CTM 360a series Maintenance And Service Manual

1318 QUAKER CIRCLE P.O. BOX 589 SALEM, OHIO 44460

PHONE: [phone]

FAX: [phone]

www.ctmlabelingsystems.com

Designers and Manufacturers of Pressure Sensitive Labeling

Equipment and Custom Product Handling

360a LABEL APPLI CA TOR

CE VERSION

MAINTENANCE

&

SERVICE MANUAL

REVISION 360a-4a.1.X.XXX

EC DECLARATION OF CONFORMITY

Declaration: The listed product fulfils all the relevant provisions of the following Directive:
Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on

the approximation of the laws of the Member States relating to Machinery
Manufacturer: CTM LABELING SYSTEMS
1318 Quaker Circle, Salem, Ohio 44460 USA
Machine Name: 360a Series Label Applicator
Model Number: 360a
Serial Number: 360a-CE-0101-0809
Drawing Identification: ASS-200CE-0401, 1 Sheet, Rev. 6, Dated; 03-Mar-2008
Standards Used:

EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and risk
reduction
EN ISO 14120:2015 Safety of machinery – Guards – General requirements for the design and construction
of fixed and movable guards
EN 1037:1995 +A1:2008 Safety of Machinery – Prevention of unexpected startup
EN ISO 13849-1:2015 Safety of machinery - Safety related parts of control systems – Part 1: General
principles for design
EN ISO 13850:2008 Safety of Machinery – Emergency stop equipment, functional aspects – Principles for
design
EN ISO 13857:2015 Safety of Machinery – Safety distances to prevent danger zones from being reached
by upper and lower limbs
EN ISO 14119:2013 Safety of machinery - Interlocking devices associated with guards - Principles for
design and selection
EN 60204-1:2006 Safety of machinery – Electrical equipment of machines, Part 1: General requirements
+A1:2009

Means of Conformity: Technical File (TF): MS4581
Compiler of TF: Safenet Ltd., UK Notified Body Number 1674, Denford Garage, Denford, Kettering,
Northants.,
NN14 4EQ United Kingdom
Other Directives met: Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014

on the harmonisation of the laws of the Member States relating to electromagnetic

compatibility (recast)

Signature: ____________________________________ Date: __________________________

CTM LABELING SYSTEMS
1318 Quaker Circle, Salem, Ohio 44460 USA

Testing Procedures

Location

Level (dB)A

M1

81.9

M2

83.6

M3

79.8

The 360a-CE applicator was tested as a merge with the product detect sensor and display attached.
Because of the many configurations and options that are available for this model, there was no way to
test all configurations. The only issue with the different noses will be machine safety. The integration of
an applicator into a product line may cause pinch points or other dangerous situations that will need
guarded. The responsibility for guarding lies with the integrator.

Safety Related Issues to Ensure Compliance

• End user is responsible for meeting the final protective ground requirements.

• The power inlet on the back of the applicator is the AC power disconnect. The end user is

responsible for determining and providing a supply disconnect for the system.

• Voltages greater than 60 volts may be present inside the applicator after a discharge time of 5

seconds.

• The end user must provide protection concerning power interruptions/restoration, if needed.

• The end user must provide earth ground fault current protection, if required.

• The end user will provide any guarding needed after integration of the applicator.

Emergency Stop Actuators

EN/ISO 13850:2015 Clause 4.3.2 requires that an emergency stop device shall be located at each operator
control station, except where the risk assessment indicates that this is not necessary.

Upon reviewing the machine with the manufacture, it was agreed that the risks posed by the labeling
machine itself are not sufficient as to require a dedicated emergency stop pushbutton at the HMI console.

An entanglement test was preformed between the Nip and Drive rollers, and it was found that no
significant pull was exerted on fabric, and that only a mild pinch was exerted on the fingers.

The main machine into which this machine is incorporated should have an emergency stop system that
will remove power and air to the 360a system, thus removing all power to its actuators.

Acoustic Emissions Data

A weighted emission sound pressure levels at workstations do not exceed 70 dB(A).

Measurement Locations:

M1 –In front of label spindle
M2 –Operator’s position when using the HMI
M3 –Rear of machine frame

TABLE OF CONTENTS

i

TABLE OF CONTENTS

INTRODUCTION ......................................................................................................…...1

MACHINE TERMS ...................................................................................................…...2

DISPLAY PANEL ................................................................................................…….…3

KEY TYPES…………………………………………………………………… 3-1
ALARMS……………………………………………………………………… 3-2
CHANGING VALUES…………………………………………………….. …. 3-3
PASSWORD………………………………………………………………….… 3-4
MAIN MENU……………………………………………………………….…. 3-5
SETUP MENUS (main setup) …………………………………………….…. 3-5
LABEL SETUP………………………………………………………………... 3-6
Label Length…………….……………………………… 3-6
Label Stop…………………...…………………………… 3-6
Label Stop Compensation ...…………………………… 3-6
Label Sensor……………………………………………… 3-7
Label Formats……………..……………………………… 3-8
APPLICATOR SETUP……………………………………………………… … 3-10
Air Blast………….………..……………………………… 3-10
Tamp Times………….……..……………………………. 3-10
Extended Air Assist……….……………………………… 3-10
Web Speed……….………….…………………………… 3-10
Pre-Dispense……….…………………………………… 3-10
Over Speed………….……….…………………………… 3-11
Label Profile…………….……………………………… 3-11
Multi-Panel…………….…….…………………………… 3-15

PRODUCT SETUP.....................................................................................…… 3-17

Label Placement……….………………………………… 3-17
Detector Lockout…….………………………………….. 3-17
Encoder Option…….…………………………………… 3-17

CONFIGURATION..............................................................…………………… 3-20

Applicator Type………..…………………………………. 3-20
Applicator Options……….……………………………… 3-20
Loose Loop…….……………..………………………… 3-21
Imprinter……….………………………………………… 3-21
Crossover……….…………….………………………… 3-22
Multi-Label……….………….………………………… 3-24
Missing Label……….……………………………………
Powered Rewind……….…….………………………… 3-25
Tamp Home Mode……………………………………… 3-25
Skip Count……….……………………………………… 3-26
Foldover………………………………………………… 3-26
Label On Pad…………………………………………… 3-27
Vacuum Off…………………………………………….. 3-27
Product Detect Queuing…………………………………. 3-27
Max And S
I/O Diagnostic……….……………………………………
Reset Label Sensor……….………………………………

lew Speeds……….………………………… 3-28

3-24

3-29

3-29

TABLE OF CONTENTS

ii

SPECIAL OPTIONS........................................................................….............. 3-29

Drive Parameters ……….………………………………... 3-29
Customer Password……….……………………………… 3-30
No Labels Found Count……..…………………………… 3-30
Software Version.…………………………………….…
Placement To Time ……………………………………... 3-30
Missing Label Mode 2 ……………………………….…… 3-31
Auto Online Option………………………………………. 3-31
Product Detect Debounce Time…………………………… 3-31
Label Sensor Model……………………………………….. 3-32

