CVC 302 Manual

OPERATION MANUAL HAWK TM LABELING MACHINE Model CVC 302 (WITH OCV)

CVC TECHNOLOGIES, INC. 10861 Business Drive, Fontana, CA 92337 TEL: (909) 355-0311 FAX: (909) 355-0411 (ISO 9001:2000 Certified)

1. 2.

Before operating the machine: Read thoroughly this Operating Manual to ensure the safety of the personnel and to keep the machine in good conditions. Machine adjustment and parts changeover are only to be done by qualified and properly trained engineers.

CVC TECHNOLOGIES, INC.

OPERATION MANUAL CVC 302

LABELING MACHINE

CONTENTS 1.

ABOUT THIS MANUAL 1.1 About This Manual ................................................................................................................ 1-1 1.2 Additional Information............................................................................................................ 1-1

2.

SPECIFICATIONS 2.1 Machine Specification ........................................................................................................... 2-1 2.2 Label Specification ................................................................................................................ 2-2 2.3 Hot Stamp Printer Specification (Optional)............................................................................ 2-3

3.

SAFETY REGULATIONS 3.1 General Safety Rules ............................................................................................................ 3-1 3.2 Warning Signs ....................................................................................................................... 3-1 3.3 Warning Signs Placement ..................................................................................................... 3-2 3.4 Important Safety Notices ....................................................................................................... 3-4

4.

INSTALLATION 4.1 Standard Area Conditions ..................................................................................................... 4-1 4.2 Minimum Machine Operation Space ..................................................................................... 4-1 4.3 Transportation Precautions ................................................................................................... 4-2 4.4 Transportation Procedures .................................................................................................... 4-2 4.5 Positioning and Adjustment of Machine Level and Height..................................................... 4-4

5.

INSTALLATION PROCEDURES 5.1 Power Connection ............................................................................................................... 5-1 5.2 C70 Type Arrangement of the Imprinting Head Plate ............................................................ 5-2

6.

MACHINE GENERAL LAYOUT 6.1 Parts Identification................................................................................................................. 6-1 6.2 Machine Parts Functions....................................................................................................... 6-2 6.3 Machine Control Parts Functions .......................................................................................... 6-3 6.4 Pneumatic Control System.................................................................................................... 6-4 6.5 General Layout...................................................................................................................... 6-5 6.6 Labeling Head Parts Identification......................................................................................... 6-5 i



LABELING MACHINE

7.

POWER BOX .......................................................................................................... 7-1

8.

TOUCH SCREEN CONTROL PANEL FUNCTIONS 8.1 Touch Screen Description ..................................................................................................... 8-1 8.2 Touch Screen Function Descriptions ..................................................................................... 8-1 8.3 Warning Message Instruction ................................................................................................ 8-26

9.

CHECK UP BEFORE OPERATION 9.1 Inspection Before Operation.................................................................................................. 9-1 9.2 Labels Installation.................................................................................................................. 9-1

10.

OPERATING PROCEDURE 10.1 Power Supply and Air Sources Check................................................................................... 10-1 10.2 Air Regulator Set Check........................................................................................................ 10-1 10.3 Machine Adjustment.............................................................................................................. 10-1 10.4 Main Power Switch ON ......................................................................................................... 10-2 10.5 Job Selections....................................................................................................................... 10-2 10.6 Job Menu .............................................................................................................................. 10-2 10.7 Label Head Check................................................................................................................. 10-2 10.8 Sensors Setup....................................................................................................................... 10-3 10.9 Self-Set A New Job ………………………………………………………………… ..................... 10-4 10.10 Checking Bottle Data .......................................................................................................... 10-6 10.11 Saving Labeling data........................................................................................................... 10-6 10.12 Select A Job from Memory .................................................................................................. 10-6 10.13 Continuing the Previous Job ............................................................................................... 10-7 10.14 Stopping Machine ............................................................................................................... 10-7

11.

MACHINE SET-UP AND ADJUSTMENT 11.1 Guide Rail and Product Separator Adjustment....................................................................... 11-1 11.2 Label Position – Vertical ......................................................................................................... 11-2 11.3 Label Head Angle – Horizontal............................................................................................... 11-2 11.4 Wrap Belt Position - Vertical ................................................................................................. 11-3 11.5 Product Speed……………………………………………………………………… ...................... 11-3 11.6 Label Dispensing Speed Adjustment (LAB HD-SPD) ............................................................. 11-3

ii



LABELING MACHINE

11.7 Product Separator Adjustments.............................................................................................. 11-5 11.8 Production Speed Adjustment ............................................................................................... 11-5 11.9 Label Extensions.................................................................................................................... 11-5 11.10 Labeling Position Adjustment (LAB. P)................................................................................. 11-5 11.11 Label Sensitivity Adjustments ............................................................................................... 11-6 11.12 Product Sensor Adjustments............................................................................................... 11-7 11.13 Missing Code Stamp Sensor Adjustments .......................................................................... 11-8 11.14 Bar Code Scanner Adjustments ........................................................................................... 11-9 11.15 Production Quantity Clearance ........................................................................................... 11-10

12.

COMPLEMENTARY TOOLS 12.1 Complementary Tools............................................................................................................ 12-1

13.

MAINTENANCE 13.1 General Precautions.............................................................................................................. 13-1 13.2 Pneumatic Arm Maintenance ................................................................................................ 13-1 13.3 Air Regulator Set Maintenance ............................................................................................ 13-2 13.4 Spare Parts List..................................................................................................................... 13-3 13.5 Maintenance and Lubrication Schedule ................................................................................ 13-4

14.

ELECTRICAL DIAGRAMS...................................................................................... 14-1

15.

PARTS LIST 15.1 Overall Assembly Scheme .................................................................................................... 15-1 15.2 Base Frame Assembly .......................................................................................................... 15-3 15.3 Conveyor Assembly ............................................................................................................. 15-7 15.4 Head Angle Adjustment Assembly......................................................................................... 15-9 15.5 Wrap Station Assembly (C Type) ........................................................................................ 15-11 15.6 Labeling Head Assembly (C Type) ........................................................................................ 15-13 15.7 Power Box............................................................................................................................. 15-15 15.8 Hot Stamp Printer.................................................................................................................. 15-17 15.9 Product Spacing Wheel Assembly......................................................................................... 15-19 15.10 Rejection System ................................................................................................................ 15-21 15.11 Safety Shield Assembly....................................................................................................... 15-21

iii


16.


LABELING MACHINE

TROUBLESHOOTING 16.1 Powering ON......................................................................................................................... 16-1 16.2 Self-Set ............................................................................................................................... 16-2 16.3 Labeling .............................................................................................................................. 16-3 16.4 Label Sensor ......................................................................................................................... 16-7 16.5 Hot Stamp Printer (Model: C70, Optional)............................................................................. 16-8

17.

APPENDIX 17.1 Hot Stamp Printer Identification (Optional)............................................................................. 17-1 17.2 Image Checker (Optional) ..................................................................................................... 17-2 17.3 HMI Password Setting........................................................................................................... 17-20 17.4 Clear Label Sensor Adjustment Procedures (Optional) ......................................................... 17-21 17.5 Inverter Troubleshooting and Parameter Setting

iv



LABELING MACHINE

Dear Customer, Thank you for purchasing a CVC 302 (with IPC) Labeling Machine. We at CVC hope you will find that the Model CVC 302 (with IPC) meets or exceeds your expectations and requirements for an affordable, reliable and innovative addition to your packaging operation. CVC specializes in fully integrated packaging lines and specialty machines for counting, filling, desiccant inserting, cotton inserting, capping, sealing, labeling and cartoning. All CVC machines are standardized for maximum reliability and to provide more economic pricing. If you are looking for service, well designed machinery and value that lasts, don’t hesitate in letting us know your questions and comments, please contact us by phone or visit our website.

CVC TECHNOLOGIES, INC. 10861 Business Drive, Fontana, CA 92337

TEL: (909) 355-0311 FAX: (909) 355-0411 www.cvcusa.com [email protected]

Yours truly, CVC Technologies, Inc.

v



LABELING MACHINE

PREFACE:

The CVC 302 labeling system is one of the most advanced automatic labeling systems designed in the world. The system features high labeling speed and the most easy-to-operate industrial computer. When a product passes through the product sensor on the conveyor, the micro processing system will get the outer bottle diameter as the sensing point of the labeling system. Label dispensing is then calculated automatically and, distance between product sensor and label peel blade is fixed and need no adjustments, as well as labeling timing. Automatic adjustment for different bottle diameters can be simply done by the micro processing system. For most conventional labeling systems, labeling sensing point is based on the front side for bottle, product sensor repositioning by the operator or changing label time is necessary when changing bottle size. For this CVC 302 Hawk labeling system, when a bottle is placed on the moving conveyor

and

passes through the bottle, the system will immediately calculate the best labeling position, at the same time, it also reaches speed synchronization for conveyor speed, label dispensing speed, wrapping speed, and label extended length setup. For those conventional labeling systems, those adjustments are very complicate and difficult, and can only rely on operator's experiences. Any improper adjustment of speed synchronization may result poor labeling quality. With CVC 302 Hawk fully automatic Self-SetTM labeling system, you can set without any trouble. The machine is automatically controlled, Touch Screen Panel is provided, where the most common operations are easily accessed, and some useful technical checking functions are featured for troubleshooting purposes. Proper job settings for a given product can be recorded in one of the job memory sets for reuse. The machine has a hygienic design that meets GMP standards, operation and adjustment are easy, minimal maintenance and fast product changeover helps increasing productivity.

vi


1. 1.1


LABELING MACHINE

ABOUT THIS MANUAL About This Manual

This Operation Manual has been written by observing the CE directives, the main purpose of the regulation is in relation to the protection of personal safety and the maintenance of the machine in good conditions, as it is intended to provide the proper operation procedures to avoid causing danger and damages to persons and to the machine. Some of the topics covered in this manual are: important notices about safety, operation procedures, operating parameters setting, explanation on error situations, maintenance, troubleshooting and clean up procedures ... etc. In the case integration to other machinery or equipment is required, it also must be done by observing the instructions given by this Operation Manual in order to minimize the chances of personal injury or machine damage due to unpredicted risk factors. This machine is not intended for use by general public, operation should be allowed to only trained and qualified persons, which can be classified into 3 categories: Administrator: Administrators are individuals who should have a deep knowledge of the operation of the machine, and should have read and understood thoroughly this Operation Manual, in addition, he has to be properly instructed on the general and local regulations about workplace safety, workers protection and work environment safety regulations in order to provide a safe condition for the personnel and the machinery. Production Manager or Section Chief: Production Chief should have a deep knowledge of the operation of the machine, and should have read and understood thoroughly this Operation Manual, the person in charge should be qualified engineers in electricity or in mechanics. The production chief should be able to perform troubleshooting procedures for the machine and it is his duty to contact the machine manufacturer when the situations requires. Operator: Operators should have a good knowledge of the operation procedures of the machine, and should have read and understood thoroughly this Operation Manual. The operator is also responsible of performing the general maintenance and clean up of the machine.

1.2

Additional Information

For all consultation regarding the machine or this Operation Manual, for example: optional attachments or problems concerning machine operation or adjustment, the customer can contact directly the manufacturer or its representatives, all efforts will be made to satisfy the questions arisen.

vii



2.

SPECIFICATIONS

2.1

Machine Specification

Applicable Label Height

Label Length Power Source Horse Power Power Consumption Air Pressure Air Consumption Humidity Required compressed air quality Environment condition Label Dispensing Speed Machine Capacity

LABELING MACHINE

CVC302A: 15~80 mm (5/8”~3 1/8”) CVC302B: 15~120 mm (5/8”~4 3/4”) CVC302C: 15~150 mm (5/8”~6”) CVC302D: 15~180 mm (5/8”~7”) 15~250mm (5/8”~9 7/8”) 220V - 50HZ - 1phase -Servo Motor (A/B/C/D Type):0.75 KW (Panasonic/Japan) -Conveyor Motor: AC Motor, 1/4 HP (220V) -Wrap Around Motor: AC Motor, 60W (220V) -Product Separator Motor: AC Motor 25W (220V) 880 W 85 psi (6 kg/cm2) 1 cfm (Used for optional C70 Hot Stamper and Rejection System) Between 10% - 90% As per ISO 8573-1 requirements Moisture, water, dust and direct sunlight should be avoided. Up to 70 M/min. Up to 250 BPM

D2: ø30 - ø110 mm (ø 1 1/8" –ø 4 3/8")

Applicable Container/Bottle Size Range

Conveyor Width Product Separator Wrapping Label Sensor Machine Dimension Machine Weight Noise Level

H: 50 - 320 mm (2" – 12 5/8")

102 mm (4”) a. 2 Spacing Wheels (Standard) b. Separation Screw (Optional) Wrap around labeling a. Photo Sensor: For General Labels (Standard) b. Special Sensor: For Transparent Labels (Optional) L:2833 x W:1240 x H: 1560 (mm) (111 1/2" x 48 7/8" x 61 1/2" ) 350 kg 75 dB

viii


2.2


LABELING MACHINE

Label Specification

Base Paper

Translucent paper (Semi-Transparent)

Label Roll Inner Diameter.

38 mm (1½”); 76 mm (3”)

Max. Roll Outer Diameter

400 mm (15 3/4”)

Gap Between Labels

2 ~ 6 mm (3/32”~1/4”)

Width of Base Paper

2 mm wider than the label on upper and lower sides.

Labels Placement

Labels are rolled around outside. Labels are rolled around inside.

2.2.1

Label Specification Diagram

76mm (or 38mm)

Translucent base paper FIG 2.2-1

2.2.2

Label Rolled Outside Diagram

Labels are on the outside and roll in clockwise. (Common use) Reserve a blank for hot stamp printer if needed. Clockwise

Hot stamped code position FIG 2.2-2 ix


2.2.3


LABELING MACHINE

Label Rolled Inside Diagram

Labels are on the inside and roll in counterclockwise. (Less common use) Reserve a blank for hot stamp printer if needed. Counterclockwise

Hot stamped code position

FIG 2.2-3

2.3

Hot Stamp Printer Specification (Optional)

Hot Stamp Printer/ Model: C70 Print Type Print Sizes

Nickel alloy 1.3mm（special size） 1.5mm（standard size） 2.0mm（standard size） 2.5mm（standard size）

Air Consumption

10 cc/print time (10cc per stroke)

Air Pressure

3 ~ 4 kg/cm2 (40 ~ 50psi)

Printing Lines

1~6 lines

Print Speed (max.)

300 prints/min.

Hot Foil Ribbon

1. Two types are available A. Width: 25mm (1") B. Width: 32mm (1 1/4") 2. Applicable printing temperature: 130˚C ~ 150 ˚C

Foil Printing Temperature

125 ˚C ~150˚C

Print Area

Length:0 ~ 70mm (2 3/4"), Height: 0 ~ 65mm (2 9/16")

x


2.3.1


LABELING MACHINE

Hot Stamp Printer (Optimum)

Printing needs to be synchronized with labeling, proper adjustment is necessary before operating the labeling machine. 2.3.2

Hot Stamp Printer Overview Hot stamp height adj. handwheel Foil roller

Air cylinder Control fit of type chase Type chase Silicone pad

Foil tape

Foil tape lock Foil advance control knob

Hot stamp horizontal position adj. handwheel Power plug

Fuse Air flow control knob

Heating switch Test button Temperature indicator

FIG 2.3-1

2.3.3

Print Area

FIG 2.3-2

xi

Magnetic valve


2.3.4


LABELING MACHINE

Type and Related Specifications Space between types Space between types Narrow type Wide type (Center to center) (Center to center)

Type Height

Typing Width

Typing

(A)

(B)

Lines

B1.3

1.5 mm

1.3 mm

1-3

2 mm

3 mm

B1.5

1.8 mm

1.5 mm

1-3

2 mm

3 mm

Type numbers Typing Max. length 12 (15.6mm) 10 (15mm)

Type

Brass Type

Brass type

Narrow type chase

Wide type chase FIG 2.3-3

(B)

Space between types Narrow type (Center to center)

Space between types Wide type (Center to center)

1.5 mm

1.8 mm

1-6

4.7 mm

Z2.0

2.0 mm

1.8 mm

1-6

4.7 mm

Z2.5

2.5 mm

1.8 mm

1-6

4.7 mm

Nickel Type

Type Height

Typing Lines

(A) Z1.5

Type numbers Typing Max. Length 18 (32.4 mm) 18 (32.4 mm) 15 (33 mm)

Type

It is recommended to use 2.0mm type height to get the optimum effect.

Nickel type

FIG 2.3-4 xii

Type chase



LABELING MACHINE

2.3.5 Actual Size of Standard Numbers 2.3.5.1 Wide Brass Type

FIG 2.3-5

2.3.5.2 Narrow Brass Type

FIG 2.3-6

2.3.5.3 Nickel Alloy Type

FIG 2.3-7

xiii



3.

