AP 230 No - contact printer/applicator system USER MANUAL UV504UGB DATAPROCESS EUROPE S.p.A. 20082 Binasco (MI) Viale dell'Artigianato, 19 Tel. (+39) 02900221 Fax.
INDEX: WARNING page. 3 WARNING DANGER page. 4 RESIDUAL RISK OF THE SYSTEM page. 5 1 - DESCRIPTION OF THE MACHINE 2 - TECHNICAL SPECIFICATION OF AP 230 SYSTEM 3 - UNPACKING AND INSPECTION page. 6 page. 8 page. 10 4 - STORAGE AND TRANSPORT 4.1 - TRANSPORT 4.2 - WORKING PLACE page. 12 page. 12 page. 13 5 - MOUNTING THE SINGLE COMPONENTS OF THE APPLICATOR 5.1 - MOUNTING THE BACKING PLATE 5.2 - MOUNTING THE ROLL HOLDER UNIT 5.3 - MOUNTING THE PNEUMATIC APPLICATION UNIT 5.
WARNING: This user manual constitutes an integrated part of the AP 230 system, it contains how-to-use instructions for professional and non-professional users. Such instructions inform and advise the users on the correct use of the system and at the same time inform and advise on the residual risk due to the improper use of the system. It is therefore compulsory to have copy of this manual near the working place.
WARNING: DANGER! Before entering into the interdiction zone, press the red stop button on the emergency stopping device EMERGENCY STOPPING DEVICE INTERDICTION ZONE DANGER ZONE safety distance AP 230 USER 1.
RESIDUAL RISKS OF THE SYSTEM WARNING: The system, during its working cycle, presents some mechanical hazards, that can be the origin of injuries due to mechanical actions of the machine parts. Do not access into the interdiction zone before carefully following the "SAFETY MODE FOR THE MAINTENANCE" procedure as described at points 1 and 2 of paragraph 8.1.
1 - DESCRIPTION OF THE MACHINE The AP 230 system is a device used for overprinting of adhesive labels and for their immediate air-jet application on stable or on moving objects. Once inserted into either a packaging or product transport line, the AP system can print and apply labels in a wide range with bar-codes and diverse texts. The AP 230 contains the same printing group of the ST 230 Thermal Transfer Printer, from which it has inherited all the features.
The AP 230 system can be easily installed according to the user’s various needs, allowing label application either on the top and on the side of the package. The high speed and precision of application, together with the indipendence from speed of the transport line, are some of the many advantages of the AP 230 systems. The "no-contact" application is ideal for either fragile or difficult to handle objects that may have surfaces not completely flat.
2 - TECHNICAL SPECIFICATIONS OF AP 230 SYSTEM PICTURE 3 - DIMENTIONS OF AP 230. PRINTER The printer specifications are the same as the ST 230 printer (see its user manual). APPLICATOR Piston movement: 200mm Application plate dimensions: 115 x 120 mm Application speed: up to 45 label/min.
INTERFACES Type: Serial RS 232C Asynchronous Buffer: 64 kbytes Protocol: Xon/Xoff or CTS/RTS Data transmission speed: 300 to 38.400 baud Alarm and synchronizations: Input and output optoisolated signals. POWER SUPPLY Electric: 220V ±10% (optional 110, 120, 240V) 50/60 Hz; 200 Va. Pneumatic: 6 bar min., 200 lt/min., filtered dry air.
3 - UNPACKING AND INSPECTION Open the packaging and check the following standard components: 1) 2) 3) 4) 5) 6) 7) 8) 9) AP 230 user manual ST 230 user manual Object sensing photocell (with reflector) Tool kit Roll holder unit including flanges Power cable ST 230 printing mechanism AP 230 pneumatic application unit Backing plate. The picture 4 on your left shows the main components and their position in the package. PICTURE 4 - AP 230 PACKAGE.
Save the packaging units and the non-impact material, to be used in case of returning the AP 230 system or for internal movement about the factories. Inspect the pakaging to ensure that no damage incurred during transport, and particularly: - Check the external parts of the device. - Open the cover port of the printer to verify possible internal damages. - Check the damages on applying assembly.
4 - STORAGE AND TRANSPORT In case of non immediate use the AP 230 should be stored with its original package. The enviromental conditions are the following: - Temperature: from 5° to 35° C - Humidity: 20% to 90% non condensing. 4.
