CTM 360 Series Manual

1318 QUAKER CIRCLE PO BOX 589 SALEM, OHIO 44460
PHONE: [phone]
FAX: [phone]
DESIGNERS AND MANUFACTURERS OF PRESSURE
SENSITIVE LABELING EQUIPMENT AND CUSTOM
PRODUCT HANDLING
360 SERIES LABEL
APPLICATOR
MAINTENANCE
&
SERVICE
MANUAL
REVISION 360-2c.10.1
050103

___________________
TABLE OF CONTENTS
TABLE OF CONTENTS
INTRODUCTION ......................................................................................................…...1
MACHINE TERMS ...................................................................................................…...4
DISPLAY PANEL ................................................................................................…….…8
MAIN MENU ………………………………………………………………………………………8
ONLINE …………………………………………………………………………………………….8
APPLICATOR TYPE …………………………………………………………………………….. 8
LABEL STOP ………………………………………………………………………………………9
LABEL SETUP …………………………………………………………………………………….9
HOME ……………………………………………………………………………………………..10
JOG ………………………………………………………………………………………………..10
WEB SPEED .........................................................................................................................…….10
ALARM RESET ................................................................................................................……….10
LABEL FORMATS..............................................................................................................…..….11
APPLICATOR OPTIONS .................................................................................................……….11
LABEL PLACEMENT ...........................................................................................................…...12
PRODUCT SETUP .................................................................................................................…...12
REAR PANEL ....................................................................................................……….14
SETUP PROCEDURES ........................................................................……………….16
JOB SETUP ............................................................................................………………………….17
LABEL SENSOR SETUP ..............................................................................................………….18
LABEL LENGTH SETUP ....................................................................................………………..20
LABEL STOP SETUP............................................................................................................…….21
LABEL FORMATS ……………………………………………………………………………….21
WEB SPEED SETUP ............................................................................................................…….22
SLEW SPEED SETUP ……………………………………………………………………………22
LABEL SETUP RECORDS
LABELER TYPE SETUP ........................................................................................…..24
MERGE APPLICATOR ........................................................................................................…….24
MERGE PROFILING .............................................................................................................……24
MERGE LEADING EDGE APPLY ………………………………………………………………28
AIR BLOW APPLICATOR .....................................................................................................…..30
TAMP APPLICATOR .............................................................................................................…...33
PRODUCT SETUP ....................................................................................................….38
PRODUCT SENSOR ……………………………………………………………………………..38
PRODUCT SETUP ………………………………………………………………………………..39
LABEL PLACEMENT …………………………………………………………………………....39
ENCODER .................................................................................................……………..42
OPTION …………………………………………………………………………………………...42
MOUNTING ………………………………………………………………………………………42
SETUP ..…………………………………………………………………………………………...43
i

___________________
TABLE OF CONTENTS
CROSSOVER OPTION .....................................................................…………………46
SETUP …………………………………………………………………………………………….46
MONITORING ……………………………………………………………………………………47
PRECAUTIONS …………………………………………………………………………………..47
PRINTER SETUP ……………………………………………………………………...49
LOOSE LOOP SETUP ..............................................................................................…………….49
IMPRINTER SETUP .................................................................................................…………….49
LABEL OPTIONS ……………………………………………………………………..51
MULTIPLE LABEL SETUP..............................................................................…………......…..51
MISSING LABEL …………………………………………………………………………...……52
SKIP COUNTER….………………………………………………………………………...……..53
CONFIGURATION MENU ….………………………………………………………. 55
RESET TO FACTORY DEFAULTS ……………………………………………………………..55
SPECIAL OPTIONS ………………………………………………………………………………55
WEB PATH DIAGRAMS ..……………………………………………………………60
MERGE LH APPLICATOR ...................................................................................................…...60
MERGE RH APPLICATOR ...................................................................................................……61
TAMP LH APPLICATOR ......................................................................................................……62
TAMP RH APPLICATOR ......................................................................................................…...63
AIR BLOW LH APPLICATOR ..............................................................................................…...64
AIR BLOW RH APPLICATOR …………………………………………………………………..65
MERGE LH APPLICATOR W/16” UNWIND .......................................................................…..66
MERGE RH APPLICATOR W/16” UNWIND .......................................................................…..67
TAMP LH APPLICATOR W/ 16” UNWIND .........................................................................…..68
TAMP RH APPLICATOR W/ 16” UNWIND .........................................................................…..69
AIR BLOW LH APPLICATOR W/16” UNWIND ..................................................................…..70
AIR BLOW RH APPLICATOR W/ 16” UNWIND .................................................................…..71
GENERAL MAINTENANCE ..................................................................................….72
DAILY …………………………………………………………………………………………….73
WEEKLY ………………………………………………………………………………………….73
MONTHLY ………………………………………………………………………………………..73
SEMI-ANNUAL …………………………………………………………………………………..74
DANCER ARM ADJUSTMENT …………………………………………………………………74
REWIND SLIP CLUTCH …………………………………………………………………………75
DRIVE BELT ADJUSTMENT …………………………………………………………………...76
TROUBLESHOOTING............................................................................................…..78
DIAGNOSTIC CHART …………………………………………………………………………...78
FAULT CODE REGISTER ……………………………………………………………………….82
FLOWCHARTS……………………………………………………………………….. 84
AIR BLOW APPLICATOR .....................................................................................................…..84
TAMP APPLICATOR .............................................................................................................…...85
ITB TAMP APPLICATOR ......................................................................................................…..86
MERGE APPLICATOR ..........................................................................................................…...87
ii