FACTORY DEFAULT...................................................................................... 3-33

3-30

REAR PANEL ....................................................................................................……….. 4

SETUP PROCEDURES ........................................................................……………….. 5

MOVING THE APPLICATOR .............................................................……….. 5-2

JOB SETUP ........................ ..................................................................……….. 5-3

LABEL SENSOR SETUP ......................................................................……… 5-4

LABEL LENGTH SETUP ........................................................................…… 5-5

LABEL STOP SETUP..........................................................................……… 5-6

WEB SPEED SETUP ................................................................................…… 5-6

SLEW SPEED SETUP...........................................................................……… 5-6

LABEL STATIC TEST.........................................................................………… 5-7

LABELER TYPE SETUP ........................................................................................…… 6

MERGE APPLICATOR .................................................................................…. 6-1

AIR BLOW APPLICATOR ..........................................................................… 6-2

TAMP APPLICATOR ....................................................……………………… 6-5

DUAL ACTION TAMP (DAT) ......................................……………………… 6-9

PRODUCT SETUP ....................................................................................................….. 7

PRODUCT SENSOR ………………………………………………………… … 7-1
LABEL PLACEMENT ……………………………………………………… … 7-2
DETECTOR LOCKOUT……………………………………………………… 7-2
ENCODER……………………………………………………………………… 7-3

GENERAL MAINTENANCE ..................................................................................….8

DAILY ………………………………………………………………………… 8-2
WEEKLY ……………………………………………………………………… 8-2
MONTHLY …………………………………………………………………… 8-2
SEMI-ANNUAL ……………………………………………………… ……… 8-3
DANCER ARM ADJUSTMENT ……………………………………………… 8-3
REWIND SLIP CLUTCH …………………………………………………… … 8-4
DRIVE BELT ADJUSTMENT ………………………………………………… 8-5

TROUBLESHOOTING............................................................................................….. 9

DIAGNOSTIC CHART ……………………………………………………… … 9-1
DISPLAY FAULTS …………………………………………………………… 9-5

TABLE OF CONTENTS

iii

ACCESSORIES .........................................................................................................…. 10

RECOMMENDED SPARE PARTS.........................................................................…. 11

CHANGEOVER INSTRUCTIONS .....................................................................…… 12

APPLICATOR CHANGEOVER …………………………………………… … 12-1
BLOW BOX NOSE ASSEMBLY REMOVAL / INSTALLATION ………… 12-3
MERGE NOSE ASSEMBLY REMOVAL / INSTALLATION ……………… 12-4
TAMP NOSE ASSEMBLY REMOVAL / INSTALLATION ………………… 12-5
NOSE ASSEMBLY CHANGEOVER ………………………………………… 12-6
MERGE PEEL EDGE CHANGEOVER ……………………………………… 12-6
BLOW BOX PEEL EDGE / FAN / GRID CHANGEOVER ..………………… 12-7
TAMP PEEL EDGE / CYLINDER CHANGEOVER ………………………… 12-8
REWIND REMOVAL / INSTALLATION / CHANGEOVER ……………… 12-9
WIRING CHANGEOVER …………………………………………………… 12-9

APPLICATOR DRAWINGS ……….....................................................................… 13

INTRODUCTION

INTRODUCTION

The CTM Labeling Systems’ 360a Series Modular Labeling System is a high-speed Applicator used to
apply pressure sensitive labels to moving products on a production line. It is essentially a self-contained
Module that may be mounted in almost any position to apply labels to the top, bottom, or sides of packages
as they pass by on a production line.

The CTM Labeling Sys t ems’ 360a Series Modular Labeling Syste m is unique in that the M ain Module can
be adapted to three different types of Applicators: Air Blow, Merge, or Tamp by changing the Nose
Assembly. The symmetrical design of the Applicator allows labels to be dispensed to the right or left side
of the Applicator. The Applicator Type and configuration (either left or right -handed) will depend on the
type of product to be labeled and the arrangement of the production line.

If your application needs changed in the fut ure, a different Nose A ssembly may be purchas ed but the Main
Module would remain the same. There is no need to purchase a completely new Applicator. The CTM
Labeling Systems’ 360a Series Modular Labeling System can be easily changed over to a different apply
type by simply removing the existing No se from the module and replacing it with a different Nose.

You can also change the configuration (right-hand or left-hand) by simply moving the Appl icator Nose
from one side of the Applicator to the other. All the parts are interchangeable*. Everything you need is
already included with each Applicator Nose to make the change usin g your existing Module.
* Tamp Pad & Manifolds as well as some Options are hand specific.

The labels should be supplied on a liner web with a minimum label gap of 1/8”. The Applicator will accept
and dispense labels from rolls up to 20” O.D. Label accuracy is mostly dependant on product handling but
the Label Stop at the Peel Edge will be within +/- 1/32 inch when using labe ls constructed with a liner that
does not stretch.

For safe trouble free operation of the Applicator, carefully follow the instructions in this Manual durin g
setup, operation, label roll change s, cleaning, a nd maintenance. The Applicator is designed to operate
under the following environmental conditions:

ELECTRICAL SUPPLY: 207-253 Volts, 3 Amps, 50 - 60 Hertz, Single-Phase
108-132 Volts, 7 Amps, 50 - 60 Hertz, Single-Phase

AIR SUPPLY: The applicator requires clean and dry compressed air at pressures between 6.2 and

6.9 bar (90 - 100 P.S.I.) with a minimum flow rate of 113.3 L/min (4 S.C.F.M).

• Note: In the t amp applicator, an incr e ase in venturi vacuum
pressure may lead to higher SCFM requirements.

ENVIRONMENT: Operating temperature range is 10 to 35°C (50 to 95°F). Operating humidity

range is 20 to 85% RH, non-condensing.

NOTE: THE 360a SERIES MLS IS NOT INTENDED TO B E OPERATED IN AN
ENVIRONMENT WHERE FLAM MABLE OR EXPLOSIVE GASS ES ARE PRESENT. THE 360a
SERIES MLS IS N OT TO BE USED IN DIRECT CONTACT WITH FOOD PRODUCTS.

READ THE INSTRUCTIONS CAREFULLY AND COMPLETELY. This Manual includes all of the
information needed to setup the Applicator under normal operating conditions. The instruc tions include
important safety precautions that must not be ignored.

1-1

INTRODUCTION

READ THE INSTRUCTIONS IN O RD ER. The instructions are written as numbered steps that will take
you safely and efficiently through the setup process. Any steps performed out of sequence may result in a
hazard and the Applicator may not operate properly.

