram (Peel Bar Down) 22
Sheet Separation Adjustment 23
Media Side Guide Adjustment 24
Rear Paper Support Adjustment 24
Loading Media 25
MEDIA TRANSPORT TEST (PAPER FEED) 25
MEDIA TRANSPORT SPEED ADJUSTMENT 26
ADJUSTING THE TAB POSITION 27
Horizontal Tab Positioning 27
Tab Fold Position Adjustment 28
OPERATING SEQUENCE 28
SECTION 4 — TROUBLESHOOTING 29
TABBING PROBLEMS: 29
MEDIA FEEDING PROBLEMS: 30
GENERAL PROBLEMS: 30
SECTION 5 — MAINTENANCE 31
CLEANING 31
Tabber Body 31
Feed Rollers and Forwarding Rollers 32
Media Sensor 32
APPENDIX – SPECIFICATIONS 33
INDEX 34

SECTION 1
GETTING ACQUAINTED
4
SECTION 1 – GETTING ACQUAINTED
Packaging/Shipping
The Tabber is shipped in appropriate packaging so that, under normal shipping
conditions, it reaches its destination without damage.
NOTICE: Report damage to the carrier. The carrier is liable for any damage during
transport. Transport and storage should take place under normal conditions, i.e. at
temperatures between +5°C and +70°C and relative air humidity of up to 80%.
Exposure to conditions that are not permissible may lead to damage which is not
externally visible.
Contents
The following items are included with your Tabber:
Qty Description (Image Reference)
1 Operations Manual
1 Rear Paper Support (1)
- thumbscrews attached to Tabber
1 Narrow Media Guide (2)
1 Back Support Guide (3)
- including thumbscrew
1 Tab Box Tray (4)
1 In-Line Guide Assembly (5)
1 In-Line Roller Assembly (6)
2 Media Side Guides (7 & 8)
- screws attached to Tabber
1 Power Cord (9)

SECTION 1
GETTING ACQUAINTED
5
Introduction: The ATS-9800 Tabber is a tabletop tabbing machine designed for the
moderate volume user. It can be used "stand-alone" or "in-line" with other devices.
The ATS-9800 Tabber applies fanfold, "tractor-fed" clear, translucent, and paper tab
stocks; which have been engineered to run on the ATS-9800.
Front View
TAKE-UP SPOOLS — Wind up the tab web material (waste).
MEDIA SIDE GUIDES — Used to position the media in the Tabber and ensure
straight feeding of media.
FEEDER INTERFACE — Used to control the start/stop function of optional
External Feeders. Feeder must accept "dry contact" input control.
BACK SUPPORT GUIDE — Allows adjustments in stack angle, based on media
type and length. Helps to force the media against the separation area.
REAR MEDIA SUPPORT — Provides the proper angle to enhance media feeding
and separation.
SHEET SEPARATORS — Used to separate a single piece of media from the
media stack.
FEED ROLLERS — Delivers the bottom piece of media from the media
stack, through the separation area, and under the Forwarding Rollers.
CONTROL PANEL — Used to control the operation of the Tabber.
TABBING MATERIAL TRAY — Holds the tabs box and guides the tabs web.

SECTION 1
GETTING ACQUAINTED
6
Rear View
POWER SWITCH — Controls the power to the Tabber.
FUSE HOLDER —The main power fuse (line fuse) is located here.
POWER INLET—AC power cord connects here.
MEDIA SENSOR —Detects the leading edge of the mail piece
(media). The knob on this assembly is used to adjust the tab fold position.
TAB DRIVE —Contains the Tab Guide Chute, Peel Bar, and Tractor Drive System.

SECTION 1
GETTING ACQUAINTED
7
Tab Drive and Media Sensor Assembly Components
PEEL BAR LOCK — Used to set the Peel Bar to the threading (up)
or tabbing (down) position. They lock the Peel Bar into position. Pull forward
to release, then slide up or down.
PEEL BAR (UP) — Upper position allows the tab web to be fed through the
opening at the bottom of the
Tab Drive Assembly, and out the back; just under the
Tractor Drive Roller.
PEEL BAR (DOWN) — Lower position creates a sharp bend in the tab web. This
sharp bend causes the tab to be released from the backing as the tab web is driven
around the bottom edge of this bar.
TAB POSITIONING DIMPLES — Alignment marks used to locate the
correct starting location for the tab on the web (backing).
UPPER EXIT ROLLERS — Provide the pressure to seal the tab to the
top of the mail piece (media).
LOWER EXIT ROLLER —Seals the tab to the bottom of the mail piece (media)
while driving the media out of the Tabber.
TAB POSITION ADJUSTMENT KNOB — Adjusts the position/angle of the
Paper Sensor, which in
-turn adjusts the fold position of the tab.
Clockwise = more tab area on bottom
Counterclockwise = more tab area on top
Tip: Start with Knob turned fully clockwise. Test and adjust from there.
Do not over tighten this Knob.

