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ASTRO ATS-8900 Operator's Manual

Tabber/stamp affixer
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ASTRO
ATS-8900
TABBER/STAMP
AFFIXER
OPERATOR MANUAL

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Summary of Contents for ASTRO ATS-8900

  • Page 1 ASTRO ATS-8900 TABBER/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 Tabber Rear View FF-30 Feeder Connections Tabber Control Panel SECTION 2 - Assembly and Installation Assembly Installing the Reel Assembly Install FF-30 Feeder SECTION 3- Operating the Tabber Adjusting the Feeder Adjusting the Tabber Adjusting Tab Fold Positioning...
  • Page 4 NOTES _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________ _____________________________________________________________________________________________...

  • Page 5: Section 1 - Getting Acquainted

    GETTING ACQUAINTED SECTION 1 – Getting Acquainted Front View Control Panel – Control and program Tabber. Pressure Roller Assembly – Presses tab to media. Reel – Load tabs or stamps on Reel Assembly. Take-up Reel – Winds up tab web after tab is applied. Media Height Adjustment Knob –...

  • Page 6: Tabber Rear View

    GETTING ACQUAINTED Tabber Rear View Emergency Stop Input – Permits an Emergency Stop of Tabber from an existing safety circuit when properly wired. Jumper plug must be used when this feature is not used. Emergency Stop Output – Permits Tabber to control emergency stopping of another machine.

  • Page 7: Ff-30 Feeder Connections

    GETTING ACQUAINTED FF-30 Feeder Connections Tabber/Feeder Control Cable – Permits Tabber to control Feeder when Mode Switch is in the Automatic position. Power Inlet Connection – Power Cord plugs in here. Fuse – Feeder Fuse is located here. Main Power Switch – Turns Feeder ON and OFF. Mode Switch –...

  • Page 8: Tabber Control Panel

    GETTING ACQUAINTED Tabber Control Panel TRANSPORT POWER SWITCH – Turns Tabber transport power ON*. SPEED CONTROL – Adjusts Tabber speed. NOTE: Maximum speed of Tabber is controlled by software. Tabber Speeds: Single Tabs: Applies up to 20,000 pieces per hour Double Tabs: Applies 12,000 pieces per hour Triple Tabs: Applies 8,000 pieces per hour.

  • Page 9: Section 2 - Assembly And Installation

    ASSEMBLY AND INSTALLATION SECTION 2 - Assembly and Installation The ATS-8900 is shipped in a single carton. Assembly Choose a Location Place the Tabber with its Feeder on a sturdy worktable or cabinet at least 12 inches from any walls. Allow enough room to place the Feeder on the same work surface. Protect the Tabber from excessive heat, dust, and moisture –...

  • Page 10: Install Ff-30 Feeder

    ASSEMBLY AND INSTALLATION 2. When the Reel Assembly is completely seated, plug in the Reel Assembly Cord [5], as shown. Install FF-30 Feeder 1. The pin [A] on the Feeder should mate with the hole [B] on the Tabber body. 2.
  • Page 11 ASSEMBLY AND INSTALLATION Plugging in the Feeder and Tabber Make sure that the Emergency Stop Switch of the Tabber is in the OFF position and the Main Power Switch above the power cord receptacle is in the OFF position. Make sure that the Power Switch on the Feeder is in the OFF position also.

  • Page 12: Section 3- Operating The Tabber

    OPERATING THE TABBER SECTION 3- Operating the Tabber ATS-8900 is capable of applying up to three tabs or stamps to the media in one pass. The steps required to set-up the Tabber for applying tabs or stamps are: Load tabs or stamps...

  • Page 13: Adjusting The Feeder

    OPERATING THE TABBER Adjusting the Feeder The Feeder is properly aligned with the Tabber when it is installed. The Operator Side Guide in the Feeder is fixed in position for proper alignment of the media. Adjusting the Feeder to feed media: 1.

  • Page 14: Adjusting The Tabber

    OPERATING THE TABBER 3. Move the Adjustable Side Guide to within 1/32-inch of the media and tighten the Locking Knob. 4. Adjust the Rear Media Support Guide so that the media is approximately 1/2-inch above the Media Support as shown. NOTE: This is a starting guideline.

  • Page 15: Adjusting Tab Fold Positioning

    OPERATING THE TABBER 2. The two Media Guides [1] should be just resting on the belts. Too much pressure will cause the media to stall while being fed. Additionally, the Guides should be positioned between 1/8" and 1/4" of the edge of the media to prevent the edges from curling.
  • Page 16 OPERATING THE TABBER 3. Release the two Press Rollers to take the tension off the Tab web. 4. Pull the Tab from the take-up end of the web until approximately 1/2 of the Tab/Stamp is showing. 5. Adjust the Tab Position Knob [5] to center the Tab on the edge of the belt as a starting point.

