Avery SS Finisher User Manual

Users Manual

SS Finisher

Operation / Maintenance

and Parts List

AVERY DENNISON

Manual Edition 2.1

02 February 2011

Manual Part Number 421385

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Contents

Warranty Information 7

Operation 9

Theory of Operation .................................................................................................... 9

Safety Issues / Warnings.............................................................................................. 9

Warning:...................................................................................................................... 9

Customer Responsibility.............................................................................................. 9

Location of SS Finisher ............................................................................................... 9

Unit Specification ....................................................................................................................10

Ultra Sonic Power Supply........................................................................................................ 11

Caution ...................................................................................................................... 11

Test Button ................................................................................................................ 12

AUTO/MAN Switch.................................................................................................. 12

CUTTING-CONTROL and US-TIME Controls ....................................................... 12

Power......................................................................................................................... 13

Connecting the Ultrasonic Power Supply .................................................................. 13

Loading the Machine ...............................................................................................................14

Loading the Tape ....................................................................................................... 14

Pressure Roller......................................................................................................................... 14

Pressure Roller Setting .............................................................................................. 14

Ultra Sonic Horn "Stack"......................................................................................................... 15

Cutter Set-up.............................................................................................................. 15

Remove Front Cover to Make Adjustments............................................................... 15

Squaring the Horn to the Blade ................................................................................. 16

Ground Detection Sonic Cutter ................................................................................. 17

Replacing the Top Knife Blade................................................................................................ 18

Overview: .................................................................................................................. 18

Note: .......................................................................................................................... 18

Leveling the Top Blade ............................................................................................. 19

Adjusting Knife Spring Pressure: .............................................................................. 19

Knife Pressure ........................................................................................................... 20

Replacing the Top Blade ........................................................................................... 20

Proximity Switch Adjustment .................................................................................................. 22

Trouble Shooting 23

Ultrasonic Noise ...................................................................................................................... 23

Sonic Troubleshooting ............................................................................................................. 24

Control Panel Operation .......................................................................................................... 25

SS Finisher Controls.................................................................................................. 25

Start ........................................................................................................................... 25

Feed ........................................................................................................................... 25

Knife.......................................................................................................................... 25

Stop............................................................................................................................ 25

Indicator Lights........................................................................................................................26

Users Manual SS Finisher •••• 3

On Line......................................................................................................................26

Sensor ........................................................................................................................26

Error........................................................................................................................... 26

Instrument Panel ......................................................................................................................27

Single Screen Input....................................................................................................27

Overview ...................................................................................................................27

Feed Length ............................................................................................................... 27

Cut Position ............................................................................................................... 28

Color Mark Sensor Adjustment................................................................................................29

Contrast Sensor.......................................................................................................... 29

Overview ...................................................................................................................29

Setup.......................................................................................................................... 29

LCD Display ............................................................................................................................30

Diagnostic Tests ........................................................................................................30

Recommended Spare Parts:......................................................................................................31

Troubleshooting Electrical ....................................................................................................... 32

Appendix A 33

Manufactures of Hearing Protectors ........................................................................................ 33

Appendix B 34

Error Messages ........................................................................................................................34

Appendix C 35

Label / Machine Speed.............................................................................................................35

Labels Rate Chart ......................................................................................................36

Appendix D 37

Multi Color Contrast Sensor Installation Instructions .............................................................. 37

Sensor Installation - Option No. 420014 ................................................................... 37

Teach-in Procedure:...................................................................................................38

Color Contrast Sensor Option Assembly ................................................................................. 39

Color Contrast Sensor Option Parts List.................................................................................. 39

Electrical Schematic 41

115V / 230V Schematic – Branson System ............................................................................. 42

Machine Interface Board Jumper Position ............................................................................... 43

Assembly Drawings Mechanical 45

Unwind Assembly.................................................................................................................... 46

Unwind Parts List..................................................................................................................... 47

Feed Pressure Roller Assembly................................................................................................48

Knife Assembly........................................................................................................................ 50

Knife Parts List ........................................................................................................................51

External Fan Assembly ............................................................................................................ 52

External Fan Parts List .............................................................................................................53

Conveyor Assembly.................................................................................................................54

Conveyor Parts List..................................................................................................................55

Stacker Assembly.....................................................................................................................56

Stacker Parts List .....................................................................................................................57

Users Manual SS Finisher •••• 4

Tamper Assembly .................................................................................................................... 58

Tamper Parts List..................................................................................................................... 59

Drive Assembly ....................................................................................................................... 60

Drive Parts List ........................................................................................................................ 61

Contrast Sensor Assembly ....................................................................................................... 62

Contrast Sensor Parts List ........................................................................................................63

Cover Assembly....................................................................................................................... 64

Cover Parts List ....................................................................................................................... 65

Users Manual SS Finisher •••• 5

Warranty Information

Warranty Policy

Avery Dennison Retail Information Systems, In-Plant Printing Solutions provides the following warranty policy.