SECTION 1
GETTING ACQUAINTED
8
Control Panel
BATCH COUNTER — Counts tab cycles. Can be reset to zero by pressing the
small
button on the Counter.
NOTE:
The Batch Counter will not count items fed in the "paper feed mode".
It only counts when the unit is in the "tab mode" (tab button illuminated).
SPEED CONTROL — Controls the media transport speed of the Tabber.
Clockwise
= faster. Counterclockwise = slower.
IMPORTANT: Changing the transport speed, also changes the tab fold
position
. Please adjust the desired transport speed before you adjust for the
desired tab fold position.
FEED BUTTON — Used to stop/start Tabber Transport. Illuminates when the
feed system is activated.
POWER LED — Illumination indicates that the Tabber's Main Power Switch
is ON, and the unit is receiving power.
TAB BUTTON — Used to turn the tab function ON/OFF.
OFF = Tab Mode Off (Feeds paper without applying tabs.)
ON (Illuminated) = Tab Mode Activated
0
Hower
Food
Tab

SECTION 2
ASSEMBLY
9
SECTION 2 – ASSEMBLY
Stand-Alone Mode
Note: This process assumes you are using the system as a "stand-alone" Tabber.
1. Attach the Rear Paper Support using the two thumbscrews and washers provided.
The finger (on bottom edge of Paper
Support) must be inserted into one of the
locator holes in the Tabber frame. Secure
Paper Support to the frame with the
thumbscrews, as shown.
When double tabbing: Set the Paper
Support to the far left locator hole. This
centers the Paper Support on the Tabber.
When single tabbing: Paper Support can
be positioned in any of the other locator
holes. Try to position the Paper Support so
it is centered on the media you are feeding.
2. Install the Paper Support Rest onto the Rear
Paper Support, using the thumbscrew and
washer supplied.
Two Paper Support Rests are included:
Narrow rest is for media 6.25" wide or less.
Standard (wider) wedge is for all other media.
3. Attach both Media Side Guides to the unit as
shown. The bottom of the Media Side Guide fits
into the brass bushing on the shaft, as shown.
The Guides are secured to the mounting blocks
using the two Phillips head screws, supplied.

SECTION 2
ASSEMBLY
10
4. Attach the Tab Box Tray. Hooks on the
Tab Box Tray fit over the upper shaft, at the
exit end of the Tabber, as shown. The Tray
hangs off the exit end of the Tabber.
5. Proceed to "Choosing a Location".
In-Line Mode
Note: This process assumes you are using the system as an "in-line" Tabber.
1.
If installed; remove the Rear Paper Support
from the Tabber. Remove the two
thumbscrews and washers shown.
Note: Reuse the thumbscrews and washers
to install the In-Line Guide Assembly,
shown later in this procedure.
2. If installed, remove the Material Guide
Assembly from the Tabber as shown.
Loosen the two thumbscrews that secure
the Assembly to the side wall as shown.
3. Remove the Assembly from the Tabber.
Tighten the thumbscrews into the side walls
of the Tabber for safe keeping.

SECTION 2
ASSEMBLY
11
4. Install the In-Line Roller Assembly.
Install the flat end of the shaft first, then insert the pointed end of the shaft.
Important! Make sure the shaft ends are inserted under the spring wire
(located behind the sidewall). When you insert the pointed end of the shaft,
the spring wire will lock the shaft in place.
5. Install the In-Line Guide Assembly:
The In-Line Guide Assembly can be
attached to a number of mounting
locations, along the front wall of the
Tabber; using the two thumbscrews and
washers; as shown above.
When Dual Tabbing; the Guide Assembly
should be installed so it is centered on the unit.
When Single Tabbing; the Guide Assembly can be offset to the right, to better
accommodate the media feeding location.
When Tabbing Narrow Pieces (3.5" minimum); the Vertical Guide needs to be
moved to the second notch on the right.

SECTION 2
ASSEMBLY
12
6. Attach the Tab Box Tray.
The hooks on the Tab Box Tray fit over the
upper shaft, at the exit end of the Tabber, as
shown. The tray hangs off the exit end of the
Tabber.
7. Proceed to "External Feeder Control
Setup".
In-Line Roller Assembly Removal
To remove In-Line Roller Assembly, a small screwdriver can be
inserted under the spring wire, through the smaller hole in the
sidewall. Push up lightly on the spring wire to release the pointed
end of the shaft; allowing the pointed end of the shaft to be
pulled out of the sidewall.
The flat end of the shaft can be removed from the sidewall without
releasing the spring wire tension.

