ALP/4500 Manual - DiagraphDiagraph - an ITW Company ALP/4500 PA Manual Introduction Page 7...

ALP/4500PAALP/4500PA

6145-010Revision F

Diagraph - an ITW Company ALP/4500 PA ManualTable of C

ontents

Table of ContentsIntroduction............................................................ 2

The ALP/4500............................................................ 2Product Safety............................................................ 2Document Conventions.............................................. 3Features and Benefits................................................. 4Specifications............................................................. 5Warranty Information ................................................ 8Orientations................................................................ 9

System Components............................................... 11

Baseplate .................................................................... 11Rear Chassis............................................................... 12Print Module .............................................................. 13Tamp Assembly Module............................................ 14Unwind / Rewind ....................................................... 15Product Detector ........................................................ 16Pneumatic Control Module ........................................ 17Inlet Air Filter / Regulator / Shutoff .......................... 17Warning Tower .......................................................... 18

Installation.............................................................. 19

Overview.................................................................... 19Tools Required........................................................... 19Stand .......................................................................... 20Mounting the Main Unit ............................................ 21Cable Connections ..................................................... 22Mounting the Inlet Air Filter / Regulator / Shutoff ... 28Threading the Label Roll ........................................... 28

Mechanical Adjustments....................................... 29

Adjusting the Tamp Cylinder .................................... 29Adjusting the Air Assist Angle .................................. 31Tensioning the Unwind Band Brake.......................... 31Adjusting the Pneumatics Regulators ........................ 32Adjusting the Print Module........................................ 34

Page i


ontents

Changing Tamp Pad Label Dimensions .................... 36

Symbols and Icons ................................................. 37

Quick Status “Stick-er”.............................................. 37Machine Errors .......................................................... 37Detailed Error Condition Icons.................................. 38Status Icons ................................................................ 39

User Interface Overview ....................................... 40

Initialization Screen ................................................... 41Home Screen.............................................................. 42Home Screen (Cont) .................................................. 43Setup Screens - Product Delay................................... 44Setup Screens - Tamp Duration ................................. 45Setup Screens - Contact Force ................................... 46Setup Screens - Auxiliary Delay................................ 47Setup Screens - Auxiliary Duration ........................... 48Setup Screens - System Status ................................... 49Setup Screens - Job Status ......................................... 50Print Module Screens - Actions ................................ 51Print Module Screens - Serial ................................... 52Print Module Screens - Calendar .............................. 53Diagnostics Screens - Pneumatics ............................ 54Diagnostics Screens - Sensors .................................. 55Diagnostics Screens - History Log ............................ 56Information Screens................................................... 57One Time Setup - Label Low .................................... 58One Time Setup - Print Mode.................................... 59One Time Setup - Repeat Mode ................................ 60One Time Setup - Aux Mode..................................... 61One Time Setup - Password....................................... 62

Theory of Operation .............................................. 63

Introduction................................................................ 63Printing State.............................................................. 63Label Presence State .................................................. 63Product Delay State ................................................... 64Application State........................................................ 64Background Tasks...................................................... 65

System Setup ......................................................... 67

Determining Label Low Position............................... 67Selecting Mode of Print ............................................. 67

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ontents

Entering Job Setup Information .......................... 68

Setting the Product Delay .......................................... 68Setting the Tamp Duration......................................... 68Auxiliary Trigger Modes (Optional Device Setup) ... 69Auxiliary Output Modes (Optional Device Setup) .... 70Setting the Auxiliary Delay (Optional)...................... 71Setting the Auxiliary Duration (Optional) ................. 71Setting Label Format Parameters............................... 71

Operation................................................................ 73

Starting Operation...................................................... 73Throughout Operation................................................ 73End of Operation........................................................ 73

Troubleshooting ..................................................... 75

Diagnostic Images...................................................... 75Symptom Diagnostics ................................................ 77Electronic Calibration ................................................ 82Test Points and Advanced Diagnostics...................... 82Interconnection Diagram ........................................... 85

Maintenance ........................................................... 86

Print Module Routine Maintenance ........................... 86Pneumatic Vacuum Generator Maintenance ............. 87Tamp Pad Maintenance ............................................. 87Warning Tower Bulb Replacement ........................... 87Fuse Replacement ...................................................... 88Cooling Fan Filter Cleaning and Replacement.......... 89Pneumatic Filter Replacement ................................... 89Unwind Slot Sensor Maintenance.............................. 89Band Brake / Unwind Spring Replacement ............... 90Rewind Belt Replacement ......................................... 90Maintenance Schedule Summary............................... 91

Replacement Parts ................................................. 92

ALP/4500 Replacement Part List .............................. 92Ribbons ...................................................................... 93

Declaration of Conformity .................................... 94

Page iii

Diagraph - an ITW Company ALP/4500 PA Manual

Diagraph, an ITW company, continually improves its products, and reserves the right to change or discon-tinue specifications and designs shown in this manual without notice and without incurring obligation. Diagraph has made every effort to verify the informa-tion contained in this manual, but reserves the right to correct any error at the time of the manual’s next revision.© 2004 Illinois Tool Works Inc. All rights reserved.Printed in the United States of America

Page 1

Diagraph - an ITW Company ALP/4500 PA ManualIntroduction

1.0 Introduction

1.1 The ALP/4500

The ALP/4500 is an advanced print and apply machine designed for modularity, continuous labeling, self-diagnostics, and ease of use. Modularity of design provides the basis for ease of installation, setup, and maintenance. A central, consol-idated operator interface is comprised of a graphics display and keypad, which controls both printer operations and applicator settings. Through the use of the symbol and icon-based menu screens, the operator is able to view several parame-ters at once, in a meaningful manner. Advanced electronics automatically self-cali-brates sensors. Next-generation diagnostics automatically monitors input sensors and output drivers and protects against shorts and overloads. This next-label-out system is capable of high volume industrial applications, providing the highest effi-ciency through a combination of intelligent electronic sensing and an efficient web path design.

1.2 Product Safety

Safety awareness is critical when working with equipment that contains moving parts and extending pneumatic cylinders. Please read all warnings and cautions thor-oughly before operating this device.

WARNINGS

• WARNING - Moving parts of this machine can present hazards. Components that cannot be guarded because of loss of functionality are marked with a warning symbol.

• Be aware of the tamp cylinder extension distance, and avoid accidental trig-gering of the photosensor.

• When servicing the unit’s electronic assemblies, always remove the power cord from the unit to prevent accidental shock.

• When running for extended periods of time, use caution when accessing the print module near the printhead. The printhead uses heat to transfer images to the label, and printing components can become hot under constant use.

• Always close the air inlet valve shutoff when removing or servicing pneu-matic module or tamp cylinder.

• Wear personal protective equipment, as instructed by your supervisor, when operating or working near this device.

• CAUTION: The controller board contains a Lithium battery. Lithium is a hazardous material that must be disposed of in accordance with local, state, and federal laws.

Introduction Page 2


• ATTENTION: Le product contient une pile au lithium. Le lithium est un matérial dangereux. Jeter cette pile conformément aux lois locales, d’état et fédérales.

COMPLIANCE

• CAUTION: Not for use in a computer room as defined in the Standard for the Protection of Electronic Computer/ Data Processing Equipment, ANSI/NFPA 75.

• ATTENTION: Ne peut être utilissé dans une salle d’ordinateurs telle que définie dans las norme. ANSI/NFPA 75 Standard for the Protection of Elec-tronic Computer/ Data Processing Equipment

• This unit has been tested and found to comply with the limits for a Class A device, pursuant to part 15 of the FCC Rules.

• This unit has been tested to comply with CE Standards.

• This unit is equipped with an Emergency Stop switch. Depressing this switchwill cause all machine operations to cease.

• This unit was tested and it was determined that a potential for tipping exists in certain orientations. In compliance with UL safety standards, the stand must be secured to the surface where it is located. Additionally, this type of securing will result in greater product application accuracy.

1.3 Document Conventions

Formatting conventions are used throughout this manual as a method of providing consistency for notes and warnings.

.

.

NoteThis symbol appears throughout the manual to provide additional information on a topic, including technical details, exceptions to the instructions and other pertinent information. Notes are identified with a note pad and pen symbol and italics text.

WARNING This symbol indicates a danger of injury to the user. Hazards are identified by the exclamation mark in a triangle and bold italics text.

Introduction Page 3


1.4 Features and Benefits

• Print and Apply rates up to 55 PPM

• Print rates up to 8 IPS

• Print on Demand utilizing product sensor or indepen-dent sensor

• Secondary Wipedown output, capable of tracking up to four (4) products in the window

• Tamp Pressure sensing to ensure contact and consis-tent application force

• Cylinder home sensing to increase throughput

• Label on tamp sensing

• Variable, software selected label low position

• Label supply out sensing

• Modular, easy to service pneumatic block

• RS232 data rates up to 57.6 kBaud

• Direct PLC interfacing

• Optional I/O interface card

• 115/230 VAC

• CE, CSA, FCC approved, ETL Listed (UL 60950)

• Bulb, valve, and output driver monitor circuitry

• Tethered graphics user interface

• Infrared data port

• History log of events with timestamp

• Time and Date clock resident in print module

• Integrated Diagnostics

• Expansion slots for discrete I/O and Ethernet

• No clutch, no brush rewind, provides constant tension.

Introduction Page 4


1.5 Specifications

General Specifications

Category Parameter

Dimensions 28” L x 21” H x 23” D (includes Yoke)

Weight 85 lbs (39 kg)

Accuracy ±0.032” (0.8 mm)

Recommended Software

EasyLabel™ or Diagraph’s Performance Series™

Certifications Œ, CSA, FCC approved, ETL Listed (UL 60950)

Serial Baud Rates 9600, 19200, 38400, and 57600 bps

Serial Framing 8 Data Bits, 1 Stop, No Parity

Handshaking None, RTS/CTS, Software XON/XOFF

Supply Roll Capacity 12 inches (304.8 mm)

Print Module CAB A3

Printing Modes Direct Thermal or Thermal Transfer

Print Speeds - 203 dpi 5, 6, 7, and 8 ips(125, 150, 175, and 200 mm/s)

Print Speeds - 300 dpi 5 and 6 ips(125 and 150 mm/s)

Print Resolution 203/300 dpi(8 / 11.8 dpmm)

Print Width (203 dpi) 1.0" (25.4 mm) Min. to 4.1” (104 mm) Max.

Print Width (300 dpi) 1.0” (25.4 mm) Min. to 4.25" (108.4 mm) Max.

Print Length 1.0" (25.4 mm) Min. to 13.0” (330.2 mm) Max.

Liner Width 1.0" (25.4 mm) Min. to 4.6” (116 mm) Max.

Ribbon Width Up to 4.5" (114 mm)

Processor 32-Bit

Memory 8 MB RAM1 MB non-volatile

Ribbon specs up to 450mFace-In or Face-Out

Label edge sensing photo sensing for die cut (gap),reflective sensor mark

Introduction Page 5


Fonts 5 Bitmap fonts (OCR-A / OCR-B)3 scalable fonts (Speedo)

Bar Codes (lineal) UPC-A, UPC-E, EAN-8, EAN-13, EAN-128, EAN/UCC 128, C39, C93, C128 A-B-C, I 2/5, Codabar, MSI, 2/5,

Matrix 2/5, postnet,Plessey, FIM, HIBC, JAN-8, JAN-13

Bar Codes (2 D) PDF417, Data Matrix, UPS Maxicode, MicroPDF, QR Code

Graphic Support .PCX,.BMP,.IMG,.TIF,.GIF, and.MAC

Electrical Specifications

Category Nominal Minimum Maximum

AC VoltageSupply

110-120 VAC, 5A 50/60 Hz

220-240 VAC, 3A50/60 Hz

85 VAC

190 VAC

132 VAC

254 VAC

Product Detector(Sensor Mode)

Low: 0 to 3 VDCHigh: 3 to 5 VDCSupplies 24VDC

0 VDC 6.8 VDC

Product Detector(PLC Mode)

Low: 0 to 3 VDCHigh: 3 to 5 VDC

0 VDC 6.8 VDC

Product Detector Pulse Width

(Either Mode)

10 mS 1 mS Infinite

Auxiliary OutputWarning Tower

0 and 24 VDC200 mA sinking

0 VDC0 mA

24 VDC300 mA sinking

Discrete Inputs(Optional)

Low: 0 to 10 VDCHigh: 10 to 24 VDC

0 VDC 26 VDC

Discrete Outputs(Optional)

0 - 240 V AC/DC at 150 mA

0 V AC/DC, 13 ohms

250 V AC/DC at 170 mA

Mechanical Specifications


Incoming Air Pressure 60 - 100 PSI 40 PSI 125 PSI

Tamp Cylinder Pressure 30 - 50 PSI 20 PSI 80 PSI

Air Assist Pressure 5 - 30 PSI 0 PSI 50 PSI

General Specifications

Category Parameter

Introduction Page 6


Vacuum GeneratorPressure

20 - 55 PSI 15 PSI 60 PSI

Temperature 50°F - 95°F 41°F 100°F

Humidity(non-condensing)

20 - 85% RH 10% RH 90% RH

Product Rate 0 - 55 PPM 0 PPM 65 PPM

Air Consumption 5 CFM at 80 PSI

3 CFM at 80 PSI

7 CFM at 80 PSI

Tamp Stroke(10 in. cylinder)

1 - 7 in. 0.5 in. 7 in.

