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Operating and Maintenance Manual
Newman 4VAL Labelling System
© NEWMAN LABELLING SYSTEMS LTD. 2008
Newman Labelling Systems Ltd owns the copyright on this Operating and Maintenance Manual
and design rights in the drawings contained therein. This manual is provided in confidence solely
for the purpose of enabling the operation, installation, repair and maintenance of equipment
provided by Newman Labelling Systems Ltd. (to which this manual and drawings relates), and
Newman Labelling Systems Ltd reserves all rights as provided by the Copyright Design and
Patents Act 1988 or otherwise at law in respect of any unauthorised reproduction of this manual
or drawings.
4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd
Page 1 of 56
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Table of Contents
Summary of Contents for Newman 4VAL
- Page 1 Newman Labelling Systems Ltd. (to which this manual and drawings relates), and Newman Labelling Systems Ltd reserves all rights as provided by the Copyright Design and Patents Act 1988 or otherwise at law in respect of any unauthorised reproduction of this manual or drawings.
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Page 2: Table Of Contents
SECTION 3B MACHINE OPERATION – ALLEN BRADLEY ......................25 3B.1 FAULT MESSAGE INDICATION..............25 3B.2 MODES ......................26 3B.3 RUN MODE FUNCTIONS ................27 3B.4 SET UP MODE FUNCTIONS ...............28 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 2 of 56... - Page 3 7.2 WEEKLY MAINTENANCE ................53 7.3 QUARTERLY MAINTENANCE ..............53 7.4 A.C MOTOR......................54 7.5 HOT FOIL CODER ...................54 7.6 LUBRICATION ....................54 7.7 SPARE PARTS....................55 INDEX ........................56 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 3 of 56...
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Page 4: Introduction
SECTION 1 INTRODUCTION 1.1 INTRODUCTION Your 4VAL machine has been carefully designed and built to very high standards but best results will only be achieved if the functions of its various parts are well understood. To ensure that the machine performs as designed, you are urged to read and understand this manual before operating the equipment. -
Page 5: Specifications
300 x 400mm Services Electrical (as standard) < 1.5kW @ 220/240V 1ph 50/60 Hz. < 20 litre/min. @ 4 bar (0.75 cfm @ 60 psi) 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 5 of 56... -
Page 6: Model Options
1.4 MODEL OPTIONS The 4VAL is manufactured as 3 main models (A, B & C) with the options shown in the table below. All models include the following features; • Interlocked applicator drum guarding • Emergency stop • Left edge leading labels. -
Page 7: Customer Contact
1.5 CUSTOMER CONTACT Spares and Contact Numbers Newman technicians are available to give assistance by telephone, letter or service visit. Always quote the machine type and serial number (stamped on machine label) and on front of the O&M manual. EXAMPLE: Machine type 4VAL Machine serial no.06123... -
Page 8: Ce Certificate Sample
Signing as the responsible person on behalf of the manufacturer; NEWMAN LABELLING SYSTEMS LIMITED, QUEENS ROAD, BARNET, HERTS. EN5 4DL ENGLAND Certificate Number : 06/123/4567 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 8 of 56... -
Page 9: Layout Of 4Val
Guard front door Fixed guide rail Adjustable guide rail Conveyor Operator console Label reel holder Tray unload area * Optional items 1.8 LABEL WINDING 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 9 of 56... -
Page 10: Section 2 General Description
Use of the machine for any other purpose or use of components, procedures, etc. not in this manual can result in a hazardous situation. Newman Labelling Systems cannot be held responsible for any loss or damage to product, machinery or personnel caused by misuse of the equipment or unauthorized modifications. -
Page 11: Training
Newman Service Engineers or Technicians can provide this training service at the time of commissioning or afterwards by arrangement. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 11 of 56... -
Page 12: Installation
The machine is supplied with all guards necessary for safe operation. If any modifications are made for any reason, care should be taken to ensure that the overall safety is not impaired. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 12 of 56... -
Page 13: Operation Overview
If a Coder is fitted, a warm-up period of 10 - 15 minutes minimum is usually necessary. If during normal machine running any of the fault conditions occur the machine will stop and display an appropriate alarm message. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 13 of 56... -
Page 14: Section 3 Machine Operation - General
The key may be removed with the switch in RUN position to prevent unauthorised access to SET UP mode. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 14 of 56... -
Page 15: On/Off Buttons
Hence, depending upon specification of machine it is recommended that checks for unlabelled containers are made after a fault condition. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 15 of 56... -
Page 16: Description Of Faults
CHECKS: Ensure BOTH guard doors are fully closed. RESTART: Acknowledge the alarm message (Siemens: enter – Allen Bradley: reset). Press the machine start button. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 16 of 56... -
Page 17: Label Runout
