AP4050 - Phoenix Italia
Contents
1. Acting on the flow regulators A and B is possible to set the speed of extension retraction of the application plate For quick applications the Swing arm dampeners KIT optional let ter D is warmly suggested As highlighted by the arrow C in the picture above the bigger air tube has to pass through the center hole drilled on the swing arm support then has to be connected to the L fitting positioned on the application plate Phoenix Italia AP4050 User s Manual 392. DIRECTIVE 2004 108 EC of 15 December 2004 on the the laws of the Member States relating to elec tromagnetic compatibility and repealing Directive 89 336 EEC Phoenix Italia AP4050 User s Manual 3 General information Rev 05 2010 Stand body Reference Title of standard Ratified year CEN EN ISO 12100 1 2003 Safety of machinery Basic concepts gen 2005 eral principles for design Part 1 Basic ter minology methodology ISO 12100 1 2003 CEN EN ISO 12100 2 2003 Safety of machinery Basic concepts gen 2005 eral principles for design Part 2 Technical principles ISO 12100 2 2003 CEN EN ISO 13857 2008 Safety of machinery Safety distances to 2008 prevent hazard zones being reached by upper and lower limbs ISO 13857 2008 CENELEC EN 60204 1 1997 Safety of machinery Electrical equipment of 1997 machines Part 1 General requirements Phoenix Italia AP4050 User s Manual Rev 03 2010 General information 1 4 Prearrangements at customer s expense Any operation on the AP4050 Applicator should be performed only by trained personnel Consider leg ally permissible minimum age In principle the labeler should be used only by persons who have re ceived a complete briefing Trainees or personnel during the briefing etc are allowed to perform tasks only supervised by an experienced person 1 4 1 Requirements to the site of installation Closed and clean room e Leveled sur
3. 4 runc 31 Phoenix Italia AP4050 User s Manual 1 Rev 05 2010 7 Machine diagnosiS it ninas 32 AR inel eec 32 1 2 Troubleshooting sees ttp ovis etende 33 8 Declaration of INCorporati0N ccccccconncnncnnnnnnnnnnnnnnncnnccnnnnnnnnnnnnn cnn ran 35 Jefe pd uiui pee M 36 A 1 Variable stroke sensor a e aa E ea aa A nn nn nnne nnn a a aa nsns senes nnns nnns nnns 36 A2 Low label sensor ii testet qun a ine LATE 37 A3 Three colors LED lamp n teca ia RE 38 Appendix B Versions EEEIIID I EE 39 SO 39 B 2 Swing atiTi Verslo i ss nu dees sees ose ser declina derby Re eene dU CRI ERR aT dane 40 B 2 1 General OVerview titi ita 40 B 2 2 Swing arm lengths and application plates ooocooccnnnnnnncccccccccnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnn 40 B 2 3 Dimensional Ta WINS iii 40 B 2 4 Assembling the Swing arm KIT eennenneereeeennenneereeeennenneerevennnnnneerenennnnneeene vennen 42 B 2 5 Stroke regulation and home sensor calibration naan ennenneeneeeennenneereneennenneereeeennenenn 42 2 Phoenix Italia AP4050 User s Manual Rev 03 2010 General information 1 General information 1 1 Introduction The Phoenix Italia AP4050 Applicator is designed to accommodate different types of print engines For print engine operation refer to the manufacturer s Print Engine Manual This chapter cove
4. Nous d clarons que les syst mes Con la presente dichiariamo che il sistema AP4050 is planned to be incorporated in a machine or to be assembled with other machines and therefore to make up a machine covered by directive 98 37 EEC welches dazu bestimmt ist in eine Maschine integriert oder mit anderen Maschinen zusammengebaut zu werden und mit diesen eine Maschine bildet die den Bestimmungen der Richtlinie 98 37 EEC entspricht Sont pr vus pour tre int gr s dans une machine ou assembl s dans d autres machines afin d obtenir un mat riel conforme la directive 98 37 EEC destinato ad essere integrato in una macchina o ad essere montato insieme ad altre macchine e a formare con queste una macchina che soddisfa le disposizioni della direttiva 98 37 EEC Is not therefore in conformity with all elements of this directive Daher nicht mit allen Bestimmungen dieser Richtlinie bereinstimmt Or tous ces l ments ne sont pas forc ment conformes cette directive Per questo motivo potrebbe non essere conforme a tutte le disposizioni di questa direttiva In addition we declare the following Zus tzlich erkl ren wir hiermit nachfolgendes C est pourquoi nous d clarons le suivant Inoltre con la presente dichiariamo quanto segue 1 The individual completing and integrating the unit will be responsible for supplying a Safety Guarding according the standards ISO 12100 1 and ISO 12100 2 1 Derjenige der diese Einheit fertig
5. always be greater than the highest pressure adjusted on the machine to avoid malfunc tions 2 2 Specifications DIMENSIONS LxHxW 710x580x235mm not including the printer dimensions for the 250mm stroke version Ref Chapter 2 5 Appendix A amp B for details of other config urations WEIGHT Base 250mm stroke version 25 kg not including the printer POWER SUPPLY 90 263 VAC 48 63 Hz Air Pressure 5 bar according to DIN ISO 8573 1 200 Nl min minimum AIR SUPPLY flow rate requirement Air Consumption 0 8 1 liter per cycle of typical application Temperature 10 35 C ENVIRONMENT Relative humidity from 20 to 90 not condensing PRINTER ENGINE Sato 8485 8490 8460 Sx Zebra 17x 110 PAX Datamax PE 4x A Class Avery DPMx PISTON STROKE From 0 to 240 mm standard up to 590 mm option Phoenix Italia AP4050 User s Manual 7 Technical data Rev 05 2010 2 3 Performances LABEL SIZE max 120 x 170 mm LABEL STOCK Up to 300 mm diameter 76mm inner diameter SPEED Up to 60 labels per minute APPLICATION DISTANCE From 0 to 50 mm depending by the label size ACCURACY 1 mm for a flight distance smaller than 50 of the shortest side of the label REWINDER Stepping motor driven microprocessor controlled for a constant ten sion of the web DISPLAY 2 x 20 characters backlit LCD CONTROLS START STOP Enter gt lt keys 2 4 Noise levels At
