Rena T-250 User manual

1
RENA
T-250
TABBER
SERVICE MANUAL
Rev. 9-8-08

SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY.
HOWEVER, CERTAIN SAFETY RULES SHOULD BE OBSERVED WHEN
OPERATING THE T-250 TABBER.
BEFORE USING THE TABBER, YOU SHOULD READ THIS MANUAL
CAREFULLY AND FOLLOW THE RECOMMENDED PROCEDURES, SAFETY
WARNINGS, AND INSTRUCTIONS:
9Keep hands, hair, and clothing clear of rollers and other moving parts.
9Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure
machine mechanisms come to a stop.
9Always turn off the machine before making adjustments, cleaning the machine, or performing any
maintenance covered in this manual.
9Use the power cord supplied with the machine and plug it into a properly grounded wall outlet located
near the machine and easily accessible. Failure to properly ground the machine can result in sever
personal injury and/or fire.
9The power cord and wall plug is the primary means of disconnecting the machine for the power
supply.
9DO NOT use an adapter plug on the line cord or wall outlet.
9DO NOT remove the ground pin from the line cord.
9DO NOT route the power cord over sharp edges or trapped between furniture.
9Avoid using wall outlets that are controlled by wall switches, or shared with other equipment.
9Make sure there is no strain on the power cord caused by jamming between the equipment, walls or
furniture.
9DO NOT remove covers. Covers enclose hazardous parts that should only be accessed by a qualified
service representative. Report any damage of covers to your service representative.
9This machine requires periodic maintenance. Contact your authorized service representative for
required service schedules.
9Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of RENA Systems, Inc., its designated
agents, customers, and their employees. The information in this guide was obtained from several
different sources that are deemed reliable by all industry standards. To the best of our
knowledge, that information is accurate in all respects. However, neither RENA Systems, Inc..
nor any of its agents or employees shall be responsible for any inaccuracies contained herein.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical,
including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher

TABLE OF CONTENTS
i
TABLE OF CONTENTS
Section 1- Introduction
General
FrontView
Rear View
Functional Operation
1
1
1
2
2
Section 2- Assembly, Installation and Operation
Assembly
Installation
Operation
Loading Tabs
Tab Sensitivity Adjustment
Adjusting the Metering Bracket and Guides
Media Supports and Side Guide Adjustment
Tab Positioning Adjustment
Feeding and Tabbing Media
Trouble Shooting
3
3
4
4
5
6
7
7
8
9
9
Section 3- Adjustments
Motor Drive Belt Adjustment
Clutch and Brake Adjustment
Tab Sensor Adjustment
Media Sensor Adjustment
10
10
11
12
14
Section 4- Disassembly and Assembly
Removing Covers
Replacing Feed Rollers
Replacing Middle Feed Rollers and Drive Shaft
Replacing Front Feed Roller
Replacing Drive Motor
Replacing Clutch and Brake
Replacing the Tab and Media Sensors
Replacing the PC Board
15
15
16
17
19
20
21
23
24
Section 5- Power & Fuse Information
Power Inputs/Outputs
Fuse Locations and Ratings
25
25
25
Section 6- Wiring Diagram & Board Layout/Connections
Wiring Diagram
Board Layout and Connections
26
26
27
Section 7- Maintenance
Cleaning
Feed Rollers and Forwarding Rollers
Cleaning the Sensors
28
28
28
23
Appendices
Specifications 29 29

TABLE OF CONTENTS
ii
NOTES
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GETTING ACQUAINTED
1
Section 1 – Getting Acquainted
General: The T-250 Tabber is a desktop tabbing machine that is designed for the
moderate volume user. It can handle documents ranging from 3” x 5” card stock to 11” x
11” booklets up to 5/32”
The T-250 Tabber will process a range of “Tabs” in most colors and either round or
square from 5/8” to 1-1/4” in length and width.
Front View
1. Tab Sensor and Guide Assembly – This assembly keeps the tab aligned so that
the sensor can sense the tab.
2. Tab Roll Side Guide – Holds the tab roll in place on the Tab Roll Support.
3. Reel Brake Assembly – Prevents the roll of tabs from unwinding when they are
not being fed.
4. Tab Take-up Reel – Winds up the tab backing material.
5. Metering Bracket Assembly – Separates the media so that only one piece feeds
at a time
6. Tracking Rollers – Guide the media through the tabber.
7. Tab Positioning Adjustment Knob – Adjusts the position the tab on the media.
8. Tab Pressure Knob – Provides pressure on the tab to hold it against the tab
advance roller.
9. Tab Advance Knob – Attached to the tab advance roller that feeds the tabs.
10. Exit Roller – Applies pressure to the tab to help it stick to the media.