Tamp Stroke(20 in. cylinder)

1 - 17 in. 0.5 in. 17 in.

Mechanical Specifications


Introduction Page 7


1.6 Warranty Information

The ALP/4500 system, including all components unless otherwise specified, carries a limited warranty.

For all warranty terms and conditions, contact Diagraph, an ITW Company, for a complete copy of the Limited Warranty Statement.

Introduction Page 8


1.7 Orientations

45” 45”

34” 34”

49”

9”

20”

60”

Side Apply

Top Down

Introduction Page 9


54”

60.5”

24”

16”

66”

26”

Nose Up

Nose Down

Bottom Up

Introduction Page 10

Diagraph - an ITW Company ALP/4500 PA ManualS

ystem C

omponents

2.0 System Components

2.1 Baseplate

Unwind Supply Roll

Rewind Roll

Rewind Dancer ArmRewind Sensor

Unwind

UnwindDancer Arm

Print Module

Tamp Cylinder

Cylinder Home Sensor

Tamp Pad

PneumaticModule

Sensor

System Components Page 11


ystem C

omponents

2.2 Rear Chassis

Rewind Stepper Motor

Power Inlet Module

Cooling Fan w/Filter

Serial Com Port

Auxiliary OutputWarning Tower

Product Detector 1

Product Detector 2

Option Ports



ystem C

omponents

2.3 Print Module

Label Gap Sensor

Ribbon AlignmentScrew

Printhead Latch

Outfeed Nip Roller

Ribbon Supply RollRibbon Take-up Roll

Peel Blade

Head BalanceAdjustment



ystem C

omponents

2.4 Tamp Assembly Module

Quick ExhaustValve Cylinder Home Sensor

Dovetail Slide

Clamshell Mount

Tamp Pad Mount

Tamp Pad

Air CushionAdjustment

Tamp Cylinder

Adjustment Bracket



ystem C

omponents

2.5 Unwind / Rewind

The unwind, also known as the supply roll, meters the label supply to the print module. This device incorporates a patent pending design to measure the remaining supply roll diameter.

The rewind, also known as the take-up roll, wraps the liner material for later disposal. The rewind also incorporates a patent pending design, where the liner tension is held constant through the use of a dancer arm, magnetic sensor, and special control algorithm.

Unwind Spindle

Unwind Disk

Unwind Dancer Arm

Unwind Sensor

Rewind Clasp

Rewind Hub

Rewind Dancer Arm

Arm Bumper

Dancer Arm Sensor



ystem C

omponents

2.6 Product Detector

There are three modes of sensing for the photosensor:

Diffused - ProximityDiffused light lenses use the sensor-emitted light that is reflected from the surface of the product to cause a start trigger. This method works well for products with con-sistent reflective properties. It also provides the simplest setup, only requiring the mounting and alignment of the sensor.

Fiber OpticThe fiber optic method utilizes plastic fiber cables that transmit light to and from the sensor. The fiber optic method improves upon the diffused and reflective methods by detecting a focused beam, which is necessary for smaller products or when a higher degree of precision is necessary. This method requires two independent mounting placements of the fiber optic cable ends, and a separate mount for the sensor.

Tri-Tronics® Lenses

Optical Block Range Type Note

O5 3 Feet DiffusedProximity

Supplied with ALP/4500

R5 7 Feet Polarized Retro-reflective

OptionalIncludes 78P Reflector

F4 1 Foot Opposed Mode Fiber Optic -

Glass

OptionalDistance increased to 20 FT

with lens

F6 9 Inches Opposed Mode Fiber Optic -

Plastic

OptionalDistance increased to 6 FT

with Lens

O4 3 Feet Diffused Proximity, Wide

Beam

Optional

The Tri-Tronics® Smarteye® EZ-PRO™ is supplied standard with the ALP/4500. This sensor has a visible light source, which aids in setting the alignment. It also features a one button calibration for distance and reflectiv-ity. Below is a guide of the Tri-Tronics® lenses:



ystem C

omponents

Retro-ReflectiveThis method incorporates a reflector mounted opposing the sensor. The product must break the beam to trigger the sensor, which is often necessary for products which do not reflect light well or have irregular surfaces.

2.7 Pneumatic Control Module

2.8 Inlet Air Filter / Regulator / Shutoff

Valve Side Vacuum Generator SideGauges

RegulatorsBlanking Plates

Valves

Vacuum Generator

Air Inlet Fitting

The air filter/regulator combines a 5 micron filter, a pressure regulator, and an OSHA approved air shut-off valve with lockout capability. The filter will remove liquid and solid particles larger than 5 microns from the compressed air. This filter is auto-purging; the trap opens when the air supply is removed. Although the ALP/4500 will operate safely up to 145 psi (1 MPa), clean, dry air is rec-ommended to ensure long product life.

To PneumaticControlModule

Quick DisconnectFitting

RegulatorPressure Adjustment

Shutoff

Filter / Trap



ystem C

omponents

2.9 Warning Tower

The segmented warning tower is designed to facilitate ease of bulb replacement. The segmented design allows for an optional change to LED segments, or an audible alarm.The red segment indicates an error condition, where the machine enters the offline mode. The yellow segment indicates a warning con-dition, where the machine continues to run, but the operator is advised to check the user interface to determine the nature of the warning. The green segment indicates the unit is ready and free of errors and warnings.

Red

GreenYellow


Diagraph - an ITW Company ALP/4500 PA ManualInstallation

3.0 Installation

3.1 Overview

The ALP/4500 first time setup installation can be performed quickly, due to the modularity and compactness of the system. The system ships with these main sections requiring assembly:

• Stand Upright

• Stand T-Base

• ALP/4500 Main unit with Yoke

• Product Detector(s)

• Warning Tower

• Power Cable

• Serial PC Cable

• Air Filter / Regulator Assembly

• User Interface Bracket

Once the unit is assembled and the AC power and compressed air are made avail-able, the unit will be ready for system setup.

3.2 Tools Required

• 1-1/8 inch wrench

• 2.5 mm Allen wrench (print module only)

• 1/4 inch Allen wrench

• 5/32 inch Allen wrench (air assist tube adjustment)

• 10 mm open-end wrench

• Medium slotted-tip screwdriver

• Small slotted-tip screwdriver

• Medium Phillips-head screwdriver

Installation Page 19


3.3 Stand

.

WARNING This unit was tested and it was determined that there is a potential for tipping. In compliance with UL safety standards, the stand must be secured to the surface where it is located. Additionally, this type of securing will result in greater product application accuracy.

Upright

CasterT-base

UprightHolder

Assemble the stand by inserting the upright threaded stud into the T-base center hole. Add washer, lock washer, and then nut to the threaded stud. Tighten securely. When stand upright is in place, lock all casters before preceding to attach unit to stand.



3.4 Mounting the Main Unit

Remove the main unit from the packaging and raise the unit’s yoke to the threaded stud on the stand column. Place washer, lock washer, and nut over the yoke and fasten into desired orientation.

WARNING The Main Unit weights over 80 pounds and will require a mechanical lift or assistance from another person to raise the unit’s yoke into place.

Washer

Lock washer

Nut



3.5 Cable Connections

Product Detector (s)Locate the appropriate mounting position for the product detector. This mounting position is critical for optimum throughput. For information on calculating the distance required for this application, see “Setting the Product Delay” on page 68.Connect the DB9 Male end of the product detector to the connector port on the rear enclosure marked, “J2”. If an additional product detect is utilized, install this connector into “J3”.

Once installed, the product detector can be calibrated by placing the target product in front of the detector. Press and hold the yellow button (“UP”) on the detector for 3 seconds, which sets the appropriate value.

NoteCalibration must be performed with the actual product and not a hand or label. Since this sensor is designed to self-compensate for dust and contaminates that accumulate on the lens over time, the optimum initial setting must be performed with the actual product.

Contrast Bargraph

Yellow Push button “UP”

Status Indicators



.

Product Detector Pin-Out

ALP/4500 J2, J3 DB9 Female Pin Description

Pin 1 N/C

Pin 2 PLC/Discrete -Terminal

Pin 3 Ground

Pin 4 PLC/Discrete Jumper 1a

Pin 5 PLC/Discrete Jumper 1b

Pin 6 +24 VDC Supply

Pin 7 N/C

Pin 8 Photosensor Input PLC/Discrete +Terminal

Pin 9 N/C

NoteTo trigger the product detect from a PLC or similar discrete output device, short pins 4 and 5 together. This will switch the input circuitry to be optically isolated from the device. Use pins 2 and 8 to generate a trigger. Do not exceed the 6.8 VDC rating.



Warning Tower

Warning Tower Pin-Out

ALP/4500 J5 DB9 Female Pin Description

Pin 1, 2, 3 N/C

Pin 4 Red (Ground Switched)

Pin 5 Yellow (Ground Switched)

Pin 6 +24 VDC Supply

Pin 7 Green (Ground Switched)

Pin 8,9 N/C

Mount the warning tower to the back of the stand as shown on the left. Fasten two screws through the bracket to secure it to the stand. Extend the warning tower cable through the bracket’s slot and fasten the coupling nut to secure the tower mast into place. Connect the warning tower male DB9 connector to J5 of the rear enclosure. Connect the grounding ring terminal to the jackscrew fastener on the plug shield.



Auxiliary Output

Auxiliary Output Pin-Out

ALP/4500 J4 DB9 Male Pin Description

Pin 1,2 N/C

Pin 3 Output (Active Low)

Pin 4,5 N/C

Pin 6 +24 VDC

Pin 7 N/C

Pin 8 +24 VDC

Pin 9 N/C

Mount the secondary wipedown or other auxiliary device to port J4.



Serial Communications CableThe ALP/4500 utilizes a special serial cable that interfaces the unit to a PC. These cables feature a 25 pin connector with a removable converting cable to directly interface to a 9 pin connector. Below are the part numbers for the different length cables.

Serial Cable Chart

Cable Part Number Description

2806-271-25 25 foot cable (Standard)

2806-271-100 100 foot cable

Serial Communications Pin-Out

ALP/4500 J1, DB25 Female Pin Description

Pin 1 N/C

Pin 2 ALP/4500 Receive

Pin 3 ALP/4500 Transmit

Pins 4,5,6 N/C

Pin 7 Signal Ground

Pins 8,9,10,11,12,13,14,15,16,17,18,19

N/C

Pin 20 Clear To Send

Pins 21,22,23,24,25 N/C



Power Cable

WARNING Incorrect orientation of the fuse block can destroy the power supply circuitry, as well as the secondary control circuits. Verify voltage arrows before connecting power to the unit.

WARNING Outside North America, substitute the power cord set with a harmonized 3 by 1.0 mm² power cord set approved by the country where the unit is located.

The power cable plugs into the power inlet filter receptacle on the rear of the enclosure. This inlet is an IEC-320 connector. The inlet filter contains a removable fuse block. The fuse block’s orientation determines the incoming AC voltage expected. Line-up the arrow to the desired voltage, either 115 VAC or 230 VAC. The default factory setting is for 115 VAC.Terminal 1 is the AC Line in.Terminal 2 is the Neutral Line in.Terminal 5 is the Earth Ground.

Fuse Block

Voltage

Power CordReceptacle

PowerSwitch

Arrows



3.6 Mounting the Inlet Air Filter / Regulator / Shutoff

3.7 Threading the Label Roll

The system threading path is shown below for the label liner and ribbon. Notice that the ribbon path for face-in ribbon is denoted by the solid line, while the dashed line represents the path for face-out ribbon. A web path label is attached inside the print module cover lid for quick reference.

The air filter/regulator mounts to the rear of the stand. Two socket head cap screws secure the unit through the mounting holes in the center of the device. Once the unit is mounted, connect the 8 mm black pneumatic hose from the filter to the Pneumatic Control Module. Next, connect the incoming air line to the quick discon-nect fitting. Turn on the shutoff valve and adjust the pressure regulator by turning the adjustment knob.

MountingHoles

To PneumaticControlModule

Quick DisconnectFitting

Pressure Adjustment Knob

Shutoff Valve

Label Liner

Ribbon PathPath


Diagraph - an ITW Company ALP/4500 PA ManualM

echanical Adjustm

ents

4.0 Mechanical Adjustments

4.1 Adjusting the Tamp Cylinder

Tamp Pad PositionThe tamp cylinder adjustments include:1.The tamp pad distance below and out from the peel blade.2.The tamp pad distance from the baseplate.3.The squareness of the tamp pad to the peel blade.4.The air cushion setting for controlling the return rate of the tamp pad.