SECTION 2
ASSEMBLY
13
External Feeder Control Setup
CAUTION
THIS PROCESS SHOULD BE PERFORMED BY A QUALIFIED SERVICE
PERSON.
PLEASE CONTACT YOUR LOCAL DEALER FOR
TECHNICAL HELP.
INFORMATION PROVIDED IN THIS SECTION IS FOR USE BY THE
SERVICE TECHNICIAN.
WARNING
BEFORE PERFORMING THIS TASK, DISCONNNECT THE TABBER
FROM ITS POWER SOURCE!
Transport Stop Delay Feature:
Allows the Tabber to continue to cycle the Transport System for a few seconds, before
the Tabber Transport stops. When used with an external Feeder; this feature is useful to
clear the Tabber of material before it stops.
x When the Feed Button is pressed to start the system: Tabber Transport
System is engaged. At the same time, the Tabber sends a signal to the external
Feeder to start the Feeder.
x When the Feed Button is pressed again to stop the system: Tabber sends
a signal to stop the Feeder, but the Tabber Transport continues to cycle for a
few additional seconds. This clears the Tabber of all media before it stops.
To enable the Transport Stop Delay feature: Jumper J7 must be removed from the
Main PCB of the Tabber. Keep the Jumper in a safe place for possible future use.
To disable the Transport Stop Delay feature: Jumper J7 must be installed on the
Main PCB of the Tabber.
Remove Control Panel Cover (2 top screws, 2 bottom screws) to access the Main PCB.
Jumper J7 installed = "stand-
alone" mode (no delay in Tabber
Transport stop.)
Jumper J7 removed = "in-line"
mode (3 second delay in Tabber
Transport stop.)

SECTION 2
ASSEMBLY
14
Connecting the ATS-9800 to an External Feeder
Using the appropriate interface cable, attach the external Feeder's Interface Port to the
ATS-9800's FEEDER Interface Port.
WARNING
IF AN INAPPROPRIATE CABLE CONNECTION IS MADE, DAMAGE
TO THE TABBER AND OR FEEDER MAY OCCUR.
If you don't have the appropriate cable or don't know if your feeder is compatible; please
contact your local dealer for technical help.
The ATS-8900's Feeder Interface Port provides the following dry contact outputs.
Maximum current capacity = 10 mA
Pin 1: Common
Pin 2: Normally Closed
Pin 3: Normally Open
Choosing a Location
Place Tabber on a flat, stable work surface that can properly support the weight of the
Tabber and any peripheral equipment (Feeder, Conveyor, media, tabs, etc...).
The Tabber should be located in an area that is away from windows or heat sources.
Sunlight will deteriorate the rubber and plastic components on the Tabber, and can cause
problems with the functioning of the Media Sensor.
NOTE: Strong overhead interior lighting can also cause problems with the
functioning of the Media Sensor.
An electrical outlet must be located near the unit. The power cord should be routed in a
way that it does not cross an access corridor.

SECTION 2
ASSEMBLY
15
Connecting Power
1. The ATS-9800 is manufactured for use on a
specific AC voltage source. Before connecting
the power cord to the Tabber; verify that you
are connecting the unit to a compatible AC
voltage source. See serial tag for the voltage
rating of your unit.
2. Verify that the Power Switch is turned OFF
(0) position.
3. Plug the power cord, supplied, into the power
receptacle; as shown.
4. Plug the other end of the power cord into the
wall outlet.
5. To protect the unit from possible power line
surges or spikes; it is recommended that you
attach the Tabber to suitable surge/spike protector.
6. To replace the fuse, unplug the power cord from the Power Inlet, depress the tab on
the bottom of the Fuse Holder and remove the Fuse Holder. Replace the fuse and
return the Fuse Holder to the socket.
CAUTION
DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO
CONNECT
THE TABBER TO THE 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.