SAFETY REGULATIONS

3.1

General Safety Rules

LABELING MACHINE

The safety regulations have been provided purely as a guide for the safety of all personnel involved in the operation, cleaning and maintenance of the equipment covered by this instruction manual. Please ensure that you have read and understood all safety notices before operating the equipment covered by this instruction manual, and that the recommendations here enclosed are strictly followed. The following safety notices must not be considered as a definitive list but should be used to form part of the overall safety plan applied by the customer when operating, cleaning and maintaining the equipment covered by this instruction manual. Customers are requested to observe all relevant statutory safety requirements, regulations or amendments that are or may become legal requirements. The equipment covered by this instruction manual has been designed to comply with existing health and safety legislation. If any of the instructions given here is in conflict with your local safety regulations, please contact the manufacturer before modifying its contents. All warning sign affixed on the machine are important and should never be detached, replacement should be done immediately if any sign is loose or lost, thus to ensure the safety of the personnel. Every reasonable precaution has been taken to ensure that it is electrically, mechanically and pneumatically safe to undertake the work for which it has been supplied.

3.2

Warning Signs Item

Signs

Description

1

WARNING: Personal danger or machine damage may be caused.

2

ELECTRIC SHOCK: Operate carefully, electric hazard is present.

3

ROLLING! Keep hands away: a rolling mechanism is present, keep hands away to avoid injury.

xiv


3.3


LABELING MACHINE

Warning Signs Placement CVC 302 Front view

FIG 3.3-1 xv



LABELING MACHINE

CVC 302 Back view

FIG 3.3-2

xvi


3.4


LABELING MACHINE

Important Safety Notices Please observe following important safety notices. Directions should be given to operating personnel ensuring the safety regulations are observed.

Heed all warning signs placed on the machine by the manufacturer.

The machine should not be installed in high temperature locations, near heat source, in potentially explosive areas or near combustible materials.

Places affected by heavy vibrations or exposed to possible shocks or impacts are not indicated for machine installation. Install the machine on a flat and vibration free floor/foundation. The machine has to be mounted strictly horizontally.

Wet floor should be avoided around the installation site, machine must be properly grounded to avoid electrical shocks.

Use a reliable power source according to voltage specified on nameplate. Machine must be properly grounded. Voltage variations should not exceed the safety limits. Keep away from moving machine parts during machine operation. For ease and safety considerations, it is advisable the operator/technician use appropriate garments or overalls with the buttons properly buttoned when installing/adjusting or operating the machine to avoid accidents. Remove all strange objects from machine surface. Operator should keep himself in good physical and mental conditions when operating the machine. Operation of the machine is prohibited if the operator is under the effects of alcohol or any drug which affects the mental condition.

xvii



LABELING MACHINE

Be sure that the operator knows the precise location of the emergency stop button, so that it can be pressed in time upon any emergency situation. Before machine start-up, also ensure that both the Stop Button and the Emergency stop button are in “0” position.

Use caution while running aggressive or corrosive products, acid, caustic.. etc. Avoid splatters to machine or personnel.

Avoid touching machine moving or rotating parts with your body during operation.

Cables around the machine should be properly laid inside trays to avoid stumbles while walking, and thus preventing accidents.

Do not use screwdrivers or hammers to inspect the machine.

Switch off the power before setting up, only switch the machine on after setup is properly done.

Shut down the machine after operation is finished by disconnecting all electrical and air supply lines.

The manufacturer assumes no liability of any kind for danger which may be brought about by misuse of the equipment or by applying the equipment to a purpose other than that for which it is intended. The equipment covered by this manual has been supplied for a particular application. It is, therefore, imperative that the customer/owner contacts his/her nearest agent or sales distributor before the equipment is used for any other application.

xviii



LABELING MACHINE

Only products listed in the order confirmation may be processed by the equipment covered by this instruction manual. Before processing any other kind of product please contact your nearest agent or sales distributor.

It is not allowed to alter the equipment’s original appearance by alterations, maintenance or by any other means carried out on behalf of the customer/owner or by a third party.

It is not allowed to place or fit any additional equipment inside any cabinet or on any part of the equipment, which are not delivered, approved or mounted by the manufacturer or sales distributor.

It is the customer/owner’s sole responsibility that all personnel likely to be engaged in the operating, cleaning or maintenance of the equipment covered by this instruction manual have read and understand this instruction manual.

It is essential that all personnel likely to be engaged in the operating, cleaning or maintenance of the equipment covered by this instruction manual are fully experienced in the type of work that they are requested to perform.

It is the customer/owner’s sole responsibility that all personnel likely to be engaged in the operating, cleaning or maintenance of the equipment covered by this instruction manual are aware of the potential hazards which may result if the equipment is not used in accordance with the instructions provided.

Before switching ON the main power switch, always ensure that all original cover doors, protective hoods and guards are fitted in their correct positions and unimpaired.

Do not stand, sit or lean on any part of the equipment covered by this instruction manual or on any other equipment serving or being served by the equipment, either during operation, cleaning, inspection or maintenance.

Never attempt to lift any part of the equipment without first knowing its weight. Always use appropriate, safety tested lifting equipment when necessary. Always seek assistance when in doubt.

xix



LABELING MACHINE

Always switch OFF the main power switch before connecting or disconnecting an electrical connection. The equipment should be serviced by qualified personnel when the equipment does not appear to operate normally or exhibits a marked change in performance. Do not attempt to clean, inspect and maintain the equipment beyond that described in this instruction manual. All other servicing should be referred to your service dept. of your nearest sales distributor.

Always wear personal protective clothing, able to resist possible dangers. Do not wear any loose hanging clothing or accessories. Cover or put up long hair.

Do not apply excessive force to the electrical, mechanical or pneumatic control elements.

Always ensure whether no moving parts of the equipment are blocked or obstructed by any form of waste materials.

Cleaning, inspection and maintenance should only be carried out by fully qualified and authorized maintenance personnel.

During cleaning or maintenance always observe all local and in-door valid labor protection, safety and environmental regulations.

Make sure all cabinets and maintenance flaps/doors are fitted in their correct position when no longer carrying out cleaning, inspection or maintenance.

xx



LABELING MACHINE

When during cleaning or maintenance no power is required, always switch OFF and padlock the main power switch.

The electronic equipment inside the electronics cabinet(s) may still be live even when the main power switch is switched OFF ! Always remove the power supply cord from the outlet prior to cleaning, inspection or maintenance work. Always keep the Power Box closed unless required for service purposes. Setting up and troubleshooting of electrical parts must be carried out by qualified electrician or engineer. Power Box should not be opened without permission, connections made by unauthorized personnel is prohibited.

During cleaning, avoid spattering water on the power box or any electric component.

If cleaning or maintenance must be carried out when the equipment is in operation, then all reasonable precautions must be taken to avoid personal injury or equipment damage.

Always use safety steps for tasks above shoulder height.

Stop the machine immediately in the event of any machine malfunction.

Routinely check the machine for worn components and have them replaced.

xxi



4.

INSTALLTION

4.1

Standard Area Conditions

LABELING MACHINE

a. Place the machine on a flat surface. Room temperature should range between 50°F - 104°F (10°C-40°C). It is recommended that the temperature of the area be at around 70 °F (25°C). Keep area free of vibration, and free of gaseous chemicals. b. Relative humidity: 10% to 90% (no condensation). c. Avoid direct sunlight over the machine, also avoid water splatters. d. Have a clearance space of at least 31½” feet (800 mm) around the machine for operation, cleaning and maintenance purposes. (Refer to FIG. 4.2-1) 4.2

Minimum Machine Operation Space Model

A

B

Height

CVC 302

4440 mm (174 13/16”)

2840 mm (111 13/16”)

2800 mm (110 1/4”)

FIG 4.2-1

xxii


4.3


LABELING MACHINE

Transportation Precautions

a.

Remove the top cover first, and then open the 4 side panels carefully. Keep the bottom wood base for later fork lift transportation.

b.

Check the machine and its accessories for shipping damage.

Note: For your own safety, please wear gloves to avoid splinters while opening the wooden case.

4.4

Transportation Procedures

a.

Transport the machine to the installation site with its wooden crate or wooden base safely using a 3 ton minimum fork lift.

b.

If the wooden base has already been removed, two people are required to hold each side of the machine to maintain balance while moving.

c.

Do not use a crane to transport the machine. No lifting attachments are provided on this machine.

d.

After the fixing wood bars and webbings are removed, place the machine accurately in its place with the fork lift as indicated in the figure.

Note: Keep the center of gravity aligned during movement, do not tilt the machine when moving. Fork lift should be operated by qualified personnel.

FIG 4.4-1 xxiii



LABELING MACHINE

Center line

Forklift

Timber

FIG 4.4-2

xxiv


4.5


LABELING MACHINE

Positioning and Adjustment of Machine Level and Height

a. Align the conveyor center line with the predetermined center line drawn on the floor. Ensure that machine outer boundaries fit in the previously drawn contour line. b. Make fine adjustment directly from the height adjustment nut of the supporting pads. The machine should rest evenly on its supporting pads without vibration or swiveling. The caster wheels are only used for moving the machine, and should keep a certain distance from touching the floor once machine is installed. Use a level over the machine flat surface to verify that the horizontal position is correct. c. Make sure that the conveyor surface level meets the previously marked lines on the wall or by considering the conveyor height of the rest of equipment, also check for horizontality. d. Alignment and level accuracy should keep within +/- 1mm. e. After machine is correctly positioned and leveled, proceed to attach the necessary parts and to connect piping according to the corresponding diagrams.

Clockwise

Counterclockwise

Nut

Height adj. swivel nut

Caster wheel

FIG 4.5-1

xxv

Base support pad



5.

INSTALLATION PROCEDURES

5.1

Power Connection

LABELING MACHINE

a. Connection of electricity supply to the machine is necessary for the operation of its electrical components. b. Connect the main power cord of the machine to the safety NFB breakers on the power source, ensuring that the voltage and amperage meet machine’s requirements. 5.2

U Type Spring Clip Mounting

Follow the illustrations given below to mount the U type spring clip before using 38mm labeling roll. It is designed to fasten the label roll when using 38mm label roll. a. Remove the PU wheel from label roll axle and replace it with the U type spring clip onto the axle. b. And then load the label roll.

Label roll Label roll Label roll

U type spring clip

PU wheel

FIG 5.2-1 Label roll axle

FIG 5.2-2 xxvi


5.3


LABELING MACHINE

C70 Type Arrangement of the Imprinting Head Plate

a. Whenever possible, it is suggested that the letter type are arranged in a centered and balanced way within the type holder area for better results. (Depend on the actual situation of the label imprinting.)

FIG 5.3-1

Note: This is not always possible for all imprinting position requirements. In all cases, after changing a new type holder or after installing new letter types, a fine adjustment is always necessary.

b. The first letter close to the border should be always non-printing letter type (space or black tension stopper), as it is not covered by the ink ribbon.

FIG 5.3-2

xxvii



LABELING MACHINE

6.

MACHINE GENERAL LAYOUT

6.1

Parts Identification

FIG 6.1-1 No. 1 2 3 4 5 6 7 8 9 10 11 12

Part Name Safety shield Pause pushbutton Wrap station Tension arm Touch-screen display Label roll axle Base frame Bar code scanner (optional) Main power switch Control panel Product separator wheel Conveyor

No. 13 14 15 16 17 18 19 20 21 22 23 24

xxviii

Part Name Rejection collector (optional) Rewind spool Power box Base support pads with casters Handwheel for wrap belt forward-back adjustment Hot stamp printer (optional) Conveyor motor Product sensor Handwheel label head height adjustment Label roll disk Rejection system (optional) Emergency stop pushbutton


6.2


LABELING MACHINE

Machine Parts Functions

A brief description of the main components functions of the machine are given in this section, please refer to “Machine Parts Identification” section for the identification of the parts on the machine. ˙ No.1:

"Safety shield ", used for protection purposes, and opened only for machine service or cleaning.

˙ No.2:

"Pause pushbutton", used to pause the machine operation.

˙ No.3:

"Wrap station", used to firmly affix label on the product.

˙ No.4:

"Tension arm" : keeps the label web straight with a proper tension.

˙ No.5:

"Touch screen", provides control and setting functions to operate the machine.

˙ No.6:

"Label roll axle", provided to fix the label roll center.

˙ No.7:

"Base frame" is to support the machine.

˙ No.8:

"Bar code scanner" , used to verify if the bar code is correct.

˙ No.9:

"Main power switch" ,provides power supply to the machine.

˙ No.10: "Control panel", provided for being equipped touch screen and control components. ˙ No.11: "Product separator wheel", responsible of providing a proper spacing between bottles . ˙ No.12: "Conveyor", used to deliver product from infeed to the label station and outfeed. ˙ No.13: "Product collector" is to collect the rejected products. ˙ No.14: "Rewind spool" is to collect the backing paper. ˙ No.15: "Power Box" , houses the electrical components and the wirings of the machine. ˙ No.16: "Base support pads with casters", provided for moving the machine and for leveling. ˙ No.17: "Handwheel for backing plate adjustment", provides to move the backing plate forwards or backwards. ˙ No.18: "Hot stamp printer" provides to print code/letter onto the label. ˙ No.19: "Conveyor motor", provides transmitting power to conveyor. ˙ No.20: "Product sensor", designed to detect product width and position. ˙ No.21: "Handwheel label head height adjustment" , designed to adjust the label head height. ˙ No.22: "Label roll disk", provides to load the label roll. ˙ No.23: "Rejection system", designed to reject improperly labeled products. ˙ No.24: "Emergency stop pushbutton", used to stop the machine operation immediately upon emergency situations.

xxix


6.3


LABELING MACHINE

Machine Control Parts Functions

Refer to section 6.1 for the location of the different control parts. 6.3.1

Main Switch

This main switch is used to connect or disconnect the machine from the power source, putting the switch in position “O” disconnects the power source, whereas putting it in “1” connects the machine to the power source.

6.3.2

Emergency Stop Pushbutton

The emergency stop pushbutton is used to immediately stop the machine upon emergency situations where the operator safety is endangered, or damages to the machine are likely to occur. The button can be released only after the problems causes are cleared. To release the button, turn it in counterclockwise direction, machine can re-start only if this button is released.

6.3.3

Touch-Screen

Provides control and setting functions to operate the machine. Refer to the “Touch Screen Control Functions” Chapter for a detailed explanation for its operation.

xxx


6.4


LABELING MACHINE

Pneumatic Control System

Pneumatic control system is provided to control the machines various mechanisms.

6.4.1

Air Regulating Set

Responsible of regulating the compressed air connected to the machine into desired pressure. The air flowing is controlled by the air adjustment knob; different air regulating set are provided according to the customers specific requirements.

Air Adj. Knob

Air Gauge

xxxi


6.5


LABELING MACHINE

General Layout

FIG 6.5-1

6.6

Labeling Head Parts Identification Bar code scanner (optional) Label dispensing roller Hot stamp printer (optional)

Tension (dancer) arm

Label advanced roller lock Label sensor Missing code sensor (optional)

Rewind spool tension adj. knob Rewind spool tension indicator

Rewind roller lock Rewind spool

FIG 6.6-1

xxxii

Label peel blade


7.


LABELING MACHINE

POWER BOX

Refer to the Chapter related to “Electrical Diagrams” for more detailed information regarding the functions of the electrical components. Disconnect switch

Filter

Inverter

Servo driver

Power supply

NFB Buzzer

xxxiii



LABELING MACHINE

Power Box Layout for Optical Character Verification (OCV) OCV, Optical character verification

Light supply for OCV TEACH button for OCV

Power supply for OCV

xxxiv



LABELING MACHINE

8.

TOUCH SCREEN DISPLAY INSTRUCTION

8.1

Touch Screen Description Touch screen

Machine model Software version

8.2

Touch Screen Function Description

8.2.1

The first screen after powering on

A - Self Set A NEW JOB B - CHOOSE A JOB FROM MEMORY C - CONTINUE THE PREVIOUS JOB

Screen 1

8.2.1.1

A - Self Set A NEW JOB

First time automatically set up for a new product to be labeled. 8.2.1.2

B - CHOOSE A JOB FROM MEMORY

Recall the previously saved job memory number from the memory bank. 8.2.1.3

C - CONTINUE THE PREVIOUS JOB

Continue with the most recent labeling job, which is the job performed before last power off.

xxxv


8.2.2


LABELING MACHINE

Screen Layout

The screen is organized and divided into functional areas as follows:

FIG 8.2.-1

Area

Description

Job memory #

Displays the job memory set # currently being used.

HD

Displays labeling head "OFF" and "ON".

SP

Displays product separator "OFF" and "ON".

MESSAGE

Displays operational messages during operation.

CURRENT CHOOSE OF MENU

Displays current operational functions, labeling data and parameter setup.

SUB MENU

Various Sub-menu function keys will show up via different selection.

KEY FOR BASIC FUNC.

Basic control buttons, including "START", "PAUSE", "REJCT RESET" and "CLEAR MESSAGE" buttons.

