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ASTRO ATS-9900 Operator's Manual

Tabber, labeler, and stamp affixer
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ASTRO
ATS-9900
TABBER, LABELER,
AND STAMP AFFIXER
Operator Manual

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  • Page 1 ASTRO ATS-9900 TABBER, LABELER, AND STAMP AFFIXER Operator Manual...
  • Page 2 In addition, follow any specific occupational safety and health standards for your workplace or area. This manual is intended solely for the use and information of Astro Machine Corp. its designated agents, customers, and their employees. The information in this guide was obtained from several different sources that are deemed reliable by all industry standards.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS SECTION 1 – Getting Acquainted Front View End View with Pressure Roller Cover Open Control Panel SECTION 2 - Assembly and Installation Assembly Installing Tab/Label Applicator Head Installation FF-14 Feeder and Feeder Base SECTION 3 - Operating Tabber Replacing Applicator Head Loading Tabs Aligning Feeder...
  • Page 4 NOTES _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...

  • Page 5: Section 1 - Getting Acquainted

    GETTING ACQUAINTED SECTION 1 – Getting Acquainted Front View Media Skew Guide – Helps press media against Fixed Media Guide. Media Guides – Help hold media on Transport Belts. Take-up Reel – Winds up tab web after tab is applied. Reel –...

  • Page 6: End View With Pressure Roller Cover Open

    GETTING ACQUAINTED End View with Pressure Roller Cover Open Operator Side Tab Folding Guide – Folds tab under media when tabbing from operator side of Tabber. Tab Pressure Roller Lock – Locks Tab Pressure Assembly in place. Applicator Head – Two Applicator Heads are supplied: one for tabs and stamps and one for labels.

  • Page 7: Control Panel

    GETTING ACQUAINTED Control Panel MAIN POWER SWITCH – Turns Tabber power ON and OFF. HEAD POWER SWITCH – Turns power to Tab/Label motor ON. TRANSPORT POWER SWITCH – Turns transport power ON and OFF. JOG SWITCH – Jogs or moves transport slowly for setup purposes. SPEED CONTROL –...

  • Page 8: Section 2 - Assembly And Installation

    ASSEMBLY AND INSTALLATION SECTION 2 - Assembly and Installation Tabber is shipped in a single carton. Base Unit is below the Head Unit. Remove cardboard carton from pallet, remove Head Unit from packing material. Next, remove Base Unit and place it on a flat working surface.

  • Page 9: Installing Tab/Label Applicator Head

    ASSEMBLY AND INSTALLATION 3. Install front mounting screw. 4. Connect two motor cables to Base Unit. Plugs are keyed to prevent improper insertion. Installing Tab/Label Applicator Head Tabber comes with two Tab/Label Applicator Heads. Narrower Head is used for tabbing and ®...
  • Page 10 ASSEMBLY AND INSTALLATION 3. Install grommet [8] in slot provided in Motor Cover. 4. Connect Reel Brake Connector to two pin connector on top of Head Assembly. 5. Mount Reel Assembly to top of Head and fasten it with three screws supplied.

  • Page 11: Installation

    ASSEMBLY AND INSTALLATION Installation Choose a Location Place Tabber with its Feeder on a level sturdy worktable or cabinet at least 12" from any walls. IMPORTANT: Allow enough room to place Feeder and Feeder Base on the same work surface. Protect Tabber from excessive heat, dust, and moisture – avoid placing it in direct sunlight.
  • Page 12 ASSEMBLY AND INSTALLATION Feeder Base Guide: 1. Remove protective tape from Feeder Base Guide [A]. NOTE: DO NOT remove the Teflon tape strip from the bottom of the channel on the Guide [B]. Remove two rubber feet [C] from the closed end of the Feeder Base.

  • Page 13: Section 3 - Operating Tabber

    OPERATING TABBER SECTION 3 - Operating Tabber Tabber is capable of applying up to three tabs to media in one pass. To set-up Tabber for applying tabs to media: Install proper Tab/Label Applicator Head in Tabber Load tabs Adjust Tabber Program Job Run Job Replacing Applicator Head...

  • Page 14: Loading Tabs

    OPERATING TABBER Loading Tabs 1. Remove Roll Side Guide and install tab roll with tabs unwinding face up from right side of roll. Remove approximately 30 tabs from roll to create a leader. 2. Release Unwind Drive Press Roller (rotate it to the left) and thread leader over Unwind Drive Roller.