The tamp pad should be positioned below the peel blade by approximately 1/16 of an inch. The distance out from the peel blade to the front edge of the tamp pad should be between 1/16 and 1/8 of an inch.

In addition to the tamp pad adjustments described above, the tamp pad requires adjustment in the lateral direction to line-up the vacuum holes with the label. By loosening the two screws which allow tamp pad movement across the peel blade, the tamp pad can be aligned with the feed position of the label. It is important that the vacuum holes used are covered by the label to avoid missing label triggers. Since the presence of a label is determined by the vacuum generated by the label covering these holes, the alignment of the tamp pad must be correct. The printing of several labels may be necessary to ensure the placement is accurate.

NoteIn addition to this tamp pad placement, the label format must have a presentation position of +20 to +40 (1/100 th of an inch). This will allow the printed label to separate from the liner.

1/16” - 1/8”

1/16”

Mechanical Adjustments Page 29


echanical Adjustm

ents

Tamp Cylinder Air Cushion

Tamp Cylinder Quick Exhaust Valve

Cylinder Home Sensor

The air cushion adjustment is made by loosening the jam nut at the top of the tamp cylinder and rotating the set screw clockwise to increase cushion or counter-clockwise to decrease cushion. The air cushion increases the life of the cylinder by stopping the cylinder return with a padding of air. If the air cushion adjustment is set too great, the return may be too slow, which will cause misfeed-ing of labels. Too little air cushion will result in metal to metal contact of the cylinder rod to the housing. There is a distinctive metallic contact noise heard at the end of each tamp cycle when this condition exists.

Air Cushion Adjust

The quick exhaust valve allows the rapid return of the tamp cylinder, while maintaining the adjustable rate of extension. This valve exhausts the tamp cylinder during retraction to increase speed. The screw located on the end of the valve regulates the cylinder return speed. Normally, this screw should be adjusted to the fully-open position, which is obtained when the screw is rotated counter-clock-wise. Once adjusted, tighten the jam nut against the body of the valve.

AdjustmentScrew

Jam Nut

The cylinder home sensor indicates the tamp pad is ready to receive the next label. The sensor must be located at a position which generates a consistent signal each time the cylinder returns home. Since this sensor is magnetic, it is important to position the sensor in the middle of the sensing range. With the system air on and the tamp cylinder home, loosen the screw on the home sensor to allow position movement. Move the sensor up until the light goes out and note the position. Move the sensor down and note this position. Mount the sensor midway between the two positions by tight-ening the screw.

AdjustmentPosition

Home Sensor

Light



echanical Adjustm

ents

4.2 Adjusting the Air Assist Angle

The air assist provides a stream of pressurized air to maintain consistent label pre-sentation and ensure the separation of labels from the liner.

4.3 Tensioning the Unwind Band Brake

The unwind supply roll meters the web supply for each label printed. To allow the printing to start with minimal drag from the unwind supply, the dancer arm rotates to supply this initial demand. Once the printer’s motor has reached a constant speed, the load of the entire unwind can be rotated. After printing is complete, the unwind supply is stopped by a band brake wrapped against the puck on the hub of the roll. The dancer arm returns home once the label supply demand is over. This return to the home position causes the band brake to wrap the puck tightly, thus stopping the unwind supply.

The band brake is attached to the dancer arm at one end and the mounting block on the other. The orientation of this mounting block will set the tension on the brake.

Set Screw In Baseplate EdgeAir Assist Tube

This adjustment begins with loosening the set screw on the bottom edge of the baseplate near the print module. Rotate the tube to the desired position and tighten the set screw. For all labels, aim the air assist tube port holes toward the first row of vacuum holes on the tamp pad. Do not increase air assist pressure until positioning is optimized. Air assist pressure above 20 psi can lead to turbulence on the label while feeding. This can have a negative effect on pre-sentation.

Mounting BlockBand Brake

Unwind Brake Puck

Dancer Arm

Unwind Spring

Dancer Arm Spindle



echanical Adjustm

ents

Loosen the socket head cap screw and rotate the block counter-clockwise to tighten the band brake. Rotate to the position where the dancer arm spindle clears the unwind disk by a 1/4 inch. Once the band brake is in the proper position, tighten the cap screw. When tightening, be sure to keep the block from rotating out of position.

4.4 Adjusting the Pneumatics Regulators

The pneumatic controls set the force and speed of the tamp cylinder, the vacuum generated to hold the label in place before application, and the burst of air required to overcome the tendency of a peeled label to curl away from the pad. These settings are adjustable for a variety of label characteristics and application requirements.

When initially setting up the system, the incoming air filter / regulator will require adjustment. To view the set pressure of this valve, use the procedure above to set the air assist regulator to the maximum setting. Once that is complete, adjust the inlet air regulator knob and read the pressure setting on the air assist gauge. This pressure should be set in the range of 60 to 80 psi. After the inlet air pressure is set, re-adjust the air assist regulator to the normal operating range.

Tamp Cylinder Pressure AdjustmentThe tamp cylinder employs a quick exhaust valve to increase the speed of return. The extension stroke pressure setting contributes to the overall system speed and tamp force experienced by the product. Use a setting in the range of 15 to 25 psi for soft tamp applications, where speed is sacrificed for lighter contact force. If the product rates are higher, use a setting range of 20 to 40 psi for a quick extension, while minimizing hard contact. If higher rates are required, or the application requires a higher contact force, set this value between 40 to 60 psi. Values higher than 60 psi are not recommended.

This system is color-coded to indicate each pneumatic line. The tamp cylinder utilizes the color blue for tamp extension pressure and red for tamp retraction. The internal pressure transducer is fed by a 4mm blue tube.

VacuumAir Assist

Tamp CylinderTo make a change of pressure setting to any of the air regulators, loosen the 10mm jam nut on the setscrew. Adjust the pressure by rotating the setscrew clockwise to increase pressure and counterclockwise to decrease pressure. Upon making pressure changes, the gauge mounted on the regulator will indicate the current set pressure. If the valve is off when the adjustment is made, the set pressure reading may not be accurate until that pressure line is exhausted. Once the appropri-ate setting is made, tighten the jam nut to avoid accidental changes.



echanical Adjustm

ents

Vacuum AdjustmentThe vacuum regulator adjusts pressure fed to the vacuum generator. This setting will vary based on label area and label material type. Settings should be above 15 psi to ensure adequate vacuum is generated, but should be kept below 50 psi. Values above 50 psi have a diminishing return in vacuum through the vacuum generator.

This system is color-coded to indicate each pneumatic line. The vacuum lines utilize the color yellow. The internal vacuum transducer is fed by a 4mm yellow tube. Air Assist AdjustmentThe air assist value should be kept between 5 and 20 psi. The angle adjustment of the air assist tube has a greater effect on label peeling and positioning than an increase in pressure. Over-pressure results in poor label presentation, and at extremes, labels will be ejected from the tamp pad. Under-pressure results in poor peeling and labels curving away from the tamp pad.

This system is color-coded to indicate each pneumatic line. The air assist line utilizes the color orange. The air assist tube is routed into the rear enclosure, and is internally connected to the air assist tube.

NoteIf a label is on the tamp pad while the vacuum is adjusted, the label presence sensor may inaccurately report a label missing or never replace a removed label. Make pressure changes gradually to avoid triggering the label sense.



echanical Adjustm

ents

4.5 Adjusting the Print Module

Head Pressure

Head Balance

The printhead pressure is set at the factory to achieve optimal print. It is strongly recommended that this adjust-ment is not used to compensate for low print darkness before software and head balance adjustments are preformed. To adjust the print head pressure, two Teflon® strips (#553 0687) are placed between the printhead and the drive roller, and the force required to pull the strip out is measured. The two strips are placed at the opposite ends of the head and the printhead latch is locked. The force required to remove the strips should be between 2.5 to 2.9 lbs (11 to 13 Newtons). To increase pressure, turn the screw clockwise. To reduce pressure, turn the screw counter-clock-wise.

Pressure Adjustment Screws

The head balance adjustment is used to level the printhead when printing on narrow labels. Sliding the knob upward (as indicated by the arrow in the illustra-tion) in the slot raises the outside end of the printhead. For media widths extending across the entire print area, use a knob setting closer to the peel blade. With media widths that are less than the full printhead area, use positions toward the printhead. It is important for good print quality and extended head life that the printhead pressure is directed to the media, and not the drive roller. By adjusting this position, only the media area will have the direct print pressure.

Head Balance Knob



echanical Adjustm

ents

Head Alignment

Label Gap Position

The head alignment is critical for proper darkness and image quality. If print is darker on one side than the other, perform the following adjustment. Loosen the printhead mounting screw by one-half turn. Adjust the alignment screw on the side with the poor print. Systematically rotate the screw in or out by a quarter turn. Open and close the printhead latch to make the change effective. Make several test prints and repeat procedure until print quality is uniform across media. Optimal print quality is realized when the printhead heat strip is directly over the center of the drive roller. Tighten the mounting screw when the optimal position is obtained.

Alignment Screws

Printhead Mounting Screw

Latch

The label gap sensor searches for the transition between labels by sensing either the light intensity through the liner material or by reflecting light off of registration marks. For labels with clear surfaces, where the transition between label and liner is difficult to sense, the registration marks provide a consistent method of sensing. The choice of gap or reflective sensing is determined in the label format software settings. The sensor is mounted in a sliding guide to allow the optimal sensing position to be set. It is recom-mended to set the position where the inner or outer edges of the label can not cause a false reading. Improper posi-tioning may cause the feeding of printed and/or blank labels for each requested print.

Gap Sensor Slider



echanical Adjustm

ents

Ribbon Wrinkle Adjustment

4.6 Changing Tamp Pad Label Dimensions

Ribbon wrinkle can contribute to poor print quality and loss of images. To remove ribbon wrinkle, begin printing a series of labels. During the printing process, adjust the ribbon alignment by rotating the red knob above the print-head. Turn the knob in the “+” direction of the reference scale to tighten the inner edge of the transfer ribbon. Turn the knob in the “-” direction to tighten the outer edge of the transfer ribbon. To eliminate ribbon wrinkle, tighten the side of the transfer ribbon where the wrinkles originate.

Ribbon Alignment Knob

Reference Scale

The patent-pending tamp pad design incorporates a series of vacuum channels with port holes to accommodate a wide range of label dimensions. The pad can be configured and re-configured as the application changes. To modify the existing configuration, remove the tamp pad from the tamp cylinder. Remove all fasteners securing the impact plate to the mounting plate. Remove or trim rubber strips as necessary. Always keep the first and last utilized rows of vacuum holes open (to slightly less than the actual label width and length). For longer length labels, leave intermediate “helper” holes open as well.

Silicon Rubber Strips

Vacuum Channel

Impact Plate

Mounting Plate



ymbols and Icons

5.0 Symbols and Icons

5.1 Quick Status “Stick-er”

5.2 Machine Errors

All Ok - Paused Critical Error All Ok - Running

System Locked Password Incorrect Password Correct

Waiting for a Print Format

Warning Condition

No Errors Unwind Error Rewind / Liner Error

Print Module / Label Error

Tamp Cylinder / Repeat Tamp Error

Air Pressure, Auxiliary Output, Miscellaneous

Error

Symbols and Icons Page 37


ymbols and Icons

5.3 Detailed Error Condition Icons

Not In Home Position Bulb Broken or Broken Connection

Repeat Action Error

Ribbon Out or Ribbon Error

Output Shorted or Overvoltaged

Rewind Tension Too Low

Print Module Head Open

Alert for Out Condition Alert for Low Condition

USB Print Module Control Error

Serial Framing Error Memory Full

Media Too Thick Print Module Head Heat

Over-Temperature

Error Condition



ymbols and Icons

5.4 Status Icons

WaitingPassword Required,

System Locked

Password Entered, System

Unlocked

IR Receiving

RS232 Receiving

Product Detector 1

ProductDetector 2

Tamping

Tamp Duration Expired

Product Contact


Diagraph - an ITW Company ALP/4500 PA ManualU

ser Interface Overview

6.0 User Interface Overview

The user interface contains graphic screens containing symbols, icons, and some text. The following screens are utilized for the setup and changing of parameters.

Splash

InitializationOne Time Settings

Information

Label Low Print ModeRepeat Mode

Setup

Product DelayTamp Duration

Auxiliary Delay

Print Module

Actions

Calendar

Diagnostics

Pneumatic SensorsHistory Log

Home

Auxiliary Duration

Serial

Auxiliary ModePassword

System StatusJob Status

Paused

PausedPaused

Paused

Paused Running

Contact Force

User Interface Overview Page 40



Initialization Screen

Initialization Screen

When the unit is first powered on, the initialization of memory, input and out-put ports, print module, and system vari-ables is performed. During this process, this screen is displayed. From this screen and only from this screen, can the one time setup functions be accessed.

