ALP/4500 FRONT APPLY SWING ARM Revision A 6145-017
Diagraph, an ITW company, continually improves its products, and reserves the right to change or discontinue specifications and designs shown in this manual without notice and without incurring obligation. Diagraph has made every effort to verify the information contained in this manual, but reserves the right to correct any error at the time of the manual s next revision. 2004 Illinois Tool Works Inc. All rights reserved. Printed in the United States of America Page 2
1.0 Introduction 1.1 The ALP/4500 Front Apply Swing Arm Applicator The Front Apply Swing Arm, referred to hereafter as the FASA, is an applicator module which allows either single or dual panel label placement. This module utilizes a linear pneumatic extension cylinder which rotates an arm containing a pivoting tamp pad to the product. 1.2 Product Safety Safety awareness is critical when working with equipment that contains moving parts and extending pneumatic cylinders. Please read all warnings and cautions thoroughly before operating this device. Introduction WARNINGS WARNING - Moving parts of this machine can present hazards. Components that cannot be guarded because of loss of functionality are marked with a warning symbol. Be aware of the tamp cylinder extension distance, and avoid accidental triggering of the photosensor. When servicing the unit s electronic assemblies, always remove the power cord from the unit to prevent accidental shock. When running for extended periods of time, use caution when accessing the drive module circuitry. The motor drive power transistors, motor case, and motor heatsink can become hot under constant use. Always close the air inlet valve shutoff when removing or servicing pneumatic module or tamp cylinder. Wear personal protective equipment, as instructed by your supervisor, when operating or working near this device. COMPLIANCE CAUTION: Not for use in a computer room as defined in the Standard for the Protection of Electronic Computer/ Data Processing Equipment, ANSI/ NFPA 75. ATTENTION: Ne peut être utilissé dans une salle d ordinateurs telle que définie dans las norme. ANSI/NFPA 75 Standard for the Protection of Electronic Computer/ Data Processing Equipment This unit has been tested and found to comply with the limits for a Class A device, pursuant to part 15 of the FCC Rules. This unit has been tested to comply with CE Standards. Introduction Page 3
. This unit is equipped with an Emergency Stop switch. Depressing this switch will cause all machine operations to cease. This unit was tested and it was determined that a potential for tipping exists in certain orientations. In compliance with UL safety standards, the stand must be secured to the surface where it is located. Additionally, this type of securing will result in greater product application accuracy. 1.3 Document Conventions Formatting conventions are used throughout this manual as a method of providing consistency for notes and warnings. Introduction. Note This symbol appears throughout the manual to provide additional information on a topic, including technical details, exceptions to the instructions and other pertinent information. Notes are identified with a note pad and pen symbol and italics text. WARNING This symbol indicates a danger of injury to the user. Hazards are identified by the exclamation mark in a triangle and bold italics text. 1.4 Warranty Information The ALP/4500 FASA system, including all components unless otherwise specified, carries a limited warranty. For all warranty terms and conditions, contact Diagraph, an ITW Company, for a complete copy of the Limited Warranty Statement. Introduction Page 4
2.0 Installation Step 1 - Assemble the Standard Unit [1] Follow the instructions in the ALP/4500 manual for assembling the standard unit. [2] If this is a conversion from a tamp applicator, remove tamp cylinder assembly and dovetail track before proceeding. Detach the cylinder home sensor from the cylinder, but leave the cable connected. Installation Step 2 - Attach the FASA Dovetail Track [1] Install the longer dovetail track with the provided 10-32 low-profile socket head cap screws. [2] Use the provided Loctite to the screw threads before tightening. Installation Page 5
Step 3 - Attach the FASA Module Cylinder Bottom [1] Slide the FASA module onto the dovetail track. [2] Connect the yellow vacuum line to the pneumatic vacuum generator. [3] Connect the blue extension pressure line from the top of the cylinder to the pneumatic block as shown in the image below. [4] Connect the red retract pressure line from the bottom of the cylinder to the pneumatic block as shown in the image below. Installation To Top of Tamp Cylinder To Bottom of Tamp Cylinder To Vacuum Pad Installation Page 6
Step 4 - Electrical Connections [1] If not already connected, insert the Cylinder Home sensor cable through the fitting in the side of the rear enclosure. [2] Connect the Cylinder Home sensor cable to the to terminal block labeled J15. The circuit board shows the correct wire color placement positions. Installation Installation Page 7
3.0 Setup Step 1 - Tamp Pad Alignment [1] Position the tamp pad as shown by adjusting the two bumper screws. This is set at the factory, and should not need adjustment. The tamp pad should be angled to approximately 20 degrees with respect to the bracket mount. This ensures smooth label transfer to the pad. [2] The shock absorber is also set at factory and should not require adjustment. If adjustment is necessary, make sure that the bumper is not allowed to bottom out on the shock cylinder body. The shock retraction rate can be adjusted by rotating the top of the shock cylinder cap. Again, this should not require adjustment. Setup Step 2 - Arm Alignment This sets in/out position only [1] With the tamp pad properly angled, slide the FASA module into position by adjusting the height offset. This is accomplished by loosening the screws shown at the left. [2] Making sure that the FASA arm will not pinch any hoses or components, turn on the air pressure for setting the final adjustments. [3] Align the pad to the peel blade so that the pad is 1/16th of an inch below the peel blade. This allows the labels to snap free of the liner. Once this position is set, tighten the offset screws. [4] With the height offset determined, set the FASA position in the dovetail so that the tamp pad is roughly 1/16th to 1/8th of an inch away from the peel blade. Height Adjustment Screws Setup Page 8
