BH-2000 Labeling

Machine

User Manual

1
 CAT 1148471
Rev. B/5-97

2
 BH-2000 MANUAL

Manufacturer: B & H Label Systems

3461 Roeding Road
PO Box 247
Ceres, California, USA
Tel: (209) 537-5785
Fax: (209) 537-6854

Type & Model: BH2000

Identification No: __________________________________________

Year of Manufacture: __________________________________________

Customer Location:
__________________________________________

__________________________________________

__________________________________________

__________________________________________

The intended use of B&H Labeling Machines is to apply labels from a continuous

roll to round containers as described in the Operations Instructions or Training

Sessions. The B&H machine shall NOT be used in any way that deviates from its

intended use as described in the Operations Instructions or Training Sessions.

Misuse of the machine can and will cause equipment damage and/or personal

injury. B&H Labeling Systems shall NOT be held liable for any intentional or

unintentional misuse.

CAT1148471

Rev. B 5/97

3
 TABLE OF CONTENTS

BH-2000 MANUAL

1. Introduction - All Models

2. Machine Description and Specifications

2.1 Machine Description

2.1.1 Label Feed Description

2.2 Machine Specifications

3. Installation Instructions

3.1 Handling and Shipping

3.2 Service Requirements

3.3 Assembly Instructions

3.4 Noise Emissions

3.5 Vibration

4. Set-Up Procedures

4.1 Introduction

4.2 Knife and Label Feed - Channels 3,4,7 & 8

4.3 Set-Up and Maintenance for Omega Cutter

4.4 Vacuum Drum Adjustment

4.4.1 Roll-On Pad Adjustment

4.5 Star Wheel Adjustment

4.6 Glue Drum

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 4.6.1 Glue Drum In and Out Control (Channels 5 & 6)

4.6.2 Glue Pattern Adjustment

4.6.3 Glue Wire Groove Pins

4.6.4 Glue Wheel Temperature Control

4.6.5 Glue Wheel to Vacuum Drum Adjustment

4.7 Not Used

4.8 Product Flow Gate Control (Channels 1 & 2)

4.9 Imprinter

4.10 Label Registration

4.10.1 Introduction

4.10.2 Basic Set-Up Procedures - EMP System

4.10.2.1 Control Amplifier - Automatic Correction to Registration

4.10.3 Set-Up Registration Procedures - EMP and PLuS Timer

4.10.4 Summary of Label Registration Set-Up Procedures

4.11 Electrical

4.12 Change-Over to Different Container or Label

5. Operating Procedures

5.1 Control Panel

5.2 Not Used

5.3 Hot Melt Glue System

5.3.2 Start-Up procedures

5.4 Start-Up Procedures

5.5 Stopping Procedures

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 5.6 Cleaning Requirements and Precautions

6. Safety Precautions

6.1 General precautions

6.2 Safety Features

6.3 Grounding

7. Preventive Maintenance

7.1 Lubrication

7.2 Air Filter Regulator

7.3 Glue System

7.4 Vacuum Pump

7.5 Roller Chain

7.6 Mechanics - Weekly

7.7 Mechanics - By-Annually

7.8 Operator’s Duties on Labeler

8. Trouble Shooting Guide

8.1 Labeling Programs

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 CHAPTER ONE

INTRODUCTION

The B & H Labeling System is a new concept in labeling. This system utilizes a

continuous roll of labels rather than labels, which are pre-cut or stacked. As a

result, high production rates with a minimum of maintenance are possible.

The following pages contain explanations of the machine’s major components,

operation, maintenance and applicable service procedures. This manual, plus

your own mechanical and electrical experience, should provide the basis for long

trouble-free operation.

The intended use of the B & H 2000 labeling machine is to apply labels from a

continuous roll to round containers as described in the Operations instructions

and Training Sessions. The B & H 2000 labeler shall not be used in any way that

deviates from its intended use as described in the Operations Instructions and

training Sessions. Misuse of the machine can and will cause damage and/or

injury. B & H Labeling Systems shall not be held for any intentional or

unintentional misuse.

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 CHAPTER TWO

MACHINE DESCRIPTION AND SPECIFICATIONS

2.1 Machine Description

2.1.1 Label Feed Description

The B & H Machine is a new concept in labeling. It utilizes the roll-fed labels rather than

stacked labels. The label web is pulled from the roll through a series of guide rails and

rollers and through the open-date printer (the printer is an optional feature) by the feed

roller. As the label passes over the feed roller, it is fed through the cutter. The label is

cut and transferred to the vacuum drum. As the vacuum drum turns, a sensor detects

the presence of the label on the vacuum drum and engages contact between the glue

roller and the vacuum drum applying glue to the label. Having received the glue, the

label is transferred to the container.

2.2 Machine Specifications

Machine Size – Weight approximately 6000 pounds (270kg)

Width overall – 56” (1422mm)

Length overall – 188” (4775mm)-including conveyor

Height overall – 60” or less (depending on model)

(1524mm)

Electrical Requirements – 440V-15amp or 220V-50amp, 3phase, 60 HZ (11.5kw),

other voltages upon request.

Air Requirements – 8cfm at 80 psi (0.2m3/mm at 550kPa)

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 CHAPTER THREE

INSTALLATION INSTRUCTIONS

3.1 Handling and Shipping

The Machines sold for export are shipped on a wooden skid frame with plywood siding

and placed in an enclosed, steel overseas shipping container. After taking the machine

out of the container and removing the plywood siding, the machine can be moved with a

forklift (10,000 lb. Capacity) from under the machine’s main steel frame. The machine is

rugged, but care should be taken not to damage the conveyor, as it extends beyond the

main steel frame at each end.

Spreader bars need to be used if the machine is to be moved with a crane and lifting

straps. Lifting the machine without the use of spreader bars can result in damaging the

machine.

3.2 Service Requirements

Electrical – The machine should be supplied with a 3-phase, 440V or 220V, 60Hz line,

at machine location. It is imperative that an earth ground be supplied to the ground plug

provided on the main electrical panel. The bond of the B & H labeler to existing

equipment on the production line, for grounding purposes, has proven unsatisfactory in

certain circumstances. Consult the electrical schematic and ordering data for your

particular machine.

NOTE – All power requirements on the machine are supplied from the 3-phase line.

Air – 80psi @ 10cfm should be supplied at the machine.

9
CHAPTER THREE – INSTALLATION INSTRUCTIONS (CONT.)

3.3 Assembly Instructions

The machine is shipped in assembled form and installation and initial testing should

normally be supervised by B & H personnel.

3.4 Noise Emissions

An airborne noise emissions survey for continuous A-weighted and peak C-weighted

sound pressure levels was done using a digital sound meter. The sound levels were

measured at 4 deg. Intervals around the machine at a distance of 1 meter from the

surface of the machine and at a height of 1.6 meters from the floor. The highest A- and

C-weighted pressure levels are recorded as follows:

Continuous A-weighted pressure level: 83.2 dB

Peak C-weighted pressure level: 84.5 dB

Due to the fact that this machine will be incorporated into a packaging line system with

numerous other machines, overall airborne noise emission levels for the entire system

will be higher than those listed above. Hearing protection devices shall be worn at all

times when operating or working around the machine. Failure to use proper hearing

protection devices can result in hearing lose.

3.5 Vibration

The machine is factory pre-assembled and should be securely fastened to the floor or

other support structure.

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 CHAPTER FOUR

SET-UP PROCEDURES

4.1 Introduction

The basic timing of the machine (knife, feed roll, flow gate, and locking gate) is

controlled by a camless limit switch. The functions of the eight channels in the limit

switch are as follows:

CHANNEL NUMBER FUNCTION

1 Flow gate out (releases containers)

2 Flow gate in (stops containers)

3 Label feed start, knife “in”

4 Label feed stop, knife “out”

5 Glue wheel “in” (applies glue to label)

6 Glue wheel “out” (does not apply glue to

label)

7 Arming circuit for channel 3 and 4

8 Disarming circuit for channel 3 and 4

The programmable camless limit switch is located in the front of the machine.

