CTM 3600-PA Manual

1318 QUAKER CIRCLE P.O. BOX 589 SALEM, OHIO 44460
PHONE: [phone]
FAX: [phone]
www.ctmlabelingsystems.com
Designers and Manufacturers of Pressure Sensitive Labeling
Equipment and Custom Product Handling
3600 PRINTER APPLICATOR
MAINTENANCE
&
SERVICE MANUAL
(REVISION 3600-2b5.x)

TABLE OF CONTENTS
TABLE OF CONTENTS
(STANDARD 3600)
TABLE OF FIGURES …………………………………………………………. 1
INTRODUCTION ………………………………………………………….…... 2
WEB PATH ……………………………………………………………………... 3
MACHINE TERMS ……………………………………………………………. 4
APPLICATOR DISPLAY ……………………………………………………... 5
Key Descriptions ……………………………….………..… 5-1
Changing Variable Fields ……………………………...…... 5-2
Alarm Screens ………………………………………...….… 5-3
REAR PANEL ………………………………………………………………….. 6
Connector Descriptions ……………...……………………... 6-1
I/O Port Functions ………………………………………….. 6-2
APPLICATOR SETUP ……………………………………………………….. 7
Unwind Installation ………………………………………… 7-1
Air Filter Installation ……………………………………….. 7-2
Valve Bank Installation …………………………………….. 7-3
Standard Tamp Installation …………………………………..7-3
Extended Peel Edge Installation ……………………………. 7-4
Swing Tamp Installation ……………………………………. 7-5
Ribbon and Label Loading …………………………………..7-6
Applicator Nose Setup ……………………………………….7-7
Tamp Setup …………………………………………………..7-8
Static Stack Test ……………………………………………...7-9
Configuration Menus ………………………………..……….7-10
PRODUCT SETUP ……………………………………………………………. 8
Applicator Attitudes ………………………………………… 8-1
Applicator Position ………………………………………..… 8-2
Product Detect Sensor (SM312LV) ……………………….… 8-3
Product Detect Sensor (S18SN6FF50) ……………………… 8-4
APPLICATOR ALARMS ……………………………………………………. 9
Alarm Light …………………………………………………. 9-1
Systems Ready Output ………………………………………. 9-1
Alarm & I/O Port .………………………………………........ 9-2
Adjusting Low Label Sensor …………………………...…… 9-2
MAINTENANCE ……………………………………………….…………….. 10
Dancer Arm Adjustment …………………………………... 10-1
Rewind Clutch Adjustment ………………………………... 10-2
Changing Clutch Pad ……………………………………… 10-3
Belt Tension ……………………………………………….. 10-4

TABLE OF CONTENTS
TROUBLESHOOTING ………………………………………………………... 11
PRINTER SETTINGS ………………………………………………………… 12
Sato Printers ……………………………………………….. 12-1
Zebra Printers ……………………………………………… 12-7
Datamax Printers …………………………………………… 12-7
RECOMMENDED SPARE PARTS ………………………………………….. 13
AND DRAWINGS
SUPPLIMENTS TO STANDARD 3600 MANUAL
Dual Action Tamp ………………………………………….… Section B
Corner Wrap …………………………………………………. Section C
Powered Unwind …………………………………….………. Section D

TABLE OF FIGURES
TABLE OF FIGURES
FIGURE 1 (Unwind Assembly) ……………………………………………… 7-1
FIGURE 2 (Valve Bank) ……………………………………………………… 7-2
FIGURE 3 (Standard Tamp Assembly) ………………………………………. 7-3
FIGURE 4 (Extended Peel Edge Assembly) …………………………………. 7-4
FIGURE 5 (Swing Tamp) …………………………………………………….. 7-5
FIGURE 6 (Web Path) ……………………………………………………...… 7-6
FIGURE 7 (Applicator in Nose Down Attitude) ……………………………... 8-1
FIGURE 8 (Applicator in Upright and Above Attitude) ……………………… 8-1
FIGURE 9 (Applicator in Nose Up Attitude) …………………………………. 8-1
FIGURE 10 (Applicator in Bottom Up Attitude) ……………………………… 8-1
FIGURE 11 (Applicator in Reels Up Attitude) ………………………………... 8-1
FIGURE 12 (SM312LV Product Detect Sensor) ……………………………… 8-2
FIGURE 13 (S18SN6FF50 Product Detect Sensor) ………………………...… 8-3
FIGURE 14 (Alarm Light) …………………………………………………….. 9-1
FIGURE 15 (Low Label Sensor on Unwind Block) …………………………... 9-2
FIGURE 16 (Low Label Sensor) ……………………………………………… 9-2
FIGURE 17 (Unwind Brake Band) …………………………………………… 10-2
FIGURE 18 (Rewind/Clutch Assembly) …………………………………...… 10-3
FIGURE 19 (DAT Valve Bank) ……………………………………………… b5-1
FIGURE 20 (DAT Tamp Assembly) …………………………………………. b5-2
FIGURE 21 (DAT Tamp Adjustments) ………………………………………. b5-4
FIGURE 22 (DAT Nose Down Position) …………………………………….. b6-1
FIGURE 23 (SM312LV Product Detect Sensor) …………………………….. b6-2
1-1

