BUSKRO BK731 User manual

BK731 Labeler
Part No. 9100619 User’s Guide V1.0

BK731 Labeler User’s Guide
By Mike Tran, Frank Baehr, Ming Ho, and Greg Yetman
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 © 2002, Buskro Ltd.
First Edition, 2002
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.
Buskro Ltd. BK731 Labeler

BK731 Labeler Table Of
Contents
Contents
1.0 General Information.............................................................................1-0
1.1 Description ............................................................................................................ 1-1
1.2 Features ................................................................................................................. 1-1
1.2.1 High Speed Production.................................................................................... 1-1
1.2.2 Simplified Mechanical Adjustments................................................................ 1-2
1.2.3 Software Controlled Labeler Head Functions ................................................. 1-2
1.2.4 Construction, Safety Features, and Maintenance............................................. 1-2
1.3 Labeler Specifications .......................................................................................... 1-3
1.3.1 Labeler System Drawing.................................................................................. 1-4
1.4 Labeler Dimensions.............................................................................................. 1-6
2.0 BK731 Options.......................................................................................2-0
2.1 Introduction .......................................................................................................... 2-1
2.2 Labeling Head Mounting fixture ........................................................................ 2-1
2.3 Photo sensor .......................................................................................................... 2-1
2.3.1 Option A – Reflective Photo Sensor................................................................ 2-2
2.3.2 Option B – Through-Beam Sensor .................................................................. 2-3
2.3.3 Option C – Diffuse Sensor............................................................................... 2-6
2.4 Encoder Assembly ................................................................................................ 2-7
2.4.1 Option A - Encoder Wheel Assembly ............................................................. 2-8
2.4.2 Option B - Programmable Encoder.................................................................. 2-9
2.4.3 Option C - Standard Encoder........................................................................... 2-9
3.0 Mechanical Adjustments......................................................................3-0
3.1 Mechanical Adjustments...................................................................................... 3-1
3.1.1 Labeling Head Lateral Positioning.................................................................. 3-1
3.1.2 Adjust Peel Point For Different Product Thickness......................................... 3-2
3.1.3 Peel Point Lateral Adjustment......................................................................... 3-3
3.1.4 Label Spool Threading and Lateral Positioning.............................................. 3-3
3.1.5 Despool Brake Adjustment.............................................................................. 3-5
3.2 Labeler Connector Panel ..................................................................................... 3-6
4.0 User Interface ........................................................................................4-0
4.1 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 Product Sensor Positional Adjustment ............................................................ 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
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4.3 Keypad Test Menu ............................................................................................... 4-5
4.4 Keypad Position Menu......................................................................................... 4-7
4.4.1 Label Spacing Option ...................................................................................... 4-7
4.4.2 Number of Labels ............................................................................................ 4-8
4.4.3 Product Length Entry....................................................................................... 4-8
4.4.4 Manual Label Position..................................................................................... 4-9
4.4.5 Keypad Labels Menu..................................................................................... 4-10
4.4.6 Label Pitch Auto and Manual Setting............................................................ 4-10
4.4.7 Type of Label Setting .................................................................................... 4-12
4.4.8 Peel Point Sensor Adjustment........................................................................ 4-12
4.4.9 Peel Point Sensor Nudge Factor .................................................................... 4-13
4.5 Operational Controls.......................................................................................... 4-13
4.5.1 Online/Offline Status..................................................................................... 4-13
4.5.2 Product Count, Production Rate, and Belt Speed Display............................. 4-14
4.5.3 Error Conditions ............................................................................................ 4-14
4.6 Maintenance Schedule........................................................................................ 4-15
Appendix A – Assembly Drawings
Appendix B – Electrical Drawings
Buskro Ltd. BK731 Labeler