GETTING ACQUAINTED
2
Rear View
1. Media Support – Supports media during feeding.
2. Media Side Guides – Help maintain position of media in relationship to tabs.
3. Tab Roll Support – The tab roll is mounted here.
4. Media Counter – Resettable counter to track number of pieces fed.
5. Tab Feed Switch – When this switch is depressed the tabs will feed when the
media switch is also depressed.
6. Media Feed Switch – This switch when depressed will cause the media to feed.
7. Tab Sensitivity Adjustment – Different tabs have different densities. This
adjustment compensates for the different types of tabs.
8. Fuse – The main power fuse is located here.
9. Power Inlet – The power cord is plugged in here.
10. Main Power Switch – Controls the power to the tabber.
Functional Operation
The T-250 is a stand-alone machine that can process media into a stacker or tray. The T-
250 will process various sizes of media and place a single “tab” on the lead edge of the
media. The media can vary in length from 3.6” to 11” and vary in thickness from a C-
folded sheet of 20# bond paper to a booklet of 5/32” thick.
The T-250 will process media at a speed up to 12,000 pieces per hour depending on the
skill of the operator, the length (depth) of the media and the type of material.
When the media is fed, a media sensor detects the lead edge of the media and starts a tab
feeding into position. The media contacts the tab and the exit roller presses the tab to the
media and carries the media out of the tabber. At the same time, the tab feed stops until
another piece of media is seen by the media sensor. The sensitivity of the tab sensor is
adjusted by the tab sensor adjustment on the rear of the tabber for different types of tabs.

ASSEMBLY, INSTALLATION AND OPERATION
3
Section 2 – Assembly, Installation and Operation
Assembly
The T-250 Tabber has to be assembled before it can be used. Follow the steps below to
prepare it for operation:
Step 1: Remove all the components from
the carton.
Step 2: Attach the two media support
guides using the two thumbscrews
provided. The pin on the guide fits into
the lower hole and the guide is secured
with the thumbscrew as shown.
Step 3: Install the two side guides over
the metering bracket support bar and then
tighten the thumbscrew.
Step 4: Loosen the thumbscrew. Place
the slot on the tab roll support over the
stud and slide it down until it reaches the
thumbscrew. Tighten the thumbscrew.

ASSEMBLY, INSTALLATION AND OPERATION
4
Installation
Place the tabber on a flat surface away
from windows or heat sources and near
an electrical outlet. Plug the power cord
into the receptacle at the side of the
tabber and then pug it into the wall outlet.
CAUTION
DO NOT USE AN ADAPTER PLUG OR EXTENSION CORD TO CONNECT
THE TABBER TO THE WALL RECEPTACLE.
DO NOT USE OUTLETS CONTROLLED BY WALL SWITCHES.
DO NOT USE AN OUTLET THAT SHARES THE SAME CIRCUIT WITH
LARGE ELECTRICAL MACHINES OR APPLIANCES.
Operation
There are six steps required to set-up the T-250 Tabber to apply tabs to your media:
Step 1: Load a roll of tabs on the tabber. (Page 5)
Step 2: Set the sensitivity of the Tab Sensor. (Page 6)
Step 3: Adjust the Metering Bracket Assembly to the media. (Page 7)
Step 4: Adjust the Media Supports and Media Side guides to the media. (Page 8)
Step 5: Adjust Tab Position. (Page 9)
Step 6: Load the media on the tabber and turn on the main power switch. Activate the
Tab switch, and then press the Feed switch to start the feed rollers.

