2111CD-1250 V0 R0 PDF

TABLE OF CONTENTS
1
LABEL-AIRE
2111 CD-1250 APPLICATOR
OPERATOR’S MANUAL
INTRODUCTION
2
Version 00 Rev 00
GENERAL INFORMATION
3
March 2000
LABEL SET-UP
4
PRODUCT SET-UP
5
SET-UP RECORD
6
OPTIONAL EQUIPMENT
7
APPENDICES
8
MAINTENANCE
9
TROUBLESHOOTING
The information contained herein is accurate at the time
10
of publication. It is normally our policy to notify
customers of any changes which may affect them.
Label-Aire reserves the right to make design changes to GLOSSARY & INDEX
items and equipment described in this manual at any
11
time and without notice.
Label-Aire P/N 7408675-100 PRINTS 12

ii
TABLE OF CONTENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cautionary Symbols and Pictograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Initial Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Applicator Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Physical Placement of the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Set-up Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Module Keys and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Microprocessor Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Machine Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Tool List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Re-installation of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unwind Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unwind Disks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Low Label Bracket (Optional Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Rewind Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air Service Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LABEL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Energizing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connection to Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connection to A.C. Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Loading Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Initial Operable Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Align Label Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Label Sens. (Itivity) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Label Detected: Yes/No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Label Detect Edge: Lead/Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Label Repeat Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Label Stop Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Peeler Bar Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Initial Air Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Vacuum Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Right Hand Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2111CD-1250 V0 R0.wpd iii

TABLE OF CONTENTS
Left Hand Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Air Assist Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Vacuum Grid Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Air Blast Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Web Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Web Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Imprinter On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Imprint Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Label Stack Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
PRODUCT SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Positioning the Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Detector Type: Beam/Retro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Product Detect Edge: Lead/Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Product Detector Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Allen Bradley Through Beam P/N 7600005-802 (Black) . . . . . . . . . . . . . . . . . . . . . . . . 82
Banner Through Beam P/N 7600005-802 (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Product Sensitivity Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Product Detected: Yes/No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Label Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Detector Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
SET-UP RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Low Label Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Low Label Alarm Trigger Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Low Label Detectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Allen Bradley Low Label Detector P/N 9009308 (Black) . . . . . . . . . . . . . . . . . . . . 100
Banner Low Label Detector P/N 9009219 (Yellow) . . . . . . . . . . . . . . . . . . . . . . . . 101
Web Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Machine Overcycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Low Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Web Break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Machine Overcycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Velocity Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
A Simple Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Velocity Comp General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Positioning the Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
The Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Product Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Velocity Comp Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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TABLE OF CONTENTS
Velocity Comp Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Individual Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Continuous Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Outboard Clamping Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Imprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Thread Diagram with Imprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Imprinter On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Imprint Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Imprint Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Label Repeat Length Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Label Loading - Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
APPENDICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Appendix A
Re-loading Labels (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Appendix B
Set-up Record Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Daily Maintenance
(Every 8 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Weekly Maintenance
(Every 40 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Monthly Maintenance
(Every 150 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Semi-Annual Maintenance
(Every 1000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Annual Maintenance
(Every 2000 Hours) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Dancer Arm Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Rewind Slip Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Pinch Roller Compression Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Right Hand Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Left Hand Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
PRINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2111CD-1250 V0 R0.wpd v
TABLE OF FIGURES
TABLE OF FIGURES
Figure 1 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 2 Design Data for 2111CD Applicator Support Structure . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 3 Machine Attitudes (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 4 Machine Parts (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 5 Left Side View of Right Hand Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 6 Right Side View of Right Hand Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 7 Machine Parts (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 8 Right Side View of Left Hand Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 9 Left Side View of Left Hand Applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 10 Module Faceplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 11 2111CD Machine Sequence Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 12 Unwind Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 13 Unwind Disks And Optional Low Label Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 14 Rewind Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 15 Air Service Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 16 Threading Diagram (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 17 Threading Diagram (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 18 Microprocessor Menu Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 19 Rapid Increase and Decrease of Microprocessor Values. . . . . . . . . . . . . . . . . . . . . . . 44
Figure 20 Label Cell Block Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 21 Preferred Detection Points For Various Label Shapes. . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 22 Label Sensor Sensitivity Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 23 Label Stop Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 24 Result of Label Dive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 25 Peeler Bar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 26 Air Blast And Air Assist Air Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 27 Grid Mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Figure 28 Air Assist Tube Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 29 Air Blast Tube Arrangement for Various Label Shapes . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 30 Label Stack Adjustment Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 31 Air assist tube adjustment to correct adhesive strings . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 32 Applicator/Product Position (Right Hand Applicator Shown) . . . . . . . . . . . . . . . . . . 78
Figure 33 Product Detector Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 34 Through Beam Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 35 Reflected Beam Product Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 36 Alternative Alignment for Reflective Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 37 Desired Label Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 38 Low Label Alarm Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 39 Low Label Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 40 Low Label Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
vi
TABLE OF FIGURES
Figure 41 Slow Launcher Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Figure 42 Fast Launcher Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 43 U6 PAL Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 44 Machine Parts Oversize (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 45 Machine Parts Oversize (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Figure 46 Outboard Clamp (For Oversize Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 47 Threading Diagram With Imprinter (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 48 Threading Diagram With Imprinter (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 49 Imprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Figure 50 Imprinter Adjustment Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Figure 51 Threading Diagram (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Figure 52 Threading Diagram (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 53 Parts Of The Unwind Brake (Right Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Figure 54 Unwind Brake Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Figure 55 Unwind Dancer Arm Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Figure 56 Spring Tension Cap Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Figure 57 Rewind Slip Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Figure 58 Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Figure 59 Pinch Roller Arm Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Figure 60 Pinch Roller Compression Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Figure 61 Pinch Roller Compression Spring (Left Hand) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2111CD-1250 V0 R0.wpd vii

viii
INTRODUCTION
The Label-Aire model 2111CD is a high speed label applicator used to apply pressure sensitive
labels to moving products of the same size on a production line. It is essentially a self contained
module that may be mounted in almost any position adjacent to the production line, to apply
labels to the top, sides, or bottom of products as they pass by.
Labels are supplied on rolls that consist of a web on which the labels are maintained by their
adhesive until peeled from the web just prior to application. After peel-off, the label is held on a
grid by a vacuum. When the presence of a product triggers the applicator, a jet of air applies the
label. In a typical set-up, a photoelectric sensor detects the leading edge of a product and initiates
an air jet to apply the label, with a placement accuracy typically within ± 1/32 inch (0.8mm).
For safe trouble free operation, the instructions in this manual must be carefully followed during
set-up, operation, change-of-rolls, cleaning, and maintenance. Also the specified environmental
conditions must be maintained.
ELECTRICAL SUPPLY: 108-132 Volts, 3 Amps, 54-66 Hertz, Single Phase
A three meter long, three wire cable with 1.00mm² conductors rated at 10 amperes (in
accordance with CENELEC HD-21) is provided for the electrical connection to the IEC
320 receptacle of the applicator. The end of the power cord is terminated with a NEMA
5-15 plug.
AIR SUPPLY: Compressed air must be provided at pressures between 90 and 100 P.S.I. (6
and 7 bar) with a minimum flow rate of four S.C.F.M. (114 liters/min). A
quick disconnect fitting is provided.
ENVIRONMENT: Operating temperature: 40-104 degrees F (5-40 degrees C).

Humidity: 20-95% RH, Non condensing.
NOTE: The model 2111CD is not intended to be operated in an

environment where flammable or explosive gases are present.
The 2111CD is not to be used in direct contact with food
products.
READ THE INSTRUCTIONS COMPLETELY. This manual includes all of the information that
you'll need to set-up the applicator under normal operating conditions. The instructions include
important safety precautions which must not be ignored.
2111CD-1250 V0 R0.wpd 9
INTRODUCTION
READ THE INSTRUCTIONS IN ORDER. The instructions are written as numbered steps that
will take you safely and efficiently through the set-up process. Any steps performed out of
sequence may result in a hazard and the applicator may not operate properly.
UNDERSTAND THE TERMS USED. Although this manual uses few technical terms, some
vocabulary may be new to you. Most of the words are defined the first time that they are used. If
you don't know what a word means, check the Glossary.
WORK CAREFULLY. Although setting up the machine is not difficult, it does take time. Do
not rush through the process: careful work will produce good results.
TRY AGAIN IF SOMETHING DOES NOT WORK. Although a machine malfunction is

possible, most problems happen because the machine is not set-up right. If the machine doesn't
operate correctly, back up and try again.
KNOW HOW TO FIND WHAT YOU NEED. This manual contains all of the information
needed including a Table of Contents, Table of Figures, Glossary, and Index. Use these tools to
locate information quickly.
UNDERSTAND OUR TYPOGRAPHIC CONVENTIONS. Machine keys and switches are

designated by brackets: "Press [SELECT]," means "Press the select key." Messages shown on the
microprocessor display are shown by type style: THIS TYPE STYLE INDICATES
MICROPROCESSOR TEXT.
NOTE: Paragraphs that are in this style give information to help handle
special circumstances, or re-emphasize important information.
FOLLOW ALL SAFETY INSTRUCTIONS. The model 2111CD applicator has been provided
with a number of safety features. Observe all safety warnings and under no circumstances
attempt to remove or defeat safeguards or operate the machine in a manner contrary to the
instructions.
10
C A U TI O N AR Y SYM B O LS A N D PICTOGRAMS
CAUTIONARY SYMBOLS AND

PICTOGRAMS
! CAUTION !
THIS SYMBOL INDICATES THE

PRESENCE OF AN UNINSULATED
DANGEROUS VOLTAGE WITH IN THE
APPLICATORS ENCLOSURE.
! NOTICE !
THIS SYMBOL IS INTENDED TO ALERT

THE USER AND SERVICE PERSONNEL
OF THE PRESENCE OF IMPORTANT
SAFETY, OPERATING, AND
MAINTENANCE (SERVICE)
INSTRUCTIONS.
! CAUTION !
THIS SYMBOL WARNS YOU THAT

THERE IS A DANGER OF BEING
INJURED BY MACHINERY. READ THE
TEXT AND FOLLOW THE
INSTRUCTIONS CAREFULLY TO AVOID
AN INJURY.
2111CD-1250 V0 R0.wpd 11
CAUTIONAR Y SYM BO L S A N D PI CTO G RAM S
This symbol on an electrical power switch indicates SWITCH ON.
F This symbol on an electrical power switch indicates SWITCH OFF.
This symbol indicates the protective EARTH connection.
12
INITIAL WARNINGS
INITIAL WARNINGS
The model 2111CD has been designed with the safety of the operator and service personnel in
mind. Proper safety features have been incorporated and the applicator safety tested to assure
safety if used as intended. Refer to the CAUTIONARY SYMBOLS AND PICTOGRAMS
definitions on the preceding page.
A risk assessment has been conducted which indicates most hazards identified by the machinery
directive to be low to nil risk. Apparent moderate risks were determined to be:
The Web Drive Rollers

The potential for finger pinch exists between the drive and pinch
rollers. Keep hands clear of the drive and pinch rollers whenever
the [FEED] switch is ON.
Enclosure
A potential for electrical shock exists if the rear cover is removed.
The cover must not be removed except by a qualified service

person. The power switch is to be turned OFF (F) and the power
cord removed prior to removing the cover.
2111CD-1250 V0 R0.wpd 13
APPLICATOR POWER CABLE
APPLICATOR POWER CABLE

The applicator is shipped from the factory with a six foot three pin power cord. One end plugs
into the IEC receptacle on the side of the applicator. The other end connects to the customer's
properly grounded and polarized power outlet.
! CAUTION !
DO NOT CONNECT THE MACHINE TO THE A.C.

POWER SOURCE UNTIL DIRECTED TO DO SO IN
THE SET-UP PROCEDURES.
Figure 1 Power Cable
14
PHYSICAL PLACEMENT OF THE MACHINE
PHYSICAL PLACEMENT OF THE

MACHINE
The model 2111CD is mounted at the installation site to provide a safe, adjustable and stable
alignment of the label to be applied, with the product.
The physical properties of the applicator are shown in Figure 2. The orientation of the applicator
label dispenser can be any of the major alignments shown in Figure 3. A gimbal function is
provided when the U-arm is used to support the applicator housing by its pivot attachments and
by the freedom provided by rotation about the 3/4 inch mounting bolt. The structure supporting
the U-arm/applicator body must be designed to safely support the 170 lb (77Kg) weight and in
some orientations, the moment generated by the support extended out by almost 15 inches
(38cm).
If the installer selects a support base that is mounted on casters, the maximum overturning
moment that can be experienced when the floor is non-horizontal must be considered in the
design of the support. Some safety agencies specify that for a truly portable stand that the design
should consider safely supporting the applicator in its worst orientation for a 10 degree tilt. Also,
the casters should have locks to prevent inadvertent motion of the support.
All portable supports should have a means to anchor the unit to the floor if the applicator need
not be moved for periods between applying labels.
Place the machine so that the vacuum grid is 5/8 inch (16mm) from the product's labeling
surface. Make sure that no part of the applicator will touch any part of the product as it passes
the machine. The position of the machine should allow the operator to easily change labels.
When you have correctly assembled and positioned the machine, tighten any adjustment locks to
prevent the machine from moving.
2111CD-1250 V0 R0.wpd 15
APPLICATOR SUPPORT STRUCTURE
Figure 2 Design Data for 2111CD Applicator Support Structure
16
MACHINE ATTITUDES
Figure 3 Machine Attitudes (Right Hand)
2111CD-1250 V0 R0.wpd 17
18
GENERAL MACHINE
INFORMATION
! CAUTION !

POWER SOURCE OR THE COMPRESSED AIR
SERVICE UNTIL DIRECTED TO DO SO IN THE
SET-UP PROCEDURES.
2111CD-1250 V0 R0.wpd 19
SET-UP SUMMARY
SET-UP SUMMARY
There is a considerable amount of detailed set-up information in this manual. If you are a first
time user of Label-Aire equipment, it is recommended that you follow the manual step by step to
completely set-up the applicator.
If you are already familiar with Label-Aire equipment, you may wish to follow the set-up
summary and refer to the manual only if difficulty is encountered.
SET-UP SUMMARY
1. Load Labels
2. Set Label Sensitivity
3. Set Label Stop Length (Position)
4. Set Air Pressures
5. Set Air Blast Dwell
6. Set-up Product Detector
7. Set-Up Product Handling
8. Document Set-up
20
MACHINE PARTS
Figure 4 Machine Parts (Right Hand)
2111CD-1250 V0 R0.wpd 21
MACHINE PARTS
Figure 5 Left Side View of Right Hand Applicator Figure 6 Right Side View of Right Hand Applicator
22
MACHINE PARTS
Figure 7 Machine Parts (Left Hand)
2111CD-1250 V0 R0.wpd 23
MACHINE PARTS
Figure 8 Right Side View of Left Hand Applicator Figure 9 Left Side View of Left Hand Applicator
24
MODULE KEYS AND SWITCHES
MODULE KEYS AND SWITCHES

[POWER] : Connects the entire system with the power supply.
[FEED]: Enables or disables the applicator labeling mode.
[SELECT]: Used to move from one microprocessor menu entry to the next.
[HOME] : Used to exit the label page and access the LABELS PER MINUTE display.
[JOG]: Used during set-up to cycle the applicator. [FEED] must be ON for this key to
function.
[INCREASE]: Used to increase values in the microprocessor, and is used with the [DECREASE]
key to enter the access code.
[DECREASE]: Used to decrease values in the microprocessor, and is used with the [INCREASE]
key to enter the access code.
Figure 10 Module Faceplate
2111CD-1250 V0 R0.wpd 25
MICROPROCESSOR MESSAGES
MICROPROCESSOR MESSAGES
ENTER ACCESS CODE: This message informs you that you must enter the access code for your
machine in order to proceed to the next microprocessor function. The display will change to
LABELS PER MINUTE = X if the correct code isn't entered within ten seconds.
FEED OFF OR LOW VOLTS : This message indicates a loss of direct current (D.C.) voltage to the
microprocessor. It may occur when the [FEED] switch is turned OFF while in label applying
mode, or if an electrical problem results in a low voltage situation.
INPUT SET FOR SWITCH : This message indicates that the machine has been set up for a switch
output label sensor or product detector. A switch style sensor is one that sends an on or off
signal to the microprocessor rather than a range of voltages that the microprocessor needs to
interpret. Label-Aire product detectors are switch output style detectors.
LABEL PAGE = X : This message indicates the label page that the machine is set to use or change.
LABELS PER MINUTE = XXXX : This message indicates the average rate at which labels are being
applied. The conveyor must supply the product at a constant speed with a constant distance
between each product for this display to be accurate. This display can be accessed by pressing
the [HOME] key from any display except the LMETER and PMETER displays.
NO LABELS FOUND : This message indicates that the label sensor isn't sensing labels. This may
be due to a break in the label stock, three or more labels missing from the liner, a malfunctioning
lamp, a malfunctioning sensor, or a label detection malfunction.
POW ER ON: LABEL PAGE = X : The microprocessor displays this message when the machine is
ready to apply labels after the machine has initially been switched ON (). The machine will not
cycle before the message appears.
SET LABEL PAGE TO = X : The machine displays this message when the label page is being
changed, and displays the page that may be either used or altered.
26
MACHINE SEQUENCE
MACHINE SEQUENCE
Figure 11 2111CD Machine Sequence Flowchart
2111CD-1250 V0 R0.wpd 27
TOOL LIST
TOOL LIST
NOTE: The mounting hardware provided is USA inch size. Inch size
tools are required as follows:
HEX HEAD WRENCHES OPEN END WRENCHES SCREWDRIVERS

