INTRODUCTION
The Low Tape warning is an important function of the BP-PLC LTNT (Low Tape No Tape) system. It provides advance warning to the operator that the roll of tape is getting low and should be replaced soon. The Low Tape warning is a not fault; The machine will continue to function normally in a low tape state. If your machine is faulted, then the Tape Monitoring function is to blame. This article specifically addresses troubleshooting as related to the LOW Tape warning.
OPERATION
When low tape is detected, the amber light on the stack will cycle on and off at a 1 second interval. The low tape condition is only checked when a box exits, after tape is dispensed, so the Amber light may continue to flash after a new roll is loaded. The next box through the machine will update the low tape status and shut the Amber Light off.
OBSERVATION
There are two sensors mounted next to the tape head. The sensor on the short bracket is for No-Tape Faults. The sensor on the longer bracket aimed at the roll is for Low Tape Warning.

The photo eyes have two adjustments: sensitivity and Light/Dark mode. Sensitivity dial adjusts the range of detection. The dial has about 270 degrees of rotation- Min to Max. The Light/Dark (L/D) mode sets the output state of the sensor when it detects an object; it has about 90 degrees of rotation.

Tape Fault (No-Tape/No-Cut) Monitoring and Low Tape Warning are two separate functions and can operate independently of each. Nuisance tape faults, caused by a bad No-Tape Sensor, can be disabled, but the status of the roll can still be monitored. For top/bottom seal only, the tape head can be removed, tape monitor disabled and the sensor state changed.
The Low tape sensor should be set to 'D' (Dark-ON mode) for detection...

... or 'L' (Light-ON Mode) if the tape head is not loaded.

When the sensor is set to Dark-On, the output only turns 'ON' (amber LED will illuminate on the sensor) when the sensor clears because of 'Low Tape'. When set to Light-ON, the sensor output should never turn 'ON' because there is no tape head or tape roll to detect.
If the Low Tape warning is active when the roll full is
1) Run a box through first to see if it will clear on its own.
2) Check low tape sensors (top/bottom) for 'Green Power On' LED
3) Check low tape sensor modes are set correctly.
* 'D' for Dark ON , if monitoring is active
* 'L' for Light-ON, if tape head is removed
4) Verify Sensor adjustment and signal stability
5) Adjust Sensor mounting bracket Position
If the Low Tape Warning is inactive when it should be on (ie. low tape roll)
1) Check low tape sensors (top/bottom) for Green- 'Power On' LED
2) Verify Sensor Adjustment and signal stability
3) Adjust the sensor mounting bracket
CONCLUSION
The most common solution of a malfunctioning Low Tape warning is usually a simple sensor adjustment. Either it is aimed incorrectly with the mounting bracket, or the sensitivity needs to be adjusted. Occasionally, the sensor may sustain mechanical damage, or the sensor cord gets severed. Understanding the Low Tape Warning system can help to quickly identify the issue and get it resolved.
Regards,
Bestpack Technical Support Team
E: technicalsupport@bestpack.com
P: (888) 507-9728
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