Step 3 - Pneumatic Calibration VAC AIR TAMP 30 20 45 [1] The vacuum pressure is factory set to 30 psi, and should not be changed. Vacuum pressures below 30 psi are not recommended. [2] The tamp pressure determines the rate at which the cylinder cycles. Pressures higher than 60 psi or lower than 25 psi are not recommended. Standard setting is at 45 psi. [3] The air assist is factory set for 20 psi. This should be adequate for most applications. If the label length is longer than 6 inches, the air assist pressure may need to be increased, but should be kept below 40 psi. Setup Step 4 - FASA Arm Application Rate Retraction Speed Control Extension Speed Control [1] The air flow controls adjust the individual rate of extension and retraction of the FASA arm. [2] The control for extension speed is located at the lower portion of the cylinder. This has been set at the factory for best possible speed. If adjustment is required, make adjustments slowly. [3] The control for retraction speed is located at the upper portion of the cylinder. This has also been set at the factory for best possible return speed. If adjustment is required, keep in mind that the cylinder home position may also require re-positioning. If the return rate is too high, the pad may bounce on return, and cause label jams. Setup Page 9
Step 5 - Parameter Settings - MTool Setup. [1] The ALP/4500 unit must have the correct application mode set for the given application. This is performed with the MTool software program (version v2.5 or later). [2] There are a few possible modes that are applicable for the FASA applicator. Tamp mode will apply one label per photosensor trip. Tamp/Tamp mode will apply two labels per photosensor trip, and be separated by the Second Product Delay time. This time can be set in MTool, or on the unit. The unit must be configured for Tamp/Tamp to display this screen in the setup menus. [3] Select the correct mode and send the values. Exit the program when complete. Note If the Tamp/Tamp mode is selected, it is still possible to apply only one time per photosensor trigger by setting the Second Product Delay to zero at the ALP/4500 unit. Setup Page 10
Step 6 - Parameter Settings - ALP/4500 [1] After selecting the correct Application Mode in MTool, set the delay(s) required to optimally position the label on the product. Use the Product Delay, as described in the ALP/4500 manual to set the first application position. [2] If the unit is in the Tamp/Tamp mode, a new screen will be accessible in the Setup screens. Second Delay determines when the FASA will apply for the second time (from one product trigger). This time begins once the first delay expires. It is important that there is enough time entered to allow the label to be printed. If the second delay expires before the second label in on the pad and ready, it will not be applied. Typical minimum delays of 1500 ms (6 inch long label at maximum print speed) are required to complete the second application. [3] If the unit is in the Tamp/Tamp mode, but the application occasionally requires only one label per trigger, set the Second Delay to zero (0) to cancel the second application. Setup. Note If the Tamp/Tamp mode is selected, it is still possible to apply only one time per photosensor trigger by setting the Second Product Delay to zero at the ALP/4500 unit. Setup Page 11
4.0 Replacement Parts 4.1 ALP/4500 FASA Replacement Part List Part Number 6145-017 6145-740 Cylinder Home Sensor 6170-009 (9405k12 McMaster Carr) Bumper, Posts 1903-345 Shock Absorber (9271k59 McMaster Carr) Music Wire Torsion Springs (6391k135 McMaster Carr) Bronze Bearing Description Replacement Parts 6170-007 (92196A533 McMaster Carr) Knuckle Shoulder Bolt 6170-004 Swing Arm Pneumatic Cylinder 6170-010 Knuckle Base 6170-014 Plate, Knuckle Pad 6170-030 Female Dovetail Bracket 6170-031 Male Dovetail Bracket 6170-033 Support Braket 6170-034 Cylinder Support Block 6170-035 FASA Shaft 6170-036 Rod Cylinder Pin 6145-002 Single Rod Cylinder Bracket 6170-037 Bracket, Shock Absorber Support 6170-038 6 inch Shaft 6170-039 L-Bracket, FASA 6170-040 Shaft, 3/8inch Threaded 6170-041 Support Block, FASA 6170-042 Knuckle Base, FASA 6170-043 Knuckle Pad Plate, FASA 6170-044 Tamp Cylinder Assembly, ALP/4500 FASA 5312-003 (6391K135 McMaster Carr) 3/8 inch Bronze Bearing, 1 LG. Replacement Parts Page 12
4.2 Exploded Assembly Replacement Parts Replacement Parts Page 13
5.0 Troubleshooting This troubleshooting section specifically covers faults with the FASA module. Please refer to the ALP/ 4500 Manual for troubleshooting the main system. Problem Cause Correction Label is feeding into the tamp pad edge Improper pad height adjustment Arm return is too slow Tamp pad should return to a position that is approximately 1/ 16th of an inch below the peel blade Increase Tamp pressure between 30 and 60 psi. Increase upper flow control by turning screw counterclockwise. Troubleshooting Second label is fed to the pad, but is not applied to the same product Change in Tamp Pressure Setting Cylinder Home sensor positioned too low Shock Absorber stiffness is too high Incorrect Application Mode Second Delay is too short If the Tamp pressure is decreased, the pad may not return as far. Decrease the Shock Absorber resistance to compensate. If the Home sensor is triggered too soon, the tamp pad may not have settled in time for the label to be fed. Slide the Home sensor further up the cylinder (while cylinder retracted) while maintaining home sense. Use the red light on the sensor to determine if the cylinder is sensed. If the shock is adjusted, it may keep the pad from returning to the two bumper posts. Decrease the shock resistance so that the arm is slowed when entering the home position, but not halted by the shock resistance. Use MTool to set mode to Tamp/ Tamp Increase the Second Delay time to allow the second label to be printed and applied. Increase the time to 5000 ms and work down to the required time for second application. Troubleshooting Page 14