6. and applied onto the product with air blow without any movement of the stroke unit Phoenix Italia AP4050 User s Manual 23 Using the applicator Rev 05 2010 4 3 Safety equipments With change of the machine setup any conformity in relation to the CE Declaration for this labeler may expire For this case apply the standards of the Machinery Directive EN ISO 13857 which designate the assembling of Safety Guarding Only after installation of Safety Panel etc according to the EN ISO 13857 the limitation to the maxim um force of 50 Newton is no longer necessary 24 Phoenix Italia AP4050 User s Manual Rev 03 2010 Instructions for the Operator 5 Instructions for the Operator 5 1 Start and Stop functions 5 1 1 Switch On To operate the machine both the main power switch located on the back panel of the unwinder rewinder group and the printer power switch must be in the ON position The applicat or senses the status of the printer This gives the possibility to control applicator and rewinder power through the printer switch that may be more easily accessible being located on the front of the machine After the power on if the air pressure is correct the following message appears on the display Note The XXXX appearing on the first row in the pictures below are purely indicatives The numbers shown in that position indicates the software version signature checksum and dif fers be
7. and not suggested NOTE Never operate the applicator before drilling holes in the application plate The total sec tion of the drills must be larger than 15 sq mm Phoenix Italia AP4050 User s Manual 15 Commissioning Rev 05 2010 3 2 4 Stroke length adjustment The applicator is supplied with the maximum allowed stroke In some applications where it is necessary to have higher rate or where it is requested to trim the extension length it is possible to reduce the stroke moving the stopper mounted on the slide bar internally to the applicator body If the full stroke is restored it is extremely important to leave free at least 10 mm on the bar where it is mounted otherwise the damper can t work properly with the consequent impact of the piston on the cylinder bottom This can cause a serious reduction of the life of the cylin der beside the noise and the vibrations created by the improper operation 13 J UV 3I a Photo 2 Maximum stroke lenght adjustment 16 Phoenix Italia AP4050 User s Manual Rev 03 2010 Commissioning 3 2 5 Tamp home adjustment The tamp home position is where the tamp pad receives the label after it has been printed The tamp will then extend to apply the label to the product RIGHT HAND Fig 1 label on tamp positioning If the tamp pad is adjusted too low the label will hit the edge of the pad and jam If the tamp pad is adjust
8. le disposizioni della direttiva 98 37 CE E intendendo la costituzione di un impianto completo comprendente la macchina oggetto di questo certificato Date datum data Signature Unterschrift firma 01 01 2009 Paolo Albertoni Director Gesch ftsf hrer G rant Amministratore 30 Phoenix Italia AP4050 User s Manual Rev 03 2010 Appendix A Accessories Appendix A Accessories A 1 Variable stroke sensor This optional optical sensor is used in combination with the AP4050 and allows to detect the prox imity of products With the correct settings of programming parameters refer to AP4050 Program ming amp Interfacing Guide for further information this sensor give the possibility to a apply labels contactless onto products with different heights The sensor is mounted on the angle of the Tamp pad counterplate see the figure below The sensitivity of the sensor is adjustable and has to be set for its activation to a constant distance The integrated Control LED light on as soon as object is detected 1 Gain control screw 2 Tamp pad 3 Control led 4 Optical sensor Phoenix Italia AP4050 User s Manual 31 Appendix A Accessories Rev 05 2010 A 2 Low label sensor With this option an optical sensor see figure below scans the label roll A signal is switched if the label roll decreases to a previously set diameter To set the diameter adjust the sensitivity us ing the g
9. stellt und vervollst ndigt ist verantwortlich f r die Lieferung einer Sicherheits Abschrankung gem den Richtlinien ISO 12100 1 und 12100 2 1 L individu charg de l assemblage de l unit doit fournir une barri re de s curit d apr s les directives ISO 12100 1 et ISO 12100 2 1 Colui che si occupa del completamento e dell integrazione dell unit responsabile per la fornitura di una barriera di sicurezza in base alle direttive ISO 12100 1e 12100 2 2 It is forbidden to operate this machine before the machine in which it will be incorporated or that which it constitutes a part of is considered in conformity with the elements of Directive 98 37 ECC meaning forming an assembly including the machine concerned by the present certificate 2 Die Inbetriebnahme dieser Maschine ist untersagt solange die Maschine in der sie integriert oder von welcher sie ein Teil ist nicht mit den Bestimmungen der Richtlinie 98 37 EEC bereinstimmt im Sinne der Bildung einer Gesamtanlage durch Einbindung dieser Maschine f r welche dieses vorliegende Zertifikat gilt 2 Avant la mise en service de notre mat riel il est imp ratif que la machine r ponde aux r gulations de la l gislation C est dire que l installation compl te ainsi que le produit doivent faire l objet de la d claration 98 37 EEC 2 vietata la messa in funzione di questa macchina fino a quando la macchina nella quale integrata o della quale parte non conforme con