WORK CAREFULLY. Although set ting up the Ap plicator is not difficult, it does take ti me. Do not rush
through the process. Careful work will produce good results.

IF SOMETHING DOES NOT WORK PROPERLY, TRY SETTING IT UP AGAIN. Although an
Applicator malfunction is possible, most problems happen because the Applicator is not setup correctly. If
the Applicator doesn’t operate correctly, back up and start over.

FOLLOW ALL SAFETY INSTRUCTIONS. The CTM 360a Series MLS applicator has been provided
with a number of safety features. Observe all safety warnings and under no circumstances attempt to
remove or defeat safeguards or operate the Applicator in a manner contrary to the instructions.

1-2

MACHINE TERMS

DEFINITION OF MACHINE TERMS

AIR BLAST JETS:

The flexible Air Blast Jets pr ess-fit into the inside face of the B low Box Grid and can be re-arranged to
provide an air stream pattern that transfers labels of various sizes and shapes to the product. The Air Jets
are connected via a Manifold to the output of the “Air Blast” Solenoid Valve located in the Valve Bank.
The Regulat or Assembly on the Valve Bank controls the air pre ssure to this Solenoid Valve. The duration
of the Air Blast is controlled by the “Air Blast Time” function. Refer to the setup procedures for
instructions.

NOTE: Any unused Air Je t Tubes should be inserted into the Storage Block at the rear of the Blow Box.

AIR ASSIST TUBE:

The Air Assist Tube is a small stainle ss steel tube, with an anti-stick coating, t hat is mounted on the
underside o f the Peel Edge. It helps to separate the label from the liner as it is being dispensed onto the
Blow Box Grid or Tamp Label Pad for application.

APPLICATOR BLOW BOX NOSE:

The Blow Box Applicator Nose is used for dispensing labels via the Air Blow applicatio n. The Blow Box
creates a vacuum to hold the label to the Blow Box Grid until it is dispensed onto the product. The Nose
Assembly is easily converted from left-hand to right -hand and vice versa using the same parts. Al so, the
Blow Box Nose Assembly can be interchanged with the Merge, Tamp, or DAT Applicator Nose Assembly.

APPLICATOR MERGE NOSE:

The Merge Applicator Nose is used for dispensin g labels via the wipe on/merge applic a tion. A label is
dispensed from the Peel Edge and the brush wipes the label onto the product as it is traveling past the
Applicator. The Merge Applicator Nose is easily converted from left-hand to right-hand and vice versa
using the same parts. Also, the Merge Nose Assembly can be interchanged with the Air Blow, Tamp, or
DAT Applicator Nose Assembly.

APPLICATOR TAMP NOSE:

The Tamp Applicator Nose is used for dispensing labels via the air blast/tamping application. A labe l is
dispensed from the Peel Edge onto the Label Pad. The Air Cylinder extends the Tamp Assembly to the
product and the label is applied with an air blast. The Tamp Extend and Retract Times are configured
during Applicator Setup. The Tamp Applicator Nose is easily converted from left-hand to right-hand and
vice versa using the same parts*. Also, the Tamp Nose Assembly can be interchanged with the Air Blow,
Merge, or DAT Applicator Nose Assembly. *Tamp Pad & Manifold is hand specific.

2-1

MACHINE TERMS

APPLICATOR DAT NOSE:

The DAT (Dual Action Tamp) Applicator Nose is used for dispensing labels via an air blast to the side of
the produc t with a tamping action and the leading or trailing panel of the same product with a swing action.
SWING ONLY and SIDE ONLY operating modes are supported as well. A label is dispensed from the
Peel Edge onto the Label Pad. Air Cylinders extend the Tamp or Swing Arm Assemblies to the product
and the label is applied with an air blast. The Tamp/Swing Extend and Retrac t Times are configured during
Applicator Setup.

BLOW BOX / VACUUM GRID:

The Blow Box/ Vacuum Grid is the cube shaped assembly located next to the Peel Edge on a Blow Box
Applicator. Two (2) Axial Fa ns mounted above the Grid create the vacuum needed to hold the label in
place prior to application.

DANCER ARM:

The Dancer Arm is attached to the Unwind Block Assembly with a shoulder bolt, thrus t bearing and a
bushing. It appears immediately after the Unwind Mandrel in the web path. The Dancer Arm has a roller
at one end that rides against the label liner and is interconnected to the Mandrel Tension Disk with a spring.
The Dancer Arm maintains t ension on the liner loop as it operates the brake on the Unwind Mandrel when
labels are being dispensed. The spring tension should be large enough to properly tension the web but still
allow proper operation of the brake. Do not over tension the Dancer Arm.

DRIVE ROLLER:

The Drive Roller is coupled to a Stepper Motor that provides the motive force for advancing the label liner.
The Drive Ro lle r in conjunction with the spring loaded Nip Roller, pull the label liner around the Peel Edge
to dispense a label onto the product, Tamp Pad, or Blow Box Grid.

LABEL MANIFOLD:

The Label Manifold is the mounting blo ck that attaches the Label Pad to the bottom of the Tamp Cylinder
on the Applicator Nose. The Label Manifold is a custom part that is manufactured exactly to the label size
being applied. If at any time the label size changes, a new Label Manifold must be purchased along with
the Label Pad.

LABEL PAD:

The Label Pad is a white delrin material mounted onto the Label Manifold at the bottom of the Tamp
Cylinder of the Tamp Applicator Nose. The Label Pad is a custom part that is manufactured exactly to the
label size being applied. If at any time the label size changes, a new Label Pad must be purchased along
with the Label Manifold.

2-2

MACHINE TERMS

LABEL TENSION BRUSH ASSEMBLY:

This is an adjustable Brush to help create tension o n the label liner. The Brush can be released while
threading the label liner.

NIP ROLLER:

The spring-loaded Nip Roller provides positive pressure to the label liner that passes between the Drive and
Nip Roller Assemblies. These rollers ensure that the liner does not slip during the label dispense cycle.
The tension on the rollers may be released by turning the knob located on the top of the Nip Roller
Assembly.

PEEL EDGE:

The Peel Edge is the beveled plate located at the end of the Applicator’s Nose. When the label liner is
pulled around the Peel Edge, the label separates from the liner and is transferred to the Blow Box Grid,
Tamp Pad, or product depending on the Applicator Type.

PEEL EDGE LABEL TENSION SPRING:

This Tension Spring is attached to the bottom of the Spring Block Assembly. It is used to keep the label
liner flat on the Peel Edge surface and a ssist in controlling the dispensing o f the labe l onto the Blow Box
Grid, Tamp Pad, or product. The tension is adjustable to accommodate varying label thickness and release
properties.

