BUSKRO BK730-2 User manual

BK730-2 Tabber 2
Part No. 9104528 User’s Guide V1.2

Buskro Ltd. BK730-2 Tabber
BK730-2 Tabber User’s Guide
Published by:
Buskro Ltd.
1738 Orangebrook Court, Unit #1
Pickering, ON, L1W 3G8
Canada
Tel.: [phone]
Fax: [phone]
All Rights Reserved. No part of this book may be used or reproduced in any form or by
any means, electronic or mechanical, or stored in a database or retrieval system,
without prior written permission of Buskro Ltd. except in case of brief quotations
embodied in critical articles or reviews. Making copies of any part of this book for any
purpose other than your own personal use is a violation of copyright laws.
Copyright © 2007, Buskro Ltd.
First Edition, 2007
Printed in Canada
This manual is sold as is, without warranty of any kind, either express or implied,
respecting the contents of this manual, including but not limited to implied warranties for
the manual’s quality, performance, merchantability, or fitness for any particular purpose.
Neither Buskro Ltd. nor its dealers or distributors shall be liable to the purchaser nor any
other person or entity with respect to any liability, loss, or damage caused or alleged to
be caused directly or indirectly by this manual.
Manual History
Version Date Description ECO No.
1.0 29-Jun-07 Manual Released. -
1.1 07-Jul-08 Appendix B-15 updated for Tabber II CPU DIP switch settings. 1090
1.2 28-Sep-11 Page update A-59, Assembly 9104144A wiring update. 1312

BK730-2 Tabber
Buskro Ltd. BK730-2 Tabber
Table Of
Contents
1.0 General Information.............................................................................1-0
1.1 Description ............................................................................................................ 1-1
1.2 Features................................................................................................................. 1-2
1.2.1 High Speed Production.................................................................................... 1-2
1.2.2 Integration with Buskro and 3rd Party Equipment........................................... 1-2
1.2.3 Simplified Mechanical Adjustments................................................................ 1-2
1.2.4 Software Controlled Tabber/Labeler Head Functions..................................... 1-3
1.2.5 Construction, Safety Features, and Maintenance............................................. 1-3
1.2.6 Tabbing Quality Considerations...................................................................... 1-3
1.3 Tabber/Labeler Base Specifications ................................................................... 1-5
1.4 Tabber/Labeler Head Specifications .................................................................. 1-6
1.5 Tabber/Labeler Base and Head Dimensions...................................................... 1-7
2.0 BK730-2 Base.........................................................................................2-0
2.1 Instrument Panel Functions ................................................................................ 2-1
2.1.1 Feed Disable Control ....................................................................................... 2-1
2.1.2 START Pushbutton.......................................................................................... 2-2
2.1.3 STOP Pushbutton............................................................................................. 2-2
2.1.4 JOG/RUN Selector........................................................................................... 2-2
2.1.5 Speed Control Module Connector ................................................................... 2-3
2.1.6 POWER Rocker Switch (Main Power)............................................................ 2-3
2.1.7 HEAD Rocker Switch (Head Power) .............................................................. 2-4
2.1.8 Production Speed Regulation Dial................................................................... 2-4
2.1.9 Tabber Connection Receptacle Panel.............................................................. 2-5
2.2 Upstream and Downstream Installation Instructions....................................... 2-6
2.2.1 Physical Alignment of Upstream/Downstream equipment.............................. 2-6
2.2.2 Electrical Connection to Upstream/Downstream equipment........................... 2-7
2.2.3 The Base Control Board (p/n 9102380A)........................................................ 2-8
2.2.4 The Speed Control Board (p/n 9102421)....................................................... 2-11
2.3 Product Setup Instructions................................................................................ 2-17
2.3.1 To adjust the base speed for smooth product transfer ................................... 2-17
2.3.2 Skidbar and Material Side Guide Adjustments.............................................. 2-18
2.3.3 Product Thickness Adjustment (Upper Transport)........................................ 2-22
2.4 Advanced Setup Instructions............................................................................. 2-23
2.4.1 Crease and Pinch Roller Adjustment............................................................. 2-23
2.5 Maintenance Schedule........................................................................................ 2-26
3.0 Tabber/Labeler Head (BK731-2).........................................................3-0
3.1 Mechanical Adjustments...................................................................................... 3-1
3.1.1 Tabber/Labeler Head Lateral Positioning........................................................ 3-1
3.1.2 Peel Point Setup for Different Product Thickness........................................... 3-2