10. 4 Standard Transversal KIT 120x160mm Tamp Pad c9 120x160 Transversal Long 160 Fig B2 5 Transversal Long KIT 120x160mm Tamp Pad Phoenix Italia AP4050 User s Manual 37 Appendix B Versions Rev 05 2010 B 2 4 Assembling the Swing arm KIT To assemble the Swing arm KIT on the Applicator Unit use the proper holes as illustrated in the figure below MAIN PLATE 7 le a Pets WES EX O YY NI eO ae o VL Frontal standard LH LN LON T Frontal standard RH OO Frontal transversal LH Frontal transversal RH Following is an example of an assembled Swing arm KIT Standard RH 120x160 38 Phoenix Italia AP4050 User s Manual Rev 03 2010 Appendix B Versions B 2 5 Swing arm pneumatic connections WARNING TO AVOID POSSIBLE INJURIES DISCONNECT THE APPLICATOR FROM THE POWER AND AIR SUPPLY BEFORE PERFORMING THIS OPERATIONS The AP4050 Stroke Unit for swing arm comes with longer tubes to supply air to the pneu matic actuator and the application plate After assembling the Swing arm KIT B 2 4 connect them as illustrated in the pictures showed below showing the pneumatic actuator on the swing arm and the flow regulators inside the Applicator Unit The letter A marks the air tube for the swing arm retraction The letter B marks the air tube for the swing arm extension
11. ENTS AND FOLLOW ALL THE INSTRUC TIONS TO AVOID A PERSONAL INJURY AND OR EQUIP MENT DAMAGE WARNING THIS SYMBOL IS USED TO WARN USERS OF DANGER FROM POSSIBLE HURT OR PHYSICAL DAMAGE READ ALL CAUTION STATEMENTS AND FOLLOW ALL THE IN STRUCTIONS TO AVOID A PERSONAL INJURY AND OR EQUIPMENT DAMAGE CAUTION THIS SYMBOL IS USED TO WARN USERS THAT MA CHINE DAMAGE IS POSSIBLE IF ALL PROCEDURES ARE NOT FOLLOWED CAREFULLY READ ALL NOTICE STATE MENTS AND FOLLOW ALL THE PROCEDURES CARE FULLY IN ORDER TO AVOID EQUIPMENT DAMAGE 6 Phoenix Italia AP4050 User s Manual Rev 03 2010 Technical data 2 Technical data This chapter covers general and logistical functions regarding the machine and its usage This includes information about air and power source specifications illustrations of the primary working components and illustrations of the various machine layouts 2 1 Power and air supply The label applicator requires electrical power and compressed air Regarding power data refer to the details on the rewinder cover The compressed air inlet is placed at the stroke unit bottom For the connection use a flexible connec tion tube attached to a filter regulator included which has to be controlled and emptied regularly For more information see Chapter 6 Maintenance on page 28 The compressed air must be dry clean and free from oil Typical Air Pressure is 4 5 bar The air supply pressure must
12. L oooccccccccnncnnnnnnnnnonnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 13 3 2 Assembling and preliminary operations ssssssssennnn eene nne nnns 14 3 2 1 Mounting the printer on the applicatOr nnnnnnnnnnnnnnnenee eeen n eenen eneen nennen 14 3 2 2 Mounting the Filter Regulator assembly seen 15 3 2 3 Drilling the application plat nennen ernenennnnnnnnnnnnnnnnnenrenreereneneeneneneennennnnnnnnnnennnnn 15 3 2 4 Stroke length adjustment nennen nennen nenne nnne vennen 16 3 2 5 Tamp home adjustment eiecti x telo des Cheep ddan e pereo tat ege Mute d d age eode exe deu seagteanes 17 3 2 6 Roll support blades adjustment eenen enennenennnenenseererrenenenenneeeneeeeeneennennnnenen 18 3 2 7 Mounting the label stock ennn veenennneeervennennveereneennnnveerneennnenneeenveennnneeeen vennen 18 E BASE EI Ie EE MISI m 20 3 2 9 TaMp speed adjustment 5 a A na ae adir Vr REUS 21 3 3 Connections TU m 2A wm m 22 3 3 4 Printer setup e pierre Rupee a ae A a EE E a nnee Rees eee UR RR A ORE RA EEA 22 A Using the appliCatOr iere erret tete rne nr anna sn ini 23 IA 23 4 2 Application MIoTe REPE 23 4 2 1 reso Ane 23 4 2 2 Tamp on ioo R 23 4 2 3 Blow or mode 5 ninae itae ERE eoe Hainan eR XR ERES naan edna RARE A REN EA suae eee n Ran AU
13. NE phoenix italia AP4050 User s Manual Revision 03 2010 back cover Rev 03 2010 1 General informatiOonh cnnucenernicaenccesecshidandsetanaecdnnnsanneosddecnsiensnadduneidaneadssuadsdadegaddennndsaneoacecnstensnaddanucdartns 3 ET INTO UCION em 3 1 2 Key LOT 3 1 3 Normative references eneen eenen ennnennnnnnnnennenseeenenseereenenneneneneennennennnnnnnnnenneneeenenenennn 3 1 4 Prearrangements at customer s expense eennnneeneeeennnver ee vennnenneerevennneneeereeeenneneeene vennen 5 1 4 1Requirements to the site of installation nennen 5 1 5 Address for support and maintenanc unne ener eeneneenennnnennnennnnnnseneenvenrenenennene nennen 5 1 6 Conventions used in this manual nnen nennen eener een eneennennnnennnnnnnennenneeneeenenneenenn nennen venen 6 FAITUIIPLIDLIcm 7 2 1 Power and Eire EET 7 2 2 Speci CAOS aa aa a a a alo AET 7 2 3 Performan ESen eee ne sedan O fi anos as sas cra ise Be i ue Re ETE EHE Ada dadde EENET AAEN ur Ere eed 8 NS EE 8 2 5 Dimensional ci ELE 9 2 6 Machine E ToU RR 10 ESer EIC M M 11 3 1 Applicator unpacking and transportation nnen enenennennnnnneneeserreerneneneee eee nenenvennennnennnnnnn 11 3 1 1 Removing the applicator from the packaging ssse emn 12 3 1 2 Mounting the applicator on the SUPpOl