RESTART: Acknowledge the alarm message (Siemens: enter – Allen Bradley: reset). Press the machine start button. Monitor printing and subsequent overprint detection after restart. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 17 of 56... -
Page 18: Missing Label Fault
NB. Overprint detection can be by ‘overprint sensor’ or by vision system. The alarm message is the same for both. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 18 of 56... -
Page 19: Barcode Fault
The applicator drum can be checked for obstructions. RESTART: Acknowledge the alarm message (Siemens: enter – Allen Bradley: reset). Press the machine start button. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 19 of 56... -
Page 20: Section 3A Machine Operation - Siemens
Refer to Machine Operation–General section for detailed description and corrective actions for fault messages. Fault message indication - press ENTER to acknowledge 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 20 of 56... -
Page 21: Modes
The following diagram shows the screens selectable in each mode for all options in the machine model range (see model table in introduction section). 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 21 of 56... -
Page 22: Run Mode Functions
Label Count: Total number of labels dispensed. NB The counters cannot be cleared in Run Mode. Product And Label Clear Count Screen Count Screen (F1 Button Inactive) 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 22 of 56... -
Page 23: Set Up Mode Functions
To jog a label, prevent containers from reaching the product sensor, switch on the machine and press F4 to dispense a single label for each press. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 23 of 56... - Page 24 Overprint Inhibit Screen UV Sensor Inhibit Screen Barcode Inhibit Screen Product Sensor Inhibit Screen 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 24 of 56...
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Page 25: Section 3B Machine Operation - Allen Bradley
Refer to ‘Machine Operation – General’ section for detailed description and corrective actions for fault messages. Fault message indication – press RESET to acknowledge 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 25 of 56... -
Page 26: Modes
The following diagram shows the screens selectable in each mode for all options in the machine model range (see model table in introduction section). 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 26 of 56... -
Page 27: Run Mode Functions
Product Count: Total number of containers counted past the product sensor. Label Count: Total number of labels dispensed. NB The counters cannot be cleared in Run Mode. Counter Screen (F1 button inactive) 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 27 of 56... -
Page 28: Set Up Mode Functions
To jog a label, prevent containers from reaching the product sensor, switch on the machine and press F4 to dispense a single label for each press. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 28 of 56... - Page 29 Overprint Inhibit Screen UV Sensor Inhibit Screen Barcode Inhibit Screen Product Sensor Inhibit Screen 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 29 of 56...
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Page 30: Section 4 Set-Up Procedure
Missing label sensor Presser pad Product sensor Guard front door Fixed guide rail Adjustable guide rail Conveyor Operator console Label reel holder Tray unload area 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 30 of 56... - Page 31 Set label sensors in accordance with instructions in subsequent section. Adjust Machine Speed to a low setting, press MAIN DRIVE start button and, with exception of label feed, the machine should now run. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 31 of 56...
- Page 32 Check the height of the labels. . If necessary, adjust by turning the LABEL HEIGHT hexagonal nut with the special spanner provided. The machine is now ready to run. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 32 of 56...
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Page 33: Set Up
Label Web Path (29917a) 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 33 of 56... -
Page 34: Label Sensors
• Re-check along the label to ensure that the LED will only come on when it reads a gap. • Set the second sensor nearest the stripper plate in the same manner as the first 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 34 of 56... -
Page 35: Proximity Label Sensors
LED illuminates. • Pass the whole of a label length through the sensor to ensure a constant setting. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 35 of 56... -
Page 36: Ultrasonic Label Sensors
• Teach is now complete. • Pull the web through again and ensure the sensor orange output light goes ‘ON’ at the gaps and ‘OFF’ at the labels. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 36 of 56... -
Page 37: Double Label Feed Inhibitor
• The label web must be stationary to set the sensor and also be in the correct stopping position. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 37 of 56... -
Page 38: Product Sensor
The lens should be positioned to achieve a consistent reading from a portion of the container such as the ‘bulb’ of ampoules. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 38 of 56... - Page 39 The sensor may sometimes be affected by local ambient light, making it hard or impossible to set. If this happens either remove the light source or shield the sensor. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 39 of 56...