3.1.3 Peel Point Lateral Adjustment......................................................................... 3-3
3.1.4 Label Spool Threading and Lateral Positioning.............................................. 3-4
3.1.5 Despool Brake Adjustment.............................................................................. 3-6
3.2 Labeler Connector Panel..................................................................................... 3-7
3.3 Wide Labeler Guidelines (BK731-2WL & UBK-731-WL)............................... 3-8
3.3.1 Importance of the Right & Left Side Guides................................................... 3-8
3.3.2 The Tabber Skidbar Assembly......................................................................... 3-9
3.3.3 Wide Label Pressure Roller........................................................................... 3-11
3.3.4 Label Backer Tension.................................................................................... 3-12
3.3.5 Idler Roller Setup........................................................................................... 3-13
3.3.6 Fanfold Supply Tray Assembly (p/n 9102031A)........................................... 3-14
3.3.7 Independent Nip Roller Height Adjustment.................................................. 3-15
4.0 User Interface ........................................................................................4-0
4.1 Tabber/Labeler Keypad Interface...................................................................... 4-1
4.2 Keypad Setup Menu............................................................................................. 4-2
4.2.1 Front or Back Product Sensor Selection.......................................................... 4-2
4.2.2 Adjustment of the Product Sensor Position..................................................... 4-3
4.2.3 Production Counter Resetting.......................................................................... 4-3
4.2.4 Software Version ............................................................................................. 4-4
4.2.5 Factory Reset ................................................................................................... 4-4
4.2.6 Life Count Display........................................................................................... 4-4
4.2.7 Form Size Error................................................................................................ 4-5
4.2.8 Displaying Metric Units on the Operator Keypad........................................... 4-5
4.3 Keypad Test Menu ............................................................................................... 4-6
4.4 Keypad Position Menu......................................................................................... 4-8
4.4.1 Label Spacing Option ...................................................................................... 4-8
4.4.2 Number of Labels ............................................................................................ 4-9
4.4.3 Product Length Entry....................................................................................... 4-9
4.4.4 Manual Label Position................................................................................... 4-10
4.4.5 Keypad Labels Menu..................................................................................... 4-11
4.4.6 Label Pitch Auto and Manual Setting............................................................ 4-11
4.4.7 Type of Label Setting .................................................................................... 4-13
4.4.8 Peel Point Sensor Adjustment........................................................................ 4-13
4.4.9 Peel Point Sensor Nudge Factor .................................................................... 4-14
4.5 Operational Controls.......................................................................................... 4-14
4.5.1 Online/Offline Status..................................................................................... 4-14
4.5.2 Product Count, Production Rate, and Belt Speed Display............................. 4-15
4.5.3 Error Conditions ............................................................................................ 4-15
4.6 Maintenance Schedule........................................................................................ 4-16
Appendix A – Assembly Drawings
Appendix B – Electrical Drawings
Buskro Ltd. BK730-2 Tabber

General Information
Buskro Ltd. BK730-2 Tabber
Chapter 1
1.0 General Information

Chapter 1 General Information Page 1-1
1.1 Description
The Buskro BK730-2 Tabber/Labeler is designed to apply pressure-sensitive tabs onto
mail pieces and can be used as a wrap-around tabbing unit or as a labeling system. The
system consists of two major components, the transport base, which conveys the mail
piece, and the tabbing head, which applies the individual tabs. The system offers full
flexibility in its ability to apply a number of tabs on either edge of the mail piece.
Simplified mechanical adjustments and software controlled tab placement functions offer
unsurpassed ease of use permitting rapid job setups.
The mail piece, which is conveyed into the system by a feeder or inkjet system, is
transported against a registration rail resulting in a tightly controlled tab-wrap. In addition,
the presence of but a few mechanical adjustments for thickness and edge selection, gives
the operator the tools necessary to accurately and rapidly setup for a variety of mail
pieces.
In keeping with Buskro’s philosophy of ease of use, the Tabber/Labeler head is designed
with many innovative features. The Tabber/Labeler head is controlled through software
via an operator keypad that permits rapid selection of the number of tabs dispensed and
their placement positions. A unique tab-sensing feature allows the operator to easily
adjust the tab pitch at a touch of a button. The Tabber/Labeler head was designed with a
few mechanical parts to allow easy tab threading and machine setup resulting in improved
productivity. The Tabber/Labeler head is mounted on two aluminum extrusion rails that
allow the Tabber/Labeler head to be moved easily from side to side to allow tabbing of
either edge of the mail piece and facilitate fine tune adjustments. In addition, the peel
point assembly can be adjusted up and down and laterally for different material and tab
thickness.
All these features, in addition to the manufacturing quality and innovative product design,
add up to an extremely functional Tabbing/Labeling system capable of years of reliable
and trouble free operation.
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Chapter 1 General Information Page 1-2
1.2 Features
1.2.1 High Speed Production
The BK730-2 is capable of high production speeds in excess of 30,000 PPH for single tab
operations, 25,000 PPH for double tab operations, and 23,000 PPH for triple tab
operations. The unit has been solidly constructed with electrical components capable of
delivering reliable, full-day production.
1.2.2 Integration with Buskro and 3rd Party Equipment
The BK730-2 can now be easily integrated with Buskro inline inkjet, flipover, feeders,
and third party equipments. This is now possible due to the new Base Control Board (p/n
9102380) that comes standard with all next generation Tabbers. The features and
technical discussion of the board’s operation is presented in section 2.3 of chapter 2.
Connections to all inline systems are made through an upstream or downstream connector
(located at the in-feed and out-feed of the base) providing all interface functions. The
required cable for Buskro machines to connect upstream and downstream equipment is the
Universal Interconnect Cable (p/n 9102083A). The Base Control Board passes on a
variety of signals including stop, momentary start signal for upstream and downstream
machines, run signal for upstream equipment, speed control, encoder, and a Heater ON
signal for downstream heaters.
1.2.3 Simplified Mechanical Adjustments
Product size acceptance and compensation is performed on the base through simple
mechanical knob controls; one for product thickness and the other for tab edge selection.
In addition, some simple adjustments can be made in the tab forming area to fine-tune the
tab-wrapping process for improved tab-wrap quality.
The Tabber/Labeler head is designed for ease of use and portability. The operator keypad
is easily accessible simply by sliding it in and out of view. The head is mounted on two
aluminum extrusion rails that allow easy movement for left and right tabbing and fine
Buskro Ltd. BK730-2 Tabber

