MCS Tabber User Manual
Contents
1. 45 26 22718 58 222 22 038 2 i fi dOLS 4 034 5 la C 2M SIADO asya gt OI AANA Ne lt r EG gt 13115 JLLINIVW ES KE 9 canis 3 Se SIND g 4015 91 24 06 dH BER RR 5 83 02 3598 SOLON 3598 lt 2 12 22 8 316 lt SD LJINNDI m ela OD 718 SOLOW 0 06 9 JINGDW AXINI 2 3AD FAQ 6 De T 7 3 1 22 033 2 4 8035011 214 N 2 01 014 e AV Ida 9015 7 DDP 2 MIVII ILX 6 0 ANNA AAA l ON EA 01 Ol _ aavoa aL L IDSLNDI 32 124491 AL 13A N8D 2 Adds 1 31714 22 NN9 22 038 wa 03803 14 22 LHA gt 24 154 2 POSS 27 180 Aldans IIMDA 35719 0V II 891 LL 22 1HP 22 038 22 99 78 LI J _ ma 7 1 2 CH IN 6 1 lt IE ila ud INS MS 13915 29 435 2333932584 9079 ATAVISE DANDO 03385 HOLIMS S3IMDd GVSH 211 5 83AHd 3594 TANVA INOS MCSPRO 1020 Tabbing System User s Guide FIGURE A2 HEAD CONTROL SYSTEM DIAGRAM 19 3559 IV 4H NIEHS YOLOANNOOD 11211 314923 ND8812 23194436240 Ol 3 oo Non2. UMS Aal LI3NNDI 11892 30 ION SOLISNNOO 59 G NANNA qavla V 6 8 1 599 8 39 ji BT JONVA 8 Bl ADTTJA na 81 10 9 E 2 8I NAD28 81 3189 8I N3489 Bl JIIHA 8131 10 95 SADA 81 2914 E 81 138 81 038 A SOLOSNNOO 5591 522 4330 5 22311HA 5 2 22 434 gt 5 35 73897 31919 SOLIINNDO 3594 I Id Ivw edd Ol Y IVAS2dd 3 1999 CC I 9VII9 IC MI I 2 384 72 22 434 2 22 311 2 22 32914 3594 EA 1 141 154 2 mn 8 1 1 158 I 22918 6 181 154 ST ADTIJA N33SD DIA SE 5 093 18891 MOOISSLNI 35994 11190129 2113 0 IN lt lt X 19 22 03 IASLNI 3SVE HOLIMS 212 3 9 205 gt 1 SOSNAS 1092 LINUDIA CX V 19 40193130 27114 22 22 033 5 0052 37918 x 22 038 J 22 259 1 ADL 3LIHM
3. should be displayed on the first line of the display 3 Press either the or vw until ENCODER 00000 is displayed on the second line of the display 4 The LCD will display a running count from the encoder The count overflows to zero after reaching a maximum count of 65 535 The encoder should register approximately 150 counts for every inch of transport belt travel 5 4 13 Factory Reset The factory reset allows the operator to reset all operator programmable settings to their original factory settings This could be necessary if the system memory becomes corrupt Symptoms that may indicate the need for a factory reset include tabs labels significantly and repeatedly misplaced or no tabs labels applied at all Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the or vw until FACTORY RESET is displayed on the second line of the display 4 Press the ENTER key to initiate the reset Upon completion the LCD will display FACTORY SETTINGS LOADED TO MEMORY MCSPRO 1020 Tabbing System User s Guide 42 Chapter 6 Troubleshooting MCSPRO 1020 Tabbing System User s Guide 43 Chapter 7 Appendix FIGURE AI BASE CONTROL SYSTEM DIAGRAM
4. The Tabbing Base is designed with two sections lower fixed base and upper sliding transport table The sliding transport table allows tabbing or labeling on the operator or non operator side Requirement Adjust transport table to begin system setup Procedure 1 Loosen transport table locking lever See Figure 5 2 Position transport table to dimension given See Figure 4 OS WG EJ Figure 4 MCSPRO 1020 Tabbing System User s Guide 13 4 1 2 Position Base The Tabbing Base has casters to move the system Roll the input end of the base up to the output end of the ink Jet base Requirement Position base to ink Jet base for product transition and centerline Procedure 1 Loosen the four height adjust lock screws Figure 5 Adjust two height adjust screws up down until bridge angle Figure 5 is Just below the belts of the ink jet base 3 Secure the four height adjust locking screws 4 Position tabber base so the bridge angle is as close to ink jet base belts without touching and position tabber base so the centerline of ink jet base matches the centerline of the transport table Figure 6 5 Set four leveling pads Figure 5 firmly to secure base in final position 6 Secure leveling pad lock nuts against base bottom Figure 5 MESPRO 1020 Tabbing Svstem User s Guide 14 FIGURE 6
5. This value should normally range from 70 to 97 when setting with liner in the sensor A value of 01 indicates sensor disconnection or sensor failure A value between 01 and 70 probably indicates that the tab sensor requires cleaning A value of 100 should always be obtained when adjusted with no liner present A value of less than 100 with no liner would indicate a dirty sensor The sensor should be adjusted without liner only as a diagnostic tool The sensor must be readjusted with liner before normal operation 5 3 6 Counter Reset The controller displays and records a product count The operator can reset this count to zero at any time The current count is retained in memory at power down and recalled at power up MCSPRO 1020 Tabbing System User s Guide 35 Procedure 1 Take the system offline 2 Press the 5 key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the or vw until RESET COUNT is displayed on the second line ofthe display The xxxxxx represent the current count 4 Press the ENTER key to reset the counter The LCD will be updated upon reset and now display RESET COUNT 000000 5 3 7 Product Sensor Selection Through beam type opto electronic sensors are used to detect the presence of product to be tabbed labeled Since the tabbing takes place at either the front or rear of the unit produ
6. PA WRAP GUIDE OP SIDE P N PLO17300 P N PL017301 SPUR GEAR 48 32 P N VT002500 P N SM009000 MCSPRO 1020 Tabbing System User s Guide BELT ROLL OUTPUT P N 5 008701 BELT ROLL INPUT SM010900 4 1 gt P N VT003400 gt N L VT003402 USED ON STANDARD BASE TRANSPORT BELTS 2 W x 781 P N VT003403 ak USED ON EXTENDED BASE Heee 016300 gt gt SHAFT LOWER PRESS ROLL P N PLO16600 SHAFT INPUT ROLL ETT P N PM016200 i SHAFT INPUT BELT GUIDE P N PL017000 VB001000 Bel 219 P N 5 008701 1 er 3 SHAFT LOWER FOLD WHEEL PL016700 7 001000 YN V AW P N 5 013200 F gt P N 5 013200 LI re 7 PULLEY 20 TOOTH 3 8 PITCH WIDE P N 5 013201 7 MCSPRO 1020 Tabbing System User s Guide 51 WAI ME Y BASE ENCODER ASSEMBLY Y 5 009000 me MOTOR SPEED CONTROL ME000400 24VDC POWER SUPPLY VC014300 MCSPRO 1020 Tabbing System User s Guide 52 PRODUCT 5 5 VC001000 BLACK PUSHBUTTON SWITCH VC014602 Cheshire Tabo THERMAL CIRCUIT BREAKER SWITCH 10A 014701 THERMAL CIRCUIT BREAKER SWITCH 5A 014700 GEARBELT URETHANE w 72 TOOTH VT003600 TRANSPORT BELTS 2 w x 46 1 2 L L SET OF 4 VT003402 TRANSP
7. base is designed to register and tightly control the product for accurate and consistent tab label application When it is used to apply tabs wafer seals to the edge of mail pieces it is also responsible for wrapping the tab around the piece All electrical controls are found on the transport base major components of the transport base are shown in Figure 1 FIGURE TRANSPORT BASE MESPRO 1020 Tabbing System User s Guide 2 2 Tabbing Head Component The tabbing head is designed for accurate and high speed application of pressure sensitive tabs labels It was designed specifically to work in conjunction with the base and is controlled by the interfaces on the base The major components of the head are shown in Figure 2 LABEL SUPPLY TAKE UP FULL SENSOR IND IDLER ROLL ND DRIVE ROLL BIN SENSOR DLER X6 UIDES X12 B LABEL SENSOR PEEL POINT DRIVE IDLER ROLL 7 HEAD POSITION SUPPORT SHAFT TAB DRIVE RU FIGURE 2 TABBING HEAD MCSPRO 1020 Tabbing System User s Guide 8 Chapter 3 Electronic Controls 3 1 Transport Control Panel The Transport Control Panel is located on the left side of the base front This panel controls system power and transport base motor condition Housed on this panel are the following six controls Base Power Rocker Switch Head Power Rocker Switch Jog Push Button Switch Start Push Button Switc