4.2 - WORKING PLACE The AP 230 system can be easily installed according to the user’s various needs, allowing label application either on the top and on the side of the package. It is necessary to exclude the interdiction zone all around the application system with deterrent and/or hamper device fixed on the floor, such as for example yellow/black stakes joint together with a protection chain of the same colour having a floor height of 100 cms. minimum and safety distance of 1.4 m.
5 - MOUNTING THE SINGLE COMPONENTS OF THE APPLICATOR The assembly of the single components of the applicator are divided in the following four phases: 5.1 - Mounting the backing plate. 5.3 - Mounting the pneumatic application unit. 5.2 - Mounting the roll holder unit. AP 230 USER 5.4 - Identification of the system fastening points on the backing plate .
5.1 - MOUNTING THE BACKING PLATE Unpack the printer and place it upside down on a table top. Remove the two rubber feet, as indicated on picture 6 on your left, unlocking the two screws that fasten them at the base of the printer. PICTURE 6 - RUBBER FEET Unscrew the M 5 x 20 mm screw located in the middle of the base of the printer, as indicated on picture 7 on your left. PICTURE 7 - MIDDLE M 5 SCREW. Place the backing plate on the printer so that the plate holes will match the printer holes.
Take off from the tool kit the two M 4 x 20 mm screws, insert and fasten the two screws on the two pre-drilled holes on the backing plate. Insert and fasten the screw M 5 x 20 mm in the hole located in the middle of the backing plate, as indicated on picture 8 on your left. Now completely tighten all the backing fastening screws to avoid them loosening when working, which would impair the proper operation of the system. PICTURE 8 - FASTENING SCREWS. 5.
Place the printer in its upright position and insert the first flange with the smooth side inward the printer, as indicated on picture 10 on your left. The flange adjustment on the roll holder unit is described at paragraph 9. PICTURE 10 - PAPER GUIDE FLANGE If the machine mainly works with a 90° rotation, also mount the plexiglass disk (available as optional), on the flange and fasten it with the two countersunk screws supplied with the disk, as indicated on picture 10 on your left.
5.3 - MOUNTING THE PNEUMATIC APPLICATION UNIT Unpack the application unit and take from the tool kit the two screws M 8 x 30 mm complete with their washers. Place the application unit in its upright position, on the front of the printer, hold it by one hand while with the other one insert the two screws in the two pre-drilled holes created on the base of the application unit so that they will match the holes on the backing plate, and fasten, without locking, as indicated on picture 12 on your left.
5.4 - LOCATING OF THE FASTENING POINTS OF THE SYSTEM The backing plate is equipped with a certain number of holes to be used to fasten the system to the application line or to mount, if desired, a backing flange for a support column, as indicated on picture 14 on your left. On the backing plate has been pre-drilled a serie of eight holes : 4 M 10 and 4 M 8.
6 - ELECTRICAL AND PNEUMATIC CONNECTIONS 6.1 - ELECTRICAL CONNECTION AP 230 system has to be connected to the power supply , through the emergency stopping device that has to be fixed outside the interdiction zone following the instructions below: 3 4 1 2 1Prepare a feeding cable with an adequate section not less than 3 x 1,5 mm, where from applicator side will be mounted the dedicated female connector that will be inserted into the plug on the rear panel of the printer.
6.
6.3 - REAR PANNEL, CONNECTIONS Connect the printer by means of the emergency stopping device, following instruction on paragraph 6.1. SWITCH BUTTON PHOTOCELL CABLE To interface the printer to an external driving device (PC, etc.), use a serial cable with connector (type D, 9 pin male). See appendix "B" for the pin number of the serial cable. SERIAL CABLE POWER CORD Connect the object sensing photocell cable on a 9 pin male connector mounted on the rear pannel of the printer.
7 - COMPRESSED AIR CONNECTION WARNING: It is highly recommended to install near the regulator filter assembly "FR" and outside the interdiction zone a detection valve to switch-off the compressed air supply in case of emergency. The compressed air tube will be installed following the instructions below: 2 1 3 1 - Connect a tube having minimum internal diameter of 6 mm (outside diameter of 8 mm) with the air applicator entrance and the air exit of the emergency stopping device.