___________________
TABLE OF CONTENTS
ACCESSORIES .........................................................................................................…. 89
ELECTRONIC CROSSOVER ……………………………………………………………………89
IMPRINTER ………………………………………………………………………………………89
LOOSE LOOP …………………………………………………………………………………….89
LOW LABEL DETECTION ……………………………………………………………………...89
TAMP SWITCH …………………………………………………………………………………..89
WEB BREAK DETECTION ……………………………………………………………………...89
RECOMMENDED SPARE PARTS.........................................................................…. 91
AIR BLOW APPLICATOR .....................................................................................................…..92
MERGE APPLICATOR ..........................................................................................................…...93
TAMP APPLICATOR .............................................................................................................…...94
DRAWINGS ...................................................................................…………………….96
W/ COMPLETE PARTS LIST
CHANGEOVER INSTRUCTIONS ..........................................................................…97
APPLICATOR CHANGEOVER ………………………………………………………………….97
BLOW BOX NOSE ASSEMBLY REMOVAL / INSTALLATION ……………………………..98
MERGE NOSE ASSEMBLY REMOVAL / INSTALLATION ………………………………….99
TAMP NOSE ASSEMBLY REMOVAL / INSTALLATION ………………………………….100
NOSE ASSEMBLY CHANGEOVER …………………………………………………………..101
MERGE PEEL EDGE CHANGEOVER ………………………………………………………...101
BLOW BOX PEEL EDGE / FAN / GRID CHANGEOVER ..………………………………….102
TAMP PEEL EDGE / CYLINDER CHANGEOVER …………………………………………..103
REWIND REMOVAL / INSTALLATION / CHANGEOVER …………………………………104
WIRING CHANGEOVER ………………………………………………………………………104
iii

___________________
TABLE OF CONTENTS
(This page is intentionally blank.)
iv

________________
INTRODUCTION
INTRODUCTION
The CTM Integration 360 Series Modular Labeling System is a high-speed applicator used to apply
pressure sensitive labels to moving products on a production line. It is essentially a self-contained module
that may be mounted in almost any position to apply labels to the top, bottom, or sides of packages as they
pass by on a production line.
The CTM Integration 360 Series Modular Labeling System is unique in that the main module can be
adapted to three different types of applicators: Air Blow, Merge, or Tamp by changing the nose assembly.
The symmetrical design of the applicator allows labels to be dispensed to the right or left side of the
machine. The applicator type and configuration (either left or right -handed) will depend on the type of
product to be labeled and the arrangement of the production line.
If your application needs change in the future, a different nose assembly may be purchased but the main
module would remain the same. There is no need to purchase a completely new applicator. The CTM
Integration 360 Series Modular Labeling System can be easily changed over to a different nose by simply
removing the existing nose from the module and replacing it with a different nose.
You can also change the configuration (right-hand or left-hand) by simply moving the applicator nose from
one side of the machine to the other. All the parts are interchangeable. Everything you need is already
included with each applicator nose to make the change using your existing module.
The labels should be supplied on a liner web with a minimum label gap of 1/8”. The applicator will accept
and dispense labels from rolls up to 20” O.D. In a typical setup, the applicator detects the leading edge of a
package and applies a label with placement accuracy typically within +/- 1/32 inch.
For safe trouble free operation of the applicator, carefully follow the instructions in this manual during
setup, operation, label roll changes, cleaning, and maintenance. The applicator is designed to operate
under the following environmental conditions:
ELECTRICAL SUPPLY: 108 - 132 Volts, 5 Amps, 50 - 60 Hertz, Single Phase
A three-meter long, three wire cable with 16 AWG (1.00mm ) conductors
rated at 10 amperes (in accordance with CENELEC HD-21) is provided for
the electrical connection to the IEC 320 receptacle of the applicator. The end
of the power cord is terminated with a NEMA5-15 plug.
2
ENVIRONMENT: Operating temperature: 40 – 104 degrees F
Humidity: 20 - 95% RH, non-condensing
NOTE: THE 360 SERIES MLS IS NOT INTENDED TO BE OPERATED IN AN ENVIRONMENT
WHERE FLAMMABLE OR EXPLOSIVE GASSES ARE PRESENT. THE 360 SERIES MLS IS
NOT TO BE USED IN DIRECT CONTACT WITH FOOD PRODUCTS.
READ THE INSTRUCTIONS CAREFULLY AND COMPLETELY. This manual includes all of the
information needed to setup the applicator under normal operating conditions. The instructions include
important safety precautions that must not be ignored.
1

