LABEL-AIRE 3115NV User manual

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2010
3115NV
Manual3115NVRev.01
P/N7408830‐100
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TABLEOFCONTENTS
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INTRODUCTION……………………………………………………………………………………………………………………………………………………………………5
CAUTIONARYSYMBOLSANDPICTOGRAMS…………………………………………………………………………………………………………………………..7
INITIALWARNINGS…………………………………………………………………………………………………………………………………………………………...9
APPLICATORPOWERCABLE……………………………………………………………………………………………………………………………………………..10
MECHANICALPLACEMENTOFTHEMACHINE…………………………………………………………………………………………………………………...11
GENERALMACHINEINFORMATION…………………………………………………………………………………………………………………………….13
CONTROLPANEL…………………………………………………………………………………………………………………………………………………………………15
MICROPROCESSORMESSAGES……………………………………………………………………………………………………………………………………21
MACHINESEQUENCE…………………………………………………………………………………………………………………………………………………..23
TOOLLIST…………………………………………………………………………………………………………………………………………………………………………..24
CONNECTIONTOA.C.POWER…………………………………………………………………………………………………………………………………….25
INITIALSETUP…………………………………………………………………………………………………………………………………………………………..26
LABELSETUP…………………………………………………………………………………………………………………………………………………………….27
LABELSENSOREDGE…………………………………………………………………………………………………………………………………………………………31
LABELREPEATLENGTH……………………………………………………………………………………………………………………………………………………..32
LABELSTOPPOSITION………………………………………………………………………………………………………………………………………………..33
IMPRINTERINSTALLED………………………………………………………………………………………………………………………………………………………35
PRINTERDWELLTIME………………………………………………………………………………………………………………………………………………………..36
ENCODERPULSERESOLUTION…………………………………………………………………………………………………………………………………………..37
SPEEDFOLLOWING……………………………………………………………………………………………………………………………………………………………38
PRODUCTSETUP……………………………………………………………………………………………………………………………………………………………….40
POSITIONINGTHEAPPLICATOR…………………………………………………………………………………………………………………………………………41
INITIALSETUP………………………………………………………………………………………………………………………………………………………….41
UPRIGHTANDABOVEATTITUDE……………………………………………………………………………………………………………………………..43
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WRAPUNIT…………………………………………………………………………………………………………………………………………………………………67
APPENDICES……………………………………………………………………………………………………………………………………………………………….74
APPENDIXC………………………………………………………………………………………………………………………………………………………………..93
MAINTENANCE…………………………………………………………………………………………………………………………………………………………103
PROGRAMMINGTHE311xAPPLICATOR……………………………………………………………………………………………………………………113
GLOSSARY…………………………………………………………………………………………………………………………………………………………………124
INDEX………………………………………………………………………………………………………………………………………………………………………127
PRINTS……………………………………………………………………………………………………………………………………………………………………..128
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TABLEOFFIGURES
Figure1115VPowerCable........................................................................................................................................................10
Figure2220VPowerCable........................................................................................................................................................10
Figure3ApplicatorSupportStructure.......................................................................................................................................12
Figure43115NVAPPLICATOR..................................................................................................................................................13
Figure5‐ElectricalPanel(RearofMachine).............................................................................................................................14
Figure6ControlPanel................................................................................................................................................................15
Figure7PeelerPlateDetail........................................................................................................................................................28
Figure8ThreadingDiagram(RightHand)..................................................................................................................................29
Figure9ThreadingDiagram(LeftHand)....................................................................................................................................30
Figure10‐NoseTiltAdjustment................................................................................................................................................44
Figure11‐NoseHeightAdjustment...........................................................................................................................................45
Figure12‐UprightandAboveAttitude......................................................................................................................................45
Figure13‐PeelerBarAdjustment..............................................................................................................................................46
Figure14‐WiringforPNPandNPNDetectors...........................................................................................................................48
Figure15ALLENBRADLEY..........................................................................................................................................................49
Figure16‐PEELERPLATEALIGNMENT.......................................................................................................................................51
Figure17‐PRODUCTDETECTORPOSITION................................................................................................................................53
Figure18BRAKEASYUNWIND..................................................................................................................................................59
Figure19LABELSENSOR&PEELTIPASY...................................................................................................................................59
Figure20‐LOWLABELALARMADJUSTMENT............................................................................................................................62
