Pack Leader PRO-625W User manual

OPERATION
MANUAL
A fully automatic front and back labeler
with speed, simplicity and easy customizaon to suit your specic requirements
PRO-625W
Front and Back Labeler
with Wrap Station

MACHINE SPECIFICATIONS
04 Machine Sub-Assemblies
05 Machine Dimensions
07 SpecicaonofLabelReel
GENERAL INFORMATION
09 SafetyRegulaons
10 LabelApplicator
13 AdjusngDrivePU&AluminumRoller
14 GuideRail
16 PosionofObjectSensor
17 PartsAdjustments
18 LabelSensorPosion
18 SensivityAdjusngofLabelSensor
MACHINE OPERATION
23 TouchScreen
24 TroubleShoong
ELECTRONIC PANEL
28 ElectronicDiagram
29 ControlBoxFrame
30 ElectronicPartsList
APPLICATOR
32 TensionBarAssembly
33 ApplicatorExplodedView
35 BasePlateAssembly
37 ApplicatorBasePlateAssembly
38 ApplicatorBackPlateAssembly
39 LableLeadAssembly1
40 LabelPressAssembly
41 LabelLeadFixedAssembly
42 LabelLeadAssembly2
43 LabelLeadAssembly3
44 LabelSensorFixingBaseAssembly
45 LabelPeelPlateAssembly
46 PURollerAssembly
47 LeverSleeveAssembly
48 BasePaperCollectAssembly1
49 BasePaperCollectAssembly2
50 ApplicatorMotorAssembly
51 ApplicatorAdjustmentAssembly
52 Up/DownAdjustmentAssembly
WRAP STATION FEATURES
54 WrapStaonAssembly
55 WrapStaonFrameAssembly
56 WrapStaonDrivingPulleyAssembly
57 WrapStaonDrivenPulleyAssembly
58 WrapStaonMotorAssembly
59 WrapStaonUp/Down
 AdjustmentAssembly
PRESSURE PLATE
62 PressurePlateAssembly
63 PressurePlateUp/DownAssembly
64 PressurePlateFront/Back
 AdjustmentAssembly
CONVEYOR
66 ConveyorFrontSidePlateAssembly
67 ConveyorAssembly
69 ConveyorBackSidePlateAssembly
70 ConveyorDrivingPulleyAssembly
71 ConveyorDrivenPulleyAssembly
72 ConveyorMotorAssembly
73 BoleSeparatorAssembly
GUIDE RAIL FEATURES
75 GuideRailA01
76 GuideRailA02
77 GuideRailA03
78 GuideRailA04
79 GuideRailA05
FOOT STAND FEATURES
81 FootStandPartsList
TABLE OF CONTENTS

MACHINE SPECIFICATIONS

MACHINE SUB-ASSEMBLIES
|4
CONVEYOR
WRAP STATION
HMI
APPLICATOR A
PRESSURE PLATE
APPLICATOR B
BASE FRAME
BOTTLE SEPARATOR
TOP HOLD DOWN
CHAIN ALIGNER
SPONGE ROLLER