  • Page 15: Aligning Feeder

    OPERATING TABBER Aligning Feeder Alignment of Feeder to Tabber is important to proper placement of tab on media. Feeder should be aligned so media is fed within 1/8" to 1/32" of Tabber's Fixed Guide (as shown). NOTE: Feeder should never be placed so media is in contact with Guide as it is being fed.

  • Page 16: Adjusting Tab Positioning

    OPERATING TABBER When running tri-folded or very light weight media, Media Guide [1] nearest Fixed Media Guide [3] can be removed and Center Media Guide [2] can be set at an angle to give more push to media to hold it against Fixed Media Guide [3].

  • Page 17: Operating Tabber

    OPERATING TABBER 3. Loosen Sensor Guide Knob [3] and position Pointer [4] over center of tab (as shown). Then check that center of Tab is aligned with Tab Folding Guide [5]. 4. Close Exit Cover and lock it in position using the two Locking Levers.
  • Page 18 OPERATING TABBER 3. Start-Up screen at right appears. Soft Keys (at bottom of display) control the following functions: a. Job # - Used to select one of four programmable jobs. More information can be found under “Programming Job” section. b. Pass-Thru – When Pass-Thru is showing, Tabber will tab pieces as they are fed through it.

  • Page 19: Running A Pre-Programmed Job

    OPERATING TABBER Running a Pre-Programmed Job Up to four jobs may be programmed into Tabber's memory. To run a pre-programmed job, release Emergency Stop Button, then: 1. Press Job # soft key. 2. Select Job (1-4) you wish to run. For this example, select Job # 2.
  • Page 20 OPERATING TABBER INFO SCREEN INFORMATION Item Description Job # Number of Job currently selected. Sensor # Indicates Sensor (#1 or #2) currently selected. #Tabs Number of Tabs being applied. Distance between lead edge of tab and the next tab (including Tab Pitch space between tabs), plus 0.01".

  • Page 21: Section 4 - Programming Tabber

    PROGRAMMING TABBER SECTION 4 – Programming Tabber Advanced Soft Key Pressing Advanced soft key displays several new soft keys. They are as follows: Control Panel Backlight Control Panel Backlight intensity can be controlled from the Advanced soft key. To access “Backlight Control” screen, press Advanced key, then Backlight key.

  • Page 22: Version

    PROGRAMMING TABBER Version On Advanced screen, pressing Version soft key displays the following: Lifetime Products: Total number of pieces transported through system. Lifetime Tabs: Total number of Tabs/Stamps applied by tab head. BIOS Version: Software version currently loaded into Tabber. BACK: Returns you to Advanced features screen.

  • Page 23: Notes Before Programming

    PROGRAMMING TABBER Notes before Programming Two methods for programming jobs on Tabber: 1. Manual – Where operator specifies tab positioning. 2. Automatic – Where Tabber is given tab information and it automatically sets up location of tab or tabs by automatically measuring the piece. In either case, some operator interaction to fine tune tab location and media feed through Tabber may be required.

  • Page 24: Sensor

    PROGRAMMING TABBER Sensor # Once Job # “Select Setup Option” screen opens, set which side of Tabber (Operator Side or Non- Operator Side) that tabbing will occur for this job by pressing Sensor #. This activates Sensor #1 (Operator Side) or Sensor #2 (Non-Operator Side).

  • Page 25: Automatic Tab Sensor (V-Tab) Adjustment

    PROGRAMMING TABBER Automatic Tab Sensor (V-Tab) Adjustment 1. Turn Feeder OFF. 2. To begin programming, select Job # from “Press Run to tab using Job #” screen. 3. Select Job Number (1-4) to use. In this example, select Job Number 1. 4.
  • Page 26 PROGRAMMING TABBER Tip: Selection for Backing (liner) does not denote type of tab material. Instead, it denotes density of the tab and liner it is affixed to, as compared to the space between tabs. Rather than thinking of this setting as a backing description, it is easier to identity if backing (liner) has a black bar between each tab or not (is space between tabs black or white?) See chart below.