Figure21‐LowLabelDetector...................................................................................................................................................64
Figure22‐WRAPUNITADJUSTMENT........................................................................................................................................68
Figure23‐PRESSUREBARPOSITION..........................................................................................................................................69
Figure24‐PRESSUREBARIN/OUTPOSITION.............................................................................................................................70
Figure26‐PEELERPLATEALIGNMENT.......................................................................................................................................73
Figure27I/OWIRING.................................................................................................................................................................94
Figure28CurveVariationsonEllipticalProduct........................................................................................................................96
Figure29CurveVariationsonEllipticalProduct........................................................................................................................96
Figure30FLATAreaStepVariationsforDifferentSizeProducts...............................................................................................97
Figure31FastRiseLengthVariationsforDifferentSizeLabels..................................................................................................97
Figure32FastRise/FlatAreaEstimation....................................................................................................................................98
Figure33RewindSlipClutch....................................................................................................................................................111
Figure34PinchRollerAdjustment...........................................................................................................................................112
Figure35ControlBoardH2&H3location..............................................................................................................................115
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INTRODUCTION
The Label-Aire model 3115NV is a high speed label applicator used to apply pressure sensitive labels to
moving products of the same size, such as packages on a production line. It is essentially a self contained
module that may be mounted in almost any position adjacent to the production line, to apply labels to the
top, sides, or bottom of packages as they pass by.
Labels are supplied on rolls that consist of a web on which the labels are maintained by their adhesive
until peeled from the web during application. In a typical set-up, a photoelectric sensor detects the leading
edge of a package and the applicator applies the label, with placement accuracy typically within ± 1/32
inch.
The 3115NV is standard with 1500 inch/minute web speed. Slower web speeds are provided for wider label
capacities.
For safe trouble free operation, the instructions in this manual must be carefully followed during set-up,
operation, change-of-rolls, cleaning, and maintenance. Also the specified environmental conditions must be
maintained.
ELECTRICAL SUPPLY: 108-132 Volts, 5 Amps, 54-60 Hertz, Single Phase
A three meter long, three wire cable with 1.00mm² 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.
OR
207-253 Volts, 5 Amps, 47-53 Hertz, Single Phase
A three meter long, three wire cable with 1.00mm² 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 unterminated and must be fitted with an appropriate plug at
installation
ENVIRONMENT: Operating temperature: 40-104 degrees F Humidity: 20-95% RH, Non condensing
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NOTE: The model 3115NV is not intended to be operated in an environment
where flammable or explosive gases are present. The 3115NV is not
to be used in direct contact with food products.
READ THE INSTRUCTIONS 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 set-up process. Any steps performed out of sequence may result in
a hazard and the applicator may not operate properly.
UNDERSTAND THE TERMS USED. Although this manual uses few technical terms, some vocabulary
may be new to you. Most of the words are defined the first time that they are used. If you don't know
what a word means, check the Glossary.
WORK CAREFULLY. Although setting up the machine is not difficult, it does take time. Do not rush
through the process: careful work will produce good results.
TRY AGAIN IF SOMETHING DOES NOT WORK. Although a machine malfunction is possible, most
problems happen because the machine is not set-up right. If the machine doesn't operate correctly, back up
and try again.
KNOW HOW TO FIND WHAT YOU NEED. This manual contains all of the information needed
including a Table of Contents, Table of Figures, Glossary, and Index. Use these tools to locate
information quickly.
UNDERSTAND OUR TYPOGRAPHIC CONVENTIONS. Machine keys and switches are designated by
brackets: "Press [FEED]," means "Press the feed key." Messages shown on the microprocessor display are
shown by type style: THIS TYPE STYLE INDICATES MICROPROCESSOR TEXT.
NOTE: Paragraphs that are in this style give information to help handle special circumstances,
or re-emphasize important information.
FOLLOW ALL SAFETY INSTRUCTIONS. The model 3115NV 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.
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CAUTIONARY SYMBOLS AND
P
ICTOGRAMS
The following symbols may be encountered on or in the machine and in the Technical manuals. They
serve to alert you to potential hazards that may cause serious harm to personnel.
This symbol warns you that there is a danger of being injured by the drive and/or nip
rollers. Read the text and follow the instructions carefully to avoid an injury.
