Ctm 360y Manual

INSTRUCTION MANUALS:

INSTALLATION,OPERATOR’S,MAINTENANCE

Standard 360a Model Y (360y) Label Applicator

Tamp

RVB

Dual Action Tamp

Air Blow

Swing Tamp

Merge

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

Table of Contents

03/2023

TABLE OF CONTENTS

Table of Contents ............................................................................................................................................................... i

Proprietary ...................................................................................................................................................................... viii

Liability ............................................................................................................................................................................ viii

Release date .................................................................................................................................................................... viii

Contact and Support ........................................................................................................................................................ ix

Contact Us ..................................................................................................................................................................... ix

Technical Support......................................................................................................................................................... ix

Spare Parts .................................................................................................................................................................... ix

Customer Training........................................................................................................................................................ ix

System Requirements........................................................................................................................................................ x

Electrical Requirements ................................................................................................................................................ x

Air Requirements........................................................................................................................................................... x

Operating Environment ................................................................................................................................................ x

Specialty Statements ........................................................................................................................................................ xi

Warning Statements .................................................................................................................................................... xi

Caution Statements ...................................................................................................................................................... xi

Notes ............................................................................................................................................................................. xi

Figures ........................................................................................................................................................................... xi

Safety Guidelines ............................................................................................................................................................. xii

Installation and Maintenance..................................................................................................................................... xii

Operation ..................................................................................................................................................................... xii

Electrical Shock............................................................................................................................................................ xii

Mechanical Hazards ................................................................................................................................................... xiii

Noise Emissions .......................................................................................................................................................... xiii

Every Time Before Starting Production.................................................................................................................... xiii

Machine Terms................................................................................................................................................................ xiv

Introduction ................................................................................................................................................................... xvii

Operating Personnel..................................................................................................................................................... xviii

INSTALLATION MANUAL ............................................................................................................................................................. 1

Unboxing............................................................................................................................................................................ 2

Instructions for Unboxing: ........................................................................................................................................... 4

Installation ......................................................................................................................................................................... 7

Connecting Cables......................................................................................................................................................... 8

Correct Connections Instructions............................................................................................................................. 8

Powering-On the applicator ...........................................................................................................................................10

Equipment Overview ....................................................................................................................................................... 11

Merge Applicator ........................................................................................................................................................ 11

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

Table of Contents

03/2023

Tamp Applicator.......................................................................................................................................................... 12

RVB Applicator ............................................................................................................................................................ 13

Air Blow Applicator .....................................................................................................................................................14

DAT Applicator ............................................................................................................................................................ 15

Swing Tamp Applicator...............................................................................................................................................16

Decommissioning the Applicator...................................................................................................................................17

Dismantling the Applicator ........................................................................................................................................17

Disposing of the Applicator........................................................................................................................................17

OPERATOR’S MANUAL................................................................................................................................................................ 1

Label Setup......................................................................................................................................................................... 2

Threading Labels ........................................................................................................................................................... 2

Sensors ........................................................................................................................................................................... 3

Banner S18-2 Sensor ................................................................................................................................................. 3

Fixed Field PD Sensor ............................................................................................................................................ 3

Retroreflective Setup ............................................................................................................................................ 3

Polarized Retroreflective Setup............................................................................................................................ 3

Diffused Setup ....................................................................................................................................................... 4

Banner Q3X Laser sensor .......................................................................................................................................... 4

Laser Description and Safety Information........................................................................................................... 4

Class 2 Lasers...................................................................................................................................................... 4

Safety Notes ....................................................................................................................................................... 4

Installation ............................................................................................................................................................. 4

Basic TEACH Instructions ...................................................................................................................................... 5

Manual Adjustments ............................................................................................................................................. 5

Banner Q4X Laser Sensor .......................................................................................................................................... 5

Laser Description and Safety Information........................................................................................................... 5

Class 1 Lasers...................................................................................................................................................... 5

Installation ............................................................................................................................................................. 6

Basic TEACH Instructions ...................................................................................................................................... 6

Manual Adjustments ............................................................................................................................................. 6

Light Operate/Dark Operate................................................................................................................................. 6

Banner DF-G3 Fiber Optic Sensor............................................................................................................................. 7

Two-Point Teach Procedure ................................................................................................................................. 7