|5
MACHINE DIMENSIONS
2800
1339
1824

|6
MACHINE DIMENSIONS
LABEL TYPES
Front and Back
Optional Wrap
SPEED
Maximum Dispensing Speed:
131.2’/min (40m/min)
Maximum Conveyor Speed:
131.2’/min (40m/min)
DIMENSIONS
Dimensions L-W-H:
112” x 72” x 56.3”
(2845mm x 1829mm x
1429mm)
Maximum Label Size:
7” x 12” (H 178mm x L 305mm)
Maximum Container Width:
7.5” (191mm)
Maximum Container Height:
13” (330mm)
Conveyor Belt Width:
6 5/16” (160mm)
Spool Diameter: 14” (356mm)
Inner Core: 3” (76mm)
POWER
Voltage: 110/220 VAC 50/60 HZ
1 Phase
Power in KW: .1320
Drive: Stepper Motor
NET WEIGHT
Approx 750 lbs (300 kgs)
CONVEYOR HEIGHT
33.5-35.5” (851-902mm)
Flexibility
• With the PRO-625, labeling for a
diverse range of containers is fast
and easy – regardless of size or
shape. The standard one-buon
teach product and label sensors
make it simple to adjust for various
labeling applicaons. And, with the
manual posion seng, your labels
are placed accurately on the product,
each and every me.
• With label heads that lt on a
12-degree x-y axis, the PRO-625
even works well for tapered or
shaped products.
• Future upgrades are simple. Thanks
to the PRO-625’s thermal or hot
foil printer controls, you can easily
incorporate a printer if the need
should arise. This integrated feature
lets printers work in sync with the
labeler to ensure accurate code
placement. The result? Easy label
customizaon you can turn on or o.
Efficiency
• The auto label-set feature conrms
label sensivity by detecng the
separaon between each label.
With one push of a buon, labeling
is automacally set up – and
posioned correctly.
• The missing label-detect feature
locates missing labels on the roll
stock, and instantly shuts the
machine down if one is found. This
preventave feature ensures each
product is labeled appropriately.
Accuracy
• Chain aligners center your product
before entering top hold-down
controls that keep the product in place.
• The auto-length set feature ensures
accuracy.
• The PRO-625’s controls are
fully synchronized, ensuring all
components run at the same speed.
• With 360-degree touchscreen
controls, the PRO-625 can be
controlled from any posion.
Productivity
• The producon preset funcon
means the machine automacally
stops once the predetermined
quanty of products has been
labeled.
• The label count feature lets you
precisely track progress at any point
during the producon run.
• The container/producon run
counter lets you see the exact
producon number for the day.
• The PRO-625 features a touchscreen
control system with job memory.
So, even aer the machine sits idle
for long periods, you benet from a
baery-free microprocessor control
system that stores default sengs.
Up to 30 sengs can be stored for
future use, so you don’t have to
waste me re-entering the necessary
informaon.
Practicality
• The PRO-625 can be easily moved to
other producon areas, allowing for
changes in producon or products.
• Maintenance is quick and simple,
thanks to slide-out controls and
electronics stored in easy-to-access
cabinets.
• All Pack Leader USA labelers are
made of 304 stainless steel and
anodized aluminum. This extremely
durable metal is specially treated
to guard against rusng and other
eects from harsher environments.
Compliance
• All Pack Leader USA labelers are
manufactured in compliance with
Good Manufacturing Pracces (GMP)
standards and meet the strict ISO
9001 quality control procedures. So,
you can have condence undergoing
required quarterly inspecons from
industry compliance auditors.

|7
MACHINE FEATURES
• The build-in instrucon of the operaon system
is very easy and well documented. This system
reduces the training me for the new operators
who can immediately increase the producon since
anyone can learn to operate it within few minutes.
• The build-in Trouble shoongs feature reduces the
down me for system breakdown. Operator can
easily follow the instrucon on the screen to solve
the problems.
• User- friendly design for seng label length, any
dierent size of label can be easily detect with a
gentle touch. This unique seng can assure the
accuracy of each label length, so that it won't be
aected by the mismatch of length from previous
memory seng (Since the space between each
label could has a slight dierence, the error will
accumulate during each labeling process). Beside
that, the set up process is very simple for new
operator.
• With the funcon of label counter, you can easily
monitor the current status of labeled quanty from
the control screen.
• With the batch counter, you can preset the total
labeling quanty. The machine will auto-stop when
it reach the preset quanty. This feature is useful
for quanty management in the producon line.
• With posion set, you can easily adjust the posion
of the label by seng a delay me to make some
adjustment on the label posion.
• Missing label auto-stop system can avoid any
missing the label on products for manufacturers to
easily do their quality control during the producon
process.
• For dierent prinng speed, printer mer can be
set for dierent demands to assure the clarity
of the each print. (The printer is oponal. All
the control circuit for printer is preset for future
installaon in all standard machines).
• Eight speed selecon for dierent working
environment to meet the requirement of dierent
producon lines.
• Automac start funcon reduces the setup me by
simply providing electricity, the system and it will
start operate by itself in the producon line.
• The conveyor has a separator wheel to space
each bole apart from each other and ensure the
correct posion for labeling. By adjusng the guide
rail, dierent size of boles can be labeled (for
producon rate of 200 ~ 400 boles per minute,
use in- feed screw for fast and stable operaon.)
• Foot-stand designed with square-shapes for small
footprint and castors for mobility. It is ready to
operate as a stand-alone machine or connected
with other in-line machine for exibility
• 30 memory slots for convenient data retrieval and
loading.