A

C

D

B

A) Electronic Serial Number (ESN). The electronic serial number is a unique identification num-ber that is utilized for tracking purposes. This number is set at the factory, and can only be mod-ified through Diagraph MTool software.

B) ALP/4500 Firmware Version. This number indicates the revision level of the firmware for the main ALP/4500 application code.

C) A3 Printer Firmware Version. This number indicates the revision level of the firmware for the print module.

D) One Time Setting Access Button. Pressing this button opens the One Time Setting menu list. This menu allows the changing of parameters that usually require setup upon installation. The following parameters are accessible from this menu:

• Label Low Position• Print Mode (Print on demand or next label out, leading and trailing edge trigger)• Repeat Mode (Threshold for repeating print, threshold for repeat tamping)• Auxiliary Mode (Trigger for start, output device type)• Password (Password value, password enabled)

NoteThese menu selections are only available by pressing the one time setting button, which is only available at power up. These menus are hidden to avoid inadvertent changes.

Diagraph - an ITW Company ALP/4500 PA ManualH

ome S

creen

Home Screen

A

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M

The Home Screen contains the overall system status and menu buttons for the ALP/4500. Upon power up and error con-ditions, this screen is presented to give the user the most general information about the state of the machine. From this screen, there are five other menu selec-tions to view detailed information about the system, or change operating parame-ters.

B

F H

C

A) Run / Stop Button. Pressing this button when the triangle is shown initiates the run mode. Pressing this button when the block is showing stops the machine from running.

B) Serial Activity Icon. This icon is shown when serial communication is in progress.

C) Maintenance Interval Icon. This icon is displayed when the preventative maintenance interval has expired. It can be reset by a qualified Diagraph Service Technician.

D) Setup Button. By pressing this button the run-safe adjustments can be made. These adjust-ments include: product delay, tamp duration, auxiliary delay, auxiliary duration, and running statistics.

E) Status Toggle Button. By pressing this button the user can toggle through several statistical counts, rates, and status details. These values are displayed in the screen area denoted by (M) and (N).

F) System Security Icon. This icon indicates the system security mode. An unlocked icon allows the user to make system setting changes without re-entering the password.

G) Quick Status “Stick-er” Icon. This status icon shows the current basic state of the system. This icon will change when an error, warning, or pending action exists.

H) Run State Icon. This icon shows the current state of the print and apply sequence. The icons displayed are listed in Quick Status “Stick-er” on page 37.

I) Print Module Button. Pressing this button will cause the system to stop, if running, and enter the print module specific adjustment screens. These screens include: batch clear, form feed, test print, time and date, backfeed, and image position adjustments.


Diagraph - an ITW Company ALP/4500 PA ManualH

ome S

creen (Cont)

Home Screen (Cont)

A

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L

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K

M

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F H

C

J) Diagnostics Button. This button permits access to the diagnostic functions allowing individual testing and troubleshooting of each input and output of the system. Entering this menu causes a running system to enter a stopped state.

K) Machine Status. This machine image changes to reflect the current status of the unit. If the unit is experiencing a warning or an error, the general location will be painted black. See Machine Errors on page 37 for the table of machine faults.

L) Information Menu Button. Pressing this button opens the on-board manual containing replacement part numbers, connector pin-outs, and other useful information. Entering this menu causes a running system to enter a stopped state.

M) Status Display Area. This area contains multiple sets of information on the system status and counts with each press of the Status Toggle Button. The following information is available:

Job Application CountPrint Batch Count

ALP/4500 Firmware Version

A3 Printer Firmware Version

Label Format Name (Mem Module)

Electronic Serial Number

ALP/4500 Up Time (Online)

ALP/4500 Down Time (Offline)

Products Per Minute

Products Per Minute Peak

System Application Count

System Printed Count

Job Application Count

Job Printed Count

Error and Warning Information



etup Screen - P

roduct Delay

A

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A) Run / Stop Button. This button reflects the mode that will be entered if pressed. The triangle symbol indicates a transition to the run state if pressed. The square symbol indicates a transition to the stopped state if pressed.

B) Home Button. Pressing this button returns the screen to home.

C) Previous Button. Pressing this button takes the user to the previous setup menu.

D) Increase Button. This button is secured by the password, if enabled. To make a change to the product delay, the password must be entered. Once entered, the user can increase the product delay. As the user continues to depress the increase button, the value will increment faster.

E) Product Delay Time. This is the current setting for the product delay in milliseconds. This delay can range from 10 mS to 10,000 mS.

F) Decrease Button. This button is secured by the password, if enabled. To make a change to the product delay, the password must be entered. Once entered, the user can decrease the product delay. As the user continues to depress the decrease button, the value will decrement faster.

G) Next Button. Pressing this button takes the user to the next setup menu.

WARNING Changing this setting while the unit is online could result in the tamp cylinder firing in front of an oncoming product. Make gradual changes and following the setup instructions in the System Setup section Setting the Product Delay on page 68.

Setup Screens - Product Delay

User Interface Overview

The Product Delay Setup Screen allows the user to adjust the timing of the label application process. This screen can be entered while running and the machine can be ran and stopped while this screen is displayed.

Page 44


etup Screen - Tam

p Duration

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F

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G




D) Increase Button. This button is secured by the password, if enabled. To make a change to the tamp duration, the password must be entered. Once entered, the user can increase the tamp duration. As the user continues to depress the increase button, the value will increment faster.

E) Decrease Button. This button is secured by the password, if enabled. To make a change to the tamp duration, the password must be entered. Once entered, the user can decrease the tamp duration. As the user continues to depress the decrease button, the value will decrement faster.

F) Tamp Duration Time. This is the current setting for the tamp duration in milliseconds. This time can range from 0 mS to 10,000 mS.


WARNING Changing this setting while the unit is online could result in the tamp cylinder firing in front of an oncoming product. Make gradual changes and following the setup instructions in the System Setup section Setting the Tamp Duration on page 68

Setup Screens - Tamp Duration


The Tamp Duration Setup Screen allows the user to adjust the maximum tamp stroke time before the cylinder is returned. This screen can be entered while running and the machine can be ran and stopped while this screen is dis-played.

Page 45



Setup S

creen - Contact Force




D) Increase Button. This button is secured by the password, if enabled. To make a change to the contact force, the password must be entered. Once entered, the user can increase the contact force. The maximum value, 10, will disable the back-pressure sensing. If the sensing is dis-abled, the system will solely rely on the tamp duration time to return the cylinder to home.

E) Contact Force Level. This is the current setting for the contact force. This value can range from 1 for a minimal force contact to 9 for a maximum force contact. A value of 10 disables the back-pressure sensing.

F) Decrease Button. This button is secured by the password, if enabled. To make a change to the contact force, the password must be entered. Once entered, the user can decrease the contact force.


Setup Screens - Contact Force

The Contact Force Setup Screen controls the pressure applied to the product before the tamp pad is returned to the home position. Since the back-pressure is monitored, force exerted to the prod-uct can be optimized.

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G


etup Screen - A

uxiliary Delay

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G

E

B F

H


B) Auxiliary Trigger Mode Setting. This symbol indicates the current trigger for auxiliary action. This selection is made in the setup screen, One Time Setup - Aux Mode on page 61.

C) Home Button. Pressing this button returns the screen to home.

D) Previous Button. Pressing this button takes the user to the previous setup menu.

E) Increase Button. This button is secured by the password, if enabled. To make a change to the auxiliary delay, the password must be entered. Once entered, the user can increase the auxiliary delay. As the user continues to depress the increase button, the value will increment faster.

F) Auxiliary Output Mode Setting. This symbol indicates the current output response for auxil-iary mode. This selection is made in the setup screen, One Time Setup - Aux Mode on page 61.

G) Decrease Button. This button is secured by the password, if enabled. To make a change to the auxiliary delay, the password must be entered. Once entered, the user can decrease the auxiliary delay. As the user continues to depress the decrease button, the value will decrement faster.

H) Auxiliary Delay Time. This is the current setting for the auxiliary delay in milliseconds. This time can range from 0 mS to 10,000 mS.

I) Next Button. Pressing this button takes the user to the next setup menu.

Setup Screens - Auxiliary Delay


The auxiliary delay sets the amount of time waited from the triggering event to the output action.

Page 47


etup Screen - A

uxiliary Duration

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F

E

B

G


B) Auxiliary Output Mode Setting. This symbol indicates the current output response for auxil-iary mode. This selection is made in the setup screen, One Time Setup - Aux Mode on page 61.



E) Increase Button. This button is secured by the password, if enabled. To make a change to the auxiliary duration, the password must be entered. Once entered, the user can increase the auxil-iary duration. As the user continues to depress the increase button, the value will increment faster.

F) Decrease Button. This button is secured by the password, if enabled. To make a change to the auxiliary duration, the password must be entered. Once entered, the user can decrease the auxil-iary duration. As the user continues to depress the decrease button, the value will decrement faster.

G) Auxiliary Duration Time. This is the current setting for the auxiliary duration in milliseconds. This time can range from 0 mS to 10,000 mS.

H) Next Button. Pressing this button takes the user to the next setup menu.

Setup Screens - Auxiliary Duration


The auxiliary duration sets the amount of time to maintain the active output level once the delay time has expired. Once this duration is complete, the output resumes the inactive state.

Page 48



Setup S

creen - System

Status


B) Labels Applied Counter. This counter shows the number of tamp cycles that resulted in label application. This counter cannot be reset.


D) ALP/4500 Firmware Version. This parameter shows the current firmware version for the ALP/4500.

E) Previous Button. Pressing this button takes the user to the previous setup menu.

F) Electronic Serial Number (ESN). The electronic serial number is a unique identification num-ber that is utilized for tracking purposes.

G) Labels Printed Counter. This counter shows the number of labels printed. This counter cannot be reset.

H) Print Time. This timer accumulates the print time, in minutes, for each printed label. This counter cannot be reset.

I) ALP/4500 Time. This timer accumulates the time, in minutes, the ALP/4500 has been powered on.

J) A3 Printer Firmware Version. This parameter shows the printer’s firmware version.

K) Next Button. Pressing this button takes the user to the next setup menu.

Setup Screens - System Status

The system status screen contains infor-mation about counters, time monitors, system specifics, and other system parameters.

A

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E K

H

FB

G

I

JD



Setup S

creen - Job Status


B) Job Labels Applied Counter. This counter shows the number of tamp cycles that resulted in label application. This counter can be reset, in addition to the other job counters, by pressing (F).



E) Job Labels Printed Counter. This counter shows the number of labels printed. This counter can be reset, in addition to the other job counters, by pressing (F).

F) Clear Counts Button. This button clears all job counters and timers when pressed.

G) Products Per Minute. This statistic shows the number of products that have been labeled per minute. This counter updates every minute.

H) Products Per Minute Maximum. This statistics number shows the maximum number of prod-ucts that have been labeled per minute. This counter updates every minute.

I) Next Button. Pressing this button takes the user to the next setup menu.

Setup Screens - Job Status

The job status screen contains informa-tion about counters, time monitors, and job specifics.

A

C

D I

F

BE

G

H

Diagraph - an ITW Company ALP/4500 PA ManualP

rint Module S

creens - Actions

A

B

C F

E

D

G

A) Clear Print Module Batch Button. Pressing this button clears the batch job running in the printer. It will also clear any Protocol errors caused by incorrect format data or serial framing errors. This button action requires correct entry of the password before the job is cleared.


C) Previous Button. Pressing this button takes the user to the previous print module menu. If a batch is running, it will not be possible to access the other print module screens. The batch must be cleared with the Clear Print Module Batch button, listed above, before those screens can be accessed.

D) Form Feed Button. Pressing this button will force a blank label to be advanced through the printer. When a label feed is performed, the rewind will not take-up the liner.

E) Test Print Button. Pressing this button will generate a diagnostic test label with the settings of the unit, counter information, and a detailed history log of the events of the system with a time/date stamp.

F) Next Button. Pressing this button takes the user to the next print module menu. If a batch is running, it will not be possible to access the other print module screens.

G) Printer Status. This is the direct status from the printer. The first character is either Y(es) or N(o) if the unit is online. The second character is the error code. The numbered value is the batch count. The last character is either Y(es) or N(o) for batch in queue.

Note This function is not active if there is a batch running in the printer. The test print function will not activate the rewind to take up the liner.

Print Module Screens - Actions


The Print Module Screen for Actions pro-vides the capabilities for clearing a printer batch, form feed a label, or print the system settings and history log with a test print button.

Page 51


rint Module S

creens - Serial

A

C

D G

E

F

B

A) Baud Rate Change Button. This button toggles the selection for baud rate. The baud rates available are 9600, 19200, 38400, and 57600.

B) Baud Rate. This number shows the current baud rate for the system.


D) Previous Button. Pressing this button takes the user to the previous print module menu.