14. ON ARMS ARE QUITE DELICATE DON T PICK UP THE APPLICATOR HANDLING THESE PARTS Phoenix Italia AP4050 User s Manual 11 Commissioning Rev 05 2010 3 1 1 Removing the applicator from the packaging Open the packaging and remove the applicator Two technician should lift the applicator from the carton grabbing it from the black faceplate Place the applicator on an adequately stable work surface that is approximately 80 cm high and that can support at least 100 Kg 12 Phoenix Italia AP4050 User s Manual Rev 03 2010 Commissioning 3 1 2 Mounting the applicator on the support If the applicator is installed on a machine stand it must be able to support at least 100 kg and have a base that is large enough to prevent the machine from tipping over When positioning the machine consider the following placement criteria The AP4050 baseplate is equipped with a set of hole made to fit the most common commercial stands and standard aluminum profiles ref Fig 1 The machine should be positioned the appropriate distance from the product The extended tamp should not touch any part of the product as it passes by the machine if is not present the Variable Stroke option The position of the machine should allow the operator to easily change labels and ribbon and reach the printer keypad Make sure that all the adjustment locks have been tightened after the machine has been cor rectly assembled and po
15. R Kaanaa EAE 23 4 3 Safety equipments dossier ern ierat nece ree bene dee nao yug eoe p Epl Une sede a ORE ise Dea Ve sod au ea eaa eO eb uua 24 5 Instructions for the Operaltor eee eieenene riri epo eon acu eL E rna Donne EXER aii 25 5 1 Start and Stop f nctiOris corde Senna pes Re ERR ERN VR S panoramica TR PR BERN E RAER han vdd eua ap 25 SAA SWIN m 25 A PLUIE cU 25 51 iS DLO BRL UE 25 5 2 FUNCHOMS meriti srki errore eoe ence eset eda aa E epad a ata iaae ideaa aaa e e iaaeao 26 5 2 1 Set down counter enen nnnnennennnnnnsneneereern ennen nee veneeenenenennnnnnnennennnnnnenenneneenneenenne enen 26 5 2 2 Rst label COUNTS 55 ets snag ebrei eror nen EE on Pe GERE EYRER edn bee FR ERR ER Rehuel va NERDS 26 5 2 3 COCK SENGS nasa A eE dadadada 26 5 2 4 Display settings nennen nneennennneereeennnneneerneennnneneereeennnnnveerneennnnnneerneennnnnneerneennnnnneennenn 26 5 2 5 AS ded MEM APL nada end da Anne eden E ankh Art OC REAMER NER dE E aa 27 5 3 Select configuratiOM ER 27 S Eel 28 6 ET cd 31 6 1 Dally GEUDCHI DIC EE 31 6 2 Weekly Maintenance ooooccccccnnnnococcncconnnonnncnnnonnnnn nn eee cnn nn rr nennen nnns nnn n nnne rin n nn r rr rra nnne rn sre n nnne nnns 31 6 3 Six month maintenant iasence araia E Aaaa Eaa Aa nnn nnt nnn nnne nest err nennen 31 6
16. a distance of 1 meter from the workstations and 1 5 meter off the floor the following sound emis sions were observed lt 72dB a weighted lt 80dB c weighted 8 Phoenix Italia AP4050 User s Manual Rev 03 2010 Technical data 2 5 Dimensional drawings Dimensional drawing for the standard 250mm Please refer to the Manual appendix for further draw ings i I1 i i i Li T i i i 1 T a a l Phoenix Italia AP4050 User s Manual 9 Technical data Rev 05 2010 2 6 Machine Layout 1 2 3 4 5 6 7 8 9 lt mA A o Display controller Main plate Unwinder Dancer arm unwinder Rewinder Dancer arm rewinder Printer not supplied Air assist Tamp Pad Low Label sensor optional Stroke Unit 10 Phoenix Italia AP4050 User s Manual Rev 03 2010 Commissioning 3 Commissioning This chapter covers all the operation that could be done before the AC power and the compressed air are connected to the machine All the procedures must be performed by an expert technician 3 1 Applicator unpacking and transportation WARNING THE APPROXIMATE WEIGHT OF THE PHOENIX ITALIA AP4050 APPLICATOR IS ABOUT 25KG PLUS THE WEIGHT OF THE PRINTER ENGINE WARNING THE STEEL BLADES MOUNTED ON THE PAPER ROLLS SUPPORT COULD BE RELATIVELY SHARP DON T PICK UP THE APPLICATOR HANDLING THESE PARTS WARNING THE PAPER TENSI
17. ain control screw on the sensor sensor s control led off low paper signal If the optional three colors LED lamp See Appendix A 3 for further details is connected the ap plicator will switch on the yellow light Beyond this a contact is also switched to the I O Interface for customer use Refer to the AP4050 Programming amp Interfacing Guide for further information 1 Low label sensor No signal Low paper signal 32 Phoenix Italia AP4050 User s Manual Rev 03 2010 Appendix A Accessories A 3 Three colors LED lamp The three colors LED lamp allows to check from distance the status of the applicator There is no additional equipment required than the optional LED lamp itself to use this feature The AP4050 comes with an 8 pin M12 connection for the Alarm Lamp If it is connected it works immediately The meanings of the colors of lights are the following Green appears when the machine is in operating mode READY Signal is true Yellow appears when Low Label or Low Ribbon is detected Red appears when the machine is in error condition READY Signal is false Refer to the AP4050 Programming amp Interfacing Guide for further information Phoenix Italia AP4050 User s Manual 33 Appendix B Versions Rev 05 2010 Appendix B Versions B 1 500mm stroke version dimensions Disegno C500mm 34 Phoenix Italia AP4050 User s Manual Rev 03 2010 Ap