8. display will indicate the current state of bin sensor while this test is being run 5 4 8 Take up Sensor Test A reflective sensor 18 used to determine when the waste take up spool 18 filled to capacity The sensor condition is displayed while this test is being run Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the or until TAKE UP BLOCKED TAKE UP UNBLOCKED 18 displayed on the second line of the display 4 The LCD display will indicate the current state of the take up sensor while this test is being run 5 4 9 Left Product Sensor Test A through beam type opto electronic sensor is used to sense the edge of the product about to be tabbed labeled The sensor condition is displayed while this test is being run Procedure 1 Take system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the a or gt until LF PRODUCT BLOCKED or LF PRODUCT UNBLOCKED is displayed on the second line of the display 4 The LCD display will indicate the current state of the left product sensor while this test is being run 5 4 10 Right Product Sensor Test A through beam type opto electronic sensor 18 used to sense the edge of the product abou
9. on the belt See Figure 20 4 Lightly secure brass tip set screw See Figure 19 MESPRO 1020 Tabbing Svstem User s Guide 24 Figure 19 i e 5 Lower wrap section to operating position and secure with swing bolts and knobs 6 Turn product thickness adjust counterclockwise to zero stop position See Figure 21 Product Thiekness Adiust Thickness An Block Resting on Screw Head C Note Idler wheel mounting block should be resting firmly on the wrap guide mounting screw head Figure 22 The block and wheels must straddle the wrap guide right angle as shown with clearance on each side 7 Raise upper wrap section to lock position Secure brass tip set screw See Figure 19 8 Repeat all procedures above for non operator s side Note The idler wheel assembly is now adjusted to its correct position and will give tight wrap on all product when the upper wrap assembly is correctly gapped See Section 4 1 6 Set Gap MCSPRO 1020 Tabbing System User s Guide 25 4 2 Head Set up The head will be set up differently for different size labels If the tabs labels backer width of less than 2 inches then the head should be set up with the Tab Sensor Assembly and the two thin Inner Spool Guides Labels with a backer width over 2 inches must be set up with the Label Sensor Assembly and the two wide label Inner Spool Guides The tabbing head utilizes optical sensors to ensure accurate
10. pea See e a 39 IAS Op Relay esti e end A A a Line 39 5 44 Motor Brake 39 D 4 5 Cover Test ssa satan nota 40 34 0 Head Cover 40 9 6 77 NA 40 5 4 8 Tak up Sensor Testen einsamen alae 41 4 9 Left Product Sensor 65 bin papa lin 41 5 4 10 Right Product Sensor Test 41 SJ Tab Label Sensor Testi um ie is 42 34 12 Encoder str siegen A 42 9 4 13 42 Chapter 6 Tro bleshootInen u n ren dese 43 Chapter _ 45 FIGURE Al BASE CONTROL SYSTEM DIAGRAM a 45 FIGURE 2 HEAD CONTROL SYSTEM DIAGRAM 46 FIGURE A3 HEAD SYSTEM DIAGRAM 47 ILLUSTRATED PART BREAKDOWTIN u _ 48 MISCELANIOUS SPARE PARTS NOT LISTED ABOVE 55 MCSPRO 1020 Tabbing Syste
11. setup parameter to be displayed and or adjusted is controlled by the a key and or key The components parameters that can be adjusted are listed below Tab Pitch Job Memory Auto Tab Calculator Product Size Product Tab Sensor Offset Tab Sensor Sensitivity Counter Reset Product Sensor Selection 5 1 1 Pitch Setting The distance between the lead edges of two consecutive tabs still attached to release liner defines the Tab Pitch This is an important value since it defines how far the tab drive will move when it applies tabs The minimum pitch is 0 75 and the maximum pitch is 7 00 Procedure 1 Take the system offline 2 Press the 5 key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the or gt until PITCH gt _ is displayed on the second line of the display The x xx represents the current setting for tab pitch 4 To increase the Tab Pitch press the key until the desired location is displayed as the current setting To decrease the Tab Pitch press the key until the desired location is displayed as the current setting Or 5 The desired pitch can be directly entered from the numeric keypad 6 Asthe new setting is entered it appears to the right of the current setting 7 Once entry of the new value is completed press the ENTER key to save the new value The LCD will indicate c
12. tab label position It is important for the tab labels to be positioned so their centers run under the optical sensor When using the label sensor the label threading path is centered on the center of the label guide idlers When using the Tab Sensor the threading path is centered about 1 3 4 off the main side frame of the head 4 2 1 Install Inner Spool Guides Choose the appropriate spool guides for the tabs labels to be run The exact location of the spool guides depends on the width of the tabs labels being run Keep in mind that it is important for the tabs labels to be centered on the optical path of the tab label sensor Select the appropriate locating slot on the spool support shaft and engage the locating latch of the guide The center location is marked on the tab label sensor and it defines the center for the full threading path 4 2 2 Secure Source Spool Slip your roll of tabs over the supporting hub of the inner spool support Push the outer spool support against the side of the source spool secure with the spool knob The knob should be tight enough to ensure that the tab label roll cannot slip on the hub of the inner spool support 4 2 3 Threading Adjust the tab label guides on the idlers for the width of the labels to be used Gap the spring loaded idlers in both the roll unwind and tab drive sections Thread according to the figure provided on the main side frame Note that the unpeeled tabs slide through the tab se
13. 10 3 2 3 2 Transport Speed The controller must be aware of the transport speed to accurately locate tabs labels on the product This speed displayed in feet minute represents the approximate belt speed of the base An example of a typical speed display follows SPEED 160 FT M NORMAL STATUS 3 2 3 3 Production Rate Another useful production item is the production rate The controller can displav the approximate real time production rate of the tabber Units for the production rate is product hour An example of a tvpical rate displav follows PROD RATE 24000 PPH NORMAL STATUS 3 2 4 Numeric Kevpad A numeric kevpad is provided to allow direct entrv of settings from the Operator Interface This kevpad is functional for tabber setup only when the unit is offline 3 2 5 Menu Selection Kevs Beneath the LCD are four menu selector kevs These kevs are used to access the different setup and test menus The four kevs are listed below e Test e Position e Setup Mode 3 3 Stop Switch Red Mushroom Cap When depressed this switch stops the transport base motor If the stop interlock cable has been used to tie in the tabber with the feeding equipment then the stop switch will also stop the in feeding equipment The operator must twist the switch in order to release the stop condition MCSPRO 1020 Tabbing System User s Guide 11 Chapter 4 System Setup 4 1 Base Set up 4 1 1 Position Transport Base