Adjustment of the set point is made with the programmer. The read out of the

machine position is on the control panel. The read out is from 0 to 360 and makes one

revolution with each container or label.

NOTE – All set-up adjustments are based on the rotation of the cutter. In other words,

the cutter is non-adjustable and all other parts are adjusted to the cutter, i.e.

vacuum drum; glue wheel, starwheel, etc. The programmer with its programmable off

set feature has been programmed so that the camless limit switch will read zero when

the knife is in the following position:

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.2 Knife and Label Feed Control (Channels 3,4,7, and 8)

The first set up is to set up channels 3, 4. 7. and 8 to enable the machine to start cutting

labels. The engagement of the stationary knife (which starts the cutting action) and start

of the label feed are controlled by channels 3 and 4. The setting of these are important

because it controls the cut position of the first label.

Once the label length is established, “fine tune” the paper stopping and starting point.

To do this, start the machine, then use manual label feed control to feed one label. The

web should STOP with approximately ¼” extending beyond the stationary knife blade. If

it is not, adjust channel 4. To move the web back, advance the point on channel 4 which

opens the relay contacts (this is the lower limit), this will stop the label feed sooner. To

get more web, retard this point.

Once channel 4 is set, the starting point of channel 3 must be adjusted. Cut about three

more “first” labels. If they are short, the starting of the label feed was too late. Advance

the point on channel 3 which closes the relay contacts (this is the lower limit) which will

start the label feed sooner. If the web section is too long, retard the lower limit of

channel 3.

NOTE – B & H recommends setting channel 3 to cut a first label that is 1/32” longer than

label length to insure the first pad on the vacuum drum is covered with a label. Use the

adjustment bolts to bring stationary blade in parallel to rotary blade. Insert label material

and adjust (fine) until cut is achieved throughout length of blades stationary in

ENERGIZED position. Now go back and tighten center clamping bolt.

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NOTE ILLUSTRATION below:

Adjustment Bolts

Stationary Blade

Rotary Head

13
 Rotary Shear Head

When Knife is in
this position,
camless limit
switch reads zero.
2 Station 180 deg

Stationary Shear Blade

Rotary Shear Head

3 Station 120 deg

When knife is
in this
position,
camless limit
switch reads
zero. Stationary Shear Blade

Rotary Shear Head

4 & 6 Station 90 deg

When knife is
in this
position,
camless limit
switch reads
zero.
Stationary
Shear Blade
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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.2 Knife and Label Feed Control (Channels 3,4,7, & 8)(cont.)

Jog the machine until the knife on the die is approximately ¼” beyond the back

up roll. Set channel 3 to activate (set the lower limit to the number of degrees on the

position read out, the light will go on), set the upper limit to go off approximately 60 later.

Next set channel 4 so the lower limit is approximately 5 later than 3 and the upper limit

45 later (10 before 3 upper limit). This is the rough adjustment of channels 3 and 4.

Fine adjustment is still to be done. The arming circuit, which is utilized to prevent

improper starting of the paper feed, must be set at this time.

The sequence of operation for channel 7 and 8 is generally the same as

discussed for channels 3 and 4. Channel 7 should be set to activate approximately 30

prior to channel 3 activating. It should be noted, however, the entire sequence of

operation for channels 7 and 8 must be completed prior to starting the sequence of

channels 3 and 4.

NOTE – The 30 setting of channels 7 and 8 is only an approximate setting and

can be set more than 30, if the sequence of operation for channel 7 and 8 is not

completed prior to channel 3 activating.

Next, check and set the label length with the EMP motor switch in the “manual”

position, cut approximately ten labels and check label length, (do not use first and last

label to make this check). During the check, the labels are not necessarily cut “in

register” but are being checked to see if they are the correct length. If not, the feed roll

is running too fast or too slow.

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.2 Knife and Label Feed Control (Channels 3,4,7, & 8)(cont.)

Make corrections to the feed roll by using the EMP control. This is done by using

only the “position” or MVC motor (this adjusts the zero max unit only) and press the

motor jog in either the advance or retard direction. Advance makes the label feed faster

and lengthens the label; retard feeds label slower making label shorter. This procedure

can and should be done with the label feed running (the reason is to adjust the zero max

while it is running.) The length should be set as close as possible (at least to within

.010). Periodically lubricate the (Ryertex) vacuum valve plate with grease by lifting the

plate against the spring tension and applying grease to surface of the vacuum plate.

ILLUSTRATION:

Spring

Vacuum Valve Plate

Lube this plate surface

between valve plate & head

Rotary Head

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.3 Set-Up and Maintenance for Omega Cutter

The B & H Omega Film Cutter has been designed for simplicity in the art of cutting and

feeding unsupported label materials. The suspension of the system is rugged and

should give optimum performance with minimum maintenance. The bearings

suspending the cutting rolls are of taper design and receive lubrication from the

lube system (where fitted). The bearings are “pre-loaded” at the factory and locked and

sealed for protection of the unit. DO NOT attempt to adjust the bearing loads. Refer to

your B & H qualified service representative if a problem is suspected.

To replace the rotary and the stationary cutting blade, refer to the following

procedures:

A. Remove the stationary blade by removing the 3 socket head cap screws

and clamp plate.

B. Unscrew the two adjusting screws on the stationary head which are used

to adjust the stationary blade to rotary (this will insure clearance of the blades when

reassembled).

C. Remove the rotary by removing socket head cap screws and clamping

plate.

D. Clean the assemblies, the vacuum holes and the surfaces of dust and foreign

matter.

E. Install the new rotary blade and tighten securely insuring seating and straightness

of the blade in mounting.

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

F. Install the new stationary blade with fasteners and clamp tightening top and

bottom screws. (Leave the center clamp bolt slightly loose until cut adjustment is made.)

Position of point of blade should be set approximatly 3/8 from the yoke mounting bracket

(adjustment will be necessary after initial setting.) ILLUSTRATION below:

Rotary Blade Insert

Stationary Blade

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FAULTING FINDING – LABEL PROBLEMS

1. Label doesn’t adhere to knife roller:

A. Adjust vacuum valve to roller (increase)

2. Label feeds long, loses registration:

A. Adjust vacuum valve to roller (decrease)

B. Check knife roller for contaminants and clean.

C. Check for poor cut of label.

3. Label won’t transfer to vacuum drum:

A. Increase velocity of blow off jet at transfer point.

B. Check knife roller for contaiminant.

4. Label won’t cut:

A. Check solenoid and cylinder for proper activation.

B. Replace rotary and stationary blade.

C. Check for correct measurement of stationary shaft angle. (Refer to set up

instructions.)

D. Possible bearing failure. (Call your authorized B&H Service Representative or

the factory.)

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4.4 Vacuum Drum Adjustment

Set the vacuum drum so that the label is centered on the vacuum drum pad. This is

done by loosening the main shaft bolt, then rotating the drum on its mounting flange to

the correct position, and then tightening the bolt. When in the correct position, the label

being fed from the feed roller and cutter will transfer to the center of the pad on the

vacuum drum.

The vacuum on the drum normally runs from 15” HG (when there are no labels) to 17”

HG (when pads are covered with labels). The location of the vacuum is controlled by the

vacuum valve plate. The point where the vacuum starts and ends can be adjusted by

the vacuum valve stop. The location of the air release or blow off is just after the end of

the vacuum, so whenever the vacuum valve is adjusted, it also adjusts the air release.

GLUE POST

VACUUM VALVE
STOP

FASTENING BOLT

VACUUM VALVE
PLATE

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.4 Vacuum Drum Adjustment (cont.)

NOTE – On Gast 4030 pumps only, the vacuum relief valve on the vacuum must be set

so that the maximum vacuum at any time is no more than 15-17 HG.

This adjustment must be made when all active vacuum holes on the vacuum drum are

covered with labels. If the machine is run at higher vacuums, not enough air will be

available to cool the pump and it could be damaged by overheating. Disregard on Gast

Regenair or Spencer Turbine equipped machines.