1/16 inch 1/2 inch #1 Phillips
1/8 inch 3/8 inch 3/32 inch flat blade
3/16 inch 5/8 inch
3/32 inch 7/16 inch
5/64 inch 9/16 inch
5/32 inch
7/64 inch
9/64 inch
11/16 inch
28
RE-INSTALLATION OF PARTS
Some parts must be removed before shipment to prevent damage in transit. Follow these
instructions to assembly the removed parts.
UNWIND BLOCK ASSEMBLY
1. Locate and unwrap the unwind block assembly.
2. Use a 5/32 inch hex head wrench to remove the mounting socket head cap screws from the
faceplate. See Figure 12.
3. Position the unwind block assembly over the mounting holes in the faceplate.
4. Use a 5/32 inch hex head wrench to install the mounting socket head cap screws.
5. Position and hold the dancer arm as indicated. Remove the slack from the unwind brake
band and tighten the lock collar in position.
Figure 12 Unwind Block Assembly
2111CD-1250 V0 R0.wpd 29
UNWIND DISKS
1. Remove the protective plastic film from the inner and outer unwind disks.
2. The inner unwind disk hub has no decal. Slide the inner unwind disk onto the unwind
mandrel (hub facing out) until the disk is parallel with the inboard edge of the vacuum grid.
Refer to Figure 13.
Figure 13 Unwind Disks And Optional Low Label Detector
3. Rotate the inner unwind disk until the set screw in the hub is over the flat on the unwind
mandrel. Tighten the set screw using a 3/16 inch hex head wrench.
30
4. Match the “Twist Lock” flat on the outer unwind disk to the flat on the unwind mandrel.
Slide the outer unwind disk onto the unwind mandrel. See Figure 13.
5. Hold the inner unwind disk while you rotate (twist) the outer unwind disk on the unwind
mandrel about 45 degrees. Release the inner unwind disk.
6. Locate the set screw on the outer unwind disk hub. Use the 3/16 inch hex head wrench to
snugly tighten the nylon tipped set screw against the unwind mandrel.
7. Hold the inner unwind disk and rotate the outer unwind disk until the “Twist Lock” flat is
aligned with the flat on the unwind mandrel. Release the inner unwind disk.
8. Slide the outer unwind disk off the unwind mandrel. If the outer unwind disk will not
release, loosen the nylon tipped set screw using the 3/16 inch hex head wrench.
9. Re-install the outer unwind disk and check that it is tight when not aligned with the unwind
mandrel flat, and loose enough to remove when aligned with the unwind mandrel flat. Adjust
as needed.
LOW LABEL BRACKET (OPTIONAL EQUIPMENT)
1. Remove the two socket head cap screws from the unwind block with a 9/64 inch hex head
wrench. See Figure 13.
2. Place the low label bracket against the unwind block with the low label detector aimed at the
inner unwind disk. Install the two socket head cap screws with a 9/64 inch hex head wrench.
The position of the low label detector will be set during the set-up procedures.
2111CD-1250 V0 R0.wpd 31
REWIND DISK
Figure 14 Rewind Disk
1. Remove the protective plastic film from the rewind disk.
2. Align the rewind disk set screw with the flat on the rewind mandrel.
3. Slide the rewind disk, hub first, onto the rewind mandrel. The rewind disk hub should be
approximately 1/16 inch (1.6mm) from the machine faceplate.
4. Use a 5/32 inch hex wrench to tighten the rewind disk set screw.
5. Locate the rewind pin and set it aside until used in the Loading Labels Section.
32
AIR SERVICE FILTER
1. Thread the air filter pipe nipple into the bulkhead fitting near the applicator power connector.
See Figure 15.
2. Tighten the air filter fitting using a 9/16 inch open end wrench.
Figure 15 Air Service Filter
PRODUCT DETECTOR
1. Locate and set aside the product detector.
2. DO NOT connect the product detector until instructed to do so in the set-up procedures.
2111CD-1250 V0 R0.wpd 33
34
LABEL SET-UP
This section of the manual explains how to adjust the machine for each type of label that you
want to apply. The microprocessor will remember the instructions for applying eight different
labels. Each set of instructions is a "Label Page."
Because all of the adjustments affect each other, it is very important that you do the steps listed
in this section in the order that they are given.
! CAUTION !

POWER SOURCE UNTIL DIRECTED TO DO SO IN
THE SET-UP PROCEDURES.
2111CD-1250 V0 R0.wpd 35
ENERGIZING SEQUENCE
ENERGIZING SEQUENCE
Use this sequence whenever A.C. power and compressed air service is applied to the applicator.
NOTE: This applicator is designed to operate at 120VAC ±10%.

Operation at higher or lower voltages can cause improper
functioning or permanent damage to the equipment.
CONNECTION TO COMPRESSED AIR
As a matter of convenience, the applicator should be connected to the compressed air service
before electrical power is connected to the applicator.
Connect the compressed air service to the 1/4 inch NPT CPC nose insert fitting.
CONNECTION TO A.C. POWER
NOTE: For convenience, connect the applicator to the compressed air

service before the applicator is connected to the A.C. power.
1. Turn OFF (F) the applicator [POWER] switch located on the control module faceplate.
2. Turn OFF the applicator [FEED] switch located on the control module faceplate.
3. With both ends of the A.C. power cord disconnected, connect one end of the A.C. power cord
to the IEC receptacle on the side of the applicator.
4. Connect the remaining end of the A.C. power cord to the electrical mains.
Go on to the Loading Labels Section.
36
LOADING LABELS
LOADING LABELS
! CAUTION !
TURN THE [FEED] SWITCH OFF BEFORE YOU

PERFORM THE FOLLOWING PROCEDURES OR
YOU MAY BE INJURED BY THE MOVING DRIVE
ROLLER.
NOTE: See Appendix A for re-loading labels.
This section of the manual explains how to thread labels through the machine. If the applicator is
equipped with an imprinter or some other option that requires a different label loading sequence,
refer to the Options Section of the manual.
1. Set the [POWER] and [FEED] switches to OFF ( F). Twist and remove the outer unwind disk.
See Figure 16 and Figure 17.
2. Slide a roll of labels onto the hub of the inner unwind disk. Make sure that the labels will be
face up as they slide over the peeler bar. Replace the outer disk and twist to lock.
3. Remove all the labels from the first six feet (two meters) of liner.
4. Loosen the label tension spring thumbscrew on the label cell block(s). See Figure 16 and
Figure 17.
5. Thread the web through the machine as shown in Figure 16 and Figure 17.
a. Make sure to thread the label liner between the air assist tube and the peeler bar.
b. If equipped with the “oversize” option, disengage the outboard pinch roller clamp.
c. Depress the detent cam to separate the pinch and drive rollers. This will make it possible
to thread the label liner between the drive roller and pinch roller.
6. Remove the lock pin from the rewind mandrel, lay the end of the liner over the lock pin slot
and insert the lock pin.
2111CD-1250 V0 R0.wpd 37
LOADING LABELS
7. Turn the rewind mandrel by hand. Check that the inner edge of the label aligns with the inner
row of holes on the vacuum grid. Adjust the positions of the inner unwind disk and the
rewind disk if necessary.
8. Re-tighten the label tension spring thumbscrew.
9. Slide the guide collars to within 1/64 inch (1.6mm) of the label liner.
10. Re-engage the pinch and drive rollers (and the outboard pinch roller clamp if so equipped).
Go on to the Microprocessor Entry Section.
38
THREADING DIAGRAM
Figure 16 Threading Diagram (Right Hand)
2111CD-1250 V0 R0.wpd 39
THREADING DIAGRAM
Figure 17 Threading Diagram (Left Hand)
40
INITIAL OPERABLE SETTINGS

The purpose of this section of the manual is to gain familiarity with the microprocessor menu and
to set initial operable settings.
The microprocessor controls all the machine electronic parameters. The parameters are listed in
the microprocessor menu. Refer to the menu map, Figure 18, throughout these instructions. The
LED panel is used to display the status of the various menu parameters and the keypad is used to
manipulate the adjustable menu parameter settings. See Figure 19.
The initial operable settings is the starting point for setting up the machine microprocessor
parameters. A previously unprogrammed label page will have random values for the menu
parameters. The microprocessor will attempt to operate the machine with these random values.
The random values may have extremely high or extremely low settings for the various
parameters. The machine may malfunction if the various menu parameters are not compatible, or
may appear to malfunction due to the extreme settings of the menu parameters.
Follow the instructions below to set the initial operable settings and to gain familiarity with the
microprocessor menu.
! CAUTION !

ROLLER.
2111CD-1250 V0 R0.wpd 41
MICROPROCESSOR MENU MAP
Figure 18 Microprocessor Menu Map
42
1. Make sure that the [FEED] switch is in the OFF position.
2. Switch the [POWER] ON (). The display will first identify the software and then read,
1
POW ER ON LABEL PAG E = X .
3. Press and release the [SELECT] button. The display will read, ENTER ACCESS CODE. You
have ten seconds to enter the correct access code for your machine. If you don't enter the
correct code within ten seconds, the display will change to LABELS PER MINUTE = X ; press
and release [SELECT] and try again.
NOTE: The access code for the machine is provided when the machine is
installed. If you don't know your access code, contact your
distributor.
4. After you enter the access code, the display will read, LABEL PAGE = X . Press and release
either [INCREASE] or [DECREASE]. The display will read ENTER ACCESS CODE: re-enter the
access code.
5. The display will read, SET LABEL PAGE TO = X . Press and release the [INCREASE] or
[DECREASE] button to reach the label page that you want to program or update. Generally,
label page one is set-up in the factory during testing to run a test label. Select an
unprogrammed label page (usually label page two) to learn how to set the initial operable
values.
Label pages are like presets on your automobile radio. You find a station for each preset
number. When you want to change stations, you just press a preset number and the radio
remembers the setting for that station. Label pages work in much the same way. Set up label
#1 in label page #1, label #2 in label page #2 etc. Then, if you have been applying label #2
and want to change to label #1, you just select label page #1. The applicator will remember
the settings for label #1 so you won't have to re-enter all the values.
6. Press and hold [SELECT]. The main menu headings will be sequentially displayed:
APPLICATOR SET-UP, followed by DETECTOR SET-UP, followed by LABEL PAGE = X ,
followed by APPLICATOR SET-UP again, etc. This feature allows the operator to quickly
change the display from one main section of the menu to another. Release [SELECT] when
APPLICATOR SET-UP is displayed.
7. When APPLICATOR SET-UP was in the display, and [SELECT] was released, the display
transitioned to the first item in the applicator set-up menu which is ALIGN LABEL SENSOR,
which then transitions to LMET ER: u.
Continue with step 8 to begin setting the initial operable settings.
1
Throughout this manual an X is used to denote a variable numeric value.
2111CD-1250 V0 R0.wpd 43
NOTE: The parameters ignored during the setting of the initial operable
settings will be set during the set-up procedures.
8. Press and hold in [SELECT] for one second and then release. The display will transition to
LABEL SENS: OK/NOT OK.
9. Press and release the [SELECT] key until LABE L DET ECT EDG E: LEA D/TR AIL is displayed.
Press and release the [INCREASE] or the [DECREASE] key one time. The selection will toggle
between LEAD and TRA IL . Use this technique to set parameters that toggle between two states
i.e. ON/O FF, BE AM/R ETR O, LEA D/TR AIL , etc.
Use the [INCREASE] or the [DECREASE] key to set LABEL DETECT EDGE: LEAD .
10. Press and release [SELECT] repeatedly until LABEL REPEAT LENGTH = XXXX is displayed.
This will be the first numeric value set to the initial operable setting. The initial operable
setting for LABEL REPEAT LENGTH is 0400.
Press and release the [INCREASE] key one time. If the random numeric value in the display
was above the maximum allowable setting for that parameter, the value displayed will be
replaced with the minimum allowable setting for the parameter.
If the random numeric value incremented by one number, the random number is less than the
maximum allowable setting for that parameter.
Press and hold in the [INCREASE] key. The numeric value in the display will begin to
increment one number at a time. While holding in the [INCREASE] key, press and hold in the
[DECREASE] key. Refer to Figure 19. The numeric value will now increase at a rapid rate.
Release both keys.
Press and hold in the [DECREASE] key. The numeric value in the display will begin to
decrement one number at a time. While holding in the [DECREASE] key, press and hold in
the [INCREASE] key. Refer to Figure 19. The numeric value will now increase at a rapid rate.
Release both keys.
Use the techniques described above to set the LABEL REPEAT LENGTH to 0400 .
Figure 19 Rapid Increase and Decrease of Microprocessor Values.
44
11. Press and release the [SELECT] key until LABEL STOP LENGTH is displayed. Use the
[INCREASE] and [DECREASE] keys to set the LABEL STOP LENGTH to 0047 .
12. Press and release the [SELECT] key repeatedly until EXTEND AIR ASSIST = XXXX is displayed.
Use the [INCREASE] and [DECREASE] keys to set the EXTEND AIR ASSIST to 0001 .
13. Press and release the [SELECT] key until AIR BLAST DWELL = XXXX is displayed. Use the
[INCREASE] and [DECREASE] keys to set the AIR BLAST DW ELL to 0100 .
14. Press and release the [SELECT] key until WEB FEED = XXXX is displayed. Use the [INCREASE]
and [DECREASE] keys to set the WEB FEED to 0400 .
15. Press and release the [SELECT] key until WEB TENSION = NORMAL/IMPRNT is displayed. Use
the [INCREASE] and [DECREASE] keys to set the WEB TENSION to NORMAL .
16. Press and release the [SELECT] key until IMPRINTER: ON/OFF is displayed. Use the
[INCREASE] or the [DECREASE] key to set IMPRINTER: to OFF .
17. Press and hold in the [SELECT] key to sequentially display the main menu headings. Release
the key when PRODUCT DETECTOR SET-UP is displayed.
18. When PRODUCT DETECTOR SET-UP was in the display, and [SELECT] was released, the
display transitioned to the first item in the PRODUCT DETECTOR SET-UP menu which is
DETECTOR TYPE: BEAM/RETRO. Use the [INCREASE] or [DECREASE] key to set DETECTOR
TYPE: to BEAM .
19. Press and release [SELECT] repeatedly until LABEL PLACEMENT = XXXX is displayed. Use the
[INCREASE] and [DECREASE] keys to set LABEL PLACEMENT to 0005 .
20. Press and release [SELECT] until DETECTOR LOCKOUT = XXXX is displayed. Use the
[INCREASE] and [DECREASE] keys to set DETECTOR LOCKOUT to 0001 .
21. If the CPU is equipped with RATE COMP. (Velocity Comp.) press and hold in the [SELECT]
key until RATE COMP. ON/OFF is displayed. Use the [INCREASE] or [DECREASE] key to set
RATE COMP. to OFF . The RATE COMP. will be set-up later.
The initial operable settings are now set. The techniques used in setting the initial operable
settings will be used throughout the set-up procedures to manipulate the microprocessor
parameter settings.
Go on to the Align Label Sensor Section.
2111CD-1250 V0 R0.wpd 45
ALIGN LABEL SENSOR
ALIGN LABEL SENSOR

This section of the manual explains how to find the proper position of the label sensor in relation
to the label, and how to align the label sensor and label lamp.
! CAUTION !

ROLLER.
1. Make sure that the [FEED] switch is OFF.
2. Loosen the thumbscrew that locks the label cell block in place (see Figure 20) and slide it to
the best detection point, which is usually the center of the label (see Figure 21 for examples).
Tighten the thumbscrew.
3. Remove a label from the liner. Position the blank liner beneath the label sensor.
4. From the APPLICATOR SET-UP portion of the microprocessor menu, press and release
[SELECT] until the display reads ALIGN LABEL SENSOR . Wait for one second and the display
will change to read LMETER:ttttt. The number of asterisks shows the amount of light
that the sensor is receiving (lots of asterisks = lots of light: no asterisks = no light).
5. Adjust the lamp position by slowly turning the label lamp adjustment screw (see Figure 20).
Rotate the lamp adjustment screw clockwise to move the label lamp outboard or clockwise to
move the label lamp inboard. Adjust the lamp to the position that produces the most
asterisks in the display. There must be at least three asterisks for reliable detection.
6. After the correct alignment is established, use a 1/8 inch hex head wrench to loosen the lock
collar on the peeler bar keyed shaft. Slide the lock collar against the label cell block and use
the 1/8 inch hex head wrench to tighten the lock collar in position. The lock collar is used to
maintain the label sensor alignment when the label cell block is re-installed after cleaning.
Go on to the Label Sens. (Itivity) Section.
46
ALIGN LABEL SENSOR
Figure 20 Label Cell Block Detail
Figure 21 Preferred Detection Points For

Various Label Shapes.
2111CD-1250 V0 R0.wpd 47
LABEL SENS. (ITIVITY)

This section sets the sensitivity of the sensor for the particular labels that you are applying. The
instructions below are for the standard label sensor.
! CAUTION !

ROLLER.
[SELECT] until the display reads LABEL SENS: OK/NOT OK.
3. Adjust the label tension spring by turning the thumbscrew so that the spring holds the label
flat against the peeler bar, but allows the label to slide freely.
NOTE: Don't skip ANY of these steps! You must do steps 4 through 7
even if the display already reads NOT OK.
48
Figure 22 Label Sensor Sensitivity Set-Up
4. Position the lightest (most transparent2) part of the label between the label sensor and label
lamp.
5. Press and hold [DECREASE] for two seconds. The display will read NOT OK.
6. Remove a label from the liner. Position the darkest (least transparent3) portion of the label
liner (without the label) between the label sensor and the label lamp.
7. Press and release the [INCREASE] key. The display will read OK . The label sensitivity is now
set. Go on to the Label Detected Section. If the display reads INPUT SET FOR SWITCH you
have made a mistake or the sensor cannot sense the label. Go back to and repeat the Align
Label Sensor Section.
After the Label Sensitivity is correctly set, go on to the Label Detected: Yes/No Section.
2
If any part of the label is completely transparent (you can see through it) do not use that part
of the label for the sensitivity set-up. Use the most transparent part of the printed portion of the
label.
3
Some label liners are blotchy or marked with colored lines. It is these types of liners that
must be set up on the darkest portion of the liner. If the liner is uniformly transparent, it does not
matter which part is used for set-up.
2111CD-1250 V0 R0.wpd 49
LABEL DETECTED: YES/NO
LABEL DETECTED: YES/NO
! CAUTION !