14. 4 wide head svstems Requirement Position upper press rolls for wrap tabbing Procedure 1 Loosen wrap section lock knobs and raise pivoting portion of wrap section Figure 17 Push press roll 1 for operator side or 4 non operator side Figure 18 to the outermost position 3 Release saftv lock pin Return wrap section to operating position and secure lock knobs Lock knobs must be secured during operation Note For labeling or stamp affixing requirements press rolls 1 through 4 mav be positioned in various configurations in front of the peel point to meet size requirements Figure 17 MESPRO 1020 Tabbing Svstem User s Guide 23 mZ 2 222 2 LI I I l I I I I DITTI L I LA A A L f IL 1 A 1 Wi Pa mm lt lt Figure 18 4 1 13 Idler Wheel Adjustments Requirement Idler wheel assemblies must be positioned and adjusted correctly to assure tab wrap performance and avoid damage to wrap guide Note Lexan cover has been removed for clarity It is not necessary to remove for the following procedure Procedure 1 Raise upper wrap section to lock position Position block assembly 8 side shown with screw head and spacer against inner frame of upper wrap section See Figure 19 3 Rotate block wheel assembly on the fixed mounting shaft causing outward pressure
15. 4 1 3 Ink Jet Base Setup requirements concerning feeding printing and product position should be met before feeding product through tabber 4 1 4 Adjust Transport Table Position Requirement Adjust transport table to edge of product path Procedure 1 product from ink jet base to transport table until it just crosses bridge angle Stop feed 2 Loosen table lever lock See Figure 5 Position transport table guide rail 1 8 from product edge See Figure 7 Lock table lever 3 Use fine adjust knob See Figure 5 to complete the adjustment if necessary The fine adjustment mav also be used as a running adjustment to move guide rail towards or awav from product edge during operation MCSPRO 1020 Tabbing System User s Guide 15 Figure 7 4 1 5 Product Guide and Strap Usage Procedure 1 Mount strap assemblies 2 provided to square shaft See Figure 8 Note Straps may be positioned on product to control flatness as desired or removed by loosening screw and rotating retainer cap 180 degrees 2 Mount Product Guide See Figure 9 Note The product guide is provided primarily for use in off line requirements when auxiliary feeders are used Its purpose is to control product skew that may be experienced using free standing feeders normally friction type Skew is not normally experienced with in line ink jet base use however guide use may be desirable The guide is designed with an oversized
16. 8 KNOB QUICK ACTING 13 P N VK000600 QTY 2 UNWIND SPOOL 55 TABBER SM001800 27 UNWIND SPOOL ASS Y LABELER P N 5 001801 47 FR gt _ UNWIND SPOOL SUPPORT 557 P N SM001604 amp gt IE SPOOL ASS Y TABBER TAKE UP SPOOL ASS Y LABELER d IDLER ASS Y UNWIND DRIVE TABBER P N 5 002200 25 IDLER ASS Y UNWIND DRIVE LABELER 8 002201 47 URETHANE ROLLER FLOAT IDLER TABBER 2 000200 URETHANE ROLLER FLOAT IDLER LABELER 4 5 008401 Wa URETHANE ROLLER UNWIND DRIVE TABBER P N 000300 URETHANE ROLLER UNWIND DRIVE LABELER P N 000301 DRIVE ROLL TABBER GRIT WHEEL DRIVE ROLL LABELER GRIT WHEEL P N PM003500 2 P N PM003501 4 IDLER ASS V TAB DRIVE IDLER ASS Y LABEL DRIVE P N 8 002100 25 SM002101 47 MCSPRO 1020 Tabbing System User s Guide 49 VB000102 SPUR GEAR 40 TOOTH 2 SPUR GEAR 20 TOOTH BORE P N 010400 BEARING ROLLER P N 000301 P N VB001000 VA 4 VB000102 SHAFT SPOOL P N PLO11103 27 SHAFT SPOOL LABELER P N PL011101 47 P N 010500 5 36 4 006100 VB000102 P N 000202 000202 1 EA WRAP GUIDE NON OP SIDE
17. D SALLING Y LAI 221 T LIW 3 22 018 LE 22 39979 MOLIDO 52 055 19 40193130 46 MCSPRO 1020 Tabbing System User s Guide FIGURE A3 HEAD SYSTEM DIAGRAM AULIINNOO lt 4 ivrerar 0168 IVMVVVVVVVVVMMVMVVVVVVMVVVVNV XODINIINI JDLVNLOV OLLINOYN 124 3 23 N 81 12 8 81 13 0 81 444 32978 AIO 18J31NI G9HH 9 H31IAS DILINDYN G 5 23v 18 20 SOLOW QAS3S 138 5 JAIXO gy 0 JLIHA AUSNJS d UNIDO T 1dAY UAS3S Ele AAING 951 al 512 AR 2974 134 072 62 MOVIE 82 2 ILHA y gt M3395 er I ADV 18 Salon 3AISG GNIMNA S JOSNIS NIE SOLOW 40 3 1 3LSVA 5 N 81 38 lt 81 38 GNIMNA 81 218 81 034 47 MCSPRO 1020 Tabbing System User s Guide ILLUSTRATED PART BREAKDOWN WASTE TAKE UP SENSOR SE001400 TAB GUIDE O RING P N VG000100 4 TAB GUIDE SPLIT RING P N PT002400 701 BIN SENSOR SE001200 4 TAB SENSOR ASSEMBLY P N SM002700 27 LABEL SENSOR ASSEMBLY P N 5 002701 47 P MCSPRO 1020 Tabbing System User s Guide 4
18. ORT BELTS 2 w 2771 SET OF 4 w _ FOLDWHEEL COATED 2 SEES 016200 LOWER PRESSWHEEL URETHANE COATED 4 MCSPRO 1020 Tabbing System User s Guide 33 PULLEY 19 TOOTH 3 8 PITCH 1 2 WIDE P N 016000 BEARING RADIAL BALL 5 8 W SNAP RING P N VB001000 4 00100 u 574 1 015600 er C 2 y IS gt 4 l 7 BEARING ROLLER 5 8 LD 000104 PULLEY FOLD FLANGE 8 012700 IT ETRE I L 4 4 M as A BEE g PULLEY 16 3 8 PITCH 34 WIDE E I P N gt I lt N P N 5 012700 2 j PULLEY 20 TOOTH 1 5 PITCH PM015501 P N VBO01000 P N 1004 P N 1000 a 1 4 P N PL019100 P N PLO19100 LA SHAFT FOLD WHEEL P N PL017500 03300 22 3 P N VB000102 PULLEY 18 TOOTH 1 5 PITCH P N 015502 BEARING ROLLER 1 2 I D P N VB000102 PRESS ROLL UPPER OP SIDE 5 012900 PRESS ROLL UPPER NON OP SIDE P N 5 012901 SHAFT UPPER PRESS ROLL P N PLO17700 MCSPRO 1020 Tabbing System User s Guide 54 MISCELANIOUS SPARE PARTS NOT LISTED ABOVE
19. TABBING HEAD VC006200 VH001900 VH003300 TABBING BASE SE000202 SE007400 VC010900 SE000700 VC014001 VC013501 VC013500 VC014500 VC014501 VC006202 VC006203 V T003902 VG000500 008101 007701 VK000700 VK000800 VK001000 VK001200 VK001201 5 009300 5 009400 5 009401 003900 VC005100 VC005200 HEAD POWER SUPPLY FUSE EXTENSION SPRING 0 25 OD 1 75 L UNWIND REAL EXTENSION SPRING 0 25 OD x 1 5 L TAKE UP OPERATOR INTERFACE BASE MOTOR ASSEMBLY POWER CORDSET HEAD POWER CABLE HEAD CONTROL CABLE RELAY 24V COIL RELAY 12V COIL CONTACT BLOCK NORMALLY OPEN CONTACT BLOCK NORMALLY CLOSED FUSE 1A TIME DELAY 24V SUPPLY FUSE 8A FAST ACTING BASE MOTOR GEARBELT L 68 TOOTH 3 8 PITCH RING CLEAR URETHANE 4 5 16 x 1 8 EXTENSION SPRING x 1 1 2 L COMPRESSION SPRING 36 OD x 1 1 4 L 2 3 8 DIA BLACK KNOB KNOB w THRU HOLE 1 1 4 DIA CRANK HANDLE 2 571 ADJUSTABLE CLAMPING HANDLE SHORT SHAFT ADJUSTABLE CLAMPING HANDLE LONG SHAFT KNOB HEAD POSITION FINE ADJUST KNOB TABLE POSITION FINE ADJUST KNOB RESGISTRATION WHEEL ANGLE ADJUST COMPRESSION SPRING 360 OD x 75 L REED SWITCH MAGNET MCSPRO 1020 Tabbing System User s Guide 55
20. User s Guide INCORPORATED MCSPRO 1020 Tabbing Svstem INCORPORATED MCS Incorporated 8101 Cessna Avenue Gaithersburg MD 20879 REV AA MCSPRO 1020 Tabbing System User s Guide Table of Contents Chapter 1 System Descriptor ies 5 Chapter 2 Syste Components u a A ET nti 7 2 1 Transport Bas Component 7 2 2 Tabbing Head Component n n anqusu amp Chapter 3 Electronic Controls bia a a 9 3 1 Transport Control Papel n eee dar So e 9 3 1 1 Base Power Rocker Switch e sin 9 3 1 2 Head Power Rocker Switch usa s an ee e sn sen 9 3 1 3 Jos Push Button Witch 52 n 9 Start rPush Button Switch t nn n aan 9 3 1 5 Transport Speed Potentiometer sens ann 9 3 2 Operator ee Rennes ena 9 3 2 1 LED Module 10 3 2 Online KEY 10 3 2 5 dont aa leet lets iz 10 3 2 3 1 Product Count ee ie 10 3 2 3 2 Transport Speed an ah ang ein S 11 3 2 3 3 Production a uum Rn au 11 3 24 Numieric Keypad 11 3 2 5 Menu Selecti
21. ation If two tabs are applied then Tab Position 1 defines the leading edge tab and Tab Position 2 defines the trailing edge tab If three tabs are applied then Tab Position 1 defines the leading edge tab Tab Position 3 and the middle tab is defined by Tab Position 2 define the trailing edge tab When using more than one tab the second or third tab position must have a value greater than the previous tab position value Tab Pitch TRAILING EDGE p LEADING EDGE 2 A Product Flow Tab Position 1 Tab Position 2 gt Tab Position 3 Procedure 1 Take the system offline 2 Press the POSITION key to access the test menu POSITION should be displayed on the first line of the display 3 Press either the or until TAB POS yy yy gt _ is displayed on the second line of the display The x represents the tab position of interest and the yy yy represents the current setting for that tab position 4 To increase the Tab Position from the leading edge press the until the desired location is displayed as the current setting To decrease the Tab Position from the leading edge press the until the desired location is displayed as the current setting Or 5 The desired position can be directly entered from the numeric keypad 6 As the new setting is entered it appears to the right of the current setting 7 Once entry of the new value is completed pre