Scope

Warranties against defects from workmanship for equipment and parts manufactured and sold from Sayre, PA. Includes time and material except as otherwise noted below.

Time

− New equipment and parts: 6 months

− Refurbished equipment and parts: 90 days

− Warranty period starts when equipment ships from selling location.

General Conditions

Avery Dennison extends warranty coverage under the following conditions.

− Equipment and parts will perform within published specifications. Promised or implied statements by any Avery Dennison employee or representative will not be deemed to vary the terms of the warranty.

− Equipment and parts must be installed and operated according to recommended procedures and operating conditions.

− Consumable elements are not covered. Consumable elements are those that show normal wear from typical equipment usage including, without limitation, printheads, knives, rollers in contact with the web, and sonic units. Avery Dennison reserves the right to determine which elements are defined as “consumable.”

− No customer maintenance may be performed except as directed by qualified Avery Dennison personnel.

− Equipment and parts damaged by negligence or abuse are not covered.

− Avery Dennison US reserves the right in its sole discretion to incorporate any modifications or

improvements in the machine system and machine specifications which it considers necessary but does not assume any obligation to make said changes in equipment previously sold.

Equipment Purchased In US and Shipped In US

− Avery Dennison US covers warranty for equipment and parts installed and operated in the Americas (United States, Canada, Mexico, Central America, Caribbean Region, and South America excluding Brazil).

− Outside the US, the local Avery Dennison office is responsible for equipment and parts warranty. Customers must ensure coverage during machine purchase.

Users Manual SS Finisher Warranty Information •••• 7

− Equipment purchased and exported to regions outside local Avery Dennison office coverage are not

covered by warranty. The purchasing agent must acquire a service contract from the Avery Dennison office where the equipment or parts are operated to ensure machine coverage. For example, if an agent purchases a printer in the US, exports to Brazil, and then needs warranty coverage, Avery Dennison Brazil has no obligation to provide warranty coverage. The agent must purchase services from Avery Dennison Brazil.

THE WARRANTIES PROVIDED HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY OR PERFORMANCE, WHETHER EXPRESS OR IMPLIED. EXCEPT THE WARRANTY OF TITLE, IN NO EVENT SHALL AVERY DENNISON BE LIABLE FOR ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF AVERY DENNISON HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

Service

When ordering machines and supplies in the U.S.A., reference all correspondence to the address below.

AVERY DENNISON Corporation

One Wilcox Street

Sayre, PA 18840

Call: 1-800-967-2927 or (570) 888-6641

Fax: (570) 888-5230

For spare parts, requests for service or technical support, contact

AVERY DENNISON Corporation

One Wilcox Street

Sayre, PA 18840

Call: 1-800-967-2927 or (570) 888-6641

Fax: (570) 888-5230

For parts and service in other countries, please contact your local AVERY DENNISON supplier.

Users Manual SS Finisher Warranty Information •••• 8

Operation

Theory of Operation

The SS Finisher was designed to cut and stack pre-printed stock using ultrasonic vibrations to cut and seal the label. This provides the label with a cut edge that is soft and smooth as the original label tape. It was also designed to accept label tapes that were printed on a variety of different machines.

Safety Issues / Warnings

This machine has some pinch points and hot surfaces. All of these areas have been well guarded and it is recommended that the safety features of this machine are never altered or defeated.

Since ultrasonics is high frequency sound, some noise will be produced as it makes its cut. It is recommended that people in the immediate area wear ear protection. (See appendix “A” for a list of manufacturers of hearing protection.)

Warning:

High voltage is present in the power supply. Never attempt to operate the unit with the cover off.

To prevent the possibility of electrical shock, make sure the power supply is properly grounded.

Keep hands from under horn. High pressure and vibrations can cause injury to hands and fingers.