ROLLER.
[SELECT] until the display reads LABEL DETECTED: YES/NO. Slowly move a strip of labels
between the sensor and lamp. The display should read LABEL DETECTED: YES when labels
are between the sensor and lamp, and LABEL DETECTED: NO when liner only is in position.
If labels are not being detected, repeat the ALIGN LABEL SENSOR and LABEL SENS . Sections
and try again.
Go on to the Label Detect Edge: Lead/Trail Section.
50
LABEL DETE CT ED GE: LE AD/TRA IL
LABEL DETECT EDGE:

LEAD/TRAIL
! CAUTION !

ROLLER.
1. Make sure the [FEED] switch is OFF.
[SELECT] until the display reads LABE L DET ECT EDG E: LEAD /TRA IL . This section will be set
either for LEAD or TRA IL , which designates for the leading or trailing edge of the label.
3. The display should read LEAD unless one or more of the following conditions exist:
If the label has a very short repeat length (less than 1/2 inch [12.7mm]), select TRA IL .
If the label has an odd shaped leading edge and a straighter trailing edge, select TRA IL .
4. Press [INCREASE] or [DECREASE] to change the displayed setting as required.
Go on to the Label Repeat Length Section.
2111CD-1250 V0 R0.wpd 51
LABEL REPEAT LENGTH
LABEL REPEAT LENGTH
! CAUTION !

ROLLER.
The LABEL REPEAT LENGTH tells the microprocessor the distance from the leading edge of one
label to the leading edge of the next. If the machine feeds one LABEL REPEAT LENGTH without
sensing a label, the microprocessor knows that the label is missing or the label sensor isn't
working properly. If three labels in a row are missing, the microprocessor will stop the machine.
[SELECT] until the display reads, LABEL REPEAT LENGTH = XXXX.
3. Measure the label and gap between labels in inches, multiply by 100 and round your answer
up to the nearest whole number4. (If you are measuring in millimeters, multiply by 4.0).
Example:
For a one inch (25.4mm) label with a 1/8 inch (3.175mm) gap, the LRL = 1.125 inches
(28.575mm).
1.125 inches x 100 = 112.5 (rounded up to 113)5

28.5 mm. x 4.0 = 114
4. Set the LABEL REPEAT LENGTH to the value that you have calculated by pressing the
[INCREASE] or [DECREASE] key.
Go on to the Label Stop Length Section.
4
The actual conversion factor is 3.937. Use of the 4.0 conversion factor is simpler and accurate
enough for most cases. If an imprinter is being utilized, use the 3.937 conversion factor.
5
Round all numbers up to the nearest whole number: 112.9= 113; 112.1 = 113
52
LABEL STOP LENGTH
LABEL STOP LENGTH

After the machine detects a label edge, the label should advance until it completely dispenses off
the peeler bar. The LABEL STOP LENGTH controls the distance that the label moves after the
label sensor detects the label edge. Use the following procedure to properly set the LABEL STOP
LENGTH.
! CAUTION !
EXERCISE CAUTION WHEN CYCLING THE

MACHINE. KEEP HANDS AWAY FROM THE
DRIVE ROLLERS.
Figure 23 Label Stop Length
[SELECT] until the display reads LABEL STOP LENGTH = XXXX.
2. Turn the [FEED] switch ON. Press and release the [JOG] key to advance a label off of the
peeler bar.
2111CD-1250 V0 R0.wpd 53
LABEL STOP LENGTH
3. Check the position of the next label on the peeler bar. The leading edge of the next label
should be 1/32 inch (0.8mm) from the end of the peeler bar, and one label should have
completely dispensed off of the peeler bar. See Figure 23.
4. Press and release [INCREASE] or [DECREASE] to change the LABEL STOP LENGTH .
a. If the label extends too far from the peeler bar, decrease the distance.
b. If the previous label doesn't completely dispense from the peeler bar, increase the
distance.
5. Press and release the [JOG] key until the machine advances the labels. If the label isn't
positioned correctly, repeat step 4.
When the label is correctly positioned, go on to the Peeler Bar Alignment Section.
54
PEELER BAR ALIGNMENT

Although the peeler bar was set at the factory to apply a test label, it may need to be changed for
the particular label that you are applying. Use the following procedure to check the alignment
and dive angle. The dive is used to insure that the trail edge of the label separates from the label
liner. See Figure 25.
! CAUTION !

ROLLER.
Figure 24 Result of Label Dive
2. Rotate the rewind mandrel to dispense a label halfway onto the vacuum grid. A typical paper
label should be at a 5 to 10 degree dive angle to the vacuum grid (Figure 25 A); a stiff or
metallic label should be flat against the vacuum grid. (Figure 25 B).
Insufficient dive will cause the label to become air borne as it dispenses which results in
inaccurate placement on the vacuum grid. (Figure 25 C).
Excessive dive will also cause inaccurate placement of the label on the vacuum grid. (Figure
25 D). If the label is at the correct dive angle, skip this step and go on to the Initial Air
Pressure Settings Section. If the dive angle needs correcting, go on to step 3.
2111CD-1250 V0 R0.wpd 55
3. Use a 1/4 inch hex wrench to loosen the socket head cap screws that secure the peeler bar
bracket to the front of the machine faceplate. The socket head cap screws are located behind
the peeler bar bracket on the back side of the machine faceplate.
a. Position the peeler bar so that it is as close to the vacuum grid as possible, while still
allowing adequate clearance for the label and liner.
b. Raise the tip of the peeler bar so that it is approximately one label thickness above the
bottom surface of the vacuum grid.
c. While maintaining the height of the peeler bar tip relative to the vacuum grid surface,
raise the tail end of the peeler bar to increase the dive angle, or lower it to reduce the dive
angle. Tighten the socket head cap screws.
4. Repeat the test in step 2 to check the dive angle of the label. If it is incorrect, re-adjust using
step 3.
56
Figure 25 Peeler Bar Adjustment
When the label dive angle is correct go on to the Initial Air Pressure Settings.
2111CD-1250 V0 R0.wpd 57
INITIAL AIR PRESSURE SETTINGS
INITIAL AIR PRESSURE SETTINGS
! CAUTION !

ROLLER.
Use the air regulators to set the following air pressures before continuing with the set-up
procedures. Refer to Figure 26.
1. Set the air blast air regulator to 60 P.S.I. (4.0 bar).
2. Set the air assist air regulator to 15 P.S.I. (1.0 bar).
Go on to the Vacuum Set-Up Section.
Figure 26 Air Blast And Air Assist Air Regulators
58
VACUUM SET-UP
VACUUM SET-UP
The vacuum is necessary to hold the label in position on the vacuum grid until the air blast
transfers the label to the product.
In the right hand 2111CD, the vacuum is generated by a fan motor and adjusted by a baffle plate.
In the left hand 2111CD, the vacuum is generated by two fan motors and adjusted by turning the
second fan ON or OFF. Use the appropriate procedure below to set-up the vacuum.
RIGHT HAND APPLICATORS
The vacuum is generated by a fan motor in the enclosure. The vacuum is controlled by the baffle
plate located on the side of the applicator. See Figure 6. The baffle plate is used to restrict the
vacuum fan air flow and thereby adjust the vacuum.
The vacuum may be insufficient to reliably hold small labels on the vacuum grid even with the
baffle plate opened fully. The vacuum can be concentrated around a small label with a grid
mask. The grid mask material is soft plastic that is easily cut by scissors. The grid mask slides
into the slot on the top side of the vacuum grid. See Figure 27.
! CAUTION !

DRIVE ROLLERS.
1. Turn the [FEED] switch ON.
2. Loosen the baffle plate thumbscrew, and position the baffle plate half way open/closed.
Tighten the thumbscrew.
3. Press [JOG] to dispense a label and hold it onto the vacuum grid with your finger.
4. Press your finger against the adhesive of the label on the vacuum grid and pull your finger
away. If the label didn’t resist the pull of your finger, the vacuum is insufficient.
2111CD-1250 V0 R0.wpd 59
VACUUM SET-UP
5. If the vacuum is sufficient, continue with the Air Assist Set-Up Section. If the vacuum is not
sufficient, adjust the baffle plate to the full open position. Repeat step #4.
6. If the vacuum is still insufficient with the baffle plate fully open, a grid mask is needed.
Cut the grid mask to the shape of your label (see Figure 27), and insert it into the grid slot.
After sufficient vacuum is generated, go on to the Air Assist Set-Up Section.
Figure 27 Grid Mask
60
VACUUM SET-UP
LEFT HAND APPLICATORS
The vacuum is generated by two fans in the enclosure. The vacuum is adjustable by the
[HIGH/LOW] fan switch located on the side of the enclosure. See Figure 9. When the [HIGH/LOW]
fan switch is set in the LOW position, only one fan operates, whereas both fans operate when the
fan switch is set to the HIGH position.
The vacuum may be insufficient to reliably hold small labels on the vacuum grid even with the
fan switch set to HIGH. The vacuum can be concentrated around a small label with a grid mask.
The grid mask material is soft plastic that is easily cut by scissors. The grid mask slides into the
slot on the top side of the vacuum grid. See Figure 27.
! CAUTION !

DRIVE ROLLERS.
2. Flip the fan [HIGH/LOW] switch to the LOW position.
3. Press [JOG] to dispense a label and hold it onto the vacuum grid with your finger.
4. Press your finger against the adhesive of the label on the vacuum grid and pull your finger
away. If the label didn't resist the pull of your finger, the vacuum is insufficient.
5. If the vacuum is sufficient, continue with the Air Assist Set-Up Section. If the vacuum is not
sufficient, flip the fan [HIGH/LOW] switch to the HIGH position. Repeat step 4.
6. If the vacuum is still insufficient with the fan switch in the HIGH position, a grid mask is
needed.
Cut the grid mask to the shape of your label (See Figure 27), and insert it into the grid slot.
After sufficient vacuum is generated, go on to the Air Assist Set-Up Section.
2111CD-1250 V0 R0.wpd 61
AIR ASSIST SET-UP
AIR ASSIST SET-UP

The air assist tube directs a stream of air at the label as it leaves the peeler bar to make sure that
the label is captured by the vacuum. The air assist begins to blow when the label stock begins to
advance, and continues to blow until the label is dispensed. The EXTEND AIR ASSIST setting
allows you to control the amount of time (in milliseconds) that the air assist tube continues to
blow air after the label has been dispensed.
! CAUTION !

DRIVE ROLLERS.
[SELECT] until the display reads EXTEND AIR ASSIST = XXXX .
2. Press and release [INCREASE] or [DECREASE] to set the display to the needed setting. The
usual setting is 0001 . Set the display to 0001 when you're first setting up a label page and
adjust it later if necessary.
3. Use the air assist pressure regulator (See Figure 26) to adjust the air assist pressure gauge to
read to between 5 and 10 P.S.I. (.3 and .7 bar). This is a typical pressure setting, but it may
be changed later if more pressure is needed.
4. Make sure that the air hole in the air assist tube is pointing at the beginning of the vacuum
grid parallel to the peeler bar tip at the center of the label. See Figure 28 If the air assist tube
has several holes, adjust the tube so that the holes are evenly spaced across the label.
The air assist tube is secured in a bracket by a 3/32 inch socket head cap screw. Loosen the
socket head cap screw and readjust the air assist tube if necessary.
Press [JOG] to dispense a label. If the vacuum doesn’t capture the label, increase the air assist
pressure and feed another label. Continue until the vacuum captures the label.
Go on to the Vacuum Grid Set-Up Section.
62
AIR ASSIST SET-UP
Figure 28 Air Assist Tube Adjustment
2111CD-1250 V0 R0.wpd 63
VACUUM GRID SET-UP
VACUUM GRID SET-UP
! CAUTION !

DRIVE ROLLERS.
The standard vacuum box contains eighteen flexible tubes (optional oversize contains 36) that
provide the blast of air that applies the label to the product. The pattern of the tubes must be
arranged symmetrically on the label to blow the label accurately onto the product. Use the
following procedure to arrange these tubes correctly.
1. With the [POWER] and [FEED] OFF (F), turn the drive roller by hand to dispense one label;
set it carefully aside.
2. With the [POWER] and [FEED] switches ON (), press and release [JOG] to dispense a label
onto the grid. Then use the other label to tape it in position on the grid. This will show you
the position of the label on the grid as you arrange the air jet tubes.
3. With the [FEED] switch OFF, remove the outer vacuum box and arrange the air jet tubes in a
symmetrical pattern. Most of the tubes should be in the center of the label (see Figure 29 for
examples). Make sure that the tubes are pushed all the way into the grid, but are not sticking
out from the grid face. Insert any unused tubes in the storage block, and replace the vacuum
box.
4. Remove the labels from the grid. Be sure to remove any adhesive from the grid face.
64
VACUUM GRID SET-UP
Figure 29 Air Blast Tube Arrangement for Various Label Shapes
Go on to the Air Blast Section.
2111CD-1250 V0 R0.wpd 65
AIR BLAST SET-UP
AIR BLAST SET-UP

The air blast transfers the label from the vacuum grid to the product. The air blast is the
combination of the AIR BLAST DW ELL and the air blast air pressure.
AIR BLAST DW ELL controls the duration (in milliseconds) of the air blast that applies the label to
the product. Various factors, such as the distance from the vacuum grid to the product, or the
size of the label will affect the length of the blast time that’s needed. To keep the machine cycle
time as short as possible, this time should only be slightly longer than the time needed to apply
the label firmly. Some experimentation will be necessary to find the best AIR BLAST DW ELL and
air pressure combination. If the air blast time seems too long, try increasing the air blast
pressure. An air blast pressure of 60 P.S.I. (4.0 bar) is typical for most labels. Very large or
very heavy labels usually require higher air blast pressure. Very small labels may skip off the
product if the air blast pressure is too high.
Use the following procedure to adjust the AIR BLAST DW ELL and pressure.
! CAUTION !

DRIVE ROLLERS.
[SELECT] until the display reads AIR BLAST DWELL = XXXX .
2. Use the [INCREASE] or [DECREASE] key to set the display to read 0040 (40 milliseconds).
3. Use the air blast air regulator (See Figure 26) to adjust the air jets pressure gauge to read 60
P.S.I. (4.0 bar). This is a typical pressure setting, but it may be changed later if necessary.
4. The Air Blast Set-Up will be tested and adjusted if needed during the Label Stack Test.
Go on to the Web Feed Section.
66
WEB FEED
WEB FEED
WEB FEED is the speed at which the label stock will advance. You can designate speeds between
400 - 1250 inches per minute (10 - 32 meters per minute).
Generally, the slower the web speed:
a) Set-up requirements for the Air Assist and Vacuum are less critical.
b) Short feed stiff labels will dispense more precisely.
c) Some label/adhesive combinations may dispense more reliably.
d) Web stretch is minimized.
e) Rewind slip clutch wear is minimized.
Of course, the Web Speed must be set fast enough to meet the throughput requirement. Multiply
the products per minute required (throughput) by the LABEL REPEAT LENGTH (in inches).
Multiply that number by 1.25 to obtain the approximate WEB FEED required.
Example: 150 products/min X 3.2 inches label repeat length X 1.25 = 600 inches/min.
Set the WEB FEED to 600 inches per minute, or slightly greater.
To set the WEB FEED :
1. Turn OFF the [FEED] switch.
[SELECT] until the display reads WEB FEED = XXXX .
3. Use the [INCREASE] or [DECREASE] key to set the display to read the number that you
estimated.
Go on to the Web Tension Section.
2111CD-1250 V0 R0.wpd 67
WEB TENSION
WEB TENSION
WEB TENSION is selectable to either NORMAL or IMPRNT (imprint). When WEB TENSION is set
to IMPRNT, the stepper motor operates at higher torque to accommodate the added drag of an
imprinter.
[SELECT] until the display reads WEB TENSION: NORMAL/IMPRNT.
3. Use the [INCREASE] or [DECREASE] button to set the display to NORMAL if the machine is not
equipped with an imprinter.
4. Use the [INCREASE] or [DECREASE] button to set the display to IMPRNT if the machine is
equipped with an imprinter.
Go on to the Imprinter On/Off Section.
68
IMPRINTER ON/OFF
IMPRINTER ON/OFF
The hot stamp imprinter is used to add a date code, batch code, or other information to the labels
before application to the product. The imprint occurs after the end of label feed and must be
completed before the next label feed begins.
[SELECT] until the display reads IMPRINTER: ON/OFF .
3. Use the [INCREASE] or [DECREASE] button to set the display to OFF if the machine does not
have an imprinter. Use the [INCREASE] or [DECREASE] button to set the display to ON if the
machine has an imprinter.
NOTE: If IMPRINTER: ON is selected, WEB TENSION must be set to

IMPRNT. Refer to the Web Tension Section.
Go on to the Imprint Dwell Section if IMPRINTER: ON was selected. Otherwise, go on to the

Label Stack Test Section.
2111CD-1250 V0 R0.wpd 69
IMPRINT DWELL
IMPRINT DWELL
Disregard this section if IMPRINTER: OFF is selected. Continue with the Label Stack Test
Section.
If IMPRINTER: ON is selected, refer to the Options Section of the manual for instructions.
70
LABEL STACK TEST
LABEL STACK TEST

Now you’re ready to test the applicator set-up. This is done by applying several labels to one
product. If the labels are applied one on top of the other in a stack (i.e. like a deck of cards), then
the applicator set-up is correct for that label.
Figure 30 Label Stack Adjustment Flow Chart
2111CD-1250 V0 R0.wpd 71
LABEL STACK TEST
! CAUTION !