22. bing system this test will now give invalid results Do not use this test to diagnose the condition of the magnetic switches on the base cover 5 4 6 Head Cover Test A magnetic switch senses the condition of the head cover This switch is used as safety interlock that prevents the system from operating while the cover is open The switch condition is displayed while this test is being run Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the a or gt until HEAD COVER OPEN HEAD COVER CLOSED 18 displayed on the second line of the display 4 The LCD display will indicate the current state of the head cover while this test is being run 5 4 7 Bin Sensor Test A retro reflective sensor is used to determine the state of the tab label bin The sensor 18 used to ensure that some tabs labels have been unwound from the source spool and are ready for application The bin condition is displayed while this test is being run Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the a or until BIN SENSOR BLOCKED or BIN SENSOR UNBLOCKED is displayed on the second line of the display MCSPRO 1020 Tabbing System User s Guide 40 4 The LCD
23. ct sensors are located at both the front and rear The operator can select the appropriate product sensor to be active Procedure 1 Take the system offline 2 Press the SETUP Key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the until PRODUCT SENSOR RIGHT FRONT LEFDREAR is displayed on the second line of the LCD The xxxxxx represent the current count 4 Press the key to change from RIGHT FRONT to LEFT REAR Press the key to change from REAR to FRONT The LCD will update sensor selection as it is made 5 2 Position Programming The location and number of tabs labels to be applied to a single product is controlled by the choices accessed by the POSITION key The POSITION key is active only when the unit is offline The position setting to be displayed and or adjusted is controlled by the key key After displaying the setting of interest it can then be adjusted by one of two methods direct keypad entry or incremental adjustment The direct keypad entry is accomplished by using the numeric keypad to directly enter the desired position After the position has been entered the ENTER key must be pressed to load the new value into memory Incremental adjustments are made by using the and or keys The current value will be increased by 0 05 every time the k
24. display Press either the gt or w until TAB POS yy yy gt _ is displayed on the second line of the display The x represents the tab position of interest and the yy yy represents the current setting for that tab position To increase the Tab Position from the leading edge press the until the desired location is displayed as the current setting To decrease the Tab Position from the leading edge press the until the desired location is displayed as the current setting 99 The desired position can be directly entered from the numeric kevpad As the new setting is entered it appears to the right of the current setting Once entry of the new value is completed press the ENTER key to save the new value The LCD will indicate completion by replacing the current setting with the new setting 5 2 2 Number of Tabs The unit can apply 1 to 3 tabs on a single product in one pass The POSITION key gives access to this setting Procedure 1 Take system offline MCSPRO 1020 Tabbing System User s Guide 37 2 Press POSITION key to access position menu POSITION should be displayed on the first line of the display 3 Press either the or vw until NUMBER OF TABS is displayed on the second line of the display The x represents the current setting for the number of tabs to be applied to a given product 4 To increase the Number o
25. e and used as a conveyor the same set up procedures for tabbing labeling or stamp affixing must be used However since securing tabs labels or stamps to the product is not a requirement the gap setting See Section 4 1 5 may be opened slightly more than normal for product flow MCSPRO 1020 Tabbing System User s Guide 19 ADJUST LEVER LOCK LIMIT STOP MINE ADJUST KNOB Figures 11 amp 12 l Fine mara Limit Gab x MCSPRO 1020 Tabbing System User s Guide 20 4 1 10 Output Drive Wheels Figure 14 5 Output Drive Wheel Assembly fe An Output Drive Wheel Assembly is provided in the Wrap Section See Figure 14 These wheels assist in controlling the mailpiece when the Wrap Section is gapped Figure 15 15 J Brass Tip Set Screw zu The Output Drive Wheel Assembly may be located on the Operator s Side or Non Operator s Side To relocate the Assembly remove Button Head Screw loosen Brass Tip Set Screw See Figure 15 and slide assembly to opposite side Using the other slot provided replace the Button Head Screw and secure the Brass Tip Set Screw MCSPRO 1020 Tabbing System User s Guide 21 Note The Output Drive Wheel Assembly position may be adjusted within the slots to avoid ink tracking Warning For pass
26. ection or sensor failure A value between 01 and 70 probably indicates that the tab sensor requires cleaning A value of 100 should always be obtained when adjusted with no liner present A value of less than 100 with no liner would indicate a dirty sensor The sensor should be adjusted without liner only as a diagnostic tool The sensor must be readjusted with liner before normal operation 4 2 6 Adjust Pitch Setting The distance between the lead edges of two consecutive tabs still attached to release liner defines the Tab Pitch This is an important value since it defines how far the tab drive will move when it applies tabs The minimum pitch is 0 75 and the maximum pitch is 7 00 Note Since it is difficult for the system to reverse itself it is always better to enter a lower number for pitch versus a larger number The system can self correct for any slightly undersized pitch whereas a system with an oversized pitch may never be able to synchronize the tab position It short an oversized pitch means bad tab label placement Procedure MCSPRO 1020 Tabbing System User s Guide 28 1 Take system offline 2 Press the 5 key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the or gt until PITCH x xx gt _ is displayed on the second line of the display The x xx represents the current setting for tab pitch 4 To increase t
27. estes uuu huu ha a maaa 28 28 4 2 7 Select Product Sensor es Ra ete HI I 29 4 2 8 29 4 2 9 Number of Tabs je torn a a 30 42310 Besin tos area 31 Chapter 5 Controller Programmine Diagnostics nasus 33 2 1 Setup Programming iR a 33 Pitch 33 1 2 5 Setup to Memory 33 5 1 3 Auto Tab Calculator Product Size mnn ennennnnnnznnennnnsnnnsnnn ann anna 34 S 14 Prod uet Tab Sensor ma 34 MCSPRO 1020 Tabbing System User s Guide 2 5 3 5 Tab Sensor A 35 33 6 Counter Reset ar ha ha bat ha Qa 35 9 3 7 Product Sensor Selec Mii er aan 36 2 2 Position Programming ee iepen u 36 5 2 1 Tab Babel Position ENY 36 5 2 2 37 5 4 Head Diagnostics a ia 38 Software Version ab apb a tsay 38 5 4 2 Drive Cycle aa jeb