Programming the Sensor ...................................................................................................................................... 7

Configuration......................................................................................................................................................... 8

Label Sensor Setup ........................................................................................................................................................ 9

Label Length Setup........................................................................................................................................................ 9

Label Static Test........................................................................................................................................................... 10

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

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03/2023

Static Test for Tamps and Air Blow Labels ............................................................................................................10

Static Test for Merge Label.....................................................................................................................................10

Static Test for Corner Wrap Label ..........................................................................................................................11

Static Test for DAT Label ........................................................................................................................................ 11

360y HMI Applicator Display.......................................................................................................................................... 12

Changing Numeric Values ..........................................................................................................................................13

Changing Text Values .................................................................................................................................................14

Passcode....................................................................................................................................................................... 14

Main Menu ................................................................................................................................................................... 12

Warning Alarms .......................................................................................................................................................12

Critical Alarms.......................................................................................................................................................... 13

Setup Menus ................................................................................................................................................................13

Formats.....................................................................................................................................................................15

Previewing/Loading Formats .............................................................................................................................15

Saving New Formats............................................................................................................................................16

Overwriting an Existing Format with a New Name ..........................................................................................16

Overwriting an Existing Format with New Settings .........................................................................................16

Erasing Formats ................................................................................................................................................... 16

Configuration Menu ................................................................................................................................................ 17

Applicator Options: ............................................................................................................................................17

Missing Label Option Menu............................................................................................................................ 17

Encoder Option ................................................................................................................................................ 17

Enable On Power Up........................................................................................................................................ 17

Auto Prime Pad Option ................................................................................................................................... 18

Loose Loop ....................................................................................................................................................... 18

Crossover Option ............................................................................................................................................. 18

Crossover Main Menu Changes ..................................................................................................................18

Primary to Secondary Transfer Process .....................................................................................................18

Secondary to Primary Transfer Process .....................................................................................................19

Imprint Menu ................................................................................................................................................... 19

Tamp Home Mode...........................................................................................................................................19

Label On Pad ....................................................................................................................................................19

Vacuum Control ............................................................................................................................................... 19

Foldover Option Menu ....................................................................................................................................20

Powered Rewind Option Menu ...................................................................................................................... 20

Multi-Label Option Menu ...............................................................................................................................20

Skip Count ........................................................................................................................................................20

Label to Placement Time Menu ......................................................................................................................20

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

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I/O Diagnostics .................................................................................................................................................... 21

Reset Label Sensor............................................................................................................................................... 21

Application Setup—Merge .....................................................................................................................................21

Multi-Panel Menu................................................................................................................................................ 21

Multi-Panel Auto Teach .................................................................................................................................. 21

Multi-Panel Setup............................................................................................................................................22

Over Speed Menu ....................................................................................................................................................22

Label Profile Menu ..............................................................................................................................................22

Label Profile Setup ..............................................................................................................................................23

Label Placement................................................................................................................................................... 23

Detector Lockout ................................................................................................................................................. 23

Application Setup—Tamp and Blow Applicators .................................................................................................23

Label Feed Setup Menu...........................................................................................................................................24

Sensor Teach ........................................................................................................................................................24

Auto Teach: ......................................................................................................................................................24

Manual Teach...................................................................................................................................................25

Leading Edge Teach.....................................................................................................................................25

Trailing Edge Teach ..................................................................................................................................... 25

Fault Log................................................................................................................................................................... 26

Clearing Faults .....................................................................................................................................................26

Applicator Setup ..............................................................................................................................................................27

Merge Applicator Setup..............................................................................................................................................27

Merge Applicator Flow Chart .................................................................................................................................27

Air Blow Applicator Setup ..........................................................................................................................................28

Air Blow Peel Edge Alignment................................................................................................................................28

Air Blow Label Stop .................................................................................................................................................28

Air Blow Grid Setup.................................................................................................................................................28

Air Blow Air Assist Setup ........................................................................................................................................29

Air Blow Air Blast..................................................................................................................................................... 29

Air Blow Flow Chart................................................................................................................................................. 29

Tamp Applicator Setup ...............................................................................................................................................30

Normal Tamp Flow Chart........................................................................................................................................30

Inverted Tamp (ITB) Flow Chart .............................................................................................................................31