Chapter 1 General Information Page 1-3
adjustments of tab positioning on the product. The peel point can also be adjusted up and
down and laterally for different product thickness. The peel point lateral adjustment
allows adjustment for different tab material widths. Tab threading is easy since the
system has few rollers and a large tab bin. In addition, the despool roller is not controlled
by a motor but a simple adjustment knob thus reducing the cost of repair. The head is
fully portable as all the electronics are located on the back of the unit and can be
integrated with third party transport bases or web presses as required.
1.2.4 Software Controlled Tabber/Labeler Head Functions
All Tabber/Labeler head functions are controlled through software and use an operator
keypad interface for command entry. A unique feature is the automatic tab pitch
configuration, which allows the operator to automatically set the distance between each
tab on the backing paper at a touch of a button. Other configuration options include the
type of tabs (i.e. clear, solid), position of tabs, full Tabber/Labeler head diagnostics,
product sensor selection, peel point sensor sensitivity adjustment, metric units, material
size error, and production and life counters.
1.2.5 Construction, Safety Features, and Maintenance
All mechanical and electrical system components in the transport base have been designed
for long-lasting and extensive use. Included is a full safety package with feedback
through the operator display, monitored by a series of interlocking sensors. The system
has been designed to facilitate maintenance, should it be required. The transport assembly
including conveying belts and the tabletops are all easily removable for complete
mechanical component access. The Tabber/Labeler operator interface is easily accessible
by a simple slide rail system on the Tabber/Labeler head.
1.2.6 Tabbing Quality Considerations
The Tabber base has been specifically designed for the tabbing process and as such
incorporates a number of unique features to optimize tabbing quality. Particular attention
was paid to the transport belts for accurate edge positioning, the tab wrap section for the
Buskro Ltd. BK730-2 Tabber

Chapter 1 General Information Page 1-4
production of consistently tight tab-wraps, and the addition and optimization of the
tabbing head software controls for ease of use and superior production speeds. The
conveying belts are biased to ensure that product registers against the material side guides
before application of tabs or labels. This ensures that tabs and labels are not applied at an
angle onto the product due to skewing of materials during transport.
Buskro Ltd. BK730-2 Tabber

Chapter 1 General Information Page 1-5
1.3 Tabber/Labeler Base Specifications
Table 1-1: Tabber/Labeler Base System Specifications
Product handling
Minimum 3.0” x 5.0” 76mm x 127 mm
Maximum 16.0” x 17.0” 405 mm x 432 mm
Thickness Single Sheet to 5/8” Up to 38 mm
Physical
Overall Length 47.5” 1203 mm
Overall Height (w/Head) 72” 1829 mm
Height 34.3” to 36.5” 869 mm to 927 mm
Overall Width 29.5” 747 mm
Weight (Crated) 550 lbs 251 kg
Production Rate
Belt Speed 0 to 600 ft/min 0 to 3.00 m/s
Cycle Speed
Single tabs (up to 1”)
0 to 30,000 pph
Cycle Speed
Double tabs (up to 1”)
0 to 25,000 pph
Cycle Speed
Triple tabs (up to 1”)
0 to 23,000 pph
Electrical Requirements
Line Voltage 115 ±15% VAC 220 ±15% VAC for Europe
Line Current 6 Amps 5 Amps for Europe
Power 690 W 1.1 KW
Machine Motor 1/3 H.P. DC controller 1/3 H.P. DC controller
Mechanical Controls
Product Thickness Rotary adjuster for product thickness
Edge Selection Rotary adjuster for lateral table movement
Skidbar Pressure control for product conveyance
Buskro Ltd. BK730-2 Tabber