  • Page 27: Manual Tab Sensor (V-Tab) Adjustment

    PROGRAMMING TABBER Manual Tab Sensor (V-Tab) Adjustment 1. Open Exit Roller Assembly. 2. Begin programming by selecting Job# with soft key under display. 3. Select Job Number (1-4) you wish to use for job. In this example, select Job Number 1. 4.
  • Page 28 PROGRAMMING TABBER IMPORTANT WHEN SETTING GAP VOLTAGE AND TAB VOLTAGE MANUALLY, SOFTWARE WILL DETERMINE IF TAB TYPE IS OPAQUE OR CLEAR BASED ON VOLTAGE READINGS YOU SELECT. Tab Type Description Gap V Level Tab V Level Tabs in which the space between tabs is Opaque High lighter than the tab even if the tab is white.

  • Page 29: Tab Position Setup

    PROGRAMMING TABBER Tab Position Setup From “Select Setup Option” screen, press “Tab Position”. “Select Tab Position Setup Option” screen appears. You can set-up Tab Sensors manually (using Manual key) or automatically (using Automatic key). Next is a description of how to set up Tab Positioning manually using Manual key.
  • Page 30 PROGRAMMING TABBER From “Select Option to edit” screen, select # Tabs. If # Tabs soft key is pressed: Display prompts you to select number of tabs to apply to mail piece. 1 – Selects one tab 2 – Selects two tabs 3 –...
  • Page 31 PROGRAMMING TABBER Pressing Tab 1, Tab 2 or Tab 3 opens “Enter offset for Tab 1 and press SAVE key” screen. If any Tab n (Tab 1, Tab 2, Tab 3) soft keys are selected, you will be asked to enter Offset Value for Tab Number you selected.

  • Page 32: Automatic Tab Positioning

    PROGRAMMING TABBER Automatic Tab Positioning Automatic Tab Positioning Features Pressing Automatic soft key from “Select Setup Option” screen puts Tabber into “automatic positioning mode”. Tabber will automatically set Offset Values (positions) based on product length and number of tabs selected. 1 Tab –...
  • Page 33 PROGRAMMING TABBER Pressing Product-L soft key from “Select Setup Option” screen opens “Enter Product Length and press Save key” screen. The following choices are displayed: Automatic – Allows Tabber to automatically measure and set piece length. It is highly recommended that you use Automatic to verify proper media feeding and sensing.

  • Page 34: Manual Product Length Input

    PROGRAMMING TABBER Manual Product Length Input As an option, you can set the piece length manually. However, doing so will not fix a tab placement problem that is caused by a media feeding or media sensing issue. In other words, if Tabber's Automatic Product Length feature is not reading piece length accurately, then setting product length manually is NOT going to fix a problem.

  • Page 35: Applying Roll Labels

    PROGRAMMING TABBER Applying Roll Labels Labels supplied in roll form such a Post-it notes and packaging labels can be treated as you would when applying single tabs. See “Program Job – Single Tabs”. Applying Fan-Folded Labels Fan-Fold Labels Up to 2" Long Fan-Folded Label Tray has to be installed in order to run fan-folded labels on Tabber.

  • Page 36: Fan-Folded Labels Over 2" Long

    PROGRAMMING TABBER 6. Remove approximately 30 labels from stack. Then place stack on Label Tray. Adjust Side Guide [4] to within 1/16" of labels. 7. Thread labels over top of Tray, then down through two Guide Rods [5] (as shown). Hook Label Plate [6] over Top Guide and behind Lower Guide, but in front of labels.
  • Page 37 PROGRAMMING TABBER 4. Install Long Label Tray over spindle (as shown). 5. Use two thumbscrews [3] to attach Long Tray Assembly to Reel Holder. 6. Remove enough labels to expose 29"-30" of backing material. Then place stack on Label Tray. Adjust Side Guide [4] to within 1/16" of labels.

  • Page 38: Applying Single Stamps

    PROGRAMMING TABBER 9. Install Tab Unwind Sensor Block [8] over Tab Sensor (as shown). Adjust Label Tension Spring [9] so it touches label but does not press label against Bin (as shown). 10. To program job, refer to “Program Job – Single Tab”.
  • Page 39 PROGRAMMING TABBER NOTES _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...

  • Page 40: Section 5 - Maintenance

    MAINTENANCE SECTION 5 – Maintenance Cleaning WARNING! TABBER IS A PRECISION MACHINE THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT MACHINE FROM ITS POWER SOURCE! Clean Tabber regularly to remove accumulated paper dust and ink. Depending on types of media run, paper dust may accumulate within Tabber and on Transport.