4.4.1 Roll-On Pad Adjustment

The roll on pad is used to hold the container against the vacuum drum while the

label is being applied. It is what holds the container while the vacuum drum makes the

container rotate. The adjustments available are the “height” to get it centered between

the starwheel and the “location” to adjust pressure on the container.

It is necessary to replace the vacuum pads as this is a normal wear item of the B & H

labeler. Also the vacuum drum and the valve plate will need periodic cleaning of ports

and holes to insure optimum vacuum efficiency.

NOTE – Lubrication of the vacuum valve plate is necessary to prevent excessive wear

caused by friction. Use a light multi-purpose assembly lube for this. ILLUSTRATION:

Apply to these
surfaces
21
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.5 Starwheel Adjustment

Adjust the timing at the starwheel so that the container contacts the leading edge of the

label on the vacuum drum. Normally, this contact point will lie on a line which connects

the centers of the vacuum drum and the starwheel. After the machine is jogged to get

the vacuum drum in the correct position, the starwheel is adjusted by loosening both the

main shaft and the flange bolts and rotating the starwheel on its mounting flange.

The pressure put on the bottle by the vacuum drum is adjusted by moving the whole

starwheel assembly toward or away from the vacuum drum. When the assembly is

moved, the starwheel drive chain will have to be re-adjusted for tightness.

In addition to timing the starwheel to the vacuum drum, an adjustment can be made to

slightly change the relation of the top starwheel to alignment of label by presenting the

container to the label correctly. By moving the top star either forward or backward, the

label mismatch (on a full wrap label) will move either up or down. This adjustment can

also be used to account for small variation from standard in the container dimensions.

Once the starwheel is set, check the sensor located on the bottle infeed guide. This

sensor (PC2) detects bottle as it enters the machine and starts the paper feed with

proper cycle. The sensor is located in such a place that when it starts the label feed, the

first label will meet the first bottle. The sensor PC2 is positioned to detect bottle #3 in

time to activate channel 7 so as to start the label feeding to meet pad #3 in the vacuum

drum.

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.5 Starwheel Adjustment (cont.)

Adjustments can be made to both the sensor location and the setting on channel 7 and

8; however, remember that the activating of channel 7 and deactivate of channel 8 must

be complete before channel 3 operates. Also remember that the sensor must be

“seeing” the container all the time channel 7 is activated.

NOTE – The vacuum drum must have been adjusted to the cutter prior to the starwheel

adjustments.

4.6 Glue Drum

4.6.1 Glue Drum In and Out Control (Channels 5 & 6)

The glue applicator is a “no label-no glue” system. On start up, a label is fed

onto the vacuum drum and is detected by an infrared scanner for its presence. Upon

detection, the glue drum moves into contact with the vacuum drum and applies glue to

that label. If the “next” label is present, channels 5 and 6 in conjunction with the scanner

will keep the glue drum engaged. (Retracts if next label is missing.)

To set channels 5 and 6, jog the machine until the trailing edge of one pad on the

vacuum drum has just passed the glue drum, stop the machine at that point. Set 5 to

activate (set the lower limit to the number of degrees on the read out.) 3-5 later set

lower limit of channel 6. Now set the upper limit of 6 approximately 35 later (this will vary

with the space between the pads on the vacuum drum), and the upper limit of 5 to

approximately 30 after that.

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.6 Glue Drum (cont.)

4.6.1 Glue Drum In and Out Control (Channels 5 & 6)(cont.)

Generally, the scanner must be positioned to “look” at the next label on the

vacuum when the vacuum drum is positioned so that the glue wheel is between vacuum

drum pads. To do this, the sensor must be positioned to be looking at the label prior to

when 5 is activated and stay “looking” at the label until the upper limit of 6. This insures

that the timing of the glue wheel is done by channel 5 and 6 and not timed by the sensor.

NOTE – The vacuum drum must have been adjusted to the cutter prior to the glue wheel

adjustments.

4.6.2 Glue Pattern adjustment

In order to obtain a gravure-type pattern from the glue applicator, the following

must be adhered to:

1. Glue wheel “run out” in its mounting should not exceed .0015” of an inch top and

bottom “wheel cold” ILLUSTRATION:

.0015” MAXIMUM

KNURL

.0015” MAXIMUM

24
 CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.6 Glue Drum (cont.)

4.6.2 Glue Pattern Adjustment (cont.)

When a pattern is on the glue drum such as a leading and trailing edge

pattern, the glue drum must be timed so the glue pattern “prints” on the correct part of

the label. This is done by removing the gear on the glue drum and setting it in the

correct position and re-installing the gear. Fine adjustment can be obtained using the

slots in the gear. ILLUSTRATION:

GLUE WHEEL

APPLICATOR BAR
ADJUSTMENT

25
 CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.6 Glue Drum (cont.)

4.6.2 Glue Drum Pattern Adjustment (cont.)

3. Glue applicator bar must be “lapped in” to glue wheel surface to obtain an exact

finish between surfaces.

Remove fiber drive gear at top of shaft. Remove springs on glue bar. Apply

pressure to glue bar against wheel. Rotate wheel in direction of normal travel to achieve

lap. Release pressure on bar and repeat. It may be necessary to do this 10 to 20 times

to create exact surface curve on bar. When this is achieved, remove 180 grit paper and

insert 400 grit finish type paper.

Lap several times to create smooth finish on bar. Reinstall springs and fiber gear and

remove any dust fillings from area to avoid contamination. ILLUSTRATION:

ROTATION OF LAPPING EFFORT

APPLY PRESSURE DURING LAP

TAPE ENDS TO WHEEL

SAND PAPER

26
 4.6.3 Glue Wire Groove Pins

The glue wheel is fitted with wires to strip label or insure position is on the vacuum drum

during application of glue to label. The grooves in the wheel are wiped clean at the glue

bar during the application of glue by means of the small brass pins in the glue bar.

Insure that the alignment of these pins are checked during installation of a new glue bar.

Adjustment vertically can be obtained by moving the glue bar mounting bar.

ILLUSTRATION:

GLUE WHEEL
BRASS PINS

ADJUSTMENT BOLTS

27
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.6.4 Glue Wheel Temperature Control

The glue wheel is heated by means of a loop coil inside the hollow glue wheel.

The temperature is controlled by a solid state controller mounted on the front of the

labeler near the glue applicator wheel. The temperature controller controls ONLY the

temperature of the wheel and DOES NOT affect the supply tank, pump, feed or return

hoses.

Temperature is surfaced monitored by a type “J” RTD sensor which rides on the surface

of the glue wheel near the applicator bar.

NOTE – RTD sensor must always be in contact with the glue wheel with a light pressure

for accurate reading and monitor of temperature. ILLUSTRATION:

GLUE WHEEL

GLUE BAR

HEATER COIL

RTD SENSOR

28
4.6.5 Glue Wheel To Vacuum Drum Adjustment

The glue wheel rotates towards the vacuum drum to apply glue to the label. There is a

stop adjustment located on the glue wheel frame post to stop the travel of the glue wheel

against the vacuum drum.

4.6.5 Glue Wheel to Vacuum Drum Adjustment (cont.)

ILLUSTRATION:

ADJUSTMENT BOLT

GLUE WHEEL

VACUUM DRUM

“BUMP”

(WRONG)

CAUTION – Excessive pressure between glue wheel and vacuum drum will shorten the

life span of the vacuum drum pads.

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.8 Product flow Gate Control (Channel 1 and 2)

The product flow gate controls the starting of containers into the machine. The flow gate

should be positioned so the gate and “stopped” containers are as near to the starwheel

or the feed screw as possible. (The gate position is adjustable so this optimum position

can be achieved.)

The flow gate should be open so the containers feed smoothly into the star or the feed

screw and close so the wedge on the gate comes in between two containers, not into the

side of one. To get these results, channel 1 and 2 are adjusted. In adjusting, the

important thing to NOTE is the sequence in which channel 1 and 2 operate. Channel 1

lower limit, 2 lower limit, 2 upper limit, 1 upper limit. As long as this sequence of

operation is maintained, the gate will operate. The lower limit channel 1 activates the

relay and opens the gate. The lower limit of channel 4 is when the gate will close. The

initial adjustment will probably need to be fine tuned or adjusted after a trial run. The

speed of the flow gate air cylinder can be adjusted to help achieve satisfactory timing of

the flow gate. The speed adjustment is located on the air solenoid valve.