18. clusively for industrial purposes All working conditions and instructions prescribed in this manual are followed Failures at the AP 4050 Applicator affecting the safety have to be reported and immediately resolved by trained and briefed operators The maintenance is performed correctly Safety equipments no to be by passed or abrogated The AP 4050 Applicator is used or operate by trained operator These persons must read and have to be familiar with the content of this manual 4 2 Application mode The AP 4050 Applicator applies label onto standing or moving products For this different application modes are available and are configurable with the Display Controller Refer to the AP 4050 Applicator Programming and Interfacing guide to set up the machine 4 2 1 Tamp blow mode For the labeling the printed label is moved close to the product via a Vacuum Tamp Afterwards the label is applied via air blow onto the stationary or passing product The Tamp Blow mode is used frequently because application is performed contact free what result in a less wear opera tion 4 2 2 Tamp on mode Unlike the Tamp Blow mode it comes with the tamp pad touching the product The label is im pressed by the Vacuum Tamp onto the stationary product This mode requires a change of the system configuration and if necessary a change of the stopper position 4 2 3 Blow on mode The printed label is taken from the Tamp by vacuum
19. e observed to correctly prepare the application plate 1 The holes must be entirely contained within the label footprint if one or more holes are not completely covered by the label vacuum suction will not work properly and the ap plicator will stop in error condition 2 They should be organized in a nearly square grid having a pitch of 5 to 15 mm de pending on label size leaving a 5 to 10 mm of distance from the label edges in case of very elongated labels different pitches may be used in the two directions 3 Select the grid pitch to avoid that any hole results in correspondence of the output of the air pipe the total number of holes may vary from 8 or 9 2x4 or 3x3 for a very small label to 70 10x7 for the biggest one 170x120 mm 4 To obtain maximum performance in terms of precision and application distance it is very important that the grid of holes results uniform and symmetrical on the label in both directions take note of the effective position of the label on the application plate after having correctly loaded and aligned the paper on the printer It is advisable to make a photocopy of the layout of the holes for future reference The application plate must be mounted on the counter plate using the supplied plate gasket by means of the 14 M4x10 mm conical head Allen screws supplied in the kit Tighten the screws gently alternating the operation on the screws on opposite sides of the plate Sealant is not re quested
20. ed too high the label will be not positioned correctly onto the pad For a proper operation the tamp position must be trimmed 0 5 to 1 mm lower than the peeling blade This adjustment may need to be changed when different label materials are used Photo 3 Tamp home adjustment The height of the application plate in the retracted position is adjustable by means of a stopper the left bar of the slide in order to align the tamp with the label peeling edge If the stopper is moved it is important to check the proper operation of the home position sensor and eventually recalibrate its position Phoenix Italia AP4050 User s Manual 17 Commissioning Rev 05 2010 3 2 6 Roll support blades adjustment Both the rewinder and the unwinder can handle cores with a nominal internal diameter of 3 The roll supports have three stainless steel blades whose position can be adjusted to com pensate for the tolerance of the diameter of the core to guarantee a perfect grip For a correct operation it is necessary that the cores do not slide otherwise the unwinder brake and or the rewinder will not work properly Although it is possible to rewind the web directly on the blades without any core it is more practical to use one for an easier web unload Photo 4 Roll support blades adjustment 3 2 7 Mounting the label stock After the adjustment of the roll blades install the paper as shown in the Fig 2 The web can be rewound directly
21. epression to keep the label firmly at tached to the plate with consequent error condition The air assist tube has three small radial holes that blow air against the glued surface of the la bel for this purpose It can be oriented for the best performance loosening the fitting that locks the tube to the sup port plate ref Photo 5 It is advisable to start with an average flow of the air then reducing it with a better orientation of the holes The air flow can be adjusted by opening or closing the flow regulator situated on the base plate in correspondence to the air assist tube ref Photo 6 During the air assist adjustment procedure the FEED button on the printer can be used to eject labels for testing Photo 5 air assist air flow direction adjustment Photo 6 air assist air flow adjustment 1 Printer not supplied 2 Tamp pad 3 Label 4 Air assist jet 5 Air assist tube Fig 3 Air assist jet adjustment 20 Phoenix Italia AP4050 User s Manual Rev 03 2010 Commissioning 3 2 9 Tamp speed adjustment The tamp speed can be adjusted by means of two regulator mounted on the solenoid valves in side the applicator body The one mounted on the upper valve trims the speed of the retraction while the one situated on the lower valve trims the speed of the extension movement To limit the shocks noise and vibration these regulators should be trimmed for the minimum speed requested by the application a