REWIND MANDREL / SLIP CLUTCH:

The Rewind Mandrel is provided to store the label liner after labels have been removed. It is equipped with
a Slip Clutch and is driven by the Stepper Motor. The pressure exerted by the Slip Clutch is adjustable.

SINKING OUTPUT CONFIGURATION:

The 360a Applicator’s Alarm, I/O, and Valve Outputs are wired in the sinking configuration. The load
current for a sinking out put flows into the o utput terminal. The load
power supply terminal (+V). When the outp ut is active , current flows from the positive t erminal of the load
power supply through t he load into the output te rminal to ground. Io (max) = 80 mA

common connection is the positive

SOURCING INPUT CONFIGURATION:

The 360a Applicator’s Low Label, Web/Tamp, and Product Detect Inputs are optically-isolated. The
Sensors connected to these pins must be able to sink the opto-coupler’s input current. The Sensor
connectio n is the negative power supply ter minal (ground or -V). When the Sensor’s output is active,
current flows from the positive terminal of the load power supply through the op tic a l c oupler circuit

out of the input pin and through the sensor output (open collector /drain or SPST N.O relay) to ground.

and
Iin (max) = 15 mA.

common

2-3

MACHINE TERMS

UNWIND ASSEMBLY:

The roll of labels is placed on the Unwind Assembly for dispensing onto the product. The Unwind Block is
used to mount the Unwind Assembly to the Main Module. The Unwind Assembly can be removed and
remounted on the opposite side of the Module for easy conversion from a right-hand to a left-hand
Applicator or vice versa.

UNWIND ROLL MANDREL:

The Unwind Roll Mandrel is equipped with an adjustable Sp ring Tension Disk, a Br ake, and a quick­change Outer Disc. The Unwind Roll Mandrel and the Dancer Arm maintain proper web tension and
prevent excessive run-out of the label liner as labels are processed through the Applicator.

VALVE BANK:

The Valve Ba nk wil l consist of single (1) valve for a Merge Applicator with an Imprinter, two (2) valves
for a Blow Box Applicator, three (3) valves for a Tamp Applicator or four (4) valves for a Dual Action
Tamp Applicator. The Valve Bank has b uilt in Regulators and Gauges, it plugs into the Valve Connector
on the Rear Panel.

WEB PATH:

The web path is the path the label liner follows from th e Unwind Assembly through the vari ous rollers to
the Applicator Nose & onto the rewind assembly.

2-4

360a DISPLAY

3-1

360a TOUCH SCREEN DISPLAY

The following descript ion provides general information about the Display and will tell the op e rator how to
change values, explain the meaning of different screens, and describe the different options and how to set
them up.

TYPES OF KEYS

Or are “go to” keys and will move the operator to
another screen.

This key is for setting something like an Applicato r Type, jog or us ed as an Alarm Reset
Key. The color of keys will vary depending on the application.

This key is for bringing the Applicator on and offline. When offli ne,
it will be as what is shown to the left, b ut when the App lic a tor is
online, it will be green with red le tte r s.

This block of keys usually turns something on or off. If the option is on, the
lamp to the left of the keys will be gre e n; o therwise it will be red.

This key will take you to the Main Menu even if you are in a setup screen.

360a DISPLAY

3-2

ALARMS

There are two types of alarms generated in the 360a Applicator:
Warning Alarm
Critical Alarm

Warning Alarm Status Box Critical Alarm Screen

Warning Alarms will appear in the upper right hand corner of the Main Menu in the Status Box. Since
these alarms are not serious, the Applicator will not be stopped. During a Warning Alar m, the amber light
on the Light-Stack (if provided) will be turned on.

Critical Alarms will stop the Applica tor (take it offline) and turn a red light on in the Light-Stack (if
provided). The Alarm Screen will cover the current screen explaining the alarm type. An Alarm Reset
button appears at the bottom of the page to clear the alarm.

Warning Alarms

The following are Warning Alarms monitored by the Applicator:
Inhibit – This alar m occurs when an external device inhibits the Applicator from dispensing a label by

activating the Inhibit Input on I/O Connector C2-12.

Tight Loop - If the Loose Loop Option is on and t he Alarm Prox (upper Prox) turns on, this alarm occurs

causing the Applicator to stop applying lab e ls u ntil the Lower Prox turns on. There is no Reset Button
for this alarm since the Loose Loop Program controls whether the Applicator is functional or not.
Although the Applicator is stopped , this is still considered a Warning Alarm since the Applicator will
resume labeling as soon as the Printer catches up with the Applicator. The Tight Loop Status Bo x will
have a red background instead of yellow to signal the alarm condition.

Low Label – This alarm occurs when the Low Label Sensor detects that the unwind roll is nearly out of

labels.

Multi-Label C-C Distance Is Too Low – This alarm occurs when the Multi-Label Opt ion is on and the

Applicator cannot place labels at the desired Center-line Distance. If the application permits, increase
the Label C-C Distance to correct the problem. For Non-Merge Applicators, you can try increa s ing the
Web Speed value or decreasing the conveyor speed value. In Tamp Applicators, reduce the Tamp
Extend/Retract Ti mes to the minimum. In Air-Bl ow Applicators, reduce the Air Blast Time to the
minimum and increase the Pre-Dispense Time if possible. In Merge applications contact the factory
concerning appropriate Accel and Decel values for your application.

DAT Label Pla cements Are Too Close – If the Applicator Type is a Dual Ac tion Tamp and the Second

Label Placement is low enough that the second label is not out onto the Pad before it should be applied,
this alarm will occur. Increasing the Second Label Placement will correct the problem. This also
could be viewed as a rate alarm.

Conveyor Speed, Profile or OverSpeed % Too High Compared To MaxSpeed - This alarm occurs on

Merge Encoder-Based Applicators when the conveyor speed or the product of conveyor speed times
the Profile or Over Speed % yields a speed greater than MaxSpeed. If possible, decrease the conveyor
speed or increase the Applicator’s MaxSpeed value. In Over Speed or Profiling app lic a tions try
decreasing the Pre-Apply Speed % or WebRatio % values respectively.

360a DISPLAY

3-3

ALARMS (cont’d)

(WARNING ALARMS)

Label Placement is Too Low – This alarm occurs in Encoder-Based

distance is too small for encoder compensation to work correctly. During label placement a speed
dependent distance is subtracted from the label placement value to pr operly position the label. If this
alarm occurs, move the Product Detect Sensor upstream more, decrease the conveyor speed, or
increase the Label Placement value.

Profile Or OverSpeed % Too High Compared To MaxSpeed – This alarm occurs in Merge Time-Based

applications when the Profiling or Over Speed % times the Web Speed value yields a speed greater
than the MaxSpeed. If possible, decrease the conveyor speed or increase the Applicator’s MaxSpeed
value. If possible, decrease the Over Speed Pre-Apply Speed % or the profiling WebRatio % values.