Large plastic parts may vibrate within the audible frequency range when cutting. If this occurs, use ear protection to prevent possible injury.

Do not allow the ultrasonically activated horn to touch a metal base or metal fixture.

Do not press the “TEST” switch when the converter is removed from the equipment.

Customer Responsibility

Location of SS Finisher

The SS Finisher weighs approximately 114 Lbs. (52Kg). A table of sufficient quality and strength to handle the load of the SS Finisher and supplies must be supplied. The work surface recommended is 96” wide x 30” deep x 32” high.

The SS Finisher should be located in an area that the ultrasonic noise emitted from the cutting operation will not affect others. AVERY DENNISON has taken many steps to keep the SS Finisher noise to the lowest level. The SS Finisher is not recommended for an office environment.

The power source of the SS Finisher should be a dedicated line. The first sign that the SS Finisher is not being supplied with sufficient power is the ultrasonics will stop cutting, but the rest of the SS Finisher will appear fully functional.

Users Manual SS Finisher Operation •••• 9

Unit Specification

cut and stacked

Label Size

Justification Material must be centered over ultrasonic horn.

Sense Mark The material must have a pre-printed sense mark on the top side. The sense mark must be a minimum

Speed Operator adjustable to match speed of printer

Stock Polyester woven edge fabric and AVERY DENNISON So-Soft® Products

Interface Cabling to printers and to Sonics

Max: up to 1.57" (40mm) - (1 9/16” (40mm) Tested) web x up to 5" (127 mm) feed -

- Up to 10.0" (255mm) feed – Without stacking

Min: 5/8" (16mm) web x 1" (25.4mm) feed - See chart Appendix C

of 1/8” (3.2mm) in the feed direction and ¼”(6.35mm) across the web. The sense mark must have a clear space of at least 0.3” (7.6mm) just prior to the sense mark.

Control

Panel

Dimensions 20.0" (508mm) high x 26" (660mm) wide x 15" (381mm) deep

Weight 114 Lbs. (52Kg.)

Electrical 90-132 / 180-265 VAC 50-60Hz 10/5 Amp - factory set

Temperature

Humidity 5% to 90% non-condensing

Other

Features

Options - Flag cutting – (Same length as label only)

Push-button SS Finisher functions with 2 Line x 24 Character International LCD Backlit Display

41°F (5°C) to 104°F (40°C)

- Life Counts

- Operator adjustable: cut position

- Error Detection of: guard open, full stacker

- Self Diagnostics

- Missed sense mark detection and correction

- Reflective Sensor (Top of Web Only)

- Spare Parts Kit

- International Hardware Kit

The SS Finisher is a modular design, which can be added to any of the AVERY DENNISON fabric printers - including the 636, 656 and 676 thermal transfer printers.

Users Manual SS Finisher Operation •••• 10

Ultra Sonic Power Supply

Caution

Only qualified technicians should service the power supply.

The ultrasonic attachment is made up of several components. They are the power supply, the horn assembly and the connecting cable. In addition there is a knife assembly with a changeable tool steel blade.

The power supply should be located next to the SS Finisher. This unit generates electrical pulses at 35 KHz to the converter. All guards must be closed for the Sonics to be activated. The power supply contains a "TEST" button, power indicator light, Auto/MAN switch, Cutting and US-Time controls and a relative power gauge.

NOTE: The power supply is adjusted for proper operation at the factory. DO NOT change any of the adjustments on the power supply.

TELESONIC

ULTRASONICS

TEST

LOAD

100

AUTO MAIN

TEST

TUNING

OVERLOAD

OVERTEMP

POWER

CUTTING-CONTROL

100

200

US-TIME

100

SG3510 CT

The Ultrasonic Power Supply is pre-programmed for the correct settings at the factory. The following instructions describe how to check and change these settings.

Users Manual SS Finisher Operation •••• 11

IMPORTANT: FOR PROPER OPERATION, USE THE FACTORY

SETTINGS AT ALL TIMES. CHANGING THESE SETTINGS MAY RENDER THE SONIC KNIFE INOPERABLE, REDUCE THE QUALITY OF THE CUT AND/OR REDUCE THE RELIABILITY OF THE SONIC KNIFE.