  • Page 17: Operating The Tabber

    OPERATING THE TABBER 8. Release the Emergency Stop Switch. Turn the Main Power Switch on the Tabber and the Feeder ON. If the Feeder Interface Cable is attached, make sure that the Selector Switch on the Feeder is set to Automatic. 9.

  • Page 18: Exceeding Tabbing Rate

    OPERATING THE TABBER c. Advanced – Press this key to place the Tabber in Advanced Mode. This mode is used to select the Automatic Tab Sensing Program and to access more information regarding the soft key menus. 3. Press RUN key (located below soft keys on Control Panel) to start the Tabber. Adjust the Speed Control to set the speed of the Tabber.

  • Page 19: Running A Pre-Programmed Job

    OPERATING THE TABBER After 15 seconds*, if the Tabber isn't slowed down, Maximum Tabbing Rate Exceeded screen appears and the Tabber will stop. To restart, reduce Tabber speed and press RUN key on Control Panel. *If the Tabber is slowed down during the warning period it will switch back to the Run Screen and continue to operate.
  • Page 20 OPERATING THE TABBER INFO SCREEN INFORMATION Item Description Job # The number of the Job that is currently selected. #Tabs The number of Tabs being applied. The distance between the lead edge of the tab and the next tab Tab Pitch including the space between tabs, plus 0.01".

  • Page 21: Section 4 - Programming The Tabber

    “Backlight Control” screen, press Advanced key, then Backlight key. Use the two arrow keys to adjust the intensity of the backlight. Click the BACK key to return the ATS-8900 to the operating mode. 50% is the normal setting.

  • Page 22: Version

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

  • Page 23: Automatic Tab Sensor (V-Tab) Adjustment

    OPERATING THE TABBER Automatic Tab Sensor (V-Tab) Adjustment Every time a new Tab/Stamp stock is used or a new job is set up, you must also set up the Tab Sensors for the Tab/Stamp stock. NOTE: To avoid wasting stamps, it is strongly suggested to manually program the V-Tab voltages, instead of using the Automatic feature.
  • Page 24 OPERATING THE TABBER Tip: The selection for Backing (liner) does not denote the type of tab material. Instead, it denotes the 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 the backing (liner) has a black bar between each tab or not (is space between tabs black or white?) See chart below.

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

    OPERATING THE TABBER Manual Tab Sensor (V-Tab) Adjustment 1. Open the Exit Roller Assembly. 2. Begin programming by selecting Job# using soft key under display. 3. Select the Job Number (1-4) you wish to use for the job. In this example, we are selecting Job Number 1.
  • Page 26 OPERATING THE TABBER Tab Type Description Gap V Level Tab V Level Tabs in which the space between the tabs is Opaque High lighter than the tab even if the tab is white. Clear Tabs with a black line between tabs. High 1.

  • Page 27: Manual Tab/Stamp Positioning Features

    OPERATING THE TABBER Manual Tab/Stamp Positioning Features Pressing the Manual soft key from the “Select Setup Option” screen puts the Tabber into the “manual positioning mode”. In this mode the operator must manually set the offset value (position) for each of the tabs/stamps being applied.
  • Page 28 OPERATING THE TABBER Separate – Allows individual adjustment of each tab/stamp position via the Offset Value. Together – Tabs/Stamps are placed next to each other, starting at the Offset Value (see below) set for Tab 1. BACK – Returns you to the previous screen. Pressing the Position soft key prompts you to set the Offset Value for each Tab/Stamp, starting with Tab 1.
  • Page 29 OPERATING THE TABBER Tab Type Description Gap V Level Tab V Level Tabs in which the space between the tabs is Opaque High lighter than the tab even if the tab is white. Clear Tabs with a black line between tabs. High 1.
  • Page 30 OPERATING THE TABBER Pitch – Pitch is very important. The Pitch setting is how the software determines how far to advance the tab. When the Pitch soft key is pressed, the display prompts you to “Enter Tab Pitch and press SAVE key”. Pitch = Distance measured from the top of one tab to the top of the next tab.

  • Page 31: Automatic Tab/Stamp Positioning Features

    OPERATING THE TABBER Automatic Tab/Stamp Positioning Features Pressing the Automatic soft key from the “Select Setup Option” screen puts the Tabber into “automatic positioning mode”. The Tabber will automatically set Offset Values (positions) based on the product length and number of tabs selected..
  • Page 32 OPERATING THE TABBER Pressing the Product-L soft key from the “Select Setup Option” screen opens the “Enter Product Length and press Save key” screen. The following choices are displayed: Automatic – Allows Tabber to automatically measure and set the piece length. It is highly recommended that you use Automatic to verify proper media feeding and sensing.

  • Page 33: Manual Product Length Input

    OPERATING THE 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 the Tabber's Automatic Product Length feature is not reading the piece length accurately then setting the product length manually is NOT going to fix a problem.