ASSEMBLY, INSTALLATION AND OPERATION
5
Loading Tabs:
1. Remove the Exit Roller, and then remove the
Tab Roll Side Guide by pulling it away from
the Tab Roll Support.
2. Mount the roll of tabs with the tab leader
coming off the roll on the exit side of the
tabber. Replace the Tab Roll Side Guide.
3. Unwind approximately 12 inches of tabs and
remove the first 12 tabs from the backing
material.
4. Thread the tab roll leader behind the Reel
Brake Assembly and then in front of the Idler
Roller. Then thread the leader through the Tab
Sensor Guide Assembly. This can be done by
pulling the leader down past the sensor guide assembly and then sliding the strip
into the slot on the guide from the side.
5. Thread the leader through the metal lip and up between the Abrasive Roller and
the Pressure Roller. It helps to release the pressure on the Pressure Roller during
this process. Release the Pressure Roller
6. Turn the Tab Advance Knob counterclockwise and feed 2” to 3” through the
center of the Tab Take-up Reel pins.
7. Center the paper backing in the black plastic Tab Guide and Sensor Assembly.
Note: Turning the Tab Pressure knob to OFF helps with the alignment. Return
the pressure knob to the ON position
after centering.
8. Set the Tab Side Guide to confine, but
not bind the tab backing. Adjust the
Tab Guide and Sensor Assembly so that
the Red centerline is in the approximate
center of the tab.
9. Replace the Exit Roller by pushing it
back into its holder.

ASSEMBLY, INSTALLATION AND OPERATION
6
Tab Sensitivity Adjustment
There are two types of tabs designed for
use in the T-250 Tabber. Type 1 is a
paper tab with a plain paper backing.
Type 2 is clear plastic, translucent or
white paper tab, with a black or brown
backing behind the tab and a white stripe
(space) between each tab. Do Not use
clear or translucent tabs that have a white
backing behind the tab and a black line
(space) between the tabs.
1. Remove the exit roller.
2. With the tab exposed under the sensor, turn the main
power switch ON.
3. Turn the Tab Sensitivity Adjustment knob fully
counterclockwise. Then turn it clockwise until the Red
LED above the adjusting knob lights.
4. Turn the Tab Pressure Knob OFF and roll the tabs
backwards until the Red LED goes OFF. Turn the Tab Sensitivity Knob
clockwise until the Red LED lights again. (Example: the LED illuminates at
position 4 with the tab under the sensor and at position 10 with the backing or
white line under the sensor. The difference between the two positions is six
clicks.) Turn the Tab Sensitivity Knob counterclockwise to position 7, which is
half way between 3 and 10.
NOTE: If during the adjusting process second number is greater than 12 and
the LED does not light the second time, then proceed as if the second number
was 12. If at any time during the tabbing process double tabbing occurs,
click one more position clockwise.
5. Turn the Tab Pressure Knob ON and advance the tab until it starts to peel away
from the backing paper.
6. Reinstall the Exit Roller.

ASSEMBLY, INSTALLATION AND OPERATION
7
Adjusting the Metering Bracket and Guides
This procedure is used to insure that only one piece of media is fed at a time.
1. Loosen the two thumbscrews that attach the Metering Bracket to its mounting bar.
2. Raise the Metering Bracket and place a piece of media under the separator
fingers, then lower the Metering Bracket until it contacts the media. Make sure
that material is between all the fingers and rollers.
3. Tighten the two thumbscrews.
4. Remove the media and make sure the bar is level and that the separator fingers are
not rubbing against the feed rollers.
5. Place one piece of media in the desired position on the media supports and adjust
the Media Side Guides to the media, leaving approximately 1/16” side play
between the guides and the media.
6. Feed one piece of media. If you have a problem feeding, check the following
before trying to readjust the feed.
Feeding
Doubles Lessen the distance between the separator fingers and the
feed roller.
Not Feeding Increase the distance between the separator fingers and the
feed roller.
Heavy
Material Place 1-1/2 times the material between the separator fingers
and the feed roller.
Skewing Place the Side Guides closer to the edges of the media.
Media Supports and Side Guide Adjustment
1. Position the media on the Media
Supports approximately where
you wish to position the tab.
2. Place one sheet of media on the
Media Supports so that it is
resting against the Separator
Fingers.
3. Reposition the Media Supports
and Stack Rests as required to
support the media.
4. Position the Side Guides so that they are approximately 1/16” from each side of
the media.