This symbol indicates the presence of an uninsulated dangerous voltage within the
applicators enclosure.
This symbol indicates a high noise level is present. Ear protection must be worn to
avoid hearing loss.
This symbol indicates that the machine should not be operated unless the
covers/guards are in place.
This symbol indicates that only authorized personnel should perform the procedure.
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This symbol indicates that it is important to maintain a safe air pressure.
This symbol indicates that you should read the Technical Manual before proceeding.
(I) This symbol on an electrical power switch indicates SWITCH ON.
(O) This symbol on an electrical power switch indicates SWITCH OFF.
This symbol indicates the protective EARTH connection.
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I
NITIAL WARNINGS
The model 3115NV has been designed with the safety of the operator and service personnel in mind. Proper
safety features have been incorporated and the applicator safety tested to assure safety if used as intended.
Refer to the CAUTIONARY SYMBOLS AND PICTOGRAMS definitions on the preceding pages.
A risk assessment has been conducted which indicates most hazards identified by the machinery
directive to be low to nil risk. Apparent moderate risks were determined to be:
The Web Drive Rollers
The potential for finger pinch exists between the drive and pinch rollers. Keep hands
clear of the drive and pinch rollers whenever the machine is ONLINE.
Enclosure
A potential for electrical shock exists if the cover is removed. The cover must not be
removed except by a qualified service person. The power switch is to be turned OFF
(O) and the power cord removed prior to removing the cover.
Environmental Exclusions
The model 3115NV is not intended to be operated in an environment where flammable or explosive
gases are present. The 3115NV is not to be used in direct contact with food products.
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APPLICATOR POWER CABLE
Do not connect the machine to the AC
p
ower source until directed to do so in the
set-up procedures.
115V applicators are shipped from the factory with a six foot three pin power cord. One end plugs into the
IEC receptacle on the side of the applicator. The other end connects to the customer's properly grounded
and polarized power outlet.
Figure1115VPowerCable
220V applicators are shipped from the factory with an unterminated power cord. An appropriate grounding
p
olarized plug will need to be installed on the power cord. Use the drawing below to wire in the appropriate
grounding polarized plug for use in your facility.
Figure2220VPowerCable
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MECHANICAL PLACEMENT OF THE
MACHINE
The model 3115NV is mounted at the installation site to provide a safe, adjustable and stable alignment of
the label to be applied, with the product.
The physical properties of the applicator are shown in Figure 3. The orientation of the applicator label
dispenser can be upright and above, nose up, nose down, and reels up. A gimbal function is provided
when the U-arm is used to support the applicator housing by its pivot attachments and by the freedom
provided by rotation about the 3/4 inch mounting bolt. The structure supporting the U-arm/applicator body
must be designed to safely support the 140 lb (63.5 Kg) weight and in some orientations, the moment
generated by the support extended out by almost 12 inches (30cm).
If the installer selects a support base that is mounted on casters, the maximum overturning moment that can
be experienced when the floor is non-horizontal must be considered in the design of the support. Some
safety agencies specify that for a truly portable stand that the design should consider safely supporting the
applicator in its worst orientation for a 10 degree tilt. Also, the casters should have locks to prevent
inadvertent motion of the support.
All portable supports should have a means to anchor the unit to the floor if the applicator need not be
moved for periods between applying labels.
Place the machine so that the peeler plate tip is 1/8 inch from the product's labeling surface. Make sure that
only the wiper will touch the product as it passes the machine. The position of the machine should allow
the operator to easily change labels.
When you have correctly assembled and positioned the machine, tighten any adjustment locks to prevent the
machine from moving.
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Figure3ApplicatorSupportStructure
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GENERALMACHINEINFORMATION
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Figure43115NVAPPLICATOR
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Do not connect the machine to the AC
p
ower source or the
compressed air service until directed to do so in the set-u
p
procedures.
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Figure5‐ElectricalPanel(RearofMachine)
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CONTROL PANEL
This section covers the control panel menu items.
Figure6ControlPanel
When the machine is first powered ON, the display will read:
IMPAXX MACHINE
SYSTEMS LABEL-
AIRE NEW 3000
SERIES
Then:
OFFLINE PRODUCTS PER MINUTE:
XXXX1
The [ENABLE] button will put the machine in ONLINE mode, for normal operation, or OFFLINE mode, for set-
up.