Base Paper:
Translucent
Reel Inner Diameter:
3" 76 mm
Reel Outer Diameter:
14" 370 mm
Interval of Label:
Min. 3 mm (between label)
Width of Base Paper:
Label Width + 4 mm
Width of Label:
180 H Label Head –
10~180 mm
200 H Label Head –
10~200 mm *optional
Length of Label:
15 ~ 300 mm (Standard)
Right side
of copy
dispenses
rst.
Left side
of copy
dispenses
rst.
|8
SPECIFICATION OF LABEL REEL
#4 WIND
#3 WIND

GENERAL INFORMATION

 
1.
2.
3.
4.
INSPECT BEFORE
OPERATING
• Make sure the power is
connected to the correct
power source
• Adjust machine to the
specified product range
• Adjust the height of
label applicator to the
appropriate position
• Adjust the guide rails
according to the width of
the product
• Adjust the object sensor
to the correct position
• Adjust label sensor to
the proper setting
• Make sure the conveyor
is clear of extra objects
• Adjust separator wheel
to accommodate the
width of the product
Do not put hands or ngers on the inner tube when adjusng the
height of the foot stand. Immediately li up the conveyor if hands
or ngers get trapped.
Beware of your clothes, hair, gloves or anything loose when the
machine is turned on, as these can be easily caught in the conveyor
or running roller that may cause injury.
Do not touch the conveyor, roller or paper receive axis when
machine is running.
Be sure hands are completely dry before inserng the plug into the
outlet. Especially, in the food industries or in wet environments.
|10
SAFETY REGULATIONS
DANGEROUS
DANGEROUS
SAFE
SAFE

2.
1.
3.
4.
Fasten the tension clip aer passing through this point to
ensure tension on the label strip and avoid loose labels.
Put the roll of label on the tray and passes it through the
tension roller so it will not spin out of control.
It is important for the labels to pass through the label
sensor slit for it detects the labels and controls the
dispensing of labels.
The dispensing plates peels the label from the base
paper for applicaon on the objects
Follow these instructions to insert the labels into the label applicator.
LABEL APPLICATOR
|11
1 1
6
6
22
3
4
55 4
3
Left applicatorRight applicator
Standard

B.
WARNING: If the aluminum knurled roller is not ghtly pressed against the PU drive roller, the labeling will be inaccurate, which
will cause incorrect labeling. If the aluminum knurled roller is pressed too ght, it will cause the PU drive roller to wear and crack.
5. The drive PU rubber roller pulls the base paper to posion the labels. The aluminum pressure roller
must be locked in place with the PU roller in order to squeeze the paper and pull eecvely.
|12
LABEL APPLICATOR
ALUMINUM PRESSURE
ROLLER
PU DRIVE ROLLER
& ALUMINUM
KNURLED ROLLER
LOOK
A.

B1.
6. Wind the base paper around the 3 pillars at the collecon of the base paper. Wind it up unl there is
some tension on. The paper for proper pickup.
|13
LABEL APPLICATOR
LOOSE SQUEEZE
WRONG
OPENED CLOSED BASE PAPER COLLECTOR
RIGHT
A1.