22. f necessary Check for air coming out of the muffler Repair replace as needed Refer to setup instructions Refer to setup instructions Refer to setup instructions Refer to setup instructions Check to make sure that the conveyor speed is constant Adju st guide rails or other product con trol devices to present the product in consistent manner Refer to setup instructions Refer to setup instructions Refer to setup instructions Refer to setup instructions Examine adjust repair or replace as necessary Refer to setup procedures Make sure that the label liner is threa ded between the air assist tube and the peeler bar Examine and replace if necessary Clear obstruction and re thread labels Adjust the switch or replace if broken 28 Phoenix Italia AP4050 User s Manual Rev 03 2010 Machine diagnosis PROBLEM POSSIBLE CAUSES No product detection Incorrect print engine parameter values SOLUTIONS Re adjust the product detector or replace if broken Refer to the print engine manual Phoenix Italia AP4050 User s Manual 29 Declaration of Incorporation Rev 05 2010 8 Declaration of Incorporation DECLARATION OF INCORPORATION HERSTELLERERKLARUNG DECLARATION l INCORPORATION DICHIARAZIONE DEL PRODUTTORE Phoenix Italia S r l Via S Andrea 10 120010 Bareggio We declare that the equipment Wir erkl ren hiermit dass das System
23. face solid floor An adequate support where to fix the machine Low vibration environments Adequate illumination No direct irradiation from sun light or heaters The machine must not operate in areas with electrostatic or magnetic fields This can result into malfunctions of the controller or application troubles Appropriate air and power supply according to the technical specifications Ref Chapter 2 1 5 Address for support and maintenance Distributor Integrator For any request please contact your local distributor integrator or the company who installed the unit Phoenix Italia does NOT provide support to end users You should be prepared with the following information Fault description give full details The serial numbers of the machine applicator rewinder and display Exact circumstances when the error occurs For a complete list of Phoenix Italia authorized dealers visit www phoenixitalia it Phoenix Italia AP4050 User s Manual 5 General information Rev 05 2010 1 6 Conventions used in this manual Following is a brief list of the conventions used in this manual Pay special attention to any procedure that may have one of the following symbols Read all of the Caution and Warning instructions and follow them when performing the corresponding procedures WARNING THIS SYMBOL IS USED TO WARN USERS OF DANGER FROM POSSIBLE ELECTRICAL SHOCK READ ALL CAU TION STATEM
24. gured time limit The above message indicates that the specified vacuum level was not detected within the configured time limit during the aspiration phase The above message indicates that after having initially detected label presence on the tamp the vacuum level subsequently dropped due to the unexpected removal of the label or to some other problem in the pneumatic circuit The above message indicates that an abnormally weak pressure peak was detected in the tamp during the blow phase possibly due to a malfunction in the pneumatic circuit The above message indicates that an abnormally high pressure peak was detected in the tamp during the blow phase possibly due to a malfunction in the pneumatic circuit tipically some obstruction like a label sticked on the tamp The above message indicates that the variable stroke sensor mounted on the tamp did not detect the approaching of the Phoenix Italia AP4050 User s Manual 27 Machine diagnosis Rev 05 2010 WRONG PASSWORD E15 product s surface within the configured time limit during the extension phase The above message may be generated only when the operator tried to access a password protected function without introducing the correct password upon request BARCODE READ ERR E16 MAX RFID REJECTS E17 The above message indicates that the optional external barcode scanner interfaced to the machine was not able to correctly read the app
25. he inside and outside of the machine enclosure using an industrial vacuum cleaner 3 Check the home position sensor Fix if loose 6 4 Yearly maintenance 1 Check the safe notes and all the items in the weekly and six month maintenance sections Examine moving parts for excessive wear Refer to the safety instructions of these sections 2 Check tension of unwind and rewind dancer arms Change springs if necessary 3 Check pneumatic tubing for cracks or wear Check all moving parts for wear and bearing clearance Replace if worn 26 Phoenix Italia AP4050 User s Manual Rev 03 2010 Machine diagnosis 7 Machine diagnosis 7 1 Error handling When an error condition is detected the machine aborts the cycle currently being executed and goes in ALARM condition in which the green LED is turned OFF and the red LED is turned ON until the op erator manually restarts operation by pressing the START button If the STOP button is pressed while the machine is in stand by its operation is restarted as if it was just switched on NOT RESPONDING E01 PARAMETERS ERROR E02 PRESSURE LOW E03 PRESSURE HIGH E04 HOME NOT FOUND E05 HOME ERROR E06 TRIGGERERROR E07 PRINTER ERROR E08 MISSING LABEL E09 INSUFF VACUUM E10 VACUUMLOST E11 MISSING BLOW E12 PEAK BLOW PRESS E13 PROXIMITY ERROR E14 before asking for the next label The above message indicates that one of the slave processors is no
