Barry-Wehmiller Accraply 204RH User manual

AUTOMATED TAMPER-EVIDENT SEAL
APPLICATOR
Customer: UCB Manufacturing, Inc.
Machine Serial Number: MSN07411
Manual Revision #: R01
Revision Date: 5/21/13
OPERATION AND MAINTENANCE MANUAL
For service and parts, call ACCRAPLY:
Phone: [phone]
Toll Free: 1-800-387-6742
(System parts/drawings found in Section 2. Head parts/drawings found in Section 4.)

iCUSTOMER SERVICE AND SPARE PARTS
CUSTOMER SERVICE AND SPARE PARTS
Customer Service and Spare Parts
Customer Service
Our trained Service Technicians are available to provide installation and training and ensure you have fast and efficient
start-up. Training your personnel in the proper operation, setup, and maintenance procedures for your Accraply labeler
ensures excellent long-term performance and reliability. Our Service Department can also assist you in retooling,
upgrading, rebuilding and adding the labor saving accessories available for your labeler. Accraply Service Technicians
are available to provide phone support Monday through Friday (excluding holidays), during daytime working hours.
To request service for an Accraply Labeler, contact our Service Department at location below.
Ordering Parts
Please use the resources provided in our manual. The Bill of Materials and corresponding drawings of the system are
in Section 2 (Head parts are in Section 4). The Bill of Material will assist you with identifying your parts needs. Feel
free to phone, email or fax your parts inquires to the Parts Department, contact information noted below.
Thank you for purchasing an Accraply Labeling System!
ACCRAPLY CANADA INC.
3070 Mainway Drive, Units 16-19
Burlington, Ontario L7M 3X1 Canada
Phone: [phone]
Fax: [phone]
3580 Holly Lane North
Plymouth, MN 55447 USA
Phone: [phone]
Fax: [phone]
760 Rochester Ave., Suite A
Ontario, CA 91761 USA
Phone: [phone]
Fax: [phone]
www.accraply.com
Our other locations that support parts and service requirements:

ii CUSTOMER SERVICE AND SPARE PARTS
CUSTOMER SERVICE AND SPARE PARTS
Recommended Spare Parts List
Assembly Number Assembly Name
Item Number Qty Item Name
080800-07411 Infeed, Metering Wheel
80369 2Wheel, Product
603 80 5 - 07411 Squaring, Assembly
117068 1 Sensor, Rotary Cylinder
603 900 - 07411 Sensor, Product Standard
105039 1 Sensor, Retro-Reflective (Banner)
621597 1 Sensor, Photo Reflective (Sick)
608888-07411 Applicator, 204 Rh
611457 1 Board, Cpu Assy 204 Prq
611458 1 Supply, Power
611459 1Panel, Operator Assy
6116 8 8 1T-Belt
611719 1 Motor, Stepper Assy
611724 1Driver, Moter
611727 1 Roller, Feed 4 (Als 204)
611776 1 Sensor, Rewinder Assy
619662 1 Sensor, Opt Label
621893 1Wipe, Squeegee
611111- 07411 Sensor, Low Label Assy. (204)
600260 1 Sensor, Omron
61320 0 - 07411 Sensor, Ultrasonic Label 20X
149772 1Sensor, Ultrasonic Label
62159 8 - 07411 Conveyor, Belt 8"W X 120" Lg
2959 1Belt, Timing 187L050
611836 1 Encoder,1000 Ppr-Pnp-M6 Shaft
621736 1 Belt, Conveyor 8"W X 120" L
62170 0 - 07411 Station ,Wipe Down
602493 2Switch, Reed
602673 2 Sensor, Magnetic
621741 1Vision, Checker Sensor
Note: Connectors may need to be ordered with certain sensors, encoders, scanners, etc. Please indicate Machine
Serial Number when requesting spare parts. (The Machine Serial Number is identified on the cover page of this
manual in the format of “MSN#####” or “RC######”).