Imprint Dwell Too High For Label Cycle – This alarm occurs if the Imprinter Valve is on when the

Applicator is ready to dispense a label to the product, Air-Blow Grid, or Tamp Pad. For Merge
applications, no label will be dispe nsed . Air-Blow and Tamp Applicators will wait for the Imprint
Dwell to timeout before dispensing a label to the Grid or Pad.

Critical Alarms

The following are the critical alarms monitored by the applicator:

End Of Web – This alarm occurs when the End Of Web sensor detects a break in the web.
No Labels Found – This alarm occurs if the number of consecutive missing labels on the liner exceeds the

Missing Label Count value. If a No Labels Found Alarm occurs when labels are present on the liner,
re-teach the label sensor sensitivity settings.

Printer Not Rea dy - This alarm occurs when the Printer is paused while the Applicator is controlling a

Printer in a Loose Loop format with the Printer Ready Input Signal active.

applications when the Label Placement

CHANGING VALUES

Values that may be changed are shown in boxes displaying the current value. In the example below, label
length is shown to have a value of 1.75”. To change this value, the operator will touch the screen in the
label length field and a keypad will appear to the side of the variable being changed. The figure to the right
shows wha t the Displa y should look like after t ouching the variable field. You can see a cursor has moved
over the rightmost digit. Also the numeric keypad has appeared to the left of the variable. As you touch
numbers on the keypad, the variable is zeroed and the new value is input to the variable box. Pressing
“ENT” will finish the process. Pressing “ES” will allow you to escape without changing the value and
“CR” will clear the value you’re changing. Note: In most cases, an out-of-range value w il l not produce
a warning message but the variable will return to the original value after pressing “ENT”.

3-4

PASSWORD

360a DISPLAY

The Setup Section of the Display is password
protected. The Standard 360a password is “1800”.
When you get to a passwor d-protected area, a screen
similar to the one to the left will appe a r.

This screen notifies the operator that the area is
password protected. Here the operator can choose
to go back to the Main Menu or co nti nue wi th
password entry by touching within the box to the
left to activate the keypad

When you touch a number on the keypad, it will
highlight. This is the only indication that a key
was pressed since the password is not displayed.
If you know you’ve enter ed a wrong number,
press “C” to clear what you have and start again.
“ENTER” finishes the process.

If the wrong password was entered, the screen above
appears. If the operator wants to try again, press the
“Try Again” key. If you do not know the password,
press the other key to go to the Main Menu.

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3-5

MAIN MENU

The Main Menu is divide d into three sections.
The upper right corner of the Display is a Status
Window. The purpose of this box is to inform
the operator of the status of the Applicator. The
display shown to the left appears immediately
after going offline. If the Applicator is online
with no alarms, the Status Windo w will have a
green background with the label rate displayed.
If a Warning Alarm occurs, the background
changes color and a message will appear
indicating the nature of the alarm. Specific
Warning Alarms were discussed previously.

The left side of the screen will change based on Applicator Type. There will always be Jog and Alarm
Reset keys and access to Label Placement.

The lower right corner has buttons to place the Applicator on and offline and keys to take you to the
Formats and Setup Menus. Plac ing the Applicator o nline applies power to the Drive Motor and arms the
Applicator for labeling. The Format Key gives access to the operator to load a saved Format. The operator
cannot change or erase Formats from here. The Setup Key takes the operator to a password-protected area
to make changes to the operation of the Applicator.

The Display is equipped with a backlight saver function that a utomatically turns off the backlight after 60
minutes of inactivity. Pressing a ny part of the Display will turn the backlight on again. Also, the
Applicator will initiate a backlight wake-up in response to any Critical Alarm condition. The later feature
insures that the operator has a visual indication of a Critical Alarm condition in systems without a Light­Stack Assembly.

SETUP MENU

Because the Setup Menus are password-protected,
pressing the Setup Key at the Main Menu wi l l
cause a password screen to appear. By entering the
correct password will cause the Setup Menu to
come up. From here the operator can go to the
different setup sections. The operator can also
bring the Applicator online while he changes the
setups. Once the Applicator is set up and the
operator exits the Setup Menu, the Applicator will
save the new s ettings. If power is cycled to the
Applicator before the Display is r e turned to the
Main Menu, the new settings will not be saved.

Note: You must be offline to enter the

Configuration Menu.

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3-6

LABEL SETUP

The Label Setup menu is accessed from the Setup Menu by pressing the Label Setup Key. The label setup
section gives the operator access to variables on the Applicator that pertain to the label.

The following items may be changed in this
section:

Label Stop
Label Length
Label Sensor Setup
Label Stop Compensation
Label Formats

Label Length -The label length is defined as the feed length of the label plus the width of the gap between
labels. Stated another way, it is the distance from the leading edge of one label to the leading edge of the
next label. Since each application cycle moves the label length distance, it is important to enter the exact
label length value. Allowed values are between 0.125-32”.

Label Stop -The Label Stop b o x lets you enter the label stop distance value. The Label Stop value is the
distance from the label edge to the Label Sensor. Allowed values are between 0.03” and (label length –

0.06”). The Label Stop value may be changed while the Applicator is running.

Label Stop Comp –Although very rare, we have found the Label Stop would vary with Web Speed when
running certain types of labels. This seems to do more with narrow labels and the materials used to convert
them. Label Compensation is normally fixed but when Label Sop is moving with Web Speed, it was found
making changes to it can make the labe l stop position better. Label stop compensation is a number that
shortens the Label Stop value the higher the Web Speed. This corrects the problem of the label position
creeping out the faster the Web Speed.
Note: This option is only for Encoder-Based Merge Applicators

Label Stop Comp Setup

Before setting this up, make sure the Label Sensor, Label Length, Label Stop and Max Speed have all been
setup. It is also important the Encoder Variables are correctly setup.

The default value for Label Stop Comp is

0.0015. Set the Web Speed to the slowest speed
the product will be traveling (let’s say 500
in/min). Use the Jog Key on the Display or the
Jog Switch o n the Applicator to dispense a
couple of labels. Take note of where the label
stops. Now change the Web Speed to the
fastest the product will be traveling and jog a
couple more labels. If the Label Stop position
moved forward, increase the Label Stop
Compensation. If the Label Stop moved back,

decrease the Label Stop Compensation. It is
unlikely that the compensation value will be less than 0.0015. If you can change Web Speeds and the
Label Stop holds pretty well, you are finished. If needed, you can make adjustments to the label stop
position so the Label Stop is back where you want it. When you exit the Label Stop Compensation screen,
the Web Speed will return to the value set in the Applicator Setup Menu.