Settings

The Power Supply is set properly at the factory. Any changes to the factory setting may result in improper operation. If necessary, the factory settings may be restored as follows:

AUTO/MAN switch AUTO

CUTTING CONTROL 0

US-TIME 0

COAXIAL CONVERTER CABLE

37 PIN CONNECTOR

AC POWER CABLE

Test Button

The "Test" button can be used to check the operation of the sonic stack assembly. This is done by depressing the switch while observing the power indicator. If more than 2 bars are illuminated, the stack requires repair.

AUTO/MAN Switch

The AUTO/MAN switch should always be in the AUTO position.

CUTTING-CONTROL and US-TIME Controls

The CUTTING-CONTROL and US-TIME Controls should always be set to 0.

Users Manual SS Finisher Operation •••• 12

Power

"Power" on pilot light indicates when the power supply is on. This only indicates that the power supply is connected to the line power. Ultrasonic energy is only generated during the actual cut cycle. This is indicated by the green light next to the US_TIME control.

Connecting the Ultrasonic Power Supply

Line Cord

Plug the line cord into the mating receptacle on the back of the power supply and secure it with the metal bail. Plug the other end of the line cord into the line (mains) receptacle.

NOTE: The Ultrasonic Power Supply does not have a power switch. It is on all the time. Ultrasonic energy is only generated during the cut cycle.

Sonic Stack Cable

The Sonic Stack Cable plugs into the mating connector on the rear of the Power Supply. Insert the plug firmly into the socket until it is fully seated.

Power Supply Control Cable

The Power Supply Control Cable plugs into the 37-pin connector on the rear of the Power Supply. Plug in the cable and secure with the retaining screws.

Users Manual SS Finisher Operation •••• 13

Loading the Machine

Loading the Tape

To load the SS Finisher, start by adjusting the Fabric Guides to the correct width, allow the fabric to slide between them without buckling. Be sure to adjust the guides evenly on both sides, as the SS Finisher must be run with the fabric centered in the machine. Adjust the Fabric Guide Bar Adjust so that it centers the Guide Bar over the fabric.

Pressure Roller

Pressure Roller Setting

The Feed Pressure roller is Spring loaded, so there is always pressure to the drive roller. The feed roller can be opened by moving the Feed Open lever to the vertical position, and then lowering it when ready to operate the machine. (Shown with the Fabric Stripper Blade removed)

Users Manual SS Finisher Operation •••• 14

Ultra Sonic Horn "Stack"

Cutter Set-up

The "Converter / Horn" assembly is called the "Stack". The stack generates the ultrasonic energy that cuts and fuses the fabric.

The converter receives the electrical pulses from the power supply and converts them to mechanical lineal motion. This motion is then amplified as it goes through the “Horn”. This causes the horn to vibrate at 35 KHz acting like a tiny impact hammer. This action causes friction heat that cuts and fuses the label tape.

CAUTION: The horn can cause burns if touched during operation

The SS Finisher has been set-up at the factory to run a checkout stock as the minimum checkout requirement. Depending on the shipping destination and the information supplied to the factory, the actual production job the customer has ordered will be tested.

At times the unit will require adjustment and maintenance. The top knife will need to be replaced and squared, the stack will also need to be adjusted to cut in a new location, and general tuning will need to be done to keep the SS Finisher in top running condition. The following sections are in order of procedure to set-up the knife and to keep the SS Finisher cutting properly.

Remove Front Cover to Make Adjustments

FRONT COVER

Users Manual SS Finisher Operation •••• 15

Squaring the Horn to the Blade

ROTATE

To square the Horn to the Blade, first loosen the four square adjusting cap screws, shown above. This will allow the stack to rotate. Next loosen the two adjusting cap screws shown below. Once they are loose, place a 3/16 ball driver next to the deck and slide entire stack against the ball driver. This will square the horn to the deck. Next, tighten the four square adjusting screws. Once they are tight, return stack to the center of the blade by turning the screw adjustment, and then tighten the two adjusting cap screws.

Users Manual SS Finisher Operation •••• 16

Ground Detection Sonic Cutter

The SS Finisher has a Ground Detect Circuit that turns the sonic power off after the blade has cut through the fabric. This reduces blade wear and increases the life and reliability of the blade.

The blade holder and blade is electrically isolated from the frame of the machine. A wire is attached to the blade holder. A circuit looks to see when the blade comes in contact with the horn surface and shuts down the sonic power source.

