T-950 (HT/TA-30)
XPS-ProTab 4.0 (HT/TA-30C)
Tabber/Labeler
& Stamp Affixer
SERVICE MANUAL
Revised: 02-26-15
Neopost Digital Print Group
910 East Main Street, STE 200
Norristown, PA 19401
Phone: (610) 650-9170
www.neopostinc.com
www.haslerinc.com
www.renausa.com
SAFETY PRECAUTIONS
THIS EQUIPMENT PRESENTS NO PROBLEM WHEN USED PROPERLY. OBSERVE THE
FOLLOWING SAFETY RULES WHEN OPERATING THE TABBER.
BEFORE USING THE TABBER, READ THIS MANUAL CAREFULLY AND FOLLOW
RECOMMENDED PROCEDURES, SAFETY WARNINGS, AND INSTRUCTIONS:
Keep hands, hair, and clothing clear of rollers and other moving parts.
Avoid touching moving parts or materials while the machine is in use. Before clearing a jam, be sure machine
mechanisms come to a stop.
Always turn off the machine before making adjustments, cleaning the machine, or performing any maintenance
covered in this manual.
Use the power cord supplied with the machine and plug it into a properly grounded, easily accessible wall outlet
located near the machine. Failure to properly ground the machine can result in severe personal injury and/or fire.
Power cord and wall plug are primary means of disconnecting machine from power supply.
DO NOT use an adapter plug on the line cord or wall outlet.
DO NOT remove the ground pin from the line cord.
DO NOT route the power cord over sharp edges or trap it between furniture.
Avoid using wall outlets controlled by wall switches, or shared with other equipment.
Make sure there is no strain on the power cord caused by jamming it between equipment,
walls or furniture.
DO NOT remove covers. Covers enclose hazardous parts that should be accessed by a qualified service representative.
Report any cover damage to your service representative.
This machine requires periodic maintenance. Contact your authorized service representative for required service
schedules.
To prevent overheating, do not cover the vent openings.
Use this equipment only for its intended purpose.
In addition, follow any specific occupational safety and health standards for your workplace or area.
This manual is intended solely for the use and information of Astro Machine Corp. its designated agents, This
manual is intended solely for the use and information of Neopost USA, its designated agents, customers, and their
employees. The information in this guide was obtained from several different sources that are deemed reliable by
all industry standards. To the best of our knowledge, that information is accurate in all respects. However, neither
Neopost USA, nor any of its agents or employees shall be responsible for any inaccuracies contained herein.
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying, recording, or any information storage and retrieval system, without
permission in writing from the publisher
TABLE OF CONTENTS
i
TABLE OF CONTENTS
SECTION 1 – Getting Acquainted 1
Front View 1
Rear View 2
Entrance End View 3
Exit End View 4
Control Panel 5
EasyFeed 120 (Optional Feeder) Connections/Controls 6
SECTION 2 - Assembly and Installation 7
Assembly 7
Installing Tab/Label Applicator Head 8
Installation 10
Aligning Feeder 10
Loading Tabs 11
Adjusting Media Guides 12
Adjusting Tab Positioning 13
SECTION 3 – Troubleshooting 15
Jams 15
Tab Placement Problems 15
Label Placement Problems 17
Stamp Placement Problems 18
SECTION 4 – Adjustments 19
Motor Drive Belt 19
Exit Roller Drive Belt 20
Transport Belt Tension Adjustment 21
Tab Guide Alignment 22
Tab Guide Plate Adjustment 23
Tab Drum Position 24
Reel Brake Adjustment 25
Head Assembly Alignment 26
Power Supply Adjustment 27
Tab Sensor Adjustment 28
Media Sensor Adjustment (Sensor 1 and Sensor 2) 29
Tab Web Sensor Adjustment 30
Speed Control Adjustment 31
SECTION 5 – Disassembly and Assembly 33
Removing Reel Assembly 33
Removing Applicator Head 33
Removing Head Assembly 34
Removing Front Cover 35
Encoder and Encoder Drive Belt 37
Removing Drive Motor 37
Removing Take-up Belts and Reel Brake 38
Replacing Exit and Tab Affixing Rollers 40
Removing and Replacing Transport Belts 41
SECTION 6 – Maintenance 44
Cleaning 44
Rollers and Transport Belts 44
Cleaning Sensors 44
Lubrication 45
APPENDIX - Specifications 48
T-950 Schematic 49
TABLE OF CONTENTS
ii
INDEX 51
GETTING ACQUAINTED
1
SECTION 1 – Getting Acquainted
Front View
1
Control Panel – The machine is controlled and programmed from this panel.
