toptack 2016705-01 User manual

OPERATING MANUAL
(Original Instructions)
Label printing & lamination station
Version: 2017-04-01
Machine number: 2016705-01
toptack GmbH
Bachleiten 3 | D-93455 Traitsching

Introduction
Label printing & lamination station - Version: 2017-04-01
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Table of contents
Introduction........................................................................................................................ 4
Basic notes ......................................................................................................................................................... 4
Copyright ........................................................................................................................................................... 4
Spare parts management................................................................................................................................... 4
Warranty............................................................................................................................................................ 5
Manufacturer and service.................................................................................................................................. 5
EC declaration of conformity according to the EC machinery directive 2006/42/EC, Annex II A....................... 6
Rating plate........................................................................................................................................................ 7
Equipment .......................................................................................................................... 8
Function description .......................................................................................................................................... 8
Intended use ...................................................................................................................................................... 8
Description of the machine................................................................................................................................ 9
Operating elements with switching cabinet...................................................................................................................10
Pneumatic distributor block...........................................................................................................................................10
Cylinder unit with vacuum lance....................................................................................................................................10
Thermal transfer printer ................................................................................................................................................11
Laminate dispenser........................................................................................................................................................11
Protective housing with safety door ..............................................................................................................................12
Dimensions ...................................................................................................................................................... 13
Technical data.................................................................................................................................................. 14
Processable materials ...................................................................................................................................... 14
Safety ............................................................................................................................... 15
General safety notes........................................................................................................................................ 15
Operator's obligations ..................................................................................................................................... 15
Obligations of the operating and maintenance staff ....................................................................................... 16
Residual dangers.............................................................................................................................................. 17
Personal protection equipment....................................................................................................................... 17
Safety devices .................................................................................................................................................. 18
Operating elements........................................................................................................... 19
Operating elements at the control cabinet...................................................................................................... 19
Brush at the laminate dispenser ...................................................................................................................... 21
Operating elements at the laminate dispenser ............................................................................................... 22
Operating processes.......................................................................................................... 23
Turning on the label printing & lamination station.......................................................................................... 23
Loading the printer label (layout) and specifying the piece number ............................................................... 25
Turning off the label printing & lamination station ......................................................................................... 29
Reset emergency off........................................................................................................................................ 30
Maintenance..................................................................................................................... 31
Maintenance plan ............................................................................................................................................ 32
Maintenance work ............................................................................................................ 34
Activate or deactivate manual mode............................................................................................................... 34
Activating manual mode ................................................................................................................................................34
Deactivating manual mode ............................................................................................................................................34
Replacing the roll of protective laminate at the laminate dispenser ............................................................... 35

Introduction
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Replacing the label roll at the thermal transfer printer................................................................................... 36
Replacing the ink ribbon at the thermal transfer printer................................................................................. 39
Cleaning the printing head of the thermal transfer printer ............................................................................. 42
Disposal ............................................................................................................................ 44
Annex ............................................................................................................................... 45

Introduction
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INTRODUCTION
Basic notes
The complete technical documentation is part of the machine according to the EC machinery
directive 2006/42/EC and must be kept near the described machine at all times.
Before commissioning of the machine, this operating manual must be read with care and
completely by the staff. No liability is assumed for any damage and operating faults that result
from non-observance of the instruction texts!
Copyright
Copyright © (2017) toptack GmbH
This operating manual is intended for the operator's staff.
The operating manual must only be reproduced or passed on to any third parties with written
permission. This applies even if only excerpts from the operating manual are copied or
forwarded.
Spare parts management
These operating instructions contain no information on spare parts of the machine.
All information that is needed to order spare parts can be taken from the separate spare parts
list.
If spare parts are used that have not been expressly released by toptack GmbH, this may impair
the safety of the machine!

Introduction
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Warranty
toptack GmbH's liability period shall be 12 months.
Any liability on the side of toptack GmbH shall be excluded upon:
Use of spare parts that have not been expressly released by toptack GmbH.
Injury and property damage caused by unauthorised or untrained staff.
Injury and property damage caused by unauthorised conversions.
Injury and property damage caused by non-observance of the operating manual.
Injury and property damage caused by work that is not described in this manual and
therefore performed without authorisation.
Manufacturer and service
If you have any questions about the delivered machine, please contact us directly:
toptack GmbH
Managing director: Rüdiger Horn
Bachleiten 3
D-93455 Traitsching
Phone: [phone] / 9048 - 477
Telefax: +49 (0) 9974 / 9048 - 479
Email: [email protected]
Internet: http://www.toptack.de