8.2.3

Normal Operation Display

Three modes are available for selection (screen 1). A – Self Set A NEW JOB: The display will change to the display shown on FIG 10.10-2. B - CHOOSE A JOB FROM MEMORY: To recall previous job setups from memory, the display will change to chapter 8.2.4.10, screen 12). C - CONTINUE THE PREVIOUS JOB when re-starting the machine after power-off, this option is used to continue with the previous last job, which, regardless of being assigned with a job memory number or not, is kept by the machine as the current job. The display will change to screen 2. If no key were touched or no changes were made after accessing labeling data display, the control panel display will automatically return to the display shown as screen 2. This screen only allows starting or stopping machine operation, labeling data is displayed but no editing allowed from this screen. This design is to avoid changing labeling data or parameters by operator's mistake. xxxvi



LABELING MACHINE

0 500

Screen 2

8.2.3.1

0

：Indicates Current Job Memory (No.1~50)

After touching A - Self Set A NEW JOB for automatic test, the operational display will show memory job: "00", indicates the job is kept by the machine but no specific job memory number has been assigned to it. Although not saved with a job memory #, this data is kept even if operator switches off the main power, it can be easily recalled by touching C - CONTINUE THE PREVIOUS JOB, instead of using " Self Set A NEW JOB". However, it is recommended to always store labeling data in memory number set. Refer to chapter 8.2.5.9 SAVE memory. HEAD ON

8.2.3.2

：Indicates the Labeling Head "ON" HEAD

HEAD

OFF , this can be ON Touch key once to switch off the labeling head and the key will change to useful when doing machine adjustment or bottle conveying test in which labeling is not required. Switch the HEAD HEAD labeling head "ON" again by touching the .ON OFFkey, and it will turn to be

8.2.3.3

SEPAR ON

： Indicates the Product Separator "ON"

To switch off the product separator by touching the

SEPAR ON

key once time when do machine adjustment or

SEPAR OFF bottle transporting test, and the key display will change to . To switch on the product separator wheels SEPAR SEPAR "ON" again by touching keyOFFagain, the key display will change back to again. ON

8.2.3.4

RUN

: Shows Various Operations and Error Messages

Including run, missing label on roll and bar code error... etc. The RUN icon indicates the machine is in run condition. Message other than this means a problem is present; refer to 16.5.2.5 “Notes 6” for more details. 8.2.3.5

：Entering Edit Data Display

Keep the key touched for several seconds to enter into data edition function (screen 5).

xxxvii


8.2.3.6

START


LABELING MACHINE

: Starts Machine and indicates Machine Running

After touching PAUSE , the machine will stop, and the key will change to start the machine and the key changes to START . 8.2.3.7

PAUSE

REJECT RESET

this key again to

: Stops Machine and Indicates Machine Stop

Press START to start the machine, the key will change to to PAUSE . 8.2.3.8

START . Touch

PAUSE . And

press this key again to change

: Quantity balance monitoring between Infeed and Outfeed.

a. This function key is to ensure both bottle infeed and outfeed remain the same quantities; and one more function is to avoid wrong bottle rejection. When both quantities of bottle infeed and outfeed are not the same, the function key will change to REJECT RESET status to alert the operator. Stop the separator by press the ON key toSEPAR clear bottles on the conveyor between product sensor and rejection sensor, the key will change SEPAR to , once OFF the bottles are removed from the conveyor between the two sensors, press REJECT REJECT SEPAR RESETthe key will change back to RESET may press OFF display again, then . Then operator key again, the SEPAR changes back to status to start ON the product separator function again.

b. Product Sensor and Rejection sensor are very important to the machine. Therefore, it is essential to make sure that both product and rejection sensors are in flashing status. If not, adjust the sensor’s sensitivity strength. If sensitivity is too strong, more than one signal is likely to be read when a transparent product passes through the sensors. Thus, these signals will dramatically affect the REJECT RESET system so that causes wrong rejection. Please note this information. 8.2.3.9

XX CONTAINERS/MIN : Labeling Speed Information

Indicates the output of labeled products per minute, this is a displayed information based on calculations, modification is not allowed. The value is updated every 20 seconds. 8.2.3.10

CLEAR MESSAG

: Erasing Error Message.

When any error message is shown on the running status, e.g. missing code-date imprint, incorrect bar code error, wrong bottle error ...etc, this key will show the error message accordingly. After solving the problem, CLEAR

press the MESSAG key to clear the error message. Once the key is pressed, the error message will change back to RUN status. 8.2.3.11 Other Display Areas Display all running messages.

xxxviii


8.2.4


LABELING MACHINE

Entering Data Edition Display

In the normal operation display, press

key on screen 2 for several seconds to enter data edition

display (Screen 3). 0

Screen 3

8.2.4.1

0

,

SEPAR ON

and

HEAD ON

.

These three keys are the same as 8.2.3 Normal Operation Display. 8.2.4.2

RUN

Use this key to return to the Normal Operation Display (Screen 2). 8.2.4.3

PAUSE : Indicates the Machine in operational mode

Press this key once to stop the system, the PAUSE key will turn to START status. Press this key one more time to start machine. 8.2.4.4

PgDn

: Entering Next Function Setting of the Labeling Item

Including labeling quantity, label remaining quantity, labeling speed... etc. totalizing 22 items. The item selected is shown in reversed color (screen 3). 8.2.5

Labeling Data Setup

Use PgDn key to enter next labeling item screen (the second and the third function setting display, e.g. screen 16 & 40); and use PgUp key e.g. screen 16, 40 to return to the first and the second function setting display. Simply touch the labeling item selected to do the labeling function setting. 8.2.5.1

OUTPUT/JOB :Setting Labeled quantity.

Screen 3 will be shown when selecting this key. Its function is to reset "OUTPUT" after auto-test is completed, or changing the "NEW JOB". a.

Touch and hold the CLEAR key for several seconds to clear labeling quantity.

xxxix


b.


LABELING MACHINE

NEW JOB : Performs product setting again. Output quantity will not be deleted after finishing Self-Set during operation. The system only performs counting job for labeled bottles after machine is in operating mode, both bottles and labels for testing purpose will not be counted.

8.2.5.2

LAB REM : Label Remaining Quantity

Screen 4 will be shown when selecting this key. Its function is to set up the remaining label quantities or product batch quantity. The procedure below is to set the label remaining quantity. a. Touch the numbers following the OUTPUT/JOB to enter screen 5, and use numeric keys 0 ~ 9 to enter the label quantity that you want to dispense from the roll of labels. (The label remaining quantity will be automatically saved in the memory even after power-off). Every label dispensed will reduce the remaining label quantity by one; an alarm will sound when label remaining quantity falls below "500", "300" and "100". The alarm sounds for every 20 dispensed labels when label remaining quantity falls below "100". The machine stops and alarms when label remaining quantity falls to "0000000". b. If no quantity control is needed, Enter 0 and ENT keys to confirm. c. Touch ESC key to exit without changes, the display will go back to screen 4.

0

0

Screen 5

Screen 4

8.2.5.3 PRO. SPD.: Labeling Speed Screen 6 will be shown when selecting this key. Its function is to set up the labeling speed in containers/minute. After Self-Set, the standard labeler speed is set at 35.0 meters per minute and the maximum speed is 70.0 meters per minute. The conveyor speed display shown is based on label size, bottle size and labeling speed setup. The average speed is displayed after 1 minute running. Adjust both "PRO SPD" and "SEPARATE SPD" functions to meet output demand (Refer to 8.2.5.4 for product separator speed adjustment). Simply touch

or

key to crease /decrease labeling speed.

xl



LABELING MACHINE

0

500

Screen 6

8.2.5.4

SEPARAT SPD. : Product Separator Speed

Screen 7 will be shown when selecting this key. Touch this key to change product separator speed. Its speed is normally set at MANUAL mode. Standard speed is set at 30.00 for auto-mode. After Self-set, the operator is able to set "AUTO" mode "ON" or "OFF" (reverse or normal color) for automatic or manual adjustments of product separator. The maximum setting is at 90.0. The value "30.0" indicates the rotating frequency of driver motor. No matter using MANU or AUTO mode, if the bottle is unable to be labeled due to the spaces between bottles are too close, it should reduce the speed to be labeled properly. Under AUTO mode, if the bottle spaces are too big and slow down the productivity, it will increase the speed automatically to the maximum of labeling. a. Touch MANUAL key and the key will change to MANUAL . And then touch or separator speed. (Labeling speed should be considered when making changes.)

key to change the

Screen 7

8.2.5.5

LAB. POS.

Screen 8 will be shown when selecting this key. This key is used for making the bottle center align with the front end of the label peel blade (FIG 8.2.5.5-1). Normally there is no need to do any adjustment (default value, 0). However, if bottle is unable to be labeled with the automatic setup, try to adjust the labeling position manually as follows:

xli



LABELING MACHINE

a. Touch or key to change labeling position right or left. key moves the label position to the right side.

key moves label position to the left ; and Wrap station

Label peel blade

Front edge of label peel blade

Screen 8

Product sensor

Wrap plate

Bottle FIG 8.2.5.5-1

8.2.5.6

PRINT TIME

Screen 9 will be shown when selecting this key. Its function is used in conjunction with the optional hot stamp printer. Normally, after running Self-Set, the printer is ON and the standard print time is 100ms. The MANUAL adjustment mode is as follows: a. Touch OFF key, the key will change to OFF status, it means that the printer can be shut off. b. Touch

or

key to change the printing time.

c. The "Print Time" display ranges from 30ms to 1000ms. Both the settings of Print Time and Print Temperature must be synchronized. When Print Time is set longer, the Print temperature should be lower, and when shorter Print Time is set, the Print Temperature should be higher. d. It is suggested that you use the standard self-set value when labeling output is lower than or equal to 200 bottles per minute. When labeling speed output value is over 150, it is able to increase temperature and decrease stamping time. Sometimes, increase a little bit of air pressure if necessary. e. When stamping detection is set up to ON, then the stamping time will be limited to more than 100 ms. Note: The stamping temperature is necessary to be set up according to chapter 8.2.5.15.

Screen 9 xlii


8.2.5.7


LABELING MACHINE

LAB. EXTENS : Label Extension Adjustment

Screen 10 will be shown when selecting this key. Its function is to set up the length of the label extension. Generally, it is not necessary to be adjusted (default value is 0), unless the default label extension value is not properly for labeling. The adjustment procedure is described as below: a. Touch

or

key to change the length of label extension. When

or

is touched, the extension

value will increase or decrease by 0.15mm. After Self-Set check, the label extension should be 1 to 5mm. In special cases the distance may be longer than 5mm. The adjustable range is limited by the label sensor, so the label should be moved up. Label extension distance approx. 1-5 mm Wrap station Label peel blade

Screen 10

Label FIG. 8.2.5.7-1

8.2.5.8

LAB. HD-SPD : Label Dispense Speed Adjustment

Screen 11 will be shown when selecting this key. Its function is to set up the labeling speed. Generally, its default setting is 0 (M/Min) after Self-set. The manual adjustment procedure is described as below: a. Simply use

or

key to change the labeling speed. The adjustable range can be from - 9.9 m/min up to

+9.9 m/min. (The speed adjustment depends on the bottles characteristics; and ensure the changes is saved to the memory).

Screen 11 xliii


8.2.5.9


LABELING MACHINE

SAVE MEM : Save Memory

Screen 12 will be shown when selecting this key. Make sure saving the job in the memory after "auto adjustment" or "manual adjustment" is done. a. Touch SAVE TO MEMORY key, and the following display will be shown (screen 13). b. Select a proper number from the empty memory sets, previously saved numbers are in reverse color icons, empty numbers are in normal color icon, and the new icon selected will flash. c. Touch SAVE key, the number selected will stop flashing, the icon will become in reverse color; and return to operational display (screen12). The saved job number will be shown on the top left side for identification (only shows the latest number). d. To clear a saved job memory, select the job memory number to be deleted, the number will start flashing, then touch CLEAR key for several seconds to clear the memory set. e. Touch CANCEL key to go back to the operational display. 1

Screen 13

Screen 12

8.2.5.10

CALL MEM

: Call Memory

Screen 14 will be shown as selecting this key. Its function is to recall the data set up by AUTO or MANUAL and the recall procedures is as follows: a. Touch CALL MEMORY key and the screen 15 is shown. The machine stops. b. Touch an available number (when the icon is in reverse color, it indicates a job is saved in that location.) c. Select the saved job number by touching the CALL key and the display will return to the operational display (screen 14). The job number called will be shown on the top left side for identification. d. Touch the job number key which to be deleted and touch CLEAR key for several seconds to delete the number selected. e. Touch CANCEL key to go back to the operational display. xliv



LABELING MACHINE

1

Screen 14

Screen 15

8.2.5.11

Label Length

Screen 16 will be shown as selecting this key. Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Its information displayed is only for viewing and unable to change. Label Length is measured by the Self-Set computer system in mm.

Screen 16

8.2.5.12

Container : Bottle Diameter

Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 17 will be shown as selecting this key. Its information displayed is only for viewing and is unable to change. Bottle Diameter is measured by the Self-Set computer system in mm.

Screen 17 xlv



8.2.5.13

LABELING MACHINE

BACK PAPER : Backing Paper Sensitivity

Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 18 will be shown when selecting this key. Its information displayed is only for viewing and is unable to change. Label Length is measured by the Self-Set computer system.

Screen 18

8.2.5.14

PAPER VALUE：：Paper Value Measurement

Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 19 will be shown when selecting this key. The paper value function is to set up a parameter for the sensitivity of the backing paper. Usually, the Self-Set computer system will calculate the correct values for "PAPER VALUE". There is no need to change this value. Only in the case the Self-Set computer system is unable to check the value, then it may be adjusted manually, adjustment procedure is described as follows: Touch or +60 to +255.

key to change the setting value of the "PAPER VALUE". Its Adjustable value range is from

Note: The paper value settings are only applicable for CVC sensors; other brand sensors are not valid.

Screen 19

xlvi



LABELING MACHINE

8.2.5.15 TEMPERATURE : Print Temperature Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 20 will be shown when selecting this key. The function of print temperature is to set for clear printing results; which is only applicable when optional hot stamp printer is present. The standard print temperature is set at 160˚C. Normally, higher temperature is set for higher labeling speed. "Print Temperature" needs to be adjusted when increasing production speed or when the numbers are not easy to be stamped. Its adjustment procedure is described as follows. a. Touch

or

key to change the Print Temperature settings. Its adjustable values range from +80 ℃

to +200 ℃. If printing result is too dark or distorted making it difficult for reading, then the operator needs to reduce the print temperature by touching

. Touch

to darken print when increasing labeling speeds.

b. When touching ON key, it will change to ON , and the printer will automatically heat up to the temperature preset. c. When touching OFF key, it will change to OFF , and the heating of the printer is shut off directly and will not heat up again. Note: * Print Time and temperature are synchronized to a pre-set value (refer to 8.2.5.6). The longer the printing time is, the lower the printing temperature is, and vice versa. * It is suggested that the printing temperature and time to be longer if the labels with PVC lining, or made of PVC or plastic materials.

Screen 20

8.2.5.16 BAR CODE : Bar Code Check (optional) Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 21 will be shown when selecting this key.

xlvii



LABELING MACHINE

The function of the BAR CODE SCANNER is to check if wrong bar code is found on the label. (But, if the machine is not equipped with the bar code scanner, the function will not be available.) Its adjustment procedure is described as follows. a. When touching OFF key, it will change to OFF , and there is no Bar Code Check function. b. When touching ON key, it will change to ON , and the scanner starts the Bar Code check operation. c. Touch or key to input the number of labels between label peel blade and bar code scanner (FIG 8.2.5.16-1). The number needs to be entered correctly; otherwise a wrong bottle rejection will occur. Touch key to decrease the label quantity, or touch key to increase the label quantity. General bar codes

Screen 22

Screen 21

Pharma code

Label peel blade Rewind spool Wrap station

OCV camera with filter Label sensor Bar code scanner FIG 8.2.5.16-1

d. When touching the SETTING key, the display is changed to the screen 22. The scanner can scan both "General bar codes" and "pharma codes". Its setup procedure is described as follows:

xlviii



LABELING MACHINE

* When touching key to enter the "Bar Code Type" display (screen 23). Place the bar code scanner at the proper position (Refer to 11.14). Then touch TESTING button, the bar code scanner will release a red beam and scan the bar code printed on the label. Suggested scanning distance range is from 80mm to 100mm. Touch TEACHING key for several seconds to execute bar code teaching guide. A buzzer should sound while executing the bar code teaching guide. The bar code scanner will sound "Bee-Bee" sound, and the display will show the scanned bar code. The bar code area will remain empty if the bar code scanner failed to scan the bar code. In this case, follow the setup procedure to scan the bar code again. And repeat to scan the bar code again until the correct bar code is displayed, if the bar code shown on the display is different from the actual bar code. Touch RETURN key to go back to the operational display of "BAR CODE" (screen 23).

Bar code area

0

4713265880216

Screen 23

Screen 24

* When touching PHAMA CODE key on the screen 22, the display will change to screen 24. And then Touch 0 key on the screen 24, it will change to screen 25. Enter the number according to the bar code line number by numeric from 0 to 9 , then touch ENT key to conform pharma code setup. After setup, the display will show screen 26; and it is able to touch ESC key to recover the previous setting display (screen 22). Please follow general bar code setup procedures to continue the pharma code setup when entering the screen 22. However, the scanning distance should be within 40~50mm. Touch TESTING key to make sure teaching operation is available after completing TEACHING work. Thus, the bar code should show up if correct TEACHING job is done. Otherwise, the bar code will not show up and send Bee-Bee sound from buzzer.

0

0

1101000111010110

016

Screen 26

Screen 25

xlix


8.2.5.16.1


LABELING MACHINE

SCAN T. XXX ms

Its function is in only valid when optional Image system (camera) is equipped. The value setup is to be done in accordance with manufacturer. Different Image system has different value. As the value is preset by factory, it is not necessary to do any adjustment unless replacing a new one. The adjustment procedure is shown as follows.