In addition to the above timing of the gate to the individual container, the machine must

be timed so a container comes together with the first label on the vacuum drum. This is

done by having the paper feed start at the correct time after the containers have started

to enter the machine.

30
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.8 Product Flow Gate Control (Channel 1 and 2)(cont.)

A sensor is located on the infeed bottle guide (downstream of the flow gate) which starts

the paper feed. The sensor (PCII) must be adjusted either upstream or downstream to

get this correct tie. The sensor must be “seeing” a container all the time channel 7 is

activated in order for the paper feed circuit to be armed. If a small container is being

run, a delay off adjustment on the PC module is set to insure the sensor holds the signal

all the time channel 7 is activated. This is the MA5 Timer located in the main enclosure.

Remember the sensor does not set the precise part when the cutter and the paper feed

starts and stops but arms channels 3 and 4 which does the starting and stopping.

4.9 Imprinter

The imprinter is set so that the LABEL ROLL moves in and out on the eccentric

shaft to contact the embossing/printing type. To adjust embossing depth, use the stop

bolt on the eccentric shaft. Additional adjustment can be made by moving the label roller

mount in or out. If ink is used with the embosser, the Porion ink roll is used. This

transfers ink to the rubber transfer roll and to the type. The adjustment of the Porion roll

to the transfer roll and to the type should be as light as possible and still achieve

satisfactory results.

4.10 Label Registration

4.10.1 Introduction

The following are the units comprising the basic components controlling the register, pick

up and control over the label cut off.

1. Registration Sensor – Located upstream from the cutter assembly and is

used to detect the registration mark on webs.

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CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

Label Registration (cont.)

2. Control Panel – Processes the registration sensor and windows pulses

(generated or by selector switch or by programmable timer) and initiates correction

voltage pulses to the correction motors on transmission as required.

3. Selector Switch – On programmable timer.

4. Double Differential Transmission – Drives the feed roll and pre-printed

web at the speed to give the correct label cut off. The transmission with its correction

motors makes slight speed changes to the web to keep the label in register.

4.10.2 Basic Set-Up Procedures for EMP system With Selector Switch

4.10.2 Control Amplifier-Automatic Correction to Registration

A. Turn the control panel on, put both position and length correction motor

switches on, and start machine.

NOTE – Flashing of green and red lights. When they are flashing alternately, which may

take awhile, if the length was not previously set exactly, the length has been adjusted.

This correction can be done quicker if it is done manually, that is override the length

correction motor with the appropriate advance or retard signal.

B. Continue reducing the correction time knobs and compensating the length

(automatically or manually) using the length motor until correction knobs are on lowest

possible setting.

NOTE –Too high a correction knob setting results in too long a correction time causing

varying registration or over correction.

C. To prevent constant correction signals and oscillations in the registration,

a dead area is introduced between the advance and retard areas in the selector switch

or channels 14 and 15 of the programmable timer.

32
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

Control Amplifier-Automatic Correction To Registration (cont.)

D. Now that the print control cut off is stabilized and the correction brought to a

minimum, check register position with respect to cut off and make final adjustment with

selector switch outer cycle dial. When changing label position, turn length switch off or

you will change label length, turn back on when adjustment is reached or by changing

position of channel 81.

4.10.3 Setting Up registration For System Using EMP and Plus Timer

Principles of controlling the distance of the registration mark from the leading edge of the

label (cut-off) is as follows:

Double differential gear box manufactured by EMP Corporation is connected via timing

belt with feed roller shaft which turns attached feed roller. Feed roller diameter is

calculated in such a way that when the transmission is in the middle of its adjustable

ratio range, the nominal label length is fed. If the registration mark is detected by a

registration sensor, this signal is passed to the EMP amplifier through the electronic gate

created by channels 14 and 15 or the Plus Programmable timer manufactured by Electro

Cam Corporation.

33
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.10 Label Registration (cont.)

4.10.3 Setting Up Registration For System Using EMP and PLus Timer (cont.)

Only the signal which happened in the interval between beginning of the RETARD

WINDOW and end of the ADVANCE WINDOW will be used for the registration

(correction) purposes. Other signals, no matter how many, will be ignored.

---If the signal of the registration sensor will happen during the duration of the RETARD

WINDOW (Channel 15), “label was too long”. Therefore, the correction motor will

receive the pulse (its length is adjusted by EMP potentiometer situated on the 250

amplifier) which will momentarily lower the EMP transmission ratio so the next label will

be shorter.

---If the signal of the registration sensor will happen in between RETARD and

ADVANCE WINDOW in so called DEAD ZONE, the label cut off (registration) is within

technical limits and no correction will be performed.

---If the signal of the registration sensor will happen during the duration of the

ADVANCE WINDOW (Channel 14), it means that signal or registration mark “came too

late” or in other words, “label was too short”. Therefore, the correction motor will receive

the pulse (opposite signal to RETARD the pulse), which will momentarily increase the

EMP transmission ratio so the next label will be longer. Proper lengths of the

WINDOWS and the DEAD BAND could be calculated using the following procedure

based on next recommendation.

34
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.10 Label Registration

4.10.3 Setting Up Registration for EMP & Plus Timer (cont.)

---Lengths of the ADVANCE and the RETARD WINDOWS should be in between 3/8 to

½ of an inch. We recommend this to be ½ inch.

---Length of the DEAD BAND should be no less than 3/32 to 1/16 and no more than 1/8.

We recommend this to be 3/32 inch. If the required width of the WINDOWS and DEAD

BAND could be calculated using the following procedure. (Not necessary in the case

you opt to use General Recommendations as printed below.)

Calculation:

Let us call nominal used label length L. Then 1 degree of the programmable timer

encoder will represent length L1 of the label.

L1 = L/360 (in inches)

and the width of the ADVANCE and RETARD WINDOWS (let us call them AW and RW

respectively) in the degrees of Channel 14 and 15 will be:

AW or RW = ½ .360 =180/L (in degrees)

as well as the DEAD BAND (called DB) width in the degrees will be:

DB = 3 . 360 = 33.75 (in degrees)

32 L L

Example:

Label Length L = 10(inches)

AW or RW for 0.5 inch width = 18

DB for 3/32 inch width = 3.375 = 3

35
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

General Recommendations:

Width of the ADVANCE and the RETARD WINDOWS is to be 15 and width of the

DEAD BAND is 3. (Note that the width of the DEAD BAND must be uneven number to

permit the value of the pointer—Channel 81 be displayed)

SETTING UP THE REGISTRATION STEP BY STEP SEQUENCE

The following is a step-by-step procedure leading to the desired position of the

registration mark in relation to the leading edge of the label. (NOTE that some steps do

not have to be performed with each new label in the case that new label’s parameters

are close to the parameters of previously used label.)

(1) With the EMP off, check the running (mechanical) label length. Check second or

third label in sequence to the printed labels on the label roll.

---If the cut off label length is +/-3/32 from the printed label length, go to step

two.

---If the cut off label length is outside the above stated tolerance, change length by

length motor switch and repeat test.

(2) Program width and position of the channels 14 and 15 to numbers specified

before (15-3-15) anywhere between 0 to 360. For instance, when starting up new

machine, you could program channels as follows:

Channel 14 --- ON = 33, OFF = 18

Channel 15 --- ON = 15, OFF = 0

(NOTE that channel 81 pointer would point in the middle between the

internal 0 to 33 and display 17).

36
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

(3) With the EMP off, manually position the label in such a way that label registration

mark is positioned in the distance from the leading edge of the label as desired +/-1/16

inch.

(4) With the EMP off, jog the machine and label feed, discard the first label and jog

the machine and the label until the registration sensor sees the leading edge of the

chosen registration mark. Stop the machine.