The applicator operating pressure should be set, between 4 and 6 bar. As indicated on picture 19 on your left, in accordance with the dimentions of the label and apply distance following the instructions on the next page. 4 / 6 bar PICTURE 19 - AIR COMPRESSED SUPPLY REGULATION. We suggest to regulate lower pressure (4 bar) for small labels and short distances, 6 bar in case of large labels and long distance.
8 - EMERGENCY STOPPING DEVICE The system AP 230 is equipped with an emergency stopping device, it allows to take under control both the electrical and pneumatic supply by stopping the system in case of loss of pressure on the pneumatic supply or in case of loss of voltage on the electrical power supply.
8.1 - SAFETY MODE FOR THE MAINTENANCE PROCEDURE WARNING: Before entering into interdiction zone created around the AP 230 system, follow carefully the indication listed in the safety mode for the maintenance procedure.
5 - Switch - off Repeat the operation indicated on point 1. 6 - Connect Connect the 4 pin connector into the proper plug mounted on the front pannel of the printer, being care to turn clockwise the appropriate fixing nut. 7 - Re-start Repeat operations indicated on point 3. WARNING: AP 230 The a/m instructions have to be carefully followed by anyone who intends to access the interdiction zone due to maintenance or label / ink ribbon loading operations.
9 - LABELS AND FOIL LOADING PROCEDURE WARNING: Before proceeding with labels and ink ribbon loading, follow carefully the "SAFETY MODE FOR THE MAINTENANCE" procedure described on paragraph 8.1 at point 1 and 2. To load the labels roll properly, proceed as follows: 1 - Insert a labels roll in the external roll holder. 3 2 - Insert the external flange on the roll holder. 3- Insert the paper into the slot locating on the rear panel of the printer, as indicated on picture 20 on your left.
9.1 - INKED RIBBON LOADING To load inked ribbons properly, proceed as follows: 4 Lift up the printhead using the proper knob, as indicated on picture 21 on your left. 2 1 - Turn the knurled knob clocktwise and remove the cartridge. 2 - Insert the ribbon roll on the support holder, remembering that the ribbon is anticlock3 wise rewinded. 3 Fasten the steady pin to one of the four 1 holes on the supporting axis, choosing the hole that permits a better blocking of the ribbon.
10 - ADJUSTING THE FLANGES ON THE ROLL HOLDER The roll holder inside flange has to be adjusted so that the paper is alligned with the first paper guide located on the printer. For that reason after loading the labels as discribed on paragraph 9, keep with one hand the label roll and with the other one bring the internal flange near. A Picture 23 on your left shows on point "B" the correct position of the flange and the properly paper alignment. Insert then the second flange near the label roll.
11.1 - POSITION ADJUSTMENT OF THE PNEUMATIC APPLYING ASSEMBLY. WARNING: This adjustment has to be made before connecting the system to electrical and pneumatic sources. This adjustment is essential to the proper working of the system, and therefore has to be executed with extreme care. A Adjust the application assembly so that the internal side of the base will be aligned and parallel to the side corresponding of the backing plate.
WARNING: Before going on with checking the right application assembly position, follow carefully the "SAFETY MODE FOR THE MAINTENANCE" procedure indicated on point 1-2-3-4- of paragraph 8.1. Wait for the printer after the re-start operations (see point 4 paragraph 8.1) to print the test label and that the led on key ON - LINE lights. Put the printer in OFF - LINE following the here below instructions: Press button ON - LINE to bring the device in OFF - LINE mode (led off).
Push the applicator unit towards the printer to adjust it lenghtwise, as shown on picture 26 on your left. To proceed with these adjustments (side and lenghtwise) the holes drilled on the applicator base has to be greater than the fastening screw diameter in order to allow such regulations. PICTURE 26 - LENGHTWISE CENTERING OF THE PLATE.
11.3 - SETTING THE DIRECTION AND AIR JET STRENGTH FROM THE NOZZLES. Now set the direction and air jet strength so that the air flow from the nozzles located on the application assembly allowing the label to be held on the plate uniformely. Generally the applicator is supplied already ready to operate with a specified label format, the table below shows how to enable/disable the nozzles to operate with label formats different from the one supplied.