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3-7

LABEL SETUP (cont’d)

Label Sensor -Pressing this key will bri ng up

the Label Sensor Menu. This is where the

sensitivity of the Label Sensor is setup. The

operator will have two choices:

Auto Teach

Manual Teach

Manual Teach

In the Manual Teach Mode, the opera tor will
first choos e whether they want to trigger on the
leading or trailing edge of the labe l. The only
reason for c hanging edges occurs when the
Label Stop is either too small or too close to the
Label Length. After selecting an edge detection
mode, the Display will provide opera tor
instructions at the bottom of the scree n. For
example, if leading edge is selected, the Display
will prompt the user to move the label and liner
under the Label Se ns or and pre s s the Teach Key
on the screen. After a couple of seconds the user is prompted to move the liner under the sensor. Move the
label stock by turning the Drive Roller to place the label gap under the sensor or remove a label. Again the
operator will press the Teach Key. After a couple of seconds the process is finished. The operator can
return to the Label Setup Menu by pressing the “Prev Menu” Key.

Auto Teach

The Auto-Te ach function not only sets the

Label Sensor Sensitivity but also calculates the

Label Length and Label Stop values. When the

Auto-Teach function is selected, the operator is

prompted to move the label gap under the

sensor. Pressing the Teach Key causes the

Applicator to dispense 10 inches of labels while

setting the Label Sensor Sensitivity.

Key is provided to skip the sensitivi ty setup for

instances where the sensitivity is known to be

correct or when a Clear Label Sensor is

installed. Following the sensiti vity setup, the
operator is prompted to move the label to the Label Stop Position and press the Teach Key. Three labels
are dispensed while calculating the Label Length and Label Stop values. If the Multi-P anel Option was on,
an extra screen appears instructing the operator to move a label to the Peel Edge to allow the controller to
calculate the Short Feed Distance. This will be discussed in more detail in the Applicator Setup section.

NOTE: The Label Sensor output lamp will be a light blue when the sensor is on. If the sensor i s se t
to “Leading”, the light will be on when the la be l is unde r the sensor. If “Trailing ”, the light will be
on when the gap is under the sensor.

NOTE: See SPECIAL OPTIONS section for information regarding the Label Sensor Mode l setting if
the Applicator is not responding correctly to label teach routines.

A Bypass

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3-8

Main Menu Format Screen

Main Format Screen

LABEL SETUP (cont’d)

Label Formats

This section allows the operator to save and load configuration setups for up to (48) different products and
labels. This is useful if a customer is running several different products or labels over and over.

Note: The Label Format Key at the Main Menu only allows the operator to only load Formats.

A format saves the following parameters:

Label Placement Encoder Option
Label Length Pulse Length
Label Stop Compensation
Detector Lockout Air Blast Time
Web Speed Ext. Air Assist
Slew Speed Tamp Extend
Max Speed Tamp Retract
Accel Pre-Dispense
Decel
Options and Variables

Consult factory for a complete list of
Parameters saved.

This screen will show the last Format
loaded. If no Formats had been loaded,
the value in t he box would be “0000”.

Saving a Format

If the curre nt setup in the Applicator is
performing correctly and you wa nt to save it,
press “Label Formats” in the Label Setup
Menu. When a “Save” key is pressed, the
Applicator will check to see if a Format
already exists in the location selected. If it
does, the operator will be prompted whether
or not to overwrite its contents with the new
information. If the name is “0000”, the
operator will be asked to enter up to four
digits for the Format Name. Pressing the
green Save Format key, saves the Format to
the name shown in the Format Name box
provided the name is not already used for another Format. If it is, the system prompts the user to sele c t a
different na m e. Pressing the red Exit Key on the screen allows the operator to exit without saving the
Format.

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3-9

LABEL SETUP (cont’d)

Viewing/Loading a Format

When the operator wants to view/load a Format File, they need to press the yellow portion of the key
associated with the desired Format name. If the number is “0000”, no Format is saved in that location.

Selecting a “0000” Format will cause a screen

to appear with a “No File Found” message.

Pressing the View/Load Ke y will not

immediately load the Format but will allow the

operator to view the values within that Format.

After reviewing the values, the operator may

press “Load Format” to load the Format. If th e

wrong format was selected, the operator can

press the “Exit W/ Out Cha n gi ng” key.

Deleting a Format

When the operator wants to delete a Format
that currently exists, pr ess the Erase Format
Key in the upper right hand corner o f the
Display. The screen to the right will appear.
Pressing any of the bo xe s with a name will
cause that Format to be erased.

Note: There is no second step to this
operation. Once you press the format box,
the Format will be erased.

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3-10

APPLICATOR SETUP

The Applicator Setup Menu is accessed from the Setup Menu by pressing the “Applicator Setup” Key. The
screen is split into upper and lower sections. The upper part does not change and allows the operator to
return to the Main or Setup Menus and place the Applicator on or offline. The lower section of the screen
changes based on the Applicator Type selected.

Depending on the Applicator Type, the operator has access to the following variables:

Tamp/Swing Extend and Retract Times
Air Blast Time
Extended Air Assist Time
Web Speed
Pre-Dispense
Label Profile Configuration
Multi-Panel Option
Over Speed

The following serves as an explanation for each
section.

Air Blast -The Air Blast Time is the interval of ti me that the Air Blast Valve is turned o n. Allowed values
are .005 - 1 second.

Tamp Extend -The Tamp Extend Time is the interval of time allotted for the Tamp Slide to extend. After
the timer has timed out, the Air Blast will occur and the Tamp Slid e will return home. To keep labeling
speeds up, this value should be as low as possible. Allowed values are between .01 - 5 sec.

Tamp Retract -The Tamp Retract Time is the interval of time allotted for the Tamp Slide to return home
before feeding another label. If this value is too small, a label will feed into the Pad or Manifold. Allowed
values are between .01 - 5 seconds. Note: In a Tamp Applicator, the Tamp Slide action may be

disabled or enabled by pre ssing the “Tamp Enabled/Disabled” Keys.
Extended Air A ssist -The Extended Air Assist Time is the interval of time after the label feed until the Air

Assist is turned off. It is used in Air Blow and Tamp Applicators to help hold the label in place on the Grid
or Pad prior to being blown onto the product. Allowed values are between .000 - 1 sec.

Web Speed -The “Web Speed” Key allows the opera tor to enter the Applicator Web Speed value. Allowed
values are between 100 and 3000 ”/min with the upper limit depending on the Max Speed setti ng in the
Configurati on Menu. The specific limits are shown above the current Web Speed value. The Web Speed
value may be changed while the Applicator is running.