General Information Chapter 1
1.0 General Information
Buskro Ltd. BK731 Labeler

Chapter 1 General Information Page 1-1
1.1 Description
The Buskro BK731 Labeler is designed to apply pressure-sensitive labels onto mail
pieces. The system offers full flexibility in its ability to apply labels onto mail pieces.
Simplified mechanical adjustments and software controlled label placement functions
offer unsurpassed ease of use permitting rapid job setups.
In keeping with Buskro’s philosophy of ease of use, the Labeling head is designed with
many innovative features. The Labeling head is controlled through software via an
operator keypad that permits rapid selection of the number of labels dispensed and their
placement positions. A unique label-sensing feature allows the operator to easily adjust
the label pitch at a touch of a button. The Labeling head mechanism was designed with
few mechanical parts to allow easy label threading and machine setup to improve
productivity. The Labeling head is mounted on two aluminum extrusion rails, which
allow the Labeling head to be moved easily from side to side to allow labels to be placed
at different locations on the mail piece and facilitate fine tune adjustment. In addition, the
peel point assembly can be adjusted up, down, and laterally for different material
thicknesses and label widths.
All these features, in addition to the manufacturing quality and innovative product design
add up to an extremely functional labeling system capable of years of reliable and trouble
free operation.
1.2 Features
1.2.1 High Speed Production
The BK731 Labeling head is capable of high production speeds in excess of 35,000 PPH
for single label operation, 30,000 PPH for double label operation, and 28,000 PPH for
triple label operation. The unit has been solidly constructed with electrical components
capable of delivering reliable, full-day production.
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Chapter 1 General Information Page 1-2
1.2.2 Simplified Mechanical Adjustments
The BK731 Labeling head is design for ease of use and portability. The operator keypad
is easily accessible simply by sliding it in and out of view. The BK731 Labeler is
mounted on two aluminum extrusion rails, which allow easy movement of the Labeling
head to place labels at different locations on the mail piece and facilitate fine adjustment
of label placement on the product. The peel point can also be adjusted up, down, and
laterally for different product thicknesses and width. Label threading is easy since the
Labeler has few rollers and a large label bin. In addition, the despool roller is not
controlled by a motor but a simple adjustment knob thus reducing the cost of repair. The
Labeler is also fully portable as all the electronics are located inside the unit.
1.2.3 Software Controlled Labeler Head Functions
All Labeling head functions are controlled through software and use an operator keypad
interface for command entry. A unique feature is the automatic label pitch setting, which
allows the operator to set the distance between each label on the backing paper at a touch
of a button. Other features include type of labels, position of labels, full labeling head
diagnostics, product sensor selection, peel point sensor sensitivity adjustment and
production and life counters.
1.2.4 Construction, Safety Features, and Maintenance
All mechanical and electrical system components in the Labeler 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 Labeling head
operator interface is easily accessible with a simple slide rail design on the Labeling head.
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Chapter 1 General Information Page 1-3
Buskro Ltd. BK731 Labeler
1.3 Labeler Specifications
Table 1-1: Labeler head system specifications
Label Specifications
Number of Labels 1,2 or 3
Label Roll Size Up to 50,000 – 3/4” (paper)
Label Core Diameter 3.00” 76.2 mm
Label Spool Size 19.75” 502 mm
Label Length 1/2” to 7.0” 12.7 mm to 51 mm
Label Width Up to 3” 76mm
Label Style Circle, square, rectangle, stamps
Label Type Clear (c/w engineered backer), Paper, Translucent
Label Placement Front, back or flat label (gate fold)
Physical
Length
C/w Unwind & rewind spools
32.2” 818 mm
Height
C/w Unwind & rewind spools
37.3” 947 mm
Overall Width 14.1” 330 mm
Weight 72 lbs 32.6 kg
Software Controls
Product Sensor Selection Selection of Front or Back Product Sensor
Label Sensor Positioning Set distance between product and peel point sensor
Product Counter Resetting Reset product counter
Software Version Display software version
Factory Reset Reset all setting to factory default
Life Count Display Display the total production to date (can not be reset)
System Test Test all system components for malfunction
Label Spacing Selection of automatic or manual label spacing
Number of Labels Select # of label per product
Label Position Entries Set the distance between labels on a product
Label Pitch setting Set label pitch automatically or manually
Type of Label setting Set opaque or clear type label
Peel Point Sensor Sensitivity Adjust the peel point sensor gain
Electrical Requirements
Line Voltage 115 ±15% VAC
Line Current 1.5 Amps
Power 173 W
Mechanical Controls
Head Position Slide head on extrusion rail c/w locking lever
Peel Point ⇑⇓Adjustment Adjustable for materials up to 1 ½” thick
Peel Point Lateral Adjustment Adjustment for different label width up to 3”
Despool Brake Adjust Adjustable for different production speed