TABLE OF CONTENTS
TABLE OF CONTENTS
TABLE OF CONTENTS
Customer Service and Spare Parts ...............i
Customer Service .......................................i
Ordering Parts .........................................i
Recommended Spare Parts List............................ii
Table of Contents
SECTION 1: SYSTEM OPERATION
1.1 Safety Procedures..........................1
1.1.1 General Guidelines ................................ 1
1.1.2 Cautions and Warnings ............................. 1
1.1.3 Maintenance Safety................................ 1
1.1.4 Machine Safety Labels ............................. 2
1.2 Introduction ..............................13
1.3 General Information .......................14
1.3.1 Shipping and Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.2 Service Requirements ............................. 14
1.3.3 Technical Data ................................... 14
1.3.4 Installation Procedures ............................ 15
1.3.5 General System Layout ............................ 16
1.3.6 General System Process........................... 17
1.3.8 Sensors ........................................ 19
1.3.9 P&ID .......................................... 21
1.4 Setup and Adjustments ....................22
1.4.1 Threading Diagram ............................... 22
1.4.2 Label Position and Application....................... 23
1.4.3 Clearance Sensor Setup ........................... 24
1.4.4 Wipe Sensor Setup ............................... 25
1.5 Operating Procedures .....................26
1.5.1 Controls ........................................ 26
1.5.2 Startup Procedure ................................ 27
1.5.3 Alarm Indicators.................................. 28
1.5.4 Alarm List....................................... 29
1.6 Maintenance .............................31
1.6.1 General Maintenance ............................. 31
1.6.2 Preventive Maintenance ........................... 32
1.6.3 Troubleshooting .................................. 33
SECTION 2: SYSTEM PARTS
2.1 Assembly List .............................1
2.2 System Parts List & Drawings ................2
MSN07411 - System Layout .............................. 2
080800-07411 - Infeed, Metering Wheels.................... 4
600008-07411 - Stand, Custom ........................... 6
600106-07411 - Pnu, Assembly 4 Station.................... 8
600107-07411 - Light, Stack............................. 10
600606-07411 - Pnu, 1 Station SMC 2100 .................. 12
600895-07411 - Control, Electrical ........................ 14
603805-07411 - Squaring, Assembly ...................... 16
603480-07411 - Guide, Rail Assembly ..................... 18
603900-07411 - Product, Sensor Assembly ................. 20
608888-07411 - Applicator, 204 RH ....................... 22
611111-07411 - Sensor, Low Label Assy (204) ............... 24
619543-07411 - Guard, 20X Pinch Roller................... 26
621598-07411 - Belt Conveyor 8”W x 10’ Lg ................ 28
621699-07411 - Turn, Assembly .......................... 30
621700-07411 - Wipe, Down Station ...................... 32
621701-07411 - Eject, Bin Assembly ...................... 34
621870-07411 - Guard, Infeed ........................... 36
SECTION 3: ELECTRICAL DRAWINGS
3.1 Electrical Drawings .........................1
200000-07411 - Sheet 1 of 9 ............................. 2
200000-07411 - Sheet 2 of 9 ............................. 3
200000-07411 - Sheet 3 of 9 ............................. 4
200000-07411 - Sheet 4 of 9 ............................. 5
200000-07411 - Sheet 5 of 9 ............................. 6
200000-07411 - Sheet 6 of 9 ............................. 7
200000-07411 - Sheet 7 of 9 ............................. 8
200000-07411 - Sheet 8 of 9 ............................. 9
200000-07411 - Sheet 9 of 9 ............................ 10
621593 - Pnu, Schematic ................................11
SECTION 4: APPENDIX
Sensor, Banner (105039)
Sensor, Rotary Cylinder (117068)
Sensor, Ultrasonic (149772)
Sensor, Low Label (600260)
Sensor, Sick (621597)
Cognex, Checker 4G Quick Start Guide
Accraply 204/206 Operator’s Manual
Accraply 204/206 Service Manual
Accraply 204/206 Spare Parts Catalog

AUTOMATED TAMPER-EVIDENT SEAL
APPLICATOR
Customer: UCB Manufacturing, Inc.
Machine Serial Number: MSN07411
Manual Revision #: R01
Revision Date: 5/21/13
SECTION 1:
SYSTEM OPERATION