Screen 27

a. Touch SCAN T. XXX ms key, the following screen will be displayed (screen 27). Entering the production value offered by factory via touching number ( 0 ~ 9 ); and then touch ENT key to conform the setup. b. Touch ESC key to go back to screen 21 without saving any changes.

8.2.5.17

DATE CHECK : Code-date stamp Check

Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 28 will be shown when selecting this key. Its function is in only valid when OCV (Optical Character Verification) system is equipped. Different Image system has different value. The adjustment procedure is shown as follows. a. When touching OFF key, it will change to OFF ,and there is no Code-date stamping Check function. b. When touching ON key, it will change to ON , Code-date stamping check function is enabled. c. Touch or key to input the label the numbers between label peel blade and bar code scanner (FIG 8.2.5.16-1). The number needs to be entered correctly; otherwise a wrong bottle rejection will occur. Touch key to decrease the label quantity, or touch key to increase the label quantity.

l



LABELING MACHINE

Screen 28

8.2.5.18

Screen 29

CONTAINER CHK : Bottle Diameter Check

Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 30 will be shown when selecting this key. Its function is to check and make sure the container diameter or width is within the standard specification. If the bottle diameter is too wide, the computer will judge that it is a fallen bottle, the system will stop automatically to protect the machine for safe operation. The labeling system will not label a bottle which has a measured diameter smaller than the labeling data saved in the memory. The bottle will be ejected from the conveyor if optional rejection system is installed on the system. a. Touch or key to set a percentage of the bottle diameter. Its adjustable range is 0 ~ 100% (Default value is 5%). Set a lower percentage by touching key to have more precise bottle diameter check. If bottle range is wider, then set a higher percentage by touching key for the computer check. Refer to FIG 8.2.5.18-1 for verification. Bottle diameter = Ø D (for example: bottle dia. is 50 mm) Percentage: K (for example: 50%) Max.: bottle dia = Ø D * (1+K) 50 * (1+0.5) = 75 (mm) Min. bottle dia. = Ø D * (1 - K) 0 * (1 - 0.5) = 25 (mm)

8.2.5.18-1

Screen 30

8.2.5.19

FUNCTION : Machine Function Check

Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 31 will be shown when selecting this key. Its function is to check if all components are in normal operation. The checking points are shown below.

li



LABELING MACHINE

Screen 32

Screen 31

8.2.5.19.1 SENSOR CHECK After touching INPUT CHECK key, the following screen (screen 32) will be displayed for checking all the sensor function. After finishing sensor checks, touch RETURN key to return to screen 31. a. PRODUCT Sensor: It is necessary to start the conveyor before performing this check function. If the conveyor is not running, touch RUN key to operate the conveyor. Then, place a piece of opaque plate to the block product sensor light (refer the FIG 8.2.5.19-1) and check if the monitor shows the test message. If the icon changes into , means that roduct sensor is in normal operation. Bottle backlog sensor Wrap station

Hand

Label peel blade Opaque plate

Hand Opaque plate Product sensor FIG 8.2.5.19-1

b. REJECT (Bottle Rejection) Sensor: Test Method is the same as the product sensor. c. ENCODER 1: Auto check. If the icon in normal operation.

changes into

and alternative flash, means that the encoder 1 is

d. BACK LOG Sensor: Place a piece of an opaque plate to the block product sensor light (refer the FIG 8.2.5.19-1), and observe if the monitor shows the test message. When the icon changes into , and after removing the plate, it changes into

, it means that the backlog sensor is in normal operation.

e. INFEED Sensor: Reserved function for further application.

lii



LABELING MACHINE

f. LABEL Sensor: Select LABEL and touch GO key, the icon is in normal operation.

changes into

, means the label sensor

g. RIBBON Sensor: Firstly, check if ribbon/foil tape is installed. If so, it should show

. Remove the ribbon out

to have the sensor been unable to detect the ribbon (FIG 8.2.5.19-2). Then, the icon will turn from into . It means that the sensor is in good status. If no ribbon, it will show . Place an opaque plate to block the sensor, and then the icon should change from to , means that the sensor is in normal status. Ribbon installed Hand

Non-ribbon installed Ribbon sensor

Hand

Ribbon sensor

Ribbon Hot stamp printer

Hot stamp printer

Ribbon rewind spool

Ribbon rewind spool

Hot stamp printer FIG 8.2.5.19-2

h. CONVEYOR Operation: Touch

RUN

key on the display and the conveyor will start; and the key RUN

should change to PAUSE . Touch PAUSE key again, it will back to

RUN

status, and the conveyor will stop

too. i. AUTO CHECKING LABEL SENSOR: To match with “Label Sensor” operation check, after touching the key GO , it will change into STOP status. And it will change back to GO status when released. 8.2.5.19.2 OUTPUT CHECK After touching OUTPUT CHECK key, the following screen (screen 33) will be displayed for checking all the output function. After finishing output checks, touch RETURN key to return to screen 31. Ensuring the following components activate after touching OFF key: a. REJECT: should activate the rejection cylinder operation of the rejection system (make sure air is on). b. PRINT: should activate the hot stamp printer operation (make sure air is on).

liii



LABELING MACHINE

Screen 34

Screen 33

8.2.5.19.3 MOTOR SYSTEM TESTING After touching MOTOR CHECK key, the following screen (screen 34) will be displayed for checking all the motor function. After finishing motor checks, touch RETURN key to return to screen 31. a. CONVEYOR M. (Conveyor Motor): The conveyor will stop and run again when "OFF" key is touched. If OFF key is not released, the conveyor will be running constantly, and it will stop after releasing the key. If not, indicates the testing components or electric circuit is malfunction. b. SERVO M. (Label Dispenser Axle Test): Both "Label Roll Disc" and "Unwind spool" will run when "OFF" key is touched. It will send out label if label roll is on the label roll disc, and it will stop after releasing the key. If not, indicates the testing components or electric circuit is malfunction. c. SEPARATOR M. (Product Separator Test): "Product Separator Wheel will stop then run. If OFF key is not released, the separator will be running constantly, and it will stop after releasing the key. If not, indicates the testing components are malfunction.

8.2.5.20 TECH SETTING : Technical Adjustment & Setting Touch PgDn key on the first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display. Screen 35 will be shown when selecting this key. Its function is to do the necessary technical adjustment and setting according to actual demand. (The factory has done initial setup before the system is equipped.) 8.2.5.20.1 Product Weight Balance When PROD. WT. COMP. (50) key is selected, the display will change to screen 36. Its function is used for "bottle weight balance" value setup. The heavier the bottle is, the higher the value is. The adjustment is shown as below:

liv



LABELING MACHINE

a. Touch the number key following the PROD. WT. COMP. (50) , the screen 36 will be shown. Key in the bottle quality value by touching numeric key from 0 to 9 . Then touch ENT key to confirm the adjustment. b. Touch ESC key to return to screen 35.

Screen 36

Screen 35

8.2.5.20.2 Hot Stamp Speed Up When

HOT STAMP SPD UP (0)

key is selected, the display will change to screen 36.

Its function is to increase the value of "Print ACC" of the Hot Stamp Printer's print speed. The higher the value is, the quicker the printing time is (The maximum value is 50 ms.). The adjustment is just same as "PROD. WT. COMP. (50)" adjustment. a. Touch the number key following the HOT STAMP SPD UP (0) , the screen 36 will be shown. Key in the speed value by touching numeric key ( 0 ~ 9 ), according to manufacture's supplied data. Then touch ENT key to confirm the adjustment. b. Touch ESC key to return to screen 35. 8.2.5.20.3 Equipment Set When touching Equipment Set key, the display will change to screen 37. Its function is to set up equipment and check if all the components are in normal operation. a. Air knife Timer (120): The setup is related to the "air blow rejection system". If the air blow rejection system is not used, then the setting will be invalid. Air blow timing setup depends on "compressed air input" and "bottle diameter" (Adjustable range is from 30 through 500, the default setting is 120ms). After touching the numeric key portion, the numeric key board will be shown on the display (screen 38). Use numeric keys 0 - 9 to do the setting, and use ENT key to confirm the setting; it will return to the previous display (screen 37). Touch ESC key to enter screen 37 without changes.

lv



LABELING MACHINE

Numeric portion

Screen 37

Screen 38

b. Number of beeps (6) (Times of buzzer sounds): Buzzer sound alerts if any emergency (adjustable setting range is from 2 - 6 times). After touching the numeric portion, the numeric key board will show on the display (screen 38). After entering the value, touch ENT key to confirm. The display will return to the previous display, or touch ESC key to enter screen 37 without changes. c. Label Offset (2): This function is to compensate the tolerance of label length. Therefore, if the change of label length is too large, the label dispensing length can be compensated by this function. After touching the numeric portion, the numeric key board will show on the display (screen 38). Use the numeric keys ( 0 - 2 ) to set the value, and touch ENT key to confirm the setup procedure. The display will return to screen 21, or touch ESC key to return screen 37 without changes. d. LAB. Sensor Value (50) (sensor sensitivity setup): Label sensor sensitivity is factory adjusted and no further adjustment is need unless it is damaged or replaced with a new one. After touching the numeric portion, the numeric key board will show on the display (screen 38), use the numeric keys ( 0 - 9 ) to set the value, and touch ENT key to confirm the setup procedure, or touch ESC key to return screen 37 without changes. e. P. Sensor Width (15): Product sensor width is factory adjusted and no further adjustment is necessary unless it is damaged or replaced with a new one. Touch the numeric key, the numeric key board will show on the display (screen 38). Use the numeric keys ( 0 - 9 ) to set the value, and touch ENT key to confirm the setup procedure, or touch ESC key to return screen 37 without changes. f. L. Sensor Width (0.5): This setup is based on the label width. The computer system will setup the label sensing width automatically. It is not necessary to do the setup in a normal working condition. (Adjustable range: 0 ~0.5). After touching the numeric portion, the numeric key board will show on the display (screen 38). Use the numeric keys ( 0 - 9 ) to set the value, and touch ENT key to confirm the setup procedure, or touch ESC key to return to screen 37 without changes. * Use Next key to switch to next setting display (screen 39), and touch Return key to return to TECH SETTING display (screen 35).

lvi



LABELING MACHINE

Screen 40

Screen 39

g. Hot stamp (optional): When coding system is selected, it will be "Auto" after Self-Set is completed. h. Rejection system (optional): When turning off the rejection system for error situations, the error message will be shown and the system will stop dispensing labels. The default setting for rejection system is "Auto". i. Machine stop miss. label: When this function is set to "ON", the labeling machine will automatically stop if any missed labeling. (It is recommended to select the "ON" when the system is not equipped a rejection system. Setting it to "OFF" when the rejection system is equipped). Use this function to reject the missing label bottle. j. Separator auto ON: This function is able to be set to "ON" or "OFF" according to user's requirement. k. Machine stop any error: When this function is setup, the machine will stop if any error occurs. (e.g. missing labeling, wrong bar code…etc.) l. Activate QC protect (Optional): This function is only valid after setting up Rejection system and Hot stamp "ON"; and Machine stop any error and Machine stop miss. Label "OFF". m. Vision system (Optional): This function is only valid after being equipped OCV (Optical Character Verification) system. * Use Previous key to return to previous setting display (screen 37), or touch Return key to return to TECH SETTING display (screen 35). 8.2.5.21 LANGUAGE Setup Touch PgDn key on the any first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display; and then touch PgDn key again on the second function setting display (e.g. screen 16) to enter the third function setting display. Screen 41 will be shown when selecting this key. Select "LANGUAGE" for language setup. (Default setting is English mode). The language selected will be saved to the computer automatically. It is quite easy to do the language mode setting by touching the language lvii



LABELING MACHINE

selected for several seconds.

Screen 41

a. Select

key to change the display into English.

b. Select

key to change the display into Chinese.

c. Select

key to change the display into Spanish.

8.2.5.22 SPEC. SET Touch PgDn key on the any first function setting display (e.g. screen 3~11,12,14) to enter the second function setting display; and then touch PgDn key again on the second function setting display (e.g. screen 16) to enter the third function setting display. Screen 42 will be shown when selecting this key. Select this item to do the special function setting and view the running hours. Its settings are described as below. a.

CLEAR ALL MEMORY

: To erase all the labeling data saved in the memory (#1~50) sets, touch the key for 6 seconds, all the memories are erased when a buzzer sound is heard. To check and ensure the erased memories are erased. Follow "call memory" procedures (8.2.5.10) to call out the memory job. If the memory number set with no reverse color is present, indicates all the memory sets have already been cleared.

0

0

Screen 43

Screen 42

lviii



LABELING MACHINE

b. REJECT LIMIT: Maximum continuous rejections permitted before machine stop. The machine will automatically stop when continuous error quantity reaches this limit. Such a condition means a serious problem is present. Touch 0 key on the screen 42 to display the numeric key board (screen 43), and use the keys to enter the maximum allowed limit. Touch ENT key to confirm it, and the display will change back to screen 42 when the setup is done. Touch ESC key to go back the previous display without changes. c. Working Time/Min : Indicates the total running hours of the machine. This value is unable to be changed or reset.

lix

PA USE



8.3

Warning Message Instruction

8.3.1

Safety Guard Open

LABELING MACHINE

This display (screen 44) is only shown after switching the power on. When the display is shown, means the safety shield is open, and the machine will stop until the door is closed.

Screen 44

8.3.2

Air Pressure Error

This display (screen 45) is only shown after switching the power on. When the display is shown, means air pressure supply is malfunction; and the machine will stop. To ensure all air hoses are fastened and no defective, and the air switch is turned on. The machine can be started again after the problem has been solved.

Screen 45

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LABELING MACHINE

9. PREPARATION BEFORE OPERATION 9.1

Inspection before Operation Ensure that no foreign objects or tools are left in the machine. Ensure that air and power supply are normal. Check that there are no loose or damaged parts in the machine. If any of the stated abnormality is observed, turn off the machine and carry out a service of the machine to fix the problem before restarting the machine. Keep the safety guard closed during operation for safety reasons.

9.2

Label Installation

Installation is according to the following steps. 9.2.1

Label Installation Types

There are 2 different types of label rolls: Rolled outside and rolled inside. 9.2.1.1 Rolled Outside (FIG 9.2.1-1)

OVC camera

FIG.9.2.1-1 lxi



LABELING MACHINE

9.2.1.2 Rolled Inside (FIG. 9.2.1-2)

OVC camera

FIG.9.2.1-2

9.2.2

Rewind Spool Fixing & Adjustment

Use "U" clipper to fasten label web backing paper onto the rewind spool. Next, turn the rewind spool in clockwise direction to tighten the backing paper (FIG 9.2.2-1).

OVC camera

FIG.9.2.2-1

lxii


9.2.3


LABELING MACHINE

Close Advance Roller Locks

Properly fasten advance roller lock. Label dispense length may vary if these two locks are improperly fasten. (Refer to the arrow direction to fasten the lock, FIG 9.2.3-1)

U clipper Advance roller lock OVC camera

FIG.9.2.3-1

9.2.4

Tighten the Backing Paper Lock

Refer to the arrow direction to tighten the backing paper lock.（FIG 9.2.4-1)

U clipper Advance roller lock OVC camera

Backing paper lock

Backing paper web is straight with tension

FIG.9.2.4-1

lxiii



LABELING MACHINE

lxiv


9.2.5


LABELING MACHINE

Backing Paper Tension Adjustment

Correct a loose rewinding web condition by tightening the rewind spool tension adjustment knob. (FIG 9.2.5-1) Rewind spool tension adj. knob

OVC camera

Rewind spool tension indicator

Bend backing paper FIG.9.2.5-1

9.2.6

Label Web Adjustment

Label web should be always straight with tension to secure quality labeling. Label dispensing may vary or cause the labels to wrinkle if the web is too tight or too loose. (FIG 9.2.6-1 and FIG 9.2.6-2) Label web is straight with tension

Label web is not straight without tension

FIG.9.2.6-1 Label web should be straight on the label peel blade

Loose label web

Label peel blade FIG.9.2.6-2

lxv



LABELING MACHINE

10. OPERATION INSTRUCTION 10.1

Power Supply and Air Sources Check

Ensure that compressed air and electric supply are properly connected. 10.2

Air Regulator Set Check

Turn on the switch on the air regulator, and check that the air pressure displayed on the air gauge is at 4 bar. If necessary, adjust the air pressure adjustment knob by pulling it up and rotate it to around 4kg /cm2. If no compressed air is available, check if the air compressor and ensure that the valve is open, if no abnormalities were found, the air regulating set may require repairing or replacement.

FIG.10.2-1

10.3

Machine Adjustment

It is necessary to adjust the machine working components to a proper position according to the product to be labeled and the label to be applied. (Refer to Chapter 11 Machine Adjustments.)

lxvi


10.4


LABELING MACHINE

Main Power Switch ON

Turn the main power switch to "I" position (FIG 10.4-1), the screen will switch from WINDOWS into CVC logo display (FIG 10.4-1), and then will show JOB selections display (FIG 10.4-2) after 10 seconds. If no display is shown as below after switching on the power, check and ensure that power cable is connected properly, otherwise the power switch may have some malfunction.