(5) Go to the programmable timer and call for Channel 80 and when it is displayed,

push ENTER. Display will read “SET”. By doing that, the printer, channel 81, moved

together with both channels 14 and 15 to the proper (for machine geometry) position.

(6) Check a few labels, cut in sequence with the EMP amplifier ON and being “in

registration”{ (red and green correction lights are interchangeable flashing). If the

registration mark is off from the desired position, “fine tune” the cut off position by

changing position of channel 81. (One degree change will change the cut off position for

approximately 1/32 inch.)

---If the distance between the registration mark and the leading edge of the label is too

short, lengthen it by decreasing the value of angle in the channel 81. (One degree

change will change the cut off position to approximately 1/32 inch.)

NOTE – All the described set up sequences do not have to be performed if registration

sensor has not moved around its roller (vertical adjustment doesn’t have any affect) and

label repeat length is within expected tolerance +/1/16 from nominal. Fine adjustment is

then done as depicted in Step 6.

37
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

SPEED COMPENSATION OF THE REGISTRATION MARK POSITION

There are numerous mechanical as well as electrical delays in the transfer of the

signal of the registration sensor and its processing until the proper correction is

executed. Net results of all these imperfections will be visible drift of the registration

mark in the high speed if compared to its position at low speed. Nevertheless, the

system will be “in registration” as far as the EMP amplifier circuits are concerned.

To overcome this problem, Plus programmable timer is equipped with a feature

called “SPEED COMPENSATION” executed by Function (FCN on keypad 4). When

appropriate channel has been programmed at this function, some angle (let’s say

10 degrees for Channel 10), this channel setting will then move forward (opposite to time

delays) with the speed to compensate for the system imperfections.

As mentioned before, if Channel 10 has been programmed at function 4 for 110

degrees, its setting would move at 1000 RPM of the encoder for 10 degrees from the

position at low speed---this move is internal and it is not displayed.

Special function of the Channels 14 and 15 as a WINDOWS is carried even to

this (FNC4) function. Therefore, if channel 14 is time compensated, channel 15 moves

with it without any additional programming required.

SPEED COMPENSATION STEP-BY-STEP PROCEDURE

(1) Bring the label “in registration” as described before being sure that all systems

are working well.

(2) Pick up label or product ran on the machine (in registration) for reference.

(3) Increase the speed of the machine to maximum speed required for machine to

run. Be sure that label is “in registration”—red and green correction lights are flashing

interchangeably in irregular intervals. (Label of product will show the registration mark to

be shifted in respect to the low speed sample.)

38
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

SPEED COMPENSATION STEP-BY-STEP PROCEDURE (CONT.)

(4) Go and enter FCN 4. Channel 1 will be displayed. Keep pushing pushbutton CHN

until 14 is displayed. On the furthest right on theLED display, there will be probably the

number 0.

Keep increasing that number until the registration mark position on the label run

in the high speed is in the same spot as it is in the low speed. When this happens, the

registration is speed compensation.

NOTE – Probable speed compensation angle will be between 15 to 20.

4.10.4 Summary Of Label Registration Set-Up Procedures

(1) Set proper label length by using “label length” correction motor (zero max motor).

This set up should normally be done as part of the set up of Cams 3 and 4 for the

starting and stopping of the label feed control, per paragraph 4.2.

(2) Depress length and correction motor so that they are “off” (light extinguished).

(3) Make sure the scanner beam to be is properly aligned along register mark track.

(4) Set the LIGHT/DARK switch to proper mode.

(5) To set the sensitivity pass sample of the web through the scanner beam while

observing the pick up light. Advance the sensitivity from zero until the marks generate

flashes of the (“pick-up”) indicator. Increase the sensitivity setting at least ½ a number

for the crisp detection. With the Sick NT-6 sensor used sensitivity has to be set

anywhere above 2 and the LIGHT/DARK switch does not work anymore.

(6) With the label feed engaged, move label into the register by pressing correction

“motor jog” (advance or retard) on the control panel to the proper cut position. Only the

position motor is on during this adjustment so as not to change the label length.

(7) Align the register mark under scanner light beam by keeping label feed “on” and

jogging machine.

39
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

(8) Set the selector switch so the arrow on the indicator dial points outward to the

center between the advance and the retard live areas when setting up.

(9) Depress both the correction and the length motor switches so they are “on”, turn

machine on and observe the signal lights. If lights are flashing alternately, reduce

correction knob setting to reduce the amount of correction time. It should be as low as

possible.

(10) If a green light is predominate, use “length” correction motor only and lengthen

until alternate signals are received.

(11) If the red light predominates, shorten the cut off length.

(12) With alternate signals being received, create a dead area on the selector switch

between the advance and the retard areas. Again, cut off length can be adjusted to

minimize the drift, thus decreasing the machine error and requiring less correction

signals. At this point, both motors should be “on”.

(13) The selector switch will locate and hold registration in any fixed position. By

rotating the switch (360 possible), the mark may be made to appear in any position with

respect to cut off. With the registration stabilized and all adjustments made, registration

may be moved forward by moving the cycle dial slowly. (“Length” correction motor off so

as not to change label length.)

40
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

4.11 Electrical

The BH2000 machine is equipped with the DC variable speed drive. This motor is

controlled by the Model VE/VEH 200 Boston Gear SCR Ratiotrol DC motor speed

control.

The maximum and minimum speeds can be set as well as the acceleration on starting

and stopping. (See appendix for a complete description.)

From 4 to 10 (depending on number of options specified) photo logic units are located at

each position. Each one of the photo logics is equipped with a setting which will make it

work on either the light sensitive or the dark sensitive pick up. Also, each unit is

equipped with a sensitivity adjustment, an on-delay time, an off-delay time, or some

combination of these if needed. The functions of the logic modules and time delay

relays are as follows:

PC I

Glue wheel located adjacent to the vacuum drum, senses label on the vacuum drum and

energizes the relay to arm the glue wheel circuit. The actual timing of the movement of

the glue wheel is done by the microprocessor, C & A Mark VII, Channels .05 and .06.

The glue wheel circuit utilizes a high sensitivity logic module.

PC II

Shear and paper feed control, which consists of the photo sensor (located at infeed

bottle guides just past the container flow gate) and the time delay OFF module in the

main electrical enclosure (TD2) Banner MA5.

41
CHAPTER FOUR – SET-UP PROCEDURES (CONT.)

Electrical (cont.)

The purpose of the control module is to time the correct starting sequence of the paper

feed and knife so the first label meets the first container. Remember the actual starting

and stopping of the label feed is done by channels 3 and 4 but the arming of 3 and 4 is

done by channels 7 and 8. The delay OFF module TD2 (MA%) is used to hold the photo

signal momentarily so that channel 7 and 8 receive the signal long enough for the

correct “latching” of that circuit.

NOTE – Too much delay OFF time will feed the extra labels after bottle flow has

stopped.

PC III

High speed infeed located on the infeed conveyor senses the accumulation of bottles on

the infeed conveyor and after the pre-determined delay (which is adjustable by means of

the internal setting inside the photo module) will complete the circuit for machine speed

to go high if the glue wheel is “in”, and the discharge conveyor is clear. Module is the

LVPR1 LM5-14 PVAT which has hold and the delay signal timers to adjust for flow

reaction time of container line.

42
PC IV

High speed discharge located on the discharge conveyor---senses the accumulation of

bottles on the discharge after pre-determined delay (which is adjustable by means of an

internal setting inside the photo module) it opens the circuit to high speed relay CR2,

thereby automatically switching the machine back to the slow speed. When the

discharge safety eye clears, the above sequence of operation is reversed and the

machine ramps back to high speed. The time delay on the PC IV is used to insure that

the sensor “sees” the backed up bottles and not each individual bottle on a moving

conveyor. Module is the LVPF1 LM-14 PVAT which has hold and delay signal timers to

adjust for flow reaction time.

PC V

Flow gate infeed located on the infeed conveyor senses when bottles have accumulated

and allow the flow gate to open.

NOTE – The machine will be in the slow speed mode when the gate closes or opens

since PC III high speed infeed will put the machine into low speed. Module is the LVPF1

LM5-14 PVAT which has hold and delay signal timers to adjust for the flow reaction time

of the container line.