Chapter 1 General Information Page 1-4
1.3.1 Labeler System Drawing
Figure 1-1: Illustration of the Labeler components.
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Chapter 1 General Information Page 1-5
Table 1-2: Labeler system components
Item Description Reference
1 Despool Roll
2 Pressure Roller
3 Despool Drive Roller
4 Label Bin
5 Bin Sensor
6 Suspension Base Block Assembly
7 Idler Roller c/w Label Guides (5)
8 Peel Point
9 Label Drive Roller
10 Take-Up Spool
11 Take-Up Sensor
12 Labeler Keypad
13 Despool Brake Adjust Knob
14 Output Connector
15 Product Connector (PNP Sensor)
16 Jam Connector
17 Inhibit Connector
18 Comm Connector
19 Power Connector
20 Encoder Connector
21 Photo F/B connector
22 Label Connector
23 Controller I/O Connector
24 Keypad Connector
25 Labeler Head Serial Label
26 Front Safety Cover
27 Labeler Head Power Switch
28 Labeler Head Position Lock Handle
29 Peel Point Lateral Position Lock Knob
30 Peel Point Up/Down Position Lock Knob
31 Labeler Head Mounting Rails
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Chapter 1 General Information Page 1-6
1.4 Labeler Dimensions
Figure 1-2: Labeler dimensions.
Table 1-3: Labeler Dimensions.
Symbol Description Dimensions
O.W. Overall Labeler Head Width 14.11” 358 mm
O.L. Overall Labeler Head Length 32.15” 816 mm
O.H. Overall Labeler Head Height 37.69” 948 mm
R.L Rail Length 27.63” 702 mm
M.D Rail Mounting Hole Dimension 2.63” 67 mm
R.M Distance Between Mounting Rails 8.59” 218 mm
C.H Clearance Height 1.86” 47 mm
X1 Despool Center Distance 9.39” 238 mm
X2 Take-up Spool Distance 19.64” 499 mm
Y1 Peel Point Height 2.18” - 3.68” 55 mm – 93 mm
Y2 Take-up Spool Height 11.00” 279 mm
Y3 Despool Height 24.00” 609 mm
Z1 Front Face Width 8.31” 211 mm
Z2 Peel point lateral distance 2.33” – 3.83 “ 59 mm – 97 mm
D1 Despool Diameter 19.75” 502 mm
D2 Take-up Spool Diameter 13.00” 330 mm
Buskro Ltd. BK731 Labeler