Users Manual SS Finisher Operation •••• 17

Replacing the Top Knife Blade

KNIFE BLADE MOUNT

LEVELING SCREWS

KNIFE BLADE

Overview:

Upper blade wear is caused by the abrasion from the ultrasonic vibration when the horn face and the edge of the blade are in contact. There are four major adjustments that control the life of the upper blade. The first is a properly tuned power supply. Second is the blade parallel the horn face. Third is the amount of pressure between the blade and the horn (factory setting .750”). Fourth is the dwell time between the blade edge and the horn face after the cut has been made (factory setting .015”). The following is a guide to properly replace the upper knife blade.

Note:

When removing the knife blade, the blade may seem tightly mounted to the knife mount pin. Pull blade off of mount pin by pulling from the top of the blade.

Users Manual SS Finisher Operation •••• 18

Leveling the Top Blade

CAUTION: Turn off the power to the power supply only.

Remove the material from the horn and knife blade area. Use a 5/32” “T”handle or Allen wrench to loosen the two leveling screws located each side of the pivot pin on the knife blade holder. Jog the machine with the START/TEST buttons to bring the blade to the horn surface under full pressure. Evenly tighten the two leveling screws located each side of the pivot pin on the knife blade holder.

Turn the sonic power supply back on. Cut some fabric to determine if the blade is level. If not level – repeat the above procedure.

Adjusting Knife Spring Pressure:

The .750 gap setting shown below – under “Knife Pressure” - is the initial starting point for a new knife blade. As the knife begins to show intermittent labels not being cut clean then an adjustment is needed to the spring pressure.

If the knife is not cutting the label clean and delivering a cut single label to the stacker then the knife should be checked for level (see leveling procedure). Never pull the labels apart to use them as they can fray when washed. If no improvement is seen, make sure the “Lock Knob” is tight, then increase the pressure one flat on the adjusting nut. If no improvement is seen then increase one more flat of the adjusting nut. This procedure can be repeated several times during the life of the upper blade until the pressure will no longer cut. At this point the pressure is greater than the power of the Sonics and will stall the horn, replace the blade.

Note: Bring the Adjusting Nut back to the .750” gap setting whenever a

new blade is installed.

LOCK KNOB

ADJUSTING NUT

SPRING

KNIFE BLADE

Users Manual SS Finisher Operation •••• 19

Knife Pressure

This new design comes with factory set knife pressure. The following diagram shows the factory settings for pressure with a new top blade. Should the unit stop cutting, the knife blade should be leveled first, and if unsuccessful, add pressure with the “Adjusting Knife Spring Pressure” instructions above.

A means to adjust this pressure is built into the knife linkage. To make this adjustment, first the .015” gap must be set - followed by the .750” gap.

To set the .015” gap, jog the machine until the knife blade is in its full down position with no fabric under the blade. Loosen the LOCK KNOB and turn the ADJUSTMENT NUT until the gap is at .015”. Retighten the LOCK KNOB.

To set the .750” gap, jog the machine until the knife blade is in its full down position with no fabric under the blade. Loosen the screw on the ADJUSTING NUT; turn the ADJUSTMENT NUT until the gap is .750”. Tighten the setscrew.

.750

.015

START & OPERATION

POSITION

Replacing the Top Blade

Turn the Ultrasonic power supply switch off.

Note: The knife button and start button combination will cycle the blade ½

revolution - from no pressure to full pressure.

Because the knife blade will eventually wear from abrasion caused by ultrasonic vibration when the horn face and the knife blade are in contact, the knife blade will need to be replaced periodically.

To replace the knife blade, remove the knife blade guard. The knife is attached to a self-leveling mount with a leveling pin. Loosen and remove the (2) knife screws and remove the blade from the leveling pin. Replace the new knife blade. Thread the (2) knife screws into the knife mount but do not tighten. The blade must be leveled each time it is replaced. See below for knife blade leveling procedure.

When removing the knife blade, the blade may seem tightly mounted to the knife mount pin. Pull blade off of mount (leveling) pin by pulling from the top of the blade.

Knife Blade leveling

Jog the knife with the TEST/START buttons until the blade is in full contact with the horn. Tighten the two clamp screws in small equal increments until they are very tight. Loose screws will shorten blade and horn life. (A loose screw may cause the blade to make a noise during the cut.)

Users Manual SS Finisher Operation •••• 20

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