28. ey is pressed The current value will be decreased by 0 05 every time the key is pressed The maximum number of tabs that can be applied in a single pass is three The minimum position is 00 00 and the maximum position is 20 00 5 2 1 Tab Label Position Entry The distance between the product lead edge and the lead edge of the tab label defines the tab label positions The system uses position units measured in inches with a precision on 1 100 of aninch The three tab positions are defined by their order of application If only one tab is being applied to a product then Tab Position 1 defines its location If two tabs are applied then Tab Position 1 defines the leading edge tab and Tab Position 2 defines the trailing edge tab If three tabs are applied then Tab Position 1 defines the leading edge tab Tab Position 3 MCSPRO 1020 Tabbing System User s Guide 36 defines the trailing edge tab and the middle tab is defined by Tab Position 2 When using more than one tab the second or third tab position must have a value greater than the previous tab position value 4 Tab Pitch gt TRAILING EDGE gt LEADING EDGE Product Flow L I Tab Position 1 Tab Position 2 Tab Position 3 Procedure 1 2 3 4 5 6 7 Take the system offline Press the POSITION key to access the test menu POSITION should be displayed on the first line of the
29. f Tabs to be applied press the key until the desired number 18 displayed as the current setting To decrease the Number of Tabs to be applied press the key until the desired number is displayed as the current setting 5 4 Head Diagnostics Test The electrical control svstem of the unit is capable of testing 15 critical components The operator must select which test is to be performed from the operator interface The unit must be offline before anv tests are run The components parameters that can be tested are listed below Software Version Tab Drive Cvcle Test Stop Relav Test Motor Brake Test Take up motor Unwind drive motor Source spool brake Base Cover Switch Test Head Cover Switch Test Bin Sensor Test Take up Sensor Test Left Product Sensor Test Right Product Sensor Test Tab Sensor Test Encoder Test Factorv Reset 5 4 1 Software Version It is often important to know the version of the firmware that is running on a system The firmware version will often determine the capabilities of the unit This test will simplv displav the version number of firmware installed on the unit Procedure 1 Take the svstem offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the displav MCSPRO 1020 Tabbing System User s Guide 38 3 Press either the a or vw until VERSION is displayed on the second line of the display X X wil
30. fline 2 Press the 5 key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the or vw until AUTO xx xx gt is displayed on the second line of the LCD The xx xx represents the current product size to be used by the calculator 4 Increase the product size by pressing the key until the desired size is displayed as the current setting Decrease the product size by pressing the key until the desired size 18 displayed as the current setting Or 5 The desired size can be directly entered from the numeric keypad As the new setting is entered it appears to the right of the current setting 6 Once entry of the new value is completed press the ENTER key to calculate the new position values The LCD will indicate completion by displaying the newly calculated positions TAB 1 TAB 2 TAB 3 XX XX 7777 5 1 4 Product Tab Sensor Offset The controller must know the distance between the product sensor and tab sensor peel point in order to accurately place tabs at the desired location When the operator makes small mechanical adjustments of the tab sensor location the distance between the product and tab sensors will also be changed This programmed offset must be kept up to date with sensor movements in order to obtain the highest positional accuracy Although the minimum offset is 2 00 and the maximum 18 9 00
31. h Transport Speed Potentiometer 3 1 1 Base Power Rocker Switch This switch controls power to the tabber base This switch must be on and lit in order for the transport base to function 3 1 2 Head Power Rocker Switch This switch controls power to the tabbing head This switch must be on and lit in order for the tabbing head to function Since this switch obtains its power from the base the Base Power Rocker Switch must also be on 3 1 3 Jog Push Button Switch This switch is provided to aid operator setup When depressed the transport base motor will run at the speed set by the speed control pot The base will stop as soon as the switch is released 3 1 4 Start Push Button Switch This switch is used to start the transport base motor The transport base motor will run at the speed set by the speed control until the Stop Mushroom Cap Switch is depressed or the electronic controls stop the unit 3 1 5 Transport Speed Potentiometer The transport speed potentiometer is used to control the speed of the base Turning this knob clockwise will increase base speed 3 2 Operator Interface MCSPRO 1020 Tabbing System User s Guide 9 The Operator Interface is located on the right side of the base front It is used to setup and control the tabbing head and consists of an array of tact switches and a LCD display The Operator Interface can be subdivided into the following 5 sections e LCD Module Online Key Menu Scroll Keys Nume
32. he Tab Pitch press the key until the desired location is displayed as the current setting To decrease the Tab Pitch press the key until the desired location 18 displayed as the current setting Or 5 The desired pitch can be directly entered from the numeric keypad 6 As the new setting is entered it appears to the right of the current setting 7 Once entry of the new value is completed press the ENTER key to save the new value The LCD will indicate completion by replacing the current setting with the new setting 4 2 7 Select Product Sensor Through beam type opto electronic sensors are used to detect the presence of product to be tabbed labeled Since the tabbing takes place at either the front or rear of the unit product sensors are located at both the front and rear The operator can select the appropriate product sensor to be active Procedure 1 Take the system offline 2 Press the 5 key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the until PRODUCT SENSOR RIGHT FRONT LEFT REAR is displayed on the second line of the LCD The represent the current count 4 Press key to change from RIGHT FRONT to LEFT REAR Press key to change from REAR to FRONT The LCD will update sensor selection as it is made Tab Label Position Overview The location and n
33. l be the version number of interest 5 4 2 Tab Drive Cycle Test The Tab Drive Cycle Test is used to test the function of the Tab Drive Motor The Tab Drive Motor is responsible for the accurate application of the tabs labels Procedure 1 Take the system offline 2 Remove tabs labels from the head before conducting this test 3 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 4 Press either the a or w until TAB DRIVE CYCLE OFF is displayed on the second line of the display 5 Start the test by pressing the ENTER key 6 While the test is being run the display should read TAB DRIVE CYCLE ON and The Tab Drive Wheel should alternate between 3 different states The wheel should run forward at high speed 2 second duration then stop or rotate very slowly 2 second duration then run reverse at high speed 2 second duration followed again by a stopped or very slow state The cycle will continue repeating until the ENTER Key is used to stop the test 5 4 3 Stop Relay Test The Stop Relay allows the control system to shutdown the base whenever serious problems have been detected This test allows the operator to test the function of this relay Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press eithe