  • Page 34: Section 5 - Maintenance

    MAINTENANCE SECTION 5 – Maintenance Cleaning WARNING! THE TABBER AND FEEDER ARE PRECISION MACHINES THAT SHOULD BE CLEANED REGULARLY TO INSURE MANY YEARS OF SERVICE. BEFORE PERFORMING ANY MAINTENANCE, DISCONNECT THEM FROM THEIR POWER SOURCE! The Tabber and Feeder must be cleaned regularly to remove accumulated paper dust and ink. Depending on the types of media run, paper dust may accumulate within machines and on the transport.
  • Page 35 If the orange LED comes “ON” even when paper is present, then the sensor intensity may need to be lowered. This is rare, but possible when high gloss media is being used. A qualified Astro service technician should make this adjustment.

  • Page 36: Lubrication

    MAINTENANCE Lubrication Several locations on the ATS-8900 Tabber require regular lubrication: 1. Place a small amount of white lithium grease where the Drive Press Roller Assembly touches the Release Cam. 2. Place a small amount of white lithium grease where Unwind Drive Press Roller Assembly touches the flat part of the Release Cam.

  • Page 37: Section 6 - Troubleshooting

    TROUBLESHOOTING SECTION 6 – Troubleshooting Troubleshooting Guide is provided to assist in solving any problems that might occur with the Tabber. We have tried to make it as complete as possible. The best advice we can offer is to make sure that the tabs, labels or stamps are threaded properly and that the machine is plugged in and turned on.
  • Page 38 TROUBLESHOOTING CONDITION SOLUTION Less of the Tab is on the top of the media than Adjust Tab Positioning Knob (Page 12) on the bottom. counterclockwise to place more of the Tab to the top side of the media. Tab is not flush with the edge of the media. Media is not being fed flush with the Fixed Side Guide.

  • Page 39: Stamp Placement Problems

    TROUBLESHOOTING Stamp Placement Problems CONDITION SOLUTION Stamps are not placed in the same place Stamp placement should be within +/- 1/8" on the media. 1. Check Pitch setting for the stamp. It should be 0.0005"-0.010" more than the stamp size plus the space between the stamps. 2.

  • Page 40: Tabber Operation Problems

    TROUBLESHOOTING Tabber Operation Problems CONDITION SOLUTION Media feeds, but no tab or stamp is applied. 1. Make sure media is feeding against the Fixed Side Guide. 2. Check Media Sensor for proper operation. 3. Check that tabs are present. Out of tabs? 4.

  • Page 41: Diagnostics

    TROUBLESHOOTING Diagnostics A diagnostic function is built into the Tabber's software. Diagnostics are accessed through the Advanced key. Pressing the Diagnostic key will start the tests in order. To bypass a test press the Next key, to return to a test press the EXIT key. Tests in order are: 1.
  • Page 42 TROUBLESHOOTING IMPORTANT REMOVE TABS FROM THE HEAD FOR THE REMAINING TESTS. 3. Clutch/Brake Test – Tests the function of the Clutch and Brake for the head. The Test OFF position has the Clutch and the Motor OFF. Clicking Test ON will cause the Clutch and Motor to turn ON and the Brake to go OFF.
  • Page 43 TROUBLESHOOTING 5. Tab Sensor Test – Tests that the Sensor in the Tab Head is working. This test should be conducted with the tabs removed from the Tabber. Insert a piece of paper into the Sensor, the display should change from UNCOVERED to COVERED.

  • Page 44: Appendix - Specifications

    APPENDIX Appendix - Specifications Speed Single Tab: Up to 20,000 pieces per hour Double Tab: Up to 12,000 pieces per hour Triple Tab: Up to 8,000 pieces per hour (11" min. piece length) Material size Minimum: 3" x 5" Maximum: 13"...

  • Page 45: Index

    INDEX Index Job# Key Automatic Advanced Features BACK Backlight, Control Panel Manual Diagnostic V-Tab Version Appendix, Specifications Assembly Keypad, Control Panel Backlight, Adjust Intensity Loading Tabs/Stamps Lubrication Cleaning Rollers and Belts Maintenance Sensors Cleaning Control Cable, Tabber/Feeder 2, 3 Lubrication Control Panel Media Sensor Test Clear Key...
  • Page 46 INDEX Tab Sensor Automatic Adjustment Manual Adjustment Tab/Stamp Automatic Positioning Clearing Loading Manual Positioning Tabber Adjusting Advanced Job# Mode Operating Pass-Thru Operate Pre-programmed Job Programming Start-Up Take-up Reel Troubleshooting Jams Stamp Placement Problems Tab Placement Problems Tabber Operation V-Tab Automatic Adjustment Manual Adjustment...
  • Page 48 Copyright 2015 All rights reserved 02/23/2015 Part Number: 100-ATS-8900 Rev. E...

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