2
Tab Drive Rollers – Advances the tabs/labels/stamps.
3
Take-up Reel – The web waste is wound up here after the tab/label/stamp is applied.
4
Take-up Reel Side Guide – Secures the web waste onto the Take-up Reel.
5
Tab Reel – The tabs, labels or stamps are loaded on this assembly.
6
Tab Reel Side Guide – Secures the tabs/labels/stamps onto the Tab Reel.
7
Unwind Drive Rollers – Unwinds the tab/label/stamp from the roll to keep the bin full.
8
Bin – Provides an area for a loop of tab//label/stamp web to accumulate.
9
Head Fine Adjustment Knob – This knob is used to make fine adjustments to the tab
fold position or label/stamp side-to-side position.
10
Exit Roller Assembly – This assembly presses the tab/label/stamp to the media and
provides sufficient transport pressure, so the media properly exits the tabber.
11
Media Thickness Adjustment –Permits the operator adjust the tabber to accommodate
the thickness of the media. The registration, head, and exit roller assemblies, move up or
down, in unison, with this single adjustment.
6
7
8
9
10
3
2
1
11
5
4
GETTING ACQUAINTED
2
5
4
3
6
7
8
1
2
Rear View
1
Tab Drive Motor Connection – Provides drive signals and power to tab drive motor.
Connection is labeled as #1 on Frame.
2
Unwind/Rewind Drive Motor Connection – Provides power to unwind and rewind
drive motors. Connection is labeled as #2 on Frame.
3
Emergency Stop Out –This connection permits the tabber to control the emergency stop
function of an external device.
4
Feeder Control Connection – (FEEDER) This connection allows the tabber to
start/stop the feeder. An appropriate cable and feeder must be used.
5
Safety Stop Input and Jumper – (SAFETY STOP) The safety circuit from other
external devices can be connected here. When this input is opened the tabber will stop.
Important!
If an external safety circuit is not being connected to this input, then the
Jumper Plug (supplied) must be connected, or the tabber’s transport power and head
power will not turn on.
6
Power Inlet Connection – The power cord is connected here. 115V AC 50/60 Hz
7
Fuse – The main fuse (7A / 250V) for the tabber is located here.
Caution! Disconnect power before replacing fuse.
8
Tab/Label Sensor Connection – (SENSOR) The sensor cable is connected here.
GETTING ACQUAINTED
Entrance End View
1
Media Sensor 1 – This sensor detects the media (mail piece).
Note: To accommodate the ability to run media down the front or back of the tabber;
there are two media sensors in the tabber. Sensor 1
is mounted near the Operator
Control Panel side (front) of the tabber, as shown. Sensor 2 is mounted opposite sensor 1
on the Non-Operator side (rear) of the tabber.
Please be sure the appropriate sensor has been selected in the Setup Menu.
2
Registration Assembly – Contains Guide Rollers that help align the media against the
Media Guide Fence.
3
Media Guide Fence (Front) – As the media feeds, it must be held against this fence to
achieve proper tabbing performance.
Note: To accommodate the ability to run media down the front or back of the tabber;
there are two Media Guide Fences in the tabber. One is located at the front of the tabber
(operator side) and one is located at the back.
4
Media Hold-down Guides & Securing Knobs – These guides are used to hold the
media against the transport belts as it feeds through the tabber. One guide is normally
positioned very close to the Media Guide Fence and the other guide is normally
positioned near the opposite edge of the media.
5
Registration Guide Roller Adjustment Knob - Used to change the angle of the
registration guide rollers, in order to push the media against the Media Guide Fence.
6
Registration Assembly Securing Knobs – Used to secure the position of the
Registration Assembly to the tabber.
7
Short Media Hold-down Guide – When needed, this guide can be positioned to
provide additional assistance to hold the media against the transport belts.
1
7
2
4
3
6
5
GETTING ACQUAINTED
4
Exit End View
* Not present in earlier units.
1
Tab Folding Guide (Front) – This plate folds the tab under the media.
2
Exit Roller Assembly Lock – This lever locks the Exit Roller Assembly in place.
3
Tab/Label Applicator Head – Two applicator heads are supplied; one for tabs or stamps and
one for labels. (Tab Applicator head shown). This device contains the Tab Sensor and provides the
peel point for dispensing tabs/stamps/labels.