26. lied label after the programmed number of retries The above message indicates that the maximum predefined number of consecutive or cumulative rejected RFID labels has been reached 7 2 Troubleshooting PROBLEM Label liner breaks Labels are not being held onto the tamp pad Label placement on the tamp pad is consistently poor Label placement on the product consi stently poor Label fails to leave the tamp Air assist does not function or is ineffective Machine will not cycle POSSIBLE CAUSES Incorrectly threaded labels Nicks or label cutter die damage on li ner Bruise on the side of the label roll Liner width varying significantly Adhesive build up on peeler bar Vacuum pump not operating Vacuum too low Air assist too high or too low Air assist tube out of position Tamp pad holes not punched out Product is inconsistently presented to the tamp pad Incorrect tamp extend time Air Blast too high or too low No Air Blast Air Blast too low Air assist flow too low or too high or badly oriented Air assist tube incorrectly positioned damaged or disconnected Labels incorrectly threaded Air assist solenoid malfunction Printer jam Tamp home switch not functioning SOLUTIONS Re thread the labels Replace the Label roll Clean as necessary and examine label roll for damage A damaged roll can cause excessive build up Replace label roll i
27. nd should be fully opened only when the full speed is re quested Extension speed Retraction speed Photo 7 Swing arm speed adjustment NOTE an excessive air pressure could damage home and end of stroke tamps Phoenix Italia AP4050 User s Manual 21 Commissioning Rev 05 2010 3 3 Connections setup 331 Printer setup To connect the printer with the AP 4050 applicator use the enclosed Printer Cable and Power Supply Cable as shown on Printer cable Printer cable The print engine needs to have printing information in its buffer in order to continue with the rest of the setup procedures The print engine must be properly set for operation for further in formation refer to your print engine manual and to the AP4050 Programming and Interfa cing Guide 22 Phoenix Italia AP4050 User s Manual Rev 03 2010 Using the applicator 4 Using the applicator 4 1 Intended use An Intended Use applies if The AP 4050 Applicator is not operating in an explosion risk areas The AP 4050 Applicator is not coming in direct contact with food products The AP 4050 Applicator is not operating outdoors The AP 4050 Applicator is used with an additional protection cabinet when operating in a wet envir onment The AP 4050 Applicator is used with an additional protection cabinet when operating in an environ ment in which particulate matter is present The AP 4050 Applicator is operating ex
28. or on an old label carton for a quick discharge Load the label roll on the blades of the inner unwind disk and up against the inner unwind disk The label roll must be oriented so that the material passes through the print head with the label side up Refer to your specific Print Engine Manual for more information on loading the label stock or print media into the printer WARNING THE STEEL BLADES MOUNTED ON THE PAPER ROLL SUPPORTS COULD BE RELATIVELY SHARP BE CARE FUL WHEN INSERTING OR REMOVING LABEL ROLLS AND USE PROTECTION GLOVES Peel off the first meter of labels from the label liner Thread the label stock Make sure that the inner edge of the label liner moves in a straight line from the inner unwind disk through the printer Turn the rewind mandrel until all the slack is removed between the peeler bar and the rewind mandrel It s good to have 2 3 wraps to start 18 Phoenix Italia AP4050 User s Manual Rev 03 2010 Commissioning Fig 2 Paper path Phoenix Italia AP4050 User s Manual 19 Commissioning Rev 05 2010 3 2 8 Air assist adjustment Proper adjustment of the air assist system is extremely important for reliable operation of the applicator the label must be kept adherent to the application plate during printout and when it has been completely detached from the backing paper it must stay flat covering all the holes otherwise the vacuum suction cannot establish enough d
29. pendix B Versions B 2 Swing arm version B 2 1 General overview If the AP4050 is equipped with an optional Swing arm KIT instead of the standard linear stroke unit the front side of an incoming product can be labelled The Swing arm KIT can be assembled in two ways frontal standard and frontal transversal These solutions allows to match most of the applications needs Refer to the dimensional drawings B 2 3 and assembling guidelines B 2 4 for further information Is it also possible to use the Swing arm KIT for a corner wrap application B 2 2 Swing arm lengths and application plates Standard KIT RH LH version 120x160mm Tamp Pad Fig B2 1 Short KIT RH LH version 120x90mm Tamp Pad gt Fig B2 2 Long KIT RH LH version 120x160mm Tamp Pad gt Fig B2 3 Standard Transversal KIT RH LH version 120x160mm Tamp Pad gt Fig B2 4 Long Transversal KIT RH LH version 120x160mm Tamp Pad gt Fig B2 5 B 2 3 Dimensional drawings 408 e a Fig B2 1 Standard KIT 120x160mm Tamp Pad Phoenix Italia AP4050 User s Manual 35 Appendix B Versions Rev 05 2010 Fig B2 2 Short KIT 120x90mm Tamp Pad S Fig B2 3 Long KIT 120x160mm Tamp Pad 36 Phoenix Italia AP4050 User s Manual Rev 03 2010 Appendix B Versions 120x160 Transversal Standard Fig B2