FIG.10.4-2

FIG.10.4-1

10.5

Job Selections

This system provides 3 available selection buttons on the touch screen. Choose one of the buttons to perform the labeling job. (Refer to the page 8.2.1 for function selections.) 10.6

Job Menu

When choose

A - SELF SET A NEW JOB , refer to the chapter from 10.9.

When choose When choose

B - CHOOSE A JOB FROM MEMORY , refer to the chapter 10.12. C - CONTINUS THE PREVIOUS JOB , refer to the chapter from 10.13 .

10.7

Label Head Check

a. Loosen the label web locker firstly (refer to the 9.2). b. Turn the label roll disk according to the arrow direction (rolled outside) (FIG 10.7-1), have a label placed in the front of label sensor (FIG 10.7-2). c. Tighten the label web locker.

lxvii



LABELING MACHINE

FIG 10.7-1

OCV camera

FIG 10.7-2

10.8

Sensors Setup

In order to ensure a correct detection of product diameter and for an accurate rejection, it is essential to set up the product sensors (infeed sensor and rejection sensor) in flashing status to make sure they correctly detects the bottle. The setup method of the product sensor is to press and hold down the yellow button on the product sensor for around 10 seconds till the indicator is flashing. While performing Self-Set, place a product 50mm in front of the sensor so that the sensor is able to get more precise diameter.

10.9

Self-Set A New Job lxviii



LABELING MACHINE

Press A - Self Set A NEW JOB button, the conveyor starts moving, and then place a bottle before product sensor on the conveyor (FIG 10.9-1). The display will show the information detected about the bottle and the label, the system will switch to the operation display after finishing Self-Set.

FIG.10.9-1

lxix



LABELING MACHINE

0.0

0.00

0 254.0 0

100

0.0

0.00

160

0.0

0.00

Label length has dispensed 2 mm

254.0

10.00

254.0

10.00

2.5

0.10

2.5

0.10

0 500

FIG 10.9-2 lxx


10.10


LABELING MACHINE

Checking Bottle Data

Place one more bottle onto the conveyor and let it pass through the product sensor to conduct trial labeling. Ensure the labeled bottle meets desired requirements. If not, enter into data edit display to set up screen (refer to chapter 8.2.5 Labeling Data Setup), and the parameters setting is based on the labeling status. After adjustment, check the labeling condition again by placing a product onto the conveyor. (FIG 10.9-1) 10.11

Saving Labeling data

If the labeled bottle meets desired requirements, save the labeling data in the memory. This will save operation time when running the same bottle and label the next time. 10.12 Selecting A Job from Memory When pressing

B - CHOOSE A JOB FROM MEMORY

button, the "CALL MEMORY" display will be shown

(FIG 10.12-1). Call the desired memory job number from the memories saved, (#1~50 are available, reverse color button e.g. 1 means it contains saved data). Press the button desired and then press call , the machine display changes to operation display (FIG 10.12-2), and the memory number display changes to operation display (FIG 10.12-2) and the memory number is shown on the upper left corner. If the memory number shown is not the correct one for the current product, press key to enter the call memory display again to change to the correct memory number. Place bottles onto the conveyor, then press START key to start labeling when the correct memory number is selected. Job Memory Number

1 500

FIG 10.12-1

FIG 10.12-2

lxxi



LABELING MACHINE

10.13 Continuing the Previous Job Check and verify that the labeling data is unchanged before using C - CONTINUE THE PREVIOUS JOB function. If the previous labeling data is changed, then use A - SETUP A NEW JOB (refer to 10.9) function to reset the product data. If the labeling data is saved in the memory number set already, then select B - CHOOSE A JOB FROM MEMORY (refer to 10.12) to recall the job number saved. After ensuring no labeling data being changed, then select C - CONTINUE THE PREVIOUS JOB function to enter the display which is shown as below (FIG 10.13-1); and then it will promptly switch to the operational display (FIG 10.12-2). Place bottles on the conveyor and touch START key for labeling job.

FIG 10.13-1

10.14 Stopping Machine Always press PAUSE button on the display to stop the labeling machine firstly; then switch and main power switch to "0" position; and then turn off the compressed air supply.

lxxii



LABELING MACHINE

11. MACHINE SET-UP AND ADJUSTMENT Machine Adjustments Note: For safety and to avoid damage to the machine, always SWITCH OFF the power before any machine adjustment. All machine adjustments should be accomplished by qualified technicians. Most adjustable parts of the machine are provided with guide rulers or numerical handwheels, proper adjustments are determined through factory test and should not be changed unless necessary. Therefore some of the sections provided in this chapter are only for reference purposes.

11.1

Guide Rail and Product Separator Adjustments

a. Place a product on conveyor, and loosen the handwheel of the guide rail. Adjust all guide rails to coincide with product width, allowing the product to move freely on the conveyor. b. Product Separator Wheel: Product Separator is used to control and adjust bottle spacing. The rail must have the product contacted with the separator wheel to create proper spacing between products for labeling. c. Proper bottle spacing is critical. If the products are spaced too close together, then some products may not get labeled. Remember, if the conveyor speed is reduced, this will cause the space between the products to change, the operator may need to change the spacing then. d. Product Separator Screw (optional) is recommended for higher speed applications when this machine is used for labeling only a few different size products. e. Remove the product from the conveyor after the adjustments are done. Label roll disk

Product separator wheel Bottle

Guide rail Guide rail adj. knob

11. 2

Label Position - Vertical

FIG 11.1-1

Adjust the label position vertically with the head handwheel located above the labeling head. Rotate the handwheel to raise or lower the labeling head (FIG 11.2-1). Handwheel for label height adjustment

lxxiii



LABELING MACHINE

FIG 11.2-1

11. 3

Label Head Angle - Horizontal

a. Generally, only adjust the label head angle at the first labeling. Unless the label skews in the same direction every time, it is not necessary to do the adjustment. b. Loosen the locking lever (FIG 11.3-1) to adjust the label head angle with the head angle handwheel. Check and write down the read value via the ruler (FIG 11.3-2). It allows easily adjusting the head angle next time.

Locking level

Head angle handwheel

Ruler FIG 11.3-1

Ruler

FIG 11.3-2

lxxiv

Horizontal line


11. 4


LABELING MACHINE

Wrap Belt Position - Vertical

"Wrap plate" is use to firmly apply the label onto the product (bottle), it helps the product to be wrapped with the label properly. If it holds the product too tightly, the product is easy to skew and arisen. If it is too loose, then the label is easy to get wrinkles. a. Place a product between the wrap plate and belt, then adjust the vertical position of the labeling belt with the wrap belt handwheel located above the wrap belt unit. Rotate the hand wheel to raise or lower the wrap belt assembly. b. Both "labeling head" and "wrap belt position" should be in the same height (FIG 11.4-1). Tight

Wrap adj. handwheel vertical Wrap plate adj. handwheel –horizontal Wrap belt assy

Wrap plate adj. handwheel –vertical Bottle Wrap plate

Label peel blade

FIG 11.4-1

11.5 Product Speed Proper adjustment of product separator is necessary before adjusting the label dispensing speed. Dispensing speed is not necessary to do any adjustment in a normal operational condition.

11.6 Label Dispensing Speed Adjustment (LAB HD-SPD) a. Only the following two situations need to do the machine adjustment: Backing paper does not lay out on the label peel blade while performing wrapping job (FIG 11.6-1). Loose label, label does not lay out on the wrap belt. (FIG 11.6-2)

lxxv



Backing paper does not lay out on the label peel blade while performing wrapping job

LABELING MACHINE

Loose label, label does not lay out on the wrap belt

FIG 11.6-1

FIG 11.6-2

a. The backing paper is loose as labeling (FIG 11.6-1), and does not close to the label peel blade. It means that the label dispensing speed is slower than the product delivery speed so that have the label been pulled out by the product to cause wrinkly backing paper. This condition is not easy to observe, it needs to pay attention to the interface of both the backing paper and the label peel blade when labeling. This symptom may cause inconstant label dispense length, poor labeling quality, and lower backing paper. ※Countermeasure: Speed up the label dispenses speed. b. Loose labels as labeling, and product does not catch the label tightly (FIG 11.6-2). It shows that the label dispense speed is faster than the product delivery speed so that the label is unable to be pulled tightly. This symptom may cause wrinkly label on the product. Under normal situation, the label is pulled out by the product as labeling. ※Countermeasure: Slow down the label dispense speed. c. Normally, the label should tightly lay out on the label peel blade. Label extension distance may be: 2mm, 3mm, 4mm if the label lay out on the blade is too loose. This also results in poor labeling accuracy. If backing paper is loose, bottle may be labeled incorrectly. (FIG 11.6-2)

Normally the product should catch the label tightly while performing wrapping job

Normally the label should tightly lay out on the label peel blade while performing wrapping job

11. 7

Product Separator Adjustments

FIG 11.6-2 lxxvi



LABELING MACHINE

Refer to 8.2.5.4 product separator speed adjustments.

11. 8

Production Speed Adjustments

Production speed adjustment should be synchronized with 8.2.5.4 product separator speed. Then adjust labeling speed (refer to 8.2.5.3) to have proper adjustment for both labeling speed and product separator speed.

11. 9 Label Extensions Refer to 8.2.5.7 for more details. 11. 10 Labeling Position Adjustment (LAB. P) a. Normally, Self-SetTM will calculate the correct label application point and it is not necessary to do any adjustment. Operator may need to do some adjustment under a few special labeling conditions. Check and verify label touch point is within standard setting range before performing the operation. (FIG 11.10-1)

FIG 1

FIG 2

FIG 3

FIG 4

Bottle

Label

FIG 11.10-1

b. FIG 2 examples above for the proper label application point. c. FIG 1 shows label is incorrectly placed on the left side. (Refer to 8.2.5.5 Label position) d. FIG 3 and FIG 4 show the label is incorrectly placed on the right side. (Refer to 8.2.5.5 Label position)

11. 11 Label Sensitivity Adjustments a. The label sensor indicates the opacity of the label and backing paper, which determines the sensitivity adjustment of the label sensor.

lxxvii



LABELING MACHINE

b. According to the different product application, the materials, thickness and opacity of the labels are also different. The label sensitivity values are automatically measured by Self- SetTM, no adjustment is required. c. Never do the sensitivity adjustments unless special conditions. Verify it by the following steps: * Transparency of Backing Paper: It is a value of the backing paper transparency that detects by the sensor. * Transparency of Backing Paper may be varying in a roll. When perform Self-Set job, the Self-SetTM will setup a standard value in accordance with the measured backing paper. The Self-SetTM is relying on the setting value to check backing paper and label. If backing paper value is 60, then the standard setting is 90. If the label sensor reading is lower than 90, it will be treated as backing paper. If the label sensor read is higher than 90, then it is treated as label. Sensing signal is to send to the Self-SetTM for further processing. d. Only the following two situations will require being adjusted: * Backing Paper setting value is larger than backing paper read value. For example, if setting value is 90, backing paper is 95, then, it is necessary to increase the setting value to a higher value (125). If the backing paper value is not set up properly, then it may cause labeling machine to dispense two labels instead of one, or several labels are dispensed without stop. * Label Minimum value is less than backing paper setting value. For example, if the setting value is at 90, and the backing paper reading value is 85, In this case, lower the setting value to 60. Otherwise label will be treated as back paper. The labeler will dispense label partially. e. While performing labeling, if the labeling machine stops before the labeling is completed, it indicates somewhere in the label surface the opacity value is less than the setting value, thus it is judged as backing paper and sends out stop signal to stop the machine. Then, the backing paper will be pulled out by the bottle. In this case, the setting value is necessary to be lowered. f. The Self-SetTM may not have standard/setting value because the value of label sensitivity is very close to the value of backing paper sensitivity. Then, it needs to set up the parameter manually. If it is still unable to set up the value, the sensor should be replaced with different type. g. Perform the label sensor value adjustment refer to 8.2.5.20.3 d. LAB Sensor Value (50).

lxxviii



LABELING MACHINE

11. 12 Product Sensor Adjustments a. The function of product sensor is to detect bottle width, and then send the signal of bottle width to Self-SetTM to perform labeling job. The sensitivity strength has been setup in factory so it is not necessary to do any adjustment. But the sensitivity is necessary to be adjusted, when transparent bottles are applied. b. To adjust the sensitivity strength, clear the bottles between "Reflector" and "Product sensor" firstly. Next, press down and hold the Sensitivity reset button on the top of the sensor for around 5 seconds. The reset indicator on the product sensor will flash in yellow. Then, release the sensitivity reset button to complete the product sensor adjustment. (FIG 11.12-1) c. Sometimes it is also installed non-reflection photoelectric sensor because of special requirement. Thus, the sensor type/model may be different. The product sensor and the rejection sensors are very important for the machine, so make sure that the indictor of these sensors must be in flashing status. If not, it indicates that product sensor emits a stronger signal than appropriate. Then, it may cause several un-identified signals when a transparent bottle passes through the product sensor because of the stronger signal. The un-identified signals will have dramatically effect on the REJECT RESET function and it will cause wrong rejections. Therefore, it is necessary to note it. But it may not so important if it is not a transparent bottle. However, when conducting auto-test process under such a condition, the product sensor is unable to correctly measure the bottle diameter (the diameter value detected is smaller). Therefore, in order to correctly detect bottle diameter and perform rejection function, the indicator of the product sensor should be setup on flashing. Press the yellow button above the product sensor for 10 seconds, until the indicator flashes. And place a product before the sensor 50mm to get more precise detection, when performing SelfSet. Reset indicator Sensitivity reset button

Receive signal light

Send signal light

FIG 11.12-1

lxxix



LABELING MACHINE

11. 13 Missing Code Stamp Sensor Adjustments (Optional) a. The function of the missing code-date stamp sensor is to detect the code on the label stamped by the hot stamp printer. If any missing code found, then it sends a signal to the Self-SetTM to conduct the rejection job. b. There are three adjustment knobs: focus adjustment, vertical adjustment, and horizontal adjustment knobs, on the missing code sensor (FIG 11.13-1). To align the detection spot with the stamped codes (FIG 11.13-2) by these adjustment knobs respectively. The detection spot size depends on the focus adjustment and also will be related to detection tolerance. The smaller the spot is, the more precise detection is. Normally, the size of the detection spot is the same as an individual stamped character. Missing code sensor Label peel blade

Vertical adj. knob

Detection spot

Missing code sensor

Label

Stamp code

Wrap plate

Focus adj. knob Label

Horizontal adj. knob FIG 11.13-1

FIG 11.13-2

c. Turn the “teaching adjustment knob” on the missing code sensor from “RUN” to “TEACH” position. (FIG 11.13-3) d. Apply the 3 adjustment knobs of the missing code sensor to align the detection spot with the stamping position on the label which is the same color background. (FIG 11.13-2) Then, press down the TEACH button and let the detection spot flash. e. Next, align the detection spot with the stamped code by the 3 adjustment knobs. Press down the TEACH button again, and the detection spot will change its color (red, blue, or green). It means that the sensor is setup to its best sensitivity. Otherwise, the missing code sensor is necessary to be re-set. f. Turn the “TEACH adjustment knob” on the missing code sensor from “TEACH” to “RUN” position.

lxxx



LABELING MACHINE

g. Finally, it is necessary to confirm the adjustments above. Place the detection spot onto a label without stamped code. Then, the indicator should light up. The indicator should light off if moving the spot to a stamped code. Missing code sensor Height adj. knob

Label

TEACH button TEACH adj. knob FIG 11.13-3

11.14 Bar Code Scanner Adjustments (Optional) a. The function of the bar code scanner is to detect the bar code on the label to see if the code is missing or wrong. In such case, it sends a signal to Self-SetTM to verify if and to conduct rejection job. b. The bar code scanner model is CLV-412, and unable to detect “RED bar code.” c. Bar code scanner is equipped with three adjustment knobs, focus adjustment, vertical adjustment, and horizontal adjustment knobs. To align the detection spot with the bar code by these adjustment knobs respective. (FIG 11.14-1) d. There are two types of bar code arrangement, vertical and horizontal bar codes (FIG 11.14-1 & 2). Thus, the position/direction of the scanner may be different based on the bar code type on the label. e. Before changing the scanner’s position/direction, it should remove the vertical adjustment knobs out, and then turn the scanner’s direction. Then, install the vertical adjustment knob back. f. Decide the detection direction according to the bar code type on the label. (Refer to 8.2.5.16 Bar Code Check) g. Press the TESTING button (refer to 8.2.5.16 screen 23) to make sure if TEACH function is OK after completing teach job. The screen should show the bar code value if correct teaching job has been done. If not, no bar code value is shown on the screen and it will sends out "BEE-BEE" sound.

Direction transferring plate lxxxi



Horizontal bar code

LABELING MACHINE

Vertical bar code

Screw hole

Focus adj. knob

Focus adj. knob

Label

Label

Bar code scanner

Bar code scanner Vertical adj. knob

Vertical adj. knob Horizontal adj. knob

Horizontal adj. knob Horizontal adj. knob

FIG 11.14-1

11.15

FIG 11.14-2

Production Quantity Clearance

Please refer to 8.2.5.1 “OUTPUT/JOB” for more details.

lxxxii



LABELING MACHINE

11.16 Clear Label Sensor Adjustment Procedures (Optional) 1.

Thread the labels around the rollers and thru the label sensor as described by the manual.

2. 3.