ASSEMBLY, INSTALLATION AND OPERATION
8
5. Place a handful of media on top of the piece already placed, and then press the
Feed button to start feeding. Once the tabber is feeding satisfactory, go to the
next step.
NOTE: When placing material on the Media Support ensure that it is shingled.
6. With media loaded on the Media Supports, press the TAB button followed by the
FEED button.
7. Run two pieces and then check the position of the tab side to side.
8. Adjust if necessary by moving the Side Guides to the left or to the right.
9. Once feeding and side-to-side tab position is satisfactory, perform the Tab
Positioning Adjustment.
Tab Positioning Adjustment
The tab should be positioned so that approximately half of the tab goes on the top of the
media and half on the bottom.
1. Check the position of the tab on
the media if incorrect, loosen
the Tab Positioning Adjustment
Knob.
2. Move the knob forward to allow
more tab on the top of the media
or back to allow more of the tab
on the bottom of the media.
Tighten the knob.
3. Run two pieces through the machine and then check the tab position top-to-
bottom on the second piece.
4. Repeat steps 1-3 until you are satisfied with the positioning of the tab.

ASSEMBLY, INSTALLATION AND OPERATION
9
Feeding and Tabbing Media
The operating sequence of the T-250 Tabber is to first turn on the Main Power Switch,
and then press the reset button on the counter located on the top of the Tabber. Next,
activate the Tab Switch located next to the piece counter. Lastly, press the Feed Switch
to start the media feeding. To Stop the Tabber press the Feed Switch.
Troubleshooting
Problem Possible Cause
1. Media does not feed properly Improper setup of separator bar.
Glazed or dirty feed rollers.
Side Guides too tight.
2. Media skews when feeding Side Guides too loose.
Separator bar not set evenly.
3. Tab placement inconsistent Tabs not threaded correctly.
Tabs not centered in front of sensor holder
centerline.
Tab Roll is loose on spindle.
Rollers dirty or glazed.
4. Tab placement moves side to side Side guides loose.
Moveable post/Sensor Holder not set properly.
Problem Possible Cause
5. Multiple tabs placed on media Tabs not centered in front of sensor holder
centerline.
Tab sensitivity adjustment incorrect.
6. Media feeds without tabs. Tab Feed Switch not turned ON.
Out of Tabs.
Tab sensitivity adjustment incorrect.
Tab Pressure knob in OFF position.
Tabs not peeling off backing.
7. Tab sensitivity LED does not
illuminate Power not on. (Perform tab sensitivity adjustment.)
8. Power not on Unit not plugged in.
Fuse blown.
9. Tabs stream feed Tab Pressure knob in OFF position.

ADJUSTMENTS
10
Section 3 – Adjustments
Motor Drive Belt
Requirement:
The tension on the motor drive belt must be proper for smooth operation of the machine.
NOTE: The motor is a fixed speed AC motor. There are no speed adjustments.
Adjustment:
1. Unplug the machine and remove the rear
cover. Unplug the Tab Sensitivity
Adjustment switch wiring.
2. Loosen the four screws [1] and push
down on the motor drive pulley.
3. Tighten the four screws [1].
4. Check for a deflection in the drive belt of
not more than 1/4”.
5. Reconnect the Tab Sensitivity
Adjustment switch and replace the rear
cover.

ADJUSTMENTS
11
Clutch and Brake Adjustment
Requirement:
The gap on the brake must be set to insure proper operation of the tab advance roller.
Adjustment:
1. Remove the top cover.
2. Loosen the two allen screws [1] that attach the brake plate to the tab advance roller
shaft.
3. Insert a 0.008 feeler gage between the brake and the brake plate.
4. Pull the tab advance shaft toward the operator side of the machine and at the same
time push, the brake plate against the feeler gage and tighten the two allen screws to
the shaft.
5. Remove the feeler gage.
6. Replace the top cover.

ADJUSTMENTS
12
Tab Sensor Adjustment
Requirement:
Adjust the Tab Sensor to detect the presence of tabs in the machine.
Adjustment:
1. Unplug the T-250.
2. Remove the left and right side covers.
Caution: When removing the right side cover; be careful not to damage the
connections to the Tab Sensitivity Adjustment knob/switch. The connection to this
switch should be temporarily disconnected, to avoid damage.
Note: The Tab Sensitivity Adjustment knob (switch) will be reconnected in one of the
next steps.
3. Remove the entrance cover (stainless steel cover that media support guides attach to),
by removing the two Philips head screws, located at the left and right side of tabber.
4. Reconnect the Tab Sensitivity Adjustment knob/switch and temporarily mount the
right side cover using one or two screws on top.
5. Remove plastic splash guard, which is located over PC Board.
6. Install/thread tabs as described in this manual.
Note: Factory adjustments are done using a roll of white
paper tabs (white tab on white backing). If you are
experiencing problems with a certain tab type, install/thread
the “problem tabs” into the T-250 for this adjustment.
7. Plug the T-250 into the power receptacle and turn it on.
8. Set the Tab Sensitivity Adjustment knob to #3.
9. Connect your DC voltmeter probes to GND and TP3 on the
PC Board.