4
Transport Belts – The belts transport the media through the tabber.
5
Safety Interlock Switches – The safety interlock switches prevent the tabber from operating
when the Exit Roller Assembly is open.
DO NOT DISABLE THESE SWITCHES AS SEVER INJURY CAN RESULT.
6
Tab Folding Guide (Rear) – This plate folds the tab under the media.
7
Media Forwarding Rollers – These rollers forward the media while the tab is being applied.
8
Tab Pressure Rollers – These rollers press the tab to the underside of the media to complete the
seal.
9
Adjustable Pressure Roller – When applying labels/stamps, this roller is responsible for
applying pressure to attach the label/stamp to the media. If necessary the set screw, that secures this
roller to the shaft, can be loosened; allowing the roller to be repositioned over the area that the
label/stamp is being applied.
10
Adjustable Media Forwarding Roller – Used to help transport the media out the exit end of
the tabber. This roller can be positioned at two different locations on the shaft. If you change its
location, please be sure it aligns with the lower drive roller.
11
*Short Media Drive Rollers– These rollers help drive short media through the exit roller
assembly area.
12
*Short Media Pressure Rollers– These rollers help drive short media through the exit roller
assembly area.
7
4
11
10
2
12
8
6
5
3
2
1
8
7
9
GETTING ACQUAINTED
Control Panel
1.
MAIN POWER SWITCH – Turns power to the tabber ON and OFF.
2.
HEAD POWER SWITCH – Turns the power on to the Tab/Label motor.
3.
TRANSPORT POWER SWITCH – Turns the tabber transport power ON and OFF.
4.
JOG SWITCH – Permits the operator to jog or move the transport slowly for setup
purposes.
5.
SPEED CONTROL – Adjusts the speed of the tabber.
6.
LCD DISPLAY – Keeps the operator informed of the status of the tabber.
7.
KEY PAD – Used to set the adjustments and program the tabber
8.
EMERGENCY STOP BUTTON –When pressed, this button will shut down the tabber
and any other units that are connected to the Emergency Stop circuit. Turn the button
clockwise to release. The tabber and all connected units will need to be powered back on.
9.
SOFT KEYS – The soft
keys are used to step through the various menu options to
program the tabber.
10.
STOP KEY – Pressing this key will stop the tabber and hold it in a ready state to resume
operation.
11.
RUN KEY – Pressing this key to start the tabber when running a job.
12.
INFO KEY – Pressing this key will change the display to the information mode.
13.
SAVE KEY – This key is used to save the entries into the memory.
14.
CLEAR KEY – This key will clear any incorrect entry before it is saved in the memory.
GETTING ACQUAINTED
6
EasyFeed 120 (Optional Feeder) Connections/Controls
1
AC Power Receptacle – Connect the AC power cord here.
Important! Please verify that voltage is correct, for your feeder, before connecting.
2
Interlock Connector – Feeder Interface Cable from tabber connects here.
3
Stand Alone Switch – Allows machine to run when not signaled by host machine.
4
Speed Control Knob – Used to set the speed of the feeder.
Important! The feeder’s transport speed must be set slower than the tabber’s transport
speed, in order to generate at least a 2” gap between pieces.
5
Power Switch – Used to power the feeder on/off.
6
Jog Button. – Runs feeder at preset speed for setup (over-rides interlock controls)
*Interlock Control Switch
This switch, located on bottom of feeder, must be set to N.C.
N.C.: Closed Input = Run
N.O.: Closed Input = Stop
NOTE: The power must be cycled (off and on) to
recognize a change in this switch position.
*This switch was a feature on older models. It isn’t present on current models. Current models are internally set
to N.C. (Closed Input = Run).
2
3
6
4
5
1
ASSEMBLY AND INSTALLATION
7
SECTION 2 - Assembly and Installation
Tabber is shipped in a single carton. Base Unit is below the Head Unit. Remove the cardboard carton
from the pallet, the remove the Head Unit from the packing material. Next, remove the Base Unit and
place it on a flat working surface.
Assembly
CAUTION
THE HEAD UNIT IS HEAVY. IT IS STRONGLY RECOMMENDED THAT TWO
TECHNICIANS INSTALL THE HEAD OF THE TABBER TO THE BASE.
1. Place open slot of Head Unit over nylon
bushing on Base Unit. Head Unit has to be
tilted at an angle to accomplish this.