  • Page 41: Lubrication

    MAINTENANCE Sensor Locations: MEDIA SENSOR TAB SENSOR TAB WEB SENSOR (Located under this plate.) Lubrication Several locations on Tabber require regular lubrication: 1. Apply white lithium grease to four Head Raising Cams. 2. Apply white lithium grease to Head Raising Drive Assembly Gears (as shown).
  • Page 42 MAINTENANCE NOTE: Access Gears (shown at right) by removing Front Cover Panel from Tabber. 3. Lightly apply a thin coat of light machine oil to two Tabber Head Guide Rods to insure smooth operation.
  • Page 43 MAINTENANCE NOTES _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...

  • Page 44: Section 6 - Troubleshooting

    TROUBLESHOOTING SECTION 6 – Troubleshooting Troubleshooting Guide is provided to assist in solving any problems that might occur with the Tabber. We tried to make it as complete as possible. The best advice is to make sure tabs, labels or stamps are threaded properly and machine is plugged in and turned on. Jams CONDITION SOLUTION...
  • Page 45 TROUBLESHOOTING Tab Placement Problems (continued) CONDITION SOLUTION Less of the tab is on the top of the media Adjust Fine Adjustment Knob (Page 12) than on the bottom. counterclockwise to place more of tab to top side of media. Tab is not flush with edge of media. Media is not being fed flush with Fixed Side Guide.
  • Page 46 TROUBLESHOOTING Label Placement Problems CONDITION SOLUTION Labels not placed in same place on media. Label placement should be within +/- 1/8" Check pitch setting for label. It should be slightly more than label size plus space between labels. Check amount of head pressure. Too little can cause media to slip when it is being fed.
  • Page 47 TROUBLESHOOTING Stamp Placement Problems CONDITION SOLUTION Stamps not placed in same place on media. Stamp placement should be within +/- 1/8" Check Pitch setting for stamp. It should be slightly more than stamp size plus space between stamps. Check amount of head pressure. Too little can cause media to slip when it is being fed.

  • Page 48: Diagnostics

    TROUBLESHOOTING Diagnostics A diagnostic function is built into Tabber software. Diagnostics are accessed through Advanced key. Pressing Diagnostic key will start tests in order. To bypass a test, press Next key. To return to a test, press EXIT key. Tests in order are: 1.
  • Page 49 TROUBLESHOOTING IMPORTANT REMOVE TABS FROM HEAD FOR REMAINING TESTS. 3. Servo Motor Test – Tests function of Servo Motor for the Head. In Test OFF position, Servo Motor is OFF. Pressing Test ON causes Servo Motor to turn ON. You should be able to hear this action.
  • Page 50 TROUBLESHOOTING 5. Web Loop Sensor Test – Tests that Sensor in Tab Head is working. This test should be conducted with tabs removed from Tabber. Insert a piece of paper into Sensor, display should change from UNCOVERED to COVERED. Press Next to proceed to Tab Sensor Test.

  • Page 51: Appendix - Specifications

    Interlocks on all adjustments Safety: Emergency Stop Switch ATS-9900: 27" W x 33" D x 37" H (67 cm x 84 cm x 94 cm) Dimensions: ATS-9950: 27" W x 33" D x 71" H (w/Console) (67 cm x 84 cm x 180 cm (w/Console)) ATS-9900: 200 lbs.

  • Page 52: Index

    INDEX INDEX Adjustable Media Forwarding Roller ......2 Fan-Folded Labels, Applying ........31 Adjustable Tab Pressure Roller ......... 2 Fan-Folded Labels, Over 2" Long ......32 Fan-Folded Labels, Up to 2" Long ......31 Adjusting Media Guides ............11 Feeder Tab Positioning ............
  • Page 53 INDEX Tabber Applicator Head ............. 9 Pitch, Tab ............27, 30 Automatic Tab Positioning ........28 Pre-programmed Jobs ..........15 Cleaning ............... 36 Programming Tabber ..........17 Diagnostics ............44 Feeder Guides ............7 Reel ................1 Install ..............7 Roll Labels, Applying ..........
  • Page 55 Copyright 2017 Astro Machine Corp. Elk Grove Village, IL 60007 01/31/2017 Part Number: 100-ATS-9900 Rev. K...

This manual is also suitable for:

Ats-9950

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