34. m User s Guide 3 Chapter 1 System Description The MCSPRO 1020 Tabbing System is designed to apply pressure sensitive tabs labels on to flat product You can use the system as a wrap around tabbing device or use it as a labeler system is made up of two major components the transport base and the tabbing head The tabbing head is movable to enable tabbing on either edge of a mail piece If the system is used as a flat tabber or labeler the head can be located to position the label anywhere on the piece Tab Label position over the length of the product is adjusted electrically through the operator interface The product is introduced into the system by a feeder conveyor or ink Jet system The product is Justified to a side guide by adjusting the transport table position and the registration wheel assembly A knob that raises and lowers the height of the tabbing head and the upper output transport assembly adjusts for product thickness When the product is transported it is detected by a through beam sensor that tells the tabbing head to apply a tab If more than one tab is to be applied to a product this can be set at the operator interface After the tab is applied the product passes through a number of rollers and guides to ensure that the tab label is firmly applied and wrapped tight against the product edge MCSPRO 1020 Tabbing System User s Guide 5 Chapter 2 System Components 2 1 Transport Base Component The transport
35. nsor while the path of the waste liner is under the bottom sensor plate The Bin Sensor must be located to sense the tab label liner for proper uwinding gt y w 4 2 4 Secure Waste Take up Spool Slip an empty tab label core over the supporting hub of the inner spool support Secure the threaded end of the liner to the empty core with tape or a label Push the outer spool support against the side of the core and secure with the spool knob The knob should be tight enough to MCSPRO 1020 Tabbing System User s Guide 27 ensure that the take up roll cannot slip on the hub of the inner spool support The Take up Full Sensor must be located to sense the waste tab label liner for overflow detection 4 2 5 Adjust Tab Sensor The tabber uses a pair of optical sensors housed in the tab sensor to register each tab These sensors are about inch from the peel point and look through the labels and liner enabling the detection of the tab label edges This sensing technique will ensure accurate detection when tuned for the tabs currently being run Adjustments are made automatically once the operator initiates the tuning process The adjustment is different for plain paper tabs versus clear plastic or translucent tabs For paper tabs make sure that only liner is present Inside the tab sensor back feed liner or peel tabs to make this possible For clear or translucent tabs make sure that the tabs are still attached to the line
36. ompletion by replacing the current setting with the new setting 5 1 2 Save Setup to Memory Two memory locations are reserved for saving the most frequent Job settings Memory location 1 can retain the Tab Pitch Tab Position 1 Tab Position 2 Tab Position 3 Number of Tabs and Product Sensor Selection settings Memory location 2 can retain the Tab Pitch Tab Position 1 Tab Position 2 Number of Tabs and Product Sensor Selection settings Procedure MCSPRO 1020 Tabbing System User 5 Guide 33 1 Take system offline 2 Press the 5 key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the or until SAVE MI or M2 gt _ is displayed on the second line of the display 4 save the current settings enter either 1 or 2 from the numeric keypad then press the ENTER key 5 The LCD will display the message Mx SAVED The x represents the number of the memory location selected by the operator 5 1 3 Auto Tab Calculator Product Size The controller can calculate the proper location s for tabs on any given mail piece The operator must enter the size of the mail piece product the number of tabs to be applied and the tab pitch The system can then calculate and program the appropriate tab positions The minimum product size is 05 00 and the maximum 18 20 00 Procedure 1 Take the system of
37. on Keys A 11 3 3 Stop Switch Red Mushroom 11 Chapter 4 Syst m 13 5 aQ a 13 4 1 1 Position Transport 13 4 1 2 Position Base BIN RI De 14 4 1 3 Ink Jet Setup en enden Les rien 15 4 1 4 Adjust Transport Table 15 4 1 5 Product Guide and Strap 16 4 6 a 17 4 1 7 Power Up system A en shaspan aa a pa AS aus 18 ANTS Peed Product A era a upa na 18 4 1 9 Adjust Registration Wheels ss sem n U h a 18 Output Drive tl ai 21 4 111 Center Belt Adjustment rd led da 22 4 1 12 Posttton Upper Press 23 4 1 13 Idler Wheel 24 4 2 Head 27 4 2 1 Install Inner Spool Guides u a ann enges 27 4 2 2 POOL a 27 4 2 3 _ 5 27 4 2 4 Secure Waste Take up 27 4 2 5 Adjust Sensor un tess
38. only small changes to the default offset should be needed Procedure 1 Take the system offline MCSPRO 1020 Tabbing System User s Guide 34 2 Press 5 key to access setup menu 5 should be displayed on the first line of the display 3 Press either the or vw until SENSOR x xx gt _ is displayed on the second line of the LCD The x xx represents the current setting for sensor offset 4 To increase the Sensor Offset press the key until the desired value is displayed as the current setting To decrease the Sensor Offset press the key until the desired value 18 displayed as the current setting Or 5 The desired offset can be directly entered from the numeric keypad 6 Asthe new setting is entered it appears to the right of the current setting 7 Once entry of the new value is completed press the ENTER key to save the new value The LCD will indicate completion by replacing the current setting with the new setting 5 3 5 Tab Sensor Sensitivity The controller must know the location of each tab edge in order to place the tab accurately on product Through beam type opto electronic sensors are used to look through the and tabs The electronics can detect a significant contrast between just liner found between tabs and the combination of tabs on top of the release liner Since this accurate detection is so important setting the correct set
39. r and the lead edge of a liner registration marker must be at the peel point edge Procedure 1 Power up the head turning on the Head Power Rocker Switch 2 Press the SETUP to access the setup menu 5 should be displaved on the first line of the displav 3 Press either the or gt until ADJUST TAB SENSOR 2 is displayed on the second line of the LCD 4 When using tvpical paper tabs it is important to have the machine fullv threaded but with no tab present in the tab sensor It is important to make this setting while only liner is present in the tab sensor When using translucent or clear tabs it is important to have the machine fullv threaded with a tab present in the tab sensor It is important not to have a liner registration mark directly under the sensor while making the adjustment Since the optical path of the tab sensor is approximatelv 2 from the peel point edge adjusting the sensor after aligning a registration mark with the peel point edge will assure that proper setting will be found 5 The controller will automatically make the optimal sensor adjustment when the ENTER key is pressed The LCD will indicate completion displaying SENSOR ADJUSTED SETTING xxx The xxx represents the electrical setting used for the sensor This value should normally range from 70 to 97 when setting with liner in the sensor A value of 01 indicates sensor disconn
