ASTRO ATS-9900 User manual

ASTRO
ATS-9900
TABBER, LABELER,
AND STAMP AFFIXER
Operator Manual

SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
OBSERVE SAFETY RULES WHEN OPERATING ATS-9900 TABBER, LABELER,
AND STAMP AFFIXER.
BEFORE USING TABBER, READ THIS 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 machine, or performing any
maintenance covered in this manual.
9 Use power cord supplied with machine. Plug it into a properly grounded, easily accessible wall
outlet located near machine. Failure to properly ground 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 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 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
End View with Pressure Roller Cover Open 2
Control Panel 3
SECTION 2 - Assembly and Installation 4
Assembly 4
Installing Tab/Label Applicator Head 5
Installation 7
FF-14 Feeder and Feeder Base 7
SECTION 3 - Operating Tabber 9
Replacing Applicator Head 9
Loading Tabs 10
Aligning Feeder 11
Adjusting Media Guides 11
Adjusting Tab Positioning 12
Operating Tabber 13
Running a Pre-Programmed Job 15
SECTION 4 – Programming Tabber 17
Advanced Soft Key 17
Control Panel Backlight 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-Folded Labels 31
Fan-Fold Labels Up to 2" Long 31
Fan-Folded Labels Over 2" Long 32
Applying Single Stamps 34
Applying Multiple Stamps 34
SECTION 5 – Maintenance 36
Cleaning 36
Rollers and Transport Belts 36
Cleaning Sensors 36
Lubrication 37
SECTION 6 – Troubleshooting 40
Jams 40
Tab Placement Problems 40
Diagnostics 44
APPENDIX – Specifications 47
INDEX 48

ii
NOTES
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GETTING ACQUAINTED
1
SECTION 1 – Getting Acquainted
Front View
1
Media Skew Guide – Helps press media against Fixed Media Guide.
2
Media Guides – Help hold media on Transport Belts.
3
Take-up Reel – Winds up tab web after tab is applied.
4
Reel – Load tabs, 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 Head Assembly
to adjust for thickness of media.

GETTING ACQUAINTED
2
End View with Pressure Roller Cover Open
1
Operator Side Tab Folding Guide – Folds tab under media when tabbing
from operator side of Tabber.
2
Tab Pressure Roller Lock – Locks Tab Pressure Assembly in place.
3
Applicator Head – Two Applicator Heads are supplied:
one for tabs and stamps and one for labels. (Label head shown)
4
Head and Reel Assembly – Contains Tab Reel, Tab Feed Rollers and
Take-up Reel Assemblies.
5
Transport Belts – 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 complete seal.
10
Adjustable Media Forwarding Roller – Adjusts to forward media under
Applicator Head when applying labels or stamps.
11
Adjustable Tab Pressure Roller – Adjustable and presses label or stamp to
media to insure proper application.

GETTING ACQUAINTED
3
Control Panel
1
MAIN POWER SWITCH – Turns Tabber power ON and OFF.
2
HEAD POWER SWITCH – Turns power to Tab/Label motor ON.
3
TRANSPORT POWER SWITCH – Turns transport power ON and OFF.
4
JOG SWITCH – Jogs or moves transport slowly for setup purposes.
5
SPEED CONTROL – Adjusts Tabber speed.
6
LCD DISPLAY – Keeps operator informed 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 "Information Mode".
13
SAVE KEY – Used to save entries into memory.
14
CLEAR KEY – Clears any incorrect entry before it is saved in memory.

ASSEMBLY AND INSTALLATION
4
SECTION 2 - Assembly and Installation
Tabber is shipped in a single carton. Base Unit is below the Head Unit. Remove cardboard carton
from pallet, remove Head Unit from packing material. Next, remove Base Unit and place it on a
flat working surface.
Assembly
CAUTION
HEAD UNIT IS HEAVY. STRONGLY 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 Head Assembly is
properly positioned, two screws [3] that
attach Head Assembly to Adjusting Guide
can be installed.

ASSEMBLY AND INSTALLATION
5
3. Install front mounting screw.
4. Connect two motor cables to Base Unit.
Plugs are keyed to prevent improper
insertion.
Installing Tab/Label Applicator Head
Tabber comes with two Tab/Label Applicator Heads. Narrower 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. 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. Route cable [5] toward rear of Tabber and
plug it in. Attach main motor cable [6]
and wind and rewind motor cable [7] at
this time.

ASSEMBLY AND INSTALLATION
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.

ASSEMBLY AND INSTALLATION
7
Installation
Choose a Location
Place Tabber with its Feeder on a level sturdy worktable or cabinet at least 12" from any
walls. IMPORTANT: Allow enough room to place Feeder and Feeder Base on the same
work surface. Protect Tabber from excessive heat, dust, and moisture – avoid placing it in
direct sunlight.
Plugging in Printer
Make sure Emergency Stop Switch is turned OFF.
1. Connect one end of power cord to rear of Tabber in
corresponding receptacle.
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, install the Feeder Guide Kit included with the Tabber.
Tabber Feeder Guide:
1. Remove protective tape from Guide.
Remove two screws [A] on the feed end of
the Tabber.
2. Align the Tabber Feeder Guide [B] with
holes in the Tabber.
3. Attach the Feeder Guide using screws
removed in Step 1.

ASSEMBLY AND INSTALLATION
8
Feeder Base Guide:
1. Remove protective tape from Feeder Base
Guide [A]. NOTE: DO NOT remove the
Teflon tape strip from the bottom of the
channel on the Guide [B].
Remove two rubber feet [C] from the closed
end of the Feeder Base.
2. Align the Feeder Guide with holes in the
Feeder Base.
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 Base along the interlocking
Feeder Guides to align the Feeder and Tabber for
different media widths [C].