2. Lower Head into position over Head-Adjusting
Guide. Two flats are cut into the Adjusting
Guide. One at the top [1] and one on the left-
hand side [2]. Head Unit Frame should rest in
the top flat [1] and against the left- hand flat
[2]. When Head Assembly is properly
positioned, the two screws [3] that attach Head
Assembly to Adjusting Guide can be installed.
ASSEMBLY AND INSTALLATION
8
3. Install front mounting screw.
4. Connect two motor cables to Base Unit. Plugs
are keyed to prevent improper insertion.
Installing Tab/Label Applicator Head
Tabber comes with two Tab/Label Applicator Heads. Narrower head is used for tabbing and stamp
affixing. Wider head is used for labels over 2" wide and up to 4" wide and Post-it
®
notes.
1. Install Applicator Head by sliding it up into
cutout between Head Frame and Head-adjusting
Guide. Attach Applicator Head to Frame using
two screws [4] supplied. Mounting holes in
Frame are oval shaped. When installing
Applicator Head, it should be held in uppermost
position when tightening screws. Slots in Frame
permit Head to be mounted in a lower position
for thin media.
2. Route cable [5] toward rear of Tabber and plug
it in. Attach main motor cable [6] and wind and
rewind motor cable [7].
ASSEMBLY AND INSTALLATION
3. Install grommet [8] in slot provided in
Motor Cover.
4. Connect Reel Brake Connector to two pin
connector on top of Head Assembly.
5. Mount Reel Assembly to top of Head and fasten
it with three screws supplied.
ASSEMBLY AND INSTALLATION
10
Installation
Choose a Location
Place Tabber with Feeder on a sturdy worktable or cabinet at least 12 inches from any walls. Allow
enough room to place the Feeder on the same work surface. Protect the Tabber from excessive heat,
dust, and moisture – avoid placing it in direct sunlight.
Plugging in the Tabber
Make sure that Emergency Stop Switch is turned OFF.
1. Connect one end of power cord into power receptacle on
rear panel of Tabber.
2. Plug other end into a 115-220 Volt AC, 50/60 Hz.
grounded outlet.
CAUTION
Do not use adapter plugs or extension cords to
connect Tabber or Feeder to wall receptacle.
Do not use outlets controlled by wall switches.
Do not use an outlet that shares the same circuit
with large electrical machines or appliances.
Aligning Feeder
Alignment of the Feeder with the Tabber is important
for proper tab placement on the media. Feeder should be
aligned so media is fed within 1/8" to 1/32" of Tabber's
Fixed Guide (as shown).
NOTE: Feeder should never be placed so media is in
contact with Guide as it is fed. Media Guides push
media against Guide for proper alignment during
tabbing process.
ASSEMBLY AND INSTALLATION
Loading Tabs
1. Remove Roll Side Guide and install tab roll with tabs unwinding face up from right side of the
roll. Remove approximately 30 tabs from roll to create a leader.
2. Release Unwind Idler Drive Press Roller by rotating it to the left. Thread the leader over the
Unwind Drive Roller. Rotate Unwind Idler Drive Press Roller so it contacts Unwind Drive Roller.
3. Thread the leader into the Bin, then over the Bin Idler Roller.
4. Continue threading the leader under the Idler Roller, then through the slot in the Tab/Label Sensor
and Applicator.
5. Bring the leader back up and under the Drive Idler Roller.
6. Lift the Drive Roller Cover and the Drive Press Roller. Then thread the leader over the Drive
Roller and around the Drive Press Roller. Close the Drive Roller Cover and bring the Drive Press
Roller in contact with the Drive Roller
7. Remove the Guide from the Take-up Reel and thread the leader through the pins on the Take-up
Reel, and then replace the Guide.
ASSEMBLY AND INSTALLATION
12
Adjusting Media Guides
Tabber is equipped with two Media Guides and an adjustable set of angular rollers to help guide the
media into position for tabbing. Adjust Guides as follows:
1. Place one of the two Media Guides next to the Fixed
Media Guide. Then place the Adjustable Guide next to it
(as shown at right).
2. Two Media Guides [1] should be just resting on
belts. Too much pressure causes media to stall
while being fed.