PC VII (Option)

Container counter sensor is located on the discharge conveyor and counts labeled

containers as they pass, and in conjunction with the bottle detector is used to sense the

location of the container so as to arm PC VIII, the no label detector. These are optional

items on the labeling machine.

43
PC VIII (Option)

Label Detector – This sensor detects the presence of a label on the container. This

sensor is used in conjunction with the PC IX, which senses the location of the container

and arms the PC VIII. The label detector triggers either the container reject system or

some type of alarm.

PC IX

Label feed safety located at the label web infeed “Light Operate” disarms the machine

main drive motor in event of the web breakage or if the machine runs out of labels.

PC X

Vacuum drum safety located at the vacuum drum between the secondary roll on belt and

the omega cutter “Dark Operate”. Disarms the machine main drive if a cut label is not

received by the designated bottle and attempts to go around the vacuum drum. Contact

located in the main drive safety circuit.

TD 1

Time delay relay (delay on)---is utilized as a safety measure to shut down the machine if

the glue wheel is not in operation (applying glue) when labels are being cut. When the

glue wheel is energized and the labels are being cut, the TD1 is disarmed. If the TD is

not disarmed because the labels are being cut while the glue wheel is de-energized, and

the TD (adjustable times out, the main line to motor control relay (MRC1) is opened

shutting down the machine.

44
4.12 Change-Over to Different Container or Label

Summaries of the items that may need to be changed are as follows:

A. Vacuum Drum-If different size label or label location.

B. Glue Wheel – If different glue pattern or wire slots.
C. Glue applicator bars.
D. Wire and wire posts on glue bar.
E. Starwheel – If container diameter changes.
F. Roll-On Pad – If container diameter or label length changes.
G. Container Infeed Guide – If container shape is changed.
H. Adjust label guides and container guides.
I. Container Infeed guide spacers.

45
 DISCHARGE SENSOR

FLOWGATE INFEED
SENSOR
APPROX. 20’
FROM THE END OF THE
TABLE
FALLEN
BOTTLE
DETECTOR
(OPTIONAL)

LABEL FEED SAFETY

IV PRODUCT COUNTER
OPTIONAL

MAIN DRIVE REGISTRATION

SAFETY SENSOR

VACUUM II. GLUE WHEEL

DRUM SENSOR
SAFETY

STARWHEEL
SAFETY SHEAR & PAPERFEED
SENSOR (ON A MACHINE
THAT THE PAPERFEED IS
STARTED BY THE
FLOWGATE, THE
CONTROL IS LOCATED IN
THE CONTROL PANEL).

APPROX. 20’ FLOWGATE INFEED

FROM THE FLOW GATE SENSOR

HIGH SPEED SENSOR

46
 CHAPTER FIVE

OPERATING PROCEDURES

5.1 Control Panel

The main control panel includes these controls:

Switches in () are included on the secondary control panel.

DESCRIPTION FUNCTION

Switch, Control (Remote) --- Energized all the control circuitry.

Control Light --- Indicates the control circuitry is on.
Glue Wheel Light --- Indicates the glue wheel will move if
label present.
Button, Motor Start (Remote) --- Starts the main drive motor.
Button, Motor Stop (Remote) --- Stops the main drive motor.
Switch, Glue-In (Remote) --- Sets the glue drum to operate
automatically. (light is on)
Switch, Glue-Out (Remote) --- Glue drum will not engage label under
any circumstances.
Switch, Speed-High (Remote) --- Machine will run the maximum setting if
containers have accumulated on the
infeed conveyor and the covered high-
speed sensor, and the discharge
conveyor is clear.
Button, Jog (Remote) --- Allows the operator to run the machine
despite the positions of other switches.
Switch, Flow Gate out (Remote) --- Puts flow gate in automatic gate will
open if containers have accumulated on
infeed conveyor and discharge conveyor
is clear.
Switch, Flow Gate in (Remote) --- Flow gate is closed and will not open
under any circumstances.

Switch, Label Feed Start --- Sets label feed to operate automatically.

Button, Manual Label Feed --- Allows operator to feed labels despite
the position of other switches. (Does
not include “control” switch.)

47
CHAPTER FIVE – OPERATING PROCEDURES (CONT.)

5.2 Hot Melt Glue System

5.2.1 Up Procedures – Glue System

A. Turn the power switch on and used the glue pump to ON.

B. Fill the melt tank with the recommended glue.

C. Turn the pump tank temperature at 300 F (to be about 10 off glue roller
temperature.)

D. Allow adequate time (approximately 50 minutes) for the adhesive to melt in tank

and system to stabilize.

E. Initially. Set the glue roller temperature at about 240 to 250 F. This is set

on the Watlow temperature controller located on the pushbutton station or on the glue

roller post. This is an approximate setting and must be adjusted during operation or the

optimum glue adherence to the label and container. Excessive temperature can

damage label and cause “smoking”.

F. Start the glue pump. Set the pump flow rate. Proper flow rate is such that in the

high speed, the glue remove from the glue roller by the “doctor blade” creates beyond

the doctor blade uninterrupted “apron”. If there is not sufficient glue flow at high speed ,

the glue pattern will be uneven or “spotty”.

G. Start the glue pump by turning on the air. Set the pump speed by adjusting the

pneumatic flow control valves on the pump. Speed should be set to get just enough to

adequately cover the drum at all speeds.

NOTE – Since the glue system is a recirculation type---the temperature of the tank, base

and drum should all be the same.

48
CHAPTER FIVE – OPERATING PROCEDURES (CONT.)

5.4 Machine Start-Up Procedures

Set controls as follows:

1. Turn control on.

2. Turn machine on.

3. Glue wheel in

4. Label feed on.

5. Flow gate on or open---THIS STARTS LABELING OPERATION

5.5 Stopping Procedures

IMPORTANT – To keep the machine in register, always switch to the low speed before

turning the label feed off.

If this is not done and labeling is stopped while in high speed, by a label jam, by

containers backing up into the machine, or by a container missing at the infeed

starwheel, the registration will be lost and will have to be reset. This can be done by

clearing the machine, setting the web to the correct starting position by using the mark

on the label guide and restarting the machine on low speed. The first label may be cut

incorrectly and must be picked off the vacuum drum.

When shut down is desired at the end of a shift, all containers can be cleared from the

conveyor by covering the “high speed eye” on the infeed conveyor and letting all

containers go through the machine. After all containers have been labeled, the following

shut down procedures must be followed:

49
CHAPTER FIVE – OPERATING PROCEDURES (CONT.)

5.5 Stopping Procedures (cont.)

1. Speed low, the flow gate in, the glue out, the label feed stop, the control off.

2. Turn temperature of the glue drum down, allow 5 minutes before step 3.

3. Motor stop, shut off the main power and air.

4. Clean the ink transfer roll and remove the ink cartridge and cover, if fitted.

CAUTION – Make sure main power is off or heat from the glue drum will damage

the vacuum drum. Position the vacuum drum between the pads of the glue drum at shut

down. If a complete shut down is not desired, such as during a work break,

simply set the machine on a low speed and then turn the product label feed to off, the

glue wheel out and the flow gate in. The machine will then idle at low speed.

5.6 Cleaning Requirements and Precautions

Like any machine, care should be taken to keep it clean. However, the

temperature controls should be protected during cleaning. Care should also be

taken not to get any foreign substances in the glue pan beneath the glue drum.

Liquid or dirt in this pan will run down the glue return hose into the hot melt unit.

Another area to avoid getting liquid in is the center of the drum. Hot melt spillage

should not be allowed to accumulate. In particular, the vacuum drum should be

kept clean of the hot melt glue. The recommended cleaner is: CHLORO-SOLV

(Formula 215); available in 1, 30 and 55 gallon containers from:

STATE CHEMICAL MANUFACTURING COMPANY

920 FRANCISCO

TORRANCE, CALIFORNIA

PHONE: (213) 538-9785

50
 CHAPTER SIX

SAFETY PROCEDURES

6.1 General Precautions

The B & H roll fed labeler comes equipped from the factory with safety guards

and circuit interlocks to aid in the prevention of misuse and hazard to the operator using

safety standards. However, as with all packaging equipment, there are procedures in

which every operator must understand and adhere to in order to properly and safely

operate the machine.