DRIVE ROLLERS.
1. Position a product in front of the vacuum grid.
2. Turn the [POWER] and [FEED] switches ON ().
3. Press [JOG] to apply several labels onto one product. If the labels are stacked one on top of
the other, you have correctly set-up the air blast. Go on the Product Detector Set-Up section.
If the variation isn't within the tolerances that you require, use the following instructions to
help you find and correct the problem.
4. CHECK THE POSITION OF THE LABEL ON THE VACUUM GRID
Each label must be dispensed to exactly the same position on the vacuum grid. If the position
is different each time, go to step 5. If it is the same, go to step 11.
5. CHECK LABEL STOP VARIATION
Press [JOG] several times and compare the stop positions of each label on the peeler bar. If
all the labels stop within 1/32 inch (0.8mm) of each other, the label sensitivity is correctly set.
Go on to step 6. If the stop position variation is more than 1/32 inch (0.8mm), repeat the
label alignment and label sensitivity adjustments and return to step 3.
6. CHECK LABEL STOP LENGTH
Press [JOG] to dispense a label. Check that the leading edge of the next label to dispense is
1/32 inch (0.8mm) from the end of the peeler bar. If the LABEL STOP LENGTH is adequate,
go to step 7. If the next label edge is greater than 1/32 inch (0.8mm) from the end of the
peeler bar, increase the LABEL STOP LENGTH . If the next label edge is less than 1/32 inch
(0.8mm) from the end of the peeler bar, decrease the LABEL STOP LENGTH . When the LABEL
STOP LENGTH is corrected, go back to step 3.
7. CHECK VACUUM GRID SURFACE
Make sure that the air jet tubes do not protrude from the grid face. Replace the air jets tubes
if necessary. Make sure that the surface of the vacuum grid is clean and free from adhesive.
If the vacuum grid is clean, go on to step 8. If it is not, clean with alcohol and go back to step
3.
72
LABEL STACK TEST
8. CHECK VACUUM
a. Press [JOG] to dispense a label. Watch the label as it slides onto the vacuum grid. If the
label buckles, the vacuum is too strong -- decrease the amount of vacuum. For right hand
machines, partially or fully close the baffle plate. For left hand machines, set the vacuum
switch to LOW.
b. Press [JOG] to dispense a label. If the label falls off or slides forward after leaving the
peeler bar, the vacuum isn't strong enough -- increase the amount of vacuum, and/or
insert a grid mask into the vacuum grid. For right hand machines, fully open the baffle
plate. For left hand machines, set the vacuum switch to HIGH.
c. If the vacuum is correct, go on to step 8. If it is incorrect, adjust it and go back to step 3.
NOTE: A good test for vacuum strength is to press your finger against the
adhesive of a label that has been dispensed onto the vacuum grid
and then pull your finger away. If the label doesn't resist the pull
of your finger, the vacuum strength is not sufficient.
9. CHECK AIR ASSIST
a. Examine the position of the air assist tube to make sure that it is parallel to the tip of the
peeler bar and that the air hole(s) is aimed at the center of the label (or evenly spaced).
Correct if necessary.
b. Press [JOG] to advance a label. If the label is sliding on the vacuum grid after it has been
completely dispensed, decrease the air assist pressure. If the tail edge of the label isn't flat
against the vacuum grid, increase the air assist pressure. If the air assist is correct, go on
to step 10, if it is not, correct it and go back to step 3.
10. CHECK FOR ADHESIVE STRINGS
a. Turn the [FEED] switch OFF. Turn the drive roller by hand to dispense a label.
b. If the label doesn't dispense easily, but follows the liner around the peeler bar, the label is
being held to the liner by adhesive "Strings." If the label is dispensing properly, go back
to step 3 and re-check the other potential problem areas. If there are adhesive strings, go
to step c (below).
c. Adjust the angle of the air assist tube so that the air hole is angled at the end of the peeler
bar rather than parallel to it (see Figure 31). You may also need to increase the air assist
pressure.
2111CD-1250 V0 R0.wpd 73
LABEL STACK TEST
If the label still feeds onto the grid incorrectly, check with the label manufacturer regarding
the type of label you're using. Replace the label roll and try again.
Figure 31 Air assist tube adjustment to correct adhesive strings
11. CHECK WEB FEED
Labels that are flimsy or have a short feed length may need to advance at a slower speed. If
the labels are wrinkling or folding as they feed onto the vacuum grid, you may need to enter a
lower value for WEB FEED . If you do lower the value for WEB FEED , you may need to either
slow the conveyor or increase the minimum product repeat length so that the machine can
still keep up with the product rate.
12. CHECK VACUUM GRID TO PRODUCT DISTANCE
The product should pass as close to the vacuum grid as possible without touching the peeler
bar or any other part of the machine. Adjust if necessary and go back to step 3.
13. CHECK AIR BLAST DWELL AND AIR BLAST AIR PRESSURE
If all other adjustments are correct, the label stack will be attained by adjusting the Air Blast
Air Pressure or the AIR BLAST DW ELL . Make sure that the AIR BLAST DW ELL is long enough
to firmly apply the label. Larger labels require a longer AIR BLAST DW ELL time and higher
air blast pressure. The longer the time, the slower the machine will operate. Shorter AIR
BLAST DW ELL times require higher Air Blast pressure. Too high Air Blast pressure will
cause the label to skid onto the product.
74
LABEL STACK TEST
Adjust the Air Blast Air Pressure to firmly apply the label. Some adjustment to the AIR
BLAST DW ELL may also be necessary. However, longer AIR BLAST DW ELL times will not aid
in applying the label if the moving product has moved past the point of label application.
14. CHECK AIR JET PATTERN
Look to see if any area of the label stack is higher than the surrounding area. If it is, then the
label isn't being applied uniformly. Re-arrange the air blast jet tube pattern and go back to
step 3. If the stack seems to lean to one side, the pattern isn't symmetrical. Re-arrange the air
blast jet tube pattern and go back to step 3.
NOTE: If equipped with dual manifolds (oversize option), make sure that
the valve is set to supply air to both manifolds.
When an adequate label stack is achieved, turn the [FEED] switch OFF, and go on to the Product
Set-Up Section.
2111CD-1250 V0 R0.wpd 75
76
PRODUCT SET-UP
This section of the manual explains how to adjust the machine for each type of product that you
want to label. Because all of the adjustments affect each other, it is very important to do the
steps that are listed in this section in the order that they are given. If you're unfamiliar with how
to move from one microprocessor display to the next, the Microprocessor Menu Map in on page
42 may be helpful to you.
! CAUTION !

ROLLER.
2111CD-1250 V0 R0.wpd 77
POSITIONING THE APPLICATOR
POSITIONING THE APPLICATOR
! CAUTION !

ROLLER.
The product must be presented to the applicator in a repeatable manner in order to attain label
placement accuracy. Adjust the conveying devices as needed to present the product to the
applicator reliably.
The applicator must be positioned so that the vacuum grid is about 5/8 inch (16mm) from the
product when it is being labeled. Make sure that all machine parts clear obstacles in the area.
See Figure 32.
Go on to the Detector Type Section.
Figure 32 Applicator/Product Position (Right Hand

Applicator Shown)
78
DETECTOR TYPE: BEAM/RETRO
DETECTOR TYPE: BEAM/RETRO
! CAUTION !

ROLLER.
Label-Aire supplies 2111CD machines with a reflected beam sensor, part number 7600005-802.
This type of detector works well under most circumstances. The instructions below are written
for the 7600005-802 product detector.
This function allows you to tell the microprocessor which type of detector you are using.
1. From the PRODUCT DETECTOR SET-UP section of the microprocessor menu, press and
release [SELECT] until you reach the DETECTOR TYPE display.
2. Press and release [INCREASE] or [DECREASE] to change the detector type display. Set the
display to read BEAM .
Go on to the Product Detect Edge: Lead/Trail Section.
2111CD-1250 V0 R0.wpd 79
PROD UCT D ETECT EDGE : LEAD /TRAIL
PRODUCT DETECT EDGE:

LEAD/TRAIL
This function allows you to tell the microprocessor which edge of the product you want it to
detect.
It is more practical to mount the product detector and its reflector before adjusting the product
detector sensitivity. However, the product detector and associated hardware may need to be re-
located when actual products are being labeled.
! CAUTION !

ROLLER.
1. With the [POWER] ON () and

the [FEED] and conveyor OFF,
align the product with the
applicator, so that the label
will be applied in the correct
position.
2. Position the product detector

so that it is even with (or
slightly upstream from) the
leading edge of the product (or
the trailing edge if you set the
product edge detection to
TRA IL ). See Figure 33.
Remove the product.
It is usually best to set the Figure 33 Product Detector Position

detector to find the leading
edge unless the physical situation prevents it, or the product has an irregular shaped leading
edge.
release [SELECT] until you reach the PRODUCT DETECT EDGE display.
80
PROD UCT D ETECT EDGE : LEAD /TRAIL
4. Press and release [INCREASE] or [DECREASE] to change the LEAD /TRA IL display to LEAD for
leading edge detection or TRA IL for trailing edge detection.
Go on to the Align Product Sensor Section.
2111CD-1250 V0 R0.wpd 81
PRODUCT DETECTOR SET-UP
! CAUTION !

ROLLER.
The following instructions are for the Label-Aire standard product detector P/N: 7600005-802.
Follow the manufacturer’s instructions for set-up if another model product detector is used.
There are two versions of the 7600005-802 product detector. One is manufactured for Label-
Aire by Banner Engineering, and the other by Allen Bradley. The Banner Engineering detector is
yellow in color, and the Allen Bradley is black in color. Follow the appropriate instructions
below.
ALLEN BRADLEY THROUGH BEAM P/N 7600005-802 (BLACK)
1. With the [POWER] switch ON, turn OFF the [FEED] switch.
2. Connect the product detector to the Product Detector connector.
3. The rear cover window on the detector must be opened before any adjustments can be made.
See Figure 34. Press the flexible retaining clip against the cable to open the window.
4. Gently slide the L/D Operate switch on the back of the detector to L (towards the retaining
clip) for Light Operation.
5. Align the product detector with the reflector. The yellow light on the rear of the detector will
indicate that the detector and reflector are in alignment. Secure in position.
6. If the orange indicator is also lit, use a 1/16 inch flat blade screwdriver to turn the sensitivity
adjustment screw counterclockwise until the orange indicator goes out.
82
7. Use the screwdriver to turn the

sensitivity adjustment screw
clockwise until the orange
indicator just goes on.
8. Place a product between the

product detector and the
reflector. The orange indicator
and the yellow light will go
out, and the green indicator
will light. Remove the
product.
9. Snap the window cover closed

on the product detector.
Go on to the Product Sensitivity

Set-Up Section.
Figure 34 Through Beam Product Detector
BANNER THROUGH BEAM P/N 7600005-802 (YELLOW)
1. With the [POWER] switch ON, turn OFF the [FEED] switch.
2. Connect the product detector to the Product Detector connector.
3. Remove the back cover of the product detector. See Figure 35.
4. Gently turn the Output Select screw on the back of the product detector completely clockwise
(L.O.)
5. Align the product detector with the reflector. The better the alignment, the faster the LED
will flash. Secure the product detector and reflector in position.
6. Place a product between the product detector and the reflector. The LED indicator will go
out.
7. Turn the Gain control clockwise until the LED turns back on (or until fully clockwise).
8. Turn the gain control two turns counterclockwise.
2111CD-1250 V0 R0.wpd 83
9. Remove the product. Replace the back

cover on the product detector.
Go on to the Product Sensitivity Set-up

Section.
Figure 35 Reflected Beam Product Detector
84
PRODUCT SENSITIVITY SET-UP
NOTE: When the microprocessor applicator controls were introduced,

Label-Aire used a light and photocell (7460800, 7460900) for the
product detector. It was necessary for the microprocessor to
interpret the voltages produced by the blocked/unblocked
condition of the photocell to establish the detection threshold.
The microprocessor items ALIGN PRODUCT DETECTOR , PMETER
= rrr, and PRODUCT SENS. OK/NOT OK were used to align the
product detector and to set-up the threshold sensitivity.
When using the 7600005-802 and similar self contained product

detectors, the microprocessor must be set to INPUT SET FOR SWITCH
to monitor the ON/OFF detection state of the self contained product
detector. All detector sensitivity is adjusted on the self contained
product detector.
When returning to the PRODUCT SENS display after the product

detector is set for switch operation, the display will read PRODUCT
SENS. NOT OK. This is the correct setting for a self contained product
detector like the 7600005-802. What the display message means is
that the sensitivity is not set for the original light and photocell
product detector (7460800, 7460900).
The standard Label-Aire product detector provides a switch output. This means that the detector
sends the microprocessor either an ON or OFF signal, and does not give a range of voltages that
the microprocessor needs to interpret. This microprocessor function allows you to set the
machine to receive a switch input.
! CAUTION !

ROLLER.
2111CD-1250 V0 R0.wpd 85
release [SELECT] until you reach the PRODUCT SENS. OK/NOT OK display.
3. Position a product on the conveyor so that the detector isn't receiving any light.
4. Press and release the [DECREASE] key; in two seconds the display will read NOT OK.
5. Press and release the [INCREASE] key. The display will read INPUT SET FOR SWITCH .
NOTE: When you return to this menu item, it will read PRODUCT SENS.
NOT OK. Don't worry when you see this message, the function is
still correct. This only means that the microprocessor is set to
monitor the ON/OFF condition of the product detector, and not
set to interpret a range of voltages.
The detector sensitivity is now set. Go on to the Product Detected Section.
86
PRODUCT DETECTED: YES/NO

This function allows you to test whether the machine is sensing products properly.
! CAUTION !

ROLLER.
release [SELECT] until you reach the PRODUCT DETECTED: YES/NO display.
2. Place a product in the detector beam; the display should read YES.
3. Move the product out of the detector

beam; the display should read NO. If
the display reads NO when it should
be detecting a product and YES when
it should not, it may mean that the
product DETECTOR TYPE function is
set for RETRO instead of BEAM .
Figure 36 Alternative Alignment for Reflective

Products.
2111CD-1250 V0 R0.wpd 87
NOTE: If the display doesn't change from YES to NO , go back to the

Detector Type Section and re-set all the product detector
functions. If the product that you are detecting is highly
reflective, light may be bouncing off the product and giving the
detector false readings. If this is happening, mount the detector at
a ten-degree angle to the product and re-align the reflector. This
will cause any extraneous light to be reflected away from the
detector. See Figure 36.
Go on to the Label Placement Section.
88
LABEL PLACEMENT
LABEL PLACEMENT
This function allows you to instruct the machine to provide a delay between the moment of
product detection and the actual time at which the label is applied. Use this function when the
position of the product detector doesn't produce the label placement that you require.
NOTE: The longer the LABEL PLACEMENT delay, the slower and less
accurately the applicator will apply labels. Try to keep this value
to a minimum by adjusting the position of the product detector.
! CAUTION !

DRIVE ROLLERS.
1. Set the conveyor to the production speed.
release [SELECT] until you reach the LABEL PLACEMENT = XXXX display. Use the
[DECREASE] key to set the display to its minimum value. Turn the [FEED] switch ON.
3. With a label waiting on the vacuum grid, send a product down the conveyor and look at the
label that is applied. If the label is applied late, reposition the detector. If the label is applied
too soon, either reposition the product detector, or use the LABEL PLACEMENT function to
produce a slight delay. See Figure 37.
4. If necessary, use the [INCREASE] and [DECREASE] keys to set the LABEL PLACEMENT to apply
the label correctly to the product.
Turn the [FEED] switch OFF and go on to the Detector Lockout Section
2111CD-1250 V0 R0.wpd 89
LABEL PLACEMENT
Figure 37 Desired Label Placement
90
DETECTOR LOCKOUT
DETECTOR LOCKOUT
This function allows you to set a time during which the microprocessor will ignore any detection
signals from the product detector. Use this function when the product detector is generating false
detection signals and the applicator cycles more than once per product. This may happen if a
shiny product is reflecting light back to the detector. Use this function only when detecting the
leading edge of the product. Set this value to 1 if you're not using it.
1. From the PRODUCT DETECTOR SET-UP portion of the microprocessor menu, press and
release [SELECT] until the display reads DETECTOR LOCKOUT = XXXX.
2. Press and release [INCREASE] or [DECREASE] to enter a low value (i.e., 10) for DETECTOR
LOCKOUT .
! CAUTION !

DRIVE ROLLERS.
3. Try running products at this low value. If the false detections are not eliminated, increase the
value for DETECTOR LOCKOUT and try again. Continue to slowly increase the setting until
the false detections are eliminated.
NOTE: If the value for DETECTOR LOCKOUT is too short, it may cause
two detections from the same product. If the value for
DETECTOR LOCKOUT is too long, it may cause inaccurate
applications or unlabeled products. Remember that any change in
conveyor speed will require a corresponding change in
DETECTOR LOCKOUT .
The Product Detector functions have now been set. Go on to the Test Run Section.
2111CD-1250 V0 R0.wpd 91
TEST RUN
TEST RUN
After all adjustments have been made, a test run should be performed to test the set-up in a
dynamic mode.
! CAUTION !

DRIVE ROLLERS.
2. Turn the conveyor ON and apply labels to products.
3. Observe the label registration on the products. Make any adjustments required.
4. After the machine set-up is verified, turn the [FEED] switch OFF.
Go on to the Set-Up Record Section.
92
SET-UP RECORD
NOTE: If this machine is supplied with any optional equipment, refer to

the Options section of the manual before proceeding with
documentation.
Documentation is an important step that many people overlook. Complete documentation will
help you to make rapid and accurate change-overs. This manual provides a form that allows you
to record all of the machine settings for each label. Although the microprocessor will keep up to
eight label pages in its memory, it is a good idea to have a written record of all of the settings.
This will enable you to quickly reset a label page if there are more than eight labels that you use,
and will provide a back-up in the event that a label page is accidentally altered.
! CAUTION !