Remove a label from under the label sensor. With the locking levers of the pinch rollers open, place tension on the label web turning the maroon waste paper take-up reel, centering the web (no label) between the sensor eyes. Adjust both screws on the label sensor “SPAN” and “SHIFT” until one of the last two green LEDs in the

4. 5. 6. 7. 8.

“WEB” region is illuminated (for sensitive set up or problem labels, the last two LED should be flickering. Advance the label web until the label and web is under the label sensor. Adjust both screws on the label sensor “SPAN” and “SHIFT” until one of the last two green LEDs in the “LABEL” region is illuminated (for sensitive set up or problem labels, the last two LED should be flickering. The LED should never stop in the “X” area (between “WEB” and “LABEL”) when looking fully on the label or web. Repeat steps 4 thru 7 until correct.

Description of “SHIFT” and “SPAN” “SPAN” Controls how wide or close together the LED’s spread apart

(see below).

“SHIFT” Uses to center the LED’s on the display. “Shift” Moves both LED’s simultaneously up (Only one LED is illuminated, so you can not see both move) (see figure below).

lxxxiii

↑ or down ↓



LABELING MACHINE

WEB

WEB

WEB

WEB

LABEL

LABEL

LABEL

LABEL

SPAN

SPAN SHIFT FIG. 11.16-1

lxxxiv

SHIFT



LABELING MACHINE

12.

COMPLEMENTARY TOOLS/CHANGEOVER PARTS

12.1

Complementary Tools

12.1.1 Tool Box A tool box is provided with the shipment, containing some useful tools (FIG 12.1-1)

FIG 12.1-1-01) (12.1

12.1.2 Inner Hexagonal Wrench Set Used for loosening/fasten the socket screw. (FIG 12.1-2)

FIG 12.1-2

(1 2. 2- 01 )

lxxxv



12.1.3 U Type Spring Clip Designed for fastening 38 mm Labeling roll (FIG 12.1-3).

FIG 12.1-3

lxxxvi

LABELING MACHINE



13.

MAINTENANCE

13.1

General Precautions

LABELING MACHINE

a. Safety ˙Before performing any maintenance job or cleanup, ensure that the power is disconnected. ˙Always take the necessary safety measures to protect both machine and personnel when carrying out maintenance job b. Machine Clean Up Use a damp fabric to clean the machine parts, don’t wash directly with water. For tough dirt, moderate flammable products can be used (e.g. solvent, alcohol for industrial use …etc.), avoid using highly corrosive or inflammable products (e.g. methane or thinner …etc.) c. Spare parts replacement Regularly check the machine for damaged or worn out parts and have them replaced if necessary. 13.2

Pneumatic Arm Maintenance

The pneumatic arm (for shock absorbent) is necessary to be maintained monthly and its maintenance steps are as follows; a. Open the safety shield and then the extension rod of pneumatic arm will extend out. Clean the shaft with a clean & soft cloth. (Step 1) b. Apply a proper lubrication on the shaft. (Step 2) c. Open and close (move back and forth) the safety shield alternatively to let the oil fully lubricate onto the shaft. (Step 3) apply lubricant cloth

move back and forth

pneumatic arm extension rod

Step 1

Step 2 FIG. 13.2-1

lxxxvii

Step 3


13.3


LABELING MACHINE

Air Regulator Set Maintenance

The air regulator is equipped with an air filter; drain the accumulated water of the reservoir and check after every usage. Inspect and ensure the lubrication oil reservoir is sufficient. Oil filler nozzle plug Lubricant regulator

Water reservoir

Lubricant level

Auto water drainer FIG 13.2-1

Lubricant type

Viscosity range

Festo special oil Aral vitam GF32

32 mm2/s

Esso Nuto H32

(=cSt) at 40oC

Mobil DET24

ISO-Class VG32 as per ISO 3448

BP Energol HLP32

lxxxviii


13.4


LABELING MACHINE

Spare Parts List

13.4.1 Labeling Machine No.

Nomenclature

Description

1

Rewind Spool Disk

Injection molding

2

Various driving Belts

ISO standard

3

Product Separator Wheel

Rubber sponge foam molding

4

Backing plate Sponge

Rubber sponge foam molding

5

Fuse

Purchasing from local

6

Label Sensor

Standard type for normal label: LABEL-302P V2.0 Optional for clear label:LRD-6100(optional)

7

Product Sensor

SICK, WL9-2N131

13.4.2 Hot Stamp Printer (C70)-Optional No.

Nomenclature

Description

1

Foil tape (32mm/25mm)

Purchasing before 30 days stock

2

Nickel type

Replacement as stamped letters unclear.

3

Brass type

Replacement as big gap created.

4

Silica spacer

Replacement as un-even flat stamping

5

Temperature sensor IC

Replacement as temperature out of control

6

Electric thermo couple

Replacement as TCB lamp flashing in red

7

Electric thermo tube

Replacement as no heating.

lxxxix


13.5 No. 1

2


LABELING MACHINE

Maintenance and Lubrication Schedule Machine parts

Maintenance

Period

Labeling head height adj.

Lubrication

Weekly

screw

(ISO VG 32)

Wrap belt height adj. screw

Lubrication

4

Label head horizontal adj.

Lubrication

screw

(ISO VG 32)

Wrap plate height adj. screw

Lubrication

Weekly

Wrap plate screw-horizontal

Weekly

Weekly

7

Lubrication

adj. screw(Optional)

(ISO VG 32)

Hot stamp printer height adj.

Lubrication

screw

(ISO VG 32)

Wipe out old grease and apply new grease.

Lubrication

Hot stamp printer horizontal


Weekly

(ISO VG 32) 6


(ISO VG 32) 5


(ISO VG 32) 3

Remarks


Weekly


Weekly


(Optional) 8

Wrap station bearing

Lubrication

Weekly

(ISO VG 32) 9

Label seat bearing

with new grease.

Lubrication

Weekly

(ISO VG 32) 10

Air regulator

Machine appearance

Wipe out old grease and apply with new grease.

Water draining

After every usage

(Optional) 11

Wipe out old grease and apply

Drain water before and after every usage

Cleaning

After every usage

Cleaning the machine before and after every usage.

xc


LABELING MACHINE

ELECTRICAL DIAGRAMS

SB1

xci

SQ2

M4

SQ3

SQ4

SQ5

SQ7

F1

SW3

SW2

VAL1

SQ8

DSP1

SW1

QS1

M3

M2 & SQ1

14.


1.25mm X 3 Power Supply 1ψ3W 50-60Hz 220Vac Wire : 1.25ｍ㎡ ×3 Fuse :10A

C002/A1 C002/A1

C002/A1


xcii

CVC TECHNOLOGIES,INC

It=10A

CVC TECHNOLOGIES, INC. LABELING MACHINE

C001/D5

C001/D5

C001/D4

C008/C1

G

T

R

0.75mm X 3


xciii


0.75mm X 4

C003/A1

C003/A1

C003/A1


G

T

R

C017/B5

2A

2A

50/60HZ

1A

1A

0.5mm X 4


xciv


0.5mm X 4

1A

C004/A1

C002/A6

2A

C004/A1

C002/A6

0.5mm X 3

C004/A1

C002/A6


C017/B5

1A

1A

1A

1A

0.5mm X 4


xcv


0.5mm X 4

1A

C005/A1

C003/A6

1A

C005/A1

C003/A6

0.5mm X 3

C005/A1

C003/A6


2A


C007/A1

C007/A1

C007/A1

C006/A1

C004/A6

2A

C006/A1

C004/A6

0.75mm X 3

C006/A1

C004/A6

CVC TECHNOLOGIES, INC. OPERATION MANUAL CVC 302 LABELING MACHINE

xcvi


LABELING MACHINE

C005/D6

C005/D6

C005/D6

1A

1A



xcvii

C005/B6

C005/B6

C005/B6

C008/D1 C010/D1

C008/D1 C010/D1


C010/D1

CVC TECHNOLOGIES, INC. OPERATION MANUAL CVC 302

xcviii

LABELING MACHINE

LABELING MACHINE

xcix

C007/D2

C007/D2

C007/D2


C009/D1

C009/D1


C009/D1


LABELING MACHINE



c

C008/B6

C008/B6

C008/B6

Comm. Adapter


ci C012/D1 C012/D1

C007/D2

C007/A6


C012/D1

C007/D2


C006/C2

C006/C2


C013/D1 C010/D6


C013/D1 C010/D6

LABELING MACHINE

C013/D1


C010/D6


cii


LABELING MACHINE



ciii

civ


Run/Stop Output

C014/D1 Alarm Out

Y9

C011/D6

Y7

C014/D1

X51

X55


C011/D6

X57

X58


X9

XB2

cv Safty Guard

Stop Button

5

XB1

X26


Encoder

X25

X62

X2

Product Sensor

X61

X1

C015/D1

Airpressure

XC 43

C013/D6

X65

X2

4

XB1-X3

27 XPS3-6

XD

C015/D1

X64

X1

XPS3

X1

X63

X5 63

X27


C013/D6

X59

60

XB2-X3

X66

X8 66

X60


C018/D1


C018/D1

C014/D6

LABELING MACHINE

C014/D6


53 54


cvi

Comm. Adapter

S1

10C

R1

10C

S2

10C

cvii


LABELING MACHINE

C003/D1 C004/D1


10C


LABELING MACHINE

10C



10C


cviii

C019/D1

C019/D1

C015/D6

C015/D6

LABELING MACHINE


XPS9

C70


Purple


cix

cx

X7


C020/D1

Backlog Sensor

C020/D1

Reject Sensor

X4

C018/D6

XPS11

XPS11-3


C018/D6

XPS10

XPS10-4


cxi


C021/D1 Alarm beacon

C021/D1

STOP Red Lamp

C019/D6 Reject valve

Y4

C019/D6

RUN Green Lamp


Alarm Yellow Lamp

LP1

4


cxii C022/D1 C022/D1

C020/D6

Barcode Scaner


C020/D6


XPS12

SQ7


LABELING MACHINE

Missing Code Sensor


cxiii

C021/D6

C021/D6

XPS13


SQ8



LABELING MACHINE

cxiv


X7 X9

X2

X1

X4

X5

X3

X10

X6

X8

X11

X12

C70




LABELING MACHINE

Electrical Parts List Position

Description

Manufacture

Specification

Article number

Drawing

C001

QS1

Disconnect switch for power input

MERZ

A 101/6.1051

C001

QF1

Circuit breaker

MERLIN GERIN Multi9 K32a C10

C001

EMI1

EMI Filter

YUNPEN

C002 C015

SV1

AC Servo Driver for Head Panasonic Motor

MSDA083A1A

C003

INV1

Inverter for Conveyor & Warp-around Motor

DELTA

VFD004S23A

C004

INV2

Inverter for Feed Roller Motor & Turn Table

DELTA

VFD004S23A

C002

M1

AC Servo Motor for Head Panasonic

YC20-T1

YC20-T1

MSMA082A1E

(3ψ 116Vac 750W) C003

M2

Conveyor (3ψ 220Vac

FUKUTA

AMVB 1/4 Hp

220W) C003

M3

Warp-around (3ψ 220Vac Panasonic 60W)

M8MA60GK4Y

C004

M4

Feed Roller (3ψ 220Vac 25W)

Panasonic

M8MA25GK4Y

C004

M5

Turntable (3ψ 220Vac 40W)

Panasonic

M8MA40GK4Y

C005

FAN1 FAN2

Cooling Fan (1ψ 220Vac YRKY 0.08A)

YK-0814HS 220/240V

C007

PWR1

DC24V Power Supply

MEAN WELL

DR-120-24

(120W) C001

SB1

EMG Switch

SCHLEGEL

MHR3+MTO

EMG-SW

C008 C012-20

PCB1

Main Board

CVC

SGBUSV4.0

SGBUSV4.0

C009

PCB2

RS232, RS485

CVC

C-NET-S2

C-NET-S2

CVC

HDIFV3.0

HDIFV3.0

C016 C010, 12 C017, 18

Communication Adapter PCB3

Head Board

cxv



LABELING MACHINE

C021, 22 C008, 16 Drawing

PLC1

Programmable Logic Controller for main

Position

Description

NAIS Manufacture

FPG-C32CT Specification

FPG-C32CT Article number

C011, 17

PLC2

Programmable Logic Controller for head

NAIS

FPG-C32CT

FPG-C32CT

C008, 16

DSP1

Programmable Display

NAIS

GT30

GT-30

C014

SQ1

Encoder Sensor

ROTARY

HES-10-2MHC

C014

SQ2

Product detective Sensor SICK

WL9-2N131

WL9-2N

C012

SQ3

Labeling Sensor

LABEL-302P V2.0

LABEL-302P

CVC

V2.0 C014

SQ4

Safe Door Switch

YAMATAKE

HPJ-D21

C014

SP1

Air pressure Sensor

FESTO

PEV-1/4B

C013

BZ1

Buzzer

ARIO

B42W29A

B42W29A

C014

SW1

Stop Button

DECA

D16LMR3-R

D16LMR3-R

C023

SW2

Push Button for C70 Test CVC Cylinder used

221B

221B

C023

SW3

Switch for C70 Power input

CVC

SW-4P

SW-4P

C019

SQ5

Reject Sensor

SICK

WL9-2N131

WL9-2N

C019

SQ6

Backlog Sensor

SICK

WL9-2N131

WL9-2N

C021

SQ7

Barcode Sensor

SICK

CLV-412

C022

SQ8

Missing Code Sensor

SICK

KT5W-2N1116

C023

SQ9

Ribbon Sensor

YAMATAKE

HPJ-D21

C023

SQ10

Thermocouple

CVC

KBSGN-43H

C013, 20

KA2

Relay for Run/ Stop Status Output

OMRON

MY2-24V

C020

VAL1

Solenoid valve for Reject FESTO Cylinder

MFH-5-1/8-24Vdc

C020

VAL1

Solenoid valve for Reject FESTO Blow

MFH-3-1/8-24Vdc

C023

VAL2

Solenoid valve for C70 Cylinder

SMC

SY5120-5G-01

SY5120

C023

HT1

C70 Heater

CVC

110V-60W

110V-60W

C020

LP1

Alarm Lamp (Indicator banks)

Eminent Main

3EL24D-LED-3, ES616 L: 150mm

cxvi

KBSGN-43H


C023

Drawing

LP2

Position


Lamp for C70 Heater power indicator Description

LABELING MACHINE

CVC

220VAC

Manufacture CVC

Specification

C023

F1

Fuse for C70 (Fuse: 30mm 3A)

PF3

C003

F4-F6

Fuse block for Conveyor DINKLE (Fuse: 20mm 2A)

FDK4LED-220V

C003

F8-F10

Fuse block for Warp

DINKLE

FDK4LED-220V

Around (Fuse: 20mm 1A) C004

F12-F14

Fuse block for Feed Roller DINKLE (Fuse: 20mm 1A)

FDK4LED-220V

C004

F16-F18

Fuse block for Turn Table DINKLE (Fuse: 20mm 1A)

FDK4LED-220V

C006

F20-F21

Fuse block for C60 or C70 DINKLE Power (Fuse: 20mm 1A)

FDK4LED-220V

C005

F42-F43

Fuse block for Power DINKLE Supply, Fan (Fuse: 20mm 2A)

FDK4LED-220V

cxvii

220VAC

Article number PF3


15. 15.1


PARTS LIST Overall Assembly Scheme

cxviii

LABELING MACHINE


No.


Part No.

LABELING MACHINE

Description

Quantity

1

32.AX.2A1

Base frame assembly

1

2

32.AX.3A1

Conveyor assembly

1

3

32.AX.400

Head angle adjustment assembly (tilt head)

1

4

32.AX.502

Wrap station (C type)

1

5

32.AX.A02

Labeling head (C type)

1

6

32.AX.EA1

Power box

1

7

51.AX.1A1

Hot stamp printer

1

8

32.AX.800

Product spacing wheel assembly (PU)

1

9

32.AX.7A1

Rejection system one-way air cylinder for 60 BMP output; Two-way air cylinder for 120 BMP output; Air blow for small bottle and over 120 BMP Output

1

10

32.AX.600

Safety shield assembly

1

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

cxix

Remarks


15.2


LABELING MACHINE

Base Frame Assembly

cxx



LABELING MACHINE

List for Base Frame Assembly (Part # 32.AX.2A1) No.

Part No.

Description

Quantity

1

DS402000

Swivel Caster wheel with nut

4

2

90R11C01

Backing plate sponge (C type)

1

3

32M27000-04

Product sensor holder

1

4

32M26000-03

Product sensor bracket

1

5

BX.NE4.WL9-2N131

Product sensor (SICK)

1

6

BX.CB6.M3X12

Semi-round cross screw

2

7

32.AX.2B1

Touch screen (HMT) assembly

1

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

cxxi

Remarks



15.2.1 Touch Screen (HMT) Assembly

cxxii

LABELING MACHINE



LABELING MACHINE

List for Touch Screen (HTM) Assembly (Part # 32.AX.2B1) No.

Part No.

Description

Quantity

1

32E10000-02

Control panel base

1

2

32E10010-04

Control panel holder

1

3

32E08050-04

Support sleeve

1

4

32E08040-06

Control panel housing

1

5

32E08003-02

Screen frame

1

6

GT30,

Programmable Display

1

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxiii

Remarks


15.3


Conveyor Assembly

cxxiv

LABELING MACHINE



LABELING MACHINE

List for Conveyor Assembly (Part # 32.AX.3A1) No.