40. r the or vw until STOP RELAY OFF is displayed on the second line of the display 4 Run the base by pressing the START button The base should stop if the ENTER key is pressed After the ENTER key is pressed STOP RELAY ON will display on the second line ofthe LCD 5 4 4 Motor Brake Test Three DC gearmotors are used to 1 unwind the source spool 2 brake the rotation of the source spool and 3 take up the waste liner The Motor Brake Test allows the operator to test the fitness of each of these gearmotors Procedure 1 Take the system offline 2 Remove any tabs labels from the head before conducting this test 3 Press the TEST key to access the test menu TEST should be displayed on the first line of the display MCSPRO 1020 Tabbing System User s Guide 39 4 Press either the or until MOTOR BRAKE OFF is displayed on the second line of the display 5 Press the ENTER key to start the test The second line of the LCD will display MOTOR BRAKE ON While this test is being run the take up motor should run continuously The unwind motor will run when the bin sensor is not blocked and stop when the bin sensor is blocked The source spool will brake when the bin sensor is blocked the braking action 18 released when the bin sensor is not blocked 5 4 5 Base Cover Test Note Due to a change intended to enhance the safety of the tab
41. ric Keypad Menu Selection Keys ajajaja D ajajaja 9 JEN 3 OPERATOR INTERFACE 3 2 1 The Operator Interface is equipped with a LCD module used to display controller information to the operator Setup parameters error descriptions and controller status can all be viewed through the LCD 3 2 2 Online Key This key toggles the head condition between online and offline When offline the head will not dispense any tabs labels The head must be offline to access setup parameters within the controller The head must be online in order to dispense tabs labels Online Offline condition is displayed on the LCD While online the second line of the LCD displays NORMAL STATUS if offline the first line of the LCD displays OFFLINE 3 2 3 Menu Scroll Keys The arrow and down arrow keys are used to scroll up and down menus to facilitate menu item selection when used during setup These keys are also used to control the display of production data when the unit is online The operator can choose between the following three different production displays e Product Count e Transport Speed e Production Rate 3 2 3 1 Product Count The controller maintains a six digit product count The operator through use of the setup key can reset this counter An example of a typical count display follows FORMS DONE 000123 NORMAL STATUS MCSPRO 1020 Tabbing System User s Guide
42. slot in the mounting block The assembly may be positioned on any angle to allow entry of skewed product and correct it as it proceeds Note The product guide may be mounted on either side of the mounting block to allow use on both the operator s side or non operator s side Remove 2 screws See Figure 9 and reposition guide using the two additional holes provided on the opposite side of the mounting block MCSPRO 1020 Tabbing System User s Guide 16 4 1 6 Set Gap The tabbine labeling system can accept flat product as thick as 5 8 inch The Product Thickness Adjust Crank controls the gap Rotate clockwise to increase gap counterclockwise to decrease gap Requirement The top wrap section must be gapped to product thickness to effectively wrap tabs or secure labels Procedure 1 Rotate Product Thickness Crank See Figure 10 clockwise Insert product sample to be tabbed between upper output belt and output roller below 2 Rotate crank counterclockwise until firm pressure is felt by pulling product sample from the belt roller Figure 10 MCSPRO 1020 Tabbing System User s Guide 17 4 1 7 Power Up System The tabber control system depends on small computer processor for its operation Since electrical line disturbances can adversely affect computers it would be prudent to use a fairly clean line to power the tabber Plug the power cord into a 120 60 source Power up the base by turning on onl
43. ss the ENTER key to save the new value The LCD will indicate completion by replacing the current setting with the new setting 4 2 9 Number of Tabs The unit can apply 1 to 3 tabs on a single product in one pass The POSITION key gives access to this setting Procedure MCSPRO 1020 Tabbing System User s Guide 30 1 Take system offline 2 Press the POSITION key to access the position menu POSITION should be displayed on the first line of the display 3 Press either the or until NUMBER OF TABS x is displayed on the second line of the display The x represents the current setting for the number of tabs to be applied to a given product 4 To increase the Number of Tabs to be applied press the key until the desired number is displayed as the current setting To decrease the Number of Tabs to be applied press the key until the desired number is displayed as the current setting 4 2 10 Begin Tabbing The system should now be ready to apply tabs labels Turn the head online by pressing the online key on the operator interface MCSPRO 1020 Tabbing System User s Guide 31 Chapter 5 Controller Programming Diagnostics 5 1 Setup Programming The operator can adjust many of the components and parameters necessary to setup the unit through the operator interface The SETUP key is used to access these adjustments and is active only when the unit is offline The
44. t adjust wheels to maximum angle Use minimum angle increase only as necessary Note Occasionally it may be necessary to angle the entire registration system See Figure 12 to assure product remains against guide rail The lever lock mounting assemblies permit a limited amount of misalignment for this purpose Caution Over adjustment of angle wheels and excessive drive pressure can cause product to ride up guide rail or cause product to distort or stall A deflector strip Figure 13 is provided along each guide rail to help hold down product 3 Turn base power on and operate base with speed control at slow speed Rotate drive wheel lift knob Figure 11 counterclockwise until all drive wheels are turning Turn fine adjustment knob screw clockwise to meet stop on square shaft Figure 12 4 Feed product and visually check to assure product is against the guide rail and not distorted or stalling before entering underneath upper press roll Further adjust angle wheels and drive wheel down pressure if necessary Operate at production speed and visually check again 5 When the requirements above have been met tabbing operation can proceed Warning For pass thru operation Not applying tabs set up as described above Product conveyed by tabber transport belts only and not controlled by top drive can skew and migrate into the gearbelts of the upper wrap section Severe damage or breakage can occur When the tabber base is left in lin
45. t to be tabbed labeled The sensor condition is displayed while this test is being run Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the or until RT PRODUCT BLOCKED or PRODUCT UNBLOCKED is displayed on the second line of the display 4 The LCD display will indicate the current state of the right product sensor while this test is being run MCSPRO 1020 Tabbing System User s Guide 41 5 4 11 Tab Label Sensor Test A through beam type opto electronic sensor is used to sense the edge of the tab label about to be dispensed The sensor condition is displayed while this test is being run Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST should be displayed on the first line of the display 3 Press either the a or gt until TAB SEN BLOCKED TAB SEN UNBLOCKED 18 displayed on the second line of the display 4 The LCD display will indicate the current state of the tab label sensor while this test is being run 5 4 12 Encoder Test optical encoder is used to sense product speed and position information The encoder test displays a running pulsewheel count from the encoder Procedure 1 Take the system offline 2 Press the TEST key to access the test menu TEST