1. Never attempt to remove a label or container from the machine while it is

in the PRODUCTION RUN MODE.

2. Never attempt cleaning the vacuum drum while in the “motor-run” mode---

always use the jog button to “inch” the machine drive forward to clean pads.

Remove hand from jog button while cleaning!

3. Never use flammable solvents to clean the vacuum drum, etc. of glue deposits

B & H recommends the use of the CHLORO-SOLV #215 to accomplish this.

4. Never lean over operating the machine as loose clothing may get caught in

mechanisms.

5. Always keep adhesive tank lid closed; never add adhesive to the supply tank

with bare hands. A “scoop type” shovel should be provided and used.

6. ADHESIVE APPLICATOR WHICH IS HOT! Never place hands or fingers near.

To remove label fragments, always use a pair of tongs or suitable tool while the machine

is stopped.

7. Before operating machine, check to insure ALL GUARDS ARE IN PLACE.

51
CHAPTER SIX – SAFETY PROCEDURES (CONT.)

6.2 Safety Features

Safety clutches are located on the starwheel, infeed starwheel (if used), and

main drive. If an overload should occur in either one of these areas, the micro switch on

the clutch will stop the main drive motor. To reset the main drive clutch, the machine

must be turned using the main drive jog button until the clutch “locks” back into place.

6.3 Grounding

It is imperative that an earth ground be supplied to the ground plug provided on

the main electrical panel. The bonding of the B & H labeler to existing equipment on the

production line for grounding purposes has proven unsatisfactory in certain cases.

52
 CHAPTER SEVEN

PREVENTIVE MAINTENANCE

7.1 Lubrication (Manual)

Machines fitted with “centralized” manual lubrication blocks should receive two

strokes of grease each for every 30 hours of operating time. In wet environments, it may

be necessary to increase the application of lube to every 16 hours for all external

bearings subject to water splash. All grease “zerk” type fittings are located at the back

side of the machine near the machine frame legs.

Some grease points are not centralized and are location identified as follows:

Label Roll Stand and Dancer Pivot

4 points on single roll stand machine

7 points on double roll stand machines

Idle pulley at the secondary roll on belt located near container conveyor at exit from

the vacuum drum – 1 point.

B & H supplies the machine with Chevron SR1 Grease 2, which can be replaced

by the following substitutes:

Mobil – Grease BRB Shell – Nerita Dolum Grease

Exxon – Andok Sun – Sun N – 52X

Texaco – Premium RB

53
All the machines should be greased according to the following schedule:

Cutter Bearings – Chevron Duralith Grease EP, NLG12.

Main Drive Gears and Chains – Chevron Open Gear Lubrication 250CB.

All other greased components – Chevron SR1

The machine is equipped with automatic lubrication to most grease points. The

automatic lubricator should be set to operate approximately once per hour (NOTE the

calibration on the timer dial is in cycles per hour.)

7.1 Lubrication (Manual)(cont.)

Most other bearings which are NOT equipped with the automatic lubrication, are

sealed bearings. If the machine is equipped with the die cutter, the back up roll should

be hand lubricated once a day.

The customer should consult with his lubricant supplier for a recommended

grease compatible with the Trabon Automatic Lube System. The system uses high

pressure (up to 2000 PSI) and high temperature (up to 375 F).

The automatic lubrication system can be checked for operation by manually

depressing the button on the lube cycle timer. The grease pressure should rise then fall

to zero. The cycle pin (one large pin on lube manifold blocks) should move

approximately once every 1020 cycles under normal operation. If the grease point is

blocked, the indicator pin on an individual block will pop out, and the cycle pin will not

operate. If this occurs, the blocked point must be traced out from the block with

projecting indicator pin. Main drive gear box, see Appendix “Miscellaneous”.

54
7.2 Air Filter Regulator

This should be checked daily to drain the water, add oil and adjust oil feed as

required by individual requirements. The rate of oil into main air lubricator should be

about one drop each five minutes. This setting should be made with air flowing through

the lines. On some machines, the air supply is purposely without on oiler but is

equipped with a Fine Aire coalescing filter. This provides extremely clean air to the

machines. The bowl of the filter must be drained and not filled to the point of reaching

the element to maintain this clean air. When the pressure drop across the filter reaches

12 to 1 PSI, the element should be replace (Fine Aire Element No. C10-025).

7.3 Glue System

The tank filter should be cleaned monthly and the whole system flushed semi-

annually. Refer to appendix for complete information on the glue system. The glue bar

should be checked weekly for proper pressure and pin alignment.

7.4 Vacuum Pump

Clean the air intake filter and flush pump as required by the individual installation.

Refer to appendix for detailed instructions.

7.5 Roller Chain

In order to minimize the roller chain wear, a #40, #50, and #60 chain should be

sintered bushed roller chain.

Every two (2) months, the following chains should be replaced:

A. Between the vacuum drum shaft and the clutch and brake unit.

B. Between the vacuum drum shaft and the omega cutter input shaft.

B. Between the omega cutter shaft and the selector switch.

55
7.6 Mechanics Weekly

1. Gear Arrangement – Check all drive for proper tension. Adjust/replace

as necessary. Check all lube lines and connections and inspect bearings and lines for

blockage or blow out.

2. Vacuum System – remove and clean or replace the following:

A. Vacuum Drum C. Filters on Pump

B. Manifold Plate D. Hose and Piping

7.6.1 Mechanics Weekly (cont.)

3. Glue System – Check glue bar for proper pressure and pin alignment.

Check temperature settings on the pot, the hose, the glue roll surface temperature.

Inspect system for foreign matter in system components (i.e. label bits). Temperatures

are recommended by adhesive and label application.

4. EMP System – Check the running label length. First label should be 1/16” to

1/8” longer than the running label. Adjust if necessary. Check the scanner, the selector

switch, the EMP panel and the drive motors using piece of label. Pass label in front of

the scanner with pointer arrow on selector switch in front of advance flag. Green light

will light and feed roll will move forward if working properly. Do same to test the retard

circuit.

56
5. Infrared Photo Logic System – This consists of the infeed bottle sensor at

the flow gate, the activating shear and the paper feed circuit. Glue wheel sensor at the

vacuum drum and the flow rate or high speed and the discharge safety conveyor

sensors. To quickly check systems, do the following:

1. Control – On

2. Motor – Run

3. Glue Wheel – On

4. Paper Feed – On

At this point, open the flow gate and close after one battle passes. If functioning

properly, the labeler will cut ONE label, apply the glue to THAT label and apply THAT

bottle.

6. Shear System Blades – Check blades for clean cut off of label (no fuzz.)

Check label guides jets and etc. for damage. Replace as necessary.

7. Inspect Labelers – for cleanliness and advise operators and management

as necessary. Visually inspect the machine for worn out and defective parts to be

replaced.

7.7 Mechanics/Bi-Annually

1. Flush out and rebuild the hot melt applicator unit. Check the following parts for

repair or replacement.

A. Pump Hose D. Check Valves

B. Pump Body E. Filter Screen

C Pump Seals

57
7.8 Operator’s Duties on Labeler

1. Operate the labeler and watch lines to and from the machine.

2. Be alert to the event of a glue spillage on the machine.

3. Monitor the glue pattern to label position on bottle.

A. Adhesion
B. Registration
C. Flagging or mismatch

4. Have a basic knowledge of the machine’s system functions and capabilities.

5. Operator should be capable of setting up the machine for product change.

(Understand and be able to set up EMP System to any label.)

6. Operator must clean and keep can labelers during their shift leaving the

labeler clean for NEXT operator.