The [FEED] button will feed a label.
The [ENTER] button (5) will select the displayed menu item.
1X denotes a numeric value.
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Pressing the [UP] and [DOWN] arrow buttons will cycle through the menu options, and increment and
decrement the value of the selected item. When selecting menu options, holding in these buttons will
move through the menu options faster.
The [LEFT] and [RIGHT] arrow buttons will move through the digits of a numeric value.
The [CUSTOM] (*) button will perform an automatic label calibration. This includes setting up the label
sensing level and the LABEL REPEAT LENGTH. Press and hold while two labels dispense to perform the
automatic label calibration.
The [ESC] button will move to the next lower menu level (For use when in the Advanced and Service
menus only).
The [HELP] (?) button has no function at this time.
MENU LEVELS
There are three menu levels: Operator, Advanced, and Service. When first powered ON, the machine is at
the Operator level. This level offers only the basic functions that may need to be changed during a product
run.
To change the menu level from Operator to either Advanced or Service, simultaneously press both the
[LEFT] and [RIGHT] buttons, then enter the ACCESS CODE for the desired menu level.
The Advanced level allows set-up of the machine for different label and product types.
The Service level allows configuration of machine specific items such as the type of machine, and
activates any options the machine is equipped with.
The following is the list of menu items for each level and their function for the 3115NV applicator.
OPERATOR LEVEL
PRODUCTS PER MINUTE - This is an informational display showing the product rate.
PRODUCT COUNTER - This informational display shows the number of products that have been detected
since the counter has been reset. There are seven decimal places in this display. PRODUCT COUNTER RESET
- Selecting YES will reset the product counter.
LABEL COUNTER - This informational display shows the number of labels that have been detected since the
counter has been reset. There are seven decimal places in this display.
LABEL COUNTER RESET - Selecting YES will reset the label counter.
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LINE SPEED - This information display shows the conveyor speed. This display is only shown if SPEED
FOLLOWING is set to YES in the Service menu.
RECALL PARAMETER FROM LABEL PAGE - This recalls the microprocessor settings that have been stored in the
indicated label page. The label page can be set from 1 to 50. Label pages can be set-up for each label type.
LABELING SPEED - This sets the speed of the web. This value can be set from 20 to 1500 (inches per
minute).
LABEL STOP POSITION - This setting determines where the next label to dispense stops. For example, if the
machine is properly set-up, the leading edge of the next label to be applied will be at the peeler bar tip. This
value can be set from 0.00 to 2.00 inches.
LABEL ON PRODUCT POSITION - This sets the delay
b
etween product detection and the application of the label.
This value is expressed in distance. This value can be set from 00.01 to 40.00 inches.
BACKLIGHT INTENSITY - This adjusts the brightness of the display backlight. This value can be set from 0 to
100.
DISPLAY CONTRAST - This adjusts the display contrast. This value can be set from 0 to 50.
CPU VERSION AND DATE - This displays the CPU version number and the date of the software. This is
informational only, these items cannot be changed.
A
D
V
ANCED LEVEL
LABEL-SENSOR TO PEEL-TIP DISTANCE - Enter the distance between the cross-hairs on the label sensor, to the
tip of the peeler bar. This value can be set from 1.0 to 40.0 inches.
LABEL REPEAT LENGTH - This value should be set to the distance between the leading edge of one label on the
web to the leading edge of the next label on the web. This is the length of one label plus the gap between
labels. This value is set automatically during label calibration, but can be adjusted if necessary. This value
can be set from 0.20 to 20.0 inches.
LABEL-SENSOR SETTING - This value is set automatically during label calibration, but can be adjusted if
necessary. This menu item controls the sensitivity of the label sensor. This value can be set from 0 to
200.
LABEL SENSOR EDGE - This can be set to LEADING or TRAILING as desired. LEADING is usually
preferred.
LABEL DETECTED - This informational display indicates weather the label detector is detecting a label or not.
It can be YES or NO.
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LABEL STOP POSITION - This setting determines where the next label to dispense stops. For example, if the
machine is properly set-up, the leading edge of the next label to be applied will be at the peeler bar tip. This
value can be set from 0.00 to 2.00 inches.
LABELING SPEED - This sets the speed of the web. This value can be set from 20 to 1500 inches per
minute.