46. thru operation Not applying tabs set up as described above Product conveyed by tabber transport belts only and not controlled by top drive can skew and migrate into the gearbelts of the upper wrap section Severe damage or breakage can occur When the tabber base is left in line and used as a conveyor the same set up procedures for tabbing labeling or stamp affixing must be used However since securing tabs labels or stamps to the product is not a requirement the gap setting See Section 5 1 5 may be opened slightly more than normal for product flow 4 1 11 Center Belt Adjustment i Center Transport Belt Adjuster Knobs Requirement Adjust Center Belt position to support Product Edge Note Transport Base must be powered up to move center belt Procedure 1 Power up Base and operate with Speed Control 2 Loosen Adjuster Knobs shown in Figure 16 3 Gently push Adjuster along it s slot to position Center Belt as required 4 Secure Knobs to maintain belt position MCSPRO 1020 Tabbing System User s Guide 22 4 1 12 Position Upper Press Rolls The upper press rolls located at the input of the wrap section may be positioned across their drive shaft to secure tabs for wrap tabbing labeling or stamp application on the product Rolls are provided to meet the requirements and are designed to move bv hand Two press rolls are provided for svstems using the standard 2 head and four rolls are supplied on the
47. ting has been made very simple This adjustment should be made periodically since dust and debris can block the optical path thus affecting operation It is also important to make the adjustment whenever setting up for a different type manufacturer of tab Procedure 1 Take the system offline 2 Press the SETUP key to access the setup menu SETUP should be displayed on the first line of the display 3 Press either the or gt until ADJUST TAB SENSOR 2 is displayed on the second line of the LCD 4 When using typical paper tabs it is important to have the machine fully threaded but with no tab present in the tab sensor It is important to make this setting while only liner is present in the tab sensor When using translucent or clear tabs it is important to have the machine fully threaded with a tab present in the tab sensor It is important not to have a liner registration mark directly under the sensor while making the adjustment Since the optical path of the tab sensor is approximately 2 from the peel point edge adjusting the sensor after aligning a registration mark with the peel point edge will assure that proper setting will be found 5 The controller will automatically make the optimal sensor adjustment when the ENTER key is pressed The LCD will indicate completion by displaying TAB SENSOR ADJUSTED SETTING xxx The xxx represents the electrical setting used for the sensor
48. umber of tabs labels to be applied to a single product is controlled by the choices accessed by the POSITION key The POSITION key is active only when the unit is offline The position setting to be displayed and or adjusted is controlled by the key key After displaying the setting of interest it can then be adjusted by one of two methods direct keypad entry or incremental adjustment The direct keypad entry is accomplished by using the numeric keypad to directly enter the desired position After the position has been entered the ENTER key must be pressed to load the new value into memory Incremental adjustments are made by using or keys The current value will be increased 0 05 every time the key is pressed The current value will be decreased by 0 05 every time key 18 pressed The maximum number of tabs that can be applied in a single pass is three The minimum position is 00 00 and the maximum position is 20 00 4 2 8 Tab Label Position Entry MCSPRO 1020 Tabbing System User s Guide 29 The distance between the product lead edge and the lead edge of the tab label defines the tab label positions The system uses position units measured in inches with a precision on 1 100 of inch The three tab positions are defined by their order of application If only one tab is being applied to a product then Tab Position 1 defines its loc
49. when product is delivered 1 8 or less from the guide rail at the entrv point See Figure 7 of Section 4 1 4 Warning Product feeding and registration must be properlv adjusted before tabbing Turn head power off and move the head aside Visually check feeding and registration with sample product Anv skew or catch points must be eliminated A Product Guide and two Hold Down Straps are provided to control the conditions above See Section 4 1 5 at the input end of tabber The primarv feeder free standing friction tvpe ink jet base friction or vacuum must also be properlv adjusted to eliminate double feeds product skew or side to side drift Requirement Registration wheels must be positioned and adjusted to consistently guide product edge along guide rail without distorting or causing product stall Note A fine adjustment limit stop Figure 13 is provided to control and maintain drive pressure Turning the knob clockwise limits the down drive pressure Turning the knob counterclockwise allows more down drive pressure to be set The limit stop allows the assembly to be raised completely from a preset drive position and returned to that position without adjustments MCSPRO 1020 Tabbing System User s Guide 18 Procedure 1 Loosen lever locks See Figure 11 Position registration wheel assembly over belt adjacent to guide rail 2 Adjust angle drive wheel knob to angle three slaved wheels towards guide rail See Figure 11 Do no
50. y the Base Power Rocker Switch The switch will light up as a confirmation of power application 4 1 8 Feed Product Start the base by pressing the Start Pushbutton and adjusting the Speed Control Knob until the speed of tabbing labeling base matches the speed of the system feeding it Feed sample product to make sure it enters the transport within 1 8 of the guide 4 1 9 Adjust Registration Wheels The tabbing labeling base uses a set of registration wheels to ensure consistent placement and wrap of tabs and labels The wheels are used to push the product against the guide rail guide and secure the product to the transport belt The first three entry wheels are slaved together on a swivel system that allows angle adjustment to drive the product against the guide for registration The following three drive wheels are fixed a straight line to maintain registration along the guide rail for accurate tab label placement on the product This registration wheel assembly is designed to function on either side of the transport base assemblv mav be positioned over anv portion of the lower transport belts along the square mounting shafts bv loosening lever locks and sliding to desired location Drive pressure mav be increased or decreased by rotating the Wheel Lift Knob This knob is also used to lift the complete assembly off the lower transport belts for repositioning The Registration Wheel Assembiv functions best
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