1SECTION 1: SYSTEM OPERATION
1.1 Safety Procedures
1.1.1 General Guidelines
• Read and understand your Operation and Service Manual. Understand how to operate the Labeler before using it.
• Keep a regular maintenance schedule. A well maintained machine operates more efficiently.
• Do not operate the Labeler unless all components have been properly installed.
• Do not operate the Labeler unless all components are working properly.
• Do not use the Labeler to label products other than those for which it was designed.
• Do not operate the Labeler at faster speeds than those for which it was designed.
• Refer to Section 4, Appendix for safety instructions for purchased components.
1.1.2 Cautions and Warnings
• Do not operate the Labeler unless it has been electrically grounded.
• Do not remove protective covers and/or guards.
• Use extreme care to keep hands away from all pinch points during machine operation, especially between the
knurled and pressure rollers on the Applicator Head.
• Do not remove the product from the conveyor while the conveyor is moving. Stop the conveyor first.
• Do not wear loose clothing, jewellery, or ties that can be pulled into the machine during operation or maintenance.
Tie back and secure long hair that may get caught in machine.
1.1.3 Maintenance Safety
• Do not work on the drive system without locking out the power.
• Do not place your hands near a potentially moving surface without locking out the power.
• Use extreme care to avoid contact with the power supply voltages when performing maintenance inside the
Applicator Head enclosure.
• Replace all protective covers and/or guards if they have been removed for maintenance or repair.
• Do not operate, troubleshoot, or maintain the equipment while under the influence of any type of drug or alcohol.
• Do not use flammable or toxic cleaning fluids such as gasoline, benzene or ether when cleaning or maintaining the
equipment.
• Do not use lubricants and spare parts not specified in this manual. Doing so will cause increased downtime, poor
equipment performance and reduce the long term operating life of the machine.
• Do not touch the print head (if applicable) without discharging your static potential by touching the metal enclosure.
The print head is an electronic module and is highly sensitive to static impacts, which will damage the unit.
SAFETY PROCEDURES

2SECTION 1: SYSTEM OPERATION
1.1.4 Machine Safety Labels
This machine is equipped with safety labels. These safety labels are placed on the machine to identify areas that may
be hazardous to the personal safety of the operator. Read, Understand and Follow these safety notices.
The descriptions in this manual cover warning labels for machines that are covered by different regulatory codes and
standards. Thus, every label described in this section is not found on every machine. Safety label descriptions for
special/extra equipment on the machines is found in the Original Equipment Manufacturer manuals that are sent to the
customer.
The safety labels used on the machines may use signal words. Each signal word is colour coded.
Background Colour Label (not actual size) Description
Red DANGER indicates an imminently hazardous situation which, if
not avoided will result in death or serious injury.
Orange WARNING indicates a potentially hazardous situation which, if
not avoided could result in death or serious injury.
Yellow CAUTION indicates a potentially hazardous situation which, if
not avoided may result in minor or moderate injury.
Safety labels can wear out. To obtain replacement safety labels for your machine, please contact our Parts Department
ACCRAPLY CANADA INC.
Parts Department
3070 Mainway Drive, Units 16-19
Burlington, Ontario L7M 3X1 Canada
Phone: [phone]
Fax: [phone]
ELECTRICAL ENCLUSURES
Name Figure Part # Approx. Size Label (not actual size)
Electrical Shock/
Electrocution
6010B-iso 850474 2” x 2-1/4”
6010C-iso 850475 1-1/4” x 1-3/8”
This label is used to mark electrical enclosers that do not clearly show
that they contain electrical devices and for enclosures that have a main
power switch and or a power cord.
SAFETY PROCEDURES