Introduction
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EC declaration of conformity according to the EC machinery directive
2006/42/EC, Annex II A
We hereby declare that the following machine corresponds to the basic safety and health
requirements of the EC directive 2006/42/EC in its design and build and in the version marketed
by us. In case of changes to the machine that have not been coordinated with us, this
declaration shall lose its validity.
Manufacturer:
toptack GmbH
Bachleiten 3
D-93455 Traitsching
Description and identification of the machine:
Designation: Label printing & lamination station
Machine number: 2016705-01
Year of build: 04/2017
Person authorised for the technical documentation:
Mr Rüdiger Horn, toptack GmbH, Bachleiten 3, D-93455 Traitsching
Managing director:
Mr Rüdiger Horn, toptack GmbH, Bachleiten 3, D-93455 Traitsching
Traitsching, 01 April 2017
Signature (Rüdiger Horn)

Introduction
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Rating plate
No.
Designation
1
Machine designation
2
Machine type
3
Machine number
4
Year of build of the machine
5
Technical information (electr. supply voltage & power, pneumatics) of the machine
6
Technical information (dimensions, L x W x H) of the machine
7
Technical information (weight) of the machine

Equipment
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EQUIPMENT
Function description
The label printing & lamination station can be used to apply labels with different print images
(layout) and provide them with a protective lamination. The print images can be selected from
an internal storage medium. The printed images can be transferred from a network or an
external computer to the station (see Appendix 7 to this manual). The finished labels must be
removed by the operating staff by hand, or can be wound up for later processing.
Intended use
The label printing & lamination station serves only for printing and lamination of labels. The
station must only be operated with materials that can be processed according to the section
"Technical data". The user must also ensure that the required personal protection equipment is
worn so that no danger to himself and to others occurs.
Inadmissible working method:
Processing of any other materials than described in item "Processable materials".

Equipment
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Description of the machine
No.
Designation
1
Operating elements with switching cabinet
2
Pneumatic distributor block
3
Cylinder unit with vacuum lance
4
Thermal transfer printer
5
Laminate dispenser
6
Protective housing with safety door
6
5
4
3
2
1

Equipment
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Operating elements with switching cabinet
Figure
Description
The operating elements applied to the machine can be used to
perform the different functions.
For a complete description of the operating elements,
see chapter "Operating elements".
All work on electrical facilities must only be performed
by trained, certified electricians licensed according to
the applicable provisions!
Pneumatic distributor block
Figure
Description
Three electro-pneumatic directional valves are used.
The 5/2 directional valve serves to control the cylinder unit (up-
and downwards movement of the cylinder).
A 3/2 directional valve is used to control the Venturi nozzle that
generates the vacuum for the vacuum lance (fastening of the
laminate upon movement at the vacuum lance).
A 3/2 directional valve switches the supporting air "on" when
dispensing the laminate, and "off" again after dispensing.
Cylinder unit with vacuum lance
Figure
Description
The vacuum lance of the cylinder unit takes the laminate at the
dispenser and presses it onto the printed label. The laminate is
held during the downwards movement by the vacuum of the
lance. After bonding the laminate, the vacuum is turned off and
the lance will move up again.

Equipment
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Thermal transfer printer
Figure
Description
Different label layouts can be chosen and printed with the
thermal transfer printer. For each production with internal
memory, the number of pieces to be printed must also be
entered. A memory card that can be plugged in on the rear of the
printer serves as data carrier for the different label layouts. (With
external data connection of the printer, see Appendix 7).
The printer has a coloured touch display. All input and settings at
the printer must be made directly at the display by touching with
a finger.
Laminate dispenser
Figure
Description
The laminate dispenser provides the protective laminate for the
printer labels at the dispensing edge for collection by the vacuum
lance.

Equipment
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Protective housing with safety door
Figure
Description
The protective housing of Plexiglas protects from crushing at the
label printing & lamination station during machine operation.
The safety door must be closed and locked during
production!

Equipment
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Dimensions
View
Top view
Designation
Value
Length (L):
500 mm
Width (B):
650 mm
Height (H):
1,100 mm

Equipment
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Technical data
Designation
Value
Total weight
approx. 92 kg
Recommended working pressure of the pneumatic
system
6 bar
Necessary minimum pressure of the pneumatic
system
4.5 bar
Electrical connection value
230 V AC, 50 - 60 Hz, 120 W
Admissible ambient temperature
min. 10 °C, max. 25 °C
Processable materials
Designation
Property
Laminate
Self-adhesive, as rolled goods
Format:
min. 10 x 10 mm to max. 12 x 100 mm*
Thickness:
Up to max. 0.5 mm
*expansible to 100 x 100 mm (constructional action of the
manufacturer required)
Label material
Self-adhesive with or without glue, as rolled
goods.
Format:
min. 20 x 12 mm up to max. 100 x 100 mm
Thickness:
Up to max. 0.5 mm

Safety
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SAFETY
General safety notes
The delivered machine corresponds to the state of the art and is operationally safe. This
machine may pose dangers if it is used by untrained staff, improperly or in a non-intended
manner.
The machine must only be taken into operation by trained staff.
Intended use also includes compliance with the operating and maintenance instructions.
In order to avoid injury, conversions or changes at the machine are only permitted with
express written release from toptack GmbH.
Operator's obligations
The staff must be able to access the operating instructions at any time.
Every person who is charged with operation and maintenance of this machine in the
user's company must read and understand the entire documentation, and specifically
the safety notes.
No working method is permitted that would impair or endanger the safety of man and
material.
The operator must ensure cleanliness and a good overview of the workplace.
The operator must keep all safety and danger notes attached to the machine in a legible
condition and replace them if necessary.
The operator must ensure that the staff wear approved and tested personal protection
equipment.
The operator must ensure that only such staff work at the machine who meet the
requirements listed in the following sections and who have the required qualifications.