E) Handshaking Change Button. This button toggles between the three selections for handshak-ing:

1.No Handshake mode provides the simplest interface, by only requiring transmit and receive serial lines and no software generated start and stop characters.

2.RTS/CTS mode adds handshaking support in the form of extra signal lines by monitoring the PC serial port for busy conditions and sending a wait signal when processing large buffer data.

3.XON/XOFF mode provides handshaking support by means of software generated characters that control the flow of data.

F) Handshaking Mode. This icon indicator shows the current mode of handshaking.

G) Next Button. Pressing this button takes the user to the next print module menu.

Note If the rate is changed, it will not take effect until this screen is exited. The system does not need to be power cycled for the new rate to take effect.

NoteIf the handshaking mode is changed, it will not take effect until this screen is exited. The system does not need to be power cycled for the new handshaking mode to take effect.

Print Module Screens - Serial


The Print Module Screen for Serial con-tains the controls for changing the serial baud rate and handshaking options.

Note: This screen is only accessible when there is no batch job in the print module.

Page 52


rint Module S

creens - Calendar

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D K

H

J

B

F

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G

E

L

A) Change Selector Position Button. Pressing this button moves the arrow (B) to indicate the active selection that will be changed when the “+” and “-” buttons are pressed.

B) Selector Arrow. This indicator points to the active selection.


D) Previous Button. Pressing this button takes the user to the previous print module menu.

E) Month Value. This value represents the month setting for the time and date clock.

F) Increase Button. Depending on the position of the Selector Arrow, the corresponding value will be increased by pressing this button.

G) Day Value. This value represents the day setting for the time and date clock.

H) Decrease Button. Depending on the position of the Selector Arrow, the corresponding value will be decreased by pressing this button.

I) Year Value. This value represents the year setting for the time and date clock.

J) Hour Value. This value represents the hour in 24 hour format for the time and date clock.

K) Next Button. Pressing this button takes the user to the next print module menu.

L) Minute Value. This value represents the minutes for the time and date clock.

Print Module Screens - Calendar


This menu permits the adjustment of the time and date clock that is resident on the print module. This time and date can be referenced by a label format to popu-late a label field. The time and date can also be adjusted in the label creation software.

Note: This screen is only accessible when there is no batch job in the print module.

Page 53

Diagraph - an ITW Company ALP/4500 PA ManualD

iagnostics Screens - P

neumatics

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B F

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A) Air Assist On/Off Button. This button opens and closes the air assist valve.

B) Air Assist Valve State. This indicator shows the requested air assist valve on / off condition.


D) Previous Button. Pressing this button takes the user to the previous diagnostics menu.

E) Cylinder Home Sensor State. This is the state of cylinder home (1 = home, 0 = not home).

F) Vacuum Valve State. This indicator shows the requested vacuum valve on / off condition.

G) Vacuum Valve On/Off Button. This button opens and closes the vacuum valve.

H) Vacuum Level. This is the value from the transducer. It ranges from 0 to 9.99 inHg.

I) Tamp Cylinder Valve State. This indicates the tamp cylinder valve on/off condition.

J) Tamp Cylinder On/Off Button. This button extends and retracts the tamp cylinder.

K) Tamp Cylinder Pressure Level. The air pressure level measured by the transducer is shown here. This value increases with tamp pressure. It ranges from 0 to 80 PSI.

L) Next Button. Pressing this button takes the user to the next diagnostics menu.

WARNING Activating the Tamp Cylinder Valve will cause the cylinder to extend and remain extended until this button is pressed again. This action should be performed offline from production and clear of any personnel.

Diagnostics Screens - Pneumatics


The Diagnostics Screen for Pneumatics provides the ability to test components that comprise the pneumatics system. These screens simplify troubleshooting, without additional tools or test equip-ment.

Note: In this section, the number “1” represents an ON condition, while a “0” represents an OFF condition.

Page 54


iagnostics Screens - S

ensors

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F

A) Auxiliary Output On/Off Button. This button turns on and off the auxiliary output.

B) Auxiliary Output State. This indicator shows the auxiliary output on / off condition.



E) Unwind Sensor Counter. This value shows the pulses per second generated by rotating the unwind disk.

F) Rewind Dancer Arm Sensor Image. This image changes as the rewind dancer arm is sensed at home and away from home positions.

G) Rewind Motor On/Off Button. Pressing this button will engage the rewind until it is depressed again.

H) Rewind Motor State. This indicator shows the rewind motor on/off state.

I) Next Button. Pressing this button takes the user to the next diagnostics menu.

J) Product Detector 2 Sensor Status. This indicator shows the current state of product detector 2.

K) Product Detector 1 Sensor Status. This indicator shows the current state of product detector 1.

Note When testing this sensor, it is important to ensure that the counter value increases as the rate of rotation increases. If this does not occur, there may be an internal trim setting required.

Diagnostics Screens - Sensors


The Diagnostics Screen for Sensors allows the simultaneous viewing of sev-eral sensor inputs. Additionally, the out-puts for the rewind motor and auxiliary port can be toggled on and off.

Note: In this section, the number “1” represents an ON condition, while a “0” represents an OFF condition.

Page 55


iagnostics Screens - H

istory Log

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B F

A) Time and Date Stamp. This field shows the timestamp of the following system history entry. The format is MM/DD HHMMSS, where MM is month, DD is the day, HH is the hour in 24 hr. format, MM is the minute, and SS is the seconds.

B) Event Field. This field contains the event that was logged. The first three characters indicate the source, USR for user initiated actions, SYS for system events, and ERR for error events.



E) History Page Increase Button. Pressing this button will increase the current history page view.

F) Current History Page. This value indicates the current page of the history log.

G) History Page Decrease Button. Pressing this button will decrease the current history page view.

H) Next Button. Pressing this button takes the user to the next diagnostics menu.

Diagnostics Screens - History Log


The Diagnostics History Log Screen is an advanced method of troubleshooting problems by viewing the events of the system. This “Black Box Recorder” gives the user or technician the chain of events proceeding a problem along with the time and date of the occurrence. The log contains the last 25 events, and can only be cleared by using MTool service soft-ware.

Page 56

Diagraph - an ITW Company ALP/4500 PA ManualInform

ation Screens

A

C

D E

B

A) Part Number. This is the Diagraph part number for the illustrated component.

B) Part Drawing. This image is used to represent the common replacement modules of the sys-tem.


D) Previous Button. Pressing this button takes the user to the previous information image screen.

E) Next Button. Pressing this button takes the user to the next information image screen.

Information Screens


The Information Screens display useful information such as: assembly images, part numbers, pin-outs for connector ports, and other details.

Page 57



One T

ime S

etup - Label Low

A) Home Button. Pressing this button returns the screen to home.

B) Previous Button. Pressing this button takes the user to the previous one time setup screen.

C) Label Low Position. This image shows the trigger level for a label low condition. There are four positions which set trip point diameters at 3.5, 4.5, 5.5, and 6.5 inches.

D) Position Increase Button. Pressing this button enlarges the trip point diameter for label low.

E) Position Decrease Button. Pressing this button reduces the trip point diameter for label low.

F) Next Button. Pressing this button takes the user to the next one time setup screen.

One Time Setup - Label Low

The label low position determines the alert diameter for the label supply roll. By setting this position for the given con-sumption rate and label size, the opera-tor can be alerted by the warning tower and the user interface at the optimal time for roll replacement.

A

B F

E

D

C



One T

ime S

etup - Print M

ode

A) Print Mode Button. This button toggles the selection for which event causes the next label to be printed.


C) Previous Button. Pressing this button takes the user to the previous print module menu.

D) Current Print Mode. This symbol shows the start of print mode.

• Indicates that the return of the tamp cylinder will start printing. Provides the

fastest throughput for static data.

• Indicates that the first product detector will initiate printing. Utilized in slow

throughput and/or changing format data applications.

• Indicates that the second product detector will initiate printing. Utilized in

slow throughput and/or dynamic format data applications.

E) Product Edge Selector Button. This button toggles between leading and trailing edge trigger.

F) Product Edge Mode. This indicator shows which end of the product will be used as the refer-ence for label placement. (Leading edge shown.)

G) Next Button. Pressing this button takes the user to the next print module menu.

One Time Setup - Print Mode

The mode of print determines when the label will be printed for the next applica-tion and which product edge triggers the application sequence. For high-speed, non-changing formats, the next-label-out mode is ideal. For dynamic fields or slow product rates, select which product detector initiates a print. The leading or trailing edge sets the justification of the label to the front or rear of the product.

A

B

C G

E

F

D

Diagraph - an ITW Company ALP/4500 PA ManualO

ne Tim

e Setup - R

epeat Mode

A

C

D H

G

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E

F

A) Print Repeat Increase Button. Pressing this button increases the number of times the printer will attempt to deliver a label to the tamp pad.

B) Print Repeat Setting. This value represents the number of times the printer will attempt to print a label to the tamp pad. A value of “1” will allow the printer to print one label, and signal an error if it is removed. A value of “0” will allow unlimited printing. The maximum number of repeat prints is 9.

C) Print Repeat Decrease Button. Pressing this button decreases the number of times the printer will attempt to deliver a label to the tamp pad.

D) Previous Button. Pressing this button takes the user to the previous one time setup screen.

E) Tamp Repeat Increase Button. Pressing this button increases the number of times the tamp will attempt to apply the label.

F) Tamp Repeat Setting. This value represents the number of times the tamp cylinder will attempt to apply the same label. The cylinder will fire once per product trigger. A value of “1” will allow the cylinder to tamp one time and signal an error if the label is still present on the pad when the cylinder is retracted. A value of “0” will allow unlimited tamping. The maximum number of repeat tamps allowed is 9.

G) Tamp Repeat Decrease Button. Pressing this button decreases the number of times the tamp will attempt to apply the label.

H) Next Button. Pressing this button takes the user to the next one time setup screen.

One Time Setup - Repeat Mode


The repeat mode functions serve to limit the number of labels printed and/or tamped without application. When this limit is exceeded for either printed labels or tamp cycles, an error is generated.

Page 60



One T

ime S

etup - Aux M

ode

A) Auxiliary Trigger Button. Pressing this button cycles through the choices for auxiliary trigger.

B) Auxiliary Trigger Mode Setting. This symbol shows the current auxiliary trigger mode set-ting. There are several trigger modes available, all are listed in Auxiliary Trigger Modes (Optional Device Setup) on page 69.


D) Previous Button. Pressing this button takes the user to the previous one time setup screen.

E) Auxiliary Mode Button. Pressing this button cycles through the choices for auxiliary mode.

F) Auxiliary Output Mode Setting. This symbol shows the current auxiliary output mode setting. There are several output modes available, all are listed in Auxiliary Output Modes (Optional Device Setup) on page 70.

G) Next Button. Pressing this button takes the user to the next one time setup screen

One Time Setup - Aux Mode

The auxiliary output can be utilized for many applications. This menu allows the setting of the auxiliary function to be specified and the trigger event. The sym-bol of the rotated box with the arrow extending indicates the auxiliary output.

A

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ne Tim

e Setup - P

assword

A

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E H

G

B

F

D

A) Password Enable/Disable Button. Pressing this button toggles the password enable mode. If enabled, all setting changes will be prefaced by a password entry.

B) Password Enabled Icon. This icon shows the current state of the password enable. Password disabled is shown.


D) Numeric Password Line. This shows the new password, and its adjustment, once the old pass-word is entered.

E) Previous Button. Pressing this button takes the user to the previous one time setup screen.

F) Password Value Increase Button. Pressing this button increases the value of the numeric pass-word. This change is not possible until the current password or backdoor password is entered correctly.

G) Password Value Decrease Button. Pressing this button decreases the value of the numeric password. This change is not possible until the current password or backdoor password is entered correctly.

H) Next Button. Pressing this button takes the user to the next one time setup screen.

One Time Setup - Password


The password screen allows the chang-ing of the password and the enabling / disabling of the requirement of password before changing application settings.

Note: The initial system password is ‘4500’. This password can be changed to any four digit sequence. If you ever lose or forget your pass-word, contact Diagraph for assistance.

Page 62

Diagraph - an ITW Company ALP/4500 PA ManualT

heory of Operation

7.0 Theory of Operation

7.1 Introduction

The ALP/4500 is a modular print and apply unit which fully automates the process of printing and applying labels to a product. To accomplish this task with the highest accuracy and precision, while maintaining a high throughput, the system employs a 32 bit Motorola processor containing an independent timing processor unit. This processor is accompanied by “smart” output drivers, communication devices, voltage converters for the pressure and vacuum transducers, and graphics LCD con-troller. Together, this system continuously monitors the print and apply process. This process of five states is outlined below.