ROLLER.
1. Make sure that the current microprocessor settings consistently apply the label accurately on
the product.
2. Place one label in the space provided.
3. Fill in the date, name of the person who set up the applicator, and the product to be labeled.
4. Record the air assist and air blast air pressures in the space provided.
5. Measure and record the distance from the vacuum grid to the product, the vacuum grid to
product detector, the conveyor speed, and products per minute.
6. Make sure the [FEED] switch is OFF.
[SELECT] to access each display. Write the information on the form.
8. From the PRODUCT DETECTOR SET-UP portion of the microprocessor menu, press and
release [SELECT] to access each display. Write the information on the form.
2111CD-1250 V0 R0.wpd 93
SET-UP RECORD
9. If so equipped, from the VELOCITY COMP SET-UP portion of the microprocessor menu, press
and release [SELECT] to access each display. Write the information on the form.
10. Include any comments or observations that might help you or someone else set up the
machine (i.e., product orientation instructions, peeler bar or air assist tube alignment,
etcetera). The applicator is now completely set up, documented, and ready for use.
94
SET-UP RECORD SHEET
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
AIR PRESSURE SETTINGS
Air Assist P.S.I.
Air Blast P.S.I.
Imprinter P.S.I. PLACE LABEL HERE
OTHER SETTINGS
OR ON BACK OF PAGE L
Grid to Product In.
P. Detec tor to Grid In.
Conveyor Speed Ft./Min.
Produc ts per Min
MICROPROCESSOR FUNCTION SETTINGS
Function Setting Function Setting
APPLICATOR SET-UP PRODUCT DETECTOR SET-UP
Label Detect Edge Lead Trail Detector Type Beam Retro
Label Re peat Leng th In./100 Product Detect Edge Lead Trail

Label Sto p Length In./100 Label Placement Millisec./10
Extend Air Assist Millisec. Detector Lockout Millisec.
Air Blast D well Millisec.
W e b Feed [IP M ] In./Min. RATE COMPENSATION SET-UP
Imprinter ON OFF Rate Comp Mode ON OFF

Imprint D well Millisec. Product Distance
Compensation
COM MEN TS:
* Additional Label Page Set-Up Record Sheets are located in Appendix B.
2111CD-1250 V0 R0.wpd 95
SET-UP RECORD SHEET
96
OPTIONAL EQUIPMENT
The following pages contain the instructions for the set-up and operation of the optional
equipment available on this machine.
2111CD-1250 V0 R0.wpd 97
ALARMS
ALARMS
Your machine may be equipped to provide an alarm output whenever it detects one of the
following alarm conditions: Web Break/No Labels Found, Low Label Supply, and Machine
Overcycle. The Low Label alarm occurs when the label supply drops below a predetermined
level. The Web Break alarm occurs when label sensor does not detect three consecutive labels.
This could be caused by a web break, the exhaustion of the label supply, the loss of label
detection, or other problems. The Machine Overcycle alarm occurs when the applicator cannot
keep up with the production rate and misses a product.
SET-UP
LOW LABEL DETECTOR
The low label detector is a photoelectric sensor which triggers the alarm light when the supply of
labels is almost exhausted. Use the following procedure to check the function of the Low Label
Detector.
! CAUTION !

DRIVE ROLLERS.
1. Set the [FEED] switch ON.
NOTE: The alarm light will not function with the [FEED] switch in the
OFF position.
2. Push the dancer arm to release the unwind brake and rotate the unwind roll of labels until the
slot in the inner unwind disk is directly in front of the low label detector.
3. Remove the outer unwind disk and slide the full roll of labels away from the inner unwind
disk.
98
ALARMS
4. If the low label alarm detector sensitivity is properly set, the alarm light will activate.
5. If the alarm light is functioning, replace the labels on the unwind and go on to the Low Label
Alarm Trigger Point.
If the alarm light is not functioning properly, go on to the Low Label Sensitivity Adjustment
Section.
LOW LABEL ALARM TRIGGER POINT
! CAUTION !

ROLLER.
Use the following procedure to adjust

the amount of label supply remaining on
the unwind roll when the alarm light
activates.
1. Set the [FEED] switch OFF.
2. Push the dancer arm to release the

unwind brake and rotate the unwind
roll of labels until the slot in the
inner unwind disk is directly in front
of the low label detector. Notice the
red spot on the label supply. The red
spot is generated by the detector and
is the alarm trigger point.
3. Use a 9/64 inch hex head wrench to Figure 38 Low Label Alarm Adjustment
loosen the low label detector’s
adjustment screws. See Figure 38.
4. Decide how much label supply should remain when the low label alarm is triggered. Slide
the detector to put the red spot at the desired trigger point. Tighten the adjustment screws.
2111CD-1250 V0 R0.wpd 99
ALARMS
LOW LABEL DETECTORS
There are two versions of the low label detector. One is manufactured for Label-Aire by Allen
Bradley, and the other by Banner Engineering. The Allen Bradley detector is black in color, and
the Banner Engineering detector is yellow in color. Follow the appropriate instructions.
ALLEN BRADLEY LOW LABEL DETECTOR P/N 9009308 (BLACK)
The low label detector’s sensitivity must be set so that:
a. The green LED on the back of the detector lights when the detector is blocked by the label
roll or by the unwind disk, and
b. The yellow LED on the back of the detector lights when it is not blocked by the label roll, or
by the unwind disk.
! CAUTION !

DRIVE ROLLERS.
2. Push the dancer arm to release the unwind brake and rotate the unwind roll of labels until the
slot in the inner unwind disk is directly in front of the low label detector.
3. The rear cover window on the detector must be opened before any adjustments can be made.
See Figure 39. Press the flexible retaining clip against the cable to open the window.
4. Gently slide the L/D Operate switch on the back of the detector to D (away from the retaining
clip) for Dark Operation.
5. Use a 3/32 inch hex head wrench to loosen the detector. Slide the detector in or out until the
red spot is sharply focused on the label stock. Secure in position. The green light on the rear
of the detector will light.
100
ALARMS
6. If the orange indicator is also lit, use a

1/16 inch flat blade screwdriver to turn
the sensitivity adjustment screw
counterclockwise until the orange
indicator goes out.
7. Use the screwdriver to turn the sensitivity

adjustment screw clockwise until the
orange indicator just goes on.
8. Rotate the unwind disk slightly so that the

red spot is directed onto the unwind disk.
The detector's green LED must remain
ON. Adjust the sensitivity if necessary so
that the green LED on the rear of the
detector remains ON when the unwind
disk or the label roll is in front of the
detector.
9. Rotate the unwind disk slightly so that the Figure 39 Low Label Detector
red spot is directed onto the label roll.
Remove the outer unwind disk and move
the label roll away from the low label detector. The green LED on the rear of the detector
must go out and the yellow LED will light. Adjust the gain adjustment if necessary and
repeat this procedure.
10. Snap the window cover closed on the detector.
11. Perform the Low Label Alarm Trigger Point procedure.
B A N NE R L OW L AB EL D E TEC T OR P/N 9009219 (YE LLOW )
The low label detector’s sensitivity must be set so that:
a. The red LED on the back of the detector lights when the detector is blocked by the label roll
or by the unwind disk, and
b. The red LED on the back of the detector goes dark when it is not blocked by the label roll, or
by the unwind disk.
2111CD-1250 V0 R0.wpd 101

ALARMS
! CAUTION !

DRIVE ROLLERS.
2. Push the dancer arm to release the unwind

brake and rotate the unwind roll of labels
until the slot in the inner unwind disk is
directly in front of the low label detector.
3. Use a 3/32 inch flat blade screwdriver to

remove the back cover from the low label
detector.
4. Locate the output select switch on the rear

of the low label detector. See Figure 40.
Use a 3/32 inch flat blade screwdriver to
set the detector to Dark Operate (D.O.) by
gently turning the switch fully
counterclockwise.
5. Locate the gain adjustment screw on the

rear of the detector. Use the 3/32 inch flat
blade screwdriver to adjust the gain so
that the red spot is focused sharply on the
label roll. The red LED on the rear of the
detector will flash quickly. Figure 40 Low Label Detector
6. Rotate the unwind disk slightly so that the red spot is directed onto the unwind disk. The
detector’s red LED must remain ON. Adjust the sensitivity if necessary so that the red LED
on the rear of the detector remains on when the unwind disk or the label roll is in front of the
detector.
7. Rotate the unwind disk slightly so that the red spot is directed onto the label roll. Remove
the outer unwind disk and move the label roll away from the low label detector. The red
LED on the rear of the detector must go out. Adjust the gain adjustment if necessary and
repeat this procedure.
8. Perform the Low Label Alarm Trigger Point procedure.
102
ALARMS
WEB BREAK
The only set-up involved for the web break detector is to set the LABEL REPEAT LENGTH
correctly, according to the Set-Up Procedures in the Operator's Manual. Make sure that the
LABEL REPEAT LENGTH is neither too long nor too short. Too much LABEL REPEAT LENGTH
will trigger the alarm long after a web break occurs. Too little LABEL REPEAT LENGTH may
interfere with the LABEL STOP LENGTH function. Refer to the Label Repeat Length Section of
the manual.
MACHINE OVERCYCLE
The only set-up required for the machine overcycle detector is to correctly set-up the applicator
relative to the production rate. The applicator must have enough time to complete a machine
cycle before the product detector detects the next product. Usually a machine overcycle
condition occurs when the products are too closely spaced.
OPERATION
When the applicator is correctly set-up, it will operate normally until the microprocessor detects
a fault condition.
LOW LABEL
The low label alarm occurs when the label supply drops below a pre-determined level.
1. When a low label condition activates the yellow alarm light, the alarm can only be stopped by
turning OFF the [FEED] switch.
2. After you correct the alarm condition, re-set the alarm by turning the [FEED] switch ON.
A low label alarm will not stop the applicator from labeling. However, the labeling function will
shut down when the supply of labels is exhausted.
WEB BREAK
The web break alarm occurs when the label sensor does not detect three (3) consecutive labels.
When the microprocessor detects this fault condition, it will shut down the applicator's labeling
function, exhibit the NO LABELS FOUND message on the display and activate the web break blue
alarm light.
1. To turn off the alarm light, turn OFF the [FEED] switch.
2. After you correct the fault condition, turn the [FEED] switch ON to continue normal
operation. The alarm is re-set when you turn ON the [FEED] switch.
2111CD-1250 V0 R0.wpd 103

ALARMS
MACHINE OVERCYCLE
The overcycle alarm occurs when the applicator is unable to keep up with the product rate. If the
yellow alarm light activates when label supply is above the low label threshold, an overcycle
condition has occurred. Check downstream of the applicator for a product without a label. An
overcycle condition will not shut down the applicator.
To stop the yellow alarm light, press and release the [HOME] key. If the yellow light will not
stop, either another machine overcycle has occurred, or the low label alarm is activated.
104
VELOCITY COMPENSATION
A SIMPLE EXPLANATION
In order to describe Velocity Compensation (V.C.), we

use an analogy to explain it’s function before we go
through the attributes and set-up procedures.
You are on an ocean cruise. In order to pass some time

you decide to try some skeet shooting.
After a few total misses, you figure out how far to “lead”
the clay pigeon before you pull the trigger. See Figure
Figure 41 Slow Launcher Speed
41.
The skeet launcher operator, seeing that you have been hitting every clay pigeon, increases the
launch speed.
Again, after a few total misses, you figure out how far to
“lead” the clay pigeons before you pull the trigger. See
Figure 42.
You intuitively figured out how long it takes for the

shotgun blast to reach the target area. And then, by
practice, how much to lead the target dependent on the
target’s speed.
Figure 42 Fast Launcher Speed
2111CD-1250 V0 R0.wpd 105

That is what VELOCITY COMP is all about, except that you must teach the microprocessor:
1. How much time it takes to get the label to the product (the “Throw Time” of the label)
2. How far (PRODUCT DISTANCE) and how fast the product is moving.
3. How much to lead the product (COMPENSATION) at a particular speed.
Basically, VELOCITY COMP figures out how much to “lead” the product dependent on the speed
of the product (COMPENSATION).
VELOCITY COMP GENERAL INFORMATION
POSITIONING THE PRODUCT DETECTOR
The product detector must be placed so that the previous label has been applied before the next
product is detected.
THE ENCODER
The encoder reports distance traveled information to the microprocessor. The microprocessor
derives the speed of the product from the number and rate of the encoder pulses received.
Each encoder pulse is equivalent to 1/100th of an inch. The encoder is equipped with a five inch
circumference rubber encoder wheel. Each revolution of the encoder shaft is equivalent to five
inches of product travel (500 encoder pulses). All Velocity Comp calculations are based on this
relationship.
When mounting the encoder, it is imperative to maintain this relationship: Five inches of product
travel equals one revolution of the encoder shaft (wheel). In installations where the Label-Aire
encoder wheel cannot be used, another drive arrangement is useable only if the five inch of
product travel per encoder shaft revolution is maintained.
If the product travels less than five inches per encoder shaft revolution, each unit of
compensation will be smaller thereby reducing the range of compensation available.
If the product travels more than five inches per encoder shaft revolution, each unit of
compensation will be larger thereby reducing the accuracy of the compensation available.
PRODUCT DISTANCE
PRODUCT DISTANCE is the distance the product travels from the point of detection to the point of
label application. The CPU uses the time that the product travels the PRODUCT DISTANCE to
calculate when to begin to apply the label.
106
If the conveyor speed changes rapidly after the calculation is completed i.e. conveyor ramping up
(or down), the label placement may be incorrect. However, the next calculation will note the
change. The label placement will continue to lag slightly as long as the conveyor is accelerating
rapidly. If the conveyor ramp up (or down) is gradual enough, all labels will be applied within ±
1/32 of an inch.
VELOCITY COMP ATTRIBUTES
VC (Original) VC2
Maximum COMPENSATION One Inch Three Inches
Minimum PRODUCT DISTANCE Setting 100 305
Min. Peeler Tip to Product Sensor Distance. 2.05 3.05
U6 PAL (See Figure 43) 7465580 7465597
Figure 43 U6 PAL Requirement
VELOCITY COMP SET-UP
VELOCITY COMP is set-up in two basic methods: For individual products, and for continuous
forms.
The product detector must detect the individual product that will be labeled next. This is very
important due to variation in individual products and product spacing.
Continuous forms can be detected at a convenient location since all the forms are identical
relative to the registration mark.
Press and hold in the [SELECT] key until RATE COMP. ON/OFF is displayed. Use the [INCREASE]
or [DECREASE] key to set RATE COMP. to ON .
Use the appropriate set-up procedure below.
2111CD-1250 V0 R0.wpd 107

INDIVIDUAL PRODUCTS
1. Set-up the applicator according to the set-up procedures. Velocity Comp will not operate
properly if the applicator is not set-up for a label stack.
2. Turn OFF (F) the applicator. Mount the encoder assembly to the conveying device. THE
ENCODER SHAFT MUST MAKE ONE REVOLUTION PER EVERY FIVE INCHES OF
PRODUCT TRAVEL.
NOTE: The encoder wheel must not ride on a chain top conveyor. An
unacceptable error is produced as the encoder wheel runs over the
gaps between the chain links.
3. Connect the encoder cable between the encoder and the applicator.
4. Turn ON () the applicator power switch and read the CPU description. If the display reads
VC , the applicator is equipped with the original Velocity Comp. If the display reads VC2 , the
applicator is equipped with Velocity Comp 2.
For VC For VC2

5. Position the product detector slightly 5. Position the product detector slightly
over two inches away from the peeler bar over three inches away from the peeler
tip. bar tip.
6. Set the PRODUCT DISTANCE to about 6. Set the PRODUCT DISTANCE to about
110 . Set the COMPENSATION to 310 . Set the COMPENSATION to
minimum. minimum.
7. Turn the [FEED] switch ON. Place a product on the conveyor and run the conveyor at a very
slow speed. The applicator will apply a label. If the label misses the product, adjust the
PRODUCT DISTANCE.
8. Run another product at the very slow speed. Repeat until the label is applied somewhere on
the product. Stop the conveyor.
9. Set the conveyor to the production speed. Stop the conveyor.
10. Place a product (the same product if possible) on the conveyor. Start the conveyor and run it
until the product is labeled.
11. Stop the conveyor. Examine the position of the label applied at the production speed. The
label should have been applied late relative to the slow speed label, or applied so late that it
missed the product.
108
Measure the offset. If the offset between the slow and fast product is more than one inch for
the original V.C., or more than three inches for V.C.-2, there is insufficient compensation
available. In this case, the conveyor speed must be reduced.
12. Increase the COMPENSATION and label another product at the slow speed. Stop the
conveyor.
13. Set the conveyor to the production speed. Stop the conveyor.
14. Place a product (the same product if possible) on the conveyor. Start the conveyor and run it
until the product is labeled.
15. Stop the conveyor. Examine the position of the last label applied at production speed relative
to the label applied at the slow speed. The goal is to place the production speed label on top
of the slow speed label.
If the label applied at production speed was applied late, increase the COMPENSATION.
If the label applied at production speed was applied early, decrease the COMPENSATION.
NOTE: Whenever the COMPENSATION is adjusted, both the production

speed label position and the low speed label position are affected.
16. Repeat this process until the lead edge of both labels are applied within ± 1/32 of an inch of
each other somewhere on the product. Ideally, the labels would be applied on top of one
another.
17. At this point, the label is being applied reliably, but at the wrong position on the product.
If the compensated labels are applied late, move the product detector upstream.
If the compensated labels are applied early, increase the PRODUCT DISTANCE setting.
18. Run another product at the production speed. Check the position of the labels on the product.
Repeat until the labels are applied at the correct position on the product.
NOTE: Any change to the Air Blast Dwell, or Air Jets air pressure will
adversely affect the set-up. Do not make any changes to the
applicator after VELOCITY COMP is set-up.
19. Turn the [FEED] switch OFF. Record all settings on the Set-Up Record Sheet.
2111CD-1250 V0 R0.wpd 109

CO NTINUOUS F OR M S
1. Set-up the applicator according to the set-up procedures. Velocity Comp will not operate
properly if the applicator is not set-up for a label stack.
2. Turn OFF (F) the applicator. Mount the encoder assembly to the conveying device. THE
ENCODER SHAFT MUST MAKE ONE REVOLUTION PER EVERY FIVE INCHES OF
PRODUCT TRAVEL.
NOTE: The encoder wheel must not ride on a chain top conveyor. An
unacceptable error is produced as the encoder wheel runs over the
gaps between the chain links.
3. Connect the encoder cable between the encoder and the applicator.
4. Turn ON the applicator Power switch and read the CPU description. If the display reads VC ,
the applicator is equipped with the original Velocity Comp. If the display reads VC2 , the
applicator is equipped with Velocity Comp 2.
For VC For VC2