If this PM Program is followed closely, it will result in optimum machine

performance. It will eliminate the frustrations of achieving maximum production

efficiency. This set up can only be achieved by total cooperation by the management,

the maintenance and the operators of the machine. The PM Program prescribed here

can be tailored around production schedules by alternating the steps during shift duties,

for example:

1. Day Shift – Steps 1 and 2.

2. Swing Shift – Steps 3 and 4.

3. Night Shift – Shift 5 and 6.

4. All Shifts – Step 7.

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 CHAPTER EIGHT

TROUBLE SHOOTING GUIDE

8.1 Labeling Programs

Loose label on upper or lower parts of containers:

Reason is the container being tilted or by the container guides or by the main starwheel

and/or the container being tapered.

Corrective actions:

Step 1:

Check the container guides and assure that the container sits flat on the

conveyor being in touch with both guides.

Step 2:

Time (off set) upper star to eliminate loose label.

If label is loose in lower part of the container, move the upper star backwards

(clockwise) about 1/32 on the tip and test again. Repeat if necessary.

If label is loose in upper part of the label on the container, move the upper star

forwards (counter clockwise) about 1/32 on the tip and test again. Repeat if necessary.

Fix at the end resulting mismatch (if any) by skewing the cutter.

Loose label all over the container:

Reason is the roll on pad being adjusted too tight or too loose and in the rare cases

the containers with condensation (dew) on the labeling surface.

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CHAPTER EIGHT – TROUBLE SHOOTING GUIDE (CONT.)

8.1 Labeling Programs (cont.)

Corrective actions:

Step 1:

Check and adjust the primary roll on pad as necessary. There should be even

compression by the container from about 2 inches before the vacuum drum and all

around the vacuum drum until exit point. Compression should be such that the container

fits firmly and rotates without any hesitation. Do not compress anymore as this will result

in loose label and bad quality of the overlap with wrinkles. Pay special attention to the

transition point where the container encounters the vacuum drum. Container must rotate

through that position without jerks or slipping.

Step 2:

If previous step didn’t correct the problem, check if the roll pad is not worn out. Roll

on pad is worn out if the rubber pattern (tips) are completely worn out and the rubber is

smooth (even if this is only in one spot). Replace if necessary.

Step 3:

If both steps were unsuccessful in curing the problem, check the container for

condensation. Condensation can be a problem if the container appears to be frosted.

Make a line on the frosted (dewed) surface with finger.

If the line gets frosted in less than about 10 seconds, solution would be to install

air knife in front of the machine (preferably hot air) to eliminate dew. Water droplets are

not the problem.

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CHAPTER EIGHT – TROUBLE SHOOTING (CONT.)

8.1 Labeling Programs (cont.)

Horizontal wrinkles on label mainly in center of label:

Reason is the main starwheel being too close to the container in the position

when the leading edge of the label is being applied or too tight to the primary roll on pad

(see previous part).

Corrective actions:

Check the starwheel position. When the container is on the leading edge pad

(higher spot), there is to be clearance between the container and bottom of the

starwheel pocket 1/16 to 1/8 of an inch. Move the starwheel assembly as necessary.

Diagonal wrinkles on the label:

Reason is unstable container (rocking) during labeling or due to the misadjusted

container guides and/or due to the primary roll on pad.

Corrective actions:

Adjust the container guides as described before (loose label top or bottom).

Adjust the roll on pad (as described before for loose label) and center it properly

on the label.

Wrinkles on overlap:

Reason is label being wrinkled by the glue roller and the label being wrinkled on

transfer from the cutter onto the vacuum drum.

Corrective actions:

Step1:

Check the label placement on the vacuum drum and the adjust air jets on the cutter

to assure smooth label on the vacuum drum. Too much air will result in a wrinkled label.

Adjust the air only as high as necessary for correct transfer at all speeds.

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CHAPTER EIGHT – TROUBLE SHOOTING GUIDE (CONT.)

Labeling Programs (cont.)

Step 2:

Check the glue roller temperature and also check if the temperature sensor is

touching the glue roller. Temperature over 300 F will cause labels to wrinkle.

Step 3:

Check the contact between the glue roller and the vacuum drum. Excessive pressure

of the glue roller will cause the label to wrinkle.

Uneven glue pattern on the label:

(weak glue pattern on the top or bottom of the label)

Reason is the glue roller is not being aligned with the vacuum drum.

Corrective action:

Adjust for a very light glue pattern and align the glue roller using the upper bearing block

until an even glue pattern is achieved. Check all pads and then lock the roller in

position.

Fading glue pattern at high speed and/or spotty glue patterns:

Reason is a plugged glue bar, or not sufficient glue flow from the pump, or burnt

glue roller.

Corrective action:

Step 1:

Check the glue pump glue flow and try to increase it. If it is not possible to do, the

filter in the glue pump is clogged and must be cleaned.

Step 2:

Check the glue bar (if glue flow is sufficient) as it can be plugged by the label debris.

Make sure that set screws at the bottom of the glue bar is at least half open and the glue

flows through this check point back into the glue pan.

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CHAPTER EIGHT – TROUBLE SHOOTING GUIDE (CONT.)

Fading glue pattern at high speed and/or spotty glue patterns:

Corrective action:

Step 2 (cont.):

If knurling pattern of the glue roller is filled by the carbonized glue, both previous

actions will not succeed. Remove the glue roller with its bearing block and de-carbonize

it by using the appropriate chemical. Do not use a wire brush clean the roller.

Do not adjust the glue pattern by the scraper (doctor) blade as severe glue over

spray will result. Scraper plunger should be adjusted “finger tight” being in firm contact

with the glue roller.

Cutting problem-bottom corner of the label tears out:

Reason is the contaminated vacuum drum, or the contaminated cutter, or excessive

friction between label and the vacuum drum.

Corrective actions:

Step 1:

Clean the vacuum drum and the cutter with solvent and in the case there are product

residues (sugar), wipe with wet rag.

Step 2:

Check if the cutter cuts with no vacuum on the vacuum drum and adjust knives (very

slightly) if necessary. If the cutter is cutting and the parts are clean, the vacuum is

adjusted as low as possible on both the cutter and repad section of the vacuum drum. If

there is still “cut-corner” problem, the co-efficient of friction of the label is too high in

respect to the vacuum drum and the label is not processable. Change label.

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CHAPTER EIGHT – TROUBLE SHOOTING GUIDE (CONT.)

8.1 Label Programs (cont.)

Cut problem-cutter lost all across the label:

Reason is the knives being worn out by the label.

Corrective action:

Slightly adjust the stationary knife. Correct procedure is as follows:

• Turn the machine on (run).

• Manually turn on the cutter by engaging the valve (do not cut labels).

• Turn the adjusting bolt no more than 15 and check the cutting.

• Disengage the cutter.

Registration problem-registration mark is moving:

Reasons are multiple and following procedure is to be done to find and rectify the

reason.

Step1:

Check and adjust sensitivity of the registration sensor and clean the lens if

necessary.

Step 2:

If problem persists and sensor is not adjustable for “clean pick-up” label graphic

and/or its color combination is not useable due to the limitation of the registration sensor,

replace label.

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CHAPTER EIGHT – TROUBLE SHOOTING GUIDE (CONT.)
8.1 Labeling Programs (cont.)

Step 3:

If the registration position has moved but it is “holding” in new position running label

length has changed or sensor is using different feature on the label for the registration.

To move the cut position (or registration as it is often called), change channel 81 on

the EMP registration system as required or change CUT OFF length on CRS system.

NOTE that the CRS will self-adjust if the correct mark is being read by sensor.

Step 4:

If the registration position has moved, but the label length did not change label is being

stretched by too high vacuum or its co-efficient of friction has increased (refer to “cut

problem”). Lower the vacuum to minimal use label level and if that doesn’t help, but

there is still no “cut problem” reset the registration position.

Step 5:

Registration is rough or erratic but no above reason we recognized. This is

probably due to the not properly functioning dancer arm tension control. If you see that

the dancer arm is reaching and hitting travel limiting stops, clean the brakes, adjust the

position to 0 and gain to 3, add or take out weights and if the dancer arm potentiometer

is damaged, replace it. Check the voltage on brake when fully engaged (5-8 (v) .

65