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Aztro DAVID G4 How To Set Up

Label applicator
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DAVID LABEL APPLICATOR
G4
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  • Page 1 DAVID LABEL APPLICATOR...
  • Page 2 DAVID LABEL APPLICATOR INDEX Chapter 1 Machine Overview 1.1 Overview 1.2 Specifications 1.3 Sequence of Events Chapter 2 How to Set Up the Machine 2.1 Label Head Wind 2.2 Label Head Thread Pattern 2.3 Component Description and Operation 2.4 Label Head Button Operations Chapter 3 Electrical/Pneumatic Diagrams 3.1 AC Wiring 3.2 Servo Wiring...

  • Page 3: Chapter 1 Machine Overview

    DAVID LABEL APPLICATOR CHAPTER 1 MACHINE OVERVIEW 1.1 OVERVIEW The David Label Applicator applies self adhesive labels to flat sided parallel products that require a flat sided or round application. The David machine may consist of the following: • 1 Right Hand stepper driven Label Head – To apply labels from the right-hand side of the machine.

  • Page 4: Sequence Of Events

    1.3 SEQUENCE OF EVENTS The sequence of events for David Labelling Application: 1. Product to be labelled enters the machine on the in-feed section of the main conveyor. 2. Product travels along the conveyor triggering the product sensor. 3. The product sensor sends a signal to start the sequence of events. The capture cylinder is activated at the completion of the start delay, turning on the capture solenoid extending the capture cylinder.

  • Page 5: Chapter 2 How To Set Up The Machine

    CHAPTER 2 HOW TO SET UP THE MACHINE 2.1 COMPONENT DESCRIPTION AND OPERATION LABEL HEAD WIND Up/Down Wind – By winding the Up/Down wind handle, the label head can be raised and lowered to set the correct position of the peel plate to the surface that is being labelled.
  • Page 6 Some label head thread patterns may vary, but the FIGURES below are the standard David Labelling Machine. The label head thread pattern may be seen on the HMI screen by pressing the AZTRO logo.
  • Page 7 2.3 LABELLER COMPONENTS LABEL HEAD The label head function is to dispense labels on to the products. The components of a standard label head are shown below: Pinch Assembly Dancer Arm Guide Rollers Label Disk Label Gap Sensor Peel Plate Waste Spool Product sensor Fig 3...
  • Page 8 Dancer Arm – The Dancer Arm has the role of tensioning the labels and braking the label disk to prevent the label roll from over running. The Dancer Assembly is a double roller system to take some load of the label head motor when the labeler is operating at higher speeds.
  • Page 9 Guide Rollers – The guide rollers direct the path of the label movement around the label head, it is very important that the correct path is threaded around the guide rollers to gain the correct operation of the labeller. Label rings are fitted to the guide rollers to aid in the tracking of the label head to give the operator a path to thread the label back at the correct height.
  • Page 10 Pinch Assembly – The Pinch Assembly is a most important part of the whole label head assembly. This assembly controls the label movement and application. The pinch assembly works by holding the label backing paper between a rubber drive roller and a knurled aluminum pinch roller, as the rubber roller is turned by the servo motor, the backing paper is pulled which in turn causes the label to be released from the backing paper as the backing paper pulls around the peel plate.
  • Page 11 2.3.1 LABEL HEAD TILT VERNIER Label Head Tilt Assembly – The label head has the possibility of adjusting its tilt left and right. This is used to straighten labels on the product. If a label is adhering on an angle every time a label is applied, this adjustment is used to have the label apply straight.
  • Page 12 ORIENTATION MODULE The orientation module is designed for labelling round containers with a single label up to 100% label wrap of the product. Also, the Orientation Module makes it possible to label a product requiring a front and back label off the same label web. This is achieved by using a motorised drive roller with two pneumatic idler rollers.
  • Page 13 TURN TABLE (Not fitted to all Machines) Some David labellers may be fitted with turn tables. There are no adjustments on the turn table. To operate the turn table, turn on the rocker switch shown in figure 4. Figure 12 Turn Table Power Switch Figure 13...

  • Page 14: Guide Rails

    GUIDE RAILS One side of the conveyor has fixed guide rails, this is the datum edge. The other side of the conveyor has moveable guide rails. The rail must be adjusted for the width of the product. To adjust the rail, loosen the star knobs as shown in figure 9. Fig 14 STAR KNOBS...

  • Page 15: Control Panel

    2.4 CONTROL PANEL Control Panel Functions Emergency Stop – The emergency stop button is used to cut power to the machine in the event of an emergency, or to turn the machine off. Push to activate the stop and twist knob in an anti-clockwise direction and release to reset the stop.

  • Page 16: Main Screen

    LABEL HEAD BUTTON OPERATIONS MAIN SCREEN Fig 15 From the Main Screen all other screens are accessible. The functions of the buttons are as follows: This button accesses the Run screen. Fig 16 This button accesses the Setting screen. Fig 17 This button accesses the Counter Screen.