Additionally, Guides should be positioned between
1/8" and 1/4" from edge of media to prevent edges
from curling. Center Media Guide [2] should be
placed so Guide Rollers are on belt nearest to Fixed
Side Guide [3]. Center Media Guide [2] should not
be placed on any other belt except the one nearest
to one of Fixed Media Guides [3]. Short Media
Guide [4] can be placed where
needed to hold media down as it passes under Applicator Head.
When running tri-folded or very light weight
media, Media Guide [1] nearest Fixed Media Guide
[3] can be removed and Center Media Guide [2]
can be set at an angle to give more push to media to
hold it against Fixed Media Guide [3]. Short Media
Guide [4] should then be placed so it is centered on
tab.
NOTE: All Guide Rollers on Center
Media Guide [2] should be riding on same
Transport Belt.
ASSEMBLY AND INSTALLATION
3. Next, adjust Center Adjustable Guide so Rollers
push media against Fixed Media Guide and media
travels straight along Fixed Guide. Turning knob
on this Guide counterclockwise causes Adjustable
Rollers to push media against Fixed Guide.
Turning Adjustment Knob clockwise causes
Rollers to exert less push on media toward Fixed
Guide. When running media on opposite side of
Tabber, adjustment is reversed.
Adjusting Tab Positioning
Once tabs are loaded, next step is to adjust tab
positioning.
1. First step is to position Head Assembly so tab
bisects edge of piece you are tabbing.
2. Loosen Tabber Head locking screw [1] and slide
Head toward operator side of Tabber.
3. Loosen Sensor Guide Knob [3] and position
Pointer [4] over center of tab (as shown). Then
check that center of tab is aligned with Tab
Folding Guide [5].
ASSEMBLY AND INSTALLATION
14
4. Close Exit Cover and lock it in position with two
locking levers. Insert one piece of media into
front of Tabber and adjust Head Pressure Control
Crank up or down until you feel a drag on media.
5. Refer to instructions under “Operating the
ATS-9900” and run one piece through Tabber.
6. Check positioning of tab or tabs on piece and
adjust Fine Positioning Knob [2] to center tab on
piece. Turning knob clockwise places more of
the tab on the bottom of the piece. Turning knob
counterclockwise places more of the tab on the top of the piece.
7. When you are satisfied with tab positioning, run the job.
TROUBLESHOOTING
15
SECTION 3 – Troubleshooting
Troubleshooting Guide is provided to assist you in solving any problems that might occur with the
Tabber. We made it as complete as possible. Make sure that tabs, labels or stamps are threaded properly
and that the Tabber is plugged in and turned ON.
Jams
CONDITION SOLUTION
Media jams in Tabber's transport section.
1. Check alignment of Feeder to Tabber.
Media should feed between 1/8" to
1/32" from Fixed Guide on Tabber.
2. Check that two Media Guides are not
pressing down too firmly on media.
3. Check that Adjustable Center Guide is
not pushing media tightly against
Fixed Side Guide.
4. Check Head pressure is not too tight.
Tab Placement Problems
CONDITION SOLUTION
Tabs not placed in same spot on media.
Tabs should be placed within +/- 1/8"
1. Check Pitch setting for tab. It should
be slightly more than tab size plus
space between tabs.
2. Check amount of Head pressure. Too
little can cause media to slip when it
is being fed.
3. Check that pointer on Applicator
Head is in center of tab.
More of the tab is on the top of the media
than on the bottom.
Adjust Fine Adjustment Knob (page 12)
clockwise to move more of the tab to the
bottom side of the media.
TROUBLESHOOTING
16
CONDITION SOLUTION
Less of the tab is on the top of the media
than on the bottom.
Adjust Fine Adjustment Knob (
page 12
)
counterclockwise to place more of the
tab to the top side of the media.
Tab is not flush with edge of media.
Media not being fed flush with Fixed
Side Guide. Should be no more than 1/8"
to 1/32" space between media and Fixed
Side Guide when media enters Tabber.
When double tabbing, one tab is not placed
properly on edge of media.
1. Media may not be traveling along
Fixed Side Guide. Adjust angle of
Guide Rollers by turning knob on
Skew Guide.
2. Check pressure between Head and
Transport. Too much pressure causes
media to flex as it is transported.
3. Too little pressure can cause media to
skew as tab is being applied.
Two or three tabs applied next to
each other.
Programming issue. When programming
multiple tabs, Together was selected
instead of Separate. Reprogram the job.
More than three tabs applied on
each piece.
Tab Sensor adjustment improper.
Check Tab Voltage and Backing Voltage
adjustments (page 21).
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