Tamp Peel Edge Alignment .................................................................................................................................... 31

Tamp Vacuum Pressure........................................................................................................................................... 31

Tamp Air Assist Tube Setup....................................................................................................................................32

Tamp Air Blast Setup...............................................................................................................................................32

Tamp Slide Setup..................................................................................................................................................... 32

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

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Tamp Extend Time...................................................................................................................................................32

Tamp Retract Time .................................................................................................................................................. 32

Corner Wrap Setup......................................................................................................................................................33

Corner Wrap Sequence ........................................................................................................................................... 33

Corner Wrap Flow Chart ......................................................................................................................................... 33

Corner Wrap General Setup Procedures................................................................................................................ 33

Positioning Corner Wrap Applicator .....................................................................................................................34

Positioning Product Detect and Swing Back Sensors...........................................................................................34

Dual Action Tamp (DAT) Setup..................................................................................................................................35

DAT: Leading Edge Sequence .................................................................................................................................35

DAT: Leading Edge Flow Chart ...............................................................................................................................35

DAT: Trailing Edge Sequence .................................................................................................................................35

DAT: Trailing Edge Flow Chart ............................................................................................................................... 36

DAT: Inverted Mode Sequence...............................................................................................................................36

DAT: Inverted Flow Chart........................................................................................................................................ 36

Incompatible DAT Options .....................................................................................................................................37

DAT Label Placement Setup ...................................................................................................................................37

DAT General Setup Procedures ..............................................................................................................................37

DAT Rotary Actuator Stop Adjustment Guidelines .............................................................................................. 38

DAT Shock Absorbers and Flow Controls.............................................................................................................. 38

Positioning the DAT Applicator .............................................................................................................................38

Mounting DAT Product Detect Sensor .................................................................................................................. 39

MAINTENANCE MANUAL ............................................................................................................................................................ 1

360y General Maintenance Procedures ........................................................................................................................... 2

Special Options Menu ....................................................................................................................................................... 2

Debounce Setup Menu.................................................................................................................................................. 2

Active Option Codes...................................................................................................................................................... 2

Servo Tuning.................................................................................................................................................................. 3

Software Version ........................................................................................................................................................... 3

Change Main Password................................................................................................................................................. 3

Apply Mode Menu......................................................................................................................................................... 3

Total Cycle Counter ....................................................................................................................................................... 3

Factory Default Menu ................................................................................................................................................... 4

Applicator Hand ............................................................................................................................................................ 4

Encoder Setup Menu ..................................................................................................................................................... 4

Compensation Setup ................................................................................................................................................. 5

Preventative Maintenance ................................................................................................................................................ 6

Daily Maintenance......................................................................................................................................................... 6

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

Table of Contents

03/2023

Weekly Maintenance..................................................................................................................................................... 6

Monthly Maintenance ................................................................................................................................................... 6

Semi-Annual Maintenance ........................................................................................................................................... 6

Dancer Arm Adjustment ............................................................................................................................................... 7

Rewind Slip Clutch......................................................................................................................................................... 7

Adjusting Slip Clutch................................................................................................................................................. 7

Drive Belt Adjustment................................................................................................................................................... 8

Changing Dispense Hand.................................................................................................................................................. 9

Applicator Changeover Sequence................................................................................................................................ 9

Nose Assembly Removal........................................................................................................................................... 9

Blow Box Nose Assembly Removal...................................................................................................................... 9

Merge Nose Assembly Removal.........................................................................................................................10

Tamp Nose Assembly and RVB Nose Assembly Removal................................................................................ 10

Nose Assembly Changeover ...................................................................................................................................10

Merge Peel Edge Changeover............................................................................................................................. 11

Blow Box Peel Edge Changeover........................................................................................................................ 11

Blow Box Assembly Changeover ........................................................................................................................11

Tamp Peel Edge Changeover ..............................................................................................................................12

Tamp Assembly Changeover ..............................................................................................................................12

Rewind Removal ...................................................................................................................................................... 12

Rewind Changeover ................................................................................................................................................12

Wiring Changeover..................................................................................................................................................13

Rewind Installation.................................................................................................................................................. 13

Blow Box Nose Assembly Installation ...................................................................................................................13

Merge Nose Assembly Installation ........................................................................................................................14