  • Page 17: Run Screen

    G4 TOUCH SCREEN OPERATOR INTERFACE The functions of the screens are as follows: RUN SCREEN Fig 20 From the run screen the Labeller and the Conveyor/wrapper assemblies can be turned ON and OFF. To turn on the Labeller, press the labeller button and the button will turn green and show labeller ON.

  • Page 18: Settings Screen

    OPERATOR INTERFACE TOUCH PANEL SETTINGS SCREEN When the settings button is pressed the screen will change to the first screen of the label settings. The screens and their operations are as follows: Fig 21 SETTING SCREEN BUTTONS PROGRAM – Pressing this button will access the PROGRAM screen were the operator can LOAD and SAVE program settings.

  • Page 19: Variable Selection

    LABELLING OPERATION SETTINGS The operation of the touch screen controller is laid out in a series of steps. The machine follows each of these steps in order and performs the function of each step, to skip a step, set the value setting to zero on that variable. i.e. if two labels are required, then to put a value setting in label 1 and label 2.
  • Page 20 3. Start Delay - This is the delay from the product sensor detecting the product to the close of the capture module. When using the wrap capture module to hold the product in place, set this delay to extend the pneumatic piston to hold the product at the right time in the centre if the wrapping module.
  • Page 21 5. Orientation – This is where the optional orientation e.g. (poisons bottle labelling) is required to orientate the product (orientating is when a second product sensor detects a feature on the product to place the label in a specific position in relation to that feature).
  • Page 22 7. Printer – This setting is for those who wish to use an Ink Jet Printer to print onto either the labels or containers while they are still moving. The signal starts as soon as the label/product starts to move and will remain on for as long as the pre- set value, this value is the amount of time required to print.

  • Page 23: Program Screen

    10. Coder delay – When using thermal printer to overprint print “USE BY” and “BATCH” detail on the label, this is done when the label has stopped moving. By setting a value, the thermal printer will print for the time set. To change this setting, touch the number panel on the screen, this will activate a new pop up a keypad.

  • Page 24: Saving A Program

    SAVING A PROGRAM Once all settings are satisfactory, save them all to a program number for future reference. Up to 49 programs can be stored. Note; all settings are in relation to the fixed position of the product and label gap sensors. if these sensors are moved in any way, the program settings will be then incorrect.
  • Page 25 LOADING A PRORGAM To revert to a previous saved program, they can be recalled at any time. By pressing the “LOAD” button the screen will display all previously loaded program numbers. Fig 37 To load a program, select the number required by pressing the select program window, and then select the program from the program list.

  • Page 26: Test Screen

    TEST SCREEN The test screen is used when setting up a capture product. When test is activated, the labeller will go through the sequence of events without ejecting a label. Fig 39 To activate the test mode, press the test mode button. When TEST mode is activated...
  • Page 27 ACCESSEING SERVICE MENU 1. Press the “SERVICE” button, the screen will say “Service menu yes/menu”. Fig 40 2. To access service menu, touch the BLANK USER panel on the screen, this will activate a new pop up a keypad). Using this numeric keypad, key in the number value 1 then press ENTER.
  • Page 28 GUIDE TO SERVICE MENU Fig 43 In the service menu, the operator is able to do the following: • Change the direction of the Servo Motor • Test all inputs and outputs • Change the conveyor speed • View machine usage counter •...
  • Page 29 Fig 47 From the service menu all inputs and outputs associated with the labeller can be monitored or tested. INPUTS The inputs are activated from different sensors. When an input is activated, the location on the service menu will change colour to green. The Inputs are as follows: Product –...
  • Page 30 1. REVERSE DIRECTION – DEPENDS ON THE DIRECTION OF TRAVEL REQUIRED FOR THE LABEL HEAD POSITION, CAN BE EITHER LEFT OR RIGHT HAND. NOTE ALL AZTRO MODEL DAVID LABELLERS ARE RIGHT HAND (LABEL COPY 4) SETTINGS FOR ONE LABEL, SIDE APPLICATION NO CODER OR PRINTER 1.

  • Page 31: Chapter 3. Electrical/Pneumatic Diagrams

    CHAPTER 3. ELECTRICAL/PNEUMATIC DIAGRAMS ELECTRICAL WORK IS TO BE CARRIED OUT BY A QUALIFIED ELECTRICAIN 3.1 AC Wiring AC WIRING INVERTER WIRING MAIN CONVEYOR / WRAPPER L1 - B L1 ( L1 ) U/ T1 V/ T2 L3 ( N) W / T3 P2 4 PS C...
  • Page 32 3.2 Servo Wiring 0Vdc 0Vdc +24Vdc +24Vdc CODER PRINTER PRINTER CODER 0Vdc +AOUT- +AN1- +AN22- PRODUCT SENSOR GAP SENSOR P R O DU C T S E N S O R G AP S E NS O R I/O WIRING, Fig 49 SERVO MOTOR AC CCTS W HI T E...