ADJUSTMENTS
13
10. Adjust P2 (L. LED) and P3 (L. SENSOR), on the PC Board, to obtain the lowest
voltage value. This is normally fully counter-clockwise; however, depending on the
potentiometer manufacturer, this could be fully clockwise or fully counter-clockwise.
11. Advance the tab stock until a tab is aligned with the sensor (tab should just start
peeling from the backing paper).
12. Adjust P3 (L. SENSOR), on the PC Board, until the red LED above the Tab
Sensitivity Dial just goes ON.
13. Position the tab stock so only the backing paper (or white space between tabs) is
aligned with the sensor. Fine tune this alignment with the sensor by slowly moving the
tab/backing position while watching the voltmeter. The optimal alignment position has
been achieved when you have obtained the lowest voltage reading on your meter.
Keep the tab stock tight.
The red LED above the Tab Sensitivity Dial should go OFF.
14. Follow the “Tab Sensitivity Adjustment” procedure described
in this manual.
15. To check the adjustment; position the tab stock so a tab is in
the sensor and verify that the red LED, above the Tab
Sensitivity Dial, goes ON.
Position the tab stock so only backing (or the white space
between tabs) is aligned with the tab sensor and this LED
should go OFF.
16. Unplug the T-250 and replace the splash guard and covers.
Make sure to reconnect the Tab Sensitivity Adjustment knob (switch), before
installing the right side cover.

ADJUSTMENTS
14
Media Sensor Adjustment
Requirement:
To adjust the Media Sensor so that it detects the media.
Adjustment:
1. Unplug the T-250.
2. Make sure the media sensor is clean (free of dust).
3. Remove the left and right side covers.
Caution: When removing the right side cover; be careful not to damage the
connections to the Tab Sensitivity Adjustment knob/switch. The connection to this
switch should be temporarily disconnected, to avoid damage.
4. Remove the entrance cover (stainless steel cover that media support guides attach to),
by removing the two Philips head screws, located at the left and right side of tabber.
5. Remove plastic splash guard, which is located over PC Board.
6. Plug the machine in and turn it on.
7. Connect a DC voltmeter to GND and TP2.
8. Insert a black test media under the media sensor and verify that LED1, located on the
main pc board, goes ON.
If not, adjust P1 (M. LED) on the PC Board to obtain 1.0 VDC or less.
If you can’t obtain this reading then the sensor may be damaged or dirty.
9. Remove the test media from under the sensor. The voltage level at TP2 should read
3.0 Volts or higher and LED1 on the main PC board should go ON.
Tip: LED1 should go ON when media is present, below the media sensor, and should
go OFF when media is not present.
10. Replace the covers.
Make sure to reconnect the Tab Sensitivity Adjustment knob (switch), before
installing the right side cover.

DISASSEMBLY AND ASSEMBLY
15
Section 4 Disassembly and Assembly
The following will assist you in disassembling the T-250 for servicing:
Removing Covers
1. Unplug the machine, then remove the four screws that
attach the front cover to the frame and remove the cover.
Under the front cover, you will find the non-resettable
counter.
2. Remove the four screws that attach the rear cover to the
frame unplug the Tab Sensitivity Adjustment Switch and
remove the cover. Under the rear cover you will find the
drive pulleys, drive belt, clutch, power receptacle and
take-up reel drive belt

DISASSEMBLY AND ASSEMBLY
16
3. Remove the two screws from the operator side and the two screws from the non-
operator’s side of the machine and remove the left hand cover.
4. Replace in reverse order.
Replacing Feed Rollers
1. Unplug the machine, then remove the Front, Rear, and Left Hand Covers.
2. Remove the two Track Roller assemblies.
3. Remove the Bearing and Bearing Cap from under the
front cover. Then remove the screw under the Front
cover that holds the top plate in place.
4. Remove the screw under the Rear cover that holds the
top plate in place. Raise the Center Plate so that it clears
the feed rollers.