7.2 Printing State

The initial state of the system is the printing state. In this state, the system deter-mines when to print the label. There are two mode selections for print mode. First, there is the Print After Tamp mode, which yields the highest throughput by printing the next label as soon as the tamp cylinder is sensed in the home position. The second mode is Print on Demand. This mode allows either product detector one or two to start the print process. This means that after the last tamp cycle, no label is printed. Only after the selected detector is triggered will the next label be printed. This mode is useful for products rates that are slow, and would allow a label left on the tamp to accumulate debris that would reduce the label’s adhesion to a product. A common application of this is in the instance where the label’s information is specific to each product. In this scenario, the label data must be sent from a remote PC or similar device just prior to the label’s application. Using the Print on Demandmode, the label will not be printed until the product is approaching, thus giving the necessary time to transmit the specific data. Once the label is on the tamp pad the next state, label presence, is active. Additionally, the product detection state is awaiting a product to tamp.

7.3 Label Presence State

The label presence state is active from the time the label is printed until the label is applied. Through the use of a vacuum transducer, the tamp pad is monitored for the existence of a label. If the label is removed by the user or becomes dislodged from the pad, the system will detect the missing label. At this point, the system’s configu-ration will determine the next course of action. If the system throughput is high, and the time the label is present to the time the tamp is executed is very short, the system may not be able to verify the label is on the tamp pad to apply. The tamp will execute, assuming the label was present. This duration of time is proportionally related to the label length. The longer the label, the longer it takes to sense the vacuum change.

Theory of Operation Page 63


heory of Operation

If the Repeat Print mode is set for a value other than one, the system will request another label to be printed. If the value is zero, the unit will continue to print until a label is firmly held affixed to the tamp pad. Once the number of printed labels exceeds the repeat print’s threshold setting, the system will cause a fault, which forces the system offline and an alert will be displayed on the user interface. Addi-tionally, the warning tower will be illuminated red.

7.4 Product Delay State

This state is entered upon the triggering of product detector one. If the print state was utilizing the Print on Demand feature with product detector one, these two processes will begin simultaneously. Upon triggering the product delay state, the system will wait the amount of time entered by the user as product delay. At the completion of the time delay, the system will enter the application state.

7.5 Application State

Once the product delay time expires, the system verifies label presence on the pad. Once verified, the system performs the application, which employs a pressure trans-ducer to detect the contact of the tamp pad with the product. On the extension of the cylinder, the pressure transducer reads the profile of the pressure with the cylinder movement. Since it requires nearly the entire set pressure to begin the cylinder movement, the initial pressure is measured and used as a reference for the contact. Now that the cylinder is moving away from the home position, there is a large reduction of pressure in the cylinder. Once the tamp pad contacts the product’s surface, there is an abrupt change in pressure. Since the pressure is constantly moni-tored, the system knows the precise instant of contact, and reverses the tamp cylin-der’s direction. In this manner, the system can apply the same force per contact, regardless of the tamp distance variations, pressure fluctuations, product’s reflectiv-ity, and environment conditions, such as temperature and lighting. It also requires no adjustment, since it calibrates the contact threshold for each stroke.

After the contact, the tamp returns home, and checks whether or not the label is still present on the pad. If the label is still present, this could mean that there was a false product trigger, or the label did not adhere to the product. By sensing this condition, the system will determine what action to take based on the user’s selection for Repeat Tamp. If the Repeat Tamp threshold is set for a value other than one, the system will attempt to apply the same label to each successive product until the threshold is exceeded. If exceeded, the system will stop and remain offline, indicat-ing an error condition. If the threshold value is set for zero, the tamp cylinder will continue to apply the same label indefinitely, or until that label is applied to the product.



heory of Operation

7.6 Background Tasks

While the system is online, there are many tasks being performed to check the integrity of the system and monitor the state of the consumable products. There are five main tasks to accomplish this, these include: Label Low, Label Out, Ribbon Out, Print Module Errors, and the Continuous Monitor Mode task.

Label Low / Label OutThis task monitors the label supply utilizing an optical slot sensor to determine roll diameter. The unwind sensor, in conjunction with the slotted unwind disk, perform as an encoder, thus accumulating counts as the unwind rotates. By using this rota-tional information combined with the label print duration, the system can accurately calculate the outer diameter of the remaining label supply roll. In this manner, a software selectable label low condition can be set by the user. This enables the user to optimally set the low condition. The label low state causes the warning tower to change to a warning fault, which is indicated by the yellow segment on the tower, and updates the user interface with the label low image. The machine continues to run, but indicates the operator will need to service the condition soon. It is therefore important to set the correct low condition size, which is based on the label length and product rate. For instance, if the label size is long or the throughput is high, the user may wish to set a larger roll diameter for a low condition. Alternately, if the throughput is low, or the label length is short, the user may opt for the smaller diameter setting. For more details on low position, see “Determining Label Low Position” on page 67.The label out condition is detected when there is no more movement from the supply roll while a label is being printed. If this condition is detected, the system is placed offline.Usually, there is an adhesive bond holding the label liner to the core. The system detects when the last few labels are remaining. At this point, the system stops the print and apply process, thus eliminating possible adhesive entry to the print module.

Ribbon OutThe ribbon state is monitored by the print module when running in a thermal transfer mode. Once the ribbon supply is exhausted, the system is set to offline and the warning tower is illuminated red.

Print Module ErrorsAll print module errors are monitored and displayed on the graphics display. All errors from the print module will cause the system to transition to offline.

Continuous Monitor ModeIn order to automatically detect failing components and sub-systems, the ALP/4500 incorporates a monitoring task with hardware dedicated to detecting intermittent and continuous faults. This monitoring includes the memory, the pneumatic valves and



heory of Operation

drivers, the warning tower and auxiliary drivers, bulbs, wiring, the infrared serial port, and the RS232 serial port communications. The memory’s integrity is checked after every power up and during all saves of user settings. The monitoring of the pneumatic valves, warning tower, and auxiliary device utilizes a similar approach. Each output is protected against shorts, opens, over voltages, and static discharges. Each output line’s status is read by the system to determine whether a valve has failed or a bulb is out. If the circuitry detects a failure, it is reported to the warning section of the system status. The infrared and RS232 ports have an integrated loopback test, where the transmit line is fed to the receive line to test the drivers and receivers.



ystem S

etup

8.0 System Setup

8.1 Determining Label Low Position

The ALP/4500 incorporates a variable position for label low alert. Although the sensor is mounted in a fixed position, the trigger point is fully adjustable through the user interface. There are four positions to choose from on the One Time Setup - Label Low on page 58. The smallest size outer roll diameter that can be set is 3.5 inches, and increments by 1.0 inch for each successive position. The position to select for this warning is based on three factors:

• Label Length. With greater label length, there are less labels remaining on the roll for a given diameter. If the label length is long, this setting should be increased to alert the operator at a larger diameter to a low condition.

• Product Rate. If the product rate is consuming labels quickly, it is advantageous to set this position to a larger diameter. If the product rate is considerably slow, it may be preferable to set this condition to the smallest diameter setting.

• User Preference. As the operator gets familiar with the system, there may be a more optimal setting that does not allow the machine to run out of labels, while avoiding a premature alert.

8.2 Selecting Mode of Print

In the Print Trigger Screen, the beginning of the print cycle can be selected from three choices. The three modes are listed below, along with their intended use.

• Print after Tamp - This will yield the highest throughput by printing the next label as soon as the tamp pad is detected in the home position.

• Print on Demand using photosensor one - This will reduce the possibility of the label losing its adhesive effectiveness by printing the label as the product approaches. Furthermore, this method permits the label format to change dynami-cally and still remain current for the approaching product. This mode specifically uses one sensor, product detector one, for both print and apply triggers.

• Print on Demand using photosensor two - This method is similar to the one above, with a key distinction that a separate trigger is controlling the print start. This can be either a photo detector or PLC-type device. As with the method above, the print process must be complete before the expiration of the product delay time, otherwise, the label will not be applied to this product.

Note If this single detector is used for both print and apply triggers, additional distance will be required between the tamp pad and the detector. If sufficient distance is not given to print the label before the product delay completes, the label will not be applied.

System Setup Page 67

Diagraph - an ITW Company ALP/4500 PA ManualE

ntering Setup Inform

ation

9.0 Entering Job Setup Information

9.1 Setting the Product Delay

Once the product detector has triggered the start of an apply cycle, the timing cycle begins counting down the time in milliseconds until the tamp cylinder should be activated to extend. This time setting is based on two factors. First, the distance from the product detector and the edge of the peel blade must be measured. The second factor is the line speed of the conveyor system. With these two values, an estimated delay can be entered for product delay. See the chart below for typical delay settings given the line speeds and distance.

This delay value is entered in the Setup Screens - Product Delay on page 44. The chart shows some typical distances and linespeeds and the resulting delay value. By trial and error, the product delay can be adjusted until the desired label placement is achieved.

9.2 Setting the Tamp Duration

The tamp duration is the time that will not be exceeded if the tamp pad does not contact the product. This time is measured in milliseconds and begins when the tamp pad leaves the home position. In normal operation, the tamp pad contacts the product, and that contact immediately returns the cylinder to the home position. In the event of a false trigger or an abrupt stop of the conveyer, the tamp cycle will start, but not sense a contact. The tamp duration time ensures that the cylinder will not be extended longer than the expected time for contact. In the case of varying

Product Delay Chart

150 ft./min. 66 ms 200 ms 400 ms

125 ft./min. 80 ms 240 ms 480 ms

100 ft./min. 100 ms 300 ms 600 ms

75 ft./min. 133 ms 400 ms 800 ms

50 ft./min. 200 ms 600 ms 1200 ms

25 ft./min. 400 ms 1200 ms 2400 ms

2 in. 6 in. 12 in.

WARNING It may be necessary to adjust the tamp dwell time to a setting that avoids contact with the product until the optimal placement is set. This will avoid accidental firing of the tamp cylinder in front of the oncoming products.

Entering Job Setup Information Page 68



ation

product heights (top down application) or varying widths (side apply or nose up/down orientations), this time should be configured for the smallest product and thus, the longest delay. Once the delay is determined, it can be entered in the Setup Screens - Tamp Duration on page 45. The home screen indicates the cause for tamp pad return, which is useful for adjusting this delay. Normally, the contact sensing should be the cause for tamp pad return.

9.3 Auxiliary Trigger Modes (Optional Device Setup)

Auxiliary Trigger Modes

Mode Description

Tamp Cylinder Return Triggers when the application cycle is complete.

Product Detector 1 Triggers when the first product detector detects a product.

Product Detector 2 Triggers when the second product detects a product.

Error Condition Triggers when an error condition exists.

Warning Condition Triggers when a warning condition exists.




ation

9.4 Auxiliary Output Modes (Optional Device Setup)

The auxiliary output is a common collector output, which means that it switches the ground in and out to complete the circuit. Using the +24 VDC in conjunction with this output, the auxiliary port can switch solenoids, valves, PLCs, and relays. The chart below outlines the many uses for the auxiliary output.

Auxiliary Output Modes

Mode Description

Secondary Wipedown This device consists of a pneumatic cylinder with a brush mounted at the extending end. To create a label that is visible on two sides, or panels, the label is printed and applied with some portion of the label extending beyond the product. The secondary wipedown fires it’s cylinder to wipe the label around the second panel. The coordina-tion requires the wipedown extension to be timed with the product arriving downstream. This delay represents the time from the product detector to the wipedown unit.

Discrete Positive This output can be configured to supply a positive voltage transition (with an external pull-up resistor) after the delay time has expired. The output will go back to inactive at the completion of the duration time.

Discrete Negative This output can be configured to supply a negative voltage transition (with an external pull-up resistor) after the delay time has expired. The output will go back to inactive at the completion of the duration time.

Hotstamp This output can be configured to activate a hotstamp device.

NoteThis system incorporates a sophisticated tracking system that allows up to four (4) products in the span between the triggering device and the secondary wipedown. This unique ability allows one product detector to be used for all operations, and allows the extended placement of the secondary wipedown position.




ation

9.5 Setting the Auxiliary Delay (Optional)

The auxiliary output can be used for many secondary operations that occur after or before the label is printed. This delay determines the time to wait after the triggering event has occurred until the output is toggled.

9.6 Setting the Auxiliary Duration (Optional)

The auxiliary output can be used for many secondary operations that occur after or before the label is printed. This duration determines the time to remain in the active output state until resuming normal output.

9.7 Setting Label Format Parameters

There are several parameters contained in the label format that must be set correctly for operation. The print module performs label generation in coordination with the applicator, and therefore the label format must contain the correct information. There are many programs that ease the creation of a label format by utilizing a graphical representation of the label and building blocks to create barcodes, images, text, and graphics. The following parameters require specific setup. Although the terms used my vary, the descriptions are provided to determine a compatible param-eter.

Printer ModelThis is also known as the printer driver. Since the print module is based on the CAB A3 tabletop printer, the typical driver choices are A3 (203 dpi) and A3-300 (300 dpi). If using EasyLabel™, there are specific ALP/4500 drivers for 203 and 300 dpi printheads, which have default values specific to the applicator.