Part No.

Description

Quantity

1

32C08000

Conveyor fixing plate

1

2

CFE01009-02

Conveyor motor housing

1

3

32C09L00-01

Conveyor supporting sleeve, left

1

4

BX.T63C4+NMRV040-25

Conveyor motor (Bodine, 1/4HP) Reducer (1/25)

1

5

32C01061-02

Motor shaft

1

6

32C20000-01

Encoder seat

1

7

HES-10-2HC

Encoder

1

8

32C21000-01

Encoder housing

1

9

32C09000-01

Conveyor supporting sleeve, right

1

10

BX.CB1.M6X16

Socket screw

1

11

BX.CB1.M6X55

Socket screw

1

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxv

Remarks


15.4


Head Angle Adjustment Assembly

cxxvi

LABELING MACHINE



LABELING MACHINE

List for Head Angle Adjustment Assembly (Part # 32.AX.400) No.

Part No.

Description

Quantity

1

32AX.401

Head angle adjustment set (Lower)

1

2

BX.CW1.8.2X13X0.8

Flat washer

2

3

BX.CW6.8.1X16X1.8

Insulating red paper ring

2

4

32AX.402

Head angle adjustment set (Upper)

1

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

cxxvii

Remarks


15.5


Wrap Station Assembly (C type)

cxxviii

LABELING MACHINE



LABELING MACHINE

List for Wrap Assembly (Part # 32.AX.502) No.

Part No.

Description

Quantity

1

32.AX.50A

Wrap around motor (Bodine, 1½HP)

1

2

32.AX.50E

Wrap driven pulley (C type)

1

3

32.AX.50F

Wrap driving pulley (C type)

1

4

BX.CB3.M6X40

Semi-round socket screw

1

5

BX.CB3.M6X16


3

6

BX.CB1.M6X40

Socket screw

2

7

BX.FR1.S20

C type collar

1

8

90R44001-02

Transmitting gear

1

9

BX.FR1.S12

Collar (C type)

1

10

BX.CB2.M5X12

Fastening screw

1

11

BX.BB2.345L-146

Wrap belt (C type)

1

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxix

Remarks


15.6


Labeling Head Assembly (C Type)

cxxx

LABELING MACHINE



LABELING MACHINE

List for Labeling Heading Assembly (Part # 32.AX.A02) No.

Part No.

Description

Quantity

1

32.AX.A09

Labeling Head

1

2

32.AX.A05

Label dispensing roller with bar code scanner (C type)

1

3

BX.CB2.M6X10

fastening screw

4

4

32.AX.A08

Rewinder, stainless steel

1

5

BX.CW1.6.6X19X1.5

Washer

2

6

BX.CB3.M6X16


2

7

32.AX.B03

Label advanced roller and rewind roller (C type)

1

8

BX.CB1.M6X70

Socket screw

1

9

32.AX.B0C

Rewind spool

1

10

32.AX.B0T

Label peel blade holder (C type)

1

11

BX.CW1.10.5X18X2

Flat washer

1

12

BX.CW2.10.2X18.4X4.2

Spring washer

1

13

BX.CN1.M10X8

Nut

1

14

32.AX.B07

Label peel blade with missing bar code sensor (C type)

1

15

BX.CB1.M8X70

Socket screw

2

16 17 18 19 20 21 22 23 24 25

cxxxi

Remarks


15.7


Power Box

cxxxii

LABELING MACHINE



LABELING MACHINE

List for Power Box (Part # 32.AX.EA1) No.

Part No.

Description

Quantity

1

32E01000-01

Power control housing

1

2

101 (MERZ)

Main power switch

1

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxxiii

Remarks


15.8


Hot Stamp Printer

cxxxiv

LABELING MACHINE



LABELING MACHINE

List for Hot Stamp Printer (Part # 51.AX.1A1) No.

Part No.

Description

Quantity

1

50H14001

Handle of type chase

1

2

50H10000

Side backing slice

1

3

50H16001

Type chase

1

4

32mm/25mm

Hot stamp ribbon

1

5

82XL037

Tooth belt

1

6

50H02020

Silicone pad for C70 stamp,

1

L 150 X W 50mm 7

50H37001

Stepping driven roller

1

8

51H99020

Casing pipe

1

9

DSM-12

Side back slice

1

10

50H23020

Fastening spacer for control plate

1

11

110V-60W

Heater

1

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxxv

Remarks


15.9


Product Spacing Wheel Assembly

cxxxvi

LABELING MACHINE



LABELING MACHINE

List for Product Spacing Wheel Assembly (Part # 32.AX.800) No.

Part No.

Description

Quantity

1

32.AX.80B

Spacing wheel assembly

1

2

32.AX.80A

Separator wheel (PU)

2

3

BX.EB1.6904ZZ

Ball bearing with locking ring

4

4

BX.M81A25GD4W-M8GA90B Separator motor (with reducer)

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxxvii

1

Remarks



15.10 Rejection System

cxxxviii

LABELING MACHINE



LABELING MACHINE

List for Rejection System (Part # 32.AX.7A1) No.

Part No.

Description

Quantity

1

32.AX.70F

Rejection collector

2

2

32.AX.70G

Housing for rejection collector

1

3

BX.CB3.M5X12


4

4

32.AX.70H

Rejecter

1

5

BX.CB3.M5X20


2

6

BX.NP8.PG-9

Straight connector

1

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxxxix

Remarks



LABELING MACHINE

15.10.1 Rejection Collector Housing Assembly

cxl



LABELING MACHINE

List for Rejection Collector Housing Assembly (Part # 32.AX.70G) No.

Part No.

Description

Quantity

1

32P22000-01

Rejection collector housing

1

2

BX.HB4.150731

Bracket

2

3

BX.CW1.13X18X0.5

Flat washer

4

4

BX.CB3.M5X25


4

5

BX.CN1.M5X4

Nut

8

6

BX.HB1.175134X150

One-way cylinder

1

7

BX.CB1.M4X12

Socket screw

4

8

BX.CW2.5.1X9.2X2.2

Spring washer

4

9

BX.HB4.JSC8-01AT

Quick snap connector

1

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

cxli

Remarks



LABELING MACHINE

15.11 Safety Shield Assembly

cxlii



LABELING MACHINE

List for Safety Shield Assembly (Part # 32.AX.600) No.

Pars No.

Description

Quantity

1

32.AX.60A

Right holder, safety shield assembly

1

2

32.AX.60C

Acrylic shield, safety shield assembly

1

3

32610000

Backing plate, safety shield assembly

1

4

BX.CB3.M6X95


2

5

BX.CB3.M6X16


2

6

32.AX.60B

Left holder, safety guard assembly

1

7

32609000

Backing slice, safety guard assembly

1

8

BX.HE4.HPJ-D21

Backing slice, proximity switch

1

9

BX.CB3.M3X6

Backing plate, proximity switch

2

10

BX.HE4.HPJ-D21

Proximity switch, for low foil tape detecting

1

11

BX.CN1.M3X2.4

Nut

1

12

BX.CB6.M3X12

Semi-round cross screw

1

13

BX.KG1.D-54-430-165-4 Shock absorbent

2

14

BX.CB3.M8X20

semi-round socket screw

2

15

BX.CB3.M8X16

semi-round socket screw

2

16

BX.CN1.M6X6.5

Nut

2

17 18 19 20 21 22 23 24 25 26

cxliii

Remarks


16.


LABELING MACHINE

TROUBLESHOOTING

The machine malfunction causes can be classified into 5 categories: problems at power-on, when doing Self-Set, labeling, sensors, and hot stamp printer. Different suggestions to solve the problems are listed below. 16.1

Powering on

16.1.1 Normal Operation a. The screen will show CVC logo for 12 seconds after turning on the main power switch. Due to the bar code scanner needs to take about 10 seconds to activate, it needs time to verify if the bar coder scanner is installed. b. After 12 seconds, it will switch to job selection screen.

16.1.2 Abnormal Conditions Symptom

Causes/Solutions

No display is shown after the ∆ No power supply. main power is turned on. ∆ Release the Emergency Stop Button. ∆ Check fuses #42, 43, and AC 220V power supply is functional. (DC power supply source) ∆ Check DC24V power supply. Measure both wires #49, 51 and verify DC24 power is supplied. ∆ Display is malfunctioned. ∆ Check on the wire connections of the display. Only shows English job selection but no first display of CVC logo; or only shows CVC logo but no job selections.

∆ The transmission wire between PLC and DISPLAY is malfunctioned. ∆ PLC switch is set at PROG mode. ∆ PLC power supply is malfunctioned. ∆ PLC unit is malfunctioned.

Display "safety door open"

∆ Close safety shield. ∆ Safety door sensor is malfunctioned or blocked. ∆ Circuit of safety door is malfunctioned.

Display "AIR SUPPLY"

∆ Air pressure source is cut off. ∆ Air pressure is lower than 2.5 kg/cm2 ∆ Air detector is adjusted improperly or abnormal because of vibration. ∆ Air detector is malfunctioned.

cxliv



16.2

Self-Set

16.2

Normal Operation

LABELING MACHINE

a. Conveyor motor driver is set at 20 Hz to drive both conveyor and wrap belt. b. Bottle diameter can be auto detected. c. Backing paper value can be auto detected, and then the yellow indicator is flashing. d. Label value can be auto set. When it spots on the backing paper, the red indicator is lit, and the yellow light is OFF. e. When the servo motor starts rotating, the label extension distance can be auto set up. f. Wrap position can be auto calculated and set up. g. The operation speed is auto set at 35.0 ± 0.1 M/min.

16.2.2 Abnormal Condition Symptom

Causes/Solutions

After selecting A - SelfSet mode, ∆ Check if the driver shows”H20”. H20 indicates current running frequency. both conveyor and wrap belt do ∆ If "H20" is shown, but motor is not running, it indicates the problem is in not start running at 20Hz speed. the motor or motor wiring. Check the wires #4-5-6, 8-9-10 and the motor plug. ∆ If "H20" is not shown, neither the motor is running; the problem is possible in signal transmission or the driver is malfunctioned. Refer to chapter 16.5.2.1, note 1. Conveyor can move, but wrap ∆ Driver is functional, wiring is malfunctioned. Check fuses #4, 5, 6 and the belt cannot move; motor. Wrap belt can move, but ∆ Driver is functional, wiring is malfunctioned. Check fuses #8, 9, 10 and conveyor can not moving. the wrap motor wiring. Unable to detect bottle size.

∆ Product sensor is malfunctioned, or the product sensor is improperly set. ∆ Refer to chapter 11.12 for proper product sensor adjustment.

Backing paper value = 0, after SelfSet is done.

∆ Main signal board is malfunctioned, or CHIP is improper version. ∆ Label sensor is malfunctioned. Refer to chapter 16.3 for label sensor troubleshooting.

cxlv



LABELING MACHINE

Backing Paper value < 5 after ∆ The label sensor detected improperly. Selfset is done, and the system ∆ Refer to chapter 16.4 label sensor adjustment for proper correction. keeps dispensing labels. Backing paper value >100. (too high)

∆ The backing paper is too thick to be labeled properly. ∆ Sensor slot is blocked (Refer to chapter 16.4 label sensor description for proper correction).

Red light is not lit, or the yellow light is not eliminated

∆ Label sensor is malfunctioning. Refer to 16.4 for the sensor problem.

Servo motor is unable to rotate.

∆ Coupling screw of the Label Dispensing shaft is loose. ∆ Check and verify servo motor driver is functional. And see if any abnormal signals were displayed on the motor drive. ∆ Check and verify servo motor is functional, refer to the servo motor manual book)

Label is dispensed continually without stop.

∆ Label gaps are less than 2mm. ∆ Improper label sensor adjustment. ∆ Label sensor testing problem, refer to sensor adjustment for proper correction. ∆ Main board chip is malfunctioned. ∆ Master board is malfunctioned.

Label extension is incorrect.

∆ Improper adjustment of transparent label sensor and label length is incorrect. ∆ Backing paper is too thin, properly adjust label sensor sensitivity.

16.3

Labeling

16.3.1 Normal Operation a. When screen displays "Heat up", the machine is unable to start up. b. The machine is unable to start up when the safety shield is open. c. If any message displays on the screen, refer chapter 16.5.2.5 relevant steps to execute machine operation. Touch ”Start” and “Reset” keys to switch the running mode . d. Products are labeled on the wrap station after passing through the product sensor. e. After a label is dispensed, labeling sensor detects on the label gap, then a signal is sent to stop label dispensing; or the labeler stop dispensing label after the label dispensing length is completed. f. Hot stamp printer performs coding after stop dispensing label. cxlvi



LABELING MACHINE

g. The optional bar code scanner starts scanning bar code while the hot stamp performs imprinting. (If bar code scanner is installed and its setup is done.) h. The optional imprinting sensor detects hot stamp code while the hot stamp performs imprinting. (If the sensor for the code-date stamp is installed and its setup is done.)

cxlvii



LABELING MACHINE

16.3.2 Abnormal Condition Symptom

Causes/Solutions

"Heat up" message is flashing on the screen, and unable to run the printer.

∆ C70 hot stamp printer is switched off. ∆ Heating wire is damaged.

Label extension gets longer and longer.

∆ Main board chip (W87E54B) is malfunctioned.

Label extension gets longer and longer and "missing label" is shown on the screen continuously.

∆ Label sensor is malfunctioned; replace it with a new one.

Label extension is improper.

∆ Label length measured by the computer is improper. ∆ Label sensor detecting position is improper (round or irregular shape label) ∆ Label sizes are not the same. ∆ Printed ads onto the backing paper ∆ Wrong memory # is recalled during operation. ∆ Label rollers are loose or malfunctioned. ∆ Embossed roller screws are loosen or damaged.

Missing labeling and shows ∆ Product separation is too fast. Reduce product separation speed. "products too close" Separating ∆ Improper guide rail adjustment causes product not to move speed will reduce smoothly. automatically. ∆ Transparent product/bottle and improper product sensor adjustment exists. ∆ Product separating mode is set improperly. Proposed using auto mode when using the separating screw, and using manual mode when using the separator wheel. ∆ When separating screw is used, the product supplement is too slow to label continually, and auto mode is being misused. Label is dispensed before product reaches the proper position.

∆ Improper detection of product size (diameter) exists. ∆ Transparent product/bottle and improper product sensor adjustment exists. ∆ Main board chip is malfunctioned.

Improper label dispensing length

∆ Label length is improperly detected. ∆ Main board chip is malfunctioned.

“Missing Label” is shown and wrong rejection.

∆ Label length is improperly detected. ∆ Wrong memory # is recalled during operation ∆ Label sensor detecting position is improper (round or irregular shape labels).

cxlviii



Missing labels on the label roll, no rejection is accomplished,

LABELING MACHINE

∆ Improperly set up. The missing label function is set to stop the machine operation.

but the machine stops instead. Missing labels on the label roll, but machine do not stop automatically.

∆ Improperly set up. The missing label function is set up to machine rejection function.

Hot stamp printer is not

∆ Improperly set up. Hot stamp function is set OFF

working after the hot stamp printer system auto test. Rejection is not working even if ∆ Improperly set up. The rejection function is set OFF. error message is shown. Abnormal cylinder or injection operation as injecting.

∆ Improperly set up. Wrong equipment selection for the rejection system.

” Wrong Bar code” is shown and wrong rejection.

∆ Improperly bar-code set up. ∆ Improperly set up for the bar code detection position (number of labels) ∆ The distance between the bar code scanner and the label is improper. ∆ Detected label is uneven or vibrates too much. ∆ Bar code scanner is malfunctioned. ∆ Transparent product/bottle and improper product sensor adjustment exists.

“Hot Stamp" is shown and improper rejection.

∆ The dispensing lengths of the labels are not the same. ∆ Label sizes are not the same. ∆ Bar code detection position is improper (number of labels). ∆ The distance between the bar code scanner and the label is improper. ∆ Detected label is uneven or vibrates too much. ∆ Sensor is malfunctioned.

Hot stamp detection is ON but no detecting work is done

∆ Hot stamp function is set up to OFF status.

Hot stamping time is unable to < 100.

∆ Hot stamp sensor function is ON. The stamping time should be > 100.

The label dispensing length is unable to adjust, or back to

∆ Main board chip is malfunctioned. ∆ Main board is malfunctioned. cxlix



LABELING MACHINE

original length after adjustment. The labeling position is unable to adjust, or back to original position after adjustment.

∆ Main board chip is malfunctioned. ∆ Main board is malfunctioned.

Machine keeps stopping

∆ Product length detection is incorrect.

because of products falling down constantly.

∆ Product sensor sensitivity is improper.

Unable to block the sensor by manual.

∆ Bottle width verification is set to "ON"

Hot stamp position is not on the ∆ The label dispensing lengths are not the same. same position. ∆ Label lengths are not the same. ∆ Hot stamping speed is too fast. No labeling action, servo driver ∆ Unstable power supply causes servo is malfunctioned. shows ERR-16.

∆ Insufficient power supply causes servo is malfunction. ∆ Servo parameter (10) is set too high. It should be set at 800.