BK731 Options Chapter 2
2.0 BK731 Options
Buskro Ltd. BK731 Labeler

Chapter 2 BK731 Options Page 2-1
2.1 Introduction
This chapter describes the BK731 Labeling Head and the accessories required to
successfully install and operate it on equipment other than the BK730 tabbing base.
Proper installation will require the following steps:
• Attachment of the labeling head to the transport base.
• Installation of a Photo sensor to trigger the label placement on the product.
• Installation of the encoder assembly.
Note: If a customized mounting solution is desired, please provide as much detailed
information as possible prior to ordering so that it may be considered.
Section 2.3 lists a number of photo sensor and encoder options available to meet the needs
of the application. These options (ordered as separate items), will have the System
Integration Discount (SID) discount applied when ordered with the system.
Note : SID discount applies to the Photocue sensor and encoder assembly when
ordered with the BK731 Labeling Head.
2.2 Labeling Head Mounting fixture
In order to mount the labeling head on a base other than the BK730 base, modifications
may be required. Eight 10-32 UNF holes must be drilled (2-3/8” apart for each mounting
foot) with the mounting hole locations shown in Figure 1-2. Note that the mounting
location along the length of the rail is adjustable in order to accommodate different size
bases.
2.3 Photo sensor
There are three main photo sensors available for purchase depending on the application
(one must be ordered in order for the Labeler to operate). They are the reflective,
through-beam, and diffuse sensors (Table 2-1).
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Chapter 2 BK731 Options Page 2-2
Table 2-1: List of recommended photo sensors
Option Description Part Number
A Reflective Photo Sensor 9101262A
B Through-Beam Sensor 615537A
C Diffuse Photo Sensor 9102036A
2.3.1 Option A – Reflective Photo Sensor
The reflective sensor is the PNP version of the standard NPN Buskro photo sensor.
Although reliable in most cases, it may be adversely affected by materials with reflective
properties. It is recommended that this photo sensor be mounted under the second rail
(Figure 2-1).
Figure 2-1: Reflective photo sensor mounting
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Chapter 2 BK731 Options Page 2-3
Figure 2-2:Mounting Bracket Dimensions (For Reflective and Diffuse Sensors)
2.3.2 Option B – Through-Beam Sensor
The through-beam sensor (standard on BK730 systems) provides more reliable operation
for a wide range of products. However, it requires more complicated mounting than the
other two. This sensor consists of a white housing LED (emitter) and a black housing
phototransistor (receiver). It is recommended that this sensor be mounted underneath the
front rail. A 1/2” diameter hole must be drilled through the tabletop to allow a clear line
of sight between the emitter and receiver. A mounting example can be seen in Figure 2-3.
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Chapter 2 BK731 Options Page 2-4
Figure 2-3: Through-Beam Sensor Mounting
Figure 2-4: Through-Beam Photo Sensor
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Chapter 2 BK731 Options Page 2-5
Figure 2-5: Top Mounting Bracket (Through-Beam Sensor)
Figure 2-6: Bottom Mounting Bracket (Through-Beam Sensor)
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Chapter 2 BK731 Options Page 2-6
2.3.3 Option C – Diffuse Sensor
The diffuse sensor can be used in applications where the product must be detected off the
transport belt. The diffuse sensor works by detecting the difference in color between two
backgrounds (i.e. the transport belt and the product). The disadvantage of the diffuse
sensor is that it may require adjustment for different jobs. In addition, if the product is the
same color as the transport belts, it may affect performance. The diffuse photo sensor
should only be used if the through-beam and reflective sensors are not options. It is
recommended that this photo sensor be mounted under the second rail (Figure 2-7).
Figure 2-7: Diffuse Photo Sensor Mounting
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Chapter 2 BK731 Options Page 2-7
Figure 2-8: Diffuse Sensor
2.4 Encoder Assembly
To make the BK731 functional, an encoder must be ordered and integrated with the
transport base. A summary of the options can be found in Figure 2-2.
Table 2-2: Encoder Options for the BK731
Option Encoder Description Part No.
A 6000 PPR Encoder Wheel Assembly with Standard Encoder. 9101543A
B Programmable Programmable Encoder 9101839A
C 6000 PPR Standard Encoder 9101259A
Note: PPR indicates pulses per revolution (number of pulses produced by an encoder
for each complete revolution of the encoder disk).
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Chapter 2 BK731 Options Page 2-8
2.4.1 Option A - Encoder Wheel Assembly
The encoder wheel assembly (Figure 2-9) is a friction wheel 3.19” in diameter that
contacts the surface of the transport belts. This option includes the standard 6000 PPR
encoder (P/N 9100188A), the encoder wheel, and the mounting hardware. The mounting
hardware (which is fixed using two ¼-20 UNC screws) must be installed with sufficient
pressure on the wheel so that the transport belt rotates it upon movement.
Figure 2-9: Encoder Wheel assembly (P/N 9101543A)
Buskro Ltd. BK731 Labeler