SECTION 3
OPERATING THE TABBER
16
SECTION 3 – OPERATING THE TABBER
Theory of Operation:
The ATS-9800 can be used as a "stand-alone" or an "in-line" machine. It can be set up
to place one or two tabs at the leading edge of the media.
When the Media Sensor detects the lead edge of the media, the tab drive cycle is started. A
tab is presented in front of the media. The media contacts the center area of the tab. As the
media advances forward, the Exit Rollers fold and press the tab to the media, as they drive
the media out of the exit end of the Tabber. The tab drive cycle stops until another piece of
media is seen by the Media Sensor.
The tab fold position is adjusted by changing the position of the Media Sensor, using the
"Tab Fold Adjustment Knob".
When the Tab Fold Knob is adjusted fully clockwise, the Media Sensor sees the leading
edge of the media at the earliest time. This provides more time for the tab to advance,
before the media makes contact with the tab; thereby providing more tab area to the
bottom of the media.
The further the Tab Fold Knob is adjusted counterclockwise, the later the Media Sensor
detects the leading edge of the media. This provides less time for the tab to advance;
thereby providing more tab area to the top of the media.
Important Operating Tips:
Media transport speed affects the tab fold position.
It is important to set your desired media transport speed first, and then adjust for the desired
tab fold position.
Example: If you slow the machine down, without readjusting the tab fold
position, you will notice that more tab area will be applied to the bottom of the media. This
occurs because a slower media transport speed allows the tab to advance further before the
leading edge of the media makes contact with the tab.
If Tab Fold Adjustment Knob is turned too far counterclockwise, erratic tab
placement on the media may occur.
This occurs because there is not enough tab area/length advancing below the surface of
the media. When the leading edge of the media hits the tab, the tab may not fold around
the edge, as expected. Instead it may slide across the top of the media and attach at any
point along the top of the media, or not attach to the media at all. If you experience erratic
tab placement behavior or tabs being dispensed off the media; reset the Tab Fold Adjustment
Knob to the fully clockwise position. Then slowly adjust the Knob counterclockwise, for the
desired tab fold position. Run at least two pieces each time you make an adjustment and
check the new tab fold position.
If you are still experiencing tab positioning problems, even after following the above
procedure, check to be sure you have threaded the tabs correctly.
See the "Troubleshooting" Section for additional information.

SECTION 3
OPERATING THE TABBER
17
Loading/Threading Tabs:
1. See the "Tab Stock Threading Diagrams" for additional help. Remove the lid
from the box of tab stock.
Tip: The box lid can be placed on the bottom of the tab box for storage.
2. Slide the tab box into the Tab Box Tray, as shown.
3. Thread the tabs over the black plastic shaft and between the two metal shafts.
IMPORTANT! Verify Proper Tab Stock Orientation.
At this point, the tab side of the stock should be facing down, as shown above.
If the tab side of the stock is facing up, then you must remove the tab box from
the Tray, turn it around 180 degrees and restart from Step 1.
4. Remove the first 18 tabs from the backing, to create a leader.
5. Lift the Peel Bar to its "threading position".
Tip: The Peel Bar locks into the upper and lower positions.
Pull forward on the Peel Bar Locks to release the Peel Bar,
and slide the Peel Bar to the new position. When you release
the Peel Bar Locks, the Peel Bar locks into the new position.

SECTION 3
OPERATING THE TABBER
18
6. Thread the tabs under the small shaft at the top of the Tab Drive
Assembly. Pull about 18 inches of tab stock out of the front of the Tab
Drive Assembly.
Verify Proper Tab Stock Orientation:
Tabs must be located on the front side of the stock,
as shown. If the tabs are located on the back of the
stock, then you must remove the tabs from the
unit, remove the tab box from the Tray and turn it
around 180 degrees. Restart process from Step 1.
7. Thread tabs under the Peel Bar and out of the
other side of the Tab Drive Assembly, as shown.
8. Position tab stock so the center hole in tab is
aligned with red dots on Tab Drive Assembly.

SECTION 3
OPERATING THE TABBER
19
9. Bring the tab backing up around the back
side of Take-Up Spools. Insert the end of
the leader into the slit in the spool.
Tip: Folding the tab backing, at the insert
point, will help it hold onto the spool.
10. Advance the Take-Up Spool until you have
removed the slack in the leader.
11. Re-verify that the center hole of the first
tab on the leader is still aligned with the
red dots at the inside edges of the Tab
Drive Assembly.

SECTION 3
OPERATING THE TABBER
20
12. Using the Peel Bar Locators, slide the Peel
Bar down to its "run position". It should
lock into position.
IMPORTANT! When the Peel Bar is in the
lower position (run position); the red dots at
the inside edges of the Tab Drive Assembly,
should align with the space between two
tabs. Verify that this alignment is correct
before you continue.
13. If only placing one tab onto the media,
tab loading/threading process is finished.
To place two tabs onto the media:
Repeat this process, beginning from Step 3,
to load/thread a second row of tab stock into
the Tabber.
See the "Tab Stock Threading
Diagrams" for additional help.
14. Proceed to "Setting Up the Feed System".