5. Position the product detector slightly 5. Position the product detector slightly
over two (or a multiple of two) inches over three (or a multiple of three) inches
away from the peeler bar tip. away from the peeler bar tip.
6. Set the PRODUCT DISTANCE to about 6. Set the PRODUCT DISTANCE to about
110 . Set the COMPENSATION to 310 . Set the COMPENSATION to
minimum. minimum.
7. Run the conveyor at a very slow speed. Turn ON the [FEED] switch. The applicator will
apply labels. Turn OFF the [FEED] switch.
8. Stop the conveyor. Note the position of the labels on the forms.
9. Start the conveyor. Set the conveyor to the production speed.
10. Turn the [FEED] switch ON and label several forms. Turn OFF the [FEED] switch.
11. Stop the conveyor. Examine the position of the labels applied at the production speed. The
labels should have been applied late relative to the slow speed label.
110
Measure the offset. If the offset between the slow and fast label is more than one inch for the
original V.C., or more than three inches for V.C.-2, there is insufficient compensation
available. In this case, the conveyor speed must be reduced, the machine cycle time
decreased, or both.
12. Start the conveyor. Set the conveyor to the slow speed. Increase the COMPENSATION
setting. Turn ON the [FEED] switch and label several forms.
13. Turn OFF the [FEED] switch and stop the conveyor. Note the position of the labels on the
forms.
14. Start the conveyor. Set the conveyor to the production speed. Turn ON the [FEED] switch to
label some forms.
15. Turn OFF the [FEED] switch. Stop the conveyor. Examine the position of the labels applied
at production speed relative to the labels applied at the slow speed. The goal is to place the
production speed labels at the same position as the slow speed labels on the forms.
If the labels applied at production speed were applied late, increase the COMPENSATION.
If the labels applied at production speed were applied early, decrease the COMPENSATION.
NOTE: Whenever the COMPENSATION is adjusted, both the production

speed label position and the low speed label position are affected.
16. Repeat this process until the lead edge of both labels are applied within ± 1/32 of an inch of
each other somewhere on the respective forms. Ideally, the labels would be applied at the
same position on each form.
17. At this point, the label is being applied reliably, but at the wrong position on the form.
If the compensated labels are applied late move the product detector upstream.
If the compensated labels are applied early, increase the PRODUCT DISTANCE setting.
18. Apply more labels at the production speed. Check the position of the labels on the forms.
Repeat until the labels are applied at the correct position on the forms.
NOTE: Any change to the Air Blast Dwell, or Air Jets air pressure will
adversely affect the set-up. Do not make any changes to the
applicator after VELOCITY COMP is set-up.
19. Turn the [FEED] switch OFF. Record the settings on the Set-Up Record Sheet.
2111CD-1250 V0 R0.wpd 111

OVERSIZE
OVERSIZE
The purpose of the oversize option is to equip the machine to dispense up to a six inch (152mm)
wide label.
The oversize option includes rollers, an outboard clamping device for the pinch roller, an
outboard supported peeler bar, an additional air jet manifold with shut off valve, and an air blast
air accumulator (reservoir). The manifold shut off valve is used to either supply air to one air jet
manifold or both.
There are no functional differences between the standard four inch (101mm) wide machine and
the six inch (152mm) wide oversize machine.
The only additional set-up required for the oversize option is for the outboard clamping device.
OUTBOARD CLAMPING DEVICE
The purpose of the outboard clamp adjustment is to equalize the pinch roller pressure across the
rubber drive roller.
! CAUTION !

DRIVE ROLLERS.
112
OVERSIZE
Figure 44 Machine Parts Oversize (Right Hand)
2111CD-1250 V0 R0.wpd 113

OVERSIZE
Figure 45 Machine Parts Oversize (Left Hand)
114
OVERSIZE
1. Make sure the threaded stud is securely screwed into the support bracket (a drop of lock-tite
should be used if the stud is loose). See Figure 46.
! CAUTION !

DRIVE ROLLERS.
2. Using a 3/8 inch open end wrench, loosen the jam nut. Rotate the jam nut until it contacts the
thumbscrew on the threaded stud.
3. Using a 3/8 inch open end wrench, loosen the adjusting nut. Rotate the adjusting nut until it
contacts the jam nut. The spring lever is not applying maximum pressure to the pinch roller
shaft.
4. Cycle the machine and observe the label stock tracking. Slowly turn the adjusting nut
(clockwise) on the threaded stud, while cycling the machine. Once the label stock is tracking
properly, use a 3/8 inch open end wrench to hold the adjusting nut in position. Use another
3/8 inch open end wrench to tighten the jam nut.
Figure 46 Outboard Clamp (For Oversize Machines)
2111CD-1250 V0 R0.wpd 115

IMPRINTER
IMPRINTER
The hot stamp imprinter is used to add a date code, batch code, or other information to the labels
before application to the product. The imprint occurs after the end of label feed and must be
completed before the next label feed begins.
The imprinter is pneumatically driven. The imprinter regulator should be set for 60 P.S.I.
(4 bar).
The imprinter heater element is factory set to 350 degrees F. Each 360 degree rotation of the
heater thermostat adjustment screw will adjust the temperature approximately 25 degrees F
(counterclockwise to increase temperature, clockwise to decrease temperature).
THREAD DIAGRAM WITH IMPRINTER
Use these diagrams to load labels when an imprinter is installed.
116
IMPRINTER
Figure 47 Threading Diagram With Imprinter (Right Hand)
Figure 48 Threading Diagram With Imprinter (Left Hand)
2111CD-1250 V0 R0.wpd 117

IMPRINTER
IMPRINTER ON/OFF
[SELECT] until the display reads IMPRINTER ON/OFF.
3. Use the [INCREASE] or [DECREASE] button to set the display to ON if the machine has an
imprinter.
NOTE: If [IMPRINTER: ON] is selected, WEB TENSION must be set to

IMPRNT. Refer to the Web Tension Section.
IMPRINT DWELL
This microprocessor function allows you to control the amount of time that the imprinter is
activated. Imprint quality is affected by a combination of factors, including IMPRINT DW ELL ,
temperature of the heating element, etc. Keep the IMPRINT DW ELL as short as possible, because
the machine cycle can increase if the IMPRINT DW ELL is too long.
[SELECT] until the display reads IMPRINT DWELL = XXXX .
2. Press [INCREASE] if you want the imprinter to remain activated longer. Press [DECREASE] if
you want the IMPRINT DW ELL to be shorter. Adjust as required.
! CAUTION !

DRIVE ROLLERS.
3. To test the IMPRINT DW ELL , turn the [FEED] switch ON and press the [JOG] button to cycle
the machine and evaluate the imprint function. Adjust as needed.
118
IMPRINTER
IMPRINT POSITION ADJUSTMENT
1. Adjust the vertical position of the imprinter so that the label liner is in light contact with the
rubber anvil insert in the imprinter.
2. Adjust the drag block spring so that the label stock is kept taut as it travels through the
imprinter.
3. Adjust the position of the imprint across the label stock by moving the position of the entire
imprinter.
4. Adjust the position of the imprinter along the label stock by moving the registration roller.
5. Adjust the angle of the imprint by using the pivot adjustment.
NOTE: Refer to the imprinter manual for detailed instructions on

imprinter adjustments, imprint quality, and maintenance.
Figure 49 Imprinter
2111CD-1250 V0 R0.wpd 119

IMPRINTER
Figure 50 Imprinter Adjustment Brackets
120
IMPRINTER
LABEL REPEAT LENGTH ADJUSTMENT
The LABEL REPEAT LENGTH is used to set the length of one label and one gap. When an
imprinter is in use, the LABEL REPEAT LENGTH is used to advance the web one LABEL REPEAT
LENGTH each machine cycle. If there is a missing label on the web, the web will only advance
one LABEL REPEAT LENGTH when the missing label passes through the label sensor. This
insures that each label receives an imprint even though a product will not be labeled.
Use this procedure to test and adjust the LABEL REPEAT LENGTH .
1. Remove one label from the label web close to the peeler bar.
3. Use the [JOG] button to cycle the applicator until the “missing label” section of the liner is on
the peeler bar. The web should stop just after dispensing the previous label. Press the [JOG]
button one more time. Check the print registration on the labels that are just past the
imprinter. The imprints should all be within registration.
If an imprint is out of registration, or missing, adjust the LABEL REPEAT LENGTH and repeat
until the label that receives an imprint when the “missing label” is at the label detection point
is correctly imprinted. Refer to the Label Repeat Length Section if necessary.
4. Cycle all mis-printed labels out of the system.
5. Turn the [FEED] switch OFF.
2111CD-1250 V0 R0.wpd 121

LABEL LOADING - OPTIONAL EQUIPMENT
LABEL LOADING - OPTIONAL

EQUIPMENT
If the applicator is equipped with an imprinter only, refer to the Imprinter Option for the label
loading sequence.
If the applicator is equipped with some optional or custom equipment that requires a deviation
from the standard loading sequence, use the diagram on the following page to load labels.
122
REPLACE WITH CUSTOM THREAD DIAGRAM IF REQUIRED.
2111CD-1250 V0 R0.wpd 123

124
APPENDICES
The following appendices contain supplemental information that may be helpful for day to day
operation of the machine.
2111CD-1250 V0 R0.wpd 125

APPENDIX A
APPENDIX A
RE-LOADING LABELS (STANDARD)
! CAUTION !

ROLLER.
This section of the manual explains how to re-load labels through the machine.
1. Set the [FEED] switch to OFF. Twist and remove the outer unwind disk.
2. Remove and discard the empty label core.
3. Slide a roll of labels onto the hub of the inner unwind disk. Make sure that the labels will be
face up as they slide over the peeler bar. Replace the outer disk and twist to lock.
4. Remove and discard all the labels from the first six feet (two meters) of liner.
5. Loosen the label tension spring thumbscrew on the label cell block(s). See Figure 51 and
Figure 52.
6. Thread the web through the machine as shown in Figure 51 or Figure 52.
a. Make sure to thread the label liner between the air assist tube and the peeler bar.
b. If equipped with the “oversize” option, disengage the outboard pinch roller clamp.
c. Depress the detent cam to separate the pinch and drive rollers. This will make it possible
to thread the label liner between the drive roller and pinch roller.
7. Remove the rewind pin from the rewind mandrel. Remove and discard the rewound label
liner.
8. Lay the end of the liner over the rewind pin slot and insert the rewind pin.
9. Turn the rewind mandrel by hand. Check that the inner edge of the label aligns with the inner
edge of the vacuum grid. Adjust the positions of the inner unwind disk and the rewind disk if
necessary.
126
APPENDIX A
10. Re-tighten the label tension spring thumbscrew.
11. Slide the guide collars to within 1/64 inch (0.4mm) of the label liner.
12. Re-engage the pinch and drive rollers (and the outboard pinch roller clamp if so equipped).
13. Turn the [FEED] switch ON to resume normal operation.
2111CD-1250 V0 R0.wpd 127

APPENDIX A
Figure 51 Threading Diagram (Right Hand)
128
APPENDIX A
Figure 52 Threading Diagram (Left Hand)
2111CD-1250 V0 R0.wpd 129

APPENDIX B
APPENDIX B
SET-UP RECORD SHEETS
130
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min

Imprinter ON OFF Rate Comp. Mode ON OFF

Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 131

APPENDIX B
132
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 133

APPENDIX B
134
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 135

APPENDIX B
136
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 137

APPENDIX B
138
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 139

APPENDIX B
140
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 141

APPENDIX B
142
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 143

APPENDIX B
144
APPENDIX B
SET-UP RECORD SHEET
Date
Set Up By
Product Labeled
Air Assist P.S.I.
Air Blast P.S.I.
OTHER SETTINGS
Grid to Product In.
Produc ts per Min


Compensation
COM MEN TS:
2111CD-1250 V0 R0.wpd 145

APPENDIX B
146
MAINTENANCE
This section gives instructions for performing ordinary maintenance and adjustments on the
2111CD applicator. The procedures recommended in the periodic maintenance sections are
detailed in the Adjustments Section.
2111CD-1250 V0 R0.wpd 147

MAINTENANCE
DAILY MAINTENANCE
(EVERY 8 HOURS)
! CAUTION !
DISCONNECT THE POWER FROM THE MACHINE

BEFORE YOU PERFORM THE FOLLOWING
PROCEDURES OR YOU MAY BE INJURED BY THE
MOVING DRIVE BELTS AND PULLEYS, OR
RECEIVE AN ELECT RIC SHOCK.
1. Examine air filter for evidence of excessive water or oil collection. Drain if necessary and
eliminate the source of contamination.
2. Examine vacuum grid, peeler bar and rollers for excessive adhesive build up. Clean if
necessary, using alcohol or other similar solvent.
3. Check generally around the machine for any evidence of loose screws, rollers, fixtures,
fittings, etc. Tighten as necessary.
148
MAINTENANCE
WEEKLY MAINTENANCE
(EVERY 40 HOURS)
! CAUTION !

1. Clean all rollers, remove adhesive and paper dust, using solvent (alcohol or equivalent).
2. Clean peeler bar and vacuum grid.
3. Clean dust from all photoelectric cells and lamps.
4. Examine air supply connections for leakage, correct if necessary.
5. Wipe down the exterior surface of the machine.
2111CD-1250 V0 R0.wpd 149

MAINTENANCE
MONTHLY MAINTENANCE
(EVERY 150 HOURS)
The follo wing proc edure sho uld only be p erformed by a

Qualified Service Technician
! CAUTION !

1. Examine dancer arm tension, adjust if necessary.
2. Examine all roller assemblies for free rotation, excessive play, etc. and correct as necessary.
3. Check the unwind brake strap for wear. Replace if necessary.
4. Replace worn or broken air jet tubes.
5. Perform the procedures listed in the Weekly Maintenance Section.
150
MAINTENANCE
SEMI-ANNUAL MAINTENANCE
(EVERY 1000 HOURS)

! CAUTION !

1. Replace air filter elements, clean filter bowl.
2. Check the trantorques for proper torque (175 lbs-in).
3. Examine the rewind slip clutch disk and o-ring and replace if necessary.
4. Check the motor drive shaft belt tension.
5. Clean the "pull-off" roller shafts. Deposit a small amount of 630-AA Lubriplate white grease
in the grooves of the roller shafts. Re-install the "pull-off" rollers.
6. Clean inside and outside machine enclosure and control pull-out drawer, using an industrial
vacuum cleaner.
NOTE: Using air pressure from the shop air supply to blow off dust, etc.,
can create more problems than it solves. There is a good
possibility that this air will contain water and emulsified oil. If
you must use compressed air, be sure that it is adequately filtered
and regulated to low pressure and remove the electronic module.
7. Perform the procedures listed in the Monthly Maintenance Section.
2111CD-1250 V0 R0.wpd 151

MAINTENANCE
ANNUAL MAINTENANCE
(EVERY 2000 HOURS)

! CAUTION !

1. Examine moving parts for excessive wear. Check the stability of roller mounts, and motor
mounts.
2. Examine timing belts for damage. Replace if necessary.
3. Replace the rewind slip clutch disk and o-ring in the rewind station assembly. Clean all
friction faces.
4. Check the one way clutch on the rewind shaft for correct operation.
5. Examine pulleys for wear. Replace if necessary.
6. Perform the procedures listed in the Semi-Annual Maintenance Section.
152
ADJUSTMENTS
ADJUSTMENTS
DANCER ARM TENSION ADJUSTMENT
! CAUTION !

YOU MAY BE INJURED BY THE MOVING
UNWIND DISK OR DANCER A R M .
Figure 53 shows the standard spring and strap arrangement. If the strap is too loose, the brake
will not stop the unwind disk. If the strap is too tight, the drive roller must pull against the
unwind brake. Use the instructions below to adjust the tension of the strap.
1. Hold the dancer arm in the

retracted position.
2. Use a 1/8 inch hex wrench to

loosen the strap collar set
screw.
3. Adjust the position of the

collar so that the strap is snug
when the dancer arm is
completely retracted. (dancer
roller about 1/4 inch [6mm]
from the unwind disk.)
Tighten the set screw.
Figure 53 Parts Of The Unwind Brake (Right Hand)
4. Make sure that the strap is
correctly wound (see Figure 54).
5. Use a 1/8 inch hex wrench to loosen the set screw that holds the spring retainer onto the
dancer arm shaft.
2111CD-1250 V0 R0.wpd 153

ADJUSTMENTS
Figure 54 Unwind Brake Configuration
154
ADJUSTMENTS
6. Position the spring retainer so that the strap is held snug on the dancer arm shaft, but the
tension releases when the dancer arm is pulled by the label stock. If the tension is too loose,
the unwind will not brake properly and a loop of loose label stock will form. If the tension is
too tight, the drive roller will be forced to pull against the unwind brake-- this will put undue
stress on the drive motor and may cause web breaks, or motor stalls.
Figure 55 Unwind Dancer Arm Position
7. If necessary, position and hold the dancer arm ad indicated in Figure 55. Remove the slack
from the unwind brake band and tighten the lock collar in position.
REWIND SLIP CLUTCH ADJUSTMENT

! CAUTION !

2111CD-1250 V0 R0.wpd 155

ADJUSTMENTS
You may need to adjust the rewind slip clutch if the rewind mandrel is not turning fast enough to
take up the label liner, or if the rewind mandrel torque is such that the liner is breaking. The skip
clutch tension is adjusted by changing the position of the spring tension cap. See Figure 57.
Sometimes it may be necessary to replace the o-ring and slip clutch disk.
Conditions that may warrant adjustment of the rewind slip clutch are:
1. A change in applicator attitude. Example: 1. Reels up.