Pre-Dispense –This is the amount of time before the Air Blast turns-off that the Applicato r begins the label
dispense. This Option applies only to A ir Blow Applicators and will speed-up the application rate. If
the value is too high, the Applicator will start disp e ns ing a label into the Air Blast stream causing the label
to fall off the Grid. Ideally, the Pre-Dispense time allows th e Applicator to get past the label Accel curve
and place the label at the edge of the air stream when the Air Blast Valve turns off.

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3-11

APPLICATOR SETUP (cont’d)

Over Speed – The Over Speed Option allows a Merge Applicator to get up to Web Speed faster by

dispensing the “Pre-Apply Feed” distance at the (Pre-Apply Speed % x Web Speed). In Multi-Label mode,
this will help place the labels closer together. Not e: This Option is only for Merg e Applicators.

(Over Speed Screen)

(Over Speed Help Screen)

Note: The Help Screen will note what Functions are disabled when this Function is turned on.

Label Profile -Profiling is a Merge only Option used to aid in labeling products that have a concave or

convex surface. If the surface of the product is convex and the web ratio is less than 100%, t he Applicator
will dispense a label at Web Speed during the “Rise Area” distance. After the “Rise area” distance, the
Web Speed changes to (web speed) x (web ratio) during the “flat area” distance. After traveling the
combined “rise” plus “flat” distances, the Applicator returns to Web Speed for the remainder of the move.
The reaso n for this action is that convex pro ducts start o ut farther away from the Peel Edge than it will be
by mid-product. The label is dispensed at normal speed at the beginni ng of the pr oduct. As the product
surface moves closer, the label must slow down so that the labels do not wrinkle. As the product surface
moves away, the label speeds-up. On concave products the label is dispensed at Web Speed initially. As
the surface of the product moves away, the label is dispensed faster to force the label into the product (Web
Ratio>100%). The label dispense speed is slowed as the product surface moves closer to the Peel Edge.

NOTE: 1) Label Profiling is a function of the Merge Applicator only.

2) Label Profiling is enabled when the “Web Ratio” is set to something different than
“100%”.

3) Max Speed for the Applicator is setup in the Configuration Menu and will range from 100
to 3000 in/min. If the Applicator exceeds the Max Speed “Conveyor Speed, Profile or
OverSpeed % Too High Compared To MaxSpeed” Warning Alarm will occur. The
Applicator will not exceed this speed even if the Web Ratio is set to a higher number.

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3-12

APPLICATOR SETUP (cont’d)

(LABEL PROFILE)

(Profile Screen)

(Profile Help Screen)

Note: The Help Screen will note Options that are incompatible with the Profiling

Option.

Profile Variables

Rise Area -This is the distance the label travels before chan ging to the mid-product labeling speed. Enter a
value between 0.1 and 20. The Applicator will be running at Web Speed during this distance.

Flat Area -This is the distance the label tr a vels while at the mid-product labeling speed. Enter a value
between .1 and 20. The Applicator will be running at a percentage (Web Ratio) of the Web Speed dur ing
this distance.

WebRatio -The Web Ratio is a scaling percentage applied to the Web Speed or conveyor speed value to
either slow-down or speed-up the Applicator during the Profile Flat Area. This nu mber will va ry
depending on product shape and is usually determined by trial and error. Enter a value between 50% and
150%.

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3-13

Condition

Product Shape

WEB RATIO < 100

Convex

WEB RATIO = 100

Flat Surface

WEB RATIO > 100

Concave

Web Ratio

Setting (%)

Speed during

0” to rise distance

Speed during

rise to flat distance

Speed during flat

to label length distance

< 100

web speed

(web speed) (web ratio)

web speed

= 100

web speed

web speed

web speed

> 100

web speed

(web speed) (web ratio)

web speed

APPLICATOR SETUP (cont’d)

(LABEL PROFILE)

Estimating Rise and Flat Areas

This process will give you a starting po int for setting Profile Variables. Some experimentation is necessary
for best results. The example shown is for a convex or oval product.

1. Apply a label by hand to the product. Measure the Rise Area by looking at the beginning of the

label to where it starts to flatten out. Also measure the length of the Flat Area. Use the diagram
below as an example.

2. Use these numbers when inputting values to the Display.

3. When using this type of product, Web Ratio is set less than 100%. This will slow the Web Speed
during the Flat Area.

PROFILING SUMMARY

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3-14

APPLICATOR SETUP (cont’d)

(LABEL PROFILE)

Rise Area and Flat Area Final Adjustment

The system will wor k best with the smallest Rise Area value and the largest Flat Area value that properly
applies the label. Use the instructions below to find these values.

1. With the Applicator online, send several products down the conveyor and observe the labels that
are applied.

2. If the leading edges of the labels were all applied at the same position on the products, go on to
step #3.

If the leading edges of the labels were placed at various positions on the products, the Rise Area

Length is too short.

Slightly increase the Rise Area Length and run some more products. Repeat until the leading edge

label placement is consistent.

3. If the leading edges of the label were applied at the required position on the product, go on to step
#4.

If the leading edge of the label is applied at the incorrect position, adjust the “LABEL

PLACEMENT”, or re-position the product detector. Run some more products. Repeat until the
leading edge of the label is applied a t the r e quired position on the product.

4. If there are no wrinkles or bubbles in the first half of the applied labels, go on to step #5.

If a wrinkle or bubbles appear from the top to the bottom of the first half of the label, the Rise

Area is too long.

Slightly decrease the Rise Area and run some more products. Repeat until the wrinkle in the first

half of the label is removed.

5. If there is no wrinkle in the center of the label, go on to step #7.

If a wrinkle appears from the top to the bottom at the center of the label, either the Web Ratio is

too high, or the Flat Area is too shor t.

The W e b Ratio will be adjusted first. Before adjusting, note the Web Ratio setting. Slightl y

decrease the Web Ratio and run some more products. Repeat until the wrinkle is removed. Go on
to step #7.

6. Increase the Flat Area slightly and run some more products. Repeat until the wrinkle is removed.

7. If the labels are applied wrinkle free from lead edge to trail edge, go on to step #8.

If small horizo ntal wrinkles appear on the trailing edge on the label, the Flat Area is too long.

Slightly decrease the Flat Area and run some more products. Repeat until wrinkles are eliminated.