TABLE OF FIGURES
FIGURE 24 (S18SN6FF50 Product Detect Sensor) ……………………………. b6-3
FIGURE 25 (Apply Sequence) …………………………………………………. c3-1
FIGURE 26 (Apply Sequence) …………………………………………………. c3-2
FIGURE 27 (Apply Sequence) …………………………………………………. c3-3
FIGURE 28 (Corner Wrap Valve Banks) ……………………………………….. c3-4
FIGURE 28 (Web Path Powered Unwind) ……………………………………… d2
1-2

INTRODUCTION
INTRODUCTION
The 3600-PA printer applicator is a high-speed labeler used to thermally print and apply pressure
sensitive labels to moving products. A thermal transfer printer is integrated into an applicator to
form a self-contained unit that will print variable data onto a label. The printer/applicator can be
mounted in almost any position adjacent to product flow to apply labels to top, sides or bottom of
products as they pass by.
Labels are supplied on rolls that consist of a liner on which the labels are held with adhesive. The
labels may be preprinted with the variable information added by the printer or blank labels with
the printer printing the entire label.
The applicator can work in two different modes:
Normal Tamp Blow
Inverted Tamp Blow
In the Normal Tamp Blow mode, the label is printed, dispensed out onto the label pad and held
there by vacuum. When the product detect sensor is made, the label and label pad are moved
toward the product using a pneumatic slide. When the slide is extended, an air blast will blow
the label off the pad and onto the product.
In the Inverted Tamp Blow mode, the label is printed, dispensed onto the label pad and the slide
extends. The applicator will wait in this position until the product sensor is made. The label is
then blown off the pad onto the product.
For safe and trouble free operation, the instructions in this manual must be followed carefully
during the set-up, operation, media changes, cleaning and maintenance. Also the specified
environmental conditions must be maintained.
Electrical Supply: 108-132 Volts, 5 Amps, 50-60 Hertz, Single phase
A three-meter long, three wire cable with 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 NEMA 5-15 plug.
Air Supply: Clean and dry compressed air must be provided at pressures
90 to 100 P.S.I. with a minimum flow rate of 4 S.C.F.M.
Environment: Operating temperature range is 40 to 95°F (5 to 35°C).
Operating humidity range is 20 to 85% RH, non-condensing.
Note: The model 3600-PA is not intended to be operated in an environment
where flammable or explosive gases are present. The model 3600-PA
MUST not be used in direct contact with food products.
2-1

INTRODUCTION
READ THE INSTRUCTIONS CAREFULLY AND COMPLETELY. This manual includes all
of the information that you’ll need to set up the applicator under normal operating conditions.
The instructions include important safety precautions, which must not be ignored.
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 UP AGAIN. Although
applicator malfunction is possible, most problems happen because the applicator was not setup
correctly. If the applicator doesn’t operate correctly, back-up and start over.
FOLLOW ALL SAFETY INSTRUCTIONS. The 3600-PA has been provided with a number of
safety features. Observe all safety warning and under no circumstances attempt to remove or
defeat safeguards or operate the machine in a manner contrary to the instructions.
2-2