2. Upright and above.
2. A change in label carrier size. Example: 1. One inch (25mm) web. (narrow)
2. 4-6 inch (101-152mm) web. (wide)
3. A change in the manual speed of the applicator.
NOTE: Depending on the attitude of the machine, you will need to

observe the response of the rewind mandrel from the beginning of
a roll, (no web liner on rewind mandrel), to the end of the roll (a
full web liner roll on the rewind mandrel). As waste builds up on
the rewind mandrel, the weight will play a roll in the way that the
rewind operates. Some further adjustments may still be necessary
to compensate for the change in load from the beginning to the
end of a roll of labels.
As the o-ring and slip clutch disk wear adjustment of the slip clutch may be required.
Follow these instructions to adjust the rewind slip clutch tension.
1. Turn the [POWER] OFF (F).
2. Disconnect the machine A.C. power cord

from the A.C. power.
3. Disconnect the A.C. power cord from the

IEC receptacle on the machine.
4. Use a #1 Phillips screwdriver to remove

the screws from the enclosure cover.
Remove the enclosure cover.

the screw from the end of the rewind
shaft.
Figure 56 Spring Tension Cap Position
156
ADJUSTMENTS
6. Carefully remove the washer P/N 7370941.
7. Remove the spring tension cap P/N 7370936.
8. For LOW tension, (7-8 pounds) place the spring tension cap over the sleeve spring guide with
the counterbore facing IN. See Figure 56.
9. For HIGH tension, (9-10 pounds) place the spring tension cap over the sleeve spring guide
with the counterbore facing OUT. See Figure 56.
10. Carefully re-install the washer and the screw. Tighten the Phillips screw onto the rewind
shaft.
11. Use a #1 Phillips screwdriver to install the enclosure cover.
12. Reconnect the A.C. power cord to the IEC receptacle on the machine.
13. Reconnect the machine A.C. power cord to the A.C. power.
14. Turn the [POWER] ON (). Test the machine and observe the rewind from the beginning of a
new roll of labels, to the end of the roll.
15. Re-adjust if necessary.
2111CD-1250 V0 R0.wpd 157

ADJUSTMENTS
Figure 57 Rewind Slip Clutch
158
ADJUSTMENTS
DRIVE BELT TENSION ADJUSTMENT

! CAUTION !

2. Disconnect the machine A.C. power cord from the A.C. power.
3. Disconnect the A.C. power cord from the IEC receptacle on the machine.
4. Use a #1 Phillips screwdriver to remove the screws from the enclosure cover. Remove the
enclosure cover.
5. Refer to Figure 58. Use a 5/32 inch hex wrench to loosen the motor mount screws, and push
the motor away from the rewind belt until all the slack is removed from the drive timing belt.
Re-tighten the motor mount screws. Now check the tension on the belt. Light finger
pressure against one side of the belt should deflect the belt approximately 1/16 to 1/8 inch
(1.6mm to 3.2mm).
2111CD-1250 V0 R0.wpd 159

ADJUSTMENTS
6. Disengage the nip roller and turn the drive roller by hand. You will feel a light resistance due
to the magnets inside the stepper motor. Make sure that there is no severe catching as you
turn the drive roller.
Do not over-tighten the belt or the drive motor may stall, or overheat and fail. Do not allow
the belts to become too loose or the label stop length will be erratic, and the belt, bearing and
shaft will wear out quickly.
7. Use a #1 Phillips
screwdriver to install
the enclosure cover.
8. Reconnect the A.C.

power cord to the IEC
receptacle on the
machine.
9. Reconnect the machine

A.C. power cord to the
A.C. power.
Figure 58 Drive Belt Tension Adjustment
160
ADJUSTMENTS
PINCH ROLLER COMPRESSION ADJUSTMENT

RIGHT HAND MACHINES
! CAUTION !

2. Disconnect the machine A.C. power cord from the A.C. power.
3. Disconnect the A.C. power cord from the IEC receptacle on the machine.
4. Use a #1 Phillips screwdriver to remove the screws from the enclosure cover. Remove the
enclosure cover.
5. Do not remove the rubber drive roller. Use a 3/16 inch hex wrench to loosen the screw in the
pinch roller arm. (This will release the tension on the spring.) See Figure 59.
6. Carefully remove the spring from the upper spring mounting stud. See Figure 60.
7. Lift the pinch roller arm to highest point (The pinch roller will be resting on rubber drive
roller).
8. Position spring anchor (mounted in pinch arm shaft) so there is 3 3/16 to 3 5/16 inches
(81mm to 84mm) between the spring anchor and the upper spring mounting stud (where the
spring connects).
2111CD-1250 V0 R0.wpd 161

ADJUSTMENTS
9. Re-tighten the pinch arm screw.
10. Carefully re-install the spring. It is now

set to the proper tension.
11. Use a #1 Phillips screwdriver to replace

the machine enclosure.
12. Reconnect the A.C. power cord to the IEC

receptacle on the machine.
13. Reconnect the machine A.C. power cord

to the A.C. power.
Figure 59 Pinch Roller Arm Screw
Figure 60 Pinch Roller Compression Spring

Adjustment
162
ADJUSTMENTS
LEFT HAND MACHINES
The pinch roller compression cannot be adjusted on left hand machines. The pinch arm spring
tension is mechanically set when the pinch arm is mounted onto the slotted pinch arm shaft.
If the pinch roller tension is insufficient, the spring must be replaced.
! CAUTION !

2. Disconnect the machine A.C. power cord

from the A.C. power.
3. Disconnect the A.C. power cord from the

IEC receptacle on the machine.

the machine enclosure.
5. Make sure that the pinch and drive rollers

are engaged (detent cam disengaged).
6. Carefully remove the pinch roller tension

spring from the upper spring mounting
stud. See Figure 61.
Figure 61 Pinch Roller Compression Spring
7. Remove the pinch roller tension spring (Left Hand)
from the pinch arm spring anchor.
8. Install the replacement pinch roller tension spring on the pinch arm spring anchor.
9. Carefully attach the pinch roller tension spring to the upper spring mounting stud.
10. Use a #1 Phillips screwdriver to reinstall the machine enclosure.
11. Reconnect the A.C. power cord to the IEC receptacle on the machine.
12. Reconnect the machine A.C. power cord to the A.C. power.
2111CD-1250 V0 R0.wpd 163

164
TROUBLESHOOTING
1. Nothing Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2. [FEED] switch lights, display board does not light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3. LOW VOLTS message on the display board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4. Label advance does not occur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
5. Label advance occurs but fails to stop or is erratic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6. Label placement on the vacuum grid is consistently poor. . . . . . . . . . . . . . . . . . . . . . . 168
7. Labels are not being held on the vacuum grid after the label advance. . . . . . . . . . . . . . 170
8. Air assist does not function or is ineffective. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
9. Air blast does not occur. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10. Label placement on the product is consistently poor. . . . . . . . . . . . . . . . . . . . . . . . . . . 171
11. Machine will not cycle. Message reads: NO LABELS FOUND . . . . . . . . . . . . . . . . . . . . 173
12. Applicator runs after missing three or more labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
13. Machine functions at random without being initiated. . . . . . . . . . . . . . . . . . . . . . . . . . 173
14. Label application rate unable to keep up with rate at which product is being conveyed.174
15. Label liner not rewinding correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
16. Label liner breaking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2111CD-1250 V0 R0.wpd 165

TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE SOLUTION
1. Nothing Works Power cord loose, defective, or not Inspect the cord to find the problem and correct as
plugged in. necessary.
A.C. line fuse blown. Find the cause-- short circuited wire or terminal
connection-- correct the problem and replace the fuse.
Main supply line circuit breaker tripped. Reset the circuit breaker. Remove other equipment
from the same supply if the problem persists.
Fuse blown (located in the power Determine cause. NOTE: This fault may require
supply). specialized attention and the fastest solution may be to
replace the control module. If any doubt exists, replace
the control module and request qualified assistance to
repair the defective unit.
Loose connectors. Examine and correct.
[POWER] switch defective. Examine and replace.
2. [FEED] switch lights, Ribbon cable from the display board not Inspect and reconnect.
display board does plugged into the microprocessor card.
not light.
Defective display board. Replace the display board or request qualified
assistance.
166
TROUBLESHOOTING
3. LOW VOLTS message Power supply not supplying the proper Replace the motherboard.
on the display board. voltage.
[FEED] switch OFF. Turn the [FEED] switch ON.
Low A.C. Voltage supplied (brown out Check A.C. source.

condition).
4. Label advance does Control module defective. Replace the control board or seek qualified assistance.
not occur.
Drive module defective. Seek qualified assistance.
Loose drive roller. Check the set screws and make secure.
Pinch roller not engaged. Make sure the detent arm is disengaged, (pinch roller
engaged).
5. Label advance Label sensor set incorrectly. Refer to the set-up procedures for instruction.
occurs but fails to
stop or is erratic. Label sensor out of alignment. Refer to the set-up procedures for instruction.
Label sensor lens blocked or Clean using a lens brush.

contaminated.
Label sensor assembly loose. Connecting Tighten to eliminate movement. Check for damage and
wires to the label sensor loose or repair or replace.
damaged.
2111CD-1250 V0 R0.wpd 167

TROUBLESHOOTING
5. Label advance Label sensor defective or lamp burned Replace as necessary.

occurs but fails to out.
stop or is erratic.
(Cont.) Mini-fuse blown. Determine cause and replace.
Drive roller assembly loose or pinch Investigate and correct. Replace the pinch roller spring
roller spring tension is poor. if necessary.
LABEL STOP LENGTH is set too long. Re-adjust.
Defective control module. Replace the plug-in card or request qualified assistance.
Incorrect LABEL REPEAT LENGTH . Refer to the set-up procedure and correct.
Spring damaged in label light assembly. Check - repair/replace as necessary.
Dancer arm/unwind roll tension Investigate and correct operation of unwind brake and
incorrect. dancer arm.
Label core slipping on the unwind hub. Build up the I.D. of the label core with labels until label
core fits snugly on the unwind hub.
168
TROUBLESHOOTING
5. Label placement on Adhesive strings on the label and liner Replace the damaged roll of labels.
the vacuum grid is usually caused by die cuts on the label
consistently poor. liner.
(Cont.)
Air assist pressure too high, too low, or Investigate and adjust the air pressure. Correct the Air
incorrectly positioned. Assist Tube position if necessary.
Incorrect EXTEND AIR ASSIST time. Refer to the set-up instructions.
LABEL STOP LENGTH is out of Investigate and correct.

adjustment.
Peeler bar dive angle is incorrectly Refer to the set-up procedures for alignment
positioned. instructions.
Label sensor incorrectly positioned (odd Refer to the Label Sensor Detection Point Section.
shaped labels).
Label sensitivity incorrectly adjusted. Refer to the set-up procedures for instruction.
Label detection edge setting incorrect. Refer to the Label Sensor Detection Point Section.
Set lead or trail (odd shaped labels).
Adhesive or other obstruction on the Clean vacuum grid-- Examine the label roll for damage.
vacuum grid. Replace if necessary.
2111CD-1250 V0 R0.wpd 169

TROUBLESHOOTING
5. Label placement on Air jet tubes protruding from the vacuum Replace damaged air jet tubes.
the vacuum grid is grid.
consistently poor.
(Cont.) Premature release of the label from the Poor adhesive quality. Replace the label roll.
liner before peel point.
Loose drive belt. Investigate and correct.
Loose trantorques. Tighten trantorques (175 lbs-in).
Detent cam engaged. Disengage detent arm (engage pinch roller).
6. Labels are not being Vacuum fan not operating. Investigate and repair/replace.
held on the vacuum
grid after the label Vacuum not high enough. Switch vacuum to high (LH), adjust baffle plate (RH),
advance. or install grid mask.
Peeler bar dive angle incorrectly set. Refer to the set-up instructions and correct.
Air assist tube incorrectly positioned. Adjust the position of the tube.
Excessive label memory. Replace label roll.
7. Air assist does not Air pressure too low or too high. Check the pressure gauge and adjust as necessary.
function or is
ineffective.
170
TROUBLESHOOTING
7. Air assist does not Air assist tube incorrectly positioned, Examine and correct tube position. Repair or replace as
function or is damaged, or disconnected. necessary.
ineffective.
Labels incorrectly threaded. Refer to the set-up procedures. Make sure that the label
liner is threaded between the air assist tube and the
peeler bar.
Air assist solenoid malfunction. Examine and replace if necessary.
Applicator control card malfunction. Replace plug-in card or request qualified assistance.
8. Air blast does not AIR BLAST DW ELL time is too short. Refer to the set-up instructions.
occur.
Machine not connected to the air supply Check air pressure gauge on the front panel. Correct as
or pressure regulator turned down. necessary.
Air blast solenoid malfunction. Investigate and replace as necessary.
Control module malfunction. Replace plug-in card or request qualified assistance.
Product detector incorrectly aligned. Refer to the set-up procedures for instructions.
Product detector disconnected from the Investigate and correct or replace as necessary.
machine or connecting cable damaged.
Product detector defective. Investigate and replace as necessary.
2111CD-1250 V0 R0.wpd 171

TROUBLESHOOTING
8. Air blast does not VELOCITY COMP MODE is set ON but not Set VELOCITY COMP MODE to OFF.
occur. (Cont.) in use.
VELOCITY COMP MODE is set ON and no Check that encoder is connected. Check encoder output
input from encoder. and wiring. Replace if necessary.
9. Label placement on Product inconsistently presented to the Check to make sure that the conveyor speed is constant.
the product is applicator. Adjust rails and/or other product control devices to
consistently poor. present the product to the applicator in a consistent
manner.
Poor placement of the label on the Refer to item 6 in this section.

vacuum grid.
Air blast pressure too high or too low. Re-adjust pressure at regulator.
Incorrect AIR BLAST DW ELL time. Refer to the set-up instructions.
Product detector sensitivity out of Refer to the set-up adjustment instructions.

adjustment.
Product detector reflector loose or Investigate and correct.

vibrating.
Incorrect LABEL PLACEMENT setting Refer to the set-up instructions.

(delay).
172
TROUBLESHOOTING
9. Label placement on Unsuitably positioned product detector. Refer to the set-up instructions.
the product is
consistently poor. Fluctuation of product conveyor speed. Investigate and correct.
(Cont.)
Inadequate product guidance. Adjust product guides as necessary.
Product too far away from the vacuum Re-adjust the label applicator position relative to the
grid. product conveyor.
Poor adhesive quality on the label. Check with the label manufacturer.
VELOCITY COMP. incorrectly set-up. Refer to the set-up instructions.
10. Machine will not Label sensor has not detected three Turn the [FEED] switch OFF momentarily.
cycle. Message consecutive labels.
reads: NO LABELS Check the label sensitivity.
FOUND .
Web break. Investigate cause, correct and re-thread the labels on the
applicator.
Applicator has not been re-set from error. Turn the [FEED] switch ON.
Pinch roller not engaged. Engage the pinch roller (disengage detent cam).
11. Applicator runs after Incorrect LABEL REPEAT LENGTH . Refer to the Label Repeat Length Set-Up.
missing three or
more labels.
2111CD-1250 V0 R0.wpd 173

TROUBLESHOOTING
12. Machine functions at Product detector loose or vibrating. Investigate and repair as necessary.
random without
being initiated. Product detector alignment or adjustment Refer to the set-up procedures.
marginal.
Loose wiring connections. Check all wiring connections. If necessary, request

qualified assistance.
13. Label application Product conveyor running too fast. Check machine specification for rate versus size of
rate unable to keep label being applied. Slow down the conveyor if
up with rate at which necessary.
product is being
conveyed. Excessive machine cycle time.
Set-up adjustments incorrectly made. Refer to the set-up instructions.
VELOCITY COMP. incorrectly set.
14. Label liner not One way rewind clutch not operating. Seek qualified assistance.
rewinding correctly.
Rewind slip clutch not operating. Slip clutch too loose, worn, or contaminated. Examine
and repair.
174
TROUBLESHOOTING
15. Label liner breaking. Incorrectly threaded labels. Thread the labels correctly.
Unwind disks, rewind disk, or guide Adjust disks and collars to guide the label stock straight
collars not aligned. Label stock path not through the machine.
aligned.
Damaged roll of labels.
Nicks or label cutter die damage on the

liner. Replace the label roll.
Bruise on the side of the label roll.
Liner width varying significantly.
Peeler bar label tension spring too tight. Adjust with knob. Examine spring and replace if
damaged.
Adhesive build-up on the peeler bar or Clean as necessary and examine the label roll for
label tension spring. damage. A damaged roll can cause excessive adhesive
build-up. Replace label roll if necessary.
Dancer arm/unwind roll tension Investigate and correct operation of unwind brake and
incorrect. dancer arm.
2111CD-1250 V0 R0.wpd 175

176
GLOSSARY
Access Code: The key-sequence that must be entered into the microprocessor before modifying
the values for a label page.
Adhesive Strings: Label adhesive which adheres to the label liner and label while the label is
dispensing. They can cause the label to be improperly positioned on the vacuum grid or pad.
Air Assist Pressure Gauge: The gauge that shows the air pressure that is being supplied to the air
assist tube.
Air Assist Tube: A small tube at the end of the peeler bar (or plate) which points a stream of air
at the label to help it break free from the label liner as it is dispensing.
Air Assist: The stream of air that the air assist tube directs at the label to help it break free from
the label liner as it is dispensing.
Air Blast: The blast of compressed air that transfers a label from the vacuum grid or pad to the
product.
Air Filter: A device that removes dust and other debris from the air.
Air Regulator: the valve that controls the amount of air which is being supplied to the machine.
Air Supply Requirements: The air pressure and delivery that are required to operate the machine.
Beam Sensor: A sensor that triggers a signal when an object breaks a light beam.
Clutch: A device that engages and disengages a driving and driven part.
Conveyor: The device (chain, rollers, hugger belts etc.) which moves the product.
Dancer Arm: The spring loaded arm that moves to maintain correct tension on the label stock as
it moves through the machine.
Decrease Key: The key on the microprocessor face-plate that is used to reduce numeric values
shown on the display.
Detection Points: The point of the label or product that causes the label or product sensor to
signal the machine.
2111CD-1250 V0 R0.wpd 177