When the air jet strength adjustment is completed, proceed with direction setting of the nozzle by turning right/left wise with an 8 mm wrench to direct the air jet to the required direction, as indicated on picture 29 on your left. PICTURE 29 - AIR JET STRNGTH DIRECTION ADJUSTMENT. To verify if the adjustment is right completed, press button "FEED" on the front panel of the printer, to eject a new label in order to check if it is correctly spread on the plate. 11.
12 - SYSTEM CONFIGURATION; FRONT PANEL OPERATIONS AND SOFTWARE COMMANDS This section describes the special commands used to set up the AP230 system. There are two different procedures: - Front panel operations. - Applicator software commands 12.
12.2 - APPLICATOR ENABLES Through the front panel it is possible to enable the applicator following a standard working cycle that takes an up-down lead time of 0.9 sec. Following instruction on paragraph 12.1 set the machine in configuration mode, than press key "HEAD LIFT" (the corresponding led lights). In that way the printer is in operating mode and you can set-up the parameters concerning command "N". Than press together keys "RIBBON ECONOM" and "HEAD LIFT".
Then press key ON LINE to select the operating mode of the photocell.
12.4 - LABEL CALIBRATION AND OFFSET ADJUSTMENT Through the front panel is possible to proceed with the calibration procedure and adjustment of the label offset (finding the dispensing point). Following instructions on paragraph 12.
12.7 - APPLICATOR CONFIGURATION The applicator configuration is fundamental for a correct use of the system, particularly a correct up-down lead time allows to optimize the working cycle, adapting it to the different needs required by the transport line.
the four figures of command "xxxx" allow to set up the label offset in points corresponding to 1/6 mm if it is used a 6 dots/mm printhead or a 1/8mm when a 8 dots/mm printhead is used.
12.9 - SINGLE APPLICATION CYCLE It is possible to execute by AP 230 system one single applying cycle, that is a downupward movement of the piston in accordance with the programmed time with command "N", without any label ejection. The command to be sent by serial line is the following: /! The complete description of the printer commands is indicated on "ST 230 USER MANUAL" in the section "PROGRAMMING GUIDE".
14 - MAINTENANCE WARNING: Before proceeding with maintenance, follow carefully the "SAFETY MODE FOR THE MAINTENANCE" procedure as indicated on paragraph 8.1 at point 1 - 2 - 3. AP 230 system does not require particular maintenance operations, it is reccomend a periodical plate cleaning with a soft cloth wetted with alcohol to keep clean the suction air holes. WARNING: When the maintenance is over, follow carefully the "SAFETY MODE FOR THE MAINTENANCE" procedure as indicated on paragraph 8.
SYMPTOM The system after the printout of the label signs error. (led lights END PAPER/ RIBBON) The system after the printout of the label signs error also if the label covers all the hole drilled on the plate. (led lights "END PAPER/ RIBBON"). POSSIBLE CAUSE ACTION The label does not cover all the holes drilled on the plate. Check that the plate is ready for the label format to be used, otherwise close the holes with adhesive ribbon and try again.
APPENDIX "A" AP 230 backing plate - low view AP 230 USER MANUAL 45
APPENDIX "B". B.1 - SERIAL CABLE PINOUT Here below the pinout of connector CANNON 9 pin female located on the rear panel of the priter: PIN SEGNAL DESCRIPTION 2 RXD Input - received data 3 TXD Output - transmit data 5 GND Ground 7 RTS Output - Request to send 8 CTS Input - Clear to send 1 - 4 - 6 - 9 not used Here below the pinout of serial cable for a PC equipped with serial port with a 25 pin CANNON connector and for a PC with a serial port with a 9 pin CANNON connector.
Cable for 9 pin connector B.2 - DESCRIPTION OF OPTOCOUPLED INTERFACE AND PINOUT OF THE 9 PIN MALE CONNECTOR. The printer is equipped with an additional connector (9 - pin, male, "D" type) located on the rear panel of the printer, which carries some optocoupled Input/Output signals useful to interface the machine to external devices (typically industrial PLCs, object sensing photocell or relays).
The PRINT signal is activated (transistor ON) at the beginning of the printing phase of each label, as soon as the stepper motor starts moving, and is deactivated (transistor OFF) at the end of the cycle, which includes the cutting or application phase, if the printer is equipped with the optional cutter or applicator and they are enabled. This signal is also activated if a single cut or application cycle is requested with the /! command.
B.