8. When the Web Ratio, Rise Area and the Flat Area are established, the setup is complete.

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3-15

A

B

E

D

C

APPLICATOR SETUP (cont’d)

Multi-Panel Apply

The Multi-Panel Apply Option is used to merge a label onto two or three panels of a product. An example
might include the leading, top, and bottom panels of a clamshell container. The Applicator is initially setup
so that the label is flagged out in fro nt o f the product but is still supported on the liner. When a product
detect signal is received, the Ap plicator will wait for the Label Plac e ment distance. At Label Placement,
the Applicator will feed the “Short Feed Distance” at encoder speed. This will place the next label at the
Peel Edge. The Applicator will wait for the “Product Clearance” distance to allow the product to pass by
the Peel Edge before moving t he next label to the flagged out position (Label Stop ) a t Slew Speed. The
figure below illustrates an example se tup with four labels between the Peel Edge and the Label Sensor
along with the measurement definitions:

A: label sensor to peel edge distance
B: label length
C: label flag distance
D’: label stop distance with C = 0 ( no t shown)
D: label stop distance
E: short feed distance

When the Multi-Panel Option is turned on, the user is prompted to go to the Label Setup Menu and perform
a Label Sensor Auto Teach operation. The Auto Teach feature will calculate all of the dimensions shown
above if the option is enabled prior to running auto teach. The operator may override these settings by
measuring values B through E above and enteri ng them via the Display. Note: Since the Multi-Panel

Apply Option is distance based, the Encoder Option must be purchase d.

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3-16

APPLICATOR SETUP (cont’d)

(MULTI-PANEL OPTION)

(Multi-Panel Screen)

Note: The Help Screen will note Options that are disabled when this Option is turne d on.

Configuring Mult i -Panel Apply With Auto Setup

1. Make sure the Applicator is powered up and offline.

2. Perform the Encoder Setup procedure outlined in the Product Setup section.

3. Press “APPLICATOR SETUP” and select “MULTI-PANEL”

4. Toggle t he Option on.

5. Enter the distance after the label is dispensed to when the product clears the Peel Edge to the

6. Go back to the Main Menu and press “LABEL SETUP” then “LABEL SENSOR”

7. Select “AUTO SETUP” and follow the screen prompts (see: AUTO TEACH on page 3-7).

Configuring Mult i -Panel Manually

1. Make sure the Applicator is powered and offline.

2. Perform the Encoder setup procedure outlined in the Product Setup section.

3. Using the hand wheel, position the label in the flagged out position.

4. Under “LABEL SETUP”, enter the distance measured for dimension D shown above. Note: If the

(Multi-Panel Help Screen)

Product Clearance box. The distance should be approximately equal to the product length.

Label Sensor is set for trailing edge de te c tion, add the label gap distance to di mens ion D.

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3-17

APPLICATOR SETUP (cont’d)

(MULTI-PANEL OPTION)

5. While in “LABEL SETUP” enter the Label Length measured for dimension B.

6. Under “APPLICATOR SETUP”, press the “MULTI-PANEL” button and turn the Option on.

7. Set the Short Feed to the distance measured for dimension E.

8. Enter the distance after the label is dispensed to when the product clears the Peel Edge into the
Product Clearance box. The distance should be approximately equal to t he product l ength.

Note: During the last part of the di spen se cycle (after the product clears the Peel Edge), the label is

dispensed at Slew Speed . This is usually faster tha n the Web Speed and is set in the
Configuration Menu.

PRODUCT SETUP

The Product Setup Menu is accessed from the Setup Menu by pressing the “Product Setup” Key.

The following parameters may be changed or
monitored in this section:

Label Placement(s)
Detector Lockout
Encoder Speed (monitor)
Encoder Option

Label Placement -The Label Placement box lets you change the Label Placement value. Label Placement
is the time or distance from the Product Detect Sensor to where the label is dispensed onto the product. If
the value entered is out-of-range, the previous value will be restored after the “ENT” key is pressed. The
allowed range of values, in seconds if time based o r in inches if encoder based, are shown below the Label
Placement Box. The Label Placement value may be changed while the Applicator is running.

Note: This Label Placement parallels the Main Menu and is located here so that the operator
can do their setups wit hout exiting to the Main Menu.

Detector Lockout -The Detector Lockout functi on is used when more t han one product detect signal is

generated per product. If the Encoder is on, Detector Lockout is in inches; if there i s not an Encoder then i t
will be in seconds. The Lockout starts at the begin ning of a labeling sequence and the Applicator will
ignore Product Detect Signals until the lockout time or distance is finished. Allowed values are between
.001 – 200 inches or seconds.

Encoder Speed -Thi s box displays the conveyor velocity obtained from the Encoder Signal connected to
the Applicator’s Encoder Port. The value displayed is the number of (pulses/min from the encoder) x (the
pulse lengt h in inches/ pulse).

Encoder Option -The Encoder Option is useful when the product veloc ity varies during the applicatio n
cycle. An example of such an ap plication is a Merge Applicator on a Forms Table. With the Encoder
installed and enabled, the Applicator adjusts the label dispense speed to insure accurate label placement on
the product.

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3-18

PRODUCT SETUP (cont’d)

(ENCODER OPTION)

The Applicator has a differential quadrature incremental encoder interface with times four interpolation
built into the controller board. The Encoder Connector, located on the rear panel, has 5 VDC supply to
power the Encoder. The Encoder wiring diagram and pin-out information appear in the drawings section in
this manual and should be consulted for user supplied encoders. Factory encoders generate 2500 pulses per
revolution.

The following parameters may be changed
or monitored in this section:

Encoder Filter
Encoder Option On/Off
Encoder Speed (monitor)
Pulse Length
Compensation

Encoder Filter – In some applications, the Encoder speed varies significantly around some average value.
This is especially problematic with Merge applicators, low-resolution Encoders and low conveyor speeds
where fewer encoder pulses are captured during the velocity calculation interval. The Encoder Filter
function allows the operator to average the Encoder Speed over a range of 1 to 10 scans to produce a
smoother label dispense. As with all filters, the response of the App lic a tor to the change in Encoder Speed
is proportional to the number of Scans. The lower scan numbers are more responsive to speed changes
while the higher number produces a smoother/quieter application with more power in the Merge
Applicator. In applications suc h as Forms Tables, where the conveyor performs start/stop moves, a lower
scan number is appropriate. In constant conveyor speed applications, a scan number closer to 8 may be
more suitable. In all instances, the performance of the system should be verified under a variety of
conditions.

Encoder Option –The Encoder Option Ke ys are for turning this Option on and off. If the Option is on, the
lamp to the left of the keys will be gre en. When the Encoder is on, Label Placement is in inches and not
seconds.

Pulse Length -The distance the product travels per pulse of the Encoder. T he pulse length may be

calculated using the following formula:

Pulse Length = (Distance Product Moves / Rev) /

((Encoder Pulses / Rev) x 4)

EXAMPLE: An Encoder is mounted to a conveyor drive pulley and the circumference of that pulley is

18.75”. Therefore, with one revolut i on of the E ncoder, the product on the conveyor w ill travel 18.75”. The

Encoder is a factory-installed encoder generating 2500 pulses per revolution.

Pulse length = 18.75” / (2500 x 4)

Pulse length = 18.75” / 10000

Pulse length = 0.001875 in/pulse