  • Page 33: Chapter 4. Spare Parts List

    REFLECTIVE SENSOR NPN QS18VN6LPQ8 LABEL SLOT SENSOR WF 40B410 8mm GAP LEAD STRAIGHT MU00041 12mm SENS LEAD STRAIGHT XS2F0719H 2 WAY BLOCK AZTRO-0217 CCC13114 T CLAMP AZTRO-0216 CCC13115 CONTROL BOX COMPONENTS EMERGENCY STOP PSN*NZ 0006 TWO BUTTON START STOP P SN/006/GR/X1-X0...
  • Page 34 DAVID BELT CONVEYOR DRIVE SHAFT Custom made CONVEYOR IDLER SHAFT Custom made Custom made DRIVE ROLLER Custom made CONVEYOR IDLER ROLLER AC MOTORS .18 KW VF30 GEAR BOX 20 . 1 AZTRO-0227 S8KA10B GEAR BOX 10 . 1 AZTRO-0227 S8KA10B...

  • Page 35: Contact For Support

    4.2 Recommended Spare Parts On Aztro machines, most of our parts are off the shelf items that are available from a variety of suppliers. Some of these suppliers are listed above in section 5.1. However, there are items which are solely available from Aztro Pty Ltd. We recommend that at least one of each of these items is carried by the machine owner.

  • Page 36: Chapter 5. Standards

    Aztro Pty Ltd Standards and Compliance References Aztro Pty Ltd builds its machines to comply with Australian guide lines and safety standards. A big part of this is to use components that will minimise or eliminate the risk of danger to personnel. Our machines are wired under a Category 1 safety The Standards listed below are the guides used in the design and construction of our labelling machines.

  • Page 37: Chapter 6 Maintenance

    CHAPTER 6 MAINTENANCE 6.1 Maintenance Schedule On the Aztro David Labeller there are very few maintenance requirements. Generally, if the machine is kept clean and looked after, problems or faults are rare. All the bearings in the machine are encased bearings which do not require any greasing. In saying this, the...
  • Page 38 6.2 Trouble Shooting Guide TROUBLE SHOOTING GUIDE FOR AZTRO LABELLING MACHINES IN GENERAL FAULT POSSIBLE FAULTS POSSIBLE FIX SCREEN NOT POWERING UP MACHINE NOT PLUGGED IN PLUG IN MACHINE MACHINE NOT TURNED ON TURN ON MACHINE IS THE FUSE BLOWN...
  • Page 39 LABEL DRAGGING ON PRODUCT EJECTION SPEED TO LOW RAISE EJECTION SPEED LABEL WEB BREAKING NOT THREADED CORRECTLY CHECK THREAD PATH TO MUCH TENSION ON WEB LOOSEN DANCER ARM TENSION LABELS DIE CUT TO DEEPLY CONTACT LABEL SUPPLIER VERTICAL CREASING OF LABEL EJECTION SPEED TO HIGH LOWER EJECTION SPEED PEEL PLATE TO CLOSE TO PRODUCT...

  • Page 40: Chapter 7 Risk Assessments

    CHAPTER 7 RISK ASSESSMENTS 7.1 Conveyor risk Assessment 7.2 Label head Risk Assessment 7.3 Orientation Unit 7.3 Control Box Risk Assessment 7.4 Turn Table...
  • Page 41 Name of Assessor: Marcus Paske Date assessed: 03/07/19 Machinery: Aztro David Best control method chosen by assessor to resolve this hazard: No jewellery or loose clothing to be worn, long hair to be tied back. This is to eliminate entanglement in the machine. Pinch points are guarded where possible.
  • Page 42 Name of Assessor: Marcus Paske Date assessed: 03/07/19 Machinery: Aztro David Best control method chosen by assessor to resolve this hazard: No jewellery or loose clothing to be worn, long hair to be tied back. This is to eliminate entanglement in the machine. Low wattage motors are used to introduce a stall factor in the event of an entanglement. Power should be isolated when re threading the labels or working on the label head.
  • Page 43 Name of Assessor: Marcus Paske Date assessed: 03/07/19 Machinery: Aztro David Best control method chosen by assessor to resolve this hazard: Operators must be made aware of the dangers. Operators are to be instructed not to put their hands near the Orientation Unit unless power is isolated. Stopper block installed to limit pinch zone.
  • Page 44 Name of Assessor: Marcus Paske Date assessed: 03/07/19 Machinery: Aztro David Best control method chosen by assessor to resolve this hazard: Any electrical work is only to be carried out by a qualified person. Before the electrical cabinet is accessed, the technician will isolate the power and tag the machine out.
  • Page 45 Name of Assessor: Marcus Paske Date assessed: 03/07/19 Machinery: Aztro David Best control method chosen by assessor to resolve this hazard: No personnel are to reach under the turn table unless power has been fully isolated. No loose clothing, jewellery or long fingernails are to be worn.

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