Neopost XPS-ProTab 4.0 User manual

Brand: Neopost

Model: XPS-ProTab 4.0

Type: User manual

This manual is also suitable for

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.

or mechanical, including photocopying, recording, or any information storage and retrieval system, without

permission in writing from the publisher

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

INDEX 51

GETTING ACQUAINTED

SECTION 1 – Getting Acquainted

Front View

Control Panel – The machine is controlled and programmed from this panel.

Tab Drive Rollers – Advances the tabs/labels/stamps.

Take-up Reel – The web waste is wound up here after the tab/label/stamp is applied.

Take-up Reel Side Guide – Secures the web waste onto the Take-up Reel.

Tab Reel – The tabs, labels or stamps are loaded on this assembly.

Tab Reel Side Guide – Secures the tabs/labels/stamps onto the Tab Reel.

Unwind Drive Rollers – Unwinds the tab/label/stamp from the roll to keep the bin full.

Bin – Provides an area for a loop of tab//label/stamp web to accumulate.

Head Fine Adjustment Knob – This knob is used to make fine adjustments to the tab

fold position or label/stamp side-to-side position.

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.

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.

GETTING ACQUAINTED

Rear View

Tab Drive Motor Connection – Provides drive signals and power to tab drive motor.

Connection is labeled as #1 on Frame.

Unwind/Rewind Drive Motor Connection – Provides power to unwind and rewind

drive motors. Connection is labeled as #2 on Frame.

Emergency Stop Out –This connection permits the tabber to control the emergency stop

function of an external device.

Feeder Control Connection – (FEEDER) This connection allows the tabber to

start/stop the feeder. An appropriate cable and feeder must be used.

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.

Power Inlet Connection – The power cord is connected here. 115V AC 50/60 Hz

Fuse – The main fuse (7A / 250V) for the tabber is located here.

Caution! Disconnect power before replacing fuse.

Tab/Label Sensor Connection – (SENSOR) The sensor cable is connected here.

GETTING ACQUAINTED

Entrance End View

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.

Registration Assembly – Contains Guide Rollers that help align the media against the

Media Guide Fence.

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.

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.

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.

Registration Assembly Securing Knobs – Used to secure the position of the

Registration Assembly to the tabber.

Short Media Hold-down Guide – When needed, this guide can be positioned to

provide additional assistance to hold the media against the transport belts.

GETTING ACQUAINTED

Exit End View

* Not present in earlier units.

Tab Folding Guide (Front) – This plate folds the tab under the media.

Exit Roller Assembly Lock – This lever locks the Exit Roller Assembly in place.

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.

Transport Belts – The belts transport the media through the tabber.

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.

Tab Folding Guide (Rear) – This plate folds the tab under the media.

Media Forwarding Rollers – These rollers forward the media while the tab is being applied.

Tab Pressure Rollers – These rollers press the tab to the underside of the media to complete the

seal.

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.

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.

*Short Media Drive Rollers– These rollers help drive short media through the exit roller

assembly area.

*Short Media Pressure Rollers– These rollers help drive short media through the exit roller

assembly area.

GETTING ACQUAINTED

Control Panel

MAIN POWER SWITCH – Turns power to the tabber ON and OFF.

HEAD POWER SWITCH – Turns the power on to the Tab/Label motor.

TRANSPORT POWER SWITCH – Turns the tabber transport power ON and OFF.

JOG SWITCH – Permits the operator to jog or move the transport slowly for setup

purposes.

SPEED CONTROL – Adjusts the speed of the tabber.

LCD DISPLAY – Keeps the operator informed of the status of the tabber.

KEY PAD – Used to set the adjustments and program the tabber

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.

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

EasyFeed 120 (Optional Feeder) Connections/Controls

AC Power Receptacle – Connect the AC power cord here.

Important! Please verify that voltage is correct, for your feeder, before connecting.

Interlock Connector – Feeder Interface Cable from tabber connects here.

Stand Alone Switch – Allows machine to run when not signaled by host machine.

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.

Power Switch – Used to power the feeder on/off.

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).

ASSEMBLY AND INSTALLATION

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

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

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

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

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

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

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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Neopost XPS-ProTab 4.0 User manual

Brand: Neopost

Model: XPS-ProTab 4.0

Type: User manual

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Neopost XPS-ProTab 4.0 User manual

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Neopost XPS-ProTab 4.0 User manual

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