SLEW SPEED - This sets the speed of web travel when advancing past missing labels. This value can be set
from 20 to 2500 inches per minute.
CONSECUTIVE MISSING LABEL COUNT - This value sets the number of consecutive labels that can be
missing on the web before an error occurs. This value can be set from 0 to 9.
PRINTER DWELL TIME - If IMPRINTER INSTALLED is set to YES in the Service menu, this sets the dwell of the
imprinter. This value can be set from 0 to 9999 milliseconds.
PRODUCT SENSOR EDGE - This can be set to LEADING or TRAILING as desired. LEADING is usually
preferred.
PRODUCT DETECTED - This informational display indicates whether the product detector is detecting a
product or not. It can be YES or NO.
LABEL ON PRODUCT POSITION - This sets the delay in distance between product detection and the
application of the label. This value can be set from 1.00 to 40.00 inches.
PRODUCT DETECTOR LOCKOUT - This function allows you to set a distance during which the applicator will
ignore any product inputs. Use this function when the product detector is generating false detection signals
and the applicator cycles more than once per product. If not needed, set this to its minimum value. This
value can be set from 0.04 to 40 inches.
LOW LABEL STOP COUNT - If LOW LABEL INSTALLED is set to YES in the Service menu, this value is the number
of labels that will be applied between the triggering of the low label sensor, and a WEB FAULT error condition.
This value can be set from 1 to 99.
ZERO DOWN TIME - If ZERO DOWN TIME is set to YES in the Service menu; this setting tells the
microprocessor if this machine is the UPSTREAM or DOWNSTREAM applicator. Set as appropriate.
NUMBER OF PRODUCTS TO SKIP - If SKIP LABELING PRODUCTS is set to YES in the Service menu, this value is
set to the number of products to skip between applying labels. This value can be set from 1 to
99.
NUMBER OF PRODUCTS TO LABEL - If SKIP LABELING PRODUCTS is set to YES in the Service menu, this value
is set to the number of labels to be applied to a single product. This value can be set from 1 to
99.
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LABELS PER PRODUCT - if MULTIPLE LABELS ON PRODUCT is set to YES in the Service menu, this value is set
to the number of labels to be applied to a single product. This value can be set from 1 to 99.
LABEL SPACING - If MULTIPLE LABELS ON PRODUCT is set to YES in the Service menu and LABELS PER
PRODUCT is set to two or more, then this value is set to the spacing between labels. This value can be set
from 1.00 to 40.00.
FAST RISE LENGTH - Refer to the Label Profiling Section.
FLAT AREA LENGTH - Refer to the Label Profiling Section.
WEB RATIO - Refer to the Label Profiling Section.
RECALL FROM LABEL PAGE - This recalls the microprocessor settings that have been stored in the indicated
label page. The label page can be set from 1 to 50. Label pages can be set-up for each label type.
SAVE PARAMETER TO LABEL PAGE - This recalls the microprocessor settings that have been stored in the
indicated label page. The label page can be set from 1 to 50. Label pages can be set-up for each label
type.
SERVICE MENU
MACHINE TYPE - This can be set to 3111NV, 3114NV, 3115NV, 3125, 3135, or 3155. This manual covers the
3115NV machine type.
UNITS - Set this to IMPERIAL (English), or METRIC as desired.
LANGUAGE - This can be set to ENGLISH, SPANISH, FRENCH, PORTUGUESE, or GERMAN. Set as desired.
SPEED FOLLOWING - Set this to YES if an encoder is being used, NO otherwise.
ENCODER PULSE RESOLUTION - If SPEED FOLLOWING is set to YES, this sets the number of encoder pulses
per inch of conveyor (product) travel if an encoder is used. This value can be set from 25.0 to
250.0 pulses per inch. When using an encoder wheel with a five inch circumference, this value will be
100.
LOW LABEL INSTALLED - If set to YES, will allow the setting of the LOW LABEL STOP COUNT in the
Advanced menu.
IMPRINTER INSTALLED - If an imprinter is installed, set this to YES, or NO otherwise. When set to YES, it
allows the setting of the IMPRINTER DWELL value in the Advanced menu.
LABEL PROFILING - This allows label profiling adjustments in the Advanced menu. Set to YES or NO as
required.
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