Improper labeling, labels are

∆ Product crashes the wrap belt plate while labeling.

tilted or wrinkled.

∆ Product is too heavy or its surface is too slippery, increase the WEIGHT BALANCE value to correct. ∆ Labeling clipping wheel is malfunctioned or loose. ∆ Labeling shaft is loose.

cl


16.4


LABELING MACHINE

Label Sensors

16.4.1 Normal Operation a. Turn ON the main power switch, the red, yellow and green lamps of the sensor will flash 5 times. Finally, both the yellow and the green lamps remain lighting. b. Red: IR=ON, Yellow: OUT=ON (ON LAB), Green: POWER ON c. When perform auto test: Firstly, the yellow lamp will flash. (SEND WEB DATA OUT TO PLC) Then, the red lamp is on. (IR=ON) When the sensor spots on the label, the yellow lamp will light. But there is no light on when the sensor spots on the backing paper.

16.4.2

Abnormal Conditions Symptom

Causes/Solutions

Turn ON the main power ∆ Replace it with a new one. switch, the red, yellow and ∆ Under the emergency, adjust the CHIP vibration frequency in CCW green lamps will flash 5 times. direction (around 3 ~5 degrees). Refer to 16.5.2.3. “Notes 3”. Finally, both the yellow and the green lamps remain lighting. And irregular flashing will be on after every 5 seconds. Unable to detect the backing paper value; and the auto-test value is zero.

∆ Sensor connector disconnected or poor wire connection. ∆ Main board chip is malfunctioning or version is incorrect. ∆ Sensor is malfunctioned; replace it with a new one.

Backing paper value detected is too low, and auto-test value is less than 5.

∆ The sensor detection hole does not spot on the backing paper. (Transparent product is not included.) ∆ Sensor is malfunctioned; replace it with a new one.

Detected value of label sensor is too low, Less than 100.

∆ Label is too thin; replace it with a sensor for transparent label. ∆ Reduce label sensitivity. Refer to chapter 16.5.2.4 “Notes 4”.

Backing paper detected value is too high, and auto-test value is more than 100

∆ The sensor detection hole is blocked. Refer to 16.5.2.5 “Notes 5” to clean it. ∆ Backing paper is printed advertising data. ∆ Backing paper is too thick; replace it with a proper label roll.

cli



LABELING MACHINE

∆ Sensor is malfunctioned; replace it with a new one.

clii


16.5


LABELING MACHINE

Hot Stamp Printer (Model: C70, optional)

16.5.1 Normal Operation a. Turn ON the power switch, the heating indicator will light after 12 seconds. b. While heating, the heating indicator will flash every second. The higher the heating temperature is, the less the heating time is; till target temperature reaches goal value. It takes about 30~60 seconds for heating. c. While stamping, heating will be performed according to every stamping signal. d. Stamping time is controlled by the stamping signal set. e. After finishing one time stamp, the foil tape will roll one time for next stamp. f. While the printer is switched OFF, the heating indicator is still on; it indicates that AC 220V power is in good condition.

16.5.2 Abnormal Conditions Symptom

Causes/Solutions

The heating indicator is always on.

∆ The electrical switch is turned off. ∆ Burned fuse or poor connection ∆ Burned heating elements or poor connection

The heating indicator will not light.

∆ Thermocouple is burned. (No heating) ∆ Heating indicator is malfunctioned (Heating is OK).

No Stamping

∆ The electrical switch on the hot stamp printer is turned off. ∆ Stamping time signal is turned off (no flashing indicator). ∆ Air solenoid is malfunctioned (heating indicator flashes). ∆ No air supply (error signal shown).

Unclear stamped letters

∆ Foil tape is damaged. ∆ Low air pressure. ∆ The pull-up length of Foil tape is insufficient, stamp overlaps. ∆ Improper stamp depth, too deep or too light. ∆ Stamping time is too long or temperature is too high. (Unclear type, excessive carbon powder is found.) ∆ Stamping time is too short or temperature is too low. (Unclear type, carbon powder is dropped.)

Unable to stamp or stamping ∆ Air pressure is set too low. cylinder is unable to draw back, ∆ Stamping shaft has poor lubrication. Refer to 16.5.2.2 “Notes 2”. cliii


causes poor stamping.


LABELING MACHINE

∆ Stamping cylinder has poor lubrication or no lubricant. ∆ Stamping valve is malfunctioning. ∆ Stamping cylinder is malfunctioning.

16.5.2.1 Notes 1: The motor driving problems between the conveyor and the product separator motor. Change the parameter 2-01 (3) of the AC motor driver (inverter) to (0), and then press RUN and speed UP button. If speed changes, it indicates that the driver is in good condition. It may be caused by the transmission control signal. Check the transmission wire and driver as follows: a. Check the C-NET on the back of the display. Normally, the power LED (green) should light on. Press one of the buttons, RUN or PAUSE, on the display; both the SD and RD lamps should flash once. b. If the POWER lamp is not lit on, check 5V voltage source & and if plug is disconnected. c. Press one of the buttons, RUN or PAUSE, on the display; if neither SD and RD lamps are lit on, then the problem should be caused by the connection of PLC and C-NET or one of the PLC or C-NET is malfunction. d. Press one of buttons, RUN or PAUSE, on the display; if only SD lamp light on, it indicates that there is no problem between the connection of PLC and C-NET. Therefore, the problem is caused by the connection of C-NET and inverter.

16.5.2.2 Notes 2

Stamping shaft, proper lubrication

FIG 16.5-1

cliv



LABELING MACHINE

16.5.2.3 Notes 3 To adjust CHIP Vibration Frequence. Notice the position and screw direction

FIG 16.5-2

16.5.2.4 Notes 4 Notice the position and screw direction

FIG 16.5-3

16.5.2.5 Notes 5

Clean the sensor detection hole

Remove the sensor cover

Remove the connection screw

FIG 16.5-4

16.5.2.6 Notes 6 When machine operates abnormally, the following error messages will be shown on the “touch-screen” (screen 2) instead of RUN status. clv


Item


Message

LABELING MACHINE

Description

Action

1

MISS LABEL ON ROLL

Missing label on the label roll

Auto rejection

2

BAR CODE ERROR

Bar code value is incorrect

Auto rejection

3

PRINT CODE ERROR

Missing stamping

Auto rejection

4

SAFE GUARD OPEN

The safety shield is opened

Machine stops and is unable to be re-started.

5

QUANTITY COMPLETED

Preset label quantity is done.

Machine stops

6

BOTTLE ERROR

Sensor detects that product/bottle is Auto rejection too small.

7

PRODUCT FAULT

Sensor detects that product/bottle width is too big or falls down.

Machine stops

8

AIR PRESSURE ERROR

Air pressure is lower than 3kg/cm2

Unable to start machine

9

SEPARATOR ERROR

Gaps between products are too close.

Auto rejection and decreasing product separator speed.

10

BACK PAPER ERROR

No sensibility of the label sensor.

Machine stops

11

RIBBON ERROR

Foil tape is exhausted or damaged. Machine stops

12

HEATER ERROR

Heating wires are damaged.

No heating but heating indicator still lights.

13

THERMOCOUPLE ERROR

Abnormal temperature is detected. Overheating, machine stop

14

EJECT LIMIT

Continuous rejection many times.*

Machine stops

15

HEAT UP

Thermocouple is heating.

Heating indicator flashing

16

Servo system error

Servo is wrong.

No labeling action

17

Inverter system error

Inverter is wrong.

Conveyor is unable to run.

*Special Setup (refer to 8.2.5.22 SPEC. SET): it is necessary to be set up before this function works.

clvi


17. 17.1


LABELING MACHINE

APPENDIX HMI Password Setting (Optional)

Machine Operations should be only allowed the trained and qualified persons to operate. The password setups can be classified into 3 levels, and the screens of the operation procedures are shown as FIG 17.2-1. a. Administrator: Administrators are individuals, who should have deep knowledge of the operation of the machine. Only administrator has the authority to change the password setting. This is to secure the machine against shifting the setup without authorization. b. Supervisor: Supervisor should deep well knowledge of the operation of the machine, and has the authority to change the parameter during the machine operation. c. Operator: Operator should have well knowledge of the operation procedure of the machine, and should be trained and qualified to operate the machine.

clvii


17.2


LABELING MACHINE

Image Checker (Optional)

Nomenclature Image Checker Optical Check Verification (OCV)

Specification A220 Vision System, NAiS (Optional)

17.2.1 General Description 17.2.1.1 Multiple Character Inspections (OCR and OCV) a. OCR: Optical Character Recognition b. OCV: Optical Character Verification OCR and OCV are use for distinguishing date code, lot numbers, and expiration dates, and its character verification tools can check for the printing quality on a majority of surfaces, and packages under deficient lighting conditions.

Is this "2013804212"

OCV: Yes, it is

What’s this?

OCR: “ABCDEF"

* CVC 302 Labeling Machine equipped with OCV system.

17.2.1.2 Setup Procedure a. To adjust appropriate light source, focus, aperture and polarizing filter. b. To establish reference point: The reference point is established by X axle and Y axle crossing each other. It provides the basic reference base for Image Checker operation. c. To set up the checker and to teach the characters to be checked: Limit the checker range, every checker is able to check 1~30 characters. While TEACH window is set up, it picks target characters and login at the same time. It should pick the target characters and login again if any character is changed. Open a new checker if the characters to be checked more than 30.

clviii



LABELING MACHINE

17.2.1.3 Image Checker Limit a. Type (Memory # set) =32 (Each type can be set 1 or 2 Checker) b. Checker =1 or 2 c. Character: Each checker limits 1~30 characters.

17.2.1.4 Check Speed a. Characters 1~10: approx. 50~100ms (360 PCM). b. Characters 11~20: approx. 100~150ms (300 PCM). c. Characters 21~30: approx. 130~180ms (250 PCM). d. Characters more than 30: approx. 150~220ms (180 PCM).

17.2.2 CVC 302 Image Checker Instructions: 17.2.2.1 Hardware Description：： a.. Image Processing Unit ：

b. Camera：

clix



LABELING MACHINE

c. Keypad：

d. Terminal：6” TFT

e. Light Source System： Light Source Unit

Light –emitting Diode

f. Power Supply： DC24V (S-60-24) for camera system, DC12V (S-60-12) for terminal

clx



LABELING MACHINE

17.2.2.2 Quick Setup

Built-in default example setting descriptions (Types: 1, 2, 3, 4, 11, 12, 13, and 14): a. Type 1, 2, 3, 4 provides user for changing the setting. b. Type 11,12,13,14, the default examples setting of factory, provides to restore Type 1, 2, 3, 4 setups by duplicated the default setting if necessary. c. Type 1 & 11：Named V30W, applies to vertical types below 30 characters.

Example

d. Type 2 & 12：Named H30W, applies to horizontal types below 30 characters.

Example

e. Type 3 & 13：Named HOVR30W, applies to horizontal types over 30 characters.

Example

f. Type 4 & 14：Named VOVR30W, applies to vertical types over 30 characters.

Example

clxi

Example



LABELING MACHINE

17.2.2.3 Image Checker Setup and Adjustment a. Flow chart

1. Start

2. Completing Labeling machine function setup

3. Is current aperture appropriate?

4. Is current type appropriate?

4a. Changing type setup to fit current condition.

End

No

Yes

3a. Adjusting lighting, aperture, focus

5. Is current ref. point appropriate?

Yes

6. Is current checker appropriate?

5a. Changing check reference point.

6a. Adjusting checker to fit current condition.

8. Performing image check

7. Taking an image and making it for the check sample

Yes

b. Flow Chart Description: 1. To do the procedure layout. 2. Appropriately adjust labeling machine for the appropriate labeling, and then ensure the proper adjustment of the Image Checker. Refer chapter 11 machine set-up and adjustment. 3. To determine appropriate Lighting, Polarized-light, Aperture and Focus Basically, they are adjusted by factory and in most cases no further adjustment is needed (go directly to Description 4) unless in special case (Description 3a.). 3a. Adjusting Lighting, Polarized-light, Aperture and Focus (if necessary): clxii



LABELING MACHINE

Lighting adjustment: Polarized-light adjustment: Aperture Adjustment: Focus adjustment: Polarizing filter Diaphragm: 4~4.5 Focus: 0.2

Lighting adj. knob

Note: To make sure the proper polarized-light, firstly set the aperture valve at 8~10, then reduce the lighting. If the image displays as the following, it means improper polarized-light adjustment, perform the polarized-light adjustment until the light-spot disappeared.

clxiii



LABELING MACHINE

4. To select and change the proper example (Type 1~4) for checking purpose. If there is no need to be changed, go to Procedure 5. Refer to Procedure 4a for changing the check example. 4a. To change check example: a. Make sure the typing direction and the number of character. Example: Type 1 (horizontal type, 16 characters)

b. Select the proper example type to perform the operations according to the following screen: (The key shown below the right of the screen is used for confirming the item selected.)

4.1

4.2

4.3

4.4

clxiv



LABELING MACHINE

4.5

4.6

4.7

4.8

4.9 Type change completed

clxv



LABELING MACHINE

5. To change the proper checker, the more the checker is, the slower the check speed is. The proper reference point selected is on the topmost and the left most of the characters. If no change is required, go to procedure 6; refer to procedure 5a to perform the checker change (The checker selected should be above the left of the characters:

Check base

5a. The change procedure of the base check. (If the screen is still on the Data Monitor screen, perform the procedure 4.1~4.6 to enter Main Menu screen.)

5.1

5.2

5.3

5.4

clxvi



5.5

LABELING MACHINE

5.6

Select horizontal checker.

5.7

5.8

Enter changing area setting.

Move the whole area.

5.9

5.10

Change the point above the left of the area.

Change the point below the right of the area. Base line

5.11

5.12

Press A key to secure horizontal checker.

Select vertical checker setting. clxvii



LABELING MACHINE

5.13 Enter changing vertical checker setting, the setting procedures are the same as horizontal checker (Procedure 5.8, 5.9, 5.10). Base line

5.14 Press A key to secure vertical checker.

* After completing the vertical and horizontal settings, check the reference point according to the setting procedure.

Base line

5.15

5.16

Select base position setting.

Press A key to secure the base position.

5.17 Complete base position setting and login.

clxviii



LABELING MACHINE

6. To set and change the checker: Select proper checker. If the current checker is proper to use, go to Procedure 8. If not, perform procedure 6a. 6a. To change checker: if the screen is still on the Data Monitor display, firstly perform Procedure 4.1~4.6 to switch to Main Menu display, and then perform the procedure as follows:

6.1

6.2 Select Inspection function.

6.3

6.4

Select OCV system.

Enter OCV system.

6.5

6.6

Select Inspection setting.

Select Area setting.

clxix



LABELING MACHINE

6.7

6.8

Move the check area.

Change the point above the left of the area.

6.9

6.10

Change the point below the right of the area.

Automatically secure the check characters.

6.11

6.12

Complete securing characters and login.

Complete login and end the procedure.

* After completing the area settings, press Procedure 8. Skip the Procedure 7.

key to go back to operation screen and directly go to

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7. Check Example TEACH button: If any character to be checked is changed, it is necessary to press this button to learn the new data for the checking example. The TEACH procedures as 7a. 7a. Press TEACH button to perform TEACH job (Procedure 7.1). a. Touch it once to read the character example (Procedure 7.2). b. Touch it twice to confirm the setting.

TEACH button

NOTE: While performing TEACH job, to read the accurate example is essential; otherwise, improper rejection will be happened.

7.1

7.2

Touch TEACH button once.

Touch TEACH button twice.

* After completing the area settings, press Procedure 8. Skip the Procedure 7.

key to go back to operation screen and directly go to

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8. Perform image check After setting is done, if simply do the example changing, the message for asking saving the data will be shown on the screen. Generally, if the lot number and date are only temporarily changed, it is not necessary to save the data, but depending on the user's requirement. Perform Procedure 8A to save the data. If the setting is changed, the screen will not display the Data Monitor, but ask for saving the data, try to save the change setting; and then the screen will display Main Menu display. Keep press key until screen 8.1 displays. It could save the data and try to change the screen to Data Monitor display. 8a. Check example saving procedures: Firstly perform the Procedures 4.1~4.6 to switch the Data Monitor display to Main Menu display. Other procedures are the same as 8b. 8b. Saving Procedures:

8.1

8.2

Select item 8 "SAVE DATA" setting.

Select "YES" setting.

8.3

8.4

Perform data save.

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8.5

8.6

Switch to Data Monitor display.

Complete data save.

* After completing the above settings, it could perform normal check.

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17.2.3 Image Check Supplement 17.2.3.1 Check Accuracy Setting Sub. Det. Area With this you can set the minimum area for groups of extracted pixels that result from comparision (diffenential) of the registered image and the target image to be subject to the setting in Sub. Det. Judgment. Pixel groups with areas smaller than the setting are not counted.

a. The more the clear of Sub. Det. Area required, the less the value is, and vice versa. b. The value range: 0~999999. c. The default value: 30.

Sub. Det. Area Value

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17.2.3.2 Color Threshold Setting This setting is used to set the difference in gray level for the extraction when comparing a target object with the registered reference image. Parts for which the difference in gray value is larger than the threshold are extracted as white pixels. a. The more similar the background color difference is, the less threshold value is; and vice versa. b. The value range: 0~99. c. The default value: 50.

Color difference value

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