3SECTION 1: SYSTEM OPERATION
Name Figure Part # Label (not actual size)
Hazardous Voltage H6010-B1.whpk 11955 4
Electrical enclosures with a disconnect that opens the only
source of power are marked with this label. The label is
used for “hard wired” and corded machines.
Name Figure Part # Label (not actual size)
Voltage Present Accraply Special 119582
Some enclosures have a disconnect that does not open
all of the power sources. If the switch is in the off position,
dangerous voltage is present.
Name Figure Part # Label (not actual size)
Potential Arc-Flash H6006-718.whpk 134778
1. Before opening any enclosure that may contain
energized circuit parts or equipment, every source
of power over 50 volts must be disconnected and
appropriate lockout/tagout procedures initiated.
2. After the enclosure is opened, a “qualified person
wearing suitable PPE must use appropriate test
equipment to test all exposed parts insuring that the
equipment is electrically safe. Special consideration
must be given to insure that all capacitors are
discharged and that all control power disconnected.
Until the testing is completes, OSHA considers the
equipment to be electrically unsafe.
There are only two exceptions to this requirment:
1. It will create a greater hazard to de-energize the
equipment typified by disconnecting ventilation to
hazardous areas, or alarm systems.
2. Access to energized equipment is required to
perform voltage, current, or other tests.
SAFETY PROCEDURES

4SECTION 1: SYSTEM OPERATION
Name Figure Part # Label (not actual size)
Protective Earth IEC-5019a-c 850483
This label may be found inside of each electrical enclosure next to the
grounding bus (protective bonding terminal). It is the protective earth
(ground) symbol.
ENTANGLEMENT HAZARDS - GUARDS
Figure Label (not actual size)
1012-02.wvpk
Part #
1195 4 6
Figure Label (not actual size)
1012-05.wvpk
Part #
1195 47
Figure Part #
1114 - 41.whp k 1195 58
Label (not actual size)
Figure Part #
8034-S9whpk 119556
Label (not actual size)
SAFETY PROCEDURES

5SECTION 1: SYSTEM OPERATION
Figure Part #
1009-02.whpk 119544
Label (not actual size)
Figure Part #
1009-05.whpk 1195 45
Label (not actual size)
Figure Part #
H1143-f6.whpk 134779
Label (not actual size)
Figure Part #
1056-ftwhpk 119550
Label (not actual size)
Figure Part #
1043-39.whpk 119551
Label (not actual size)
SAFETY PROCEDURES

6SECTION 1: SYSTEM OPERATION
Figure Part #
1014-04whpk 104501
Label (not actual size)
Figure Part #
1143-388.whpk 121574
Label (not actual size)
CUTTING HAZARDS
Figure Label (not actual size)
1018-82.wvpk
Part #
119552
Figure Label (not actual size)
H1007-04.wvpj
Part #
123217
SAFETY PROCEDURES

7SECTION 1: SYSTEM OPERATION
SYMBOLS
Label Example Description
ISO “Warning Safety Sign”. This type of label is meant to tell you what the hazard is
(e.g. Burn hazard/hot surface).
ISO “Prohibition Safety Sign”. This label tells you about an action NOT to take in order
to avoid a hazard (e.g. Stay clear of area).
ISO “Manditory Action Safety Sign”. This label tells you about an action that NEEDS
to be taken in order to avoid a hazard (e.g. Lock out electrical power).
GENERAL DANGER
Name Figure Part # Label (not actual size)
General Danger 6014B-iso 850477
There are some machine functions that need a general danger warning.
ENTANGLEMENT HAZARDS
Name Figure Part # Label (not actual size)
Rotating Shaft 114 6 B -i so 120958
Entanglement of fingers or hand/ rotating shaft. Keep hands clear of the
machine. Do not operated the labeler with the guard removed. Follow your
company’s lockout procedure before servicing the machine.
SAFETY PROCEDURES

8SECTION 1: SYSTEM OPERATION
Name Figure Part # Label (not actual size)
Belt Drive 1009B-iso 850470
Entanglement of hand/belt drive. Keep hands clear of the machine. Do
not operated the labeler with the guard removed. Follow your company’s
lockout procedure before servicing the machine
Name Figure Part # Label (not actual size)
Rotating Gears 1014B-iso 850484
Entanglement of hand/rotating gears. Keep hands clear of the machine.
Do not operated the labeler with the guard removed. Follow your
company’s lockout procedure before servicing the machine.
CRUSH HAZARDS
Name Figure Part # Label (not actual size)
Roller Pinch Point 1043B-iso 850472
Crush of hand/roller pinch point. Keep hands clear of the machine. Do
not operated the labeler with the guard removed. Follow your company’s
lockout procedure before servicing the machine.
SAFETY PROCEDURES