________________
INTRODUCTION
READ THE INSTRUCTIONS IN ORDER. The instructions are written as numbered steps that will take
you safely and efficiently through the setup process. Any steps performed out of sequence may result in a
hazard and the applicator may not operate properly.
WORK CAREFULLY. Although setting up the applicator is not difficult, it does take time. Do not rush
through the process. Careful work will produce good results.
IF SOMETHING DOES NOT WORK PROPERLY, TRY SETTING IT UP AGAIN. Although an
applicator malfunction is possible, most problems happen because the applicator is not setup correctly. If
the applicator doesn’t operate correctly, back up and start over.
FOLLOW ALL SAFETY INSTRUCTIONS. The CTM 360 Series MLS applicator has been provided
with a number of safety features. Observe all safety warnings and under no circumstances attempt to
remove or defeat safeguards or operate the machine in a manner contrary to the instructions.
2

________________
INTRODUCTION
(This page is intentionally blank.)
3

_________________
MACHINE TERMS
DEFINITION OF MACHINE TERMS
AIR BLAST JETS:
The flexible air blast jets press-fit into the inside face of the vacuum grid and can be re-arranged to provide
an air stream pattern that transfers labels of various sizes and shapes to the product. The air jets are
connected via a manifold to the output of the “Air Blast” solenoid valve located in the valve bank. The
filter regulator assembly mounted upstream of the value controls the air pressure to this solenoid valve.
The duration of the air blast is controlled by the “Air Blast Time” function. Refer to the setup procedures
for instructions.
NOTE: Any unused air jet tubes should be inserted into the storage block at the rear of the blow box.
AIR ASSIST TUBE:
The air assist tube is a small stainless steel tube mounted on the underside of the peel edge. It helps to
separate the label from the liner as it is being dispensed onto the blow box or tamp label pad for
application.
APPLICATOR BLOW BOX NOSE:
The blow box applicator nose is used for dispensing labels via the air blow application. The blow box
creates a vacuum to hold the label to the vacuum grid until it is dispensed onto the product. The nose
assembly is easily converted from left-hand to right-hand and vice versa using the same parts. Also, the
blow box nose assembly can be interchanged with the merge or tamp applicator nose assembly.
APPLICATOR MERGE NOSE:
The merge applicator nose is used for dispensing labels via the wipe on/merge application. A label is
dispensed from the peel edge and the brush wipes the label onto the product as it is traveling past the
applicator. The merge applicator nose is easily converted from left-hand to right-hand and vice versa using
the same parts. Also, the merge nose assembly can be interchanged with the air blow or tamp nose
assembly.
APPLICATOR TAMP NOSE:
The tamp applicator nose is used for dispensing labels via the air blast/tamping application. A label is
dispensed from the peel edge onto the label pad. The air cylinder extends the tamp assembly to the product
and the label is applied with an air blast. The tamp extend and retract times are configured during
applicator setup. The tamp applicator nose is easily converted from left-hand to right-hand and vice versa
using the same parts. Also, the tamp nose assembly can be interchanged with the air blow or merge nose
assembly.
4

_________________
MACHINE TERMS
BLOW BOX / VACUUM GRID:
The blow box/vacuum grid is the cube shaped assembly located next to the peel edge on a blow box
applicator. Two axial fans mounted above the grid create the vacuum needed to hold the label in place
prior to application.
DANCER ARM:
The dancer arm is attached to the unwind block assembly with a shoulder bolt and a bushing. It appears
immediately after the unwind mandrel in the web path. The dancer arm has a roller at one end that rides
against the label liner and is interconnected to the mandrel tension disk with a spring. The dancer arm
maintains tension on the liner loop as it operates the brake on the unwind mandrel when labels are being
dispensed. The spring tension should be large enough to properly tension the web but still allow proper
operation of the brake. Do not over tension the dancer arm.
DRIVE ROLLER:
The drive roller is coupled to a stepper motor that provides the motive force for advancing the label liner.
The drive roller in conjunction with the spring loaded nip roller pull the label liner around the peel edge to
dispense a label onto the product, tamp pad, or blow box grid.
LABEL MANIFOLD:
The label manifold is the mounting block that attaches the label pad to the bottom of the tamp cylinder on
the applicator nose. The label manifold is a custom part that is manufactured exactly to the label size being
applied. If at any time the label size changes, a new label manifold must be purchased along with the label
pad.
LABEL PAD:
The label pad is a white delrin material mounted onto the label manifold at the bottom of the tamp cylinder
of the tamp applicator nose. The label pad is a custom part that is manufactured exactly to the label size
being applied. If at any time the label size changes, a new label pad must be purchased.
LABEL TENSION BRUSH ASSEMBLY:
This is an adjustable brush to help create tension on the label liner. The brush can be released while
threading the label liner.
NIP ROLLER:
The spring-loaded nip roller provides positive pressure to the label liner that passes between the drive and
nip roller assemblies. These rollers ensure that the liner does not slip during the label dispense cycle. The
tension on the rollers may be released by turning the knob located on the top of the nip roller assembly.
5