Presentation PositionThis setting is also known as backfeed distance. This parameter controls the distance that the label is fed forward beyond the gap of the next label. This allows the label to be fully released from the liner to reach the tamp pad. Once the label is printed, the printer’s motor reverses direction and the next label is returned to the ready to print position. This distance is based on the separation distance between the tamp pad and the peel blade. Typical distances vary from 0.20 inches to 0.60 inches (20 to 60 since the entry is measured in 1/100 th of an inch).

Backfeed SpeedThis setting controls the speed that the label is returned to the printhead following the presentation feed. This speed should be between 2 and 4 inches per second for proper rewind control. Speeds higher than 4 inches per second can cause image reg-istration issues.




ation

Print ModeThis setting is also known as the application mode. Choices include Batch, Peel-off, and Tear-off. The correct mode of operation is Peel-off.

Direct ThermalThis setting enables or disables the ribbon sensor. This mode disables the ribbon out sensor. The other mode is Thermal Transfer, which utilizes a ribbon to create print information on the label. This mode enables the ribbon out sensor.

Note Direct Thermal does not require a ribbon, and therefore decreases downtime and consumables required. Direct Thermal requires a slightly more expensive label and the labels are sensitive to heat.

Note Thermal Transfer does require a ribbon, but the print quality is superior to Direct Thermal. Thermal Transfer labels are less expensive, and are not sensitive to heat.



peration

10.0 Operation

10.1 Starting Operation

Before starting the ALP/4500 for the beginning of a production run, examine the following list of operational checks to ensure safety and maintain the longevity of the ALP/4500 system.

• Verify the correct threading of the label liner through the machine. Areas to check thoroughly include the path at the air assist tube, label gap sensor, and the rewind dancer arm.

• Check the unwind band brake by rotating the supply. With the brake on, the move-ment should be resistive. With the unwind dancer arm rotated toward the print module, the movement should be smooth.

• Inspect the tamp pad for any label material or contaminants blocking the vacuum port holes.

• Visually check the air inlet filter for excessive contamination.

• Visually inspect the air lines for breaks, cuts, and abrasions.

• Check that all electrical enclosures are securely closed.

• Rotate the E-stop switch in the direction of the arrows on the top of the switch to unlock it.

• Turn the unit on at the AC power inlet.

• Open the Air Filter shutoff valve to pressurize the pneumatic lines.

• Allow the system to initialize. The Home screen will be displayed when the unit is ready.

• Load appropriate label format.

• Bring unit online and active by pressing the run icon on the Home Screen.

10.2 Throughout Operation

The operation of the ALP/4500 is automatic once it is in the online mode. The only user interaction required will be when the label and/or ribbon roll must be changed out.

10.3 End of Operation

By following the end of operation steps below, the safety of personnel working with the machine is greatly increased.

• Offline the unit by pressing the stop icon on the Home Screen.

Operation Page 73


peration

• Remove any labels remaining on the tamp pad.

• Wipe down the unwind slot sensor, which may have accumulated dust from the liner.

• Shut off the air inlet filter valve and perform lock-out, tag-out procedures.

• E-stop the unit by pressing down on the emergency stop switch. Verify the power is now off.

• Turn off the unit’s main power switch at the AC power inlet.

• Cover the unit if operated in a wash-down environment.

Operation Page 74

Diagraph - an ITW Company ALP/4500 PA ManualTroubleshooting

11.0 Troubleshooting

11.1 Diagnostic Images

Problem Cause Correction

Not In Home Position

Tamp Cylinder is not home when entering run mode

Verify Inlet Air Supply valve is not shut off

Verify air pressure is present at tamp cylinder pressure regulator

Verify Cylinder Home sensor is positioned where indicator light is on when tamp is home

Ribbon Out or Ribbon Error

Ribbon is out Replace ribbon

Ribbon is jammed in drive roller

Remove drive roller and clean, repair ribbon supply.

Ribbon is broken Splice ribbon at take-up roll.

Print Module Head Open

Print Module head latch is open

Close latch

USB Print Module Control Error

Print Module was not detected by CPU Board.Possible cabling disconnection.Serial communication transmission while initializing.

Reconnect cabling.

Hold serial communication while power-up initialization is being preformed.

Media Too Thick

Print Module detected media too thick to run properly.

Reduce media thickness

Perform print head balancing

Troubleshooting Page 75


Bulb Broken or Broken Connection

Warning Tower Bulb has failed

Replace bulb as described in Warning Tower Bulb Replacement on page 87

Pneumatic Valve has failed

Replace pneumatic valve or pneumatic control block

Broken electrical connection

Verify all suspected wiring

Output Shorted or Overvoltaged

Warning Tower, Auxiliary Output, or Pneumatic Valves have experienced an output shorted or overvoltage.

Inspect device causing fault, correct wiring problems or short circuits. Outputs are protected, and do not require replacement.

Alert for Out Condition

Label supply roll is empty Replace supply roll

Print Module reports labels out

Inspect Print Module for label jam

Air Supply has dropped below threshold for operation

Check inlet air pressure. Check inlet air regulator setting.

Serial Framing Error

Incorrect baud rate, parity, or number of bits

Set serial communications for 9600, 19200, 38400, or 57600 baud, no parity, 8 data bits, and 1 stop bit.

Noise, Grounding Decrease baud rate.Decrease serial cable length.Identify noise source, and remove.Remove grounding connection at PC end of cabling.

Print Module Head Heat

Over-Temperature

Illegal Head Temperature Decrease label format heat level. Normal heat level setting should be between -10 and 0.




11.2 Symptom Diagnostics

PRINTING

Repeat Action Error

Repeat Tamp Occurred Check that tamp pad is clear of labelsCheck the distance of extension meets product

Repeat Print Occurred Check for obstruction in front of tamp pad.Check vacuum, air assist, tamp pad surface.

Rewind Tension Too Low

Rewind dancer arm did not lower during liner take-up

Check for liner broken

Check for labels wrapped around rewind dancer arm, remove labels

Check for proper web path

Alert for Low Condition

Label supply roll is at low threshold diameter

Replace supply roll when supply roll is out

Memory Full

Print Module memory is full

Reduce label format size

Error Condition

Critical condition exists to stop machine operation

Correct fault condition and set mode to run


Print Batch is not registering on Home Screen

Framing errors detected Verify baud rate, handshaking, and number of data bits at PC and ALP/4500 match

Ensure proper grounding and shielding to avoid noise

Labels print without start signal from applicator

Incorrect label format mode

Change print mode to Peel Off




Label will not print, but there is a batch in the print module

Unit is not online Press the run button on the home or setup screens

Demand mode enabled Either trigger the selected demand mode source or switch mode to Print After Tamp

Label backfeeding “hunting”, bidirectional feeding without printing

Head balance incorrect Adjust head balance for the appropriate label width. Correct darkness problems through head pressure and heat setting, not through head balance

Print on label is not consistent across the width of the label

Print head alignment, balance, or pressure is out of adjustment

Correct adjustment as outlined in Adjusting the Print Module on page 34

Print quality is too light or dark

Print head pressure requires adjustment

Correct adjustment as outlined in Adjusting the Print Module on page 34

Format darkness requires change

Change format setting for print darkness, or heat level

Print module ribbon out error

Ribbon is out Replace ribbon

Ribbon is jammed in drive roller

Remove drive roller and clean, repair ribbon supply.

Ribbon is broken Splice ribbon at take-up roll

Ribbon not securely held to unwind roll in print module.

Tighten roller force against ribbon core by turning the green ribbon unwind knob counter-clockwise.

Print module signalling ribbon out when ribbon supply is loaded

Ribbon spindle not sensing movement

Tighten the knob on the ribbon supply hub

Print module does not signal the ribbon out error after ribbon supply is exhausted

Incorrect thermal mode selected

Change print mode to thermal transfer




Print module is skipping labels when printing

Label format incorrect Re-measure label length and change value in format. Verify label gap distance is also correct.

Vertical white lines in the print image

Printhead requires maintenance

Clean or replace print head as described in Print Module Routine Maintenance on page 86

Multiple labels are fed to the tamp pad, printed image exists on each label.

Vacuum setting too low Increase vacuum generator pressure to 20 PSI or greater

Clogged tamp pad orifices Clean tamp pads as recommended in the section on Tamp Pad Maintenance on page 87.

Uncovered vacuum orifices when label is on pad

Align tamp pad position to match open vacuum orifices

Vacuum label presence line disconnected

Check 4mm yellow vacuum pneumatic line connecting vacuum generator to CPU Board

Label presentation incorrect. Next label over-extending during end of print. Next label dislodges label on pad.

Decrease presentation position (backfeed distance)

Label presentation incorrect. Label not extending out of print module far enough to seat on tamp pad.

Increase presentation position (backfeed distance)

Multiple labels are fed to the tamp pad, printed image exists only on the first label, remainder is blank labels.

Label liner is incorrectly threaded

Check liner path is between the gap sensor prongs

Multiple labels are fed to the tamp pad, all are blank labels.

Label gap sensor level requires positioning

Move label gap sensor level to a position which is within the label width. See Label Gap Position on page 35.




APPLYING

Label buckles on the tamp pad.

Vacuum set too high. Decrease vacuum.

Labels are feeding into the edge of the tamp pad.

Tamp pad position too low Set tamp pad to a distance just below the peel blade. See Adjusting the Tamp Cylinder on page 29.

Cylinder home sensor position too low

Move the cylinder home sensor to a position where the cylinder is detected home later. See Cylinder Home Sensor on page 30.

Air cushion set to slow The air cushion slows cylinder travel at the return position. Too much cushion cause reduce speed at the home position. Set cushion at optimal position between slow return and end of travel contact. See Tamp Cylinder Air Cushion on page 30.


Label is on the tamp pad, but tamp cylinder does not fire

Product detector not triggered by product

Verify in Diagnostics (Diagnostics Screens - Sensors on page 55) that the product detector can repeatedly detect the product. Adjust sensor as necessary

Apply trigger occurred before label was on tamp pad

Increase distance of product detector from tamp pad to allow printing to complete




Tamp pad is contacting product with too much force or for too long a duration

Pressure feedback signal line disconnected

Check 4mm blue pneumatic line connecting the tamp cylinder extension line and the connection to the transducer on the CPU Board.

Supply roll is signalling label low too soon

Label low threshold set too high

Enter new low position in the supply roll warning screen

Incorrect adjustment of the unwind sensor

Perform setup of unwind sensor as described in the section on the Unwind Sensor on page 82




11.3 Electronic Calibration

The electronic sensors are calibrated at the factory, and generally do not require further adjustment. In the event that these components require adjustment, follow the instructions below.

Unwind Sensor

User Interface ContrastThe contrast adjustment for the user interface is located on the display circuit board inside the tethered remote. Remove four captured screws on face of the remote and uncover the display board. Adjust R2, which controls the contrast. When making this adjustment, make sure the display has reached operating temperature. If it has not, the contrast may vary slightly when re-assembled.

11.4 Test Points and Advanced Diagnostics

Test PointsThere are several locations on the ALP/4500 circuit boards where voltage signals can be measured to determine the source of a problem. It is strongly recommended that troubleshooting begins with the diagnostic menus, where inputs and outputs can be tested without the need for test tools. If the diagnostic menu tests indicate a problem with either an input or an output, then it must be determined which end is at fault, the sensor/actuator or the circuit board. The test points provide a convenient way to further examine the problem with the aide of a multimeter or oscilloscope.

The adjustment for the unwind sensor is located on the main CPU circuit board. This adjustment is performed by turning the potentiometer and observing the feedback LED when rotating the supply disk. Rotate the unwind disk to a position that illuminates the unwind LED. Rotate the potentiometer screw until the LED turns off. Slowly rotate the potentiometer back to illuminate the LED and continue to rotate the screw one more turn. Verify the position is correct by entering the Diagnostics screen (see “Diagnostics Screens - Sensors” on page 55.) Rotate the supply roll slowly, observe the pulses per second (PPS) reading on the display. Rotate the supply roll quickly, observe the reading increase. If the reading decreases at any point with an increase in supply roll rotation speed, re-adjust the unwind potentiometer.



Test Point Expected Signal How to Fix

CPU Board 6145-300

TP 1SYSTEM CLOCK

Disabled

TP 2RESET

5 VDC Running0 VDC at Power Up

Incorrect FirmwareImproper Cabling

TP 75 Volt DC Supply

5 VDC Steady Check D3 for ohms. If 0, replace Main CPU Board.Additionally, check the Power Supply Board for correct voltage supplies.Check Power Supply Fuse


24 VDC Steady Check D6 for 0 ohms. If 0, replace Main CPU Board.Additionally, check the Power Supply Board for correct voltage supplies.Check Power Supply Fuse


39 VDC Steady Check D7 for 0 ohms. If 0, replace Main CPU Board.Additionally, check the Power Supply Board for correct voltage supplies.Check Power Supply Fuse

TP 12 Rewind Dancer Arm

0 VDC = Home5 VDC = Not Home

No transition with arm movement:Check wiring at J9Check for 0 ohms across D12. If 0, replace power supply board.