9SECTION 1: SYSTEM OPERATION
Name Figure Part # Label (not actual size)
Roller Pinch Point 115 6 B -i so 122950
Crush of hand/roller pinch point. Keep hands clear of the machine. Do
not operated the labeler with the guard removed. Follow your company’s
lockout procedure before servicing the machine.
Name Figure Part # Label (not actual size)
Roller Pinch Point N/A N/A
Crush of hand/roller pinch point. Keep hands clear of the machine. Do
not operated the labeler with the guard removed. Follow your company’s
lockout procedure before servicing the machine.
Name Figure Part # Label (not actual size)
Hand Crush, Force From Side 1042B-iso 850471
Crush of hand/force from side. Keep hands clear of the machine. Do
not operated the labeler with the guard removed. Follow your company’s
lockout procedure before servicing the machine.
Name Figure Part # Label (not actual size)
Hand Crush, Force From Above 1017B-iso 850485
Crush of hand/force from above. Keep hands clear of the machine. Do
not operated the labeler with the guard removed. Follow your company’s
lockout procedure before servicing the machine.
SAFETY PROCEDURES

10 SECTION 1: SYSTEM OPERATION
CUTTING HAZARDS
Name Figure Part # Label (not actual size)
Cutting Of Fingers Or Hand, Rotating Blade 1007B-iso 123216
Cutting of fingers or hand/rotating blade. Keep hands clear of the
machine. Do not operated the labeler with the guard removed. Follow your
company’s lockout procedure before servicing the machine.
HEATED SURFACE HAZARDS
Name Figure Part # Label (not actual size)
Burn Hazard, Hot Surface 6043B-iso 850479
Burn hazard/hot surface. Keep clear of the machine. Do not operated the
labeler with the guard removed. Follow your company’s lockout procedure
before servicing the machine.
ELECTRICAL HAZARDS
Name Figure Part # Label (not actual size)
Lock Out Electrical Power 6 011B - iso 850476
This label informs the user to lockout the electrical power. Follow your
company’s lockout procedure before servicing the machine.
SAFETY PROCEDURES

11SECTION 1: SYSTEM OPERATION
Name Figure Part # Label (not actual size)
Switch Power Off Before Beginning Work 6058B-iso 119553
This label alerts the operator to switch off the electrical power before
beginning any service or repair work. Follow your company’s lockout
procedure before servicing the machine.
Name Figure Part # Label (not actual size)
Unplug Before Opening U.S. Plug 6057B-iso 850480
This label informs the user to pull the electrical plug to disconnect the
power. Follow your company’s lockout procedure before servicing the
machine.
Name Figure Part # Label (not actual size)
Read Operators Manual 6017B-iso 850478
The label is placed on the machine to instruct the user to refer to the
operator/service manual for safety information.
Name Figure Part # Label (not actual size)
Stay Clear 6008B-iso 850473
The label is placed on the machine to instruct personnel to stay clear of the
area.
SAFETY PROCEDURES

12 SECTION 1: SYSTEM OPERATION
Name Figure Part # Label (not actual size)
Do Not Operate With Guard Removed 6060B-iso 850481
Do not to operate the machine with the guard removed.
Name Figure Part # Label (not actual size)
CE Label CE-D.75x.75 11392 2
This label is placed on machines that are built to meet the European
Community standards. This label is used for CE rated machines.
Name Figure Part # Label (not actual size)
PE Label Figure PE-E 1195 48
Physical earth.
ADDITIONS
This section allows for additional safety images and definitions between major content updates.
Name Figure Part # Label (not actual size)
Do Not Operate With Guard Removed 6062B-iso 850482
No access for unauthorized persons.
SAFETY PROCEDURES