Safety
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Obligations of the operating and maintenance staff
Every person who is charged with operation and maintenance of this machine must read
and understand the entire operating manual.
The operating staff must report any unknown or unusual sounds and operating
conditions of the machine that occur to their supervisory at once.
The effectiveness of operating and adjustment parts must not be impaired or influenced.
Before starting any work on the machine, observe the following provisions:
oDo not wear loosely hanging clothing!
oCover long hair with a hair net!
oTake off loose jewellery, rings and other personal objects that may be caught by
the machine!
Protective devices must only be removed for maintenance purposes:
oAt machine standstill,
owith the main switch turned off and secured against unauthorised reactivation.
Before activation of the machine after maintenance work, check that all safety devices
have been properly attached or closed and are fully functional,
Regionally applicable safety and accident prevention provisions must be observed.

Safety
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Residual dangers
Electrical dangers
Danger to life from contact with parts that are subject to high electrical voltage!
Observe warning notes on control cabinet doors and operating panels!
Disconnect the power supply before conducting any maintenance work!
All work must only be performed by trained, certified electricians licensed
according to the applicable provisions!
Danger of crushing
Danger of crushing injury at the label printing & lamination station!
Before activating the station, ensure that the safety door is closed and the lock
locked! The key must be worn "on the person".
Danger of tripping and slipping
Observe all edges, attachment and lines in the machine area.
Remove contamination on the floor (e.g. waste) at once in order to avoid
tripping and slipping hazards!
Personal protection equipment
Wear personal protection equipment
The staff must wear personal protection equipment when operating and working on
the label printing & lamination station:
Wear close-fitting work clothing and a safety hood.
Additionally observe the current operational provisions.

Safety
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Safety devices
Type of safety devices:
Type A: Separating safety device
Type B: Non-separating safety device
Type C: Deflecting safety device
Figure
How
Main switch with emergency off function (type B)
Switches the entire power supply of the label printing &
lamination station on or off. The facility cannot be operated in
the deactivated condition.
Disassembly, damage or decommissioning of the main
switch are forbidden!
Perform a visual inspection for proper condition and
inspection of the function at least once per year and
after any maintenance work!
Control cabinet (type A)
Protects from electric shock at electrical facility.
Operation of the label printing & lamination station with
the control cabinet doors open is forbidden!
Access to the control cabinet is only permitted to
electrical specialists!
Disassembly, damage, decommissioning of the control
cabinet are forbidden!
Perform a visual inspection for proper condition at least
once per year and after any maintenance work!
Protective housing of Plexiglas (type A)
Protects from crushing injury at the label printing & lamination
station.
The station must not be operated with the protective
housing disassembled or defective!
Disassembly, damage or decommissioning of the
protective housing are forbidden!
Perform a visual inspection for proper condition at least
once per year and after any maintenance work!

Operating elements
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OPERATING ELEMENTS
Operating elements at the control cabinet
No.
Function
1
Main switch with EMERGENCY OFF function.
Switches the entire power supply of the label printing & lamination station on or off. The
machines cannot be turned on in the OFF position.
The main switch must be turned off before any work (e.g. maintenance, repair,
troubleshooting, etc.) and secured against unauthorised reactivation with a padlock.
2
Setting the operating mode at the label printing & lamination station:
0 = No operating mode
1 = Operating mode manual mode (operating elements no. 3 - no. 8 active)
2 = Operating mode automatic (controlled production)

Operating elements
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No.
Function
3
Pushbutton, manual mode: Printing label.
Note: Function of the pushbutton only in operating mode "Manual mode" (no. 2).
4
Pushbutton, manual mode: Infeed laminate dispensing.
Note: Function of the pushbutton only in operating mode "Manual mode" (no. 2).
5
Pushbutton, manual mode: Moves the cylinder up.
Note: Function of the pushbutton only in operating mode "Manual mode" (no. 2).
6
Pushbutton, manual mode: Moves the cylinder down.
Note: Function of the pushbutton only in operating mode "Manual mode" (no. 2).
7
Latching switch, manual mode: Supporting air "on" / "off".
Note: Function of the latching switch only in operating mode "Manual mode" (no. 2).
8
Latching switch, manual mode: Vacuum "on" / "off".
Note: Function of the latching switch only in operating mode "Manual mode" (no. 2).