OPERATING TABBER
9
SECTION 3 - Operating Tabber
Tabber is capable of applying up to three tabs to media in one pass.
To set-up Tabber for applying tabs to media:
x
Install proper Tab/Label Applicator Head in Tabber
x
Load tabs
x
Adjust Tabber
x
Program Job
x
Run Job
Replacing Applicator Head
Tabber comes with two Tab/Label Applicator Heads. Narrower 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 reassemble in reverse order.
Applicator Head should be held in uppermost position
when tightening screws. Lower position is for thin
media and small tabs.

OPERATING TABBER
10
Loading Tabs
1. Remove Roll Side Guide and install tab roll with tabs unwinding face up from right side
of roll. Remove approximately 30 tabs from roll to create a leader.
2. Release Unwind Drive Press Roller (rotate it to the left) and thread leader over Unwind
Drive Roller. Rotate Unwind Drive Press Roller so it contacts Unwind Drive Roller.
3. Thread leader into Bin, then over Bin Idler Roller. Adjust Bin Roller Tension Spring 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 Drive Roller.
7. Remove Side Guide from Take up Reel and thread leader through pins on Take-up Reel,
and then replace Side Guide.
8. Make sure Adjustable Web Guides on Bin Idler Roller and Idler Roller lightly contact
edge of tab/label backing.

OPERATING TABBER
11
Aligning Feeder
Alignment of Feeder to Tabber is important to
proper placement of tab on media. Feeder should
be aligned so media is fed within 1/8" to 1/32" of
Tabber's Fixed Guide (as shown).
NOTE: Feeder should never be placed so
media is in contact with Guide as it is being
fed. Media Guides will push media against
Guide for proper alignment during tabbing.
Adjusting Media Guides
Tabber is equipped with two Paper Guides and an adjustable set of angular rollers to help guide
media 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 Media Guide [2] should be placed so
Guide Rollers are on Belt nearest to Fixed
Side Guide [3]. Center Media Guide [2]
should not be placed on any other Belt
except one nearest to one of the Fixed
Media Guides [3]. Short Media Guide [4] can be placed where needed to hold media
down as it passes under Applicator Head.

OPERATING TABBER
12
When running tri-folded or very light
weight media, Media Guide [1] nearest
Fixed Media Guide [3] can be removed and
Center Media Guide [2] can be set at an
angle to give more push to media to hold it
against Fixed Media Guide [3]. Short Media
Guide [4] should then be placed so that it is
centered on tab.
NOTE: All Guide Rollers on Center
Media Guide [2] should be riding on same
Transport Belt.
3. Next, adjust Center Adjustable 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 Positioning
Once tabs are loaded, next step is to adjust tab positioning.
1. Position Head Assembly so tab bisects the
edge of the piece you are tabbing.
2. Loosen Tabber Head locking screw [1] and
slide Head toward operator side of Tabber.

OPERATING TABBER
13
3. Loosen Sensor Guide Knob [3] and
position Pointer [4] over center of tab (as
shown). Then check that center of Tab is
aligned with Tab Folding Guide [5].
4. Close Exit Cover and lock it in position
using the two Locking Levers. Insert one
piece of media into front of Tabber and
adjust Head Pressure Control Crank up or
down until you feel a drag on media.
5. Refer to instructions under
“Operating Tabber” and run
one piece through Tabber.
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.
2. Turn Tabber ON by pressing Main Power Switch, then press Head Power Switch and
Transport Power Switch.
NOTE: If Feeder Interface Cable is installed, make sure Feeder Selector Switch is set to
“Automatic” so Tabber's Speed Control controls Feeder speed.

OPERATING TABBER
14
3. Start-Up screen at right appears. Soft
Keys (at bottom of display) control the
following functions:
a. Job # - Used to select one of four
programmable jobs. More
information can be found under
“Programming Job” section.
b. Pass-Thru – When Pass-Thru is showing, Tabber will tab pieces as they are fed
through it. Pressing this key takes Tabber out of Tabbing mode and puts it in
Pass- Thru mode. In Pass-Thru mode, display shows Operate. When Operate
is showing, Motor and Main Drive Belts of Tabber run, but Tabber will not tab.
This mode is used when Tabber is in-line with other equipment and there is no
need to tab the pieces going through the machine.
c. Advanced – Places Tabber in Advanced mode. Press this key to place Tabber in
Advanced mode. This mode is used to select 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 turning it clockwise, then
press RUN key.
When Tabber is running, screen at right
appears. It contains the following
information:
a. Number of the programmed job
that is running.
b. Number of tabs being applied to
the piece.
c. Rate or speed in pieces per hour.
d. Number of pieces that have been run. This can be reset by pressing CLEAR key
on Control Panel before starting job.
Operation of Tabber is the same whether you are tabbing, applying labels or stamps. Refer to the
parts of this section regarding setting up Tabber for type of application you are performing for
more information.

OPERATING TABBER
15
Running a Pre-Programmed Job
Up to four jobs may be programmed into Tabber's memory. To run a pre-programmed job,
release Emergency 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.

OPERATING TABBER
16
INFO SCREEN INFORMATION
Item
Description
Job #
Number of Job currently selected.
Sensor #
Indicates Sensor (#1 or #2) currently selected.
#Tabs
Number of Tabs being applied.
Tab Pitch
Distance between lead edge of tab and the next tab (including
space between tabs), plus 0.01".
Paper-L
Length of piece in selected measurement (inches, cm, mm).
Offset
Position on 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 screen to
running mode so that Rate in Pieces
per Hour and number of Pieces Run
are displayed.
2. To stop Tabber, press Red Stop key (next to RUN key on Control Panel).