30. rs the pur pose and scope of this manual the conventions used to convey information and the manual outline Customer Support information is located at the end of this chapter For specific information about configuration and programming of the applicator refer to the AP4050 Programming and Interfacing Manual 1 2 Key features Robust and corrosion resistant anodized aluminum and stainless steel construction Up to 60 labels per minute Stepping motor driven tension arm controlled unwinder rewinder mechanism Direct blow tamp blow and tamp on application Low force lt 50 N on the application plate assures the operator safety Application plate exchangeable in few seconds Multiple trigger inputs allowing separate print and apply activation Splash proof control panel with large clearly visible 2x20 characters display USB port for diagnostics remote control firmware upgrade and configuration Universal power supply 90 264 VAC with switch off driven by the printer Optional three colors status lamp Optional end of paper sensor Solid state vacuum and pressure sensors Festo pneumatics 1 3 Normative references DIRECTIVE 98 37 EC of 22 June 1998 on the approximation of the laws of the Member States relating to machinery DIRECTIVE 2006 95 EC of 12 December 2006 on the harmonization of the laws of Member States re lating to electrical equipment designed for use within certain voltage limits
31. sitioned Keep in mind all points of the description Intended Use on chapter 4 1 Fig 1 AP4050 fixing holes Phoenix Italia AP4050 User s Manual 13 Commissioning Rev 05 2010 3 2 Assembling and preliminary operations 3 2 1 Mounting the printer on the applicator Mount the printer on the applicator main plate as shown in the photo below and fix it using the five supplied M5x10 screws Connect the 15 poles printer cable to the printer and the Printer port on the back of the re winder unit Connect the supplied AC Power cable to the printer power input socket and on the Power OUT socket on the back of the rewinder unit 14 Phoenix Italia AP4050 User s Manual Rev 03 2010 Commissioning 3 2 2 Mounting the Filter Regulator assembly The filter regulator must be mounted with the tank vertical with the exhaust valve on the bottom If it is necessary to install the FR group away from the applicator the tube between the FR and the applicator must not be longer than 1 m 28 mm 3 2 3 Drilling the application plate The shipped application plate normally it is not drilled To allow proper operation of the applicator a series of holes whose layout depends on label size must be drilled on the application plate through these holes the label will be kept on the plate by vacuum suction and then shot on the product by an air blast The following rules must b
32. t responding to master commands probably due to a connection problem typically when the applicator cable is disconnected or to a hardware fault or strong interference The above message may be displayed just after switch on and it indicates that the integrity check performed on the parameters stored in the internal memory has failed It is normal to get this message after a chip reprogramming or a factory default reset of the parameters One of the above messages indicates that air supply pressure is not within the limits established for correct operation of the machine The above message indicates that the sensor indicating the home position fully retracted of the application plate did not activate within the configured time limit during the retraction phase The above message indicates that the home sensor did not deactivate within the configured time limit at the beginning of the plate extension phase The above message can be generated only if the trigger status check has enabled in configuration and it indicates that the status of the selected trigger input was not returned to the inactive condition since last activation or that it was activated too early so that the applicator did not recognize the active transition The above message indicates that a FAULT signal was detected from the printer or that the PRINT signal was already active The above message indicates that the requested label did not start printing within the confi
33. tween every versions For more detail please refer to the AP 4050 Applicator Program ming and Interfacing Guide 5 1 2 Start Pressing the START key the applicators enters in the READY status Pressing START anytime even during the programming the applicator goes in operative mode 5 1 3 Stop Pressing STOP anytime even during the programming the applicator goes in STAND BY and on the display will appear Pressing STOP another time the applicator will reset and the air supply cut Phoenix Italia AP4050 User s Manual 25 Maintenance Rev 05 2010 6 Maintenance 6 1 Daily maintenance 1 Examine the tamp and peeler bar for excessive adhesive build up Clean if necessary using Alco hol or some other similar compatible solvent 2 Examine filter regulator for evidence of excessive water or oil collection Drain and eliminate the source of water oil if possible by opening the valve at the bottom 3 Check the machine for any evidence of loose screws rollers fixtures etc 6 2 Weekly maintenance 1 Clean dust from the product detector and low label sensor Is suggested to use a soft brush 2 Examine air supply connections for leakage correct the damage if necessary 3 Examine all roller assemblies for free rotation excessive play etc and correct as necessary 6 3 Six month maintenance 1 Replace the air filter elements and clean the filter bowl 2 Clean t
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