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Page 40: Reject Sensor
• Release the set button and wait for the ‘ready / error’ LED to turn green. • The sensor is now set. • The output LED will be on when a label is detected. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 40 of 56... -
Page 41: Missing Label Detection
No. 3 shows the reject sensor late but still acceptable. No. 4 shows the reject sensor too early and this will stop the machine. UV Sensor Timing (29920a) 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 41 of 56... -
Page 42: Ultrasonic Label Runout Sensor
The clearance ‘X’ should allow for the passage of the label web, but should not exceed 1 mm. Re-tighten the bolts. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 42 of 56... - Page 43 • To set the stripper arm parallel with the top surface of the conveyor, and so avoid feeding in the label web tilted, loosen bolts ‘B’ and ‘G’ (refer to Fig. 5.9.1) and 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 43 of 56...
- Page 44 After making the adjustment, re-tighten the securing bolt. Run the machine to check that the label web tracks correctly. If necessary, make a further adjustment 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 44 of 56...
- Page 45 Observe results after a few more containers are labelled and if necessary make further similar adjustments until satisfactory results are obtained. • Turn key-switch to "RUN". Place a few containers at the infeed and label them. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 45 of 56...
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Page 46: Section 5 Change Over Procedure
• Set position of both label sensors to ensure both correct flag at stripper plate and label pitch. • Set Barcode reader (where fitted). 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 46 of 56... - Page 47 • Switch key to RUN mode. NOTE: Ensure that all security devices (missing label, overprint and barcode verifiers) are tested at start of production. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 47 of 56...
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Page 48: Label Feed Roller Adjustment
Loosen bottom screw located under the head plate. The top screw can now be adjusted to suite web thickness. Retighten bottom. Remove the bolt from the eccentric shaft. Replace guard assembly. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 48 of 56... - Page 49 Alternative Label Feed Rollers The 4VAL machine is normally fitted with Newman standard serrated label feed rollers (as shown in the previous Operating & Maintenance manual). Subject to machine testing and with certain web materials, the stainless steel knurled and rubber rollers shown below may have been fitted to improve performance.
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Page 50: Section 6 Fault Diagnosis
W E B TE NS IO N AL O NG L AB E L A RM W E B FO R D IECU TTING 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 50 of 56... - Page 51 CHECK EMERGENCY STOP BUTTONS ARE RELEASED POW ER TO CHECK FUSE FU1 ECR ? CHECK EMERGENCY STOP CIRCUIT FOR CONTINUITY POW ER TO CHECK FUSE FU1 PLC? 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 51 of 56...
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Page 52: Section 7 Maintenance And Spares
Check that neither labels or adhesive have contaminated the web tensioner. If necessary, release bracket to gain access to the surface of the tensioner. Clean and replace. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 52 of 56... -
Page 53: Weekly Maintenance
Clean the fan air filters on the electrical enclosure at the back of machine. Remove filter cover for access to filter. Renew filter if necessary. 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 53 of 56... -
Page 54: Motor
The lubricants used on our model 4VAL are as listed below. On open gears we use Shell Alvania Grease On chain drives Rocol Chain & Drive Spray Light oil Shell Tellus 22 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 54 of 56... -
Page 55: Spare Parts
LABEL SENSOR – OPTICAL - DATASENSOR 29876 LABEL SENSOR – ULTRASONIC - LEUZE 29253 OVERPRINT DETECTOR - DATASENSOR 29253 MISSING LABEL LUMINESCENCE - DATASENSOR 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 55 of 56... -
Page 56: Index
Training ....11 Noise Levels .....11 Guard Open ..15, 16 UV Sensor..23, 28, 40 Operational Functions Hazards....10 ......14 Hot foil tape .... 17 4VAL Operating & Maintenance Manual Version 1.1 © Newman Labelling Systems Ltd Page 56 of 56...
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