TP 13Unwind Roll

0 - 4 Volt Pulses when unwind rotated

0 Volts:Check wiring at J10Adjust R34

TP 14 Unused

Remote 6145-204


5 VDC Steady Check connector J3Check Power Supply Fuse

TP 25 Volt Return

0 VDC Steady Check connector J3



TP 3KEYDATA

5 Volts when no key pressed, 0 Volts when key pressed

Check connector J1Check membrane keypad

TP 4Infrared Receive

0 volts when low3 to 4 volts when high

Check for transmission of infrared dataCheck U1 for damage

TP 5Infrared Transmit

0 volts when low3 to 4 volts when high

Check for transmissionCheck connector J3

Power Supply6145-252

TP 1Unregulated 39 VDC

39 Volts DC± 1 Volt500 mV ripple Max.

If 0 Volts, check Fuse F1

TP 2System Ground

0 VDC

TP 3Regulator Source Power

39 Volts DC± 1 Volt500 mV ripple Max.

If 0 Volts, check Fuses in power inlet module.

TP 4Regulated 24 VDC

24 Volts DC, steady 0 Volts, check Fuse F2

TP 5Regulated 5 VDC

5 Volts DC, steady 0 Volts, check Fuse F3

Test Point Expected Signal How to Fix



11.5 Interconnection Diagram



aintenance

12.0 Maintenance

12.1 Print Module Routine Maintenance

Printhead

Label Gap Sensor

The printhead will accumulate dirt and paper dust while running. It is therefore recom-mended to clean the printhead at every supply roll change. The printhead heating elements are located under the head support. Clean the surface with a cotton swab coated with isopropyl alcohol. Allow printhead to dry before resuming operations.

During operation, paper dust can accumulate on the label gap sensor. Do not use solvents to clean the optics, but instead use a soft brush or isopropyl alcohol on a cotton swab. The entire assembly can be slid out to make cleaning easier.

Optical Sensors

Maintenance Page 86


aintenance

12.2 Pneumatic Vacuum Generator Maintenance

12.3 Tamp Pad Maintenance

Dirt, label adhesive, and paper particles on or in the tamp pad can reduce the effec-tiveness of the vacuum holding strength. During daily maintenance of the unit, it is recommended to clean the surface of the impact plate with isopropyl alcohol and a cloth to reduce the build up label adhesive and dust particles. Depending on the environment, it may also be necessary to unclog vacuum ports with compressed air. It is not recommended, however, to use compressed air in the vacuum lines. These lines feed a sensitive electronic transducer that would be damaged by high pressure.

12.4 Warning Tower Bulb Replacement

Exhaust Muffler

Vacuum Filter

The vacuum generator contains two filters that require replacement on a bi-yearly basis. Remove the exhaust filter by loosening the three screws which hold the generator in place. Press the exhaust muffler out by hand. Install the new one by pressing it into position. Remove the vacuum filter by unscrewing the knob at the base of the generator. Clean this filter monthly. Replace filter cartridge in the same manner.

Replacement parts contained in 6145-021 kit

TSL24V5W

Warning tower bulb replacement is easily facilitated through the segmented bulb sections. Rotate the base of the defective bulb segment counter-clockwise to release it. Press down on the bulb and rotate it counter-clockwise to release the bulb. Replace with a new bulb. Line up the white arrow and line on the segment removed with the remaining tower segments. Once aligned, rotate the segment clockwise to tighten.


Maintenance Page 87


aintenance

12.5 Fuse Replacement

Power Inlet Module

Power Supply Board Fuse Replacement

The power supply fuses are located on the power supply circuit board, which is mounted on the inside of the rear enclosure against the baseplate wall. These fuses are located in fuse holders at the positions marked above. These three fuses protect the corresponding voltage lines:

• Fuse F1, 8 Amps @ 250 Volts, protects the + 39 VDC Motor supply line.

• Fuse F2, 8 Amps @ 250 Volts, protects the + 24 VDC Print Module, Valve, and Warning Tower circuits.

• Fuse F3, 3 Amps @ 250 Volts, protects the + 5 VDC Logic supply for the main CPU board.


Fuse Block

The AC power fuses are located within the fuse block of the power inlet module. This fuse block contains two fuses, one which is used for the 110-120 V orienta-tion and the other for the 220-240 V ori-entation. Only replace the fuse for the voltage range utilized. Replace the 110-120 V fuse with a 5 Amp, 250 V Slo-Blow fuse. Replace the 220-240 V fuse with a 3 Amp, 250 V Slo-Blow fuse.

Replacement parts contained in6145-022 kit

Fuse F1 = 8 Amp / 250VSlo-Blow



Maintenance Page 88


aintenance

12.6 Cooling Fan Filter Cleaning and Replacement

12.7 Pneumatic Filter Replacement

Pneumatic Control Module Muffler

12.8 Unwind Slot Sensor Maintenance

The fan blades are protected from contact, but it is still recommended the unit be power off to perform this proce-dure. To remove the cooling fan filter for cleaning or replacement, insert a flat screwdriver head or finger in the slot and snap inner cover open. Either replace the filter or clean it with warm soapy water. Dry the filter and replace it. Snap plastic cover into slot on fan shroud.

Replacement part contained in6145-022 kit

Muffler

The pneumatic control module muffler reduces the noise of the exhausting air. If this muffler becomes clogged or dirty, there will be a degradation in performance. Replace this muffler by unscrewing the device in a counter-clockwise direction. Replace with new muffler by rotating clockwise. Teflon tape is not necessary for thread installation.

Replacement part contained in 6145-021 kit

Unwind Slot Sensor

After prolonged use, the unwind slot sensor may gather paper dust and require cleaning. To remove the sensor, loosen the two mounting screws on the face of the sensor block. Rotate the block away from the unwind disk. Clean surfaces of the optics with a cotton swab and isopropyl alcohol. Re-install by reversing disassembly instructions.

Maintenance Page 89


aintenance

12.9 Band Brake / Unwind Spring Replacement

12.10 Rewind Belt Replacement

The band brake and unwind dancer spring should be replaced at the same time when maintenance is performed. The band brake is most easily accessed with the unwind supply inner and outer disks removed. The outer disk is removed by pulling the center hub lock out while pulling on the disk. The inner disk is removed by loosening the two set screws on the puck. Once the two disks are removed, the brake and spring will be visible as shown to the left. Loosen the socket head cap screws on the dancer arm and the mounting block. Install new band and reverse disassembly instruc-tions. Replace spring by using pliers to unhook one end of the spring. To adjust position, see “Tensioning the Unwind Band Brake” on page 31.


Band Brake Spring

Anchors

Dancer Arm

Remove the four (4) screws from the rear of the rewind belt guard. Remove guard. Gain access to the screws on the front of the motor by removing the rewind hub and support disk. Loosen those screws to remove tension from the rewind belt. Inspect belt and replace if worn or cracked. Tension the belt by sliding the rewind motor away from the rewind bearing hub. Tension is optimal when the maximum belt deflection at the midpoint of the belt is 1/8 inch. Re-assemble by reversing disassem-bly process.

Replacement part contained in 6145-020 kit

Midpoint positionfor tension check

Maintenance Page 90


aintenance

12.11 Maintenance Schedule Summary

Maintenance Schedule Chart

After Each Label

Supply Roll

Daily Monthly Every Year

Clean Printhead √

Clean Label Gap Sensor

√

Clean Unwind Slot Sensor

√

Clean Tamp Pad Impact Plate

√

Inspect Air InletFilter

√

Replace Air Inlet Filter

√

Inspect Rewind Belt and Unwind Band

Brake

√

Replace Rewind Belt and Band Brake

√

Inspect Cooling Fan Filter

√

Replace Cooling Fan Filter

√

Clean Vacuum Filter √

Replace Vacuum Generator Filter and

Muffler

√

Replace Unwind and Rewind Tension

Springs

√

Maintenance Page 91


aintenance

13.0 Replacement Parts

13.1 ALP/4500 Replacement Part List

Part Number Description

6145-010 ALP/4500 Manual

6145-200 Operator Interface Unit (Includes 6145-204)

6145-252 Linear Power Supply Board

6145-300 Main CPU Board

6145-400 Discrete I/O Board (Optional Device)

6145-828 Warning Tower Assembly

6145-501 Warning Tower Bulb Kit (Incandescent)

6145-503 Warning Tower Bulb Kit (LED)

6145-504 Rewind Stepper Motor

6145-506 Cooling Fan

6145-700 Pneumatic Control Module

6145-701 Quick Exhaust Valve

6145-738 Tamp Cylinder, 10 inch stroke w/Home Sensor

6145-739 Tamp Cylinder, 20 inch stroke w/Home Sensor

6145-800 Print Module, CAB A3

6145-801 A3 Print Module 203 dpi Printhead

6145-802 A3 Print Module 300 dpi Printhead

6160-423 Inlet Air Filter / Regulator / Shutoff

6145-910 Tri-tronics Photosensor, 10 ft.

6145-020 Unwind / Rewind Kit

• Band Brake• Rewind Belt• Unwind and Rewind Springs• Spring Anchors• Dancer Arm Bearings• Dancer Arm Thrust Washers

Replacement Parts Page 92


aintenance
Please contact Diagraph at 1-800-526-2531 or visit www.diagraph.com to request replacement parts or schedule service.
13.2 Ribbons

The ALP/4500 Print Module will accept either face-in or face-out ribbon. The ribbon type and age will determine the heat setting required for operation. Some ribbons and heat settings are not compatible. If the ribbon begins to bond to the printhead or illegal heat errors are generated, decrease the heat setting. Below is a listing of ribbons that have been tested and work well with the ALP/4500.

6145-021 Pneumatic Filter Kit

• Inlet Air Filter• Pneumatic Control Module Muffler• Vacuum Generator Filter• Vacuum Generator Muffler

6145-022 Bulb/Fuse Kit

• Warning Tower Bulbs (3)• Inlet Power Module Fuses (2)• Power Supply Board Fuses (3)• Cooling Fan Filter


RS0153 110 mm (4.3 in.) x 410 mm, Premium Wax (SATO)

RS0297 110 mm (4.3 in.) x 450 m, Premium Wax (Zebra)

RS0152 76 mm (3.0 in.) x 410 m, Premium Wax (SATO)


RS0115 53 mm (2.1 in.) x 410 m, Premium Wax (SATO)


RS0221 101.6 mm (4.0 in.) x 360 m, Resin (for Anchor Film labels)


Replacement Parts Page 93


eclaration of Conform

ity

14.0 Declaration of Conformity

DECLARATION OF CONFORMITY

Diagraph, an ITW Company, hereby declares that the equipment specified below has been tested and found compliant to the following directives and standards-

Directives:• EMC 89/336/ECC

• Low Voltage 73/23/EEC

• Machinery 98/37 EC

Standards:• EN 55011:1998, Class A, Group 1

• EN 61000-6-2:1999

• EN 61000-3-2:1995

• EN 61000-3-3:1995

• EN 60204-1:1997

• EN 292-2:1991

• EN 418:1992

• EN 294:1992

• EN 60950:2000

Equipment Type: Label Printer/Applicator

Model Number: ALP/4500

Bruce CastroQuality/Safety Manager

Diagraph, an ITW Company1 Missouri Research Park Dr.St. Charles, MO 63304USA

Declaration of Conformity Page 94

Diagraph - an ITW Company ALP/4500 Manual

Page a

AAccuracy 5Air Assist Adjustment 33Auxiliary Output

Pin-Out 25 BBackfeed Speed 71Bar Codes (2 D) 6Bar Codes (lineal) 6 CCertifications 5 DDimensions 5Direct Thermal 72 FFonts 6 GGraphic Support 6 HHandshaking 5Humidity 7 IIncoming Air Pressure 6 LLabel Format 71 MMemory 5 PPresentation Position 71Print Length 5Print Mode 72Print Module

Head Alignment 35Head Balance 34Head Pressure 34

Label Gap Position 35Ribbon Wrinkle Adjustment 36

Print Resolution 5Print Speeds - 203 dpi 5Print Speeds - 300 dpi 5Print Width 5Printer Model 71Printing Modes 5Product Detector 16

Cabling 22Diffused - Proximity 16Fiber Optic 16Pin-Out 23Retro-Reflective 17

Product Rate 7 SSerial Baud Rates 5Serial Cable Chart 26Serial Communications Cable 26Serial Communications Pin-Out 26Serial Framing 5Software 5Supply Roll Capacity 5 TTamp Cylinder

Air Cushion 30Home Sensor 30Pressure Adjustment 32Quick Exhaust Valve 30Tamp Pad Position 29

Temperature 7Thermal Transfer 72 VVacuum Adjustment 33 WWarning Tower 24

Pin-Out 24Weight 5

ALP/4500PA

Rev F

ALP/4500PAALP/4500PA

Rev F

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