GLOSSARY
Detent Arm: The device that is used to separate and hold the pinch roller from the drive roller to
simplify threading labels.
Disk: The flat, plastic circle which holds the roll of labels on the supply mandrel.
Display Board: The LED display above the keypad,
Display: The portion of faceplate that shows the microprocessor messages.
Encoder Pulses: The measurement of conveyor travel: the number of pulses per inch is usually
100, but may vary depending upon the encoder used.
Encoder: A device mounted to the conveyor drive system that reports Distance Traveled
information to the microprocessor(s).
Feed Switch: The switch that must be ON in order for the machine to initiate the applicator
sequence.
Gain Control: The control on the photoelectric product detector that regulates the amount of
light that is necessary to activate the sensor.
Increase Key: The key on the microprocessor faceplate that is used to reduce numeric values
shown on the display.
Label Lamp: The light source that is used by the label sensor to sense labels.
Label Liner Guide Collar: The rings that keep the label stock in the proper lateral position as it
feeds through the machine.
Label Liner: The paper to which labels are affixed prior being to being dispensed.
Label Page: The set of values that are stored in the microprocessor menu for applying a
particular kind of label.
Label Placement: The function that allows you to instruct the machine to provide a delay
between the moment of product detection and the actual time at which the label is applied.
Label Sensor: A photoelectric or mechanical device that sends a signal to the microprocessor
when it detects the presence of a label edge
Label Stock: The label liner with labels still attached.
Leading Edge: The first edge of the product or label enters the sensor's detection beam.
Lmeter: Label meter. The microprocessor function which allows you to set the label sensor
sensitivity
178
GLOSSARY
Lock Pin: The metal piece that secures the label liner to the rewind spool.
Machine Sequence: The order in which the machine executes the steps necessary for a complete
cycle.
Mandrel: A shaft that can spin on its axis, on which another device is mounted
Menu: The list of microprocessor functions that are available for use.
Microprocessor Board: The circuit board that contains the central processing unit (C.P.U.).
Microprocessor Menu: The microprocessor functions and the way that they are arranged and
accessed.
Motherboard: The DC power-supply for the applicator.
Optional Equipment: Standard equipment that is not required to operate the machine, but can be
purchased and employed with the machine to accomplish some additional task (e.g., imprinter).
P.S.I.G.: Pounds per square inch gauge. (BAR = PSIG ÷ 14.4)
Peeler Bar: The flat bar that the separates the label from the label liner as the label stock slides
around it.
Photocell: A device that varies the intensity of an electric current according to the amount of
light it is receiving. It is used in the label sensor and product detector.
Pinch Roller: The cylinder that presses the label liner to the drive roller so that the label stock
can be pulled through the machine.
Pitch: The distance from product leading edge to leading edge as they exit the feed screw.
Pneumatic: Moved or operated by air pressure.
Product Detector: A device, usually photoelectric, which detects the presence of a product edge
and sends a signal to the microprocessor.
Rate Compensation: An optional feature that permits the correct application of labels despite
variations in the conveyor speed.
Registration Roller: The roller that moves to adjust the position of the labels relative to the print
head of the imprinter.
Repeat Length: The distance from the leading edge of one label (or product) to the leading edge
of the next.
2111CD-1250 V0 R0.wpd 179

GLOSSARY
Rewind Station: A motor driven mandrel that stores the label liner from which labels have been
removed.
S.C.F.M.: Standard Cubic Feet per Minute
Select Key: The key on the microprocessor faceplate that is used to advance from one
microprocessor menu item to another.
Slip Clutch: A clutch that disengages by slipping when there is enough tension on the driven part
(used on the rewind).
Solenoid: An electromagnetic switch.
Label Stack: A stack of labels that have been applied one on top of the other like a deck of cards.
A good label stack will have less than 1/32 inch (0.8mm) variation in any direction.
Thread Sequence: The manner in which the label stock or ribbon are threaded through the
machine rollers.
Trailing Edge: The last edge of the product or label to leave the detection beam.
Unwind Brake: The device which prevents the unwind roll from turning unless there is a
demand for labels (see unwind dancer arm).
Vacuum Venturi: A device which uses compressed air to create a vacuum,
Web: See Label Stock.
180
INDEX
Access code 25, 26, 43, 177 Code 25, 26, 43, 69, 116, 177
Adhesive strings 73, 74, 168, 177 Compensation 95, 105-111, 131, 133, 135,
Air assist 37, 45, 58, 60-63, 67, 73, 74, 137, 139, 141, 143, 145, 179
93-95, 126, 131, 133, 135, 137, Conveyor 26, 74, 80, 86, 89, 91-93, 95,
139, 141, 143, 145, 168-170, 177 107-111, 131, 133, 135, 137, 139,
Air assist pressure gauge 62, 177 141, 143, 145, 171, 172, 174,
Air assist tube 37, 62, 63, 73, 74, 94, 126, 177-179
168, 170, 177 Cpu 45, 106, 108, 110
Air assist tube adjustment 63, 74 Dancer arm 29, 98-100, 102, 150, 153, 155,
Air blast 20, 45, 58, 59, 65, 66, 72, 74, 75, 168, 175, 177, 180
93, 95, 109, 111, 112, 131, 133, Dancer arm tension adjustment 153
135, 137, 139, 141, 143, 145, Decrease key 177
171, 172, 177 Detection points 47, 177
Air blast dwell 20, 45, 66, 74, 75, 95, 109, Detector lockout 45, 89, 91, 95, 131, 133,
111, 131, 133, 135, 137, 139, 135, 137, 139, 141, 143, 145
141, 143, 145, 171, 172 Detector type 45, 78, 79, 87, 88, 95, 131,
Air blast tube arrangement 65 133, 135, 137, 139, 141, 143, 145
Air filter 33, 148, 151, 177 Detent arm 167, 170, 178
Air jet 9, 64, 72, 75, 112, 150, 169 Detent cam 37, 126, 163, 170, 173
Air jet pattern 75 Disk 30-32, 37, 38, 98-102, 126, 151-153,
Air jet tubes 64, 72, 150, 169 156, 174, 178
Air regulator 58, 66, 177 Display 10, 25, 26, 41, 43-46, 48-53, 62,
Air supply 9, 149, 151, 171, 177 66-69, 77, 79-81, 85-89, 91, 93, 94,
Air supply requirements 177 103, 108, 110, 118, 166, 167, 177,
Alarm light 98, 99, 103, 104 178
Alarm output 98 Display board 166, 167, 178
Alarms 98 Documentation 93
Align label sensor 43, 45, 46, 49, 50 Drive belt 159, 160, 169
Align product sensor 81 Drive belt tension adjustment 159, 160
Applicator 9, 10, 13-16, 20, 22, 24, 25, 33, Edge detection 80, 81
36, 37, 43, 46, 48, 50-53, 59, 62, Electrical power 12, 36
66-69, 71, 78, 80, 85, 89, 91, Encoder 106, 108, 110, 171, 178
93-95, 98, 103, 104, 108-111, Encoder pulses 106, 178
118, 121, 122, 131, 133, 135, Encoder wheel 106, 108, 110
137, 139, 141, 143, 145, 147, Extend air assist 45, 62, 95, 131, 133, 135,
156, 170-173, 178, 179 137, 139, 141, 143, 145, 169
Baffle 59, 60, 73, 170 Fan 59, 61, 170
Beam sensor 79, 177 Feed screw 179
Belt 151, 159, 160, 169 Feed switch 178
Clutch 67, 151, 152, 155, 156, 158, 174, Filter bowl 151
177, 180 Friction 152
Clutch adjustment 155 Fuse 166, 168
2111CD-1250 V0 R0.wpd 181

INDEX
Gain control 83, 178 178, 179

General machine information 19 Led 41, 83, 100-102, 178
Glossary i, 10, 177 Length 20, 44, 45, 51-54, 66, 67, 72, 74, 95,
Imprint dwell 69, 70, 95, 118, 131, 133, 135, 103, 121, 131, 133, 135, 137, 139,
137, 139, 141, 143, 145 141, 143, 145, 160, 168, 169, 173,
Imprinter 37, 45, 52, 68-70, 95, 116-122, 179
131, 133, 135, 137, 139, 141, Lmeter 26, 43, 46, 178
143, 145, 179 Lock pin 37, 179
Imprinter adjustment brackets 120 Lockout 45, 89, 91, 95, 131, 133, 135, 137,
Imprinter on/off 68, 69, 118 139, 141, 143, 145
Increase key 178 Machine rollers 180
Index i, 10, 181 Machine sequence 27, 179
Initial warnings 13 Maintenance i, 9, 11, 119, 147-152
Introduction i, 9 Mandrel 30-32, 37, 38, 55, 126, 156,
Label adhesive 177 178-180
Label detect edge 44, 50, 51, 95, 131, 133, Menu 25, 41-43, 45, 46, 48, 50-53, 62,
135, 137, 139, 141, 143, 145 66-69, 77, 79, 80, 86, 87, 89, 91, 93,
Label detected 49, 50 94, 118, 178-180
Label detected: yes/no 49 Metal piece 179
Label dive 55, 57 Microprocessor 10, 25, 26, 35, 38, 41, 42,
Label feed 69, 116 44-46, 48, 50-53, 62, 66-69, 77, 79,
Label lamp 46, 49, 178 80, 85-87, 89, 91, 93-95, 103, 106,
Label liner 37, 38, 49, 55, 119, 126, 127, 118, 131, 133, 135, 137, 139, 141,
156, 168, 170, 174, 175, 177-180 143, 145, 166, 177-180
Label liner guide collar 178 Microprocessor board 179
Label page 25, 26, 35, 41, 43, 62, 93, 95, Microprocessor entry 38
177, 178 Microprocessor menu 25, 41, 42, 46, 48,
Label page set-up record 95 50-53, 62, 66-69, 77, 79, 80, 86, 87,
Label placement 45, 78, 88-90, 95, 107, 131, 89, 91, 93, 94, 118, 178-180
133, 135, 137, 139, 141, 143, Microprocessor menu map 42, 77
145, 168-172, 178 Microprocessor messages 26, 178
Label repeat length 44, 51, 52, 67, 95, 103, Module 9, 25, 36, 151, 166-168, 171
121, 131, 133, 135, 137, 139, Motor 59, 68, 151, 152, 155, 159, 160, 180
141, 143, 145, 168, 173 Motor drive shaft belt 151
Label sens. 46, 48, 50 Nip roller 160
Label sens. (Itivity) 46, 48 Optional equipment i, 31, 93, 97, 122, 179
Label sensor 26, 43, 45, 46, 48-50, 52, 53, Oversize machine 112
98, 103, 121, 167-169, 173, 178, P.s.i.g. 179
179 Pad 177
Label sensor alignment 46 Parameter 41, 44, 45
Label sensor sensitivity 49, 178 Peeler bar 37, 46, 48, 53-57, 62, 72-74, 94,
Label sensor sensitivity set-up 49 108, 110, 112, 121, 126, 148, 149,
Label set-up i, 35 169, 170, 175, 177, 179
Label stock 26, 62, 67, 100, 115, 119, 155, Peeler bar adjustment 57
174, 177-180 Peeler bar alignment 54, 55
Lamp adjustment screw 46 Photocell 85, 179
Leading edge 9, 51, 52, 54, 72, 80, 81, 91, Pinch roller 37, 38, 112, 115, 126, 127,
182
INDEX
161-163, 167, 168, 170, 173, 118, 130, 131, 133, 135, 137, 139,
178, 179 141, 143, 145, 167-174
Pinch roller arm 161, 162 Signal 26, 85, 177-179
Pinch roller compression adjustment 161 Slip clutch 67, 151, 152, 155, 156, 158, 174,
Pitch 179 180
Placement of the machine 15 Socket head cap screw 62
Pmeter 26, 85 Solenoid 170, 171, 180
Pneumatic 179 Solvent 148, 149
Pounds per square inch gauge 179 Stack test 66, 69-71
Print head 179 Standard cubic feet per minute 180
Prints i, 185 Steps 10, 35, 48, 77, 179
Product detect edge 79, 80, 95, 131, 133, Supply mandrel 178
135, 137, 139, 141, 143, 145 Table of contents i, iii, 10
Product detected 86, 87 Test run 91, 92
Product detection 89, 178 Thread sequence 180
Product detector 20, 26, 33, 45, 72, 79, 80, Threading diagram 39, 40, 117, 128, 129
82-89, 91, 93, 95, 103, 106-111, Threading diagram with imprinter 117
131, 133, 135, 137, 139, 141, Threading labels 178
143, 145, 171-173, 178, 179 Timing belt 159
Product detector type 87 Trailing edge 51, 80, 81, 180
Product distance 74, 95, 106-111, 131, 133, Troubleshooting i, 165
135, 137, 139, 141, 143, 145 Typographic conventions 10
Product sens 85, 86 Unwind brake 29, 98-100, 102, 150,
Product sensor 81, 107, 177 153-155, 168, 175, 180
Product set-up i, 75, 77 Unwind dancer arm 155, 180
Pulses 106, 178 Unwind disk 30, 31, 37, 38, 98-102, 126,
Rate compensation 95, 131, 133, 135, 137, 153
139, 141, 143, 145, 179 Unwind mandrel 30, 31
Reels up 156 Vacuum box 64
Reflected beam 79, 84 Vacuum fan 59, 170
Reflected beam product detector 84 Vacuum grid 15, 30, 38, 55, 56, 59, 61, 62,
Reflective products 87 64, 66, 72-74, 78, 89, 93, 126, 148,
Registration roller 119, 179 149, 168-170, 172, 177
Repeat length 44, 51, 52, 67, 74, 95, 103, Vacuum venturi 180
121, 131, 133, 135, 137, 139, Voltage 11, 26, 167
141, 143, 145, 168, 173, 179 Web 9, 13, 37, 45, 66-69, 74, 95, 98, 103,
Rewind slip clutch 67, 151, 152, 155, 156, 118, 121, 126, 131, 133, 135, 137,
158, 174 139, 141, 143, 145, 155, 156, 173,
Rewind slip clutch adjustment 155 180
Rewind station 152, 180 Width 175
S.c.f.m. 9, 180
Select key 10, 180
Sensor's detection beam 178
Set-up i, 9, 10, 14, 19, 20, 25, 31, 33, 35,
43-46, 48-53, 58-62, 64, 66-69,
71, 72, 75, 77, 79, 80, 82-87, 89,
91-95, 97, 98, 103, 105, 107-112,
2111CD-1250 V0 R0.wpd 183

184
PRINTS
2111CD-1250 V0 R0.wpd 185

PRINTS
186

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TABLE OF CONTENTS

Label-Aire P/N 7408675-100 PRINTS 12

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

GENERAL MACHINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2111CD-1250 V0 R0.wpd iii

Left Hand Applicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Velocity Comp Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Figure 41 Slow Launcher Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

2111CD-1250 V0 R0.wpd vii

ELECTRICAL SUPPLY: 108-132 Volts, 3 Amps, 54-66 Hertz, Single Phase

ENVIRONMENT: Operating temperature: 40-104 degrees F (5-40 degrees C).

NOTE: The model 2111CD is not intended to be operated in an

TRY AGAIN IF SOMETHING DOES NOT WORK. Although a machine malfunction is

UNDERSTAND OUR TYPOGRAPHIC CONVENTIONS. Machine keys and switches are

CAUTIONARY SYMBOLS AND

THIS SYMBOL INDICATES THE

THIS SYMBOL IS INTENDED TO ALERT

THIS SYMBOL WARNS YOU THAT

 This symbol on an electrical power switch indicates SWITCH ON.

F This symbol on an electrical power switch indicates SWITCH OFF.

This symbol indicates the protective EARTH connection.

The Web Drive Rollers

The cover must not be removed except by a qualified service

APPLICATOR POWER CABLE

DO NOT CONNECT THE MACHINE TO THE A.C.

Figure 1 Power Cable

PHYSICAL PLACEMENT OF THE

Figure 2 Design Data for 2111CD Applicator Support Structure

Figure 3 Machine Attitudes (Right Hand)

DO NOT CONNECT THE MACHINE TO THE A.C.

Figure 4 Machine Parts (Right Hand)

Figure 7 Machine Parts (Left Hand)

MODULE KEYS AND SWITCHES

[FEED]: Enables or disables the applicator labeling mode.

Figure 10 Module Faceplate

Figure 11 2111CD Machine Sequence Flowchart

HEX HEAD WRENCHES OPEN END WRENCHES SCREWDRIVERS

UNWIND BLOCK ASSEMBLY

1. Locate and unwrap the unwind block assembly.

Figure 12 Unwind Block Assembly

Figure 13 Unwind Disks And Optional Low Label Detector

LOW LABEL BRACKET (OPTIONAL EQUIPMENT)

Figure 14 Rewind Disk

1. Remove the protective plastic film from the rewind disk.

AIR SERVICE FILTER

Figure 15 Air Service Filter

1. Locate and set aside the product detector.

DO NOT CONNECT THE MACHINE TO THE A.C.

NOTE: This applicator is designed to operate at 120VAC ±10%.

CONNECTION TO COMPRESSED AIR

CONNECTION TO A.C. POWER

NOTE: For convenience, connect the applicator to the compressed air

Go on to the Loading Labels Section.

TURN THE [FEED] SWITCH OFF BEFORE YOU

NOTE: See Appendix A for re-loading labels.

8. Re-tighten the label tension spring thumbscrew.

Go on to the Microprocessor Entry Section.

Figure 16 Threading Diagram (Right Hand)

Figure 17 Threading Diagram (Left Hand)

INITIAL OPERABLE SETTINGS

TURN THE [FEED] SWITCH OFF BEFORE YOU

Figure 18 Microprocessor Menu Map

1. Make sure that the [FEED] switch is in the OFF position.

This symbol on an electrical power switch indicates SWITCH ON.