Tamp Nose Assembly Installation.......................................................................................................................... 14

Troubleshooting Chart ....................................................................................................................................................15

360y Display Faults.......................................................................................................................................................... 17

Drive Faults .................................................................................................................................................................. 17

No Controller Connection........................................................................................................................................... 17

Software Mismatch Error ............................................................................................................................................ 17

Reboot Required.......................................................................................................................................................... 18

Stop Input ....................................................................................................................................................................18

End of Web Alarm ...................................................................................................................................................18

E-Stop Input .............................................................................................................................................................18

Fault Correction ........................................................................................................................................................... 18

360y Accessories ..............................................................................................................................................................19

Spare Parts ....................................................................................................................................................................... 20

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

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Table of Contents

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360y Core Unit Spare Parts......................................................................................................................................... 20

Non-powered Unwind Assembly Spare Parts ........................................................................................................... 21

Merge Spare Parts .......................................................................................................................................................22

Air Blow Spare Parts.................................................................................................................................................... 22

RVB Spare Parts ...........................................................................................................................................................22

FFS Spare Parts ............................................................................................................................................................23

Tamp Spare Parts.........................................................................................................................................................23

Swing Tamp ................................................................................................................................................................. 24

DAT ...............................................................................................................................................................................24

Options .........................................................................................................................................................................25

APPENDICES............................................................................................................................................................................... 1

Appendix A: Applicator Options Compatibility Chart.................................................................................................... 2

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

viii

Proprietary | Liability | Release Date

03/2023

PROPRIETARY

This document is the property of CTM Labeling Systems Inc. (“CTM”) and contains proprietary and confidential information. The

information contained is intended for persons operating and maintaining the equipment described herein. No unauthorized use,

reproduction, or disclosure of this information is permitted to any other parties for any other purpose without the express, written

permission of CTM Labeling Systems.

LIABILITY

CTM acts to ensure that the information provided in manuals and other documentation is correct; however, reserves the right to make

changes to this manual and other documentation without notice and disclaims liability resulting therefrom. Any obligation to extend

these changes to equipment previously delivered is excluded.

CTM or any other party involved in the creation, production, or delivery of the accompanying product shall not be liable to the

customer nor to any other party for any damages, including without limitation, damages due directly or indirectly to occurrences or

consequences which arise from

•Operation or failure of the equipment to operate.

•Any losses or damages, including without limitation:

oEconomic and consequential losses.

oDirect or indirect, incidental, exemplary, and punitive damages whether in contract, tort or otherwise.

oAny other claims or expenses in any manner resulting, including without limitation or liability:

Losses or damages directly or indirectly from, or connected with:

•Operation of the equipment.

•Discovery or elimination of all hazards.

•Failure to so discover or eliminate all hazards.

•Reason for any action, omission, active negligence, passive negligence, including gross negligence

or any error or omission in the equipment or any use of application thereof.

•Misrepresentation, misstatement, imprudence, lack of skill or error of judgement of or by CTM or

its officers, directors, agents, and servants.

Some jurisdictions do not allow the limitation of incidental or consequential damages, so these limitations may not apply to you.

RELEASE DATE

03/2023

Instruction Manuals: Installation, Operators Maintenance Standard 360a Model Y (360y) Label Applicator

Contact and Support

03/2022

CONTACT AND SUPPORT

Any questions or concerns can be answered by contacting the following:

CTM Labeling Systems

1318 Quaker Circle

P.O. Box 589

Salem, OH. 44460 U.S.A.

Phone: (330) 332 – 1800

Fax: (330) 332 – 2144

Web: www.ctmlabelingsystems.com

e-mail: [email protected]

Technical Support

Support Hours: 8:00am – 4:00pm EST Monday through Friday

Phone: (330) 332 – 1800 ext. 129

Fax: (330) 332 – 2144

e-mail: techsupport@ctmint.com

Spare Parts

Phone: (330) 332 – 1800 ext. 113

Fax: (330) 332 – 2144

e-mail: spareparts@ctmint.com

Customer Training

CTM recommends that service or maintenance personnel complete a Customer Training Course including the model equipment used.

For information on the availability of Customer Training Courses, contact your distributor or Technical Support.

NOTE: Manuals are a supplement (not a replacement) to CTM customer course training.

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