WARNING: If the guide rail’s width is not adjusted to conform with the object’s dimensions, this will aect the precision of the
applied labels. So it is very important to adjust the guide rails according to the objects dimension. The margin must be minimal for the
Guide Rail: To guide the products into the right posion or direcon
|14
GUIDE RAIL
ADJUSTMENT LOCK
GUIDE RAIL
RIGHT

1.
4.
2.
3.
Conveyor adjustment: To adjust the tension
of the conveyor belt, loosen the two nuts
on the screws. Turn counter clockwise to
loosen and clockwise to ghten. Make sure
the conveyor is centered to reduce any
noise. See A.
Paper press piece adjustment: First, loosen
screw (A) turn the rod (2) counter clockwise
and hold it. Use your other hand to ghten
screw A and then release it.
Top hold down belt adjustment: To adjust
the ghtness and centering the belt, adjust
the screw. When adjusng, use only small
increments and let the belt run for a while to
determine the nal posion.
In adjusng the side pressure’s roller chain,
there has 1 places to adjust, screws A. When
adjusng A , the 2 screws must be adjusted
evenly and must check if the degree of
ghtness is the same. Another thing to check
is if the side pressure’s roller chains are level
with each other. If the rollers are not level,
the boles will not be oriented properly. It is
important for the rollers to be leveled.
|15
PARTS ADJUSTMENTS
A
ADJUST SCREW
A
A
2

To adjust wrap around station widths: As
follow drawing show, put object between
wrap around belt and pressure plate.
Adjust frontward and backward screw E,
let pressure plate press object with suitable
pressure. Then turn on conveyor to check
object and be turned smoothly.
Wrap around belt adjustment: To adjust the
ghtness and centering the belt, adjust the
screw A. When adjusng, use only small
increments and let the belt run for a while
to determine the nal posion. A belt that is
not centered will slip up or down.
To adjust wrap around staon height: only
adjust screw C and D so you can adjust wrap
around belt and pressure plate height.
|16
PARTS ADJUSTMENTS
5. Wrap around station adjustment:
Wrap Around Belt
Pressure Plate
High & Low Adjust
High & Low Adjust
Frontward & Backward Adjust
A
B
C
D
E
HIGHER LOWER
21
E
A B
D
C
A

1.
2.
3.
Please follow the direcon of diagram to install the label sensor.
Adjust the sensivity of label sensor to the appropriate posion aer the label is passed through the
label sensor.
Kindly place the label through the detect point of label sensor.
|17
LABEL SENSOR POSITION

1. Remove a label from the backing substrate before the sensor.
4.
Again, hold down “Length Set” on the HMI unl the next
label is posioned in the sensor. If the sensor is setup
correctly, the green and red LED will be on when a label is
posioned in the sensor. Also, check the HMI and conrm
that the counter for “Length Set” is increasing and holding the
count aer you release the “Length Set” buon (Figure 4).
3. On the label sensor, hold down the “NORMAL” buon unl
the green LED ashes and then turns solid (Figure 3).
2.
On the HMI touchscreen, hold down “Length Set” (Figure 1)
unl the backing substrate only is posioned in the sensor
(Figure 2).
5. Lastly, positon the next label to dispense no more than 3mm
past the end of the peel plate.
NOTE: The status of the red LED and output transistors can be inverted by pressing both buons simultaneously. When the output
status has been inverted, the red LED and the output transistors will turn o when the label comes into view.
NOTE: This sensor cannot detect transparent labels.
|18
SENSITIVITY ADJUSTING OF LABEL SENSOR
FIGURE 1
FIGURE 2
FIGURE 3 FIGURE 4 LABEL SENSOR

MACHINE OPERATION

1A
1B
2D
1C
2C
1D
2B
2A
2E
3A
Please follow steps and instruction for machine operation.
Plug-in the appropriate power supply voltage.
Press “Wrap Around ON/OFF” to switch two
sides labeling mode and round bole labeling
mode.
The display will shows as diagram 1.
Turn of the power (Turn on the emergency stop
switch if in “o” condion).
Press AUTO LENGTH icon to get in diagram 3-2
to start label length seng. Two ways to seng
label length: Auto and Manual length set.
Press “Enter” to get into next diagram or wait
for 3 seconds.
Press “Guide Mode” for showing machine
operaon instrucon.
Press “Seng Mode” for set up machine
informaon and speed.
Press “Memory Mode” for memory setup.
Press “Labeling Mode” to enter diagram 3-1 or
wait 5 seconds for next diagram.
|20
MACHINE OPERATION
DIAGRAM 1
DIAGRAM 2
DIAGRAM 3-1