MACHINE TERMS
MACHINE TERMS
Adhesive Strings: Label adhesive that attaches to the label and liner while the label is dispensing
onto the label pad. They can cause the label position on the label pad to become inconsistent.
Air Assist Tube: A small diameter tube with small hole in it mounted under the peel edge. The
purpose is to direct a stream of air to help the label onto the label pad.
Air Assist: The stream of air from the Air Assist Tube.
Air Blast: A blast of compressed air that moves the label from the label pad to the product. The
duration of the blast is controlled by the Air Blast time accessible through the applicator display.
Air Filter: A device on the inlet of the air supply that removes debris from the air supply.
Critical Alarm: An alarm that will stop the applicator from applying labels. Critical alarms
include end of web, out of labels (from printer) and no ribbon (from printer).
Cycle Time: The amount of time it takes for the applicator to print and apply a label to a product,
starting from the product detect signal.
Dancer Arm: The function of the dancer arm is to release the brake on the unwind when labels
are being printed and to stop the unwind mandrel when printing stops.
Detector Lockout: Time span after the applicator starts the labeling sequence that will cause the
applicator to ignore any additional product signals. This is useful if a product triggers the product
detect sensor more than once.
Extended Air Assist: The air assist is always on while the label is being printed (dispensed).
Extended air assist allows the air assist to stay on longer to aid in putting the label on the pad.
Extended Peel Edge: An applicator nose assembly that adds a peel edge that moves with label
flow. This will enable the back feed option to be turned off to the printer so higher labeling rates
can be obtained.
Inverted Tamp Blow (ITB): A mode of operation in which the tamp pad is in the extended
position waiting for the product detect signal to start the labeling sequence.
Label Feed: The moving of the label stock through the machine.
Label Liner: The backing material that supports the labels before dispensing.
Label Manifold: The aluminum block mounted under the tamp slide. The label pad is mounted to
it. Vacuum and the air blast are channeled through it to the pad.
Label Pad: Mounted under the manifold and is usually made from white delrin. This part
supports the label before application.
4-1

MACHINE TERMS
Label Placement: The time from when the product sensor is made to when the labeling sequence
starts.
Label Sensor: The sensor that detects the leading or trailing edge of the label.
Label Size: The width and length (or feed) of a label. Length equals the distance from the leading
edge of the label to its trailing edge. Width is the distance across the label.
Leading Edge: Refers to the signal sent from a sensor when the first edge of a product or label is
detected.
LED: Light Emitting Diode
Normal Tamp Blow: A mode of operation where a label is dispensed onto the label pad and the
applicator waits for the product detect sensor to turn on before starting the labeling sequence.
Parity: A data bit that provides a means of checking for errors in the data stream.
Peel Edge: A machined part just before the label pad used to transfer the label onto the pad as the
liner is pulled around the part.
Rewind: This is the rotating mandrel that takes up the liner after the labels have been removed.
Static Stack: When labels are applied to a stationary target on top of each other to check
repeatability of the applicator.
Tamp/Swing Extend Time: The time allowed for the tamp slide to fully extend.
Tamp/Swing Retract Time: The time allowed for the tamp slide to return from it’s extended
position to it’s retracted position.
Trailing Edge: Refers to the signal sent from a sensor when the last edge of a product or a label
is detected.
Unwind: The rotating mandrel where the roll of labels is placed to be printed and applied.
Valve Bank: The typical valve bank for a tamp has three valves in it. Each valve has a built in
regulator and gauge. The assembly is made to be bolted on either side of the applicator.
Warning Alarm: This alarm serves as a warning that the applicator is low on labels or ribbon.
Web Path: The path the label liner follows leading fromthe unwind, through the printer and ends
at the rewind.
4-2

APPLICATOR DISPLAY
APPLICATOR DISPLAY PANEL
On power-up, the display will scroll the software version screen for 30 seconds. This will allow
time for all of the different types of printers to go through their diagnostics. The applicator can
be switched from Normal Tamp mode to Inverted Tamp Mode through the display. See the
applicator setup section on how to do this.
The following is a list of the keys on the display and what they do:
Menu:
This key will allow the operator to scroll through the following sub-menus:
 Label Rate - Displays the rate in which labels have been applied per minute. After 61
seconds passes by with no apply signal 0 labels/min is displayed.
 Label Placement - Time from when the product detect sensor turns on until
the labeling sequence starts. Aid for putting the label in the right position on the
product.
 Tamp Extend Time - Time allowed for the tamp slide to extend before continuing with
the labeling sequence.
 Tamp Retract Time - Time allowed for the tamp slide to return to receive a label from
the extended position.
 Air Blast Time - Time the air blast valve will stay on.
 Extended Air Assist - The air assist is on as long as the applicator is printing a label.
Extended air assist is the time after the printing stops until the assist turns off. This can
be useful in placing a label on the label pad.
 Detector Lockout - Used when receiving more than one product detect signal from a
product. The detector lockout timer starts with the product detect and will ignore other
signals until the timer has timed out.
 Product Counter Access Screen - Pressing the Home key while within the Detector
Lockout screen will access this screen. Pressing Ent will reset the counter. When cycling
power to the applicator the count will be reset to zero.
5-1